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 E Office of Nuclear Reactor Regulation
To:
References
IN-91-031, NUDOCS 9105070063
Download: ML031190629 (14)

UNITED STATESNUCLEAR REGULATORY COMMISSIONOFFICE OF NUCLEAR REACTOR REGULATIONWASHINGTON, D.C. 20555May 9, 1991NRC INFORMATION NOTICE NO. 91-31: NONCONFORMING MAGNAFLUX MAGNETIC PARTICLE(14AM) PREPARED BATH

Addressees

All holders of operating licenses or construction permits for nuclear powerreactors.

Purpose

This information notice is intended to alert addressees of a product recallnotice issued by the Magnaflux division of Illinois Tool Works Inc.(Magnaflux), regarding their aerosol cans of fluorescent magnetic particleprepared bath (14AM Magnaglo) (Attachment 1). The recall notice has beentransmitted by Magnaflux through its distribution channels; however, allcommercial nuclear and industrial end-users may not receive this information.It is expected that recipients will review the information for applicability totheir facilities and consider actions, as appropriate, to avoid similar problems.However, suggestions contained in this information notice do not constitute NRCrequirements; 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 theAmerican Society for Mechanical Engineers Boiler and Pressure Vessel Code(ASME Code), Article 25, Standard SE-709, 1986 edition. MQS found the particleconcentration levels of batches 90F12P and 90HOlK to be out of compliance withthis ASME standard. Subsequently, nondestructive testing personnel ofConsumers Power Company performed a particle concentration check on batch90F12P and confirmed the conclusion of MQS.MQS notified Magnaflux of the deviation on February 11, 1991. On the basis ofthis information, Magnaflux initiated an investigation on the particleconcentration levels of Magnaflux 14AM Magnaglo and, as part of its correctiveactions, issued the attached recall notice. Additional information on theMagnaflux recall may be obtained by calling Magnaflux Customer Service at (708)867-8000.50 63 ZA to4IN 91-31May 9, 1991 This information notice requiresyou have any questions about theof the technical contacts listedno specific action or written response. Ifinformation in this notice, please contact onebelow or the appropriate NRR project manager.Qr es E. Ro~ss, i'rec-toDivision of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical Contacts:Joseph J. Petrosino, NRR(301) 492-0979Nancy Campbell, NRR(301) 492-0836

Attachments:

