ML20236F995
| ML20236F995 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 10/30/1987 |
| From: | Schnell D UNION ELECTRIC CO. |
| To: | NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM) |
| References | |
| ULNRC-1666, NUDOCS 8711020368 | |
| Download: ML20236F995 (5) | |
Text
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Yh(kDI Etscraic n
1901 Gratiot Street, St. Louis i
Donald F. Schnell
. Vce President 3
October 30, 1987
[l LU.S. Nuclear Regulatory Commission L
Document Control Desk 3
E Washington, D.C.
20555 ULNRC-1666 l
Gentlemen:
RESPONSE TO NRC LETTER ON THE QUALITY OF SPENT FUEL RACKS FABRICATED BY U.S.
TOOL AND DIE AND ITS PREDECESSOR This is in response to the letter sent by Mr. David I. Wigginton, Acting Director of Project Directorate III-3 of the Division of Reactor Projects.
The information requested is provided below in the same order as the re-quest.
1.
Please describe the extent to which the U.S. Tool and i
Die QA/QC program was relied upon to assure rack
[
quality.
Response
Union Electric, through SNUPPS and Bechtel Power Corporation (Gaithersburg, Maryland - Standard Power Block A/E), awarded the contract for fabrication of the spent fuel racks to Wachter Associates, Inc. and later to U.S.
Tool and Die.
Through the procurement contract and specification, Bechtel required Wachter and U.S. Tool and Die to have and to implement a quality program to assure the completeness and correctness of the racks.
Bechtel performed Quality 1
Program Audits and Quality Program Verifications (UE
)
participated in one of the audits) to verify Wachter's i
and U.S. Tool and Die's implementation of the contracted quality program for the spent fuel racks.
In addition, SNUPPS contracted with Nuclear Energy Services (NES) to perform third-party inspections at the manufacturing plant and at callaway Plant.
Union i
Electric's Quality Assurance personnel also
)
participated in one of the early NES inspections.
No significant finding indicating a breakdown in the U.S.
Tool and Die inspection programs was observed.
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2.
Please describe your in-factory and/or receipt inspec-tion of the racks.
Response
A Bechtel inspector at the U.S. Tool and Die factory performed Quality Program Verifications which l
included:
1 a.
Witnessing of manufacturing and inspection (in-I cluding dimensional and NDE of welds) activities.
b.
Inspecting on a random basis various rack details, including welds.
I c.
Release inspections on racks that U.S. Tool and i
Die had indicated were ready for shipment.
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]
d.
Reviewing manufacturing, inspection and training l
documentation.
The Quality Program Verifications performed by Bechtel were surveillance of specific program elements for a sample of activities.
Daniel International performed receipt inspections of all spent fuel racks received at Callaway Plant.
The receipt inspections included the following attributes:
a.
Cleanliness b.
Dimensions and material physical properties were according to specification c.
Visually inspected welds on items fabricated to AWS Standards on a sample basis for cracks (weld and base metal), overlap, arc strikes, slag, undercut, insufficient throat, and leg
- length, d.
Checked that corners and edges have been ground off, rounded or chamfered e.
Material was identified with heat numbers or codes traceable to CMTRs f.
Material was identified in accordance with Purchase Order drawings g.
Checked connecting bolt threads for damage 3.
& 4.
What findings were made during your receipt inspection of the racks and if your receipt inspections found deficiencies in the racks, what corrective actions were taken.
Response
Material Receiving Inspections (MRIs) were developed by Daniel International based on Bechtel Specification 10466-C-175 (Q).
The inspection
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'ULNRC-1666 L
Page 3 of 4 l
attributes are provided in the response to Question 2 above.
Based on the MRIs, Daniel Quality Control (QC).
and Daniel Engineering inspected each rack when it was received.
The inspections identified problems with spot welds not being ground off, sharp edges at the top of cells, indentations in-one of the cells and one coll's cap, and concerns with alignment of the cells from top to bottom.
