ML20114B660
| ML20114B660 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 01/18/1985 |
| From: | Hall D ILLINOIS POWER CO. |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| 55-84-11, U-10241, NUDOCS 8501290405 | |
| Download: ML20114B660 (4) | |
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.s 1A.120 ILLINDIS POWER 00MPANY U-10241 CLINTON POWER STATION. P.O. BOX 678. CLINTON, ILLINOIS 61727 January 18, 1985 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 two (2) interim reports (Ref. IF letter U-10172, D. P. Hall to J. G. Keppler, dated July 3, 1984; and IP Letter U-10205, D. P. Hall to J. G. Keppler, dated October 18, 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.
that this interim report provides you sufficient We trust background information to perform a general assessment of this potentially reportable deficiency and adequately describes our overall approach to resolve the issue.
Sincerely yours, D.
Hall Vice-President RLC/ lag (NRC2) 85o129oy 5 fgn % g 0
Attachment cc:
NRC Resident Office Director, Office of I&E, US NRC, Washington, DC JAd5543 G8rJ 20 Illinois Department of Nuclear Safety INPO Records Center A
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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-0-Lets Manufactured from Unqualified Stock Material Interim Report
-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-E ly'1,035 small bore flanges were purchased without proper docu-L'
' mentation? certifying that the material met the requirements of
_ ASME ~ III, : NA-3700/NCA-3800.
JAn. internal review of Quality Assurance records by Gulf &
- Western (G&W)/ Bonney: Forge, a supplieritc Hub, Inc., revealed
. that various: stainless: steel thread-o-lets were manufactured.from
[
stock ~ material which was neither,urchased under the provisions of ASME NCA-3800 nor did the stoc'c material' receive ~.the product-
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-analysis for upgrading per ASME requirements.
Investigation Results/ Corrective Action
' Illinois Power has prepared 1and is im)lementing an inves-
- itigation plan toLdetermine the extent of this' problem at Clinton-Power: Station (CPS).
The investigation plan includes:
- 1. -
Review of Architect / Engineer material andidesign require :
tments found in design' documents and specifications, p
b 2.
Review of Construction. Quality Control procedures ands inspection basis, s'
3i Review of: material _ procurement and receiving _ inspection methods,-
14L cReview of-the: record. review programs to determineLeapability~-
p to: identify ~ certification deficiencies,.and 5.
Review.of. deficiency document's (Nonconformance Reports-
~
u (NCRs),' audit findings, etc.)_which11dentify certification
~~
. discrepancies.
Page:1 of 3 Y
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= ATTACHMENT A (continued)
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" Linclusive, in ratings of 300f and 600f.
Nonconformance Report (NCR)LNo.;70178 states that the Certified Material Test Reports (CMTRs) for these items'do not indicate compliance with ASME NA-3700/NCA-3800.
There was also no objective evidence that National Flange and Fitting Co. (the-suaplier to Barr Saunders) was an'ASME Quality System Certificate holder or that-they were audited.by'either Barr Saunders or Baldwin Associates-(BA).
In order to identify those systems in which the uncertified flanges may_have been installed. BA-Resident Engineering (BARE)
. performed a review of all safety-related isometric drawings.
BARE thenl 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 item _ received under RIR No. S-5635 was returned to the warehouse and placed on' hold.
- BAQA Document Review Group (DRG) which has;the.responsibil-ity of~ conducting a final review of all vendor - supplied and taite-generated records, including Fire Protection and Augmented Class.D, also identified one (1) additional safety-related installation (Ref:
NCR No. 70363).
-The following is'a status (as determined by the-above review):of the'1035 flanges received under_RIRs No. S-5111 and S-5635:
-Number!of flanges' issued to construction 253 Numberiinstalled in~ safety-related-
systems-77 Number not installed in safety-related systems 176-Total issued 253 Number of flanges:on warehouse
- hold 782
. Total flanges received 1035 Page 2 of 3
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ATTACHMENT A (Continued) 4
.Nonconformance= reports or traveler addendums were generated
- which, replaced, with certified material, the 77 uncertified e
- flangescinstalle
- o in safety-related systems.
All of the replaced
-flanges as-well as those on hold have been scrapped (Ref: NCR 24613).
I'
-The stainless _ steel thread-o-lets manufactured from.unqual-ified stock material were purchased from Hub Inc. under P.O. No.
L
-C-26876 <nd 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 are accept-f able based.upon jurisdictional boundaries of the Code such that
-NA-3700/NCA-3800 is not applicable (Ref: Nonconforming Material =
Report (NCMR)'l-0258 and 1-0259, respectively).
Corrective action taken to date includes the issuing of-
' Corrective-Action-Request (CAR) ik). 147 to document and obtain 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.)
...,Ourfinvestigation is currently' involved _in evaluating additional ~ deficiencies.similar to'those associated'with this Jissue.
These' deficiencies involve various piping fittings installed in ASME systems for which there is no objective
- evidence that'the fittings were manufactured or material 1 procured under a program meeting the requirements of ASME (NA-3700/NCA-3800).
Safety Implications / Significance Illinois Power Company's investigation.of-this potentially reportable deficiency is-continuing for'those additionali
~. deficiencies discussed above. 'The safety-implications and
. significance:of-these deficiencies will be assessed'after further Lbackgroundfinformation'is evaluated.. S&L has performed'a safety significance evaluation of the NCRs involving the rubject-flanges and has concluded that if the identified deficiencies had-
.goneruncorrect'ed they would not have adversely affected the-safety ofJoperations of CPS. (Ref:-S&L Letter SLMI-13835).- It is
' anticipated approximately'45: days will be necessary;to complete
- ourninvestigation,-determine reportability.and file a final
. report'on the matter.
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