ML20134A710

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Forwards Copies of Matls Presented During 961116 Mtg
ML20134A710
Person / Time
Site: 07000036
Issue date: 01/14/1997
From: Sharkey R
ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY, ASEA BROWN BOVERI, INC.
To: Shear G
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
NUDOCS 9701290058
Download: ML20134A710 (27)
v • d • e


Text

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!b9 January 14,1997 Gary L. Shear, Chief Fuel Cycle Branch Division of Nuclear Materials Safety U. S. Nuclear Regulatory Commission Region III 801 Warrenville Road Lisle, Illinois 60532-4351

Dear Mr. Shear:

As promised during our November 16,1996 meeting, enclosed are copies of the materials presented during this meeting.

Very truly yours, COMBUSTION ENGINEERING, INC.

Robert W. Sharkey Director, Regulatory Affairs RA96/537

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ABB CENO Fuel Operations Combustion Engineenng Inc.

3300 State Road P Telephone (314) 937-4691 Post Omce Box 107 (314) 296-5640 9'01290058 970114 Hematite. MO 63047 Fax (314) 937 7955 i' ?'~1 ADOCK 07000036 s

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AGENDA USNRC

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1200 L.wh l

j Combustion Engineering meeting

" "O,":".'..,_., m, a Cmuley entsty SHAAKR> FREEMAN and plant tour ic-.--

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s. Pesdayquesses owntnusuons PAGE/TOLAN d EchsMe.f egy.ncent ashv.se la IM5HARKEY

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.H-n s leeressensanens SHARKEY h R.shsermJudieselmannanne EAfr0 Hematite, MO i 0~,,"' ~ - "^*-

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t Noyember 16,1996

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CRITICALITY SAFETY PROGRAM UPDATE Criticality safety

+ Three qualified criticality specialists j

j GOAL

+ Make the system simple i

+ CSPU (Gantt Chart)

Enhance the programmatic elements of the Hematite Criticality Safety Program and reexamine and update the criticality safety

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bases for plant processes l

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ABB ABB i

i CSPU Schedule Clean up program l"yM,q""WT"M9 g

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+ Labeling / postings

+ Outside storage

<,o n w ; g - :se-am mmar w ier m i:e L M**d'a,;__..,,

+ Organization of storage areas 5 l O *""""~~ E e,s g",,,

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+ NH system actions completed 3

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+ 40,000 ft) disposed or released from the site

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4 this YT last shipment for 1996 sent last d

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+ Goals for 1996 accomplished y, :==~C_9---

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ANHYDROUS AMMONIA Facility / process modifications i

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+ PHAcomplete

  • All recommendations '

+ Plantimprovements 1996

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- powder preparation complete

- oxide j

+ EPA Risk

- clean rooms l

Management Plan

- erbia lab I

Evaluation Required l

(waiting standard

- mcmeramr r

industry guidance)

- plant environment (AC, noise)

- Filtrate, spent KOH, waste water boildown l

ABB ABB i

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FILTRATE BOILDOWN Waste water and spent KOH boildown

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+ dedicated plumbin g

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Facility / Process Modifications R-53 pellet presses l

+ Plant improvements 1997

+ Replacepellet i

- R-53 presses sluggmg presses with j

- HF Scrubbers E****

- Recycle / Recovery

- R2/R3 conversion reactors

- Grinder to PAM with IDMD j

- Gadolinium room j

- BWR assembly

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HF Scrubbers Recycle / Recovery j

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+ replacedryscrubbers

+ Continueremovalof l

hy obsolete plumbing j

with wet scrubbers j

and recover j

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+ improve current hydrofluoric acid

.e piping

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i Conversion Reactor Replr7ement Grinder to PAM with IDMD q

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+ 1996replacedR2/3 i;.

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+ Automated pellet E

+ Developed leaks ill, pi' grindmg, measunng andalignment

  • Reinstalled modified l

old reactors

+ Significantreduction J

  • 1997 install new R2/3h-l

't in operator handling of l

puets reactors i

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i ABB i

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Schedule of significant activities in 1997 Licensing Activities I

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  • Annual PhysicalInventory July

+ Chapter 4 (NCS) license amendment IQ97 4

  • Plant Shut down July.

