ML20101K297

Rev 1 to Palo Verde Nuclear Generating Station Presentation to NRC on Cardinal Industrial Products (CIP) Fastener Matls

ML20101K297
Person / Time
Site:	Palo Verde
Issue date:	12/14/1984
From:	ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR
To:
Shared Package
ML20101K274	List: ML20101K270 ML20101K297
References
NUDOCS 8412310286
Download: ML20101K297 (35)

Text

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12/14/84 7

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PVNGS PRESENTATION TO THE NRC ON CARDINAL INDUSTRIAL PRODUCTS (CIP) FASTENER MATERIALS t

i DECEMBER 14, 1984 Revision 1 J

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. Revision 1

'12/14/84 AGENDA PVNGS NRC PRESENTATION - CIP MATERIALS EVALUATION -

I. INTRODUCTION /bVERVIEW' -E. E. VAN $ RUNT, JR./W. E.' IDE II. CHRONOLOGY OF EVENTS R. C. FULLMER III. TECHNICAL ACCEPTABILITY W. G. BINGHAM /R. MANLEY/D. SACHS IV. PROGRAMMATIC EVALUATIONS W. E. IDE V. CONCLUSIONS W. E. IDE

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s Revision ~1 12/14/84-OVERVIEW s

. 4 HAVE NOT HAD A' PHYSICAL FAILURE OF CARDINAL BOLTS HAVE BEEN SOME DEFICIENCIES NOTED WHICH WILL BE ADDRESSED NRC IDENTIFIED CARDINAL DEFICIENCIES AND ACCEPTED CARDINAL RESOLUTION HAVE PERFORMED A DETAILED REVIEW. EXTENSIVENESS OF REVIEW PARTLY DUE TO PR0XIMITY TO FUEL LOAD

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Revision 1 12/14/84 CHRONOLOGY OF EVENTS ~~

DEC/1979' PROJECT PERFORMED SURVEY AT CARDINAL ~ INDUSTRIAL PRODUCTS - BASED ON RESULTS CARDINAL'ADDED TO BECHTEL EVALUATED SUPPLIERS LIST.

NOV/1980 .-PROJECT BEGAN PIACING PURCHASE ORDERS WITH CARDINAL.

JAN/1981 FULL SCOPE AUDIT CONDUCTED AT CARDINAL'- 8 FINDINGS NOTED WITH ONE HOLD ON SHIPMENT FEB/1981 RE-AUDIT CONDUCTED AT CARDINAL - HOIS ON SHIPMENT RESTRICTION REMOVED AND & FINDINGS CLOSED M Y/1981 RE-AUDIT CONDUCTED AT CARDINAL - 1 FINDING CLOSEDI DEC/1981 FULL SCOPE AUDIT CONDUCTED AT CARDINAL - 1 PREVIOUS FINDING CLOSED.

NO NEW AFRs ISSUED DEC/1982 FULL SCOPE' AUDIT CONDUCTED AT CARDINAL - NO FINDINGS NOV/1983 FULL SCOPE AUDIT CONDUCTED AT CARDINAL - NO FINDINGS FOR'PVNGS NOV/1983 NRC CONDUCTED AUDIT AT CARDINAL IN OCTOBER / NOVEMBER, 1983. PROBLEMS WERE DISCOVERED BUT SCOPE OF PROBLEMS NOT IDENTIFIED UNTIL FORMAL REPORT ISSUED 6/84 _

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.NOV/1983 -ASME' CONDUCTED' AUDIT OF CARDINAL - CERTIFICATES ISSUED JAN/1984.

DEC/1983 ARKANSAS POWER & LIGHT INFORMED PVNGS IN LATE 12/83 THAT THE NRC HAD FOUND. PROBLEMS AT CARDINAL WITH PVNGS MATERIAL.

JAN/1984 PVNGS CONTACTED CARDINAL AND THE NRC AS FOLLOW-UP TO AP&L INFORMATION. RESUI.TS:

CARDINAL DENIED HAVING ANY PROBLEMS NRC WOULD GIVE NO SPECIFICS ON TYPES OF PROBLEMS FEB/1984 APS CONDUCTED A FULL SCOPE AUDIT AT CARDINAL ON CARDINAL'S "ASME" APPROVED PROGRAM AND APS DIRECT PROCUREMENTS.

ONLY (2 DIRECT P.O.s/1 INDIRECT P.O.) - 3 FINDINGS ISSUED.

APRIL /1984 NON-ROUTINE, UNANNOUNCED INSPECTION OF RECEIVING INSPECTION AND PROCUREMENT DOCUMENT CONTROL CONDUCTED BY REGION IV AT PVNGS.

IDENTIFIED TO PVNGS THAT PRIOR NRC INSPECTION AT CARDINAL HAD REVELAED THAT CIP HAD PURCHASED ASTM MATERIAL AND SUPPLIED IT TO e

PVNGS AS ASE >SECTION III MATERIAL AND THERE WAS NO DOCUMENTATION AVAILABLE TO INDICATE THAT THE MATERIAL HAD BEEN UPGRADED.

INDICATED THAT THE NRC<HAD IDENTIFIED PROBLEMS AT CARDINAL AND A FORMAL REPORT WOULD BE FORTHCOMING. NO SPECIFICS WERE GIVEN.

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NO VIDIATIONS OR DEVIATIONS WERE IDENTIFIED AS A RESULT 0F-THIS

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-INVESTIGATION.

MAY/1984 PROJECT INVESTIGATION AT CARDINAL IDENTIFIED PROBLEMS AND

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CONCLUDED MAT 5 RIAL SUPPLIED TO PVNGS BY CARDINAL TO.BE INDETERMINATE.

i' MAY/1984 DER 84-41 ISSUED.

