United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9510110287

                           Aerofin Corporation
                                 Aerofin

   Home              Standard and Custom Engineered         New York
  Office              Heating and Cooling Surface           Chicago
and Plant                                                    Dallas
Lynchburg                                                San Francisco
 Virginia                     P.O. BOX 10919                 Atlanta

1-800-AEROFIN          LYNCHBURG, VIRGINIA 24506
Phone: 804-845-7081
Fax: 804-845-3508           October 4, 1995

CC: (with attachments)
Document Control Desk
U.S. Nuclear Regulatory Commission
Washington, D.C. 20555

Ms. Barb Dotson
Consumers Power Company
Palisades Nuclear Plant
22780 Blue Star Memorial Highway
Covert, MI 49043-9530

Subject: 10CFR21 Report

Reference: 1) Consumers Power Purchase Order G0109437

           2) Aerofin Shop Order No. 947963

           3) 10CFR21 Report from Consolidated Power Supply to Aerofin
           dated October 3, 1995 (attached)

           4) Aerofin ASME Design Report dated 11/7/94 (cover page and
           pages 26 & 27 only - attached)

Dear Ms. Dotson:

Aerofin received notification on October 3, 1995 from Consolidated Power
Supply that a report has been issued to the United States Nuclear
Regulatory Commission (NRC) regarding fastener products manufactured by
Cardinal Industrial Products.  Included in the report to the NRC were
1,475 hex bolts (5/8"-11 x 3 inches, ASME SA193, Grade 137) 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 1). These thirteen coils (twelve coils plus one spare)
were shipped to the Palisades Nuclear Plant on or about November 16,
1994.

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

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 CX1).  Of the 1,475 bolts purchased by
Aerofin, 1,456 were actually used in the coils.

The deficiency involves apparently inadequate heat treatment which has
resulted in mechanical properties below required minimums, although no
actual test results have been received at this time.  Please see the
attached copies (Reference 3) of the notification received from
Consolidated Power Supply and reports from Cardinal Industrial Products.

Preliminary information indicates that the worst condition identified to
date is tensile strength that is 70 percent of required value.  Because
we have no official data at this time with which to evaluate whether a
substantial safety hazard may exist and as required by 10CFR21, we are
also notifying the NRC of this condition by copy of this letter.

It is worthy of note that the margin of safety for the header bolts as
evidenced by Aerofin's ASME design report calculations (Reference 4) is
quite high.  Coupled with the fact that actual maximum system operating
pressure is on the order of 80 psig compared to a design pressure of 150
psig, there is significant margin available to accommodate substandard
bolt strength characteristics.

As soon as additional information is received by Aerofin it will be
communicated to Consumers Power Company.  If you have any questions at
this time, please contact me at 804-528-6210 (telephone) or 804-528-6243
(telefax).

Very truly yours,

Brian C. Elliott, P.E.
Manager
Nuclear and Code Products

cc: D. L. Corell, Aerofin President and Chief Operating Officer

                        CONSOLIDATED POWER SUPPLY
                          3556 MARY TAYLOR ROAD
                       BIRMINGHAM, AL (USA) 35235

                         PHONE: (205) 655 - 5515

                          FAX: (205) 655 - 5511

                      FACSIMILE TRANSMISSION TICKET

DATE:                                             TIME:

NUMBER OF SHEETS TO FOLLOW:

TO:

FROM:

TYPE OF DOCUMENT TRANSMITTED:

COMMENTS:

Consolidated
Power Supply

CpS

October 3, 1995

Aerofin Corporation
4621 Murray Place
Lynchburg, VA 24505

Attn: Mr. Tony L. Hawks
      QA Lead Auditor

Subject: 10CFR21 Report

Reference: Aerofin Purchase Order 13822, Dated March 15, 1994

Dear Mr. Hawks:

Consolidated Power Supply (CPS) has received correspondence from Cardinal
Industrial Products that a report has been issued to the United States
Nuclear Regulatory Commission regarding fastener products provided to
your company against the referenced order.  Included in the report were
1475 each of 5/8"-11 X 3" SA193 B7 hex bolts, which were initially
certified by CPS and shipped to your Lynchburg facility on May 25, 1994.

