ML19350D672

First Interim Deficiency Rept Re Concrete Expansion Anchor Bolts Mfg by Hilti Industries Failing to Meet QA Requirements,Initially Reported 810410.HILTI Removed from Approved Vendor List

ML19350D672
Person / Time
Site:	South Texas
Issue date:	05/08/1981
From:	Oprea G HOUSTON LIGHTING & POWER CO.
To:	Seyfrit K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
References
10CFR-050.55E, 10CFR-50.55E, ST-HL-AE-665, NUDOCS 8105180326
Download: ML19350D672 (4)

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The Light company mms,e u sties & sre e, ro. 8ex iroo tiees,e . rex 77"oi i'i3> 228-92ii May 8,1981 ST-HL-AE-665 SFN: V-0530

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Mr. Karl Seyfrit Director, Region IV fluclear Regulatory Commission 611 Ryan Plaza Drive, Suite 1000 Arlington, Texas 76012

Dear Mr. Seyfrit:

South Texas Project Units 1&2 Docket Nos. STN 50-498, STN 50-499 First Interim Report Concerning HILTI Industries 0A Program

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On April 10, 1981, pursuant to 10CFR50.55(e), Houston Lighting &

Power Company notified your office of an item concerning HILTI Industries QA Program. The first interim report is attached. The next report con-cerning this item will be submitted to your office by July 17, 1981.

If there are any questions concerning this item, please contact Mr. Michael E. Powell at (713) 676-8592.

Very truly yours ,

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N. ' p y Exec 0tive Vice President MEP/ par Attachment N

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810518o346

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Houston Lighting & Power Company May 8,1981 ST-HL-AE-665 cc: J. H. Goldberg SFN: V-0530 D. G. Barker Page 2 C. G. Robertson Howard Pylc R. L. Waldrop H. R. Cean D. R. Beeth J. D. Parsons -

L. K. English J. W. Briskin .

R. A. Frazar STP RMS -

H. S. Phillips (NRC)

J. O. Read (Read-Poland,Inc.)

M. D. Schwarz (Baker & Botts)

R. Gordon Gooch (Baker & Botts)

J. R. Newman (Lowenstein, Newman, Reis, & Axelrad)

Director, Office of Inspection & Enforcement Nuclear Regulatory Commission Wasnington, D. C. 20555 ,

M. L. Borchelt -

Charles Bechhoefer, Esquire President Chairman, Atomic Safety & Licensing Board Central Power & Light Company V. S. Nuclear Regulatory Commission P. O. Box 2121 Washington, D. C. 20555 Corpus Christi, Texas 78403 R. L. Range Dr. James C. Lamb, III Central Power & Light 313 Woodhaven Road P. O. Box 2121 Chapel Hill, North Carolina 27514 Corpus Christi, Texas 78403 R. L. Hancock Mr. Ernest E. Hill Director of Electrical Utilities Lawrence Livermore Laboratory City of Austin University of California P. O. Box 1088 P. O. Box 808, L-123 Austin, Texas 78767 Livermore, California 194550 T. H. Muehlenbeck Citizens for Equitable Utilities, Inc.

City of Austin c/o Ms. Peggy Buchorn P. O. Box 1088 Route 1, Box 1684 Austin, Texas 78767 Brazoria, Texas 77422 J. B. Poston Pat Coy Assistant General Msnager of Operations Citizens Concerneo About Nuclear Power City ublic Service Board 5106 Casa Oro P. O. Box 1771 San Antonio, Texas 78233 San Antonio, Texas 78296 A. vonRosenderg Lanny Sinkin City Public Service Board 2207-D Nueces P. O. Box 1771 Austin, Texas 78705 San Antonio, Texas 78295 Brian E. Berwick, Esquire Jay Gutierrez, Esquire Assistant Attorney for the State of Texas Hearing Attorney P. O. Box 12548 Office of the Executive Legal Director Capitol Station U. S. Nuclear Regulatory Conmission Austin, Texas 78711 Washington, D. C. 20555 4-2B-8'

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FIRST INTERIM REPORT CONCERNING HILTI INDUSTRIES QA PROGRAM

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SUMMARY

During routine preparation for an annual audit of the HILTI Industries facility in Tulsa, Oklahoma, it was discovered that HILTI was working to a Quality Assurance Manual which had been re-issued in January of 1980 and revised in June of 1980 without receiving Brown & Root approval. HILTI Industries is a supplier of HILTI " Kwik-Bolt" concrete expansion anchor bolts for the South Texas Project (STP).

