ML17309A621
| ML17309A621 | |
| Person / Time | |
|---|---|
| Site: | Hatch, Calvert Cliffs, Seabrook, Crystal River, Ginna, Vogtle, FitzPatrick  |
| Issue date: | 09/29/1997 |
| From: | Secre W AFFILIATION NOT ASSIGNED |
| To: | Monday J NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| REF-PT21-97 NUDOCS 9710090068 | |
| Download: ML17309A621 (6) | |
Text
Master Builders c.
23700 Chagrin Boulevard Cleveland, Ohio 44122-5554 Phone 216/831-5500 IEll lilt)
September 29, 1997 Document Control Desk U.S. Nuclear Regulatory Commission:,
Washington DC 20555 Attn.
Mr. Joel Monday RE:
Final Disposition ofMasterflow 713 (CMTR) and Embeco 636 (CMTR)
Grout Nonconformance
Dear Mr. Monday:
This is to provide you with a summary ofthe final disposition ofMastcrflow 713 (CMTR) and Embcco 636 (CMTR) Grout nonconformance reported by Master Builders, Inc. earlier this year.
Please find attached, a letter ofnotification tliat willbc mailed to thc alfcctcd nuclear utilities. It summarizes thc nature ofthc reported nonconforiaanc, suspected cause, additional testing/points of relevance, and actions to prevent recurrcncc.
As mcntioncd in the letter, the suspcctcd cause ofthe nonconformance is an incompatibility between key formulation coinponents and the locally available portland cement (Strcctsboro, OH) used in thc above mcntioncd products.
Further, wc have detcrmincd that thc specific nonconforming behavior is observed only afler the Streetsboro, OH formulated products "ages" (shelf-life) for morc than 3 months.
These problems DO NOT exist with thc products produced at our Rancho Cucamonga, CA plant from portland cement which is locally availablc in Southern California.
Additionally, the matter was discussed extensively with rcprcscntativcs from Entcrgy Operations during a NUPIC audit in March ofthis year. Unfortunately, these discussions produced no additional insights as to the exact cause ofthc nonconformance.
In any cvcnt, we arc issuing the attached letter in an clfort to bring this issue to closure. Itwill be mailed to all utilities originally notified earlier this year.
Ifyou have any questions, or nccd additional inforinatio, plcasc contact John Dorado or myself at 216-831-5500.
Respectfully Yours, WilliamK. Secre Vice President, Research &Dcvclopmcnt Master Builders, Inc.
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L. M. Shydlowski, J. P. Boycr, P. Vinocur, B. Violatta, L. Yappcl Q 9 0 P P $
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Date Page1of2 Customer Sample Attn.
RE:
Final Disposition ofMasterflow 713 (CMTR) and Embeco 636 (CMTR)
Grout Nonconformance
Dear Customer,
This is to provide you with a summary ofthc final disposition ofMastcrflow 713 (CMTR) and Embeco 636 (CMTR) Grout nonconformance reported by Master Builders, Inc. earlier tins year.
Nature ofthc Ohscrvcd Nonconformance As reported by Grand GulfNuclear, in November 1996, the followingnonconformances werc observed during their testing ofMasterflow 713 (CMTR) Grout:
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foaming/frothing
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segregation
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sluinkage
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slow setting
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low compressive strength Material was returned to the Master Builders Streetsboro, Ohio QC Lab for testing. Our preliminary testing confirmed the nonconformanccs noted by Grand GulfNuclear with the exception ofthc low strengths (1 day comprcssivc strengths ofapproximately 2,900 psi were obtained from our testing).
In addition, wc have tested several bags ofmaterial, produced at different points ofthe year, and liave observed thc saine foaming/frotlung and segregation.
Similar behavior was also observed for Strectsboro produced Embcco 636 (CMTR) Grout, which is based on the same primary formulation as Masterflow 713 (CMTR) Grout.
The suspected cause ofthe nonconformance is an incompatibility between kcy formulation components and the locally available portland ccmcnt (Streetsboro, OH) used in the above mcntioncd products. Further, we liave determined tliatthe specific nonconforming behavior is observed only afler the Strcctsboro, OH formulated products "ages" (shelf-life) for more titan 3 months.
These problems DO NOT exist with the products produced at our Rancho Cucamonga, CA plant from portland cement which is locally available in Southern California.
Additional Tcstin pints ofRelevance Testing to date, has deinonstrated tliat any Masterflow 713 (CMTR) Grout or Embeco 636 (CMTR) Grout that was used witlun 3 months ofthe manufacture date is not alIected by the suspected shelf-life instability problem. Initially,testing was performed by Grand GulfNuclear and subsequently rctested by Master Builders on a lot ofMasterflow 713 (CMTR) Grout (Lot No. 244844-W6) that was less than 3 months old. In both cases, thc grout performed as expected (i.c. no signs offoam/froth or scgrcgation).
Subscqucntly, this material lias been rctestcd at 3, 4, 5 and 6 months ofagc. Wc found that, up to 5 months, thc material performed in an acceptable manner.
However, thc material showed signs of the undesirable behavior at 6 months. Testing ofEmbeco 636 (CMTR) Grout produced similar results. In any event, the 3 month timcfmme is a very conservative estimate.
Page 2 of2 In addition, we have confirmed tluough testing that the irregular bcliavior only occurs in thc unhardened state, immediately after mixing. Therefore, material tliat does not exhibit tins bcliavior (i.e.
foaming/frothing, segregation) willperform as expected in the hardened state (i.e. conformance to the requirements ofASTMC1107 and CRD-C621).