Heat codes included TU2 (856 each) and CX1 (619 each) and were shipped to
Aerofin directly from Cardinal's Las Vegas, NV facility.  The material
was certified as meeting the requirements of the ASME Code, Section III,
1989 Edition No Addenda.

The deficiency involves the apparent inadequate heat treatment of the
bolts, which has effected the mechanical properties.  No actual test
result values have been conveyed at this time by Cardinal; however, the
testing indicates results below the required minimums based upon tile
Cardinal reports.  Please find attached a copy of the reports received by
CPS on 1012/95 from Cardinal relative to the referenced order.

As soon as additional information is received by CPS it will communicated
immediately to Aerofin.  If there are any questions please contact the
undersigned.

Sincerely,

Steven W. Andrews
Quality Assurance Manager

Attachment - Cardinal Reports (4 Pages Total)
cc:  H. Kerr - President, CPS, w/a
     M. Mathias - Gen.  Mgr., CPS, w/a

   3556 Mary Taylor Road o Birmingham, Alabama 35235 o (205) 655-5515

    A Division of Consolidated Pipe & Supply Co., Inc. Birmingham, AL

                     Cardinal
               INDUSTRIAL PRODUCTS
Nuclear Division of B&G Manufacturing Company, Inc.
3673 West Oquendo o Las Vegas, Nevada 89118-3098
      (702) 739-1966 o Fax (702) 739-1960

Date: SEP 29 1995

Customers Name: Consolidated Power Supply
                3556 Mary Taylor Road
                Birmingham, AL 35235

Attention:      Steve Andrews
                Manager of Quality Assurance

From:           David Z. Hathcock, Quality Assurance Manager

Subject:        10 CFR Part 21 notification reporting of Defects
                and Noncompliance.

Reference:      Description 5/8-11 x 3" A193 B7 Hex Bolt

                Purchase order D65-49042 Line Item 1 Qty. 856

                Product Marking B7. C. TU2 Shipment Date 05/24/94

Please be advised that the above referenced fasteners that were supplied
to you by Cardinal Industrial Products L.P.  originated from a heat lot
charge that contained defective product.

This discrepancy was discovered during a customer's receipt inspection,
B&G Manufacturing Co., Inc's Cardinal Industrial Products division, which
earlier this year purchased certain assets from Cardinal Industrial
Products, L.P.  including the name, has conducted an preliminary internal
investigation which has confirmed that as many as 25% of the fasteners
from the beat lot charge may have mechanical properties below the
specified minimums.

Early indications suggest that the discrepancies resulted from inadequate
heat treatment. A comprehensive investigation is being conducted to
determine the exact cause of the problem. We will provide a detailed
report within sixty (60) days.

                                                              Page 2 of 2

This notification is provided by B&G as a service to its current
customers who may have purchased this product from the prior owner, so
that you can conduct an evaluation to determine if this product defect
creates a substantial safety hazard in accordance with 10 CPR Part 21
paragraph 21.21 (a) (1) (ii) and (b) (1) . We have reported this problem
to the Nuclear Regulatory Commission (NRC) Inquiries may be directed to
me at (702) 739-1966, Fax (702) 739-1960.

cc: Customer file

                    Cardinal
               INDUSTRIAL PRODUCTS
Nuclear Division of B&G Manufacturing Company, Inc.
 3873 West Oquendo o Las Vegas, Nevada 89118-3098
      (702) 739-1966 o Fax (702) 739-1960

Date: SEP 29 1995

Customers Name:     Consolidated Power Supply
                    3556 Mary Taylor Road
                    Birmingham, AL 35235

Attention:          Steve Andrews
                    Manager of Quality Assurance

From:               David Z. Hathcock, Quality Assurance Manager

subject:            10 CFR Part 21 notification reporting of Defects and
                    Noncompliance.

