ML20011D187
| ML20011D187 | |
| Person / Time | |
|---|---|
| Issue date: | 04/07/1989 |
| From: | Baker E, Cilimberg R Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20011D185 | List: |
| References | |
| REF-QA-99901144 99901144-89-01, 99901144-89-1, NUDOCS 8912220007 | |
| Download: ML20011D187 (7) | |
Text
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bRGANIZATION: HARDWARE SPECIALTY COMPANY, INCORPORATED
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LONG ISLAND CITY, NEW YORK REPORT INSPECTION INSPECTION NO.: 99901144/89-01 DATE: 02/07-10/89 OH-SITE HOURS: 88 l
t CORRESPONDENCE ADDRESS: Mr. James Lewis, Manager Nuclear / Ships Divisions Hardware Specialty Company, Incorporated 48-51 36th Street Long Island City, New York 11101 r
ORGANIZATIONAL CONTACT: Mr. James Lewis TELEPHONE NUMBER:
(718)361-9320 NUCLEAR INDUSTRY ACTIVITY: Supplier of fasteners (bolts, nuts, and studs) to 1
the nuclear industry, military and commercial customers.
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ASSIGNED INSPECTOR:
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OTHERINSPECTOR(S):
- 1. Barnes A. Pjur
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Date E'.'T. Baker, SGction Chig ' Vendor Inspection Branch (RIS-1)
V INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR 50, Appendix B, 10 CFR Part 21, ASME Boiler and Pressure Vessel Code.
B.
SCOPE:
Obtain information to determine if fasteners supplied to the nuclear industry met customer requirements.
PLANT SITE APPLICABILITY: Palo Verde 1/2/3 (50-528/529/530), Limerick 1/2 (50-352/353), South Texas 1/2(50-498/499), Pilgrim 1 (50-293), Brunswick 1/2 (50-325/324), Harris 1 (50-400), Robinson 2(50-261), Indian Point 2/3(50-247/286),
Hatch 1/2 (50-321/366), Vogtle 1/2(50-424/425), Oyster Creek 1 (50-219), Three Mile Island 1/2(50-289/320), River Bend 1 (50-458), Shoreham (50-322),
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' ORGANIZATION: HARDWARE SPECIALTY COMPANY, INCORFORATED LONG ISLAND CITY, NEW YORK REPORT INSPECTION NO.:
99901144/89-01 RESULTS:
PAGE 2 of 7 PLANT SITE APPLICABILITY:
(continued)
Fitzpatrick (50-333), Nine Mile Point 1/2(50-220/410), Peach Bottom 2/3 (50-277/278), North Anna 1/2 (50-338/339), Surry 1/2 (50-280/261),
1(50-029)},MaineYankee(50-309),Waterford Yankee-Rowe 3 (50-382),
1/2 (y 1/2 (50-348/364 Farle 1/2(50-315/316)(,50-317/318), Comanche Peak i
Calvert Cliffs 1/2 50-445/446), D.C. Cook Susquehanna 1/2 (50-387/388).
A.
VIOLATIONS:
None I
B.
NONCONFORMANCES:.
l 1.
Contrary to paragraph NC-2311 of ASME Section 111, 1977 Edition through Summer 1979 Addenda, Hardware Specialty Company, Incorporated (HSC) supplied bolts with a nominal size greater than 1 inch to Louisiana Power & Light (LPL) without reporting Charpy impact test results, and the documentation did not indicate that impact tests had been performed.
(89-01-01) 2.
Contrary to paragraph 10.2.3 of SA-193 of ASME Section 11 and Subsection NC of ASME Section III,1977 Edition through Sumer 1979 Addenda, HSC supplied SA-193, Grade B8, Class 1 bolts to LPL which exceeded the maximum specified hardness of 223 Brinell.
(89-01-02) 3.
Contrary to Subsection NCA-3867.4(a) of ASME Section Ill,1977 Edition through Summer 1979 Addenda, HSC supplied austenitic stainless steel studs and hex nuts to LPL with certified material test reports (CMTRs) that did not state the minimum solution anneoling temperature.
(89-01-03) 4.
Contrary to Subsection NCA-3867.4(e) of ASME Section 111, HSC certified code compliance of domestic and foreign material furnished to ASTM and AISI specifications without testing each piece of material greater than 1 inch in diameter or establishing traceability by surve'ying, qualifying, and auditing the Quality System Programs of HSC vendors.
(89-01-04)
C.
