ML20195B358
| ML20195B358 | |
| Person / Time | |
|---|---|
| Issue date: | 05/13/1986 |
| From: | Cilimberg R, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20195B352 | List: |
| References | |
| REF-QA-99900001 NUDOCS 8605290248 | |
| Download: ML20195B358 (21) | |
Text
{{#Wiki_filter:. ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA INSPECTION INSPECTION REPORT DATE: 02/24-28/86 JN-SITE HOURS: 107 NO.: 99900001/86-01 CORRESPONDENCE ADDRESS: Babcock & Wilcox Company 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 NUCLEAR INDUSTRY ACTIVITY: Nuclear fuel assembly supplier for Babcock and Wilcox (B&W) and Westinghouse designed reactors.
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ASSIGNED INSPECTOR: [.d. ("g7MM
'R. L. CilT1nberg, Specffl Projects Inspection
~ f[Xi/'ft Date Section (SPIS) V OTHER INSPECTOR (S): R. P. McIntyre, SPIS D. J. King, Program Coordination Section J. F. Cook, EG&G APPROVED : \h NY o n W. Cra<g, Chief, SPIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR 50, Appendix B and 10 CFR 21 B. SCOPE: This inspection was made to review fabrication and inspection activities and QA program implementation. PLANT SITE APPLICABILITY: PWR facilities with fuel supplied by Babcock and Wilcox. 0605290240 060927 9NOO00N DR
ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA REPORT INSPECTION N0.: 99900001/86-01 RESULTS: PAGE 2 of 14 A. VIOLATIONS None.
B. NONCONFORMANCES None. C. UNRESOLVED ITEMS
~
None. D. STATUS OF PREVIOUS INSPECTION FINDINGS
- 1. (Closed) Nonconformance (84-01, Item B):
Contrary to Criterion V of 10 CFR 50, Appendix B, and Babcock and Wilcox (B&W) procedure MA 450, Revision 12, an operator was handling end caps without wearing gloves. The NRC inspectors confirmed during this inspection that the operator who was not wearing gloves was advised of the requirement to follow procedures. Signs have been posted at work stations that emphasize the requirement for all personnel to wear gloves when handling in-process fuel bundle components. Operator training has been improved by holding regular meetings to sensitize operators to the critical operations in which they are involved. This item is considered closed.
- 2. (Closed) Unresolved Item (84-01, Item C):
This inspection revealed that B&W does not apply 10 CFR Part 21 to the purchase of fuel pellets from General Electric (GE) because B&W believes that fuel pellets could not contain defects which would create a substantial safety hazard. The NRC inspectors determined that B&W performs a number of overchecks to ensure that fuel pellets are free of defects. B&W also classifies the fuel assembly as safety related which requires that fuel pellets be continuously analyzed by B&W for defects that might affect the basic component status of the fuel assembly. There-fore, B&W purchases fuel pellets as commercial grade items which are not a part of the fuel assembly until after dedication in accordance with 10 CFR 21.3(c-1). This item is considered closed.
F ORGANITATION: BABC0CK & WILCOX COMPANY
- LYNCHBURG, VIRGINIA R PORT INSPECTION NO.: 99900001/86-01 RESULTS: ) AGE 3 of 14 E. INSPECTION FINDINGS AND OTHER COMENTS:
- 1. Entrance and Exit Meetings B&W 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 February 28, 1986.
