ML20138E384

Forwards List of Questions Resulting from Review of 851010 Summary of Util/Bechtel QA Program for First Four Filter Canisters.Response Requested in Writing,Including Explanation of Implementation of Program

ML20138E384
Person / Time
Site:	Three Mile Island
Issue date:	10/17/1985
From:	Travers W Office of Nuclear Reactor Regulation
To:	Standerfer F GENERAL PUBLIC UTILITIES CORP.
References
CON-NRC-TMI-85-077, CON-NRC-TMI-85-77 NUDOCS 8510250008
Download: ML20138E384 (6)

Text

_.

DISTRIBUTION:

Ofi 50-320 NRCPOR LOCAL PDR 1 DCS TMI HQ r/f ,

TMI Site r/f October 17, 1985 BJSnyder NRC/ Tit!85-077 WDTravers MTMasnik RAWeller PGrant RCook Docket No. 50-320 CCowgill LChandler IE Mr. F. R. Standerfer ACRS Vice President / Director TNI-2 M-Town Office l GPU Nuclear Corporation Service List P.O. Box 480 i Middletown, PA 17057

Subject:

Resolution of Quality Assurance Issues Relating to Fuel Canisters

Reference:

Letter from F. Standerfer to B. Snyder, 4410-85-L-0202, dated October 10, 1985, Sumary of GPU Nuclear /Bechtel Quality Assurance Surveillance Program for the First Four Filter Canisters The referenced letter forwarded the completed QA surveillance checklists on the first four filter canisters and described the prograa that generated and completed the checklists. It described the actions taken by GPU Nuclear and Bechtel to verify that the first four canisters were built in compliance with the design specifications. This program and its results were discussed at a meeting between our technical staffs on October 15, 1985. The attachment is a list of questions resulting from our review of the referenced letter and the subsequent neeting. The questions in the attachment primarily pertain to the

resolution of the quality assurance issues relative to the first four filter canisters already delivered to the site, however, there are additional 4 questions that are generic to all canisters and will assist us in our review of the Canister TER.

Please respond in writing to the questions in the attachment. In addition, in your response explain how your progran for ensuring that the design specifications are met for subsequent canisters fabricated by NES Manufacturing as well as other canister vendors will be implemented. In particular, explain how it will differ in scope from the program for the first four canisters.

i T I i 8510250000 851017

_ , , , , PDR ADDCK 05000320 1 P PDR om > ..[  !

9. . . .g . . ..f.. ...,..

unc ronu ns uo-soi n9cu ono OFFICIAL RECORD COPY _ _ _ , _ . . _ _ _ _ . _ _ _ _ ,

fir. F. R. Standerfer October 17, 1985 If yoO have any questions, please call ce.

Sincerely, 1

l l

William D. Travers Deputy Program Director Till Program office Attachncnt: As Stated cc: T. F. Dartitt R. E. Rogan ,

S. Levin W. H. Linton J. J. Byrne A. W. 4 iller

"'C'

. JIPO... . P0... h11P0 .. ... . .... . .. ... .. ....... . ...........

• * ^"'

AThomas:wa. .?JGrant..... .W Ae s... ..... .. ... . . ... .. ... . . ..... ......... ...

^7"> 10p,1, /85

,/Q/85 10 10/( /6 ,, ,,,,, ,,,,, ,,,,,,,,,,,,, ,,,,,,,,,,,, , ,,,, ,,,,,

sne ronu ais oosoinneu o24 i OFFICIAL RECORD COPY _ _ _

ATTACHMENT

1. Describe the program controls implemented to assure proper catalyst loading during canister fabrication at NES Manufacturing. Include the following aspects:

a) What assurance was obtained that the catalyst received from AECL and Englehard met the design specifications. If CofC's or CMTR's were included, submit these for our review.

b) What receipt inspection was performed by Bechtel and/or NES, and how was the material stored, handled, and controlled in bulk form.

c) How was the catalyst transferred from bulk form to the individual quantities for loading into the lower head cartridges and the upper cartridges for all types of canisters. How were the individual packages labeled and controlled, including maintaining traceability to ir.dividual lot numbers.

d) During weighing operations what inspection / verification of weights was performed by NES, what Quality Control witnessing was performed by NES, and how was it documented. What weight verification was required to be performed by the Bechtel Supplier Quality Representative (SQR) and what verification was actually performed by the SQR.

e) What verification of catalyst loading was performed prior to installing the retaining screen, f) What was your basis for selecting the frequency of verification by the SQR and what was your justification for not requiring 100 percent Quality Control verification by the fabricator.

