ML20236H656
| ML20236H656 | |
| Person / Time | |
|---|---|
| Issue date: | 07/28/1987 |
| From: | Cilimberg R, Stone J Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20236H641 | List: |
| References | |
| REF-QA-99900001 NUDOCS 8708050283 | |
| Download: ML20236H656 (7) | |
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ORGANIZATION: BABC0CK & WILCOX COMPANY NUCLEAR FUEL SERVICES LYNCHBURG, VIRGINIA REPORT INSPECTION INSPECTION NO.: 99900001/87-01 DATES: 06/01-05/87 ON-SITE HOURS: 60 CORRESPbhDEkCE ADDRESS: Babcock 6 wiicox company l
Nuclear Fuel Services ATTN: Mr. R. H. Ihde Manager Post Office Box 1260 Lynchburg, Virginia 24505 ORGANIZATIONAL CONTACT: Mr. W. T. Engelke, Manager of Quality Assurance TELEPHONE NUMBER:
(804) 522-5654
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NUCLEAR INDUSTRY ACTIVITY: Nuclear fuel assembly supplier for Babcock & Wilcox (B&W) and Westinghouse designed reactors.
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ASSIGNED INSPECTOR:
h R. L. Cilimberg, Program Devy/opment and Reactive Date Inspection Section (PDRIS)V OTHER INSPECTOR (S):
K. C. Leu, PDRIS
[-
777 APPROVED BY:
J. C./ Stone, Chief, PDR15, Vendor Inspection Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR 21, 10 CFR 50.
B.
SCOPE:
Review fuel assembly fabrication activities, document control, internal audits, material control, control of nonconformances and related corrective action, and evaluations of leaking fuel by B&W at various facilities.
PLANT SITE APPLICABILITY: Haddem Neck (50-213); Oconee 1/2/3 (50-269/270/287);
Three Mile Island 1 (50-289); Crystal River 3 (50-302); Rancho Seco (50-312);
Arkansas 1 (50-313); Davis Besse 1 (50-346); (continued on next page) 870B050283 870731 0000 b # $DR
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ORGANIZATION. BABC0CK & WILC0X COMPANY NUCLEAR FUEL SERVICES LYNCHBURG. VIRI 1NIA REPORT INSPECTION NO.: 99900001/87-01 RESULTS:
PAGE 2 of 7 PLANT SITE APPLICABILITY:
(continued) McGuire 2 (50-370); Bellefonte 1/2 (50-438/439).
A.
VIOLATIONS None.
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B.
HONCONFORMANCES None.
C.
UNRESOLVED ITEttS None.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS Not applicable.
E.
I.NSPECTION FINDINGS AND OTHER C0lliENTS 1.
Entrance and Exit Meetings The NRC staff informed B&W management representatives of the scope of the inspection during the entrance meeting and summarized the inspection findings and observations during the exit meeting on June 5, 1987.
2' Internal Audits The inspectors reviewed internal audit reports for 1986 and 1987 to determine conformance with Section 18 of the B&W " Nuclear Fuel and Associated Components Quality Assurance Program llanual (QAM),"
Revision 14, dated May 18, 1987.
Internal audits are performed in accordance with QC-1411. " Internal Audits of the CNFP Quality Control Program," Revision 11, dated February 24, 1986.
Internal audit reports contain a review by the auditor of fuel fabrication compared to an audit checklist on form QC-R-1067B, Revision 1, which outlines the requirements in the QAli, procedures, and instructions for the production and inspection areas in the plant. Production and inspection areas are audited at intervals of at least once each calendar year.
ORGANIZAT10N: BABC0CP, & WILCOX COMPANY NUCLEAR FUEL SERVICES
, YNCHBURG. VIRGINIA 1
REPORT INSPECTION NO.: 99900001/87-01 RESULTS:
PAGE 3 of 7 Personnel performing internal audits must meet the requirements of QC-1416. " Instruction and Training of CNFP Quality Audit Personnel,"
Revision 7, dated January 9, 1985. The NRC inspectors determined that the 1986 and 1987 internal audit reports are in compliance with the B&W QAM, Revision 14, and QC-1411, Revision 11. Corrective action was performed as required by the QAM and QC-1411, Revision 11.
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The inspectors reviewed the qualification'and training files for auditors performing the 1986 and 1987 internal audits and determined that the auditors met the requirements of QC-1416, Revision 7.
No nonconformance or unresolved items were identified.
3.
