t:)P

UNITEDSTATES

NUCLEARREGULATORY
COMMISSION
WASH|NGTON, D.C. 2055$0001

Decsnber
16. 1999
Mr.MarkJ. Kelly
10955SouthForkRoad
Dillsboro,
Indiana47018
SUBJECT:
ALLEGATION
NO. NRR-1999-A-0057
DearMr.Kelly:
Thisletterrefersto yourletterdatedSeptember12, 1999,to FionaTobler,NuclearRegulatory
(NRC).In thisletteryouexpressed
Commission
concernsrelatedto X-raydiffraction
texture
analyses
of zirconiumalloytubingperformed
at LambdaResearchLaboratory.Thisletteralso
refersto yourletterdatedOctober19, 1999,to MaryKayFahey,NRC,in whichyou provided
polefiguredatausedin thetextureanalysis.ln summary,you believe
examples
of erroneous
thaterroneous
or distortedanalysisresultsmayhavebeenreported
to fuelcladding
manufacturers
in the nuclearindustry.
On September
30, 1999,we hada conference
callwithyouto gatherinformation
relating
specifically
to a potential
discrimination
issueyouidentified
to us on September
29, 1999. On
October9, 1999,we a hadfollowup conference
callwithyouto identifythe agentassigned
to
the investigation
andto schedulean interview.Duringour conversation
you requested
NRCto
putthediscrimination
investigation
on hold,butpursuethetechnical
allegations.
Basedupon
yourrequestthe Officeof Investigations
willnot pursueyourallegation
of discrimination.
ln pursuing
the technicalissueswe informed
youon October27, 1ggg,of our intentions
to
contactexpertsin the fieldof textureanalyses
to helpus understand
the safetysignificance
of
yourallegation.Baseduponour reviewandthe information
obtainedfromthe experts,we
believethatthe problems
withLambdaResearch's
textureanalysismaybe attributed
to poor
controlof specimenpreparation
andtextureanalysisprocedures.
Further,we believethat
textureanalyses,
in general,cannotbe usedto inadvertently
qualifyunacceptable
material.The
intrinsic
properties
mechanical
of zirconium-based
tubingmaterialcannotbe determined
from
textureanalysis.Therefore,
we haveconcluded
thaterrorsresulting
fromthe textureanalysisat
LambdaResearchin the development
of engineered
components
is not a safetyconcern.NRC
did notpursuethe issuefurthersincewe determined
it is nota safetyconcern.
C ER T I F I EMA
D IL
RETURN
RECEIPT
REQUESTED

CornplainantExhibit
Page:fl
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fll
Mr.M. Kelly

-2-

Theenclosure
to thisletterprovidesa moredetailedsummaryof the resolution
of your
us of yourconcerns.We feelthatour actionsin thismatter
concerns.Thankyoufor informing
havebeenresponsive
to thoseconcerns.We takeoursafetyresponsibilities
to the publicvery
andwillcontinueto do so withinthe boundsof our lawfulauthority.Unlessthe NRC
seriously
receives
additional
information
thatsuggests
thatour conclusions
shouldbe altered,we planno
questions,
furtheractionon thismatter.Shouldyou haveanyadditional
or if we can be of
in thismatter,pleasecallFionaTobleror GregCwalina,SeniorAllegation
furtherassistance
on the NRCSafetyHotlineat 1-800-368-5642
Coordinators,
or FaxNumber1-301-415-3741.
Sincerely,

f/r-/"e & I
TheodoreR. Quay,Chief
VendorInspection,
QualityAssurance,
Maintenance
andAllegations
Branch
Divisionof Inspection
ProgramManagement
Officeof NuclearReactorRegulation
Enclosure:Statement
of Concernsand
NRCResponse
Allegation
No.NRR-1999-A-0057