MAY/1984 REMOVED CARDINAL FROM PVNGS APPROVED BIDDERS LIST. '

i JUNE /1984 FULL SCOPE AUDIT CONDUCTED WITH 42 PVNGS P.O.s REVIEWED IN DETAIL. .9 FINDINGS ISSUED.

4.

JUNE /1984 IE NOTICE 84-52 ISSUED BY NRC.

! JULY /1984 PROJECT INSTIGATED A 100% REVIEW 0F ALL PVNGS CMTR's AT CARDINAL.

AUG/1934 PROJECT PROCEEDED WITH A LIMITED SCOPE TESTING PROGRAM TO SUBSTANTIATE MATERIAL VALIDATING.

SEPT /1984' CARDINAL INFORMED BECHTEL THAT THE AUDITORS WERE NO LONGER WELCOME AT CARDINAL. CARDINAL CONFISCATED ALL BECHTEL DOCUMENTS

PERTAINING TO REVIEW.

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4 Revision 1 12/14/84-

'0CT/1984 - PERFORM EXTENSIVE TESTING OF. WAREHOUSE STOCK MATERIAL.

NOV/1984 - PRESENTATION OF INVESTIGATION AND EVALUATION RESULTS TO NRC REGION V.

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'-Revision l'. .9

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w TECHNICAL ACCEPTABILITY s 7

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TYPES OF MATERIALS ASME III CLASS 1, 2, and-3 1

ASTM L

I NO MATERIAL FAILURES EXPERIENCED GOAL OF VERIFICATION PROGRAM - DEMONSTRATE THAT MATERIAL IS r j ACCEPTiBLE FOR USE AT PVNCS REVIEWED P.O.s AND FOUND THAT ALL ASME III .CIASS 1 MATERIAL WAS SATISFACTORILY TESTED OR WAS ACCEPTABLE TO "USE AS IS" BASED ON i '

CODE EFFECTIVE DATE ,

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COMBUSTION ENGINEERING INDICATED'THAT THEY 'USED 1" CIASS 1 BOLT' i:

4 SUPPLIED BY CIP IN THE RCP HIGH PRESSURE SEAL COOLER (NOT INSIDE THE RCP)

.. THERE IS NO. ASME CIASS 1 MATERIAL AVAIIABLE IN THE WAREHOUSE 1

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Revision 1 12/14/84 NOT NECESSARY TO REMOVE ASME CIASS 1 MATERIAL FROM THE UNIT FOR THE FOLLOWING REASONS:~ '

PASSED THE TORQUE TEST - NO FAILURES TO DATE 100% REVIEW OF CMTRs'& SUPPORTING INFORMATION IS IN COMPLIANCE WITH THE CODE NO CLASS 1 BOLT GREATER THAN 1" DIAMETER USED ON THE PROJECT ONLY DIFFERENCE BETWEEN 1" AND LESS CLASS 1 and class 2 IS THE VISUAL INSPECTION FOR HARMFUL DISCONTINUITIES WHICH IS DONE BY THE SUPPLIER RESULTS OF CLASS 2 TESTING IS TRANSPORTABLE TO CLASS 1 FOR 1" AND BELOW TESTING WAS LIMITED TO VERIFICATION OF MATERIAL IN OTHER THAN CLASS 1 TESTING WAS PERFORMED ON WAREHOUSE MATERIALS SINCE THERE WAS AN ADEQUATE CROSS-SECTION OF MATERIALS AVAILABLE FOR A VERIFICATION TESTING PROGRAM

Revision;1 12/14/84  :*.

MATERIAL TESTING PROGRAM AN EXTENSIVE MATERIAL VERIFICATION PROGRAM WAS CONDUCTED ON SAMPLES OF CIP MATERIAL SUPPLIED TO PVNGS.

SCOPE MATERIAL VERIFICATION - NOT MATERIAL CERTIFICATION PROGRAM PHASE I - LIMITED VERIFICATION TESTING PHASE II - EXTENDED VERIFICATION TESTING ADDITIONAL TESTING l REVERIFICATION OF CIP CERTIFIED MATERIAL TEST' REPORTS (CMTR's) r.

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Revision 1 12/14/84 RATIONALE USED TO DEVELOP MATERIAL TESTING PROGRAM TESTING WAS LIMITED TO , VERIFICATION OF MATERIAL IN CLASSES OTHER THAN CLASS I.

TESTING WAS PERFORMED ON WAREHOUSE MATERIALS ONLY.

PHASE I LIMITED VERIFICATION TESTING EVALUATE TEST RESULTS TO VERIFY THAT THE MATERIAL CONFORMED TO THE APPLICABLE MATERIAL SPECIFICATION AND CODE REQUIREMENTS.

SAMPLE SELECTION WAS BASED ON DOING THE REQUIRED NDE AND MECHANICAL AND CHF'lICAL TESTING FOR EACH ASTM /ASME SPECIFICATION, GRADE, CLASS, AND DIAMETER. A SINGLE SAMPLE WAS USED FOR EACH TYPE OF TEST PERFORMED.

PHASE II:

EXTENDED VERIFICATION TESTING

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l R'evision 1 12/14/84 l THE PROJECT IMPLEMENTED A' MORE COMPREHENSIVE MATERIAL TESTING PROGRAM TO VERIFY THAT MATERIAL CONFORMED TO THE'APPLCABLE MATERIAL SPECIFICATION AND CODE REQUIREMENT FOR THE FOLLOWING ATTRIBUTES:

, HARDNESS MECHANICAL PROPERITES -

CHEMISTRY SAMPLE SIZE SAMPLES WL:RE TAKEN FROM "Q" CLASS STOCK CODES (ASME AND ASTM) 1/2 INCH NOMINAL' DIAMETER AND GREATER. ' ALL FASTENERS WERE TESTED FOR HARDNESS PER ASTM A-370.

