ML20198E063

Part 21 Rept Re Shipment by Dubose National Energy Svcs,Inc, of 40 Pieces of 4 inch,90 Degree Elbows Which Did Not Meet ASME Section II SA-234 Requirements

ML20198E063
Person / Time
Site:	Millstone, Columbia, Comanche Peak
Issue date:	01/07/1998
From:	Dailey J External (Affiliation Not Assigned)
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-98 NUDOCS 9801090004
Download: ML20198E063 (11)

Text

-- . - - _-. .. - .- - - - - . -

c. , dub,ose Nationcil Energy Services,Inc.

.r January 7,1998 Attn: NRC Operations Center Document Control Desk US Nuclear Regulatory Commission Washington,DC 20555

Subject:

10 CFR 21 Dear Sir; I am writing to pass along information provided to us by Tube Forg:ngs of Amenca (TFA), a qualified vendor of ours. TFA has informed us that material supplied to thern by USS/Kobe Steel was mixed at the mill.

DNES received 40 pieces of 4" 90" elbows and shipped them to our customers. The customers, order number *, and quantities are listed here.

i Washington Public Powa. 251756 20 Pieces 1 N E Nuclear 02017957 16 Pieces l TU Electric S02208826D2 3 Pieces SC Electric & Gas SR 700786 1 Piece i

Attached is a copy of the letter from TFA, and USS/Kobe Steel describing the problem in detail.

We have notified 6ne above customers so that they can evaluate the material which may j have been installed in their facility.

1 If you need any additional information please contact me at 1-910-590-2151.

Sincerely,

/8tw C'

f James N. Dailey i

QA Manager [/'h y ec: Carl Rogers Sales DNES Customers D00.ko!Oojj43 PDR: ll ll!lllll ]l rlllr .ll

...,e (910) 5%2151 = l-800-590-2150 = FAX (910) 5%3555 P.O. Box 499

• Clinton. NC 2832B l

'JAN. 5. I99Gl 32 $2tH TFA gg tube forgings _ .

OP AMEmeC A 4NC. ,

DECEMBER LL,1997 .

smoo N.w. rMONT . PORTL.AND, OREGON FT210

-u. . . .m . .

DUBOSE NATIONAL ENCROY PO BOX +99 CL!hTON, N.C.

28328 ATTN 1 LAMES D AILEY RE. POTENTIAL 10 CPR PART 21 DEAR MR. DAILEY AS A FOLLOW UP TO THE TFA AND US STEEL LETTERYOU RECEIVED AND BASED ON A REVIEW OF ORDERS OF MATERIAL SUPPLIED TO YOU, RE : YOUR PURCHASE ORDER #

11301-63,WE ARE ADVIS!NG YOU OF A POTENTIAL PFOBLEM WITH 4 S7D LR 90,40PCS, TFA HEAT CODE 0348.

A PARENT HEAT WAS FOUND AT TFA. DURINO SAMPLINO INSPEC770N, TO CONTAIN .18 MOLEDDENUM AND .76 CHROME.DUE TO THE ALLOYING ELEMENTS THE YTELD, TENSILE AND ELONOATION AS WELL AS THE CHEMIST"" TES NOT MEET ASME SEC U SA 234 ORWPB. THE TTA HEAT CODE WHICH HAD THE rAOBLEM WAS 0347 WEICH YOU NEVER RECE!VED, HOWEVER AFTER EVALUA710N BY US STEEL IT WAS DETERMINED BY THEM

. THAT HT 0348 IS ALSO SUSPECT.

%TTHOUT USING THE PROPER WELD PROCEDURES THE CHROME / MOLY MATERIAL WIL HAVE A HIGH HARDNESS UP TO 34 RC IN THE HAZ.WHICH CONTAINS LWTEMPERED MARTENSITE, B ASE MATERIAL HARDNESS CAN RANCE UP TO RC24 IN THE HOT PORMED CONDITION.

MATERIAL THAT IS LEFT !N YOUR STOCK SHOULD BE ISOLATED AND IF YOU DESIRE YOUR MAY OBTAING AN ROA FROM OUR SALES DEPART >ENT FOR CREDIT AND SEND THE MATERIAL RACK TO US. On YOU MAY WANT TO PERFORM A CHEM CHECX PER PIEC USING A SUITABLE METHOD . COSTS WILL BE REIMBURSED PER USS STEEL LITIER.

