Information Notice 1991-31, Nonconforming Magnaflux Magnetic Particle (14AM) Prepared Bath

Nonconforming Magnaflux Magnetic Particle (14AM) Prepared Bath

ML031190629
Person / Time
Site:	Beaver Valley, Millstone, Hatch, Monticello, Calvert Cliffs, Dresden, Davis Besse, Peach Bottom, Browns Ferry, Salem, Oconee, Mcguire, Nine Mile Point, Palisades, Palo Verde, Perry, Indian Point, Fermi, Kewaunee, Catawba, Harris, Wolf Creek, Saint Lucie, Point Beach, Oyster Creek, Watts Bar, Hope Creek, Grand Gulf, Cooper, Sequoyah, Byron, Pilgrim, Arkansas Nuclear, Three Mile Island, Braidwood, Susquehanna, Summer, Prairie Island, Columbia, Seabrook, Brunswick, Surry, Limerick, North Anna, Turkey Point, River Bend, Vermont Yankee, Crystal River, Haddam Neck, Ginna, Diablo Canyon, Callaway, Vogtle, Waterford, Duane Arnold, Farley, Robinson, Clinton, South Texas, San Onofre, Cook, Comanche Peak, Yankee Rowe, Maine Yankee, Quad Cities, Humboldt Bay, La Crosse, Big Rock Point, Rancho Seco, Zion, Midland, Bellefonte, Fort Calhoun, FitzPatrick, McGuire, LaSalle, Fort Saint Vrain, Shoreham, Satsop, Trojan, Atlantic Nuclear Power Plant
Issue date:	05/09/1991
From:	Rossi C Office of Nuclear Reactor Regulation
To:
References
IN-91-031, NUDOCS 9105070063
Download: ML031190629 (14)

UNITED STATES

NUCLEAR REGULATORY COMMISSION

OFFICE OF NUCLEAR REACTOR REGULATION

WASHINGTON, D.C. 20555 May 9, 1991 NRC INFORMATION NOTICE NO. 91-31: NONCONFORMING MAGNAFLUX MAGNETIC PARTICLE

(14AM) PREPARED BATH

Addressees

All holders of operating licenses or construction permits for nuclear power

reactors.

Purpose

This information notice is intended to alert addressees of a product recall

notice issued by the Magnaflux division of Illinois Tool Works Inc.

(Magnaflux), regarding their aerosol cans of fluorescent magnetic particle

prepared bath (14AM Magnaglo) (Attachment 1). The recall notice has been

transmitted by Magnaflux through its distribution channels; however, all

commercial nuclear and industrial end-users may not receive this information.

It is expected that recipients will review the information for applicability to

their facilities and consider actions, as appropriate, to avoid similar problems.

However, suggestions contained in this information notice do not constitute NRC

requirements; therefore, no specific action or written response is required.

Description of Circumstances

While under contract by Consumers Power Company, MQS Inspection, Inc. (MQS),

tested some aerosol cans of Magnaflux 14AM Magnaglo in accordance with the

American Society for Mechanical Engineers Boiler and Pressure Vessel Code

(ASME Code), Article 25, Standard SE-709, 1986 edition. MQS found the particle

concentration levels of batches 90F12P and 90HOlK to be out of compliance with

this ASME standard. Subsequently, nondestructive testing personnel of

Consumers Power Company performed a particle concentration check on batch

90F12P and confirmed the conclusion of MQS.

MQS notified Magnaflux of the deviation on February 11, 1991. On the basis of

this information, Magnaflux initiated an investigation on the particle

concentration levels of Magnaflux 14AM Magnaglo and, as part of its corrective

actions, issued the attached recall notice. Additional information on the

Magnaflux recall may be obtained by calling Magnaflux Customer Service at (708)

867-8000.

50 63 ZA

to4 IN 91-31 May 9, 1991 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact one

of the technical contacts listed below or the appropriate NRR project manager.

Qr es E. Ro~ss, i'rec-to

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts: Joseph J. Petrosino, NRR

(301) 492-0979 Nancy Campbell, NRR

(301) 492-0836 Attachments:

1. Magnaflux 14AM Aerosol Recall Notice

2. List of Recently Issued NRC Information Notices

Attachment 1

[4~IJX WAS LUXMayiI.A.