Complainant Exhibit
Page:77.
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l7L
ALLEGATION
NRR-1
999-A-0057
CONCERNS
1 THRU3
ANALYSES
ALLOY
TEXTURE
OF ZIRCONIUM
1
CONCERN
at LambdaResearch
textureanalysesof zirconium
alloytubingperformed
X-raydiffraction
thatanalysesperformed
at Lambdaare in error
are in question.Theallegerbelieves
Laboratory
may
have
been
reported
like
GE
Nuclear.
He
alsosuspectsother
results
to clients
anddistorted
BettisandWesternZirconium
maybe involved.Writtenprocedures
at
clientslikeWestinghouse
andsomesimplycannotbe followed,becauseof the problems
werenotfollowed,
the laboratory
training,andsoftware.
withthe procedure,
NRCRESPONSE:
and requires
thatpropersamplepreparation,
Theareaof textureanalysisis veryspecialized
personneltraining
procedures,
andequipment
are utilizedto produceaccurateresults.As
Techniques
for ZircaloyCladding:
notedin a 1982paper,"TextureMeasurement
A Roundwhichwaspublished
by J.E.,Lewis,et al.in the FifthConference
RobinStudy,"
on Zirconium
in
thereare manyareasthatrequirecarefulconsideration
whenperforming
the NuclearIndustry,
withparticular
textureanalyses.Theseareasincludeproperspecimenpreparation
attention
to
properspecimenalignment
on the goniometer
theflatnessof the specimen,
axis,diffraction
of the correct2O-peak,
focusingcircle,andselection
amongotherthings.
12,1999,letter
As notedin yourSeptember
to NRCandothersupporting
documents,
Lambda
seemsto havehadsomeproblems
Research
controlling
the flatnessof the specimenand
identifying
the correct20-peakpositionpriorto conducting
textureanalyses.Thesedeficiencies
"distorted"
werereportedby the allegerto haveresultedin
intensity
distributions
andthishas
LambdaResearch
alsoproducedpolefigureson severaloccasions
beensubstantiated.
which
of a 90-degree
specimenrotationproblem.However,
it seemsthat Lambda's
wereindicative
of thistypeof errorandrequested
thatLambdarepeatthe analysis.
clientswerecognizant
theseproblemsare indicative
of the needfor bettertrainingof LambdaResearch's
Overall,
personnel
whoprepare
runtheequipment
thespecimens;
andacquire
the data.
in specimenpreparation
(i.e.,
Withrespectto the deficiencies
andthe textureanalysistechnique
position),
identification
of the correct2O-peak
we believethatthe allegeris makingeveryattempt
and producemoreaccurate,
to correctthe situation
consistent
data. Adherence
to the most
TestMethodfor Preparing
recentASTMStandardE 81-96,"Standard
Pole
Quantitative
whichcontainsupto-dateprocedures
Figures,"
for conducting
textureanalysiswithmodern
mayhelpto preventthesetypesof problemsin the future.Further,
x-raydiffraction
equipment,
providedat the endof thisdocumentmaybe usefulfor makingcomparisons
the references
dataandotherdatasetsregarding
betweenLambdaResearch's
the textureof various
materials.
zirconium
Complainant Exhibit
Page:13
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we consulted
withtwo expertsin thisfield.
Sincethe areaof textureanalysisis veryspecialized,
professor
was conducted
witha materials
scienceandengineering
who
Oneof the interviews
manypaperson thetextureanalysis
of zirconium-based
alloys.Thesecond
haspublished
was conducted
witha seniorengineerof oneof the majornuclearfuelfabrication
interview
in textureanalysisfroma fuelcladdingdesignperspective.
who hasexperience
companies
results"canbe
Thesetwoexpertsstatedthatthe generation
of "baddata"and/or"distorted
poorsamplepreparation,
including
to manysources,
inexperienced
attributed
analysts
or
controlof thedataacquisition
andinadequate
equipment
andprocedures.
technicians,
thatthetechniques
for textureanalysiscannotinadvertently
However,
theybelieved
employed
material.In otherwords,the datafroma properlyprepared
be usedto qualifysubstandard
prepared
usingequipment
thathasbeenadequately
fortextureanalysis,
specimen,
willproduce
(or material's)
resultsthatare representative
of the specimen's
texture.Forexample,one
that,usingthe basaldirectpolefigure,substandard
expertconcluded
materialcouldbe
if the peakintensities
and/orthe locations
identified
of the peakmaximawereoutsidetheir
ranges.Thus,if the textureanalyses
acceptable
wereconducted
on "goodmaterial"
butthe
poorly
prepared
(e.9.,
was
specimen
the surfaceis roughorwavy),the textureanalysisresults
wouldtendto havecharacteristics
thatcouldindicate
the materialmaybe "unacceptable."
if thetextureanalysisis performed
Alternatively,
on poorqualitymaterial,
the characteristics
of
poor.
the datawouldshowthe materialis
Bothexpertsbelieved
thattextureanalysis,
alone,
properties
cannotbe usedto determine
the intrinsic
mechanical
of zirconium-based
tubing
material.Rather,as oneexpertsuggested,
textureanalysiscanbe usedto estimatemechanical
properties
relativeto certaindirections
of the tubing(e.9.,the resultsof a textureanalysismay
showthatthetensilestrengthof the tubein the axialdirectionis larger,or smaller,thanthe
in the radialdirection).
tensilestrength
We areunsurehowGE Nuclearor LambdaResearch's
otherclientsusethe textureanalysis
results.However,
oneof the expertsstatedthathiscompanydoesnotconducttexture
i.e.,directpolefigures,
on a routinebasistoevaluate
analyses,
characteristics
of thetubing.
The
textureanalysesare conducted
typicallyas partof an evaluation
of newproductmaterialor a
process.Alternatively,
newmanufacturing
hiscompanyemploysa testthatevaluates
the
contractile
strainratio(CSR)as a checkon the controlof the tubingmanufacturing
processes.
properties
Then,the mechanical
of the claddingare correlated
to the CSR, Whenthe calculated
properties
CSRis foundto be withina specified
range,the mechanical
of the materialarefound
to be acceptable.In additionto the CSR,the expert'scompanyalsoperformsa tensiletestto
properties
the mechanical
evaluate
of thecladding
on a perlotbasis.
In summary,
the problemsassociated
withLambdaResearch's
textureanalysis,
we believe,
poor
preparation,
from
control
stem
of specimen
training,softwareandtextureanalysis
procedures.
Thesedeficiencies
resultedin "distorted"
intensity
distributions,
andthishasbeen
substantiated.
However,
we alsobelievethattextureanalysesalonecannotbe usedto
qualifyunacceptable
properties
inadvertently
material.The intrinsic
mechanical
of
zirconium-based
tubingmaterialcannotbe determined
fromtextureanalysis.We have
thaterrorsresulting
fromthe textureanalysisat LambdaResearchin the
concluded
-2Complainant Exhibit
page:1y .
2_3