Reference:          Description 5/8-11-x 3" A193 B7 Hex Bolt
                    Purchase order D65-49042 Line Item 1A Qty.  619
                    Product Marking B7, C, CX  Shipment Date 05/24/94

Please be advised that the above referenced fasteners that were supplied
to you by Cardinal industrial Products L.P.  originated from a heat lot
charge that contained defective product.

This discrepancy was discovered during a customer's receipt inspection,
B&G Manufacturing Co., Inc's Cardinal Industrial Products division, which
earlier this year purchased certain assets from Cardinal Industrial
Products, L.P. including the name, has conducted an preliminary internal
investigation which has confirmed that as many as 25% of the.  fasteners
from the heat lot charge may have mechanical properties below the
specified minimums.

Early indications suggest that the discrepancies resulted f rom
inadequate heat treatment.  A comprehensive investigation is being
conducted to determine the exact cause of the problem.  We will provide a
detailed report within sixty (60) days.

                                                              Page 2 of 2

This notification is provided by B&G as a service to its current
customers who may have purchased this product from the prior owner, so
that you can conduct an evaluation to determine if this product defect
creates a substantial safety hazard in accordance with 10 CFR Part 21
paragraph 21.21 (a) (1) (ii) and (b) (1).  We have reported this problem
to the Nuclear Regulatory Commission (NRC) inquiries may be directed to
me at (702) 739-1966, Fax (702) 739-1960.

cc: customer file

                              DESIGN REPORT

                  ASME BOILER AND PRESSURE VESSEL CODE

          SECTION III, DIVISION 1, CLASS 3, SUBSECTIONS ND & NF

                         1989 EDITION NO ADDENDA

                     BUYER: CONSUMERS POWER COMPANY

                         PALISADES NUCLEAR PLANT

                     PURCHASE ORDER NUMBER G0109437

                          AEROFIN TYPE R COILS

                      AEROFIN SHOP ORDER CR-947963
                                        Items 001 thru 013

                       SPECIFICATION M-60A, REV. A

                              page 1 of 39

                        AEROFIN CALCULATION FILE
                        CA-529-546           Rev 4

                                        PREPARED BY :
AEROFIN CORPORATION                                    KIM W. LIENBERGER
4621 MURRAY PLACE                                      PROJECT ENGINEER
PO BOX 10819
LYNCHBURG,VA 24506
                                        APPROVED BY:
                                                       GARY CARROLL
                                                       VICE PRESIDENT
                                                       ENGINEERING

ASME SECTION III, SUBSECTION ND DESIGN REPORT          PAGE 26 OF 39

AEROFIN CALCULATION FILE CA - 529 - 546 REV. 1
------------------------------------------------------------------------
HEADER BOLT ANALYSIS

Bolt Material: ASME SA-193 Gr. B7       5/8 in. Diameter.
Tensile Stress area = .226 in**2
Allowable stress = 25000 psi [ASME Section III Table I-7.3]
Minimum ultimate tensile strength = 125000 psi [Table I-7.3]

The header bolts are subjected to loads due to pressure, gasket seating,
and nozzle loads.  These loads are summed to find the worst case stress
on any of the bolts.

From the specification, Nozzle Forces (lbs) and Moments (in-lbs) are Fx=
1200 Fy= 1200 Fz= 1200 Mx= 7200 My= 7200 Mz= 7200

PRESSURE LOAD  Ref. ASME Sec.III, Appendix XI-3220

Pforce = Force / bolt due to pressure
Pforce = pressure * area / number of bolts
Pforce = 150 * (18.5 51.0) / 56 = 2,527.3 lbs/Bolt

GASKET LOAD    Ref. ASME Sec. III, Appendix XI-3221.1

Effective gasket seating width: Ref.  ASME Section III Table XI-3221.1-2

  For perimeter gasket bo1 = (W + T)/2 = (1.5 + .125) / 2 = .8125
                        b1 = .5 * sqrt (bol) = .5 * sqrt(.8125) = .4507
  For baffle gasket    bo2 = (W + N) / 4 = (.25 + .375) / 4 = .156
                        b2 = bo = .156
     Gi = Perimeter at gasket reaction
     G1 = 18.5 in.
     G2 = 51.0 in.