THE SAMPLE SIZES WERE AS FOLLOWS:

l STOCK CODE INVENTORY SAMPLE SIZE

• 2 TO 15 PIECES 2 16 TO 50 PIECES 3 51 TO 150 PIECES 5 151 TO 500 PIECES 8 l 501 TO 3,200 PIECES 13 3,201 TO 35,000 PIECES 20 35,001 TO 500,000 PIECES 32 500,001 PIECES AND UP 50

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• SAMPLESIZEWASBASED'ONMIL-STD105-S3 ANDS 1 RATIONALE'ANDTHk.

INVENTORY.0F CIP MATERIAL AVAILABLE'IN A STOCK CODE.

NOTE: IT WAS. DECIDED TO TEST ONLY MATERIAL 1/2 INCH IN DIAMETER:AND'

' GREATER BECAUSE ANYTHING SMALLER THAN 1/2= INCH IN DIAMETER NORMALLY WOULD-NOT BE USED FOR CRITICAL FASTENER APPLICATIONS (I.E., PRESSURE RETENTION AND COMPONENT SUPPORTS), ALTHOUGH THERE ARE SOME SMALLER' DIAMETER, MATERIALS USED IN SMALLER DIAMETER PIPING SYSTEMS. .

IN ADDITION TO THE HARDNESS. TESTS DESCRIBED ABOVE, MATERIAL 1-INCH NOMINAL.

DIAMETER AND GREATER WAS TESTED FOR CHEMISTRY AND MECHANICAL PROPERITES.

THE SAMPLE SIZES WERE AS FOLLOWS:

STOCK CODE INVENTORY SAMPLE SIZE *-

2 TO 50 PIECES 2 51 TO 500 PIECES 3 501 TO 35,000 PIECES 5 35,001 PIECES AND UP 8

• SAMPLE SIZE WAS BASED ON MIL-STD 105-S3 AND S1 RATIONALE AND THE INVESTORY OF CIP MATERIAL AVAILABLE IN A STOCK CODE.

THE TESTS WERE PERFORMED ON THE BOLTING THAT K(S UTILIZED FOR THE HARDNESS TEST, WITH THE EXCEPTION OF BOLTING THAT REQUIRED A. WEDGE TEST. IN THOSE INSTANCES, ADDITIONAL SAMPLES WERE MQUIRED.

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Revision 1 12/14/84

SUMMARY

OF LIMITED TESTING J

MATERIAIS AND QUALITY SERVICES PERFORMED A TOTAL OF 78 VERIFICATION TESTS ON NUTS, BOLTS AND STUDS. TEST AND EXAMINATION RESULTS ARE SUMMARIZED BELOW.-

(1) ELEVEN TESTS AND EXAMINATIONS WERE PERFORMED ON SAI93 GRADE B7 STUDS; THREE CHEMISTRIES,~THREE REDUCED SECTION TENSILE TESTS, ONE CHARPY TEST,.

THREE METALLURGICAL EXAMINATIONS, AND ONE NONDESTRUCTIVE EXAMINATION.

(2) TWENTY-FOUR TESTS AND EXAMINATIONS WERE PERFORMED ON SA194 GRADE SM NUTS; FIVE CHEMISTRIES, FOUR PROOF TESTS, FIVE HARDNESS TESTS, FIVE METALLURGICAL EXAMINATIONS AND FIVE NONDESTRUCTIVE EXAMINATIONS.

(3) TEN TESTS AND EXAMINATIONS WERE PERFORMED ON SA194 GRADE 2H NUTS: TWO CHEMISTRIES, IWO CONE STRIPPING TESTS, FOUR HARDNESS TESTS, AND TWO NONDESTRUCTIVE EXAMINATIONS.

(4) FIVE TESTS AND EXAMINATIONS WERE PERFORMED ON A325 TYPE 1 BOLTS: ONE CHEMISTRY, ONE WEDGE TEST, ONE PROOF TEST, ONE HARDNESS TEST, AND ONE NONDESTRUCTIVE EXAMINATION.

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Revision 1 12/14/84 (5) EIGHT TESTS'AND EXAMINATIONS WERE PERFORMED ON A490 BOLTS: ONE CHEMISTRY, ONE REDUCED SECTION TENSILE TEST, THREE WEDGE TESTS, ONE HARDNESS TEST, AND TWO NONDESTRUCTIVE EXAMINATIONS.

(6) TWENTY TESTS AND EXAMINATIONS WERE PERFORMED ON SA564 TYPE 630 STUDS:'FOUR CHEMISTRIES, FOUR REDUCED SECTION TENSILE TESTS, FOUR HARDNESS TESTS, FOUR CHARPY TESTS, AND FOUR NONDESTRUCTIVE EXAMINATIONS. l

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i P. vision 1 1.1/14/84 LIMITED TESTING TESTS DESCRIP- TEN- HARD-SIZE TION' . CODE /STD CHEM. SILE NESS OTHER RESULTS SA193 GRADE B7 2-1/4 - 8x10-1/2 STUD ASME'III X X ME OK CLASS 2 CVN W79 VT 1-1/2 - 8x14-1/2 STUD ASME III X X ME OK CLASS 2 W75 7/8 - 9/8 STUD ASME III X X ME OK CLASS 2 M75 SA194 GRADE 2H 7/8 - 9 NUT ASME III X -

X CS OK (1)