UNRESOLVED ITEMS:
l None l
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. ORGANIZATION:
HARDWARE SPECIALTY COMPANY, INCORPORATED LONG ISLAND CITY, NEW YORA REPORT INSPECTION NO.: 99901144/09-01 RESULTS:
PAGE 3 of 7 D.
STATUS OF PREVIOUS 1NSPECT10N FINDINGS:
Not Applicable E.
INSPECTION FINDINGS AkD OTHER COMMENTS:
i 1.
The Nuclear Regulatory Commission (NRC) staff informed HSC management representatives of the scope of the inspection during the entrance meeting on February 7,1989, and summarized the inspection findings during the exit meeting on February 10, 1989.
===2.
Background===
During an NRC inspection at Waterford 3, the inspectors determined that HSC issued a certificate of compliance (C of C) on gland studs that were supplied to LPL in 1981. The C of C indicated that the material conformed to SA-193, Grade B8, and met ASPE 5ection III, Class 2 requirements. HSC does not have an ASME Quality System Certificate (QSC) ar.d LPL is neither a QSC or an "N" type certificate holder. Therefore, LPL cannot qualify HSC to supply material to Section 111 requirements and HSC cannot supply Section 111 material to LPL. The NRC questioned whether HSC is supplying material which meets nuclear customer requirements and initiated this inspection of HSC.
3.
Document Review Documents were reviewed which covered material supplied during two time periods.
Prior to 1983, the QA Manual (QAM) was deficient and the' program was found to not neet certain requirements which are discussed in 3(a) below. The QAM was revised by a consultant and the program was improved as discussed in 3(b) below:
(a) Material Supplied Prior to 1983 Documents covering material supplied prior to 1983 were stored in cardboard files on a platform in a remote section of the warehouso.
Purchaseorders(P0s)whichappliedto this material had been discarded by HSC. The inspectors randomly selected 29 files covering material that HSC supplied to either EBASCO or LPL for use at the Waterford nuclear site in Louisiana. Examples of materials which did not comply with customer requirements are as follows:
(1) LPL issued to HSC P0 LO1478, dated December 30, 1981,
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ORGANIZATION:
HARDWARE SPECIALTY COMPANY, INCORPORATED LONG ISLAND CITY, NEW YORK REPORT INSPECTION N0.: 99901144/S9-01 RESULTS:
PAGE 4 of 7 for 1 1/16-inch diameter SA-193 B7 alloy bolts (items 25 and 26) to be supplied in accordance with ASME Section Ill, Subsection NC, 1977 Edition, Summer 1979 Addenda, and 10 CFR 50. Sullivan Bolt Company, Incorporated (SBC),inCommerce, California,suppliedthe material to HSC and issued CMTRs, dated April 22, 1982, which certified that items 25 and 26 met ASME SA-193 B7, Section 111 Subsection NC, 1977 Edition through Summer 1979 Addenda. The CMTR reported chemi..a1 analysis, tensile properties, and heat treatment times and temperatures but did not report impact test results.
Paragraph NC-2311 of ASME Section 111, 1977 Edition, Sungner 1979 Addenda requires that Charpy impact tests be performed on fasteners greater than 1 inch.
HSC C of Cs, dated April 27, 1982, certified that the material conformed to ASME SA-193, Grade B7, and ASME Section 111 Subsection NC, 1977 Edition through Summer 1979 Addenda. HSC CMTRs, dated April 27, 1982, did not provide impact test results which is a nonconformance with NC-2311.
(See Nonconformance 89-01-01)
(2) During review of material certifications applicable to LPL P0 L01478, examples were noted of questionable solution annealing certification statements.
As discussed in paragraph 3.(a)(1) above, the requirements of Section 111 of th ASME Code, Subsection NC,1977 Edition through Summer 1979 Addenda were applicable to this P0.
Items 55; 56, and 57 of this P0 required HSC to supply 1/4-inch diameter SA-193, Grade B8, austentic stainless steel bolts.
Fry Steel Company, a material supplier in Los Angeles, California, supplied the material for these items with a copy of the original mill test report data. This data identified that the material was in the annealed condition and complied with the requirements of ASTM A-193, Grade B8, Class 1.
The reported Brinell hardness range was, however, 241 to 248 which exceeds the 223 maximum value permitted by the specification.
The tensile and yield strengths reported for the material were 100,200 and 70,000 pounds per square inch, respectively. The reported strength and hardness values sug9est that the material has been cold worked and is not in an annealed condition. HSC issued a C of C to LPL for tnese bolts indicating compliance with the material specification and ASME Section 111 t
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ORGANIZATION: HARDWARE SPECIALTY COMPANY, INCORPORATED LONG ISLAND CITY, NEW YORK REPORT INSPECTION NO.: 99901144/89-01 RESULTS:
PAGE S of 7 l
Code requirements. The out-of-specification hardness value is identified in Nonconformance 69-01-02.