1. Magnaflux 14AM Aerosol Recall Notice2. List of Recently Issued NRC Information Notices Attachment 1[4~IJX ....IN 91-31WAS iI.A. LUXMay 9, 1991 4AM AEROSOL RECALL NOTICETesting has revealed that particle concentration may be out of specification in some aerosol cansof 14AM in batches 90O11P, 90F12P, and.4OHO1K. Indications are that a very small percentage ofcans were affected. However, in order to avoid any possibility of the affected cans being used ininspections, we are hereby recalling ihe three batches identified above.Nature of the DeficiencyAn intermittent problem occurred in the aerosol canning process. As a result, the particleconcentration may be light' (too few particles) in some cans, and 'heavy' (too many particles) ianothers. This only affected a small numbermf cmns in each batch. The vast majority of cans in thesebatches are of the proper concentration.Bulk 14AM. 14A Powder. Carrier 11 Are UnaffectedThese products are not affected. The problem relates only to the aerosol canning process and not tothe materials themselves.Corrective Action Has Been TakenThe source of the problem has been positively identified. Process changes have already been madeto prevent any recurrence, and appropriate Quality Control checks are in place. The problem has beencorrected in 14AM aerosol batches beginning with 91B03K. This material is in stock and availablefor immediate shipment.Recall Procedures1. Telephone MAGNAFLUX Customer Service to request a Returned Goods Authorization andshipping instructions -- (708) 867-8000.,Please identify the number of cans you wish to return, the batch number(s) and wherepurchased.Inform MAGNAFLUX of any Sppcial circumstances, such as an urgent need for an interimsupply, until the replacement shipment arrives. We will make every effort to accommodateeveryone'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 14AMBecause 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 areaffected. Our investigation continues at this time, however, and in the event any evidence of furthererrors is found, you will be informed immediately. No other batches are affected.Recognition of the Problem in the FieldIt is likely that an experienced inspector may notice a defective can as being 'light' in color or almostdevoid of particles under black light. Similarly, other cans might exhibit an abnormally high amountof background. However, depending on field conditions and the type of parts being inspected, theearor may not be obvious to the eye. The situation could be confirmed by discharging the contents intoa 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 I Chicago, llihnois 60656 1 Telephone: 708-867.80001 Telex 277858 MAGX UR I Fax 708.867-6833 VAGk4 tFLUX Page 2Final Report: 14AM RecallI. IntroductionA small percentage of cans from recent batches of 14AM aerosol have been foundto have a particle concentration outside MAGNAFLUX acceptance specifications.This report summarizes the investigation of the problem and outlines thecorrective actions taken. The bulk material is manufactured at the MAGNAFLUXmanufacturing 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:90EOIP90F12P90HOIKII. Nature of the ProblemMAGNAFLUX was first notified of a possible problem on February 11, 1991, byWilmer 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 hadproduced the following results:Table 1MQS Data, Batches 90F12P & 90HOlKMAGNAFLUX 90F12P 90HOlKControl LimitsParticle .25-.40 .08 1.03Concentration .09 1.02(ml/100 ml bath) 1.50 3.00III. Investiga-tionA. Testing of MAGNAFLUX Retain SamplesThe retain samples of both of these batches were checked; all were withinthe control limits. Mr. Plamoottil requested that Mr. Blankenship returnthe 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 3B. Development of a Standard Test MethodA standard testing method was developed to eliminate variables from thetesting procedure. For example, if not properly shaken throughout theexpulsion, an artificially low reading would be attained. If, on the otherhand, a can had been used for some time and had not been well shaken, andthen tested, an artificially high reading would be attained.Only new cans were tested (verified by inspection of the spray tip andweight). All material was evacuated from the can into a glass beaker, andthe can was cut open to verify that no particles remained.C. First Visit to IKISince MAGNAFLUX had a scheduled canning run of two totes of 14AM(5000 cans each), Mr. Plamoottil visited IKI on February 14. The run wascompleted 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 writteninstruction to both canners to perform these tests on all suspended particleproducts until further notice (See attached document).Soon after the batch was delivered to De Witt, a can was pulled from everypallet layer and tested for concentration (Table 3). Beginning with thisbatch, IKI stamped each can with a serialized number.Table 2Data Taken at IKI During Run of Batch #91K03KParticleConcentrationl_ (ml/100 ml bath)Tote 1 Beginning .30Middle .27End .30Tote 2 Beginning .30Middle .30End .30 iPage 4Table 3Batch #91B03K--Each Pallet LayerSerial I Particle Serial I ParticleConcentration Concentration(mi/100 ml bath) (mnl100 mI bath)493 .29 3022 .30703 .28 3061 .30933 .28 3384 .28990 .29 3719 .231076 .28 4414 .311581 .30 4379 .311968 .30 4629 .302010 .30 4650 .3024131 .29 4836 .302623 .30 5057 .292956 .30 5192 .30D. MOS Visit to Chicago LabOn Tuesday, February 26, Ron Faloon, Executive Vice President ofMQS and Mr. Blankenship visited the Chicago office. We discussedwhat steps had been taken so far, and assured them of ourcommitment to uncover the cause of the problem and correct it. Cansfrom the two suspect batches were run, the results of which confirmedthe 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 thisbatch. We agreed that when the cause of the problem was determinedand corrected, we would invite them to audit us at De Witt and ateach canning facility.E. Visit to PlazaIn order to determine the cause of the concentration inconsistency,one-tote runs were scheduled at each canning facility. Plaze wasvisited March 5 and 6, by myself, Mr. Plamoottil, and Cheri Zeleznikand Sei Song from the Chem Lab. The cause of the problem wastraced to inadequate mixing of the filling material during line shutdowns.-

