ML20211B727
ML20211B727 | |
Person / Time | |
---|---|
Issue date: | 02/03/1987 |
From: | Cilimberg R, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
To: | |
Shared Package | |
ML20211B611 | List: |
References | |
REF-QA-99900003 NUDOCS 8702190525 | |
Download: ML20211B727 (16) | |
Text
ORGANIZATION: GENERAL ELECTRIC CCMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION INSPECTION NO.: 99900003/86-01 DATES: 12/08-12/86 OH-SITE HOURS: 58 CORRESPONDENCE ADDRESS: General Electric Company Nuclear Fuel and Components Manufacturing Facility ATTN: Mr. E. A. Lees, General Manager Post Office Box 780 i
Wilmington, North Carolina ORGANIZATIONAL CONTACT: Mr. J. W. Currier, Jr.
TELEPHONE NUMBER: (919) 343-5874 NUCLEAR INDUSTRY ACTIVITY: Nuclear fuel assembly and BWR core hardware supplier for GE designed reactors and fuel pellet fabrication for Babcock and Wilcox (B&W) fuel assemblies.
n n ASSIGNED INSPECTOR: . op A9 f7 Date R.'t. Cilimberg, Kecial Projects Inspection Section (SPIS)
OTHER INSPECTOR (S): P. J. Prescott, SPIS D. J. Lynn, Consultant B. J. Mincher, C nsultant APPROVED BY: -
- [5/f7 Da'te ohn VI. Craig, Chief, SPIS, Vendor Program Branch INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR 50, Appendix B and 10 CFR 21.
B. SCOPE: Review fuel assembly fabrication and testing activities.
follow-up on previous inspection findings and fuel problems reported l
at LaSalle Unit 2.
PLANT SITE APPLICABILITY: BWR facilities with fuel supplied by GE and B&W facilities with fuel pellets supplied by GE.
I G70P19052D 070206
, PDR GA99Y ENVGENE 99900003 P!1R
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION N0.: 99900003/86-01 RESULTS: PAGE 2 of 12 A. VIOLATIONS:
None.
B. NONCONFORMANCES:
None.
C. UNRESOLVED ITEMS:
None.
D. STATUS OF PREVIOUS INSPECTION FINDINGS:
- 1. (Closed) Ncnconformance (84-01-01): Contrary to Criterion V of 10 CFR 50, Appendix B, and GE Quality Control Operator Requirements (QCOR) 14.1.4, complete tubeshell corrosien improvement heat treat analog tenperature recordings (strip charts) are not being obtained for all tubeshells.
The NRC inspectors determined that strip charts were being obtained during this inspection. Additionally, Operator Parameter Sheet (0PS) 4.8.176.1, "Tubeshell Heat Treat," Revision 7, dated May 19, 1986, requires the operator to insure that sufficient chart paper is available prior to heat treating by checking the indication mark on the chart paper. This item is considered closed.
- 2. (Closed) Nonconformance (85-01-01):
Contrary to Section 10. " Inspection," and Section 12, " Control of Measuring and Test Equipment," of NED011209-04A, Revision 4, dated December 31, 1982, and GE SCP No. 208, Revision 3, dated May 24, 1983, analyses conducted during the time period October 12, 1984, to November 1, 1984, were not conducted in accordance with established procedures in that wet iron test results were calculated using outdated calibration values. (85-01-01)
The NRC inspectors determined that the analyses for wet iron are being conducted in accordance with established procedures using current calibration values. The current procedure is Chemical Metallurgical and Spectrochemical (CMS) 1.2.9.4, " Determination of Iron in Uranium 0xide and Uranyl Nitrate Solutions," Revision 5,
~
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION N0.: 99900003/86-01 RESULTS: PAGE 3 of 12 dated September 25, 1986. Step 7.3 of CMS 1.2.9.4 indicates that calibration values are defined in Station Control Plan (SCP) 202,
" Wet Iron," Revision 8, dated December 2, 1986. Step 5.0 of SCP 202, Revision 8 defines the calibration values which are being used. This item is considered closed.
