ML20133E800
| ML20133E800 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley, Hatch, Calvert Cliffs, Peach Bottom, Palisades, Perry, Catawba, Saint Lucie, Grand Gulf, Cooper, Summer, Seabrook, Surry, Ginna, Vogtle, Clinton, FitzPatrick  |
| Issue date: | 01/08/1997 |
| From: | Secre W AFFILIATION NOT ASSIGNED |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| NUDOCS 9701130161 | |
| Download: ML20133E800 (8) | |
Text
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Mastar Builders, Inc.
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e' 23700 Chagrin Boulevard Cleveland, Ohio 44122-5554 ll ll Phone 216/831-5500 9
January 8,1997 Document Control Desk U.S. Nuclear Regulatory Commission Washington DC 20555 RE:
Notification of Potential Nonconformance for Masterflow 713 (CMTR) Grout To Whom It May Concern:
This is to advise you of a reported nonconformance related to MasterDow 713 (CMTR) Grout, w hich Master Builders, Inc. has supplied as a nuclear safety-related product to 18 nuclear power plants.
Please find attached a letter of notification that was mailed to the affected nuclear utilitics. It summarizes the nature of the reported nonconformance. Also attached is the distribution list for the notificatica letter, We are currently awaiting response from the various utilities.
At this point, we have not determined u hether or not this situation has created a substantial safety hazard at any of the affected nuclear utilitics. As stated in the notification letter, the scope and impact of the nonconformance is highly dependent upon use, age of the material at the time of placement, and behavior of the material during placement. Nevertheless, we feci that it is prudent to keep your ofTice informed of all developments and activitics pertaining to this situation.
Finally, future correspondence regarding this matter will be handled by John Dorado, Quality Control Manager or Tom Will, Assistant Product Manager, w ho are coordinating all activitics related to this matter, with the exception of an incident intohing a subctnntini safety hazard. Upon completion of our evaluation, and if necessary, all correspondence related to the reporting of a substantial safety hazard caused by this nonconformance will be submitted by me.
If you have any questions, or need additional information, please contact John or Tom at 216-831-5500. If needed, you may contact me at the same telephone number, as well.
Respectfully Yours, L fA,$ /
W G
William K. Secte Vice President, Research & Development Master Builders. Inc.
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l L M. Sh dlowski, J. P. Boycr, P. Vinocur, J. Truax, C. Soeder, cc:
3 B. Smith, T. Will, T. Coverdale, B. Caine, R. Wells, J. Dorado l
nrc9701/jd 9701130161 970108 PDR ADOCK 05000171 p
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Master Builders, Inc.
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, 23700 Chagrin Boulevard Cleveland, Ohio 44122-5554 ll ll Phone 216/8315500 1
Date Page 1 of 3 Customer Sample Attention:
RE:
Notification of Potential Nonconformance for Masterflow 713 (CMTR) Grout
Dear Customer,
Master Builders recently received notice (written notice on 11/14/%) from the Entergy Operations' Grand Gulf Nuclear Station (Port Gibson, MS) regarding potentially defective Masterflow 713 (CMTR) Grout.
Based on our records, and in accordance with the requirements and standard operating procedures of the Master Builders Quality Assurance Program, we are notifying any nuclear facilities that have ordered Masterflow 713 (CMTR) Grout from Master Builders in 19% of the foregoing situation.
Priority has been given to those facilitics that have been shipped the specific lots in question (see below).
j Please be advised that wc are currently in the evaluation stage of the process to determine the scope and cause of the problem.
Nature of the Observed Nonconformance As reported by Grand Gulf Nuclear, the following nonconformances were observed during their testing:
foaming / frothing e
segregation e
shrinkage e
slow setting e
low compressive strength e
Material was returned to the Master Builders Streetsboro, Ohio QC Lab for testing. Our preliminary testing confirmed the nonconformances noted by Grand Gulf Nuclear with the exception of the low strengths (1 day compressive strengths of approximately 2,900 psi were obtained from our testing).
lx>t Numbers in Ouestion The following are the lot numbers in question:
e 24-3849-W5 e 24-4187-N6 e 24-4582-S6
1 Page 2 of 3 Other Masterhw 713 (CMTR) lots from 1996 Although our testing has focused on the above referenced lots, other lots of Masterflow 713
)
(CMTR)producedin 1996 include:
24-4427-R6 e
24-4884-W6 No material from Lot No. 24-4427-R6 was available for retesting.
l 1
Lot No. 24-4884-W6 was tested by the Grand Gulf Nuclear Station and performed in an acceptable manner (i.e. no frothing / foaming or segregation). Retesting of material from this lot on material by the Master Builder Strcctsboro Ohio QC Lab confirmed acceptable performance.