Furthermore, wc Iiavc confirmed that the undesirable behavior occurs only when thc grout is mixed to a fluidconsistency (20-30 sec. tlirough a flowcone).
Suspect grout mixed at flowable, stiffor damp-pack consistencies does not exhibit thc beliavior, and perforins as intended (i.e. no foaming, frothing, segregation; and meeting the requirements ofASTM C1107 and CRD-C621).
Actions to Prevent Rccurrcncc Since the initialrcport from Grand GulfNuclear, Master Builders lias discontinued production of Mastcrflow 713 (CMTR) and Embcco 636 (CMTR) Grouts at the Strectsboro, OH plant. Allorders for Mastcrflow 713 (CMTR) and Embeco 636 (CMTR) Grouts have bccn and willcontinue to bc supplied from our Rancho Cucamonga, CA plant. Mastcrflow 713 (CMTR) and Embcco 636 (CMTR) Grouts, produced at this facility, have not exhibited thc same undesirable behavior.
We are continuing to monitor the shelf-life ofMasterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts produced at Rancho Cucamonga, as a precautionary measure.
In terins ofnuclear safety-related orders, we arc slupping material from the Rancho Cucamonga, CA plant to thc Streetsboro, OH plant (being held at and shipped from the Aurora, OH warehouse).
The material is being dedicated for safety-related use by the Strcctsboro QC lab, in accordance withPolicy 10-Commercial Grade Dedication ofProducts, ofthe Master Builders QA Manual. Furthermore, we will continue to dedicate Rancho Cucamonga produced Mastcrflow 713 (CMTR) and Embeco 636 (CMTR)
Grouts in this manner, until the shelf-life issue with Strectsboro, Oluo produced Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts is resolved.
As I mentioned, our plan is to either rcforinulatc Masterflow 713 (CMTR) and Embcco 636 (CMTR) Grouts, or develop replacement grouts forMastcrflow 713 (CMTR) and Embcco 636 (CMTR)
Grouts in order to correct and prevent recurrencc ofthe nonconforining bcliavior. Untilthat time, Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts, as mcntioncd above, willonly produced at our Rancho Cucamonga plant, and dedicated pcr our Policy 10.
I hope that this information is helpful to you. Please review thc above information, and contact mc, ifany additional actions need to be taken. Unless we hear othcvvise, we willconsider tins matter closed.
Ifyou have any questions, or need additional inforination, please contact me at your earliest convenience at 216-831-5500, extension 2240.
Sincerely, John Domdo Product Manager (formerly Quality Control Manager)
Master Builders, Inc.
cc:
B. Caine, G. Culton ertnotfinal/jd
Multi Li i
~Final notification willbeforwarded to all affected utilities, originallynotified, that DIDNOTrespond.
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South Carolina Gas &Electric Co.
P.O. Box 88 Jenkinsville, SC 29065
'Attention:
Mr. Thomas Borch - Product Quality
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Bechtcl Power Corporation (R.E. Ginna Nuclear Station) 89 East Ave.
Rochester, NY 14649 Attention:
Mr. Dave Frcdrickson
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Rochester Gas &Electric Co.
1503 Lake Rd.
Ontario, NY 14519 Attention:
Mr. Richard Biedcnbach, Director, Safety &Health, Nuclear Power
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Public Service Electric &Gas Co.
965 Chestcrbrook Blvd.
Mail Code 63C-1 Wayne, PA 19087 Attention:
Mr. BillBradley, Nuclear Quality Assurancecc:
Ms. Cathy Talbert (Buyer)
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VirginiaPower Co.
Innsbrook Teclmical Center 5000 Dominion Blvd.
Glen Allen, VA23060 Attention:
Mr. JeffBailey
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Consolidated Edison ofNew York 4 IrvingPlace Room 615 S New York, NY 10003 Attention:
Mr. ArthurNg, Q.A. Engineer
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Southern Nuclear Operating Co.
Georgia Power Co. (rc: Hatch and Vogtle plants)
P.O. Box 1295 Birtninglmm, AL35201 Attention:
Nuclear Engineering &Licensing Meager and Manager - Materials Services
Georgia Power Co. (rc: Vogtlc plant)
Nuclear Operations P.O. Box 1600 Wayncsboro, GA, 30830 Attention:
General Manager Entergy Operations, Inc.
P.O. Box 31995 Jackson, MS 39286-1995 Attention:
Glenn Green Consumers Power Co.
212 West Miclugan Ave.
Jackson, MI49201 Attention:
Ms. Nancy Borton Ncw YorkPower Authority James A. Fitzpatrick Nuclear Power Plant 268 Lake Rd.
P.O. Box 41 Lycoming, NY 13093 Attention:
Mr. Doug Mullens and Mr. Dan Sullivan Baltimore Gas &Electric Co.
Calvert CliffsNuclear Power Plant 1650 Calvert CliffsParlavay Lusby, MD 20657 Attention:
Supervisor, Vendor Audits North Atlantic Energy Services Seabrook Station Box 300 Seabrook, NH 03874 Attention:
B.L. Drawbridge, Executive Director, Nuclem Production R.J. DeLoach, Executive Director, Engineering &Licensing M.D. Harrington, Material Requirements Departtnent Supervisor American Electric Power Co.
Indiana/Michigan Power Co.
1 Riverside Plaza Columbus, OH 43215 Attn.
Manager - Nuclear Safety Licensing &Fuels Division
<<<< *Sentforinformational purposes only.
Florida Power Corporation Crystal River Energy Complex 15760 W. Power Linc St.
Crystal River, FL 34428-6708 Attention:
Mr. J. O. Poston, Senior Nuclear Quality Assurance Specialist
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