ML20115B740
| ML20115B740 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 09/22/1992 |
| From: | Fojtik A UNR LEAVITT |
| To: | Andrews S CONSOLIDATED PIPE & SUPPLY CO., INC. |
| References | |
| REF-PT21-92 NUDOCS 9210160223 | |
| Download: ML20115B740 (9) | |
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UNR-Leavitt 4
4 Septemt,er 22,1992 5
Devson of UNR,Inc.
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1717 West 115m Street
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l [f checago, Hlmois 60643 Mr. Steven W. Andrews c g ggg g 9,,
mo> us.vm Quality Assurance Manaper Consolidated Power Supply g go
,g,3 3,,an r u otti e ra2ee 3556 Mary Taylor Road Birmingham, AL 35235 s
Dear Mr. Andrews:
REF:
- 1. Your letter to me dated September 1,1992
- 2. Draft report dated August 19,1992 regarding examination of 4 x 4 x 1/2" ASTM 500 Grade B tubing by John For * :*t.-llurgical Engineer Restart Eng. Mechanical / Nuclear Department This report covers the evaluation of a 4" x 4" x 1.'2" wall section of ASTM A-500 Grade B steel tubing heat number T42510 % coil number 924544. This sample was found to have a cracked weld by your customer, TVA/Bechtel at the Browns Ferry Nuclear Plant in Alabama. This tubing was supplied to Consolidated Power 1
Supply on P.O. #S65-17742.
Visual examination of the sample showed a crack in the weld seam on one end of the sample. The other end of the 12" long sample did not show a crack. Photo-graph #1 shows the as received condition of the tube. A six inch scale was plar ed on the sample near the end with the cracked weld. To determine the cause nf the crack, a microanalysis was done on each end of the sample. Photomicrograph 1 shows the cracked end at 100X at a point naar the outside diameter. It appears the edges did not come in contact to form a weld. Photomir,rograph 2 shows the other end of the tube at 100X. The arrow on the photomicrograph indicates the weld line and complete fusion was observed. The end with the crack showed fusion only near the tube inside diameter. In f act, only the bottom 25% of the tube was welded. This indicates that the strips bottom edges came into contact at the point of weld but not enough or no contact was made near the tube outside diameter to fuse these edges together. Photomicrograph 2 does not show this condition, it can be concluded that a mill set up adjustment was in the process and that this sample represents the pisco of tubing which adjustments were made.
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'Page two A history of mill production of 4" x 4" x 1/2" tubing was examined.- in the last.-
year and a half UNR Leavitt produced 152,830 feet of this alze and thickness. The-internal scrap rate was 15,816 feet or 9.4%. A five and a half year history of claims for poor weld was examined for this size and wall. The results show a customer rejection rate u, 0.65% on 423,121 feet of tubing shipped.
An examination of Quality Control reports for the date this tubing was produced (11/5/91) shows a weld test was performed on coil 924544. - Results _were acceptable, however, the inspector noted the inside diameter w:Id flash was not normal. No acn.n was taken on thla.
An examination of othy nuclear _ customers' shipping records shows no tubing wrs shipped to them on this sire, wr ;nd heat number.
The sample represents a portion of a defective tube which in turn represants a portion of the overal10.65% customer rejection rate due to poor _ weld for this size and thickness of tubing. The lack of fusion was due to incorrect mill set-up and is not heat or material related.
The corrective action requested by your letter will take the form of reinstructing the mill operator, mill foreman and other rn!Il personnel on the importance of weld quality. If the operator is making an adjustment which could affect weld qeality, he is to immediately advise the Quality Controlinspector so that weld quality can be examined. This meeting will talte place within the next 30 days.
Regarding reportability with respect to 10CFR Part 21, UR Leavitt cannot assess _-
that this defect,if went unnoticed would create a substantial safety hazard. UNR-Leavitt, however, will report this defect to the NRC using this and the reference -
report and letter as the evaluation.
