ML20154F129

Forwards Response to NRC Bulletin 88-005 Re Results of Investigation Concerning Matl Supplied by Piping Supplies, Inc or West Jersey Mfg.Description of Investigation Performed & Test Results Encl

ML20154F129
Person / Time
Site:	Rancho Seco
Issue date:	09/14/1988
From:	Croley B SACRAMENTO MUNICIPAL UTILITY DISTRICT
To:	NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM)
References
AGM-NTS-88-217, IEB-88-005, IEB-88-5, NUDOCS 8809190261
Download: ML20154F129 (16)

Text

___________ ,____- _

4

.OSMU-sacnameNTo MUNICIPAL UTsLITY DISTRICT U 6201 S Street. P.O. Box 15830. Sectemento 0.A 958521830.1916) 452 3211 AN ELECTRIC SYSTEM SERVING THE HEART OF CALIFORNIA AGM/NTS88-217 September 14, 1988 U. S. Nuclear Rcgulatory Commission Attn: Document Control Desk Washington, DC 20555 Docket No. 50 312 Rancho Seco Nuclear Generating Station License Wo. DPR-54 NONCONFORMING MATERIALS

References:

(1) NRC Bulletin No. 88-05, dated May 6, 1988 (2) NRC Bulletin No. 88-05, Supp. 1 dated June 15, 1988 (3) NRC Bulletin No. 88-05, Supp. 2, dated August 3,1988 Attention: George Knighton The Sacramento Municipal Utility District hereby submits tesults of the I investigation concerning material supplied by Piping Supplies Inc. (PSI) or l West Jersey Manufacturing (HJM). The investigation was performed in response to the referenced NRC Bulletins and was terminated in accordance with reference (3) on August 3, 1988. This letter complies with the 120-day report requirement contained in reference (1).

i Attachment I is a description of the investigation performed by the District concerning nonconforming material supplied by PSI and HJM. Attachm9nt !!

provides the test results for those potentially nonconforming materials which the District submitted to an independent testing laboratory. Attachment III is a Justification for Continued Operation for those fittings which, based on test results, do not meet material specification requirements (SA-105).

Members of your staff with questions requiring additional information or clarification may contact Steve Crunk at (209) 333-2935, extension 4913.

8809190261 090914 PDR ADOCK 05000312 fMI Il CANCHO SECO NUCLEAR GENERATING STATION D 14440 Tw n Cit.es Road. Hera'd. C A 95638 9799.(2o9) 333 2935

.

• George Knighton AGM/NTS88-217 State of California SS County of Sacramento Bob G. Croley, being first duly sworn, deposes and says: that he is Assistant General Manager, Nuclear Technical Services of Sacramento Municipal Utility District (SMUD), the licensee herein: that he has executed the foregoing document; that the statements made in this document are true and correct to the best of his knowledge, information, and belief, and that he is authorized to execute this document on behalf of said Itcensee.

.f Bo6 G. Croley Assistant Gener Manager Nuclear Technt al Services Subscribed and affirmed to before me on this M ay of LIblO,1988.

~/

" '" ^om cw n u, N['M,<l }O["'#

5 ,

( /*

[:/jpah. renamsc.11tiCHDi ESTER H c MO-VA ( Esther H. Hughes y Q,m .g uenwwocesay Notary Public Na,p u, ce t.m, x n. n u w%, .mswww Attachments cc: A. D'Angelo, NRC, Rancho Seco J. B. Martin, NRC, M41 nut Creek i

l ,

l l

l ATTACHMENT I Description of Investigation a

' Attachment I Page 1 of 4 Description of Investigation A. Historv/Investication Methodolocy The District raceived NRC Bulletin 88-05 on May 13, 1988. The Manager of the Material Control Department became the lead indi-vidual for the investigation begun in response to the Bulletin.

Bulletin 88-05, Tablo 1 identified the Dubose company as the "Purchaser" of concern to the District. Rancho Seco's Material Coding and Classification Unit (CCU) began reviewing Purchase Or-ders (Pos), contracts, certified Material Test Reports (CMTRs),

and the heat number log book, as well as Rancho beco's computer-

ired material tracking system to perform a comprehensive review of all resources which could identify purchases from Dubose with certifications by West Jersey Manufacturing (WJM) or Piping Sup-plies, Inc. (PSI). The CCU also began r3 searching records to discover purchases fr.)m the remaining vendors (other than Dubose) listed in Table 1. The CCU reviewed 631 Pos.

i As a result of the investigation, the Material CCU investigators i realized that heat numbers were an important tool for the identi-fication of suspect material. On June 20, 1988, the District received Supplement 1 to NRC Bulletin 88-05 which also focused upon heat numbers.

