ML20210V143
| ML20210V143 | |
| Person / Time | |
|---|---|
| Issue date: | 10/07/1986 |
| From: | Abbate C, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20210V134 | List: |
| References | |
| REF-QA-99900005 NUDOCS 8610100547 | |
| Download: ML20210V143 (13) | |
Text
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ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION INSPECTION N0.: 99900005/86-01 DATE: 8/18-20/86 ON-SITE HOURS: 62 CORRESPONDENCE ADDRESS: Westinghouse Electric Corporation Nuclear Fuel Division ATTN: Dr. Richard Slember General Manager Post Office Box 355 Pittsburgh, Pennsylvania 15230 ORGANIZATIONAI. CONTACT: Ron Cost TELEPHONE NUMBER:
(412) 374-2359 NUCLEAR INDUSTRY ACTIVITY: Nuclear fuel tubing supplier for Westinghouse.
O i
ASSIGNED INSPECTOR:
L
.L ft I
7 &[o f (M. Abbate, Special Projec q Ins Wction Section t
,SPIS) d OTHER INSPECTOR
- 5) :
P. J. Prescott, SPIS D.
. L nn, S,, Consultant h@fo APPROVED BY:
(fahnW.Craig, Chief,SPIS,VqorProgramBranch Uate L
INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21, 10 CFR Part 50.
B.
SCOPE: Observe fuel tube manufacturing activities, review ultrasonic testing (UT) activities, review QA program implementation and follow-up Westinghouse corrective action on previous NRC inspection fir. dings.
PLANT SITE APPLICABILITY: Nuclear power facilities using Westinghouse fuel.
0610100S47 861000 OA999 Et1VWEST PDR PDR 9990000S
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION NO.: 99900005/86-01 RESULTS:
PAGE of 9 A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
1.
Contrary to Section 17.1.2 of WCAP-8370/7800, Revision 10A/6A, dated August 1984 and Section 6.12 of Specialty Metals Plant (SMP) Product Assurance Department Administrative Procedure PA-003, Revision C, the standard used in ultrasonic testing (UT) to validate tube ovality is not serialized and maintained under the equipment calibration control system nor are the dimensions of the standard traceable to National Bureau of Standards (NBS) instrumentation.
2.
Contrary to Section 17.1.5 of WCAP-8370/7800, Revision 10A/6A, dated August 1984 and Manufacturing Orders (MO) 200 and 206, both dated February 25, 1986, the data fr>r vertical linearity, horizontal linearity and calibrated attenuation was not recorded on the cali-bration data reports, dated February 24, 1986 and March 27, 1986, for two UT flow detectors (serial numbers 33 and 40).
3.
Contrary to Section 17.1.6 of WCAP 2370/7800, Revision 10A/6A, dated August 1984, procedures QS-231,05-249, QS-261, and QS-262 were not revised when QS-118 was superseded by PA-103.
C.
UNRESOLVED ITEMS:
Paragraph 4.5.3 of Material Specification NFD 31008, " Seamless Zircaloy -
4 Tubing," Revision 28, dated May 16, 1986, requires, in part, that tube ovality not aceed 0.0013-inch Total Indicator Reading (TIR).
Paragraph 6.4 of Procedure QC-301, " Final Inspection-Ultrasonic Dimensional Setup and Calibration," Revision J, outlines the method used to certify that this dimensional requirement is met. While QC-301 is accurate, it is unclear whether the actual requirement of TIR is being met. This item is discussed below in Section E.2.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Nanconformance (82-02, Item B.1)
Contrary to Section 5 of the Topical Report and Material Specification NFD 31008, paragraph 3.3.1 and Table I, there was no evidence of the submittal to and approval by the purchaser of the procedures for the outside surface finish process, chemical composition testing, and tensile testing.
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION N0.: 99900005/86-01 RESULTS:
PAGE 3 of 9 During the inspection, Material Specification NFD 31008, " Seamless Zircaloy-4 Tubing," Revision 28, dated May 16, 1986 and the list of approved documents were reviewed. The inspector verified that the purchaser had reviewed and approved the procedures for the outside surface finish process, inside surface finish process, chemical composition testing and tensile testing. This item is considered closed.