CLASS 2 VT M75 1-1/2 - 8 NUT ASME III X X CS OK (1)

CLASS 2 VT M75 SA194 GRADE 8M 3/4 - 10 NUT ASME III X X P OK CLASS 2 VT S81 ME 1-1/2 - 8 NUT ASME III X X P OK CLASS 2 VT S81 ME 2-8 NUT ASME III X X VT OK CLASS 2 ME S81 1/2 - 13 NUT ASME III X -

X P OK CLASS 2 VT S81 ME 1-3/8 - 8 NUT ASME III X X P OK CLASS 2 VT W79 ME c ,

Revision 1 12/14/84 LIMITED TESTING TESTS DESCRIP- TEN- HARD-SIZE TION CODE /STD CHEM. SILE NESS OTHER RESULTS A325 TYPE 1 7/8 - 9x7-1/2 BOLT ASTM 1982 X X W OK' P

VT ,

A490 1-1/4 - 7x5-3/4 BOLT ASTM 1975 X X X -VT (2)

MT

-W SA564 TYPE 630 3/4 - 10x5-1/2 STUD ASME III X X X CVN OK CLASS 2 VT S81 1-1/2 - 8/10 STUD ASME III X X X CVN OK CLASS 2 VT W81 1-1/2 - 8110 STUD ASME III .X .X .X CVN OK CLASS 2 VT W81 2 - 8x19 STUD ASME III X X X CVN OK CLASS 2 VT S81 NOTES:

(1) TWO HARDNESS TESTS 1AKEN PER NUT.

(2) TWO OUT OF THREE WEDGE TESTS HAD VALUES TOO HIGH - 6,250 POUNDS AND 9,250 POUNDS AB0VE THE MAXIMUM OF RANGES ALLOWED (164,750 Pounds). FAILURE OCCURRED IN THREADS WITH DUCTILE FRACTURE. HARDNESS VALUES WERE SATISFACTORY. A TENSILE TEST ON A SIMILAR BOLT WAS WITHIN LIMITS.

LEGEND:

CVN = CHARPY V NOTCH ME = METALLURGICAL EXAMINATION CS = CONE STRIPPING TEST VT

• VISUAL TEST P = PROOF TEST W = WEDGE TEST MT = MAGNETIC PARTICLE TEST

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, Revision 1 12/14/84 EXTENDED MATRRTATR TESTING PROGRAM THIS PROGRAM CONSISTED OF MECHAN' I CAL, HARDNESS AND CHEMISTRY VERIFICATION

1 . TESTING TO MATERIAL SPECIFICATION REQUIREMENTS. TESTING WAS PERFORMED ON

! - STATISTICALLY SELECTED SAMPLE SIZES BASED ON AVATT.ARTA INVENTORIES OF <

~ APPROXIMATELY 157 DIFFERENT STOCK CODES.

I TO DATE, 1346 INDIVIDUAL TESTS HAVE BEEN PERFORMED. ITHIS INCLUDES OVER'243 MECHANICAL TESTS, 273 CHEMICAL' ANALYSES AND 830 HARDNESS TESTS.- THE

SUMMARY

OF

RESULTS IS SHOWN IN TABLE A BELOW.

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TABLE A r

MATERIAL SPECIFICATION CHEMISTRY MECHANICAL HARDNESS SA-193-B7 167 168- 478

, SA-193-B8 9 SA-194-2H 9 31-SA-194-8M 6 16

SA-194-8 1 8 i SA-564-630 70 69 190 I SA-574 2 A-194-2H 11 43 A-307-A -

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l. A-307-B 3 12 j A-325 3 3* 28 A-490 3 3 8 l Totals 273 243 830 i l ,

• WEDGE TESTS l AS EXPECTED IN ANY STATISTICALLY-BASED MATERIALS TESTING PROGRAM, NOT ALL THE i

MATERIALS MEET ALL SPECIFICATION REQUIREMENTS.  ;

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! 0F CONSEQUENCE TO THIS PROGRAM ARE THE SMALL OUT-OF-SPECIFICATION RATES AND THE l FACT THAT ENGINEERING DISPOSITIONS ON THE OUT-OF-SPECIFICATION CONDITIONS WOULD

BE "USE-AS-IS".

I PLEASE NOTE THAT:

I o 24 ASME AND ASTM MATERIAL SPECIFICATIONS WERE PURCAHSED FROM CIP BY THE

! PROJECT. THE MATERIAL SPECIFICATIONS TESTED ABOVE REPRESENT 50% OF THE SPECIFICATIONS PURCHASED BY THE PROJECT. HOWEVER, THE 12 MATERIAL SPECIFICATIONS THAT WERE TESTED REPRESENT APPROXIMATELY 418,557 0F THE FASTENERS PURCHASED FROM CIP, THIS IS APPROXIMATELY 98% OF THE TOTAL ASTM & ASME MATERIALS PURCHASED FROM CIP.

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Revision 1 12/14/84 0 MATERIAL VARYING IN SIZE FROM 1/4" IN DIAMETER TO 31/4" IN DIAMETER WAS .

PURCHASED FORM CIP. - THE MATERIAL TESTED ABOVE REPRESENTS 76% OF THE SIZES PURCHASED FORM CIP AND 94% OF THE SIZES 1/2" IN DIAMETER AND ABOVE.

THE OUT-OF-SPECIFICATION DATA ARE SHOWN IN TABLE B.

TABLE B MATERIAL SPECIFICATION CHEMISTRY MECHANICAL HARDNESS 4

SA-193-B7 6 16 SA-194-8 - 3 SA-564-630 .

