ML18065A144

Part 21 Rept Re Fastener Products (Hex Bolts) Mfg by Cardinal Industrial Products.Bolts Used as Header Cover Plate Bolts in Safety Related Containment Air Cooler Replacement Cooling Coils Furnished by Aerofin Corp to CPC

ML18065A144
Person / Time
Site:	Palisades
Issue date:	10/04/1995
From:	Elliott B External (Affiliation Not Assigned)
To:	Dotson B CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.), NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-95 NUDOCS 9510110287
Download: ML18065A144 (11)

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'4£RDFIN CDRPDRt4TIDN AERO FIN STANDARD AND CUSTOM ENGIH£ER£D New York Home Chicago Office HEATIND AND CODLING SURMCE Dallas and Plant San Francisco Lynchburg Atlanta Virginia P.O. BOX 10819 LYNCHBURG. VlllGINIA 24506 1-800-AEROFIN Phone: 804-845-7081 Fax: 804-845-3508 October 4, 1995 C~C.=-~w.itf.l.a.ttaef.irner:fts~7 Document Control Desk CJ:S.-..:ol'NUGlear~F.aegul-ator;y...G0m missi0A!

Washington, D.C. 20555 Ms. Barb Dotson Consumers Power Company Palisades Nuclear Plant 22780 Blue Star Memorial Highway Covert, Ml 49043-9530

Subject:

10CFR21 Report

Reference:

1) Consumers Power Purchase Order G0109437

2) Aerofin Shop Order No. 947963

3) 10CFR21 Report from Consolidated Power Supply to Aerofin dated October 3, 1995 {attached)

4) Aerofin ASME Design Report dated 11f7/94 {cover page and pages 26 & 27 only - attached)

Dear Ms. Dotson:

Aerofin received notification on October 3, 1995 from Consolidated Power Supply that a report has been issued to the United States Nuclear Regulatory Commission (NRC) regarding fastener products manufactured by Cardinal Industrial Products. Included in the report to the NRC were 1,475 hex bolts {5/a*-11 x 3 inches, ASME SA193, Grade B7) which were used as header cover plate bolts in the Safety Related containment air cooler replacement cooling coils furnished by Aerofin to Consumers Power Company (Reference 1). These thirteen coils (twelve coils plus one spare) were shipped to the Palisades Nuclear Plant on or about November 16, 1994.

~-~\) .

( 9510110287 951004 1I

. PDR ~ADOCK 05000255 s_ *----* L __ . ___ PDR

Ms. Barb Dotson Consume~ Power Company

• 10CFR21 Report Page 2 Tlie bolts' in question are listed as Item #16 on *as-builtu drawing QA-R-1012 dated 11/1/94 included with the Aerofin Quality Assurance Data Package for this equipment.

• These bolts are identified by Cardinal Industrial Products Heat No. CK256 (856 pieces, Trace Code TU2) and Heat No. L63051 (619 pieces, Trace Code CX1). Of the 1,475 bolts purchased by Aerofin, 1,456 were actually used in the coils.

The deficiency involves apparently inadequate heat treatment which has resulted in mechanical properties below required minimums, although no actual test results have been received at this time. Please see the attached copies (Reference 3) of the notification received from Consolidated Power Supply and reports from Cardinal Industrial Products.

Preliminary information indicates that the worst condition identified to date is tensile strength that is 70 percent of required value. Because we have no officiaJ data at this time with which to evaluate whether a substantial safety hazard may exist and as required by 10CFR21, we are also notifying the NRC of this condition by copy of this letter.

It is worthy of note that the margin of safety for the header bolts as evidenced by Aerofin's ASME design report calculations (Reference 4) is quite high. Coupled with the fact that actual maximum system operating pressure is on the order of 80 psig compared to a design pressure of 150 psig, there is significant margin available to accommodate substandard bolt strength characteristics.

As soon as additional information is received by Aerofin it will be communicated to Consumers Power Company. If you have any questions at this time, please contact me at 804-528-621 O (telephone) or 804-528-6243 (telefax).

Very truly yours,

/L(!

Brian C. Elliott, P.E.

Manager Nuclear and Code Products cc: D. L. Corell, Aerofin President and Chief Operating Officer

CONSOL/DA TED POWER SUPPLY 3556 MARY TAYLOR ROAD BIRMINGHAM, AL (USA) 35235 PHONE: (205) 655 - 5515 FAX: (205) 655 - 5511 FACSIMILE TRANSMISSION TICKET DATE: ___.J.......,~)--=3~/__

~,

C)...._~--- TIME: /Z..2 S:

NUMBER OF SHEETS TO FOLLOW: _b ______

TO: -J;;;,7 J-k,.J/u FROM: $~ ,(/nc/r~s_

TYPE OF DOCUMENT TRANSMITTED: ----~=-°'"-"cf'--**__z~l----.f'"~l!,/):;o.;"......dt

. .* . _l.. .<:<~**lf:c_.