- 2. Procurement ,
The inspection in this area consisted of a review of the B&W Com-mercial Nuclear Fuel Plant (CNFP) Quality Assurance (QA) Program relating to procurement practices. Revision 13 of the B&W QA Program for CNFP, and the implementing . procedure, Section 4, " Procurement Document Control," establish the elements of procurement relating to commercial nuclear items. a) Procurement program review. The inspector reviewed the CNFP QA program for procurement to verify compliance with the regulatory requirements, codes, and standards. QA manual, Section 4, " Procurement Document Control," which is the CNFP procedure relating to procurement of materials, components and services was reviewed. The procurement process at CNFP hegins upon receipt of a Manufacturing Release (MR) or a Procurement Authorization (PA) from the B&W Nuclear. Power Division (NPO) for fabrication of a commercial nuclear item. CNFP Manufacturing Engineering prepares an Applicable Document List (AOL) which lists all the part names and numbers to be procured and designates whether the part is safety or non-safety related. This is attached to the PA. Any component designated as safety related must be procured with 10 CFR Part 21 imposed on the Vendor. This is accomplished on the CNFP Purchase Order (P0). The AOL, which includes a bill of materials, consolidates infor-mation such as part name and number, drawing and speci_fication numbers, process outlines and make/ buy data. Manufat.turing Engineering is also responsible for preparing a purchased material list for those items to be procured. This list is reviewed by Data Evaluation for conformance with contract TAs.
ORGANIZATION: BABC0CK & WILC0X COMPANY
' LYNCHBURG, VIRGINIA REPORT INSPECTION N0.: 99900001/86-01 RESULTS: ) AGE 4 of 14 The purchased materials list includes any Engineering Requirements (ERs) and Quality Requirements (QCRs) specified by CNFP. ERs consist of the technical requirements contained in the customer drawings and specifications that need to be supplemented or further defined by CNFP. QCRs are the quality requirements contained in the customer drawings and specifi-cations that need to be supplemented or further defined by CNFP.
ERs are prepared by Manufacturing Engineering while QCRs are prepared by CNFP Quality Assurance. Production Control now prepares a purchase requisition from the approved purchased~ materials list for transmittal to purchasing. The final step is the preparation of the P0 by the Purchasing Department for transmittal to an approved Vendor. This is prepared using the information contained in the purchase requisition. The P0 is checked by Data Evaluation to verify that the Engineering and Quality requirements in the P0 are in accord with the approved purchased materials list. Any materials, components and services for commercial nuclear items purchased by CNFP are procured from Vendors who have been evaluated and audited, and a determination was made that the vendor has an acceptable QA program and that their manufacturing and technical capability is sufficient to produce commercial nuclear items. These areas are discussed further in the sections on control of purchased material, equipment, items and services and vendor audits. The inspector reviewed Procurement Authorizations, Applicable Document Lists, purchased material lists, bill of materials, and purchase requisitions for Contract No. 97J, Duke Power Oconee-1 Cycle 10 fuel reload. The inspector also reviewed four P0s affiliated with this contract. The P0s were written to Sandvik Special Metals: fuel rod tubing, Cadmet Corporation: various castings, General Electric: fuel pellets and Stratford Tool and Die: inconel strips. These P0s were reviewed for compliance with technical require-ments, scope of work, QA program requirements, imposition of 10 CFR Part 21 and Part 50 Appendix B, and requisition of Certificate of Conformance (C of C) as specified on the purchased materials list. All P0s reviewed were in compliance with B&W specification 09-1212-01, " Quality Assurance Program Requirements for Nuclear Equipment." The inspector reviewed the referenced ERs and QCRs for each P0 to assure conformance with the above specification.
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~ ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA REPORT INSPECTION NO.: 99900001/86-01 PESULTS: ' AGE 5 of 14
- 3. Control of Purchased Materials, Equipment and Services The CNFP QA Manual, Section 7, " Control of Purchased Material, Equip.nent,fItems and Services" is the procedure which defines the
' requirements for control of purchased commercial nuclear items. To
' assure that purchased material, equipment and services conform to
< purchase' specifications and requirements, an evaluation process is perforted.