• 6Page 5During filling, material is pumped from the bottom of the totethrough a pipe and hose to a hopper. The filling is triggered by alevel sensor in the hopper, and during normal operation occurs every30-40 seconds. Between tote and filler nozzle, there is a total volumeof 4 gallons, including the hopper (1-2 gallons).Although material was being mixed constantly in the tote throughoutthe run, no mixer was present in the hopper. If the line were to shutdown for an extended period of 30 minutes or more, particles wouldsettle in the hopper and in the transfer plumbing, causing unevenparticle distribution in the resulting cans. To confirm this, the linewas shut down for 30 minutes with material in the lines and restartedwithout mixing. The resulting cans were out of specification.F. Visit to IKIIKI was visited March 14 by Mr. Fijalkowski and Ms. Zeleznik.Similar to Plaze, the plumbing between tote and filler nozzle is about4 gallons. Although a mixer had always been used in the hopper, nospecial precautions had been taken during break periods to preventparticles from settling.G. Concluson1. Scope of ProblemAny batch which might have been subject to a 30 minute break ormore during its run might have as many as 80 cans per breakaffected. For two breaks in a 10,000 can run, this would amountto 1.5% of the total.2. Other Products AffectedOnly 14AM, 7CF, and 9CM have fast enough settling rates to havebeen affected. 7CF and 9CM, however, are canned from drumsand are run continuously from start to finish without break.3. Other Batches of 14AMRecords were requested from both canners on the number andduration 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 90K08Kmight have been affected.To date, based on testing of cans returned from the field, onlycans from batches 90F12P, 9OE01P, and 90HOlK have beenverified to have cans outside MAGNAFLUX control limits (See Page 6Appendix 2).Batches prior to those listed in Appendix 1 were either cannedfrom drums and not subject to long break periods or were cannedby MAGNAFLUX. Batches starting with 91B03K were notsubject to the conditions which caused the problem.IV. Corrective ActionA. Written ProceduresBoth IKI and Plaze have been given the following in writing:1. Settling Test Procedure2. Setup Procedure.Fit tote with double prop mixer blade at bottom of tank..Mix and recirculate through bottom valve back into tote for 30minutes..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 backinto tote..For breaks longer than one hour, recirculate for 30 minutesbefore restarting.4. OC ProcedureSample ungassed cans from the beginning, middle, and end ofeach tote.5. Training.A request to train all personnel making them sensitive to thequick settling rate of 14AM, 7CF, and 9CM particles.B. Training of MAGNAFLUX PersonnelMAGNAFLUX personnel shall be trained to respond to customerquality complaints by:Immediately informing the appropriate Product Manager, the SalesRepresentative, and Sales Manage Page 7C. Recall/Warning IssuedMAGNAFLUX has recalled the following batches:9OEOIP90F12P90HO1KAlthough no evidence has been found, due a similarity in process,MAGNAFLUX has also issued a WARNING for the followingbatches:9OAO1K 90E02P90E03P 90K08K91A02P 91A03POur investigation continues at this time and in the event any evidenceof further errors is found, you will be informed immediately.No other batches are affecte Page 8Appendi z14AM Batches Using TotesRecall IssuedBatch # -Can90EO1P 10,28490F12P 10,71190HO1K 10,716Warning Issued90E02P/9OE03P 3,9249OAOK 10,46590K08K 10,18091A02P 3,9969IA03P 10,560Not Affected89J04K/89JO5K 8,98489L04K 10,56490C06K 10,71690KO1K(Gov't.) 3,77091B03K 10,53691COlP 10,56091COlK* 2,650All subsequent batches are not affecte K)Attachment 2IN 91-31May 9, 1991 LIST OF RECENTLY ISSUED.NRC INFORMATION NOTICESInformation Date ofNotice No. Subject Issuance Issued to91-3086-21,Supp. 291-2991-2891-2789-90,Supp. 1Inadequate Calibration ofThermoluminescent Dosi-meters Utilized to MonitorExtremity Dose at UraniumProcessing and FabricationFacilitiesRecognition of AmericanSociety of Mechanical Engi-neers Accreditation Pro-gram for N Stamp HoldersDeficiencies IdentifiedDuring Electrical Distri-bution System FunctionalInspectionsCracking in FeedwaterSystem PipingIncorrect Rotation ofPositive Displacement PumpPressurizer Safety ValveLift Setpoint ShiftPotential NonconservativeErrors in the Working FormatHansen-Roach Cross-SectionSet Provided with The Kenoand Scale Codes04/23/91 All fuel cycle licensees andother licensees routinelyhandling unshielded uraniummaterials.04/16/91 All holders of OLs or CPsfor nuclear power reactorsand all recipients ofNUREG-0040, Licensee Con-tractor and Vendor InspectionStatus Report' (White Book).04/15/91 All holders of OLs orCPs for nuclear powerreactors.04/15/91 All holders of OLs orCPs for pressurized waterreactors (PWRs).04/10/91 All holders of OLs orCPs for nuclear powerreactors.04/10/91 All holders of OLs orCPs for nuclear powerreactors.04/02/91 All fuel cycle licenseesand other licensees, in-cluding all holders ofoperating licenses fornuclear power reactors,who use physics codes tosupport criticalitysafety in the use offissile material.91-26OL = Operating LicenseCp = Construction Permit IN 91-31May 9, 1991 This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate NRR project manager.Charles E. Rossi, DirectorDivision of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical Contacts:Joseph J. Petrosino, NRR(301) 492-0979Nancy Campbell, NRR(301) 492-0836

