ML20062L086
| ML20062L086 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 01/09/1981 |
| From: | Jackie Cook CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, MCAR-45A, MCAR-45B, NUDOCS 8101140653 | |
| Download: ML20062L086 (16) | |
Text
.
COUSlim0iS L 6j;N l Power D p/
James W Cook Ulley$g pc.
L) l El Vice PresiJcnt - Proj~ cts, Engineering and Construction General offices: 1945 West Par 9all fload, Jackson, MI 49201 + (517) 788 0453
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January 9, 1981 E2
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Mr J G Keppler, Regional Director 5
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3 GN Office of Inspection and Enforcement US Nuclear Regulatory Commission y
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Region III p,
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C 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND PROJECT -
DOCKET NOS 50-329, 50-330 LOW ALLOY QUENCHED NID TE4PERED BOLTING 1h IUCHES AIID GREATER IN SUPPORT OF SAFETY RELATED SYSTE'S FILE:
0.h.9.h6 UFI:
73*10*01, 023h3(s), 03003(E),15230(E) SERIAL:
10996 In accordance with the requirements of 10 CFR 50.55(e), this letter constitutes an interim report on the status cf the subject bolting.
An extension of the initial submittal of this report was granted until January 9,1981 by Mr R C Knop in a telephone conversation with Mr W R Bird.
Attachments No 1 to 3 to this letter provide a description of the ' condition and the planned investigation.
Attachnent No k provides the present3y known information on the manufacturing and fabrication facilities involved in production of the RCP snubber anchor bolts.
Another report, either interim or final, vill be sent on or before March 31, 1981.
f.,.. $lpg&Q I
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JLW/lr Attachments:
1.
MCAR LSA - Reactor Coolant Pump Snubber Bolts Hardness Values 2.
MCAR LSB - Reactor Coolant Pump Snubber Bolts Hardness Values 3.
MCAR h5 A & B - Interim Repert #1 - Reactor Coolant Punp Snubber Bolts Hardness Values h.
React or Coolant Pump Snubber Bolts - Material Suppliers, Polt Enericaters un:1 Prime Contractors THIS DOCUMENT CONTAINS 810114 D I.86 P00R QUAUTY PAGES s
2 Serial 10996 CC:
Director, Office of Inspection & Enforcement Att Mr Victor Stello, USNRC (15)
Director, Office of Management Information & Program Centrol, USHRC (1)
RJCook, USHRC Resident Inspector Midland Huclear Plant (1)
CBechhoefer, ISLB Panel GALinenberger, ASLB Panel FPCowan, ASLB Panel l
AS&L Appeal Panel t
!GICherry, Esq MSinclair CRStephens, USNRC WDPaton, Esq, USNRC FJKelly, Esq, Attorney General SHFreeman, Esq, Asst Attorney General l
GTTaylor, Esq, Asst Attorney General WHMarshall GJMerritt, Esq, TNK&J
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- Att.ncle.c:it 1' i
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QUALITY ASSURANCE PROGRAM serial &
MANAGEMENT CORRECTIVE ACTICN REPORT MCAR.1 018588 REPORT NO.:
45A JOB NO.:
7220 O NO.:
DATE:
12/17/80 a
i DESCRIPTION * (includ:ng References):
Preliminary investigation of hardness tests performed by Telodyne Engineering Services on Midland Plant Units 1 and 2 reactor coolant pumps snubber bolts, shows that 207 of the 384 bolts checked have hardness readings outcide the range specified.
The attached tabulation shows the results of these tects.
I i
i
. RECOMMENDED ACTION * (Optiona!):
l'repare schedule and implement a program to accomplish the following:
1.
Complete a detailed review of all quality verification records pertaining to the processing and heat treatment of these snubber bolts. Derive appropriate conclusions from this review.
REFERRED TO:
E Engineering O Construction O OA Management 0
g'g
[,j 0 Procurement i
/y? M.A. Dietrich ISSUED DY:.
12/17/80 P,wt oa tns.nw o.