.... IN 91-31

9, 1991 14AM AEROSOL RECALL NOTICE

Testing has revealed that particle concentration may be out of specification in some aerosol cans

of 14AM in batches 90O11P, 90F12P, and.4OHO1K. Indications are that a very small percentage of

cans were affected. However, in order to avoid any possibility of the affected cans being used in

inspections, we are hereby recalling ihe three batches identified above.

Nature of the Deficiency

An intermittent problem occurred in the aerosol canning process. As a result, the particle

concentration may be light' (too few particles) in some cans, and 'heavy' (too many particles) ian

others. This only affected a small numbermf cmns in each batch. The vast majority of cans in these

batches are of the proper concentration.

Bulk 14AM. 14A Powder. Carrier 11 Are Unaffected

These products are not affected. The problem relates only to the aerosol canning process and not to

the materials themselves.

Corrective Action Has Been Taken

The source of the problem has been positively identified. Process changes have already been made

to prevent any recurrence, and appropriate Quality Control checks are in place. The problem has been

corrected in 14AM aerosol batches beginning with 91B03K. This material is in stock and available

for immediate shipment.

Recall Procedures

1. Telephone MAGNAFLUX Customer Service to request a Returned Goods Authorization and

shipping instructions -- (708) 867-8000.,

Please identify the number of cans you wish to return, the batch number(s) and where

purchased.

Inform MAGNAFLUX of any Sppcial circumstances, such as an urgent need for an interim

supply, until the replacement shipment arrives. We will make every effort to accommodate

everyone's needs.

2. Return material to MAGNAFLUX, De Witt Plant, freight collect.

3. Replacement material will be shipped to you directly, freight prepaid.

Other Aerosol Prodnct:

Only 14AM aerosol was affected.

Other Batches of 14AM

Because of a similarity in process, we are issuing a WARNING for batches 9DA01K, 90E02P,

90E03P, 90K08K, 91A02P, and 91A03P. No evidence has been found that these batches are

affected. Our investigation continues at this time, however, and in the event any evidence of further

errors is found, you will be informed immediately. No other batches are affected.

Recognition of the Problem in the Field

It is likely that an experienced inspector may notice a defective can as being 'light' in color or almost

devoid of particles under black light. Similarly, other cans might exhibit an abnormally high amount

of background. However, depending on field conditions and the type of parts being inspected, the

earor may not be obvious to the eye. The situation could be confirmed by discharging the contents into

a container and using a centrifuge tube to test settling volume--just as for a normal particle bath.

MAGNAFWX. A Division. of linots Tool Works Inc.

7300 West Lawrence Avenue IChicago, llihnois 60656 1 Telephone: 708-867.80001 Telex 277858 MAGX UR IFax 708.867-6833

VAGk4 tFLUX Page 2 Final Report: 14AM Recall

I. Introduction

A small percentage of cans from recent batches of 14AM aerosol have been found

to have a particle concentration outside MAGNAFLUX acceptance specifications.

This report summarizes the investigation of the problem and outlines the

corrective actions taken. The bulk material is manufactured at the MAGNAFLUX

manufacturing facility in De Witt, Iowa and is canned by two contract fillers, IKI,

of Edgerton, WI, and Plaze, Incorporated of St. Louis, MO.

MAGNAFLUX has recalled the following batches:

90EOIP

90F12P

90HOIK

II. Nature of the Problem

MAGNAFLUX was first notified of a possible problem on February 11, 1991, by

Wilmer Blankenship of MQS Inspection, Inc., who contacted Mathew Plamoottil, Quality Control Manager, De Witt Manufacturing Plant.

Wilmer reported that testing of cans from two batches, 90F12P and 9OHOlK had

produced the following results:

Table 1 MQS Data, Batches 90F12P & 90HOlK

MAGNAFLUX 90F12P 90HOlK

Control Limits

Particle .25-.40 .08 1.03 Concentration .09 1.02 (ml/100 ml bath) 1.50 3.00

III. Investiga-tion

A. Testing of MAGNAFLUX Retain Samples

The retain samples of both of these batches were checked; all were within

the control limits. Mr. Plamoottil requested that Mr. Blankenship return

the suspect cans for confirmation.