- 3. (Closed) Nonconformance (85-01-02):
Contrary to Section 12, " Control of Measuring and Test Equ.ipment,"
of NEDO 11209-04A, Revision 5, dated March 1, 1985, items of measuring and test equipment are not suitably, nor uniquely identified to provide traceability to calibration test data in that both Beckman instruments in the' Chemet laboratory were labeled 2.01, and all wet iron test results entered in the computerized data system were identified as having been performed using instrument 201.
The NRC inspectors determined that only one instrument, a Beckman model 0V-5 is presently used in the Chemet laboratory and this instrument is labeled 202. Current wet iron test results in the computerized data system are identified as having been obtained using the instrument labeled 202. This item is censidered closed.
4 (Closed) Nonconformance (85-01-03):
Contrary to Section 12 " Control of Measuring and Testing Equipment,"
NE00-11209-04A, Revision 5, and GE SCP No. 202, " Wet Iron," Revision 5, dated May 3, 1984, the calibration curves centained in the yellow work station book for the Beckman instrunent were dated January 7, 1981, based upon calibration tests performed using a Peckman Model 25 instrument. The Beckman instruments currently used in the Chemet laboratory are both model DU-5.
The Beckman model 25 instrument is not being used. One Beckman model 00-5 labeled 202 is the only spectrophotometer used in the Chemet laboratcry. The current calibration value in the yellow work station book for the Beckman model DU-5 has an expiration date of October 1, 1987. This item is considered closed.
- 5. (Closed) Nonconformance (85-01-04):
Contrary to Section 10, "Irspection," NE00-11209-04A, Revision 5, procedures for examinations and measurements were not adequately defined, in that, GE Analytical Test Method No. 1.2.9.4, Revision 4, dated July 12,1984, Step 7.7 requires sample vcTumes to be 200 m1,
( .-
- ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION RESULTS: ) AGE 4 of 12 NO.: 99900003/86-01 and COI 203, Revision 1, dated June 3,1985, Step 4.3 contains references to nonexistent steps 4.5.1.2. through 4.5.1.5.
I CMS 1.2.9.4, Revision 5 specifies a sample dilution volume of 100 ml which is the correct volume presently used with the Beckman model 00-5 instrument. Calibration and Operation Instruction (COI) 203, Revision 1, dated June 3, 1985, has been replaced by COI 218,
" Waste Water Analysis for Ammonia," Revision 0, dated November 5, 1985, and COI 219, " Waste Water Analysis for Nitrate," Revision 1, dated August 22, 1986. C01 218 and COI 219 contain the procedural steps which are presently being performed in the Chemet labcratory.
This item is considered closed.
- 6. (Closed) Nonconformance (85-01-05):
Contrary to Section 5, " Instructions, Procedures and Drawings,"
NED0-11209-04A, Revision 5, and Step 7.8 of GE Analytical Test Method No. 1.2.9.4, Revision 4, technicians did not wait 30-45 minutes prior to measuring absorbarce of samples.
A review of CMS 1.2.9.4, Revision 5 determined that the wait time is a minimum of 20 ninutes and a maximum cf 75 minutes before measuring absorbance of samples. The change in the wait time was supported by a study documented in Quality Notice (RN) F-Q-1618,
" Color Stability of Iron-Orthophenanthroline Complex," Revision 0, dated August 9, 1985. QN F-Q-1618 concludes that a minimun wait time cf 20 minutes will ensure the required color development for this analytical method. The technicians were observed to wait at least 20 minutes before measuring absorbance of samples. This item is considered closed.
- 7. (Closed) Nonconformance (85-01-06):
' Contrary to Section 5, " Instructions, Procedures and Drawings,"
NED0-11209-04A, Revision 5, Step 7.7 cf GE Analytical Test Metbed No. 1.2.9.4, Revision 4, and Step 4.3.1.2 of GE COI No. 203, Revision 1, (1) technicians diluted to a 100 ml volume of mix solution instead o# the 200 mi specified, ard (2) technicians did not prepare a 25 mi blank.