Item 149 of LPL P0 LO1478 required HSC to supply 7/8-inch diameter SA-193, Grade BB, Class 1, austenitic stainless steel studs. Delackner Fasteners, Incorporated, of Mount Vernon, New York, supplied the studs to HSC with a CMTR from Roldan S.A. of Barcelona, Spain, which indicated that the studs were nanufactured from ASTM A-276 bars. This CMTR did'not include any statement on heat treatment condition. The C of C issued by HSC to LPL stated, however, that the material had been carbide solution treated at 1900'F. No documented basis for the C of C heat treatment statement was present in the HSC files. The furnishing of material for ASME Section III applications, without documentation showing perform-ance of material specification heat treatment, is a nonconformance with the requirements of ASME'Section Ill,SubsectionNCA-3867.4(a).
(See Nonconformance 89-01-03)
Item 118 of LPL P0 L01478 required HSC to supply 1 1/8-inch SA-194, Grcde 8, austenitic stainless steel heavy hex nuts. Texas Bolt Company of Houston, Texas, furnished these items to HSC with their own CMTR, which indicated that the material supplied was ASTM A-194, Grade 8.
This CMTR also containec no heat treatment statement. HSC subsequently transcribed the chemical and mechanical test data from the Texas Bolt CMTR onto their own CMTR and also issued a C of C which stated that the material had been carbide solution treated.
No documented basis for the C of C heat treatment statement was present in the HSC files. This is an additional example of nonconformance with the require-ments of ASME Section Ill, Subsection NCA-3867.4(a).
(SeeNoncor.formance 89-01-03)
It should be noted that the reported mechanical prooerties for both Item 118 and 149 materials were consistent with a solution annealed heat treatment condition.
(3) The HSC QCM, Revision D, dated April 8, 1981, lists two permissible methods that can be utilized for materials procurement. With the first method, HSC procures raw materials from either holders of nuclear certificates
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'tRGkNIZATION: HARDWARE SPECIALTY COMPANY, INCORPORA1ED
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LONG ISLAND CITY, NEW YORK 1
REPORT INSPECTION NO.: '99901144/89-01 RESULTS:
PAGE 6 of 7 of authorization, or companies apprcved by HSC custoners, and ships the material to HSC vendors for manufacture of fasteners. With the second method, HSC vendors are permitted to procure raw materials from their normal sources of supply.
For this nethod HSC l
utilizes an independent laboratory to check parts for 1
accuracy of raw material certifications and compliance with specification requirements.
i The discarding of HSC P0s precluded specific checking of the technical requirements imposed on HSC vendors.
Review of vendor certifications showed, however, that i
the majority of CMTRs, which were applicable to the LPL and EBASCO procurements for the Waterford site, were for domestic and foreign materials furnished only to ASTM and AISI specification requirements. With the exception of SBC-furnished fasteners, no reference was noted on vendors' CMTRs that the fasteners had been manufactured in accordance with the requirements of Section 111 of the ASME Code.
Similarly, the HSC CMTRs and files for the above procurements reflected only vendor-furnished material specification information, with no evidence that upgrading activities had been performed in accordance with the provisions of NCA-3867.4(c) of Section 111 of the ASME Code. The certification of materials produced by a manufacturer whose Quality System Program has not been qualified under NCA-3800, without appropriate upgrading activities is a nonconformance with the requirements of NCA-3867.4(e) of Section 111 of the ASME Code.
(SeeNonconformance 89-01-04)
(b) Current Program The inspectors reviewed the HSC Identification and Verifica-tion Manual, Revision 2, dated July 4, 1986, and reviewed a sample of documents related to material supplied to the nuclear industry by HSC during 1988. This review indicated that HSC currently obtains material from an ASME Quality System Certificate holder for sale to the nuclear industry or performs upgrade testing in accordance with the require-ments of NCA-3800 for nuclear application. No violations or items of nonconformance were identified in this part of the inspection.
0RGANIZATION:
HARDWARE SPECIALTY COMPANY, INCORPORATED i
LONG ISLAND CITY, NEW YORK.
REPORT INSPECTION NO.:. 99901144/89-01 RESULTS:
FAGE 7 of 7 i
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PERSONS CONTACTED:
R. Agnone
- J. Lewis
- A. Mueller
- Attended Exit meeting.
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