2. In light of recent discussions on the apparent discoloration of the catalyst screens and pellets seen on one in process lower head, what actions have been or will be taken to determine if there is any potential for catalyst degradation from heat of welding.

j 3. Submit copies of the reports of all QA surveillances and audits performed l at NES. Additionally, provide all existing and future reports, as available, of audits and surveillances performed at all other canister fabricators.

4. What testing has been performed to demonstrate the compatibility of the recombiner catalyst with all expected chemical contaminants, including the hydraulic fluids used with the defueling tools and the core boring equipment.

5. Describe the program controls implemented to assure proper Bg C loading during canister fabrication at NES Manufacturing. Include the following aspects:

l l

l - - - . -__ _ _ _ _ _ _ . __ . _ _ _ _ _ _ . , , _

d) What assurance was obtained that the poison material received from the supplier met the design specifications. If CofC's or CMTR's were included, submit these for our review.

b) Bechtel Specification 15737-2-M-101A, section 5.3.1, requires the canister vendor to perform a prototype tast of the manufacturing process which demonstrates that the minimum 8 3g content requirements are met. Explain how this specification was satisfied and submit the related docmentation.

c) What receipt inspection was performed by Bechtel and/or NES of the B3 C material, and how was the material stored, handled, and c6ntrolled.

d) Describe the program for transferring the poison material from bulk supply to the individual poison tubes. In particular, how was the quantity of material installed in the tube controlled and verified, what independent verification was performed, and how was traceability to individual lots maintained.

6. You have stated that there is considerably more conservatism in the catalyst bed design than that stated in the Technical Evaluation Report.

Provide a description of the design conservatism and the calculations and experimental data to support these statements.

7. Iron oxide was observed on the canister lower heads, presumably from forming these heads on a carbon steel die. Provide a justification for your conclusion that carbon steel impregnation of the stainless steel heads will not affect the acceptability of the shell to head welds and the long term structural and corrosion properties of the canisters. Will any action be taken to remove this iron oxide.

8. Describe your testing program to assure that the cement filler material in the fuel canister will not degrade as a result of inmersion in water.

In particular, address the affects of innersion on the structural strength of the material and the potential for leaching material from the cement that may act as a contaminant to the RCS, the fuel pool, or the recombiner catalyst.

9. Attachment 6 to your letter 4410-85-L-0202 dated October 10, 1985, is the completed filter canister checklist package. It is marked as revision 1.

What resisions were made to the checklists after their completion. If additional revisions are to be made, submit the completed final revisions with an explanation of the revision for our review.

! 10. Attachment 1 to the completed checklist states in section 4 that l imposition of ANSI N45.2 was not necessary since CMTR's/CofC's were l requested. Did you verify that the suppliers held a current ASME Quality System Certificate. If not, justify how a CMTR/CofC can be considered valid if not supported by an approved QA program.

i l

11. Explain in further detail how the upper heads are traceable to their heat numbers. At what point in the process were the heat numbers removed.

Justify how this meets the ASME Code requirements on material traceability.

