ML20210C986
| ML20210C986 | |
| Person / Time | |
|---|---|
| Issue date: | 09/15/1986 |
| From: | Cilimberg R, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20210C966 | List: |
| References | |
| REF-QA-99900002 NUDOCS 8609190029 | |
| Download: ML20210C986 (21) | |
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ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT REPORT INSPECTION INSPECTION N0.: 99900002/86-01 DATES: 7/21-25/86 ON-SITE HOURS: 76 CORRESPONDENCE ADDRESS: Combustion Engineering Incorporated ATTN: Mr. H. V. Lichtenberger Vice President - Nuclear Fuel 1000 Prospect Hill Road Windsor, Connecticut 06095 ORGANIZATIONAL CONTACT: Mr. P. Ferwerda TELEPHONE NUMBER: (203) 285-3352 NUCLEAR INDUSTRY ACTIVITY: Nuclear fuel assembly supplier for Combustion Engineering (CE) and Westinghouse designed reactors.
ASSIGNED INSPECTOR: h N.I h BR. R. L. Cilimberg, Special Projects Inspection k!!6!I(0 Date Section (SPIS)
OTHER INSPECTOR (ji,)': C. M. Abbate, SPIS
/ C. Hirayama 3C onsultant APPROVED BY: M '\ II hn W. Craig, Chief, SPIS, Vefdor Program Branch Date INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR 50, Appendix B and 10 CFR 21.
B. SCOPE: This inspection was made to review fabrication, inspection, and j testing activities.
i PLANT SITE APPLICABILITY: PWR facilities with fuel supplied by Combustion Engineering.
8609190029 860916 PDR GA999 ENVC-E 99900002 PDR
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ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT REPORT INSPECTION N0.: 99900002/86-01 RESULTS: PAGE 2 of 15 A. VIOLATIONS:
None.
B. NONCONFORMANCES:
- 1. Contrary to Section 6.6.2 of the CE Quality Assurance Manual (QAM),
Revision 1, dated January 22, 1986, ink changes were made to Sections B.4.0 and B.5.0 of Operation Sheet (0.S.) Number 925 " Leak Test,"
Revision 32, dated June 1,1984, without the p.oper approvals.
- 2. Contrary to Section B.7.0 of 0.S. Number 945, " Leak Test," Revision 32, dated June 1, 1984, the helium leak test was not being conducted for a minimum of 30 seconds as required.
C. UNRESOLVED ITEMS:
None.
D. STATUS OF PREVIOUS INSPECTION FINDINGS:
Not applicable.
E. OTHER FINDINGS AND COMMENTS:
- 1. Entrance and Exit Meetings The Combustion Engineering (CE) representative was informed of the scope of the inspection during the entrance meeting on July 21, 1986.
The inspection findings and observations were summarized during the exit meeting on July 25, 1986.
- 2. Helium Leak Test a) Procedure Review The inspectors reviewed 0.S. Number 945, " Leak Test," Revision 32, dated June 1, 1984. The procedure contains the steps used for start-up and shut-down of system equipment, calibration of the equipment, testing of fuel rods, processing ar.d retesting of leaking rods, cleaning of test chambers, and processing of paperwork. During the review, the NRC inspectors noted that Sections B.4.0 and B.5.0 of the 0.S. had been changed from loading two fuel rods into the test chamber to loading four
ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDS 0R, CCNNECTICUT REPORT INSPECTION NO.: 99900002/86-01 RESULTS: PAGE 3 of 15 fuel rods into the test chamber. This change was made with an ink pen and did not have the approval of Manufacturing, Engineering, and Quality Control Engineering, as required by Section 6.6.2 of the CE QAM. When CE was informed of the unapproved ink changes by the NRC inspectors, the proper approvals were obtained.
Nonconformance 86-01-01 was identified in this area.
b) Observation of Testing The helium leak test consists of putting two to four fuel rods
'into the test chamber. A vacuum is then exerted on the test chamber. The actual monitoring for helium leaking from the inside of a fuel rod occurs after a vacuum is achieved and the
" Start Test" button is pressed. The leak detector meter measures helium leakage and is to be monitored by the operator. The required duration of the test is a minimum of 30 seconds. The meter must be stable before accepting or rejecting a reading and the reading must be below the specified value in order for the test to be acceptable. The NRC inspectors observed that the operator was not performing the leak test for the required 30 seconds during multiple tests. When this matter was brought to the attention of the QC Manager and the Inspection Supervisor, the operator was instructed to assure that the specified minimum test duration of 30 seconds elapsed before accepting or rejecting the rods. The QC Manager also indicated that a Deviation Notice (DN) would be written, the entire fuel rod cart would be retested, and other operators would be instructed on the importance of assuring that the test is performed for a minimum of 30 seconds.
