ML20092D828

Part 21 Rept Re Several Documentation Inconsistencies Disclosed on Brown & Root Purchase Order 35-1197-16105 for South Texas Project.Amended Documentation Packges Will Be Forwarded Prior to 820906

ML20092D828
Person / Time
Site:	South Texas
Issue date:	09/01/1982
From:	Weightman R LONE STAR SCREW CO.
To:	Jay Collins NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
References
REF-PT21-82 NUDOCS 8406220163
Download: ML20092D828 (15)

Text

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Lone Star Screw Co.

SCREWS BOLTS NUTS e

WASHER 5 4

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Liil HOUSTON, TEXAS 77020 I

5826 ARMOUR DRIVE P. o. Box 15211 AREA CooE 713 PHONE: 675 5201 September 1, 1982

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1 United States Nuclear Regulatory Commission, Region IV l

h 9 lggg fl, f,k 611 Ryan Plaza Drive Arlington, Texas 76011 l

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QJ Attn:

Mr. John Collins Regional Administrator

Subject:

Reportage of Defects and Noncompliances pursuant to 10CFR Part 21, Paragraph 21.21 " Notification" (see attachments)

Dear Sir:

Based upon a Nuclear Regulatory Commission investigation conducted on August 25, 1982 by Messrs. John R. Boardman and Donald D. Driskill, several documentation inconsistancies were disclosed on Brown & Root Purchase Order #35-1197-16105 for the South Texas Project.

Pursuant to this investigation, the Lone Star Screw Company reviewed all of the subject documentation and found that documentation packages for Purchase Order #35-1197-16105 were incomplete.

The results of this review were satisfactory with the exception of the three (3) items identified below.

Amended documentation packages for these items in question (i.e., except those identified as noncomplying) will be forwarded to:

(a)

Mr. John R. Boardman United States Nuclear Regulatory Commission; and (b)

Mr. Dennis Keating South Texas Project Site Project Quality Assurance Supervisor (HL&P)

P. O. Box 308 Bay City, Texas 77414 The amended documentation packages will be forwarded prior to September 6, 1982.

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.Mr. John Collins 9/1/82 Page 2 j

OV Noncompliance #1 Noncompliance #1 was reported at 7:25 P.M. on August 27, 1982 to United States Nuclear Regulatory Commission, Region IV, Duty Officer, Mr. Eric Johnson.

Objectivo evidence indicates that the material and the mechanical test drops were heat treated in diffenent heat treat batches (ref. Attachment I).

The material was heat treated on Jur:e 27, 1979, as indicated by Lindberg/

Cook Heat Treat Chart #72092, and the mechanical test drops were heat treated on June 29, 1979, as indicated by Lindberg/ Cook Heat Treat Chart

1. 72083.

Material

Description:

a)

Brown & Root Purchase Order #35-1197-16105 b)

Purchase Order Item #11 c)

==

Description:==

(Parts) 2 1/2" 9 X 43" Long, ASTM A-540 B23, Class 3, Double End Studs (40 pieces) d)

==

Description:==

(Drops) 2 1/2" 9 X 6" Long, ASTM A-540 drops (2 pieces) e)

Heat Code No.: 7B

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f)

Crubicle Mill Heat No.:

115950 Resolution one piece of the subject material (i.e., (1) 2 1/2" 9 X 43" Long, D.E.

Stud, Heat Code #7B)'was located during the investigation of June 21 through 23, 1982 and identified in the Lone Star Screw Company response of July 28, 1982, and tested to verify conformance to the material specification (ref. Attachment II). The results are satisfactory as indicated by the Laboratory Report.

Please accept these results as a representation of Purchase' Order Item-

1. 11 - Heat Code #7B.

Noncompliance #2 Noncompliance #2 was reported at 11:18 A.M. on August 30, 1982 to United States Nuclear Regulatory Commission, Region IV's Mr. Uldis. Potapovs.

There is no objective evidence of mechanical test drops being heat treated with Heat Code #7D for Item.#20 (ref. Attachment III).

The material was heat treated on May 31, 1979, as indicated by Lindberg/

Cook Certification #70633. There is no objective evidence, as referenced by Lindberg/ Cook Supplement to.the. Certification, dated may 31, 1979, of mechanical test drops being heat treated with the subject material.

73

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U.S; N.R.C.

Mr. John Collins 9/1/82 Page 3 LO Material Description a)

Brown & Root Purchase Order #35-1197-16105 b)

Purchase Order Item #20 I

c)

==

Description:==

1 1/2" $, ASTM A-540, B23, Class 3, Heavy Hex Nuts (5 pieces) d)

. Heat Code No.: 7D e)

Crucible Mill Heat No.: 64410 Resolution Based upon the satisfactory mechanical results of Heat Code #6B and Heat Code #3B (as referenced on Lindberg/ Cook's Supplement to Cert-4 ification #70633 - Attachment III),-the Lone Star Screw Company sin-cerely believes that the integriry of the subject material (i.e.,

4 5 pieces of. Heat Code #7D) has not been impaired. Therefore, please allow the Lone Star Screw Company to perform mechanical testing on i

one (1) piece of the subject material to verify conformance to the material specification.

