ML20211M984

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Partially Withheld Insp Rept 70-1113/86-15 on 860714-18 (Ref 10CFR2.790(d) & 73.21).Violation Noted:Failure to Follow Approved Plant Procedures
ML20211M984
Person / Time
Site: 07001113
Issue date: 07/30/1986
From: Mcalpine E, Son Ninh
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20211M455 List:
References
FOIA-86-704 70-1113-86-15, NUDOCS 8612180099
Download: ML20211M984 (7)
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Report No.: 70-1113/86-15 Licensee: General Electric Company P. O. Box 780 Wilmington, NC 28401 Decket No.: 70-1113 License No.: SNM-1097 Inspection Conduct July J -18, 1986 Inspector: bo

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S. WNinh, Fliel Facilities inspector 7/Jo/ ff, Date Si~gned A; proved by: OW E. J. McAlpine, Chief) Material Control and 7/3o[86 Date Signed Accountability Section, Nuclear Material',

Safety and Safeguards Branch Division of Radiation Safety and Safeguards ,,

SUMMARY

Scope: Areas examined during this routine, unannounced inspection included measurements, training and certification records, physical pre-inventory observation, scales and balances, followup on inspector identified items, and independent inspection efforts.

Results: One violation was identified - Fai bre to follow approved plant procedures. ,

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8612180099 861205 -

PDR FOIA '" -

RATNER 86-704 PDR

REPORT DETAILS

1. Persons Contacted Licensee Employees

'J. E. Bergman, Manager, Fuel Manufacturing

  • W. W. McMahon, Manager, Quality Assurance

'C. M. Vaughan, Manager, Regulatory Compliance

  • T. P. Winslow, Manager, L&NMM
  • B. F. Bentley, Manager, Fuel Production
  • R. G. Patterson, Manager, Fuel Manufacturing Engineering
  • D. L. Pensinger, Manager, Chemet Lab
  • R. J. Mack, Acting Manager, Component Manufacturing "R. M. McIver, Acting Manager, Sites Operations and Materials Systems
  • G. R. Mallett, Senior Engineer, Measurements and Statistics
  • R. L. Bruce, Specialist, NMM Systems
  • P. N. Denison, Specialist, SS Representative
  • R. O. Foleck, Senior Specialist, Ltcensing Engineering
  • B. S. Dunn, Specialist, Licensing Support P. R. Jasinski, Supervisor, Chemet Lab F. A. Schaefer, Senior Engineer, Chemet Lab The inspector also interviewed several other licensee employees.
  • 0enotes those present at the exit interview.
2. Exit Interview ,

The inspection scope and findings were summarized on July 18,1986, wit 5 those persons indicated in paragraph 1 above. The following issues were discussed in detail: One violation concerning failure to follow approved standard operating procedures for calibrating scale and balance equipment

(paragraph 4). The licensee was subsequently informed that the difference l between their measurements and those performed by New Brunswick Laboratory was an unresolved item ** (paragraph 3). The licensee acknowledged the inspection findings and took no exceptions.

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3. Followup on Inspector Identified Problems (92701)

(Closed) IFI (86-07-02) During the subject inspection, it was determined that the frequency of two control standards fallin of warning 200 ppm U and UNH006) fo methods, respectively, was er than normally expeqtydr ng this inspe tion, the NRC inspector examined the control limits for control An Unresolved Item is a matter about which more information is requried to determine whether it is acceptable or may involve a violation or deviation.

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standard UNH006 for period of January 1 - February 27, 1986, and determined that the control measurements were in accordance with the licensee's written procedure for calculating limits using a suf ficient database. No signifi-cant variation occurred during that .

It was also noted that the licensee had discontinued using ethod since June 10, 1986. Therefore, this item is .

(Closed) IFI (86-07-01) Samples taken to verify the acceptance of the licensee's measurements (Table !!!). A review of the data revealed a statistically significant dif ference between New Brunswick Laboratory and the licensee values at the 0.05 level of significance. The licensee was notified by telephone on July 30, 1986 that a significant difference existed. The licensee ag to verify the accuracy of the General Electric values by checking the data presented in Inspection Report No. 70-1113/86-07 agains icensee internal records. This issue is unresolved pending the licensee's accuracy verification and pending further review by NRC (86-15-04).

4 Measurements (85207)

The following analytical procedures used for accountability purposes were examined during this inspection.

Analytical Test Method Procedure No.1.2.15.1, R8, Determination of Uranium and Oxygen-to-Uranium Atomic Ratio in Uranium Dioxide Powders and Pellets, dated June 6,1983.

Analytical Test Method Procedure No.1.2.21.6, RS, Determination of l Uranium By Dichromate Titration, dated August 25, 1982.

s Calibration and Operation Instructiotr Procedure No. 002, R11, Chemet Laboratories Control Charting, dated December 12, 1985. -

Quality Assurance Section Administrative Routine Procedure No. 8004, R8, Certification of Chemet Laboratories Test Personnel, dated August 15, 1985.