13 1 4 SA-574 - 2 A-325 - -

3 Totals 19 17 12 i

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OUT-OF--SPECIFICATION D&TA MATERIAL STOCK CODE DESCRIPTION (1) SA-193-B7 Y530780015-2' (4) SAMPLES EXHIBITED LOW CARBON

. CONTENT 0.35% VS 0.36% REQUIRED MINIMUM.

(2) SA-193-B7 Y530780259-2 (1) SAMPLE EXHIBITED A HIGH CHROMIUM CONTENT OF 1.3% VS 1.15%

ALLOWED MAXIMUM.

(3) SA-193-B7 Y530780361-2 (1) SAMPLE EXHIBITED IDW YIELD 4

STRENGTH (YS) AND LOW ULTIMATE TENSILE STRENGTH (UTS) 79.2KSI, YS/106.2KSI, UTS VS 105.2KSI, YS/125.KSI, UTS MINIMUM REQUIRED, THIS SAME SAMPLE ALSO EXHIBITED A

, LOW MOLYBDENUM CONTENT OF 0.10%

VS 0.13% REQUIRED MINIMUM.

(4) SA-193-B7 Y530780267-2 (1) SAMPLE EXHIBITED A LOW ELONGATION OF 14.0% VS 16%

4 REQUIRED MINIMUM.

(1) SAMPLE EXHIBITED A LOW ELONGATION AND A LOW REDUCTION OF AREA 15,0% ELONGATION AND 47.1%

REDUCTION OF AREA VS 16%/50%

4 MIMIMUM REQUIRED.

(5) SA-193-B7 YS30780052-2 (1) SPECIMEN EXHIBITED LOW YS AND LOW UTS 102.2KSI YS and 123.7KSI UTS VS 105 KSI/125 KSI MINIMUM i REQUIRED.

i (1) SPECIMEN E'UlIBITED . LOW YS OF 103.1KSI VS 105 KSI MINIMUM i REQUIRED.

1 j (6)SA-193-B7 Y530780165-2 (2) SPECIMENS EXHIBITED LOW UTS j OF 121.2KSI & 122.2 KSI VS j MINIMUM REQUIRED OF 125 KSI.

(7) SA-193-B7 Y530780261-2 (3) SPECIMENS EXHIBITED I4W ELONGATION OF 15% VS 16% MINIMUM

REQUIRED.

, (8) SA-193-B7 Y530760014-2 (1) SPECIMEN EXHIBITED LOW YS OF

99.6 KSI VS 105 KSI MINIMUM REQUIRED.

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. Revision 1 12/14/84 MATERIAL STOCK CODE DESCRIPTION

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' (9) SA-193-B7 Y530750875-2 (1) SPECIMEN EXHIBITED LOW YS AND

UTS OF 91.1KSI AND 108.5 KSI VS 105/135 KSI. MINIMUM REQUIRED.

l (10)SA-193-B7 Y530750852-2 (1) SPECIMEN EXHIBITED LOW 3 ELONGATION OF 14.5% VS 16%

i - (11)SA-193-B7 Y530750851-2 (3) SPECIMENS EXHIBITED LOW UTS l OF 124.2 KSI, 123.7 KSI and 124.2 .

KSI VS 125 KSI MINIMUM REQUIRED.

(12)SA-194-8 J440011271-1 (3) SPECIMENS EXHIBITED HIGH 1 HARDNESS OF HRC 32,31 & 30 VS A

] MAXIMUM ALLOWED OF HRB 96.

1 j (13)SA-564-630 Y530780063-2 (1) SPECIMEN EXHIBITED A LOW j HARDNESS VALUE OF HRC 31 VS A

)

MINIMUM REQUIRED OF HRC 32. i (14)SA-564-630 Y530780039-2 (1) SPECIMEN EXHIBITED A LOW J

HARDNESS VALUE OF HRC 31 VS A MINIMUM REQUIRED OF HRC'32.

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(15)SA-564-630 Y530780093-2 (1) SPECIMEN EXHIBITED A LOW

] HARDNESS OF HRC 27 VS A MINIMUM j OF HRC'32.

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(1) SPECIMEN EXHIBITED A LOW HARDNESS OF HRC 27 (HRC 32 MINIMUM) AND A LOW YS OF 109.2 i

KSI VS A MINIMUM REQUIRED OF 115 KSI.

(16)SA-564-630 Y530780022-2 - (13) SPECIMEN EXHIBITED A CHROME -l YS30780061-2 CONTENT BETWEEN 15.0%, 15/2%. THE l Y530780093-2 BOLTS WERE ORDERED TO THE 1980 Y530780096-2 CODE WHICH ALLOWS A CHROME CONTENT i YS30780185-2 0F 14.8% MINIMUM. THE PROJECT -

YS30780243-2 CODE DATE 1975, WHICH ALLOWS A YS30780284-2 CHROME CONTENT OF 15.3% MINIMUM.

]

(17)SA-574 J440011162-1 (2) SPECIMENS EXHIBITED A

HARDNESS OF HRC 37 & 38 VS a MINIMUM REQUIRED OF HRC 39. ,

l (18)A-325 C531080050-1 (3) SPECIMENS EXHIBITED A LOW i HARDNESS OF HRC 22,22&21 VS A j MINIMUM REQUIRED OF HRC 24. 1 l

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Revision 1 12/14/84

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REVERIFICATION OF CMTR'S 0 FCUR ITEMS WITH CMTR'S WERE SELECTED FOR RETESTING OF CHEMICAL CONTENT.

O CHEMICAL ANALYSIS WAS PERFORMED BY AN INDEPENDENT LABORATORY. ONE ELEMENT, CHROME, WAS RETESTED BY A SECOND, (CHECK) INDEPENDENT IABORATORY.