Attachments:

1. Magnaflux 14AM Aerosol Recall Notice2. List of Recently Issued NRC Information Notices*SEE PREVIOUS CONCliRANCE%,X OE*3NP ' F *C/OGCB:DOEA:NRRCeiffosft' CHBerlinger05/7/91 05/01/91*OGCB:DOEA:NRR*RVIB:DRIS:NRR *C/RVIB:DRIS:NRRNCampbell JJPetrosino GCwalina04/25/91 04/25/91 04/26/91*RPB:ADMTechEd04/24/91*D/DRIS:NRRBKGrimes04/26/91*MQS InspectionJFaloon04/26/91*Magnaflux Corp.JChase04/25/91OFFICIAL RECORD COPYDocument Name: IN 91-31 IN 91-XXApril xx, 1991 This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate NRR project manager.Charles E. Rossi, DirectorDivision of Operational Events Assessment~ Office of Nuclear Reactor RegulationTechnical Contacts:A Petrosino, NRR(301) 492-0979Nancy Campbell, NRR(301) 492-0836

Attachments:

1. Magnaflux Magnetic ParticleBath Recall Notice2. List of Recently Issued NRC(14AM) PreparedInformation NoticesDocument Name:INFO NOTICE -CAMPBELL*SEE PREVIOUS CONCURRENCESOGCB:DOEA:NRRNCampbel4iA04/2r/91 ' sftRyW :NRRJ sino04/,Z791A //BR 4 :NRRGCwalina04/A/91D/DOEA:NRRCERossi04/ /91,8)bRIS:NRR(jK~rimes{4/591C/OGCHBerlingerQK/ 1/91*RPB:ADMTechEd04/24/91Hag 4ux Corporation1.& .7-,AVF70db) 8 47-3. 9'A. -1I I 4) S :7r&5w4 eXT 1a J00n , Exew. 11P by c eo.O (0) -9 / .5 777

-aIN 91-XXApril xx,Page 2 of1991This information notice requires no specific action or written response. If 2rtx. *you have any questions about the information in this notice, please contact Wetechnical contact'listed below or the appropriate NRR project manager. 8Charles E. Rossi, DirectorDivision of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical Contacts:Joe Petrosino, NRR(301) 492-0979Nancy Campbell, NRR(301) 492-0836

Attachments:

1. Magnaflux Magnetic ParticleBath Recall Notice2. List of Recently Issued NRC(14AM) PreparedInformation NoticesDocument Name:INFO NOTICE -CAMPBELLD/DOEA:NRRCERossi04/ /91_D/DRIS:NRRBKGrimes04/ /91OGCB:DOEA:NRRNCampbell04/ /91RVIB:DRIS:NRR C/RVIB:DRIS:NRRJJPetrosino04/ /91 04/ /91C/OGCB:DOEA:NRRCHBerlinger04/ /91TechEi04 P7/91