Bulletin 83-06: Nonconforming Materials Supplied by Tube-Line Corporation Facilities at Long Island City, New York; Houston, Texas; and Carol Stream, Illinois
SSINS No.: 6820
OMB No.: 3150-0011
IEB 83-06
UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
WASHINGTON, D.C. 20555
July 22, 1983
IE BULLETIN NO. 83-06: NONCONFORMING MATERIALS SUPPLIED BY TUBE-LINE
CORPORATION FACILITIES AT LONG ISLAND CITY, NEW
YORK; HOUSTON, TEXAS; AND CAROL STREAM, ILLINOIS
Addressees:
For action:
All nuclear power reactor facilities or fuel facilities holding an operating
license (OL) or construction permit (CP).
Purpose:
Power reactor and nuclear fuel facilities received initial notification of
nonconformities with materials supplied by Tube-Line Corporation (T-L) in
Information Notice No. 83-07 dated March 7, 1983. This bulletin is being
issued as a result of the findings from Region IV Vendor Program Branch
inspections at the T-L facilities at Long Island City, New York; Houston,
Texas; and Carol Stream, Illinois. It was concluded from these inspections
that there are potential generic safety implications at plants which either
have received direct shipment materials furnished by T-L (i.e., pipe
fittings and flanges) or receive piping subassemblies and other components
from holders of ASME Certificates of Authorization which incorporate these
materials. Therefore, we ask all recipients of this bulletin to review the
information herein for applicability to their facilities and: (1) to take
appropriate actions to confirm the adequacy of affected components for
intended service; or (2) submit reports stating that T-L materials received
from the referenced manufacturing locations will not be used in
safety-related systems at their facilities.
Description of Circumstances:
1. On December 6, 1982, Capitol Pipe and Steel Products Company (CPSP
Co.) sent a letter to the NRC which identified nonconformities with
certain materials that they had obtained from T-L and furnished to
their customers. In this letter, CPSP Co. identified the customers who
had received the T-L materials and stated that the customers had been
notified in regard to the material nonconformities. The products
identified by CPSP Co. were carbon steel pipe fittings (caps, tees,
and elbows) and flanges. The nonconformities identified were shipment
from an unapproved nuclear source, failure to
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IEB 83-06
July 22, 1983
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perform required heat treatment, and failure to perform nondestructive
examinations in accordance with the applicable provisions of the ASME
Code.
2. A 10 CFR Part 21 report dated January 10, 1983, was received from the
Babcock & Wilcox Company (B&W) which additionally addressed T-L carbon
steel materials that had been furnished by CPSP Co. This report stated
that certain materials furnished to B&W had been supplied by the
Houston, Texas, facility of T-L which was not an approved nuclear
supplier per NCA-3800 requirements. It was additionally stated that
B&W had performed mechanical testing of four heats of received
fittings and flanges and had found that the strength properties in two
heats of flange materials were lower than shown on the material
certifications; one heat was below the minimum requirement in the
procurement specification. Subsequent testing initiated by Carolina
Power & Light Company has further identified strength properties in
fittings (caps) that were below material specification requirements
and differences in chemical analysis from that reported on the T-L
Certified Material Test Report.
3. Direct inspections by the Region IV Vendor Program Branch have
identified discrepant conditions at both the, T-L carbon steel
facilities in Long Island City, New York; and Houston, Texas; and the
stainless steel facility in Carol Stream, Illinois. Known and intended
recipients of these materials are listed in Table 1 - Carbon Steel
(see Attachment 2) and Table 2 - Stainless Steel (see Attachment 3).
4. As a result of the inspections performed by the Region IV Vendor
Program Branch, the following additional pertinent information has
been obtained in regard to materials furnished by T-L:
a. Certain carbon steel materials were procured from unsurveyed
sources and improperly certified to CPSP Co. and Dravo
Corporation, Marietta, Ohio, as having been manufactured in
accordance with the quality program which CPSP Co. and Dravo
Corporation had audited and approved as meeting the requirements
of NCA-3800 in Section III of the ASME Code. Similarly, certain
stainless steel materials were procured from unsurveyed sources
and improperly certified to customers as having been manufactured
in accordance with the requirements of NCA-3800 and referencing
the T-L (Carol Stream) ASME Certificate of Authorization No.