The weld. inspections were performed visually by qualified QC personnel.
Daniel Deficiency' Reports (DRs) were written to document the j
problems with sharp edges and with the spot welds.
l These DRs (Nos. 2SD-3989, 4408, 4423, 4697, 4758, 4820, and 4893) were superseded by various Nonconformance L
Reports (NCRs) and finally superseded by DR No. 2SD-5309-CW.
This DR identified the plan to correct the deficiencies found.
Based on the disposition, Daniel, Bechtel, and Union Electric had j
the vendor come on site and correct the deficiencies to the fuel racks.
The corrections were reviewed and inspected by U.S. Tool and Die, Inc., Daniel International's Civil Engineering and Mechanical Q.C.
groups, and Bechtel.
In addition to performing receipt inspections of the racks, Daniel International reviewed the inspection j
documentation furnished by U.S. Tool and, Die.
The j
documentation received included results from Dye
{
Penetrant Non-Destructive Examination tests for the welds.
No discrepancies with the documentation were noted.
Once the deficient racks were corrected, they were j
installed in the spent fuel pool.
The alignment of cells was checked by Westinghouse personnel during the installation process.
The alignment of the cells was verified as being within the tolerances established in the Bechtel Specification.
I An indentation was found in one of the cells (cell R-31 i
of Rack M120-29).
The dent was corrected by peening.
l The problem was identified on Daniel NCR No. 2SN-5477-C and Westinghouse NCR No. SCP-007.
Another dent problem was found on the cap of Cell M44 on Rack M120-30.
Since the dent was not detrimental to the cell, the Daniel NCR (2SN-55050-C) was dispositioned use-as-is by Bechtel.
5.
Please describe any additional actions or examinations you plan to undertake to assure that your racks meet the original design and regulatory requirements.
l l
Response
No further action is planned by Union Electric.
The audits, surveillance and inspections performed and corrective actions taken by U.S.
Tool and Die to satisfy identified concerns and problems
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i ULNRC-1666 Page 4'of'4.
provide adequate-assurance-that our spent fuel racks-
~
meet regulatory? requirements and'our-design 1 specifications.
l If you have.any questions regarding this response'orfif additional information:is required,.please11et me..'know..
.Very truly'yours, s-g Donald F.-Schnell cci A.
B. Davis'- Regional-Administrator,' Region-III.
~
D. L. WiggintonL-Acting Director. Project Directorate III-3,; Division of Reactor Projects J. M. Hinds'- Chief, Reactor Projects, Section -1A,..
USNRC Region III Tom Alexion - USNRC Licensing. Project Manager i
(2 Copies)
B. H. Little - USNRC Senior Resident Inspector j
' Manager, Electric Department,. Missouri Public Service il Commission G. Charnoff:- Shaw, Pittman,-Potts, & Trowbridge v >
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.ULNRC-1666' l
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. bcc:-A160.761 (QA Record) (CA-460) l G210.16f(Commercial Record) (CA-460) (File with 08/24/87 letter DLW w/NRC to DFS) i G210.16 (File with 08/24/87 letter DLW w/NRC to 1
DFS). (QAPS CA-460)
'G210.16'(File) (470 QAQE) (File with 08/24/87 letter j
DLW w/NRC to DFS)
Nuclear Date File (S. L. Auston) (470)
NSRB (S. L. Auston) (470)
D.
F. Schnell (Chrono)
R. J. Schukai G. L. Randolph C.
D. Naslund J..D.
Blosser f
Quality Assurance (A. P. Neuhalfen/F. D. Field) (CA 460)
M. A. Stiller Licensing (A. C. Passwater/D. E. Shafer/D.
J. Walker)
(470)
J.-E. Davis H. Wuertenbaecher (100)
O. Maynard (WCNOC)
J. R. Veatch/W.
S.
Strothman J. V. Laux C. E.
Slizewski L. H. Kanuckel R. L. Plautz' R.
H.
Ripley J.
J. Cassmeyer/B. K.
Stanfield
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