Part 21 Report - 1998-051
ACCESSION #: 98010900040
DuBose
National Energy Services, Inc.
January 7, 1998
Attn: NRC Operations Center
Document Control Desk
US Nuclear Regulatory Commission
Washington, DC 20555
Subject: 10 CFR 21
Dear Sir,
I am writing to pass along information provided to us by Tube Forgings of America (TFA), a qualified vendor of ours.
TFA has informed us that material supplied to them by USS/Kobe Steel was mixed at the mill.
DNES received 40 pieces of 4" 90 Degrees elbows and shipped them to our customers. The customers, order numbers, and
quantities are listed here.
Washington Public Power 251756 20 Pieces
N E Nuclear 02017957 16 Pieces
TU Electric S02208826D2 3 Pieces
SC Electric & Gas SR 700786 1 Piece
Attached is a copy of the letter from TFA, and USS/Kobe Steel describing
the problem in detail.
We have notified the above customers so that they can evaluate the material which may have been installed in their
facility.
If you need any additional information please contact me at 1-910-590-2151.
Sincerely,
James N. Dailey
QA Manager
cc: Carl Rogers
Sales
DNES Customers
(910) 590-2151 o 1-800-590-2150 o FAX (910) 590-3555
P.O. Box 499 o Clinton, NC 28328
tube forgings
OF AMERICA INC.
DECEMBER 18, 1997
5200 N.W. FRONT o PORTLAND, OREGON 97210
DUBOSE NATIONAL ENERGY [Illegible Print]
PO BOX 499
CLINTON, N.C.
28323
ATTN: JAMES DAILEY
RE. POTENTIAL 10 CFR PART 21
DEAR MR. DAILEY
AS A FOLLOW UP TO THE TFA AND US STEEL LETTER YOU RECEIVED AND BASED ON A REVIEW OF ORDERS OF MATERIAL SUPPLIED TO YOU,
RE: YOUR PURCHASE ORDER # 11501-63, WE ARE ADVISING YOU OF A POTENTIAL PROBLEM WITH 4 STD LR 90,40PCS, TFA HEAT CODE
G348.
A PARENT HEAT WAS FOUND AT TFA, DURING SAMPLING INSPECTION, TO CONTAIN .18 MOLEBDENUM AND .76 CHROME. DUE TO THE
ALLOYING ELEMENTS THE YIELD, TENSILE AND ELONGATION AS WELL AS THE CHEMISTRY DOES NOT MEET ASME SEC II
SA 234 GRWPB. THE TFA HEAT CODE WHICH HAD THE PROBLEM WAS G347 WHICH YOU NEVER RECEIVED, HOWEVER AFTER EVALUATION BY US
STEEL IT WAS DETERMINED BY THEM THAT HT G348 IS ALSO SUSPECT.
WITHOUT USING THE PROPER WELD PROCEDURES THE CHROME/MOLY MATERIAL WILL HAVE A HIGH HARDNESS, UP TO 34 RC IN THE HAZ,
WHICH CONTAINS UNTEMPERED MARTENSITE, BASE MATERIAL HARDNESS CAN RANGE UP TO RC24 IN THE HOT FORM CONDITION.
MATERIAL THAT IS LEFT IN YOUR STOCK SHOULD BE ISOLATED AND IF YOU DESIRE YOUR MAY OBTAING AN RGA FROM OUR SALES
DEPARTMENT FOR CREDIT AND SEND THE MATERIAL BACK TO US. OR YOU MAY WANT TO PERFORM A CHEM CHECK PER PIECE
USING A SUITABLE METHOD. COSTS WILL BE REIMBURSED PER USS STEEL LETTER.
PLEASE NOTIFY US OF YOUR DESIRED COURSE OF ACTION.
MATERIAL THAT IS OUT IN THE FIELD SHOULD BE DEALT WITH THE SAME.
WE APOLOGIZE FOR THIS INCONVENIENCE.
SINCERELY,
JOHN G. PEACHEY
MGR. OF Q.A. & STATISTICS
cc: PAT BENAVIDES-TFA VP AND GENERAL MANAGER
ISO 9002 Certified
tube forgings
OF AMERICA INC.