Control of Nonconformances and Corrective Action The inspectors reviewed 25 CDRs (6 use-as-is, 10 rework, and 9 repair) for 1986 and 1987 to determine conformance with section 15 of the B&W QAM, Revision 14. Section 15 of B&W QAM, " Nonconforming,
Materials, Parts or Components," Revision 14, dated May 18, 1987, requires that component nonconformances at receiving, in-process, or:
fi?al inspection be recorded on component discrepancy reports (CDR).:
Requirements for control, segregation, and disposition of noncon-forming componer.ts and instructions for CDR are provided in QC-1413
" Nonconforming 11aterials, Parts or Componets," Revision 5, dated June 16, 1986. Nonconforming components are identified and tagged in accordance with QC-822, " Tagging Components, Parts, Assemblies, Shipping Containers and Equipment," Revision 7, dated November E0, 1985.
Section 16 of B&W QAM, " Corrective Action," Revision 14, sets the requirements for corrective action for nonconforming items.
Section 16 requires that CDRs be analyzed by a Review Board to determine cause of nonconformances and recommend corrective action.
The NRC inspectors determined that control of nonconforming components, corrective action, and activities of the B&W review board were performed in accordance with the above B&W QAM and procedures.
No nonconforrtance or unresolved items were identified.
j 4.
Material Control The inspectors traced four items (lower end plug, holddown spring, j
lower end fitting (LEF), fuel roo tubing) to their origin. The t
status of the items during inspection, test, and fabrication for use in fuel assembly numbers NJ0-4D8, NJ0-4C2, and NJ0-469 was indicated in accordance with Section 14 of B&W QAM, " Inspection, Test and Operation," Revision 14. The four items were identified and controlled in accordance with Section 8 of B&W QAM, " Identification and Cc,ntrol of Materials, Parts and Components," Revision 14.
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ORGANIZATION: BABC0CK & WILCOX COMPANY
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NUCLEAR FUEL SERVICES LYNCHBURG. VIRGINIA REPORT INSPECTION l
N0.: 99900001/87-01 RESULTS:
PAGE 4 of 7 l
Specific instructions for indicating the status of the four items during fabrication are defined in QC-1408, " Control of Inspection, Test, and Operating Status," Revision 2, dated February 28, 1984.
Specific instructions for ensuring that fuel rod tubing meets specification requirements are delineated in QC-522, " Receiving j
Inspection - Fuel Rod Cladding Mark B and Mark C," Revision 5, dated d
January 22, 1986. The four items are tagged and identified in accordance with QC-822, Revision 7.
The NRC inspectors determined that the above four items were trace-able to their origin and could be identified by their heat and lot numbers with controls to prevent a mixup of material traceability.
The status of the four items was controlled throughout processing to the completed fuel assemblies with the proper physical identification visible to the NRC inspectors at each step in the process.
The inspectors also reviewed six items (holddown spring, LEF assembly, hold down spring retainer casting, tubular spacer, end caps, guide tube upper nut) in storage for proper identification and determined
- those items to be in accordance with applicable procedures.
No nonconformance or unresolved items were identified.
5.
QA Records The. inspectors reviewed QA records to determine compliance witn Section 17 of B&W QAM, "QA Records," Revision 14, which requires that records be collected during procurement, fabrication, and inspection to document the quality of items and activities affecting quality.
The records to be retained and the responsibility for record collection and retention are defined in QC-1414, " Retention.of QA Records," Revision 2, dated October 16, 1984, The methods and responsibility for storage of QA records are defined in QC-1418,
" Storage of QA Records," Revision 2, dated August 16, 1984. Form QC-R-1032, " Record Verification," dacuments record transfer, record receipt, and review and receipt of microfilm of quality records.
The method by which conformance certifications (CC) and supplier certificates of conformance (C of C) cre prepared is defined in QC-1424, Revision 3, dated February 5, 1987. The Data Evaluation organization performs final review of inspection data and the QA Manager must authorize and approve CC and C of C.
The NRC inspectors determined that QA records including audit reports, personnel qualification records, and test records conformed
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'0 ORGANIZATION: BABC0CK & WILC0X COMPANY
' NUCLEAR FUEL SERVICES LYNCHBURG. VIRGINIA REPORT INSPECTION NO.: 99900001/87-01 RESULTS:
PAGE 5 of 7 to procedural requirements. QA records were identifiable, retrievable, and complete. No nonconformance or unresolved items were identified.
6.
Document Control I
The NRC inspectors reviewed seven documents at six work stations to determine if the latest revisions of the applicable documents were being used. The NRC inspectors also reviewed four purchase orders (P0) to determine if P0 changes, procurement, and review and approval were being processed according to document control proce-dures.