Nonconformance 86-01-02 was identified in this area.
- 3. Leaking Fuel The NRC inspectors met with Ian Rickard, the CE Project Manager who incidents of leaking fuel at a number was responsible of pressurized water reactors for evaluating (PWR) that use CE fuel.San Onofre 3 (SONGS-3), St. Lucie 1, Maine Yankee, Calvert Cliffs 1, and Arkansas
-0ne-Unit 2 have all exhibited incidents of leaking fuel in varying degrees from June, 1982, to the present.
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ORGANIZATION: CCFBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT l
REPORT INSPECTION NO.: 99900002/86-01 RESULTS: PAGE 4 of 15 CE has performed an in-depth evaluation of SONGS-3 cycle 1 which contained 105 leaking fuel rods in 23 fuel assemblies. The evaluation covered a number of possible fuel failure mechanisms such as pellet-cladding interaction, corrosion, fabrication defects, handling damage, spacer-grid fretting, and debris in the primary system. An in-depth anaiysis of recent fuel failures at other facilities has not been performed. Almost 50% of the leaking fuel rods in SONGS-3 were in Assemblies A-004 and A-005 which prompted CE to look at the fabrica-tion of these assemblies. The leaking fuel rods were believed to be a result of primary hydriding because Iodine 131 was detected early in the fuel cycle and failures occurred from the inside of the rods based on visual examination. Records of hydrogen analysis for the fuel pellets in the failed rods indicated that the pellet hydrogen content was considerably below the maximum limit in the CE specifica-tion. A similar examination of pellet density values indicated adherence to the CE specification.
As a result of their evaluation, CE concluded that the failed fuel rods in SONGS-3 were caused by moisture inside the fuel rods due to improper drying and a low vacuum during fabricaticn. This resulted in hydriding of the zircaloy and subsequent perforation of the cladding during the start of cycle 1. Based upon this evaluation CE has implemented several corrective actions: Vacuum gage calibra-tion procedures were revised, a lock box was installed on vacuum gaaes '
at the end cap welding stations, and a new dryer was installed to dry tubes after cleaning.
- 4. End Cap Welding a) Lov:er End Cap Weld The lower end cap weld is described in 0.S. Number 500 " Weld 1st Cap," Revision 42, dated May 29, 1986. The procedure outlines how the welding equipment should be set-up and shut-down, the daily check's that are to be made on the equipment, and the steps for making the weld. An addendum to the 0.S.
lists the amperage limits and gage and control levels for each contract number and tooling required for each contract.
The process starts by placing a lower end cap and zircaloy tube in the welding chamber. The chamber is closed and pumped oown to the vacuum specified in the welding procedure. In order to prevent the operator from lowering the specified vacuum, a locked cage has been placed over the vacuum gage.
This was done as a result of the leaking fuel problem identified at San Onofre (as discussed in E.3). When the specified vacuum
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ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDS 0R, C0KNECTICUT INSPECTION j REPORT N0.: 99900002/86-01 RESULTS: PAGE 5 of 15 is reached, the chamber is backfilled with helium and the end cap is welded in the tube. This process is performed on each ,
of the tubes in the cart and on a specified number of sample '
rods. At the conclusion of welding the lot, an inspector is notified and the welds are visually examined.
b) Upper End Cap Weld The upper end cap weld is made after the fuel pellets have been loaded into the tubes and is described in 0.S. Number 852,
" Weld 2nd Cap," Revision 55, dated June 10, 1986. This procedure is similar to 0.S. 500 and also outlines how the welding eouip-ment should be set-up and shut-down, the daily checks that are to be made, and the steps for making the weld.
The upper end cap weld procedure follows the same basic steps as the lower end cap weld procedure. The differences are that a spring is inserted into the tube before the weld is made and a strip recording chart which records room temperature and chamber pressure must be checked by the operator. A cage has also been installed around the vacuum gage to eliminate tampering.
