ML050770271
| ML050770271 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 03/15/2005 |
| From: | AmerGen Energy Co, Exelon Corp, Precision Surveillance Corp |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| -RFPFR | |
| Download: ML050770271 (401) | |
Text
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WATER/nRY RESERVE(1 ) 1 .) 1 1 WEIGHT (2) SAMPLE TENDON CHLORIDES NITRATES( ) SULFIDES( . ALKALINITY IDENTIFICATION END (PPMl (PPM) (PPM) _% (BASE NUMBER)
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SUBURBAN LABORATORIES, Inc.. A . 4140 Litt Drive Hillside, Illinois 60162-1183 'a Tel. (708) 544-3260 Toll Free (800) 783-LABS
- Fax (708) 544-8587 www.SuburbanLabs.com - O I Il>;ID -
Client ID: Precision Surveillance Corp. CASENARRATIVE Project Name: Grease Samples Lab Order: 04120719 Date: January 27, 2005 Chain of Custody #PO 0 Temperature of samples upon receipt in our Lab: C QCLevel: Level I p. General Comments:
- All results reported in wet weight unless otherwise indicated. (dry = Dry Weight)
- Sample results relate only to the analytes of interest tested and to sample as received by the laboratory.
- Environmental compliance sample results meet the requirements of 35 IAC Part 186 unless otherwise indicated.
- Accreditation by the State of Illinois is not an endorsement or a guarantee of the validity of data generated.
- For more information about the laboratories' scope of accreditation, please contact us at (708) 544-3260 or the Agency at (217) 782-6455.
Abbreviations:
- Reporting Limit: The reporting limit is designed to be the lowest concentration that can be reliably achieved within specified limits of precision and accuracy during routine laboratory operatingconditions.
- J: The analyte was positively identified above our Method Detection Limit and is considered detectable and usable; however, the associated numerical value is the approximate concentration of the analyte in the sample.
- ATC: Automatic Temperature Correction. - TNTC: Too-Numerous To Count
- In Laboratory: EPA recommends this analyte be analyzed "immediately" (e.g., tests that should be performed in the field within 15 minutes of collection). Analytes with "immediate" hold times are analyzed as soon as possible upon receipt by the laboratory.
- TIC: Tentatively Identified Compound (GCMS library search identification, concentration estimated to nearest internal standard).
Method
References:
For a complete list of method references please contact us.
- E: USEPA Reference methods
- SW: USEPA, Test Methods for Evaluating Solid Waste (SW-846)
- M: Standard Methods for the Examination of Water and Wastewater Project Specific Comments:
All tests performed per attached procedure SQ 7.2, REV. 0, Dated 7/23/04. Rpt Ver ID: 1127/05 10:05 AM Jason Page 2 of 17
JI=Suburban LaboratoripeTC. L ~aboratory Results I Client ID: Precision Surveillance Corp. Report Date: January 27, 2005 Project Name: Grease Samples Lab Order: 04120719 Client Sample ID: V164 FIELD Matrix: GREASE Lab ID: 04120719-27 Date Received: 12/20/2004 9:15 AM Collection Date: 11/23/2004 12:00 AM Report Dilution Parameter Result Qual. Limit -Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 . Analyst: BL Chloride 0.60 c 0.50 ppm 1 01/07/2005 10:00 AM R39257 MOISTURE BYASTM Method: D95 Analyst: SL Moisture Content 0.19 c 0.10 Wt% 1 01124/2005 12:00 AM R39612 NITRATE BY ASTM Method: D992 Analyst: BL Nitrate ND c 0.50 ppm 1 01/111/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: SL Base Number 45.2 C 0.500 mg KOH/g . 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA - Method: APHA427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/2612005 2:00 PM R39660 REVIEWED BY pjre Q. A. PERSONNEL DATsE - I'
.BY -K Qudifirers~-
- Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank
- B..Rj,pr1- c Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range C-fi~,-~2004 G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded J Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist)
Rpt Ver ID: 1/27105 10:05 AM Jason Page 16 of 17
A A02v0 Suburban Laboratories,Inc. d
- 4140Litt Drive, Hillsid. IL 60162 (708)544.3260 ILaboratory Results l Client ID: Precision Surveillance Corp. ReportDate: January 27, 2005 Project Name: Grease Samples Lab Order: 04120719 Client Sample ID: V140 SHOP Matrix: GREASE Lab ID: 04120719-25 DateReceived: 12/20/2004 9:15 AM CollectionDate: 08/31/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 0110712005 10:00 AM R39257 MOISTURE BYASTM Method: D95 Analyst: BL Moisture Content 0.14 c 0.10 wt% 1 0112412005 12:00 AM R39612 NITRATE BY ASTM Metho& D992 Analyst: -EL Nitrate ND c 0.50 ppm 1 01/1112005 8: 00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 46.7 c 0.500 mg KOH/g 1 01/1812005 12:00 AM R39467 SULFIDE BY APHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01/26/2005 2:00 PM R39660 Client Sample ID: V140 FIELD Matrix: GREASE Lab ID: 04120719-26 Date Received: 12/2012004 9:15AM Collection Date: 09/01/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor- - Date Analyzed Batch ED CHLORIDE BY ASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1- 01/07/2005 10:00 AM R39257 MOISTURE BY ASTM Method: D95 Analyst: BL Moisture Content ND C 0.10 wt% 1 01/24/2005 12:00 AM R39612 NITRATE BY ASTM Method: D992 Analyst EL Nitrate ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: EL Base Number 1.85 c 0.500, mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BY APHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01126/2005 2:00 PM R39660 REVIEWED by pad Q. A. PERSONNEL DATE 3-05
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Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank c Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Ccal-ns004 G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded J Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27/05 10:05 AM Jason Page 15 Of 17
W,1,:-vzzyA-99= A SuburbanLaboratorlesjnc. 4140 Litt Drive, Hillside, IL60162 (700) 544-3260 I Laboratory Results I Client ID: Precision Surveillance Corp. Report Date: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: V66 FIELD - Matrix: GREASE Lab ID: 04120719-23 Date Received: 12/20/2004 9:15 AM Collection Date: 09/01/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed BatchID CHLORIDE BYASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 0110712005 10:00 AM R39257 MOISTURE BY ASTM Method: D95 Analyst: BL Moisture Content ND c 0.10 wt% 1 01124/2005 12:00 AM R39612 NITRATE BYASTM Method: D992 Analyst: EL Nitrate ND c 0.50 ppm 1 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: D974 MOD Analyst EL Base Number 2.70 c 0.500 mg KOHIg 1 0111812005 12:00 AM R39467 SULFIDEBYAPHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01/26/2005 2:00 PM R39660 Client Sample ID: V86 FIELD Matrix: GREASE Lab ID: 04120719-24 DateReceived: 12/20/2004 9:15 AM Collection Date: 11/23/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: EL Chloride ND C 0.50 ppm 1 01/07/2005 10:00 AM R39257 MOISTURE BYASTM Method: 095 Analyst: EL Moisture Content 3.7 c 0.10 wt% 1 01124/2005 12:00 AM R39612 NITRATE BYASTM Method: D992 Analyst EL Nitrate ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD -Analyst: EL Base Number 41.4 c 0.500 mg KOHIg 1 01118/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 - ppm 1 0112612005 2:00 PM R39660 REVIEWED BY pe' Q. A. PERSONNEL DATE h BY Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank N.R~pn.t c Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Co,,i-W3O4 G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1127105 10:05 AM Jason .Page 14 of 17
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' . SuburbanLaboratories,Inc. I Laboratory Results A d
- 4140 Lin Drive, Hillside, 1L60162 (709) 544.3260 Client ID: Precision Surveillance Corp. ReportDate: January 27, 2005 Project Name: Grease Samples Lab Order: 04120719 Client Sample ID: V53 FIELD Matrix: GREASE LabID: 04120719-21 Date Received: 12/20/2004 9:15 AM- Collection Date: 09/01/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 01107/2005 10:00 AM R39257 MOISTURE BYASTM Method: D95 Analyst: BL Moisture Content ND c 0.10 wt% 1 01/2412005 12:00 AM R39612 NITRATE BYASTM Method: D992 Analyst: BL Nitrate ND c 0.50 ppm 1 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 2.91 c 0.500 mg KOH~g 1 01118/2005 12:00 AM R39467 SULFIDE BY APHA -- Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 0112612005 2:00 PM R39660 Client Sample ID: V66 SHOP Matrix: GREASE Lab ID: 04120719-22 - Date Received: 12/20/2004 9:15 AM Collection Date: 08o/31/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 01/07/2005 10:00 AM R39257 MOISTURE BYASTM Method: D95 Analyst: 6L Moisture Content ND c 0.10 wt% I 0112412005 12:00 AM R39612 NITRATE BYASTMI. Method: D992 Analyst: EL Nitrate ND - c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: EL Base Number 55.7 c 0.500 mg KOHIg 1 01/1812005 12:00 AM R39467 SULFIDE BYAPHA Method: APiHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01/26/2005 2:00 PM R39660 REVIEWED BY
-YQ. A. PERSONNEL DATE
- - ; BY Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank Analyte not included in SLI scope of accreditation E' Estimated, analyte detected above quantitation range Coe-,.zp-e.
Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded Estimated, analyt6 detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27/05 10:05 AM Jason Page 13 of 17
Suburban Laboratories, Inc. Laboratory Results
- 4140 Litt Drive, Hillside. IL 60162 (708) 544-3260 ClientID: Precision Surveillance Corp. ReportfDate: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: V32 FIELD Matrix: GREASE Lab ID: 04120719-19 Date Received: 12/20/2004 9:15 AM Collection Date: 09/01/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 0110712005 10:00 AM R39257 MOISTURE BY ASTM Method: D95 Analyst: BL Moisture Content 0.31 c 0.10 wt% 1 0112412005 12:00 AM R39612 NITRATE BY ASTM Method: D992 Analyst: EL Nitrate ND c 0.50 ppm 1 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 25.8 c 0.500 mg KOHIg 1 01118/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/2612005 2:00 PM R39660 Client Sample ID: V53 SHOP Matrix: GREASE Lab ID: 04120719-20 DateReceived: 12/20/2004 9:15 AM Collection Date: .08/31/2004 12:00 AM Report Dilution Parameter Result Qual. - Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: D512 Analyst: BL Chloride ND C 0.50 ppm 1 01/07/2005 10:00 AM , R39257 MOISTURE BYASTM Method: D95 Analyst: BL Moisture Content 0.14 C 0.10 Wt% 1 01/2412005 12:00 AM R39612 NITRATE BYASTM Method: D992 Analyst: BL Nitrate ND c 0.50 ppm 1 01/1112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: EL Base Number 42.6 -c 0.500 mg KOHIg 1 01/1812005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA427 Analyst: BL Sulfide ND c 0.50 ppm i 01/2612005 2:00 PM R39660 REVIEWED BY p1d Q. A. PERSONNEL
- DATE I2.7 -S-BYWI Qualifiers:
- Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank 8.~.eq... c Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q
Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1127/05 10:05 AM Jason Page 12 of 17
zcn/P' ' "d-- Suburban Laboratories, Inc. [ Laboratory Results I AOXE 7 . AI& .,m.in Hil.id II (7mz 54i;AA , , Client ID: Precision Surveillance Corp. Report Date: January 27, 2005 Project Name: Grease Samples Lab Order: 04120719 Client Sample ID: D-342 FIELD Matrix: GREASE Lab ID: 04120719-17 Date Received: 12/2012004 9:15 AM Collection Date; 11/03/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: 0512 Analyst: EL Chlouide ND c 0.50 ppm 1 01/0712005 10:00 AM R39256 MOISTURE BYASTM Method. D95 Analyst: EL. Moisture Content ND c 0.10 Wt% 1 01/24/2005 12:00 AM R39612 NITRATE BY ASTM Method: D992 Analyst: EL Nitrate ND c 0.50 ppm 1 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: EL Base Number 0.700 C 0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BY APHA Method: APHA 427 . Analyst: EL Sulfide ND c 0.50 ppm 1 01126/2005 12:00 PM R39659 Client Sample ID: V32 SHOP Matrix: GREASE Lab ID:- 04120719-18 Date Received: 1212012004 9:15 AM Collection Date: 08/31/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: D512 - Analyst: EL Chloride ND c 0.50 ppm I - 0110712005 10:00 AM R39256 MOISTURE BYASTM Method: D95 Analyst: EL Moisture Content 0.64 c 0.10 Wt% 1 0112412005 12:00 AM R39612 NITRATE BY ASTM - Method: D992 Analyst: EL Nitrate ND c 0.50 ppmr 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: D974 MOD Analyst: EL Base Number ' 68.1 c 0.500 mg KOH/g 1 01/18/2005 12:00'AM R39467 SULFIDE BY APHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01126/2005 12:00 PM R39659 REVIEWED BY
-sC Q. A. PERSONNEL DATE _3 :°1 BY W Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank B...Rpon. Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Cmid-~2004 G Refer to case narrative page for specific comments .H Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist)
Rpt Ver ID: 1/27/05 10:05 AM Jason Page 11 of 17
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. Suburban Laboratories, Inc. Laboratory Results
. 4140 Litt Ddve, Hillsidc, IL 60162 (708) 544-3260 ClientID: Precision Surveillance Corp. ReportDate: January27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: D-230 SHOP Matrix: GREASE Lab ID: 04120719-15 Date Received: 12/a0/2004 9:15 AM Collection Date: 11/11/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 - Analyst: 8L Chloride ND c 0.50 ppm 1 -0110712005 10:00 AM R39256 MOISTURE BY ASTM Method: D95 Analyst: BL Moisture Content ND c 0.10 wt% 1 01/2412005 12:00 AM R39612 NITRATE BY ASTM Method: D992 Analyst: EL Nitrate - ND c 0.50 ppm 1 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM - Method: D974 MOD Analyst: BL Base Number 1.37 C 0.500 mg KOH/g 1 01118/2005 12:00 AM R39467 SULFIDE BY APHA . Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm 1 01126/2005 12:00 PM R39659 Client Sample ID: D-230 FIELD Matrix: GREASE Lab ID: 04120719-16 Date Received: 12/20/2004 9:15 AM Collection Date: 11/11/2004 12.00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Amalyzed Batch ID CHLORIDE BYASTM Method: 0512 Analyst: BL Chloride 0.60 . c 0.50 ppm 1 0110712005 10:00 AM R39256 MOISTURE BYASTM Method: D95 Analyst: BL Moisture Content ND c 0.10 Wt% 1 01/24/2005 12:00 AM R39612 NITRATE BY ASTM Method. D992 Analyst: BL Nitrate ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: D974 MOD Analyst: BL Base Number 52.0 c 0.500 . mg KOHIg 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm . 1 01/26/2005 12:00 PM R39659 REVIEWED BY
-QR'/ Q. A. PERSONNEL DATE .Ž.ZoL
-BY Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank a3-R,,oe- C Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Cod.6-004 G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery isoutside SLI in-house .S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist)
Rpt Ver ID: 1127105 10:05 AM Jason Page 10 of 17
Suburban Laboratories, Inc. 4140 Lit Drive. Hillside, IL 60162 (708) 544-3260 ILabor-atory Results ClientID: Precision Surveillance Corp. ReportDate: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: D-225 SIOP Mlatrix: GREASE Lab ID: 04120719-13 DateReceived: 12/20/2004 9:15 AM CollectionDate: 09/14/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 01107/2005 10:00 AM R39256 MOISTURE BYASTM Method: D95 Analyst: BL Moisture Content 0.31 c 0.10 wt% 1 01/24/2005 12:00 AM R39612 NITRATE BY ASTM Method D992 Analyst: BL Nitrate ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 65.2 c 0.500 mg KOH/g 1 01118/2005 12:00 AM R39467 SULFIDE BYAPHA . Method: APHA427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 Client Sample ID: D-225 FIELD Matrix: GREASE Lab ID: 04120719-14 DateReceived: 12/2012004 9:15 AM Collection Date: 09/14/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: DL Chloride ND c 0.50 ppm 1 01/07/2005 10:00 AM R39256 MOISTURE BYASTM Method: D95 Analyst: 8L Moisture Content 0.15 c 0.10 Wt%1 01/24/2005 12:00 AM R39612 NITRATE BYASTM Method: D992 Analyst: BL Nitrate ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: D974 MOD Analyst: DL Base Number 48.9 c 0.500 mg KOHIg 1 01116/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA427 Analyst: DL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 R-qEvvED BY F Q. A. PERSONNEL L_ ~Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank Bae¢Fd C Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range i I G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded L i Q Estimated, analyte detected below quantitation limit Internal standard recovery is outside SLI in-house ND S Not Detected at the SLI Reporting Limit Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27/05 10:05 AM Jason Page 9 of 17 P
9
' 4Zj
,;j' Suburban Laboratories, Inc.
41401LinDiive, Hillside,1,L6016? (708)544.3260 I Laboratory Results I Client ID: Precision Surveillance Corp. ReportDate: Januaty 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: D-213 SHOP Matrix: GREASE LabID: 04120719-11 Date Received: 12120/2004 9:15 AM Collection Date: 09/13/2004 12:00 AM Report Dilution Parameter Result' Qual. ' Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: 8L Chloride , ND c 0.50 ppm i 01/07/2005 10:00 AM R39256 MOISTURE BY ASTM Method: D95 Analyst: BL Moisture Content ND C 0.10 Wt% 1 0112112005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst: EL Nitrate ND c 0.50 ppm 1 01111/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst BL Base Number 3.23 c .0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA427 . Analyst: BL Sulfide ND C 0.50 ppm 1 01/26/2005 12:00 PM R39659 Client Sample ID: D-213 FIELD Matrix: GREASE Lab ID: 04120719-12 Date Received: 12/20/2004 9:15 AM Collection Date: 09/11/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: EL Chloride ND c 0.50 pprM 1 01/07/2005 10:00 AM R39256 MOISTURE BYASTM Method: DO5 Analyst: 8L Moisture Content ND c 0.10 Wt% 1 01121/2005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst: 8L Nitrate ND C 0.50 ppm 1 01/1112005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: D974 MOD, Analyst: BL Base Number 34.9 c 0.500 mg KOH/g 1 01/1812005 12:00 AM R39467 SULFIDE BY APHA Method: APHA 427 . Analyst: BL Sulfide ND c 0.50 ppm . 1 01/26/2005 12:00 PM R39659 REVIEVIVED BY
?3i Q. A. PERSONNIEL-DATE By _ _ _ _
Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank Bs.R.5Pos1 c Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range CinkW25OJ G Refer to case narrative page for specific comments H -Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit -ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27/05 10:05 AM Jason Page 8 of 17
M Suburban Laboratories, Inc. Laboratory Results V 4140 Litt Drive, Hillsidt, IL 60162 (705) 544-3260 Client ID: Precision Surveillance Corp. ReportDate: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: H62-26 SHOP Matrix: GREASE Lab ID: 04120719-09 DateReceived: 12/20/2004 9:15 AM Collection Date: 09/22/2004 12:00AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: EL Chloride ND c 0.50 ppm 1 0110712005 10:00 AM R39256 MOISTURE BY ASTM Method: 095 Analyst: BL Moisture Content ND c 0.10 wt% 1 01121/2005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst BL Nitrate ND c 0.50 ppm 1 01I1112005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: 0974 MOD Analyst BL Base Number 56.6 c 0.500 mg KOHIg 1 01118/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/2612005 12:00 PM, R39659 Client Sample ID: H62-26 FIELD Matrix: GREASE Lab ID: 04120719-10 DateReceived: 12/20/2004 9:15 AM CollectionDate: 09/27/2004 12:00AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 01/0712005 10:00 AM R39256 MOISTURE BY ASTM - Method: D95 Analyst: EL Moisture Content ND c 0.10 wt% 1 0112112005 12:00 AM R39591 NITRATE BY ASTM Method: D992 . Analyst: BL Nitrate ND c 0.50 ppm I 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 59.5 c 0.500 mg KOHig 1 01118/2005 12:00 AM R39467 SULFIDE BY APHA Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 REViEWED BY rse, Q. A. PERSONiNEL DATE 2 --.-- BY -_ _ - Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank BA.Rpo.A C Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Ccni-.M04 Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLEin-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27105 10:05 AM Jason Page a 7 of 17
Sllb2Z
< ,Suburban Laboratories, Inc. Laboratory Results 4 140 Lit Djive. Hillside, IL 60162 (705) 544-3260 Client ID: Precision Surveillance Corp. Report Date: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: H62-IS SHOP Matrix: GREASE Lab ID: 04120719-07 DateReceived: 12/20/2004 9:15 AM CollectionDate: 11/05/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: EL Chloride ND c- 0.50 ppm 1 01107/2005 10:00 AM R39256 MOISTURE BY ASTM Method: D95 Analyst: EL Moisture Content ND c 0.10 wt% 1 0112112005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst: EL Nitrate ND c 0.50 ppm 1 01111/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: EL Base Number 6.04 c 0.500 mg KOHIg 1 01/1812005 12:00 AM R39467 SULFIDE BYAPHA . Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm '1 0126/2005 12:00 PM R39659 Client Sample ID: H62-18 FIELD Matrix: GREASE Lab ID: 04120719-08 DateReceived: 12/20/2004 9:15 AM CollectionDate: 11/02/200412:00AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: EL Chloride ND c 0.50 ppm 1 0110712005 10:00 AM R39256 MOISTURE BYASTM Method: D95 Analyst EL Moisture Content ND c 0.10 Wt% 1 01121/200512:00 AM R39591
-NITRATE BY ASTM Method: D992 Analyst: EL Nitrate ND c 0.50 ppm 1 0111112005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: EL Base Number 2.91 c 0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 REVIEWED 63Y fe Q. A. PERSONNEL DATE Ž -3f-Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank B..Rtpo,-
C-6-2pa0-Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range G Refer to case narrative page for specific comments -H Holding times for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internat standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27/05 10:05 AM Jason Page 6 of 17
b) 02oSuburbanLaboratories,Ihc. IR
- 4140 Litt Drive, Hillside, IL 60162 (708) 544-.260 I Laboratory Results Client ID: Precision Surveillance Corp. Report Date: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: H46-25 SHOP Matrix: GREASE Lab ID: 04120719-05 Date Received: 12/20/2004 9:15 AM Collection Date: 11/05/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: D512 Analyst. BL Chloride 0.60 c 0.50 ppm 1 01/07/2005 10:00 AM R39256 MOISTURE BYASTM Method: 095 Analyst: EL Moisture Content ND c 0.10 wt% 1 0112112005 12:00 AM R39591 NITRATE BYASTM Method: D992 Analyst: BL Nitrate ND c 0.50 ppm I 011/12005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 1.27 C 0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDEBYAPHA Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/2612005 12:00 PM R39659 Client Sample ID: H46-25 FIELD Matrix: GREASE Lab ID: 04120719-06 DateReceived: 12/20/2004 9:15 AM Collection Date: 11/08/2004 12:00 AM Report . Dilution Parameter Result Qual. Limit Uniti Factor -Date Analyzed Batch ID CHLORIDE BYASTM - Method: D512 Analyst: EL Chloride ND c 0.50 ppm 1 01107/2005 10:00 AM R39256 MOISTURE BYASTM Method: 095 Analyst: EL Moisture Content ND C 0.10 Wt% 1 01/21/2005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst: BL Nitrate ND c 0.50 ppm 1 011112005 8:00 AM R39315 NEUTRALIZATION NUMBER BYASTM Method: D974 MOD - Analyst: BL Base Number 1.74 c 0.500 mg KOHIg 1 01/11i2005 12.00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: EL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 REVIEWED BY
? Q. A. PERSONNEL DATE 1 2-`-f BY2Z>-
Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank B-R5~po.a Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Cooh.oouo4 G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded J Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) t I i- Rpt Ver ID: 1127/05 10:05 AM Jason Page 5 of 17
Air Suburban Laboratories, Inc.
*WARN 4140-LittDrive, Hillside,1L60162 (708)544-3260 ILaboratory Results Client ID: Precision Surveillance Corp. Report Date: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: H35-49 SHOP Matrix: GREASE Lab ID: 04120719-03 DateReceived: 12/20/2004 9:15 AM Collection Date: 09/16/2004 12:00AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: 0512 Analyst: 3L Chloride ND c 0.50 ppm 1 0110712005 10:00 AM R39256 MOISTURE BYASTM Method: 095 Analyst: 8L Moisture Content ND c 0.10 wt% 1 01/2112005 12:00 AM R39591 NITRATE BYASTM Method D992 . Analyst: BL Nitrate ND c 0.50 ppm 1 01I11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst BL Base Number 6.17 c 0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA Method: AP-IA427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/2612005 12:00 PM R39659 ClientSampleID: H35-49 FIELD Matrix: GREASE Lab ID: 04120719-04 Date Received: 12/20/2004 9:15 AM Collection Date: 09/15/2004 12:00 AM
'Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM Method: D512 Analyst: BL Chloride ND c 0.50 ppm 1 01/07/2005 10:00 AM R39256 MOISTURE BYASTM Method: D95 Anaiyst: BL Moisture Content 0.15 C 0.10 wt% 1 01l21/2005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst:' BL Nitrate ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: D974 MOD Analyst: BL Base Number 3.12 c 0.500 mg KOH/g 1 0111812005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA 427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 REVIEWED BY p-e . A. PERSONNEL DATE 2-7^o5 BY _ _ _ _ _
Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank B...R~pon. c Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range C.nL,~104 G Refer to case narrative page for specific comments H Holding times for preparation or analysis exceeded J Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery isoutside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist) Rpt Ver ID: 1/27/05 10:05 AM Jason Page 4 of 17
ACNE" Suburban Laboratories, Inc. 4140LinDrive, Hillside, IL60162 (708) 544-3260 I Laboratory Results I ClientID: Precision Surveillance Corp. ReportDate: January 27, 2005 ProjectName: Grease Samples Lab Order: 04120719 Client Sample ID: H13-lI SHOP Matrix: GREASE Lab ID: 04120719-01 DateReceived: 12/20/2004 9:15 AM CollectionDate: 11/13/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BY ASTM Method: D512 Analyst: BL Chloride 1.0 c 0.50 ppm 1 0110712005 10:00 AM R39256 MOISTURE BY ASTM Method: D95 Analyst: BL Moisture Content ND c 0.10 wt% 1 01/21/2005 12:00 AM R39591 NiTRATE BY ASTM Method: D992 Analyst: 1L Nitrate ND C 0.50 ppm . 1 01111/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: 0974 MOD Analyst: BL Base Number 3.09 C 0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA427 Analyst: BL Sulfide ND c 0.50 ppm 1 01/26/2005 12:00 PM R39659 Client Sample ID: H13-11 FIELD Matrix: GREASE Lab ID: 04120719-02 DateReceived: 12/20/2004 9:15AAM CollectionDate: 11/12/2004 12:00 AM Report Dilution Parameter Result Qual. Limit Units Factor Date Analyzed Batch ID CHLORIDE BYASTM - Method:. D512 . Analyst: 8L Chloride 0.60 c 0.50 ppm 1 01/07/2005 10:00 AM R39256 MOISTURE BY ASTM Method: D95 Analyst EL Moisture Content ND c 0.10 Wt% 1 0112112005 12:00 AM R39591 NITRATE BY ASTM Method: D992 Analyst: '13L
-Nitrate X ND c 0.50 ppm 1 01/11/2005 8:00 AM R39315 NEUTRALIZATION NUMBER BY ASTM Method: 0974 MOD , . Analyst: 1BL Base Number 4.58 c 0.500 mg KOH/g 1 01/18/2005 12:00 AM R39467 SULFIDE BYAPHA Method: APHA427 Analyst E3L-Sulfide ND c 0.50 ppm 1 01126/2005 12:00 PM R39659 RE'VIEWED BY
-- d Q. A. PERSONNEL DATE Zeo-
',By Qualifiers: Value exceeds Maximum Contaminant Level B Analyte detected in the associated Method Blank
' C Analyte not included in SLI scope of accreditation E Estimated, analyte detected above quantitation range Crn,!-.2004 G Refer to case narrative page for specific comments H Holding times.for preparation or analysis exceeded Estimated, analyte detected below quantitation limit ND Not Detected at the SLI Reporting Limit Q Internal standard recovery is outside SLI in-house S Spike Recovery outside accepted recovery limits criteria (no method specific requirements exist)
I Rpt Ver ID: 1/27/05 10:05 AM JasonP Page 3 of 1i7
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I RVEILLANCE CORPORATION 3468MWATLING ST. EAST CHICAGO, IN46312 (219) 397-5826 FAX (219) 397-5867 I I)ecember 17,2004 I Suburban Laboratories, Inc.. 4140 Lift Drive IHillside, IL60162 Attention: Mike Chung Please test the following twenty-seven (27) grease samples per PSC - P.O.#884. SAMPLE I.D. 13-11 SHOP H13-1I FIELD H35-49 SHOP H35-49 FIELD H46-25 SHOP 1146-25 FIELD 1162-18 SHOP 1162-18 FIELD H62-26 SHOP H62-26 FELD D-213 SHOP D-213 FIELD D-225 SHOP D-225 FIELD D-230 SHOP D-230 FIELD D-342 FIELD V32 SHOP V32 FIELD V53 SHOP V53 FIELD V66 SHOP V66 FIELD V86 FIELD V140 SHOP VI40 FIELD V164 FIELD NOTE: IF NEUTRALIZATION NUMBER c.5 THEN SPECEAL RETEST REQUIRED PER SECTION 6 OF P.
O. PROCEDURE
Would like results 10-15 days after receipt of samples. Any questions or problems please call me. The above-samples being shipped to you via UPS Ground in 2 boxes on 12/17/04. I Thanks,
-Page 17 fc17 RptVer ID: 1/27105 10:05 AM Jason
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PSC PROCEDURE QA 7.0 D Y) IP~ciflan~ I.' SCIAL FIELD REVtStON! M17F~OL PSC vOfAIIo FIEL.D CWGZC REQUZST NO. FCRe2 ?-- 6OY.' Re que sted By _T11 itc Ie: ~~ ~Date: 16 Zs--.O PFROCErDRE NUMER:5.4Z. REV. NO: D. FROCEDUIRE TIL:64,S C%4eA AYFECTED SECTION: evisimOta Yanut1 Required XJ NCR REQdIRED: Yesf No [v/ NCR. No. I1o1d Z-a No. ,, DlETAILED DESCRrPTION OF EXtSXING COHDrTIO-": (use exrra pages or write an back) A. - - -q - -r I pSr approval.: Quality Assurance. qualginerin ON SITE OWMR/AcrF.-,, -aBmRV ox. Mmm . Acr' u A-PPROVU'ZSITZ QA AM~ORITY: TZULE: 1)4TE: DISPOSlIIOli pSC Q H1OI. TAO APPLIED 'HOLD AG M~OVED ______ Q).C.' INSPECTOR': DATE: Distribution: ____Quality Arau.rance Owmer.
- Quality- Control ow~ner QuarlerAa-stmae- PSC Qualicy Control pSC
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Ii VLI/ iiM-4 '1) I9 Aurtert,. 011.'S.14 -- R-1"I " AmerGen Energy Company. LLC Telephone: 717-948-8000 An Exelon Company Three Mile Island Unit 1 Route 441 South, P.O. Box 480 Middletown, PA 17057 November 17, 2004 Mr. Brian Giometti Precision Surveillance Corporation 3468 Watling Street East Chicago, IN 46312
Dear Mr. Giometti:
Please find attached the requested information on V-137 and V-141. The attached includes predicted forces and adjusted elongation for both tendons. Also attached are the normalizing factors for the two tendons. If you have any questions, please give me a call at 717-948-8494. Sincerely, Luis F. Terr as LFT/dms cc: J. J. Piazza - Manager,-Mechanical/Structural Engineering
i r lo Base level predicted force and nonnalizing factor for vertical tendon V-137 are listed below. Also listed are forces equal to 90% and 95% of the base level predicted forces. _ l Tendon Base Level 95% of 90% of Base Normalizing No Predicted Force,, kip Base Level, level, kip Factor, kip Ikip I V-137 I 1,185 1,126 1 1,067 1 -7 l
GPU -TMI UNIT 1 - TENDON FORCE PREDICTION VERTICALTENDON NO., Vii-AVERAGE ALL VERTICAL TENDON FORCE (Flol) 1432 (KIPS) File Code: DC-5390-22.SE ORIGINAL AVERAGE FORCE (Fi[o]) l41T.(i~lPS) W.O.: 04-5390-225 TOTAL ELASTIC SHORTENING LOSS (ES) 628 (KIPS) Pnje 1 74-TOTAL STRESS SEQUENCE (N) 29.* STRESS SEQUENCE (n) 26 ** Originator: R. Chang Date: 03129194 WIRE FACTOR (VF) .000. Veriicer D.D. K(rause Dale: 03/29194 INDIVIDUAL LOSSES (FORCES IN KIPS) PREDICTED FORCES (KIPS)' NORMALIZING STRESS CONCRE1'E CONCRETE FACTOR INSvecTION ELASTIIC RELAXATION CR1EE' SIhRINKAGIE TOTAL LOSS BASE 95% lBASE 90%b BASE (K iP'S) P'ERIOD Sl1ORTENING I'ERCENT FORCE FORCE FORCE FORCE FORCE FORCE PElRCENT
- WF 'WF _ _
6.) (2) (3) (4) (5). (6) (7) (8) '(9) (10) (11) (12) t(13) 1 6.5 9.03% 131.7 12.0 12.0 1.0 1.0 151.2 10.37% 1307 1242 1176 _ - 47 3 6.5 10.03% 146.2 14.9 14.9 1.6 1.6 169.2 11.61% 1289 1224 1160 -47 5 6.5 10.60% 154.5 17.6 17.6 2.0 2.0 180.6 12.39% '1277 1213 1150 -47 10 6.5 11.53% 168.1 21.4 21.4 2.9 2.9 198.9 13.64%,, 1259 1196 1133 -47 15 6,5 12.10% 176.4 24.2 24.2 3.4 3.4 210.5 14.44% 1247 1185 1123 . -47 20 6.5 12.51% 182.4 26.6 26.6 3.9 3.9 219.4 15.05% 1239 _ 1177 1115I -47 25 6.5 12.88% 187.8 28.5 28.5 4.2 4.2 227.0 15.57% 1231 1169 1108 -46 35 it;:3.43 6:6 '595 "30.9 3t).9 4.7 4.7 237.9 16.32% 122a0 -R71159 1098 -46 40 , 6.5 13.68% 199.5 32.0 32.0 4.9 4.9 242.9 16.66% 1215 1154 1094 -46 (1) ES' (N-n)/N,Ref.TMITendoi ElasticSliorLeniingLossGcaleuilaloii (2) RcE.'l'MI Tendon Wire Relexalion Loss Calculation (3) Filo] ' (2) WFI (4) RcE.TMI Tendon Creep Loss Calculation (5) WF ' (4) (6) Rc[.TMI Tendon Shrinkage Loss CaIculalion (7) WFI ' (6) (8) Sum of Columns (1), (3), (5), and (7). (9) (8) / Filol ' I100 (10) Filo] - (8) (11) 0.95 '(10) (12) 0:90 ' (10) (13) ((Flo] - FiPo])) (1 - (2) /100) + ES I (N - 2n + 1)! 2N). Iile: V141.WK3
" TMIn'lcndon Sulvlilancc Loss Cailculations
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PRECISION SURVEILLANCE CORPORATION 3468 NVATLNG ST. EAST CHICAGO, IN 46312 PHONE: 219-397-5826 FAX: 219-397-5867 October 26, 2004 Mr. Bruce Kaplan Amergen Nuclear Three Mile Island Route 441 South Middletown, PA 17057
Dear Mr. Kaplan:
After discussing the situation concerning the end of tendon H-62-026 that is inside the Turbine Building with the PSC QA/QC department, it has been decided that the use of PSC Procedure SQ 6.0 does not apply, because that phase of the surveillance has already been completed. The removal of the grease cap on the field end of H-62-026 was performed and documented per TMI Procedure 1301-9.1 Section 8.2.5 on 9/27/04 using PSC Procedures SQ6.0, SQ6.1, and SQ7.0. Due to the surveillance being shut down it was necessary to provide temporary protection of the anchorhead for an extended period of time, as per TMI Procedure 1301-9.1 Section 8.2.3. In order to satisfy TMI Procedure 1301-9.1 Section 8.2.4, hot grease was used to temporarily protect the anchorhead on 10/0 104. When commencing the surveillance on the field end of H-62-026 it will not be necessary to have QC present during the removal of the grease cap because it is in a temporary state, similar to when a plastic bag is used to protect the anchor head overnight. Upon removing the temporary protection, surveillance will continue with QC present at Section 8.2.6 of TMI Procedure 1301-9.1. Sincerely, Brian Giometti PSC Field Engineer Cc: Paul Smith Luis Terrazas File
Number 11L-1 D! TMI - Unit 1 Surveillance Procedure , . 1301 -9.1.
, Itle Revision No.
RB Structural Integrity Tendon Surveillance 18 DATA SHEET 12 Page I of I VT-1 C I VT-3C Examiner Qualification Name of Examiner Employer DXL\/)CL ' ' ((& T1-r (7-6 -/OaJ x t/, X/vCCZCoP. Hel/--C-Zns rcg5" (X6i so k .C ta k lave reviewed the records relevant to the experience and training of the above named individuals and have, as
..ecessary, trained these individuals in the requirements applicable to the performance of VT-1 C / VT-3C examinations of the containment concrete surface. Based on this review and, if applicable, training, I find that these individuals are qualified to perform said examinations.
Responsible Engineer: Name . WA 2D '7- AXOL' _ Registration State License No. Expiration Signature _ Date a1 ( 41
i I- T-1 i6,1-01 0)
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I Am e r to A= o ir"I's M, AmerGen Energy Company, LLC Telephone: 717-948-8000 An Exelon Company Three Mile Island Unit 1 Route 441 South, P.O. Box 480 Middletown, PA 17057 November 17, 2004 Mr. Brian Giometti Precision Surveillance Corporation 3468 Watling Street East Chicago, IN 46312
Dear Mr. Giometti:
Please find attached the requested information on V-137 and V-141. The attached includes predicted forces and adjusted elongation for.both tendons. Also attached are the normalizing factors for the two tendons. if you have any questions, please give me a call at 717-948-8494. Sincerely, Luis F. Terra as LFT/dms cc: J. J. Piazza - Manager, Mechanical/Structural Engineering
Base level predicted force and normalizing factor for vertical tendon V-137 are listed below. Also listed are forces equal to 90% and 95% of the base level predicted forces. Tendon Base Level 95% of 90% of Base Normalizing No Predicted Force, kip Base Level, level, kip Factor, kip V-17 ip
-V-I'37 1 1,185 1,126 1 1,067 -7
GPU - TMI UNIT 1 - TENDON FORCE PREDICTION VERTICAL TENDON NO. V14i' AVERAGE ALL VERTICAL TENDON FORCE (F[o]) '1432 (KIPS) File Code: DC-5390-225.SE ORIGINAL AVERAGE FORCE (Fi[o]) .:`;-';.1458 (KIPS) TOTAL ELASTIC SHORTENING LOSS (ES) W.O.: 04-5390-225 2:8(KIPS) TOTAL STRESS SEQUENCE (N) "age 1 74. 29 STRESS SEQUENCE (n) 26* WIRE FACTOR (WF) Originator: R.Chang Dale: 03/29194 1 000 Verifier D.D. Krause Date: 03129194 INDIVIDUAL LOSSES (FORCES INKIPS) PREDICTED FORCES (KIPS) N I STRESS CONCRETE CONCRETE. INSPECrION ELASTIC RELAXATION FACTOR CREEP SHlRINKIAGE' TOTAL LOSS BASE PERIOD 95%BUASE 90%IBASE (KIPS) SHIORTENING PERCENT FORCE FORCE FORCE. FORCE FORCE FORCE PERCENT _. ' WF IWF WT . ()(2) , ()(4) -_(?(6) 1 (7) ()(9) (10) , 1) ' (12) 6.5 9.03% 131.7 12,0 12.0 1.0 1.0 (13) 151.2 10.37% ,1307 1242 1176 -47 3 6.5 10.030/4 146.2 14.9 14.9 1,6 1.6 169.2 11.61% 1289 1224 1160 5 6.5 10.60% 154.5 17.6 -47 17.6 2.0 2.0 180.6 12.39% 1277 1213 1150 -47 10 6.5 11.53% 168.1 21.4 21.4 2.9 2.9. 198.9 13.64% 1259 1196 1133 15 6.5 12.10% 176.4 24.2 -47 24.2 3.4 3.4 210.5 14.44%1 1247 1185 20 6.5 12.51% 182.4 1123 -47 26.6 26.6 3.9 3.9 219.4 15.05% 1239 25 6,5 12.88% 1177 1115 -47 187.8 28.5 28.5 4.2 4.2 227.0 15,57% 1231 1169 1108 -46 35 40 [ 6 6.5 13.43% 13.68% 195.8 199.5 30 32.0 30.9 32.0 4.7 4,9 4.7 4.9 237.9
' 242.9 16.32%
16.66% I'
'1220 1215 1 9 1154 1098 1094 l _ 46
-46 (1) ES ^ (N-n)I N, Ref.TMITcndon Elastic Shortening Loss Calculation (2) RcL.TMI Tendon Wire Relexalion Loss Calculalion
*(3) Fi[oj ' (2) ' \VF (4) Rcf.TMI Tendon Creep Loss Calculation (5) WFI(4)
(6) Rcf.TMI Tendon Shrinknae Loss Calculation (7) WF ' (6) (8) Sum of Columns (1), (3),(5), and (7). (9) (8)/FrifoJ
- 100 (10) Fibo] - (8)
(11) 0.95 (10) (12) 0,90'(10) (13) ((F[ol - Fijo]) (1 - (2)/100) + ES (N -2n + 1)/ 2N).
" TMI Tendon Surveillance Loss Calculations File: V414.WK3
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L ps --- -- 1'1a PRECISION SURVEILLANCE CORPORATION 3468 WATLING ST. EAST CHICAGO, TN 46312 PHONE: 219-397-5826 FAX: 219-397-5867 October 26, 2004 Mr. Bruce Kaplan Amergen Nuclear Three Mile Island Route 441 South Middletown, PA 17057
Dear Mr. Kaplan:
After discussing the situation concerning the end of tendon H-62-026 that is inside the Turbine Building with the PSC QA/QC department, it has been decided that the use of PSC Procedure SQ 6.0 does not apply, because that phase of the surveillance has already been completed. The removal of the grease cap on the field, end of H-62-026 was performed and documented per L TMI Procedure 1301-9.1 Section S.2.5 on 9/27/04 using PSC Procedures SQ6.0, SQ6.1, and SQ7.0. Due to the surveillance being shut down it was necessary to provide temporary protection of the anchorhead for an extended period of time, as per TMI Procedure 1301-9.1 Section 8.2.3. In order to satisfy TMI Procedure 1301-9.1 Section 8.2.4, hot grease was used to temporarily protect the anchorhead on 10/01/04. When commencing the surveillance on the field end of H-62-026 it will not be necessary to have QC present during the removal of the grease cap because it is in a temporary state, similar to when a plastic bag is used to protect the anchor head overnight. Upon removing the temporary protection, surveillance will continue with QC present at Section 8.2.6 of TMI Procedure 1301-9.1. Li Sincerely, Brian Giometti PSC Field Engineer L Cc: Paul Smith Luis Terrazas File
REPORT OF THE VT-3C INSPECTION DEMONSTRATION FOR THREE MILE ISLAND UNIT 1 CONTAINMENT BUILDINT EXTERIOR CONCRETE
*~ 4' d 1V-Ib+
PURPOSE: The VT-3C inspection demonstration is required by Exelon procedure ER-AA-335-018, Rev. 2 to perform examinations provided the remote technique being used has been
,qualified by use of a near - distance vision chart for the maximum distance being viewed.
Personnel performing the demonstration: Clifford W. Peters Level II Inspector. Precision Surveillance Corp. Personnel witnessing the demonstration: Luis F. Terrazas Cognizant Mech./Structural Engineer AmerGen Energy Rodney Turner NDE Level III AmerGen Energy Description of demonstration: The visual target for the demonstration was an ASME Section XI 1995/1996 Addenda near- distance vision chart using 0.105" high characters ( 4' with a minimum of 50' fc of lighting. Level II Inspector, Clifford W. Peters was able to view the characters at 25' maximum using 8-24x25 binoculars and at 75' maximum using theodolite (transit) with a 30x-power telescope, at a light intensity of 50fc and greater. CONCLUSION: The demonstration proved to be successful in being able to identify any area of potential distress on the containment building concrete surface as required by Exelon procedure ER-AA-335-018, Rev. 2; The above qualification provides the maximum distance and the minimum lighting requirements for containment inspections. Demonstration accepted by: J. a Cognizant Mechanical/St uctural Engi eer Date NDE Level III / te
SECTION DOCUMENT NO: I DOCUMENT TYPE: ENO
!HYDRAULIC JACK CALIBRATION REVISION # - 0 Jack Calibration Record SAFETY RELATED - _. X 2 ef, NON-SAFETY RELATED I PAGE I
= =
COMPUTED BY:
=
CEC
=
DATE: 02/04/05 l REVIEWED BY: .NtP. I DATE: OL! 1-)j
. .i._=
OF , 3 Project:. Post TMI - Contract No: N924 - Jack
Description:
Pine Size: 1000 Tons Register No:. 9365 Theoretical Ram Area: 212.65 sq. in. Max Pressure: 8440 psi Calibrating Device Used: Teledyne Register No: 4734 Constant: 33005 Calibrating Gauge Used: Heise Register No: S9-22260 Due Date: 02/03/08 Raw Data By: Daniel P. O'Shea Date: 02/04/05 Witness: -_ . _ _ _ _ _ Mean Ram Area: ji2H54 sq. in. K= S3633 kips Agency: ,9 Date: .4 Computed By: Christopher E. Cox QC Check: -_if,_ _
Title:
Field Engineer Date: 2-z -0fTitle: - q e'k Q,4, c Date:. fag Target Pressure (PSI)] Gauge Reading (PSI) l Load Cell Readout Comments
-1000 1006 6.38 RUN: 1 POSITION: 2" 2000 . 2002 12.78 3000 3000 19.22 4000 4001 . 25.66 5000 5002 32.10 6000 6002 . 38.52 7000 7003 . 44.96 8000 8003 51.38
-1000 1007 6.36 RUN: 2 POSITION: 4" 2000 2004 12.80 3000 3002 19.24 4000 4001 25.66 5000 5000 32.10.
6000 .6004 38.56 i 7000 8000 7004
- 8003 45.02 II 51.44 I
k I 1000 . 1001 . 6.32 RUN: 3 -POSITION: 6" i 2000 2002 - 12.76 I I 3000 - 3001 19.22 I 4000 4001 25.66 I 5000 5001 32.10 i 6000 - 6000 . 38.54 I 7000 7002 44.98 z 8000 8002 51.44 i P i i
DOCUMENT'NO: j DOCUMENT TYPE: ENO HYDRAULIC JACK CALIBRATION REVISION / 0 Linear Regression Analysis SAFETY RELATED X ON-SAFETY RELATED
, PAGE 1 2 - OF 3
- _ _ _ = . _ _
-02104/05 1 REV]EWEDBY: b DATE: 9fudild
-I Project: Post TMI Contract No: N924 Jack
Description:
Pine Size: 10130 Tons Register No: 9365 - Theoretical Ram Area: 212.65 sq. in. Max Pressure: 8440 psi Calibrating Device Used: Teledyne Register No: 4734 - Constant: 33005 Calibrating Gauge Used: Heise Register No: S9-22260 Due Date: 02103/08 Actual Gauge Reading (psi) Load Cell Readout 3 Computed Force (kips) 1006 6.38 210.572 2002 - 12.78 421.804 3000 19.22 634.356 4001 25.66 846.908 5002 32.10 1059.461 6002 38.52 1271.353 7003 _ 44.96 1483.905 8003 51.38 1695.797 1007 - . 6.36 209.912 2004 12.80 422.464 3002 19.24 635.016 4001 25.66 846.908 5000 32.10 1059.461 6004 38.56 1272.673 7004 45.02 1485.885 8003 51.44- 1697.777 1001 - 6.32 208.592 2002 12.76 421.144 3001 19.22 634.356 4001 25.66 846.908 5001 32.10 -1059.461 6000 38.54 1272.013 7002 - 44.98 - 1484.565 8002 51.44 1697.777 Indicates these readings have been omitted from thefinal computations Errors In Jack Calibration Error In Standard ................................................................. 0.0100 ksi Interpolation in Gauge .................................................................. 0.0000 ksi Accuracy of Gauge ................................................................. 0.0000 ksi Errors In Gauge Calibration Interpolation in Master .................. ; 0.0000 ksi Interpolation in Field Gauge .................. . 0.0050 ksi Accuracy of Master............. ; . -0.0100 ksi Accuracy of Field Gauge ........................... .................... 0.0275
; ksi Errors In Field Use of Gauge Interpolation Error.......................................................................... 0.0050 ksi Accuracy Error .................... ; .. 0.0275 ksi Maximum Gauge Reading Used ...................... :. ; .: 8.0030 Iksi FORCE (kips) = 212.544 (in2 ) X-GAUGE READING (ksi) + -3.633 (kips)
Correlation = 0.99999936 N/NO = 1.0000 '(Not < 0.66667) Maximum Error Ratio In Jack ..................... 0.0025 Maximum Error Ratio In Gauge ........................ 0.0052 Maximum Total Error Ratio .................. - ; 0.0058
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RAM/JACR-t CLIBRATION RECORD .- F0RH 12. 8. G PSC Formerly Inryco Surveillance I PROJEcT ___________ CONTRACT/PART NO. ,V96%0 l( Jack Description _____ Size /I6M4 - lons Regiscer No 936 , Theoretical Ram Area "/a/eLa_%. Pressure Lfs'a PSI Calibrating Device 7dVc Register No. ;L:r5/ Constantc f Calibratinz Gauze e- - Reister No. Date , -vy Raw Data fBy c WITNESS :WM _ _ Hean Ram Area a sq.in.
- Agency __ _ __ Date Computed By g CCek .
Title fr/WtJh9//1teY Date itle __- i4cA. Q.a Da Dzce __ _ Target PSI Gauge Readinz PSI Load Cell Readout CO?2ENTS
- I - G,3' - RUN/ POSITION j sov oor -/2,71 .
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Jack Description 4,ve- Size-5 / . Tons Register-No.ro. Theoretical Ram Area Z/2 Max. Pressure w'/'o PsI Calibrating Device 721i-g':r Register No. Y73 1 Constant_3___7-S_ Calibrating Gauge _______ Register No.59-ZtZ.6D Dace, P-/-°S' _ Ra; Data By Z 2 d- WITINESS ____- sean Ran Area 6_ gency __2_ VIA _S_ _ _6_7 Diap Date ___1_ Comvuted By __ _ _ _ _ _ _ _ _ _ _ QC Check _____ Title 1e/2fasg Date 7-09 y Title _M- t Daee Z Tarze: PSI 1 Gauze Reading PSI '.Load Cell Readout COXMENTS 1 !.
- I 3I RUL M POSITION Z j
_ _ _ K _ _ _ .I '7, 96 _________I 30 2 . I - VOOY I '-A'I! ZS'70 ___ ___ I- ZD 7 1 __-_3Z.____ G°eDo 16 6 1 I_______ _ _ ______1______ _______I ?o 3 1 _- _ _ _ _ _ _ _ _ RUN1 Z- POSITION _ I Z /I 9 /l.Z Soo°~~~~ o7f 3 9 e"D00' I
/Z70 0 I . 3,1 .7 F~oo I aS I S LIZ, I I ,"/ I -6.Y RUN 3 - POSITION 6i, 1co , _ _ .1 -
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JACK CALIBRATION - LINEAR REGRESSION ANALYSIS PROJECT Post Byron/Pre-TMI CONTRACT NO. N905/N9 JACK DESCRIPTION: Pine TONS: 1000 REGISTER NO.: 9365 C THEORETICAL RAM AREA (sq.in): 212.65 ,7;9
- MAX PRESSURE (psi): 8440 CALIBRATING DEVICE USED: Teledyne REGISTER NO.: 4734 CONSTANT= 32987.5 CALIBRATING GAUGE DESCRIPTION: Heise REGISTER NO.: S9-2226
.INPUT.