1 Once suspect daterial either failed e,esting or was identified as having no extra on hand for test samples (all suspect material l installed), Nuclear Engineering persocnol performed system walk-downs to identify ths specific use of the material.

The District developed a field test procedure (NDEI-0915) to be used by Quality control Engineers for in situ hardness testing.

The investigation continued entil receipt of NUCLEAR NETWORK mes-sage TI 1677 on August 5, 1988, alerting licensees to the suspen-cion of activity concerning Bulletin 88-05. At that time, all l investigative activities associated with NRC Bulletin 88-05 were l terminated.

B. Q1tgovery/Tastino of Suspect Materigl Review of the 631 Por revealed the presence of nine different l heat numbers for material purchased from PSI through Dubone.

Samples for seven of the heat numbers were available for off-sita chemical testing; the remaining two heat numbers had no spares available to use as test samples. All suspect matetial identi-fied in this review was located in TDI diesel genera *or support systems.

l i

l

• i Attachment I l Page 2 of 4 +

Five of the seven heat numbers met all SA-105 requirements for  :

tensile strength, yield strength, hardness, and chemical composi-tion. Two of the heat numbers did not meet the requirements.

Heat number CTY, which consists of 2einch, 150# carbon steel flanges, did not meet tensile strength requirements. Meat numcor 7611, which consists of 12-inch, stainless steel pipe caps, did not meet yield strength requirements. All the heat numbers met  ;

chemical composition requirements. (Results from this testing are included as Attachmen1 ;I.) Potential Deviation from Quality (PDQ) 88-1241 was written upon receipt of test results. Follow-ing a system walkdown to identify specific component us6, Lican-sing notified the NRC as specified by Action 4 of the Bulletin.

The two heat numbers identified in PDQ 88-1241 having no samples I available for testing are CND and CMP. This raterial was pur-chased from PSI through Dubose and is installed on the TDI diesel generators. Heat number CND failed to meet requirements at the Shearon Harris plant, as reported on UUCLEAR NETWORK. The Dis- r trict had not performed in situ testing prior to the receipt of f Supplement 2 of Bulletin 88-05 (August 3, 1988). '

A total of 679 hea* numbers of material supplied by WJH or PSI were either iden*,1fied by Rancho Seco or reported by various l utilities through NUCLEAR NETWORK. The CCU investigated these numbers for the existence of suspect material at Rancho Seco.

Each heat number was cross-referenced against coatracts and other documentation. The CCU discovered material with 12 heat numbers identified by other facilities which were supplied to Rancho Seco by WJM/ PSI through subvendors. The 12 heat numbers were docu-mented on three additional PDQs (88-1315, 88-1337, and 88-1401) as documented below.

PDQ 88-1315 listed three heat numbers (1757, 1090, and 04553).

The material was identified as being installed in the TDI diesel radiator cooling water system. It was supplied by ITT Grinnell as part of the diesel radiatort therefore, no spares are avail-able for chemical testing. The District had not performed in situ hardness testing by August 3, 1988.

PDQ 88-1337 listed four heat numbers (A39, A91, E143,3, and A79).

The material was identified as being installed in the TDI diesel fuel oil day tanks. It was supplied by TransAmerica Delaval with attached piping; therefore, no spares are available for chemical testing. The District had not performed in situ hardness testing by August 3, 1988.

. Attachment I  !

Page 3 of 4

PDQ 88-1401 listed five neat numbers (R6842, 04096, 41687, 04020,  !

I and A101). The matarial was identified as being installed on

, the diesel generator auxiliary skids. (A detailed system walk-

down to identify the specific use of the material had not been i performed by August 3, 1988.) The material was supplied by i

TransAmerica Delaval with attached piping assembliest therefe**,

no spares are available for chemical testing. The Distrj not performed in situ hardness testing by August 3, 198' 1

I The field hardness test procedure (NDEI-0915) wnG in t te sw j and approval cycle when NRC Bulletin 88-05 activities s ;s-pended; therefore, no in situ hardness testing was performed j prior to August 3, 1988.

I C. Engineerino Evaluation of_tionconformina Matgr(al

]

As previously stated, two heat numbers of the material tested at

an independent laboratory did not meet requirements.

Failed hnat number 7611 consists of 12-inch, schedule 40 stain-l less steel pipe caps. The entire stock is available (none are

installed) and there are no system concerns. The stock has been l placed on hold.