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il 11EPORTAhLE DEFICIENCY:
l POTENTIALLY NOTIF ED EdENT:
12/5/80 0 NO
) 'ES De[w4
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fil CAUSE:
CORRECTIVE ACTION TAKEN:
J AUTHORIZED BY:
o.
ALP 0 DISTR %TeoN PROJ CtSTRICU110N oTHER DitiRISUTION uon or co staucim cHo consta oc tNcR ucn or ca. tPo FORMAL REPORT TO CLIENT uon or No.Nune cutNr or o. on won (If Sect.'onll Applies)
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use or enocurarutNr Proct taro oa usa uGM Or PROJ ortmaTONS PROACT CON $TR uM4
$4 Fo ca uGR uan or ouaut, assunwer PaoJrcia e rta CORRECTIVE ACTION IMPLEMENTED cONSinucicN uGR PHOACT uGR t WNIE stNG MGH PROJ PHOcunf.ur NT uGR
$$PLtt N otauf t UOR Sitt uGR or surtaasen VERIFIED BY
- Descr bo in SpacP provided and attach reference docurrent
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Piq.cioneng.,
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I au w a Section Number Pago of
MCAR 45A Ql8ggg December 17, 1980 Page 2 l
DESCRIPTION (Cont)
The above condition was notified to the NRC by Consumers Power Company as poten-tially reportable on November 25, 1980.
Note: MCAR-45B addresses the overall implications of the results of the hardness tests performed.
i RECOM!! ENDED ACTION (Cont) 2.
Conduct a design evaluation of the test recults and determine what, if any, design changes or other actions are necessary to accomplish the intended safety function of the snubber holts.
3.
Provide status reporting to support Consumers Power Company interim 50.55(e) reports to the NRC.
i I
4.
Prepare the first interim ctatus report for coordination with Consumers l
Power Coupany and issue by December 22, 1980.
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Rev 1 Data supplied by Pcul CeRunn' Bechtel - FE TABULATION OF IN-PLACE ITARDNESS RP.SULTS FOR 3R4 RCP SNUBBER RELATED BOLTS-CD TOTAL
- OF FOLTS
- OF BOLTS
- OF WITil LOW LGJEST WITII IIIG!!
IIICIIEST ASTM BASE HEAT I SIZE BOLTS READINGS READING READINGS READING SPEC.
l{ATERIAL REMARKS co m
63315 2 1/4 56 17 531 7
636 A-354 4145 P.O. F-14700, ACO-2704 BD 63575 2 1/2 164 66 535 29 675 A-354 4145 P.O. F-14780, AEO-2704 BD 62609 3
24 3
557 10 683 A-354 4145 P.O. F-14780, AEO-2704 BD 54404 3 1/2 24 0
20 693 A-354 4145 P.O. F-14780, AE0-3109 and BD All 3 1/2" G holts in 54004 Unit 2.
Individuni heats couldn't be 4
separated 50415 3
6 1
571 0
A-354 Not 2 holts were refabri-BD Civen cated and used as con-nection bolts in 1-2 and D-4 in linit 1.
P.O. F-21R92. AEO-4044 =
raw materini 61951R1 3 1/2 24 16 538 0
A-354 Not P.O. F-21892, AEO-4044 DD Civen raw naterial. All 3 1/2" G bolta in Unit i 91196R1 3
7 7
522 0
A-354 4140 All bolta in I-2 cobed DD in Unit 2.
P.O. F-24671, AEO-4862 655A196 3
17 0
2 63G A-354 Not All bolts in I-I and BD Civen I-2 enheds in Unit 2.
P.O. F-19091, AEO-4522
a TOTAL F OF BOLTS
- OF BOLTS I OF WITil L0ti LCITEST WITH IIICH MICHEST ASTX BASE HEAT #
SI7.E BOLTS READINGS READING READINGS READING SPEC.
MATERIAL REMARKS f
519GO 3
24 22 518 0
A-354 4142 All bolts in I-1 and 3D I-2 enheds in Unit 1.
