ML19345D507
| ML19345D507 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 11/14/1980 |
| From: | Harbison D NPS INDUSTRIES, INC. |
| To: | Stello V NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| References | |
| REF-PT21-80-232-001 DGH-714, NUDOCS 8012150252 | |
| Download: ML19345D507 (14) | |
Text
- . ;- -
PART 21 IDBRIFICATION NO. %- 2.5 z-con CUPAW IWE.We+ri% Lt.-
1 RTE OF LET1R ukW\6o DOCKET NO.60-37A 33o DAR DISTRIBUTED ideo e rn . ORIGIIML REPORT SLPPLDENTARY E
DISTRIBUTION: -
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PEACTOR (R) i FLEL CYCLE & SACEGLIARDS (Sh J IEFILES [WTERIALS (FD IE files '
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VSiD3R BR. R-IV VsO3R BR R-IV \C.]R BR. R-IV IIFB / FPA FIB 5715 RSS / FO S SS-395 NRR/D7_
EOD tiG 7632 LDEB/FPA fig 5715 IM S / SG SS-881 N??HE AEDD FTB 7602 LOEB/FPA FIG 5735 N?P/DSI ASB? FM 450 EOD f4G 7602 IEN '
SAD /SP tiG-7210A ASBP E/W 450 -
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CENTRALFILES 016 CENTRALFILES 016 ASBP % 450 CSiTRAL files ( G RON) CB1 TRAL FILES (CHRON)
C6iiRAL FILES 016 PDR CENTRALFILES SS-395 CasTRAL FILES (CHRON) LPDR . PDR PDR TERA LPDR LPDR TERA M7=
ACTION:
FRELIMINARY EVALUATION OF THE' ATTACHED REPORT IfOICATF.S LEAD RESPONSIBILI'P/ FOR FO'LOWJ? AS SH3WN BELOW:
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.. ops IndUStn,eS 31003 ,to-232-cm one hormon plcza ::ovember 14, 1980 secoucus.new Jersey 07094 DGH-71'.
ops m sos-osso teiex i4 i43s File
Reference:
NPSI/NRC-01-001 Nuclear Regulatory Co==issim b "D~d- DM Office of Inspectim & Enforcement .
Washingtm, DC 20555 Attentim : Victer Stello - Director
Subject:
Reporting of Defect & Nmccepliance Reference : NPSI Letter DGH-573, dated June 1c, 1980 Scuthern Bolt & Foundry Gentlemen :
Tnis letter will serve as a follow-up to the reference letter which informed you of a potential defect of Noncompliance under the rules of Federal Register 10 CFR Part 21.
At the time of our report on June 16, 1980, preliminary investigaticns had revealed the potential defect. Since that time a very theurough investigaticn by Bechtel, NPSI, and Southern Bolt & Foundry has been ccnducted. The results of that investi-gation is detailed in Attachments I & II. Acditimal documents are en file and available for review if necessary. Both Censumers Power and Bechtel-Midland Project have been kept informed of the status during the investigaticn.
Defective caterials have been identified anc corrective acticn has been completed with the exception of final Taplacecent cf the materials at the site. As identified in SEF ccver letter ( Attachment II) the replacement caterials are awaiting heat treatment processing. The date for completim cf that process and final source inspecticn by NPSI is expected to be approximately December 1, 1930. A final repcrt will be for-warded to you after the replacement =aterials have been installed or received at the site and the defective raterials have been retu:ted to S3F.
^ 21d you have any questicns regardin3 this re pert , please contact us.
Very truly ycurs, NPS I JSTRIES, "C.
~
/Y pcnald Harbison Corpcrate Mgr. of Quality Assurance E :C cc: New Jersey Austin Portland
~
J. Barton - President R.O. Nermand J. Takeuchi
. L. Hovi - Sr. Vice President L. Walker A. Halamay F. Sugar .
. K. Hanna R. Alexander - Scuthern Bolt & Foundry
SOUTHEAN BOLT C F ARTEN2R CORDORATSON P. O. BOX 7196 301 MONTGOWER Y TELETHONE A REA l2181221-4251 SHREVEIOR T. L OutSIA r.:.
iSBi .
July 9, 1980 h7S Industries, Inc.