]

Failed heat number CTY consists of eight 2-inch, 150# carbon steel flanges. Four of these flanges are installed in the fuel oil piping for the "A" TDI dierel generator. A fifth flange was scrapped and three have not been issued. Nuclear Engineering evaluated the test results and the use of the flanges in the di&-

, sel fuel oil systen and determined that interim use of the four j flanges is acceptable. The flanges should, however, be replaced i at a future outage with material having proper certifications.

J (See Attachment III for a Justification for continued operation.)

D. Failed /St'spect Material Chain of Purching The following table lists the chain of purchase for failed or suspect (but not tested prior to August 3, 1988) material identi-

fied in the course of the investigation.

lifA1_1 Rescriptinn Chain of_Purchan_t CND 4-in, 150f flange PSI -> Dubose -> SMUD 6-in, 1500 flange CMP 6-in, 1509 flange PSI -> Dubose -> SMUD

t Attachment I Page 4 of 4  !

Heat i Description chain of Purchama '

i CFY 2-in, 1500 flange PSI -> Dubose -> SMUD (

t 7411 12-in, SS pipe cap PSI -> Dubose -> SMUD  !

i l

1757 8-in, 1506 flange MJM -> ITT Grinnell -> SMUD l l

1090 4-in, 1500 flange WJM -> ITT Grinnell -> SMUD l I

04553 6-in, 1500 flange WJM -> ITT Grinnell -> SMUD A39 3-in, 1500 flange WJM -> Capitol Pipe & Steel -> r TransAmerica Delaval -> SMUD f l l A91 2-in, 1509 flange WJM -> Capitoi Pipe & Steel -> L I TransAmerica Delaval -> SMUD E1413 1 1/2-in, 1500 flange WJM -> Capitol Pipe & Steel -> f TransAmerica Lelaval -> SMUD  !

l l

A79 1-in, 1506 flange WJM -> Capitol Pipe & Steel ->

TransAmerica Delaval -> SMUD R6442 3-in, 1506 flange WJM -> TransAmerica -> SMUD f

(

04096 4-in, 1506 flange WJM -> TransAmerica -> SMUD (

41687 8-in, 1500 flange WJM -> TransAmerica -> SMUD 04020 5-in, 1500 flange WJM -> TransAmerica -> SMUD A101 5-in, 1500 flange WJM -> TransAmerica -> SMUD l 1 I I

l; l

t I

i l

l l

ATTACHMENT II Laboratory Test Results  !

i t

i t

i f

I i

l

}

l

[

I i

r l

i I

l s

l t

I l

I t

l

. e- .. +. .

t.ABORATORY CERTIFIC ATE Anamet Laboratories, Inc.

m . . n .- - . u a e . ~ ~ e. e w ,o o i. ........,, i.,,,......,,

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

Saoramento Municipal Utility Dist.

Rancho Seco Nuclear Generator Station Atta: Jim Holbrook 14440 Twin Cities Road Ke sid, CA 95638-9799 __

SUBJEC*_

Seven fittings were submitted for chemical analysis, tensile1. and hardness testing. The samples ass identified in Appendix Recuirements SPECTRCCHEMICAL ANALYSIS A5TM A 152-du, Iruported in wt! 5) F304 h Max.

Heat Heat Mark: #104839 #A10u0 0.01 - 0.08 (C) 0.06 18.00 20.00 Carbon 18.95 18.81 Chromium (Cr) 1.57 - 2.00 Mangenese (Mn) 1.64 Information (Mo) 0.24 0 37 11.00 Molyedenum 10.45 8.00 (NL) 10.51 0.040 Nickel 0.025 0.022 -

1.00 Phospnorus (?) 0 30 (31) 0.59 0.030 S licon O.018 0.024 .

Sulfur (S) ,

, _ Requirements X57M A uC3-au, WP304

, Min. Max.

Heat Merk: A7611

- 0.08

(

(C) 0.006 18 0 20.0 Carton 19 63 2.00 Chromium (Cr) 1.05 Fanganese (Mn) 0.15

nformatten Molybdenum (Mo) 8.00 11.0 (N1) 9 96 0.045 Nickel 0.024 1.00 Phosphorus (P) 0.50 (Si) - 0.030 tilicon (5) <0.005 f ulfur lff

..e- -

LA80R Af oRY CERTIPic ATE Anamet Laboratories, Inc.

HaTCaiO. L' AWomesta Lab. No. 688.138 Page 2 Recuirements SPECTRCCHEMICAL ANALYSIS ( coritinu ed ) ASTM A 105-53.

-Su Min. Mar.

