ML20151H613

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Rev 0 to Matl Control Dept Action Plan for Rancho Seco Nuclear Generating Station
ML20151H613
Person / Time
Site: Rancho Seco
Issue date: 07/15/1988
From: Redican T
SACRAMENTO MUNICIPAL UTILITY DISTRICT
To:
Shared Package
ML20151H601 List:
References
IEB-88-005, IEB-88-5, PROC-880715, NUDOCS 8808010382
Download: ML20151H613 (16)
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MATERIAL CONTROL D8PARTMENT ACTION PLAN FOR RANCHO SECO NUCLEAR GENERATING STATION SACRAMENTO MUNICIPAL UTILITY DISTRICT NUCLEAR REGULATORY COMMISSION BULLETIN 88-05 REVISION O JULY 15, 1988 0"

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Mana4er, M&teTial Control 7/<;)s5-T. E. Redican hh' b 7/ Id cleute Licensing //

Cunhua L Svc

/~ Manager,NuclearEngineering

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7hrks .

G. V. Cranston -

MW Director, N@Jear Quality

? K J. V. VinquTst 7/>

ssistant Cieneral Ma ager /' /

d Technical and Admin'strative services R. G. Croley DISTRIBUTION: CEO. Nuclear Nuclear AGMs Nuclear Directors Nuclear Department Managers Department Files Nuclear Department Supervisors (Information Copy) 8808010382 880720 PDR ADOCK 05000312 O PEC a _ _ _ _ _ _ _ _ .-

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EXECUTIVE

SUMMARY

The Nuclear Regulatory Commission issued NRC Bulletin No. 88-05 May 6, 1988 which presented all holders of operating licenses &

construction permits for nuclear power reactors, with informa-tion that Piping Supplies, Incorporated (PSI) and West Jersey Manufacturing Company ( WJM ) had supplied material with certi-fled material test reports (CMTRS) that contained false infor- '

marion.

Supplement 1 for NRC Bulletin 88-05 was issued June 15, 1988 providing additional infor reduced the scope to fitti,mation onflanges, ngs and PSI / WJM supplied material, delineated licencee required action, and clarified action required when material is found not complying to specifications.

I This action plan defines the necessary action to satisfy the required action for the, bulletin and supplement 1.

The action completed and in progress is listed below:

1. 619 purchase orders from suppliers identified on NRC Bulle-tin 88-05 were reviewed for PSI / WJM material.
2. 9 Heat Numbers were identified as being received from PSI for installation in the TDI Emergency Diesel Generators.
3. 7 of the 9 heat numbers were available and were sent to an independent laboratory for testing. 2 of the 7 samples failed the physical tests. All 7 passed the chemical test.
4. PDQ 88-1241 was written identifying the potentially devia-tion from quality. Interim disposition of the PDQ has pro-vided analysis for Justification of Continued Operations (JCO). '
5. Continuing investigation of heat numbers received from other entities have; approximately 185 to date, identified additional material from WJM purchased by contract with tr.e TDI diesels systems as the intended placement. This was identified on PDQ 88-1315. This is an ongoing effort.
6. The Nuclear Management and Resources Council ( NUHARC ) is providing a industry representation to the NRC concerning the bulletin.

0

o .0 INTRODUCTION 1.1 HRC Bulletin 88-05 identifies potentially nonconforming materials supplied by Piping Supplies, Inc. ( PSI ) at Folsom, New Jersey and West Jersey Manufacturing ( WJM )

at Williamstown, New Jersey. Certified material test re-ports from PSI,and WJM have been identified containing ,

false information about material supplied to the nuclear industry.

1.2 This action plan defines necessary activities to satisfy

  • the required action for this bulletin.

1.3 The Manager, Material Control is responsible for the ad-ministration of the NRC Bulletin 88-05 Action Plan.

2.0 ACTION PLAN 2.1 PURPOSE 2.1.1 Define Rancho Seco action /s required to control material found during the resolution of NRC Bulletin 88-05 with material identified which has been received from WJM and PSI.