5200 N.W. FRONT o PORTLAND, OREGON 97210
December 11, 1997 [Illegible Print]
RE: 4 STD LR 90 A234WPB Fittings Heat Codes G347 & G348
4 STD 45 A234WPB Fittings Heat Codes G347 & G348
4x3, 4x2.5, 4x2 STD LA 90 A234WPB Fittings Heat Codes G347 & G348
Company
Address
City, State, Zip
Attention: Quality Assurance Manager/Branch Manager
Gentlemen:
We are writing to pass along important information from US Steel
regarding a mixed heat/grade situation on a shipment of tubular products
received by Tube Forgings of America. From one to five lengths of pipe,
out of a shipment of 1,614 lengths, was of a different heat/grade
material. This shipment was used to manufacture the above referenced
fittings.
Based on our records, you have received some of these fittings. The
enclosed information from U.S. Steel describes the irregularity in their
shipment, and the resulting non-conformance in some of the fittings
manufactured. Please note the remedial course of action recommended by
U.S. Steel and that U.S. Steel is assuming full responsibility for all
costs of recall, grade verification, replacement, or other necessary
remedies. Dave Snively of USS/Kobe Steel is standing by to assist you;
at 1-800-227-7113 (enter 2776 after the prompt, or dial 1-440-277-2776).
We have asked U.S. Steel for verification that corrective actions are
being taken to ensure that this non-conformance will not occur again.
These corrective actions are outlined in their letter as well.
We pledge to work with you to minimize any inconvenience. I hope you
will call Pat Benavides, Vice President/General Manager, John Peachey,
Quality Assurance, Manager, or myself, should you have any questions or
concerns about U.S. Steel's resolution of the problem. We have set up a
toll-free number at Tube Forgings of America for your use, 1-800-291-3606
(enter 124 after the prompt).
We regret any inconvenience you may experience. We fully expect that you
can continue to rely on the dedication to superior service and a quality
product which have been a hallmark of our company since 1955.
Sincerely,
Jay N. Zidell
President
U. S. Steel
600 Grant Street
Pittsburgh, PA 15219-2749
December 2, 1997
To Whom It May Concern:
Subject: Mixed Steel - Heats B00050 & B00056
3-1/2" x .270" Wall Fittings Pipe
Dear Sir:
During the routine testing of fittings produced from the subject heats at
Tube Forgings of America, Inc, a suspected mixed steel was detected.
This suspicion was based on mechanical test results associated with a
fitting that was tested. Chemical analysis of the suspect fitting
further verified that the material used to manufacture the fitting did
not meet Tube Forgings of America's specification requirements, nor did
the resulting finished fitting meet all of the requirements of ASTM A234
WPB-96, Standard Specification for Pipe Fittings of Wrought Carbon Steel
and Alloy Steel for Moderate and High Temperature Service. Further
testing of the fitting, which was manufactured from the Cr-Mo Alloy steel
pipe produced by USS/Kobe Steel Company, showed test results which varied
from the specification requirements and were unacceptable for ASTM A234
WPB-96.
ASTM A234 WPB-96 fittings produced from these off-grade lengths of pipe
failed to meet the specification requirements in the following areas:
1. The elements Molybdenum (Mo) and Chromium (Cr) exceeded the
element contents specified in ASTM A234-96a. Molybdenum and
Chromium contents of the referenced material are 0.19% and
0.76% respectively.
2. The Hardness values exceed the specification limit of 197 BHN,
Actual hardness values could be as high as 240 BHN.
3. The Mechanical Properties exceed the requirements of ASTM A234
WPB-96. Elongation results also fall below the minimum
requirement of the specification.
Since you were a recipient of fittings produced from the subject heat,
you should promptly segregate the fitting identified in Tube Forgings of
America, Inc.'s correspondence from your remaining inventory, and
initiate grade verification processes. Where possible, you should recall
and grade verify any remaining fittings or arrange for grade verification
of verification of installed fittings. If, as a recipient, you have sold
or otherwise
U. S. Steel Group
A Unit of USX Corporation
transferred any fittings to your customers, you should provide this
notice to all transferees.
All recipients of these fittings will be reimbursed for reasonable costs
associated with locating, segregating, grade verifying, and/or replacing
these questionable fittings.
All recipients of these fittings should clearly understand that if you
(they) do not promptly comply with this notice, we will not be
responsible for any resulting claims.
Corrective actions are being implemented at USS/Kobe Steel Company to
prevent the recurrence of this situation. All tubular products destined
for TFA, fitting applications will be subjected to a made verification
test prior to shipping.