10420 Metric Blvd.
Austin, TX 78758 ATTN: Mr. Don Harbeson Re: SBF letter to NPSI dated 6/11/80
Dear Don:
Enclosed please find a copy of the completed SBF investigation of the defective material covered by our MTR No. 5795. As agreed to earlier, we conducted a thorough in-house investigation of the events surrounding the occurrence, and are now satisfied with the conclusions drawn by the investigators.
Upon your review of the report (attached to the NCR No. 157-A),
please immediately advise me should you have any questions. Also, please be advised that the report for the defective material described by MTR's 6370, 6371, 6372,'6373, 6374 shall be sent next week under separate cover as it has a different NCR assigned to it. Our estimate of completing this investigation apparently did not allow ample time for the paperwork to get done. Please accept our apologies.
Sincerely, ,
S OL ' S' T FASTENER CORPORATION
/, '/
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~
.L. Alex nder Vice ' President RLA/skc cc: SBF QA Department E.W. Nelson, Jr. - SBF J.F. Barton - NPSI (S ecaucu s , NJ)
Attachments: NCR No. 157-A with its accompanying Report No. 157-A.
AhMGM'T 1
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LAAGE BOLTS G NUTS [!KOf.;*j STAINLESS & ALLOY
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OHANTTD' CHECKED ; i. 2>n. ay z. wanhoW " Lij,5 ~ , f, 7 I OUANTITY NONCONFORMING 8 / 2 EE n .!f // red OPERATION d'4 Sf72/24/ED NKrE //?L)
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_DFSCPTPTION OF NONCONFOPATANCE a= uwaemma resr ,eeseir.s TRANSMITTED osawan (Ae 4e5 4%9J.rE2) Q^/vd /-ri4/4 TN9PECTrn Av-(As .1 *N' b ~ 9 '20 FOR CORRrCTIVE ACTION TO: M / A/Ce/
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To ESTURN BE R4 CoffPLETEb 7E-CORRECTTVE ACTION REOUTRE AS 1b CRUE CP DEFfc7' Dett7', 4A<D i9M. t%7me/,4& *TH A 7' /.s Ar~ esta . A'p2Wre Conescrits 19eneAl-A%97dD D5772 MINED " 77 l$,Eh @W
& Cot >E2GuD /A/ /*2/TiiS+l FE?%e7 NATURE OF F '&W f0 MA AAfb A.SS/6AlfD 42/77/ S4rnE NHHBEsE.
YES NO
- 1. WROLE ORDER REJECTED w s I PART OF ORDER REJECTED YES h
- m mcs-rm.armsa vOUANTITY +'7 V67'-
[ ISSUED REPLACEisIENT PRODUCTION ORDER NO.
m (A. A sssGwco cwcy w wir.Eter cF ,es/ovccm e=+q-YES mi. ,zt. c.) NO
- 2. DEFECTIVE PARTS REWORKED AN PUT IN STOCK w 3 M9 OUANTITY A'/A PRODUCTION ORDER NO. ISSUED YES N v 2 DEFECTIVE PARTS PUT DIRECTLY INTO STOCK ES) NO' DEFECTIVE PARTS TOTALLY SCRAPPED
- 3. INSPECTED BY: 6 <-(-9-EO DATE:
~~ 'T "' E I M
- M S/'CuS~ W' [
PRODdCTION M ANAGER h # - >~ d
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OITAT. TTY ASSTTRANCF M ANAGER
~ / (CQS Adivuurs7P% 7 Upon completion of form return to Quality Assurance.
h@ I SB-27 lhh ' 9AC4 2 of 7 _
Rev. 1
I SBF GA NONCONFORV.ANCE REPORT NO.DATE / d - f-- h l d
DEFECTIVE FATERIAL NPSI P.O. NO. PDX 9478N 7 2 pc s .--l - 1/8 " : ASTM A-540 Gr. B23 C1. 3 FSY HEX B L . LOT #359)
I
- 1. PROBLEM: Bolts described above and furnished to NPSI do not meet all the specified requirements, as purchased, of the ASTM specification.
Bolts were manufactured by SBF and heat treated in SBF Ht. Lot No. 359.