Noncompliance #3 Noncompliance #3 was reported at 7:25 P.M.: on August. 30, 1982, to United O

States nec1 ear aes taterr Ce issien, aesien v. o tv officer ur. stane Murray.

I Objective evidence indicates that the-hardness of the subject material exceeds l

the maximum range' allowed by the' material specification (ref. Attachment.IV).

1 In addition, the subject material was heat. treated in a different lot-than th'e parts identified in Noncompliance #2.

M_aterial Description.

a)

Brown & Root Purchase Order #35-1197-16105 b)-

Purchase Order Item #19 c)

==

Description:==

l'l/2" W, ASTM A-540, B23,' Class 4, Heavy Hex Nuts (200 pieces) d)

Heat Code No.:

7D -

e)

Crucible Mill Heat No.: 64410 Resolution j

i.

It is apparent that the sub' ject. material exceeds maximum hardness requirements of the material specification.. Thereforei the Lone Star Screw Company requests that the subject material'be' recalled, t'empered,-

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and re-tested to demonstrate compliance to the material specification.-

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U.S. N.R.C.

Mr. John Collins 9/1/82 Page 4 J

O If you should have any questions regarding this matter, please do. not hesitate to contact me.

Your continued cooperation is greatly appreciated.

Sincerely,

[W d f R. T. Weightman Quality Manager RTW/dhi cc: Judith C. Jandl, President Joe Kratoville, Vice President Quality Files, Lone Star Screw Company Quality Files, Jandl Manufacturing t

Attachments:

I - Heat Treat Records for Heat Code #7B - Item #11 II - (a) Page 2 of 4 and 3 of 4 of July 28, 1982 response-(b) Laboratory Report for Heat Code #7B d("%

III - Heat Treat Records-for Heat Code #7D - Item #20 IV.- Laboratory Test Report for Mechanical Results of Heat Code #7D -

Item #19 a

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SUPPLEMENT

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CERTIFIC ATIO N OF H E AT TR E ATM E N T i

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CERTIFICATION NO-_

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The fo!!owing items are reflected in ottoched certification:

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ITEM # 12 21/2 OD x 6 IS CLASS 3 DROPS CODE 3D 2

ITEM # 12 21/2 OD x 6 ID CLASS 3 DDOPS CODE 4B i

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CERTIFIC ATIO N OF H E AT TR E ATMEN T DATE:

G/25/79 I

I CERTIFICATION NO.

740_S3 9 I

I CUSTOMER'S ORDER NO.

11080 LONE STAR SCREW CO.

OTHER ORDER NOS.:

'(NONE)

NUMBER OF PARTS: TWENTY FOUR (24)

.st siesav cintisv t At twi Pants cisce4sts wret e,'.is t ! ronow.oc, t At tat ati.,ist PART NUMBERS:

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We further certif,j;,thp',t,.5iAff reatment described ahnve is true and enrrect and that tem-peraPJres and,, test r'esults hh,4 igtained with standard approteel methods.

Suh e I and sworn to Itfr this 1.I N D e c n c eCOO M HEAT TR E ATI NG CO M PA N Y g

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6/25/79 CERTIFICATION NO.

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CUSTOMER'S ORDER NO.

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(NONE)

NUMBER OF PARTS: FORTY (40) we.santav cratiry THAT THE Pants ciscerato want civis rHe sottow No hf Af Tal ATMENs PART NUMBERS: ITE! # 11 TWE AT HEAT COOtANT NORMAUZED

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JULY

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Unit'ed States-Nucient i

Regulatory Commission 7/28/82 Page 2 2-M.

9 Sir:

. Upon performing a thorough evaluation and compilation of data for the subject deficiencies, please find enclosed the Lone Star Screw Company, Jandl Manufacturing Division response.

-Noncompliance #1 Based upon the results of the investigation it has been disclosed that the materials. referenced in Attachment I have been heat treated in batch type ovens, as confirmed by the " Letters of Confirmation" (Attachment II) from the applicable vendor.

The original vendor Material Test Report

. -or Laboratory report (as subcontracted by this company)* shows actual Charpy impact test results.

Therefore, it is our belief that the subject material is acceptable based upon the type of heat treatment (i.e., batch type) and the ASME l

response to Code Interpretations III-1-78-172 (Attachment III) and III-1-79-166 ( Attachment IV)..

