ML20214C979

Insp Rept 99900005/85-01 on 851112-15.Noncompliances Noted: Autoclave Left Uncovered When Not in Use,Rod Pressurization Determined Per Soi R-0618 Instead of Soi R-0563 & Signoff for Lab Technician Missing from Evaluation Sheet

ML20214C979
Person / Time
Issue date:	02/10/1986
From:	Cilimberg R, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20214C954	List: ML20214C951 ML20214C965 ML20214C979
References
REF-QA-99900005 NUDOCS 8602210362
Download: ML20214C979 (12)

Text

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. ORGANIZATION: WESTINGHOUSE ELECTRfC CORPORATION NUCLEAR FUEL DIVISION PITTSBURGH, PENNSYLVANIA REPORT INSPECTION INSPECTION NO.: 99900005/85-01 DATE(S): 11/12-15/85 ON-SITE H00FS: 92 CORRESPONDENCE ADDRESS: Westinghouse Electric Corporation Nuclear Fuel Division ATTN: Dr. Richard Slember, General Manager Post Office Box 355 Pittsburgh, Pennsylvania 15230 ORGANIZATIONAL CONTACT: Mr. R. Cost, Manager of Quality Assurance TELEPHONE NUMBER: (412) 374-2359 NUCLEAR INDUSTRY ACTIVITY: Nuclear fuel assembly supplier for Westinghouse designed reactors.

An r p 2 /4/f/'.

ASSIGNED INSPECTOR: -

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R.L.Cilimberg, Spec [plProjectsInspection

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Date V

Section (SPIS)

OTHER INSPECTOR (S): R. L. Pettis, SPIS J. C._ Harper, Reactive Inspection Section D.Mdikrant,EG(

APPROVED BY: 36 John W. Craig, Chief, SPjS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:

A. BASES: 10 CFR 50, Appendix B and 10 CFR 21.

B. SCODE: This inspection was made to review procedures and practices in the metallurgical and chemical testing laboratories.

PLANT SITE APPLICABILITY: PWR facilities with fuel supplied by Westinghouse.

0602210362 860219 PDR GA999 ErtWEST 99900005 PDR

o ORGANIZATION: WESTINGHOUSE ELECTRfC CORPORATTON NUCLEAR FUEL DIVISION PITTSBURGH, PENNSYLVANIA REPORT INSPECTION N0.: 99900005/85-01 RESULTS: PAGE 2 of 7 A. VIOLATIONS:

None.

B. NONCONFORMANCES:

1. Contrary to Section 17.1.5, " Instructions, Procedures, and Drawings,"

of WCAP 8370, Revision 10A and WCAP 7800, Revision 6A, dated August 1984, and Quality Control Instruction (QCI) No. 108857, Revision 6, dated October 22, 1984, an autoclave was left uncovered when not in use. (85-01-01)

2. Contrary to Section 17.1.5 of WCAP 8370, Pevision 10A and WCAP 7800, Revision 6A, and QCI No. 108823, Revision 0, rod pressurization was determined according to S0I R-0618 and not 50! R-0563 as specified by the QCI. (85-01-02)

3. Contrary to Section 17.1.5 of WCAP 8370, Pevision 10A and WCAP 7800, Revision 6A, and Product Assurance Procedure (PAP) 2.2.2, Revisior 4, dated December 2, 1982, management approval sign-off for qualification of a metallurgical laboratory technician was missing from the evaluation sheet. (85-01-03)

C. UNRESOLVED ITEMS:

None.

D. STATUS OF PREVIOUS INSPECTION FINDINGS:

Not applicable.

E. INSPECTION FINDINGS AND OTHER COMMENTS:

1. Entrance and Exit Peetings Westinghouse management representatives were informed of the scope of the inspection during the entrance meeting. The inspection findings and observations were summarized during the exit meeting on November 15, 1985.

, ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION NUCLEAR FUEL DIVISION pITTSBURGH, PENNSYLVANIA REPORT INSPECTION NO.: 99900005/85-01 RESULTS: PAGE 3 of 7

2. Chemical Laboratory

a. Measuring and Test Instruments The NRC inspectors reviewed procedures and practices for the control of measuring and test instruments used in the analytical laboratory. The chemical analysis procedures (C0CL) specify the steps for the calibration and standardization of test and measurement equipment for each analytical method. Standards are used to verify the accuracy of each analytical method. When standards do not meet the statistical requirements of the analytical method, calibration curves are re-established by analyzing additional standards prior to an analysis being performed by that method.

b. Procedure Review The NRC inspectors reviewed 14 procedures which ccvered: the determination of impurities in uranium, uranium spectrographic standards, isotopic composition, potentiometric titration, x-ray fluorescence, uranium in uranium hexafluoride, fluoride by specific ion electrode, format for analytical procedures, technician training program, sample log, uranium dioxide powder blend chemistry and isotopic sampling, excess uranium control, sampling and release of in-process uranyl nitrate, and use of instructions for quality control. These procedures are contained in three categories of documents: the analytical laboratory manual, prodt.ct and process procedures (C0CL), and Quality Control Instructions (QCI). The procedures were technically correct and complete. The procedures had also been properly reviewed and contained the required signature approval.

c. Observation of Analyses The NRC inspectors observed technicians performing sample analyses utilizing the procedures discussed above. Observations are itemized below:

(1) A technician used one of three mass spectrometers to analyze uranium for isotope content in accordance with procedure number C0CL M-01, " Isotopic Uranium Analysis,"

Revision 3, dated November 11, 1985. The steps of the

• ORGANIZATION: WESTfNGHOUSE ELECTRIC CORPORATION NUCLEAR FUEL DIVISION PITTSBURGH, PENNSYLVANIA REPORT INSPECTION NO.: 99900005/85-01 RESULTS: PAGE 4 of 7 procedure were properly followed. A record of analyses results and standards checked are kept in a log book. Any changes to results entered in the log are made with one line crossing out the entry, and the correction is initialed and dated.

(2) A technician determined fluoride content in accordance with procedure number C0CL P-03, " Fluoride by Specific lon Electrode," Revision 1, dated November 8, 1985. The steps uf the procedure were followed without deviation and standards were analyzed to verify the accuracy of the method.

(3) A technician determined the uranium content in a standard sample in accordance with procedure number C0CL U-01,

" Uranium by Potentiometric Titration," Revision 6, dated October 1, 1985. This procedure is commonly known as the Davis and Gray Method. The technician demonstrated competence during.this analysis as he timed the steps of the procedure with a stopwatch and obtained the standard value within the statistical accuracy of the method.

(4) A technician analyzed multiple standards and generated a calibration curve prior to sample analysis. All analyses were performed acceptably in accordance with procedure number C0CL U-03, " Uranium by X-Ray Fluorescence "

Revision 3, dated September 7, 1984 A New Brunswick Laboratory (NBL) standard was used for the sample analysis.

The technician was well trained for performing the analysis and he obtained the standard value within the statistical accuracy of the method.

d. Training The NRC inspectors reviewed the training requirements for technicians. These requirements are specified in attachment 11.1-1 to the Analytical Laboratory Manual, dated November 15, 1983. On the job training is used as the primary training method. The technicians are required to analyze a series of

" blind" standards prior to qualifying on each method. Training records are maintained for each technician including the analysis the technician is qualified to perform. The training files of four, full-time technicians and one part time technician indicated that written tests are used to show proficiency for several methods.

ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION NUCLEAR FUEL DIVISION PITTSBURGH, PENNSYLVANIA REPORT INSPECTION N0.: 99900005/85-01 RESULTS: PAGE 5 of 7

e. Conclusions Based on the above reviews and observations the NRC inspectors determined that the technicians are well trained and are using calibrated equipment in accordance with written procedures.

These procedures are used to perform analyses on samples to verify the quality of final products and support the quality control of in-process material. No items of nonconformance were identified in this area.

3. Metallurgical Laboratory (Met. Lab.)

a. Procedure Review and Observation of Analysis The NRC inspectors reviewed procedures which covered autoclave testing, operation of tensile tester, fuel rod pressurization, metallographic sample preparation, metallurgical records and documentation, corrosion sampling and evaluation, U02 pellet chamfer measurement, and tool and gage inspection.

(1) During review of QCI No. 108857, " Operating Procedure for Autoclaves," Revision 6, dated October 22, 1984, the NRC inspectors noted that section C.6 requires that autoclaves be covered when not in use. One autoclave not in use in the Met. Lab, was missing a cover. This procedural requirement is a practice to ensure the proper water quality in the autoclave. Control of water quality is also provided by a resistivity test. Met. Lab. personnel put the top on the autoclave when they were informed by the NRC inspectors that it was not in place.