Upon completion of observations of the end cap welding and review of the two procedures, the inspectors determined that the proce-dures were being followed by the operators.
No items of nonconformance or unresolved items were identified in this area.
- 5. Zircaloy Tubing a) Tubing Specifications CE utilizes zirc:loy tubing to manufacture fuel rods. CE l Specification Number 00000-FMD-201, " Specification for Zircaloy-4 Fuel Rod Cladding Tubes," Revision 01, dated October 27, 1981, outlines the scope, the respcnsibilities of the seller and purchaser, the applicable references, the chemical, mechanical, hydride trientaticn, surface finish, and dimensional requirements, the quality assurance program and test requirements, packing, marking and shipping requirements and documentation required from the seller. The specification references ASTM 353-77A and identifies wrought Zircaloy a, ASTM designation UNS #R60804, as defined in ASTM 353-77A, as the material to be used in the fabrication of the tubes.
ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT REPORT INSPECTION NO.: 99900002/86-01 RESULTS: PAGE 6 of 15 b) Purchase Orders The NRC inspectors reviewed purchase order (P0) 9530077, dated May 16, 1985, with respect to'the zircaloy tubing. This P0 was from Baltimore Gas and Electric Co. (BG&E) to CE Nuclear Products Manufacturing for Batch L fuel bundle assemblies to be used for the Calvert Cliffs 1 reload. The P0 included the final design drawings and material specification numbers to be used and included additional instructions to be followed during the manufacturing of the fuel assemblies. CE Specification Number 00000-FCD-0100, " Standard Engineering Specification for 14 x 14 Fuel Assemblies," Revision 01, dated November 26, 1979, was ,
referenced as the basic specification for the manufacturing of the fuel assemblies. This specification was reviewed with respect to the tubing and was found to include the scope, the seller's and purchaser's responsibilitiet, the applicable documents, the manufacturing requirements and reports, records, and documents to be furnished by the seller. Specification Number 00000-FCD-0100 references and requires the cladding to be fabricated in accordance with Specification Number 00000-FMD-301 (described above).
F0 9530077 imposed 10 CFR Part 21 on CE and also required CE to obtain mean and upper and lower 95/95 confidence limit measurements of the tubing outside diameter (00), wall thick- "
ness and ovality on at least 300 tubes.
F0 Number 9690036-05303, dated March 19, 1986, to Sandvik Special Metals (SSM) from CE for Zircaloy-4 seemless tubing v.as also reviewed. The P0 was issued for the BGM fuel assembly order and outlines the dimensional tolerances of the tubing, the special requirements and/6r exceptions tb the specification, certification requirements, delivery requirements and SSM procedure submittal requirements. The j P0 stated that 10 CFR Part 21 was applicable and described the 10 CFR Part 21 reporting requirements. The P0 also required SSM to provide CE with the 00, wa'll thickness, and ovality measurements of 300 randomly selected tubes (as stated above). .
This P0 was written in accoraance with Section 4.0, " Procurement Document Control," of the CE CAM and included the appropriate specifications, standards, and drawing r6coirements.
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~ i ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT REPORT INSPECTION '
NO.: 99900002/86-01 RESULTS: PAGE 7 of 15 c) Material Certifications The requirements outlined in CE Specification Number 00000-FMD-301 and imposed on SSM are listed on SSM form PS-02.04, Revision 7. SSM takes random samples irem each let .snd performs tests on those samples tc ensure the lot treets thG requirements.
These chemical and mechanical tests consitt of chemical impurity ,
testing, corrosion resistance testir.g, grain size . testing, hydride orientatlon testing, ingot chemical analysis. (taken at top, middle and bottomh and mechanical property ttl sting. For each chemical end mechanical test perfc med on the samples the specification reference, acceptance criteria, and results are listed. Ultrasonic testing is performed on all tubes, and visual .
inspection is performed on the tubes as 6n ayerall quality check. ;
Other infomaticn contained an SSM Form Sua'oer PS-02-04 includes the supplier and custcnor names, specifict. tion numbers, ingot vendor name, beat number, lot number, F0 nun'iber, certification number and date and quar.tity shipped. Also cn the form is an area for CE to review the release chech and accept er reject the submittals made by SSM. ;
In a letter dated June 9, 1986 to the CE QA Maneger from the Quality Assurance Engincerin0 Manager, t,he required dimensional data submitted by SSM was document 4d. The letter contained the dimensional t.olerances as *.pecified ir the PD, the sample size, the mean, the standard deviation, and the 05/95 confidence linits <
for the wall tnickness,f)D and OD uality.