' ' aD Noncompliance #2 Based upon the results of the investigation it has been d'isclosed that:

(A) Objective evidence is ~ unclear to demonstrate full compliance

. to paragraph 12.2 of A540 (i.e., discard requirements) although common shop practice is to discard, during the cutting operation, 4-at least one -(1) end of each bar where a complete (length) ' item cannot be removed from the bar stock.

(B & C)

Obj ective evidence indicates that:

(1)

Some work orders for the ' subject material (identified;in.

Attachment V). reference the-cutting of -(2) test coupons per heat code number (MC#); at)d, (2)- laboratory reporti reflect mechanical.results -for -_(1)'

coupon only.

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'Therefore it is apparent that objective evidence is insufficient to ' demon-

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strate full compliance to-paragraph 13.l'.1 of AS40.

In addition several pieces of material -(1.e., overages from the origin'l a

Customer Orders of the materials ref erenced in. Attachment V) have been -

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located in our Nuclear Stock. area.

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United. States Nuclear.

j Regulatory Com51ssion 7/28/82 Page 3 s

The subj ect materials - are:

(a) 2'3/4" O Heavy hex Nuts - HC# 7C, 8C and 9C

];; (b) 21/2" 0 X 43" D. E. Anchor Bolt - HC# 7B The subj ect material-was charpy impact. tested, tensile tested and hardness tested to verify compliance to A540.

Subsized tensile specimens had to be 4

utilized for HC#'s 7C, 8C, and 9C (2 3/4" Heavy Hex Nuts). However, full sized charpy specimens were available.

j; Full sized tensile /charpy specimens were available 'for HC# 7B (21/2" X 43" D. E. Anchor Bolt).

The test results were acceptable (Attachment VI) meeting the original Customer R6quirements as follows:

[

Results Original Requirements HC# 7C AS40 Grade B23

.[)

AS40 Grade B23 Class 3 and 4 Class 3 HC# 8C A540 Grade B23 A540 Grade B23 Class 1 and 3 Class 1 and 3 HC# 9C AS40 Grade B23 A540 Grade B23 Class 3 and 4 Class 3

))* HC# 73 A540 Grade B23.

AS40 Grade B23 Class-3 and 4 Class 3 and 4 s

Also, please be advised that ohj ective evidence indicates that the subj ect.

materials were purchased in the E-4340-H unheat treated condition and heat treated (via subcontract) by Lone Star Screw Company in the semi-finished (i.e., blanks cut to the ~ required size) condition and.not in bar

. fo rm.

Heat treatment lots consisted of the_ semi-finished pieces and test drops (sec' Attachment VII for heat treat' cert'ifications).

Please accept-these results as a. representation of the mater 1'ls identified' a

in Attachment V basel upon the laboratory test results in-Attachment VI and the method of' heat treatment ~ (1.e., _ not in bar fo rm).

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i July 19, 1982

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Attn: Mr. B. Weightman' Report No. 82-3836=4 c

IDENTIFICATICV:: 2-1/2" x 43" Iq., SA-540 D.' E. Stud, SN-78-11-26 TENSIIE TEST s

(0.2% offset).505" Dia. Tensile Dia.

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134,000 149,400 19.0 62.9 IM?1CT TEST O

(Iongitudinal):

10mn x 10mn CVN @ + 10' F Foot / Pounds Lateral I'xoansion (mils)

% Shear s

71.0 35 100 68.0

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100 67.0 42 100

!!NCNESS TEST B!'N

-321-

• All activities performed for this order shall be performed in accordance I

with a quality system meeting tho' requirements.of ASMS Section III, Sub '

1section NCA-3800 as audited and approved by ISS ccmpany on 7-21-81 and so, i

-certified in the above test' report..

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HEAT TREATING f[ LINDBERG COMPANY

' CO RPO R ATIO N P. O. BOX 24147

• HOUSTOt4. TEXAS 77029

• 713/672 6601 CERTIFIC ATION OF HE AT TRE ATMENT 5/31/79 DATE:

l CERIlFICATION NO.

70633

_N.

11080

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CUSTOMER'S ORDER NO.

L0fiE STAR SCREW CO.

OTHER ORDER NOS.:

(N0E)

TWO HUtiDRED TWENTY'EIGHT (228)

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PART NUMBERS:_SEE._SUEELEMENT we stae ar cu ar.r. rwai ist raars ce,(e-se o wine caven rut Fottow,nc star ret arutut itA?E AT HEAT COOT Araf

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HARDNESS TEST 302_-321_BHN We further certify that heat treatment elescrile.1 alm.ve is true amt rs rrect atul that tem peratures an.! test results were..htainewl with tanitaril approvtwl mrth.=l(

Subwrite.1 n.1 sw..rn t.. lief..re m. this u.in nnonc coox nonT Turn ru na c6 r.s t.n 15Th, _

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