The initial evaluation consists of a review of the vendors QA manual, QC plans and procedures, and a Supplier Quality Evaluation. The Supplier Quality Evaluation is conducted to procedure No. QC-1429, "CNFP Supplier Quality Evaluation." Once the Vendor is determined acceptable for further evaluation, the CNFP Supplier Pre-Award Evaluation is. cor. ducted. Prior to the procurement of any ithms from a vendor, the Supplier Pre-Award Evaluation is made to evaluate the vendors facilities with respect to his quality program. This evaluation assures that the vendor can effectively demonstrate quality controls within his organization as well as any subcontractors he utilizes. This
' evaluation is ' conducted using procedure No. QC-1403, "CNFP Supplier Pre-6 ward Evaluation." The QA program evaluation is performed to the requirements of NPD Specification 09-1212-01, " Quality Assurance Program Requirements For Nuclear Equipment." This specification incorporates the requirements of 10 CFR 50 Appendix B and is also used on CNFP P0s to impose these requirements on the vendors. This specification is used as reference in QA-1403.
The inspector reviewed the documentation for the Supplier Quality 7 Evaluation and the Supplier Pre-Award Evaluation, as well as the final Vendor Evaluation Report for three vendors. These were reviewed for their compliance to procedures QC-1429 and QC-1403. Vendors-who have been a determined acceptable by a CNFP Supplier Pre-Award evaluation are placed on the CNFP approved vendors list which is called the " Supplier Status List." This list is maintained by the. Data Evaluation Group. The Furchasing Department can only issue P0s to suppliers who are indic'ated on the Suppliers Status List. The approved vendors on this list are categorized as either "A" or "B". A vendor listed as "A" is considered to have an approved QA program, and is periodically audited to assure that quality requirements are met and maintained. Vendor audits are discussed in
ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA REPORT INSPECTION RESULTS: ) AGE 6 of 14 NO.: 99900001/86-01 section four of this report. A vendor listed as "B" is also approved, but they supply material such as bar stock, plate material, or wire which is specified in accordance with ASTM material specifications.
This material is subject to receiving and inspection at CNFP to verify physical and chemical requirements. All venders who are categorized as "A", are also subject to receipt inspection for the components or material they supply. When a receipt inspection on purchased items cannot be performed at CNFP, then a source inspection is performed at the suppliers facility.
- 4. Vendor Audits Vendor audits are performed on a regular schedule for suppliers who supply material or items to current P0s. These audits are performed to procedure No. QC-1409, " Quality Program Audit for CNFP Vendors,"
and the results are documented in a written report. Section 18 of the QA manual, " Audits," describes the overall requirements to be followed for both internal and supplier audits. The inspector reviewed the 1985 and 1986 Vendor Audit Schedule to assure that all planned audits were being conducted. The inspector reviewed five (5) vendor audit reports for their compliance to procedure no. QC-1409. All audits reviewed met the requirements of this procedure.
- 5. Fuel Pellet Inspection The NRC inspectors reviewed fuel pellet inspections conducted in accordance with Section 10, " Inspection," of the QA manual for receiving inspections of purchased items. The inspections reviewed were associated with contract no. 68H, Lot Number 0237 for fuel pellets received from General Electric (GE) Wilmington, NC.
Section 10 of the CNFP QA manual, " Inspection," is the top level document which sets the requirements for source, receiving, in-process and final inspection. Quality Control Procedure QC-589,
" Fuel Pellet Inspection (MK B Or MK C) Purchased Pellets," is the procedure which defines the type and degree of inspection to be performed on fuel pellets purchased from an outside vendor. The inspector reviewed the inspection results and documentation required for fuel pellet receiving inspections for their compliance to QC-589.
The inspector verified the receipt of a C of C from GE Wilmington, NC.
ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA _
REPORT INSPECTION RESULTS: 2 AGE 7 of 14 N0.: 99900001/86-01
- a. Physical Inspection The Quality Control Inspection Unit is responsible for performing all physical inspection on the fuel pellets while the metallurgical laboratory obtains samples for performing chemical analyses and other tests at CNFP or outside laboratories. The Data Evaluation Unit is responsible for assuring that all inspection and analyses of fuel pellets meet applicable specification and drawing requirements prior to release of the pellets for loading into the fuel rods. ,
The inspectors reviewed the fuel pellet inspection results of a master sample from lot 0237 for the following inspections and tests:
- Diameter
- Length
- Density
- Dish Dimensions
- End-Face Perpendicularity Surface Condition
- Pellet Marking
- Cleanliness
- Surface Finish
- Loadability Test
- U-235 per Linear Inch Test All test results were in compliance with specifications and B&W procedure QC-589. This was verified through review of the test documentation for lot 0237 on file with The Data Evaluation Unit. The NRC inspectors also verified that fuel pellet lot number, pellet enrichment, letter code, and color code were properly identified at the inspection work stations.
