ML18065A500

Part 21 Rept Re Hex Bolts Mfg by Cardinal Industrial Products (Cip).Aerofin Will Provide Replacement Bolts for Bolts in Question If Util Notify Aerofin in Writing within 30 Days of Date of ltr.10CFR21 Rept from CIP Encl

ML18065A500
Person / Time
Site:	Palisades
Issue date:	02/15/1996
From:	Elliott B External (Affiliation Not Assigned)
To:	Dotson B CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.), NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-96 NUDOCS 9602220425
Download: ML18065A500 (5)

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'4-ERDFIN CDRPDRATIDN IJ.ERDFIN Home 5TAN0t4RD t4ND CUSTOM ENGINEERED New York Office Chicago HEATING t4NO COOLING SURFACE Dallas and Plant Lynchburg P.O. BOX 10819 Atlanta Virginia LYNCHBURG, VIRGINIA 24506 1-800-AEROFIN Phone: 804-845-7081 February 15, 1996 Fax: 804-528-6242 1CC: (with attachments) I

.~Document Control Desk i

.V~S. Nuclear Regulatory Commission' Washington, D.C.

• 20555 . - - * * *

• Ms. Barb Dotson

• Consumers Power Company*

Palisades Nuclear Plant 22780 Blue Star Memorial Highway Covert, Ml 49043-9530

Subject:

10CFR21 Report: Deviation Evaluation

Reference:

1) Letter from Aerofin (Brian Elliott) to Consumers Power (Barb Dotson) dated October 4, 1995 regarding 10CFR21 notification (copy of same telefaxed to U.S. NRC on October 5, 1995)

2) Consumers Power Purchase Order G0109437

3) Aerofin Shop Order No. 947963

4) 10CFR21 Report from Cardinal Industrial Products as transmitted to Aerofin by Consolidated Power Supply by letter dated February 13, 1996 (attached)

5) Aerofin ASME Design Report dated 11n/94 (copies of original cover page and pages 26 & 27, attached)

6) Aerofin ASME Design Report dated 11n/94 (copies of original cover page and pages 26 & 27 marked up and attached to show effects of reduced bolt tensile strength and actual maximum system operating pressure)

i l ... ,

'i Ms. Barb Dotson 10CFR21 Report Consumers Power Company Page 2

Dear Ms. Dotson:

This letter follows up our initial notification to Consumers Power Company and the U.S. NRC (Reference 1) which addressed 1,475 hex bolts (5/8"-11x3 inches, ASME SA 193, Grade 87), manufactured by Cardinal Industrial Products and supplied to Aerofin by Consolidated Power Supply, which were used as header cover plate bolts in the Safety Related containment air cooler replacement cooling coils furnished by Aerofin to Consumers Power Company (Reference 2). These thirteen coils (twelve coils plus one spare) were shipped to the Palisades Nuclear Plant on or about November 16, 1994.

The bolts in question are listed as Item #16 on "as-built" drawing QA-R-1012 dated 11/1/94 included with the Aerofin Quality Assurance Data Package for this equipment.

These bolts are identified by Cardinal Industrial Products Heat No. CK256 (856 pieces, Trace Code TU2) and Heat No. L63051 (619 pieces, Trace Code CX 1). Of the 1,475 bolts purchased by Aerofin, 1,456 were actually used in the coils.

a Enclosed is complete copy of the 10CFR21 Report from Cardinal Industrial Products as transmitted to Aerofin by Consolidated Power Supply by letter dated February 13, 1996 (Reference 4) and received by Aerofin on February 14, 1996.

Review of the Cardinal Industrial Products repo*rt conclusions reveals that they can make no guarantees as to what percentage of bolts may actually be substandard, but they do state that the actual tensile strength of any substandard bolts is between 60,000 and 70,000 psi as compared to a minimum tensile strength requirement of 125,000 psi for ASME SA-193, Grade 87 material. Given this information, several conclusions can be drawn regarding the header cover plate bolts:

• The allowable stress for ASME SA-193, Grade 87 bolts is 25,000 psi (reference ASME Section Ill, Table 1-7.3) which represents a safety factor of five when compared to the material minimum tensile strength of 125,000 psi. Bolt stresses i.n substandard bolts should be compared to a lower allowable stress. Using an allowable stress equal to one-fifth of the reduced tensile strength is consistent with the safety factor inherent in the Code material mechanical properties. This gives an allowable stress for substandard bolts of 12,000 to 14,000 psi.