ACTUAL GAUGE LOAD CELL COMPUTED READING (psi) READOUT FORCE (k) 1011 6.34 209.141* 2038 12.96 427.518 3015 19.28 635.999 4011 25.70 847.779 5007 32.08 1058.239 6013 38.48 1269.359 7013 44.76 1476.521 8033 51.12 1686.321 1017 6.44 212.440 2019 12.94 426.858 3013 19.40 639.958 4001 25.78 850:418 5017 32.34 1066.816 6010 38.70 1276.616 7004 45.04 1485.757 8016 . 51.42 1696.217 1014 6.44 212.440 2016 12.94 426.858 3013 19.42 640.617 4016 25.90 854.376 5010 32.32 1066.156 6011 38.82 1280.575 7011- 45.24 1492.355 8012 51.60 1702 .155
- THESE READINGS HAVE BEEN OMITTED FROM THE FINAL COMPUTATIONS ERRORS IN JACK CALIBRATION ERROR IN STANDARD ............... 0 .0100 ksi INTERPOLATION IN GAUGE .......... .0.0000 ksi ACCURACY OF GAUGE ............... 'O.0000 ksi ERRORS IN GAUGE CALIBRATION INTERPOLATION IN MASTER ......... 0.0000 ksi i
INTERPOLATION IN FIELD GAUGE .... 0.0050 ksi i ACCURACY OF MASTER. 0.0100 ksi i I
- ACCURACY OF FIELD GAUGE ... 0.0275 ksi I I
ERRORS IN FIELD USE OF GAUGE INTERPOLATION ERROR ............. 0.0050 ksi I i I ACCURACY ERROR .................. 0.0275 ksi i MAXIMUM GAUGE READING USED ................ *8.0160 ksi j
** FORCE (k) 211.815 (sq.in.) X GAUGE READING-(ksi) -0.077 (X i I
I i CORRELATION = 0.99994045 N/NO= 0.9583 (NOT < .66667)- Ii MAXIMUM ERROR RATIO IN JACK .0135 . I MAXIMUM ERROR RATIO IN GAUGE . 0052 iI I MAXIMUM TOTAL ERROR R TIO ........... .0144 . r i i COMPUTED BY: / j DATE: CHECKED BY: DATE - 2
-i
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VI+f r.,rl DOCUMENT TYPE: ENG HYDRAULIC JACK CALIBRATION REVISIONt . u Jack Calibration Record SAFETY RELATED X NON-SAFETY RELATED _______ E : B PAGE DAE OF 3-
. COMPUTED BY: -BAG . DATE: 02/07/05 REViEWED BY. At-DATE: 1 -a Project: POST TMI Contract No: N924 Jack
Description:
PINE Size: 850 Tons Register No: 6001 Theoretical Ram Area: 190.45 sq. in. Max Pressure: 8500 psi Calibrating Device Used: TELEDYNE Register No: 4734 . Constant: 33,005.00 Calibrating Gauge Used: HEISE Register No: S9-22260 Due Date: 02/03/08 Raw Data By: DANIEL P O'SHEA -Date: 02/04105 . Witness: ____ Mean Ram Area: 931sq. s9 in., K= S6.358 kips Agency: _ pate: D_ Ai!. Computed By: BRIAN GIOMETTI QC Check: _ _____ _____
Title:
FIELD ENGINEER Date: 02/07/05
Title:
- a d., 4 - Date: Z.'>-f Target Pressure (PSI) Gauge Reading (PSI) l Load Cell Readout Comments 1000 1010 5.72 RUN: I POSITION: 1-1/2" 2000 2022 11.50 3000 3008 17.18 4000 4015 23.02 5000 - 5004 28.76 6000 6010 34.60 7000 7004 40.36 8000 8010 46.20 8500 8505 49.08 1000 1014 5.74 RUN: 2 POSITION: 3" 2000 2017 11.48 3000 3000 17.16 4000 4017 23.06 5000 5010 28.80 6000 6011 34.60 7000 7009 - 40.38 8000 8000 46.12 8560 8500 49.02 1_00 1010 5.14 RUN: 3 POSITION: 4-1/2" 2000 2015 11.42 3000 3010 17.20 .
4000 4013 23.02 5000 5008 28.76 6000 -6008 34.54 7000 7006 40.30 8000 8000 46.06 8500 8505 49.00
l i v q } b t DOCUMENT NO: HYDRAULIC JACK CALIBRATION PEVISION* LinearG Regression Analysis SAFETY RELATED NON-SAFED RELATED X D B: . D Caa~>4 -- PAGE . 1_, 2 OF 3 1 REVIEWED BY. DATE- 7-0 A_ . C0OMPUTED BY:
-.. BAG DATE:
_. -02/07105 p Project: POST TMI - _ Contract No: N924 Jack
Description:
PINE Size: 8510 Tons Register No: 6001 Theoretical Ram Area: 1590.45 sq. in. Max Pressure: 8500 psi Calibrating Device Used: TELEDYNE Register No: 4734 Constant: 33005 Calibrating Gauge Used: HEISE Register No: S9-22260 Due Date: 02/03108 Actual Gauge Reading (psi) Load Cell Readout l Computed Force (kips) 1010 5.72 188.789 2022 11.50 379.558 3008 17.18 567.026 4015 23.02 .759.775 5004 28.76 . 949.224 6010 34.60 1141.973 7004 40.36 L 1332.082 8010 46.20 1524.831 8505 .49.08 . 1619.885 1014 5.74 189.449 2017 _ 11.48 378.897 3000 . 17.16 566.366 4017 23.06 761.095 5010 28.80 950.544 6011 -34.60 1141.973 7009 40.38 1332.742 8000 . -46.12 1522.191 8500 49.02 '; -. 1617.905 1010 5.14 169.646 2015 . 11.42 376.917 3010 17.20 567.686 4013 - 23.02 759.775 5008 28.76 949.224 6008 - 34:54 1139.993, 7006 40.30 1330.102 8000 46.06 1520.210 8505 49.00 1617.245 Indicates these readings have been omitted from thefinal computations Errors In Jack Calibration
- Error In Standard ................................. 0.0100 ksi Interpolation in Gauge .................. . 0.0000 ksi Accuracy of Gauge ................................................................ 0.0000 ksi Errors In Gauge Calibration Interpolation in Master .................. : 0.0000 ksi Interpolation in Field Gauge ..................... ;............ 0.0050 ksi Accuracy of Master ................
- 0.0100 ksi Accuracy of Field Gauge ; .... 0.0275 ksi Errors In Field Use of Gauge Interpolation Error............................................................................. 0.0050 ksi Accuracy Error................................................................................. 0.0275 ksi Maximum Gauge Reading Used ....................... .. . . . .: 8.5050 ksi FORCE (kips) = 190.993 (in2 ) X GAUGE READING (ksi) + -6.358 (kips)
Correlation = 0.99999735 . ' NINO = 0.9630 (Not < 0.66667) Maximum Error Ratio In Jack.0.0120 Maximum Error Ratio In Gauge............................................................................ 0049 Maximum Total Error Ratio .................... .. 0.0130
I f I . , f i t B RAM/JACK CALIBAPTION RECORD FORH 12.8.G PSC Formerly Inryco Surveyi,1nce 1 PROJE CT 7-r 7 CONTRACT/PART NO. rc/ - Jack Descr-iption _ _ _ Size 0:0 Tons Register No, c Theoretical Ram Area /9Oa' Hba-. Pressure Sf! / PSi Calibrating Device c-o yoz- Register No. Constantt , Calibratinz Gauge #ir,' Resister No, 9-A.vf Daeedr-g-3--~y Rav Data By y- '-6~ WITNESS ____ 5 sean Ran Area /9'.9.93 sq-in. K--6 Kip Agetcye Computed By 29/A-' G,'cwen7777 QC Check 7. Title f Date Z/7/CS Title _ q Date-2 -'5~ Target PSI Gauge Reading PSI ! Load Cell Rea-dout COX2=,ENTS I______-_!__-_ _I -~- 7f2 RU-N POSITION zŽ. Ioo - < c~ - ! -//,&! ° If-t. r ! ..I ~ 1nI'... I rr' S POSTTIIIN 7 I .. /voo I - -f, 7 / I . li
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I .e io k,,rr RAM/JACK CALIBRATION RECOPJ FORM 12.8.G PSC Forrmrrly
,ROJECT a A- Inryco SuryiJJlancI PRO -CT 444.1111tf-le CONTRACT/PART-NO.fJ< ^
Jack Description /`/ Size -2Tons RegisterNo , 691 Theoretical Ram Area fJI-ix. M. Pressure S7LO PSI Calibrating Device -7De)46Ji - Register No. 73- Constant3Z? .* Calibrating Gauge __ A/se Register No.57-ZU6 Date: / Data By -az 2 /
< - " WITTNES -
Mean rm Area IQC 74 sq.in. K.7y4 KipD ,Agency - U6 Datee 2 i Computed By ( C- QC Check ,
,Title Ae@Ere Date LjTitle IA _ __6, _ __ _ _ Date ___
Target PSI 1 Gauze Reading PSI, I Load Cell Readout L COfENTS 1_lioiz _ia. 1 RUN / POSITION j*
-abD 3& - {-/7.Z
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3 7.0Z. 7Dio - l7014--I- Y __ i
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r1vuv, k_ JL M AX/ YJE TM - CONTRACT NO. N923/N9Z JACK DESCRIPTION: PINE TONS: 850 REGISTER NO.: 6001 THEORETICAL RAM AREA (sq-in): 190.45 MAX PRESSURE (psi): 8500 varied .- k5 CALIBRATING DEVICE USED: TELEDYNE REGISTER NO.: 4734 CONSTANT= 32987.5 9i CALIBRATING GAUGE DESCRIPTION: HEISE REGISTER NO.: S9-222Q
.INPUT.
ACTUAL GAUiGE 1- LOAD CELL COMPUTED READING (pa si) READOUT FORCE (k) 1012 , 5.72 188.689 2023 11.54 380.676 3007 17.26 569.364 4016 23 .-10 762.011
-5022 28.92 953.999 6011 34.70 1144..666 7016 40.54 1337.313 8014 - 46.34 1528.641 8513 49-.24 1624.305 1011 5.68 187.369 2016 11.44 377.377 3016 17.24 568.704 4013 -23.06 760.692 5012 28.88 952.679 6013 34.70 1144.666 7015 40.54 1337.313 8014 46.36 1529.301 8506 49.24 1624.305 1012 5.72 188.689 2018 -11.52 380.016 3012 17.30 570.684 4017 23.14 763.331 5011 28.92 953.999 6011 34.76 1146.646 7012 40.60 1339.293 8015 46.44 1531-.940 8516 49.36 1628.263
- - - THESE READINGS HAVE BEEN OMITTED FROM THE FINAL COMPUTATIONS.
ERRORS IN JACK CALIBRATION ERROR IN STANDARD-........... 0 .0100 ksi INTERPOLATION IN GAUGE .......... 0.0000 ksi ACCURACY OF GAUGE ............... 0.0000 ksi ERRORS IN GAUGE CALIBRATION INTERPOLATION IN MASTER .......... 0.0000 ksi INTERPOLATION IN FIELD GAUGE 0.0050- ksi ACCURACY OF MASTER. 0.0100 ksi ACCURACY OF FIELD GAUGE .... 0.0275 ksi ERRORS IN FIELD USE OF GAUGE INTERPOLATION ERROR .......... 0.0050 ksi ACCURACY ERROR........... 0.0275 ksi MAXIMUM GAUGE READING USED ................ 8.5160 ksi-
** FORCE (k) = 191.784 (sq.in.) X GAUGE READING (ksi) -7.404 (k) **
CORRELATION = 0.99999626 - N/NO= 1.0000 (NOT < .66667) - MAXIMUM ERROR RATIO IN JACK .......... .0108 MAXIMUM ERROR RATIO IN GAUGE . .0.. ... .0049 MAXIMUM TOTAL ERROR RATIO ..... .. .0118 a COMPUTED BY: X DATE: / 4 /'y CHECKED BY: ?-/A DATE A.t f I .I 11 I - r - ---:-
0 ea (1,; n5 I II -:- >,;--, I C-0 (I11I.-- 7,3-) .- I 'ES ITT Ar-P I I17 1 TI? o 1c:K~-2
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I~~.- 1 Ii I I I I , DOCUMENT NO: DOCUMENT TYPE: ENG
~S~ 2 # g HYDRAULIC JACK CALIBRATION
\.
Jack Calibration Record REVISION i N SAFETYRELATED
.NON-SAFETYRELATD PAGE I OF 3 0
COMPUTED BY: CEC DATE: 02/04/0 1 REVIEWED BY: Adj DATE: x
. I J Project: Post TMI Contract No: N924 Jack
Description:
Pine . Size: 850 Tons Register No: 6002 Theoretical Ram Area: 190.45 sq. in. Max Pressure: .8500 psi Calibrating Device Used: Teledyne Register No: 4734 Constant: 33005 Calibratino Gauge Used' Heise Register No: S9-22260 Due Date: 02/03/08 lRaw Data By: Daniel P. O'Shea Date:. 02/04105 Witness: ,/, 49 M ean Ram Area: P190.823:sq. in. K= <6t382 1 kips Agency: PM_ _ Date: ulX Computed By: Christopher E. Cox QC Check: __, ,Title: Field Engineer Date: -02/04/05
Title:
d /,! . Date: ; - -oS Target Pressure (PSI) [ Gauge Reading (PSI) Load Cell Readout . Comments 1000 1045 5.90 RUN: 1 POSITION: 1.5" 2000 2010 11.36 3000 3009 17.10 4000 4028 22.98 5000 5005 28.62 6000 6003 34.42 7000 7010 40.22 8000 8010 - 46.02 8500 8507 48.90 1000 1012 5.72 RUN: 2 POSITION: 3" 2000 2017 11.48 3000 3008 - 17.20 4000 4011 23.00 5000 5013 28.80 6000 6010 34.56 7000 7017 40.42 8000 . . 8008 46.16 8500. 8504 49.04 1000 1017 5.76 RUN: 3 POSITION: 4.5" 2000 2000 - 11.38 3000 3011 -17.24 4000 4008 23.02 5000 5008 28.80 6000 6010 34.60 7000 7011 40.40 8000 8008 46.20 - 8500 8503 49.08
"l Li' / ,R LC-.1 RA2-/JAC7 CALIBRATION RECORD FORH 12. 8. G PSC Formcrly I
inryco Survtillahce PROJECT A, 72- . CONTRACT/PFART NO. ,V9A5 iSI ;: Jack Description ', Size - 0 --- T ons R-egiscer No 60Ot I1 1 Theoretical Rara Area /40, Nax. Pressure RSon PSi Calibrating Device gzssyw- Register No. >.Rg Constantq3no Calibratinz Gauge - - Register No. -i Date ,- - Raw Data By -- - lEESS K J14 Xean
. Ram Area . sq.in. K=. Kip Agency -AIM_ _- Date _ _/
Compueed By @ < .'6_ -IQC Check . - 4 7 Tltle ,<cI0I £./41 ~ Date~ O Title RG., 4. Datc ______ Targec PSI Gauze Reading PSI Load Cell Readout; CONENTS
/00 I / j -RUN POSITION /i<
_____'-_____I~
* ?Ot - I .,#12 1.I ,,
- .9
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i00
- -Ir/ -A d -
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/- UNL POSITION ALH AR &
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. 11-"'f' RAM/JACK CALIBRATION REECORD FOPRf 12.8.G PSC Formerly
_ . Inryco Surveillance I PROJECT P, Fo Wo/>CONTRACT/?A^RT_.,- NO N ..A? Sg, z Jack Description ?/A) . Size --- Tons Regiscer N - Theoretical Ram Area ____ _ =iax. Pressure 'Th PSI Calibrating Device 7-:co:qV - Register No. 'T, Constant_3___7_ Calibratinc GaUge £/JSE Register No. L Date] '-/
.paw Data By v4,TL) 4- %-c5/ jwT'ESs W _(
XIean P am Areza ______sq. in. L= 1ip lgency Daeate- G / Computed By II C QC Check _ _ _ _ _ Titl e teTfif.A:
--- DateSi/lv Title A 641., , , Date __-
Target PSI Gauze .Readinz PST I Load Cell Readoutl CONENTS IbL) ! 1_6_ _-___ -__ __ RU f POSITION /> 3g Qi2. 3'/ _ _ _ _ _ _ I I.
- I~i 1/7.dG -
40 2a1 gD IfDP e*ao/ j 7D gD&}g
-_-_ l-
____Z s".g 7 J 0D/i; -l_ _.-- ZwI- 7-z ______________3 Li I - ]- --b I - <- 7 V RUN t. POSITION j.- CXJ W I /&'JL- - I ,,c v 14I? - -I/5Z, Li /C I cbv, 1 -/Z~wc
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_ _ - _w_ -_ _ __ __. A t v C. J / 'v :; 7-JACK DESCRIPTION: PINE TONS: 850 REGISTER NO.: 6002 Pi
'THEORETICAL RAM AREA (sq.in): 190.45 MAX PRESSURE (psi): 8500 f/k~q" -
CALIBRATING DEVICE USED: TELEDYNE REGISTER NO.: 4734 CONSTANT= 32987.5 CALIBRATING GAUGE DESCRIPTION,: HEISE REGISTER NO.: S9-2226
.INPUT.
ACTUAL GAUG E LOAD CELL COMPUTED READING (ps READOUT FORCE (k) 1015 5.78 190.668 2011 11.52 380.016 3019 17.36 572.663 4015 23 .10 762.011 5016 28.90 953.339 6014 34.68 1144.007 7013 40.50 1335.994 8014 46.32 1527.981 8510 49.22 1623.645 1012 5-.78 190.668 2012 11.52 380.016
,3011 17.30 570.684
- ,4015 23.08 761.352 5014 28.88 952.679 6017 34.70 1144.666 7022 40.56 1337.973 8015 46.34 1528.641 8512 49.26 1624.964 1010 5.76 '190.008 2011' 11.56' 381.336 3010 17.38 573.323 4017 23.24 ,766.629 5015 29.04 - 957.957 6012 34.88 1150.604 Kl1 7011 8015 - 40.70 46.56 1342.591 1535.898 8510 49.46 1631.562
* .-- THESE READINGS HAVE BEEN OMITTED FROM THE FINAL COMPUTATIONS ERRORS IN JACK CALIBRATION -
ERROR IN STANDARD .'.............. 0.0100 ksi INTERPOLATION IN GAUGE .......... 0.0000 ksi ACCURACY OF GAUGE ............... 0.-0000 lksi ERRORS IN GAUGE-CALIBRATION INTERPOLATION IN MASTER ......... 0 .0000 ksi INTERPOLATION IN FIELD GAUGE 0.0050 ksi ACCURACY OF MASTER ..'............ 0 . 0100 ksi ACCURACY OF FIELD GAUGE ......... 0.0275 ksi ERRORS IN FIELD USE OF GAUGE INTERPOLATION ERROR,............. 0.0050 ksi ACCURACY ERROR .................. 0.0275 ksi MAXIMUM GAUGE READING USED ................ 8.5120 ksi
** FORCE (k) 191.565 (sq.in.) X GAUGE READING (ksi) -z4.911 (k) **
CORRELATION = 0.99998420 N/NO=.1.0000 (NOT < .- 66667) MAXIMUM ERROR RATIO IN JACK ... ....... .0091 MAXIMUM ERROR RATIO IN GAUGE ... ,..,..,,_. !_Q,049 MAXIMUM TOTAL ERROR RATIO ............. .0103 COMPUTED BY: DATE: )/. 1 CHECKED BY: / ' 7 JI DATE:
4, .~n_.K/11- eole/i 6
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0, .
SECTION 9
- ~~ . f 3'le PSC PRECISION SURVEILLANCE CORPORATION CONTROLLED MANUAL NO.:
IN-SERVICE INSPECTION MANUAL FOR AMERGEN ENERGY THREE-MILE ISLAND) UNIT 1 (8TH INSPECTION PERIOD) (3OTH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE REVISION A REVISION Z I \ -,2-S-o L REVISION A REVISION A REVISION A 4 PREPARED BY: W. TITLE: A &", Q,H. DATE: g z-oY III
?Lr~.
APPROVED BY: it c_ APPROVED BY: /3ad/(,TTLE:
/ TITLE:
- 0. /7,
*q&4c,-zDATE:
DATE: s anr
-A 'f OS
I~' rx'FDo IN-SERVICE INSPECTION MANUAL Precision PSC Surveillance ACKNOWLEDGEMENT OF.RECEIPT FORM Corporation This page shall be removed or a facsimile provided and returned to: Precision Surveillance Corporation Quality Assurance Section 3468 Watling Road East Chicago, IN 46312 Attention: H. F. Hendrickson The return of this page from Controlled Manual Number______________ Will indicate acknowledgement of receipt for document control purposes.' Failure to r'eturn this page or otherwise provide acknowledgement shall be just cause for
.termination of the controlled status of this' document.
RETURN OF THIS RECEIPT SHALL NOT CONSTITUTE:APPROVAL FOR THE CONTENTS HEREIN. If this page is stamped "UNCONTROLLED MANUAL", do not return this. page. The person 'acknowledgingreceipt will be.considered the-permanent holder of this manual. For more infor'mation regarding responsibility attendant with this manual refer to the Manual Control Policy Statement. Date of Submittal____________ L Date of Receipt______________ Name___________________ Signature_________________ Title__________________ Company__________________ Project__________________ Contract In-Service Inspection Manual Issue Date_________ Revision___________ 1 is I evisione Ioa: Formerly "Inryco Surveillance"
IN-SERVICE INSPECTION TENDON SURVEILLANCE PROGRAM MANUAL CONTROL POLICY Page 1 of 1 A. Controlled copies of this manual shall be submitted for review and approval according to the distribution and quantity requirements established by the Contract Documents. Where this is not specified, Precision Surveillance Corporation shall submit a minimum of one controlled Manual. Where applicable, an uncontrolled copy may be submitted to assist in the review process. To avoid fabrication or construction delays, a line of communication should be established with the personnel responsible for initiating approval for the Manual or Revisions thereto, rather than incurring the delay for gravitation to that level. B. Acknowledgement of Receipt is mandatory upon receiving a Controlled Manual and a form is supplied to facilitate this response. This form or a copy, shall be filled in with the information requested and returned in order to activate the Control status of this Manual, otherwise it will be treated as an uncontrolled manual and no attempt shall be made to keep it in a current condition. C. The responsibility for keeping the uncontrolled Manuals up to date shall be incumbent on the person acknowledging receipt of the Controlled Manual. D. Reproduction of the Manual TS NOT AT TMO)RTF7T), except for copies made by the owner/or his agent for internal distribution review and use, without the expressed written consent of the Precision Surveillance Corporation Quality Assurance Section responsible for the maintenance of the Manual. (E. Where required, uncontrolled manuals shall be submitted at the pre-bid stage of the project. In the event of non-award of the project to Precision Surveillance Corporation, the uncontrolled Manual shall be returned to the Quality Assurance Section. F. INTERNAT, Those Precision Surveillance Corporation personnel receiving Controlled Manuals or revisions thereto, shall be responsible for reviewing and understanding those portions of the Quality Program that they and their subordinates are responsible for. The return of the Acknowledgement of Receipt' shall constitute certification that the person receiving that Prograrn/Revision has reviewed the contents and has taken appropriate action to notify or train those personnel under his control that are affected by that document or the revisions thereto. mcp.TMI.04isi
f-A fleM3 AMERGEN ENERGY PSC Precision ji, THREE MILE ISLAND Surveillance UNIT 1 ( 8 TH INSPECTION PERIOD) (30TH YEAR) Corporation REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE IN-SERVICE INSPECTION SURVEILLANCE MANUAL INDEX STATUS SHEET SECTION Pages Original Issue. Revised Status Rev. Date Rev. Date Title 1 0 7-23-04 1 8-25-04 Receipt - To be returned 1 0 7-23-04 1 8-25-04 Manual Control Policy 1 N/A N/A Index Status Sheets 1-4 .0 7-23-04 1 8-25-04 Revision Control Sheet 1 N/A N/A .1 8-25-04 Definitions 1-5 N/A N/A Safety Comments 1-3 N/A N/A 1301-9.1, Surveillance Procedure 1-79 18 8-24-04 ER-AA-335-018, VT 1-22 -1 Level 2 Reference use Examination - SQ 3.0 - Const. Equipment 1-2 0 7-23-04 l SQ 4.0 - Q.C. Equipment 1-3 0 7-23-04 SQ 6.0 - Grease Cap Removal 1-6 0 7-23-04 _ Data Sheet 6.0 1 0 7-23-04 SQ 6.1 - Inspect. F/Water 1-6 0 7-23-04 Data Sheet 6.1 1 0 7-23-04 :_ SQ 6.2 - Water Analysis .1-3 0 7-23-04 SQ 7.0 -- Grease Samples 1-3 0 7-23-04 1 8-25-04 SQ 7.1 -Anchorage Meas. 1-5 0 7-23-04 Data Sheet 7.1 1 0 7-23-04 Appendix 1 1 0 7-23-04 Appendix 2 1-2 0 7-23-40 Appendix 3 1-5 0 7-23-04 Appendix 4 4 0 7-23-04 1 8-25-04. SQ 7.2 - Grease Analysis 1-5 0 - 7-23-04 Effective Peiu Date: 7
~--43-oy Revision:zL eiinZ\8z-cV r Page: 1 of 4
A;6 1 IL( AMERGEN ENERGY PSC Precision THREE MILE ISLAND Surveillance UNIT 1 (8TH INSPECTION PERIOD) ( 3 0 TH YEAR) Corporation REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE IN-SERVICE INSPECTION SURVEILLANCE MANUAL INDEX STATUS SHEET : SECTION Pages Original Issue Revised Status Rev. Date Rev. Date SQ 10.2 - Test Wire Removal 1-5 0 7-23-04 _ Data Sheet 10.2 1 0 7-23-04 SQ 10.3 - Testing of Wires 1-5 0 7-23-04 Data Sheet 10.3 1 -0 7-23-04 ; FigureD.- 1 - N/A N/A Figure D.2 1 N/A N/A SQ 10.5 - Continuity Test 1-4 0 7-23-04 Data Sheet,10.5 1 0 7-23-04 Figure2 1 N/A N/A SQ 12.0 - Grease Cap Replac. 1-5 0 7-23-04 - Attachment 1 1 0 7-23-04 Attachment 2 - 1 0 7-23-04. SQ 12.1 - Grease Replacement 1-8 0 7-23-04 1 8-25-04 Data Sheet 12.1 1 0 7-23-04 1 8-25-04 Sketch 8-1 1 N/A N/A SQ 12.2 - Grease Volumes 1-2 0 7-23-04 Effective Previous Date: ~ . , - Revision: A~ ').2Z3oc Reii nZ ~Page: 2 of 4
L ("n AMERGENENERGY PSC Precision THREE MILE ISLAND Surveillance UNIT 1 (8TH INSPECTION PERIOD) (3 0 TH YEAR) Corporation REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE IN-SERVICE INSPECTION SURVEILLANCE MANUAL INDEX STATUS SHEET SECTION Pages Original Issue Revised Status Rev. Date Rev. Date QUALITY ASSURANCE QA 1.0 - Program Purpose 1-2 0 7-23-04 QA 2.0 - Program Scope 1-2 0 7-23-04 QA 3.0 - Organization 1-2 0 7-23-04 QA 4.0 - QC Responsibility 1-2 0 7-23-04 QA 4.1 - Qualifications 1-2 0 7-23-04 QA 5.0 - Training 1-2 0 7-23-04 QA 6&0 -Procurement 1-2 0 7-23-04 _ QA 7.0 - Field Change Request 1-3 -0 7-23-04 FCR Fonn I N/A N/A FCR Index Log 1 N/A N/A QA 8.0 - Document Control 1-3 0 7-23-04 ' _ QA 8.1 -Revision Control 1-5 0 7-23-04 Revision Control Sheet 1 0 7-23-04 X QA 9.0 - Nonconformances 1-7 0 7-23-04 Tags and Sample Logs 1 0 7-23-04 Sample NC/CA Report 1 0 7-23-04 NC/CAR Form I N/A N/A NCR Index Form II N/A N/A Hold Tag Log Form 1 N/A N/A _ Reject Tag Log Form 1 N/A N/A QA 10.0 - Calibrations 1-6 0. 7-23-04 1 8-25-04 QA 10.1 - Calib. Verif. 1-5 0- 7-23-04 Gauge Calib. Record Form 1 N/A N/A QA 11.0 - Inspections 1-3 0 7-23-04 QA 12.0 - Audits 1-2 0 7-23-04 Effective Previous Date: 7 Revision: &S 7.i3.-' Revision: iL v. Page: 3 of 4
1 f3a \ IIf' AMERGEN ENERGY THREE MILE ISLAND PSC Precision Surveillance UNIT 1 (8 ' INSPECTION PERIOD) (3 0 TH YEAR) Corporation REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE IN-SERVICE INSPECTION SURVEILLANCE MANUAL INDEX STATUS SHEET SECTION Pages Original Issue Revised Status
- Rev. Date Rev. Date CALIBRATION PROCEDURES Q 12.2-General 1-2 0 9-19-86 Q 12.5 - Calibration Recall 1 0 9-19-86 Q 12.8.B-W-Micrometer 1-2 0 6-17-87 Calibr. Form - Exhibit A 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A Q 12.8.C-W - Pressure Gauge 1-3 0 6-17-87 Calibr. Form - Exhibit A 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A _
Q 12.8.D-W-Thermometers - 1 0 6-17-87. Thermometer Calib. Record 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A Q 12.8.E-W - Feeler Gauge 1-2 0 6-17-87 Calibr. Form - Exhibit C 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A Q 12.8.F -Dial Indicator 1-2 1 8-26-99 Calibr. Form - Exhibit C 1 N/A N/A QA 12.8.G-W-Rams 1-5 2 8-26-99 _ Ramn/Jack Calibr. Record 1 N/A N/A Appendix I - Linear Regr. 1-4 1 8-28-90 Appendix 2 = Sample Printout 1-2 N/A N/A QA 12.8.K - Thread Wires .1-6 0 5-01 Calibr. Form QA 12.8K 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A - QA 12.8.L-Thread Wires 2 -.0 5-01-87 Calibr. Form - Exhibit C 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A QA 12.8.N - Bar Standards 1-2 0 5-01-87 : Calibr. Form - Exhibit C 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A QA 12.8.P - Optical Comparator 1-4 0 9-19-86 Calibr. Form - Exhibit C 1 N/A N/A Calibr. Record - Exhibit B 1 N/A N/A Effective Previous Date: , 2J-Y Revision:,*\s o' Revision:,\ -z.o Page: 4 of 4
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IN-SERVICE INSPECTION 'C/ TENDON SURVEILLANCE PROGRAM DEFINITIONS Page 1 of 5 ACTIVE CORROSTON Corrosion on a component that exhibits metal loss that has occurred since fabrication or construction, and/or exhibits pitting visible to the naked eye. Active corrosion usually is a reddish/rust color. ATTF.RNATF, LFT OFF MFTHOTh) Alternate method to determine lift off force by measuring jack pressure versus distance the anchorage has moved during stressing. A plotted graph is used to depict the as found data when performing this method. ANMCOR AGE (Stressing Washer)- The round machined components at the end of each end of the tendon through which tendon wires are passed. The anchorage contains a field end component, bushing in some cases, and shims. RFARPNT PTLATE (RBsepllte Tnimplate). The steel plate at the end of the tendon, embedded in the concrete. The tendon is passed through the hole in the plate and the anchor head bears against the plate or shim which in turn transfers the load to the concrete. BROKFN WTRF-
*Awire within a tendon assembly that is broken and not capable of accepting prestressed load.
Wires that excessively protrude from the anchorage components are suspected to be broken. RETITTON PFATh-The end of the tendon wire that was mechanically deforned during fabrication or construction, which seats on each anchorage. COMMON OR CONTR OT. TFNDT) N A tendon from a tendon type (as defined in Table -IWL251-l) selected from the first year inspection sample. CONTTNI JTTY TFST-A method of determining if wires are intact and not broken within a tendon. This is an optional test that may be recommended as a corrective action if abnormal degradation is identified. CORROSTON PR OTCTTION MEDIUTM (grease (Ca ing Filler). Grease injected into tendon duct and anchorage caps for corrosion protection. Also referred to as grease or sheathing filler grease. def.byn.04isi
IN-SERVICE INSPECTION TENDON SURVEILLANCE PROGRAM ~1(ID/ 5 DEFINITIONS Page 2 of 5 L1- -- EFFECTIVF WIRFE Tendon wire capable of maintaining required post tensioned force. FT ONGATTON-The distance a tendon/wire stretches when being stressed. PPFTER CATTGE. MPTI-IC) The method used to determine lift off during a test that utilizes the placement of feeler gauges within the anchorage components while the tendon is underjack/ram load. FTFITD FND-The end of the tendon on which button heads are formed after the tendon is installed. The field end usually does not have a bushing.
.FRFF WATPR -
Any quantity of water collected from a tendon grease cap, anchorage components, shim gaps, or tendon duct. GfRFASR CAP-Steel container bolted to the bearing plate or anchor head. A grease cap encases the anchorage assembly to provide permanent corrosion protection. (T TAR ANTPED M MTJM ITTLTTMATF. TF.N.STT.F- STR.NGTTT4 (G-T TT-S-The tensile strength of the tendon assembly based upon the tensile strength of the wire used in construction and the quantity of effective wires. The minimum Guaranteed Ultimate Tensile Strength of l/4" (o.25") diameter wire is 240,000 pounds per square inch or 11,781 pounds. N1NSPFCTTON PEPRTODD-The period in which an inspection is completed at a specific site. JACK (Rain) A cylindrical, hydraulic device used to stress the tendon. Also referred to as a "Ram". JACK CATR That device attached to the front of the ram and bears against the bearing plate, which provides the lift height for the tendon as it is being stressed. def.byn.04isi
IN-SERVICE INSPECTION - TENDON SURVEILLANCE PROGRAM DEFINITIONS Page 3 of 5 L r-- T.1FT OFF FOR CF* The actual force or pressure required to lift the anchor head off the tendon anchorage assembly shim stack. T.OCK OFF FOR CF-The final seating force of a tendon after tensioning during construction or retensioning thereafter. MTNTM TM T)FqT(NFnR (P.F(kin)c-The minimum acceptable prestress force for a tendon or group of tendons to maintain the design basis of the containment structure. MTISTNGY WIRP-A wire that is identified as missing from the tendon. MO NITO(RiNGr OF FOR CF. That series of operations that determine the force or prestress remaining in the tendon. NET )T TCT VOT TMF-The volume within a tendon duct that is capable of being filled with corrosion protection medium.. Th-is is the gross duct volume minus the volume taken by the tendon wires and components. OVFRSNTRF.SS FORCF: The maximum force that can be applied to a tendon during lift off testing and retensioning. This force is 80% of the tendon's ultimate tensile strength. For wire specification ASTM A421, 80% of the minimum Guaranteed Ultimate Tensile Strength of the wire is 9,425 pounds for each 1/4" diameter wire. POST TFN5STONNGT-A method of prestressing concrete in which the tendons are tensioned after the concrete has cured. PR FDTCTFT) FORCF-: The precalculated force (in kips) based upon the measurement of the prestressing forces during installation minus the losses in prestressing forces that were predicted to have occurred since that time because of material and structural characteristics. This is the calculated minimum force that should be required to achieve lift off.' This value is the acceptance criteria for measuring prestress forces. The as found value should be equal to or exceed this value. def.byn.04isi
IN-SERVICE INSPECTION TENDON SURVEILLANCE PROGRAM 1-Colfa DEFINITIONS L (-'-: . .. Page 4 of 5 PRFSTRFSSF CONCRFETF: Reinforced concrete in which there have been introduced internal stresses of such magnitude and distribution that the stresses resulting from loads are counteracted to a desired degree. PRFTFNSTNTNWT FOPRCF-The force achieved during retensioning where the slack and mechanical clearances have been removed. PROTRTMTNCT OR TTNSFATF= WTRF-A wire within a tendon assembly that is extending beyond a tendon anchorage after stressing and is not seated against the anchorage. The wire must be evaluated. PTUMP A mechanical device used to pump hydraulic fluid into the jack and apply the force required to stress the tendon. RAM-Synonym for Jack. (See Jack) FRPA1IRPPTLAfClMFNT-A repair or replacement activity as defined in IWA-4000 and IWL-4000. RFPGRF.qS.TON ANATYSTS-The determination, based upon evaluation of measured forces, of the capability of a tendon or group' of tendons to maintain the minimum design prestress force(s) until the next scheduled inspection or beyond. RFSPONSITB. FNGTTNFER (RPFP)- A Registered Professional Engineer as defined in ASME Section XI Subsection iWL experienced in evaluating the inservice condition' of structural concrete. The Responsible Engineer shall have knowledge of the design and construction codes and other criteria used in the design and construction of concrete containment structures in nuclear power plants. SHTFATHNGT (Conduit Duct Void)- The thin-walled tubular steel used for creating a void in the concrete through which the tendon is passed. (Also referred to as: duct, conduit, void.) def.byn.04isi
IN-SERVICE INSPECTION TENDON SURVEILLANCE PROGRAM f DEFINITIONS
- Page 5 of 5 SHIM STA CK-A series of steel shims installed between the anchor head and bearing plate so that the desired prestress force is obtained. They must be installed in pairs.
SHOP FNND-The end of a tendon on which the button heads are formed prior to installation. These button heads' are formed in a shop environment and not in the field. The shop end of a tendon has a bushing. SJXESS.N'ING-i Connecting the ram to the tendon and pulling until a predetermined force and elongation is achieved. STRF.SSING ADAPTOR (Coupler) That threaded device attached to the pull-rod of the ram, which couples with the anchor head to be stressed. TFND)ON:, A separate continuous multiwire tensioned element anchored at both ends to an end anchorage assembly. An assembly of prestressing steel-and anchorage components which imparts prestressing forces to concrete. TFNDON ENn ANCORACTF A OD ASRMPRTY That portion of the tendon which extends beyond the bearing plate while in a stressed condition which consists of the bearing plate, shim stack, anchor head and wire. TFNDT ON G(RO TTP Groups based upon geometry and position in the containment structure. Horizontal, vertical, and dome tendon groups are applicable to Three Mile Island Unit 1. TENMONTT.nrATTQN NI TNfRP The identity of a tendon with regard to it's location in the structure. TFŽ\)NI TYPF. A tendon type is defined by its geometry and position in the containment structure; e.g., horizontal (hoop), vertical, and dome. WTRP.- 1/4" diameter wire manufactured to ASTM A421.
.r def.byn.04isi
IN-SERVICE INSPECTION TENDON SURVEILLANCE PROGRAM I?L4f5al SAFETY COMMENTS Page 1 of 3
- 1. PIIRTROSE The purpose of this document is to create an awareness for those safety considerations that must be observed by those personnel working around or directly involved in Post-Tensioning System operations.
- 2. TFNFR ATL All personnel directly involved with the Post-Tensioning System operations shall be made aware of the magnitude of the working forces and safety requirements for the various operations.
- 3. S AFFTY 3.1. WIRE.
The wire used for fabricating the tendons has a minimum breaking strength of 240,000 pounds per square inch. This means that each 1/4 inch diameter wire is capable of withstanding a minimum breaking load of 11,781 pounds per wire. Multiply this by the number of wires in a tendon and you are dealing with forces in excess of 1 million pounds for a 90 wire tendon and in excess of 2 million pounds for a 170 wire tendon. 3;1.1. CAUTION NEVER CONNECT A WELDING GROUND, PERFORM WELDING ON, OR STRIKE AN ARC NEAR A STRESSED TENDON. NEVER APPLY AN OPEN FLAME OR LIGHTED TORCH TO THE BUTTON HEADS, THE WIRES OR ANCHORAGES OF A STRESSED TENDON. NEVER STRIKE THE BUTTON HEADS, THE WIRES OR THE ANCHOR HEADS OF A STRESSED TENDON WITH A HAMMER OR ANY OTHER METAL OBJECT. 3.1.1.1.The above actions could-cause a button head or wire to fail. During tendon tensile testing, broken wires or butt6n heads have been observed to penetrate hard lumber in excess or 4 inches in thickness, about the equivalent of a .32 caliber bullet. i-saf .TMI . 04isi
IN-SERVICE INSPECTION a<*6I f5al TENDON SURVEILLANCE PROGRAM SAFETY COMMENTS II - ' Page 2 of 3 3.2. STPPSI1NGl OPFR ATTONS During detensioning or stressing operations the following cautions shall be observed. 3.2.1. CATUIOQN NEVER EXCEED THE OVERSTRESS FORCE OR PRESSURE - 80% OF TENDON GUTS FOR THE AMOUNT OF EFFECTIVE WIRES IN A TENDON. 3.2.2. AUlTTON DO NOT STAND BEHIND THE JACK WHEN IT IS UNDER LOAD. KEEP FINGERS OUT OF ANY PINCH AREAS. BE ALERT DURING SHIM PLACEMENT AND REMOVAL. 3.3. STRFtSING ADAPTOR (COUPLER) Prior to applying ANY FOR CE to the tendon, the stressing adaptor, coupler, must be fully engaged with the anchorage to be stressed or detensioned. 3.3.1. CAUIITON BE SURE THE STRESSING ADAPTOR (COUPLER) IS FULLY ENGAGED WITH THE ANCHORAGE BEFORE APPLYING ANY LOAD, REGARDLESS OF HOW SMALL THAT LOAD MIGHT BE. 3.4. ANC(HOR A TF. ENCTACTPMTFNT During coupling and uncoupling of the stressing adaptor with the bushing and the small anchor head, and especially where some difficulty is encountered with the actually coupling, there is a possibility that the small anchor head may become partially or completely unthreaded from the bushing. Therefore, where any difficulty has been encountered in coupling the adaptor to any anchorage, especially where repeated thread-on and unthreading is noted, before any load or jacking force,'is applied to that tendon, the proper engagement of the shop anchor head to the bushing shall be checked. This shall be done by visually verifying that the small anchor head does- not protrude beyond the bottom face of the bushing. The uncoupling could occur as a result of tight, sticking or slightly damaged threads. saf.TM1.04isi
IN-SERVICE INSPECTION TENDON SURVEILLANCE PROGRAM 11_11 a SAFETY COMMENTS Page 3 of 3 3.4.1. CATETTON BE SURE THAT THE SMALL ANCHOR HEAD REMAINS FULLY ENGAGED WITH THE BUSHING. 3.5. GTREAASING OPER ATTONS During greasing operations the grease may be pumped under pressure and may have temperatures in excess of 150 0 F and injury could occur through carelessness. It is therefore essential to avoid direct contact with the hot grease and to make sure all connections are secure. Exercise caution when climbing tendon buttress and gallery ladders. The potential for slippery surfaces created by grease on shoes exists. Ladder rung, etc. shall be wiped clean if coated in grease. 3.5.1. CATJTO(N DURING GREASING, BE AWARE THAT THE GREASE IS HOT AND MAY BE PUMPED UNDER PRESSURE. 3.5.2. During heating of grease be aware that belt heaters are hot and could cause injury if touched. It is also essential to ensure that no flammable materials are allowed to touch belt heaters when in operation. 3.5.3. Belt heaters draw large amounts of current, ensure that power supply and any extension cords used are suitable for the power requirements. 3.6. CONSIRTI TTAON SAFFTY As in other heavy construction, care should be exercised while working from scaffolds, platforms, ladders, high or restricted access locations. Respect for the safety and well-being of the other trades and personnel in the area must be observed, especially during hoisting operations. 3.6.1. CAUTTON DO NOT STAND UNDER LOADS WHILE STATIONARY OR DURING HOISTING. DO NOT PERMIT OTHERS TO STAND UNDER LOADS. DO NOT THROW OR DROP OBJECT FROM THE SCAFFOLD. 3.7. If there are any doubts or questions concerning a point of operation, safety or quality, refer to PSC Construction or Quality Control personnel before starting that operation or proceeding any further. saf .TMI . 04isi
Number it AerGen TMI - Unit 1 Surveillance Procedure 1301-9.1 L (7- -e xeision~ N. Revision No. RB Structural Integrity Tendon Surveillance 18 Applicability/Scope USAGE LEVEL Effective Date TMI Division .
- I. .. t! ..PA l_ .__I - l /1 08/24104 This document is within QA plan scope X- Yes No 50.59 Applicable LX Yes = No List of Effective Pages Page Revision Page Revision Page Revision Page -Revision 1 18 41 18 2 18 42 18 3 18 43 18 4 18 44 18 5 18 45 18 6 18 46 18 7 18 47 18.
8 18 48 18 9 18 49 18 10 18 50 18 11 18 51 18 12 18 52 18 13 18 53 18 14 18 54 18 15 18 55 18 16 18 56 18 17 18 57 18 18 18 58 18 19 18 59 18 20 18 60 18 21 18 61 18 22 18 62 i8 23 18 63 18 24 18 64 18 25 18 65 18 26 18 66 18 27 18 67 18 28 18 68 18 29 18 69 18 30 18 70 18 31 18 71 18 32 18 72 18 33 18 73 18 34 18 -74 18 35 18 75 18 36 18 76 18 37 18 77 18 38 18 78 18 39 18 79 18 40 18 1
-fre/fy t Number TMI - Unit I Surveillance Procedure 1301-9.1
- ,tle e Revision No.
RB Structural Integrity Tendon Surveillance 18 TABLE OF CONTENTS L Section Page 1.0 PURPOSE 4
2.0 REFERENCES
4 3.0 PLANT STATUS 6 LL 4.0 PREREQUISITES 6 5.0 LIMITS AND PRECAUTIONS 8
6.0 DESCRIPTION
AND LOCATION OF SYSTEMIASSEMBLY 9 7.0 SPECIAL TOOLS, MATERIALS AND PERSONNEL QUALIFICATIONS 9 8.0 PROCEDURE 13 9.0 ACCEPTANCE CRITERIA 22 0 REPORTS 25 FIGURES
- 1. Tendon Detail - Typical Hoop/Dome 26 DATA-SHEETS
- 1. Prestress Force Confirmation Test - Dome Tendons 27
- 2. Prestress Force Confirmation Test - Hoop Tendons 28
- 3. Prestress Force Confirmation Test - Vertical Tendons 29 1 4. Elongation/Tendon Force Record 30
- 5. Average of the Normalized Lift-off Force 34
- 6. Retensioning Criteria Confirmation 35
- 7. Tendon Force Measurement Record 36
- 8. Diameter Check on Anchorage and Ram Adaptor 37
- 9. Tendon Anchorage Area Moisture/Free Water Inspection 38 2
L - Number TMI - Unit I Li Surveillance Procedure 1301-9.1
- -Itle Revision No.
RB Structural Integrity Tendon Surveillance 18 TABLE OF CONTENTS (Cont'd) Section Page DATA SHEETS (Cont'd)
- 10. Tendon Anchor Head Rotation Inspection 39
- 11. Tendon Surveillance Program 40
- 12. VT-1 C i VT-3C Examiner Qualification 41
- 13. Review/Acceptance of Contractor Procedures 42 ENCLOSURES I. Stressing Ram Calibration 43
- 2. ScopeofEachScheduled-Surveillance 45 i.
- 3. Collection/Lab Analysis of Filler Grease 50 L Tendon Wire Removal/Physical Testing 56
- 5. (Deleted) 61
__ 6. AnchoragelInspections 62
- 7. Additional Inspection Commitments Due to Previous Abnormalities 78 3
Number TMI - Unit 1 Surveillance Procedure 1301-9.1 '- -Title Revision No. RB Structural Integrity Tendon Surveillance 18 1.0 PURPOSE 1.I To provide instructions and acceptance criteria for RB tendon inspections as required by TMI-1 Technical Specification, Section 4.4.2. 1.2 Tendon surveillance is performed at intervals after initial containment Structural Integrity Test (SIT), as follows:
- a. One (1) year after SIT. Completed 1975.
- b. Three (3) years after SIT. Completed 1977.
- c. Five (5) years after SIT. Completed 1980.
- d. At successive 5-year intervals for remaining station life.
NOTE 21 tendons were inspected at each of first three surveillance periods; see Table I of Enclosure 2. Unless surveillance results indicate abnormal degradation of the prestressing system, 11 tendons shall be {~ inspected for each subsequent surveillance period. Prior to Cycle 7, and for subsequent periods, an additional vertical tendon was selected in order to comply with Table IWL-2521-1. Total is twelve (12). Enclosure 2, Tables I and 2, provides identification of tendons for each inspection period per GAI DC-5930-225.02-SE. Tendon selection is random and meet the requirement of NRC R.G. 1.35 Rev. 3 and IWL 2520. In the event that a randomly selected tendon becomes Inaccessible, it shall become exempt. Exempt tendons shall be inspected per IWL 2524 and 2525. Substitute tendons shall be selected per IWL-2521.1(b).
2.0 REFERENCES
2.1 TMI Unit 1 Technical Specifications Section 4.4.2, "Structural Integrity" 2.2 TMI Industrial Safety'and Health Manual 2.3 NO-AA-10, Quality Assurance Topical Report 2.4 RP-AA-403, Administration of the Radiation Work Permit Program 2.5 1001J.1, Surveillance Testing Program 2.6 OP-AA-201-009, Control of Transient Combustible Material 2.7 MA-AA-716-100, Maintenance Alterations Process Q 2.8 MA-AA-716-025, Scaffold Installation Modification and Removal Request Process 2.9 Inryco, Reactor Building Tendons, VM-TM-2485 4
L . .N ber TMI - Unit 1 Surveillance Procedure 1301-9.1
!t rite. Revision No.
RB Structural Integrity Tendon Surveillance 18 2.10 IEN 85-10 and Supplement I to same, entitled Post Tensioned Containment Tendon Anchorhead Failure; date February 6, 1985 2.11 SP-1101-23-007, Latest Revision, RB Tendon Surveillance Specification 2.12 TMI-1 Operating manuals and calibration charts for hydraulic stressing jack, pumps, and controls (supplied by vendor). 2.13 Building'Pre-Stressing System Tendon History, including Tendon Pulling, Buttonheading, and Stressing Records (cards). l 2.14 Reports from previous surveillance o 1974 Structural Integrity Test - GAI Report 1838 O 1975 Tendon Surveillance - 1301-9.1 - GAI Report 1880 o 1977 Tendon Surveillance - 1301-9.1 - Report GQL 0204 o 1980 Tendon Surveillance - 1301-9.1 - TDR 229 0 1985 Tendon Surveillance - 1301-9.1 - Topical Report 025 0 1990 Tendon Surveillance - 1301-9.1 - Topical Report 069 O 1995 Tendon Surveillance - 1301-9.1 & Topical Report 093 O 1999 Tendon Surveillance - 1301-9.1 and Topical Report 136
' '1977 RB Ring Girder Surveillance Three Years After S.l.T. - 1303-8.2 2.15 1410-Y-83, RB Tendon End Cap Installation 2.16 1440-Y-23, RB Concrete Surface Crack Repairs 2.17 GAI DC-5390-225.01-SE and GAI DC-5390-225.02-SE, TMI-1 Reactor Building Post-Tensioning System Tendon Selection and Force vs. Time Curves Surveillances 6 through 10.
2.18 Regulatory Guide 1.35, Rev. 3, Inservice Inspection of Ungrouted Tendons in Prestressed Concrete L'Containments. 2.19 'G/C Calculation 1:01:01.01, "Structural Design Review Book 1" (Source Document) - 2.20 MA-AA-716-021, Rigging and Lifting Program 2.21 MA-AA-1010, Oversight of Contractors 2.22 10CFR 50.55a, Codes and Standards 2.23 EN-MA-501, Controlled Materials and Hazard Communication Program 5
L 3Number TMI - Unit 1 L (7L Surveillance Procedure 1301-9.1
-ifle .Revision No.
RB Structural Integrity Tendon Surveillance 18 2.24 ASME Xi 1992 Edition through 1992 Addenda, Subsection IWL L 2.25 ACI 201.1 R-92 and ACI 201.1 R-68, 'Guide for Making a Condition Survey of Concrete In Service" L 2.26 ACI 349.3R-96, "Evaluation of Existing Nuclear Safety Related Concrete Structures" 2.27 TMI-1 C-1101 -153-E410-031, 032, and 033, Tendon Grease Void Calculations for Vertical, Horizontal, and Dome Tendons, respectively
.2.28 TMI-1 Relief request Nos. RR-1 thru RR-7, Implementation of Subsections IWE and IWL, Letter No.
5928-00-30179, Dated 4/27/00 2.29 Reactor Building Drawings TMI 1-0014/0015/0016, IWE Component Rollout-Outside Containment Concrete 2.30 ER-AA-330-006, Inservice Inspection and Testing of the Pre-stressed Concrete Containment Post Tensioning System L 3.0 PLANT STATUS 3.1 Operating or Shutdown. NOTE RB entry not necessary for tendon inspection. 3.2 For safety reasons, during plant operation no tendons with end caps located above steam safety valves are to be scheduled for surveillance. 4.0 PREREQUISITES 4.1 TENDON SURVEILLANCE CONTRACTOR (CONTRACTOR) shall perform tendon surveillance in accordance with this procedure, per Reference 2.3 and 2.11. 4.1.1 CONTRACTOR shall have a quality assurance program in place which meets requirements of 10 CFR 50, Appendix B. This program and associated QANISI procedures shall have been submitted to TMI for review/approval prior to commencement of work. 4.1.2 CONTRACTOR shall be on TMI Evaluated Vendors List (EVL). 4.2 CONTRACTOR shall ensure TESTING LABORATORY equipped to perform following services shall be available for this surveillance: o Inspection of removed wires for corrosion and other defects, and to perform required tensile tests. (See Enclosure 4.)
.; oInspection of bulk filler grease samples and test for chlorides, sulfides, nitrates, base number and moisture content. (See Enclosure 3.)