I

ConsO,idat:ed Po1Ner §upply October 3, 1995 Aerofin Corporation 4621 Murray Place Lynchburg, VA 24505 Attn: Mr. Tony L. Hawks QA Lead Auditor

Subject:

10CFR2 l Report

Reference:

Aerofin Purchase Order 13822, Dated March 15, 1994

Dear Mr. Hawks:

Consolidated Power Supply (CPS) has received correspondence from Cardinal Industrial Products that a report has been issued to the United States Nuclear Regulatory Commission regarding fastener products provided to your coinpany agaimt the refemiced order. Included in the report were 1475 each of s1s*-11 X 3* SA193 B7 hex bolts, which were initially certified by CPS and shipped to your Lynchburg facility on May 25, 1994.

Heat codes included TU2 (856 each) and CXl (619 each) and were shipped to Aerofin directly from, Cardinal* s Las Vegas, NV facility. The material was certified as meeting the requirements of the AS.ME Code, Section lil, 1989 Edition No Addenda.-

The deficiency involves the apparent inadequate heat treatment of the bolts, which has effected the mechanical properties. No actual test result values have been conveyed at this time by Cardinal; however, the testing indicates results below the required minimums based upon the Cardinal reports.

Please find attached a copy of the reports received by. CPS on 10/2/95 from Cardinal rel~ve to the

• referenced order.

As soon as additional information is received by CPS it will communicated immediately to Aerofin. If there are any questions please criutact the undersigned.

Sincerely,

~t~

Steven W. Andrews Quality Assurance Manager Attachment* Cardinal Reports (4 Pages Total) cc: H. Kerr - President. CPS, w/a M. Mathias - Gen. Mgr., CPS, w/a 3556 Mary Taylor Road

• Birmingham. Alabama 35235 * (205) 655-5515

~ 01\1sion of C.:msolidared Pipe & SuP'-Y Co,, Inc. Birmingham, AL

cardi*al INDUSTRIAL. PRODUCTS Nucll!ar Oiv1s1on of B&G l\l;tnufacturinq Company. Inc.

3873 Wast Oquendo

• Las Vegas, Nevada 89116-3098 (702) 739-1968

• Fex (702) 739-1960 Date: SEP 2 9 1995 customers Name:~...-.C~o~n~s~o~l~iydua~t~e~d=--P~o~w~e~r.......:S~u~p~p~l~Y

.....~~~~

3556 Harv Taylor Road Birmingham. AL 35235 Attention: Steve Andrews Manager of Quality Assurance From: David Z. Hathcock, Quality Assurance Manager

Subject:

10 CFR Part 21 notification reporting of Defects and Noncompliance. *

Reference:

Description 5/8-11 x 3" Al93 B7 Hex Bolt PU.rchase order P65-49042 Line Item l Qty. 856 Product MarltjJlq B7, c. TU2 Shipment Date 05/24/94 ,*

Please be advised that the above referenced fasteners that .were s.upplied to you by cardinal Industrial Products L. P. originated from a heat lot charge that ~ontained defective product.

This discrepancy was discovered during a customer's receipt inspection.. B&G ManUfacturing Co. , Inc's Cardinal Industrial Products division, which earlier this year purchased certain assets from Cardinal Industrial Products, L.P. including the name, has conducted an preliminary internal investigation which has confirmed that as many as 25% of the fasteners from the heat lot charge may have mechanical properties bel~w the specified minimUlllS.

Early indications suggeSJt that the discrepancies resulted from inadequate heat treatment *. A comprehensive investigation is being conducted to determine the exact cause of the problem. We will provide a detailed report within sixty {60) days.

-* Page 2 of 2 This notification is provided by B&G as a service to its current customers who may have purchased this product from the prior owner, so that you can conduct an evaluation to determine if this product defect creates a substantial safety hazard in accordance with 10 CFR Part 21 paragraph 21.21 (a) (1) (ii) and (b) (1). We have reported this problem to the Nuclear Regulatory Commission (NRC)

Inquiries may be directed to me at (702) 739-1966, Fax (702) 739-1960.

cc: customer file

Cardi*al INDUSTRIAL PRODUCTS tJuclear 01vis1on ol B&G Manutaclurrnq Company. Inc.