PLEASE NOTIFY US OF YOUR DESIRED COURSE OF ACTTON.

$ MATERIAL THAT IS OUT TN THE FTELD SHOULD BE DEALT WITH THE SAME.

5 WE APOLOGIZE FOR THIS INCONVENIENCE.

{

0

, SIN LY, r 6 EACbY

~o 0 MO . OF Q.A.& STA'!1STICS cc: PAT DENAVIDES TFA VP A.ND GENERAL MAN *.OER I

l 1  !SO 9002 Certised j

i f

1 i

-- . . - - . . -.- . . . . - . . . .- . . ~ _ . .. . ,

JAN. 5.1999 12:53PM TFA N04348 P.3/10 -

e tube forgings QP A,me M,c A Ime, smoo n.w. rnowT . comrue.o. emseas era. t e g g997 RE: 4 STD LR 90 A234WPB Fittings Heat Codes G347 & G348 4 STD 45 A234WPB Fittings Heat Cedes G347 & 0348 4a3,4x2.5,4x2 STD LR 90 A234WP5 Fitdngs Pfear Codes G347 & G348 Company Addre.ss City, Stata, Zip Artention: Quality Assursace Manager / Branch Mmager Gentlemen:

Wa are writing to pass along important inforrcation from US Steel regarding a mixed bes:/grude simadan on a shipment of tubular products received by 'Ibbe Forgings of America. Pain ame to Ove lengthe et pipe.

ont of a snipment of 1,614 lengths, was of a different heat / grade material nis shipment was used to manufacmre the above referenced fl: rings.

Baset. tm our records, you have received sotas of these 6ttin$s, no enclosed information from U.S. Semel describes che frrugulertcy in their shipsnent, and the resul:ios non conformance in some of the fimags

=e =4. Pienne noes the reinedial course of action recommandad by U.S. Steel, and that U.S. Sealis l

asseaung full responsibility for all costs of recall, grade vari 5cacion, replaeaaw'at, or other wesasary rume-dies. Dwe Salvsty of USS/Kobe Steel is standing by to assist you; at 1-800 227-7113 (eneer 2776 after the prompe, or dial 1-440 277-2776).

--We have asked U.S. Steel for venfication that conecdve actions are being taken to e.r4 the this non-conformance will not occur again. These cotractive accons are outlined in their Icw as well..

e We pledge to work with yoc to rmnimus any inconvenience. I hope you will es11 Pat Benevices,95cs W Preside.at/ General Manager. John Peschey. Quality Assmance Manager, or myestf, should you have any quesdous or concerns about U.S. Steel's resolution of the problem. We have set up a toll-free reumber at 7hbe Forgings of America for your use,1-800 291-3Cc6 (eneer 124 after the protupt).

We regrec any inconvenience you may exponence. We fully expect that you can continue to rely on the I dedicadon to superior service and a quality product which have been a haffmark of our company since 1955.

Sincerely, s

t

.E Jay N. Zidell

-ef President b

E 1

4 J % 5.1998- 22:53pr1 Tra gm ,

U'. S. Steet -  :

< .. sco arent sweet ,

. I- Pmseurgn. PA t$219 274s

- December 2,1997

.i To WhomIt May Concern:

Sabinet Mlaed Steel Heats B000$0 4 800056 3.laa x .270" wad Fittinas Pipe

Dear Sir:

During the routine tasdag of Stdags produced tom the subject heats at Tube Forgings of A +. lac, a suspected mixed semel was dewed. This suspicion was based ou '

=d=k=1 test results associated with a Stting that was tested. Chemical analysis of the suspect S ting further verlSai that the maserial used to ==*ture the fidos did not meet Tube Fongings of Amsrica's specifcation requir===en, nor did tbs resulting fiainhad Stdng meet all of the requirements of ASTM A234 WPB-96, Standard SpealScadon for Pipe Fittings of WrotJt Carbon Steel and Alloy Steel fer Moderate and High Temperature Service. Further tasting of the fluins, which was manufh hed kom l

' the Cr-Mo Alloy steel pipe pmdued by USS/Kobe Steel Company, showed test results which varied bom the speclEcazion m@au and wm unacceptable for ASTM A234 WPB-96.