P.O. F-25013, AE0-5103 97847 3
10 1
569 0
A-540 E4340 Connection holts in B23 C1 3 AQ I-1. I-2, and D-4 Units 1 ned 2.
P.O. F-3107, Re1 15, AEO-6152 115544 2 1/2 4
0
~
0 A-540 E434cn connection holts in
~
B23 C1 3 n-5 Units 1 and 2.
P.O. F-3107, Re1 II, AEO-6152 91039 2 1/4 24 6
559 0
A-540 E4340AQ Connection holts in 4
B23 C1 3 I-1, 1-2, and n-4 Units 1 and 2.
P.O. F-3107, Rev 15, AE0-6153 TOTALS 384 139 518 G3 693 NOTES:
1) flardness readings in "L" numbers.
" Low" or "high" recdings are those cutside the following 11mics:
A354-74 2 '1/4", 2 1/4" 588L-+ 634L (32 R-HP33 K )/ 3", 3 1/2" 573L-?634L (30 R-t 38 R )
A540-/ 5 2 1/4". 2 1/2", 3" 5800->G43L (35.9 R -<F39.1 a >
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2)
See 60 sheets of actual results of conversion charts for further infornation.
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At r.aeir.cnt 2
- ?
OUALITY ASSURANCE PROGRAM Serial 10996 fAANAGEfAENT CORRECTIVE ACTION REPORT MCAR1 1
REPORT NO.:
45B 0l8588 JOB NO.: _l220 0 NDa DATE:
12]_)2180 i
i DESCRIPTION * (including References):
Preliminary investigation of hardness tests perfor cd by Teledyne Engineering Services on Midland Plant Units 1 and 2 reactor coolant pumps snubber bolts, chovs that 207 of the 384 bolts checked have hardness readings outside the range specified. The attached tabulation shows the results of these tests.
i 4
RECOMMENDED ACTION * (Optionat):
Preparc, schedule, and implement a progr.,ta to accomplish the following:
1 1.
Consumers Power Conpany's coenitnent (refererae NRC letter dated
}
August 18, 1980, Docket Nos. 50-329 and 330) to undertake a review to i
confirm that safety-related low alloy steel bolting and/or components i
l REFERRED TO:
M Engineering O Construction O QA Management O
b6 Procurement i((h ISSUED DY:.,
M.A. Dietrich 12/17/80
/
nwioAcy ~
oe.
I il REPORTABLE DEFICIEN0Y:
POTENTIALLY 12/5/80 NOTIF ' CLIENT:
M.
REPORTABLE
/_/[/)('
/ /
O NO DUYES 4,Y1 67/ M i
l
'nwi um os.
h: CAUSE:
CORRECTIVE ACTION TAKEN:
AUTHORIZED 5(:
e oc.
AAPD DISTR: Butt 0N PaoJ Da57Atavit0N OTHER DISTMeUTCN uGa or coNsraucto.
c er consta oc eNGn uGa or oA. tPo FORMAL REPORT TO CLIENT uGn or aNwn tn:ho cusNr cPo.oA wGa (If Section11 Applies) oc.
MCArV Mt0cus4ptNT PFOct LAPo. oA UGR war (* fw0J (WE RAT'OP.S PROJ[Cf CoNSTR WGn SFPD. on MGR uGa or cuaui. AssuaANet PaOnctrec Necn CORRECTIVE ACTION IMPLEMENTED con $7Ruc10N W.H Pf1OACT UGR j
iNGAtIsuNG puM P90J fHOCunt utNT MGR
$Urf'ULR QUAU!Y MGR SIT [ MGA or suPtamoa VERIFIED BY
- tsscr.tv m space orovided and attach reference occument.
Pewt o4:s-or.
uro om Section Number Page of
MCAR 45B December 17, 1980 0l8588 Page 2 DEFINITION (Cont)
The above condition was notified to the NRC by Consumers Power Company as pote'n-tially reportabic on November 25, 1980. On November 26, 1980, the consumers l'ower Company expanded the 50.55(c) to include in the potentially reportable condition all the low alloy, quenched and tempered bolting materials 1-1/2 inches in diracter and above used in support of safety-related systems.