Representative samples of other bolting materials heat treated in this lot were checked and found to be acceptable, but the NPSI bolts (MTR No. 5795) were found to be unacceptable and therefore classified as defective.
- 2. INVESTIGATION AND ANALYSIS MADE AS TO THE CAUSE OF THE PROBLEM: The cause of the defect as described above is believed to be that the wrong material type was used. Chemical and, physical tests and analysis were conducted from representative samples of the bolting materials heat tre:-
in SBF Ht. Lot No. 359. All those results were acceptable, except for the results from the NPSI material sample. Results from the analysis conducted on that material revealed the chemical composition of the material samples to be equivalent to AISI 1020 steel requirements. A review of the heat treating records by SBF and NPSI failed to turn up any evidence which would indicate anything being wrong with- the heat tr-process used. This was further substantiaued by the acceptable met-allurgical results obtained from re-checking representative material samples (See attachment No.1) that were processed in Ht. Lot No. 359.
With an apparent co tbination of 1020 and 4340 material in the lot only the 4340 would have responded properly to the treatment, and 1020. mater.
would not have developed the desired pro,perties. The material origin-l ally intended to be used for the order was 1-1/8" dia., E4340H, furnis' l
to SBF from Crucible Specialty Metals Division, under heat number ll52F A thorough review of all quality related records did not reveal an i apparent reason for this unique occurrence. The actual problem, thoug'r t
is believed to have occurred in production at a point somewhere betweer the point of production order release for the material to be taken and
" sheared" into forging lengths, and when the actual forging operation
- was performed. The exact origin from which the wrong material tha apparently was used came can not be determined due to the length of tir that has elapsed since the event occurred and also because personnel l
that were directly involved with the work have either left or have otherwise been replaced since then. No evidence has been discovered that would place any other production order under suspicion since this occurrence, although very unfortunate, appears to be isoletr,d to S/O #1849-010.
r PAGE _I_ OF k paa mee 1 9u:,e ~d of l
\
r arr 9.-nesesserew - -r em-- a l
O'ld records, some not necessarily cuality related, were also reviewed.
Research back through old inventory records (current during that time period) has confirmed that the material originally intended for use on this NPSI bolting requirement (E4340-E, Crucible Ht. N,. 115261) is in inventory. SBF metallurgical lab and OA personnel took a representativt sample of that raw material and reverified that it is in fact the Crucible E4340H, 1-1/8" diameter, SBF Code A154, tHeat #115261 material.
No evidence such as an unexplained decrease in inventory count was found during the examination of the records to substantiate a possibili:
that the wrong NPSI material that was used was taken from some 1-1/8" dia., 1040 bars in stock.
~.?b\
In the final analysis of the results of the completed investigation, conclusions must be made realicing that due to the fact that it is know:
the purchase documents did not soecify the provisions of 10CFR21 and Section III, NCA-3800, some slack existed in the degree of controls recuired. However, the results do indicate some sloppy workmanship was used by those persons processing S/O #1649-010.
By the conclusion made as to the cause of the defective material being unique to the locating, transporting, and handling of the 1-1/8" diamet; material for S/O #1849-010, and no proof or other known evidence has been reported for any other shop orders, no furtber action is believed warranted to be taken regarding any other bolting material, particular1; code material, which was being produced. All the defective bolts affec are believed to have been Identified (MIR Eo. 5795), their final disposition determined, and is reportedly being undertaken.
The analysis of the results also gives strong credit to the fact that al material processed, and then heat treated in Ht. Lot No. 359, did have representative samples checked during the investigation to verify chemical composition and heat treatment ,See( Attachment No. 1).
- 3. SCOPE OF THE PROBLEM: The defect, es described, war limi ced to only t'.
headed bolts supplied to NPS Industries . P.O. No. PDX 9478N, and (See A-tachment No. 1 for additional in-l described by SEF MTR No. 5795.
formation). It has been determined fror evidence found during the ,
investigation, and supported by the fact that all of the oricinal material (5 bars of 1-1/8" dia. E4340E, Crucible Ht. No. 115261) is l
presently located at the SBF Plant, under SBF control. As shown by Attachment No. 1, samples of all material heat treated in SBF Lot No. 2:
were located and their proper ties were 're-verified. The NPSI material
- (forged hex bolts), was found to be ur. acceptable, both for chemical composition and for mechanical properties.