ASTM A234 W/B-96 fittings produced hem these off-grade tangths ofpipe failsdto mest tha speciScation requiremsms in the following areas:

1. The alements Molybdanum (Mo) and Chromium (Cr) exceeded the d===at contents WA=d in ASTM A234-96a. Molybdanum and Chromima onuments

' of the referenced material are 0.19% and 0.76% respectively.

2. The Hardness values exoned the specifiestion limit of 197 BHN. Actual '

hardness values could be as high as 240 BHN.-

3. The Machanimal Propemes exceedthe requiremens of ASTM A234 WPB-96.

Elongation results also fh11 below the sninimum requirement of the specifloation.

Since you were a recipient of Sttings produced &o n the subject heat, you should prtunptly segregate the Rtungs idemiSed in Tube Forgings of America. Inc.'s ,

correspondence &cm your r=m*tata= inventory, and initis.e grade verEcation processes.

Whsre possible, you should recall and grade verify any r-aining Sttings or arrange fbr grade verincadon ofinstalled Sttings, If, as a recipient, you have sold or otherwise

{ .i

-- u. S. Steel Grouc

%,,,,,, /

A '. rut of USX Corporrtcr=

j

- , , , , , , , , - < - - ,,r, --

. .- -. . -- .-- = - _ . -- - - .

4 m . s.19ee- 22:54PM Tra gg ,

transferrtzi any fittings to your custorners, you should provide this notics to all transferees.

A!! racipien:s of these fittings will be reimbursed for reasonable oosta associated with locating, segregating. Stade verifying, and/or teptscing these questionable fittings.

All reciplants of these fittings abould clearly tedarstand that if you (thej) do not promptly comply with this notice, we will not be responsible for any assulting claima.

Corrective actions are being implemented at USS/Kobe Steel Company to preycot the recurrence of this situation. AR tubular products destined for TFA ftsting applications will be subjected to a grada verification east' prior to shipping.

< U. S. Steel Tubular Products and USS/Kobe sincerely zogret the inconvenience that this situation may cause. We do believe that the hoplemented corrective action shall, ., a a future recurrunce of & problem.

Any inquiries concaming & situadon should be directed to Dave Snively Tubular Products, at US3/Kobe Steel Company.

By phone, he can be reached by dialing 1 800 227-7113, and ti'an autering 2776 after the prompt; or by dialing 1 440-277-2776.

By email, ha enbe reached at topalovo@uaskoba.com By mall, ha can be reached at USS/Kobe Steel Company 1807 East 28* Street Lorain, Ohio 44055 Attention: Dave Sniwly Quality Assurance - Tubular Box,21A Very truly yows, Frank M11mls1d Manager,Metallegy & Quality Assurance '

' U. S. Steel Tubular Products . l

JAN. D.J998 ,12854PM TTA- gm p, g s *

1. ar==, s.ie L - _ r -

M M A D E M 5a WW K Mw R 4032 H. Cuner CircleIsas. 4to P.O. Bos 1.7126 r

• e. o

' m -

IN,TERTF*C

.50.t2891778 Fen: 28919)9 nioin.- andsm ame, w auib and NasweelMenness*

August 27,1997 Project EARX 97 0108 Raport 0547-2226 Mr. John Psechy Tube Forgings of America, Inc. ,

$200 Northwest Front Aven:a Portland, Oregon 97210

Dear Mr. Peachy:

Re: Chauncal and Mechanical Analysis perfberned on sesel fittings received on August 4,1997, pursuant to your Purchase Order Number P40149. '

Item: 4* STD, L/R 90* Elbows Heat Number G347, Cr-Mo Alloy

- 0956, ASTM A234 Orade WPB-96 Analysis (Units: % by weight)

!Il42 Car bo n (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 Manganese (Mn) ........................s,.... 1,27 l

Sillcon (El) ................................. 0.29 l

Nickel (NI) ............................... , 0.020 0,76 Chrornium (Cr) ...............................