Note: MCAR-45A addresses the specific problem with the snubber bolts.
I RECOMMENDED ACTION (Cont) support naterials, which have been tempered and quenched and are i
7/8-inch or greater in diameter have been procured in accordance with proper codes and standards.
2.
Evaluate and disposition the results of the review relative to the intended safety functions.
3.
FSAR Section 3.8.1.6.4.1 identifies high strength bolts as ASTM-A-325.
Clarify the application of this statement. Verify that any FSAR descrip-tion of the specification and procurement requirements for the onubber bolts is in conformance with :he actual activities.
4.
Determine the root cause of the discrepancies, if any, and the over-all implications of the same. Determine and implement appropriate corrective action to prevent recurrence.
5.
Provide status reporting to support Consumers Power Company interim 50.55(e) reports to the NRC.
6.
Prepare the first interim status report for coordination with Consuners Power Company and' issue by December 22, 1980.
1
?
Rev 1 Data supplied by Pcul Conued Ecchtel - FE TABUIATION OF IN-PIACE HARDNESS RESULTS FOR 384 RCP SNUBBER RELATED BOLTS C
m TOTAL
- OF BOLTS
- OF BOLTS
HEAT f SIZE BOLTS READINGS READING READINGS READING SPEC.
MATERIAL REMARKS m 63315 2 1/4 56 17 531 7
686 A-354 4145 P.O. F-14780, AEO-2704 BD 63575 2 1/2 164 66 535 29 675 A-354 4145 P.O. F-14780, AEO-2704 BD 62609 3
24 3
557 10 688 A-354 4145 P.O. F-14780, AEO-2704 BD
~
54404 3 1/2 24 0
20 693 A-354 4145 P.O. F-14780, AEO-3109 and r,D All 3 1/2' 0 bolts in 54004 Unit 2.
Individual heats couldn't he separated 50415 3
6 1
571 0
A-354 Not 2 bolts were refabri-BD Given cated and used as. con-nection holts in I-2 and D-4 in Unit 1.
P.O. F-21892, AEO-4044 =
rav naterial 61951R1 3 1/2 24-16 538 0
A-354 Not P.O. F-21892, AEO-4044 BD Given rav naterin1. All 3 1/2" O bolts in Unit 1 91196R1 3
7 7
522 0
A' 4
4140 All bolts in I-2 embed AD in' Unit 2.
P.O. F-24621, AEO-4862 655a196 3
17 0
2 636 A-354 Not All bolts in I-1 and BD Given I-2 embeds in Unit 2.
P.O. F-19091 AEO-4622
TOTAL f 0F BOLTS
- OF BOLTS
~
f OF WITH LOW LOUEST WITH HIGH HIGHEST ASTM BASE HEAT #
SIZE BOLTS READINGS READING READINGS READING SPEC.
MATERIAL REMARXS 51980 3
24 22 518 0
A-354 4142 All bolts in I-1 and ED I-2 cabeds in Unit 1.
P.O. F-25013, AEO-5103 97847 3
10 1
569 0
A-540 E4340 Connection holts in B23 C1 3 AQ I-1, I-2, and 0-4 Units 1 and 2.
P.O. F-3107, Re1 15 AEO-6152 115544 2 1/2 4
0 0
A-540 E4340H Connection bolts in B23 C1 3 E-5 Units 1 and 2.
P.O. F-3107, Re1 15, AEO-6152 91039 2 1/4 24 6
559 0
A-540 E4340AQ Connection bolts in B23 C1 3 I-1, I-2, and D-4 Units 1 and 2.
P.O. F-3107, Rev 15, AEO-6153 384 139 518 68 693 TOTALS liOTES:
1)
Hardness readings in "I" numbers.