2.1.2 Provide identification of internal Rancho Seco (RS) res-ponsibility and interfaces for the required action in the resolution of NRC BulleLin 88-05.

2.1.3 Provide identification of responsibilities and interfaces with organizations external to RS during the resolution of NRC Bulletin 88-05.

2.2 SCOPE 2.2.1 This action plan applies to activities associated with NRC Bulletin 88-05.

2.3 REFERENCES

AND COMMITMENT DOCUMENTS 2.3.1 References 2.3.1.1 RSAP-0401 Preparation and Processing of Purchase

Requisitions

! 2.3.1.2 RSAP-0601 Nuclear Records Management

, 2.3.1.3 RSAP-0803 Work Request l

2.3.1.4 RSAP-1308 PotCntici D3viction From Quality 2.3.2 Commitc0nt Documonts 2.3.2.1 NRC Bulletin 88-05 2.4 DEFINITIONS - Definitions are provided in the Referencing procedures or the text of this action plan.

2.5 ACTION TO BE TAKEN 2.5.1 Responsibilities 2.5.1.1 The Material Coding and Classification Unit ( CCU ) is responsible for:

2.5.1.1.1 Providing a contact point for the Nuclear Management and Resources Council ( NUMARC ) inquiries including other member and participating utilities.

2.5.1.1.2 Reviewing manufacturer, supplier, heat number, and other documentation to identify WJM or PSI material received at RS.

2.5.1.1.3 For all PSI / WJM material found received at RS, perform a review of issue history to determine intended usage of the material in the uait.

2.5.1.1.4 Initiating Purchase Requisition Worksheets ( PRW ) for testing of identified WJM / PSI material; as required for NRC Bulletin 88-05 and replacement of stock warehoused material removed for salvage per Ref 2.3.1.1.

2.5.1.1.5 Initiating Potential Deviation From Quality ( PDQ ) per Ref 2.3.1.5 for WJM / PSI identified material received at at R3. -

2.5.1.1.6 Quarantine any identified PSI / WJM material found pend-ing NE dispostion of PDQ's.

2.5.1.1.7 Provide status reports as required by management or other associated organizations.

2.5.1.2 The Manager, Nuclear Engineering is responsible for:

2.5.1.2.1 Disposition of PDQ's per Ref. 2.3.1.4.

2.5.1.2.2 Perform walkdown or identify walkdown and work require-ments for installed material, per Ref 2.3.1.3.

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o 2.5.1.2.3 Provide procedures and a standard work plan for the field in selection and obtaining samples of material for test and analyses.

2.5.1.2.4 Support Nuclear Licensing with justification for contin-ued plant power operations when applicable.

2.5.1.3 The Director, Nuclear Quality is responsible for:

2.5.1.3.1 Surveillance and audit activities to provide assurance of adherance to the action plan, and the site QA Program.

2.5.1.3.2 Develop in place hardness testing procedure for NE re-view and approval.

2.5.1.3.3 Supply NDE personnel to perform hardness testing.

2.5.1.4 The Manager, Nuclear Licensing is responsible for 2.5.1.4.1 Coordinating information between Rancho Seco Organiza-ons to provide reports as required for NRC Bulletin 88-05.

2.5.1.4.2 Coordinating information with outside agencies (e.g.NRC, NUMARC) to exchange information on NRC Bulletin 88-05.

3.0 SCHEDULE 3.1 Materials identify bulk of PSI / WJM material at RS by 9/30/88.

3.2 Quality have approved EquoTip Hardness Testing Procedure 7/22/88.

9 3.3 NE prepare technical requirements / procedure for associa-ted work activity to support PDQ disposition's.