U. S. Steel Tubular Products and USS/Kobe sincerely regret the
inconvenience that this situation may cause. We do believe that the
implemented corrective action, shall prevent a future recurrence of this
problem.
Any inquiries concerning this situation should be directed to Dave
Snively - Tubular Products, at USS/Kobe Steel Company.
By phone, he can be reached by dialing 1-800-227-7132, and then entering
2776 after the prompt; or by dialing 1-440-277-2776.
By email, he can be reached at topalove@usskobe.com
By mail, he can be reached at USS/Kobe Steel Company
1807 East 28th Street
Lorain, Ohio 44055
Attention: Dave Snively
Quality Assurance - Tubular
Box 21A
Very truly yours,
Frank Mikulski
Manager, Metallurgy & Quality Assurance
U. S. Steel Tubular Products
BRAUN [Service Mark] Braun Intertec Corporation
INTERTEC 6032 N. Culter Circle, Ste 480
P.O. Box 17126
Portland, Oregon 97217
503-289-1776 Fax. 289-1918
Engineers and Scientists Serving
the Built and Natural Environments
August 27, 1997 Project EARX-97-0108
Report 05-087-2226
Mr. John Peachy
Tube Forgings of America, Inc,
5200 Northwest Front Avenue
Portland, Oregon 97210
Dear Mr. Peachey;
Re: Chemical and Mechanical Analysis performed on steel things received
on August 4, 1991, pursuant to your Purchase Order Number P40149.
Item: 4" STD, L/R 90" Elbows
Heat
Number: G347, Cr-Mo Alloy
G956, ASTM A234, Grade WPB-96
Analysis
(Units: % by weight)
G347
Carbon (C) 0.23
Manganese (Mn) 1.27
Silicon (Si) 0.29
Nickel (Ni) 0.020
Chromium (Cr) 0.76
Molybdenum (Mo) 0.18
Copper (Cu) 0.010
Vanadium (V) <0.005
Aluminum (Al) 0.010
Phosphorous (P) 0.010
Sulfur (S) 0.006
Columbium (Cb) <0.005
Carbon Equivalent (AWS D1.1) 0.68
Tube Forgings of America, Inc.
Project EARX-97-0108
Report 05-097-2226
August 27, 1997
Page 2
Mechanical Analysis
Yield Strength, 0.2% Officer, psi 103,700 91,800
Tensile Strength, psi 127,000 120,300
Elongation in 2 Inch, % 19.1 18.4
Reduction in Area, % 53.7 45.0
Hardness, BHN, 3,000 kg 229 223
Charpy Impact Tests
Weld Heat Affected Zone, 5 x 10mm @ +20 Degrees F
Weldability Test
Reduced Section Tensile Strength Transverse to Weld
Ultimate Tensile Strength 81,300 psi
Location of Failure Weld Zone
Tube Forgings of America, Inc.
Project EARX-97-0108
Report 05-097-2226
August 27, 1997
Page 3
Guided, Bend Tests
Root Bend Passed
Face Bend Passed
Hardness Survey, Rockwell
G347 Base Metal C23.0
G347 HAZ C34.5
Weld Zone B87.5
G956 HAZ B81.0
G956 Base Metal B86.0
Microstructure
G956 Base Metal
Heavily banded (anisotropic)pearlite in a matrix of fine grained ferrite.
G956 HAZ at Fusion Line
Ferrite delineating prior austenite grain boundaries and large grain
acicular ferrite mixed with fine pearlite.
G347 Base Metal
Structure consists of a mixture of ferrite pearlite and martensite.
G347 HAZ at Fusion Line
Larger grain size consisting of ferrite, alloy carbides, banite and
untempered martensite. This structure is consistent with higher hardness
values found.
Tube Forgings of America, Inc.
Project EARX-97-0108
Report 05-097-2226
August 27, 1997
Page 4
Weldability
The fittings were welded easily using E6010 and E7018 electrodes with the
SMAW process. Visual and Magnetic Particle inspection after welding did
not detect any underbead or HAZ cracking. No preheat was used. The
welded fitting was allowed to cool normally in ambient air condition
after welding. No difficulties during welding were observed.