2.
(Closed) Nonconformance (82-02, Item B.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 Specification NFD 31008 listed on the QCF-3003 form in reference to Order No.
548H20313.
During this inspection, form QCF-3003s, " Customer and SMP Inspection Requirements Fuel & WABA Type Tubing Lots," for ten months were reviewed to verify that the correct revision of Specification NFD 31008 was specified. Based upon the documents reviewed, this item is considered closed.
3.
(Closed) Nonconformance (82-02, Item B.3)
Contrary to Section 5 of the Topical Report and Specification NFD 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 reworked 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.
During this inspection, the accountability (traceability) system implemented by the SMP was reviewed. The ingot and lot numbers are recorded on the follow sheets (travelers) at the beginning of the fabrication ; rocess. The lot numbers are also etched on the end of each tube and are maintained there until the tube is cut to length.
From that point on, accountability is maintained solely by the follow sheet.
If a tube has to be reworked, a separate follow sheet is
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION N0.: 99900005/86-01 RESULTS:
PAGE 4 of 9 generated from the original by a computer. As a final accountability check, the total number of tubes in a lot which are ultrasonically tested must equal the sum of the tubes from that lot which are boxed and the tubes from that lot which were scrapped. These numbers are recorded on form QCF-3004-2, " Lot Piece Accountability Log Sheet," and form QCF-3005-1, " Scrap Accountability Log Sheet."
If all the tubes are accounted for the lot is released.
During the inspection the inspector noted that the tubes,' including rework tubes, were being properly identified with follow sheets and the etched lot numbers were maintained on the tubes and accounta-bility was maintained. Based upon these observations and reviews, this item is considered closed.
4.
(Closed) Nonconformance (82-02, Item B.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.
During this inspection, the inspector reviewed Procedure QC-318, "Dispositioning of Fuel and WABA Tubing After UT Dimensional and Flaw Inspection," Revision F, dated August 15, 1986, which outlines the use of T tags, and observed the implementation of the procedure and T tags on the shop floor.
Based on the review and observation, this item is considered closed.
5.
(Closed) Nonconformance (82-02, Item B.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.
During this inspection Procedure BI-108, " Corrective Action System,"
Revision A, dated February 20, 1986, was reviewed. The procedure requires form BI-1080, "Above Normal Reject / Scrap Investigation,"
to be filled out when an above normal reject rate is observed by an operator. This form then goes to the Quality Engineer for dispositioning and the Process Engineer who determines the cause of the problem. The inspector reviewed several instances where the procedure was followed and form BIF-1080 was used by the operators.
This item is considered closed.
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA 1
REPORT INSPECTION NO.: 99900005/86-01 RESULTS:
PAGE 5 of 9 E.
INSPECTION FINDINGS AND OTHER COMMENTS:
1.
Entrance and Exit Meetings An entrance meeting was conducted on August 18, 1986 at the Westinghouse Specialty Metals Plant (SMP) located in Blairsville, Pennsylvania. The purpose and scope of the inspection were discussed at that time. The SMP Quality Assurance (QA) program is outlined in Topical Repcrt WCAP 8370/7800, " Westinghouse Water Reactor Divisions Quality Assurance Plan," Revision 10A/6A, dated August 1984. The topical report, which was reviewed and approved by the NRC, describes the QA program of the Westinghouse Corporation.
During the exit meeting on August 20, 1986, the inspection findings and observations were summarized.
2.
Ultrasonic Testing Areas examined during the inspection pertaining to the ultrasonic testing (UT) of tubes included equipment calibration, training and qualification of personnel, procedures and observation of tes ting.
A verification of calibration and certification of UT equipment was conducted on seven pieces of equipment, including standards used for calibration. During this review, it was noted that the standard used to validate tube ovality was not serialized and maintained in the equipment calibration control system nor were the dimensions of the standard confirmed to any known NBS traceable instrument.