3.4 Licensing issue required responses as specified 'in NRC Bulletin 88-05.

4.0 RESOURCES 4.1 Manager, Material Control nas contracted for 3 additional personnel to perform documentation review in support of NRC Bulletin 88-05.

4.2 Any additional personnel or resources required beyond the baseloading for the RS Organizations will be addressed by each department manager / director.

.' 5 . 0 GENERIC GUIDELINES o

.5.1 PSI / WJM will bo looked at without regard to dato of manufacture.

5.2 **

Where available full chemical and physical analysis will be performed on all PSI / WJM material.

5.3 Inaccessable material will be addressed by NE on PDQ's when identified.

6.0 RECORDS -Records are controlled in accordance with Ref.

2.3.1.2.

7.0 APPENDIX 7.1 APPENDIX At Purchaser of PSI / WJM material, Purchase Orders reviewed. ,

7.2 APPENDIX Bt LATER ( Testing Procedure for EquoTip Hard-ness Testing of Metallic Materials )

.I e

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  • APPENDIX A NRC BULLETIN 88-05 ACTION PLAN
619 TOTAL PURCHASE ORDERS REVIEWED.

] 7 TOTAL PSI /WJM CERTS FOUND.

134 TOTAL NON-Q PURCHASE ORDERS REVIEWED.

, 466 TOTAL PURCHASE ORDERS REVIEWED THAT ARE Q/C-1.

N.R.C. BULLETIN 88-05

SUMMARY

VENDOR # P/O # P/O # P/O COMMENTS

NAME LKD AT FOUND NON-Q PSI /WJM 1 o AMERICAN 2 0 2 PLUMBING FITTINGS i

STANDARD o BELLOWS O C O NON SMUD VENDOR o CAPITOL 20 0 0 i PIPE STL 4

o CHICAGO '

O O O NON SMUD VENDOR

, TUBE / IRON o CONAX 28 0 3 o CONSOL 7 0 1 i POWER l o DRAVO INC 0 0 0 NON SMUD VENDOR 3

o DUBOSE 31 6 0

) o GULFALLOY l 0 0

o GUYON 65 0 3 ALLOYS l INC 1 o HUB INC 165 0 8 1 o ITT 288 0 117, GRINNELL o JOLIET 0 0 0 NON SMUD 7ENDOR VALVE INC i o LOUIS P. 0 0 0 NON SMUD VENDOR

! CANUSO l o MCJUNKIN ! 11 0 0 *

, o OSBORNE O 0 0 NON SMUD VENDOR l BROS.WLD -

l o P.S.E/G 0 0 0 NON SMUD VENDOR y o PULLMAN 0 O O NON SMUD VENDOR j POWER 1

PRODUCTS l o RADNOR 0 0 0 NON SMUD VENDOR 4 ALLOYS l o TYLER 0 0 0 NON SMUD VENDOR j DAVISON 1 o TRANSAMER 1 1 0 1 DELAVAL

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I Attachment IV Justification for Continued Operation l

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Attachment IV Justification for Continued Operation Page 1 of 2 j I

A.  !

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f Four flanges were installed in the "A" TDI diesel generator fuel oil system I which do not meet specification requirements. Engineering determined that  !

, operation of "A" TDI diesel generator may continue with these flanges in the fuel oil system.

{

The flanges were identified as part of an investigation being performed in  :

response to NRC Bulletin 88-05. This Bulletin deals with nonconforming l 5 materials supplied by Hest Jersey Manufacturing and Piping Supplies j Incorporated. l B. AffectedJystem/ Safety Function of Afferted System [

This Justification for Continued Operation affects the Emergency Generator i System (USAR Section 8.2.3.1.2), specifically TDI diesel generator GEA2.

[

The safety function of the Emergency Diesel Generators is to automatically supply the associated 4160V AC Nuclear Service buses upon loss of voltage or SFAS actuation. The Emergency Diesel Generators supply all AC loads necessary .

to ensure continued operation of essential reactor and station auxiliary '

equipment. j The District installed the TDI diesel generators to support the additional [

electrical loads resulting from "THI Modifications". The Emergency Diesel i

) Generator System consists of two independent and redundant trains with a  !