The NRC inspectors verified that all tools and gauges used as part of the physical fuel pellet inspections had been calibrated within the required due dates and had calibration due date stickers on the tools and gauges.
ORGANIZATION: BABC0CK & WILC0X COMPANY LYNCHBURG, VIRGINIA REPORT INSPECTION N0.: 99900001/86-01 RESULTS: ) AGE 8 of 14
- b. Chemical Analysis of Fuel Pellets The NRC inspectors reviewed the results of the analyses of fuel pellets which were sampled from lot numbers 212 through 221.
These pellets were supplied by the General Electric (GE) nuclear fuel manufacturing plant in Wilmington, North Carolina under B&W contract 97J. This review determined that the GE analyses and the B&W overcheck analyses by ledoux Laboratory met the requirements of B&W specification number 08-1005753,
" Sintered Uranium Dioxide Pellets (GE Sublet Specification),"
Revision 3, dated October 10, 1985.
- c. Moisture and Hydrogen Control (1) Measuring and Test Instruments The NRC inspectors reviewed procedures and practices for the control of measuring and test instruments used to determine the hydrogen content in U0, fuel pellets and moisture content in burnable poison ellets. The quality control procedures (QC) specify the steps for the calibration of measuring and test equipment. Standards are used to verify the accuracy of the instrument readings prior to performing an analysis of a production sample.
(2) Procedure Review The NRC inspectors reviewed four procedures which covered: fuel pellet hydrogen evaluation, hydrogen analysis of UO2 fuel pellets, evaluation of burnable poison pellets for maximum moisture level, and determination of moisture
- l. content in burnable poison pellets. The procedures were technically correct and complete. The procedures had also been properly reviewed and contained the required signature approval.
(3) Observation of Analysis The NRC inspectors observed technicians performing sample analyses utilizing the procedures discussed above. Observations are itemized below:
ORGANIZATION: BABC0CK & WILC0X COMPANY LYNCHBURG, VIRGINIA REPORT INSPECTION RESULTS: ) AGE 9 of 14 NO.: 99900001/86-01 (a) A technician used a Leco hydrogen analyzer to analyze U0 pellets for hydrogen content in accordance with pr cedure Fuel number Pellets," QC-919, Revision 4, "dated Hydrogen MayAnalysis of U0khe 28, 1985. steps of the procedure were properly followed. A record of analyses results and standards are documented on form numbers QC-R-820, R1 and QC-R-268, R3. (b) A technician determined the moisture content of burnable poison pellets in accordance with procedure number QC-904, " Fuel Pellet, A10 73-B3C Burnable-Poison Pellet, B gG Control Pellet MoTsture Determination, Revision 3, dated May 3, 1982. The steps of the procedure were followed without deviation and standards were analyzed to verify the accuracy of the method.
- 6. Tubing and Fuel Rod Inspection and Testing The inspection in this area consisted of a detailed review of hydride orientation testing of Sandvik tubing, metallographic examination of fuel rod end plug welds, corrosion testing of tubing, nondestructive examination of tubing and fuel rod end plug welds, helium leak tests of fuel rods, gamma scans and alpha counting of fuel rods.
The NRC inspectors verified that all equipment used to test tubing and fuel rods were calibrated within the required due dates and calibration due date stickers were physically attached to the equipment.