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- 4. CORRICTIVB ACTION: Upon the evaluation and acceptance of the results
. and conclusions of the completed investigation of bolting material
' f's # manufactured and then heat treated in SBF Ht. Iot No. 359, SBF Manage-ment, as a additionai step of precaution, instructed the SEF QA Manager, utilizing qualified persons from his own department, to completely revic implementation of all the current procedures used for the following specific actions:
A. Receipt and identification of code material before manufacturing B. Control of code material during manufacturing C. Handling of code material scheduled to be thermal treated in-house.
The current SBF QA Manual was to be used as a guide against objective evidence to verify compliance and implementation of our current quality system for code ~ material. The order to accomplish this review was giver with the knowledge that although the bolting required by NPSI on P.O.
No. PDX 9478N was"not specifically requested under the provisions of 10CFR21 and Section III, NCA-3800, the action still was warranted out of the desire to offer assurance and every ounce of precaution. The deadline for completion of the review assigned to the QA Manager was August 29, 1980. To correct the immediate problem in the field, upon confirmation that the material was defective (6-10-80), SBF notified NPSI Quality Assurance by phone on 6-10-80 and followed that with a .lett (dated 6-11-80) of its responsibility to advise that all materials ~supp; and described by MTR No. 5795 may not be in compliance with the specific P.O. requirements. Further, NPSI was ordered to return all the describc material to SBF for immediate replace::.iat. SBF has subsequently been notified by NPSI by phone that steps were underway to have this done, and that a replacement order was forthcoming. SBF also requested that NPSI accept whatever responsibility that existed for reporting under 10CFR21 provisions, since their procuremsnt document, PDX 9478N, did no:
! clearly specify that the provisions of such were applicable to the order A comparative analysis of applicable system elements which were current at the time the NPS material was processed (1976) and those currently being used for code work, (1980), is summarized as follows:
A. THEN: Raw material received, documents reviewed, and an identification number assigned so that material was l
permanently identified by SEF before QA authorized its release.
NCE: After above occurs, a sample bar is cut from the raw material, l
l identified by stamping each sample cut with identification
! to the Mill heat, and the sample is forwarded to the Metallurgist and Metallurgical lab for further verification and
'esting prior to QA releas'e from the receiving HOLD area.
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B. THEN: Upon completion of heat treating operations, the items were placed in a HOLD area, and sample bars were forwarded to a designated QC person who ha'd the test samples machined and testing performed. After satisfactory test results were received, the items were then released by QA by a sign off of the appropriate HOLD POINT.
NOW: After heat treatment operations are accomplished, the items are placed in a HOLD area, and sample bars (which have been stamped with material ID) are forwarded to the Metallurgist and Metallurgical lab for testing.
Heat Treat Charts are also reviewed by the lab and QA.
After acceptance by Metallurgical and QA personnel, the HOLD POINT is signed off the QA, and the items,are released.
As indicated by the above, the overall quality system has obviously-since been improved by other SBF continuing efforts to technically up-grade all phased of its quality program.
50 FOLLOW-UP OF CORRECTIVE ACTION: SEF QA Manager shall report to the President of SBF the results of the review described above by 8-29-80.
Any findings reported at that time shall be immediately placed with the appropriate manager or supervisor for corrective action to prevent recurrence. Upon receipt of the material from NPSI and the field, all the material shall be disposed of by SSF QC so that it will not be used The QA Manager shall follow up on this and document that it has been de h w t, .77
ATTACIIMENT NO. 1
SUMMARY
OP MATERIAL RE-VERIPICATION: SBF IIEAT TREAT LOT NO. 359 __
REPORTED TYPE IIEAT SDP S/04 QTY. RUN (1) MATERIAL NUMDER COMMENTS SSF~ LAB AG VE!?/f!G.D //rn7 '/9t av 7- A BriMG kaproste ,G'ain pur's. Sirinsfa 1666-040 141 pas. 4340-M Rep. 6076970 4xere e/r-JBA-(S/>Se/o,6a.BN 4d 3-3/4" dia.