Bruce-GM diesel (GEA/GEB) and a TDI diesel (GEA2/GEB2) in each train. In i Train A GEA supports bus 4A and GEA2 supports bus 4A2. Similarly, in Train  ;

B, GEB supports bus 4B and GEB2 supports bus 482. Each train alone is i

! sufficient to accomplish the safety function.  ;

i C. [L[gts on Safety Function /Ana]ysis of Effetti

The heat number of the material in question is CFY. This material consists of I 2-inch, 150# carbon steel flanges. These flanges are ASME !!! ND (C13), {

SA-105 material. A total of eight flanges with heat number CFY were received i a on site, three are in stock, one was scrapped, and the remaining four were j installed in the "A" TDI diesel generator fuel oil system (two in each of two j lines), j I

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F Attachment IV Justification for Continued Operation Page 2 of 2 l The maximum calculated combined pipe stress level for code compliance for the l "A" TDI diesel fuel oil lines is less than 6000 psi. This figure results in a l

stress ratio on the fuel oli lines of less than 0.25 (Actual Stress / Allowable Stress). The maximum allowable pressure for a 150#-rated flange at a design temperature of 125'F is approximately 255 psig, whereas the design pressura of i the system is only 100 psig. Hence, there exists a conservative margin of I

safety of over 50%.

The actual tensile strength of the sample was 66,400 psi (see test results, Attachment V). The required tensile strength is 70,000 psi. This results in a reduction of tensile strength of 5.14%. Based on this slight reduction in strength of the flange, when compared to the conservative margin of safety l which remains Engineering has determined that an adequate margin of safety I

exists to assure the integrity of the fuel oil system and justify the interim use of the flanges. The final disposition is to replace the degraded flanges with materials having proper certification at the next available outage.

D. Summary Four flanges were installed in the "A" TDI diesel generator fuel oil system which do not meet specification requirements. The District identified these flanges as part of the investigation required by NRC Bulletin 88-05.

This Justification for Continued Operation affects the Emergency Generator System TOI diesel generator GEA2. The TOI diesel generators support the additional electrical loads resulting from "THI Modifications."

The heat number of the material in question is CFY. This materlat consists of 2-inch, 150# carbon steel flanges. These flanges are ASME !!! ND (C13),

SA-105 material. Based on the minimal reduction in measured strength of the flange when r,ompared to the conservative margin of safety which remains, the Engineering evaluation concludes that an adequate margin of safety exists to justify the interim use of the flanges.

1 Attachment V Anamet Laboratories Test Results

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.  ;.;. . .., . ~. l L AEORATORY CERTIFIC ATE Anamet Laboratories, Inc.

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Laboratory Number: 688.138 Purchase order: RQ-88-08-26278 S/N: 48961 June 13, 1988 Date Submitted: June 21, 1988 Oate Reported:

Saoramento Municipal Utility Dist. i Rancho Seco Nuclear Cererator station l '

At ni Jim Holbrook 16440 Twin Cities Road Hea ald, CA 95638-9799 _

S'J B J E CI

$even fittings were submitted for chenical analysis, tensile1. and

! hardness testing. The samples are identified in Appendix Recuire=ents SPECTRCCHEM! CAL ANALYS!$ E PF A 152-64, d

H eported in wt. 1) T304 l Min. Mer.

Marks Heat Heat

  1. 104839 _

dA10ao 0.06 0.01 - 0.08 carbon (C) 18.00 20.00 I Crromium ( Cr ) 18.95 18.81 1.64 1.57 - 2.00 l Ne,n g e n e a e (Mn) Information j Molyedenus (Mo) 0.24 0 37 10.51 10.45 8.00 11.00  ;

Nickel (NL) 0.040 i Phospnorus (?) 0.025 0.022 -

1.00 (31) 0.59 0.30 -

5 licon 0.018 0.024 - 0.030 Sulfur (5) '

i

/ R.quir.s.nte I!!M A 403-54, l WP304 Nin. M6x.