Heat Heat Heat f4s rk : dCFW

1. AXSX du1971_

(A1) <0.005 <0.005 0.03 Information A'uminum 0.18 0 34 - 0 35 faroon ( C) 0.28 0.11 Information (Cr) 0.04 0.12 Chrcmium 0.0u 0.18 0.20 Information Copper ( Cu) O.88 0.60 1.05 Manganese (Mn) 0 99 1.23' Information (Mo) <0.005 0.02 0.05 Holyedenum 0.03 0.09 0.13 Information Nickel (N1) 0.009 - 0.040 Phospnorus (P) 0.007 0.013 0.35 (S1) 0.12 0.23 0.21 -

Silicon 0.019 0.013 - 0.050 Scirur (S) 0.010 Information (V) <c.005 0.06 <0.005

'la n a dium

• Product Analysis - Requirements: Manganese - 0.505 Minimuri and 1 35 % Maximum. Beauirements~

A5ME SA-105,

'77 Ed.,

78 Add.

Min._ Max.

< ark: Heat

1. CTY 0.04 Information Aluminum (A1) - 0.35 Iarton (C) 0.20 Information (Cr) 0.04 Chromium 0.02 information Copper ( Cu ) 0.60 1.05 Manganese (Mn) 0.93 Information Molyoconum <0.005

( Mo )

0. 0 ? Information Nickel (M1) - 0.0u0 Phosphorus (P) 0.019 - 0.35 Silicon (51) 0.21 - 0.050 Sulfur (S) 0.019 a.fr

l LA8oR AToRY CE ATiflC ATE Anemet Laboratories, Inc s*.tvw A A0. C A UPomest A Page 3 Lab. No. 688.138  ;

1 Requirements TENSILE TES;

~~ ASTM A 152.gu, F30u Mark: Heat Heat

1. 1G4839 #A1040 Diameter of Specimen: 0 357 In. 0 35 4 In .

0.100 Sq.:n. 0.0984 Sq.In.

Area Tensile Strength: Su300 Psi 76700 Psi 75000 Psi Min.

Yield Strength f 0.2% offset: 38800 Psi 3u300 Psi 30000 Psi Min.

Elongation in 40 Gage: 61 1/25 65% 301 Min.

Reduction of Area: 70.4% 74.7% $01 Min.

Recuirements A5TN A 403-64 WP304 Mark: Heat

1. 7611 Diameter of Specimen 0.249 Inches Area:

0.0487 Square Inches 71nsile Strength: 79600 Psi 75000 Psi Min.

~

Yield Strengt h 0.25 Offset: 28500 Psi 30000PsiMih El ngetto in Ga g el 97 455 Min.

Roduction of Area: 85 25 35% Min.

Requirements _

A5ME 5A-105, Marks Heat '77 Ed.,

ACTY

'73 Add.

Diameter of Specimen: 0 349 Inches 0 In:hes A" y -

Tensile Strength: 66400 Psi 70000 Psi Min.

Yield Strengtn 0.2% offset or 36000 Psi Min.

0 5% E.U.L: u1800 Psi 225 :41 n .

Elongation in iD Cages 36 1/24 59 65 305 Min.

Reduction of Area:

Py3 &h' i 1

T'.-i LAgo A AfoRY CERflFICATE Anarnet Laboratories. Inc.

naVWam0 C ALipome.i A Page 4 Lab. No. 68 8.138 TENSILE TEST (continued)

Mark Heat Heat Heat 4ASXS #41971 dC[W Diameter of Specimen: 0.251 In. 0 349 In. 0 356 Ir..

0.0495 Sq.In. 0.0957 Sq.:n. 0.0995 Sq.In.

Area 79800 Psi 84100 Psi gu200 Pai Tensile Strength:

Yield Strength i 0.2% offset 42900 Psi 55400 Psi 51000 Psi Clongation in 4D Oage: 32% 27% 23%

Roduction of Area: 64.2% 65 9% 50.7% .

Requirements: Ultimate Tensile Strength - 70000 Psi Minimum, Yield Strength 8 0.2f Of fset - 36000 Psi Minimum, Elongation in uD onge - 22% Minimum and Reduction of Area - 301 Minimum per ASTM A 105-33, -84 3RINELL HARDNESS TEST (3GC0 <g. load; 10mm ball)

Soecimen Result Ht. #AXSX 152 HB Ht. #41971 183 HB Mt. #CTW 183 HS Mt. dCTY 137 HS Requirement: 187 HB Max. per ASTM A 105-83, -84 and ASME SA-105, '77 Ed. with '78 Addenda.