- a. Hydride Orientation (1) Background Meeting l The NRC inspectors met with John Schemel, Chief Metallurgist
( of Sandvik Special Metals Corporation and Chairman of the American Society for Testing and Materials (ASTM) subcom-l , mittee B-10.02 on Zirconium and Hafnium. Mr. Schemel i provided the NRC inspectors with the following explanation of why the hydride orientation test is performed on samples of zirconium tubing, l l
ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA REPORT INSPECTION N0.: 99900001/86-01 RESULTS: > AGE 10 of 14 Prior to 1963 in the manufacture and use of zircaloy tubing in fuel rods, it was discovered that a part of the hydrogen generated during the corrosion process was absorbed by the zircaloy and precipitated as platelets in the microstructure. When these platelets were oriented in the radial direction of the tubing, relatively small amounts of hydrogen would make the tube brittle, while similar amounts of hydride platelets oriented in the circumferential direction had little effect on tensile ductility. This behavior was reported by R. P. Marshall and M. R. Louthan, Jr. in the article " Tensile Properties of Zircaloy With Oriented Hydrides," transactions ASM, Vol. 56, No. 3, 1963, p. 693.
Manufacturers stopped fabricating tubing by the cold drawing method and initic.ted the use of cold pilgering for making zircaloy tubes to be used for nuclear fuel cladding. The cold pilgering process produces zircaloy tubing with circumferential hydride orientation. Current industry specifications require that not more than 30% of the platelets shall be oriented less than 40 degrees from the radial direction. This corresponds to an Fn value at B&W which is less than 0.3. When the Fn value is greater than 1.0, the tubing exhibiting that value can be crushed between the thumb and index finger. (2) Procedure Review The NRC inspectors reviewed B&W specification number 08-1214, " Zirconium Alloy Tubing," Revision 10, dated October 10, 1985. Section 4.2 of this specification requires that radial hydride platelets be counted for Fn values greater than 0.1 as depicted in a standard photomicrograph. If the Fn value is less than 0.1, Section 4.2 does not require the counting of radial hydride platelets. B&W procedure number QC-902, "Metallographic Examination of Hydrides in Zircaloy Material," Revision 2, dated February 9, 1984, provides the detailed steps for sample preparation and determination of the Fn values on zircaloy tubing procured from Sandvik Special Metals Corporation. The specification and the procedure for hydride orientation were technically correct and complete. The procedure had been properly reviewed and contained the required signature approval.
ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA REPORT INSPECTION RESULTS: 3 AGE 11 of 14 N0.: 99900001/86-01 (3) Observation of Testing The NRC inspectors observed a technician performing hydride orientation tests utilizing the procedures discussed above. The tests were performed in accordance with the procedures.
(4) Fn Determination The NRC inspectors randomly selected samples taken from 10 lots and examined the orientation of the hydride - platelets. The Fn value for the 10 samples examined was determined to be less than 0.1 when compared with the standard photomicrograph.
- b. Metallography of Welds (1) Procedure Review The NRC inspectors reviewed B&W procedure number QC-900 (Addendum I), "Metallographic Sectioning MK B, MK C or Conn. Yankee Zircaloy Fuel Rods," Revision 6, dated March 20, 1984. This procedure provides the detailed steps for sample preparation and evaluation of fuel rod end plug welds. The procedure had been properly reviewed and contained the required signature approval.
(2) Observation of Testing The NRC inspectors observed a technician evaluating fuel rod end plug welds utilizing the procedure discussed above. The evaluation was performed in accordance with the procedure. (3) Overchecks by NRC Inspectors The NRC inspectors randomly selected samples of fuel rod end plug welds taken from 10 lots of fuel rods and evaluated the samples in accordance with QC-900, Revision 1. The NRC inspectors determined that the samples met the quality requirements of the procedure.
ORGANIZATION: BABC0CK & WILC0X COMPANY
. LYNCHBURG, VIRGINIA REPORT INSPECTION NO.: 99900001/86-01 RESULTS: PAGE 12 of 14
- c. Corrosion Testing (1) Procedure Review Section 4.1 of B&W specification number 08-1214, Revision 10 requires that corrosion tests be performed on 2 samples from each lot of finished tubing in accordance with ASTM-specification 8353-77A, " Standard Specification for Wrought Zirconium and Zirconium Seamless and Welded Tubes for Nuclear Service." B&W procedure number QC-823
" Corrosion Testing Specification," Revision 3, dated-April 10,1985, and B&W procedure number QC-823 App.I,
" Corrosion Testing Procedure," Revision 2, dated January 22, 1981, and B&W procedure number QC-823 App. II, " Corrosion Test Results," Revision 1, dated October 23, 1978, provide the steps necessary for implementation of ASTM B353-77A.