Marks Heat ,

A7611 i 0.006 - 0.08 l Carton (C) 16.0 20.0 t Chrom 1un (Cr) 19.63 - 2.00 (Mn) 1.05 Panganese (Mo) 0.15 :ntornatten ,

Molytcenun $.00 11.0 l Aickel (N1) 9 96 - 0.045 Thospherus (P) 0.024 - 1.00 it11:en (31) 0.50 0.030 fulfur (3) G.005 -

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LABOR ATORY Cf Afl8 5 A73 Anamet Laboratories. Inc. t wwano. en urone Pa{e 3 Lab. No. 688.136 i

  • t45:LE TES; Pequire-ents l ASTM A 152-54, ,

r30u '

Mark Heat Heat

  1. 104819 #A1040, 01ameter of 5pecimen: 0 357 In. 0 354 In.

Apes: 0.100 Sq.In. 0.0984 54.In.

Tcnstle strength: 34500 Psi 76700 Psi 75000 Psi Min.

Yield Strength 9 O.25 Offset: 38800 Psi 34300 Psi !0000 Psi Min.

Elongation in 4D Oage: 61 1/2% 65% 301 Min.

  • oduction

=

of Area: 70.4% 74.71 50% Min.

R e cui r e's e n t s I A3IN A 403-54 WP30s

!!a rk Heat

  1. 7611 4.

< Diameter of Specimen 0.249 Inches l 0.0487 Square Inches Area 71n_tt i_e Strength: 79600 P 1 75000 Psi Min.

Y1ols Strongt

, 0.21 Offset: 2!500 Psi -

30000PsiMih El go iW%7 ~

yys glit Min.

Moduction of Area: 85 25 351 Min.

Require-ents Parks Heat A3ME sA-105,

  1. CTY '77 Ed.,

'73 Adc.

01aseter of Spect=en 0 349 Inches asil tren 70000 -Psi M

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u.10str.ns;n y 0.2% offset or 0 5 % ! . ','. L a '41300 Psi 36000 Psi Min.

l tiongation in eD cage 36 1/2*. 2 2 '. :fi n .

! Feduction of Area: 59 6% 3 0 '. M i r. .

0-pl?-hV

m : a. 2 .at , . . , ,a.n., g.

L ABORAToRY CERTIFIC ATE Anamet Laboratories. Inc.

Havname,caupopma Page 2 Lab. No. 688.138 SPECTR0 CHEMICAL ANALYSIS (continued) Recuirements

~

T5TTi A 105-53,

-84 Min. Max.

Mark: Heat Heat Heat

  1. AXSX d u 1971_ #CT4 Aluminum (A1) <0.005 <0.005 0.03 Information Carbon ( 0) 0.28 0.18 0 34 - 0 35

' Chromium (Cr) 0.04 0.12 0.11 Information Copper ( Cu ) 0.04 0.18 0.20 Information Manganese (Mn) 0 99 1.23' O.80 0.60 1.05 Molybdenum (Mo) <0.005 0.02 0.05 Information Nickel (Ni) 0.03 0.09 0.13 Information Phosphorus (P) 0.007 0.013 0.009 - 0.040 Silicon (Si) 0.12 0.23 0.21 - 0.35 nulfur (S) 0.010 0.019 0.013 - 0.050 i Vanadium (V) <0.005 0.06 <0.005 In f o r= s t i e r.

O Product Analysis - Requirements: Manganese - 0.60% Minimun and 1 35 % Maximum.

Pecuirements~

ASME SA-105,

'77 Ed.,

78 Add.

Min. Max.