O Calibration (traceable to NIST) of all hydraulic rams and gauges to be used. 6
Number I TMI-Unit1 T, Surveillance Procedure 1301-9.1
- itle Revision No.
RB Structural Integrity Tendon Surveillance 18 NOTE
,. Stressing ram shall be calibrated per Enclosure 1or CONTRACTOR may propose an alternative method prior to mobilization to TMI-1 and within 15 days after demobilization from L TMI-1 (IWL-2522).
- 2. IFalternative used, CONTRACTOR should submit method for TMI-1 approval at least 30 days prior to start of tendon surveillance and procedure must then be included InCONTRACTOR report.
- 3. CONTRACTOR's QA program shall be imposed on Testing L -Laboratory.
4.3 CONTRACTOR shall ensure all necessary inspection, detensioning/retensiohing/greasing equipment is obtained and calibrated as specified herein. 4.3.1 CONTRACTOR shall ensure detailed operating instructions and calibration documentation are supplied with rams. 4;3.2 CONTRACTOR should submit calibration records to OWNER at least 15 days prior to start of tendon surveillance work and again within 15 days after demobilization from TMI-1. In no case shall work be allowed to start without TMI approval of calibration
- ~~records. '-;
4.4 CONTRACTOR shall field verify proposed stressing rams are of proper configuration for TMI-I dome tendons. 4.5 CONTRACTOR must perform and document training of supervisory personnel with respect to this procedure prior to starting work. 4.6 CONTRACTOR shall verify communication equipment (i.e., headsets, walkie talkies) for use in communication between work crews isoperable. 4.7 CONTRACTOR QC/QV personnel should report to Site QV and NDE Manager. 4.8 IF lifting and handling equipment is to be used, CONTRACTOR shall ensure rigging and lifting devices have been inspectedlapproved for use per Reference 2.20. 4.9 OWNER shall verify calibration documentation is acceptable for calibrated inspection and stressing equipment. 4.10 COGNIZANT WORK COORDINATOR (per Reference 2.21) or designated alternate shall notify on-shift TMI-1 Shift Manager/Control Room Supervisor of work scope to be performed by CONTRACTOR at beginning of each work day of Tendon Surveillance or related activities. 4.11 IF working on or in radiologically controlled area, initiate RWP, per Reference 2.4. ( 4.12 Install required scaffolding per Reference 2.8. 4.13 Work Coordinator shall ensure ANII is notified prior to start of work. 7
Number s TMI - Unit 1 Surveillance Procedure 1301-9.1
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RB Structural Integrity Tendon Surveillance 18 4.14 Work Coordinator shall ensure required indoctrination and training of CONTRACTOR per Reference 2.21 is conducted prior to start of work. 4.15 CONTRACTOR Examiner shall use a visual VT-1NT-3IVT-1CNT-3C examination procedure(s) qualified to meet the distance and illumination requirements contained in the Code (Ref. 2.24), or in any TMI relief requests from the Code requirements. TM] and the ANII shall approve the qualification of the procedure. 4.16 COGNIZANT WORK COORDINATOR verify that Amergen Energy has assigned a Responsible Engineer who meets the requirements identified in the 1992 Edition (with 1992 Addenda) of the ASME Boiler and Pressure Vessel Code, Section XI, Par. IWL-2320. 4.17 COGNIZANT WORK COORDINATOR verify that the experience and training of Contractor personnel performing VT-1 C / VT-3C examinations satisfy the requirements established by the Responsible Engineer. Verify that these individuals are identified on Data Sheet 12 and that the Responsible Engineer has signed that data sheet to attest acceptance of these individuals as VT-1 C VT-3C examiners. 5.0 LIMITS AND PRECAUTIONS 5.1 Conduct this procedure in accordance with Reference 2.5 and 2.7. 5.1.1 IF AS FOUND conditions do not meet acceptance criteria, notify COGNIZANT MECHANICAL/STRUCTURAL ENGINEER as soon as practical and initiate Surveillance Deficiency Report (SDR) per Reference 2.5. 5.2 Ensure all work is done in accordance with TMI-1 Safety and Health Manual. 5.2.1 CONTRACTOR shall report IMMEDIATELY to COGNIZANT WORK COORDINATOR, any working condition which appears to be unsafe. 5.3 Some work may be near plant equipment required for safe shutdown or which may CAUSE shutdown if damaged. Use special care when suspending or moving stressing rams tacks) or other heavy surveillance equipment. 5.3.1 TMI WORK COORDINATOR should work with CONTRACTOR FOREMAN to predict such hazards, and shall keep Operations Shift Manager informed when working in such vital areas. 5.3.2 Discuss all lifting arrangements inside plant buildings with COGNIZANT MECHANICAL/STRUCTURAL ENGINEER and obtain verbal approval to ensure no damage to plant equipment. 5.3.3 Discuss routes for transporting heavy equipment through plant buildings with COGNIZANT MECHANICAL/STRUCTURAL ENGINEER and obtain verbal approval. 5.4 Protect all roof surfaces from grease, oil, and debris as spillage will result in roof degradation. Use drop cloths or similar covering to prevent roof damage. 5.5 Protect all built-up roof surfaces when erecting scaffolding, moving or storing heavy equipment, tool boxes, etc., by installing planking on roof surface. 8
L Number TM I - Unit .1 Surveillance Procedure -1301-9.1 Revision No. RB Structural Integrity Tendon Surveillance 18 5.6 Minimize transient combustibles per Reference 2.6. Clearly label all receptacles containing combustibles such as grease, solvent, used rags, etc. 5.7 All chemicals utilized shall be controlled and evaluated per Reference 2.23. L
6.0 DESCRIPTION
AND LOCATION OF SYSTEMIASSEMBLY 6.1 RB tendons located within concrete shell of Reactor Building. Access to tendons is from outside of RB. 6.2 Layout of tendon system, location and identification can be found in VM-TM-2485. Lb NOTE Testing of tendons around Main Steam' Safety Valve exhaust area shall L not be scheduled during plant operation due to personnel safety concerns. 7.0 SPECIAL-TOOLS, MATERIALS AND PERSONNEL QUALIFICATIONS 7.1 General NOTE CONTRACTOR must document any substitution of materials along with TMI-1 COGNIZANT MECHANICAUSTRUCTURAL ENGINEER approval. 7.1.1 (2) - powered staging platforms consisting of roof trolley and working platform with hoisting equipment for jack handling; Platforms will provide access to'tendon ends being inspected and will support jacks during lift off measurement at each end. L 7.1.2 Permanent 460 volt electrical outlets on top surface of ring girder for miscellaneous uses. 115 volt outlets on working platform to powver hydraulic stressing jack, pumps,' and other L lelectrically-powered7.1.3 equipment. Li: Electrical cables or heavy duty extension cords as necessary for lights, hydraulic stressing L 7.1.4 jack pumps, and other miscellaneous power tools. 7.1.5 Lift for two (2) men and hand tools. L 7.1.6 Portable work platforms for use inside buildings. 7.1.7 Communications equipment for work crew communications. 7.1.8 Miscellaneous hand tools. s 7.1.9 Solvent - for removing grease from around tendon anchorage and cleaning any stained L concrete (CRC Natural Degreaser Aerosol or EPA 2000). 9
L Number TMI- Unit I Li ( Surveillanc6 Procedure 1301-9.1
*,tle Revision No.
L RB Structural Integrity Tendon Surveillance 18 7.1.10 Cleaning rags - approximately 3 bales. 7.1.11 Ambient temperature monitoring equipment. 7.2 DetensloninglRetensioning Equipment 7.2.1 (2)- tendon stressing rams (acks) with 1600 KIPS or greater capacity. 0 Rams body configuration must not conflict with ring girder cut-outs and must have a stroke of at least 6 inches unless clearance and/or weight restrictions require the use of a ram with a shorter stroke. a Ram heads (stressing ram adapters) must mate with Inland Ryerson 170 wire threaded anchor head. O Ram must have a longer than standard chair piece to fit TMI dome tendons. 0 Ram chair shall have access openings at 1800 to permit installation and removal of feeler gauges at about 1800 apart under the stressing washer to obtain lift-off readings. L - '*NOTE Considerable critical path time was spent by CONTRACTOR during inspection number 2 and 3 to modify Ft. St. Vrain rams. Jury rigging of improper equipment can cause personnel or equipment hazards. L 7.2.2 Pumps, hoses, pressure gauges, controls, hydraulic fluid, etc. as required for use of stressing ram; 7.2.3 Files for dressing threads on damaged anchorage heads. 7.2.4 Shims - 170 wire split type of various thicknesses, such as 1/8", 1/4", 1/2", 3/4", and 1", (5) sets or more of each thickness, as required (Inland-Ryerson part No. 101006-8, 101006-5, 6, 7, and I respectively). o Specifications for replacement shims shall require certificate of compliance to ASTM A36 with S2 requirements (material to be silicon'-killed fine grain practice) and certified mill test reports showing chemical and physical test results. L 7.2.5 Wooden or plastic paddles or spatulas to scoop out bulk filler grease from around anchorage assembly. 10
Number TMI - Unit I Surveillance Procedure 1301-9.1 ftle Revision No. -RB Structural Integrity Tendon Surveillance 18 7.3 Inspection Equipment NOTE Calibration Documentation required for allmeasuring equipment in this section. 7.3.1 Feeler gages for crack measurements. Required range of blade sizes is 0.005" to 0.010" by 0.001" increments. 7.3.2 Feeler gages for lift-off tests. Gage thickness is 0.030" and width 1/2". 7.3.3 Optical comparators with 0.001" accuracy for measuring crack widths in concrete or buttonheads. 7.3.4 Grid paper for showing concrete crack patterns at vertical and hoop tendons. 7.3.5 Magnifying glass, 5x (minimum) 7.3.6 Wire cutters to cut 1/4 inch diameter, high strength (240,000 PSI) tendon wires. 7.3.7 Extraction tool suitable for removing wires subject to tensile tests. 7.3.8 Come-along hoist, or similar device, for extracting test wires. 7.3.9 Six-foot diameter wire coiler to coil removed wire. 7.3.10 GO/NO-GO thread plug gages for anchorage thread 'measurement. 7.3.11 Inside and outside micrometers for anchorage thread measurements. 7.3.12 Visual inspection equipment to perform VT-3C and VT-1 C exams. 7.4 Equipment for.Greasing and End Cap Replacement 7.4.1 Grease pump, transmission lines, various fittings mounted on storage tank equipped with heating system to heat grease to between 140OF and 2001F. 0 Grease pump must be fitted with discharge relief valve set for maximum of 300 PSIG. 7.4.2 (5) gallon drums of bulk filler grease, Visconorust 2090P4, by Viscosity Oil Co., or EQUAL as approved by the COGNIZANT MECHANICALISTRUCTURAL ENGINEER. NOTE Grease quantity is estimate only. More or less may be required. 0@ Certifiedftest report for grease is required indicating water soluble chloride, sulfide, nitrate, reserve alkalinity and moisture content. 11
I .Number TMI - Unit 1 Surveillance Procedure 1301-9.1
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RB Structural Integrity Tendon Surveillance 18 O Tests and acceptance limits shall be per Enclosure 3. 7.4.3 (Approx. 6) gallon capacity drums for holding waste grease. Should be steam cleaned and air dried until no moisture or dirt is observed. o To be clearly labeled on top and side: 'WASTE TENDON GREASE ONLY". 7.4.4 (Approximately 10) gallon capacity cans with bails. 7.4.5 End Cap Consumables and Hardware per 1410-Y-83. 12
Number TMI - Unit 1 Surveillance Procedure 1301-9.1
;itle Revision No.
RB Structural Integrity Tendon Surveillance 18 8.0 PROCEDURE NOTE The CONTRACTOR may use its own procedures to perform any or all steps of this surveillance. The CONTRACTOR's procedures shall be reviewed and approved by the TMI COGNIZANT MECHANICAUSTRUCTURAL ENGINEER. Data Sheet 13 shall document the review and acceptance of CONTRACTOR's procedures. 8.1 Equipment Setup _ 8.1.1 Verify all applicable equipment listed in Section 7.0 available.
-8.1.2 Verify Operating manuals and calibration charts for hydraulic stressing jack, pumps, and controls available for use.
o Verify all personnel familiar with operating manuals of equipment to be used during inspection. 8.1.3 Verify stressing jacks, pressure gages, optical comparators, and all other measuring devices have been calibrated and are in good working condition. O Ensure calibration documentation signed, dated, and traceable to NIST. I Verify stressing jack-pressure gauge system is capable of measuring tendon force within an accuracy of i 1.5% of the calibration range specified in Enclosure I (IWL-2522[b]); O During inspection, check pressure gauge calibration daily against a master pressure gauge used only for this purpose. CONTRACTOR shall document this check. 8.1.4 Verify TESTING LABORATORY prepared to receive wire and grease samples. 8.1.5 Complete Data Sheets 1, 2, and 3 with: o tendon number, o location, o previous force, O expected lift-off force, and C previous shim thickness. U 1NOTE. U Value in Column 5 is Base Value force obtained from applicable Force
- versus Time curve contained in DC-5390-225.01-SE.
8.1.6 Complete Rows 1through 6, 8, 9, 10 and 12 of Data Sheet 4 for tendons to be o. tdetensioned. 13
Number TMI - Unit 1 ( Surveillance Procedure 1301-9.1 tIe Revision No. RB Structural Integrity Tendon Surveillance 18 NOTE Values to be entered in Rows 1 through 4 of Data Sheet 4 are given in Table 7 of VM-TM-2485. 8.1.7 Enter Normalization Factor (NF) obtained from applicable force versus time curve contained in DC-5390-225.01-SE, in Column 2 of Data Sheet 5 for selected tendons. 8.1.8 IF working in areas exposed to steam vents, verify plant is shut down. 8.2 Hoop and Dome Tendon Inspection NOTE. Oncerinspection of a given tendon has started, it should be completed as soon as possible to avoid unnecessary exposure of anchorage head. 8.2.1 Protect roof surface as required prior to starting inspection. 8.2.2 Place platforrns in position at ends -of tendon to be inspected. 8.2.3 IF tendon inspection is not completed during a work shift, protect anchorage 'area and grease cans from exposure to moisture, dirt and any other potentially damaging materials. 8.2.4 Tendons shall be regreased (filled)'within 30 days maximum after removal of an end cap. 8.2.5 Corrosion Protection System-
- a. Depressurize and remove end caps per 1410-Y-83 and PSC ISI Manual Procedure SQ6.1.
- b. Inspect for presence of free water in end cap and at anchorage area per this procedure and PSC ISI Manual Procedure SQ6.1.
- c. Enter inspection results on Data Sheet 9.
CAUTION When removing grease to make visual inspection, ensure no damage to steel (by scratching) and no increase of corrosion effects occurs. NOTE Free water shall not be included in the grease sample (IWL-2525.1 [a]).
- d. Take a representative grease sample from each end anchorage of selected
-4o'.Ritendons.
- e. When present, free water sample shall be taken where-water is present in quantities sufficient for lab analysis. Record quantity of free water and request lab analysis for PH (IWL-2525.2[b]),
14
Number
* -~TMI - Unit I Surveillance Procedure 1301-9.1
-itle_ .Revision No. RB Structural Integrity Tendon Surveillance 18
- f. Have grease sample tested per Enclosure 3.
- g. Verify sample meets acceptance criteria specified in Enclosure 3.
- h. Remove and collect remaining bulk filler from tendon anchorage area using wooden or plastic scoops and cleanup using solvent and rags.
- i. Record the total amount of bulk filler grease removed up until reinstallation of the end cap per the guidelines of 141 0-Y-83.
8.2.6 Inspect Anchorage prior to Lift-Off test.
- a. Perform VT-1 inspection of tendon anchorage assemblies and associated hardware (bearing plates, stressing washers, stressing shims, buttonheads, etc.) for signs of corrosion, cracks, missing wires, and broken wires. If broken or damaged wires are detected, the tendon shall be detensioned and the wire removed for testing as specified in Section 8.2.9.
- b. Perform VT-1 C inspection of the concrete around tendon anchorage area, and for a distance of 2 feet extending outward from the bearing plate for crack width and general cracking pattern and for indications of abnormal material behavior.
- c. Complete data sheets in Enclosure 6.
- d. IF crack widths in concrete > 0.010" are identified, record and report immediately to COGNIZANT MECHANICAL/STRUCTURAL ENGINEER for evaluation and resolution.
NOTE Crack widths in concrete > 0.01 o" are potentially reportable per 10 CFR 50.72.
- e. IF crack widths > 0.05"' are identified, record and report immediately to COGNIZANT MECHANICALUSTRUCTURAL ENGINEER for IMMEDIATE evaluation and investigation to determine amount of structural impairment upon containment structure and its continued integrity.
- f. IF any condition not meeting acceptance criteria in Enclosure 6 is noted, document using sketches, photographs, etc. as applicable and report immediately to Cognizant Mechanical/Structural Engineer.
- 9. CONTRACTOR shall ensure TMI-I has evaluated any out-of-specification condition prior to making condition inaccessible. A written evaluation will be provided to CONTRACTOR for his report.
- h. Cracks 2 0.050" must be repaired after TMI-A Engineering does an evaluation. Repair will be per 1440-Y-23, "RB Concrete Surface Crack Repairs".
15
Number TMI- Unit 1 Surveillance Procedure 1301-9.1
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l RB Structural Integrity Tendon Surveillance 18 L 8.2.7 Lift-Off Test NOTE In lieu of performing thread dimensional checks per this procedure, it is acceptable to perform them in accordance with PSC ISI Manual Procedure SQ7.1. L a. Perform dimensional check of threads on stressing ram adaptor and anchorhead per VM-TM-2485. Complete Data Sheet 8, indicating if major, minor and pitch diameters for anchorage and stressing ram adaptor are: O CONFORMING AND ACCEPTABLE (C/A), O NONCONFORMING BUT ACCEPTABLE (NC/A), or I NOT ACCEPTABLE (N/A).
- b. IF NOT ACCEPTABLE condition exists, immediately notify COGNIZANT L MECHANICAUSTRUCTURAL ENGINEER.
- c. Record ram area and ram identification number (I.D.) in Column 3 of Data Sheet I or 2.
- d. Measure and record thickness of shim stack in Column 10 of Data Sheet 1 or 2.
_ e. Lubricate anchorage washer threads with a small amount of bulk filler grease as required.
- f. Thread ram onto anchorage washer per ram operating instructions.
- 9. Attach stressing jack to stressing washer and bearing plate per Jack manufacturer's instructions. Ensure full thread engagement of the coupler to the stressing washer.
- h. Visually examine jack prior to each use for damage or deformation.
16
I Number TMI - Unit 1 Surveillance Procedure 1301-9.1
- l ile Revision No.
RB Structural Integrity Tendon Surveillance 18 WARNING Jack is being operated up to 1,600 KIPS of force. Exercise extreme caution and strict adherence to all safety regulations as contained in operating manual. DO NOT stand behind hydraulic jack while stressing a tendon. Exercise extreme caution if fingers or hands are required near tendon anchorage head during testing. [ CAUTION DO NOT exceed 70% of ultimate tensile stress (equivalent to a jack force of 1393 KIPS (for a tendon with 169 effective wires) when performing lift-off test (IWL-2523.3). 1
- i. IF lift-off is not achieved at jack force of 1393 KIPS, STOP, unload jack and immediately notify COGNIZANT MECHANICAUSTRUCTURAL ENGINEER.
i- Observe the position of the anchorhead prior to applying pressure. Count the anchorhead revolutions about the tendon -axis, if any, during lift-off. Record the number of revolutions on Data Sheet 10. L ( k. Begin applying pressure to jack, and continue applying pressure until stressing washer (anchorhead) lifts off shim pack just enough to insert (2) - 0.030" thick feeler gages, located approximately 180 degrees apart, between anchor head and shim pack or shim pack and bearing plate;
- 1. Reduce jack pressure to achieve corresponding force reduction of approximately 100 KIPS. Obtain relationship between jack pressure and force from Calibration Equation recorded on Data Sheets 1 or 2.
- m. Slowly increase jack pressure until both feeler gages becomes loose enough to move. When this occurs, STOP increasing jack pressure and record jack pressure reading and corresponding force in Column 4 of Data Sheet 7.
- n. Complete Column 8 of Data Sheet 7.
- 0. Repeat lift-off measurement tests until 3 consecutive force measurements (Column 4) are all within 25 KIPS.
NOTE When tests are all within 25 KIPS of each other, official lift-off force for tendon end is the mean of the 3 consecutive force measurements, Lwhich is obtained from Column 8 of Data Sheet 7. P. CONTRACTOR shall record information on Data Sheet 7 and attach Data Sheet 7 to Data Sheets I and 2. I 14W-..44 Lf q. Record gage pressure corresponding to official lift-off force on Data Sheet 1 or 2, Column 6. 17
Number TMI
.. - Unit 1 Surveillance Procedure 1301-9.1 ilMe - Revision No.
RB Structural Integrity Tendon Surveillance 18
- r. Record official lift-off force in Column 7 of Data Sheet I or 2.
- s. Slowly decrease pressure on jack to allow stressing washer to reseat onto shims. No additional shims are to be added at this time.
NOTE DO NOT detension either end until lift-off has been recorded for both ends.
- t. Repeat lift-off test at other end of tendon.
- u. Calculate average value of forces required to achieve lift-off of tendon, and enter in Column 8 of Data Sheet I or 2;
- v. Verify force meets Acceptance Criteria specified in Step 9.3.
- w. During lift-off testing, record reactor building internal temperature and the temperature of the concrete adjacent to the tendon anchorage in Columns 14 and 15 on'Data Sheets 1 and 2.
- i. -NOTE Use value recorded from RTD TE 6551, TE 655U or TE 655P in Control Room for RB internal temperature.
- x. Enter lift-off force from Column 8 of Data Sheet I or 2 in Column I of Data Sheet 5.
- y. After lift-off tests are completed for all selected tendons in a group, e.g., all dome tendons, complete Data Sheet 5.
- z. Verify average of all normalized lift-off forces in a group meets Acceptance Criteria of Step 9.3.
aa. The COGNIZANT MECHANICAL/STRUCTURAL ENGINEER shall review the results and trends of the measured prestress forces from consecutive surveillances for the control tendons and tendons as a group. Perform a statistical analysis of time dependent lift-off force trends and verify that the criteria of Step 9.3 are satisfied. Plot lift-off for control tendons on force vs. time curves. 18
f 6/ f-Number TMI - Unit 1
. Surveillance Procedure C. - .1-1301-9.1 itle Revision No.
RB Structural Integrity Tendon Surveillance 18 8.2.8 Detension Tendon CAUTION
- 1. DO NOT exceed 70% of ultimate tensile stress (equivalent to a jack force of 1393 KIPS (for a tendon with 169 effective wires)
(IWL-2523.3).
- 2. During plant operation, detension ONLY ONE tendon at a time.
- NOTE
- 1. To prevent holding jacks under pressure for periods of time, it is recommended that both ends of tendon be detensioned simultaneously.
- 2. Shims are paired and must be stacked in pairs.
- a. Increase pressure to jacks until shims can be removed.
- b. Remove split shims from shim stacks.
C. Slowly decrease pressure (rate < 2000 PSIG/MIN) on jacks to completely detension tendon. NOTE DO NOT uncouple jacks until tendon is completely detensioned.
- d. Uncouple jack, while minimizing twisting of tendon to 1/2 of a revolution.
- e. Record on Data Sheet 10 the number of revolutions of the anchorhead (if any) during uncoupling.
8.2.9 Remove Wire and Test
- a. Perform VT-1 inspection of the detensioned tendon'anchorage assembly for missing, broken, and/or damaged wires protruding from the anchorhead.
- b. Record results on Data Sheets 1 and 2 in Enclosure 6 specifically noting any results observed after detensioning.
- c. Remove a randomly selected wire that had been stressed prior to detensioning from each selected detensioned tendon listed in Enclosure 2, Table 2.
- d. Also remove all broken or damaged wires (if any). Remove enough of each broken or damaged wire to allow tensile testing and visual examination to evaluate the cause of breakage or damage.
19
I;7 Number l -- TMI - Unit I H .
' itle f
Surveillance T -n Procedure 1301-9.1 Revision No. RB Structural Integrity Tendon Surveillance 18
- e. Follow procedure in Enclosure 4 and PSC ISI Manual Procedure SQ10.3 for testing and examining all removed wires and completing Data Sheets.
8.2.10 Retension Tendon CAUTION DO NOT exceed 80% of ultimate tensile stress (equivalent to a jack force of 1593 KIPS (for a tendon with 169 effective wires).
- a. Retension both ends of a tendon approximately simultaneously, such that force difference between ends does not exceed 250 KIPS at any time during retensioning.
- b. Prior to starting retensioning, complete Columns 2 through 5 on Data Sheet 6 by recording the following Information.
(1) Number of effective wires. L (2) 70% of tendon ultimate strength (8.24 kip x Number of Effective Ii- Wires). (3) Predicted Base Force from DC-5390-225.01-SE or separate calculation. (4) Target lock-off force; [70% of ultimate strength + Predicted Base Force]÷2.
-c. Verify Rows 1, 2, 6 through 9 and 12 of Data Sheet 4 have been completed.
- d. At each tendon end, stress tendon to gauge pressure recorded In Row 2 on Data Sheet 4. Record actual pressure in Row 3.
- e. Record ram extension in Row 5 of Data Sheet 4.
- f. Stress tendon to gauge pressure recorded in Row 9 of Data Sheet 4. Record actual pressure in Row 10.
- 9. Record ram extension in Row 11 of Data Sheet 4.
- h. Stress tendon to gauge pressure recorded in Row 12 of Data Sheet 4.
Record actual pressure in Row 13.
- i. Record ram extension in Row 14.
- j. Stress tendon to gauge pressure recorded in Row 7 of Data Sheet 4. Record actual pressure in Row 15.
- k. Record ram extension in Row 17.
I. Record tendon force at overstress in Row 16. 20
Number TMI - Unit 1 ( Surveillance Procedure 1301-9.1 I itle Revision No. RB Structural Integrity Tendon Surveillance 18
- m. Reduce ram-force to the lesser of the following and insert shims to fill gap (final gap will be less than the thickness of the smallest shim).
(1) 100 kip above the force listed in Col. (5) of Data Sheet 6. (2) The force listed in Col. (3) of Data Sheet 6.
- n. Perform lift-off to determine actual tendon force and corresponding gauge pressure.
- o. Record final lift-off (Lock-Off) force in Column 6 of Data Sheet 6.
- p. Verify that final lock-off force is between the Predicted Base Force and 70%
of ultimate tendon strength and document verification in Col. (7) of Data Sheet 6.
- q. Complete Data Sheet 6 for all detensioned tendons.
- r. Record final gauge pressure, force, and shim stack thickness in Columns 11, 12, and 13 of Data Sheet 1 or 2.
- s. For comparison of tendon elongations occurring at Original Stressing and Retensioning, complete Data Sheet 4.
- t. Verify fractional difference in Row 10 on Part 4 of Data Sheet 4 is within +/- 0.1.
Indicate whether this criterion has been met on Part 4 of Data Sheet 4.
- u. IF NOT within +/- 0.1, immediately notify COGNIZANT MECHANICAUSTRUCTURAL ENGINEER and investigate to determine if cause is wire failure or slip of wire in anchorage(s). Difference of more than 0.1 requires identification in the ISI Summary Report per IWA-6000 (IOCFR50.55a).
8.2.11 Restore Tendon Force NOTE Following steps apply to any tendon which has lift-off force below its specified 90% Base Value, and has not been required to be detensioned.
- a. Completely de-tension the tendon and follow the instructions in Par.- 8.2.10.
8.2.12 Reinstall Grease Can and Regrease per 1410-Y-83. 8.3 Vertical Tendon Inspection
- a. Follow same steps for dome and hoop tendons (Section 8.1 and 8.2) with following exceptions:
0 Working platforms remain stationary during test of one tendon. 21
Number TMI - Unit 1
- Surveillance Procedure 1301-9.1 iitle Revision No.
RB Structural Integrity Tendon Surveillance 18 (Access O to opposite end of tendon is from tendon gallery. L o Entire column of grease may drain from tendon conduit. Ensure sufficient receptacles available to contain up to 120 gallons of drained grease from i each tendon (C-1101-153 - E410-031).
- 0Lift-off, detensioning, and retensioning of vertical tendon will be performed from one end only; i.e., from top of ring girder.
e Data to be filled in on Data Sheet 3. 8.4 Concrete Cracks at Dome Tendon Anchorage Area
- a. Visually inspect the 9 dome tendon anchorage areas per Enclosure 6.
- b. Complete Data Sheets 8 and 9 of Enclosure 6.
8.5 Perform VT-3C examination of accessible exterior of the containment and document results per instructions in Enclosure 6. 8.6 Perform 30 Year examinations and tests listed in Enclosure 7 and document results. 8.7 Grease Can Seal Repairs NOTE To maintain tendon grease seals, scope of work includes replacement of leaky seals, even on tendons which are not part of surveillance scope listed in Table I and Table 2 of Enclosure 2. 8.7.1 Perform repairs per 1410-Y-83 (Reference 2.15). 8.8 Recalibrate-all calibrated equipment at end of tendon surveillance. 9.0 ACCEPTANCE CRITERIA 9.1 Tendon Anchorage and concrete inspection meets criteria specified by Enclosure 6. 9.2 Tendon Wire Physical Condition meets criteria specified by Enclosure 4. 9.3 Tendon Prestress Force Confirmation Test (IWL-3221.1) 9.3.1 The average of all normalized tendon lift-off forces, including those measured in 9.3.2.2, for each type of tendon (vertical, dome, or hoop) is equal to or greater than the required minimum average tendon force at the anchorage for that type of tendon. 22
I Number TMI - Unit 1 f
. Surveillance Procedure 1301-9.1 I - _ - .flWe Hevision No.
RB Structural Integrity Tendon Surveillance 18 NOTE Required minimum average tendon forces are: 1033 Kips for Vertical Tendons 1064 Kips for Dome Tendons 1108 Kips for Hoop Tendons 9.3.2 The measured force in each individual tendon is not less than 95% of the Predicted Base Value (Predicted Force) obtained from VM-TM-2485, unless the following conditions are satisfied. 9.3.2.1 the measured force in not more than one tendon is between 90% and 95% of the predicted force; NOTE Tendons H46-24 and V-31 were de-tensioned during Surveillances 2 and 3, respectively. Also, the V-30 liftoff force was measured during Surveillance 4 and its anchorage force may have been affected-during by k Q;__;_, this activity. To ensure that tendons adjacent to specified sample tendons are also in an undisturbed condition, the following are designated as the adjacent tendons to examine should the need for such examination arise. V-29 is the designated adjacent tendon located counter-clockwise from specified sample tendon V-32. H46-23 is the designated adjacent tendon located below, specified sample tendon H46-25.
-Also, the'Responsible Engineer may designate alternatives to the above or to other adjacent tendons as necessary to satisfy accessibility, safety and other significant concerns.
9.3.2.2 the measured forces in two tendons located adjacent to the tendon in 9.3.2.1 are not less than 95% of the predicted forces (Predicted Base Values); and 9.3.2.3 the measured forces .in all the remaining sample tendons are not less than 95% of the predicted force. 9.3.3 IF the requirements of 9.3.1 and 9.3.2 are not met, extent of investigation into cause, including additional lift-off testing to determine cause and extent of such occurrence, shall be determined by COGNIZANT MECHANICAL/STRUCTURAL ENGINEER. 9.3.4 IF average value of selected tendon end forces required for lift-off falls below 90% Base Value, tendon should be detensioned and an investigation conducted to determine extent and cause. 23
Number TMI - Unit 1 Surveillance Procedure 1301-9.1 Revision No. - RB Structural Integrity Tendon Surveillance I 18 9.3.5 IF minimum group average normalized tendon force is NOT MET on Data Sheet 5, an additional sample of 4% with a minimum of 4 and a maximum of 10, of same group of tendons, should be inspected. (TMI-1 Guidance/not Reg. Guide). 9.3.6 IF results of the anchorage force statistical analysis show a significant probability that the mean for any tendon group will fall below the minimum required value prior to the late finish date of next scheduled surveillance, additional lift-off testing to determine the cause and extent of such occurrence shall be done as directed by the COGNIZANT MECHANICALUSTRUCTURAL ENGINEER. This evaluation shall be reported per Engineering Evaluation Report prescribed in IWL-3300. 9.3.7 IF total population of each group of sampled tendons meets criteria, structural integrity of containment shall be considered acceptable. 9.3.8 IF structural integrity of containment has not been demonstrated to be acceptable within 72 hours, then be in at'least HOT STANDBY within next 6 hours and in COLD SHUTDOWN within following 30 hours. L 9.4 Corrosion Protection System Inspection. 9.4.1 Grease sample contaminant levels and base numbers meet the criteria specified in L MEnclosure3. 9.4.2 Water in grease sample shall be that ratio of water to dry weight does not exceed 10%. 9.4.3 Amount of grease replaced does not exceed 4 gallons more than the amount of grease removed. 9.4.4 Presence of free water. 9.4.5 Grease leakage detected during general examination of the containment exterior surface has been evaluated for housekeeping, fire safety and personnel safety concerns. 9.5 Post Test Calibration L 9.5.1 The post test calibration shall not differ from the pre-test calibration by more than the specified accuracy tolerance of hydraulic rams and gauges (IWL 2522[b]).
-9.6 All Data Sheets complete and signed off.
9.7 IF the Acceptance Criteria of 9.1, 9.2, 9.3, 9.4 and 9.5 are not met, it shall be considered as a possible abnormal degradation of the containment structure. The condition shall be immediately brought to the attention of, and evaluated by the COGNIZANT MECHANICAL/STRUCTURAL ENGINEER, a Surveillance Deficiency Report (SDR) generated, and addressed in the tendon surveillance report submitted to the NRC. 24
Number TMI- Unit I Surveillance Procedure 1301-9.1 tle. :Revision No. RB Structural Integrity Tendon Surveillance 18 10.0 REPORTS 10.1 CONTRACTOR should prepare written report of results and conclusions for inspection period for TMI within 30 days of test and inspection completion. 10.1.1 CONTRACTOR shall include pre and post-test calibration records in CONTRACTOR'S final report. 10.2 TMI shall ensure Enclosure 7 is kept updated with extra commitments for inspections as a result of abnormal conditions in each inspection period. 10.3 TMI shall submit a report on tendon surveillance to NRC within 90 days following completion. 10.4 TMI shall submit an ISI Summary Report per IWA-6000. It should include the following conditions, if found (10CFR50.55a). 10.4.1 Sampled sheathing grease contains chemically combined water exceeding 10% by weight L- or the presence of free water. 10.4.2 The absolute difference between amount of grease removed and amount replaced exceeds 10% of the tendon net duct volume, i.e.,12 gallons for vertical tendons, 11 gallons for hoop tendons, and between 7 gallons and 9 gallons for dome tendons L ... (dependent on length), (Source: C-1101-153-E410-031,032, and 033, respectively). 10.4.3 Grease leakage is detected during general visual examination of containment surface. 10.4.4 When conditions in accessible areas could indicate the present of, or the result of degradation in inaccessible areas, those inaccessible areas shall be evaluated for-- 10.4.4.1 description of the type and extent of degradation, and the conditions that led to the degradation L 10.4.4.2 an evaluation of each area and results of same 10.4.4.3 a description of necessary corrective actions. L 25
fL Number Number TMI - Unit 1 Surveillance Procedure 1.301 130. 9.1
. .. I.n P _
- .Ale Revision No.
RB Structural Integrity Tendon Surveillance 18 18 FIGURE 1 Page 1 of I Tendon Details Typical HooplDome Bearing Plate 20-1/2" x 3-3/4" x 20-1/2" Grease Can Holding Ring
-- Prestressing Wire Washer \ Tendon (2-Piece Shop Washer Shown)
_ -1 W\ I I1 Grease Plug - At 1-1/4" NPT Grease Can Grease Can / Hold Down Dolts/Nut, so Gasket and Grease Seals (Closed cell I - 8 f1" TNC2 Y' Dia. Wires 2" - Deep Neoprene Sponge) with Buttonheads NOTE Vertical tendons have a different type of grease can. -Q1 26
I I[177
- -:7 n r- 7 F-= [1-- - [7-- [-7F [1--77 F--- [7 1 7 r: r77- [--
DAki - ;,.lEET 1 1301-9.1 I Prestress Forcd.Confirmation Test Revision 18. Dome Tendons Page 1 of I INSPECTION PERIOD_ INSP. BY VERIF. BY REACTOR DATE CONTR. COGNIZANT TENDfON LIFT-OFF CONDITION RETENSIONING BLDG. TEMP. INSP. FOREMAN oV. INSP. EXPECTED FORCE FINAL RAM PREVIOUS LIFT-OFF GAGE AVG. OF SHIM. GAGE SHIM IDIAREA FORCE FORCE PRESS. FORCE 2 ENDS THICKNESS (IN.) PRESS. FORCE THICKNESS *F L.D. LOCATION (SQ.IN.) (KIPS) (KIPS) (KSI) (KIPS) (KIPS) PREVIOUS AS-FOUND (KSI) (KIPS) (IN.) INT. EXT. 17U SIGNATURE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
- 1. / ______ ___ _______
_ I_ 4._L- I_
- 3. . I __ _ _ _ _
I 5-- 5.4'_ _ . I I__ _ _ _ _ _ ____ I_____ NOTE A: CALIBRATION EQUATIONS FORCE CALCULATION: FORCE @ LIFT-OFF = JACK PRESSURE X RAM AREA RAM ID EQUATION OR FROM CALIBRATION EQUATION LEGEND: LOCATION: NW, NE, SW, SE QUADRANT SHIM THICKNESS: CLEAR DISTANCE BETWEEN BEARING PLATE AND STRESSING WASHER. PREVIOUS: AT TIME OF ORIGINAL INSTALLATION OR, IF APPLICABLE, FROM PREVIOUS SURVEILLANCE COGNIZANT MECH/STRUCT ENGINEER REVIEWED BY DATE: 27
(7 F- I [:--- IV-- [7 F= [-- F- 17 m= F- [ [1 77 F- ,[ a_ I7_F DAti< j~.LI-EET 2. 1301-9.1 '1 Prestress Force Confirmation Test Revision 18 Hoop Tendons Page 1 of I INSPECTION PERIOD_ INSP. BY VERIF. BY REACTOR DATE CONTR. COGNIZANT
~~_
TENDON LIFT-OFF CONDITION RFTFNqInNI"(1
._-- v. -.-- . c i Al nr.v TFMA . 1KIC0 .
,sr..a CtfDC.AAK
*1/4JfrIeilI' are ..- ::
W.V. IN::or. EXPECTED FORCE FINAL RAM PREVIOUS LIFT-OFF GAGE AVG. OF SHIM GAGE SHIM . ID/AREA FORCE FORCE PRESS. FORCE 2 ENDS THICKNESS (IN.) -PRESS. FORCE THICKNESS eF I.D. LOCATION (SQ.IN.) (KIPS) (KIPS) (KSI) (KIPS) (KIPS) PREVIOUS AS-FOUND (KSI) (KIPS) (IN.) INT. EXT. SIGNATURE SIGNATURE t 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1.- P I______ __________
-I
- 2. -
_I 3.- I ______ _________ I I_____ .________
- 4. _
I. ___ __ _ 5.- I-6. NOTE A: CALIBRATION EQUATIONS FORCE CALCULATION: FORCE @ LIFT-OFF = JACK PRESSURE X RAM AREA RAM ID EQUATION. OR FROM CALIBRATION EQUATION LEGEND: LOCATION: i to 6- NUMBER OF BUTTRESS NEARER TO END OF I .. TENDON SHIM THICKNESS:. CLEAR DIST/ \NCE BETWEEN BEARING PLATE AND STRESSING 'NASHER. PREVIOUS: AT TIME OF ORIGINAL INSTALLATION OR, IF APPLICABLE, FROM PREVIOUS SURVEILLANCE COGNIZANT MECH/STRUCT ENGINEER REVIEWED BY, - DATE: 28
I- I - 1- F ----- 17 1- -77 '(- I . F.=l I-- = ( ' 1'--- 177* I F-- [_- F__ d%,'* "' 4U, v DA: EET 3 1301 -9.1 . i Prestress ForciiConfirmation Test Revision 18 Vertical Tendons Page 1 of 1 INSPECTION PERIOD_ INSP. BY VERIF. BY REACTOR DATE CONTR. COGNIZANT TENDON LIFT-OFF CONDITION RETENSIONING BLDG. TEMP. INSP. FOREMAN QV. INSP. RAM PREVIOUS EXPECTED LIFT-OFF GAGE FORCE AVG. OF SHIM GAGE FINAL SHIM I ID/AREA FORCE FORCE PRESS. FORCE 2 ENDS THICKNESS (IN.) PRESS. FORCE THICKNESS °F I.D. LOCATION (SQ.IN.) (KIPS) (KIPS) (KSI) (KIPS) (KIPS) PREVIOUS AS-FOUND (KSI) (KIPS) (IN.) INT. EXT. SIGNATURE SIGNATURE 1 2 3 4 5 6 7 8 9 10 11 12. 13 14 15 16 17 18
- 1. I ________________
2._ / _________________ 3._ I _________________ 4_- ___I ____
.4-.
5._ I ________________
-1.-*
6._ I NOTE A: CALIBRATION EQUATIONS FORCE CALCULATION: FORCE @ LIFT-OFF = JACK PRESSURE X RAM AREA RAM ID EQUATION OR FROM CALIBRATION EQUATION LEGEND: LOCATION: T OR B - TOP OR BOTTOM OF VERTICAL TENDON SHIM THICKNESS: CLEAR DISTANCE BETWEEN BEARING PLATE AND STRESSING WASHER. COGNIZANT MECH/STRUCT ENGINEER PREVIOUS: - AT TIME OF ORIGINAL INSTALLATION OR, IF APPLICABLE, REVIEWED BY DATE: - FROM PREVIOUS SURVEILLANCE 29
INumber TMI - Unit 1 Surveillance Procedure 1301-9.1 I - -- Revision No.
.RB Structural Integrity Tendon Surveillance 18 DATA SHEET 4 Page'l of 4 Elongation /Tendon Force Record Re-Tensioning Data for De-Tensioned Tendons Tendon ID Surveillance No.
Part 1 Original Stressing Data NOTE PTF force is that equivalent to a ram pressure of 1,000 psi. PTF removes tendon slack and is the starting point for elongation measurements. OSF force Is 80% (may be less) of tendon ultimate strength. The tendon is loaded to OSF in order to provide the required force distribution. It is also the force at which final elongation is measured. PTF force I elongation, OSF force I elongation and number of effective wires are documented in 1,C.- I construction records. i t: Table 1 Row, R Parameter Value I Shop End PTF Force kip 2 Field end PTF force kip 3 Mean PTF Force = (RI + R2)12' kip 4 Shop End PTF Elongation in. 5 Field End PTF Elongation in. 6 Total PTF Elongation = R4 + R5 in. 7 Shop End OSF Force kip 8 Field end OSF force kip 9 Mean OSF Force = (R7 + R8) /2 kip 10 Shop End OSF Elongation in. 11 Field End OSF Elongation in. 12 Total OSF Elongation = R10 + R11 in. 13 Differential Force R9 -' R3 kip 14 Differential Elongation = R12 - R6 in. 15 ' Number of Effective Wires 16 Elongation Rate = R14 x R15/ R13 30
I Number
.. TMI - Unit 1 C :iue Surveillance Procedure 1301-9.1 PRevision No.
RB Structural Integrity Tendon Surveillance , 18 DATA SHEET 4 Page 2 of 4 Elongation I Tendon Force Record Re-Tensioning Data for De-Tensioned Tendons Tendon ID Surveillance No. Part 2 Shop End Re-Tensioning Data in2 Ram ID Ram Area, A Ram k kip
- NOTE The number of effective wires entered in R1 must be the same as the number entered for the field.end in Table 3. Also, the calculations identified in Rows 4, 16, 18 & 19 (shaded) may be done after stressing work at both ends of the tendon is complete.
r-C:
. :-.W,
.1 W
31
INumber TMI - Unit 1 7.-. Surveillance Procedure 1301-9.1 -I we I - . . - . -- - Revision No. RB Structural Integrity Tendon Surveillance , 18 DATA SHEET 4 Page 3 of 4 Elongation I Tendon Force Record Re-Tensioning Data for De-Tensioned Tendons Tendon ID Surveillance No. Part 3 Field End Re-Tensioning Data Ram ID Ram Area, A in2 Ram k kip NOTE The number of effective wires entered in RI must be the same as the number entered for the shop end in Table 2. Also, the calculations . identified in Rows 4, 16, 18 & 19 (shaded) may be done after stressing work at both ends of the tendon is complete. Table 3 Row, R Parameter - Value Signature Date I Number of Effective Wires 2- PTF Target Pressure 1,000 psi 3 PTF Actual Pressure psi WNK7 B '$10 5 PTF Elongation in. 6 OSF Maximum-Force = RI x 9.4 kip 7 OSF Max. Pressure = (R6 + k) /A psi 8 1/3 Pressure Interval = R7 /3 - 330 psi 9 Target 1/3 Pressure = 1,000 + R8 psi 10 Actual 1/3 Pressure psi 1 1/3 Elongation in. 12 Target 2/3 Pressure = R9 + R8 psi 13 Actual 2/3 Pressure psi 14 213 Elongation in 15 OSF Actual Pressure psi 17 OSF Elongation in. ____~iffe -X ~~
, 7 , . _ _ _ _ _ _ _ _ _ _ _ _ _
32
611/ fI2' TMI - Unit 1 e-C: :. Surveillance Procedure 1301-9.1
- -. 1 Lie Revision No.
RB Structural Integrity Tendon Surveillance 18 DATA SHEET 4 Page 4 of 4 Elongation ITendon Force Record Re-Tensioning Data for De-Tensioned Tendons Tendon ID Surveillance No. Part 4 Elongation Comparison Table 4 Row, R Parameter Value 1 Shop End Differential Force from Table 2, R1 8 kip 2 Field End Differential Force from Table 3, R18 kip 3 Average Differential Force = (RI + R2) /2 kip 4 Shop End Differential Elongation from Table 2,' R19 in. 5 Field End Differential Elongation from Table 3, R19 in. 6 Total Elongation - R4 + R5 in. C. -7 Ace4UIIIUMI - ha. .roL_ SII of Uf^.+.- UI ULAVV IAI;PA-VV II fC-, 1ju11 Treho 1 IIIdU 4a, D 4 P7I 8 Re-Tensioning Elongation Rate = R6 x R7 / R3 9 Original Elongation Rate from' Table 1, R16 10 Fractional Difference in Rates = (R8.- R9) / R9 - Absolute value of the above Fractional Difference in Rates
- 0.1 Yes No Signature: Date:
33
1301-9.1 Revision 18 DATA SHEET 5 Page 1 of 1 r.' AVERAGE OF THE NORMALIZED LIFT OFF FORCE (1) (2) (3) (4) Lift Off Normalizing Normalized Acceptance Tendon ID Force Factor (NF) Lift Off (1) + (2) Yes No Dome Tendons 1. 2.
- 3. (Average Equal
- 4. to or greater
- 5. than 1064
- 6. kips)
Total Average Vertical Tendons 1.
- 2. (Average Equal
- 3. to or greater l 4. than 1033.
_ 5. _ _ _ _ _ kips) Li' ; i.: 6. S._ II t ; :-r Total - Average Hoop Tendons 1. 2.
- 3. (Average Equal
- 4. to or greater
- 5. than 1108
- 6. kips)
- 7. ...
8. 9. 10. Total Average Cognizant Mech/Struct Engineer Reviewed By: - . -Date: L (.formed By: Date: 34
a 5i/f39 1301-9.1 Revision 18 DATA SHEET 6 Page 1 of 1 Retensioning Criteria Confirmation 1 (1) (2) (3) (4) (5) (6) (7) TENDON ID NUMBER OF 70% OF PREDICTED AVERAGE LOCK- (4)<(6)<(3)
- iI EFFECTIVE ULTIMATE BASE OFF WIRES [(3)+(4)] .2 Yes/No 1;1 STRENGTH FORCE' FORCE
[8.24 X (2)] DOME I SHOP END i-i _FIELD END _ SHOP END II FIELD END I VERTICAL ,iL _ SHOP END i I; _ SHOP END ______SHOP END L HOOP TENDONS II:I SHOP END FIELD END It -I _ SHOP END L_ FIELD END I, I SHOP END I FIELD END L;: II Cognizant Mech/Struct Engineer Reviewed By: Date: Performed By: Date: C"'t-
' Predicted Base Force from DC-5390-225.01-SE or separate calculation.
35
- (--- [r F- or r'7 r- [ (7. I- - 17_ I7 I17 r--- r-- r-1 I ) - Ti F-
!~,I-)
1301-9.1 Revision 18 DATA SHEET 7 Page 1 of I Tendon Force Measurement Record Gaae Pressure (PSIG)/Force (KIPS) Inspection Period Tendon I.D. MEASURE- DATE INSP. BY VERIFIED BY END MENT FEELER GAGE RUNNING INSP. CONTR. COGNIZANT LOCATION NUMBER WITHDRAWAL AVERAGE FOREMAN QV INSP. 1 2 . ..... _. 8 _ ._9 .4 1 11 1 I. I ________I. I 2 I / I I (SHOP =I 3 I. / I_______ I OR: '/_ 4 I I I_______ FIELD) 5 I. I I_______ I. 6 I_______________ I I I_ 7 I_________________ I_______ I I I 8 I_________________ I_______ I I. 9 '1_______ I_______ I I, 10 I____ I_______ I I RUNNING AVERAGE: ENTER IN COLUMN 8 THE AVERAGE OF THE GAGE PRESSURES AND FORCES
)
A FROM COLUMN 4 OF THE CURRENT AND PREVIOUS TWO MEASUREMENTS. STOP LIFT-OFF FORCE MEASUREMENTS WHEN THE VALUES OF FORCE IN COLUMN 4 OF THE CURRENT AND TWO PREVIOUS MEASUREMENTS ARE C;) ALL WITHIN 25 KIPS OF EACH OTHER. ENTER FINAL GAGE PRESSURE AND FORCE VALUE FROM COLUMN 8 IN COLUMN 6 AND 7 OF DATA COGNIZANT MECH/STRUCT ENGINEER SHEETS 1, 2, OR 3. REVIEWED BY: _ DATE: 36
[7"*- F*7 [- - 1 r -- U-7-- I-- r-7 (<1 r-7 r- -- I 17 r--- r- 1777 1 F [7 L-- rl *1 el-t.,r 1 1301-9.1
'.', I:'
Revision 18 DATA SHEET 8 Page 1 of 1 Minor, Major, and Pitch Diameter Checks - Anchorage and Ram Adapter MAJOR O.D. AND MINOR LD. DIAMETER CHECK MINOR O.D. AND MAJOR l.D. DIAMETER CHECK I PI DIAMETER CHECK IDENTITY OF TOTAL INSP.BY VERIF.BY ANOCORAGE 3RID 6TH AVERAGE I 3RD 9TH AVERAGE PI CONTR. COGNIZANT
> OR ADAPTOR DIA. TnR1EAD FTIIREAD ITHREAD DIA. C/A NC/A NA I THREAD ITHREADI DIA. I C/A IC/A NA DIA. CIA NC/A MAI CIA NC/A MA FORrMEAN ONSP I- --..
O.D. _ IO.D. _ O.D. 0D. I-O.D. _ CNI.D. _____ I.D. _ I-- - _____ 0.0. I.D. I___ I - - - _ - 1.0. CALIBRATION CONTRkOLS I O. MICROM ETER NO. CALDATE GO-GAUGE NO. - CALDATE - 1.D. MICROMETER NO. CALDATE NO GO-GAUGE NO. - CAL.DATE MICROMETER NO. CAL DATE sHr Iv SIZE NO.. CAL-DATE TH1 SiZE lE NO.. CALDAT.. VIRRE S5ZE NOD. CAL.DATE. NOTE: NOT ACCEPTABLE (NA) RAM ADAPTOR (I.D.) ANCHORAGE (O.D.) COGNIZANT MECH/STRUCT ENGINEER REVIEWED BY: _ 9.238 MAX. 9.221 MIll 9.333 MAX. 9.30 MIN I 2MAX 9LI33MAI 2mi 9LI9LMIN j9 205 XAX 9-172XM 9.276 MAX 9.247 IMN DATE: 9.428 MAX. 9.395 MIN _ 9.-S MAX, S.3 YIN CON FORMING/ACCEPTABLE NONFORIING/ACCEPTABLE CONFORNINO/ACCEPTACLE (C/A) (NC/A) (C/A) 37
t* - [U,- I- - F r-7 tI-- I -R- [7- r- I Vi7- r--- 177 I:. C._. I_ I- - C:, 1301. .9.1 Revision 18
;.I DATA SHEET 9 Page 1 of 1 Tendon Anchorage Area MoisturelFree Water Inspection Inspection Period Tendon Moisture/Water Inspect. By No. Location (Yes or No) Description of Free Moisture/Water-Quantity, Location Date Insp. (Initials) 1.