Nonconformance Item 85-01-01 was identifed in this area.

(2) A review of QCI No. 108823, " Fuel Rod Pressurization Records Check and Disposition Practices," Revision 0, dated March 26, 1985, indicated that rod pressurization be checked using Standard Operating Instruction (501) number R-0563, Revision 20, dated January 18, 1983. The NRC inspectors determined that SOI number R-0618, Revision 15, dated November 5, 1985, was the document being used by manufacturing personnel. The inspectors reviewed both S0ls and determined that rod pressurization checks were acceptable using either 501.

QCI 108823 was corrected to properly reference 50! R-0618 prior to the completion of inspection.

Nonconformance Item 85-01-02 was identified in this area.

, ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION NUCLEAR FUEL DIVISION PITTSBURGH, PENNSYLVANIA REPORT INSPECTION NO.: 99900005/85-01 RESULTS: PAGE 6 of 7 (3) Corrosion testing of fuel pins was performed by a Met. Lab.

technician in accordance with QCI No. 108857. Procedural steps such as the rinse cycle, pH, resistivity measurements, autoclave preparation and start-up, and coupon weighing were followed as required by the procedure.

(4) A review of QCI No. 108860, "U0, Pellet Sample Preparation and Chamfer Measurement," Revision 1, dated July 22, 1985, and observations of the measurement and evaluation of U0 2 pellet chamfer by the technician indicated that the work was in accordance with the procedure.

(5) The NRC inspectors reviewed the calibration and calibration certificates for scales, measurement scope, tensile tester, microhardness tester, micrometers, and master blocks. Based upon this review the inspector determined that measuring instruments were properly calibrated and traceable to standards of the National Bureau of Standards,

b. Qualification and Training -

The NRC inspectors reviewed the requirements for qualification of a Met. Lab. Technician Level C. Certificate of Qualification, Q.C. Form 423, Revision 1, dated February 1, 1985, requires that a technician be certified in accordance with PAP 2.2.2 which further reouires that the technician make metallographic evaluations including micrographic evaluations. This review revealed that the Indoctrination and Evaluation Sheet was completed by the technician and signed off by the appropriate manager. However, the manager's signature was missing for visual metallographic examinations and, therefore, micrographic examinations. The inspectors determined that the technician was qualified to perform microscopic evaluations and knew how to use the microscopic quality standards.

Nonconformance Item 85-01-03 was identified in this area,

c. Conclusions Based on the above reviews and observations the NRC inspectors determined that the technicians in the Met. Lab. are using calibrated equipment in accordance with written procedures other than the exceptions noted. Further, corrective action was initiated for the items of nonconformance identified in the Met. Lab prior to the conclusion of this inspection.

, ORGANIZATION: WESTINGHOUSEELECTRICCORPORATIdN NUCLEAR FUEL DIVISION PITTSBURGH, PENNSYLVANIA REPORT INSPECTION N0.: 99900005/85-01 RESULTS: PAGE 7 of 7 F. PERSONS CONTACTED:

K. Barrett, level B Technician, Chemical Lab E. Black, Level A Technician, Chemical Lab

• D. Brown, Level C Technician, Metallurgical Lab

• J. R. Bush, Quality Control Manager H. Cory, Mechnical Inspection Manager

• R. R. Cost, Operations Product Assurance Manager

• J. E. Hart, Process Engineering Manager K. Hunter, Ceramic, Metallurgical Lab

• L. D. Kays, POPA Manager

• E. Keelen, Manufacturing Manager F. Kulas, QC Supervisor A. LeGrand, Chemist G. Lindler, Level B Technician, Metallurgical Lab

• C. Perkins, Quality Control Manager T. Pham, Chemist

• R. K. Pollard, Quality Control Engineering Manager

• A. M. Schwartzman, OPTIM Director, Metallurgical Lab J. Snyder, Level C Technician, Metallurgical Lab

8. Torrey, Wet Chemist E. Waters, Level B Technicial, Chemical Lab C. Wessinger, Level B Technician, Metallurgical Lab M. Wessinger, level B Technician, Chemical Lab H. Whitaker, Chemist

• G. R. Wilson, OC Supervisor, Chemical Lab

• G. D. Workman, Analytical Services Manager

• present during exit meeting

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