O THE RETESTING VERIFIED THAT THE CMTR'S ARE CORRECT.

O THIS INFORMATION PROVIDES ADDITIONAL VERIFICATION THAT THE CMTR'S ARE PROPERLY MATCHED TO THE MATERIAL.

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{ 12/14/84 REVERIFICATION TEST RESULTS l

ELEMENT TYPE 4140 TYPE 4140 TYPE 4140 '316 SS' METL METL METL METL

CIP IAB CIP LAB CIP LAB CIP LAB I CERT TEST CERT TEST CERT TEST CERT TEST CARBON .410 .400 .410 .410 .410 .410 .050 .030 SULFUR .019 .013 .008 .011 .010 .015 .019 .021 PHOSPHORUS .020 .022 .027 .020 .021 .019 .022 .020 SILICON .260 .280 .270 .270 .270 .300 .430 .580

• CHROMIUM .960 .830 1.100 .830 1.030 .820 17.200 17.100 NICK 2L .020 .010 .020 .020 . .050 12.500 12.000

, MANGANESE .340 .650 .850 .700 .750 .790 1.580 1.550 l COPPER .010 .010 .010 .010 .-- .100 . .044

! MOLYBDENUM .190 .250 .190 .230 .170 .210 2.170 2.500 t

• 0RIGINAL METL VALUES SHOWN l

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TYPE TYPE TYPE CHROMIUM 4140 4140 4140

! CIP .96 1.10 1.03 METL RETEST .93 .93 .91 CHECK LAB .98 .99 1.01 1

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i Revision 1-12/14/84-RESULTS THE RESULTS OF THE VERIICATION TESTING PROGRAM WERE EVALUATED FOR COMPLIANCE WITH THE 1974 ASME CODE EDITION, WINTER 1975 ADDENDA AS SPECIFIED BY PROJECT DESIGN CRITERIA.'

O LIMITED YERIFICATION TESTING

~A TOTAL OF 78 INDEPENDENT TESTS AND EXAMINATIONS WERE CONDUCTED, AND THE RESULTS CONFIRMED THAT MATERIAL SUPPLIED BY CIP COMPLIED WITH PROJECT DESIGN CRITERIA REQUIREMENTS.

o EXTENDED VERIFICATION TESTING APPROXIMATELY 1346 INDEPENDENT TESTS AND EXAMINATIONS WERE CONDUCTED.

THE RESULTS OF THIS ADDITIONAL TESTING AGAIN CONFIRMED THAT THE MATERIAL SUPPLIED BY CIP COMPLIED WITH PROJECT DESIGN CRITERIA REQUIREMENTS.

THE INDIVIDUAL TESTS THAT WERE OUTSIDE SPECIFICTION LIMITS ARE SMALL.

- THE TEST RESULTS OUTSIDE SPECIFICATION LIMITS WERE WITHIN THE EXPECTED SCATTER BAND DURING TESTING OF A LARGE SAMPLE OF BOLTS.

o REVERIFICATION OF CMTR'S THE CHEMICAL ANALYSIS OF THE FOUR DIFFERENT BOLTS WHEN COMPARED WITH THEIR CORRESPONDING CMTR CONFIRMS THAT THE MATERIAL MEETS SPECIFIED REQUIREMENTS. THE QUANTITIES OF EACH ELEMENT HAVE THE SAME PATTERN, WHICH SUPPORTS THE CONCLUSION THAT THE CMTR REPRESENTS THE BOLTS SUPPLIED BY CIP.

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SUMMARY

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0 AN EXTENSIVE VRIFICATION TEST PROGRAM CONFIRMED THAT THE MATRIAL CONFORMED TO THE APPLICABLE MATERIAL SPECIFICATION AND CODE REQUIREMENTS.

O VARIATIONS TO MATERIAL SPECIFICATION REQUIREMENTS WERE MINOR AND RANDON, AS WOULD BE EXPECTED IN A VRIFICATION TEST PROGRAM, AND NOT INDICATIVE ,

OF ANY GENRIC MOBLEM VITH MATERIAL FURNISHED.

O MECHANICAL PROPERITES TEST RESULTS INDICATED GOOD DUCTILITY EVEN WHEN

< YEILD AND ULTIMATE TENSIEL STRENGTHS WRE OUTSIDE THE RANCE SPECIFIED BY l SPECIFICATI0h. THE FEW SUCH DEVIATIONS THAT OCCURRED ARE STILL WELL WITHIN DESIGN SAFETY FACTORS.

4 0 THRE WAS NO INDICATION THAT MATERIAL WAS OTHER THAN WHAT IT WAS SUPPOSED TO BE OR THAT MATERIAL MANUFACTURING PROCESSES WERE NOT PROPERLY CONTROLLED.

l 0 THE VERIFICATION TEST DATA RESULTS SUPPORT THE CONCLUSION THAT THERE IS NO QUALITY PROBLEM WITH CIP-FURNISHED MATERIALS. I 1  !'

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! DEVIATIONS WERE S0 MINOR THAT ENGINEERING DISPOSITIONS WOULD BE "USE-AS-IS". '

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l TECHNICAL RECOMMENDATION BASED UPON THE SATISFACTORY RESULTS OF AN EXTENSIVE AND THOROUGH MATERIAL VERIFICATION PROGRAM, PROJECT IS JUSTIFIED IN INSTITUTING ACTION TO DISPOSITION THE DELIVERED CIP MATERIAL "USE-AS-IS" AND TO ALLOW THE USE OF THE EXISTING MATERIAL IN CONSTRUCIION.

