Part 21 Report - 1997-030

ACCESSION #: 9701130161 NOTE: This text document was processed from a scanned version or an electronic submittal and has been processed as received. Some tables, figures, strikeouts, redlines, and enclosures may not have been included with this submittal, or have been omitted due to ASCII text conversion limitations. In order to view this document in its entirety, you may wish to use the NUDOCS microfiche in addition to the electronic text. Master Builders, Inc. Master Builders Technologies 23700 Chagrin Boulevard Cleveland, Ohio 44122-5554 Phone 216/831-5500 January 8, 1997 Document Control Desk U.S. Nuclear Regulatory Commission Washington DC 20555 RE: Notification Of Potential Nonconformance for Masterflow 713 (CMTR) Grout To Whom It May Concern: This is to advise you of a reported nonconformance related to Masterflow 713 (CMTR) Grout, which Master Builders, Inc. has supplied as a nuclear safety-related product to 18 nuclear power plants. Please find attached, a letter of notification that was mailed to the affected nuclear utilities. It summarizes the nature of the reported nonconformance. Also attached is the distribution list for the notification letter. We are currently awaiting response from the various utilities. At this point, we have not determined whether or not this situation has created a substantial safety hazard at any of the affected nuclear utilities. As stated in the notification letter, the scope and impact of the nonconformance is highly dependent upon use, age of the material at the time of placement, and behavior of the material during placement Nevertheless, we feel that it is prudent to keep your office informed of all developments and activities pertaining to this situation. Finally, future correspondence regarding this matter will be handled by John Dorado, Quality Control Manager or Tom Will, Assistant Product Manager, who are coordinating all activities related to this matter, with the exception of an incident involving a substantial safety hazard. Upon completion of our evaluation, and if necessary, all correspondence related to the reporting of a substantial safety hazard caused by this nonconformance will be submitted by me. If you have any questions, or need additional information, please contact John or Tom at 216831-5500. If needed, you may contact me at the same telephone number, as well. Respectfully Yours, William K. Secre Vice President, Research & Development Master Builders, Inc. cc: L. M. Shydlowski, J. P. Boyer, P. Vinocur, J. Truax, C. Soeder, B. Smith, T. Will, T. Coverdale, B. Caine, R. Wells, J. Dorado nrc9701/jd Master Builders, Inc. Master Builders Technologies 23700 Chagrin Boulevard Cleveland, Ohio 44122-5554 Phone 216/831-5500 Date Page 1 of 3 Customer Sample Attention: RE: Notification of Potential Nonconformance for Masterflow 713 (CMTR) Grout Dear Customer, Master Builders recently received notice (written notice on 11/14/96) from the Entergy Operations' Grand Gulf Nuclear Station (Port Gibson, MS) regarding potentially defective Masterflow 713 (CMTR) Grout. Based on our records, and in accordance with the requirements and standard operating procedures of the Master Builders Quality Assurance Program, we are notifying any nuclear facilities that have ordered Masterflow 713 (CMTR) Grout from Master Builders in 1996 of the foregoing situation. Priority has been given to those facilities that have been shipped the specific lots in question (see below). Please be advised that we are currently in the evaluation stage of the process to determine the scope and cause of the problem. Nature of the Observed Nonconformance As reported by Grand Gulf Nuclear, the following nonconformances were observed during their testing: o foaming/frothing o segregation o shrinkage o slow setting o low compressive strength Material was returned to the Master Builders Streetsboro, Ohio QC Lab for testing. Our preliminary testing confirmed the nonconformances noted by Grand Gulf Nuclear with the exception of the low strengths (1 day compressive strengths of approximately 2,900 psi were obtained from our testing). Lot Numbers in Question The following are the lot numbers in question: o 24-3849-W5 o 24-4187-N6 o 24-4582-S6 Page 2 of 3 Other Masterflow 713 (CMTR) Lots from 1996 Although our testing has focused on the above referenced lots, other lots of Masterflow 713 (CMTR) produced in 1996 include: o 24-4427-R6 o 24-4884-W6 No material from Lot No, 24-4427-R6 was available for retesting. Lot No. 24-4884-W6 was tested by the Grand Gulf Nuclear Station and performed in an acceptable manner (i.e. no frothing/foaming or segregation). Retesting of material from this lot on material by the Master Builder Streetsboro, Ohio QC Lab confirmed acceptable performance. Suspected Cause At this point, we are in the preliminary stages of our assessment to determine the root cause of the problem. We suspect that there may be some type of shelf-life instability associated with one or more of the raw materials. However, we can only speculate as to the cause until additional information becomes available. Testing to date, has demonstrated that any Masterflow 713 (CMTR) Grout that was used within 3 months of the manufacture date is not affected by the suspected shelf-life instability problem. As mentioned, testing performed on a recent lot of Masterflow 713 (CMTR) Grout (Lot No. 24-4884-W6) by Grand Gulf Nuclear and subsequently retested by Master Builder shows it to perform as expected (i.e. no signs of foam/froth or segregation). In addition, the irregular behavior only occurs in the unhardened state, immediately after mixing. Therefore, material that does not exhibit this behavior (i.e. foaming/frothing, segregation) will perform as expected in the hardened state (i.e. conformance to the requirements of ASTM C1107). Several efforts are underway to isolate the source of the problem in order to rectify the situation. Request for Information An important part of our evaluation to gain insight as to the scope and possible cause of the problem, is information from the nuclear utilities that have been shipped Masterflow 713 (CMTR) Grout in 1996. Consequently, we respectfully request that you provide us the following information regarding Masterflow 713 (CMTR) shipped to your facility(s) in 1996. o The amount of material that has been installed by lot number. o How was the material used (type of application/installation). o When was the material installed. o Specific lot number(s) of the material used. o Lab or field test reports pertaining to the material installed (i.e. performance data, observations about the material behavior, etc.) o Any additional documentation that may be helpful. Page 3 of 3 For any material that has not been placed into service, we recommend that you do not use such material (put on QA "Hold"). Please contact Tom Will at ext. 2018 to work out the details on its disposition and replacement. In addition, we recommend that you evaluate any of the subject lots of Masterflow 713 (CMTR) Grout that you have placed into service to ensure that it met the requirements of your specific application. As mentioned earlier, based on our testing to date, it has been demonstrated that any material that was used within 3 months of its date of manufacture is unaffected by the suspected shelf-life instability problem. The best indication of the material's acceptable performance is whether or not the material exhibited any foaming/frothing after mixing. This behavior would be noticeable immediately after mixing. If the material did not exhibit this behavior, then the material was not affected. Finally, in order for us to proceed with our evaluation in an expeditious manner, we request that you provide us with the above mentioned information by 1/17/97. As mentioned, the information is an important part of our evaluation to determine the scope and cause of the problem, and to rectify the problem as soon as possible. If you have any questions, or need additional information, please contact me at your earliest convenience at 216-831-5500, extension 2240, or Tom Will at extension 2018. Sincerely. John Dorado Quality Control Manager Master Builders, Inc. cc: L. M. Shydlowski, J. P. Boyer, W. Secre, P. Vinocur, J. Truax, C. Soeder, B. Smith, T. Will T. Coverdale, R. Wells, L. Huang, B. Caine, G. Culton, Streetsboro QC extnot0s/jd Attachment "Masterflow 713 (CMTR) - Notification Distribution List" 4 pages, omitted. *** END OF DOCUMENT ***

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