3873 West Oquendo

• Las Vegas. Nevada 89118-3098

,. .(702) 739-1966 *Fax (702) 739-1960 Date: SEP 2 9 1995 Customers Name:~_...c_o~n=s~o_l~i_d_a~t~e~d.....,.P~o-w~e~r-..S~u~p~p~l~v.._~~~~

3556 Marv Taylor Road Birmingham, AL 35235 Attention: Steve Andrews Manager of Quality Assurance From: David z. Hathcock, Quality Assurance Manaqer

Subject:

10 CFR Part 21. notification reportinq of Defects and Noncompliance.

Reference:

Description S0~-11 x 3 11 Al93 B7 Hex Bolt Purchase order 065-49042 Line Item lA Qty. 619 Product Marltj.nq BZ. C. CX1 Shipment Date 05/24/94 Please be advised that the al::love referenced fasteners that were supplied to you by Cardinal. Industrial Products L.P. originated from a heat lot charge that c:::ontained defective product.

This discrepancy was discovered durinq a customer's receipt inspection. B&G Manufacturinq co. , °Inc's Cardinal Industrial Products division, which earlier this year purchased certain assets from Cardinal Industrial Products, L.P. including the'name, has conducted an prelilninai:y internal investigation which has confirmed that as many as 25% of the fasteners from the heat lot charge may have mechanical properties below the specified minimums.

Early indications suggest that the discr~pancies resulted from inadequate heat treatment. A comprehensive investigation is being:

conducted to determine the exact cause of the problem. We will provide a detailed report within sixty (60) days.

.. Page 2 of 2 This notification is provided by B&G as a service to its current customers who may have purchased this product from the prior owner, so that you can conduct an evaluation to determine if this product defect creates a substantial safety hazard in accordance with 10 CFR Part 21 paragraph 2l..2l. (a) (l.) (ii) and (b) (l.). We have reported this problem to the Nuclear Regulatory Commission (NRC)

Inquiries may be directed to me. at (702) 739-l.966, Fax (702) 739-1960.

cc: customer file

~***

DESIGN REPORT ASME BOILER AND PRESSURE VESSEL CODE SECTION rn, DIVISION l, CLASS 3, SUBSECTIONS ND & NF iqeq EDIT!ON ~c ADDENDA BUYER: CONSUMERS DOWER COMPANY REVIEWED FOR PALISADES NUCLEAR PLANT PURCHASE CRDER NUMBER G0109437 CONSUMERS POWER CO.

SARGENT & LUNDY ENGINEERS

1. \{NO 8<CEPT!ON TAKEN. comAACTOR AERCF IN TYPE R co I LS I\ MAY FRCGF:ED WITH FABRlCATION OR GONSTRUCTICN.

2 1 RE\'ISE AS NOTED AND RESUBMIT. AERCFIN SHOP OP.DER CR-947963

.... CmlTRACTOR CAN PROCEED SA SEO I t e 111 s

• 001 th r u 013 ON \1Al\ING REVISIONS NOTED.

3. 0 RESULTS DO NOT M£ET sr:C!F!CA*

TION REQUIREMENTS. REVISE ANO RESU8~.1:T SPECIFICATION M-60A, REV. A ANY ACTION SHOWN ABOVE IS SUBJECT TO THE TEP.MS Or THE CONTRi'~cr AND DOES NOT RELIEVE CONTRACTOR FROM H!S OBL!GA-TiONS UIWER THE CONTR.~.CT, INCLUD!~iG DESIGN AND CETAIUNG.

FOR *****-**~*~ ..~--..f?:.~~~.t::.!.~.'::!I._921~-s page l of 39 EQUIPMENT NO .....Y.'.H.~::L_f._.L~---

BY ...l..~-~..':?.~.~}.~.DATE ... -H::..!.~~1-AEROFIN CALCULATION FILE SPEC. NO.~~.?.- PROJ. NO. .3J_~o CA-52q-546 Rev 4 9\qlo-ol PREPAF!ED BY

• I/ Y,y AEROFIN CORPORATION NBERGER 4621 MURRAY PLACE ENGINEER PO BOX 10819 . ,, .,

LYNCHBURG, VA 24500 ~/

APPROVED BY: 6--:-r'-</" //- /-~'* Y' AR ROLL VICE PRESIDENT ENGINEERING

ASME SECTION III, SUBSECTION ND DESIGN REPORT PAGE 26 OF 39 AEROFIN CALCULATION FILE CA - 529 - 546 REV. 1 HEADER BOLT ANALYSIS Bolt Material: ASME SA-193 Gr. 87 5/8 in. Diameter.

Tensile Stress area = .226 in 2 Allowable stress = 25000 psi [ASME Section III Table I-7.31 Minimu~ ultimate tensile strength = 125000 psi [Table I-7.31 The header bolts are subjected to loads due to pressure, gasket seating, and nozzle loads. These loads are summed to £ind the worst case stress on any 0£ the bolts.