A 100 mi volume of mix solution is presently used in eccordance with CMS 1.2.9.4, Revision 5. COI 218, Revision 0, and COI P19, Revision 1, which replace COI 203 do not require that a 25 mi blank be used to determine nitrate or ammonia in wast ( water. This item is considered closed.
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA .
REPORT INSPECTION N0.: 99900003/86-01 RESULTS: PAGE 5 of 12
- 8. (Closed) Nonconformance (85-01-07):
Contrary to Section 5, " Instructions, Procedures and Drawings,"
) NED0-11209-04A, Revision.5, and Section 4.4.E of GE Practices and Procedures No. 30-33, Pevision 6, dated April 22, 1985, Chemet laboratory personnel used white-out on data forms rather than drawing a single line through incorrect data entries.
The Cheret procedures which were reviewed during this inspection contained a statement that white-out nust not be used. The use of white-out was not observed by the NRC inspectors. This item is considered closed.
E. OTHER FINDINGS OR COMMENTS:
- 1. Entrance and Exit Meetings GE Management representatives vere informed of the scope of the inspection during the entrance meeting. The inspection findings and observations were summarized during the exit meeting on December 17, 1986.
- 2. Chemet Laboratory The NRC inspectors reviewed test procedures and results and observed analytical work in The Chemet laboratory to determine GE corrective action on previous ir.spection findings D.2 through D.8 above.
- a. Procedures Analytical work in the Cheret laboratory is presently performed according to the following procedures: CMS 1.2.9.4,
" Determination of Iron in Uranium Oxide and Uranyl Nitrate Solutions," Revision 5, dated September 25, 1986, and Station Control Plan (SCP) 202, " Wet Iron," Revision E, dated December 2, 1986; Calibration and Operation Instruction (C01) 215, " Wet Iron i
Analysis by Chemet Test Operators," Revision 1, dated December 8,
! 1986; CMS 1.2.14.1, " Determination of Nitroger in Zirconium, Zircaloy and Uranium Dioxide with or without Gadolinia Additive,"
Revision 5, dated October 6, 1986; COI 217, "pH Measurement of Process Water," Revision 0, dated October 29, 1985; COI 218,
- " Waste Water Analysis for Arrenia (NP 3 )," Revisior. O, datad Noverber 5, 1985; COI 219, "Vaste Water Analysis fer Nitrate (NO 3 )," Revision 1, dated August 22, 1986;'SCP 225, " Nitrogen, Ammunia, and Nitrate Calibration Curves," Revisior 4, dated l
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ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION NO.: 99900003/86-01 RESULTS: PAGE 6 of 12 August 20, 1986; SCP 208, " Nitrogen in U09 and Zirconium Alloys," Revision 4, dated January 13, 1986; COI 015. " Measure-ment Control Blind Standard Program," Revision 6, dated March 7,1986; COI 027, " Chemet Laboratory Records Completion,"
Revision 0, dated December 18, 1985; and QN F-Q-1618, " Color Stability of the Iron Ortha Phenanthroline Complex,"
Revision 0, dated August 9, 1985.
Revisions have been made to all levels of " vet iron" related procedures. Clarifications concerning color development time, volume of final sample dilution, and the use of a single spectrometer, the Beckman DU-5 labeled 202 have been instituted. No procedural inconsistencies were found. The Beckman model 25 instrument was not referenced in the procedures reviewed.
COI 203, " Waste Water Analysis, Revision 2, dated September 20, 1985, was cancelled by the letter CL-85-257, dated November 18, 1985. COI 203 was replaced by COI 218 and COI 219.
COI 218, Revision 0, provides direction for the completion of the ammonia analysis. Calibration values which support COI 218, Revision 0 cre provided in SCP 225, Revision 4, and expire August 3, 1987.