Section 6 of B&W QAM, " Document Control," Revision 14, defines a system for the control, preparation, revision, and distribution of QA records. The instructions and responsibility for the review and,
approval of drawings, specifications and procedures that apply to fuel manufacturing are provided in QC-1421, " Review and Approval of -
Drawings, Specifications and Procedures," Revision 2, dated April 10; 1986. The responsibility for the preparation, distribution, and quality control of temporary procedure revisions (QCTPR) is defined in QC-1432, "QCTPR," Revision 6, dated November 2, 1984. QCTPR are documented on form QC-R-517-6 and listed on the QCTPR log. The.
procedure for the inspection, test, and operating status of materials and components is provided in QC-1408, Revision 2.
The inspection and manufacturing steps are recorded on route cards which else contain the applicable procedures used. QA reviews and approves route cards to verify the use of approved procedures and the proper inspection sequence.
The NRC inspectors determined that control of the documents reviewed was in conformance with the latest revision of applicable procedures.
No nonconformance or unresolved items were identified.
7.
Fuel Performance a.
Background
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B&W has manufactured fuel bundles / assemblies for 13 pressurized-water reactors (PWRs). The PWRs that have operated with B&W fuel are Oconce Units 1, 2, and 3; Rancho Seco; Davis-Besse L
Unit 1; Crystal River Unit 3; Arkansas Unit 1; TMI Units 1 and 2 and Haddam Neck. B&W fuel has been manufactured for Bellefonte Units 1 and 2 and McGuire Unit 2, but has not been loaded in 1
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ORGANIZATION: BABC0CK & WILC0X COMPANY
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NUCLEAR FUEL SERVICES 1
l l
LYNCHBURG. VIRGINIA
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REPORT INSPECTION NO.: 99900001/87-01 RESULTS:
PAGE 6 of 7 the reactors. Although B&W fuel has leaked in operating 1
reactors, B&W evaluations have not been able to conclude any relationship between leaking fuel in operating reactors and variables in the fuel manufacturing process, b.
B&W Fuel Evaluation The Fuel Engineering Department of the Nuclear Power Division of B&W estimated that 129 new leaking B&W fuel rods occurred from 258,000 total rods per year in service in seven reactors between 1980 and 1987. The overall integrity level was estimated by B&W to be greater than 99.99 percent. The estimates of leaking rods was based on radiochemistry of the primary coolant at each of the seven reactors. All but one of the 27 leaking rods at two reactors during 1986 and 1987 were believed to be related to debris in the reactors. Five of the seven operating-reactors did not experience leaking fuel rods during 1986 and 1987. Leaking fuel in Oconee Unit 3 is believed to have been caused by debris resulting from the failure of a reactor coolant pump.
c.
B&W Fuel Inspection at Reactors B&W has used their ECH0-330 ultrasonic fuel inspection system to nondestructively test fuel rods at reactor sites. The ECH0-330 system uses an ultrasonic probe to test each fuel rod in a bundle above the spent fuel storage pool at operating reactors by sensing the presence or absence of moisture on the inside of the fuel rod.
If water is detected in a fuel rod, that rod has experienced a breach in the cladding. The ECH0-330 system has been used to inspect fuel rods at the following operating reactors:
(1) Calvert Cliffs Unit 1 - November 1986 Inspection of 42,416 fuel rods showed that 76 rods contained water and 22 rods were suspect.
d (2) Byron Unit 1 - March 1987 Inspection of 50,952 fuel rods showed that 8 rods contained water.
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l ORGANIZATION: BABC0CK & WILCOX COMPANY e'
NUCLEAR FUEL SERVICES LYNCHBURG. VIRGINIA REPORT INSPECTION NO.: 99900001/87-01 RESULTS:
PAGE 7 of 7 (3) Calvert Cliffs Unit 2 - April 1987 j
Inspection of 40,304 fuel rods showed that 17 rods I
contained water.
(4) Oconee Unit 3 - May 1987 d
Inspection of 21,632 fuel rods showed that 16 rods contained water.
The above identification of breached cladding by the presence of water inside the fuel rods was based on ultrasonic indica-tions by the ECH0-330 system. B&W has entered a joint program with EPRI to correlate ECH0-330 testing with physical examina.
tion of fuel rods identified as containing water at Oconee Unit 3.
The physical examination of rods at Oconee Unit 3 is expected to provide addition *.1 information on the relationship :
between ultrasonic indications and fuel rod physical characteris-i tics.
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The results of this program will be evaluated during a future inspection.
F.
PERSONS CONTACTED
- R. Alto
- J. Brown
- 5. Carter C. Deaner C. Dideon C. Dodson
- W. Engelke
- D. Ferree C. Floyd
- J. Ford K. Graham
- K. Harris t
H. Hassan B. Mann H. Marshall
- R.
Penoza B. Pugh J. Sapyta T. Schuler J. Willse
- Attended exit meeting.
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