Mark: Heat

  1. CFY Aluminum (A1) 0.04 Information Carbon (C) 0.20 - 0.35 Chromium (Cr) 0.04 Information Copper ( Cu ) 0.02 Information Manganese (Mn) 0 93 0.60 1.05

, Holyodenum (Mo) <0.005 Information Nicke; (N1) 0.02 Information Phosphorus (P) 0.019 - 0.000 Silicon (Si) 0.21 - 0 35 Sulfur (S) 0.019 - 0.050 3ff

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LA8e A AToRY CERflFICATE Anamet Laboratories. Inc.

Mf.YWARD C ALIPCRNIA Page 4 Lab. No. 688.138 TENSILE EST (cont'.nued)

Marks Heat Heat Heat eASXS #41971 g Dia.%eter of Specimen: 0.251 In. 0 349 In. 0 356 In.

Area 0.0495 Sq.In. 0.0957 Sq.In. 0.0995 Sq.In.

Tensile Strength: 79800 Psi 84100 Psi gu200 Pai Yield Strength e 0.2% of fset : 42900 Psi 55400 Psi 51000 Psi Elongation in 4D Cage 32% 27% 23%

Roduction of Area: 6u.25 65 9% 50.7% .

Roquirements: Ultimate Tensile Strength - 70000 Psi Minimum, Yield Strength i 0.2% offset - 36000 Psi Minimum, Elongation

, in uD Cage - 225 Minimum and Reduction of Area - 30% Minimum per ASTM A 105-33, -84 3RINELL HARDNESS TEST

'3000 4g. load; 10mm ball)

Soecimen Result Ht. #AXSX 152 MB Mt. 441971 183 HB 4t. SCFW 183 HB

.N t . #CTY 137 H3 Requirement: 187 HB vax. per ASTM A 105-83, -84 and ASME SA-105, '77 Ed. with '78 Addenda.

This testing was performed in accordance with the purchase order and, with the exception of the tensile results on Ht. 07611 and #CTY, the results meet the listed requirements.

Submitted by:

b.GDOhvw-E. A. Foreman 3c/bh6*736 Manager, Ouality Controi

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LAsoA Af oRY CERMICATE gnamet Laboratories. Inc.

H AVW A40. C ALIPomMI A Page 5 Lab. No. 688.138 APPENDIX 1 Item No. 1, Distribution / Stock Code #472501, 1 each Flange, Slip-On, RF, 6" 1500 S.3. ASTM A 182, F304, Heat #104839 ('984), SMUD stock Iode 8702495 .e-Item No . 2, Distribution / Stock Code 0472501, 1 each Pipe Cap. 12" Sch.

40 S.S. ASTM A 403, WP304 Buttweld, Heat #7611 (1984), SMUD Stock Code

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Item No. 3, Distribution / Stock Code e472501, 1 each r'ange, Slip-On, 3" 150# RF, S.S., ASTM A 182, T304, Heat dAiou0 (1984), SMUD Stock Code 702$12.

Item No. 4, Distribution / Stock Code #472501, 1 each Cap, Pipe, 8" Sch.

80 SW CS, ASTM A 105-84, Heat #AXSX, SMUD Steck Code #036926.

Item No . 5, Distr!bution/ Stock Code 4472501, 1 each , Tiange, Slip-On ,

3" 150d RT, ASTM A 105-83, Sch. 80, H e * '. OCTW Carbon Steel, SMUD Stock Code 70127 . v Item No. 6. Distribution / Stock Cot'c #472501, 1 each, riange, 2" -

150d, SW RF, ASME III ND (C13) SA~:05, Heat #CTY, Carbon steel 77 odition - 78 Addenda, SMUD Stock Code #113345.

Ites No. 7, Distribution / Stock Code #472501, 1 each Flange, Slip-on, 5" - 150# RF, CS, ASTM A 105, Heat #41971 (1984), SM')D stock code 9702395 P4 SfS

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