Quality Notice Procedure No. F-G-1421, R0, Certification of U0, pellet standard CER003, dated August 13, 1985.

Procedures were determined to be adequate and properly approved by appropriate facility management. Procedures were als ound to be available at work stations. A laboratory operator performin was observed and the inspector noted that procedures were being owe .

Standards for several analytical methods were examined for frequggcy._of use, storage to protect their integrity, and traceability to nationaF-standards.

No deviations from approved procedures were noted.

In order to verify licensee measurements, five 00 2 pellet samples were randomly taken from each of three different enrichment trays. The samples

were fontarded to the new Brunswick Laboratory for analyses of grams uranium

!" 3 per gram and isotopic enrichment on form DOE /NRC-741, transfer series YLJ-CBJ No. 27, dated July 18, 1986. Data for these samples are presented in Table I. The analytical results from these samples will be evaluated and the findings will be furnished to Itcensee. This is an inspector followup item and will be examined during a subsequent inspection (86-15-01).

The training and certification records for eight laboratory o o prepare and anal re sam les for NM content and 0/U ratio using respectively were examined ing this Laboratory operator training emphasized adherence to approved inspection.

l Chemet Laboratory Procedures and on-the-job ach certified laboratory operator was required to analyze standards and demonstrate acceptable results as specified roce ure. In order to

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maintain continued qualification, each ator is required to perform a measurement at least once every Requalifications required similar operator train to th tia tification and were being performed on a basis as required. The inspector determined that the program for ning, initial certification, continued qualification, and recertification was being practiced, documented, and maintained in I accordance with the approved plant procedures and the licensee's FNMC Plan.

The licensee's program for monitoring and controlling the performance of standard measurements for analytical methods used for accountability purposes was examined during this inspection. The analytical r ur and U-235 have warni ont mits d ach mea limits that are re-eva uated at least o'r each measurement system, the numb measurements falling outsi warning limits, the number of measurements falling outside of control l}jnits, and the total number of measurements performed during the periolds examined are presented in .

Table II. The inspector selected several measurements noted to be outside the 0.05 significant level and determined that they had been investigated and acceptable corrective actions had been taken as required. These investigations were properly documented.

The frequency of control measuremen 111ng outside of warning limits at the .05 significance level for the ontrol standard was noted to be ly lower than normally expected while control standard, was noted to be predominant hi her than normally expected.

rol standard re used for This is an nsp p em )

and will be examined d ng a subsequent inspection. Following a review of control data, the inspector concluded that the licensee's control limits at the 99% significance level were correctly stated.

Calibration requirements for accountability scales were examined'during this inspection. Paragraph 4.1.5.3 of Quality Information Equipment Plan (QIEP) procedure entitled Scales and Balances, No. B-40.1, Revision 8, requires the licensee to maintain calibration data on each scale. Paragraph 8.1.1 of this QIEP procedure also required the licensee to calibrate accountability

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l 'e scale The inspector determined that on June 1 , ontrol and ru' mentation Support (C&IS) group had initiated and implemented changes to paragraph 4.3.4 of Practices and Procedures (P/P) entitled Scales and Balances Program, P/P 70-25, Revision to require that C&IS calibrate accountability scales and balances The including tne hed between and This procedural change had no een reviewed and approved by responsible cility managers prior to implementation as required. The NRC inspector observed th ale I ta indica ed on th being the ca ibration expiration was indic ed as i

e. s stated voove,~this violation was caused by the premature implementation of a procedure which had not been approved by management (86-15-03).
5. Pre-Inventory Observation (85211)

On 986, the licensee scheduled thet he scensee used their facturing Information C er CS) inventory listing to Each fuel rod cabinet was denti ted by a MICS accountability station ar each abinet was identified by location. A inventory te uring t is inspection, t r attende a or inventory teams and to the extent observed, the licensee was determined to be following approved pre-inventory instructions.

4 No violations or deviations were detected." .

6. Independent Inspection Effort (92713) i A tour of the manufacturing process areas was conducted during this inspection. Observations and examinations of procedural requirements in the l areas of physical inventory preparations and nuclear criticality safety were emphasized during the tour.

No violations or deviatiord were detected.

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I TA8LE I NRC SANFLES i

1 Semote 10 Container ID Tare Wt.

' Cross WL. Net WL, MomJnet_[nr.iqu9ent i 796101 3227 QZ 7045 3.9172 ~~

796102 11.4548 7.5376 3227 QZ 7068 3.8642 11.4126 7.5484 796103 3227 QZ 7056 3.9553 796104 11.7387 7.78?9 3227 QZ 7074 3.9384 11.4147 7.4163 ,

796105 3227 QZ 7117 3.8608 11.6101 796106 .3004 ZE 2606 7.7493 1

796107 3.8450 13.0341 9.1897 1 2004 ZE 2586 3.8500 13.0846 9.7346 796108 2004 ZE 2622 3.7902 I

796109 2004 ZE 2647 1?.9398 9.1496 i l 3.8053 13.3197 9.5144 796110 2804 ZE 258 7 i