COI 219, Revision 1, provides direction for the completion of the nitrate analysis. Calibration values which support COI 219, Revision 1 are provided in SCP 225, Revision 4 and expire August 8, 1987.
COI 027, Revision 0 prohibits the use of white-out on laboratory records and the NRC inspectors did not observe the use of white-out during this inspection.
- b. Observation of Analyses The NRC inspectors observed technicians perforring sample analyses utilizing the procedures discussed above. Observations
' are itemized below:
(1) A technician analyzed 13 samples of uranium solutions to determine the iron content according to CMS 1.2.9.4, Revision 5. Standards were analyzed according to SCP 202, Revision 8 and COI 015, Revision 6. The values obtained for the standards were withir the acceptance limits of l
l
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION NO.: 99900003/86-01 RESULTS: PAGE 7 of 12 plus or minus five percent specified in Section 10 of CMS 1.2.9.4, Revision 5. The technician followed the steps of the procedures without deviation. The technician diluted the samples to 100 ml according to step 8.7 and waited the time required by step 8.8 before measuring the absorbance of the solution.
(2) Technicians change pH test buffer solutions weekly as required by section 3.2 of COI 207 and as noted on the worksheet at the pH test station.
(3) No reagent blanks are run and a zero absorbance blank is assumed for analyses according to CMS 1.2.9.4, Revision 5 and CMS 1.2.14.1, Revision 5. A blank reference solution is used when calibratinn values are determined to assure a positively biased error in the analyses.
(4) The calibration values for wet iron analysis will not expire until October 1, 1987, and were determined for the Beckman DU-5 labeled 202 which is the only spectrophotoreter in the Chemet laboratory. The calibration values for nitrogen and ammonia will not expire until August 3, 1987, and August 8, 1987, respectively.
(5) A review of the computer print-out of wet iron analytical test results determined that the calibration values discussed in (4) above were used to obtain thnse results.
- c. Training The NRC inspectors reviewed the training requirements for technicians in t'u Chemet Laboratory. These requirements are specified in Quality Assurance Section Administrative Routine (QASAR) 80.04, " Certification of Chemet Laboratories Test Personnel," Revision 8, dated August 15, 1985. On the job training is the primary training method. The technicians are required to analyze five stendards to qualify on each method. Training certificates are maintained for each technician which includes the analysis that the techniciar is qualified to perform. The training records for three full-time technicians were reviewed to determine that the training requirements had been properly documented. ,
ORGANIZATION: GENERAL ELECTRIC COMPANY WitMINGTON, NORTH CAROLINA REPORT INSPECTION NO.: 99900003/86-01 RESULTS: PAGE 8 of 12
- d. Conclusions Based on the above reviews and observations the NRC inspectors determined that the. technicians are trained and are using calibrated equipment in accordance with written procedures.
Corrective action on previous inspection findings is acceptable as detailed in Section D. above. No items of nonconformance er unresolved items were identified.
- 3. Fuel Rod Manufacture The NRC inspectors reviewed procedures for loading fuel pellets in tubing, outgassing the leaded tubes, and welding the final end plugs on the fuel rods. Each step in the fuel rod manufacturing process was observed by the NRC inspectors to determine that the fuel rods were being manufactured acccrding to the reviewed procedures by cualified operators. Fabrication of fuel rods was performed in accordance with the following procedures: Quality Control Operator Requirements (QCOR) 4.1.5.1, " Fuel Rod Leading-Automatic Rod Loader U0 2
," Revision 8, March 4,1986; Quality Control Inspection Instruction (0CII) 4.2.2.1, " Fuel Rod Loading (UO2 )," Revision 16, dated October 15, 1986; Equipment Operating Instruction (E0I) 40.31,
" Automatic Rod Leader," Revision 3, dated October 28, 1981; E01 40.41, "6 Unit Red Outgassing," Revisien 2, dated October 10, 1983; QCII d.2.4, "U0, Fue' Rod Outgassing," Revision 23, dated March 28, 1985; OCOR 4.1.4, " Fuel Rod Outgassing (U0 2 ), Revision 23, March 18, 1986; E0I 40.52, " Duplex Welder," Revision 0, dated October 23, 1986; QCOR 4.1.3.1, " Final Welding," Revision 16, dated October 23, 1986; and QCII 4.P.5.1, " Fuel Rod Final Welding," Revision 18, March 4, 1986. No items of nonconformance or unresolved items were identi-fied.