It was also noted that the data for vertical linearity, horizontal linearity, and calibrated attenuation was not recorded on the calibration data reports, dated February 24, 1986 and March 27, 1986, for two UT flow detectors (serial numbers 33 and 40).
f Nonconformance Items 86-01-01 and 86-01-02 were identified in this l
area.
Training and qualification records for three operators and two supervisors were examined.
In the instances reviewed, the training, testing, qualifications and maintenance of qualifications met the requirements outlined in ASNT SNT-TC-1A, " Training and Qualification of Nondestructive Test Personnel."
i 1
l
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION J
NO.: 99900005/86-01 RESULTS:
PAGE 6 of 9 The inspector also observed a UT operator calibrating the equipment and performing UT on tubes in lot no. P41-8726. This was accomplished by using Procedure QC-301, " Final Inspection - Ultrasonic Dimensional Setup and Calibration," Revision J, and Procedure QC-320, " Final Inspection - Operation of Ultrasonic Tester," Revision F.
The inspector found that the operator followed these procedures and had a good working knowledge of the procedures and equipment being used.
Paragraph 4.5.3 of NFD 31008, " Seamless Zircaloy-4 Tubing,'" Revision 28, dated May 16, 1986, requires, in part, that ovality not exceed 0.0013-inch Total Indicator Reading (TIR). The setup to determine tube ovality by UT is outlined in Procedure QC-301 and is conducted in the following manner: A tube sample of the same size and material composition (referred to as a dynamic reference standard) is squeezed in a vice and measured with the aid of a laser micro-meter to determine true ovality. The dynamic reference standard is then run on the UT machine -at predetermined speeds to obtain the UT ovality reading. The two readings are then compared to assure the UT equipment is performing accurately.
Technically, this procedure as used to verify tube ovality is accurate.
However, it is unclear whether the actual requirement of TIR is being met since TIR implies that the reading is taken in one plane, 360 around the circumference rather than obtaining an average as done in QC-301. An average is obtained due to the fact that the tube is moving as the reading is being taken instead of being stationary.
Unresolved Item 86-01-01 was identified in this area.
3.
Procurement The NRC inspector examined several procurement records to determine whether the Westinghouse procedures and their implementation met the requirements of 10 CFR 21 and the. applicable quality requirements as specified on the Westinghouse purchase order form 200. These require-ments are imposed on the subvendors supplying Westinghouse with the raw material used in the manufacturing process. A selective sample of purchase orders and Certificates of Compliance for the raw material procured from subvendors by Westinghouse were examined.
These documents were in compliance with the requirements of 10 CFR Part 21 and quality requirements. The subvendors used for these purchases appeared on the latest revision of the approved vendors list.
Required documentation was in place and the Westinghouse QA procedures for the use of such documentation had been impimented as required.
)
i ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSFECTION N0.: 99900005/86-01 RESULTS:
PAGE 7 of 9 4.
Equipment Calibration Procedures QC-600, " Gage Control System," Revision F, dated June 20, 1986, QC-601, " Calibrations-Micrometer," Revision C, dated January 6, 1986, and associated calibration records for the equipment utilized during the in-process inspection of the material being manufactured at the SMP were examined by the NRC inspector.
The calibration records examined were found to be current and in compliance with QC-600. The associated logs and files were also found to be accurate and in ccmpliance with the applicable quality control procedures.
5.
Material Rejection Notice The NRC inspector reviewed Material Rejection Notice (MRN) No.
348244, for compliance with WCAP-8370/7800 and Purchasing Department Procedure PD-251, " Purchasing of Controlled Materials and Services," dated April 2, 1986. The MRN is a form used by Westinghouse to document discrepancies noted upon the receipt of raw material supplied by subvendors. The form includes a description of the discrepancy noted and a disposition which requires a review by the Westinghouse Engineering Department.
During the review of MRN No. 348244 by the NRC inspector, it was noted that on May 15, 1986 a subvendor (Western Zirconium) shipped defective raw material, unknowingly, to Westinghouse who received the material, along with material certifications, on May 19, 1986.