Suspected Cause i
At this point, we are in the preliminary stages of our assessment to determine the root cause of the problem. We suspect that there may be some type of shelf-life instability associated with one or more of the raw materials. flowever, we can only speculate as to the cause until additional information becomes available.
Testing to date, has demonstrated that any Masterflow 713 (CMTR) Grout that was used within 3 months of the manufacture date is not affected by the suspected shcif-life instability problem. As i
mentioned, testing performed on a recent lot of Masterflow 713 (CMTR) Grout (Lot No. 24-4884-W6) by j
Grand Gulf Nuclear and subsequently retested by Master Builder shows it to perform as expected (i.e. no signs of foam / froth or segregation).
In addition, the irregular behavior only occurs in the unhardened state, immediately after mixing.
Therefore, material that does not exhibit this behavior (i.e. foaming / frothing, segregation) will perform as expected in the hardened state (i.e. conformance to the requirements of ASTM Cl107).
Several efforts are underway to isolate the source of the probicm in order to rectify the situation.
Request for Information An important part of our evaluation to gain insight as to the scope and possible cause of the problem, is information from the nuclear utilitics that have been shipped Masterflow 713 (CMTR) Grout in 1996. Consequently, we respectfully request that 30u proside us the following information regarding Masterflow 713 (CMTR) shipped to your facility (s) in 1996.
The amount of material that has been installed by lot number.
flow was the material used (type of application / installation).
e When was the material installed.
Specific lot number (s) of the material used.
Lab or field test reports pertaining to the material installed (i.e. performance data, observations about the material behavior, etc.)
Any additional documentation that may be helpful.
e
l l
Page 3 of 3 i
For any material that has not been placed into senice, we recommend that you do not use such l
material (put on QA " Hold). Please contact Tom Will at ext. 2018 to work out the details on its i
disposition and replacement. In addition, wc recommend that you evaluate any of the subject lots of l
Masterflow 713 (CMTR) Grout that you have placed into senice to ensure that it met the requirements of l
3our specific application.
l As mentioned earlier, based on our testing to date, it has been demonstrated that any material that was used within 3 months ofits date of manufacture is unaffected by the suspected shelf-life instability problem. The best indication of the material's acceptable performance is n hether or not the material eshibited any foaming / frothing after mixing. This behasior would be noticeable immediately after mising. If the material did not exhibit this behavior, then the material was not affected.
Finally, in order for us to proceed with our evaluation in an expeditious manner, we request that
)
you proside us with the above mentioned information by 1/17/97. As mentioned, the information is an important part of our evaluation to determine the scope and cause of the problem, and to rectify the problem as soon as possible.
If you have any questions, or need additional information, please contact me at your earliest convenience at 216-831-5500, extension 2240, or Tom Will at extension 2018.
Sincerely, John Dorado Quality Control Manager Master Builders, Inc.
cc:
L M. Shydlowski, J. P. Boyer, W. Secre, P. Vinocur, J. Truax, C. Soeder, B. Smith, T. Will T. Coverdale, R. Wells. L Huang, B. Caine, G. Culton, Streetsboro QC l
extnotos/jd l
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a Masterflow 713 (CMTR)- Notif"scation Distribution List Company Station / Plant Q
Mailed 1.
South Carolina Gas & Electric Co.
VC Summer Station extnot01 12/30/ %
P.O. Box 88 4
Jenkensville, SC 29065 Phone: 803-345-4318 l
Attn. Mr. Thomas Borch - Product Quality j
2.
Bechtel Power Corporation R.E. Ginna Station extnot02 1/2/97 89 East Ave.
for Rochester Gas & Electric
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Rochester, NY I4519 Phone: 716-724-8739 i
Attn. Dave Fredrickson 3.
Rochester Gas & Electric Co.
R.E. Ginna Station extnot03 12/20/ %
1503 Lake Rd.
j Ontario, NY 14519 Attn. Mr. Richard Biedenbach i
4.
Public Service Electric & Gas Co.
cxtnot04 1/6/97
%5 Chesterbrook Blvd.
Mail Code 63C-1 Phone: 610-640-5678 Waync PA 19087 Fax: 610-640-5676 Attn. Mr. Bill Bradicy, Nuclear Quality Assurance i
Also sent (fax): Ms Cathy Talber, Puyer Phone: 717-456-4101 Fax: 717-456-4450 i
5.