Mol ybdenum (Mo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 0,010 Co pp er (Cu) . . . . . . . . . . , , , , , , . . . . . . . . . . . . . . . . .

Va nad ium (V) , , . . . . . . . . . , , . . , . . . . , , . . . . . . . . . <0.005 Aluusiemnt (A1) ........................,...,,. 0.010 Phosphorous (P) ......................... ..... 0.010 suttur (s) ................................... 0.006 Columbium (Cb) .......,,,....,,..,,,,,....... < 0.005

. Carbon Equivalent (AWS DI.1) . . . . . . . . . . . . . . . . . . . . . 0.68 l+

i i;

~

JAN. 5.3999 12:55m TTA - NO.1Q p.7/g3

'1%e Forgiass of America,Inc.

.* Project EARX-97-0108 Report 05 067-2226 .

.  !- August 27,1997 ,

Page 2 -

M.,hant,.I Analysis Yield Strength, 0.215 Other, psi - . . . . . . . . . . 103,700 91.800

'127,000 120,300 Tensus Strength, psi . . .. ...............

Elongadon in 2 lach, % . . . . i . . . . . . . . . . . 19.I 18.4 Reduction in Area, is . . . . . . . . . . . . . . . . . 53.7 45.0 Hardnans. 3HN,3,000 kg .............. 229 223 k

Charpy Isupact Tens Wald Hast Affected Zane,5 x 10mm e +20*F

. . . i ., . ....

'c . . . .

,,'/

, ,,i 'Jaapses5trungph,. - . ,' , l.at=4 , .: .

IkynnaloalImik l ' P%esent'#%sar

Esat bmberi , .Tast.W'unber , .

., 3 . ft. b.' ' . . ) ,

6 15 to 0347 1 6 16 10 d 2 Average 7 15,5 <

10 20 28 30 0956 1 2 20 30 30 Average 20 29 30 Weldabluty Test  ;

Raduced Section Tensile Strength Transverse to Wald Uldmate Tensu s Serength . . . . . . . . . . . . . . . '. . . . . . . 81,300 ps!

Location of Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . Wald Zone s

l

M . 5.1999 12355PM TF*A to. 2 4 P.8/m

.- Tube Forgings of Annarica, Inc.

Project EARX-974108 Repon 054s7-2226 .

Auses 27,1997 Pass 3 y

Gulded Band Tesu Root Bend ................................ Pansed Fat - Band ................................ Passed Hardness Survey, Rockwell G347 Base Meta! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C23.0 G 347 HAZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C34.5 W ald Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B87.5 0956 H AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581.0 0956 Base Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B56.0 Microstructure G934 Basa Metal Heavily banded (anisotropic)pearlita la a matrix of nne gralnad ferrite.

G984 HA2 at Fumian Une Ferrite delinenting prior austanits grala boundaries and large grain acicular ferrite mixed with flee pearlits.

G347 Base Masal Strue:ure consism of a misure of ferrita pearilts and raanensite.

G347 HAZ at Fusion Line Larger grain size consisting of ferrite. alloy carbides, banite and unnunpered martensite. *1111s structure la consistems with higher hardness valumn thund, c

S W.~5.1998 '22:55Prl TrA m,3 g p,p3g Tube Forgings of America, Inc.

Project EARX-97 010g

, .- Raport 05 og7 2226 ,

Aug at u,1991 Page 4 -

Waldabuky The finings were welded eastly using E6010 and E7018 electrodes with the SMAW process.

Visual and Magnetic Pardcle laspection after welding did not detecs any underbead or HAZ cracking. No peehaat was used. The welded fining was allowed to cool normally la ambient

' sit opedition aher 'weidlog. No dWouldas during welding wars observed.

Discussion .

Tests have shown tha Heat Number G341 (Cr-Mo alley) has a propensity fbr HAZ transformation to hard, brittle coasdtuents (untampered mansastre). 'ne result is a tandancy fbc -

" underbead (H AZ) cracking and high residual stress. .

The American Welding Society lists two (2) basic motbods fbr estiandag welding wh to avoid cold cracking.