J Other information related to the tubing Nbich was reviewed !
during the inspection includeo Quality Coctrol Naterial Releass Number 9690036 4, dateo June 16, 1996, tha standard Surveiliance Operation Sheat and Trip Report, dated June 6, .
1956, the Surveillaitce Cher.klist for Zircaloy-4 Cladding, und the Snipoing Release-Quality Centrd (Vendor). This information was filled out by bath CE and S(M and recorded the lot numbers, heat nut.bers, ingut nuaters, the tests perforried on the tubes cnd if the results were acreptable.
Although CE does . net perforfa receipt inspection (eyctapt for shipping dan:ane) er cne'rical ard Icechanical ' tests, they do ,
l perform schedu)0d audits of SSM's quality prcgram an.1 cerf.crm surveillance of SSM during the fabrication' of a CE order.
During the relcase of material trcm the supplier to CE. the tubit9 and paperwork are re'tiewed and controlled in order to
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- NO.: 99900002/86-01 RESULTS: PAGE 8 of 15 i maintain trace 6bility. Traceability is achieved througn heat, iagot, and lot nunbers. The NRC inspectors observed that the forms which contained acceptance test results were filled out with the proper identification numbers and were reviewed and -
i approved by the appropriate personnel.
e) Cleanliness of Tubing Af ter the tubes are received at CE and are receipt inspected ,
for shipping damage, they undergo a cleaning process. This :
process is described on Shop Traveler " Tube Cleaning,"
Revision 4, dated June 12, 1986, and includes si>. separate steps which are subsecuently described in 0.5. Numbers 106, 107, 103, 104, 2402, and 1742.
0.S. Number 106, " Vapor Dagrenser." Revision 1, dated December 12, 1969, 0.5. Number 107, " Detergent clean,"
Fevision 1, dated April 7, 1970, 0.S. Number 103, " Process Vater Rinse," Revision 1, dated April 7,1970, and 0.S.
Ut.mber 104, "Demineralire Water Rins6," Revision 2, all have steps which describe how to perform equipment shut-dcwn, ar.d hcw to run the process. 0.S. Numoer 2402, " Oven Dry,"
Revision 3, dated June 19, 1986, outlines the safety precautions, set-up parameters, including temperature and time settings, and the production process. 0.5. Number 1242, " General Ir.spection Instructions," Revision 13, dated Jurie. 18, 1986, ;
outlines the minimum requiremer.ts for each inspection operation.
The areas delineated include the camputer system in use for traceability of fuel and poison rods, review of shop /wcrk
'irstructions, and inspection procedure general instructions.
The 9eneral instructions include part acceptance, repair procedures, part rejection, and sampling plans based on lot size.
Although an entire cleaning process was r.ot cbserved, the inspectors did observe that the clean, ory tubes were covered l
with cheesecloth, that both ends were plugged to prevent contamination frcm outside sources and that the proper revision of the 0.5. Number was present at each work station.
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( f) Audit of Tubing Supplier I
ihe inspectors reviewed a CE Vender Quality Audit Report of SSM, ,
l dated January 16,19S6. The report consisted cf a checklist, l
a comment area, and attachments, which specifically listed the l
areas audited in more detail than the cnecklist and problems
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ORGANI2ATION: COMBUSTION ENGINEERING INC0RPORATED WINDSOR, C0FNECTICUT REPORT INSPECTION NO.: 99900002/86-01 RESULTE:
PACE G cf 15 which were identified. The incpector determined that thL audit ,
was performed and the report was written ir acccrdance with the requireinents prescribed in Section 18.0, " Audits" of the CE 0AM and that SSM met tne requirements set forth ir QC-14*09, "Guallt.v Assurance Progrcm Reouir@ ment,s fcr Suppliers to Combustien Engineering Nuclear Products Manufacturing-Windscr."
i No items of rcr conforma,nce c'r un.esclved items were identified in this area.