" Low" or "high" readings are those outside the following liuits:
A354-74 2 1/4", 2 1/4" 588L4 634L (32 R->38 R )/ 3", 3 1/2" 573L-t634L (30 R + 38 R )
A540-75 2 1/4", 2 1/2", 3" 580L->643L (36.9 R -> 39.1 P )
C C
e 2)
See 60 sheets of actual results of conversion charts for further information.
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Attach =ent 3 Serial 10996
SUBJECT:
MCAR 45A&B (irmued 12/18/80)
Reactor Coolant' Pump Snutber Bolt Hardness Values
).9503 INTERIM REPORT 1 l
DATE:
January 8, 1981 e
t PROJECT:
Consumers Power Company
[
Midland Plant Units 1 and 2 i
Ecchtel Job 7220
[
_Introductica i
MCAR 45A_
The anchor bolts in question are 2-1/4, 2-1/2, 3, and 3-1/2 inches in diameter and vary in icngth from 3 feet, 6 inches to 7 feet, 1 inch. They are embedded in the secondary shield wall as well as the refueling canal vall and serve as anchor bolts for the snubbers. These snubbers restrain i
the reactor coolant pumps during seismic and loss-of-coolant accident loads.
~
The anchor bolts were purcha:;cd from various vendors during 1977,and.1978 by Bechtel Construction. The belts were purchased in accordance with eitfier j
ASTM A354, Grade BD or ASIM A-540, Grade B23, Class 3.
The bolto are
~
embedded'in the concrcto and have not been tensioned as of this date.
Thesc bolts verc intended to be tensioned to a nominal preload of es much as 84 hsi l
to maintain the specified snubber spring rates under all loading conditions.
L Because of previous experience and to accertain that the bolts could with-stand long-tcrn loads of this magnitude without becoming susceptibic to stress corrosion cracking, Consumers Power Company asked Teledyne Engineering Services (TES) to conduct hardness tests on the exposed end of the embedded bolts. TES carried out these hardness tests from November 21 through November 23, 1980.
The tests results showed that 207 bolts are outside the 7
range of hardness specified by tht ASIM specification (see attached test results' summary).
MCAR 45B On November 26, 1980, Consumers Power Company expanded the 50.55(c) to include in the potentially reportable condition all the low alloy quenched and tempered bolting materials 1-1/2 inches in diameter and above used in wp support of safety-related systems.
Investigation Action MCM 45A y
Aptech Engihcering Serviccc.nf Palo Alto, California, has been retained by Consumers Power Company to review the hardness data. Aptech will eval-cate the effect of the measured hardnesses on the ability of the stud to withstand prestress and " accident" loadings. Based upon preliminary Aptoch cevaluations, it appears to be desirabic to lower the preload to assure
.that the bolts will not failsdue to stress corrosion cracking.
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0i9503 The requirement for reduced pretension forces is being reviewed uith Babcock & Wilcox.
B&W will consider the resultant change in spring constants for these snubbers during the re-analysis required for resolving MCAR 37.
Procurement documentation packages for these 1 olta are presently being revicued by Ouality Assurance.
Bechtel, in conjunction with Consumers Power Company, vill establish a plan and schedule to review the quality verification records for the subject bolts,~and will determine if any additional actions vill be required.
_MCAR I.53 Consumers Power Company and Itechtel are in the process of establishing the scope of the necessary investigations to prepare, schedule and implement a program to resolve any identified safety concerns.
Safety Implications MCAR 45A i If the subject bolts were tensioned according to the original design re-
' quirements, there may have been a safety deficiency in that some of the studs may haec failed due.to stress corrosion cracking.
If uncorrected, this deficiency could have adversely affected the safety of Midland plant operations during theeexpected life of the plant.
MCAR 45B s
At this time the existence of any adverse safety implications relative to"other safety-related bolting is undetermined.