i
$8F AiCT dnB Ef-J'E//F7ED /kg7~ 7Et
/)$ Bgias/G /k*Cf/'rdBJE Abn2 414 7 d',
1200-020 134 pcs. 4340-M Rep. 8070419 gg,97 ,, g,cg7,.3 g 7 ,$ g g, s 3-3/4" dLa. (,93yo, gg, gysp, g , g)
A/RS-[ /far'? l SB/~ DIB L'E7EcTA2 du 7: side LAB TESf Ef.StlLfS 6bm]
11149-010 (2) 84 pcs. E4 340-Il Cruc. 115261 doets/O sit /oA/ A'dT Type E'/J'/0//j M//]
1-1/B" dia. styr ziro Edstit 75 of //tt'nd t'ica e (i\/f'u'% Lh>i ries) propreTies A/or //cceproct'y we s, SBF L48 EE VE2/F*/CD //r/)r7;"i/,
4340-M Bs /G &EprMic Rom 7 1200-070 21 pcs. Ilexed from Rep. 6075519 sArr/p2E T426d FW SBA~ /A/vF N roun bars / 'O /
IKYPES :
(1) - Includes additional material for use as test bars.
(2) - NPSI Material 1/0" x 6-1/4" livy. Ilex Bolts - as described SBF MPR. No. 5795.
Chemical and mechanical propertics not acceptable per _ ASTM AS40, Gr. D23, Cl. 3.
l'HEPARED DY: - DATE: /- O p P SDF fotallurgical Lab h a HN
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SOUTHERN SCLT P. C. 5:x 719C - 33t A St 'G:vE P ' TELEPMDAE APES t2'E::2r.e251 S Mi?E VEPOR *. L OU!S14 t. 4
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8-14-80 and 9-1-80 NPS Industries, Inc.
10420 Metric Blvd. -
Austin, TX 78758 ATTN: Mr. Don Harbeson Re: SBF letter to NPSI dated 7-9-80
Dear Don,
Enclosed please find a copy of the final segment of the defective material covered by our MTR's 6370, 6371, 6372, 6373, and 6374. Also, be advised that we now plan to ship the replacement bolts before the defective bolts are returned as agreed upon with Bechtel's Mr. Bob Dann (San Francisco) to facilitate matters at the jobsite. Bechtel has assured us that measures will be takstn to prevent any misuse of the defective bolts, and they are fully aware of our concern that such cautic:
be used.
Our schedule of heat treating the replacement bolts has been interrupted again, due to equipment malfunction in our No. 1 furnace.
Also, to complicate matters further, Bechtel's OA audit team which visited our plant on 8-27-80 thru 8-29-E0, recorded a finding in the heat treat area, and therefore has written a "stop shipment" and "stop heat treat" order until our furnace repairs are completed and re-surveyed, etc.
Obviously the finding was directly related to the equipment malfunction mentioned. During our recent plant shutdown (July 18-31), we installed new equipment in the heat treat plant, and the problems are with that equipment.
l l Your patience and cooperation has been appreciated. When we get ..
our equipment repaired, which should be done by 9-18-80, I will be contacting Bechtel OA with regards to clearing the audit findings.
- Source inspection could possible be made by you by 10-15-80.
Sincerely, f' #. - AM4NCRF\E%T 3\
, m(, e. Lexancer 6
TNG E:. \ e7 5 l .
A ttachments : NCR No.157-B with its Report No. 157-5 C a, , A LA AGS BOLTS & NUTS pOf7%] STAINLOS & ALLOY o
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l- -- M: D EE EWen T hh^p bP- bod 5Ntu<'1.WFc)>
PROD. DATP CUSTO: DER NAM E /JPS Lc1 w s ORD.NO. uff
$$ YN: , h f ,d O'4 3ccT5 PART DESCRIPTION ,
Astn A41o OUA h-"ITY O S/ N / M b o-o I es- mI WlA Id'Y A '&b
.OUANTIrv CHECKED - i OUANTITY NONCONFORhiING A//A [ h - ~ / N E M d E d .,c.}
OPERATTON A/, A %< mZ- ~16)
OPERATOR 4 'I.m- A M )
DFSCPTPTION Di NONCONFORM ANCF h um Am /S A ru da// wa a neo TRANShMTTED n . FOR i. ,
fI /y t s N ,@# b- 7-80 YW-TNSPECTrn nV- CORRECTIVE ACTION FO/ /- - . . / _
jG~22{ fM %ciF ED o@O. CORRECTIVE ACTION REPORT f/kh scc IJCR- !5'7-A CORREf'TIVE ACTION REQUIRED 26 b -
q _
I I
8
, NATURE OF PZWORK S NO
- 1. WHOLE ORDER REJECTED -
PART OF ORDER REJECTED YES w s l
ISSUED REPLACEMENT PRODUCTION ORDER NO. Mr AceN O DEFECTIVE PARTS REWORKED AN PUT IN STOCK YES 2.