- 6. Spacer Grids a) Spacer Grid Assembly The inspector observed the asseably of thc spacer grids. A spacer grid is assembl0d by connecting fouP zircoloy plates and fctming a square. Additional plates are added and the grid is turned over and thirteen or f-ifteen more plates are attached in rows at ,
the 90' angles to the first set of rows. The different pieces l
usec in the proces.s are segre' gated in a marked holder to assure L that the assecbler uses the correct part 9n the assembly. 0.S.
l Humber 1799, "Banch Asscmble and Weld,14 x 14,16 x 16 Spacer
- Grids," Revision 18, dated November 27,1936, describes this process. The irspector verified that the 0.S. was present at tha wcrk station, and the assembler was following the procedure, b) Grid Intersection Feld 0.S. huinber 1799 also cutlines the steps to be followed when
( welding the grid intersections on the spacer grids. The welds are performcd using a computerized welding machine which, af ter being progrdrmed, welds each intersection.
l The operatur oversees the wcidir.9 and watches c ccmputer i screen to assure that the weld is made at the correct lcca-tion and is of the correct dinensions.
I c) Welder Cualifications The inspector reviewed the qualifications of three welders. Each welder is classified as either Level I, II, or III; Level III l
being tre nost quclified. The welder's level of oualification, the kelding Procedure Specification (WPS) number which he is qualifiec to pertcrm and his requalification dates are liste.1
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ORG A.N1'ZATIGH: COMBUSTION El5INEERING INCORPORATED WINDSOR, CdNNECTICLi r - __ l
\ I REPORT INSPECTION FESUl.TS: ,PAGE 10 cf 15
. fic. : 99900002/86-01 ,
on the " Welder Qua'11fication" form. A "Keld Qualification Log" ,
and " Engineering Notices" wer' e reviewed for each of the three weldefs. These Porns tontainGd the we%ers nan.e. level, WPS number to Which he f s qualified, the date of the original qualf fication, requalification dates (yearly), cod the 0.S.
numbe.r and lct nunter used for the weld. This is done tc
' assure that the welder is qualified to perforti specific velas s and to assure that he Iemains cualified.
The inspector determined tnat the three welders were qualified i
ta $crform the welds specified en their cualification forres and through interviews with the welders, and observation Of their work, def.erinined that they followed the 0.S. and WPS forms.
fio items of nonconformance or unresolved items were identified in this area.
- 7. Fuel Eundle Assembly During the inspection, the final cssenfaly of the fuel burdle was i observed. The procedure used durfog the process was 0.s. N wbrar 1524,
" Fuel Burile Loading and Inspection," Ravision 43, dated April 10, 1956.
This proass began with sne row of fuel rods being unloaded from the crestack tray and placed on the pushing table. The pushing tcble has an indentation on it fer each it.el rod. The rod serial nunibers or the b' otton end c.ar werc read off and entered inco the computer
~co assure that the ccrrect rod was Leing placed in tb.e prepar grid location. If the rod is in an inco rect location, the computer, which has been progr.arfaed for the acceptable rnds, will displ.ay an e rrcr . The operatcr pt.nches the nunber in 49ain and if an error ,
appears again, a bt! is written and must be dispositioned bafore the ftel cun:le is released.
l AYter the rod:; in the row were indicated as teing in the correct ,
, locations, t!!ay are wiped clean and pusbed through the assembly -
and spacer grids. At the conclusica of cach -ow being pushed into the bundie, the rod; are checked for n' roper fit.
Tre entire procest is repeated unt11 all the fuel rods have been leaded into the b'u ndle. The fuel b;.ndle is t en visually inspected and placed in a cleaning chamber elich rinses and uries the fuel oundle. The upper end fitting is installed and the finished fuel assembly is reaGy for the final quality check; faade before being shipped.
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OPGANIZATION: COMSUSTION ENGINEERING INCORPORATED -
WINDSOR, CONNECTICUT
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REPORT INSPECTION flC. : 999C0002/85-01 ! RESU TS: PAGE 11 of 15 TI',ere are two basic quality checks performed on the final fuel a$sembly. The first is a free path dimensional check. Four rollers ferr, ting a square are slid up the assembly. The rollers are set at .
the dimensicnal tolerances specified in the P0 and specifications and j 11 any of tFe dimensions are exceeded, the operator can read the '
amount by which it is out of tolerance on the dial indicators. This check is perfortred to assure that the fuel assembly is straight and l no bcwing has occurred during ranufacturing.
i The second test is an overall visual examination of the fuel assembly by a quality control inspector. This inspection consists of examining the exposed surfaces of the fuel rods, grids, and end fittings for any unacceptable cor.dttions such as scratches, loose material on grids, rust, and grease, and examining all spacer grid corner welds to assure that they are free of cracks. If no problems are identified, the fuel assembly is either wrapped in plastic and held in storage or )
i placed into a shipping container which holds two fuel assemblies. ;
The inspectors observed the perscnnel following the procedure and no items of nonconformartce or unresolved items were ident'#ied in this area.