2. 3. 4. 5. 6. 7. 8. 9.. 10. 11. 12. NOTE: Location: Hoop Tendons: 1 to 6 - Buttress number at Cognizant QV Inspector end of tendon Verification By: Date: Vertical Tendons: T or B- Top or Bottom Dome Tendons: 1 to 6 - Number of buttress nearest Cognizant Mech/Struct Engineer to end of tendon Review By:, - Date: 38
{711 [7 I r[-7-:--, l-7[--[- lF - - t: z---
- - 1 r--
F- C-7-: F77, - {-~:-0 r-- ,and t"-, . :I 1301-9.1 ,:: :,-,
... V Revision 18 DATA SHEET 10 Page 1 of 1 Tendon Anchor Head Rotation InspectiotI Inspection Period LIFTOFF DETENSIONING RETENSIONING Tendon No. of Insp.By/ No. of lnsp.Byl / No.of Insp.By/
No. Location Turns Dir.*. Date Turns Dir.* Date Turns Dir.* Date 1. 2.
- 3. --
4. 5. 6. NOTE: Location: Hoop Tendons: 1 to 6 - Buttress number at Cognizant QV Inspector end of tendon Verification By: Date: A Vertical Tendons: T or B - Top or Bottom Dome Tendons: 1 to 6 - Number of buttress nearest Cognizant Mech/Struct Engineer to end of tendon Review By:. _ Date: Turn = a revolution of anchorhead about axis of tendon.
- Direction - Clockwise (CW) or Counter Clockwise (CCW) when looking at anchor head.
39
-; F-,-. 17 Fr 1 [ . X, fI .. . 17- t.7. [17 1-- [7 - -C -' 1--- I'. rir 17 n... . His..
I .; --} ! .5 .tJ 1301 -9.1 Revision 18 DATA SHEEET 11. Page 1 of 1 Tendon Surveillan ce Program Inspection Period Gallons Removed* Gallons Replaced* Diff.** Between Tendon Shop Field Shop & Shop Field Shop & Removed & Acceptable No. End End Field End Comments End End - Field End Replaced (Yes or No) 1. 2. 3. 4. 5. 6.
'7.
8. 9. 10. 11.
- Only one end of vertical tendons may be used for Cognizant.QV Inspector removal and replacement of grease. Verification By: Date: C Differences greater than 4 gallons require TMI-1 evaluation. Cognizant Mech/Struct Engineer Review By: Date: : _ _ _
Due~to the relatively high coefficient of thermal expansion of the grease that is installed at a high temperature, experience during surveillances has been that ~ the quantity of replacement grease frequently exceeds the arbitrary acceptance criteria. Exceeding the acceptance criteria is primarily an indication that an inspection and assessment for possible grease leakage within the structure is necessary. The visual examination of the anchorage and wire will determine whether the corrosion protection system is functioning effectively. 40
Number TMI - Unit 1 Surveillance Procedure 1301-9.1
-itle Revision No.
RB Structural Integrity Tendon Surveillance 18 DATA SHEET 12 Page I of I VT-1 C / VT-3C Examiner Qualification Name of Examiner Employer (:-ee.ienave reviewed the records relevant to the experience and training of the above named individuals and have, as
- ,2-kcessary, trained these individuals in the requirements applicable to the performance of VT-IC /VT-3C examinations of the containment concrete surface. Based on this review and, if applicable, training, I find that these individuals are qualified to perform said examinations.
Responsible Engineer: Name Registration State License No. Expiration Signature - Date 41
I Number M1 - Unit 1 rf . .Il . Survel Ilance Procedure 1301-9.1 RBtitle rl Revision No. RB Structural Integrity Tendon Surveillance 18 DATA SHEET 13 Page 1 of 1 Review I Acceptance of Contractor Procedures Procedure Number / Title Revision Reviewed/Accepted by Date
.. Z 42
Number TMI - Unit 1 t Surveillance Procedure 1301-9.1 ritle Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE I Page 1 of 2 Stressing Ram Calibration 170 Wire Stressing Equipment NOTE Calibration will demonstrate a i 1.5% accuracy-of complete stressing unit within the calibration range specified in this enclosure.
- 1. Attach entire stressing system to a 1600 K load cell which has been calibrated traceable to NIST.
- 2. Check unit at 3 ram extensions of 25%, 50%, and 75% of full extension and at loads specified on attached data sheet.
2.1 Bring stressing unit to gauge pressures equivalent to pressures listed on Data Sheet of this enclosure, and record actual force as read from load cell.
- 03. Record and plot values on a Gauge Pressure versus Force Chart to establish current ram calibration constants for each jack.
Date all calibrations and paint (or inscribe, attach cal sticker, etc.) calibration date on stressing unit.
- 5. Maintain I copy of current calibration with stressing unit at job site.
l 6. Include calibration data and certificate in surveillance report. 43
. I-.: 1:I' - [^ -:-- F,
[--' ( ___ I.-- r- [7- 17 v---- Iw IL r-- [W-- r[- F-0~l"l 1301-9.1 Revision 18 ENCLOSURE I Page 2 of 2 Data Sheet Stressing Ram Calibration RAM DESCRIPTION_ LOAD CELL CONSTANT RAM CALCUL; %TED TARGET TARGI ET AVERAGE LOAD PRES S. AT 25% = IN AT 50% = IN AT 75% = IN LOAD (KIPS) (PSIC LOADING #1 4. LOADING #2 4.- LOADING #3 (KIPS) LOAD CELL (KIPS)* LOAD CELL (KIPS)* LOAD CELL (KIPS)* I 150K 300K 500K 600K 700K I 800K 900K: 1000K 1100K 1200K ---.-- 1300K 1400K 1500K x --- nul RAM CALIBRATION CONSTANTS DETERMINED FROM SLOPE AND INTERCEPT OF STRAIGHT LINE FITTED TO AVERAGE LOAD AND PRESSURE DATA . USING THE METHOD OF LEAST SQUARES. AREA IN' INTERNAL RESISTANCE(K)_KIP *LOAD CELL X LOAD CELL CONSTANT t ATTACH CERTIFICATIONS OF NBS TRACEABILITY FOR TESTING APPARATUS APPROVED BY COGNIZANT MECH/STRUCT ENGINEER. DATE PREPARED BY LABORATORY TECHNICIAN:- DATE VERIFIED BY LABORATORY SUPERVISOR: DATE 44
r(lf,3-a I Number TMI - Unit 1 Surveillance Procedure 1301 -9.1 Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE2 Page 1 of 5 Scope of Each Scheduled Surveillance (Random Selection Per GAI DC-5930-225.02-SE) TABLE I Selected Tendons and Corresponding Inspection Periods
-- ____ -VERTICAL TENDONS -
INSPECTION PERIOD _ Comments _ _ Times (Adjacent Tend~on 1 2 3 4 _ 6 7 - 9 10 Insp. Tendons
*1 - X1 10.12 14 . _ Done 16 X 1. Done 18_._._._ 1 Done 22 X _1_- Done 24 X 1 Done 27 _ i2 __. __ . _ 1- . _--
Done_-
- 30. X 1- Done 31 = X I Done
-32 - X X X X X X 6 29, 33Control
_!: 40__ - = =- X. - - Done 48 xX Done
-Done 50.; 1 -. ona -
53 X 1 52,54 55-. X 1 Done 61 X I Done 66- X 1 65,67
.72 X . 1 Done -
78 . . I Done.- 84 X X 2 -Done - 86, X- 1 Done 90 18 .91: 97 X 1 Done 105 X = 1 Done 108 X 1 107,109 114 X 1 Done 119 . 1 Done 126 X 1 Done 132 X 1 I 131,133 138 X 1 Done 140 - 1 139.141 146 .n 1 145,147 152 - X - 151,153 158 X _ _ . Done 160 X _ . Done 164 1 Done TOTAL 5 5 5 5 3 3 4 4 .4 4 42 X= Lift-Off i Lift-Off &Wire Test 45
Number TMI - Unit I
-.-z Surveillance Procedure 13;01-9.1 I -. -fiMe Revision No.
RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 2 Page 2 of 5 Table I (Cont'd) Selected Tendons and Corresponding Inspection Periods _______ ~~~~HOOP TENDONS _ _ _ _ _ _ _ _ _ INSPECTION PERIOD __IComments Times (Adjacent Tendon ___2 __31__ 161 10 1Insp. Tendons) 13-11 X 13-10, 13-12 13-28 X Done 13-34 X Done 13-36 XI Done 18 X 13-40,13-42~ 13-46 X IDone 13-50 - - Done 24-19 J x ~ J~ J JJ IDone' 24-20 j.l - I Done
'24-21 x I Done
? 2 4-23 I 24-22, 24-24
~"24-26 X I Done 24-28 - - I Done 24-30 X I Done 24-33 X 1 24-32, 24-34 24-40 X .I Done 24-47 X___ I Done 24-48 XIDone 2449IDone 24-50 XI 24-49, 24-51 24-51 X___ I Done 35-10 ___ IDone 35-11 X1 Done 35 - IDone, 35-23 X1Done 35-26 ___IDone 35-28 XI Done 35-29 X 1 Done 35-33 XIDone 35-47 -1Done 549x ___ 1 35-48, 35-50 X= Lift-Off C-4
§M -Lift-Off &Wire Test 46
fcoQ3/f-.gak 1' Number
!-7 , TMI - Unit 1 Surveillance Procedure 1301-9.1
-Title Revision No.
RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 2 Page 3 of 5 Table I (Cont'd) Selected Tendons and Corresponding Inspection Periods HOOPTENDONS (Cont'd) . _ INSPECTION PERIOD Comments
. _ 1 . 1 Times (Adjacent Tendon 1 2 3 4 5 6 7 8 9 1 10 Insp. Tendons) 46-24 X _ Done 46-25 1 46-23, 46-26 46-28 X 1 'Done 46-30 . 1 Done 46-32 X 1 Done 46-34. = I Done 46-37 X I' Done 46-50 = = X =_ 1 46-49, 46-51
.51-11 Tx X J [ I Done
- Z-_1 - !
.51-12. Jx. Jj i Done
;-,-L f t,_,_
; .L 51-13 x I Done
%::1 k". 51-16 x I 51-15, 51-17 51-43 T T I xT x 1 1 1 Done 51-49. . . lll-_ OR, 1 1 51-48, 51-50 62-10. X X ____ 2 Done 62-11 X l I Done 62-13 X l 1 Done
.62-16 X 1 Done 62-18 Xl 1 62-17, 62-19 62-26 X X X X X X X 7 62-25, 62-27 Control 62-28 X - 1 Done 62-30 X I Done 62-41 l__l X 1 62-40, 62-42 62-47 l Done 62-49 X 1 Done 62-51 - I Done 62-53 X 1 Done TOTAL 10 10 10 5 5 5 5 5 5 65 - Lift-Off
- tr-,'n Lift-Off & Wire Test C;
47
1Number TMI - Uniti1 Surveillance Procedure 1301-9.1 RB Structural Integrity Tendon Surveillance ENCLOSURE 2 (Cont'd) Page 4 of 5 Table I (Cont'd) Selected Tendons and Corresponding Inspection Periods _________ DOME TENDONS_ _ _ _ 1INSPECTION PERIOD ___]Comments I-I~.- I ]Times (Adjacent Tendon IJ2 3j 4 5J6 7 8 9J 10 J nsp. jTendons) 101 X ____ 1Done 102. ______ 1 .Done 104. X _ __ 1Done*
.116 X - - - -- - -IDone 122 X ___ 1. 121.123 130 X ____ Done 131 X 1Dn 133 . 1Done:
141 __X 1 Done 143 __ _ X I '.142.144
*145 I . Done 17X ___ ___ 1 Done 18 __ X __ __ I Done 201 X . .I .. Done
. I . Done
~~P 203 X - Done 213 X 1 .212.214 216 X X 2 Done 219 X I Done 220 X . Done
-225 X X X X X X 6 224, 226 Control 230 __ I ~ 2,3 237 ____ x! 1 236,238 248 . `1 Done
- 301 __ 1-~ Done 303 Jq 1 . 302,304
.313 X ____ I Done 314 .I Done 316 X ______ IDone.
322 - - - - __ -1321.323
.334 .X ___ ___ I Done 336 ___ ___ Done 342 [XIJ~ -1 341,343 346 X jDone 347 X ____ 1Done 348 X ____ 1 . . Done TOTAL 6 6 6 3 3 3 4 14 3.- 4' - 42 j X= Lift-Off j~ I-Ift-Off and Wire Test
[XI = For plant on-line, Inspect for corrosion, wire breakage and grease quality on end away from main steam relief valve zone. For plant off-line. perform all Inspections Including lift off measurements.
- D104 Is exempt from detensloning as Insufficient clearance from the adjoining vent stack (Buttress 5) to successfully access the tendon end
-;,exists. D102 has been selected as D104's (Cycle 7)substitute tendon per IWL-2521.1. D104 shall be examined per Sections 8.2.1 through (r-:.'8.2.6 and associated enclosures/data sheets completed (IWL-2521.1.[c]).
48
-fc4f3a Number TMI - Unit I
(.,- i:. Surveillance Procedure 1301-9.1 title Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 2 (Cont'd) Page 5 of 5 Table 2 Tendons Selected for Detensloning and Tendon Wire Removal!Lab Tests Inspection . Tendon Location_ _ _ _ Period Vertical I Hoop I Dome I V-27 H-35 D-301 2 V-119 H-62-47 D-202 3 V-18 H-46-30 D-336 4 V-14 H-35-26 D-314 5 V-50 H-46-34 D-145 6 V-78 H-35-47 D-248 7 V-164 H-1 3-50 D-102 8 V-140 H-46-25 :D-230
.I. 9 V-90 H-51-49 D-322 10 V-146 H-24-23 D-237 49
Nube I Number oT 'MV'- Unit I A-;'t~e Surveil lance Procedure 1301-9.1 tle BStc Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE3 Page I cif 6 COLLECTIONILAB ANALYSIS OF FILLER GREASE PURPOSE: Confirm the ability of filler grease to perform its intended corrosion protection function. LIMITS AND PRECAUTIONS:
- 1. Use Wooden or plastic paddles or spatulas to scoop out bulk filler grease from around the anchorage. DO NOT use metal implements.
PROCEDURE:
- 1. Inspection Grease 1.1 Contact TESTING LABORATORY to determine size of sample required.
1.2 Take one random sample of bulk filler grease from tendon end and put into' clean container supplied either by TESTING LABORATORY or TENDON SURVEILLANCE CONTRACTOR. T 1.3 Attach an identification tag to container with tendon group, tendon number, and tendon end specified. (Example: Dome105NW)
- 2. Fresh Grease 2.1 Commercial Grade Dedication of new bulk filler grease requires that at least 25% of the barrels for each grease lot number be sampled for lab analysis.
2.2 Attach an identification tag to each sample and corresponding identification on each drum sampled.
- 3. Old Grease (to be reused) 3.1 If grease obtained from tendons is intended to be reused to refill tendons (termed "old grease") perform lab-analysis on "old grease".
3.2 Heat each container of old grease to be-reused to approximately 1500 F to ensure a homogeneous mixture. 3.3 Attach an Identification tag to each sample and corresponding identification to each drum.
- 4. Package all samples and ship to TESTING LABORATORY in such a way that condition of grease is not adversely affected or altered.
50
I Number TMI - Unit 1
.n .-
Surveillance Procedure 1301-9.1
.-ritle X'Revision No.
RB Structural Integrity Tendon Surveillance 1N 8 ENCLOSURE 3 Page 2 of 6
- 5. Test lab perform corrosion protection medium analysis as follows (excerpt Table IWL-2525-1):
Characteristic Test Method Acceptance Limit Water Content ASTM D 95 10% by weight Water Soluble Chlorides ASTM D 512 (Note [1]) 10 ppm maximum Water soluble nitrates ASTM D 992 (Note [1]) 10 ppm maximum Water soluble sulfides APHA 427 (Note [IB) 10 ppm maximum (Methylene Blue)
.deserve Alkalinity ASTM D 974 (Note [3])
.:Case Number) Modified (Note [2] and Note [4])
NOTES: (1) Water Soluble Ion Tests. The inside (bottom and sides) of a one (1) liter beaker, approximate OD 105 mm, height 145 mm, shall be thoroughly coated with between 90 and 110 grams of the sample. The coated beaker is to be filled with approximately 900 ml of distilled water and heated in an oven at a controlled i-temperature of 100 degrees F +1-2 degrees F for 4 hours. Water extraction is tested by the noted test procedures for the appropriate water soluble ions. Results are to be reported as PPM in the extracted water. (2) ASTM D 974 Modified. Place 10 g of.sample in a 500 ml Erlenmeyer flask. Add 10 cc isopropyl alcohol and 5 cc toluene. Heat until sample goes into solution. Add 90 cc distilled water and 20 cc i NH 2SO4; Place solution on a steam bath for 1/2 hour. Stir well. Add a few drops of indicator (1% phenolphtalein) and titrate with 1NNaOH until the lower layer just turns pink. If acid or base solutions are not exactly I N, the exact normalities should be used when calculating the base number. The Total Base Number (TBN) expressed as miligrams of KOH per gram of sample, is calculated as follows: TBN = [(2O)(NA)-(B)(NB)156.1 W Where, B = milliliters NaOH NA = normality of H2 S04 NB normality of NaOH solution W = weight of sample in grams 51
Number TMI - Unit 1 Surveillance Procedure 1301-9.1 tile Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 3 Page 3 of 6 (3) The base number shall be at least 50% of the as-installed value, unless the as-installed value is 5 or less, in which case the base number shall be no less than zero. If the tendon duct is filled with a mixture of materials having various as-installed base numbers, the lowest number shall govern acceptance. Two kinds of bulk filler grease were used for the initial fill at TMI-1. These are 2090P and 2090P-2 both by Viscosity Oil Co. The 2090P was essentially neutral with a Base Number of zero. The 2090P-2 has a Base Number of 3. Expected Base Number for 2090P and 2090P-2 is zero or higher with a tolerance of -.5. Since reserve alkalinity was not reported on the certifications for 2090P and 2090P-2, the testing of samples of this grease is primarily to detect significant changes in Base Number over a period of time that might indicate abnormal degradation of the corrosion inhibiting properties, e.g., a trend developing where the grease is progressively becoming acidic overtime. Fresh new grease is 2090P-4 by Viscosity Oil Co. with a Base Number of 35. Acceptance Criteria for the fresh grease before it is mixed with existing grease is a Base Number of 17.5 or higher. (4) Grease samples which exhibit reserve alkalinity number of <.5 shall be retested per the unmodified version of ASTM D974 Section 9 and an acid number generated for the sample. Both the reserve alkalinity number and the acid numbers shall be reported with the test results when this occurs. Acceptance criteria for Acid Number is that it must be < 1. 52
[9- -- F ".7 F7 ?-- [7 [717 1777 [7 7 V-- 1- (1777 [77 17--- [77- (77
. - '4l-.
1301-9.1 Revision 18 ENCLOSURE 3 Page 4 of 6 Data Sheet I Laboratory Analysis of Bulk Filler Grease Dome Tendons i INSPECTION PERIOD_ _ WATpR/nRY RESERVE(') SAMPLE TENDON CHLORIDES( 1 ) NITRATES( 1 ) SULFIDES( 1 ) WEIGHT (2) ALKALINITY IDENTIFICATION END (PPM) (PPM) (PPM) % (BASE NUMBER) 1.
- 2. -
3.-
- 3. _
(1) ACCEPTANCE CRITERION IS GIVEN ON PAGE 2 OF LABORATORY TECHNICIAN ENCLOSURE 3. PREPEARED BY: DATE: (2) ACCEPTANCE CRITERION IS 10% MAXIMUM BY WEIGHT. LABORATORY SUPERVISOR TENDON END: NW, NE, SW, SE *VERIFIED BY: DATE: COGNIZANT MECH/STRUCT ENGINEER APPROVED BY: -DATE:_ _ 53
Fl?
-i~ I77 [7 I!-,- [a 7 FIT
-- I V-- VI
-:- [--- rod FY17? [--- Air7 [-=7 [a Cm111 ;!, 1301-9.1 Revision 18 ENCLOSURE 3 Page 5 of 6 Data Sheet 2 Laboratory Analysis of Bulk Filler Grease Vertical Tendons INSPECTION PERIOD_
WATER/DRY RESERVE(') SAMPLE TENDON CHLORIDES(') NITRATES(') SULFIDES(1 ) WEIGHT (2) ALKALINITY IDENTIFICATION END (PPM) (PPM) (PPM) (BASE NUMBER)
- 1. I 3.-
4. (1) ACCEPTANCE CRITERION IS GIVEN ON PAGE 2 OF LABORATORY TECHNICIAN ENCLOSURE 3. PREPEARED BY: D,ATE:_ (2) ACCEPTANCE CRITERION IS 1 0% MAXIMUM BY WEIGHT. LABORATORY SUPERVISOR TENDON END: NW, NE, SW, SE VERIFIED BY: D_ATE: COGNIZANT MECH/STRUCT ENGINEER APPROVED BY: D)YATE: 54
r.- -- r, 1--- r " F fZi---* e- i -- [- F-, F7 T V f.[7771 L F1 7 ( 7 C, FT.. 1301-9.1 r .i Revision 18 ENCLOSURE 3 Page 6 of 6 Data Sheet 3 Laboratory Analysis of Bulk Filler Grease Hoop Tendons INSPECTION PERIOD WATER/DRY RESERVE(') SAMPLE TENDON CHLORIDES(') NITRATES(') SULFIDES(1 ) WEIGHT (2) ALKALINITY IDENTIFICATION END (PPM) (PPM) (PPM) % (BASE NUMBER)
- 1. .
- 2. :
3.- 3~. ,_ _ _ __ _ _ _ __ __ _ __ __
- 4. _ _ _ _ _ .__ . .__
.4 .
(1) ACCEPTANCE CRITERION IS GIVEN ON PAGE 2 OF LABORATORY TECHNICIAN ENCLOSURE 3. PREPEARED BY: DATE: (2) ACCEPTANCE CRITERION IS 10% MAXIMUM BY WEIGHT. LABORATORY SUPERVISOR TENDON END: NW,'NE, SW, SE VERIFIED BY: DATE: COGNIZANT MECH/STRUCT ENGINEER APPROVED BY: DATE: 55
Number 0 if ,:, lTM[ - Unit 1 Surveillance Procedure 1301-9.1 rife Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 4 Page 1 of 5 L TENDON RANDOM WIRE REMOVALIPHYSICAL TESTING (See Table 2 of Enclosure 2 for three tendons which require wire removal). LIMITS AND PRECAUTIONS I. Ensure proper Identification of tendon before cutting and pulling test wire.
- 2. Use care to avoid damage to adjoining wires/buttonheads.
- 3. Avoid unnecessary marks on wire while removing it.
PROCEDURE
- 1. IDENTIFY ONE PULLABLE WIRE L Select one of the protruding wires (with tendon totally detensioned) and tap on it or pull while observing movement of buttonhead at other end to identify both ends. Confirm wire identification before cutting.
CUT Cut off button head at opposite end from where puller will be installed.
- 3. INSTALL PULLER Install wire puller and slowly commence pulling. Verify cut end starts moving through end washer.
- 4. PULL AND COIL Use a come-along or some similar method to pull approximately 170 feet of wire. A cable gripper may be used to grip wire but avoid as much as possible making surface marks on the wire.
While pulling, coil wire to approximately six foot diameter and secure coil from unwinding. WARNING A coiled tendon wire has considerable spring force. Inadequate binding could result In violent uncoiling which could Injure people.
- 5. TAG Attach metal tag indicating following:
- a. Tendon Number 56
Number l~ AnTMI - Unit I Surveillance Procedure 1301-9.1 rifle Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 4 Page 2 of 5
- b. At tagged end:
- 1. TOP for vertical tendons.
- 2. BUTTRESS NUMBER for hoop tendons.
L 3. NW, NE, SW, or SE for dome tendons.
- 6. PACKAGE/STORE/SHIP Wrap wire with plastic sheeting and tape securely to protect from elements.
- 7. LABORATORY TESTING 7.1 Clean and carefully inspect entire length of wire for pitting, corrosion, orother signs of deterioration..
Record this information on Data Sheet 1 of this enclosure. NOTE Wire tests, and determination of elongation and yield strength, to conform to the requirements of ASTM A421 and, per reference therin, ASTM A370 or technically equivalent requirements. 7.2 CUT SAMPLES Cut three (3) samples from each wire, one from each end and one from middle. A fourth sample shall be cut from the area of worst corrosion, if any (IWL-2523.2b). Length of each sample shall be maximum length acceptable for test apparatus being used. Areas shall be representative of any significant corrosion or pitting but should riot include any cable gripper marks. L 7.3 IDENTIFY LOCATION OF SAMPLES Show on Data Sheet I of this enclosure, location along wire length where each sample was taken. 57
/I Number TMI - Unit I Surveillance Procedure 1301 -9.1 I'itle Revision No.
RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 4 Page 3 of 5 7.4 TENSILE TEST
- a. Determine YIELD STRENGTH, ULTIMATE TENSILE STRENGTH, and PERCENT ELONGATION AT ULTIMATE TENSILE STRENGTH.
- b. Record this data on the Data Sheet 2 of this enclosure.
- c. Produce stress strain curves for each test section.
_ ACCEPTANCE CRITERIA - TENDON RANDOM WIRE PHYSICAL TESTING
- 1. No failure below minimum guaranteed ultimate stress of 240,000 psi.
- 2. Elongation at failure is not less than 4%.
- 3. Wire shows not evidence of damage or active corrosion.
L.
- 4. If there is rejectable corrosion on the wire, or the wire fails the tensile test, the Cognizant Mechanical/Structural Engineer must evaluate. Each case shall be treated as an abnormal degradation of l the containment structure and reported to the NRC.
58
5f-/ I I I Number [ -.
;. -:...U e Str I 'MI - Unit I Surveil lance Procedure
+
1301-9.1 Revision No. l i RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 4 Page 4 of 5 Data Sheet I Tendon Wire Inspection Data INSPECTIC)N PERIOD Ter idon Identificatio ....- 0 25' 25' 50' 50' 75' 75' 100' 100 I 125' 125 I
.150' 150 I 175'
..1;
.1
. _:F; 175 I 180' Wire Sample Diameters At Breaking Sample for Tensile Test(2) At 1/4-Points Points Sample 1: ft to ft Sample 2: ft to ft Sample 3: ft to _ ft NOTE
- 1. Corrosion or any sik gns of deterlorai:ion shall be indicated full length as shown on the abiove chart.
- 2. Sample shall includ e areas represe !ntative of significant corrosion or pitting ifthey exi,it on removed tE3ndon wire.
- 3. Diameter at Breakirig Point Is to be interpolated from 114-point diameters on either side of breakingg points.
Laboratory Technician prepared by: Date_ _ _ Laboratory Supervisor Verified by: Date
'Cognizant Mech/Struct Engineer Approved by: Date_
59
7 177 1 I F7 [ 1777I [77 [77 177 1 f._0 i, [-- r -- a-=
-- F--
f ,--- r- - I - ~ I- I. V.',.:: 1301-9.1 .' Revision 18 ENCLOSURE 4 Page 5 of 5 Data Sheet 2 Tendon Wire Test Results INSPECTION PERIOD LOCATION (2) TENDON WIRE (1) FROM END OF YIELD (3) ULTIMATE PERCENT (4) SAMPLE NO. WIRE STRESS (ksi) STRESS (ksi) ELONGATION COMMENTS DOME 1. 2.
- 3. _
VERTICAL I 1. 2. 3. HOOP 2. 3. NOTES: Laboratory Technician Prepared By: Date (1) See Section 7 of this enclosure. (2) End starts from end of zero length as indicated on Data Sheet 1 of Laboratory Supervisor this enclosure. Verified By: Date (3) Yield stress is defined per ASTM A421. (4) At Ultimate Tensile Strength. Cognizant Mech/Struct Engineer Approved By: Date 60
*~-~ -~ - -. ' ~ - -- ---- __-=_---- - - _ _a I Number I *T'Ml - Unit I 1301-9.1 I Surveil lance Procedure itle Revision No.
RB Structural Integrity Tendon Surveillance 18 . ENCLOSURE5 GREASE CAN REMOVAL/REPLACEMENT/REGREASING DELETED Refer to 1410 -Y-83 (Reference 2.15) (r U. 1I'. 61
- ---- -.- -na,xzurnj... . Number TMI - Unit I [ , Surveillance Procedure 1301-9.1
-- itle Revision No.
RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 6 Page 1 of 16 ANCHORAGE AND CONCRETE INSPECTIONS A. NORMAL ANCHORAGE AND CONCRETE INSPECTIONS
- 1. PURPOSE Visual inspection/documentation of physical condition of anchorage assembly components, i.e.,
buttonheads, washers, bearing plates. _
- 2. LIMITS AND PRECAUTIONS
[ WARNING Each tendon wire Is tensioned to nearly 8000 lb. DO NOT strike tendon end assembly with any metal object while tendon is tensioned. Avoid getting in a direct line with the tendon end while It is tensioned.
- 3. PROCEDURE 3.1 PRIOR TO LIFT-OFF TEST 3.1.1 Observe each tendon anchorage for buttonheads which are missing or which protrude. Document on Data Sheets 1, 2, 3, and 4 of this enclosure.
3.1.2 Check anchorheads for any sign of cracking or serious degradation. Cracks, resulting in failure of anchorheads, have occurred at other plants. Before applying hydraulic ram the condition of each tendon anchorhead should be inspected to avoid potential personnel hazard. Notify Cognizant Mechanical/Structural Engineer immediately if degradation is noted. Be advised that this has been a problem at other plants in the past. 3.2 WHILE DETENSIONED, IF APPLICABLE Inspect for buttonheads which protrude much farther than adjoining one. Make note of these on Data Sheet 4 of this enclosure to facilitate location (for reinspection after retensioning). 62
Number TMI - Unit 1 Surveillance Procedure 1301-9.1 Title Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 6 Page 2 of 16 3.3 AFTER LIFT-OFF TEST AND, IF APPLICABLE, AFTER RETENSIONING L 3.3.1 Inspect for buttonheads which are missing or which protrude. Document on the Data Sheet 1, 2, 3, and 4 of this enclosure. 3.3.2 Perform VT-I inspection of buttonheads. Document active corrosion and damage. 3.3.3 Document buttonhead inspection results on Data Sheets 1, 2, 3, and 4 of this enclosure. L 3.3.4 Perform VT-1 inspection of anchorage washer/shims/bearing plates. Document cracks and corrosion on Data Sheets 1, 2, and 3 of this enclosure 3.3.5 Perform VT-IC of concrete for a distance of 2 feet extending outward from the bearing plate, for cracking or voids and for gaps between bearing plate and concrete. Use an optical comparator or feeler gages. 3.3.6 Document findings on Data Sheets 5, 6, or 7 of this enclosure. Use grid paper and Data Sheet 9, of this enclosure as necessary to identify significant crack patterns and widths. K 3.3.7 Immediately after inspection of the buttonheads, butter the end of the anchorhead with clean bulk filler grease completely coating all buttonheads to provide temporary corrosion protection until the tendon is bulk filled.
- 4. ACCEPTANCE CRITERIA 4.1 No evidence of cracking in anchor heads, shims, washers, or bearing plates (IWL 3221.3).
4.2 No anchorage assembly shims, buttonheads or washers with active corrosion. 4.3 Anchorage assembly shims, buttonheads or washers with evidence of active corrosion are subject to rejection and shall be further evaluated by the Cognizant Mechanical/Structural Engineer. 63
Number TMI - Unit I ( Surveillance Procedure 1301-9.1 Iitle Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 6 Page 3 of 16 4.4 No bearing plates with active corrosion. 4.5 Bearing plates with evidence of active corrosion are subject to rejection and should be further evaluated by the Cognizant Mechanical/Structural Engineer. 4.6 Cracks in surrounding concrete face greater than 0.010 inch wide shall receive engineering evaluation. 4.7 Cracks in surrounding concrete face greater than/equal to 0.050 inch wide shall be repaired after appropriate engineering evaluation. Repair per TMI-1 approved repair procedure. 4.8 Cracks larger than 0.020 should be monitored in future Tendon Surveillances until repaired. 4.9 IF any missing, broken and/or damaged wires are detected, check inspection reports from previous inspections to determine if damage was noted previously. Record findings on Data Sheets 1, 2, and 3 under "comments" section and on Data Sheet 4 of this enclosure. 4.10 Ensure Data Sheets I through 10 of this enclosure are filled out and signed. B. CONCRETE CRACKS AT 9 SELECTED DOME TENDON ANCHORAGE AREAS IDENTIFIED ON DATA SHEET 8 of this enclosure (Periods 4, 5 6, and 7)
- 1. PURPOSE Inspection for concrete crack growth at Ring Girder anchorage areas. Required per Tech. Spec.
4.4.1.2.5 and also per report to NRC for 15 year Tendon Surveillance. C;. 64
Number TML - Unit 1 (. Surveillance Procedure 1301-9.1 I;Ue Revision No. RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 6 Page 4 of 16
- 2. PROCEDURE 2.1 Perform VT-1 C of concrete around dome tendon anchorage areas for crack growth for a distance of 2 feet extending outward from the bearing plate during 10 (Perio.d.4), 15 (Period 5), 20 (Period 6), 25 (Period 7), and 30 (Period 8) year inspections by monitoring cracks greater than 0.005 inch in width.
2.2 Measure width, depth (if depth can be measured with simple existing plant instrument, i.e. feeler gauges,'wires) and length of selected cracks by charting, as necessary. 2.3 Use Data Sheets 8 and 9 of this enclosure to document inspection results. NOTE Results of crack measurements made during the 3 years after SIT are filed under 1301-8.2, "Ring Girder Surveillance Program". (The L *procedure has since been cancelled and the procedure number was re-assigned to a different procedure). L 3. ACCEPTANCE CRITERIA 3.1 Data Sheets 9 and 10 of this enclosure filled out and signed. 3.2 Submit completed Data Sheets 9 and 10 of this enclosure to Cognizant Mechanical/Structural Engineer for evaluation. This inspection'may be discontinued if the concrete cracks show no sign of growth. If, however, these inspections indicate crack growth, an investigation of the causes and safety impact shall be performed. 3.3 Cracks in surrounding concrete face greater than 0.010 inch wide shall receive engineering evaluation. 3.4 Cracks in surrounding concrete face greater than/equal to 0.050 inch wide shall be repaired after appropriate engineering evaluation. Repair per TM-1 approved repair procedure. (1440-Y-23). C. VISUAL INSPECTION OF CONTAINMENT L 1. PURPOSE Visual inspection of 100% of all accessible surfaces of the exterior concrete surfaces of containment, and examination of tendon end caps for grease leakage or end cap deformation. 65
lf . /f_- I Number TMI - Unit I Surveillance Procedure 1301 -9.1
-itle Revision No.
RB Structural Integrity Tendon Surveillance 18 ENCLOSURE 6 Page 5 of 16
- 2. PROCEDURE NOTE Areas that have suspect indications or require more sensitivity shall receive a VT-IC inspection. All potentially unacceptable indications shall have a sketch generated detailing the indication's size and location, for trending or Engineering Evaluation purposes.
2.1 Perform VT-3C visual examination of the exterior -concrete surface of the containment including the foundation mat around the bottom vertical tendon anchorages noting results of examination on DATA SHEET 10 of this enclosure. 2.2 The VT-3C examination shall detect, describe, and locate evidence of conditions defined in ACI 201.1 R-92 and any of the following indications of possible abnormal degradation: Large spall, severe scaling, grease leakage, other surface deterioration. 2.3 Visually inspect all tendon end caps for grease leakage or grease cap deformation. Removal of grease caps is not necessary for this inspection. NOTE Areas considered inaccessible, shall be evaluated when conditions exist in accessible areas that indicate the presence of, or result in degradation of inaccessible areas.
- 3. ACEPTANCE CRITERIA 3.1 Concrete surface indications meeting the surface condition attributes listed in Section 5.1 of ACI 349.3R-96, are generally acceptable without further Engineering Evaluation.
Conditions non-compliant with Section 5.1 shall be submitted to Cognizant Mechanical/Structural Engineer in order to ascertain if there is evidence of damage or degradation sufficient to warrant further evaluation or repair. 3.2 Tendon end grease caps shall show no evidence of active grease leakage. 3.3 Tendon end grease caps shall show no evidence of grease cap deformation, which may be indicative of anchorage hardware deterioration. (7 66
I' I---:'- F- I- I:- [7- r-- [- 1L7 [77 [r= [- I [--7 [7;.- I7-, I - 1*-., [77 - f~ "`w.- Y-i :i'-j 1301-9.1 Revision 18 ENCLOSURE 6 Page 6 of 16 Data Sheet I Anchorage Assembly Surveillance Inspection Dome Tendons INSPECTION PERIOD INSP. BY VERIF. BY STRESSING WASHER DATE CONTR. COGNIZANT TENDON END BUTTONHEADS & NUT SHIMS BEARING PLATE INSP. COMMENTS FOREMAN QV INSP. NCD.OF MIS SING, BR( )KEN, AN DIOR DAN AGED I.D. Location Corr. WI 'RES CORR. SKETCHED CORR. CRACKS SKETCHED CORR. CRACKS SKETCHED CORR. CRACKS SKETCHED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17. 18 19 3._ _ 43_ __ 4._ 5._ 6._ _ LEGEND GENERAL TENDON END-LOCATION Y=YES IDENTIFY TENDON END (SHOP OR FIELD) AND NW, NE, SW, SE N=NO 67
I7 I- - 1- I I 1 lo I 177 177. F-7 [7- 1- - F -7 - -. I ' I[7 [7 1301-9.1 Revision 18 ENCLOSURE 6 Page 7 of 16 Data Sheet 2 Anchorage Assembly Surveillance Inspection Vertical Tendons INSPECTION PERIOD_ INSP. BY VERIF. BY STRESSING WASHER DATE CONTR. COGNIZANT TENDON END BUTTONHEADS & NUT SHIMS BEARING PLATE INSP. COMMENTS FOREMAN QV INSP. NO. OF MISSING, BROKEN, ANDIOR DAMAGED I.D. Location Corr. WIRES CORR. SKETCHED CORR. CRACKS SKETCHED CORR. CRACKS SKETCHED CORR. CRACKS SKETCHED 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20
- 1. _ _ _ _ _
I 2._
- 3. _ _ _ __ _
I 5. 6. LEGEND GENERAL TENDON END-LOCATION Y=YES IDENTIFY TENDON END (SHOP OR FIELD) AND TOP (T) OR BOTTOM (B) OF TENDON N =NO 68
[1 [..I F - 17 [77_ [7 ,7 [7- E, ri-7 [7 [7 -: [I- [ F77 [-: [77. [-7 F-T 1301-9.1 :: :.' Revision 18 ENCLOSURE 6 Page 8 of 16 Data Sheet 3 Anchorage Assembly Surveillance Inspection Hoop Tendons INSPECTION PERIOD INSP. BY VERIF. BY STRESSING WASHER DATE CONTR. COGNIZANT TENDON END BUTTONHEADS & NUT SHIMS BEARING PLATE INSP. COMMENTS FOREMAN OV INSP. NO. OF MISSING, BROKEN, AND/OR DAMAGED I.D. Location Corr. WIRES CORR. SKETCHED CORR. CRACKS SKETCHED CORR.' CRACKS SKETCHED CORR. CRACKS SKETCHED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1._ _ -
- 2. _
_ 7 '-
- 3. - -
4. S. 6.- LEGEND GENERAL TENDON END-LOCATION Y=YES IDENTIFY TENDON END (SHOP OR FIELD) AND NUMBER OF BUTTRESS (1TO 6) NEAREST TO TENDON END N = NO 69
[- F--T F -- 7 [7 V - [a 7 177-- r--7 7 F 7-- in .4 t. I_ .
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Revision 18 ENCLOSURE 6 Page 9 of 16 Data Sheet 4 Tendon Buttonhead Inspection RB Tendon Surveillance COMMENT: INSPECTED BY CONTRACTOR FOREMAN Date VERIIFIED BY COGNIZANT QV INSPECTOR __ _ Date COGNIZANT MECH/STRUCT ENGINEER Date_ REVIEWED BY Tendon# _ _I INSPECTION PERIOD_ END: FIELD (1 piece washer) SHOP (2 piece washer) 70
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1301-9.1 . Revision 18 ENCLOSURE 6 Page 10 of 16 Date Sheet 5 Tendon Anchorage Area Crack Inspection Dome Tendons Inspection Period Insp. By Verify. By Tendon Cracks with width >0.01" Date Contr. Cognizant No. Location Remarks about Crackinq Pattern Location Width (IN.) insn. Foreman QV Insp.
- 1. . .
2. I
- 3. -
4. Date: I 5. 6. NOTE: Location Cognizant Mech/Struct Engineer Reviewed By: Identify Tendon End (Lhopor Field) and NW, NE, SW, SE 71
[7- F-., F -7 1F 1.: 1.:
-- -- 1, I- (1 _-_ 1_._- . __
[77~~17 [77 [F C"',, 1301-9.1 :.. Revision 18 ENCLOSURE 6 Page 11 of 16 Data Sheet 6 Tendon Anchorage Area Crack Inspection Vertical Tendons Inspection Period Insp. By Verify. By Tendon Cracks with.width >0.01" Date Contr. Cognizant No. Location Remarks about Cracking Pattern Location Width (IN.) Insp. Foreman QV Insp. 1. 2. 3. 4. 5. 6. 7. NOTE: Location Identify Tendon End (whop or Field) and Cognizant Mech/Struct Engineer T or B - Top or Bottom of Vertical Tendon Reviewed By: Date: 72
-- 1-- l-- 7 [77 1=- 17 .7_ I1 . 77. [7 17 7 7 I - _-- .- . _ . - I I , - -- f" & - F - I -
1301-9.1 . Am Revision 18 ENCLOSURE 6 Page 12 of 16 Date Sheet 7 Tendon Anchorage Area Crack Inspection Hoop Tendons Inspection Period Cracks with width >0.01" Date Insp. By Verify. By Tendon No. Location Remarks about Cracking Pattern Location Width (IN.) Insp. Contr. Foreman Cognizant QV InsD. 1. 2. 3.
- 4. __ _ _ ___ _ _ _
- 5. _ _ _ _ _ _ _ _
- 6. __ _ _ ___ _ _ _
- 7. _ _ _ _ _ _ _ _
. 9. _ _ _ T.
- 10. _ _ _ _
NOTE: Location Identify Tendon End (Shop or Field) and. Cognizant Mech/Struct Engineer 1 to 6 - Number of Butress Nearest to End of Tendon Reviewed By: Date: 73
I I I -- -- E1 1 I * [1 [ _ I--7 [-1-- 1 7 = I-i47 iI. 1301-9.1 , Revision 18 ENCLOSURE 6 Page 13 of 16 Date Sheet 8 Crack Growth Inspection Dome Tendons Inspection Period Insp. By Verify.-By I Tendon Cracks with width >0.01" Date Contr. Cognizant } No. Location Remarks about Cracking Pattern Location Width (IN.) Insp. Foreman QV Insp. .1
- 1. D-103 NE END
- 2. D-118 SW END
- 3. D-203 NE END
- 4. D-218 SE END I
- 5. D-225 NW END :
I
- 6. D-249 SE END r = I
_ .I
- 7. D-313 SE END
- 8. D-329 SW END
- I
- 9. D-334 NW END
- 10. I' 11.
'1i 12.
NOTE: Location . i_ Identify Tendon End (Shop or Field) and Cognizant Mech/Struct Engineer NW, NE, SW, Se Reviewed By:_ __ _ Date: 74
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Revision 18 ENCLOSUFME 6 Page 14 of 16 DATA SHEET 9 Crack Growth Inspections Choose the sketch which is most appropriate and plot the observed cracks. INSPECTED BY CONTRACTOR DATE_
-9 VERIFIED BY COGNIZANT QV INSPECTOR _ DATE_ .1\
0?"'
>L}J REVIEWED BY COGNIZANT MECH/STRUCT ENGINEER DATE_
75
ENCLOSURE 6 1301-9.1 Data Sheet 10 Revision 18 General Containment Inspection Results Page 15 of 16 MAat Foundation in Tendon Gallery , Tendon Grease Caps Buttress I to 2 Qj.:tttress 2 to 3 Butrs 3 o4 I Cognizant Mech/Struct Engineer _- reviewed By: Date: Performed By: Date: 76
f A--T :, 0i ENCLOSURE 6 1301-9.1 Data Sheet 10 Revision 18 General Containment Inspection Results Page 16 of 16 uttress 4 to 5 Buttress 5 to 6 L
!. ,IjButtres s 6 to 1 L -. ;tS Dome Area
- Cognizant Mech/Struct Engineer I Reviewed By: Date: I ._A1 .L Performed By: Date: 77
I Number TMI - Unit 1
.1 sn .I urveilance t-rocedure' oUr -U. l
-itle . Revision No.
RB Structural Integrity Tendon Surveillance 18 ENCLOSURE?7 Page I of 2 Additional Inspection Commitments Due to Abnormalities Previously Documented in 1301-9.1 Inspection Abnormality Period Noted Commitment Comments 1 5/21/75- NONE NONE NONE 7/02/75 2 Tendon H-51-13 had Inspect H-51-13 buttonheads 8/17/77 - numerous cracked in period.3 to determine if NONE 11/11/77 buttonheads. cracking continues. 3 V31 Lift off 3 Do lift off on V30 and V32 LER 81-010 sub - 4/17/80 - kips low and in period 4. Reinspect to document incom-8/6/80 adjacent tendons V1138 in period 4 to plete inspect. during not lifted off. better document the 1980 surveillance. V138 Category corrosion and evaluate. H-51-13 inspection 4 Corrosion showed no continued cracking.
--. 4 Lift off of V30 & V32 was
!I. 5/85 - NONE NONE performed with acceptable
.Z.;-,6/85 results. The corrosion on V138 was evaluated & found acceptable.
5 Some cracks During period 6 repeat 10/89 - appeared to have the concrete cracks 1/90 grown slightly inspection as required in NONE from previous. Enclosure 6. 6 - All SDR's accept condition(s) 9/94 - 11/94 As captured in SDR's I None found with no further action and 9/95 through 6 required 7* Grout overlay repairs Consider performing repairs 30 Year Exam not completely sound (T.R. 136, Sec. 4.3) SE quad above ring Reexamine rebar and/or 30 Year Exam girder - Grout cover consider grout repair coming off & Underlying rebar exposed (T. R. 136, Sec. 4.2)
- Reference Topical Report (T.R.) No. 136, Tendon Surveillance 25 th Year (Period 7) for details surrounding the abnormalities noted and commitments made to the regulator in that Topical Report for Period 7.
78
I Number TMI - Unit I Surveillance Procedure 1301-9.1 iUe j Revision No. RB Structural Integrity Tendon Surveillance . 18 ENCLOSURE 7 Page 2 of 2 Inspection Abnormality Period Noted Commitment Comments 7* (Cont'd) Construction joint reexamine crack & ensure 30 Year Exam above ring girder stable between D320NE & D321 NE - Crack ©
.018" wide (T.R. 136, Sec. 4.5)
Crack @ H46-37 @ reexamine crack & ensure 30 Year Exam
.013" wide wain 2' of stable base plate edge (TR.
136, Sec. 4.7) Some grease samples Ensure grease samples wI <.5 30 Year Exam exhibit Reserve retested per Unmodified Version Alkalinity No. < .5 ASTM D974 Sec. 9 for acid number V164 field end wI Reexam of 2nd sarple found 30 Year Exam nitrates @ 10.3 ppm SAT. Resample V164 field end (T.R. 136, Sec. 4.8) to ensure nitrates stable. V86 - assurance of resample grease @ field end 30 Year. Exam complete Tendon void V86 & top off with grease. grease fill not satisfied (T. R. 136, Sec. - 4.9) Some areas found Reexam spalled areas - ensure 30 Year Exam spalled during IWL stable and/or grout repair exam (T.R. 136, Sec. 4.4) Cracks found over FHB Perform VT-1 C exam & ensure 30 Year Exam Roof between stable wi no active degradation buttresses 3 & 4 (T.R. Mechanism 136, Sec. 4.1)
- Reference Topical Report (T.R.) No. 136, Tendon Surveillance 2 5 th Year (Period 7) for details surrounding the abnormalities noted and commitments made to the regulator in that Topical Report for Period 7.
79
L fq /tJ ER-AA-335-018 Revision 2 Page 1 of 24 Nuclear Level 2 -Reference Use GENERAL, VT-1, VT-IC, VT-3 AND VT-3C, VISUAL EXAMINATION OF ASME CLASS MC AND CC CONTAINMENT SURFACES AND COMPONENTS L
- 1. PURPOSE 1.1. This procedure provides the inspection requirements for personnel performing Inservice Inspection (ISI), Visual Examination, General, VT-1, VT-1 C, VT-3 and VT-3C of containment surfaces and components, in accordance with Subsections IWE (ASME Class MC) and IWL (ASME Class CC) of the American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, ASME B&PV Code, Section Xl, 1992 Edition, 1992 Addenda through 1998 Edition.
L 1.2. This procedure is also applicable for Stations having authorized or granted Code Relief Requests for the use of portions of this procedure, as applicable. 1.3. The definitions of discontinuities in concrete, coating failures, and post tensioning L systems (tendons) indications are provided in Attachments 1, 2, and 3.
- 2. MATERIALS AND SPECIAL EQUIPMENT 2.1. When performing direct VT-1 or VT-1 C examinations, a minimum illumination of 50 foot candles (fc) at a maximum distance of 2 feet shall be maintained. Calibrated light meters shall be used for verification of illumination levels.
2.2. When performing direct VT-3 or VT-3C examinations, a minimum illumination of 50 ll foot candles (fc) at a maximum distance of 4 feet shall be maintained. Calibrated light meters shall be used for verification of illumination levels. 2.3. When performing remote VT visual examinations required by ASME Section Xl, Subsection IWE (Class MC surfaces and components), the illumination levels as specified in 2.1and 2.2 may be reduced and the distances as specified in 2.1 and 2.2 may be extended provided that the conditions or indications for which the visual L examination is performed can be detected at the chosen distance and illumination. KL 2.4. General Visual Examinations may be performed either directly or remotely. Illumination levels shall be sufficient to assess the general condition of the surface or component and detect evidence of degradation on the surface or component being examined. ( 2.5. Borescopes, mirrors, telescopes, closed circuit television, cameras or other devices may be used for remote examination, provided such devices or systems have a resolution capability at least equivalent to that attainable by direct visual examination.
ER-AA-335-01 8 Revision 2 Page 2 of 24 2.6. Magnifying glasses, mirrors, depth gages, crack comparators, surface replication techniques and weld gages may be used to supplement direct examination should the need arise. 2.7. Measuring and Test Equipment (M&TE) or visual aids used shall be recorded on the Work Order (WO) and/or on the applicable Visual Examination Record, (Attachments 4,5, or 6) or equivalent.
- 3. PRECAUTIONS, LIMITATIONS, AND PREREQUISITES 3.1. Precautions 3.1.1. Personnel performing examinations shall ENSURE that all Site Safety Standards are observed.
3.2. Limitations 3.2.1. ENSURE that this procedure meets the appropriate code requirements for the scope of inspections to be performed. 3.2.2. ENSURE that the requirements and criteria contained in authorized or granted site specific Code Relief Requests are met. 3.2.3. When performing direct VT-1 or VT-1 C examinations, ENSURE a minimum illumination of 50 foot candles (fc) at a maximum distance of 2 feet is maintained. Calibrated light meters shall be used for verification of illumination levels. 3.2.4. When performing direct VT-3 or VT-3C examinations, ENSURE a minimum illumination of 50 foot candles (fc) at a maximum distance of 4 feet is maintained. Calibrated light meters shall be used for verification of illumination levels. 3.2.5. When performing remote VT visual examinations required by ASME Section Xl, Subsection IWE (Class MC surfaces and components), the illumination levels as specified in 3.2.3 and 3.2.4 may be reduced and the distances as specified in 3.2.3 and 3.2.4 may be extended provided that the conditions or indications for which the visual examination is performed can be detected at the chosen distance and illumination. 3.2.6. General Visual Examinations may be performed either directly or remotely. Illumination levels shall be sufficient to assess the general condition of the surface or component and detect evidence of degradation on the surface or component being examined. 3.3. Prerequisites 3.3.1. Personnel performing Examinations shall be a minimum Level II qualified and certified in accordance with TQ-AA-122, Qualification and Certification of Nondestructive (NDE) Personnel, or in accordance with an approved vendor qualification and certification procedure.
ER-AA-335-018 Revision 2 Page 3 of 24 3.3.2. Procedure Demonstration/Qualification
- 1. A written procedure and report of examination results is required: For procedure demonstration, a near-distance vision test chart containing text with lower case characters without an ascender or descender (e.g., a, c, e, o) in accordance with ASME Section Xi, Table IWA-2210-1 is required.