• Hydrogen control e Heat affected zone hardness control Using tow hydrogen elecuade/ process with medium consusing the minimum preheat /laterpass '

, wyssuts tbr this maearial should be 2507

'De critical cooltag raza to contro! MAZ hartiness below Rockwell-C -36 is 41*F (5'C)/second.

These guldalines are based on a CE of 0.68 and Pcm of 0.36.

During welding o? the test fitting preheating, malatnamaca of incorpass tempensures and ooanol of coollas rata amts.agg perfbemed and although RAZ hardness is near the upper limit the critical hardness was not exceeded and cracking did not occur.

Itese tests have demonstrated that tfie Cr-Mo aUoy fittings can be successfully welded using procedure settable ibe welding A2.34, Grade WPB ftstings.

-no.sse p.se/20 ,

W . 5.199e 12sseen Tra .

l Tube Forgings of America, Inc. *

. l Project EARX47-0108 Report 05437 2226

' August 27,1997 Page 5 Jervices parcii.ad tbr this project have bass oceducted wkh hatlevd of cars sad sidit ordlearily exercised by members of es profession curraady praedcing in this area vede budget and time restraints. No warrancy, expressed or impiled, la made.

All work wu pedbemed la compliance with Brun Istenac Q.C. Mamal dated 02-23-94, Revision I and NDE Supplersees dated 06 0744, Revision 0.

We appreciera to oppormnhy to be of savios a you Should you Ewe any questions reg 6e coments of the report of h' we may be of futther asstsamco in any way, plause eoinact. us as (503) 975 4714 or (800) 78H9&$, e-mau pirishebrauncorp.com.

Sincarity, i

J p A

~

.M Taehafal Dtractcyr pl:sjg 4

36 sump *WetWmNesf4* dam)s. 7 i

OTHER NUCLEAR MATERIAL EVENT NUMBER: 33500 LICENSEE: DUBOSE 3ATIONAL ENERGY SERVICES,INC NOTIFICATION DATE 01/07/98 CITY: CLINTOhY REGION: 2 NOTIFICATION TIME: 10:00 [ET]

COUNTY: STATE: NC EVENT DATE: 01/07/98 LICENSE #: AGREEMENT: Y EVENT TIME: 10:00(EST)

DOCKET: LAST UPDATE DATE: 01/07/98 NOT!FICATIONS LAURIE PELTTSO, R1 RDO NRC NOTIFIED BY: JAMES N. DAILEY KEN BARR R2DO HQ OPS OFFICER: JOHN MacKINNON BLAIR SPITZBERG R4DO VERN HODGE NRR EMERGENC" CLASS: NOT APPLICABLE 10 CFR SECTION:

CDEG 21. 21(c) (3) (i) DEFECTS / NONCOMPLIANCE EVENT TEXT 10CFR PART 21 REPORT -

DUBOSE NATIONAL ENERGY SERVICES, INC, (DNES) SHIPPED A TOTAL OF 40 PIECES OF 4 INCH, 90 DEGREE ELBOWS WHICH DID NOT MEET ASME SEC II SA-234 REQUIREMENTS TO SEVERAL NUCLEAR POWER PLANTS.

TUBE FORGINGS OF AMERICA (TFA), A VENDOR OF DNES, NOTIFIED DNES THAT MATERIAL SUPPLIED TO TFA BY US STEEL /KOBE STEEL WAS MIXED AT THE MILL. FROM ONE TO FIVE LENG1HS OF PIPE, OUT OF A SHIPMENT OF 1,614 LENGTHS, WERE MADE OF A DIFFERENT HEAT / GRADE MATERIAL. THIS SHIPMENT WAS USED TO MANUFACTURE A TOTAL OF 40 PIECES OF 4 INCH, 90 DEGREE ELBOWS WHICH WERE SHIPPED TO THE FOLLOWING NUCLEAR POWER PIANTS:

CUSTOMER ORDER NUMBER QUANTITY WASHINGTON PUBLIC POWER 251756 20 PIECES NE NUCLEAR 02017957 16 PIECES TU ELECTRIC S02208826D2 3 PIECES SC ELECTRIC & GAS SR 700786 1 PIECE THE ABOVE CUSTOMERS WERE NOTIFIED OF THE PROBLEM.