Discussion
Tests have shown that Heat Number G347 (Cr-Mo allay) has a propensity for
HAZ transformation to hard, brittle constituents (untempered martensite).
The result is a tendency for underbead (HAZ) cracking and high residual
stress.
The American Welding Society lists two (2) basic methods for estimating
welding conditions; to avoid cold cracking.
o Hydrogen control
o Hear affected zone hardness control
Using low hydrogen electrode/process with medium constraint the minimum
preheat/Interpass temperature for this material should be 250 Degrees F.
The critical cooling rate to control HAZ hardness below Rockwell-C -36 is
41 Degrees F (5 Degrees C)/second.
These guidelines are based on a CE of 0.68 and Pcm of 0.36.
During welding of the test fitting preheating, maintenance of interpass
temperatures and control of cooling rate were not performed and although
HAZ hardness is near the upper limit the critical hardness was not
exceeded and cracking did not occur.
These tests leave demonstrated that the Cr-MO alloy fittings can be
successfully welded using procedure suitable for welding A2.34, Grade WPB
fittings.
Tube Forgings of America, Inc.
Project EARX-97-0108
Report 05-097-2226
August 27, 1997
Page 5
Services performed for this project have been conducted with that level
of care and skill ordinary exercised by members of the profession
currently practicing in this area under similar budget and time
restraints. No warranty, expressed or implied, is made.
All work was performed in compliance with Braun Intertec Q.C. Manual
dated 02-23-94, Revision 1 and NDE Supplement dated 06-07-94, Revision 0.
We appreciate the opportunity to be of service to you. Should you have
any questions regarding the contents of this report of if we may be of
further assistance in any way, please contact us at (503) 978-4714 or
(800) 783-6985, e-mail pirish@brauncorp.com.
Sincerely,
Paul Irish
Technical Director
pi:sjg
[Illegible print]
OTHER NUCLEAR MATERIAL EVENT NUMBER: 33500
LICENSEE: DUBOSE NATIONAL ENERGY NOTIFICATION DATE: 01/07/98
SERVICES,INC
CITY: CLINTON REGION: 2 NOTIFICATION TIME: 10:00 (ET]
COUNTY: STATE: NC EVENT DATE: 01/07/98
LICENSE#: AGREEMENT: Y EVENT TIME: 10:00[EST]
DOCKET: LAST UPDATE DATE: 01/07/98
NOTIFICATIONS
LAURIE PELUSO, R1 RDO
NRC NOTIFIED BY: JAMES N. DAILEY KEN BARR R2DO
HQ OPS OFFICER: JOHN MacKINNON BLAIR SPITZBERG R4DO
VERN HODGE NRR
EMERGENCY CLASS: NOT APPLICABLE
10 CFR SECTION:
CDEG 21.21(c)(3)(i) DEFECTS/NONCOMPLIANCE
EVENT TEXT
10CFR PART 21 REPORT -
DUBOSE NATIONAL ENERGY SERVICES, INC, (DNES) SHIPPED A TOTAL OF 40
PIECES
OF 4 INCH, 90 DEGREE ELBOWS WHICH DID NOT MEET ASME SEC II SA-234
REQUIREMENTS TO SEVERAL NUCLEAR POWER PLANTS.
TUBE FORGINGS OF AMERICA (TFA), A VENDOR OF DNES, NOTIFIED DNES THAT
MATERIAL SUPPLIED TO TFA BY US STEEL/KOBE STEEL WAS MIXED AT THE
MILL.
FROM ONE TO FIVE LENGTHS OF PIPE, OUT OF A SHIPMENT OF 1,614 LENGTHS,
WERE MADE OF A DIFFERENT HEAT/GRADE MATERIAL. THIS SHIPMENT WAS
USED TO
MANUFACTURE A TOTAL OF 40 PIECES OF 4 INCH, 90 DEGREE ELBOWS WHICH
WERE
SHIPPED TO THE FOLLOWING NUCLEAR POWER PLANTS:
CUSTOMER ORDER NUMBER QUANTITY
WASHINGTON PUBLIC POWER 25175G 20 PIECES
NE NUCLEAR 02017957 16 PIECES
TU ELECTRIC S02208826D2 3 PIECES
SC ELECTRIC & GAS SR 700786 1 PIECE
THE ABOVE CUSTOMERS WERE NOTIFIED OF THE PROBLEM.
*** END OF DOCUMENT ***
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