- 4. Fuel Bundle Assembly The NRC inspectors reviewed the Fuel Bundle Matrix sheet for bundle serial number LYG757 which documerts the manufacture of one bundle in Reload 1 for Limerick Unit 1. The matrix sheet identifies all componerts for each bundle and designates the rod identifications for each rod in the bundle. Drawing numbers are identified for each component in the fuel bundle along with the lot numbers, serial numbers, and renarks which apply. Inspection and operation steps are recorded on the metrix sheet with the number of the operator who performed the step and the date perforned. The computer selects the proper rod'for insertion in the tundle in accordance with the matrix sheet.
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION RESULTS: PAGE 9 of 12 N0.: 99900003/86-01 The NRC inspectors observed each step in the assembly of a fuel bundle to assure that the process was performed according to written procedures by qualified operators. Assembly of bundle serial number LYG764 for. Limerick Unit 1 was performed in accordance with the following procedures: E01 50.30, " Bundle Assembly-ABAM,"
Revision 5, dated June 18, 1986; QCOR 5.1.6.1, " Fuel Bundle Assembly-ABAM," Revision 2, March 4,1986; E0150.50, " Fuel Bundle Assembly-Secure Upper Tire Plate," Revision 4, dated January 25, 1978; QCOR 5.1.8, " Fuel Bundle Assembly-Set Upper Tie Plate," Revision 12, January 15, 1986. No items of nonconformance or unresolved items were identified.
- 5. Nondestructive Testing (NOT)
The NRC inspectors reviewed GE procedures for ultrasonic testing (UT),
radiographic testing (RT), helium leek testing (LT), gamna scan and the NDT certification program for the NDT of fuel rods.
The procedures were technically correct and complete. The procedures had also been properly reviewed and contained the required signature approval. The NRC inspectors observed cperators performing NDT utilizirg these procedures. Observations of NDT, RT film review, and review of the NDT certification program are itenized below:
- a. Ultrasonic inspection of barrier tubing ir Lot 6183-07 for fuel rod cladding was performed according to Quality Information Equipment Plan (QIEP) A-20.5, "UT Inspection of Zirconium Tubing Using the Rohrer II Automated System,"
Revision 4, dated December 17,1985; QCII 16.6.8, " Barrier Fuel Tube-UT Dimensional," Revision 2, dated March 25, 1985; and QCII 16.6.9 " Barrier Fuel Tube-UT Flaw," Revision 2, dated January 15, 1985. The steps of the procedures were properly followed and the results were documented.
- b. Radiographic inspection of final end plug welds on fuel rods f was performed according to QIEP B-30.1, " Fuel Rod and Water Rod l
Radiography," Revision 18, dated March 10, 1986. The review of 48 film was performed according to QCII 4.2.13, " Radiographic Interpretation," Revision 1, dated March 16, 1984. The steps of the procedures were properly followed.
- c. During the above film review, the NRC inspectors noted that an optical instrument which is used to measure indications on the film should have traceability to the' National Bureau i
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION NO.: 99900003/86-01 RESULTS: PAGE 10 of 12 of Standards (NBS). A certificate of traceability was not available in GE files, but the vendor was contacted and the certificate was put in the GE files before the NRC exit meeting on Decenber.12, 1986.
- d. The NRC inspectors observed garma scanning. The testing included calibration using approved standards, scanning of in-process fuel rods and docunentation of test results.
Operations were performed according to QCII 9.2.2, "U0, Fuel Rod Scanning-Active Scanner," Revision 27, dated November 24, 1986. The steps of the procedure were properly followed.