PRODUCTION ORDER NO. ISSUED X/- A QUANTITY /[-A YES / NO)
DEFECTIVE PARTS PUT DIRECTLY INTO STOCK s s
'E S NO DEFECTIVE PARTS TOTALLY SCRAPPED - w s
- 3. INSPECTED BY: 1* bN - DATE: b-T-PO
, PROOTTOTTON M ANAGER //-/t "I /IhD 1 OTTAT. TTY A SSTTDANCF M ANAGFR.
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l 67,q 19 a'm id l '
Upon cc.r.pletion of form return to Quality Assurance.
o . . . , . .
ATTAf. % MhT I R '
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0
. 53F NONCONFOPEANCE REPORT 50. l 67- 6 DATE b-9-bC DEFECTIVE MATERIAL ,
NPSI P.O. NO. PDX 9461 98 pcs.--lh" x 2,4,4h" ,5,5 " ; ASTM A-4 90 MTR. NO. 6370, 6371, 6372, 6373, and 6374 s HVY HEX SOLT (HT. LOT #36-HEAT #69784)
- 1. PROELEM: Bolts described above and furnished to NPSI all do not meet all the soecified recuirements, as purchased, of the ASTM soecification. The bolts were manufactured by 53F and furnished to NPSI, as described by the MTR numbers listed above, and because the returned sample analyzed by our Metallurgical Lab during the week of June 9,1980 did not meet the A490 specification completely, it was therefere classified as defective by SEF, and all material of Heat #69784 from Heat Lot #36 was investigated t:
determine the cause.
- 2. INVESTIGATION AND ANALYSIS MADE AS TO THE CAUSE OF THE PROBLEM: The cause of the defect described above is believed to be that the bolts were not heat treated properly. The bolts were h9at treated by SEF in Mt. Lot
- 36 as they were being manufactured for Stock. Upon the review of processinc records, it has been determined that the A490 bolts did not al_
receive a full heat treatment processing. Our findings indicate that sor<
were only " normalized" and were not further hardened and quenched and tempered. This caused the p.roblem of the NPSI bolts failing to pass.the required mechanical properties. Southern Bolt needed 98 bolts to comple:
the required quantity of 845 pieces on H?SI P.O. No. PDX 9461, (which only required the bolts to meet A490 and a purchase order requirement-als for an impact test performed @+400F meeting 25 mils lateral expansion) against which 747 p;eces were already supplied. The 98 bolts were obtained from an active stock order of " blanks" that were heat treated in HT. LOT #36, (They only needed to be cut to the lengths required and threaded up, etc. for NPSI). These bolts are cescribed as follows:
MTR NO. DESCR. OTY HEAT NO. ET L OT .
- 6370 1 " x 5h" (A490) 15 69784 36 l 6371 1h" x 3" ( A4 90) 11 69784 36 l 6372 1 " x 5" (A490) 19 69784 36
, 6373 1 " x 4h" (A490) 42 69784 36 6374 1 " x 4" (A490) 11 69784 36
- During the investigation it was also discovered that the MTR's were not properly prepared by the documentation personnel who were responsible fc
~
l such at that time. The MTR's report prcperties as coming from mill cer:r when they actually did not since the Heat Treatment was by S3F. However, this was classified as a " paperwork mistake" which merely contributed
[
! con fu sion . An oversight or a mistake like that is not believed to be a NT'%C+-WWE E PAGE l OF P A-g ;_ g e9 g L
4 safety related threat since corrected copies of the MTR's are easily obtainable. Because of the elapsed arcun: of time and the fact that many of th'e key personnel who were directly invcived with the processing of this order have since departed, the investigation went a lot slower than originally expected. All recorcs that were checked show that the NSPI bolts (identified above) of heat number 69784 were heat treated along with two other groups of material (4340M and E4340H) not supplied to NSPI, and were for SEF stock. The prescribed first step of the heat treating process for Lot #36 was to normtline for three hours at heat and then air cool to room temperature. The next step was to harden for four hours at heat, and finally quench and temper.
