ML20107D725

Interim Deficiency Rept 55-84-11 Re Uncertified Flanges Installed in ASME Sys & Stainless Steel thread-o-lets. Initially Reported on 840525.Investigation to Determine Extent of Problem Continuing

ML20107D725
Person / Time
Site:	Clinton
Issue date:	10/18/1984
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
55-84-11, U-10205, NUDOCS 8411030420
Download: ML20107D725 (4)

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/LLINDIS POWER 00MPANY U~10205 I CLINTON PCMER STATION, P.O. BOX 678 CLINTON ILLINOIS 61727 October 18, 1984 Docket No. 50-461 Mr. James G. Keppler Regional Administrator Region III U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, IL 60137

Subject:

Potential 10CFR50.55(e) Deficiency 55-84-11:

Uncertified Flanges Installed in ASME Systems; Stainless Steel Thread-0-Lets Manufactured from Unqualified Stock Material

Dear Mr. Keppler:

On May 25, 1984, Illinois Power Company notified Mr. F.

Jablonski, NRC Region III, (Ref: IP memorandum Y-21457 dated May 25, 1984) of a potentially reportable deficiency concerning uncertified flanges installed in ASME systems and stainless steel thread-o-lets manufactured from unqualified stock material. This initial notification was followed by one (1) interim report (Ref.

IP letter U-10172, D. P. Hall to J. G. Keppler, dated July 3, 1984). Our investigation of this issue is progressing, and this letter is submitted as an interim report in accordance with the requirements of 10CFR50.55(e). Attachment A provides the details of our investigation to date.

We trust that this interim report provides you sufficient background information to perform a general assessment of this potentially reportable deficiency and adequately describes our overall approach to resolve the problem.

Sincerely yours, l

D. P. Hall hDR DO O 00 i Vice President S PDR RLC/ lag (NRC2) cc: NRC Resident Office OCT 2 2 E84 Director, Office of I&E, US NRC, Washington, DC 20555 Illinois Department of Nuclear Safety INPO Records Center

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ATTACHMENT A ,

Illinois Power Company Clinton Power Station ,

Docket No. 50-461 Potential 10CFR50.55(e) Deficiency 55-84-11 1 Uncertified Flanges Installed in ASME Systems: .

Stainless Steel Thread-O-Lets -

Manufactured from Unqualified Stock Material i Interim Report 5 Statement of Potentially Reportable Deficiency / Background During a review of purchase order files by Baldwin Associ-ates Quality Assurance group, it was identified that approximate- r ly 1,035 small bore flanges were purchased without proper docu- -

mentation certifying that the material met the requirements of i ASME III, NA 3700/NCA 3800. -

An internal review of Quality Assurance records by Gulf &

Western (G&W)/ Bonney Forge, a supplier to Hub, Inc., revealed -

that various stainless steel thread-o-lets were manufactured from +

stock material which was neither purchased under the provisions  ?

of ASME NCA 3800 nor did the stoca material receive the product analysis for upgrading per ASME requirements. 2 t

Investigation Results/ Corrective Action Illinois Power has prepared and is implementing an inves- e tigation plan to determine the extent of this problem at Clinton Power Station (CPS). The investigation plan includes: i w

1. Review of Architect / Engineer material and design require- i ments found in design documents and specifications, E r

2. Review of Construction Quality Control procedures and  ;

inspection basis, ,

3. Review of material procurement and receiving inspection i!

methods,

4. Review of the record review programs to /.etermine capability to identify certification deficiencies, and

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5. Review of deficiency documents (Nonconformance Reports (NCRs), audit findings, etc.) which identify certification discrepancies.

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n ATTACHMENT A (continued)

I The data compiled above is being reviewed to determine if there exists a possible generic concern of materials not meeting s

the requirements of codes and specifications and will provide the root cause for the problems. Appropriate action necessary to identify the scope of the problem, correct specific deficiencies, and to preclude recurrence can then be determined.

The uncertified flanges were purchased from Barr Saunders Inc. under P.O. No. C-14951 and received under Receipt Inspection Reports (RIRs) No. S-5111 and S-5635. The total quantity of flanges received was 1035 in sizes ranging from 1/2" to 2" inclusive, in ratings of 300# and 600f. Nonconformance Report (NCR) No. 70178 states that the Certified Material Test Reports j (CMTRs) for these items do not indicate compliance with ASME NA-3700/NCA-3800. There was also no objective evidence that.

E National Flange and Fitting Co. (the supplier t.o Barr Saunders) l was an ASME Quality System Certificate holder or that they were audited by either Barr Saunders or Baldwin Associates (BA).

e

• In order to identify those systems in which the uncertified 5"

flanges may have been installed. BA Resident Engineering (BARE) performed a review of all safety-related isometric drawings.

2 BARE then identified the corresponding travelers containing pipe sizes between 1/2" and 2" inclusive and identified 76 flanges, (with RIR No. S-5111) all of which were installed. The single t

item received under RIR No. S-5635 was returned to the warehouse.

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BAQA Document Review Group (DRG) which has the responsibil-ity of conducting a final review of all vendor - supplied and

. site-generated records, including Fire Protection and Augmented 7 Class D, also identified one (1) additional safety-related installation (Ref: NCR No. 70363).

? The following is a ctatus of the 1035 flanges received under RIRs No. S-Sill and S-5635:

I Number of flanges issued to construction 253 e

% Number installed in safety-related systems 77

Number not installed in safety-related systems 176 Total issued 253 e

Z Number of flanges on warehouse hold 782 1

} Total flanges received 1035 Page 2 of 3

ATTACHMENT A (Continued)

Nonconformance reports or traveler addendums have been generated to replace, with certified material, the 77 uncertified flanges installed in safety-related systems.

The stainless steel thread-o-lets manufactured from unqual-ified stock material were purchased from Hub Inc. under P.O. No.

3 C-26876 and received under RIR No. S-12101. NCR No. 16881 identified these items as being manufactured from material that

was not procured to the requirements of ASME NA-3700/NCA-3800.

Of the 12 items received, 10 are currently on hold and are to be downgraded for use on Non-ASME systems, and the remaining 2 which

were installed under travelers F-WF-776-A and WZ-810 will be acceptable based upon jurisdictional boundaries of the Code such that NA-3700/NCA-3800 is not applicable.

Corrective action taken to date includes the issuing of Corrective Action Request (CAR) No. 147 to document and obtain 1 resolution regarding the requirements of ASME Section III, Subsection NA-3700/NCA-3800. Training programs were conducted for personnel involved in activities associated with ASME

Materials (procurement requisitions and purchase orders, vendor qualifications, document review, etc.)

Safety Implications / Significance Illinois Power Company's investigation of this potentially reportable deficiency is continuing. The safety implications and significance of the issue will be assessed after further back-bround information is evaluated. It is anticipated approximately ninety (90) days will be necessary to complete our investigation and to file a final report on the matter.

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