Westinghouse did not generate MRN No. 348244 until they were notified of the defective material by Western Zirconium on May 23, 1986.
In an interview with a Westinghouse Quality Engineer, it was stated that Western Zirconium could not have notified Westinghouse prior to the shipment because the actual material qualification documentation had not been completed by the subvendor. Other MRN's reviewed during the inspection by the NRC inspector were found to be in compliance with the applicable procedures and no nonconformances or violations were
~
noted.
6.
Manufacturing Activities A sample of Process Engineering (PE) procedures which define fabrica-tion activities were reviewed including:
PE-202, "Zircaloy - ID Blasting," Rev. K, April 25, 1986; PE-208, "Zircaloy - S:C Grit Blasting," Rev. D, April 25, 1986;
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION N0.:
99900005/86-01 RESULTS:
PAGE 8 of 9 PE-216, "Zircaloy Stress Relief Annealing of Final Size Zirc-4 Tubing," Rev. D July 7, 1986; PE-218, "Zircaloy-Vacuum Annealing," Rev. I, June 11, 1986; and PE-250, "Zircaloy-Swaging Thimble Tube," Rev. H, July 9, 1985.
Following this review, activities controlled by the procedures were observed and the procedures were discussed with personnel at their work stations. Plant personnel were knowledgeable and demonstrated a good working knowledge of PE's.
Work areas were clean and proce-dures at the work stations were complete and current.
A sample of Quality Services Standard Operating Procedures (QS) which control testing in the laboratory were reviewed including:
QS-2310 " Determination of Dimensions on Non-Destructive Test Standards," June 18, 1984; QS-261C, " Chloride Ion Determination By Solid State Electrode Method," June 13, 1984; QS-2498, " Determination of ASTM Grain Size of Inconel 600 Final Size Tubing," June 28, 1984; and QS-262A, " Room Temperature Bend Testing of Inconel and Titanium Tubing on Satec Tester," June 8, 1984.
Each of these procedures contained a reference to a procedure which had been deleted, QS-118.
QS-118 had been replaced by Product Administrative Procedure PA-103, " Quality Services Laboratory Sample and Data Handling," Rev. B, May 5, 1986.
PA-103 was initially issted on July 7, 1985.
These procedures were being reviewed for deletion at the time of the inspection and were deleted prior to the conclusion of the inspection.
Additionally, QS-503, " Determination of Hydride Orientation of Tubing," August 13, 1986 was reviewed and discussed with laboratory personnel. The laboratory personnel observed while preparing samples for analysis were knowledgeable ans nroficient.
Nonconformance Item 86-01-03 was identified in this area.
l
ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION NO.: 99900005/86-01 RESULTS:
PAGE 9 of 9 F.
PERSONS CONTACTED:
- G. S. Pail, Manager, Product Assurance
- R. Carmody, Manager, Manufacturing
- J. B. Narayan, Fellow Engineer, Product Assurance
- W. A. Long, Lead-Supervisor of Audit
- R. Cost, Manager, Quality Assurance, Nuclear Fuel Division
- J. E. Czesnakowski, Manager, Process Engineering
- R. D. Petrosky, Manager, Programs and Document Control
- G. A. Ruby, Quality Assurance Engineer
- G. D. Federowicz, Controller
- C. R. Mitchell, Manager, Human Resources
- T. M. Sanders, Manager, Advanced Process Development
- H. B. Werner, Manager, Laboratory
- J. R. Bellas, Unit Manager of Inspection
- J. Yurigan, Laboratory Technician
- L. A. Winter, Quality Engineer
- D. L. Himes, Document Control Coordinator
- M. Nance, Document Control Coordinator
- K. Trosell, Manager, Materials
- R. S. Wengewics, Senior NDE Engineer P. Moore, Senior Technician J. Sabo, Senior Quality Engineer B. Patz, Level I UT Operator R. J. Joschak, Quality Assurance Engineer D. Mazurek, Laboratory Technician J. Wilkinson, Laboratory Technician f
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