- 2. Measurements of the near-distance test chart shall be made once before initial use with an optical comparator (1OX or greater) or other suitable instrument to verify that the height of a representative lower case character, for the selected type size, meets the requirements of Table IWA-221 0-1.
- 3. The remote examination procedure shall be demonstrated to resolve the required test chart character.
3.3.3. A Responsible Engineer (RE) shall be a knowledgeable and qualified individual appointed by management. The RE shall be a Registered Professional Engineer experienced in evaluating inservice conditions of structural concrete. The RE shall be responsible for: Development of plans and procedures for examination of ASME Class CC (IWL) containment surfaces and post tensioning systems (tendons);
- Approval, instruction and training of concrete examination personnel;
- Evaluation of examination results;
- Preparation of repair procedures;
-. Submittal of reports to the Owner documenting results of examination and repairs.
3.3.4. A Responsible Individual (RI) shall be a knowledgeable and qualified individual appointed by management. The RI shall be knowledgeable in the requirements for design, inservice inspection and testing of Class MC and metallic liners of ClassOCC components. The RI shall be responsible for:
- Development of plans and procedures for examination of ASME Class MC (IWE) containment surfaces;
- Instruction, training and approval of visual examination personnel;
- Performance or direction of general and detailed visual examinations;
- Evaluation of examination results;
- Submittal of report to the Owner documenting results of examinations.
3.3.5. VERIFY that the owner defined/site specific acceptance criteria for IWE components have been established prior to the conduct of examination.
- 4. MAIN BODY 4.1. Surface Preparation
ER-AA-335-01 8 I (?-;Revision 2 Page 4 of 24 4.1.1. If necessary, REMOVE dirt, grease, or other foreign matter that would mask indications or interfere with the examination. 4.2. Examination 4.2.1. PERFORM Visual Examination by direct or remote visual examination method or a combination thereof. 4.2.2. GENERAL VISUAL (GV) EXAMINATION GV examinations shall be performed by, or under the direction of, a Registered Professional Engineer or other individual knowledgeable in the requirements for design, inservice inspection, and testing of Class MC and metallic liners of Class CC components. The examination shall be performed either directly or remotely, by an examiner with visual acuity sufficient to detect evidence of degradation that may affect either the containment structural integrity or leak tightness. 4.2.3. VT-1, VISUAL EXAMINATION VT-1 examinations are conducted to detect discontinuities and imperfections on the ( >surfaces of metallic surfaces, components, supports, and tendon anchorage hardware including such conditions as cracks, wear, corrosion, or erosion. 4.2.4. VT-3, VISUAL EXAMINATION L. VT-3 examinations are conducted to determine the general mechanical and structural condition of metallic surfaces, components, and their supports, by verifying parameters such as clearances, settings, and physical displacements; and to detect discontinuities and imperfections, such as loss of integrity at bolted or welded L connections, loose or missing parts, debris, corrosion, wear, or erosion. 4.2.5. VT-1 C, VISUAL EXAMINATION VT-1 C examinations are conducted to determine concrete deterioration and distress for suspect areas detected by VT-3C and to determine the condition of concrete extending 2.0 feet beyond the edge of tendon anchorage hardware bearing plates. 4.2.6. VT-3C VISUAL EXAMINATION i_ VT-3C examinations are conducted to determine the general structural condition of concrete surfaces of containments by identifying areas of concrete deterioration and distress, such as defined in the American Concrete Institute Specifications ACI 201.1 R-68 and ACI 349.3 R-96. 4.2.7 Suspect area: an area with a relevant condition that has exceeded the owner defined pre-established acceptance criteria.
ER-AA-335-O'18 Revision 2 Page 5 of 24 4.2.8 Recordable Indication: any visually observed abnormal conditions that may potentially impact the integrity of the component design function. These conditions are identified as "Recordable Indication Type Codes" in Attachments 4, 5, and 6. 4.3. Direct Examination 4.3.1. CONDUCT a direct (near distance) VT-3 Visual Examination using a near distance vision test chart containing text with lower case characters without an ascender or descender (e.g. a,c,e,o) with maximum lower case height of 0.105 inches at a maximum distance of 4 feet and a minimum illumination of 50 fc. Measurements of the near distance test chart shall be made once before initial use with an optical comparator (1OX or greater) or other suitable instrument to verify that the height of a representative lower case character meets the height requirement. 4.4. Remote Examination 4.4.1. Remote examinations may be substituted for direct examinations provided the remote technique being used has been qualified by use of a Near-Distance Vision Chart for the maximum distance being viewed and that the system is capable of distinguishing and differentiating between colors applicable to the component. 4.4.2. When a containment vessel or liner is painted or coated to protect surfaces from corrosion, PERFORM preservice and inservice visual examinations without the removal of the paint or coating. 4.4.3. When removal of paint or coating is required, REMOVE it in a manner that will not reduce the base metal or weld thickness below the design thickness. Reapplied paint and coating systems shall be compatible with the existing system. 4.4.4. DOCUMENT minimum illumination, maximum direct examination distance, and maximum procedure demonstration lower case character height per IWA-2210, for VT-1 or VT-3 visual examination procedure qualification. 4.4.5. When performing remote visual examinations in accordance with ASME Section Xl, Subsection IWE, the requirements specified in Table IWA-2210 for maximum distance may be increased and the minimum illumination may be decreased provided the indications for which the visual examination is performed can be detected. Adequate illumination and resolution can be determined by the ability to resolve a 1/32" wide black line on an 18% neutral gray card. 4.5. Examination of Class MC Components 4.5.1. Examination Boundary 1.- In accordance with ASME Section Xl, 1992 Edition with 1992 Addenda, the examination boundary for components shall INCLUDE either the
ER-AA-335-01 8 Revision 2 L VPage 6 of 24 ACCESSIBLE INTERIOR or the EXTERIOR surface areas including welds and base metal.
- 2. In accordance with ASME Section Xl, 1998 Edition, the examination boundary for components shall INCLUDE all ACCESSIBLE INTERIOR and EXTERIOR surface areas including welds and base metal.
4.5.2. Standards for Examination Category E-A, Containment Surfaces I 1. Visual Examination - General In accordance with IOCFR50.55a(b)(2)(ix)(E), at least once each Inspection Period, PERFORM the General Visual Examination by or under the direction of a Registered Professional Engineer or other individual knowledgeable in the requirements for design, inservice inspection and testing of Class MC and metallic liners of Class CC components. A. RECORD indications in accordance with Attachment 4. l B. COMPARE the recorded indications fo the owner defined pre-
.. . established acceptance criteria.
C. ACCEPT conditions that may affect containment structural integrity or leak tightness by engineering evaluation, or REPAIR/REPLACE in accordance with IWE-3122. - 2. VT-3, Visual Examination on Coated Areas EXAMINE the area to be inspected, when painted or coated, for evidence of flaking, blistering, peeling, discoloration, and other signs of distress. A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. C. ACCEPT suspect areas by engineering evaluation, or REPAIRIREPLACE in accordance with IWE-3122. D. When specified as a result of the engineering evaluation, PERFORM supplemental examinations in accordance with IWE-3200.
- 3. VT-3, Visual Examination on Non-coated Areas EXAMINE the area to be inspected for evidence of cracking, discoloration, wear, pitting, excessive corrosion, arc strikes, gouges, surface discontinuities, dents, and other signs of surface irregularities.
A. RECORD indications in accordance with Attachment 4.
ER-AA-335-01 8 Revision 2 L r'-- Page 7 of 24 B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. C. ACCEPT suspect areas by engineering evaluation, or REPAIR/REPLACE in accordance with IWE-3122. i D. When specified as a result of the engineering evaluation, PERFORM supplemental examinations in accordance with IWE-3200. 4.5.3. Standards for Examination Category E-B, Pressure Retaining Welds
- 1. VT-1, Visual Examinations on Coated Areas I EXAMINE the area to be inspected, when painted or coated, for evidence of flaking, glistering, peeling, discoloration, and other signs of distress.
I A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria.
.i -e C. ACCEPT suspect areas by engineering evaluation, or REPAIR/REPLACE in accordance with IWE-3122.
D. When specified as a result of the engineering evaluation, PERFORM I. supplemental examinations in accordance with IWE-3200.
- 2. VT-1, Visual Examination on Non-coated Areas EXAMINE the area to be inspected for evidence of cracking, discoloration, wear, pitting, excessive corrosion, arc strikes, gouges, surface discontinuities, L dents, and other signs of surface irregularities.
A. RECORD indications in accordance with Attachment 4. JJ B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. L C. ACCEPT suspect areas by engineering evaluation, or REPAIR/REPLACE in accordance with IWE-3122. D. When specified as a result of the engineering evaluation, PERFORM
-1 supplemental examinations in accordance with IWE-3200.
il L 4.5.4. Standards for Examination Category E-C, Containment Surfaces Requiring Augmented Examination L ' ..-: I . : 1. VT-1, Visual Examination on Coated Areas
ER-AA-335-018 Revision 2 Page 8 of 24 EXAMINE the area to be inspected, when painted or coated, for evidence of flaking, blistering, peeling, discoloration, and other signs of distress. A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. C. ACCEPT suspect areas by engineering evaluation, or REPAIR/REPLACE in accordance with IWE-3122. D. When specified as a result of the engineering evaluation, PERFORM supplemental examinations in accordance with IWE-3200.
- 2. VT-1, Visual Examination on Non-coated Areas EXAMINE the area to be inspected for evidence of cracking, discoloration, wear, pitting, excessive corrosion, arc strikes, gouges, surface discontinuities, dents, and other signs of surface irregularities.
A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. C. ACCEPT suspect areas by engineering evaluation, or REPAIR/REPLACE in accordance with IWE-3122. D. When specified as a result of the engineering evaluation, PERFORM supplemental examinations in accordance with IWE-3200. 4.5.5. Standards for Examination Category E-D, Seals, Gaskets, and Moisture Barriers
- 1. VT-3, Visual Examination of Seals and Gaskets EXAMINE the seals and gaskets on airlocks, hatches and other devices for wear, damage, erosion, tears, surface cracks, or other defects that may violate the leak-tight integrity.
A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. C. CORRECT conditions that may violate containment leak-tight by repair or replacement in accordance with IWE-3122.2 or IWE-3122.3 (1992 Edition and 1992 Addenda only).
*tO/1('n 3 ER-AA-335-01 8 Revision 2
! Page 9 of 24
- 2. VT-3, Moisture Barriers EXAMINE the internal and external containment moisture barrier materials at concrete-to-metal interfaces intended to prevent intrusion of moisture against the pressure retaining metal containment shell or liner for wear, damage, erosion, tears, surface cracks, or other defects that may violate the leak tight integrity.
A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-established acceptance criteria. L C. CORRECT conditions that may violate leak-tight integrity by repair or replacement IWE-3122.2 or IWE-3122.3 (1992 Edition and 1992 Addenda only) L 4.5.6. Standards for Examination Category E-G, Pressure Retaining Bolting
- 1. VT-1, Visual Examination of Bolted Connections EXAMINE the bolts, nuts, bushings, washers and threads in base material and flange ligaments between threaded stud holes.
A. RECORD indications in accordance with Attachment 4. B. COMPARE the recorded indications to the owner defined pre-L established acceptance criteria. C. CORRECT conditions that cause bolted connections to violate either containment leak-tight or structural integrity by replacement in accordance with IWE-3122.2 (1998 Edition) or IWEO-3122.3 (1992 Edition and 1992 Addenda). 4.6. Standards for Examination Categorv L-A, Class CC Components (Concrete) 4.6.1. Examination Boundary
- 1. The examination boundary for the concrete shells, shall INCLUDE the ACCESSIBLE surface areas.
4.6.2. Standards for Examination of Concrete
- 1. Concrete surface areas, including coated areas, except those exempted by
_ IWL-1 220(b), shall be VT-3C visual examined for evidence of conditions
ER-AA-335-01 8 Revision 2 Page 10 of 24 indicative of damage or degradation, such as defined in ACI 201.1 R-68 in l accordance with IWL-231 0(b). A. RECORD indications in accordance with Attachment 6. B. The recorded indications are acceptable for continued operation without further corrective actions if accepted by the RE. C. ACCEPT the recorded indications, which have evidence of damage or degradation sufficient to warrant further corrective actions as determined by the RE, by engineering evaluation, or REPAIR/REPLACE in accordance with IWL-3210.
- 2. Selected areas, such as those that indicate suspect conditions, shall receive a VT-1 C examination in accordance with IWL-231 0(a).
- 3. Concrete extending 2'-0" from the bearing plate for tendons selected in accordance with IWL-2520 and IWL-2521 shall receive a VT-1 C examination.
- 4. The examination shall be performed by, or under the direction of, the i ;Responsible Engineer.
- 5. Visual examinations may be performed from floors,-roofs, platforms, walkways, ladders, ground surface, or other permanent vantage point, unless temporary close-in access is required by the inspection plan.
L 4.7. Standards for Examination Category L-B Unbonded Post Tensioning Systems (Tendons) L 4.7.1. Examination Boundary The examination boundary shall include containment tendon anchorage hardware L including bearing plates, anchor heads,-shims, wedges and wire button heads, as a minimum. 4.7.2. As a minimum, tendon anchorage components shall be examined for evidence of free water, active corrosion, broken or protruding wires, missing buttonheads, misaligned or displaced shims, and cracks.
- 1. RECORD indications in accordance with Attachment 5.
If free water is observed, then QUANTIFY amount of free water.
- 2. The recorded indications are acceptable for continued operation without further corrective actions if accepted by the RE.
- 3. ACCEPT the recorded indications, which have evidence of damage or degradation sufficient to warrant further corrective actions as determined by the RE, by engineering evaluation, or REPAIR/REPLACE in accordance with IWL-321 0.
ER-AA-335-01 8 Revision 2 Page 11 of 24 4.8. Examination of reinforced steel of IWL Concrete Containments 4.8.1. Exposed reinforcing steel identified during as found examination or that exposed during concrete repair shall receive a VT-1 examination.
- 1. RECORD indications in accordance with Attachment 6.
- 2. The recorded indications shall be evaluated by the RE to determine necessary corrective actions.
4.9. Evaluation 4.9.1. NOTIFY the Station RE or RI for evaluation of recordable indications identified. during visual examinations of IWE and/or IWL components and for comparison to previously recorded indications.
ER-AA-335-01 8 Revision 2 Page 12 of 24 - 4.10. Reporting 4.10.1. INCLUDE as a minimum in the Examination Record the following information. USE L the applicable Attachment 4, 5, 6 (or similar) to document examination results. Other equivalent forms may be found in T&RM ER-AA-335-1004.
- Examination Data Sheet number, if applicable
- Date of examination
- Examination procedure and revision
- Examiner's signature and NDE level
,- Identification of component (e.g., EIN, EID, System, etc.)
- Type of examination (direct or remote)
- Illumination used, if any
- Direct Visual aids used, if any
- Remote Visual equipment used, if any
- - Examination results L RECORD location and size of the Recordable Indication (RI) as required to perform an accurate evaluation and use during subsequent evaluations.
L ATTACH asketch or drawing if required. 4.10.2. RECORD on Attachment 4, 5, or 6, or similar, the Containment Visual Examination results associated with ASME Section Xl repairs or replacements. These records shall become part of the final Work Order (WO) documentation. 4.10.3. RECORD the Containment Visual Examinations performed for scheduled inservice examinations and FORWARD to the VT Level IlIl, Responsible Engineer/individual and ANII for review as applicable. Then, route to the Containment ISI Program Owner for inclusion in the ASME Section Xl program in accordance with the applicable procedures. 4.11. Final Conditions 4.11.1. LEAVE the surface of the part or component in a better than found condition. L 5. RETURN TO NORMAL - None
- 6. REFERENCES 6.1. Commitments - None 6.2. TQ-AA-122, Qualification and Certification of Nondestructive (NDE) Personnel
ER-AA-335-01 8 Revision 2 Page 13 of 24 6.3. ER-AA-335-1004, Non-Destructive Examination Forms 6.4. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section Xl, 1992 Edition, 1992 Addenda through 1998 Edition. 6.5. The American Concrete Institute Specification ACl 201.1 R-68 6.6. The American Concrete Institute Specification ACI 349.3R-96
- 7. ATTACHMENTS 7.1. Attachment 1, Definitions of Discontinuities in Concrete 7.2. Attachment 2, Definitions of Coating Failures 7.3. Attachment 3, Definitions of Post Tensioning Systems (Tendons) Indications 7.4. Attachment 4, ASME IWE (Class MC) Containment Visual Examination Record 7.5. Attachment 5, ASME IWL (Class CC) Containment Tendon Anchorage VT-1 Visual i ^: Examination Record 7.6. Attachment 6, ASME IWL (Class CC) Containment Concrete Visual Examination Record
ER-AA-335-018 Revision 2 Page 14 of 24 ATTACHMENT I Definitions of Discontinuities in Concrete Page 1 of 6 A.1 Crack - A complete or incomplete separation, of either concrete or masonry, into two or more parts produced by breaking or fracturing. A.1.1 Checking - Development of shallow cracks, closely spaced by irregular intervals on the surface of plaster, cement paste, mortar, or concrete. A.1.2 Craze cracks - Fine random cracks or fissures in a surface of plaster, cement paste, mortar, or concrete. Crazing - The development of craze cracks; the pattern of craze cracks existing in a surface. A.1.3 D-cracking - A series of cracks in concrete near and roughly parallel to joints, edges, and structural cracks. A.1.4 Diagonal crack- In a flexural member, an inclined crack caused by shear stress, usually at about 45 deg to the axis; or a crack in a slab, not parallel to either the lateral or longitudinal directions. A.1.5 Hairline cracks- Cracks in an exposed concrete surface having widths so small as to be barely perceptible. A.1.6 Pattern cracking- Fine openings on concrete surfaces in the form of a pattern; resulting from a decrease in volume of the material near the surface, or increase in volume of the material below the surface, or both. A.1.7 Plastic cracking - Cracking that occurs in the surface of fresh concrete soon after it is placed and while it is still plastic. A.1.8 Shrinkage cracking - Cracking of a structure or member due to failure in tension caused by external or internal restraints as reduction in moisture content develops, or as carbonation occurs, or both. A.1.9 Temperature cracking - Cracking due to tensile failure, caused by temperature gradient in members subjected to external restraints or by temperature differential in members subjected to internal restraints. A.1.1 0 Transverse cracks - Cracks that develop at right angles to the long direction of the member.
ER-AA-335-01 8 I'.:
!Revision 2 Page 15 of 24 ATTACHMENT I Definitions of Discontinuities in Concrete Page 2 of 6 A.2 Deterioration--1) Physical manifestation of failure of a material (e.g., cracking, delamination, flaking, pitting, scaling, spalling, straining) caused by environmental or internal autogenous influences or hardened concrete as well as other materials; 2) Decomposition of material during either testing or exposure to service.
Disintegration- Reduction into small fragments and subsequently into particles. A.2.1 Abrasion damage - Wearing away of a surface by rubbing and friction. A.2.2 Blistering - The irregular raising of a thin layer, frequently 25 to 300 mm in diameter, at the surface of placed mortar or concrete during or soon after completion of the finishing operation; blistering is usually attributed to early closing of the surface and may be aggravated by cool temperatures. Blisters also occur in pipe after spinning or in a finish plastic coat in plastering as it separates and draws away from the base coat. } A.2.3 Cavitation damage - Pitting of concrete caused by implosion, i.e., the collapse of vapor bubbles in flowing water which form in areas of low pressure and collapse as they enter areas of higher pressure. - A.2.4 Chalking - Formation of a loose powder resulting from the disintegration of the surface of concrete or of applied coating, such as cement paint. L A.2.5 Corrosion- destruction of metal by chemical, electrochemical, or electrolytic reaction with its environment. L A.2.6 Curling - The distortion of an originally essentially linear or planar member into a curved shape such as the warping of a slab due to creep or to differences in temperature or moisture content in the zones adjacent to its opposite faces. A.2.7 Deflection - Movement of a point on a structure or structural element, usually measured as a linear displacement transverse to a reference line or axis. A.2.8 Deformation - A change in dimension or shape.
ER-AA-335-018 Revision 2 Page 16 of 24 ATTACHMENT 1 Definitions of Discontinuities in Concrete Page 3 of 6 A.2.9 Delamination - A separation along a plane parallel to a surface as in the separation of a coating from a substrate or the layers of a coating from each other, or in the case of a concrete slab, a horizontal splitting, cracking or separation of a slab in a plane roughly parallel to, an generally near, the upper surface; found frequently in bridge decks and other types of elevated reinforced-concrete slabs and may be caused by the corrosion or reinforcing steel; also found in slabs on grade caused by development, during the finishing operation, of a plane of weakness below the densified surface; or caused by freezing and thawing, similar to spalling, scaling, or peeling except that delamination affects large areas and can often be detected by tapping. A.2.10 Distortion - See Deformation. A.2.11 Dusting - The development of a powdered material at the surface of hardened concrete. L. A.2.12 Efflorescence -A deposit of salts, usually white, formed on a surface, the substance having emerged in solution from within either concrete or masonry and subsequently been precipitated by evaporation. A.2.13 Erosion - Progressive disintegration of a solid by the abrasive or cavitation action of gases, fluids, or solids in motion. A.2.14 Exfoliation - Disintegration occurring by peeling off in successive layers; swelling up and opening into leaves or plates like a partly opened book. A.2.15 Exudation - A liquid or viscous gel-like material discharged through a pore, crack, or opening in the surface of concrete. A.2.16 Joint spa/I - A spall adjacent to a joint. - A.2.17 Pitting - Development of relatively small cavities in a surface; in concrete, localized disintegration, such as a popout; in steel, localized corrosion evident as minute cavities on the surface. A.2.18 Peeling - A process in which thin flakes of mortar are broken away from a concrete surface, such as by deterioration or by adherence of surface mortar to forms as forms are removed. A.2.19 Popout- The breaking away of small portions of a concrete surface due to localized internal pressure, which leaves a shallow, typical conical, depression. A.2.19.1 Popouts, small- Popouts leaving holes up to 10 mm in diameter, or the equivalent.
ER-AA-335-018 Revision 2 Page 17 of 24 ATTACHMENT 1 Definitions of Discontinuities in Concrete Page 4 of 6 A.2.19.2 Popouts, medium - Popouts leaving holes between 10 and 50 mm in dianieter, or the equivalent. A.2.19.3 Popouts, large- Popouts leaving holes greater than 50 mm in diameter, or the equivalent. A.2.20 Scaling - Local flaking or peeling away of the near-surface portion of hardened concrete or mortar; also of a layer from metal. A.2.20.1 Scaling, light - Loss of surface mortar without exposure of coarse aggregate. A.2.20.2 Scaling,.medium - Loss of surface mortar 5 to 10 mm in depth and exposure of coarse aggregate. A.2.20.3 Scaling, severe - Loss of surface mortar 5 to 10 mm in depth with some loss of mortar surrounding aggregate particles 10 to 20 mm in depth. A.2.20.4 Scaling, very severe - Loss of coarse aggregate particles as well as mortar, K 'generally to a depth greater than 20 mm. A.2.21 Spall - A fragment, usually in the shape of a flake, detached from a larger mass by a blow, by the action of weather, by pressure, or by expansion within the large mass. A.2.21.1 Small spa/I - A roughly circular depression not greater than 20 mm in depth nor 50 mm in any dimension. A.2.21.2 Large spall - May be roughly circular or oval or in some cases elongated, more than 20 mm in depth and 150 mm in greatest dimension. I A.2.22 Warping - A deviation of a slab or wall surface from its original shape, usually caused by either temperature or moisture differentials or both within the slab or wall. A.3 Textural features and phenomena relative to their development. A.3.1 Air Void - A space in cement paste, mortar or concrete filled with air; an entrapped air void is characteristically 1 mm or more in size and irregular in shape; an entrained air void is typically between 10 Om and 1 mm in diameter and spherical or nearly so. 1/2 A.3.2 Bleeding - The autogenous flow of mixing water within, or its emergence from, newly placed concrete or mortar; caused by the settlement of the solid materials within the mass; also called water gain.
ER-AA-335-01 8 Revision 2 Page 18 of 24 ATTACHMENT I Definitions of Discontinuities in Concrete Page 5 of 6 A.3.3 Bugholes - Small regular or irregular cavities, usually not exceeding 25 mm in diarieter, resulting from entrapment of air bubbles in the surface of formed concrete during placement and consolidation. A.3.4 Cold-joint lines - Visible lines on the surfaces of formed concrete indicating the presence of joints where one layer of concrete had hardened before subsequent concrete was placed. A.3.5 Discoloration - departure of color from that which is normal or desired. A.3.6 Honeycomb - Voids left in concrete due to failure of the mortar to effectively fill the spaces among coarse aggregate particles. A.3.7 Incrustation - A crust or coating, generally hard, formed on the surface of concrete or masonry construction or on aggregate particles. A.3.8 Joint-- A physical separation in concrete, whether precast or cast-in-place, including cracks if intentionally made to occur at specified locations; also the region where structural members intersect such as a beam-column joint. A.3.9 Laitance - A layer of weak and nondurable material containing cement and fines from aggregates, brought by bleeding water to the top of overwet concrete; the amount is generally increased by overworking or over-manipulating concrete at the surface by improper finishing or by job traffic. A.3.10 Sand pocket - A zone in concrete or mortar containing fine aggregate with little or no cement. I A.3.11 Sand streak - A streak of exposed fine aggregate in the surface of formed concrete, caused by bleeding. A.3.1 2 Segregation - The differential concentration of the components of mixed concrete, aggregate, or the like, resulting in non-uniform proportions in the mass. A.3.1 3 Stalactite - A downward-pointing deposit formed as an accretion of mineral matter produced by evaporation of dripping water from the surface of L! concrete, commonly shaped like an icicle. A.3.14 Stalagmite - An upward-pointing deposit formed as an accretion of mineral matter produced by evaporation of dripping water, projecting from the surface of concrete, commonly conical in shape.
ER-AA-335-01 8 Revision 2 Page 19 of 24 ATTACHMENT I Definitions of Discontinuities in Concrete Page 6 of 6 A.3.15 Stratification - The separation of overwet or overvibrated concrete into horizontal layers with increasingly lighter material toward the top; water, laitance, mortar, and coarse aggregate tend to occupy successively lower positions in that order; a layered structure in concrete resulting from placing of successive batches that differ in appearance; occurrence in aggregate stockpiles of layers of differing grading or composition; a layered structure in a rock foundation. A.3.1 6 Water void - Void along the underside of an aggregate particle or reinforcing steel which formed during the bleeding period; initially filled with bleed water.
ER-AA-335-018 Revision2 Page 20 of 24 ATTACHMENT 2 Definitions of Coating Failures Page 1 of I LB.1 Discoloration - Change in color of the coating, fading. Cause could be age, heat, dye or pigment bleeding or surface contamination (dye penetration, grease, dirt, etc.) B.2 Chipping - Small void in coating system caused by impact from foreign object. B.3 Chalking - A surface phenomenon that appear soft or powdery. The cause is a breakdown in coating binder, which disintegrates, leaving the surface covered with pigment. B.4 Checking - Appears as small breaks in coating surfaces that are formed as coating ages and becomes harder and more brittle. Checking, for the most part, is a formulation related to reaction, were the resins and pigments do not B.5 properly combine. B.5
>S Cracking (Coating)- Appears as non-linear line running through the coating system. Cracking is caused by expansion or contraction throughout the film L -layer and the film and substrate (primer or metal surface).
1B.6 Flaking/Peeling - Appears as flaking or heavy peels on the surface of the metal. It is generally caused where the tensile strength of the coating is higher than the adhesive strength or bond strength. B.7 Blistering - Appears as large or small, round or hemispherical projections of the coating from the surface and are either dry or liquid filled. The usual cause of the condition is the penetration of moisture through an area of poor adhesion. B.8 Pinpoint Rust- Appears as small specks of rust or corrosion. Cause may be lower or the absence of zinc/binder ratio, where pinpoints of rust propagate. L g 13.9 Undercutting -Appears as a raised coated rust bloom. Undercutting is actually rust forming under the coating and acting as a wedge to push the coating of the metal surface. B.10 Minor Rust- A degree of in the form of iron oxide formation on steel, where no apparent base metal is lost. B.1 I Medium Rust - A degree of in the form of iron oxide formation on steel, where L (less than 5% of the base metal is lost. B.12 Major Rust-A degree of in the form of iron oxide formation on steel, where L more than 5% of the base metal is lost.
ER-AA-335-01 8 Revision 2 Page 21 of 24 ATTACHMENT 3 Definitions of Post Tensioning System (Tendons) Indications Page 1 of I C.1 Active Corrosion -- Corrosion on a component or surface that exhibits metal loss that has occurred since fabrication or construction, and / or exhibits pitting visible to the naked eye. Active corrosion is usually a reddish / rust color. C.2 Broken Wire -- A wire within a tendon assembly that is broken and not capable of accepting prestress load. Wires that excessively protrude from the anchorage components are suspected to be broken. C.3 Missing Button Head -- The end of the deformed portion of a wire that accepts the prestressed force is missing. The end of the wire may be visible within the anchorage.
- C.4 Protruding or Unseated Wire -- A wire within a tendon assembly that extends beyond a tendon anchorage after stressing and is not seated against the anchorage.
C.5 Excessive Shim Gaps -- Shims that have slipped out of position leaving gaps in excess of construction tolerances between the halves C.6 Uneven Shim Stack -- Shims that have shifted out-of position creating a condition where the pre stress load is not evenly distributed over the shim. stack assembly C.7 Free Water -- Water seeping or dripping from the tendon anchorage components or within the grease can. QUANTIFY all free water.
fir<l@ ER-AA-335-01 8 Revision 2 Page 22 of 24 ATTACHMENT 4 ASME IWE (Class MC) Containment Visual Examination Record Pagee of 1 Station: Unit: Exam Data Sheet. No.: Exam Date: System: Examination Procedure Rev. Work Order No(s): Location: Building: Elev.: Col.: Row: Azimuth/Radius: Exam Type: EGeneral E!VT-1 QVT-3 Type Of Exam: UDirect (:Remote Matl. Type: Design Drawing(s) Visual Aids: Surface: ID OD Surface / Components Coated: ai] YES NO N M&TE Used: IUTC or Serial No. ICal. Due Date: Illumination Used Illumination Verified: l Date: Time: Special / Specific Instructions: Component I Item Number and RESULTS Explanation I Notes Description . NI RI TYPE I.N. (As a minimum, Record Location and Size of (e.g. EIN, EID, etc.) Recordable Indications as applicable) Results Legend: NI - No Indications RI - Recordable Indication I.N.- Indication Number (if applicable) Recordable Indication Type Codes: A. Wear G. Blistering M. Missing Components S. Deviation From Design Drawing B. Corrosion I Pitting H. Peeling N. Loose Components T. Missing Paint Or Coating C. Mech. Damage 1. Discoloration 0. Tears -U. Bulges /Deformation D. Erosion J. Pitting P. Coating Damaged V. Missing I Incomplete Welds E. Cracks K Nicks Gouges _ Q. Leakage / Moisture W. Arc Strikes F. Flaking Dents R. Dislodged Seal, Gasket, Z. Other (Provide Explanation) L. _ or Moisture Barrier Supplemental Information: flYes LNo U Sketch C Photo FVideo 7 Other (Describe): VISUAL EXAMINER SIGNATURE: lLEVEL = DATE: I VT LEVEL III SIGNATURE: DATE: RESP. INDIVIDUAL SIGNATURE: DATE: FINAL DISPOSITION BY LEVEL III I RESP. INDIVIDUAL U Accept U Reject Comments: ANII REVIEW SIGNATURE: __DATE:
ER-AA-335-01 8 Revision 2 Page 23 of 24 ATTACHMENT 5 ASME IWL (Class CC) Containment Tendon Anchorage VT-1 Visual Exam Record PageI ofI L Station: Unit: Exam Data Sheet. No.: Exam Date: Work Order No(s).: Tendon Anchorage No.: Tendon End: Al Shop E Field I Location: Tunnel, Gallery, Buttress: Elevation: Bearing Plate l.D.: Bearing Plate I.D. Anchor Head l.D. Bushing l.D. Examination Procedure Rev. Type Of Exam: ElDirect E]Remote ll As Found Exam El As Left Exam Following Retensioning Of Tendons Which Have Been Detentioned Design Drawing(s) Visual Aids: M&TE Used: UTC or Serial No. Cal. Due Date: Illumination Used Illumination Verified: Date: Time: Special I Specific Instructions: . Component / Item Number and RESULTS Explanation I Notes Description NI RI TYPE I.N. (Sketch Shall Be Attached Depicting Location Of All Missing, Protruding, Unseated Wires) L. Results Legend: NI - No Indications RI - Recordable Indication l.N.- Indication Number (if applicable) Recordable Indication Type Codes: ! A. Missing Wires H. Cracks- 0. Other (Explain) B. Missing Button Heads 1. Pitting C. Protruding / Unseated Wires J. Nicks, Gouges, Mechanical Damage D. Broken Wires K. Uneven Shim Stack E. Active Corrosion L Excessive Shim Gaps F. Other Corrosion M. Gasket Seating Surface Damage G. Evidence Of Free Water (Quantify) N. Surface Discontinuities, Deflections Supplemental Information : ElYes [iNo L Sketch L]Photo LlVideo LI Other (Describe): VISUAL EXAMINER SIGNATURE: LEVEL DATE: RESPONSIBLE ENGINEER SIGNATURE: DATE: L FINAL DISPOSITION BY RESPONSIBLE INDIVIDUAL- F Accept a Reject Comments: ANII REVIEW SIGNATURE: DATE: __ _
ER-AA-335-01 8 Revision 2 Page 24 of 24 ATTACHMENT 6 ASME IWL (Class CC) Containment Concrete Visual Examination Record Page 1 of I Station: Unit: Exam Data Sheet. No.: Exam Date: System: Examination Procedure Rev. Work Order.No(s).: Location: Building: Elev.: Col.: Row: Azimuth/Radius: Exam Type: []General EJVT-IC EJVT-3C Type Of Exam: ElDirect EIRemote Matl. Type: Design Drawing(s) Visual Aids: Surface: ID OD Surface I Components Coated: E] YES O NO M&TE Used: UTC or Serial No. Cal. Due Date: Illumination Used Illumination Verified: Date: Time: Special / Specific Instructions: Component / Item Number and RESULTS Explanation / Notes Description . NI RI TYPE I.N. (As a minimum, Record Location and Size of (e.g. EIN, EID, etc.) Recordable Indications as applicable) I-.. .-. 1 I .. Results Legend: NI - No Indications RI - Recordable Indication I.N.- Indication Number (if applicable) Recordable Indication Type Codes: A. Cracks (Characterize and Size) G. Settlements Or Deflections M. Scaling / Dusting B. Exposed Reinforcing Steel H. Degraded Patches or Repairs N. Coating Deterioration C. Exposed Metallic Items (Other) I. Popouts, Voids, Honeycomb 0. Abrasion, Cavitation, Wear D. Evidence Of Grease Leakage J. Spalls P. Air Voids / Bug Holes E. Evidence Of Moisture K Cold Joint Lines 0. Efflorescence F. Leaching Or Chemical Attack L. Corrosion Staining R. Other (Explain) Supplemental Information : ]Yes E]No El Sketch [Photo ElVideo E] Other (Describe): VISUAL EXAMINER SIGNATURE: LEVEL DATE: RESPONSIBLE ENGINEER SIG.: DATE: FINAL DISPOSITION BY RESPONSIBLE ENGINEER E[Accept E Reject Comments: ANII REVIEW SIGNATURE: DATE:
PSC PROCEDURE SQ 3.0 EQUIPMENT - CONSTRUCTION JULY 23, 2004 Page 2 of 2 REVISION 0
- 1. FQ2TEPMFNI The following list of equipment should be available for use during the Surveillance operations. This list is only intended as a guide.
1.1. Miscellaneous shackles, hooks, chain hoists, come-alongs, hoisting slings. 1.2. Banding equipment. 1.3. Communications equipment - Walkie Talkies or Sound Powered Phones. 1.4. Buckets, pails, rags, brushes. 1.5 Miscellaneous Tools, hammers, wrenches, ratchets, sockets, bundling wire, screw drivers, pliers, heavy duty wire cutters, files, pry bars, etc. 1.6. Miscellaneous nuts, bolts, pins, washers, wooden blocks, rags, lights, extension cords, tape, etc. 1.7. Hydraulic pumps for rams. 1.8. Platforms, scaffolding, ladders, man-lifts, cable, ropes, etc. 1.9. Button header. 1.10. Plastic Bags, Plastic Sheeting (Visqueen). L 1.11. Wirecoiler. 1.12. Band or Drum heaters. 1.13. Fluid Pump for drum. 1.14. Empty 55 Gallon drums. 1.15. Stressing Shims. 1.16. 55 Gallon drums of Viscosity Oil Visconorust 2090P-4 (Certified). 1.17. CRC Natural Degreaser Aerosol or EPA 2000 as provided by AmerGen Energy. L sq3-O .TMI . 04isi
PSC PROCEDURE SQ 4.0 EQUIPMENT - QUALITY CONTROL JULY 23, 2004 Page 1 of 3
- REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (30T YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE QUALITY CONTROL EQUIPMENT LIST Prepared by ,4'. v'j Title - Do,; GQ.E . Date I)>237o Approved by 4e / C Z,_- Title &c0 c /-5K 4r Date /Z?-e Approved by R. P, 4 Title C .Date - u$ fL sq4-O.TMI.04isi
PSC PROCEDURE SQ 4.0 EQUIPMENT - QUALITY CONTROL JULY 23, 2004 Page 2 of 3
- REVISION 0
- 1. TNSPFCTTON FQUT TPMFNT The following items shall be required for the Inspections stated in each procedure. Each piece of testing and measuring equipment shall be in a currently calibrated condition. Items in excess of those shown as
' ibeing required for that procedure and being used during the Inspections of that procedure shall be documented on the appropriate Data Sheet where they were used, for Name, Identification and Recalibration Date. 1.1. SQ 6-0 L 1.1.1. Surface Thermometer. 1.1.2. Pocket-Probe Thermometer. 1.1.3. Sample of new 2090P-4 grease in a closed container (for Color Match). 1.2. SQO2l L 1.2.1. Suitable quantities of clean, unused 1 quart containers: plastic or steel. 1.3. SQO1-0 1.3.1. Magnifying Glass 5x (minimum) with suitable illumination. 1.3.2. Optical Comparator with 0.001" Measuring Reticle. 1.3.3. Steel Ruler, Steel Tapeline. 1.4. S(Q 9 1 (IfNecry) L 1.4.1. 400 Grit Wet or Dry Sandpaper. 1.4.2. Steel Wool - Medium Coarseness. Li 1.5. SQ&& 1.5.1. Optical Comparator with 0.001" Measuring Reticle. 1.5.2. Feeler Gauges. 1.5.3. Steel Ruler, Steel Tapeline. 1.6. SOQ9-.0 & SIQ. L 1.6.1. Stressing Jacks. 1.6.2. Pressure Gauges. sq4-O.TMI.04isi
PSC PROCEDURE SQ 4.0
/ EQUIPMENT - QUALITY CONTROL JULY 23, 2004 Page 3 of 3
( -REVISION 0 1.6.3. Steel Ruler. 1.6.4. Caliper (Optional). 1.6.5. Heise Digital Gauge (Verification of Pressure Gauge Calibration, refer to Procedure QA 10.1). 1.6.6. Surface Thermometer. 1.6.7. Feeler Gauges. 1.6.8. Dial Gauge (0.001" increments for detension deflection measurements). 1.7. Q1O 1 Refer to Section 1.3 of this procedure - same equipment. 1.8. S(O 10n 2 1.8.1. Tendon Wire Pulling Ram.(Optional) 1.8.2. Steel Ruler, Steel Tapeline. 1.8.3. Pressure Gauge, if used with the hydraulic pump for the Pulling Ram. 1.9. s.JJL 1.9.1. Steel Ruler, Steel Tapeline. 1.9.2. 1" O.D. Micrometer. 1.9.3. Wire Test Apparatus. 1.9.4. Pressure Gauge, if used with the hydraulic pump for the Apparatus. 1.10. SoQ 10.. 1.10.1. Steel Ruler, Steel Tapeline. 1.11. SQJ21f Refer to Section 1.6 of this procedure - same equipment. 1.12. SOQ2III 1.12. 1. Surface Thermometer. 1.12.2. Pocket-Probe Thermometer. 1.12.3. Steel Ruler, Steel Tapeline. sq4-O.TMI .04isi
f\9a6/ ^\t PSC PROCEDURE SQ 6.0 GREASE CAP REMOVAL JULY 23, 2004 Page 1 of 6 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (30TH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION ! (c J r IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE GREASE CAP REMOVAL Prepared by 4. k4 Title Date 2 ?-° Y
.d/rA f Approved by, Z-:
._ Title =cM'rC '7z- Date Approved by. IR , /A2
- Title I.c /?2, Date 72.'.3-of" sq6-O .TM1 . 04isi
XIIl3S PSC PROCEDURE SQ 6.0 GREASE CAP REMOVAL JULY 23, 2004 Page 2 of 6 REVISION 0
- 1. PTIRPOSE This procedure will establish the requirements for the removal of Grease Caps for purposes of evaluation and visual inspection during In-Service-Inspection (surveillance) of the Post-Tensioning System Tendons of Three Mile Island Unit 1.
- 2. R FSPONSTRBT JTY As stated in PSC Procedure QA 4.0.
- 3. QIJATLW CATTON As stated in PSC Procedure QA 4.1.
- 4. FQITTPMEN The gauges and test equipment necessary for the Quality-Control activities will be itemized in PSC
!i ; Procedure SQ 4.0.
- 5. QITAT.TTY CO(NTOT.
All Quality Control Documentation (QCD) points noted in this procedure are Hold Points. The work shall not progress past or through a QCD without a verbal release from the Inspector. The required information or evaluative data shall be documented on Data Sheet 6.0.
- 6. PRFCAATTONS 6.1. A tendon grease cap could weigh in excess of 100 pounds with grease. Be prepared to support this weight when the grease cap is unbolted and removed.
6.2. The sheathing fill, grease, may be in liquid, gel or solid form. Tendons in the area of steam or feed penetrations in operating plants, may'.contain hot grease and some caution should be exercised. It is not necessary to drain all the grease fromna tendon void and is to be avoided if possible. 6.3. CALJT1OI NEVER STRIKE THE :BUTTON HEADS, THE WIRES, OR THE ANCHORAGES OF A STRESSED TENDON WITH A HAMMER OR ANY OTHER METAL OBJECT. 6.4. Have sufficient quantities or sizes of containers on hand to catch the grease, as it may fall from the tendon void, anchorage or grease cap. sq6-O.TMI.04isi
At PSC PROCEDURE SQ 6.0 GREASE CAP REMOVAL JULY 23, 2004 Page 3 of 6 REVISION 0 6.5. IF AT ANY TIME A CRACKED OR BROKEN ANCHOR HEAD IS DETECTED AS A RESULT OF THESE INSPECTIONS, ALL WORK SHALL STOP. ALL PERSONNEL SHALL BE MOVED AWAY FROM THAT AREA. THE PSC CONSTRUCTION SUPERVISOR SHALL BE NOTIFIED. THE WORK AND/OR INSPECTION SHALL CONTINUE AFTER A SAFETY EVALUATION HAS BEEN MADE AND ONLY AT THE DIRECTION AND CONTROL OF THE PSC CONSTRUCTION SUPERVISOR AND THE RESPONSIBLE ENGINEER REPRESENTING THREE MILE ISLAND UNIT 1 DURING THE IN-SERVICE INSPECTION.
- 7. PRFREQIJISJJZES 7.1. QCD- Document the tendon identification, tendon end or buttress number on Data Sheet 6.0.
7.2. Provide support for the Grease Cap. Be prepared to catch any grease that may fall during loosening and removal. A 7.3. It may be advantageous to pack the outside of the grease cap with dry ice to further solidify the grease column. This will be at the option of the PSC Construction Superintendent. 7.3.1. Once the grease cap has been removed, the tendon end anchorage and shims -may be packed with dry ice to further solidify the grease column. This will be at the option of the PSC Construction Superintendent. 7.4. QCD- Document the use of dry ice to solidify the grease column on Data Sheet'6.0, for each occurrence.
-7.5. QCD- 'Document the temperature of the surface of the concrete near the tendon with a surface thermometer, within a 3 foot radius of the center of the grease cap or tendon void, on Data Sheet 6.0. The temperature shall be taken of the normal concrete. It shall not be necessary to take the temperature again, if dry ice is used. Also document the ambient air temperature.
7.6. Care shall be exercised to avoid splashing or spilling grease on concrete and other surfaces. Spilled grease shall be removed and cleaned using CRC Natural Degreaser Aerosol or EPA 2000 or equivalent as supplied by AmerGen Energy, by scrubbing with brushes and wiping the excess with rags. It may be advantageous to tape plastic sheeting around the bearing plate and concrete to lessen the effect of spilled grease. C.' . 8. RFMOVAT OF GRFASE CAP 8.1. At the option of the PSC Construction Superintendent, the grease inlet plug may be removed from the grease cap to allow any excess pressure to escape. Reinstall the plug after depressurization. It is advisable to perform this removal if the grease is in a liquid condition. sq6-O .TMI . 04isi
PSC PROCEDURE SQ 6.0 GREASE CAP REMOVAL JULY 23, 2004 Page 4 of 6 REVISION 0 8.1.1. In the event that the plug cannot be removed, loosen the top bolts of a horizontal or dome cap or one side of a vertical cap a few turns. Then loosen the bottom bolts on a horizontal or dome cap or the opposite side bolts on a vertical cap. The horizontal or dome cap shall then be broken loose from the top or the vertical cap broken loose from one side if not already loose. The purpose here is to relieve any pressure that might be present, which could cause the grease to exit in an unpredictable manner. 8.2. Remove all the grease can hold down bolts. 8.3. Carefully, remove the grease cap to prevent any foreign matter from dropping into the grease in that cap. 8.4. Be sure to maintain control of the gasket retainer and the gasket. The gasket will be scrapped, but the retainer will be reused. (- 8.5. Carefully, clean any sediment or dirt from the bottom of the grease cap flange. Do not brush this into the grease in the cap, if that grease is to be reused. 8.6. If the grease is still in an acceptable condition and fit for reuse, that cap shall be covered with a plastic bag or sheeting to prevent any dirt or water from entering the cap. 8.7.- QCD- Determine the amount of grease that may -have been lost during removal of the grease cap on Data Sheet 6.0. The Grease Loss from the tendon duct shall be' kept separate and posted as required of Section 10.3 of this procedure. 8.7.1. If the grease in the grease cap is to be scrapped, that quantity shall be documented on Data Sheet 6.0. The sheathing filler grease that is in the grease cap needs to be removed only if it appears to be degraded. It also needs to be removed if the color of the sheathing filler grease in the grease cap and the color of the new, unused grease is not a reasonable match, free water is mi'xed in the grease or free water was collected from the grease cap. 8.7.2. If the grease is to be reused, this fact shall be documented on Data Sheet 6.0. Also document the covering of the cap. 8.8. QCD- Observe the coating of grease on the inside of the grease cap, on the bearing plate, shims, anchorage and button heads. Note the completeness of the grease coverage on each item and document that evaluation accordingly on Data Sheet 6.0. 8.8.1. Where the coverage is complete, check as Complete coverage.
.- r,-n 'PMT nAi.,4
PSC PROCEDURE SQ 6.0 GREASE CAP REMOVAL JULY 23, 2004 Page 5 of 6 REVISION 0 8.8.2. Where the coverage is incomplete and bare metal is visible, check as Partial coverage and estimate the Percentage of Uncoated metal for each item. 8.8.2.1.Uncoated metal is defined as that area that is dry and without any coating of grease. Some care should be used in judging uncoated metal, as the thickness of the coating has no bearing on acceptability. Very thin coatings will be slightly tacky and will readily hold fingerprints. 8.9. QCD- Any other unusual conditions shall be documented on Data Sheet 6.0, such as: water or other liquid present or draining during grease cap removal and document the quantity; quantities of dirt or other foreign matter in or around the tendon end or grease cap, etc. 8.10. QCD- The color of the grease on or around the tendon shall be compared to a sample of new unused grease for color or other variations from the new sample. While color is not a factor requiring acceptance, significant variations in color could be a sign of degradation of the protection medium. 8.10.1. If the colors of the samples are reasonably close to each other, check the Match area on Data Sheet 6.0 and identify the color. 8.10.2. If the colors vary greatly, check the No Match area and identify the color and variation, i.e., medium brown, darker than new sample.
- 9. ANCH4OR AGF CTL.ANIhP Where the tendon is to be monitored for retention of forces or detensioned, or visually inspected, it will be necessary to perform a cleanup of the tendon end anchorage assembly to permit inspection.
9.1. Any grease removal shall be performed in such a manner to prevent damage, such as scratches, on the anchorage or tendon wires. The removal process shall not add any contaminants to the remaining grease or that grease which could be taken for chemical analysis. 9.2. If a large quantity of grease is to be removed, it shall be necessary to provide a clean container to hold the grease until the inspections are completed. It may be necessary to take the samples for chemical analysis from this material, so cleanliness shall be maintained. 9.2.1. It is suggested that a plastic bag or sheeting be used to line the temporary storage container. This way the material remains clean and reusable or may be easily scrapped. 9.3. Excess grease shall be removed from the tendon anchorage using clean non-metallic devices. Use bristle brushes of medium stiffness with suitable quantities of solvent to dilute and wash away the grease. This cleanup must be sufficient to provide satisfactory condition for thread inspection. sq6-O .TMI . 04isi
. : atr- m_'. _ . . _ . .. ....:;. - ..;..:." _-
- PSC PROCEDURE SQ 6.0 GREASE CAP REMOVAL JULY 23,2004
, Page 6 of 6 REVISION 0 9.4. Continue the cleanup of the remaining portions of the tendon end, to include the shims, button heads, anchorage and bearing plate as necessary.
9.5. CRC Natural Degreaser Aerosol or EPA 2000 or equivalent as supplied by AmerGen Energy shall be used to complete whatever cleanup may be necessary to perform subsequent activities. 9.6. QCD- Document the quantity of grease removed from the anchorage on Data Sheet 6.0.
- 10. TENDDN PROTECTIQN Any tendon end and anchorage exposed to the weather shall be protected by covering with a plastic bag or sheeting whenever the tendon is not being worked on. Smear or brush a light coating of grease onto the wires, button heads and anchorage prior to covering.
10.1. It will be acceptable to replace the grease caps as a temporary measure, using the old gaskets, until that tendon can be completed. L; b. ,- ,: ii .V.._.. 10.2. QCD- Document the method of tendon protection on Data Sheet 6.0. 10.3. QCD- Document only the Grease Losses that are detected from the tendon duct. These losses shall be kept separate from the losses that occur from the tendon end anchorage assembly and the grease cap.
- 11. nCTUTMFNTATTON The items requiring documentation in this procedure shall be documented on Data Sheet 6.0 included with this procedure.
11.1. The Data Sheet references the applicable Section number of the procedure for each QCD point. 11.2. Some information from Data Sheet 6.0 will require posting to Data Sheet 12.1 of PSC Procedure SQ 12;1. 11.3. Some information from PSC Procedure SQ 7.0 will require posting to Data Sheet 6.0 of this Procedure.
- 12. ATTACHMENTS 12.1. Data Sheet 6.0.
sq6-O.TMI. 04isi
SC PROCEDURE SQ 6.0 GREASE CAP REMOVAL DATA SHEET 6.0 L (re JULY. 23, 2004 PAGE 1 OF 1 REVISION 0 PROJECT: THREE MILE ISLAND UNIT 1 TENDON NO.: TENDON END/BUTTRESS NO.: SURVEILLANCE YEAR: 30TH Q.C. FILLER DATA Date Removal Started Sirnoff (7.4) Dry Ice Used on Grease Cap , Dry Ice Used Around Anchorage _ (7.5) Temp. of Concrete F. Thermometer No._ Recalib. Date Ambient Temp. F. Thermometer-No., Recalib. Date (8.7) Amount of Grease Lost Gal. (8.7.1) Amount of Grease in Cap : Gal. (8.7.2) Grease to be Reused YES NO (8.7.2) Grease in Cap Protected' (8.8) GREASE COATING Grease Cap - Complete Partial Uncoated % Buttonheads - Complete Partial ' Uncoated -_%_ ' Anchorage - Complete ' Partial Uncoated % Shims - Complete Partial - Uncoated % Bearing Plate - Complete - Partial Uncoated % (8.9) Unusual Conditions: - (8.10.1) Grease Color: Match Color Comment (8.10.2) No Match Color Comment (9.6) Amount of Grease Removed Gal. - Will this be scrapped? YES NO SO 7.0 SAMPLES (6.1) Grease Samples Taken Quarts. (6.1) Samples Identified (6.1) Location of Sample Removal - -
; FILLER DATA (Continue SO 6.0)
(10.2) Method of Tendon Protection (10.3) Amount of Grease Lost Gal. - Will this be scrapped? YES NO (11.2) Add quantities of lost grease as each applies; Post total on Data Sheet 12.1 (8.7) + (8.7.1) + (9.6) + SQ 7.0 (6.1) + (10.3) = TOTAL GREASE LOSS Gal. Post-to DS 12.1 QC Review Level Date
,I4r-_n TMT nlAi4
PSC PROCEDURE SQ 6.1 f\3@/f3l INSPECT FOR WATER JULY 23, 2004 Page 1 of 6
"., REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1(8 TH INSPECTION PERIOD) (30 T YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE INSPECTION FOR WATER IN THE TENDON VOID, IN THE GREASE CAP AND AROUND THE TENDON ANCHORAGE Prepared by Title JAtGe qt.A Date '2-y-~o Approved by /m., / C A Title dc- Aj, k -Date 7-tLoV7 Approved by - A.0 Zd"+ - Title, , /e _Date 7- Z 3 -y _QIi sq6-1 .TMI . 04isi
PSC PROCEDURE SQ 6.1 INSPECT FOR WATER JULY 23, 2004 Page 2 of 6 REVISION 0
- 1. PURPEOS This procedure will establish the requirements for performing an inspection of the Post-Tensioning Tendon System for evidence of water during the scheduled In-Service Inspection of the Tendon System of Three Mile Island Unit 1.