9 ttstrb

l-)
components
is nota safetyconcern.Therefore,
the NRCdid not
of engineered
development
pursuewhetherdistortedresultswerereported
to Lambda's
clients.
C O N G E R2N:
refusedto allowthe allegeror anyoneelseto reviewthe
Theownerof the companyrepeatedly
pastzirconium
alloytextureanalysisreportsanddata,whichwoulddetermine
if the problems
have
caused
bad
data
withthe analyses
to be reported
to the clients.
NRCRESPONSE:
Baseduponour response
to Concern1 andourdetermination
thatthe issuesinvolvedwerenot
the NRCwillnotpursuethisconcern.
safetysignificant
C O N C E R3
N:
Fearof Retaliation:
Theallegerbelieves,
if the ownerof LambdaResearch
wereto findoutthathe discussed
these
probably
withNRC,GE Nuclear,
concerns
or otherclients,he would
makechanges.
N R CR ES P ON S E :
30, 1999,we hada conference
On September
callwithyouto gatherinformation
relating
to a potential
discrimination
issueyouidentified
specifically
to us on September
29, 1999.On
October9, 1999,we hada followup conference
callto identifythe agentassigned
to the
investigation
andto schedulean interview.We explained
thatan investigation
by ourOfficeof
Investigations
intoyourallegation
of discrimination
by LambdaResearch
couldnot be pursued
withoutyourapprovalto releaseyouridentity.Duringourconversation
yourequested
NRCto
putthediscrimination
investigation
on hold,butpursuethetechnical
allegations.
Basedupon
yourrequestthe Officeof Investigations
willnotpursueyourallegation
of discrimination.
Therefore,
NRCdoesnotplanon takinganyactionon thisconcern.