MAGNAFWX. A Drvision of Illinois Tool Works Inc.

7300 West Lawrence Avenue I Chicago. Illinois 606561 Telephone: 708-867-80001 Telex:

277858 MAGX UR I Fax: 708-867-6833

Page 3

B. Development of a Standard Test Method

A standard testing method was developed to eliminate variables from the

testing procedure. For example, if not properly shaken throughout the

expulsion, an artificially low reading would be attained. If, on the other

hand, a can had been used for some time and had not been well shaken, and

then tested, an artificially high reading would be attained.

Only new cans were tested (verified by inspection of the spray tip and

weight). All material was evacuated from the can into a glass beaker, and

the can was cut open to verify that no particles remained.

C. First Visit to IKI

Since MAGNAFLUX had a scheduled canning run of two totes of 14AM

(5000 cans each), Mr. Plamoottil visited IKI on February 14. The run was

completed with no breaks and assigned batch # 91B03K.

Samples were taken from ungassed cans from the line at the beginning, middle, and end of each tote (Table 2). Mr. Plamoottil provided written

instruction to both canners to perform these tests on all suspended particle

products until further notice (See attached document).

Soon after the batch was delivered to De Witt, a can was pulled from every

pallet layer and tested for concentration (Table 3). Beginning with this

batch, IKI stamped each can with a serialized number.

Table 2 Data Taken at IKI During Run of Batch #91K03K

Particle

Concentration

l_ (ml/100 ml bath)

Tote 1 Beginning .30

Middle .27 End .30

Tote 2 Beginning .30

Middle .30

End .30

i

Page 4 Table 3 Batch #91B03K--Each Pallet Layer

Serial I Particle Serial I Particle

Concentration Concentration

(mi/100 ml bath) (mnl100 mI bath)

493 .29 3022 .30

703 .28 3061 .30

933 .28 3384 .28

990 .29 3719 .23

1076 .28 4414 .31

1581 .30 4379 .31

1968 .30 4629 .30

2010 .30 4650 .30

24131 .29 4836 .30

2623 .30 5057 .29

2956 .30 5192 .30

D. MOS Visit to Chicago Lab

On Tuesday, February 26, Ron Faloon, Executive Vice President of

MQS and Mr. Blankenship visited the Chicago office. We discussed

what steps had been taken so far, and assured them of our

commitment to uncover the cause of the problem and correct it. Cans

from the two suspect batches were run, the results of which confirmed

the results earlier obtained by Mr. Blankenship.

Assured that the most recent batch, 91B03K, was a good batch, Mr.

Faloon indicated they would replace all returned material with this

batch. We agreed that when the cause of the problem was determined

and corrected, we would invite them to audit us at De Witt and at

each canning facility.

E. Visit to Plaza

In order to determine the cause of the concentration inconsistency, one-tote runs were scheduled at each canning facility. Plaze was

visited March 5 and 6, by myself, Mr. Plamoottil, and Cheri Zeleznik

and Sei Song from the Chem Lab. The cause of the problem was

traced to inadequate mixing of the filling material during line shut

downs.

-

• 6 Page 5 During filling, material is pumped from the bottom of the tote

through a pipe and hose to a hopper. The filling is triggered by a

level sensor in the hopper, and during normal operation occurs every

30-40 seconds. Between tote and filler nozzle, there is a total volume

of 4 gallons, including the hopper (1-2 gallons).

Although material was being mixed constantly in the tote throughout

the run, no mixer was present in the hopper. If the line were to shut

down for an extended period of 30 minutes or more, particles would

settle in the hopper and in the transfer plumbing, causing uneven

particle distribution in the resulting cans. To confirm this, the line

was shut down for 30 minutes with material in the lines and restarted

without mixing. The resulting cans were out of specification.

F. Visit to IKI

IKI was visited March 14 by Mr. Fijalkowski and Ms. Zeleznik.

Similar to Plaze, the plumbing between tote and filler nozzle is about

4 gallons. Although a mixer had always been used in the hopper, no

special precautions had been taken during break periods to prevent

particles from settling.