- 2. S.COPE This procedure will be limited to performing and documenting the inspection for water from the tendon void or around the tendon anchorage assembly, including the grease cap. This inspection shall be performed just prior to removal of the grease cap and during the physical inspection of the tendon anchorage assembly.
- 3. RFSPONSIBTRITY As stated in PSC Procedure QA 4.0.
- 4. QITAT AIFCATTONS As stated in PSC Procedure QA 4.1.
5.' EQIM21 nMEDT 5.1. CONSTRUICTION No special equipment is required. It is expected that this inspection take-place as part of the procedure-for the removal of grease cap. 5.2. QT ATATTY CONTROL F.QTTPMFNT 5.2.1. Suitable quantities of clean, unused non-metallic containers for obtaining water samples. 5.2.2. Clean unused rags or wipers. 5.2.3. Indelible permanent marking devices and/or labels for the sample containers. 5.2.4. Flashlights and batteries. 5.2.5. Pens; Markers; Data Sheets; Tendon Inspection List. sq6-1. TMI . 4isi
PSC PROCEDURE SQ 6.1 INSPECT FOR WATER JULY 23, 2004 Page 3 of 6 7.- REVISION 0
- 6. PRECATITTIONSZ Review the Safety Comments provided in the Surveillance Program Quality Control Manual for the following items that shall apply both for tendon force control and personnel safety.
6.1. Section 3.1: Tendon Wire Breaking Strength 6.2. Section 3.2.2: Personnel Safety 6.3. Section 3.5: Construction Safety: Personnel Safety 6.4. A tendon grease cap weighs in excess of 100 pounds with grease. Be prepared to support this weight when the grease cap is unbolted and removed. 6.5. The sheathing filler, grease, may be in liquid, gel or solid form. Tendons in the area of steam or feed penetrations in operating plants, may contain hot grease and some caution should be exercised. It is not necessary to drain all the grease from a tendon void and is to be avoided, if possible (unless it is a tendon scheduled to have grease drained or blown out). 6.6. CAUfTION - NEVER STRIKE THE BUTTON HEADS, THE WIRES, OR THE ANCHORAGES OF A STRESSED TENDON WITH A HAMMER OR ANY OTHER METAL OBJECT. 6.7. Have sufficient quantities or sizes of containers on hand to catch the grease, as it may fall from the tendon void, anchorage or grease cap. 6.8. IF AT ANY TIME A CRACKED OR BROKEN ANCHOR HEAD IS DETECTED AS A RESULT OF THESE INSPECTIONS, ALL WORK SHALL STOP. ALL PERSONNEL SHALL BE MOVED AWAY FROM THAT AREA. THE PSC CONSTRUCTION SUPERVISOR SHALL BE NOTIFIED. THE WORK AND/OR INSPECTIONS SHALL CONTINUE AFTER A SAFETY EVALUATION HAS BEEN MADE AND-ONLY AT THE DIRECTION AND CONTROL OF THE PSC CONSTRUCTION SUPERVISOR AND THE RESPONSIBLE ENGINEER REPRESENTING THREE MILE ISLAND UNIT 1 DURING THE IN-SERVICE INSPECTION.
- 7. ( TATLTYT ONTRO)T.
There are no hold points for this operation. Quality Control Inspectors shall perform the inspections that are described in this procedure and document those results on Data Sheet 6. 1. 7.1. The Quality Control Inspector shall be responsible for properly identifying any water samples that may have been collected. The Inspector shall also be responsible for controlling those samples until they are sent out for testing. sq6-1 .TMI . 04isi
PSC PROCEDURE SQ 6.1 INSPECT FOR WATER JULY 23, 2004 Page 4 of 6 REVISION 0
- 8. PREREQUIISITES
- 8.1. QCD- Document the tendon identification, tendon end, buttress number, unit number and other information on Data Sheet 6.1. - 8.2. Provide support for the Grease Cap. Be prepared to catch any grease that may fall during loosening and removal - 8.3. Care shall be exercised to avoid splashing or spilling grease on concrete and other surfaces. Spilled grease shall be removed and cleaned using Viscosity Oil, Viscor #16A industrial solvent or equivalent. It may be advantageous to tape plastic sheeting around the bearing plate and concrete to lessen the effect of spilled grease. 8.4. This inspection will be performed as a prelude to the removal of the grease cap. It is expected that all the tools and preparation for the removal of the grease cap will be in place or have been performed. As the main purpose of this procedure is to detect the presence of water in the tendon _ _void, the Inspector shall be afforded access to the tendon during loosening of the grease cap bolts to see if water is in evidence.
- 9. (3RFARF. CAP REMOVAT.
If upon removal of the grease cap, it is determined that the anchor head is broken, all work shall stop on that tendon and all personnel shall leave the area of the tendon. The PSC Construction Supervisor and the
.Responsible Engineer of the Owner/Agent shall determine the seriousness of this event and evaluate the feasibility and safeness of continuing operations on that tendon.
9.1. Position platform, as required, at the end of the tendon to be inspected. (As part of Grease Cap Removal Procedure, SQ 6.0) 9.2. Place a container and/or a protective cover under the tendon grease cap to protect adjacent areas from dripping grease. (As part of Grease Cap Removal Procedure SQ 6.0) 9.3. Have a clean dry plastic container available for catching water samples. 9.4. As the main purpose of this procedure is to determine the presence of water in the grease cap or around the anchor head, the Inspector shall be alert to obtain samples of that water as the cap is loosened and removed and to estimate the quantity detected. 9.4.1. QCD- Document the quantity of water detected and if a sample was collected. sq6-1.TMI.04isi
PSC PROCEDURE SQ 6.1 f I 1-%. u
'< INSPECT FOR WATER JULY 23, 2004 Page 5 of 6 REVISION 0 L 9.5. Remove the bolts securing the grease cap (the pipe plug may be removed first from the grease cap for vertical tendons). The grease cap must be fully supported as the bolts are being removed. Care should be taken when removing the end cap since the bulk filler may drop off or drip as a liquid of medium viscosity. Allow the Inspector the opportunity to obtain water samples, if any water is present. (As part of Grease Cap Removal Procedure SQ 6.0) 9.6. CATJT1OIN - BE PREPARED TO SUPPORT THE GREASE CAP. IT MAY WEIGH UP TO 100 POUNDS.
9.7. Carefully remove the grease cap to avoid spilling the contents. The Inspector shall inspect the interior of the cap for the presence of water and if possible collect a sample of that water. 9.7.1. QCD- Document the quantity of water detected and if a sample was collected. L 9.8. Inspect the tendon anchorage assembly, shims, bearing plate, anchor head and button heads for the presence of water. 9.8.1. QCD- Document the quantity of water detected and if a sample was collected. 9.9. Work:shall continue for the In-Service Inspection as regularly scheduled or as required by the Procedures in the Surveillance Program Quality Control Manual. 9.10. The next point that water could be encountered would be during or just after Detensioning the Tendon. Therefore, the Inspector shall be especially vigilant during this portion of the In-Service Inspection to detect the presence of water. Inspect -for the presence of water during or after Detensioning the Tendon. 9.10.1. QCD- Document the quantity of water detected and if a sample was collected.
- 10. DISTiWGITFSITING. CA'RA ACT-PRTRTTCS The quantity of water observed in or on the tendon during the -In-Service Inspection is important from the standpoint of the Corrective Action which could be required by the Owner/Agent. The quantity could vary from condensation, wetness without running off, to that condition where water pours out from the tendon L void. The following terms will be used to describe the condition of moisture that will be reported to the Owner/Agent.
10.1. ORSEIRVART.R MOTSTTTRF. C; "Observable Moisture" is defined as that quantity of water which has been immediately observed by the Inspector to be concentrated, collected or draining out from the grease cap or tendon anchorage assembly. While this is intended to describe that moisture condition associated with condensation, it could be present in quantities of less than 8 ounces. sq6-1 .TM1. 04isi
PSC PROCEDURE SQ 6.1
-1
-N INSPECT FOR WATER JULY 23, 2004 Page 6 of 6 REVISION 0 10.2. STIlNMFIC ANT MOTITI TRE "Significant Moisture" is defined to be a quantity of water 1/2 pint (8 ounces) or more which has collected, concentrated or observed to be draining out of the tendon anchorage assembly or grease cap. This quantity is considered to be from a condition other than water formed through condensation.
- 11. NOTTFTCATTON The Owner/Agent shall be formally notified when water, regardless of quantity, has been detected during the In-Service Inspection. This Notification shall define the condition detected referencing Section 10 of this Procedure and the specific quantity detected.
11.1. The Owner/Agent shall be responsible for any corrective action and/or Notification to Regulatory Agencies should that be required. 11.2. The work and inspection shall continue until completed or formal notification by the Owner/Agent halt the work at some agreed on point.
- 12. SAMLE.. REIM. ONLESTING-i The samples shall be temporarily retained by the PSC Quality Control Inspector until such time that they are sent out for pH testing per PSC Procedure SQ 6.2..
12.1. QCD- Verify that the water samples are adequately identified. 12.2. QCD- Document the location of storage for the samples.
- 13. DOCLIIIENTATTON The items in this procedure requiring documentation shall be documented on Data Sheet 6.1.
13.1. The Data Sheet references the applicable section number of the procedure for each QCD Point.
- 14. ATTACHMJ.NIS 14.1. Data Sheet 6.1.
sq6-1 .TMI . 04isi
,(: i
-r-0- I PSC PROCEDURE SQ 6.1 INSPECT FOR WATER (7> DATA SHEET 6.1 JULY 23, 2004 PAGE 1 OF 1 REVISION 0 PROJECT: TMI UNIT 1 DATE:
TENDON NO.: TENDON END/BUTTRESS NO.: SURVEILLANCE YEAR: 30TH (9.4) DURING LOOSENING OF GREASE CAN (9.4.1) Water Detected Yes No Quantity Sample Taken Yes NO Comments (9.7) IN GREASE CAN (9.7.1) Water Detected Yes No Quantity Sample Taken Yes NO Comments (9.8) AROUND TENDON ANCHORAGE (9.8.1) Water Detected Yes No Quantity Sample Taken Yes NO Comments (9.10)DURING DETENSIONING (9.10.1) Water Detected Yes No Quantity Sample Taken Yes NO Comments (11.) OWNER/AGENT NOTIFIED Yes No Date - CONDITION: OBSERVABLE SIGNIFICANT (12.1)SAMPLES ADEQUATELY IDENTIFIED Yes NO (12.2)SAMPLES STORED AT QC Signoff Level Date _ IIj QC Review Level Date ds6-1.TM'.04isi
PSC PROCEDURE SQ 6.2
'ATER SAMPLE ANALYSIS JULY 23, 2004 9' - Page 1 of 3 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8 TH INSPECTION PERIOD) (30TH YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE WATER SAMPLE ANALYSIS Prepared by A:#/4, Title EG6* ;,,4 Date 972--Y Approved b y,_ / ce 4 -J Title 1c5o- 4rZizr Date2g7Ž
/
Approved b yAP wyI Title G. nr/V, Date 7 cq C.0:.1, sq6-2 . TMI . 04isi
,(j1AC/f-2A PSC PROCEDURE SQ 6.2
( WATER SAMPLE ANALYSIS JULY 23, 2004 Page 2 of 3 ( !REVISION 0
- 1. PPTTRPOSE This procedure will establish the requirements for laboratory pH analysis of Water samples taken during the 30TH Year In-Service-Inspections (surveillance) of the Post-Tensioning System Tendons of Three Mile Island Unit 1.
- 2. RESPONSIIITY 2.1. The laboratory that performs the testing/analysis shall be responsible for controlling the samples, performing the analysis, documenting the analysis on Laboratory.letterhead stationery and submitting the reports to:
PRECISION SURVEILLANCE CORPORATION 3468 Watling Street East Chicago, IN 46312 Attention: Quality Assurance 2.1.1. The Laboratory shall further be responsible to utilize trained personnel for the analysis and maintain the calibrated status, traceable to the NIST, as applicable, for all test or measuring devices that may be used in providing test results. 2.1.2. The Laboratory shall provide open access for inspection, survey or audit, as the need might arise, to PSC or its customers. 2.2. The PSC Quality Assurance Section shall be responsible for the qualification of Laboratory sources. 2.3. Where specified in the Contract Documents, -the Owner or his Agent shall have the right of approval for Laboratory sources. 2.4. The PSC Quality Control and/or Engineering Department shall review the reports for accuracy and content. 2.4.1. This report shall be submitted to the Owner or his Agent with the final Surveillance Report.
- 3. .SAMPLTES The Water Samples shall be sent to the Laboratory by any convenient mode of transportation. The samples have been marked to show the unit number, the tendon number and the tendon end or buttress identification. The sample shall be securely closed to prevent leakage and packaged to prevent damage.
3.1. The samples shall maintain a form of identification throughout testing, that shall provide traceability to the original sample identification. sq6-2.TMr .04isi
PSC PROCEDURE SQ 6.2
' WATER SAMPLE ANALYSIS JULY 23, 2004 Page 3 of 3 REVISION 0 3.2. The Laboratory shall notify PSC if it appears that the sample container has been, damaged, tampered with; or any other occurrence that could contaminate the water sample.
- 4. TEST TFqRS TPTTQNS Each sample of Water shall be analyzed for:
4.1. pH
- 5. TEST MFST()1 Each sample of Water shall be tested by the below cited test method.
5.1. pH by ASTM D-1293 or EPA 150.1 or equivalent.
- 6. RFPORI Two copies of each report for the analysis of water shall be submitted to PSC.
6.1. Each report shall bear the date of testing and sample identification as it appears on each sample container. 6.2. Each report shall be signed by the Laboratory Manager, who shall ultimately be responsible for the content.
- 7. SAMPTUF TTSPOS AT.
The remaining water samples may be scrapped 30 days after the issue of the report, unless the Laboratory is requested in writing to hold the samples for a longer period of time. sq6-2 .TMI . 4isi
+v4Aa l[</9j. PSC PROCEDURE SQ 7.0 ACQUIRE GREASE SAMPLES JULY 23, 2004 Page 1 of3 (7. REVISION 0 REVISION 1, 8/25/04 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (30TH YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE GREASE SAMPLES - ACQUIRE AND EVALUATE A Prepared by , v .. . .. Title A(GAQ. o.. Date 9-2.5'-aL( AApprovedby xd,/ c v - Title 6A cs A 0 apoc
$ Date P-tr-cy Ij A Approved by Title -, m Date _-__5_ -_
Q-lsq7-0.TMI.04isi
-ft\1AO/ m\ ~ PSC PROCEDURE SQ 7.0 ACQUIRE GREASE SAMPLES JULY 23, 2004 Page 2 of 3
' REVISION 0 REVISION 1, 8/25/04 I. PUJRPOSE This procedure will establish the requirements for the taking of Grease Samples for purposes of laboratory Chemical and Physical analysis during In-Service Inspections of Post Tensioning System Tendons of Three Mile Island Unit 1.
- 2. RF.SPONSTRILTTy As stated in PSC Procedure QA 4.0. This procedure only requires Quality Control actions.
- 3. QTTATTFTCATIONS As stated in PSC Procedure QA 4.1, only for Quality Control Personnel.
- 4. PRFRE.QTSTTP, 4.1. Two, one quart, unused paint cans, with lids, will be required for each tendon end.
4.2. The preliminary actions of PSC Procedure SQ 6.0 shall be completed.
- 5. QTTAT.TYCC ROT.
The Quality Control Documentation (QCD) point in this procedure is a Quality Control Hold Point. Work shall not progress beyond this point without a verbal release from the Inspector. The required information or evaluative data shall be documented on Data Sheet 6.0 of PSC Procedure SQ 6.0.
- 6. SAMPT.F RPMOVAT.
6.1. QCD- Two, one quart samples of grease shall be taken from each end of the tendon. Each sample can shall be identified by unit number, tendon number, tendon end, sample number and date. It is preferred that the grease be taken from the area of the anchorage, but may also be taken from the grease cap or tendon void. Document the amount of samples taken and the location of removal on Data Sheet 6.0 of PSC Procedure SQ 6.0. 6.1.1. Sample #1 shall be sent to the testing laboratory for analysis in accordance with PSC Procedure SQ 7.2. Sample #2 may be turned over to the Owner/Agent to be held in reserve in the event of loss, retesting or for verification of the results of the original testing. It is unlikely that a suitable quantity of Sample #1 shall remain after the original tests to perform supplemental tests, therefore any remainder of Sample #1 will be scrapped.
,j 6/x.J4L c enO wJ/r 1sq7-0.TMI.04isi
PSC PROCEDURE SQ 7.0
-o, fs& ACQUIRE GREASE SAMPLES JULY 23, 2004 Page 3 of 3
!' REVISION 0 REVISION 1, 8/25/04 L4\7. DELETED A7.1. DELETED A7.2. DELETED A18. DELETED DELETED DELETED M--", itil". f ,-q. kJ i A /U/ao yf L Ei lu a lsq7-O .TMI . 04isi
fLo fr"1-tl PSC PROCEDURE SQ 7.1 THREAD MEASURING JULY 23, 2004 r7 Page 1 of 5 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (30T YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE THREAD MEASURING _D OF POST-TENSIONING ANCHORAGES Prepared by_ ;?/. 4 Title A16-O. 4 Date 9.?-3-o'Y Approved by /Z/ C, Title 14v1-c;17 ,-K .4 Date 7-t7oy Approved by. A. )) /t Title G, in. Date 74-Z3iO/t( (9J sq7-1 .TMI . 04isi
PSC PROCEDURE SQ 7.1 r 3 TTHREAD MEASUJRING JULY 23, 2004 Page 2 of 5 REVISION 0
- 1. PTIERD-SE This procedure will be used as the means of measuring anchorage thread diameters to assure that the external threads of a tendon anchorage meet a minimum strength requirement of 120% of the minimum Guaranteed Ultimate Tensile Strength (GUTS) of a tendon, when coupled with a specific Stressing Adaptor.
- 2. S.COIIPE This procedure shall address only those anchorages that have a 4 pitch stub ACME Thread (Class 2G). The anchorage material shall be a Grade 4140 steel, heat treated to a Brinell Hardness of 355 to 401.
Furthermore, this procedure shall be limited to those anchorages of tendons to be monitored or detensioned for retensioning. 2.1. If the anchorage material is not of the type mentioned above, then the thread strength prediction equations shall be adjusted accordingly by the PSC Engineering Department.
- 3. RFSqPQN`.JTr.TTY A PSC Quality Control Inspector shall be responsible for taking thread measurements. The PSC Manager of Engineering, or his designee, shall be responsible for generating tables listing allowable external thread diameters for a specific Stressing Adaptor.
- 4. T)cLOT TWENTATTQN All measurements shall be recorded, signed -and dated by the Inspector on the form provided with this procedure. The only Hold Point in this procedure is the acceptability of the measurements and acceptable match up with a stressing adaptor.
4.1. QCD- All measurements, gauge identification and calibration status shall be documented on Data Sheet 7.1 as required.
- 5. MWASTITNG TN.QTRT MPNTS The following instruments shall be necessary for thread measurements.
5.1. Standard Outside Measuring Micrometer capable of reading to 0.001" or better. 5.2. Standard Inside Measuring Micrometer capable of reading to 0.001 or better. 5.3. Special Pitch Diameter Go and No-Go Thread Plug Gauges. 5.4. A set of three hardened standard stub ACME thread wires (diameter 0.129" to 0.162"). 5.5. Shims, used in the three-wire method of measurement. sq7-1.TMI.04isi
Lh 'I lPSC PROCEDURE SQ 7.1 ttA {^1! THREAD MEASUJRING x T DMJLY 2 3 , 2004 L (~~ i Page 3 of 5 6 RREVISION 0
- 6. MF A.'ST RTNC-' TTTR F AT) TTAME.TFR S Two readings in perpendicular directions shall be taken for each thread measured. A centering head and
! rule should be used to assure that the readings are perpendicular to each other. Crayon or soapstone can be used to mark locations, but care should be taken so as not to place the marks exactly where readings are taken, which would interfere with the accuracy of the measurements. i_ 6.1. PXTERNAT.MAT(ORD)TAMETFR.S External Major Diameters shall be measured for the 3rd, 6th and 9th threads. Measurements shall be made with an Outside Micrometer as shown in Figure 1 of Appendix 1. 6.1.1. The Major Diameter is given' directly by the micrometer reading. 6.2. EXTERNAT. PJT4TT TTAMFTFRR.P External Pitch Diameters shall be measured for the 3rd and 9th threads. Measurements shall be made with an Outside Micrometer and three stub ACME thread wires of equal diameters as shown in Figure 2 of L Appendix 1.Standard stub ACME thread wires of diameters ranging from 0.129" to 0.162" shall be used. Wire diameters shall be selected such that: (1) the wire rests on the tapered sides of the thread, not on the root flat, and (2) the wire protrudes beyond the crest of the thread as shown in Figure 2 of Appendix 1. 6.2.1. The Pitch Diameter Constant dimension shall be determined from Appendix 2 for the wire diameter used. The shim thickness shall be added to the constant and the total subtracted from the micrometer reading to give the pitch diameter. 6.3. FXTER.NAT. MNOR I)TAMPTPR.S External Minor Diameters shall be measured for the 3rd and 9th threads. Measurements shall be made with an Outside Micrometer and three wires of equal diameters as shown in Figure 3 of Appendix 1. Wire diameter shall be selected such that: (1) the wire rests on the root flat, not on the tapered sides of the thread, and (2) the wire protrudes beyond the crest of the thread as shown in Figure 3 of Appendix 1. 6.3.1. The sum of twice the selected wire diameter and shim thickness, shall be subtracted from the micrometer reading to give the minor diameter. 6.4. NTPRNAT.MAJTOR DTAMETFRS Internal Major Diameters shall be measured for the 3rd and 9th threads. Measurements shall be made with an Inside Micrometer with needle points as shown in Figure 4 of Appendix 1. Precautions shall be taken to reduce the angularity of the micrometer to a minimum, as shown. The angular reading overestimates the diameter by 0.00013" or less. This small discrepancy shall be ignored. 6.4.1. The Major Diameter is given directly by the micrometer reading. sq7-1.TMI.04isi
PSC PROCEDURE SQ 7.1 THREAD MEASURING JULY 23, 2004
~' Page 4 of 5 REVISION 0 6.5. INTERNAT. PITCH DIAMFTFR S Internal Pitch Diameters shall not be measured. However, a check shall be made using Go and No-Go Plug Gauges to ensure that pitch diameters fall within specified limits. If the Go gauge does not go, or the No-Go gauges goes, that fact shall be recorded.
6.6. TNTERNATLMTINOR DIAMETERS Internal Minor Diameters shall be measured for the 3rd, 6th and 9th threads. Measurements shall be made with an Inside Micrometer as shown in Figure 5 of Appendix 1. 6.6.1. The Minor Diameter is given directly by the micrometer reading.
- 7. ANCn-TOR ACTF T)TSPOSTTTON 7.1. STRESSNGT ADAPTOR (INTPRNATTI-RFAADSR)
The Stressing Adaptor shall have been accepted by PSC based on acceptance of the NO-GO thread plug gauge test fit. Actual major and minor thread diameters shall be documented. 7.2. ARTISTIST FITFT ANCTIORTHFA) (EXT1ERNATf.TRFAD ) For purposes of expediency the bushing or'field anchor head external threads shall be identified as external threads in this section of the procedure since the measurements and requirements are identical, but shall be documented for specific identity. 7.2.1. Once an adaptor-has been measured,.the'PSC Engineering Department shall generate.a Stressing Adaptor'Disposition Table for that Adaptor. These tables list allowable external thread diameters for a bushing or field anchor head to be coupled-to a specific adaptor and still meet the minimum strength requirements. 7.2.1.1.These tables are based on calculations that consider that it shall be necessary to maintain fill engagement with the ndaptnr and external thread (flashing or field anchor head) at all times during
;tressing or detensioning oerations 7.2.2. Select a stressing adaptor and external thread to be dispositioned.
7.2.3. Select the Stressing Adaptor Disposition Table, Appendix 4, for the adaptor to be evaluated. The Adaptor Identification will appear near the top of the table. 7.2.4. Using the major diameter of the external thread and referring to the columns under the heading Major Ranges, within the first two lines representing the range of major dimensions, locate that range into which the major dimension of the external thread will fall. This shall establish the Major control vertical column for that external thread. sq7-1 .TMI .04isi
LAC) , PSC PROCEDURE SQ 7.1 THREAD MEASURING JULY 23, 2004 Page 5 of 5 REVISION 0 7.2.5. With the pitch diameter of the external thread and using the Pitch Range column at the left edge of the table, read down to that range of dimensions into which the pitch diameter measurement of the external thread will fall. This shall establish the Pitch control horizontal line for that external thread. 7.2.6. The intersection of the Pitch control horizontal line with the Major control vertical column shall provide the Minor diameter control dimension. 7.2.6.1. If the Minor diameter control is less than the measured minor dimension of the external thread, then that combination of external thread and stressing adaptor is acceptable. 7.2.6.2.If the Minor diameter control dimension is greater than the measured minor dimension of the external thread, that combination is not acceptable and another stressing adaptor shall be selected to be mated to the external thread. Therefore, Section 7.2.6 shall be repeated until acceptable matches are provided.
- 8. DOC.UM.ENIATTON The items requiring documentation in this Procedure shall be documented on Data Sheet 7.1 as each might apply.
- 9. ATTAGRMENTIS 9.1. Data Sheet 7.1 9.2. Appendix 1 - Figures for Thread Diameter Measurements (These figures are used to illustrate the manner of measuring thread diameters.)
9.3. Appendix 2 - Pitch Diameter Constant For 3 Wire Method (This table lists the pitch diameter constant dimensions necessary for calculating an external pitch diameter.) 9.4. Appendix 3 - NBS (NIST) Allowable Diameter Ranges (This is a computer generated table of allowable external and internal diameter ranges for 4 pitch stub ACME threads (Class 2G) as specified by Federal Standard Publication FED-STD-H28/13.) 9.5. Appendix 4 - Stressing Adaptor Disposition Tables (These tables shall be used for dispositioning a bushing or field anchorhead paired with a specific Stressing Adaptor. One table shall be computer generated for each Adaptor. Since these tables cannot be generated until the Adaptors are measured, it is possible these tables will be added to this procedure at a later date than initial submittal of this procedure. However, these tables shall be supplied as soon as possible.) sq7-1.TMI .04isi
I o ft/2' - Precision ANCHORAGE -THREAD MEASUREMENT - PROCEDURE SQ 7.1 Surveillance Corporation
--. DATA SHEET 7.1 - INSPECTION DOCUMENTATION _ _
1 PROJECT SURVEILLANCE NO. YEAR TENDON INO. TENDON END/BUTTRESS NO. - UNIT ANCHORAGE I.D. ADAPTOR I.D. - 1. MEASUREMENTS THREAD I WIRE IWIRE SHIM AVG THREAD READ 3RD 6THI 9TH AVG. CONST. lDIAM. SIZE DIAM. EXT. .- I___ MAJOR 2 __l_- _ PITCH 2 G #C2E MINOR 2 -. INT. 1. _____ _ MAJOR 2 _ _ _ _ _ _ INT. 1I_ _ _ _ _ _ _ _ MINOR 2 _ _ _ _ _ _ _ _ _ INT. GO GAUGE #~_____ RECAL DATE _____RESULT,.'
.PITCH NO-GO GAUGE 1#______ RECAL DATE ______RESULT____
NOTES: 1. EXT. PITCH DIAH. = AVG. - WIRE CONSTANT - SHIM SIZE
- 2. EXT. MINOR DIAM. = AVG. - (2 x WIRE DIAM.) - SHIM SIZE
- 3. DISPOSITION I TRIAL 1 I TRIAL 2 I TRIAL 3 I TRIAL 4 1 ADAPTOR MARK .1 I I I II I MIN. MINOR DIAM. FROM ADAPTOR TABLE- -
ACCEPTABLE? (YES, NO) Q.C. Signoff Date Q.C. Review Level Date I I.`-, Title Effective us Revision'A :Pag - D~te - y 3 -.0 On: zFr y Suv ill-a3n e l 1 of 1 FormerlY "Inryco Surveillance":
$+/-/f 5< 1 : _
I Precision APPENDIX 1 - PROCEDURE SQ 7.1 _ f rI- In-51 -t - Ou3 Vl L-iCAMV Corporation MICROMETER - STUB
. SHIM ACME WIRE FIG. 1_- EXTERNAL
_- _ MAJOR
- DIAMETER FIG. 2 EXTERNAL PITCH DIAMETER (NOTE WIRES REST ON SIDE OF THREAD AND PROTRUDE BEYOND CREST)
FIG. 3- EXTERNAL MINOR DIAMETER (NOTE.WIRES REST ON ROOT AND PROTRUDE BEYOND CREST) FIG. INTERNAL MAJOR DIAMETER (NOTE DIAMETER MEASURED WITH MINIMUM
\ ANGULARITY)
FIG. 5 INTERNAL MINOR DIAMETER Formerly "Inryco Surveillance"
j I 'I Precision j APPENDIX 2 - PROCEDURE SQ 7.1 . I Surveillance I, .. PITCH DIAMETER CONSTANT FOR 3 WIRE METHOD Corpolation I I From Fed Standard H28/13 C = w(1 + cosec a) - (cot a) 21n gives CON = 4.993929(M -0.483392 i i II F=P -IFT C:J -1 D lCIr: i- Q I w r--.- FcJ0FrIt 3; ItnJ 111EIE if-I Hf 0 Ep I j I I i WI RE WI RE 1,1 I r:E WIRE WI RE SIZE CO N- SIZE CON . SIZE CON. SIZE CON. SIZE CON. I i II . 1465 . 2 48 I 0 Cy . 2,-'
"6 .1535 . 283 .1570 .301- .1605 .311 i . 14 i66. .249 . 1 so01 .266 .1536 ..28.4 .1571 .301 .1606 .319
. 1467 .2 49 .1502r .267 .1537 .284 .1572 .302 .1607 .319
.1468 .250 15S03 . 267 .1538 .285 .1573 .302 .1608 .320
. I1169 . 25() . 1 504 .268 .1539 * .285 .1574 .303. .1609 320
. 14*70 . 251 . 1505 , 268 . 1540 .286 .1575 .303 .1610 .321
. 1471 .251 . 1506 .26c 1541 .286 .1576 .301 .1611 .321
. 147 2 .252 .1 S07 . 269 .1542 .287 .1577 .304 .1612 .322
. 1.473 252 .1508 .270 .1543. .287 .1578 .305 .1613 .322
.1474. .253 .1509 .270 .15e4 .288 .1579 .305 .1614 .323
! 1475 .253 *.1510 .271 . 545 .288 .1580 .306 .1615 .-323
, 1476 .254 .1511 .271 1546 .289 . 1581 *306 .1616 -. 324 I 1477 *254 .- 1 512 .272 1547 2 89 . 1582 .307 .1617 . 324
( .1478
- 255 . 1513 .272 .1548 .290 . 83 ..307 . 1618 .325 L] 14809 .256
. 255 .1514 273 .1549. *.290 .308 .161? .325
.-1584
.256 . 151E .273 15506 .291 .308 .1620 . 326
.1481 1 j51~6 .27-4 .1551 .291 .1586 .1621 .326
.257 .. 309 1517 .27'74 .1552 .292 1587 .30? .1622 . 327
,1 257 . 1518 .275 .1553 .292 .1588 .310 . 17623 .327
.1484 .258 . 1519 .275 .1554 .293 .1589 . 3 C} . 1624 .328
.25B .1520 .276 .1555 -. 1590 .311 .328
- 294
.1489 .259 .1521 . 1556 .1591 .311 .. 1626 . 329 II I1487' . 259 .1522 .277
.. 294
.2 'E7
.1t557 .295? .1592 .312 1.627 -. 329
- .1488 .260 .1523 .277 . 1558R .1593 . 312 .1628 .330
.14918 .260 .-278 . 1559 . 295 .1594 .313 !1629 . -. 330
- 264'
..261 2 6 14£90 .278 .296 .1595 .313 .1630 .331
.261 -.279 .1561 .,1596 - 314 . 1631 .331 U_ ..1496 14212 .262 .279. .1562 .1597 .314 *.1632 .. 332
.1532
.1t528 .280 . 299 .315 .1633 . 332 9.4 .262
_14 . 280 . 1564 .1 599 .315 .1634 .;333*
.2363 *1565
. 1530 .281 .1600 .316 .1635 .333
.263
. 2 ,52 , 15665
. 14?6 .281 .6N01 .-3 16 .1636 .3 34
. 265£ . 1529 I S33 .282 .1567 299 .1602 -317 1.637 ;334 9I .265 .1l533 .282- 1568. n300 .1 603 .317 .1638 .335
. 1534t .283 1569 .300 .1604 .318 *.1639 .335 Ef fectlve l Previous A- Revision: - A Page dt ._ Revision. _ A 7 .3_aLI 2 of 2 1 1 Dte: _
L-Formerly "Inryco Surveillance"
li Precision APPENDIX 2 - PROCEDURE SQ 7.1 Sreillan PSC SPTrveillatnce ( - PITCH DIAMETER CONSTANT FOR 3 WIwLRE CJMCoportio From Fed Standard H28113 C = w(1 + cosec a) - (cot a) 21n gives . CON = 4.993929(VM -0.483392 F:-IFETC-f E I Eir^ rCiNP T GOF< PWJIFaE MPEr OT WIRE WIRE IW1IRE W4I RE -WIRE W:LF:E SIZE CON. SIZE CO N. SIZE COlNr. SIZE CO N. SIZE CON. I .1290 .161 . 1325 .178 .1360 - 196 .1395- .213 . i430 .231
.1-291 . 161 .1326 i179 . 1361 196 . 1396. .214 1431 - 231
. 1292 ..162 . 1327. .179 .1362
- 197 . 1357
,, 2 1'5 . 1432
. 1293 - 1,62 .1328 .1363 .197 rr 1.397£7 .215 -1433 '232
.233
. 1294 .163 . 1329 .180 . 1364 .,196 . 1399 .216 - 1434 :233
. 1295 - 163 ..1330 . 181 .1365 .198 . 1400 .216 .1435 .2331
.12596 - 164 .1331 .181 .1366 -199 . 1401 .216 -1436 .. 234
. 1297
- 164) . 1332 . 1 32 .1367 ; 199? .1402 21 7
.1437 .234
.217
.1298 .1 65 - 1333 . 182 .1368 .200 .1403 1 438
- 1299
- 165 - 1334 . 1 83 .1369 . 1404] .218 143? .235
.'2iB t1439
. 1300
- 166 *. 1335 .183 .1370 201 - 140t~5. ..218 1440 ..236
.1301 - 166 .1336 .1371 201 .1406 .219 .236
.1302 - 167 .1337. .1814 .1372 ..202 1-407 1-442 .237
. 1 84
- ~1303 . 167 - 1338 .1373 ..202 .220 .1. 44Z3 .237
.130-t
= .168 13359 .185 - 1374 .203 1409 .220 -1444 .238
.1305 .168 . 1340 . 186 .1375 .2 03 .14 10 .238
.169
.186
= 1306 .1341 .1376 '204 .1411 .221 I 446 .239
.1307 .169 . 1-342 .187 .1377 ..204 I1412 .222 144 7 .239
. 1308 *. 170 '13143' -187 1378 .205 .1413 .222
- 1448 .240
.1309 .170 - 1 344 - 188 -137? 205 - .1414 .22,3 .1449 .24 0
.174
. I. 48
- 1310 . 171 . 1345 .1380 .. 206 .1415 .223 .241
. 138y
. 1311 .171 . 1346 .1381 "206 , i416 .241i
. 172 i450
. 1312 .1347 .189 .1382 . 1417 .225}
-..22.74. 1-l 52 2f 2
.1454
.- 313 . 172 . 1348 . 190 .1383 .207 1418 .224
. 173 .227
. 1314 i349 3 .190 .1384 .208 1419 .243
.24.3
.1315 . 173 .1350 .191 .1387 209 .1420 22S . 1455
..226
- 1631 1351 .191
- 1386 .209 .21421 228 . 1456
.-174 .2453
.1317 .1352 .192 .1387 "209 1422 .1457 ,2 4
. 2454
. 1318 . 175 .1353 .192 .1388 *210 .1423 .1 4S8
. 1319 .175 . 13514 .193 .1389 .21 0 . 1424 .228 1459 ,s';
.1320 . 176 , 1 355 . 193 .1390 .211 v 1425 . 228 'I460 , 246
.1321 , 176 ,1356 .194 . i391 .211 . 1426 .229 .1461 .246
.1322 .177 - 1357 .1392 .212 . 1427 *229 1462 .247
. 1 323 .177 .1-9 S .1393 212 t -1 428 - 230 41463 - 247
. 1324 . I7 1. . 1359 . 19t5 .1394. .213 . 1 429 - 230 1A64 . 2/4e i
Eaffectlve. Date: rn 3_f Previous IRevision: A A .1ReIS~n-A "7 ; z-_0 Page I ;I
- i. _- . _ I I 1 I.
of 2 I L. Formerly "Inryco Surveillance"
r--7 [c:- f VT r177 77 _ 11_ (117 i:771 viz r r= VIZ riz r-. vi
--------- EXTERNAL THREADS --- -> <------------- NTERNAL THEADS MAYR MIN MINOR DIAMETER SSTRESS SHEAR THX MIN MAX D IN MINO IAX MIN I .V s_
MAX MIN MAX AREA AREA VI) uD 0.2500 C).2375 0.1710 0.1530 C1.0800 0.0020 0.2700, 0.2880 0.1750 ).1930 0.1000 4i 0.1125 0.0091 0.2605 0.37S0 C1.3625 0.2951 0.2764 C'.2050 I- x
-0 0.1863 0.3950 0.4 137 0.3000 C).3187 0.2250 0.2375 0.0420 0.4692
.io 0. 5000 ().4875 0.4193 0.4001 Cp.3300 0.3108 0.5200 0. 5392 0. 4250 ).4442 0.3500 0.3625 0.0992 0.6774 0.6250 C).6125 0.5437 0.523? D.4550 0.4353 0.6450 0.6647 0. 5500 ).5697 0.4750 0.4875 0.1806 0.8950 m 0.7500 C).7375 0.668i 0.647? ).5800 0.5598 0.7700 0.7902 0.6750 ).6952 0.6000 0.6125 0.2864 1.0922 2 0 0.8750. ().8625 0.7925 0.771? C).70S0 0.6844 0.9?50 0.9156 0.8000 0.8206 0.7250 I 0.7375 0.4164 1.2988 m m 1.0000 ).9875 0.9170 0.8960 ).8300
-< m 0.8090 1. 0200 1. 0410 0.9250 0.9460 0.8500 0.8625 0.5708 1.5050 nC, 1.1250 o ° :L.1125 1.0415 1.0202 ).9550 ri '
0.9336 1.1450 1.1664 1. 0500 1.0714 0.9750 0.9875 0.7495 1.7107 I- 1.2500 ' :L.237S 1.1661 1.1443 L.0800 1.0583 1.2700 1.2917 1.1750 1.1967 1.1000 1.1125 0.9526 1.9160 I- 1.37SO 1.3625 1.2906 1.2686 1.2050 1,.1830 .1.3950 1.4 170 1.3000 1.3220 1.2250 1.2375 1.1801 2.1208 0 1.5000 1.4875 1.4152 1.3929 1.3300 C C 1.3077 1.5200 1.5423 1.4250 1.4473 1.3500 1.3625 1.4319 '2.3253
.. 1.6250 1.6125 1.53,8 1.5172 1.4550
, D, 1.4324 1.6450 1.6,76 1. 5500 1.5726 1.4750 1.4875 1.7082 2.5293 1.7500 1.7375 1.6b44 1.6415 1.5800 1.5571 1.7700 1.7929 1.6750 1.6979 1.6000 1.6125 2.008S 2.7330 1.8750 1.8625 1.7890 1.7658 0 1.7050, 1.6818 1. 8950 1.9182 1.8000 1.8232 1.7250 1.7375 2.3338 2.9363 r- 2. 0000 1.9875 1.9137 1.8902
-t 1.8300 1.8065 2.0200 2.0435 1. 9250 1.9485 1.8500 1.8625 2.6833 3.1393 2.1250 2.112S 2.0383 2.0146 1.9550 1.93i3 2.1450 2.1687 2.0500 2.0737 0
1.9750 1.9875 3.057i 3.3419 2.2500 2.2375 2.1630 2.1390 2.0800 2.0560 2.2700 2. 2940 2.1750 2.1990 2.1000 2.1125 3.4554 3.5441 2.3750 2.3625 '2.2877 2.2634 i 2.2050 2.1808 2.3950 2.4192 2. 3000 2.3242 V.. 2.2250 2.2375 3.8780 3.7b61 2.5000 2.4875 2.4124 2.387? 2.3300 2.3055 2. 5200 2.5445 2.4250 2.4495 2.3500 2.3625 4.3251 3.9477 2.S250 2.6125 2.5370 2.5123 2.4550 2.4303 II 2.6450 2.6697 2.5500 2.5747 2.4750 2.4875 4.7967. 4.1490 q 2.7500 2.7375 2.6617 2.6368 2.5800 2.5551 2.7700 2.7949 2.6750 2.6999
-r1 2.6000 2.6125 5.2926 4.I3499 2.8750 2.9625' 2.7864 2.7613 2.7050 2.6798 2.8950 2. 9202 2.8000 2.8252 2.7250 2.7375 5.8130, 4.5506 3.0000 2.9875 2.9111 2.8858 2.8300 2.8046 3.0200 3.0454 2. 9250 2.9504 2.8500 2.8625 6.3579 4.7510 3.1250 3.1125 3.035, n Cn 0 3.0103 2.?550 2.9294 0 5- I-r 3.1450 3.1706 3. 0500. 3.0756 .2.9750 2.9875 6.9271 4.9511 0 3.2500 3.2375 3.1606 3.1348 g~ < fli' 3.0900 '3.0542 3.2700 3.2?58 3.1750s 3.200a 3.1000 3.1125 7.5208 5.150? t,1
-. 3750 3.3625 3.2853 3.2593 *- C,)
3.2050. 3.1790 3.3950 .3.4210 3.3260 Sjo
"-TI 3.2250 3.2375 S.1389 5.3504
- 3. S00 3.4875 3.4100 3.3838 3.3300 3.3038 3.5200 )3.5462 3. 4250 3.4512 3.3500 3.3625 8.7815 5.5496 2.6250 2.612S 3.-5348 2.5083 3.4550 3.4286 3.6450 3.6714 3.5S00 3.5764 3.4750 3.4875 9.44SOS S. 74 86 __~
__ - - f- .- f__ I.- r,--- F.-7-, c(717 77 yr -i r--. Li VT L..~ . t.~...... ~. (f ,.-_- -_
. I -
-4, 7~
I 4 T C 5T UM t A C MrE: TFiCE-ADS CLA S 2C ;.
- . . !.g
------ <' - EXTERNAL THREADS -------------------
iNTERNAL THREADS >
! " MAJOR DIAMETER PITCH DIAMETER MINOR DIAMETER MAJOR DIAMETER PITCH DIAMETER MA M MMAX MIN MINOR DIAMETER STRESS SHEAR MAX MiIN MIN MAX MIN MAX MIN MAX AREA AREA -u I, I 3.7500 3.7375 3.6595 3.6329 3.5800 3.5534 3.7700 3-79A6 3.A750 3.7016 3.6000 3.6125 10.1400 5.9473 z L4 3.8750 3.8625 3.7S43 3.7574 3.7050 3.6782 3.8950 1 3.9218 3.8000 3.8268 3. 7250 3.7375 10. 8559 6.1457 CN m
- 4. 0000 3.9875 3.90970 3.8820 3.8300 3.8030 4.0200 4.0470 3.9250 3.9520 3.S500 3. 8625 11.5963 6.3438 4.1250 4.1125 4.0330 4.0066 I-4
~-A rn 3.9550 3.9278 4.1450 4.1722 4.0500 4. 0772 3.9750 3.9875 12.3611 6.5418 CZ 4.2500 4.2375 4.15S5 4.1311 4.0800 4.0526 4.2700
;o 4.2974 4.1750 4. 2024 4.1000 4.1125 13.1503 6. 7394 rr m
4.3750 4.3625 C-) X) 4.2833 4.2557 4.2050 4.1775. 4.39SO 4.4225 4.3000 4.327S 4.2250 4.2375 13. 9640 6.9368 ,E
,o -~ 4.5000 4.4875 4.40O8 mt rD . 4.3803 4.3300 4.3023 4.5200 4.5477 4.4250 4.4527 4.3500 4.3625 14. 8022 7.1340 __ - o 4. 62S0 4.6125 4.532S 4.5049 o C 4.4550 4.4271 4.6450 4.6729 4.5500 4. 5779 4.4750 4. 4875 a,- 15. 6648 7.3309 4.7500 4.7375 4.6576 4. 629S 4.5800 4.5519 4.7700 4.7981 4.6750 4.7031 4.6000 4.6125 16. 5519 7.5276 4.8750 4.8625. 4.7823 4.7541 4.7050 4.6768 4.9950 4.9232 4.8000 4.8282 4.7250 4.737S 17.4635 7.7240
- 5. 0000 4.9875 4.V9071 4.8707 4.8300 4.8016 S.0200 S. 0404 4.9250 4.9534 4.8500 4. 8625 18.3995 7.9202 5.1250 5.1125 5.0319 5. 0033 4.9550 4.9264 5.1450 5.1736 5.0500 5.0726 4.9750 A4.9075 19.3599 8.1162 5.2Soo 5.2375 5.1i67 S.i279 5.0800 5.0513 5.2700 5.2987 5.1750 5. 2037 S.1000 5. 1125 20.S3447 8. 3119 5.3750 5.3625 5.2815 5.2525 5.2050 :5.1761 5.3950' 5. 4239 5.3000 5.3289 5. 2250 5. 2375 21.3543 8.5074 5.5000 .SA75 A6AA 0 5.3- 772. 5.3300 5.3009 5.5200 5.5491 .5.4250 5.4541 5.3500 5. 3625 22.3881 8.7027 5.6250 5.6125 5.S310 5.5018 5-4550 5.4258 5.6450' 5.6742 5.5500 5.5792 5. 4750 5.4875 23. 4464 8.8978 5.7500 5.7375 5.6558 5.6264 5.5B00 5.5506 5.7700 5.7794 5.6750 5.7044 5.6000 S. 6125 24. 5292 9.0927 5.8750 5.8625 5.7806. 5.7511 5.7050 S.6755 5.S950 5.9245. 5.8000 S. 8295 5.7250 5.7375 25. 6365 9.2673
.6.0000 5.9875 5.9054 5.8757 5.8300 5.8003 6.0200 .6.'0497 5. 9250 5.9547 5'. 8500 5.8625 26.7682 ?.4817 6.1250 6.1125 6.0302 6.0004 5.9550 S.9252 6.i450 6. 1748 6.0500 6.0798 5.9750 5.9,875 27.9244 9.6759 6.2500 6.237S 6.1550 6.1250 6.0800 6.0500 6.2700 6.3000 6.1750 6.2050 6. 1000 6.1125 29. 1050 9.8699 6.3750 6.3625 6.2798 6.2497 6.2050 6.1749 6.3950 6. 4251 6.3000 6.3301 6.2250 6.2375 30.3101 10.0837 6.SOOO. 6.4875 6.4046 6.3743 6.3300 .6.2997 6.5200 6.5S03' 6.4250 6.4553 6.3500 6.3625 31.5397 10.2573 6.6250 6.6125 6.5294 6.4990 6.4550 6.4246 6.6450 6.6754 6.5500. 6.5904 6.4750 6.4875 32.793B 10.4507 0 _-0 :
6.7500 6.7375 6.6542 6.6236 '-1S S; c:~q 6.5SOO 6.5494 6.7700 6.B006 6.6750 6.7056 6.6000 6.6125 34.0723 10.6439? 0 K-1 6.8750 6.8625 6.7790 6.7483 6.7050 6.6743 6.8950 6. 9257 .6.8000 6.8307 6.7250 6.7375 35.3753 10.8369 : : 7.0000 6.9875 6.9038 6.8730 0 0p 6.8300 6.7991 7.0200 7.0509 6.9250 6.9559 6.S500 6.8625 36.7028 11.0296 7.1250 7.1125 7.0286 .6.9976 6.9550 6.9240. 7.1450 7.1760 7.0SOO 7.010 6.9750 6.9875 38.0548.11.2222
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------------- 7- EXTERNAL. THR:EADS ------- ----- >, <-------------- INTERNAL THREA1DS __
......... SHEAR MeJOR DIAMETER PITCH DIAr IETER MINOR DIAMETER 1AJOR DIAMETER PITCH DIAMETER
~1I MAX MIN' MAX MINOR DIAMETER STRESS SHEAR HIN MAX MIN MIN MAX MIN MAX' MIN MAX AREA AREA Ln 1-0 i 7.2500 7.2375 7. 1535 7.1223 7.0800 7.0486 , r i
.J. 7.2700 7.3012 7.1750 7.2062 7.1000 7.112S 39.4312 11.4146
' i 7. 3750 7.3625 7.2783 7.2470 7.2050 7.1737 I-. C 1* '.3950 7.4263 7.3000 7.3313 7.2250 7.2375' 40.8321 I-
- 11. 6068
.o.
- 7. 5000 0 7.4875 7.4031 7.3717 7.3300 7.2986 7.5200 7.5514 7.4250 7.4564 7.3500 7.3625. 42.257S 11.7988 V 7.6250 7. 6125 7. 5279 7.4963 7.4550 7.4234. r 7.6450 7.6766 7.5500 7.'5816 7.4750 7.4875 43.7073 1. 9906 I 7.7500 m
7.73-75 7.6527 7.6210 7.5800 7.5483 7.7700 -u 7.8017 '7.6750 7.7067 7.6000 Z.6125 45.1817 12.1822 x Err 7.B750 7.8625 7.7776 CF 0 7.7457 7.7050 7.6732 ?.8950 7.9268 7.8000 7.8318 7.7250 7.7375 46.6805 12. 3737 -I
-. 8.0000 7.9875 7.9024 D m
- 7. 8704 7.8300 7.7980 3.0200 8.0520 7.'9250 7.9570 ;o C 7.8500 7.8625 48.203B 12. 5649 B. 1250 6.1125 8.0272 7.9951 7.9550 H
7.9229 3.1450 8.1771 8.0500 8.0921 7.9750 7.9875 49.75i5 12. 7560 rn S.2500 8.2375: S.1520 8.1196 8.0800
'S 8.0478 3.2700 8.3022 8A1750 8.2072 8.1000 6.1125 51.3238 12.9469 8.3750 S.3625 8.2766 8.2445 m 8.2050 .8.1726 3.3950 6.4274 8.3000 8.3324 8.2250 8.2375 52.9205 13.1375 B.5000 (C)
S.4875 8.4017 8.3692 8.3300 8.2975 3.5200. 8.5525 8.4250 8.4575 .8.3500 8.3625 54.5417 13.3291 I-. 8.6250 8.6 125 8.S265 8.4?3? 8.4550 8.4224 3.6450 6.6776 8.5500 S.5826 8.4750 S.4875 56.1874 13. 5184 8 7500 8.7375 8.6513 8.6186 8.5800 8.5473 3.7700, 6.8027 8.6750 8.7077 8.6000 8.6125 57.8575 13.7086 8.8750 8.8625 S.7762' 8.7433 8.7050 8.6721 9.89S0 80.279 8.8000 8.8329 8.7250 8.7375 59.5522 13.895.