+ FNMCPIQ97 i

+ State System of Accounting and Control

+ EmergencyPlan2Q97 l

course with LANL and IAEA May

+ Security Plan IQ97

+ QA Program for Shipping Packages for Radioactive material lO97

+ Inventoryscheduleamendment2Q97

+ Particlesizeamendment2Q97

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  • Organization amendment 2Q97 l

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+ Well#4, retention ponds,20.304 buria ABB 1

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4

i SelfAssessment Results of Radiological Monitoring

+ Program is being formalized RAAP.110

+ Assessed by Lapel Air Sampling which is e License Program conservative

- AnnualRadiologicalandCriticalitySafety

, Highest dose year to date. 23mSv

- Quarterly multi disciplinary team inspection

+ Projected highest dose for 1996 25mSv e Radiological, waste, industrial safety, criticality safety

- Monthly MC&A audits

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- BiennialMC&A assessment

+ Conservative by factor of two due to I i

- Annualtransporhtionaudit micron particle size assumption

+ Additional audits / inspect'ons/ assessments

- Security, statistics, shipping ABB ABB l

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l Fire safety program Other Programmatic Improvements j

. umit on combustible loading in non sprinkled plant areas

+ Training

+ Prs fire planjoindy developed with local fire department

+ Reviewed as part of change taanagement process e Fire Safety is a key consideration durms IsAs

. Firs eatinguisher training and routine inspection of extinguishers j

e Reviewed daily by HP and covered in quarterly inspections

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. Entensive alarm system using smoke and heat detectors

+ 200,000g water supply i

+ 1.500 gpm booster pump ABB ABB Staffing changes in 1996

- Gil Prge to Ceramic Operations

- Bob Tolan hired to run Assembly 0;vr dons j

- Hired Oxide Plant Engineer

- Hired Senior Manufacturing Engineer

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- Added Training / Emergency Preparedness' person to Regulatory AfTairs

- Hired Criticality Safety Engineer

- Created new training position and hired highly qualifled individual ABB 4

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'l MC&A Team Conclusion How Does it Work for the Criticality Team?

i Actions 50% Complete Team Formed 1000/96 Held 2 Mectmas Team Participation is Excellent Team Owner is Strong (Dave Harris)

- Rom cau or emw.m. No sim.uication.

Team and improvements Are Ongoing

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- Team Walk Down or Red Room Format Change to Get Faster & More *llands On" a

ABB A3B Criticality Team Conclusions New Approach to Criticality Training Problem Identincation - Daily Walk Down of the Entire Three Sources of Problems Plant :

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- Collect Onucahiy Concems & operator Suggestions a Review Cnticality Signs and Exclusion Lines

. us,m 4,,o, i, u, a House Keeping Training - Shon Burst Trammg

- Operating Strategy

- Imn Fm Each $hiA Tmu a %ek (Mon & Fri) l

- Imn Fwany rm Red Rain Each Wednesday

  • IncreaseJ Red Room Operation

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  • Additional Storage Rmgs

- Training - New Training Program ABB ABB Red Room Procedures Where is the TTP Headed?

Complete Criticality Work ~1/97 Red Room Procedures Currently Being Rewritten by Engineenns Complete Red Room Review ~2/97

- Review Procedure Style and Guidelines Develop Lesson Plans for Critical

- Review Operability - Does it Work?

Procedures

- Review Labeling in Plant TBD. Maintain Flexibility to Respond.

- Operator Training on New Procedures ABB ABB 2

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i J. Other Programmatic Improvements What's my Background?

. BSME & MBA 2 years Dechtel Power Plant Construction Technical Tram..mg Proj.ect 4 y,,,,,,,,, ABB at wmasor - soies. stategic Piannmg 9 years with ABB at llematite. Major Capital Projects.

l Don Rohde Producten Schedulmg, Tearn Buildmg Trammg ABB Combustion Engmeenng

. Willme to try new & dtfrerent noorn=chaa to tramme?

liematite, Missouri December 16.19%

ABB ABB l

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l What is the Technical Training Project?