- 8. Fluorescope Inspection CE performs fluoroscope inspection on all the fuel rods. 0.S. Number 990, " Fluoroscope Inspection," Revision 19, dated February 20, 1986, delineates the orocess. The 0.S. describes how to perform equipment start-up and how tc perform the inspection.
The fluorescope inspection consists of passing the fuel rod through '
a chan.ber. As the fuel rod is passed through the chamber, the operator is able to see an inage of the fuel red. The 0.S. outlines i whet the operator should see and also has a chart of conditions which would result in rejection of the rod, the permitted corrective action and the required action when a deviation is found. In most cases when a deviaticn is identified, the rod is rejected and a DN written.
The inspectors determined that the operator was performing the fluorscope inspection as described in the 0.S. and no items of nonconformance or unresolved items were identified.
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ORGANIZATION: COMBUSTION ENGINEEEING INCORPORATED WINDSOR, CCNhECTICUT REPORT INSPECTION NO.: 99900002/86-01 RESULTS: PAGE 12 cf 15
- 9. Chemical Analysis of Fuel a) Measuring and Test Instruments The NRC inspectors reviewed procedures and practices related to the control of measuring and test instruments used in the analytical laboratory to determine elements and impurities in oxides of uranium. The procedures discussed in (b) below specify the steps for using the measuring and test equipment.
Standards are used to verify the accuracy of the instrument readings prior to performing an analysis of a production sample.
b) Procedure Review The NRC inspectors reviewed five procedures which covered:
spectrographic analysis of low boron in uranium dioxide, rare earth and thorium in uranium oxides, and common impurities in uranium dioxide; chromatographic analysis of carbon in uranium oxides, and gravimetric determination of oxygen to uranium ratio and percent uranium in uranium dioxidc. The procedures had been properly reviewed and contained the required signature approval. The procedures were complete but centained the incorrect information diccussed in (c) below. These ,
procedures were revised during the inspection.
c) Observation of Analysis The NRC inspectors observed technicians performing sam?l e analyses utilizing the procedures discussed above. Observa-tions are itemized below:
(1) A technician used an ARL spectrometer to analyze uranium dioxide for impurities in accordance with Precedure Number 10, " Standard Operating Procedure for the Emission Spectro-graphic Determinations of Common Impurities in Uranium Dioxide," Revision 2, dated February 18, 1982. The ,
procedure specifies that the sample being converted from U07 to U 30a be heated to 450 25*C. The technician was ob5erved t5 heat the sample in a muffle furnace at a maximum temperature of 540 C. While the higher temperature i
does not adversely effect the test results, CE issbed Revision 3 of the procedure during the inspection to permit use of the higher temperature.
ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT REPORT INSPECTION NO.: 99900002/86-01 RESULTS: PAGE 13 of 15 (2) Section 8 of Procedure 10, Revision 2 states that the overall precision of the method is approximately plus or minus 25 percent of the amount present. An examination of the calibration data by the NRC inspectors showed that the precision (numerical magnitude) of the data was significantly larger than plus or minus 25 percent for some of the elements such as iron. The spectrographic data for a standard deter-mined on June 27, 1986, shows a difference of as much as 100 percent from that specified by the supplier of the standard sample. Revision 3 of Procedure 10 was revised during the inspection and notes that the precision of the method may vary depending upon the impurity element being analyzed and the working range of the standard curve for each element.
(3) A spectrograph is used to analyze uranium oxide for rare earths and thorium in accordance with Procedure Number 24,
" Standard Operating Procedure for Spectrographic Determina-tion of Rare Earths and Thorium in Uranium 0xides," Revision 0, dated September 2, 1983. The analysis uses calibration curves drawn from measurements on standard samples. The curves for the rare earth elements are drawn through five points at 0.5 to 5 micrograms while that for thorium is drawn through five points at 0.1 to 4 microgram. Examination of the calibration curves indicated that the curves for most cf the eler.ents increased abruptly at the highest content of the element. Consequently, if the quantity of these elements in a uranium oxide sample were greater than 5 micrograms for the rare earth, and greater than 4 micrograms l
for thorium, the extrapolation of the calibration curve
! to these high concentrations becomes highly questionable.