7his testing was performed in accordance with the purchase order and, with the exception of the tensile results on Mt. #7611 and #CTY, the results meet the listed requirements.

Submitted by:

.C Ohu~

E. A. foreman 3c/bn6*738 Manager, Ouality Control Y ($

~

, ,~ ., ,,

1 l

LAsom Af oRY oERTIFICATE Anamet Laboratories, Inc.

H AVWA RD, C A(lPQ ANie Lab. No. 688.138 Page 5 APPENDIX _1 Item No. 1, Distribution / Stock Code du72501, 1 each Flange, slip-On, 3F, 6" 15Cv S.S. ASTM A 182, r30s. Heat 4103839 (198t), SMUD Stock Iode 8702495 Item No. 2, Distribution / Stock Code du72501, 1 each Pipe Cap, 12" Sch.

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

Code

~^

N 1 each riange, slip-on, It em No . 3, Distribution / Stock Code duT2501, 3" 1500 RF, S.S., ASTM A 182, F304, Heat dA1040 (1984), SMUD Stock Code 702512.

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

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

1 each, Flante, slip-on, Item No. 5, Distribution / Stock Code 4u72501,dCTV Carbon Steel, SMUD Stock 3" 1500 RT, ASTM A 105-83, Sch. So, Heat Code 70127 .

1 each, riange. 2" -

Item No. 6, Distribution / Stock Code #472501, #CTY, carbon steel 77 150d. SW RF, ASME III ND (C13) SA-105, Heat edition - 78 Addenda, SMUD Stock Code #1133u5.

Ites No. 7, tock Code su72501, 1 each Flange, slip-on, 5" - 1504 RF, CS, ASTM A 105, Heat #41971 (198u), SM')D stock code 1702395 fy Sff

l l

ATTACHMENT III Justification for Continued operation

y _

Attachment III Page 1 of 2 Justification for Continued Operation This Justification for Continued Operation was previously submit-ted with District letter CEO 88-092.

A. Purcose Four flanges were installed in the "A" TDI diesel generator fuel oil system which do not meet specification requirements. Engi-neering 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 materials supplied by West .7ersey Manufactur-ing and Piping Supplies, Incorporated.

B. Affected System / Safety Function of Affected System This Justification for Continued Operation affects the Emergency Generator System (USAR Section 8.2.3.1.2), specifically TDI die-sel 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 Die-sel Generators supply all AC loads necessary to ensure continued operation of essential reactor and station auxiliary equipment.

The District installed the TDI diesel generators to support the additional electrical loads resulting from "TMI modifications."

The Emergency Diesel 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 Train A, GEA supports bus 4A and GEA2 supports bus 4A2. Similarly, in Train B, GEB sup-ports bus 4B and GEB2 supports bus 4B2. Each train alone is suf-ficient to accomplish the safety function.

C. Effects on Safety Function / Analysis of Effects The heat number of the material in question is CFY. This mater-ial consists of 2-inch, 150# carbon steel flanges. These flanges are ASME III ND (C13), SA-105 material. A total of eight flanges with heat number CFY were received on site; three are in stock, one was scrapped, and the remaining four were installed in the "A" TDI diesel generator fuel oil system (two in each of two lines).

Attachment III Page 2 of 2 The maximum calculated combined pipe stress level for code com-pliance for the "A" TDI diesel fuel oil lines is less than 6000 psi. This figure results in a stress ratio on the fuel oil lines of less than 0.25 (Actual Stress / Allowable Stress). The maximum allowable pressure for a 150#-rated flange at a design tempera-ture of 125 0 F is approxima*ely 255 psig, whereas the design pres-sure of the system is only 100 psig. Hence, there exists a con-servative margin of safety of over 50%.

The actual tensile strength of the sample was 66,400 psi (see test results, Attachment II). The required tensile strength is 70,000 psi. This results in a reduction in tensile strength of 5.14%. Based on this slight reduction in strength of the flange, when compared to the conservative margin of safety which remains, Engineering has determined that an adequate margin of safety 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 certi-fication at the next availabic 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 TDI diesel generator GEA2. The TDI diesel gen-erators support the additional electrical loads resulting from "TMI modifications."

The heat number of the material in question is CFY. This mater-ial consists of 2-inch, 150# carbon steel flanges. These flanges are ASME III ND (Cl3), SA-105 material. Based on the minimal re-duction in measured strength of the flange when compared to the conservative margin of s&fety which remains, the Engineering evaluation concludes that an adequate margin of safety exists to justify the interim use of the flanges.