Duquesne Light Co.
Beaver Valley Power Station extnot05 12/30/96 P.O. Box 4 Mail Drop SBX-P Shippingport, PA 15077 Attn. Mr. Bruce Becker, Supervisor, Materials Procurement Engineering 6.
Virginia Power Co.
Surry Power Station extnot06 12/20/96 Innsbrook Technical Center 5000 Dominion Blvd.
Glen Allen, VA 23060 Attn. Mr. JefT Bailey 7.
Florida Power & Light Co.
St. Lucie Power Plant extnot07 12/20/ %
P.O. Box 4332 Princeton, FL 33032 Attn. Ms. Natalic Borrelli a:so sent to Mohammad Af/21
... _. ~. _. - -. _. - -..
i Company Station / Plant M
Mailed l;
1 8.
Consolidate Edison of New York Cooper Nuclear Station extnot08 1/2/97
]
4 Ining Place l
Room 615 S Phone: 212-460 4261 j
New York, NY 1(XX)3 Fax: 212-533-7004
'l Attn. Mr. Arthur Ng. Q.A. Engineer 9.
Georgia Power Co.
Hatch & Vogtle Plants extnot09 12/31/ %
llatch:
Southern Nuclear Operating Co.
P.O. Box 1295 Birmingham, AL 35201 Attn.
Nuclear Engineering & Licensing Manager and Manager - Material Scnices Vogtle:
Georgia Power Co.
Vogtle Project P.O. Box 1295 Birmingham, AL 35201 Attn.
Nuclear Engineering & Licensing Manager and Georgia Power Co.
cxtnot9a 12/31/96' Nuclear Operations P.O. Box 1600 Waynesboro, GA 30830 Attn.
General Manager
- 10. Entergy Operations Grand Gulf Nuclear Plant extnotto 12/30/ %
P.O. Box 31995 Jackson, MS 39286-1995 Attn.: JefTCurry Entergy Operations Grand Gulf Nuclear Station P.O. Box 756 Port Gibson, MS 39150 Attn. Mr. Robert Burnett Mail Unit G-U2Wil-MAT
- 11. Consumers Power Co.
Palisades Generating Plant extnotl1 12/30/96 212 West Michigan Ave.
Jackson, MI 49201 Attn. Ms. Nancy Borton
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..m 4
- n, Company Station / Plant Egle Mailgd
- 12. New York Power Authority James A. Fivpatrick Nuclear extnotl2 12/30/ %
James A. Fiupatrick Nuclear Power Plant Power Plant 268 Lake Rd.
P.O. Box 41 Lycoming, NY 13093 i
Attn. Doug Mullens and Dan Sullivan
- 13. Philadelphia Electric Co.
Peach Bottom Atomic extnotl3 12/31/96 Correspondence Control Desk Power Plant P.O. Box 195 Wayne. PA 19087 Attn. Manager-Licensing Section
- 14. Illinois Power Co.
Clinton Power Station extnotl4 12/30/96 Clinton Power Station P.O. Box 678 Clinton. IL 61727 Attn. Mr. Roger Weber, Nuclear Engineer and Mr. Ron Frantz, Sr. Licensing Engineer
- 15. Duke Power Co.
Catawba Nuclear Station extnotl5 12/30/ %
Catawba Nuclear Station 4800 Concord Rd.
York, SC 29745 Attn. Ms. Debbie Shires Fax No. 803-831-3408 and Chuck Ballard and Paul McBride
- 16. Baltimore Gas & Electric Co.
Calvert Cliffs extnot16 12/31/ %
Calvert Cliffs Nuclear Power Plant 1650 Calvert Cliffs Parkway Lusby, MD 20657 Attn. Supervisor, Vendor Audits
- 17. Cleveland Electric illuminating Co.
Perry Nuclear Plant extnotl7 1/2/97 10 Center Rd.
North Perry, OH 44081 Phone: 216 280-5462 Fax: 216-280-8000 Attn. Mr. Kevin Koski, Sr. Purchasing Agent
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i Company Station / Plant File Mailed i
- 18. North Atlantic Energy Senices -
Seabrook Station extnotl8 12/31/ %
Scabrook Station 5
Box 300 i
Scabrook, Nil 03874 Attn.
B.L. Drawbridge, Executive Director - Nuclear Production i
j and R.J. DeLoach, Executiv' Director - Engineering and Licensing e
and M.D. Ilarrington, Material Requirements Department Supenisor i
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