ML20079R108
| ML20079R108 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse, Oconee, Midland, 05000000 |
| Issue date: | 06/17/1983 |
| From: | Taylor J BABCOCK & WILCOX CO. |
| To: | Deyoung R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| References | |
| REF-PT21-83-906-000 PT21-83-906, PT21-83-906-000, TAC-48349, NUDOCS 8306220007 | |
| Download: ML20079R108 (4) | |
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Utility Power Generation Division Babcock & Wilcox a McDermott company 3315 Old Forest Road P.O. Box 1260 Lynchburg, Virginia 24505-1260 (804) 385-2000 June 17, 1983 Mr.
R. C. DeYoung, Director Office of Inspection and Enforcement U.
S. Nuclear Regulatory Commission Washington, DC 20555
Dear Mr. DeYoung:
This letter is a follow-up to our report dated January 10, 1983 on the adequacy of fittings supplied by Tube-Line Corporation to B&W through Capitol Pipe and Steel Products, Co., for use on new auxiliary feedwater headers for Oconee 3, Duke Power Co.,
Davis Besse 1, Toledo Edison Co., and Midland 1 & 2, Consumers Power Co.,
The original letter was sent to you in a time period between the B&W/ Capitol Pipe audit of Tube-Line, Houston, Texas facility and our inspection of their Long Island City facility.
The following is a summary of findings, actions and decisions made since that initial report:
Qualification Audit Examination of Capitol Pipe and Tube-Line records raise some questions as to the adequacy of the Capitol audit to meet the qualification requirements of ASME Code Section III, NCA-3800.
Review of the audit checklist indicated that the Capitol auditor only cenducted a " desk audit" of the Tube-LIne QA program by review of the manual and did not verify implementation by review of objective evidence such as content of Tube-Line Purchase Orders.
Tube-Line, Long Island City, N.Y.,
was approved as a result of this audit.
Material Procurament Capitol Pipe placed their order for the tees, caps and flanges with Tube-Line, Long Island City, N.Y.,
on May 13, 1982.
At this time, the required tees, caps and flanges were in stock at the Tube-Line, Houston facility and Tube-Line, Long Island City directed the Houston facility to fill the Capitol order.
The flanges in stock at the Houston facility had been processed at the Long Island City facility and shipped to the Houston facility to balance inventories.
$7 O
tn Babcock &Wilcox
. Mr.
R. C..DeYoung June 17, 1983 The flanges were' ordered by Tube-Line, Long Island City as rough forgings from Matalfar in Como, Italy in two lots of 2,000 each on September--2, 1980 and June 29, 1981, respectively.
1705'of these flanges were received by Tube-Line, Long Island City in January, 1981 and assigned Heat Code EXP.
1700 of these flanges were received by Tube-Line, Long Island in August, 1981, and assigned.HeatiCode EUUA.
Tube-Line, Long Island City processed the rough forgings into flanges by machining, drilling, stamping and painting.
The caps were ordered by Tube-Line, Houston as finished products from Hackney in Dallas, Texas, in a lot of 200 pieces on Oct. 19, l
1981.
125 of these caps were received by Tube-Line, Houston in February, 1982, and assigned Heat Code NDUC.
Tube-Line, Houston painted and stamped these caps.and placed them into their inventory.
The tees were ordered by Tube-Line, Houston as finished products from BKL Fittings in Worchestershire, England, in a lot' of 250 pieces on June 29, 1981.
167 of these tees were received by 4
Tube-Line, Houston, painted, stamped and placed into their inventory.
i '
The starting material sources for these fittings could not be determined at Tube-Line, Houston or Long Island City.
Subsequent to the vendor facility visits, B&W obtained the follow-ing information relative to the flange material procurement history.
Metalfar obtained the flange material from the original melter, LAcciaierie Ferriere Pugliesi, in Italy.
Acciaierie Ferriere Pugliesi performed ' the material testing and established the original heat numbers, 4/5558 -(EKP) and 1/2026 (EUUA).
Material Testing Independent material testing performed by B&W, Nuclear Equipment Division in Barberton, Ohio confirmed that the caps and tees met the requirements of the material specification and were consistent with the chemical and physical data reported in the Material Test Reports.
The independent tests of the flangcc, however, failed to confirm the material test report values.
In the case of both. heats for the flanges the yield strength values were lower than shown on.the Material Certifications and for one heat the yield strength _was below the minimum required in the procurement specification and used in the ASME code stress analysis.
In addition one heat showed lower manganese content than indicated by the Material Certification.
Further investigations by B&W have revealed that in addition to having low strength, the Tube-Line records indicate that the flanges were not heat treated as required by the material specification.
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M&h Mr. R. C. DeYoung, Director June 17, 1983 Recertification and Replacement-The audit of. Tube-Line, Houston, Texas,. facility did show that material identity was maintained by Tube-Line for the caps and tees.
1 AsLa result of this traceability and the physical and chemical testing performed by NED, B&W can recertify these fittings to be ASME code class material since the test results agree with c
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the data on.the Material Test Reports.
It is, however, necessary to' sample the fittings installed and by chemical tests results show that the material' originally tested at NED is the same as that in the field.
i.
Recertification_to ASME code will be provided for the caps and tees at Davis Besse l'and Midland 1 and.2after site testing verify-ing material compatibility. Since the Oconce III AFW headers were designed to sNtS B31'.l and not ASME III, Class.
2, sampling and chemical testing of. -installed caps and tees 'will not be required to recertify the material to the required ASTM classification.
hnen the low physical properties of the flanges were established by testing, B&W and Duke Power Co. performed analyses using the lowest yield' strength obtained from results of tests at NED and Tube-Line.
The analyses showed that the-integrity of the AFW headers at Oconee 3 (DPCO analysis),
and Davic Besse (B&W analysis) wv11d be maintained for expected operational modes.
Since the flanges were not classifiable as ASME-III Class 2 fittings,
'because of the low yield strength,'they were considered "special fittings" for the purpose of this analysis.
Due.to. this lack of agreement with the physical properties between the material certification and the NED test results, dua lack of evidence of heat treatment and the questionable material trace-ability, the flanges can not be recertified, therefore, properly certified new flanges are being shipped to the affected plants.
In summary.the final resolution of this concern is being accomplished as follows:
Oconee III
- Caps and Tees - Recertify as ASTM class material
Babcock &Wilcox
_4_
Mr. R. C. DeYoung June 17, 1983 Davis Besse 1 & Midland 1 & 2
' Caps and Tees - Sample installed fittings
- Verify the match of chemical properties with results from NED test
- Recertify as ASME Section III, Class 2 material
' Flanges
- Replace with qualified ASME Section III, Class 2 flanges This information brings you up to date on the investigations, actions, and decisions on the problem of potentially inadequate caps, tees, and flanges at three B&W designed plants.
B&W plans no further report of this concern.
If you have any questions please contact me (804-385-2817) or T.
L. Baldwin (804-385-3142) 4 of my staff.
Very trul your,
. H. Taylo Manager, Licensing Services JHT/fw cc:
R. B. Borsum - B&W Bethesda Office
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