G. Concluson

1. Scope of Problem

Any batch which might have been subject to a 30 minute break or

more during its run might have as many as 80 cans per break

affected. For two breaks in a 10,000 can run, this would amount

to 1.5% of the total.

2. Other Products Affected

Only 14AM, 7CF, and 9CM have fast enough settling rates to have

been affected. 7CF and 9CM, however, are canned from drums

and are run continuously from start to finish without break.

3. Other Batches of 14AM

Records were requested from both canners on the number and

duration of all breaks during from all previous batches of 14AM

(See Appendix 1). Based on these data, batches 9NEOWP, 90E02P,

90E03P, 90F12P, 91A02P, 91A03P, 9OAO1K, 90HO1K, and 90K08K

might have been affected.

To date, based on testing of cans returned from the field, only

cans from batches 90F12P, 9OE01P, and 90HOlK have been

verified to have cans outside MAGNAFLUX control limits (See

Page 6 Appendix 2).

Batches prior to those listed in Appendix 1 were either canned

from drums and not subject to long break periods or were canned

by MAGNAFLUX. Batches starting with 91B03K were not

subject to the conditions which caused the problem.

IV. Corrective Action

A. Written Procedures

Both IKI and Plaze have been given the following in writing:

1. Settling Test Procedure

2. Setup Procedure

. Fit tote with double prop mixer blade at bottom of tank.

. Mix and recirculate through bottom valve back into tote for 30

minutes.

. Sample tote for settling test.

. On approval from QC, fill hopper and start mixer.

3. Filling Instructions:

. Mixers shall be on throughout run.

. For any break in line operation, empty transfer plumbing back

into tote.

. For breaks longer than one hour, recirculate for 30 minutes

before restarting.

4. OC Procedure

Sample ungassed cans from the beginning, middle, and end of

each tote.

5. Training

. A request to train all personnel making them sensitive to the

quick settling rate of 14AM, 7CF, and 9CM particles.

B. Training of MAGNAFLUX Personnel

MAGNAFLUX personnel shall be trained to respond to customer

quality complaints by:

Immediately informing the appropriate Product Manager, the Sales

Representative, and Sales Manager.

Page 7 C. Recall/Warning Issued

MAGNAFLUX has recalled the following batches:

9OEOIP

90F12P

90HO1K

Although no evidence has been found, due a similarity in process, MAGNAFLUX has also issued a WARNING for the following

batches:

9OAO1K 90E02P

90E03P 90K08K

91A02P 91A03P

Our investigation continues at this time and in the event any evidence

of further errors is found, you will be informed immediately.

No other batches are affected.

Page 8 Appendi z

14AM Batches Using Totes

Recall Issued

Batch # -Can

90EO1P 10,284

90F12P 10,711

90HO1K 10,716

Warning Issued

90E02P/9OE03P 3,924

9OAOK 10,465

90K08K 10,180

91A02P 3,996

9IA03P 10,560

Not Affected

89J04K/89JO5K 8,984

89L04K 10,564

90C06K 10,716

90KO1K(Gov't.) 3,770

91B03K 10,536

91COlP 10,560

91COlK* 2,650

All subsequent batches are not affected.

K)

Attachment 2 IN 91-31 May 9, 1991 LIST OF RECENTLY ISSUED.

NRC INFORMATION NOTICES

Information Date of

Subject Issuance Issued to

Notice No.

Inadequate Calibration of 04/23/91 All fuel cycle licensees and

91-30 other licensees routinely

Thermoluminescent Dosi- meters Utilized to Monitor handling unshielded uranium

Extremity Dose at Uranium materials.

Processing and Fabrication

Facilities

Recognition of American 04/16/91 All holders of OLs or CPs

86-21, for nuclear power reactors

Supp. 2 Society of Mechanical Engi- neers Accreditation Pro- and all recipients of

gram for N Stamp Holders NUREG-0040, Licensee Con- tractor and Vendor Inspection

Status Report' (White Book).

Deficiencies Identified 04/15/91 All holders of OLs or

91-29 CPs for nuclear power

During Electrical Distri- bution System Functional reactors.