ComplainantExhibit
lf .
Page:
77

-3-

B f,$rstio

R E F ER E N GE S :
"Thermomechanical
andJ.H.Schemel,
Controlof Textureand
J.M.Dahl,R.W.McKenzie
ASTMSTP551,
TensilePropertiesof Zircaloy-4Plate,"in Zirconiumin NuclearApplications,
pp.
AmericanSocietyfor TestingandMaterials,
1974, 147-159.
"Texture
andR.B.Adamson,
Measurement
J.E.,Lewis,G. Schoenberger,
Techniques
for
A
Cladding:
Round-Robin
Study,"
in
Zircaloy
Zirconiumin the Nuclearlndustry:Fifth
ASTMSTP754,D.G.Franklin,
Conference,
Ed.,AmericanSocietyfor Testingand Materials,
1982,pp 39-62.
"A Reviewof TextureandTextureFormation
E. Tenckhoff,
in ZircaloyTubing,"in Zirconium
in
ASTMSTP754,D.G.Franklin,
the Nuclearlndustry:FifthConference,
Ed.,AmericanSocietyfor
TestingandMaterials,
1982,pp.5-25.
"TextureDevelopment
and P.L.Rittenhouse,
E. Tenckhoff
andTextureGradients
in Zircaloy
Tubing,"in Applications-Related
Phenomenafor Zirconiumand ltsAlloys,ASTMSTP458,
1 9 6 9p, p . 5 0 - 6 7 .

Complainant Exhibit

Z7

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Pase:
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h t tso?

UNITED
STATES
NUCLEARREGULATORYCOMMISSION
wASHtNGTON,D.C.20555-0001

M a r c h1 0 , 2 0 0 0
Mr.MarkKelly
10955SouthForkRoad
Indiana47018
Dillsboro,
NO.NRR-2000-A-0009
SUBJECT:ALLEGATION
DearMr.Kelly:
concernsrelatedto
Thisrefersto yourletterdatedFebruary18,2000, in whichyouexpressed
for raisingissuesregarding
aboutretaliation
LambdaResearchInc.Youwereconcerned
of information.
testingandfalsification
inaccurate
yourconcernsas we understand
them. We haveinitiated
1 to thisletterdocuments
Enclosure
of your
on the basisof our understanding
actionsto examinethe factsandcircumstances
is notaccurate,pleasecontact
of yourconcernsin the enclosure
concerns.lf the description
your
beforewe startour review.
concerns
understand
we
correctly
that
I
assure
me so that can
please
for raisingsafetyconcerns,
discrimination
Bothof yourconcernsinvolvesemployment
andwilldetermine
of discrimination
all allegations
be awarethatthe NRCdoesnot investigate
youwould
identifying
without
your
An
evaluation
in
case.
is
warranted
investigation
an
whether
please
that
in
aware
be
investigate,
NRC
does
if
the
Therefore,
difficult.
be extremely
NRC
Furthermore,
yournamewillbe disclosed.
yourclaimof discrimination,
evaluating
complete.
18
months
to
to
maytakeup
discrimination
of yourclaimof employment
evaluation
of Labor.lf you
withthe Department
thatyouarefilinga complaint
Yourletterto us indicated
withDOL,pleasesenda copyto us also.
havefileda complaint
regarding
to yourallegation
In my earlierletterto youdatedOctober20, 1999,pertaining
Concerns
Safety
"Reporting
youan NRCbrochure
entitled,
tambdaResearchInc.,I provided
protection,
andthe
process,identity
on the allegation
to the NRC." lt includesinformation
of Labor.
againstworkers,handledby the Department
processing
of claimsfor discrimination
please
me.
contact
you
copy,
Should needanother
our
Thankyoufor notifyingus of yourconcerns.We willadviseyouwhenwe havecompleted
interim
the
during
questions
or comments
shouldyou haveany
reviewof thismatter.However,
at 1-800-368-5642.
toll-free
me
or
please
Greg
Cwalina
either
call
matter,
this
regarding
Sincerely,
i ..,/

,.-/.*/

.// r2

/tt {/-.t*-,t.,
, Y-r'*,'*
/
Coordinator
F ionaT. Toblbr,SenioiAllegations
Officeof NuclearReactorRegulation
Enclosures:As stated
MAIL
CERTIFIED
REQUESTED
RECEIPT
RETURN

Complainant Exhibit

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