• For the design pressure load and nozzle loading, the worst calculated stress is the tensile stress on the short side bolts (13,323 psi - see Reference 5). This is within the range for the reduced allowable stress of 12,000 to 14,000 psi.

l I~ ,f Ms. Barb Dotson Consumers Power Company

• 10CFR21 Report Page 3

• Actual maximum system operating pressure is on the order of 80 psig which is based upon the zero flow pressure head developed by the system pumps. Compared to a design pressure of 150 psig, there is significant margin available to accommodate substandard bolt strength characteristics. (See Reference 6.)

• The maximum calculated bolt torque corresponding to the minimum reduced tensile strength is 99 ft-lbs. This is sufficient to seat and seal the EPDM gasketed pressure boundary.

THEREFORE, IT IS CONCLUDED THAT NO SUBSTANTIAL SAFETY HAZARD EXISTS DUE TO THE POSSIBLE PRESENCE OF ANY SUBSTANDARD BOLTS.

Based upon the conclusions of the Cardinal Industrial Products report, it is unlikely that any of the containment air cooler replacement cooling coils has header cover plate bolts that are entirely (or even that a majority are) substandard. Consequently, it is expected that the equipment will operate satisfactorily with substandard bolts, even if they are present, throughout the equipment's expected operating life. However, it certainly is recognized that Consumers Power Company may have received an indeterminate quantity of bolts that do not meet ASME Code specifications.

Therefore, Aeroiin wiii provide repiacernen( boils ior ir1e 1,453 (5/8"-i i x 3 iiiches)

ASME SA 193, Grade B7 bolts if Consumers Power Company will notify Aerofin in writing within 30 days of the date of this letter of its desire to receive replacement bolts.

By copy of this letter, we are also notifying the NRC of this evaluation and thereby have completed our reporting obligations as required by 10CFR21.

If you have any questions or require any additional information at this time, please contact me at 804-528-621 O (telephone) or 80_4-528-6243 (telefax).

Very truly yours,

/L(1Y24f Brian C. Elliott, P.E.

Manager Nuclear and Code Products cc: D. L. Corell Aerofin President and Chief Operating Officer Michael D. King Consumers Power Company Project Manager Dan Depuydt Consumers Power Company Containment Cooler Responsible Engineer

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Consolidat:ed Power §upply February 13, 1996 Aerofin Corporation 4621 Murray Place Lynchburg, VA 24505 FEB 1 4 1996 AEROFIN CORPORATION Attn: Mr. Barry DeHart QA Manager

Subject:

Submittal of the Cardinal Industrial Products Final 10CFR Part 21 Report

Dear Mr. DeHart:

Please find enclosed a complete copy of the subject document. Consolidated Power Supply (CPS) received the document on 2/12/96 from Cardinal Industrial Products, which is now known as Accutech. CPS will retain a copy in our Nonconformance file, which is being closed based on issuance of this correspondence. As all CPS customers affected by the report have been notified, as well as the Nuclear Regulatory Commission, no further actions by CPS are deemed ..

necessary at this time regarding the questionable fasteners.

CPS and Aerofin personnel have had discussions concerning replacement of the fasteners (1475 each, 5/8" - 11 X 3" SA193 B7 hex bolts) that were supplied by CPS against Aerofin Purchase Order 13822. It has been conveyed that these fasteners were used in a component manufactured by Aerofin that was supplied to Consumers Power. If replacement fasteners will be required, it is. suggested that Aerofin obtain written correspondence to this affect from the applicable licensee, including written correspondence from Aerofin indicating the same. Exact quantities should be identified.

If there are questions or_ comments relative to the enclosed in(orn:i~_tion or this corres1xmdence please contact the undersigned.

Sincerely,

~t.J~_,

Steven W. Andrews Quality Assurance Manager Enclosure - Cardinal Final Report (44 Pages) cc: H. Kerr - President, CPS, w/o; M. Mathias - Gen. Mgr., CPS, w/o; NCR# 95-150,w/a 3556 Mary Taylor Road 0 Birmingham, Alabama 35235 * (205) 655-5515 A Division of Consolidated Pipe & Supply Co., Inc. Birmingham, AL

'L DATE: February 5, 1996 CUSTOMER: CONSOLIDATED POWER SUPPLY 3556 MARY TAYLOR ROAD BIRMINGHAM, AL 35235 ATTENTION: STEVE ANDREWS, MANAGER OF QUALITY ASSURANCE

SUBJECT:

10 CFR Part 21 Final Report

Dear Mr. Andrews:

Attached is Cardinal Industrial Products' final report that was submitted to the Nuclear Regulatory Commission (NRC) as required by 10 CFR Part 21. This final report is being provided to you as a courtesy to assist you in resolving this issue.

This report was submitted to the NRC on November 21, 1995. As of this date, the NRC has not provided a reply or correspondence.

Should you have any questions, please contact David Z. Hathcock at (702) 739-1966.

cc: 10 CFR Part 21 file

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