Reportability HCAR 45A&B This condition relative to the reactor coolant pump snubber bolts was
~
identified as "potentially reportable" by Consumers Power Company to the NRC under 10 CFR 50.55(e) on November 25, 1980 and expande.l'on November 26, 1980 to include all the low alloy quenched and tempered bolting materials 1-1/2 inches in diameter and above used in support of safety-related systems.
Prepared by: /DMr%
Der-piuh Yuan Reviewedby:[
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L.H.
fr n Concurred-by _
8 K'.D.) Bailey BD/LD/tb(C)
Attachment:
Test Results' Summary
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,q TOTAL F OF BOLTS i 0F 30LTS
',I I CF VIT11 LOW LUT.ST WITII MICH
- dICHEST ASTM 3ASE o
HEAT f SI7.E BOLTS RCADINGS READING READINGS READING SPEC.
MATERIAL REMARKS SI9CO 3
24 22 518 0
cn A-334 4142 All holto in 1-1 and BD I-2 embeds in Unit Ic P.O. F-25013, AEO-516 97847 3
10 1
569 0
A-540 E4340 Connection holta in E23 C1 3 Aq I-1, I-2, and D-4 Unita 1 and 2.
P.O. F-3107, Re1 15 Ato-6152 115544
'2 1/2-4 0
C A-540 2434CH Connection bolts in E23 C1 3,
D-5 Unita 1 and 2.
P.O. F-3107, Re1 15, AED-6152 91039 2 1/4 24 6
359 0
A-540 C5360AQ Connection holte in L23 C1 3 I-1, I-2, r.nd D-4 Unita 1 and 2.
P.O. F-3107, nev 15 AEO-6153 TOTALS 384 139 513 GG 693 NOTES:
1)
!!ardness rendinge in "L" numbern.
A354-74 2 1/4", 2 1/4" 580L-4* 634L (32 R-->38 R" Low" or "high" reedings are the o cutnido the followina linitet 3540-75 2 1/4", 2 1/2", 3" 580L->G43f, (30.9 ng+C)39/in )/ 3",
31/2" 573Di'634L (30 R-t-36 R )
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t Attachment h Serial 10996 REACTOR COOLNIT PUMP S iUBBER NICHOR BOLTS i
MATERIAL SUPPLIERS, BOLT FABRICATORS NID PRIME CONTRACTORS
. Material Bolt i
i Heat #
Bolt Size Total Number Supplier's Fabricator 's of Bolts Code Code i
63315 2k" 56 S-1 r1 i
h2 l
i F-1 63575 2"
16h S-1 F-2 62609 3"
2h S-1 f2
(
Shh0h and F-1 i
Sh00h 2h S-1 F-P o
8-2 50h15 2"
6 F-3 g_
61951 24 S-2 t
R1 F-3 E-3 8-2 91196R1 3"
7 F-3 F-h 655A196 3"
17 S-h 4
1
_5 51980 3"
2h l_-2 F-3 l
i 978h7 3"
10 S-3
.F-6 F-7 F-6 11554h 2b" h
F-7 i
F-6 91039 2h" 2h S-3 F,
i 1
'4aterial Suppliers S-1 Joseph Dyson & Sons, Inc Painesville, Ohio S-2 Pressure Vessel Nuclear Steel Hillside, New Jersey 4
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Attachment b Serial 10996 Page 2 S-3 Copperveld Steel Co.mpany Warren, Ohio S-h I.aSalle Steel Company Chicago, Illinois S-5 Colt Industries Crucible Inc Midland, Pennsylvania Bolt Fabricators and Prime Contractors F-1 Haven Busch Company (Prime)
Grandville, Michigan F-2 Joseph Dyson & Sons (Fabricator)
Painesville, Ohio F-3 Wiltce Company (Now Out Of Business) (Fabricator)
Saginau, Michigan F4 Inland Ryerson Construction Co (Prime)
Southfield, Michigan F-5 Quality Bending and Threading (Fabricator)
Detroit, Michigan F-6 NPS Industries (Prime)
Portland, Oregon F-7 Schmitt Steel Inc (Fabricator)
Portland, Oregon JLW/1r 1/8/81
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