Sincerely, b
Alex Fojti Director, Quality Assurance
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attachment cc:
R. Herman, President R. Hunt, Senior Vice President P, Katssfanas, Regional Sales Manager 9y.
D, g6 UNR-Leavitt a UNR industries Company
' 1717 West 115th Street Chicago, miros 60643 4399 L;&LInfa
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Conssolidated Power Eiiupply September 1, 1992 UNR Leavitt 1717 West 115th 3treet Chicago, IL 60643 Attn: Mr. Alex Fojtik Supervisor of Quality Assurance
Subject:
Corrective Action Request on A500 Grade B Tubing
Dear Mr. Fojtik:
As discussed on August 28, 1992, please find attached Consolidated Power Supply (CPS) Corrective Action Request (CAR) /V92-98.
The CAR is issued to document and track the deficiency with a 10CFR Part 21 evaluation being noc;ssary under your program's evaluation and reporting measures.
A written response to the deficiency is requested'to be submitted to CPS no later than September 18, 1992.
In addition, upon completion of your evaluation, c copy of any correspondence regarding a 10CFR Part 21 condition shall be submitted te CPS.
Upon receipt of such Information, CPS Wjll in turn notify all customers affected by the report, which at the current time. is limited to TVA/Bechtel, Browns Ferry i
Nuclear Plant, pending yoci ovaluation.
f I have enclosed a copy of TVA Significant Corrective Action Report #BFSCA920017, Rev.
O, for your information.
Please l
note that the date of discovery is identified as 8/12/92 l
(SCAR Item 1L), which does n'ot coincide with the dates conveyed during the meeting of 8/28/92.
This has an inrnct on the interim evaluatioF. deadline and the time allowed for i
reporting of a defect or failure to comply under the requirements of 100FR Part 21.
f The above requested response should include, as a minimum, the following information:
- 1) A statement regarding the' root cause of the deficiency,
- 2) Measures that have been or will be taken to norrect the deficiency, Page 1 of 2 3556 Mary Taylor Road Birmingham, Alabama 35235- * (205) 655-5515 A Division of Co* V.:,ted Pipe & Supply Co., Inc. Birmingham, AL
UNR Leavitt CAR Response Letter Dated 9/3/92
- 3) Measures that have been or.will be taken to prevent recurrence, and
- 4) The date your corrective actions and preventative measeres were or will be completed Please complete the applicable sections and return a copy of the CAR with your response.
If you need any assistance in documenting your evaluation or post-evaluation correspondence please contact me at your earliest convenier.co.
Sincerely, kP Steven W.
Andrews Quality Assurance Manager I
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Attachment - CAR V92-98 l
cc:
G.
Johnson, Gen. Hgr. - CPS H. Kerr, President - CPS L
C. Marr, Sales Mgr. - CPS UNR Leavitt Fila - CPS QA i
Page 2 of 2 i
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C')RRECTIVE ACTIOt3 REQUEST 4
COMPANY / DEPARTMENT: [2Al[ I_fdd CAR NUMBER:
2.- h[
ISSUED TO: J[gi jd[
DATE:
/ 92 DATE RESPONSE IS REQU RED:
/8 9 2.
DESCRIPTION OF DEFICIENCY See Adae4me,}/
%9///9z CAUSE OF DEFICIENCY:
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PROPOSED CORRECTIVE ACTION:
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DATE CORRECTIVE ACTION WILL BE COMPLETED:
NAME OF PERSON RESPONSIBLE FOR CORRECTIVE ACTION:
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SfGNATURE:
DATE:
l TITLE:
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[ } ACCEPTED
[ ] REJECTED j
MANAGER OF QUALITY ASSURANCE l
FOLLOW-UP VERIFICATION:
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0 4 to CAR V92-98 i
CONSOLIDATED POWER SUPPLY CORRECTIVE ACTION RT. QUEST /V92-98 1-t DESCRIPTION OF DEFICIENCY:
The end user (TVA/Bechtel Power:
Corporation -' Browns Ferry Nuclear Plant)_has: identified a concern on one piece.of 4" X.4" X.1/2" X 20' A500 Grade B i
square. tubing, heat #T42510..The material;was identifiedLas having a crack in.the weld seam, which was; observed after l
receipt of the material by the end-user-from Consolidated i
Power. Supply.