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COMMENTS BY DAN SACHS I AM A SENIOR MECHANICAL ENGINEER AND A METALLURGIST IN THE ANPP OPERATIONS ENGINEERING DEPARTMENT.

I HAVE BEEN PROVIDING TECHNICAL ASSISTANCE TO THE CARDINAL INDUSTRIAL PRODUCTS (CIP) EVALUATION EFFORT SINCE AUGUST, 1984, DURING WHICH TIME ALL PHASES OF THE TESTING PIAN WERE CONDUCTED.

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I AM AWARE OF BOTH UTILITY AND NRC CONCERNS WITH STRESS CORROSION CRACKING AND BRITTLE FRACTURE OF BOLTING. AFTER A FULL REVIEW OF ALL THE TESTING DATA, AND l PERSONALY WITNESSING MANY TEST, I AM FULLY STAISFIED THAT ANPP DOES NOT HAVE A l PROBLEM WITH WAREHOUSED OR INSTALLED CIP BOLTING. I FULLY CONCUR WITH THE BECHTEL CONCLUSIONS THAT WERE JUST PRESENTED TO YOU BY R. A. MANLEY.

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- Revision l' 12/14/84 PROGRAMMATIC EVALUATION <

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O PVNGS QUALITY PROGRAM EVALUATION i

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' QUALITY PROGRAM EVALUATION PVNGS PROCUREMENT DOCUMENT DEFICIENCIES 0 PROJECT CODE EFFECTIVE DATE NOT AIRAYS SPECIFIED 0 PROPER MATERIAL GRADE NOT SPECIFIED CARDINAL QUALITY PROGRAM WEAKNESSES NOT DISCOVERED BY AUDIT O VENDOR PROGRAM IMPLEMENTATION O INSPECTOR NOT PROPERLY CERTIFIED 0 SUBSIZED CHARPY COUPONS 0 SUBSUPPLIER CONTROL 0 INADEQUATE DOCUMENTATION OF SUBVENDOR AUDITS AND QA PROGRAM REVIEW 0 INCONSISTENCIES BETWEEN VENDOR AND SUBVENDOR CMTR 0 CONTROL OF FOREIGN SUPPLIERS 0

NO VENDOR QUALIFICATION FOR TRADING COMPANY 0 NO ENGLISH TRANSIATION FOR CMTR'S CARDINAL DEFICIENCIES NOT DISCLOSED BY RECEIVING INSPECTION O

FAILURE OF CMTR TO MEET CODE TECHNICAL REQUIREMENT 0 HEAT TREATMENT o IMPACT TESTING 0 NDE O NCA-3800 STATEMENT r

Revision 1 12/14/84 QUALITY PROGRAM CORRECTIVE ACTIONS PROCUREMENT DOCUMENT C

PROCEDURE WILL BE STRENGTHENED TO REQUIRE SPECIFICATION OF CODE EFFECTIVE DATE O

PROJECT QUALITY PROGRAM PROCEDURE CHECKLIST WILL BE MODIFIED TO PROVIDE A REVIEW OF THE CODE EFFECTIVE DATE O

TRAINING WILL BE CONDUCTED FOR BECHTEL FIELD ENGINEERS AND QA VENDOR QUALIFICATIONS 0 MORE EMPHASIS WILL BE PLACED ON HARDWARE DURING AUDITS DUE TO CHANGE IN INDUSTRY and I&E INFO NOTICE

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O BPC IS INCLUDING I&E NOTICE 84-52 WITH ALL AUJIT PACKAGES TO PROVIDE INSIGHT d

C BPC WILL ENHANCE THEIR AUDIT CHECZLISTS TO PROVIDF A MORE DEFINITIVE REVIEW d 0 BPC IS INCLUDING TECHNICAL PERSONNEL ON ALL NCA 5000 SURVEYS 0 BPC IS CONDUCTING TRAINING SESSIONS CONCERNING UTILIZATION OF NEW CHECKLISIS 1

0 APS WILL ALSO PLACE EMPHASIS ON HARDWARE DURING SUPPLIER AUDITS RECEIVING INSPECTION O

QC INSPECTORS WILL BE RETRAINED IN THE USE OF THE CODE O

USERS 9.ST WILL BE CONDUCTED FOR BULK BOLTS RECEIVED BY CONSTRU.CIION O A SAMPLE OF FASTENER CMTR'S RECEIVED FROM OTHER SUPPLIERS WILL BE REVIEWED TO EVALUATE WHETHER CMTR ERRORS IS A GENERIC PROBLEM OVERALL 0 A REVIEW 0F PROCUREMENT, RECEIVING INSPECTION AND MATERIAL CONTROL HAS BEEN COMPLETED TO EVALUATE THE ADEQUACY OF BECHTEL AND APS PROGRAMS TO CONTROL T3ESE ACTIVITIES. CORRECTIVE ACTION ' '

HAS BEEN TAREN WHERE APPROPRIATE O AN INTEGRATED AUDIT OF PROCUREMENT, RECEIVING INSPECTION AND MATERIAL CONTROL (WAREHOUSING) WILL BE PERFORMED

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EFFECT ON OTHER PROCUREMINT l PVNGS PROCUREMENT DOCUMENT DEFICIENCIES ITEM EFFECT 0 PROJECT CODE O REIATED TO FIELD PURCHASE EFFECTIVE DATE OF BULK COMMODITIES.