However, when the first step 2escribed ibove was completed, a shift change occurred, and a different operator took over. It is believed that particular operator failed to realize that he had not completed the process on all the bolt of heat number 69784, as intended. Records show that there were 205 pieces (including test bars) of this material scheduled to be heat treated, as described, along with the other material. Exactly how many of the bolts of heat number 69784 that did not make it throur' the complete heat treatment can not be determined, but some material of that heat apparently did because test results were obtained'to verify the heat treatment and some bolts reportedly were field tested and passed tensile at 104,000 psi. It was concluded fror this, hcwever, that all bolts from that heat number (69784) could be su spec tec. as cefective anc either be re-veri:lec by qua,_itlec inspecticn, or be returned to S3F for dirposition. No evidence was found to cause ccncern over the other two croups of material treated in Lot #36 and samples were also rE-Verified. The Cperatcr error whiCh Caused this problem did not have any affect en the c her 747 bolts (A490) because they were not processed at the same time. Representative samples of those bolts were reportedly field tested and passed. Also, SEF received samples from the field and those all passed the re-testing.
By the conclusion made ts to the cause of the defective material being unique to the heat treat ing of this material, and no proof or other known evidence has surfaced since the defect was discovered and reported.
the investigation into this incident is believed to have included all :?
affected bolts, and they have all been identified. Their disposition . .
.nas ceen ceterminec, anc it is reportec,y ceing uncertaken: the materia _.
l furnished to NPSI described by MTR No. 6370, 6371, 6372, 6373, and 6374 are to be returned to SEF and replacement bolts shall be furnished which meet all the requirements of their purchase order. Also, records are still being checked to determine if any other nuclear jobsite--Bechtel or otherwise--may have received defective material caused by this prob'_er h.o evicence to date has sur:acec con:1rming t..nat anyone else c...ic.
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SCOPE OF THE FROELEM: The defect, as described, was limited to the bolts (heat number E9784) heat treated in Et. Lot. #36.' It has been determinef f rom the evidence examined during the inve etigation that no other A490 bolts were affected by this problem. Further, verification was made by the SSF investigation that the properties of a returned sample from other A490 bolts supplied NSPI on the same order were acceptable as ordered:
TESIED TESTED MTR No. Ht. Lot. CHEMICALLY MECHANICALLY SPEC 5718 336 passed passed A490 CORRECTIVE ACTION: Upon the evaluation and acceptance of the results of the completed investigation of the bolting materials as described, SBF management has directed the corrective action to follow that as reported in Report No. 157-A dated 6-9-80 for another NPSI bolting nonconformance which was investigated simultaneously with this one.
KPSI was notified by SBF letter dated 6-11-80 of the posibility that all the material supplied may not be in compliance with their P.O. requiremen:s Since the material was not procured to 10CFR21 provisions or ASME Section III provisions, no code violation is believed to have occurred. All available records shall be examined by the QA Manager to determine whether any nuclear site may have received either directly or indirectly any of the material. If evidence should be found which confirms that one did, then the customer we seret the bolts to shall be notified. Although the changes of thi- have been reported as extremely unlikely, this shall':-
thoroughly checked by QA as described.
FOELOW-UP OF CORRECTIVE ACTION: SEF QA Manager shall report to the President of SBF the results of the action described above by 8-29-80.
Any findings reported at that time shall be immediately placed with the appropriate manager or supervisor for corre'ctive action to prevent it recurring. Upon receipt of the material from NPSI and the field, all the material shall be disposed of by SEF QC so that it will not be used.
The OA Manager shall follow up on this and document that it has been done.
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