What is are the goals of the TTP7 l

TTP is a Program of Apphed Traimng and improvement

. Goals:(in order) l With Emphasis on Operator Participation.

- Reduce MC&A Discrepancies

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- la ihe Plant" Hands un"Trmning l

- op-ior T Idenairyprobi.m a prw.d. saluaans

- Assure Compliance With Criticality Procedures

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- F.edback Tranmg so Engmeenng.

- Improve Red Room Procedures Dnver: NRC Fmdmgs Suggestmg an Enhancement of the

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. Hidden Agenda: Develop Operator Ownership in the Plants Regulatory & OS System.

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l What is the TTP Team approach?

How has TTP worked so far?

MC&A Team Formed 10/16/96 Operator Team Reviews the Existing a

Conditions Held 7 Meetings So Far i

Operator Team identifies Problems Reviewed 6 Months ofInternal Audits Operator Team Resolves Problems Meet With NRC MC&A Audit Team Make Changes to Procedures and Physical Generated 32 Action items Plant 4

Train on Changes M9FFOn _

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l Project Definition Deve.op Hematite and Addison Road

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capabilities to manufacture BWR fuel pellets, rods and bundles I

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Project Scope BWR Shipping Container Procurement i

Pellet Fabrication 1

Bundle Assembly Mag Force Weld Qualification j

Rod Fabrication Scanner Qualification Addison Rod Components 1

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i Project Summary Make fuel type transparent to operation Procure, refurbish and license shipping containers Modify existing facilities and equipment where necessary

- Qualify new and existing processes for 1

BWR manufacturing Implement LFA program Manufacture BWR reloads domestically i

m Rod Assembl I

i Pellets From End Cap +

Cladding Kardex Spring t

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U To Weld End Deflash Weld End Deflash Rod

& Bundle l

Cap Weld Cap Weld Scanner J L J L J L J L Assembly l

End Caps Tare Gross Measure Helium Weight Weight Rod Length Leak Test i

i ABB Nuclear Operations 12/13/96

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b Bundle Assembl f

i Rods Fron Upper End Matrix Fitting i

V Assemble FreePath Bundle Push Swage Contain Inspection &

Upper Enc +

Check

-erize l

Pre-Stack Rods Post Fitting Straightnes ;

V S;., To tustomers i

ABB Nuclear Operations 12/13/96

ID Task Name May l Jul l

Sep l

Nov l

Jan l Mar l May l Jul l

Sep l

Nov 1

Shipping Containers 2

Purchase Comainers 3

Refurbish Comainers 4

License Containers 5

Pellet Production 6

Idemify Paential Processes 7

Purchase Necessary Equipmem 8

Test Alternate Methods 9

Install Necessary Equipmem yys..s..

7.g g.3g 10 Qualify Selected Process y fgg.jg g 11 Mag Force Weld Qualification (LFA) 12 Purchase Materials for Weld Samples

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13 Modify Tooling 14 Weld Samples p.g 15 Corresion Test Samples g

16 Perform Metalographic Exams g

h 17 Perform Mechanical Tests g

18 Prepare Reports 19 Mag Force Wold Qualification (All welders 20 Modify Tooling J yr

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21 Weld Samples y

22 Corrosion Test Samples 4

Task

$lhidiE@I*$lNC Summary RoIIed Up Progress Progress Rolled Up Task 74d2$W6$fMM Dae 2n/96 Milestone k

Rolled Up Milestone O Pagei

ID Task Name May l Jul l

Sep l

Nov l

Jan l

Mar l May l

Jul l

Sep l Nov 23 Perform Metalographic Exams 24 Perform Mechanical Tests

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25 Prepare Reports gj-26 Bundle Assembly 27 Design Bundle Assembly Finure 28 Fabricate Fixture 29 Qualify Process with new fixture g