NOT ALWAYS SPECIFIED 0 LITTLE EFFECT SINCE CODE REQUIREMENTS HAVE BECOME MORE STRINGENT l

0 PROPER MATERIAL 0 ISOLATED TO MATERIAL WITH SPECIFICATION (ASTM A325) SIZE LIMITS IN CODE O CODE REFERENCES THE PROPER REQUIREMENTS TO BE USED ABOVE THE SPECIFIED SIZE. THESE REQUIREMENTS WERE MET I

CONCLUSION: THERE IS NO DETRIMENTAL EFFECT ON OTHER PURCHASES AS A RESULT OF THESE DEFICIENCIES f

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-, e Revision 1 l 12/14/84 l EFFECT ON OTHER PROCUREMENT l CARDINAL QUALITY PROGRAM WEAKNESSES NOT DISCOVERED BY AUDIT ITEM EFFECT 0 VENDOR PROGRAM IMPLEMENTATION O INSPECTOR NOT CERTIFIED 0 ISOLATED TO ONLY 1_ PERSON.

AUDIT WOULD NOT BE APECTED TO DISCOVER ISOLATED CA3E.

0- SUBSIZED CHARPY COUPONS 0 NOT A DEFICIENCY FOR PVNGS SUBSUPPLIER CONTROL 0 O BECHTEL AUDIT CHECKLIST INADEQUATE DOCUMENTATION OF SUBVENDOR AUDIT AND QA REQUIRES VERIFICATION OF PROGRAM REVIEW SUBVENDOR QUALIFICATION BUT DID NOT INCLUDE IN-DEPTH

- GUIDANCE IN ASSESSING THE ADEQUACY OF SIMILAR PROGRAMS 0 APPLICABLE PRIMARILY TO SUPPLY OF BULK MATERIAL WITHOUT FURTHER TESTS FOR FORM, FIT, PERFORMANCE O

AUDIT CHECKLIST (ITEM 6.3)

REQUIRES THAT SUPPLIERS RECEIVING INSPECTION PROGRAM VERIFIES INCOMING SHIPMENTS FOR CONFORMANCE TO PURCHASE ORDER REQUIREMENTS THEREFORE MINIMIZING EFFECT ON MATERIAL 0 INCONSISTENCY BETWEEN O APPLICABLE PRIMARILY TO VENDOR AND SUBV12iDOR FASTENERS BECAUSE THIS IS CMTR'S PRIMARY AREA IN WHICH DATA IS TRANSFERED FROM ONE CMTR TO ANOTHER m; a 4 - . ,

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n . Revision 1 12/14/84 O AN ADDITIONAL FASTEFER SUPPLIERS TEXAS BOLT AUDITED '4ITHOUT NOTING THIS PROBLEM 0 ~ CONCLUSION

THIS IS NOT A' GENERIC PROBLEM 0 CONTROL OF FOREIGN SUPPLIERS o .BPC AUDIT CHECKLIST IS NOT GEARED TO IDENTIFY THE TYPES OF DIFFICULTIES WHICH COULD OCCUR BECAUSE OF USE OF FOREIGN (JAPANESE) SUPPLIERS FOR BULK COMMODITIES / MATERIAL 0 CARDINAL IS THE ONLY KNOWN VENDOR ~

THAT UTILIZES FOREIGN MATERIAL AIJf0ST EXCLUSIVELY CONCLUSION: ADDITIONAL DEPTH DURING AUDITS IS NECESSARY TO EVALUATE SUBSUPPLIER CONTROL. HOWEVER, BECAUSE THE MATERIAL SUPPLIED IS INSPECTED BY THE SUPPLIER AT RECEIVING AND THEN MUST PERFORM IN SUPPLIER'S EQUIPMENT, THIS IS NOT A SIGNIFICANT PROBLEM FOR PVNGS l

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, p Revision 1 12/14/84 APS DIRECT PROCUREMENT EVALUATION TWO (2) PURCHASE ORDERS WERE PIACED BY APS DIRECTLY WITH CARDINAL (USING APS PROCUREMENT PROCESS) A REVIEW OF ACTIONS ASSOCIATED WITH THIS PROCURFMENT REVEALED:

0 TECHNICAL AND QUALITY REQUIREMENTS WERE SPECIFIED PER PROCEDURE o RE/IEW OF CARDINAL SUPPLIER DOCUMENTATION REVEALED THAT DOCUMENTATION WAS~ PROPER AND IN COMPLIANCE WITH PURCHASE ORDER 0 TESTING OF MATERIAL RECEIVED VALIDATED A DIRECT CORREIATION BETWEEN CMTR'S AND MATERIAL RECEIVED 0 APS AUDIT OF CARDINAL WAS LIMITED TO MATERIAL SUPPLIED DIRECTLY TO APS AND INDICATED MATERIAL WAS ACCEPTABLE CONCLUSION: A REVIEW OF APS ACTIONS IN THIS AREA DID NOT DISCLOSE ANY PROGRAMMATIC PROBLEMS

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CONCLUSION THE MATERIAL RECEIVED PROM CARDINAL INDUSTRIAL PRODUCTS IS CAPABLE OF SERVING ITS INTENDED FUNCTION.

DEFICIENCIES IDENTIFIED DO NOT AFFECT THE SAFETY OF PVNC .

THE FAILURE OF THE PVNGS QUALITY PROGRAM TO DETECT DEFICIENCIES IN CARDINAL'S QUALITY PROGRAM, DOCUMENTATION AND MATERIAL IS NOT INDICATIVE OF A MAJOR BREAKDOWN OF THE PROGRAM REQUIRING EXTENSIVE EVALUATION OF ALL PREVIOUSLY SUPPLIED MATERIALS.

QUALITY PROGRAM IMPROVEMENTS ARE BEING IMPLEMENTED TO STRENGTHEN THE CONTROL OF PURCHASED MATERIAL.

DER 84-41 WILL SUMMARIZE TODAY'S DISCUSSION l