Inspections

Cracking in Feedwater 04/15/91 All holders of OLs or

91-28 CPs for pressurized water

System Piping

reactors (PWRs).

Incorrect Rotation of 04/10/91 All holders of OLs or

91-27 CPs for nuclear power

Positive Displacement Pump

reactors.

Pressurizer Safety Valve 04/10/91 All holders of OLs or

89-90, CPs for nuclear power

Supp. 1 Lift Setpoint Shift

reactors.

Potential Nonconservative 04/02/91 All fuel cycle licensees

91-26 and other licensees, in- Errors in the Working Format

Hansen-Roach Cross-Section cluding all holders of

Set Provided with The Keno operating licenses for

and Scale Codes nuclear power reactors, who use physics codes to

support criticality

safety in the use of

fissile material.

OL = Operating License

Cp = Construction Permit

IN 91-31 May 9, 1991 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact one

of the technical contacts listed below or the appropriate NRR project manager.

Charles E. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts: Joseph J. Petrosino, NRR

(301) 492-0979 Nancy Campbell, NRR

(301) 492-0836 Attachments:

1. Magnaflux 14AM Aerosol Recall Notice

2. List of Recently Issued NRC Information Notices

• SEE PREVIOUS CONCliRANCE%,

XOE*3NP F ' *C/OGCB:DOEA:NRR *RPB:ADM *MQS Inspection

Ceiffosft' CHBerlinger TechEd JFaloon

05/7/91 05/01/91 04/24/91 04/26/91

• OGCB:DOEA:NRR*RVIB:DRIS:NRR *C/RVIB:DRIS:NRR *D/DRIS:NRR *Magnaflux Corp.

NCampbell JJPetrosino GCwalina BKGrimes JChase

04/25/91 04/25/91 04/26/91 04/26/91 04/25/91 OFFICIAL RECORD COPY

Document Name: IN 91-31

IN 91-XX

April xx, 1991 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact one

of the technical contacts listed below or the appropriate NRR project manager.

Charles E. Rossi, Director

Division of Operational Events Assessment

~ Office of Nuclear Reactor Regulation

Technical Contacts:A Petrosino, NRR

(301) 492-0979 Nancy Campbell, NRR

(301) 492-0836 Attachments:

1. Magnaflux Magnetic Particle (14AM) Prepared

Bath Recall Notice

2. List of Recently Issued NRC Information Notices

Document Name: INFO NOTICE - CAMPBELL

• SEE PREVIOUS CONCURRENCES

D/DOEA:NRR C/OG

CERossi CHBerlinger

04/ /91 QK/ 1/91 OGCB:DOEA:NRR RyW :NRR A

//BR 4 :NRR ,8)bRIS:NRR *RPB:ADM

NCampbel iA4 J sino GCwalina (jK~rimes TechEd

04/2r/91 ' sft 04/,Z791 04/A/91 {4/591 04/24/91 Hag 4ux Corporation I 4) S :7r&5w4 e

I

.

XT 1a

A.

J00n-1

, Exew. 11P by c eo

1.&

. 7-,AV

F70db) 8 47-3. 9' O (0) -9 / .5777

- a

IN 91-XX

April xx, 1991 Page 2 of

This information notice requires no specific action or written response. If

• 2rtx.

you have any questions about the information in this notice, please contact We

technical contact'listed below or the appropriate NRR project manager. 8 Charles E. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts: Joe Petrosino, NRR

(301) 492-0979 Nancy Campbell, NRR

(301) 492-0836 Attachments:

1. Magnaflux Magnetic Particle (14AM) Prepared

Bath Recall Notice

2. List of Recently Issued NRC Information Notices

Document Name: INFO NOTICE - CAMPBELL

D/DOEA:NRR C/OGCB:DOEA:NRR

CERossi CHBerlinger

04/ /91_ 04/ /91 OGCB:DOEA:NRR RVIB:DRIS:NRR C/RVIB:DRIS:NRR D/DRIS:NRR

NCampbell JJPetrosino BKGrimes TechEi

04/ /91 04/ /91 04/ /91 04/ /91 04 P7/91