796111 3.7915 13.1370 9.339*,

3954 ZL 5597 3.8475 13.0131 9.1656 796112 3954 ZL 5596 3.8123 796113 13.6641 9.8518  !

3954 ZL 5595 3.8291 12.9147 i

796114 3954 ZL 5619 3.8679 9.0856 1 795115 3954 ZL 5594 13.4169 9.5490 3.8024 14.3853 10.5829 TABLE il i

CONTROL CHART DATA

  • tt-0.05 Control 0.001 Cont rol Number of Mea su rement Limit Exceeded W

Method _ Standa rd Limit Exceeded Standards Numbe rl Pe rcen t Numbe rl Pe rcent t9en gu red 7,i_ag_Pe r,e_od_

UNH006 0 0 0 0 CR003 1 0 0 0 Prod Isotopic RIP 003 4 17 0 0 Prod Isotopic RI P009 0 0 0 0 ICP 10X 0 0 0 0 8t TMI %) N8L-Stend 6 17 0 0

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l TABLE III EVAtuAftog OF C[NERAL ELEC1RIC MEASUREMENT PERFORMANCE Uranium Assay GE CE NBL NBL

10. Craviestry Cravinetry Titrimetry Di rre rence Of f rerence Dirrerence 1 2 3 4 2-3 2-4 3-4 9MP0329 87.83 87.73 87.71 0.10 0.17 0.02 9MP2028 87.70 AF.69 81.725 0.01 -0.025 -0.035 9MP2136 87.76 87.69 81.70 -0.01 0.06 -0.01 9MP1740 87.68 81.60 87.60 0.08 0.08 0 9MP1809 87.80 87.72 87.7T 0.08 0.03 -0.05 9MP1944 87.76 87.66 87.65 0.10 0.11 0.01 9MP2247 87.76 87.64 87.64 0.12 0.08 0 DML2143 87.70 87.61 87.62 0.09 0.08 -0.01 OHL2315 87.69 87.59 87.60 0.10 0.09 -0.01 ONL4862 87.73 87.64 87.665 0.09 0.065 -0.025 OML2482 87.76 87.67 87.675 0.09 0.085 -0.005 OML2549 87.77 .. 87.66 87.71 0.11 0.05 -0.05 OML2557 87.77 87.66 87.695 0.11 0.015 -0.035 Ave rage 87.747 87.658 87.674 0.017 0.073 -0.015 Standa rd 0.0447 0.0431 0.0509 0.0518 0.0443 Deviation 0.0220 Enrichment Assay CE ID. N8L Nr5 Dirrorence 1 ft 2 J_ 2-3 9M P0379 .0047 9MP2028 .0024 9MP2136 0017 9MP1740 .0101 9MP1809 .0038 i

' 9MP1944 .0089 9MP2247 .0182 OML2143 .0191 OML2315 .0144 OML4862 .0344 OML2482 .0117

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OML2549 .0042 '

OML2557 .0026

'k 1.3 Ave rage .0033 Standard .01064

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\.7.'..#' AUG 0 61986 Docket No. 70-1113 License No. SNM-1097 General Electric Company ATTN: Mr. Eugene A. Lees, General Manager Nuclear Fuel and Component Manufacturing P. O. Box 780 Wilmington, NC 28402 Gentlemen:

SUIMECT: NOTICE OF VIOLATION (NRC INSPECTION REPORT NO. 70-1113/86-16)

This refers to the Nuclear Regulatory Commission (NRC) inspection conducted by D. W. Jones on July 21-25, 1986. The inspection included a review of activities authorized for your Wilmington facility. At the conclusion of the inspection, the findings were discussed with those members of your staff identified in the enclosed inspection report.

Areas examined during the inspection are identified in the report. Within these areas, the inspection consisted of selective examinations of procedures and representative records, interviews with perFonnel, and observation of activities in progress.

The inspection findings indicate that certain activities appeared to violate NRC requirements. The violation, references to pertinent requirements, and elements to be included in your response are described in the enclosed Notice of Violation.

The enclosed Inspection Report documents an oral commitment (see page 2) made by a licensee representative and discussed in the exit interview. If your understanding of this commitment differs from the report statements, please inform this office promptly.

In accordance with 10 CFR 2.790(d) and 10 CFR 73.21, safeguards activities and security measures are exempt from public disclosure; therefore, the enclosures to this letter, with the exception of the report cover page which presents a nonexempt summary, will not be placed in the NRC Public Document Room.

The responses directed by this letter and its enclosures are not subject to the clearance procedures of the Office of Management and Budget as required by the Paperwork Reduction Act of 1980, PL 96-511.

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General Electric Company 2 AUG 0 61986

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Should you have any questions concerning this letter, please contact us.

Sincerely,

.' hilip ohr, Director Division of Radiation Safety and Safeguards

Enclosures:

1

1. Notice of Violation (Exempt from Disclosure)
2. NRC Inspection Report (Exempt from Disclosure) cc w/encis:

T. Preston Winslow, Manager Licensing and Nuclear Materials Management I

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