The bolts are used in Seismic Category I applications at the facility.

HILTI's original QA Program at the McGelloch Industries facility in Minneapolis, Minnesota, had been reviewed and approved prior to award of a Purchase Order. Brown & Root continued to purchace expansion anchor bolts, without knowledge of any change to HILTI's QA P-ogram during the period from January,1980, through November of 19PO. At that time, a copy of HILTI Industries' new QA Manual was obtained by Brown & Root for review and approval. This manual did not contain sufficient information to satisfy the procurement documents quality assurance requirements. Iterative attempts were made by Browi & Root to obtain additional documentation from HILTI which could allrw approval of their QA Program. However, sufficient information was not submitted from HILTI Industries to allow the approval of thei revised QA Program. HILTI Industries was then removed from the STP list of approved vendors. The quality of the HILTI " Kwik-Bolt" concrete expansion anchor bolts has been determined by Houston Lighting & Power to be questionable due to the f act that the manufacturing was accomplished without accep?ed procedural controls.

II. DESCRIPTION OF INCIDENT:

HILTI Industries, Inc. is a supplier of expansion anchor bolts which have been used at STP in Seismic Category I applications. HILTI was approved by pre-tward survey on November 6, 1979. This survey included review and approval 3y Brown & Root of the HILTl QA Proaram, consistent with procurement documents QA requirements.

In November,1980, during routine preparation for an annual audit of HILTI Industries, it was discovered that they had completely changed their QA Manual in January of 1980 and further revised it in June of 1980. HILTI was immediately asked to provide their current QA Manual to Brown & Root for review and approval prior to any audit. The manual was reviewed by B&R and found to be " Incomplete; Disapproved".

HILTI was notified of this action on December 8,1980, and was subsequently removed from the project's approved vendors list. In

' January, 1981, a hold on the installation of permanent concrete expansion anchor bolts had been initiated on the South Texas Project.

HILTI was then requested to provide additional operatinnal procedures for review and approval which might supplement their QA manual and allow approval of their Quality Program for the period in question.

After numerous delays these procedures were received and reviewed.

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Tne additional procedures were also found to be incomplete and unacceptable.

It has been determined that approximately 136,000 concrete expansion anchor bolts have been supplied to STP by HILTI Industries since Janua ry , 1980. A number of these bolts have blen installed in Seismic Category I areas. Since tnere has been a failare by HILTI to meet the QA requirements of the procurement documents, che quality of the HILTI

" Kwik-Bolt" expansion anchor bolts is consi'dered to be questionable.

In order to resolve the question of bolt adequacy, a " user's" test will be performed by an independent testing agency'on a significant sample of bolts in stock at STP. This test will be conducted in accordance with applicable ASTM standards to determine the actual physical and chemical characteristics of the bolts.

III. CORRECTIVE ACTION:

When Brown & Root became aware that HILTI Industries was operating to a QA Manual that was not reviewed and approved by Brown & Root, HILTI was removed from tne Approved Vendors List. All expansion ancnor Dolts to be used for permanent installations at STP were placed on

" Hold" on December 12, 1980. The current HILTI QA Manual was

" conditionally approved", pending satisfactory completion of an audit of HILTI's facility in Tulsa, OK. On April 15 and 16,1981 a team compromised of Quality Assurance Auditing, STP Site Engineering and HL&P personnel tisited HILTI's Tulsa, Oklahona facility. The purpose of this visit was to (1) audit HILTI to their present manual (Revision 4/1/81) and (2) to evaluate HILTI's performance es it would have ,

related to their previously accepted QA Manual for the period of .

January 2,1980 to date, and hence, the quality of the bolts supplied to STP during this period. The results of this audit are (1) HILTI's QA Program f ailed to satisfy the STP QA requirements as stated in the procurement documents, and (2) HILTI failed ta satisfy Brown & Root that adequate control processes were in effect since January,1980.

HILTI has agreed to incorporate certain recommended changes into their current QA Manual. HILTI also has been re-informed of the STP requirement to submit any changes to the QA Program for Brown & Root review and approval prior to implementation of sucn changes.

IV. SAFETY EVAL 0ATION:

A " user's" test will be conducted at an independent laboratory under the direction and surveillance of Brown & Root to determine the actual chemical and physical characteristics of the HILTI " Kwik-Bolt" concrete expansion anchor bolts presently in stock at STP. An evaluation of the safety significance of this time item is pending receipt of test results. No pnysical defects with the bolts have been identified to date.

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