QSC-435. It was additionally established at T-L (Carol Stream)
that the basis for approval of some vendors of materials and
services (i.e., heat treatment, NDE, mechanical testing, and
chemical analysis) was a self-evaluation form filled out by the
vendor.
b. Numerous instances were observed at T-L (Long Island City) in
which commercial carbon steel materials (i.e., materials procured
solely in accordance with a material specification) had been
procured and manufacturing had been completed before the
establishment of the T-L quality program. These materials were
then furnished to CPSP Co. and Dravo Corporation and improperly
certified as being both in accordance with specified Section III
of the ASME Code requirements and as having been manufactured in
accordance with the quality program
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IEB 83-06
July 22, 1983
Page 3 of 6
which these companies had audited and approved as meeting the
requirements of Section III of the ASME Code. Similar procurement
and certification of commercial stainless steel materials was
identified by direct inspection at T-L (Carol Stream).
c. Several 3", 600 lb. ASTM A105 carbon steel weld neck flange
forgings (e.g., 362 from T-L Heat Code EUUA and 1480 from T-L
Heat Code EKP) which have not been appropriately heat treated
have been shipped to various customers (both nuclear and
non-nuclear). Similarly, the NRC has been notified that
documentation was not available to demonstrate that approximately
530 SA-182 stainless steel flanges received the required solution
annealing heat treatment. These flanges have been shipped to
various customers.
d. Direct inspection has resulted in the current identification that
T-L (Carol Stream) furnished 521 stainless steel fittings welded
with filler metal to various customers and that vendor
documentation for these fittings does not indicate compliance
with Section III of the ASME Code requirements in regard to:
(1) Manufacture by a holder of a ASME Certificate of
Authorization for an NPT symbol using the ASME accepted QA
program.
(2) Use of welders and welding procedure specifications which
have been qualified in accordance with the requirements of
Section IX of the ASME Code.
(3) Inspection during manufacture by an Authorized Nuclear
Inspector and certification by issue and signing of a
Partial Data Report Form NM-1.
e. Foreign material manufacturers were surveyed and approved by T-L
(Long Island City) representatives as having documented quality
assurance programs which were in compliance with the requirements
of NCA-3800 in Section III of the ASME Code. Interviews and
examinations of available survey/audit records established,
however, the following:
(1) Certain manufacturers were approved although they did not,
in fact, have documented quality assurance programs.
(2) Other manufacturers were approved although their documented
quality assurance programs were not available in the English
language and the auditors were unable to read the applicable
quality assurance manuals.
(3) Certain manufacturers were maintained on the Qualified
Supplier List after identification that previous
surveys/audits had improperly stated that the documented
quality assurance programs were in full compliance with the
requirements of NCA-3800 in Section III of the ASME Code.
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July 22, 1983
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f. Materials were procured for T-L (Long Island City) without
specification of the applicable nondestructive examination (NDE)
requirements contained in Section III of the ASME Code.
Subsequent purchase orders to NDE subcontractors referenced
either that only commercial NDE was required or specified that a
paragraph in section III of the ASME Code was applicable without
reference to or assuring use of an approved NDE procedure.
Failure to assure use of approved subcontractor NDE procedures
was also identified at T-L (Carol Stream). It was further
established that T-L (Carol Stream): (1) failed to have records
demonstrating that UT and PT was performed; (2) had no records of
eye examinations being given to their level II examiner; (3)
failed to have qualification records of their NDE subcontractor's
personnel; and (4) did not address acceptance criteria in their
PT procedure.
5. Tube-Line Corporation representatives, in a letter to Region IV dated
April 8, 1983, stated they would send letters to all identified
end-users of their carbon steel products in nuclear facilities. The
letters would request meetings with the affected end-users to
determine whether the products met the necessary requirements, or to
determine whether upgrading or replacements are necessary.
Additionally T-L, in letters to Region IV (dated April 25, April 27,
May 3, May 6, and May 13, 1983), stated they would send letters to the
identified end-users of their stainless steel products of concern.
6. The information available to date indicates that T-L started supplying
ASME Code components to the nuclear industry in 1981.
Actions To Be Taken by Holders of Operating Licenses or Construction
Permits:
1. Review the lists of purchasing and receiving companies given in
Attachments 2 and 3 and determine if any T-L supplied ASME Code
materials have been furnished to your facility. The lists of
purchasing and receiving companies given in Attachments 2 and 3 have
been developed based on correspondence from T-L and inspections at
T-L; however, NRC has not verified the completeness of these lists.