TMI-2 SERVICE LIST a Dr. Thomas Murley Willis'Bisby. Site Manager Regicnal Administrater. Region ! U.S. Cepartment of Energy U.S. hvclear Regulatory Comission P.O. Boa 88 631 Fark Avenue Middletown, PA 17057 0311 King ef Prussia. PA 19406 David J. McGof f )

Joen F. belf e, Eso. . Chairman. Division of Three Mile Island Programs Administrative Judge *E*23 3c0g PepSerd St. U.S. Department of [nergy Chevy Chase. MD. 20015 hashingten. D.C. 20545 -

Cr. Oscar H. Pa ris billiam Lochstet Acministra tive Judge 104 Davey Laboratory Atomic saf ety and Licensing Pennsylvania State University Board Panet University Park. FA 16802 -

U.S. Nuclese Regula tory Comission hashingian. 0.C. 20555 Randy Myers, Editorial The Patriot Dr. Fredertch H. Shon 812 Market St.

Administrative Judge Harrisburg, PA 17105 Atomic Safety and Licensing Board Panel Robert 8. Borsum U.S. Naclear Aegulatory Comission Babcock & Wilcom Washington. 0.C. 20555 huclear Power Generation Division Suite 220 -

Karin h. Carter 7910 Woodmount Ave.

Assistant Attorney General bethesda, MD. 20814 505 Esecutive House P.O. Box 2357 Michael Churchh111. Esq.

harrisburg, PA 17120 PILCOP 1315 Walnut St.. Suite 1632 Dr. Judith M. Johnsrud Philadelphia, PA 19107 (nvironmental Coalition on Nuclear Pe er Linda W. Little

.._ 433 Orlanco Ave. 500'3 Hermitage DR.

-~ 5 tate College PA 16801 Raleigh,NC 27612

". 8 George F. Troweridge. Esq. Marvin I. Lewis L sha=, Pittman. Potts and 6504 Bradford Terrace

.a Trowbridge Philadelphia, PA 19149

-g 18C0 M. St. hd.

A., Washington, D.C. - ^36 Jane Lee f' 183 valley Rd.

Atomic Safety aN ticersing Board Panel Etters,PA 17319 U.S. huclear te:alatory Comission

• washington, :.; 20555 J.B. Liberman. (soufre

[ Berlack.!sraels, Liberman

. 'I' Atomic Safety and Licensing Appeal Panel 26 droadway U.S. huclear Regulatory comission hew York. NY 10004 hashington, D.C. 20555 Walter W. Cohen, Consumer Advocate Secretary Department cf Justice

_ U.S. huclear Regulatory Comission 5trawterry Souare. 14th Floor

,f. ATTh: Chief. Docketing & Service Branch Harrisburg PA 17127 washington, D.C. 20555 Pr. Larry Hochendoner Ed.ard O. 5. art

'~

Board of Supervisors 04uphin County Comissioner m Londonderry Township P.O. Box 1295 arD #1 Geyers Church Rd.

Harrisburg,*PA 17108-1295 Middletown, PA 17057 John t. Minnich, Chairperson, , Robert L. Knupp. Esc,utre Caupnin County Board of Ccenissioners Dauphin County Courthouse Assistant Solicitor

- Knupp and Andrews Front and Market Streets P.O. Bom P harrisburg. PA 17101 407 N. Front St.

P,,

La Harr'sburg. PA 17108

• Cauphin County Of fice of Emergency i -

Prepa rednes s John Levin. Esowire -

Cout t House. Room 7 Froic & Market Streets Pennsylvania Public Utilities Com.

P.O. Eos 32E5 Marrisburg, PA 17101 Harrisburg PA 17120 U.S. Environmenta l Prote: tion Agency Region !!! Office ATTN: E!S Coordinater Curtis Eutiding (Sixth Floor) s Eth & nelnut Streets Philadelphia, PA 19106 Mr. (;.in rintner Esecutive vice President Thomas M. Gerus6y, Director General Public Utilities huclear Corp. '

.' Eureau of Radiation Protection 100 Interpace Part-ey Departrent of Environmental Resou rces Parsippany. NJ 07054 P.O. bor 2063

'. Mar *isburg. PA 17120

~~

La r. Lennecy Ae traHe 0* ' t a :' Le v i rory,tSta l hiernimt b O "EIU ** lre

~'

b* "

• "e:

uesem** c' invirona.eetal *esources I 5.t b:, 20e tancaste . n u

,. na**lsDurg. PA *I12C

,q l

e