NRC Bulletin 87-02

Fastener Testing to Determine Conformance with Applicable Material Specifications

November 6, 1987

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Bulletin 87-02: Fastener Testing to Determine Conformance with Applicable Material Specifications

SSINS No.: 6820

OMB No.: 31500011

NRC Compliance

Bulletin 87-02

UNITED STATES

NUCLEAR REGULATORY COMMISSION

OFFICE OF NUCLEAR REACTOR REGULATION

WASHINGTON, D.C. 20555

November 6, 1987

NRC COMPLIANCE BULLETIN NO. 87-02: FASTENER TESTING TO DETERMINE CONFORMANCE

WITH APPLICABLE MATERIAL SPECIFICATIONS

Addressees:

All holders of operating licenses or construction permits for nuclear power

reactors.

Purpose:

The purpose of this bulletin is to request that licensees 1) review their

receipt inspection requirements and internal controls for fasteners and

2) independently determine, through testing, whether fasteners (studs, bolts,

cap screws and nuts) in stores at their facilities meet required mechanical

and chemical specification requirements.

Description of Circumstances:

Over the past year, some NRC procurement inspections have included the col-

lection and testing of a small sample of fasteners. This limited program was

initiated in response to a concern by the Industrial Fastener Institute over

the potential use of inferior fasteners in military and industrial

applications, including nuclear power plants. The results of NRC testing of

fasteners obtained from San Onofre, Palo Verde and Rancho Seco indicates that

11 out of the 32 fasteners tested do not meet specification requirements for

mechanical and/or chemical properties. Nine of the nonconforming bolts from

Palo Verde and San Onofre were out of specification based on chemistry. Five

nonconforming bolts came from Palo Verde and were all marked as SAE Grade 8

but were actually found to be SAE Grade 8.2. The four nonconforming fasteners

from San Onofre were slightly out of specification for nickel or chromium.

Two bolts from Rancho Seco with ASTM A193 B7 head markings were determined to

have an average ultimate tensile strength of approximately 55 ksi instead of

the specified 125 ksi for ASTM A193 B7 bolting material. The chemical

analysis of these bolts indicated that they were medium carbon steel material.

Rancho Seco is still investigating the extent and safety significance of these

substandard fasteners.

In a separate effort, Calvert Cliffs recently tested 1539 fasteners following

their discovery that commercial grade fasteners had been used in

safety-related applications. The test results indicated that 399 failed to

meet specification requirements for mechanical and/or chemical properties.

Based on evaluations performed by Calvert Cliffs, the fasteners which did not

meet specification would have still fulfilled their safety function.

Actions to be Taken:

The results of the limited testing described above have demonstrated the need

to obtain additional information on the adequacy of fasteners used in nuclear

power plants.

Within 60 days from the receipt of this bulletin, licensees are requested to

provide the following information concerning their receipt inspection and

internal control procedures for fasteners and the results of independent

testing of fasteners:

1. Describe a) the characteristics currently examined during receipt

inspection of fasteners (i.e., head markings for grade and manufacturer

symbols, review of certified material test report or certificate of

conformance), and b) internal controls utilized during storage and

issuance from stock to assure the appropriate use of fasteners.

2. Select a minimum sample of ten (10) non-safety related fasteners (studs,

bolts, and/or cap screws), and ten (10) safety-related fasteners (studs,

bolts, and/or cap screws) from current, in use, stock. The sample is to

be obtained by the licensee with the participation of an NRC inspector.

Fasteners procured to meet the following chemical and mechanical

properties are of interest: A-193 grades B7, B8, and B16; SAE J429

grades 5 and 8; A-449; A-325 Types 1,2 or 3; A-354 grades BB, BC, BD;

A-490; A-320 LTM; A-307; A-563; or equivalent.

3. For the selected sample of fasteners in item 2, include a sample of

typical nuts that would be used with each fastener (one-for-one). In

particular, nuts purchased to the chemical and mechanical speci-fications

of A-194 are of interest.

4. Chemical testing shall be performed on all samples. Mechanical testing

shall be performed on each safety-related fastener. Hardness testing

shall be performed on each nut and non-safety-related fastener. All

testing shall be performed by a laboratory which the licensee has quali-

fied for this type of testing and appears on the licensee's approved

vendor list. Testing performed shall be done in accordance with the

requirements of the fastener's specification, grade, and class, and the

test shall evaluate the ultimate tensile strength, hardness and chemical

properties as required by the fastener's specification, grade, and class.

Each sample shall be tagged with the sample's ID number.

5. The results of all tests, together with supporting information, are to be

reported to the NRC utilizing the format shown in Attachments 1 and 2 of

this bulletin. Include the names and addresses of suppliers and

manufacturers of safety-related fasteners and, to the extent possible, of

non-safety-related fasteners. For any fastener found out of specifica-

tion, provide an evaluation of the safety significance including

consideration of the most limiting application.

6. Based on the results of the testing and review of current procedures,

describe any further actions being taken to assure that fasteners used in

the plant meet the requisite specifications and requirements and that the

operability of safety-related plant components is not affected.

The written reports shall be submitted to the appropriate Regional

Administrator under oath or affirmation under provisions of Section 182a,

Atomic Energy Act of 1954, as amended. Also, the original copy of the cover

letters and a copy of the reports shall be transmitted to the U.S. Nuclear

Regulatory Commission, Document Control Desk, Washington, D.C., 20555 for

reproduction and distribution.

This request for information was approved by the Office of Management and

Budget under a blanket clearance number 31500011. Comments on burden and

duplication may be directed to the Office of Management and Budget, Reports

Management, Room 3208, New Executive Office Building, Washington, D.C., 20503.

If you have any questions about this matter, please contact one of the

technical contacts listed below or the Regional Administrator of the

appropriate regional office.

Charles E. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts: J. T. Conway, NRR

(301) 492-9740

E. T. Baker, NRR

(301) 492-4783

J. C. Harper, NRR

(301) 492-4143

Attachments:

1. Fastener Testing Data Sheet

2. Data Summary

3. List of Recently Issued Bulletins

.

Attachment 1

Fastener Testing Data Sheet

• Sample ID#

Fastener Description:

Description of Sample Stock Location:

Material Specification as Documented by Licensee Records:

Head Marking (Specification and Manufacturer):

• • Class/Procurement Level:

General Plant Application (e.g., Pressure Boundary, Structural)

Vendor:

QA Requirements Imposed on Vendor:

Licensee Representative:

Signature Date

• The sample ID# shall have a prefix that contains the licensee facility

initials.

• • If applicable, please provide an explanation for your classification system.