2. For ASME Code materials furnished by T-L which are either not yet
installed in safety-related* systems at your facility or are installed
in safety-related systems of plants under construction, the following
actions are requested: (Perform action a and either action b or c)
a. Provide a list of T-L supplied materials and identify the systems
in which these materials are/will be installed.
*For the purpose of the applicable actions of this bulletin "safety-related"
constitutes those systems covered by the definition given in 10 CFR Part
100, Appendix A Sections III.(c)(1), III.(c)(2), and III.(c)(3). In
assessing the impact of T-L supplied materials in other systems at their
facilities, licensees should consider the provisions of GDC 1 to 10 CFR Part
50 Appendix A.
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July 22, 1983
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b. Implement a program which provides assurance that received
materials comply with ASME Code Section III and applicable
procurement specification requirements, or which demonstrates
that such materials are suitable for intended service. This
program should include specific verification that received
austenitic stainless steels are in a nonsensitized condition.
c. Replace fittings and flanges with materials which have been
manufactured in full compliance with ASME Code Section III and
the applicable procurement specification requirements.
3. For ASME Code materials furnished by T-L which are installed in
safety-related* systems in operating plants, the following actions are
requested:
a. Provide a list of the T-L supplied materials and identify the
systems in which the materials are installed.
b. Implement a program as discussed in 2b or 2c above.
c. Provide a basis for continued plant operation if the program
requested by Item 3b has not been completed by the time of the
bulletin response.
4. Provide a written report within 120 days of the date of this bulletin
that either:
a. States that no T-L supplied materials have been furnished for
your facility for use in safety-related systems.
b. Provides the results of those actions taken in response to Items
2a, 2b, and 2c above, as they apply to materials not yet
installed and to materials installed in plants under
construction. The report should include your plan and schedule
for completing actions 2b and/or 2c.
c. Provides the results of those actions taken in response to Items
3a, 3b, and 3c above, as they apply to materials installed in
operating plants. The report should include your plan and
schedule for completing item 3b and your basis for continued
operation if item 3b has not been completed.
Although the specific details involving the nonconforming materials
supplied by T-L may not directly apply for your facility, you are
requested to review the general concerns expressed in the bulletin for
applicability at your facility. Your response should describe the
results of the review, and if the general concerns apply, you should
describe the short-term and long-term corrective actions to be taken
and the schedules thereof.
*For the purpose of the applicable actions of this bulletin "safety-related"
constitutes those systems covered by the definition given in 10 CFR Part
100, Appendix A Sections III.(C)(1), III.(c)(2), and III. (c)(3). In
assessing the impact of T-L supplied materials in other systems at their
facilities, licensees should consider the provisions of GDC 1 to 10 CFR Part
50 Appendix A.
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July 22, 1983
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The written reports required by Items 4a, 4b and 4c above shall be submitted
to the appropriate Regional Administrator under oath or affirmation under
the provisions of Section 182a, Atomic Energy Act of 1954 as amended. In
addition, the original copy of the cover letters and a copy of the reports
shall be transmitted to the U.S. Nuclear Regulatory Commission, Document
Control Desk, Washington, D.C. 20555 for reproduction and distribution.
This request for information was approved by the Office of Management and
Budget under clearance number 3150-0011.
Although no specific request or requirement is intended, the following
information would help the NRC evaluate the cost of implementing this
bulletin:
1. Utility staff time to perform requested inspections and evaluations.
2. Radiation exposure attributed to requested inspections.
3. Utility staff time spent to prepare written responses.
If you have any questions regarding this matter, please contact the Regional
Administrator of the appropriate NRC Regional Office, or the technical
contact listed below.
Richard C. DeYoung, Director
Office of Inspection and Enforcement
Technical Contact: J. R. Fair, IE
(301) 492-4509
Attachments:
1. List of Recently Issued IE Bulletins
2. Table 1 - Listing of known and intended recipients of Tube-Line
Corporation furnished carbon steel materials
3. Table 2 - Listing of known and intended recipients of Tube-Line
Corporation furnished stainless steel materials
Page Last Reviewed/Updated Tuesday, March 09, 2021