. 9.0000. *8.9875 8.?o010 8.8680 8.8300 8.7970 9.0200 9.0530 8.9250 8.?560 8.8500 8.8625 61.2713 14. 0883 9.1250 9.1125 ?.0258 8. 9927 8.9550 S.9219 9.1450 9.1781 ?.0500 1'0831 8.?750. 8.9875 0 63.0149 14.2780 I
9.2500 9.2375 9.1507 9. 1174 9.0800. 9.0468 9.2700 9.3032 9.1750 9.2082- 9.1000 9.1125 64.7830 14. 4674 9.3750 9.3625 9. 2755 9.2421 9.2050 9.1716 9.3950 9.4284 9.3000 9.3334 9.2250 9.2375 66.5756 14. 6567
- 9. 5000 9.4875 9.4003 9.3668 9.3300 9.2965 9.5200 ?.5535 9.4250 9.4585 9.3500 9.3625 68.3926 14. 6458 1-ttf 9.6250 9.612S 9.5252 9.4916 9.4550 9.4214 9.6450 q.6786 9.5500. 9.5836 9.4750 9.4875 70.2342 15. 0347 o
_S 9.7500 9.7375 9.6500 9.6163 9.5800 9.5463 9.7700 9.8037 9.6750 9.7.087 9.6000 9.6125 72.1002 15. 2235 9.8750 9.8625 9.7749 9.7410 9.7050 9. 6711 9.8950 9.9289 '9.8000 9.8339 9.7250 9.7375 73.9907 15.4121
- 10. 0000 9?.875 9. 8997 9.8657 ?.8300 9.7960' 0.0200 10.0540 9.9250 9.9590 9.8500 ?.B625 75.9057 15. 6006 10.1250 10.1125 10. 0245 9.905 (U
?.9550 9.920? 0.1450 10'.1791 10.0500 10.0841 9.9750 9.7075 77.8452 15. 7888 0
- 10. 2500 10.2375 10. 1494 10. 1152. 10.0600 10.0458: L0.2700 10.3042 0 10.1750 10.20?2 .10.1000 10.1125 79.8091 15. 9769 0 0. 0
-t1 10. 3750 10.3625 10. 2742 10. 2399 10.2050 10.17107 .0.39S50 10.4293 10.3000 10.3343 10.2250 10.2375 I-i. wr -
81.7976 16. 1649 5
- 10. 5000 10.4875 10.3991 0 10.364610.3300,10.2956.1 .0.5200 10.5544 10.4250 O.,4594-LO.3500 10.3625 83.8105 16. 3526
-10. 6250 10.6125 10.5239 10.4894 10.4550 10.4204 10.6450 10.6796 10.5500 10.5346 10.475I0 10.48*75 5 8480 16i. SA03
- 85. 1I - 1
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------- -- - EXTERNAL THREADS ------------ > <------------- INTERNAL THREADS .. I MAJOR- DIAMETER PITCH DIAHETER MINOR DIAMETER MAX MAJOR DIAMETER PITCH DIAMETER MINOR DIAMETER STRESS HIN MAX HIN MAX MIN SHEAR MIN MAX MIN MAX MIN MAX AREA A RE A 10.7500 ,10.7375 10.6488 1.0.6141 10.5800 10.5453 10.7700 10. 8047 1 0. 6750 10.7097 10.6000 tn 1-2. I 10.6125 07. 9099 16.7277 III
-:1: z
-7 10.8750 1 0. 8625 10.7736 1.0.7388-10.7050' 10.6702'10.8950 r- C
- 10. 9298 1'0.8000 10.8348 10.7250 110.7375' 89. 9963 16.9150 r- Z
- 11. 0000 1 0.9875 10.8985 1LO.8636 I.0.8300 io.7951 11.0200 11.0549 .0. 9250 10.9599 10.8500 1.0.8625 '92. 1072 I 17.1021 11.1250 1.1.1125 11.0233 110. ?BE13J 10.9550 LO.9200 .11.145011.1800
.1.0500 li.0850 10.9750 1 .0.9875 94.2425 17.2891 CD
_u 11.2500 1.1.2375 11. 14821 11.1130 11.0800 CD f Io
-. 11.044? 11.2700'-11'.3051 11.1750 11.2101 11.1000 111. 1125 96.4024 17. 4759
- 11. 37501 1. 3625 11.2730 11.2378 11.2050 rn, m 11.1698 11.3950 111.4302 ;11.3000 11.3352 11.2250 111.2375 O fI
- 98. 5867 17.6626 nCX l1l 5000'1 11. 4875 11.3979 ll.-:625 11.3300 ll.2?47 11.5200 11. 5553 11.4250 11.4603 11.3500 :L1.3625 100. 7956 17. 8491 m No a 11.6250 111. 6125 11.5227 11.4873 11.4550 C 0; 11.4195 11.6450 11.6BOS 11,5500 11. Sa55 P0 11.4750 I11.4875 103.0289 18. 0354 m 11.7500 111. 7375 .11. 6476' 11.6120 11.5800 rn 0 11.5444 11.7700 11'.80Sb 11.6750 11.7106 11.6000 11.6125 105.2867 --- tJ)
C? 18.2216 D 11. 87S0 L. 8625 -11'.7724 11.7368 11.7050 CJ E(D co 116693 11.8950 11.9307 11.8000 11.8357 11.7250 11.7375 107. 5690 18.A077 zI C) C' 12.000o i 97875 11.8973 11.8615 11.8300 I 11.7942 12.0200 12.0558 11.97250 11.7608 .11.8SoO 11.8625 -1 _.c 109. 87se 18. 5936
- 12. 12 50 12.1125 12.0221 11.9863 Z_o 12. 9550 11.91991 12.1450 .12.1809 12,0500 12. 0859 11.,9750 11.9875 112. 2071 18. 77q3 0
0C') 12.2500 12.2375 12.1470' 12.1110 12.0800 12.0440 12.2700 12.3060 12. 1750 12. 2110 Li 12.1000 12.1125 114. 5629 18. 9649 12.3750' 12.3625 12.2719 12.2358 12. 2050 r_ 12w1689 12.3950 12.'4311 12,3000 12.3361 12.2250 1'2.2375 (n 116. 9432 19.I503 a) 12. 5000 12.487.5 12.3967 12.3605 1Z.3300 12.2938 12.S200 12.5562 12.4250'12.4612 12.3500 i2.3625 w: l.3479 19.3356 D1 12.6250 12. 6125 12. 5216 12.48'3 12.4550 12.4187 12.6450 12.6813 12.5500 12.5863 12.4750. 12.4875 121.7772 19. 5207 127500 12. 73755 12.6464 12.6100 12.5800 12.5436 12.7700 12. 8064 12.6750 12.711I4 12. 6000 12.6125 124.2309 19.7057
- 12. 8750 12.8625 12.7713 12.7348 12.7050 12.6685 128?O50 12. 9315 12.8000.12.8365 12.7250- 12.7375 Ž126.7072 19' 8906 0I 13.0000 12. 987E 12.8962 12.'8595 12.8300 12.7934. 13.0200 13. 0566 12. 9250 12. 9616 12.8500 12. 8625 129.211? 20.0752
- 13. 12S0 13. 112! 13.0210 12. 9843 12.?S50 12.9183 13.i450 13.1817 13.0500, 13. 0867 12. 9750
.to 12.9875 131. 7391 20.2598.
13.2500 13. 237!5 13.1459 13.1090 13. 0800 13.0432 13.2700 13.3068 13.1750 13.2115 t 13.1000 13.1125 134.2908 20.4442 13.3750 13.362! 513.2707 13.2338. 13.2050 13.1681 13.3950 13. 4319, 13. 3000 13.3365 13.2250 13.2375 136.867C K 20.6284 13.5000 13. 487!5 13.3Y56 13.3586 13.3300 13.2930 13.5200 13. 5570 13.4250 13.462C V 13. 3500 13.3625 139.4677 20.8126 s.-1 13. 6250 13.612!S 13.5205 13.4833 13.4550 13.4179 13.6450 13. 6821 13.5500 13. $871 i13.4750 13.4875 142.0925 20.'9965 0 co 13.7500 13.737! 5 13.6453 13.6081 13. 5800 13.5428 .13.7700 13. 8072 13, 6750 13. 712 13.6000 13612! 144.742t 3'21.1804 0 CD
- 13. 8750 13. 862!5 13.7702 13.7329 13.7050
'.13.6677 13.8950 13.9323
~1 a
(-) 13.0000 13.837: 3 13.7250 13.737! 147.416i 3 21.3640 I l,, 0o CD 0
- 14. 0000 13. Y87 5 13.8391 13.8576 13.8300 13.7926 14.0200 14.0574 13.9250 13. 962,4 13.8500 13.862! 150.115!5 21.5476
.I _4.12S0 14-1125 14.0179 13.9024 13.9175 14.1450 14.1825 14.0500 14.0875 13.9750 13.9875 152.0386 21.7310
r= - 1_ r.--. t_ r-, t- (--: K7-- F IX 111 r-- r- 1777 (,_: r ._t
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4-------------- EXTERNAL THREADS -> <------------- INTERNAL THREADS (n MAJOR DIAMETER PITCH DIAMETER MINOR DIAMETER MAJOR DIAMETER -PITCH DIAMETER m MAX MIN MINOR DIAMETER STRESS SHEAR z N MAX MIN MAX 'MIN HIN MAX MIN. MAX NINH MAX :AREA AREA r- 1-I ' r-
- 14. 2500 14.2375 14.1448 14. 1072 14.0800 14.0424. 14.2700 i4.3076 14.1750 14.2126 14.1000 14.1125 155.5863 21.9142 I 14. 3750 14.3625 14.2697 14.2319 14.2050 14.1673 14.3950 14.4327 14.'3000 14.3377 14.2250.14.2375 158.3584 22.0974 I
- 14. 5000 14. 4875 14.3945 14.3567 i4.3300 14. 2922 14.5200 14.5578 14. 4250 14.4628 14.3500 14.3625 161.1551 22.2803 I-,
14.6250 14.6125 14. 5194 14.4815 14.4550 14.4171 14.6450 14.682?. 14. 5500 14. 5879 14.4750 14.4875 163.9762 22.4632
.14.7500 14.7375 14.6443 14.6062.14.5800 14.5420 14.7700 14.8080 14.6750 14.7130 14.6000 14.6125 166.B219 22.6459 V... c-n
- 14. 8750 14.8625' 14.7691 14.7310 14.7050 14.6669 14.88950 14.9331 14.8000 14. 8381 14.7250 14.737S 169.6920 22.8284 0 a 15 0000 14.9875 14.8940 14.8558'14.8300 14.7918 .15.0200 15.0582
- 14. 9250 14.9632 14.8S00 14.8625 172.5867 23.0109 15.1250 15.1125 15. 0189 14.9806 14.9550 14.9167 15.14S0 15.1833 15.0500 15. 083 14.9750 14.9875 '175.5058'23.1932 15.2500 15.2375 15S.1438 15.1053 15.0800 15.0416 15.2700.
15.3084 15. 1750 15.2134 15.1000 15.1125 178.4494 23.3753 Vts, 15.3750 15.3625 15.2686 '15.2301 15.2050 15. 1665 15.3950
'15.4335 15.3000 15.3385 15.'2250 1S.2375 181.4175 23.5574
- 15. 5000 15.4875 15.3935 15.3S4? 15.3300 15. 2914 15.5200 15.5586 15.4250 1i5.4636 15.3500 15.3625 184.4102 *23.7392 IS. 6250 15.6125 15. 5184 IS.4797 15.4550 .15.4163 15.6450 15.6837.
15.5S00 15.5887 15.47S0 15.4875 187.4273.23.9210 0 15. 7500 15. 7375 15.6433 15.6044 15. SSOO 15.5412 15.7700 15.'8088 15.6750 15.7138 15.6000 15.6125 190.'4689 24.1026 15.8750 15. 8625 15.7681 15.7292 15.7050 15.6661 15.8950 15.9339 15.8000'15.8389 15.7250 15.7375 193.5350 '24.2841 16.0000 15.9875 15.8930 15.8540 15.8300 15.7910'16.0200 16.0590 .o 15.9250 15.9640 15.8500 15.8625 196.6256 24.4655 i' IZ -1 oI
. n 0
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_ _ _ _f3a] APPENDIX 4 - PROCEDURE SO 7.1 j.STRESSING ADAPTOR DISPOSITION TABLES-ALLOWABLE EXTERNAL DIAMETER RANGE:S MINIMUM MINOR DIAMETER PROJECT: THREE MILE ISLAND 2004 08- 19-2 004 BASIC DIAMETER= 9.3750 ENGAGEMEENT LENGTH = 3.000 170 WIRES 150 YI ELD 1290 ! rl G.U.T.S I i INTERNAL MARK : D4 MAJOR DI:AMETER= 9.3950 MINOR DIAMETER= 9.2360 i'i . <---__ ____----------- M A J O R c2 1 c- ' : KAll R A N G E S- --- --->
. PITCH 9.345 9.355 9.365 9.375 9.385 9.395 9.405 9.415 9.425 9.435 RANGES 9.354 9.364 9.374 9.384 9.394 9.404 9.414 9.424 9.434 9.444 9.150 9.043 9.024 9.004 8.984 8.964 8.944 8.923 8.902 8.881 8.860 9.163 1l ; .: 9.164 8.918 8.886 8.853 8.820 8.786 8.751 8.717 8.681 8 .645 8.608 9.177 i l 9.178 8.856 8.821 8.786 8.750 8.715 8.680 8. 644 8 . 609 8.573 8.538 9.191 L.:,
9.192 8.841 8.804 -8.768 8.731 8.694 8.657 8.621 8.584 8 .547 8.510 9.205- 'L.'t, B 9.206 8.826 8.788 8.750 8.712 8.674 8.635 8.597 8.559 8.521 8.482 9.219
! 9.220 9:233 8.811 8.771 8.732 8.692 8. 653 88. 613 8.574 8.534 8.494 8.455 9.234 8.796 8.755 8.714 8.673 8.632 8.591 8.550 8.509 8.468 8.427 i._ . 9.247 9.248 8.781 8.739 8.696 8.654 8.612 8.570 8.527 8.485 8.442 8.400 L- 9.261 9.262 8.766 8.722 8.679 8.635 8.592 8 . 548 8.504 8.460 8.417 8.373 9.275 l l L 9.276 9.289 8.751 8.706 8.661 8.616 8.571 8.526 8.481 8.436 8.391 8.345
- 1. 9.290 9.303 8.736 8.690 8.644 8.598 8.551 8.505 ,.8.458 8.412 8 .365 8.318 9.304 8.722 8.674 8.626 8.579 8.531 8.483 8.435 8.388 8.340 -8.292 9.317 9.318 8.707 8.658 8.609 8.560 8.511 8.-462 8 .413 8.363 8 .314 8.265 i . 9.331 9.332 8.692 8. 642 8.592 8.542 8.491 8.441 8.390 8.339 8.289 8.238 A 9: 9.345 9.346 8.678 8 .626 8.575 8.523 -8.471 8 . 419 8.367 8.315 8.263 8.211 9.359 at
! fi Date.
tive Previous Revision:/3\ A L* 2o
.Revtsion:
j JA
/ -
9-z..,c/ (J Page
)f Formerly "Inryco Surveillance"
-r-',r-
)/T-- I Precision APPENDIX 4 - PROCEDURE SQ 7.1 PSC Surveillance Corporation
~..I STRESSING ADAPTOR DISPOSITION TABLES ALLOWABLE EXTERNAL DIAMETER RANGE'3 MINIMUM MINOR DIAMETER PROJECT: THREE MILE ISLAND SURVEILLANCE 2004 08- 19-20 04 BASIC DIAMETER= 9.3750 ENGAGEMENT LENGTH = 3.000 170 WIRES 150 YIELD. 120 % G.U.T.S.
INTERNAL MARK : C6001 MAJOR DIAMETER= 9.4190 MINOR DIAMETER= 9.2220 C ;~~ - _ __ __---- M /. -----! L A J O R R A N G E S-- _ _ __ __ _ _ _ _ _ _ _ _ >_ PITCH 9.345 9.355 9.365 9.375 9.385 9.395 9.405 9.415 9.425 9.435 RANGES 9.354 9.364 9.374 9.384 9.394 9.404 9.414 9.424 9.434 9.444 ir 9.150 8.867 8.835 8.802 8.769 8.735 8.701 8.666 8.631 8.595 8.558 9.163 1-9.164 8.793 8.758 8.723 8.688 8.652 8.617 8.582 8.546 8.511 8.475 1, 9.177 9.178 8.776 8.740 8.703 8.666 8.630 8.593 8.556 8.519 8.482 8.445 I i 9.191
.,-6@<o 9.192 8.759 8.721 8.683 8.645 8.607 8.569 8.531 8.493 8.454 8.416 9.205 I-9.206 8.742 8.703 8.664 8.624 8.585 8.545 8.506 8.466 8.426 8.386 9.219 1I !
9.220 8.726 8.685 8.644 8.603 8.562 8.521 8.480 8.439 8.398 8.357 9.233 ij 9.234 8.709 8.667 8.624 8.582 8.540 8.498 8.455. 8.413 8.370 8.328 9.247 9.248 8.692 8.648 8.605 8.561 8 .518 8.474 8.430 8.386 8.343 8.299 9.261-
- 1. I 9.262 8.675 8.630 8.585 8.541 8.496 8.450 8.405 8.360 -8.315 8.270
~.: , 9.275 i....
9.276 8.659 8.612 8.566 8.520 8.473 8.427 8.381 8.334 8.287 8.241 9.289 9.290 8.642 8.594 8.547 8.499 8.451 8.404 8.356 8.308 8.260 8.212 9.303 9.304 8.626 8.577 8.528 8.479 8.430 8.380 8.331 8.282 8.233 8.183
. r 9.317 I . 9.318 8.609 8.559 8.509 8.458 8.408 8.357 8.307 8.256 8.205 8.155 9.331 9.332 8.593 8.541 8.489 8.438 8.386 8.334 8.282 8.230 8. 178 8.126 9.345 9.346 8.576 8.523 8.470 8.417 8.364 8.311 8.258 8.205 8 .151 8 .098 9.359 Effective Pr A sev1s Revision:A
- Page DFteo R evrl1'ny 7 co Suvil-a ce Formerly "Inryco. Surveillance"
X; 1l 14 I L Precision
! APPENDIX 4 - PROCEDURE SO 7.1 PSC Un . STRESSING ADAPTOR DISPOSITION TABLES Surveillance Corporation ll ALLOWABLE EXTERNAL DIIAMETER RANGES MINIMUM MINOR DIAMETER PROJECT: TMI SURVEILLANCE 2004 08-19-2004 BASIC DIAMETER= 9.3750 ENGAGEMENT LEN 'GTH = 3.000 170 WIRES 150 YIELD 120 % G.U.T.S.
INTERNAL MARK : C6002 MAJOR DIAMETE:R= 9.4140 MINOR DIAMETER= 9.2260 C , _ _ _
---M A J O R at ? *'(
R A N G E S-----------------------, si/ PITCH *9.345 9.355 9.365 9.375 9.385 9.395 9.405 9.415 9.425 9.435 RANGES 9.354 9.364 9.374 9.384 9.394 9.404 9.414 9.424 9.434 9.444 9.150 8.929 8.902 8.874 8.845 8.817 8.787 8.757 8.727. 8.697 8.665 9.163 9.164- 8.816 8.781 8.746 8.712 8.677 8.642 8.607 8.572 8.-537 8.501 9.177 9.178 8.799 8.763 8.727 8.691 8.654 8.618 8.582 8.545 8.509 8.472 j 9. 191 9.192 8.783 8.745 8.708 8.-670 8.632 8.595 8.557 8.519 8.481 8.443 9.205 9.206 8.767 8.728 8.689 8.650 8.610 8.571 8.532 8.493 8.453 8.414 9.219 9.220 8.750 8.710 8.669 8.629 8.589 8.548 8.507 8.467 8.426 8.385 9:233 9.234 8.734 8.692 8.650 8.609 8.567 8.525 8.483 8.441 8.399 8.357 9.247 9.248 8.718 8.675 8.631 8.588 8.545 8.502 8.458 8.415 8.371 8.328 I - 9.261 9.262 8.702 8.657 8.613 8.568 8.523 8.479 8.434 8'.389 8.344 8.299 9.275 9.276 8.685 8.640 8.594 8.548 8.502 8.456 8.410 8.363 8.317 8.271 9.289 9.290 8.669 8.622 8.575 8.528 8.480 8.433 8.385 8.338 8.290 8.243 9.303 9.304 8.653 8.605 8.556 8.508 8.459 8.410 8.361 8.312 8 .263 8 .215 I, 9.317 L 9.318 8.637 8.588 8.538 8.488 8.438 8.387 8.337 8.287 8.237 8.186 9.331 9.332 8.622 8.570 8.519 8.468 8.416 8.365 8.313 8.262 8.210 8.158 9.345 9.346 8.606 8.553 8.501 8.448 8.395 8.342 8.290 8.237 8.184 8.131 9.359 i l ei __ J._ Effective Date: Previous Revision: I-j isvY2 Revision:A I Page ___. _I _ . ' - _._I - VY .-_ c Formerly "Inryco Surveillance"
Z-\0 /3, I, I ~L\
. J AAPPENDIX 4 - PROCEDURE S Q-71 TRESSING ADAPTOR DISPOSITION TABLES PSC Precision Surveillance Corporation
- INTENTIONALLY LEFT BLANK L -- Eti, v Previous . Revisio n: Page
} fifective Revision:
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Formerly "Inryco Surveillance"
PSC PROCEDURE SQ 7.2 SHEATHING FILLER ANALYSIS JULY 23, 2004 Page 1 of 5 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (30 YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE SHEATHING FILLER ANALYSIS Prepared by_ , Title - A14e, .A Date 9 23 oY Approved by. 2 ell, Title °C h f Date 7_____ Approved by A I. / _Title C( . M/ Date __2__- __ sq7-2.TMI. 04isi
PSC PROCEDURE SQ 7.2 SHEATHING FILLER ANALYSIS JULY 23, 2004 Page 2 of 5 ('-:1~9 IREVISION 0
- 1. PTIRPC)qE This procedure will establish the requirements for laboratory physical and chemical analysis of Sheathing Filler (Grease) samples taken during the In-Service Inspection (surveillance) of the Post-Tensioning System Tendons of Three Mile Island Unit 1.
- 2. RFSPON¶TB1TITT 2.1. The laboratory that performs the testing/analysis shall be responsible for controlling the samples, performing the analysis, documenting the analysis on Laboratory letterhead stationery and submitting the reports to:
Attention: Quality Assurance PRECISION SURVEILLANCE CORPORATION 3468 Watling Road East Chicago, IN 46312 2.1.1. The Laboratory shall further be responsible to utilize trained personnel for the analysis and maintain the calibrated status, traceable to the NIST as applicable, for all test or measuring devices that may be used in providing test results. 2.1.2. The Laboratory shall provide open access for inspection, survey or audit, as the need might arise, to PSC or its customers.
- 22. ' The PSC Quality Assurance Section shall be responsible for the qualification of Laboratory sources.
2.3. Where specified in the Contract Documents, the Owner or his Agent shall have .the right of approval for Laboratory sources. 2.4. The PSC Quality Control and/or Engineering Department shall review the reports for accuracy and content as required by PSC Procedure SQ 7.2 and for evaluation of the acceptability of those results according to the requirements of PSC Procedure SQ 7.0, Section 7. 2.4.1. This report shall be submitted to the Owner or his Agent with the final Surveillance Report.
- 3. S AMPET SR The Grease shall be sent to the Laboratory by any convenient mode of transportation. The sample cans have been marked to show the unit number, the tendon number, the tendon end or buttress identification and sample number. The can shall be securely closed to prevent leakage and packaged to prevent damage.
( 3.1. The samples shall maintain a form of identification throughout testing, that shall provide traceability to the original sample identification. sq7-2.TMI.04isi
PSC PROCEDURE SQ 7.2 SHEATHING FILLER ANALYSIS JULY 23, 2004 Page 3 of 5 REVISION 0 3.2. The Laboratory shall notify PSC if it appears that the sample container has been damaged, tampered with, or any other occurrence that could contaminate the grease sample.
- 4. T2I I FS T .RIR PTIONS IEach sample of Grease (Sheathing Filler) shall be analyzed for Chemical Properties and Physical Properties as specified in the following section 5 and 6.
L 5. TEST METHOD - CHEMTCAAT.PROPFRTTFS Each sample of Grease shall be mixed and tested as follows: 5.1. WATER SOT .TST PLTyPT 1TRTTFS (ASME SECTION XI TABLE IWL 2525-1) L A water extraction of each sample of grease shall be made and tested as follows: l 5.1.1. Using a spatula, coat the inside, bottom and sides, of a one liter glass beaker with 100-(plus or minus 10) grams of the grease. L i 5.1.2. The coated beaker shall be filled with about 900 ml of distilled water at room temperature. 5.1.3. Heat the filled beaker in an oven or by use'of an immersion heater to 100 0 F (37.80 C) plus or minus Li 20 F for 4 hours. DO NOT HEAT ON A HOT PLATE. 5.1.4. Run a blank on distilled water. If titrate use a microburet, 1 ml or 5 ml with 0.01 - 0.05 ml graduation levels. 5.1.5. Decant water and analyze for soluble ions. Test only for salts in leached water. 5.1.6. The water extraction shall be tested by the below cited test procedures for the appropriate water l ( soluble ions. The results shall be reported as parts per million (ppm) in the extracted water. 5.1.6.1. Chlorides (Cl) by ASTM D-512 5.1.6.2.Nitrates (NO3) by ASTM D-992 5.1.6.3.Sulfides (S) byAPHA 427C "MetflyleneBlue Method") (*) APHA 427C (1 5th Edition replaced by APHA 4500-S D 18 Edition)
- 6. TFST METHTOD - PTNYSTCAT. PROPFRTTFS
. Each sample of Grease shall be tested as follows:
L 6.1. Moisture Content by ASTM D-95 sq7-2 .TMI .04isi
L +\i1 PSC PROCEDURE SQ 7.2 SHEATHING FILLER ANALYSIS JULY 23, 2004 Page 4 of 5 (REVISION V 0 6.2. Neutralization No. by ASTM D-974 Modified 6.2.1. The Neutralization Number (Reserve Alkalinity/Total Base Number) shall be performed in accordance with ASTM D-974 and the following modification (per ASME Section XI, Table LWL-2525-1): 6.2.1.1.Place 10 g of sample in a 500 ml Erlenmeyer flask. Add 10 cc isopropyl alcohol and 5 cc toluene. Heat until sample goes into solution. 6.2.1.2. Add 90 cc Distilled water and 20 cc lNH 2SO4 . 6.2.1.3.Place in a steam bath for one-half hour. Stir well. 6.2.1.4.Add a few drops of indicator (1% phenolphthalein) and titrate with 1NNaOH until the lower layer just turns pink. 6.2.1.5.If acid or base solutions are not exactly IN, the exact normalities should be used when calculating the base number. 6.2.1.6.The Total Base Number (TBN), expressed as milligrams of KOH per gram of sample, is calculated
-~ as follows.
[(20) (NA) - (B) (NB):] 56.1 TBN =---------------------------- W where B = milliliters NaOH L NA = normality of H2SO4 solution NB = normality of NaOH solution W = weight of sample in grams Two kinds of bulk filler grease were used for the initial fill at TMI-1. These are 2090P and 2090P-2 both by Viscosity Oil Co. The 2090P was essentially neutral with a Bas Number of zero. The 2090P-2 has a Base Number of 3. Expected Base Number for 2090P and 2090P-2 is zero or higher with a tolerance of -.5. Since reserve alkalinity was not reported on the certification for 2090P and 2090P-2, the testing of samples of this grease is primarily to detect significant changes in Base Number over a period of time that might L indicate abnormal degradation of the corrosion inhibiting properties, e.g., a trend developing where the grease is progressively becoming acidic over time. L - .~ Grease samples which exhibit reserve alkalinity number of <.5 shall be retested per the unmodified version ( of ASTM D974 Section 9 and an acid number generated for the sample. Both the reserve alkalinity number and the acid numbers shall be reported with the test results when this occurs. Acceptance criteria for Acid Number is that it must be < 1. sq7-2.TMI.04isi
PSC PROCEDURE SQ 7.2 L -SHEATHING FILLER ANALYSIS JULY 23, 2004 Lj of~ -Page 5 of 5 REVISION 0
- 7. REPOQRT L Two copies of each report for the analysis of grease shall be submitted to PSC.
7.1. Each report shall bear the date of testing and sample identification as it appears on each can. L 7.2. Each report shall be signed by the Laboratory Manager, who shall ultimately be responsible for the content. 7.3. ACCURACY 7.3.1. The concentration of water soluble chlorides, nitrates and sulfides shall be reported within an accuracy of 0.1 ppm. 7.3.2. The concentration of water shall be reported within an accuracy of 0.1 percent of dry weight of grease. L 7.3.3. The Neutralization Number shall be reported within an accuracy of 0.01 mg. reagent per gram of grease. L 8. - _SAMPL_ _ SPOAT L The remaining sample grease may be scrapped 30 days after the issue of the report, unless the Laboratory is requested in writing to hold the samples for a longer period of time. 8.1. The PSC Quality Control Department shall retain the option of disposing of the samples in less than 30 days if the results of the grease analysis are acceptable. L Li sq7-2 .TMI . O4isi
,tt/g33 1 PSC PROCEDURE SQ 10.2 TEST WIRE REMOVAL JULY 23, 2004 7 ' Page 1 of 5 6 ..- ,.,: I REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8 TH INSPECTIONPERIOD)(301 YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE Cut: TENDON TEST WIRE REMOVAL A, Prepared by ' _.Title *W0 . <.4 . Date ). l cy Approved by -7 ZZ c A7/ _Title , ,;/It Date_____e_ Approved by_& 44z6u _Title G A - Date 2-24i-091" sqlO-2 .TMI . 04isi
-t*P l / \ PSC PROCEDURE TEST WIRE REMOVAL SQ 10.2 JULY 23, 2004 Page 2 of 5 REVISION 0
- 1. PT TREOEE This procedure will establish the requirements for removing a sample wire to be used for physical testing, during In-Service Inspection (surveillance) of the Post-Tensioning System Tendons of Three Mile Island Unit 1.
- 2. RESPONSITRBTLY As stated in PSC Procedure QA 4.0.
- 3. OTTATITFTC'ATTONS As stated in PSC Procedure QA 4.1.
- 4. ROIT TRMENT Quality Control gauges or test equipment will not be required for this activity, except where hydraulic devices and gauges are used.
- 5. PRECATTMONS 5.1. Caution - When pulling individual wires, never exceed the yield strength of that wire when pulling with the pulling device - 9425 pounds.
5.2. Discontinuous wires shall not be used for physical testing. 5.3. If other Broken/Missing Wires are found in this tendon as a result of this inspection or-previous inspections, it shall be necessary to select a wire from this tendon that would tend to balance the forces in that tendon anchorage and try to maintain symmetry with the missing wires in the hole pattern. 5.4. BE SURE THAT THE CORRECT WIRE HAS BEEN LOCATED BEFORE CUTTING. 5.5. - BE .STIRF that this tendon requires sample wire removal. 5.6 TISEF CARRE to avoid damaging other wires or button heads. 5.7. AVOIDf unnecessary marks or damage to the wire while removing. 5.8. U2SE. SCARE when coiling the wire and securing it into a coil. This wire has considerable spring - force and must be prevented from uncoiling violently. sqlO-2 .TMI . 04isJ
PSC PROCEDURE SQ 10.2 TEST WIRE REMOVAL JULY 23, 2004
; RPage 3 of 5 C REVISION 0
- 6. PRFRFQIITISIIE 6.1. The Anchorage Inspection will be complete and Data Sheet 8.0 available.
6.2. The tendon will be Detensioned; Monitoring of Forces will have been completed.
- 7. WTRF REMOVAT.
7.1. A wire shall be selected. 7.2. The Tendon Surveillance Wire Puller shown in Figure 2 of PSC Procedure SQ 10.5 shall be attached to the selected wire. 7.3. The wire shall be pulled with the Wire Puller using as little force as possible, but not to exceed 9425 pounds. 7.3.1. If the wire cannot be moved by hand, it shall be acceptable to use any mechanical device to accomplish that purpose, such as a "Come-Along", "Chain-Hoist", "Chain Pawl" or hydraulic ram. 7.3.1.1.It is unlikely that anything but the hydraulic ram will be able to exert such an amount of force so as to yield or break the wire. Therefore hydraulic devices shall be controlled for force through a calibrated gauge or controlled for maximum force through a locking valve to control the amount of pressure to be exerted. 7.3.1.2.There remains a possibility that the wire might not be moved by a limited force. It shall be necessary to abandon that wire and select a new wire, continuing this process until a wire can be moved. 7.4. Once a tendon wire is located that can be moved, it shall be witnessed for that movement at the opposite end of the tendon to verify that this is a continuous wire. 7.5. Prepare to cut the wire at the opposite end of the tendon from where the wire is to be pulled. 7.5.1. QCD- Document the location of wire removal on Data Sheet 8.0 of Procedure SQ 8.0. Once this is posted, document that action on Data Sheet 10.2 of this Procedure. 7.5.2. Measure back from the button head 1 inch plus or minus 1/16 inch and mark or scribe a line; it shall be acceptable to notch the wire with a file. 7.5.3. Cut the wire somewhere between the button head and the marked line, but not on the line. X4 7.5.4. Pull the wire completely through the tendon duct. 7.5.4.1.While pulling, the tendon wire shall be observed for Corrosion Condition and evaluated in accordance with PSC Procedure SQ 8.1, Section 1, for every 10 feet of length. sqlO-2.TMI.04isi
Addl Ig33\ PSC PROCEDURE SQ 10.2 TEST WIRE REMOVAL JULY 23,2004 Page 4 of 5 REVISION 0 7.5.4.1.1. QCD- Document the Corrosion Condition rating on Data Sheet 10.2, for every 10 feet of length. 7.5.4.1.2. If the Corrosion Condition has progressed beyond Condition "D" as defined in Section i of PSC Procedure SQ 8.1, the Owner shall be notified with a nonconformance report. The Owner shall provide the final corrective action, which could include removing additional wires and performing Physical Testing. 7.5.4.2. While the tendon wire is being pulled, it shall be cleaned of excess grease and coiled into coil form of not less'than 60 inches in diameter. Solvent cleaning may be performed to facilitate cleaning before inspection. 7.5.4.2.1. It shall be acceptable to cut the wires into about 10 foot lengths if coiling is impractical. The cut Wires shall be identified as required of Section 7.5.5 of this procedure. 7.5.4.3.After the tendon wire has been pulled through, it shall be measured for length while being coiled, before being coiled or during cutting to short lengths. 7.5.4.3.1. QCD- Document the total length of wire on Data Sheet 10.2. Remember to include the one inch of wire length to be added from the marked line of Section 7.5.2. 7.5.4.4.If the wire testing is to be performed on site, it shall be acceptable to cut the 3 sample wires while the wire is being pulled out and coiled. Refer to PSC Procedure 10.3 foi the control and documentation requirements. The sample shall be cut from each end and the middle of the wire and as cited in Section 7.5.4.4.1 below and shall be about 108" long, unless the wires are to be cut to the required testing length. 7.5.4.4.1. Sample selection shall include areas representative of significant corrosion or pitting if this condition exists on the removed wire or provide additional samples of this condition in addition to the original 3. Samiples shall not contain gripper marks from the pulling device. 7.5.4.4.2. As a note of caution, be sure that the wire is moving freely before cutting. Otherwise there could be difficulty in removing the wire, requiring assist devices that could leave surface marks on the wire. 7.5.4.4.3. QCD- If the wire is cut for samples while being pulled, document the area of removal on Data Sheet 10.2 for later-transfer to Data Sheet 10.3 of PSC Procedure SQ 10.3. Document each location of sample removal and tag each cut length for area of removal and tendon identification. 7.5.5. Attach a tag to the end of the wire being pulled that identifies the tendon and end of removal. If the wire is cut for samples during removal, the cut lead or front end of the wire shall be identified by tendon number and end of removal to permit reconstruction of that wire as it existed in the tendon. sqlO-2 .TMI . 04isi
-p l'qPSC PROCEDURE SQ 10.2 TEST WIRE REMOVAL JULY 23, 2004 Page 5 of 5 REVISION 0 7.5.6. The coiled wire, whether a single piece or cut pieces, shall be securely tied and covered with plastic sheeting or a plastic bag to protect the wire from inclement conditions.
7.5.6.1.The covered coil of wire may be handed over to the Owner for storage and control. 7.6. If it becomes necessary to remove any additional wires from a tendon for physical testing, this procedure shall be followed to include additional documentation. This includes Broken Wires or wires with Corrosion Condition evaluated as Rejected Condition "E". 7.7. -QCD- The wire or each wire that has been removed for physical testing during this surveillance shall be documented for location of removal on Data Sheet 8.0 of-PSC Procedure SQ 8.0, using the appropriate Code Symbol. Document the posting of this information on Data Sheet 10.2. 7.8. QCD- Document the identification and recalibration date of the measuring device and the wire Pulling Ram, if used, on Data Sheet 10.2.
- 8. Dfl\ILNTATTflON The items requiring documentation in this procedure shall be documented on Data Sheet 10.2.
8.1. Some information documented on Data Sheet 10.2 shall require subsequent posting to Data Sheet 8.0 of PSC Procedure SQ 8.0 and to Data Sheet 10.3 of PSC Procedure SQ 10.3.
- 9. ATTACH ENTIS 9.1. Data Sheet 10.2 C;
sq10-2.TMI.04isi
rrq PSC PROCEDURE SQ 10.2 TEST WIRE REMOVAL i-:. DATA SHEET 10.2 JULY 23, 2004 Page 1 of 1 REVISION 0 WIRE REMOVAL INSPECTION DOCUMENTATION PROJECT: THREE MILE ISLAND SURVEILLANCE YEAR: 30TH TENDON NO. TENDON END/BUTTRESS NO. UNIT 1 DATE OF REMOVAL DATE OF INSPECTION INSPECTED BY (7.5.4.3.1) LENGTH OF WIRE (7.5.4.1.1) & (7.5.4.4.3) BUTTONHEAD END 0' 30'
/
I I. .1 30' 60
-I
'I I. /
60' 90
/ . / /
9O0I - 120 I I
/ / /
120' 150'
/ . / d
/
150' / -. 180'
/ I .
F 180' 210' P
. . . - / 1./
210' -240' r
/ .I-. d/ .
240' 270'
/ /
270' _ 300'
/ -0 /
300' 330'
// /
- CUT END Remember to add the 1 inch from the marked line to the length of the wire.-
As the sample specimens are removed, mark the location of removal here. (7.8) Measuring Device I.D. - Recal. Date Wire Pulling Ram I.D. E CORROSION LEVEL (Refer to PSC Procedure SQ 8.1) A = EXCELLENT B = GOOD C = FAIR Document the Cor 'rosion Level D = USABLE for each 10 fo ot segment. E = REJECTED (Pitted) (7.5.1) & (7.7) Post the location of wire removal to Data Sheet 8.0 Q.C. Review Level Date dslO-2 .TMI . 04isi
f nq act)I PSC PROCEDURE SQ 10.3 TESTING TENDON WIRES JULY 23, 2004 Page 1 of 5
- n. REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (30TH YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE
,01zis PHYSICAL TESTING OF TENDON WIRES Prepared by_ 7/; Title )G6*; G,,9. Date 9-24.oy Approved by Title / g r,-n Date Approved by KT. A.6 14Z7LAd. Title 6K Date. I-2-joV' rC-"
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PSC PROCEDURE SQ 10.3 TESTING TENDON WIRES JULY 23, 2004 Page 2 of 5 REVISION 0
- 1. - PTTRPO.qF This procedure will establish the requirements for the Physical Testing of tendon wires removed from Post-Tensioning System Tendons for purposes of testing and evaluation, during the In-Service Inspection (surveillance) of Three Mile Island Unit 1.
- 2. SCOPF The intention of this procedure is to provide the means of physically testing an Acceptable Wire removed from a tendon. However, this Procedure shall also apply for the physical testing of wires which may have been found to be Broken or in an Unacceptable Corrosion Condition, should that be required by the Project Specification.
- 3. RESPONS.T1TITTY As stated in PSC Procedure QA 4.0.
-4. ITTATCFTCATTONS, As stated in PSC Procedure QA 4.1.
- 5. EQLUPMFNT Steel tapeline, steel ruler, 1" O.D. Micrometer, Wire Test Apparatus, Pressure Gauge.
6: (ITTAT.TTY (ONTRRT. There are no Hold Points in this procedure, however all Quality Control Documentation (QCD) points shall require documentation as required on Data Sheet 10.3.
- 7. PRFCATITONS 7.1. Avoid looking into the test apparatus while the wire is being tensioned.
7.2. Always maintain identification control of the samples so that the tendon identification is maintained, the direction of removal of the wire and the location of that sample as it was removed from the tendon wire. 7.2.1. As a means of maintaining consistency for testing, the end of the sample that is tagged (closest to pulling or button head end) shall always be placed into the Wire Test Apparatus (Figure D 1) opposite or away from the ram end.
- 8. PHYSTCAT. TFSTING Tendon wires shall be tested to meet the requirements of ASTM A421 Type BA wire. The following steps shall be used to test any tendon wire removed from the tendon, whether that is an Acceptable Wire, a Broken Wire or a Wire of an Unacceptable Corrosion Condition.
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L L PSCPROCEDURESQ 10.3 TESTING TENDON WIRES JULY 23, 2004 Page 3 of 5 REVISION 0 8.1. The specimen wires will be of a length of 108", as removed during the performance of PSC Procedure SQ 10.2. Develop a separate Data Sheet for each sample tested. It will be acceptable to cut the sample to the Button heading Length of 101 inches plus or minus one inch. (See Section 8.3 of this Procedure.) 8.1.1. ACCE.PTABTE WTRI Three specimens shall be tested. One sample shall be taken from approximately the middle of the tendon wire length, with the two remaining samples being taken, one from approximately each end of the tendon wire. 8.1.2. BR OKENWIM-If Broken Wires require testing, three specimens shall be tested. One sample shall be taken from the wire length about one foot from either side of the break. The two remaining samples shall be taken, one from approximately each end of the tendon wire. 8.1.3. TJNACCFPTARTFP CORRO5qTON CONDTTTON If Unacceptable Corrosion Condition Wires require testing, at least one specimen shall be tested, with that B l sample being taken from what is judged to be the worst representative section of the wire length. Other samples may be selected and/or tested at the request of the Owner or his agent. 8.1.4. QCD- Document the wire identification, location of removal and overall length on Data Sheet 10.3 from Data Sheet 10.2 ofPSC Procedure SQ 10.2. 8.2. Measure the diameter of the wire in 3 locations, each end and the middle. 8.2.1. QCD- Document the measurement of the wire and the measuring device on Data Sheet 10.3. Calculate and document the average of the 3 measurements. 8.3. Cut each wire test sample to 101" long; this must be a square, neat cut to permit button heading. 8.3.1. Slide two Wire Test Stressing Washers (see Figure D 2) onto the wire, making sure the chamfered seats face to the outside of the wire. 8.3.2. Button head both ends of the wire. 8.3.2.1.QCD- Document the acceptance of the button heads on Data Sheet 10.3 using the acceptance criteria shown in PSC Procedure SQ 8.2. 8.4. Measure the Gauge Length of the wire; from inside of the button head at one end to the inside of the button head at the other end within an accuracy of plus or minus 0.050". 8.4.1. QCD- Document the Gauge Lengthof the wire and the identification and recalibration date for the measuring device. sqlO-3 . TMI. 04isi
L PSC PROCEDURE SQ 10.3 T E STIN G T E ND)ON WICRSES JULY 23, 2004 L (Page 4 of 5 REVISION 0 8.5. Place the specimen into the Wire Test Apparatus and check for proper seating of the Stressing Washers in the pulling adaptors. 8.6. Preload the wires to about 2.45 kips +0, -10% to seat the button heads in the Stressing Washers. 8.6.1. QCD- Document the preloading pressure and force, the identification and recalibration date of the Wire Test Apparatus. 8.6.1.1.To obtain pressure when the force is specified, divide the force in pounds (kips X 1000) by the ram L area to provide the required or actual gauge pressure.
-8.7. Reduce the preload force to 0 force.
8.7.1. QCD- Document the release of the preload force. 8.8. Load the wire to 1.42 kips plus or minus 5%; this will provide 0.1% elongation. 8.8.1. QCD- Document the initial loading of the wire in force, pressure and actual elongation at this point. Elongation shall be measured to an accuracy of 0.050". I 8.9. Preset the Dial Indicator on the Wire Test Apparatus to measure 0.9% elongation. (0.9 in a Gauge length of 100") 8.9.1. QCD- Document the setting of the Dial Indicator. 8.10. Load the wire until the Dial Indicator. shows signs of movement, signaling the 0.9%. elongation L (pressure at 1% elongation). 8.10.1. QCD- Document the force or pressure at 1% elongation. L 8.11. Remove the Dial Indicator. 8.11.1. QCD- Document the "Rule" dimension reading at 1% elongation (approximately 1") to an accuracy of 0.050". k_ 8.12. Continue to load the wire to failure. 8.12.1. QCD- Document the maximum elongation measurement from the "Rule" to an accuracy of 0.050". L 8.12.2. QCD- Document the maximum force or pressure reading at failure. L 8.13. Remove the sample wire (two pieces) and remove the Stressing Washers.- 8.13.1. QCD- Document the type of failure, ductile or brittle, and the location of the wire break from the Ltagged end of the wire (opposite the ram). sqlO-3.TMI.04isi
PSCPROCEDURE SQ 10.3 TESTING TEND ON WIRES JULY 23, 2004 Page 5 of5 REVISION 0 8.14. Calculate the following and document on Data Sheet 10.3. 8.14.1. QCD- Calculate the ultimate stress. 8.14.2. QCD- Calculate the yield stress from the pressure reading at 1% elongation. 8.14.3. QCD- Calculate the percent of elongation under load at the point of failure, based on the actual Gauge length of the wire.
- 9. NOTTFICATTON - XJNA FPTART F CONDITTT)NS The Owner shall be formally notified when each one or more of the following unacceptable conditions are detected as a result of the inspection or Physical Testing of a Tendon Wire.
9.1. The diameter 6f the wire exceeds 0.250" plus or minus 0.002". 9.2. The Corrosion Condition of the wire is Rejected Condition "E" as described in PSC Procedure SQ 8.1 . 9.3. The wire fails to meet the ultimate strength of 240,000 psi. 9.4. The elongation at failure of a tendon wire test is less than 4% or 4 inches when measured in a gauge length of 100 inches.
- 10. - c.IM.ENTATION The items in this procedure requiring documentation shall be documented on Data Sheet 10.3.
10.1. The Data Sheet references the applicable section number of the procedure for each QCD Point. 10.2. Some information from Data Sheet 10.2 of PSC Procedure SQ 10.2 shall require posting to Data Sheet 10.3.
- 11. ATTAC9MENTL 11.1. Data Sheet 10.3 11.2. FigureD..
11.3. FigureD.2 sqlO-3.TMI.04isi
1;flc/ PSC PROCEDURE SQ 10.3 TESTING TENDON WIRES DATA SHEET 10.3 JULY 23, 2004 Page 1 of 1 REVISION 0 PROJECT: THREE MILE ISLAND SURVEILLANCE YEAR: 30TH UNIT: 1 TENDON NO. - TENDON END/BUTTRESS NO. Q.C. SIGNOFF LEVEL -DATE (8.1.4) Wire ID and Location of removal feet Length _ _ inches (8.2.1) Wire Diameters: Tag End. in.Middle in. Ram End _ in.Avg. in. Measuring Device ID Recal Date - (8.3.2.1) Buttonhead Inspection: Tag End Ram End (8.4.1) Gauge' Length of-Wire in.Measuring Device ID - Recal Date -_ - ii (8.6.1) Preload force kips Preload Pressure psi Pressure Gauge ID Recal Date Li Ce - Ram Identification (8.7.1) Force reduced to 0 Ram Area_--_ sq. in. K = kips Recal Date (8.8.1) Initial load of wire force - kips (0.1% elongation) Initial load of pressure _ psi Elongation -inches. (8.9.1) Preset Dial Indicator (0.9% elongation) Indicator ID Recal Date._.._ (8.10.1) Force at 1% elongation kips ;Pressure psi-(8.11.1) "Rule" reading measurement at 1% elongation - inches (8.12.1) Maximum elongation at failure, from "Rule"' reading inches (8.12.2) Maximum force at failure kips ; Pressure psi (8.13.1) Type of break Location of break inches (8.14) CALCULATIONS: - 2. (8.14.1) Ultimate Stress ksi Max. Force _i ( 7TDam. 2 4) (8.14.2) Yield Stress at 1%-elongation -_ksi Force 8 1% - (r- Diam.2 e 4) (8.14.3) % elong. at failure % [1 in. + ("Rule" Dim 8 Failure - "Rule" Dim 8 1%)] (9) Sample: Accept - Unacceptable - Owner/Agent Notified Q.C. Review _ Level__ Date_ __________________________evl_______ ds1O-3.TMI.04isi
I W. PSC PROCEDURE SQ 10.3 TESTING TENDON WIRES FIGURE D.1 Paqe 1 of 1 WIRE TEST APPARATUS - FIGURE D.1 I.:....:. -- E.
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-,. PSC PROCEDURE SQ 10.5 CONTINUITY TEST JULY 23, 2004 Page 1 of 4 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT I (8T INSPECTION PERIOD) (30T YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION-IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE CONTINUITY TEST OF TENDON WIRES Prepared by _ .. ., . ., . Title ks646;~.A Date 9- -joy Approved by r1ft A 7 Title 0 -cc 1 , Date g-° Approved by 9 PezAt*_ - Title Date 7-24-or sqlO-5. TM1. 04isi
7 1 - PSC PROCEDURE SQ 10.5 CONTINUITY TEST JULY 23, 2004 Page 2 of 4 REVISION 0
- 1. PU1RPOSE This procedure will establish the requirements for performing a Continuity Test of tendon wires for purposes of visual inspection and evaluation or, usually, Protruding/Unseated tendon wires for Post-Tensioning System Tendons, during In-Service Inspection (surveillance) of Three Mile Island Unit 1.
- 2. SCOPLE.
The Continuity Test on' every wire of a tendon should be considered when a quantity of 4 or more tendon wires are found to be Protruding/Unseated during the Button head Inspection of PSC Procedure SQ 8.0. Also, if visual observation during detensioning indicates the possibility of broken or damaged wires, such as a wire extending more than 3 inches beyond the button head group, a positive continuity check should be performed on each of the suspected broken or damaged wires. 2.1. The Continuity Test may be performed at the request of the Owner, but this is not considered to be a requirement for a normal surveillance. 3.. RSPONSTMILITY As stated in PSC Procedure QA 4.0.
- 4. QTATLTFTICATTI)NS As.stated in PSC Procedure QA 4. 1.
- 5. FQ(UITPMFNT A tapeline shall be the only Quality Control equipment required to perform the Continuity Test, except where calibrated hydraulic devices and gauges are used.
- 6. PRFCATMONS 6.1. CAUTITTON - WHEN PULLING INDIVIDUAL WIRES, NEVER EXCEED THE YIELD STRENGTH OF THAT WIRE WHEN PULLING WITH THE PULLING DEVICE - 9425 POUNDS.
- 7. EREREQIJISTIRS 7.1. The Grease Cap will be removed and grease samples taken.
7.2. The Anchorage Inspection will be complete, with protruding wires in evidence. 7.3. The tendon will be Detensioned; it will have been Monitored for Forces. sqlO-5.TMI.04iSi
PSC PROCEDURE SQ 10.5
-- < CONTINUITY TEST JULY 23, 2004 Page 3 of 4
- - REVISION 0 7.4. Each wire that was determined to be Protruding/Jnseated as a result of the Button head Inspection of PSC Procedure SQ 8.0 will be adequately identified either by marking, tagging or reference to Data Sheet 8.0.
7.5. The anchorages at each end of the tendon will be pushed back about 12 inches.
- 8. CONTNT TITY TFST 8.1. The Protruding/Unseated wire shall be located.
-8.2. The Tendon Surveillance Wire Puller shown in Figure 2 of this procedure shall be attached to the wire to be tested. 8.3. The wire shall be pulled with the Wire Puller using as little force as possible, but not to exceed 9425 pounds. 8.3.1. If the wire cannot be moved by hand, it shall be acceptable to use any mechanical device to accomplish that purpose, such as a "Come-Along", "Chain-Hoist", "Chain-Pawl" or hydraulic cylinder. 8.3.1.1.It is unlikely that anything but the hydraulic cylinder will be able to exert such an amount of force so as to yield or break the wire. Therefore, hydraulic devices shall be. checked for area and controlled for force through a calibrated gauge or controlled for maximum force through a locking valve to control the amount of pressure to be exerted. 8.3.1.2.There remains a possibility that the wire might not be moved by a limited force. It maybe possible
-to break that wire loose with force in excess of 9425 pounds. This attempt shall only be undertaken with the mutual consent of the Owner's Engineer responsible for the In-Service Inspection and the PSC Construction Manager.