From the specification, Nozzle Forces <lbs> and Moments (in-lbs> are Fx= 1200 Fy= 1200 Fz= 1200 Mx= 7200 My= 7200 Mz= 7200 PRESSURE LOAD Re£. ASME Sec.III, Appendix XI-3220 Pforce = Force I bolt due to pressure P£orce = pressure

• area I number 0£ bolts P£orce = 150

• Cl8.5

• 51.0> I 56 = 2,527.3 lbs/Bolt GASKET LOAD Re£. ASME Sec. III, Appendix XI-3221.1 E££ective gasket seating width: Re£. ASME Section III Table XI-3221.1-2 For perimeter gasket bol = CW+ T>l2 = Cl.5 + .125> I 2 = .8125 bl = .5 *sqrt Cbol> = .5

• sqrtC.8125> = .4507 For ba££le gasket bo2 = <W + N > I 4 = C. 25 +

• 375 > I 4 =

• 156 b2 = be= .156 Gi = Perimeter at gasket reaction Gl = 18. 5 in.

G2 = 51. 0 in.

G£orce = Force I bolt due to gasket reaction G£orcei = 2

• bi

• mi

• pressure

• Gi I number 0£ bolts G£orcel = 2

• 0.4507 * . 50

• 150

• 20.0 I 56 = 24.1 lbs/bolt G£orce2 = 2

• 0.156 * . 50

• 150

• 51. 0 I 16 = 74.6 lbs/bolt G£orce = 24.1 + 74.6 = 98.7 lbs/bolt NOZZLE LOADS Axial £orces on bolts are induced by Fx, Fy, Fv, My, & Mv.

Bl = # of bolts on long side; Bs = # 0£ bolts on short side Dl & Ds = Center to center distance between bolts on long & short sides Bl = 1 7, Bs = 7, Dl = 52.5, Os= 20.0

AS'ME *sE:c:rION III, SUBSECTION ND DESIGN REPORT PAGE _27 OF _39 AEROFIN CALCULATION FILE CA - 529 - 546 REV. 2 HEADER BOLT ANALYSIS continued Fl = £orces on long side bolts due to Fx, Fy & Mv Fl = <Fx I Bl> + (2 * <Mz + Fy

• a) I <Bl

• Os>>

Fl = (1200 I 17) + <2 * <7200 + 1200

• 9.875) I (17

• 20. 5) )

Fl = 180 per bolt Fs = £orces on short side bolts due to Fx, Fv & My Fs = <Fx I Bs> + <2 * <My + Fz

• a> I <Bs

• 01))

Fs = (1200 I 5> + <2 * <7200 + 1200

• 9.875) I <5

• 52. 5) )

Fs = 385.1 per bolt TOTAL TENSILE STRESS Long side tensile £orce per bolt = Tl = Fl + plead + gload

= 180 + 2,527.3 + 98.7 = 2806 Short side tensile £orce per bolt = Ts = Fs + plead + gload

= 385.1 + 2,527.3 + 98.7 = 3011. l Tensile stress = Tensile Force I Stress area Tensile stress on long side bolts = 2806.0 I .226 = 12,416 psi Tensile stress on short side bolts= 3011.1 I .226 = 13,323 psi For calculations use the larger 0£ short or long side stress Total tensile stress = Saxial = 13,323 psi SHEAR STRESS Shear stresses are induced by Mx Shear £orce = Fs = 211x I 4*d, d = longest perpendicular distance £ram moment to bolts <4 corner bolts>

Shearing Force =-- 2

• 7, 200 I 4

• 40 = 90 Shear Stress= Shear £orce I stress area= 90 I .226 = 399 psi MAXIMUM BOLT TORQUE <Re£ Spotts p 276>

T = 0.2 *Area* dia<major> * <0.7

• Ult strength>

T = 0.2

• 0.226

• 0.625 * <0.7

• 125000> /12 <12 converts to £t-lbs>

T = 206 £t-lbs COMBINED TENSILE AND SHEAR STRESSES Combined tensile and shear stresses must not exceed the ellipse equation given in NF-3324.6<3> (1986 Code].

The 1989 Code does not address allowable shear stresses £or non-welded pressure-retaining components. There£ore, using allowable shear stress equation £or structural components in 1989 Code NF-3324.6, Fvb = .62 *Su I 3 = .62

• 125000 I 3 = 25,833 Ftb = Su I 2 = 125,000/2 = 62,500

<£ta I Ftb 2 > + <£v 2 I Fvb 2 > S 1 (13,323 2 I 62,500 2 ) + <399~ I 25,833~> = .0454 + .00024 = .04568 << 1 CONCLUSION: The ellipse equation is satis£ied. Actual bolt stresses art within allowable limits.