- e. Leak testing of bundle number LYG-762 for Limerick Unit I was performed according to QCII 5.2.7, " Fuel Rod / Bundle Leak Check,"
Revision 27, dated August 23, 1984 and QIEP B-10.1, " Bundle Leak Inspection," Revision 11, dated March 7, 1985. The steps of the procedures were properly followed and the results were properly documented.
- f. The training and qualification records of five rondestructive test personnel were reviewed to determine whether their training, testing, and certification met the requirenents of Practices and Procedures (P/P) 70-32 " Qualification of QC Inspection, Exanination, and Test Persornel," Revision 10, dated January 24, 1985. Documentation describing examinations and record of training was complete and net the applicable requirenents.
No items of nonconformance or unresolved items were identified.
- 6. Fuel Problems at LaSalle Unit 2
! During January, 1986, LaSalle Unit 2 exhibited an increase in
! pretreatment noble gas activity (Xenon and Krypton) from ar average of 0.2 E-2 microcuries per second to 0.4 E-2 microcuries per second. The reactor continues to operate with this activity which is below the technical specification limit of 3.4 E-5 nicrocuries per second. GE will investigate the cause of the increased activity after sipping the fuel to determine leaking fuel rods during the refueling which is planned for January,1987.
I
/
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ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION NO.: 99900003/86-01 RESULTS: PAGE 11 of 12
- 7. Pellet Fabrication
- a. Powder Dumping and Rotory Pressing y
The NRC inspectors reviewed OCOR 3.1.0.1, " Powder Dumping,"
Revision 3, dated July 10, 1981 and QCOR 3.1.1, " Pellet Pressing," Revision 27, dated March 18, 1985. The steps of both procedures were properly implemented during the powder dumping process and rotory pellet pressing for U0p mixture No.
3951AP5603, at station 4B.
- b. Pellet Sinterino and Density Inspection (1) Procedure Review:
Tlia NRC inspectors reviewed QCOR 3.1.3.1, " Pellet Sintering," Revision 20, dated November 1, 1985, 0011 3.22, " Pellet Sampling / Release," Revision 23, dated September 4, 1986 and QCII 3.2.4, " Sintering Inspecticn/
Density Check," Revision 18, dated October 21, 1985. The procedures were complete and had been properly reviewed and contained the renuired signature approval.
(2) Observation of Operatinn The NRC inspectors observed the sintering process, selection of fuel pellets for pellet density inspection, and observed the GE inspector performine the ganna densitometer inspection. The steps of the 3 procedures were being properly implemented during the sinterirg process, pellet sanpling, and gamma densitometer inspection.
- c. Pellet Grinding The NRC inspectors reviewed QCII 3.2.3.1, " Pellet Grinding,"
Revision 20, dated May 19, 1986, for checking the pellet integrity and diameter of the pellets after grinding. The procedure describes the test prept. ration and setup, and estab-lishes criteria for identifying pellets with integrity and dieneters which are outside the allowable limits.
l
ORGANIZATION: GENERAL ELECTRIC COMPANY WILMINGTON, NORTH CAROLINA REPORT INSPECTION NO.: 99900003/86-01 RESULTS: PAGE 12 of 12
- d. GE Inspector Certifications The NRC inspectors reviewed the certifications for the GE 3 inspectors who were. observed performing the pellet grinding inspection and the gamma densitometer inspection. The certifications reviewed for the GE inspectors were found to be current and ret the requirements of P/P 70-32, Revision 10, dated January 24, 1985.
No items of nonconfornance or unresolved items were identified.
F. PERSONS CONTACTED:
- W. Baker *J. Lieberman
- T. Brechtlein *W. McClanahan S. Chinnis *W. McMahon J. Currier R. Pearson G. Fennell *D. Pensinger H. Fields A. Schaefer P. Hasson *L. Sheely W. Ivey *C. Vaughan P. Jasinski
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