Gforce = Force / bolt due to gasket reaction
     Gforcei = 2 * bi * mi * pressure * GI / number of bolts
     Gforce1 = 2 * 0.4507 * .50 * 150 * 20.0 / 56 = 24. 1 lbs/bolt
     Gforce2 = 2 * 0.156 * .50 * 150 51.0 / 16 = 74.6 lbs/bolt
Gforce = 24.1 + 74.6 = 98.7 lbs/bolt

NOZZLE LOADS
Axial forces on bolts are Induced by Fx, Fy, Fv, My, & Mv.
B1 = # of bolts on long side; Bs = # of bolts on short side
D1 & Ds = Center to center distance between bolts on long & short aides

B1 = 17, Bs = 7, D1 = 52.5, Ds = 20.0

ASME SECTION III, SUBSECTION ND DESIGN REPORT     PAGE _27_ OF _39
AEROFIN CALCULATION FILE CA - 529 - 546 REV. 2

------------------------------------------------------------------------
HEADER BOLT ANALYSIS continued

F1 = forces on long side bolts due to Fx, Fy & Mv
F1 = (Fx / B1) + (2 * (Mz + Fy * a) (B1 * Ds))
F1 = (1200 / 17) + (2 (7200 + 1200 9.875) / (17 * 20.5))
F1 = 180 per bolt

Fs = forces on short side bolts due to Fx, Fv & My
Fs = (Fx / Bs) + (2 * (My + Fz * a) (Bs * D1))
Fs = (1200 / 5) + (2 * (7200 + 1200 * 9.875) / (5 * 52.5))
Fs = 385.1 per bolt

TOTAL TENSILE STRESS

Long side tensile force per bolt = T1 = F1 + pload + gload
                                       = 180 + 2, 527.3 + 98.7 =2806
Short side tensile force per bolt = Ts = Fs pload + gload
                                  = 385.1 + 2,527.3 + 98.7 = 3011.1
Tensile stress = Tensile Force / Stress area
Tensile stress on long side bolts = 2806.0 / .226 = 12,416 psi
Tensile stress on short side bolts = 3011.1 / .226 = 13,323 psi
For calculations use the larger of short or long side stress
Total tensile stress = Saxial = 13,323 psi

SHEAR STRESS

Shear stresses are induced by Mx
Shear force = Fs = 2Mx / 4*d, d = longest perpendicular distance from
                                  moment to bolts (4 corner bolts)
Shearing Force = 2 * 7,200 / 4 * 40 = 90
Shear Stress = Shear force stress area = 90 / .226 = 399 psi

MAXIMUM BOLT TORQUE (Ref Spotts p 276)
T = 0.2 * Area * dia(major) * (0.7 * U1t strength)
T = 0.2 * 0.226 * 0.625 * (0.7 125000) /12 (12 converts to ft-lbs)
T = 206 ft-lbs

COMBINED TENSILE AND SHEAR STRESSES
Combined tensile and shear stresses must not exceed the ellipse equation
given in NF-3324.6(3) [1986 Code].
The 1989 Code does not address allowable shear stresses for non-welded
pressure-retaining components.  Therefore, using allowable shear stress
equation for structural components In 1989 Code NF-3324.6,
Fvb = .62 * Su / 3 = .62 125000 / 3 = 25,833
Ftb = Su / 2 = 125,000/2 = 62,500
(ft**2 / Ftb**2) + (fv**2 / Fvb**2) 





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