The material.was ordered by Consolidated Power Supply on Purchase Order-#S65-17742, item-#4.
Approximately l
240' ofLthe-subject heat was supplied by UNR Leavitt to-Consolidated Power: Supply.
No indications were' observed-l during inspection activities at~ Consolidated Power Supply.
Ons piece-(approximately 12" in length) of the subject l
material is being provided to'UNR,Leavitt for evaluation..
The balance of the 20' piece is being' retained by TVA/Bechtel-in their QC Hold area.
The deficiency is consideredza l
violation of-ASTM A500, paragraph 5.2, which. states-"the longitudinal butt joint of welded tubingishall be welded i
f across.its thickness in such a manner that-the structural' l
design strengtn of the tubing sectien is assured".
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DRAFT l
To:
Joe McCarthy August ig,19g2 TRIP REPORT, EXAMINATION OF TUBE STSEt, i
Dubject:
Condition Splitting of welded squete tube n' teel. Heat i T42510.
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I examined tube 4" X 4" X %" tube steel et the request of Mods. The product Discuselor.
form was ASTM ABOO Gr. 8_ welded tubing.- A long 4
il been welded to e semicircular wrapper plate end following welding the sp t 'yes noticed. Another piece from the seme joint of tube steel exhibited this simlier
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l eplittid0 ebout 15" in length in the es-found condhion.
l Tne specifications for this material include very few requirements _for the weld, which is e resistence (no tillcr motell weld.- ASTM A500 specifies theti the l
longitudinalbuit }oht of welded tubhg shsN be wekled scross its thid ness in such
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a menner that the structum!slosiert sfrength Of the rubMg section is ousured. No ecceptance test, NDE of Inspection orlieria are imposed on the weld t,y the apoolfication.
I Further examination of the oilginsi piece conslated of Happer wheel surface properation, etching with 2% nital, and examinetton with a stereo microscope.'
i The primary focus of this additiottel examination woe on th i
I The weld appeared to be cound end fully fused in eroes where spiltting was not observed. No latent or subeurface defsts were noted in stees of the tubing that l
were not spilt. Atees exhibiting spiltting appenrod to.be the result of incomplete fusion of the adjoining sides of the wold joint, l.a., failure of the resistance welding -
procoes to produos e completely fused joint. -
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. I performed visual examinetton of 200 edditional feet of thb nest of meterial in the Impound eres of MPC, No splitting of tble tubing was no'.ed in this examinetion.
i Mertnetic particle testing was performed on both ends et three }oints of this hwat
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end no relevant Indications ware ncted. Additionally b')th ends of two joint 3 of -
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heat T42500 were magnetic particle tested and no rel'svent Indiostions were I
'noted.
Conclusion
., mag of me tubing is ee,e.uit of iecompioie too n f,_ ise weidag,,osee.
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............. ~~~ TD i 2 0 5 2 3 0 5 2 5 2 AUG 20'92 11150 No.005 P.03 6
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ueed in the manufseturing of the # 3pe, The splitting obs i
i of $e lock of NDE of testing on the weld. Visual examination of the outside surface of me tubing is sufficient to detect the condWon. The loint of tubine that exhibited spiltting should be disposed sa nonconforming. Sufficient additional joints have. boon vleuelly examined to have confidence in the remaining ma l
The remainder of the materiel should be reisseed for use.
I i
i John Fox Metallurgical Engineer i,
Restart Engineering Mechanical / Nuclear Deperiment -
1 00:
1 Robert Phlillos, EOS George Clark, MOD-K Derek Selva, SWEC, CFC-18 l
l Virgil Barton, SWEC, CFC 18 Don Hernon, SWEC, CFC 18 l
. Leonard Madison, ATH3 1
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