United States Nuclear Regulatory Commission - Protecting People and the Environment

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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