The specifications and procedures for corrosion testing were technically correct and complete. The procedures had been properly reviewed and contained the required signature approval. (2) Observation of Testing The NRC inspectors observed a technician performing corrosion tests utilizing the procedures discussed above. The tests were performed in accordance with the procedures.
- d. Nondestructive Examination (1) Procedure Review The NRC inspectors reviewed the B&W procedures for ultrasonic testing of tubing and fuel rod end plug welds, helium leak tests, gamma scans, alpha counting, and visual examinations. The procedures had been properly reviewed and contained the required signature approval.
( 2.) Observation of Testing The NRC inspectors observed technicians performing the above tests in accordance with procedures itemized as follows:
ORGANIZATION: BABC0CK & WILC0X COMPANY
- LYNCHBURG, VIRGINIA REPORT INSPECTION NO.: 99900001/86-01 RESULTS: ) AGE 13 of 14 (a) A technician performed circumferential and axial ultrasonic scans of zircaloy tubing in accordance with B&W procedure number QC-704, " Ultrasonic Testing of Tubing," Revision 2, dated October 23, 1981. The steps of the procedure were properly followed and results documented.
(b) A technician performed ultrasonic scans of the lower fuel rod end plug weld in accordance with procedure number QC-701, " Ultrasonic Examination of Clad to End Cap Weld of Mark B Fuel Rod," Revision 3, dated January 11, 1985. The steps of the procedure were properly followed and results documented. (c) Fuel rod assembly integrity is confirmed by helium leak testing. An operator filled the interior of the rods with helium through a hole in the end cap and fused the hole with a laser weld. This rod preparation was performed in accordance with B&W procedure number MA-451, "NSC Fuel Rod Weldment," Revision 41 dated October 30, 1985. The leak test was performed with a Veeco MS-90 helium leak detector in accordance with B&W procedure number QC-700,
" Helium Leak Detection," Revision 3, dated July 13, 1981. The steps of the procedure were properly followed and results documented.
(d) Final acceptance of loaded fuel rods requires alpha counting at the rod loading end for external contamination. The calibration of the alpha counting equipment was performed in accordance with B&W procedure number QC-703, " Procedure for Technical Setup and Process Qualification of Alpha Counting Equipment," Revision 1, dated April 7, 1978. The steps of the procedure were properly followed and results documented.
- (e) The NRC inspectors reviewed records of tests and equipment for gamma scanning of fuel rods in accordance with B&W procedure number QC-712, " Fuel Rod Scanning," Revision 2, dated October 15, 1980.
The test results provide information on enrichment detection of gaps in the fuel stack, and length of fuel in the rod. Observation of scanning verified that the steps of the procedure were properly followed and results documented.
ORGANIZATION: BABC0CK & WILCOX COMPANY
' LYNCHBURG, VIRGINIA REPORT INSPECTION RESULTS: ' AGE 14 of 14 N0.: 99900001/86-01
- 7. Conclusions Based on the above reviews and observations the NRC inspectors determined that B&W personnel are well trained and are using calibrated equipment in accordance with written procedures. No items of nonconformance were identified in the areas inspected.
F. PERSONS CONTACTED Babcock & Wilcox Corporation ,
*R. Al to
*W. T. Engelke
*R. J. Flicker
*B. W. Pugh
*C. W. Speight
*W. T. Foot
*J. L. Brown
*D. V. Ferree
*K. Harris E. Marshall R. Harper E. Elder J. Davis R. Davidson S. Carter G. Day J. R. Mayberry A. Reynolds C. Tweedy Sandvik Special Metals Corporation l J. Schemel
- Attended exit meeting.
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