Discussions on this matter with CE personnel indicated that additional determinations are made under these circumstances with reduced quantities of UO9 samples, so that the spectro-graphic readings fall within the valid region of the calibration curves. Procedure 24, Revision 0, did not clearly define the method for the redetermination with the reduced quantity of uranium oxide, so that accurate determinations may be made for these elements. CE issued Revision 1 of the procedure during the inspection to ensure that the correct curves are used for the quantity of sample -
chosen.
ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDS 0R, CONNECllCUT REPORT INSPECTI0t' NO.: 99900002/86-01 RESULTS: PAGE 14 of 15
- 10. Moisture and Hydrogen Control a) Measuring and Test Instruments The NRC inspectors reviewed procedures and practices for the control of measuring and test instruments used to determine hydrogen and moisture content in uranium dioxide fuel pellets.
The procedures discussed in (b) below specify the steps for using the measuring and test equipment. Standards are used to verify the accuracy of the instrument readings prior to performing an analysis of a production sample.
b) Procedure Review The NRC inspectors reviewed four procedures which covered:
determination of hydrogen in uranium dioxide pellets, moisture in uranium dioxide, hydrogen analysis of special fuel, and moisture analysis of uranium dioxide powder. The procedures had been properly reviewed and contained the required signature approval. The procedures were technically correct and complete with the exception of the wrong units being used on a reporting form discussed in (c) belcw. The reporting form units were corrected during the inspection.
c) Observation of Analysis The NRC inspectors observed technicians performing sample analyses utilizing two of the procedures discussed above. Observations are itemized below:
(1) A technician used a Leco hydrogen analyzer to analyze uranium dioxide pellets for hydrogen centent in accordance with Procedure Number 12. " Determination of Hydro.;en in Uranium Dioxide Pellets," Revision 1, dated February 27, 1977. The steps of the procedure were properly followed without deviation and standards were analyzed to verify the accuracy of the method.
(2) A technician used a hydrogen analy:er to analyze a special fuel for hydrogen content in accordance with 0.S. Number 2144, " Hydrogen Analysis-SCE Fuel," Revision 2, dated October 2, 1985. The procedure was technically correct and complete with the exception of the reporting form entitled " Hydrogen Analysis Sheet", Figure 11. Figure 11 incorrectly indicated millimeters of mercury for
ORGANIZATION: COMBUSTION ENGINEERING INCORPORATED WINDSOR, CONNECTICUT REPORT INSPECTION N0.: 99900002/86-01 RESULTS: PAGE 15 of 15 barometric pressure instead of the centimeters of mercury being measured by the technician. The reporting form was revised to specify the correct units.
- 11. Sampling and Density Measurement The NRC inspectors reviewed 0.S. Number 1487, " Chemistry Sampling,"
Revision 14, dated November 30, 1984, and 0.S. Number 1475, " Chamfered Fuel Pellet Inspection," Revision 29, dated June 18, 1986. These procedures were found to be technically correct and complete.
Observations of technicians using these procedures found that the steps of the procedures were properly followed.
No items of nonconformance or unresolved items were identified in this area.
- 12. Qualification of Chemistry Technicians The NRC inspectors reviewed Procedure Number QC-14-20. " General Procedure for Analytical Chemistry Technicians," Revision 2, dated June 24, 1986, and observed the performance of personnel who had been qualified to this procedure. Technicians at CE are selected on the basis of passing examinations utilizing the skills required for effectively performing the operations affecting accurate chemical analyses of samples submitted to the analytical laboratory. The NRC inspectors determined that the Technicians were well qualified to perform the analyses that were observed. The Technicians adhered rigidly to the steps of procedures that were utilized.
No items of nonconformance or unresolved items were identified in this area.
F. PERSONS CONTACTED:
- G. Chalder E. Chan
- P. Ferwerda B. Sharp
- W. Graves A. Mistos H. Nelson R. Davis '
I. Rickard D. Byerly S. Hanson I. Corser P. Nelson F. Magnan l
- Attended exit meeting.
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