30 Desigtvfabricate Bualle Inspection Fixture g

i 31 Modify Procedures for new process g

32 Rod Fabrication 33 Identify Tooling reeded for LFA 34 Fabricate Tooling for LFA g

35 Qualify Processes for LFA Fabrication g

36 Identify Tooling needed for Reload j

37 Fabricate Tooling for reload gggggg 38 Qualify Processes for Reload Fabrication gg 39 Spacer Capture Head Welding 40 Review Atom's Process y

41 Purchase Equipmert

. p 42 Fabricate Fixtures 3jg 43 Qualify Process

gg 44 Scanner Qualification Task NMIEE Summary Rolled Up Progress -

Project-Date: 12n/96 Progress Rolled Up Task S S$53 M $$

Milestone k

Rolled Up Milestone O Page 2

ID Task Name hiay l Jul l

Sep l

Nov l

Jan l

Afar l hiay l

Jul l

Sep l

Nov 45 Identify hlaterial Needs g

46 Purchase Needed hiaterials g

47 Fabricate Test Rods y

48 Run Qualification 49 Addison Road Components 50 Request Casting Quotes 51 Select Casting Vemfor g

52 Fabricate Tooling

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wa...>,. w zw;m..wu sw 53 Develop hiachining ggg 54 Qualify hiachining g

Task EsENM@ldE2W M Summary Rolled Up Progress Da e 12n/96 Progress N

Rolled Up Task

$EEKMM}$d hiilestone k

Rolled Up htilestone O Page 3

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.l Benefits Domestic BWR customers receive fuel from domestic ABB supplier Reduced import duties and shipping costs l

Increased Hematite volume t

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h GAD PROJECT XRC Review December 16,1996 t

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Objective a To Provide Gadolinium-Uranium Fuel Rod Manufacturing Capability at ABB CEXO in Hematite, Missouri.

1 m To implement controls that prevent cross contamination of the Uranium and Erbium-Uranium Fuel manufacturing facilities.

i a To provide capability to do final assembly of all rod types at ABB CEXO at Hematite.

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Project Scope Gad Pellet Shipping Container Procurement Build Gad Processing Facility Pellet Receiving Qualification Bulk Drying Qualification Rod Loading Development & Qualification Scanner Qualification

I Gadolinium E

E Visual Inspection eceipt

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from " Cert" Pool for Process Flow

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Kardex Pan Make-up Diagram a

K.

Transport to Ceramics I

Bulk Dry in Ceramics Factory t

Kardex Storage in

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Ceramics Trash to burial 4

Kariex Pan Transport to Bu;1 ding 230 Return Scrap Pellets and Chips RW W M N 4-Repair Rods room to Vendor F

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on Rod Une t

UEC Weld on Rod Une

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Qualification Summary m Bulk Drying / Kardex storage of Gadolinium-L ranium Fuel Pellets -

Qualification Plan being modified.

m Rod Scanning of Gadolinium-E ranium Fuel Rods - Manufacturing Spec and Qualification Plan being modified.

l m Demonstration of Rod Line to assure no damage to Fuel using new equipment.

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Gad Rod Project

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C+iMa RodProject 8%l 1M3

, 4 34 ABBGreenSheetSubmited 3%l 115 M 124

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i AB8!ssuePOforGadRoomDesign 100%

119[11#

tih,, 9 125 BuHngPennt 0%

l iik i 228 M BuidGadPam 2%

Change W 0%

124 N 12NS s

t QualifrationsoftheGadProcess 24%

1853 j

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E BukDry/Karde: Storage 8%

12/I6 l

41 y

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RodScanner 38%

1853 4'30 i

12/2 g125j E

RodLine 5%

122 N125j g Procedures 1%

M Renews 1%

115,

1";

y E Requests 4%

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y ReadytoProcessRods 0%

K00 i

. ScheduleforKoreanContract 1%

122 614 i

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u. ProcessRodsforCartract(Schedk) 0%

4'24 p!ii t2 E Brde Assedfy for Cartract (schedule 0%

$53 m MwsNpDate 0%

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Schedule Task Completion Date Isolation Room February 24,1997 Construction Pellet Fabrication March 20,1997 Bulk Dry Pellets May 6,1997 Rod Loading May 20,1997 Bundle Assembly June 4,1997 i

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