8.3.1.2.1. If it is decided to exceed the control force, the amount of force used to move that wire shall be documented and evaluated for impact on the strength of the wire and the force to be applied to the Retensioning of the tendon. 8.3.1.2.2. QCD- Document the maximum force used to move the wire on Data Sheet 10.5, if over 9425 pounds. 8.3.1.3. The wire shall be considered continuous if it can be observed to move at the opposite end of the tendon. 8.3.1.3.1. QCD- Document that wire as continuous on Data Sheet 10.5. 8.3.1.4.If the wire cannot be observed to be moving, it could be broken and the pulling shall continue until that wire is removed. sqlO-5.TMI.04isi
PSQ PROCEDURE SQ10.5 CONTINUITY TEST JULY 23, 2004 Page 4 of 4 REVISION 0 - 8.3.1.4.1. QCD-Document that wire as discontinuous on Data Sheet 10.5. As the wire is drawn out it shall be checked for condition and to determine the cause of breakage, if possible. Document -the condition of the wire using PSC Procedure SQ 8.1, Corrosion Evaluation Criteria for Tendon Wire/Button heads. Also document, where possible, the reason for breaking. 8.3.1.4.2. QCD- If the wire is Broken, it shall be shown as broken on Data Sheet 8.0 and added to the total of Broken/Missing Wires and the Code Symbol modified to reflect that fact. 8.3.1.4.2.1. If any or all of the Protruding/Unseated wires since the original installation or previous surveillance are found to be broken and when added to the amount of Broken/Missing Wires on Data Sheet 8.0 totals 1 or more, it shall be necessary to notify the Owner of this condition in accordance with the requirements of PSC Procedure SQ 8.0, Section 9. i 8.3.1.4.2.2. It shall be acceptable to continue working and notify the Owner at the earliest opportunity, but within 24 hours of discovery. L 8.3.1.5.If any or all the Protruding/Unseated wires have been determined to be continuous, each shall be reinspected for Protrusion after Retensioning to see if they have seated themselves. An evaluation ] C W of that condition shall be performed after Retensioning. 8.3.1.5.1. QCD- If any or all the Protruding/Unseated wires remain unseated after Retensioning, it shall be reported as required of PSC Priocedure SQ 8.0, Section 9.6.
- 9. DOGLNTATIEN The items requiring documentation shall be documented on Data Sheet 10.5 or to Data Sheet 8.0 of PSC Procedure SQ 8.0.
9.1. Some information maybe required to be posted to Data Sheet 8.0 of PSC Procedure SQ 8.0.
- 10. ATTAG(HEFNTS L 10.1. Data Sheet 10.5 10.2. Figure 2 L.
sqlO-5 .TMI . 4isi
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PSC PROCEDURE SQ 10.5
-CONTINUITY TEST LI_(--i DATA SHEET 10.5 Page 1 of 1 Revision 0 CONTINUITY TEST - INSPECTION DOCUMENTATION PROJECT __ SURVEILLANCE NO. YEAR TENDON NO. TENDON END/BUTTRESS NO. - _- UNIT Row! Force if Posted Corrosion Q.C ire No. Continuous Over 9425 Broken to DS 8.0 Condition COMMENTS IS'___f_
2- 8 _ 3 -11__ _ 4 12_ 5 13 _ _ _ _ __ _ _ _ _ _ _ _ _ _ 6 - 14 = 7 -13
.8-14 . , .- -. '_' ,,__
9 - 13 _ _ _ _ _ _ _ _ _ _ _ _ _ _ 10 - 14 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 11 - 13. - -
,2:
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- I 4-F_ _-_ __, _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __I_
~114 - 8 1
1 4- 1 -- 4 F I 115 - . I I I. . I . I I . I I . . I . , _,__--~~--__>_Row Wires , : __ Note that this form can be -used to verify up to 17 individual wires 0000001 -7 '-in columnar fashion; if more than 0000000 2 - 8 i 17 are to be verified or if the 0000000000 3 - 11 entire tendon is to be verified,
-00000000000 0 4 - 12 then a row by row inspection shall 000000000000 5 - 13 00000000000000 - 14 i be performed.
000000000000 7 - 13 000000000000.00- -r 14 Orient the anchorage sketch with 00000-0000000 9 -13 the Heat Code Identification and 00000000000000 10 -14 note the wire number as it appears 00000000000000 1 -13
- 12 in each row starting at the left
.000000000000 12 0000 00000000 13 - 11 side in each row.
00000000 14: 8
- 000000 15 --.7 ,The Comments Area shall be used to identify particular wires or provide inspection remarks.
Q.C. Review Level -Date Title -
L_ O.*.el
.I PSC PROCEDURE SQ 10.5 CONTINUITY TEST FIGURE 2,.
Page 1 of 1 TENDON SURVEILLANCE WIRE PULLER -FIGURE 2 This is submitted for information only as the final product may vary somewhat from this design. Not a Quality Control Device. Li 0, NOTES:
- 1. The nut with the pulling ring welded to it may be replaced with an eye nut.
,zI, Z. The anchor head must be pushed into the tru npet to give a clear distance of at least one foot between butionheads and anchor head in order to use this tool. This pernlits the wires to move apart so that the tool will slip over the buttonheads.
"Iz "l PSC PROCEDURE SQ 12.0 REPLACE GREASE CAP JULY 23, 2004 Page 1 of 5 C REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8 TH INSPECTION PERIOD) (30T YEAR) i I V....... - REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE I i PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE GREASE CAP REPLACEMENT Prepared by. 2/
7 Title /W?.i A.,4 Date 7- -3.cP' Approved by /,/ Adz -/Z v Title .<R-G rag Date Approved by , .i. AS X Title KG. 1A2d Date 7 -*2af°r s-X sql2-O.TMI .04isi
L -PSC PROCEDURE SQ 12.0 REPLACE GREASE CAP JULY 23, 2004 L71Page2 of 5 REVISION 0
-1. PURPOflSIE This procedure will establish the requirements for the Replacement of Grease Caps after visual inspection and evaluation has been completed for the tendon end anchorages, shims, bearing plates and wires during In-Service Inspection (surveillance) of Post-Tensioning System Tendons of Three Mile Island Unit 1.
- 2. RRESPONSIBILITY As stated in PSC Procedure QA 4.0.
- 3. QTIAT.TFITCATIONS
- As stated in PSC Procedure QA 4.1.
- 4. F TQUPMET, MATERTATS i 4.1. Miscellaneous hand tools.
4.2. Come-alongs and associated rigging. The end caps weigh approximately 200# when filled with grease. 4.3. Solvent - for removing grease and cleaning equipment. (EPA 2000 or CRC Natural Degreaser l Aerosol is acceptable to TMI). 4.4. Spray galvanizing type paint made by LPS Research Laboratories, Inc. or approved EQUAL Commercial grade. 4.5. Modified 1-1/16" socket sets with body approximately 3" long in order to clear end cap hold-down L-studs on original type end cap hold-down configuration. 4.6. Cleaning rags. 4.7. Tendon End Cap fasteners, gasket, and clamps. 4.7.1. Top (Shop End), Vertical End Cap Materials:
'4.7.1.1.Flat Under-Can Gaskets, 1 per end cap, SS#286-100-0500 (Inland Ryerson Drawing No.
i170WAC5)- 1/2 inch thick, closed cell neoprene, 17-1/2" O.D. (+1/16, -0) x 14-1/2" I.D. (+0, - 1/16), Manufacturer - Rubatex Corp. or equal. 4.7.1.2. Stud Gaskets, 4 per end cap, SS#929-03l-3000-1. 1/8 inch thick neoprene, 3/8" O.D. x 5/8" I.D. (, - Manufacturer - J.D. Rohrback Company of Lancaster or equal.'. 4.7.1.3.Belleville Spring Washers, 4 per end cap, SS#000-454-4810-1. -5/5" standard, Manufacturer - Rolex Co. Hillside, NJ or equal. sqI2-0.TMI.04isi
PSC PROCEDURE SQ 12.0 REPLACE GREASE CAP JULY 23, 2004 Page 3 of 5 REVISION 0 4.7.2. Bottom (Field End), Vertical End Cap Materials: 4.7.2.1.0-Ring Gaskets, 1 per end cap, SSt459-046-7500-1. 5/8" cross-section, 17-1/4" I.D., 60-80 durometer neoprene. 4.7.3. Hoop and Dome Tendon End Cap Materials: 4.7.3.1.Flat Under-Cap Gaskets, 1 per end cap, SS#286-110-0500-1 (Inland Ryerson Drawing No. 170WAC5) -1 2 inch thick, closed cell neoprene, 17-1/2" O.D. (+1/16, -0) x 14-1/2" I.D. (+0, - 1/16), Manufacturer - Rubatex Corp. or equal. 4.7.3.2.End Cap Pipe Plugs, 4 per end cap, YA" NPT Galvanized. 4.7.3.3.End Cap Pipe Plugs, 1 per end cap, 1/4"NPT Galvanized. 4.7.3.4.Hold-Down Clamps, 4 per end cap, (Ref. P.O. 0436005), Manufacturer - Precision Surveillance or equal. 4.7.3.5.Hold-Down Bolts and Washers; 4 per end cap. 1" - 8UNC x 2-1/2" Galvanized. 4.7.3.6.POP-A-PLUG, P/N PSC-0750-S, SSN 000-478-0820-1. 4.7.3.7.POP-A-PLUG Installation Tool. 4.7.3.8.Teflon tape thread sealant.
- 5. (TTATTTY CCNTROT.
There is no need for Quality Control Documentation in this procedure.
- 6. PRFCATMTION, Be prepared to support the weight of the grease cap.
- 7. PRFRE-Q(IST FS--
All inspections and evaluations shall be completed with the exception of Grease Replacement. See Section 8 of this procedure.
- 8. GMTRFASF RFPT.ACFMFNT Prior to replacing the Grease Can, the total Grease Loss from Data Sheet 6.0 of PSC Procedure SQ 6.0 shall be known: The method of replacement, as cited in PSC Procedure SQ 12.1, shall be reviewed prior to the actual placement of the Grease Cap on the bearing plate.
sql2-O.TMI .04isi
PSC PROCEDURE SQ 12.0 REPLACE GREASE CAP JULY 23, 2004
- Page 4 of 5 REVISION 0
- 9. iRF.AsFT CAP RFPTACF.mNT General:
The RB tendon end caps will be re-installed in one of the following configurations depending upon which tendon group they are in: Preferred Configuration for Hoop andDlonme (See Attachment 1) The cap is removed and the main gasket is replaced with the conventional Rubatex gasket. The original through-cap mounting bolting is replaced with hold down clamps, and the through-cap holes plugged with Pop-A-Plugs. A 1/41"4 vent plug is installed. Primarily used on the upper end of verticel tendons (See Attachment 2). This alternative makes no changes to the existing design. A Rubatex gasket and "thru-can" bolting are used. Used on vertical tendon lower end cips. This makes no modifications to the existing design. An 0-ring is installed in the end cap which is bolted directly into'the bearing plate. 9.1. Hoop and Dome: 9.1.1. Clean and dry the gasket seating surface of the tendon end cap and bearing plate using approved solvent or other approved cleaner. 9.1.2. If not already installed, in the OD of the cap, approximately 6" from the flange and in line with the fill plug, drill and tap for a /4" NPT vent plug; 9.1.3. Using a 1" -8 UNC tap or thread chaser, clean up the four bolt holes in the base plate around the end cap. 9.1.4. If not already done, the four hold down stud holes are to be plugged for hoop and dome tendons. This method of plugging is with Pop-a-plugs, however, l/2" NPT plugs may be substituted. 9.1.4.1.Prior to installing a Pop-a-Plug, ensure that the hole in the can is free of gouges or scoring that, would affect its ability to effect a seal. 9.1.4.2. Install the Pop-a-Plug in accordance with the manufacturer's instructions. Use na pipe sealant. 9.1.4.3.If unable to install a Pop-a-Plug, tap the hole to accept a l/2 " NPT Galvanized Pipe plug. Apply Teflon tape and install the plug. 9.1.5; Installation of replacement Rubatex Gasket configuration for hoop and dome tendons. 9.1.5.1.Bond the Rubatex gasket to the face of the flange using pliobond. 9.1.5.2.Align the tendon end cap over the anchorage against the bearing plate using care to avoid damaging or misaligning the gasket which has been glued to the enid cap flange. sql2-0 . TMI . 04isi
L 'PSC PROCEDURE SQ 12.0 j . REPLACE GREASE CAP MULY 23, 2004 Page 5 of 5 REVISION 0 9.1.5.3. Secure four tendon end cap hold down clamps with bolts and washers to the bearing plate holes and hand tighten them. 9.1.5.4.Recheck that the gasket has not slipped or become crimped and that the tendon end cap and hold down clamps are aligned properly. 9.1.5-5.Tighten each bolt, equalizing the load on each as much as possible, to evenly compress the Rubatex main gasket by approximately 1/8". (No torquing is required) 9.2. Installation of Rubatex gasket with top (shop end) vertical "through-can" bolting. 9.2.1. Bond the Rubatex gasket to the face of the flange using Pliobond. 9.2.2. Align the tendon end cap over the anchorage against the bearing plate using care to avoid damaging or misaligning the gasket which has been glued to the end cap flange. ' 9.2.3. Install the four tendon end cap hold down nuts (with gaskets and conical washers) on the studs and hand tighten them. 47 -9.2.4. Recheck that the gasket has not slipped or become crimped and that the tendon end cap is properly aligned. 9.2.5. Tighten each nut, equalizing the load on each stud as much as possible, to evenly compress the Rubatex main gasket by approximately 1/8". (No torquing is required.) 9.3. Install of O-Ring gaskets on lower vertical tendons with bearing plate bolting. 9.3.1. Bond the O-Ring gasket in place using-Pliobond. 9.3.2. Align the tendon end cap over the anchorage against the bearing plate using care to avoid damaging or misaligning the O-ring which has been glued to the end cap. 9.3.3. Install the four tendon end cap hold down bolts and hand tighten them. 9.3.4. Tighten each bolt, equalizing the load on each bolt as much as possible, to evenly compress the 0-ring main gasket. The flange should be pulled up tight against the bearing plate. Bring the bolts to a "snug-tight"* condition and then tighten the bolts by an additional 1/4 to 1/3 turn of the bolt head. (*"Snug.-tight" is defined as the tightness attained by the full effort. of a person using an ordinary spud wrench.) ( 10. OCTIJMBNTATTON
;< None required for this operation.
- 11. ATTACETMFNTS -
11.1. Attachment 1 - "Hoop and Dome Tendon End/End Can Assembly Latest Design" 11.2. Attachment 2 - "Original Can Hold-Down Design" sql2-0.TMI.04isi
If9Lfy PSC PROCEDURE SQ12.0 REPLACE GREASE CAP ATTACHMENT 1 l t-JULY 23, 2004 Page 1 of 1 REVISION 0 PROJECT: THREE MILE ISLAND UNIT 1 SURVEILLANCE YEAR: 3 0 TH I .
-!, -1, -,
HCLD-DOWN CLA/S WMTH SOLTS AND WASHEFRS-AiCAP HOOP & DOME TENDON END/END CAN ASSEMBLY
- LATEST DESIGN ATTI .12-O.TMI.04isi
f I 0jul PSC PROCEDURE SQ 12.0 REPLACE GREASE CAP ATTACHMENT 2 - JULY 23, 2004 Page 1 of 1 REVISION 0 PROJECT: THREE MILE ISLAND UNIT 1 SURVEILLANCE YEAR: 3 0 TH UNDER-CAN GASKET
.O'RING OR FLAT RUSATEX DESIGN.
ORIGINAL CAN HOLD-DOWN DESIGN ATT2.12-O.TMI.04isi
1(3 , I--,;
.N PSC PROCEDURE SQ 12.1 I .- -,, "
GREASE REPLACEMENT JULY 23, 2004 Page 1lof 8 REVISION 0 REVISION 1, 8/25/04 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (3 0 TH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE GREASE REPLACEMENT H.4 ..... A\Prepared by Title 4et*, Q .,4. Date 8-S ¢at Z Approved by Title Ir - > Date & use Al Approved by &,.'D. ZA7-, Title - , /27a Date ____- °
- 1..- ..t ..K i . V lsql2-1.TMI. 04isi
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C PSC PROCEDURE SQ 12.1 GREASE REPLACEMENT JULY 23, 2004 Page 2 of 8 REVISION 0 REVISION 1, 8/25/04
- 1. PT RPOSF This procedure will establish the requirements for the Replacement of Grease in the tendon duct after visual inspection and evaluation of Post-Tensioning System Tendons during In-Service Inspections (surveillance) of Three Mile Island Unit 1.
- 2. S.COPF.
This procedure is intended to provide the Grease Replacement requirements for the wire post-tensioning system.
- 3. RFSPONSTRTH.ITY As stated in PSC ProcedureQA 4.0.
- 4. QmTATITFCATTONS As stated in PSC Procedure QA 4.1.
- 5. FQT T[PMFENT 5.1. Drum belt heaters.
5.2. Hand pump for pumping hot grease fromff a 55 gallon drum. 5.3. Thermometer (calibrated to measure replacement grease temperature 0-3000 F. 5.4. Viscosity Oil Co. Visconorust 2090P-4 Casing Filler Grease. 5.5. Plastic bags, plastic sheeting, rags, buckets and drums for waste grease.
- 6. QTTATTTY CONTROT.
All Quality Control Documentation (QCD) points noted in this procedure are Hold Points. The work shall not progress past or through a QCD without a verbal release from the Inspector. The required information or evaluative data shall be documented on Data Sheet 12.1 of this procedure. It shall be necessary to acquire the Total Grease Loss for the tendon from Data Sheet 6.0 of PSC Procedure SQ 6.0.
- 7. PRECAT TTTONS During greasing operations the grease may be pumped under pressure and may have temperatures in excess of 150 degrees F. It is therefore essential to avoid direct contact with the hot grease and to make sure all connections are secure. Spilled grease could create a slipping safety hazard and damage roof surfaces.
During all operations, it should be cleaned up-and placed into waste containers. lsql2-1.TMI.O4isi
PSC PROCEDURE SQ 12.1
-y 1j 1t l GREASEREPLACEMENT JULY 23, 2004 Page 3 of 8 REVISION 0 REVISION 1, 8/25/04
- 8. PRFEFQT1ISTTIS L 8.1. All Inspections will be complete.
8.2. The tendon will be in a stressed condition. 8.3. The Grease Cap shall be ready to be installed or has been installed. 8.4. QCD- Enter the quantity of Total Grease Loss from Data Sheet 6.0 for this end of the tendon. 8.5. QCD- Enter the quantity of Total Grease Loss from Data Sheet 6.0 for the other end offthe tendon. 8.6. QCD- Enter any Estimated Grease Loss that may have occurred as a' result of Leaks from the Grease Cap or Gasket since the original installation or previous surveillance for this end of the tendon. 8.7. QCD- Enter the Estimated Grease Loss that may have resulted from Leakage for the other end of the tendon. 8.8. Calculate the TOTAL TENDON GREASE LOSS by adding the Total Grease Loss of Data Sheet 6.0 to Estimated Grease Loss, as each might apply. 8.8.1. QCD- Document the TOTAL TENDON GREASE LOSS on Data Sheet 12.1. 8.9. QCD- Document the ambient temperature near the tendon, and Thermometer Identification and Recalibration Date. 8.10. QCD- Document the date of grease can removal shown on Data Sheet 6.0 of PSC Procedure. SQ L_ 6.0 for this tendon. Document the date of grease replacement and calculate the Elapsed Time.
- 9. CONTRP)TS FOR REM LMUTTTM TTFNDON.VOTF) 9.1. The replacement of grease shall be performed prior to demobilization of the tendon surveillance equipment and personnel, provided that the tendon anchorages have been-lightly coated with grease and grease can properly installed.
L 9.2. Hoop or Dome Tendon 9.2.1. For a Hoop or Dome Tendon where less than 10 gallons of grease has been lost from the tendon void (duct, or less than 5 gallons either end excluding grease loss from the grease caps, anchorage or samples. Each end will be hand pumped with hot grease until it reaches a level 1-1/2" to 2" i below the vent hole to allow for the expansion of the grease. 1\hS b HekAA)e no lsql2-1 .TMI. 04isi
PSC PROCEDURE SQ 12.1 5- BGREASE REPLACEMENT JULY 23, 2004
'Page 4 of 8 REVISION 0 REVISION 1, 8/25/04 9.2.2. A Hoop or Dome Tendon will be pressure pumped where more than 10 gallons of grease has been lost from the tendon void (duct), or more than 5 gallons either end excluding grease loss from the grease caps, anchorage or samples. The Hoop or Dome Tendon will be pressure pumped with hot grease from one end until it exits the Opposite End.
9.2.2.1.Where there is no grease Exiting Outflow from the Opposite End of a Hoop or Dome Tendon, it shall be necessary to hand pump hot grease into the Opposite End grease cap until it reaches a level 1-1/2" to 2" below the vent hole to allow for the expansion of the grease. 9.3. Vertical Tendon 9.3.1. Where less than 10 gallons of grease has-been lost from the tendon void (duct) at the lower end excluding grease loss from the grease caps, anchorage or samples. Hot grease will be poured or hand pumped into the top end until it reaches a level 2" to 3" below the vent hole to allow for the expansion of the grease. 9.3.2. Where more than 10 gallons of grease has been lost from the tendon void (duct) at the lower end excluding grease loss from the grease caps, anchorage or. samples, the tendon will be pressure pumped with hot grease from the bottom end until it exits the Top End. 9.3.2.1.Where there is no grease Exiting Outflow from the Top End of a Vertical Tendon, it shall be necessary to pour or hand pump hot grease into the Top End grease cap until it reaches a level 2" to 3" below the vent hole to allow for the expansion of the grease. 9.4. The grease in the drum shall be pumped at a minimum temperature of 1400 F and not be permitted to exceed a maximum temperature of 2000 F at any time during pumping as measured at the drum. 9.5. The pressure required for pressure pumping hot grease into the tendon in an effort to have the grease exit the Opposite End of the tendon shall not exceed 100 psig at the filler end for hoop and dome tendons and 150 psig for the lower end of a vertical tendon. 9.6. 'Pumping shall be stopped immediately if it is suspected or known that the grease is going somewhere else besides the immediate tendon void. 9.8. MPASTTRFMFNT OF OTRFA SP, RFPT.ACCFMFNT 9.8.1. The grease may be in a large storage container or in 55-gallon drums. The large storage container shall have an automatic thennostat control for temperature, while drum heaters shall be used to heat the grease in drums. 9.8.2. The grease shall be monitored for quantity by a volume gauge at the pumping mechanism or by '-measuring the quantity of grease remaining in the drum or by measuring the drum to determine the' quantity that has been pumped out. Jsq12-1.TM1.04iSi '
L A PSC PROCEDURE SQ 12.1 GREASE REPLACEMENT JULY 23, 2004 L Page5 of8
'-REVISION 0 REVISION 1, 8/25/04 9.8.3. To provide a grease volume number in gallons based on a standard 55 gallon drum, divide the 55 gallons by the usable height of the drum (31 inches). This provides a figure of 1;77 gallons per inch of drum height. Note that a typical 55 gallon drum is 34 inches high, but based on actual observation, grease shrinkage and the depressed lid take up 3 inches of height.
9.8.3.1.QCD- Document the method of measurement (dimension); document the gallons perinch in that area of the Data Sheet. ZiA9.8.4. Take a measurement of the height of the grease in the drum with a clean measuring d6vice before pumping any grease. It will be acceptable to take the measurement from the top of the grease in the drum to the top edge of the drum. 9.8.4.1.QCD- Document the grease height dimension to the nearest 1/8 of an inch. QCD- Document the temperature of the grease (1400 F -2000 F), Thermometer Identification and _Recalibration Date. L2 9.8.5. Take a measurement of the height of the grease in the drum afiet pumping the grease. 9.8.5.1 .QCD- Document the final grease height dimension to the nearest 1/8 of an inch. 9.8.5.2.Calculate and document the Total Quantity of grease pumped into the can to the nearest 0.25 gallon. 9.8.5.2.1. EXAMPLE: If the initial grease height was 25-1/2" and each inch of grease height or depth represents 1.77 gallons; where the final grease height was 6-1/4", this is a 19-1/4" reduction multiplied by 1.77 gallons per inch which equals 34.1 gallons pumped in. 9.9. MFASTRFMNT OF REASF WAST-P When it becomes necessary to determine the volume of grease that was pumped into the tendon void, it will be necessary to add the waste grease outflow, spillage, the grease remaining in the pump-in hose, the grease remaining in the waste line hose and subtract that from the grease volume that was pumped from the drum into that tendon. 9.9.1. If the waste grease is pumped into a 55 gallon drum, then each inch of drum height will equal to 1.77 gallons. 9.9.2. The standard grease filling hoses have an internal diameter of 1-1/2". The formula for volume of a 2 cylinder measured in inches is pi(3.1416) X r X L (in inches) divided by 231 cubic inches per gallon. Therefore, each 12" of this hose would contain 0.092 gallons. The same volume formula would apply to determine the capacity of other types of cylindrical containers; buckets, cans, etc. A, lsq12-1.TMI .04isi
PSC PROCEDURE SQ 12.1 GREASE REPLACEMENT JULY 23, 2004 L {7 Page 6 of 8
-REVISION 0 REVISION 1, 8/25/04 9.9.3. Smaller containers shouldbe evaluated for size to determine the capacity.. These types of containers would only require a simple estimate for the waste grease contained therein.
9.9.4. Before pumping any waste grease into a container, always verify the quantity within that container before pumping.
- 10. (HRFAS, REPTLACEMENT The Grease Replacements described in this Procedure are for one end of a tendon. The terms Tendon Void, Tendon Conduit, and Tendon Duct are synonymous.
10.1. HTAND PTT TPNTG Where less than 10 gallons of grease has been lost from the tendon void (duct), or less than 5 gallons from either end of a hoop or dome tendon excluding grease loss from the grease cap, anchorage or samples, each end will be hand pumped until it reaches a level 1-1/2" to 2" below the vent hole to allow for the expansion of the grease. Where less than 10 gallons of grease has been lost from the tendon void (duct) at the lower end of a vertical -tendon excluding grease loss from the grease cap, anchorage or samples, the Top end of will be poured or hand pumped to replace the grease until it reaches a level 2" to 3" below the vent hole to allow for the expansion of the grease. 10.1.1. Remove the grease can plug, attach the "Y-Device" shown in Sketch 8.1 (or a similar device) and hand pump grease in at a minimum temperature of 140 F, but no greater than 2000F as measured at the drum. 10.1.2. Remove the "Y-Device" apply Teflon tape .to the grease inlet and vent plug threads and tighten L them securely. Verify no grease is leaking. 10.1.3. Repeat sections 10.l1. and 10.1.2 for the other end of a hoop or dome tendon. 10.1.4. QCD- Document the quantity of hot grease Hand Pumped into this end grease cap. QCD- Record grease level below vent hole (1-1/2" to 2" for Hoop and Dome Tendons, 2" to 3" for 'l top end of Vertical Tendon). 10.1.5. QCD- Document the quantity of hot grease Hand Pumped into the other end grease cap.
-10.2. PRF .SST TRF PT TWpING A Hoop or Dome Tendon will be pressure pumped where more than 10 gallons of grease has been A~l lost from the tendon void (duct), or more than 5 gallons either end excluding grease loss from the grease caps, anchorage or samples. The Hoop or Dome Tendon will be pressure pumped with hot grease from one end until it exits the Opposite End.
Aim'5111Y- 94 014A)W lsql2-1 .TMI . 04isi
!L PSC PROCEDURE SQ 12.1 GREASE REPLACEMENT JULY 23, 2004 Page 7 of 8 REVISION 0 REVISION 1, 8/25/04 Where more than 10 gallons of grease has been lost from the tendon void (duct) at the lower end of a vertical tendon excluding grease loss from the grease cap, anchorage or samples the tendon will be pressure pumped from the Lower End until it exits the Top End.
10.2.1. Remove the grease cap plug, attach the "Y-Device" (or a similar device) and pump hose to the end of the grease cap to be pumped into. Connect the waste outflow hose to the opposite end of the Hoop, Vertical or Dome Tendon. Be sure to have a suitable quantity of waste containers on hand to collect the waste. 10.2.2. Be sure that adequate communication is provided at each end of the tendon so that the crew at each end of the tendon will know what actions are taking place. 10.2.3. Pressure pump grease in with a pressure not to exceed 100 psig at the Filler End for hoop and dome tendons and 150 psig for the Lower End of a vertical tendon, at a minimum temperature of 140&F, but no greater than 200°F as measured at container. l 10.2.4. Hot grease shall be pressure pumped for not more than 1/2 hour. If the grease exits the Opposite End of a hoop tendon or dome tendon or Top End of a vertical tendon within the 1/2 hour time limit, grease pumping shall continue until a minimum of 1 gallon of clean grease has exited from the opposite end after the waste outflow was determined to be free of foreign substances. 10.2.4.1. Where there is no grease Exiting Outflow from the Opposite End of a hoop or dome tendon or Top End of a vertical tendon within the 1/2 hour time limit, it shall be necessary to hand pump hot grease into the Opposite End of a hoop or dome tendon or TOP End of a vertical tendon grease cap until it reaches a level 1-1/2" to 2 ",bel6w the vent hole,for hoop or dome tendons or 2" to 3" below the vent hole for top end of vertical tendon to allow for the expansion of the grease. 10.2.5. QCD- Document the quantity of hot grease Pressure Pumped into this grease cap. Also document the Thermometer Identification, Recalibration Date and the temperature of the grease pumped in. 10.2.6. QCD- Document the quantities of Exiting Outflow Grease, if any. 10.2.7. QCD- Document the QUANTITY REPLACED by Hand Pumping from the other end of the tendon, if applicable. QCD- Record grease level below vent hole (1-1/2" to 2" for Hoop and Dome Tendons, 2" to 3" for top end of Vertical Tendon). 10.2.8. QCD- Calculate. the TOTAL TENDON QUANTITY REPLACED by adding the quantities of grease replaced by Hand Pumping (10.1.4 and 10.1.5 or 10.2.7) to the quantity of grease f - . 1. Pressure Pumped (10.2.5) minus the quantity of Exiting Outflow Grease (10.2.6). l ' .W, ' Ai cIX
/,6.? xaIFo.,
lsql2-2.TMI.04isi
PSC PROCEDURE SQ 12.1 GREASE REPLACEMENT JULY 23, 2004 Page 8 of 8 REVISION 0 REVISION 1, 8/25/04 10.2.9. QCD- Compare the TOTAL TENDON QUANTITY REPLACED to the TOTAL TENDON GREASE LOSS. Calculate the percent difference by the following formula: TOTAL TENDON QUANTITY REPLACED (10.2.8) - TOTAL TENDON GREASE LOSS (8.8.1)
- -X100 NET VOLUME TENDON VOID (SQ 12.2)
L 11. OTHE1R CO(NTROTLS 11.1. Verify that no grease is leaking. If there is some leakage, the deficiency shall be corrected and cleanup performed. 11.2. QCD- Document the acceptance of leak tightness. 11.3. QCD- Document the acceptability of the refilling. 11.4. QCD- Document any comments of unusual occurrences or references that could assist in evaluating the refill or for future surveillances.
- 12. NOTIFICATTIN Notify the Owner if amount if the difference in the amount replaced at any tendon end minus the amount removed from that end exceeds 4 gallons.
If the absolute difference between the amount of grease removed and the amount of grease replaced on a given tendon exceeds 10% of the net duct volume, it shall be necessary to draft a nonconformance report and submit it to the Owner.
- 13. D.OCUMENJM TATTON The items requiring documentation shall be documented on Data Sheet 12.1.
13.1. Some information shall be posted from Data Sheet 6.0 of PSC Procedure SQ 6.0 onto Data Sheet
' 12.1.
13.2. The Data Sheet references the applicable section number of the procedure for each QCD point.
- 14. ATTACHNMENTS
- 14.1. Data Sheet 12.1
' 9 14.2. Sketch 8-1 A\ Vx/"Y' JG g1oodr lsql2-1. TMI . 04isi
-? PSC PROCEDURE SQ 12.1 LGREASE REPLACEMENT DATA SHEET 12.1 JULY 23, 2004 Page 1 of I REVISION 0 REVISION 1, 8/25/04 GREASE REPLACEMENT - INSPECTION DOCUMENTATION - PROJECT: THRFF, MT F TSTIAND ITNT1 SURVEILLANCE YEAR: ME TENDON NO. TENDON END/BUTTRESS NO. Q.C L - Signoff (8.4) TOTAL GREASE LOSS from Data Sheet 6.0 for THIS tendon end Gal.
(8.5) TOTAL GREASE LOSS from Data Sheet 6.0 for OTHER tendon end Gal. (8.6) Estimated grease losses fromleaks for THIS tendon end Gal. (8.7) Estimated grease losses from leaks for OTHER tendon end Gal. (8.8.1) TOTAL TENDON GREASE LOSS Gal. (8.9) Ambient Temp. _ _F. Thermo. ID - Recal Date - (8.10) Cap Removal Grease Replacement Days Elapsed (9.8.3.1) Pump Gauge Dimension Gallons per inch L (9.8.4.1) Grease Height in Drum BEFORE (9.8.5.1) AFTER Calculations: Total L(2 (9.8.4.1) Temperature of grease _F Thermo. ID (10. 1.4) Quantity of grease HAND PUMPED into TIS tendon end Recal Date Gal. (10. 1.4) Grease level below vent hole inches
' (10. 1.5) Quantity of grease HAND PUMPED into OTHER tendon end Gal.
(10.2.5) Quantity of grease PRESSURE PUMPED into THIS tendon end Gal. L Thermo. No. Recal Date Grease Temp. (10.2.6) Quantity of Exiting Outflow Grease ' Gal. L (10.2.7) Quantity of grease Hand Pumped into OTHER tendon end Gal. (10.2.7) Grease level-below vent hole -_-_'_-_inches (10.2.8) TOTAL TENDON QUANTIY REPLACED - Gal. (10.2.9) PERCENT VARIATION DIFFERENCE % TOTAL TENDON QUANTITY REPLACED (10.2.8) - TOTAL TENDON GREASE LOSS (8.8.1)
-x 100 NET VOLUME TENDON VOID (SQ 12.2)
- (11.2) Grease Leaks: YES or NO -
(11.3) REFILL ACCEPTABLE: YES or NO If TOTAL TENDONREFILL difference more than 10%: _ Owner Notified NCR #_ - - Iy':,; (11.4) COMMENTS: Q.C. REVIEW LEVEL DATE ldsl2-1. TMI. 04isi A,1 Fltf/04 HoC t
KIT u.77 [77 r[77 LI 1771- [7 (77_ FY17 F4 [17 [7 F IT- 7_ I_-~- r=- [.-, . r-i~~~..
.. .1 I
TYPICAL HOOK-UP FOR FILLING TENDON VOIDS A- Grease Can Body - B - Pipe C - Grease Can Filler Bushing D - Y-Device Body I - Male Quick Coupler F. - Operating Shaft & Handle G - Square Male Pipe Plug Wrench . H- Pipe Plug I - Casing Filler I-lose Female Quick Coupler K - Packing Box L- Packing Box Gland M- Relief Valve - Optional (n~n* C/ w u) _0 U ID) mm n3o j(D -) - o
*0 COD11 ) )
_t) I x M .,.._ r cC r Dm zMED z F L
.j
.~c a ~ n Voi Fil.g T o Y-DEVICE . Sketch 8-1
o~,k1 PSC PROCEDURE SQ 12.2 GREASE VOLUMES JULY 23, 2004 I: . Page 1 of 2 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (30T YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY CONTROL PROCEDURE ( .' NET TENDON DUCT GREASE VOLUMES FOR GREASE REPLACEMENT Prepared by 'a, 4, ; Title s&W- A Date 9- 3-°r Approved by Ho/ C ok Title ° A e Date y7-za 4 / Approved by Title 0-*,r2t, Date 7_ 2-AnoP 6' sql2-2.TMI .04isi
PSC PROCEDURE SQ 12.2 I -~, I GREASE VOLUMES JULY 23, 2004 Page 2 of 2 f REVISION 0 PURPOSE This procedure will establish the Net Tendon Duct Grease Volumes to be observed during the refilling of the Post-Tensioning System Tendons with Corrosion Protection Material (Grease) during In-Service Inspections (surveillance) at Three Mile-Island Unit 1. i:
- 2. SCQPFE This procedure shall apply to PSC Procedure SQ 12.1.
- 3. VOTITME CHARTS 3.1. TNThIT I-TENDONq CqHFD1XTFD FOR Inf Y-FAR PTTYqT(AT. STRVFT FT AWT(KTC.
TENDON I.D. 10% NET TENDON DUCT' NET TENDON DUCT GREASE VOLUMES (GALLONS) VOLUMES (GALLONSq) V-32 12.1 121.0 V-53 12.03 120.32 V-66 12.08 120.83 V-140 12.07 120.69 H13-11 11.1 111.04 1H35-49 11.05 110.54 H46-25 11.09 110.94 H62-18 11.06 110.58 H62-26 11.06 110.57 D-213 9.34 93.38 D-225 9.83 98.30 D-230 9.72 97.18
'A . T1T1
. l-3)ThV' AR PT-TV T(- AT. ADTJA rPENT TEPNDM NS J.>
TENDON I.D. 10% NET TENDON DUCT NET TENDON DUCT GREASE VOLUMES (GALLONSq) VOLUMES (GALLONS) V-31 12.06 120.64 V-33 12.08 120.76 V-52 12.04 120.37 V-54 11.97 119.75 V-65 12.07 120.74 V-67 12.04 120.39 V-139 12.12 121.22 V-141 12.04 120.44 H13-10 11.14 111.38 H13-12 11.21 112.06 H35-48 11.06 - 110.61 H35-50 11.07 110.73 H46-24 - 11.11 111.06 H46-26 11.07 110.69 H62-17 11.1 110.96 H62-19 11.1 .111.04 H62-25 11.08 110.79 H62-27 11.06 110.59 D-212 9.24 92.37
.D-214 9.41 - 94.08 D-224 9.84 - 98.42
-D-226 9.81 98.14 D-229 9.8 : 97.96 D-231 9.71 97.10 sql2-2 . TMI . 04isi
DOCUMENT NO: I ETMI-N924-020 DOCUMENT TYPE: ENG THREE MILE ISLANDM REVISION A' 0
*:e",p, X "GREASE VOID CALCULATIONS" SAFETY RELATED NON-SAFETY RELATED X PAGE I I -OF 40
___________ L PREPARED BY: (X1 DATE: 7/.23/e I REVIEW'ED B Y:: DATE: 1A2 3jbD SURVEILLANCE TENDONS ADJACENT TENDONS TENDON TENDON VOID 10% VOID TENDON VOID 10% VOID GALLONS GALLONS TENDON GALLONS GALLONS V-32 121.0 12.1 V-31 120.64 12.06 V-53 120.32 12.03 V-33 120.76 12.08 V-66 120.83 12.08 V-52 120.37 12.04 V-140 120.69 12.07 V-54 119.75 11.97 H13-11 111.04 11.1 V-65 120.74 12.07 H35-49 110.54 11.05 V-67 120.39 12.04 H46-25 110.94 11.09 V-139 121.22 12.12 H62-18 110.58 11.06 V-141 120.44 12.04 H62-26 110.57 11.06 H13-10 111.38 11.14 D-213 93.38 9.34 H13-12 112.06 11.21 D-225 98.30 9.83 H35-48 110.61 11.06 D-230 97.18 9.72 H35-50 110.73 11.07
-D-342-88:40 884 H46-24 111.06 11.11 H46-26 110.69 11.07 H62-17 110.96 . 11.1 H62-19 111.04 11.1 H62-25 110.79 11.08 H62-27 110.59 11.06 D-212 92.37 9.24 D-214 94.08 9.41 D-224 98.42 9.84 D-226 98.14 - 9.81 D-229 97.96 9.8 D-231 97.10 9.71 D-341- 90.03--
D-343-. . 86:98--- -8.7
le . f 00LL-e V -11 fearsjA I /"A _/ PSC PROCEDURE QA 1.0 PROGRAM PURPOSE JULY 23, 2004 Page 1 of 2 (:., REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (TH INSPECTION PERIOD) (30TH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION 1 ('-' QUALITY ASSURANCE PROCEDURE PROGRAM PURPOSE Prepared by Title 4At, .A Date .t3-oy Approved by. xez /' r-_ ",/ _ ,.t Title 6i c.r z Date L7 zk7z7_ Approved by '.Y,
- w. - , , Title - - /n r Date 7-2-3 -e' r' qal-O.TMI.04isi
- 0. '\ 5'3\ PSC PROCEDURE QA 1.0 PROGRAM PURPOSE JULY 23, 2004 Page 2 of 2 REVISION 0
- 1. PUIRPOSE This section of the Surveillance Quality Control Manual shall outline the Quality Assurance/Quality Control activities necessary to insure that the In-Service Inspection operations are performed in accordance with approved procedures and provide the required quality level, consistent with the project specifications, industry standards, regulatory code requirements and the Precision Surveillance Corporation Quality Assurance Program.
qal-O.TMI . 04isi
'-1o PSC PROCEDURE QA 2.0 PROGRAM SCOPE JULY.23, 2004 Page 1 of 2 C.,i REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (3 O0 YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION
- IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE PROGRAM SCOPE Prepared by W. r7J.io Title /1 6, 4. 4, Date 9-2 3of{
Approved by ' )q' /Jvr /'1 Title _In Date 7z2 ?-!s, Approved by Title r 7,?, Date 7-2 3e o-I iIlA QA2-O.TMI.04isi
_-, o C",,
/I0, % PSC PROCEDURE QA 2.0 PROGRAM SCOPE JULY 23, 2004 Page 2 of 2 REVISION 0
- 1. SCOPE The Quality Assurance Procedures within this Section of the Surveillance Program Quality Control Manual are intended to be supplemental to the Precision Surveillance Corporation (PSC) Quality Assurance Manual. They are not intended to replace any Criteria of the Quality Assurance Manual. The Quality Assurance Manual remains as the highest category of document within the Quality Assurance Program hierarchy of documents.
QA2-O.TMI . 04isi
f,-,
- a. -, T"- PSC PROCEDURE QA 3.0 QUALITY ORGANIZATION JULY 23, 2004 Page 1 of 2 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1(8 PERIOD) (30 YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE i QUALITY ORGANIZATION Prepared by - Title A&,Q? ,4. Date 9.23-o' Approved by Title -r Date Approved by r'A D-, V. AgeL4 Title tl ~l:-, Date 7-Z o3f q'a3-0 . TMI . 04isi
\ I- 'z
,i-1 PSC PROCEDURE 4.0 RESPONSIBILITY - Q.C.
JULY 23, 2004 Page 1 of 2 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8 TH INSPECTION PERIOD) (3 0T YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE QUALITY CONTROL RESPONSIBILITY Prepared by. Title Wu4, 1.,< ,Date O. >)-D/ Approved by
- t K An__ 0 Title- f .svA tE -/ SV . '7 2,--rv Cf Date 7-2*2--
Approvedby 9J2- Title Date j- ; 3 - v v qa4-O.TMI.04isi
PSC PROCEDURE QA 3.0 QUALITY ORGANIZATION JULY 23, 2004
-Page 2 of 2 REVISION 0
- 1. )ORCTANZATTON PSC Field Quality Control Inspectors operate under the immediate direction of the Lead Field Quality Control Inspector, who in turn reports to the PSC Manager, Quality Control.
1.1. The Field Quality Control Inspectors shall have full authority and responsibility in all matters pertaining to or affecting the quality control function for the Surveillance of the Post-Tensioning System. These Inspectors shall have the authority to accept, reject, or recommend changes to the field operations or performance. 1.2. The Field Quality Control Inspectors, and the Quality Assurance personnel shall have the authority to issue a "Stop Work Order" for any activity, material, or procedure not in conformance with the project specifications, the Quality Assurance Manual or the. Surveillance Quality Control Manual. The stop work action shall be coordinated through the PSC Manager of Quality Assurance. 1.3. The Quality Control Procedures section of this manual shall serve to further outline the duties and responsibilities of those personnel engaged in performing the quality control functions for the Surveillance of the Post-Tensioning System. 1.4. All personnel engaged in those activities that affect the quality function for the Surveillance operations, shall be qualified by experience or training, prior to the initial performance of their assignments. 1.5. Documentation of qualification and/or training shall be maintained in the quality files on site for those personnel engaged in quality activities. qa3-O.TMI.04isi
PSC PROCEDURE 4.0 RESPONSIBILITY - Q.C. JULY 23, 2004 Page 2 of 2 REVISION 0 01 TAT-ITY CONTR OT. RESPoN.ghTTTY 1.1. The responsibility for the Quality Assurance and Quality Control functions for this project shall be incumbent on those organizations performing that portion of the work described within the various sections of this manual, or as otherwise agreed to in the contract documents. 1.2. Portions of the work not performed by PSC, but where PSC supplies only the equipment or material, shall be subject to the quality requirements specified within the applicable PSC Quality Manual, where that Quality Manual has been developed to comply with the project specifications or contract documents. 1.2.1. The development of the Quality Assurance and Quality Control procedures for the Surveillance operations shall be the responsibility of those organizations performing that portion of the work, unless otherwise agreed to in the contract documents. 1.3. PSC Field Quality Control Personnel shall provide the Quality Control actions for that portion of the work, where PSC or its subcontractors are performing the work or as agreed to in the project specifications or contract documents. All subcontractors performing work as an agent of-PSC, shall be subject to the Quality requirements of the project specifications and the applicable PSC Quality Program. 1.4. PSC and its subcontractors and vendors, shall maintain open access for Inspection, Survey and Audit by the Owner or his authorized agent for all portions of the work being performed for the project. qa4-O.TMI.04isi
PSC PROCEDURE QA 4.1 PERSONNEL QUALIFICATIONS JULY 23, 2004
- Page 1 of 2 REVISION 0
.1, AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (30TH YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE PERSONNEL QUALIFICATIONS Prepared by_ Title M1.0 6. 4. Date ')En of Approved by 'L c, Title i@,E 'f:'eS Date c , Approved by. R.I -/ Title C, , I, . , Date 7-qa4-1. TMI .04isi
*n 3,PSC PROCEDURE QA 4.1.
PERSONNEL QUALIFICATIONS JULY 23, 2004 Page 2 of 2 REVISION 0
- 1. QUTATTTFCATTI)NS 1.1. OT TATITY CONTE nT. INSPECTORS 1.1.1. All Quality Control Inspectors performing Inspections and Tests shall be qualified to minimum of Level II capability in accordance with the requirements of. ANSI N45.2.6-1978. Inspectors performing VT-1, VT-C examinations are to be qualified as a Level TI (VT-1, VT-I C -or VT-3C) examiner as set forth in the 1992 Edition and 1992 Addenda of the ASME Boiler and Pressure Vessel Code, Section XI, Subsection IWL as defined in PSC's written certification practice or as qualified by AmerGen Energy.
1.1.2. All Lead Field Quality Control Inspectors shall be qualified to a minimum of Level TI capability in accordance with the requirements of ANSI N45.2.6-1978. 1.1.3. All Field Quality Control Inspectors performing reviews of Quality Control Documentation for the various procedures in the PSC Surveillance Quality Control Manual shall be qualified to a minimum of Level II in accordance with the requirements of ANSI N45.2.6-1978. 1.1.4. All Quality Control Inspectors shall be certified to specific skill Levels by a Quality Control Inspector who has been qualified as Level If or III in accordance with the requirements of ANSI N45.2.6-1978. 1.2. CTONSTRTTCTTON PFRSONNPT. Precision Surveillance Corporation Field Construction Personnel shall be responsible for the physical activities associated with the Surveillance of Post-Tensioning System Tendons. Construction Personnel shall be fit by skill, training and/or experience to-perform these activities. 1.3. CONSTRUCTICON STTPPRVTSTON PSC Supervisory and Field Representative Personnel shall be responsible for administeringthe progress of the work and directing PSC Field Construction Personnel as necessary. These Personnel shall be fit by skill, training and/or experience to perform these duties. 1.3.1. Construction Personnel or Construction Supervision need not be qualified to ANSI N45.226 as they. are supervised or overseen by a qualified individual participating in the inspection, examination, or test. 1.4. AUMITORS. PSC Personnel performing audits of field operations shall be qualified as auditors in accordance with the requirements of ANSI N45.2.23-1978.
- 2. DO~CTIMFNTATT)ON Records of training and personnel skill, certifications shall be documented in accordance with the requirements of the governing ANSI N45.2 or daughter specifications and shall be retained on site for those personnel so certified and/or trained.
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Ir'bee PSC PROCEDURE QA 5.0 PERSONNEL TRAINING JULY 23, 2004 (.. I - Page 1 of 2 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (3 0 TH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE PERSONNEL TRAINING Prepared by /. ; '# 4 1 Title Ai<. a. A. Date ' Ahoy Approved by. . _ . cAJA ,- Titlezn< red Date Approved by. R /1o, Title a, - .Date 7-te3-0o qa5-O.TMI .04isi
Ig PSC PROCEDURE QA 5.0 PERSONNEL TRAINING JULY 23, 2004 Page 2 of 2 REVISION 0 T1. RATN1T Precision Surveillance Corporation personnel on site involved in the surveillance of the Post-Tensioning System, shall be qualified and experienced in all phases of Post-Tensioning operations. 1.1. All training activities shall be conducted and coordinated by qualified, experienced, PSC personnel. 1.2. At the start of the work and usually at the beginning of each new phase of the Post-Tensioning operations, the field crews shall be instructed to perform the work in a safe manner and in accordance with the approved surveillance-procedures manual. They shall further, be trained in the use of the Post-Tensioning equipment for the operation for which they are being qualified, and for any subsequent actions during those operations that may affect the quality or integrity of the Post-Tensioning System. 1.3. The duration of the training period shall not be of a predetermined period of time, but shall instead be of such a length of time, that the PSC training personnel feel confident that the personnel being trained are sufficiently knowledgeable in the methods and procedures of the operation for which L they are being trained. Each trainee shall be oriented by on-the-job training prior to the initial performance of any quality oriented function and each time he performs a different job assignment j - not previously trained or qualified for. 1.4. A list of the trained and qualified personnel shall be maintained on site, indicating the training received and the dates of training. Newly trained personnel shall be added to the list as the training is completed. This list shall be reviewed and controlled by PSC Field Quality Control personnel. Crew proficiency shall be verified during the progress of the work, through the mediums. of inspection, surveillance or audit. 1.5. Procedures shall be used for training those personnel not-familiar with Post-Tensioning Systems or U Surveillance activities. L qa5-0.TMI. 04isi
f PSC PROCEDURE QA 6.0 PROCUREMENT JULY 23, 2004 f..- .:.. Page I of 2 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (30T YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE PROCUREMENT Prepared by Title m 4I.A Date 9-.y.oy Approved by Title 14a:J4r2a Date Approved by . A, g , /
. 0 - " , - ,, - :7 X
Title A' , 17 Date ? 7 @- 1t/ 6' qa6-O .TMI. 04isi
r<y@ U E\PSC PROCEDURE QA 6.0 Vu} wv)PROCUREMENT JULY.23, 2004 Page 2 of 2 REVISION 0 1 ., PROCLTREMENT 1.1. SAFFTY-1RFT.ATFT) The purchase of any safety-related material or service to be used for the Post-Tensioning System or Surveillance operation shall be performed by the Procurement Section of the Precision Surveillance Corporation in accordance with the requirements of the Quality Assurance Program requirements in effect at that time and the requirements stated below. 1.1.1. Field personnel shall initiate a procurement request by a written or verbal order to the Construction or Project Management Section. 1.1.2. A requisition shall be prepared and submitted to the PSC Quality Assurance Section for attachment of the applicable quality documents and/or comments and returned to the Project Management Section. 1.1.3. The requisition shall be sent to the Procurement Section for drafting of the purchase order, pricing, L vendor selection, etc. 1.1.4. The purchase order shall be submitted to the Quality Assurance Section for review of quality content, approved vendor selection and sign-off' Other pertinent quality.documents may be. attached or referenced and then the purchase order shall be returned to the Procurement Section. 1.1.5. The purchase order. shall be submitted to the. vendor. and copies of the order distributed to appropriate personnel.
' 1.1.6. Changes to, the original purchase order 'shall be provided through the. use of.a .Supplemental
*Purchase Order, which shall be subject to. the same review and control process as the original .
purchase order. 1.2. NON- AFFTY-RET ,ATFTD
- Miscellaneous non-safety-related field purchases may be initiated by the field personnel or Procurement Section within the confines of the operating procedures established by the Operating or Construction Departments, independent of this manual.
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PSC PROCEDURE QA 7.0 I k\ FIELD CHANGE REQUEST JULY 23, 2004 Page 1 of 3 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT. 1 (8T INSPECTION PERIOD) (30 YEAR) REACTORBUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE FIELD CHANGE REQUEST Prepared by. Title AGE-a, Q,4. Date f- -3, Approved by i isc Title A~f ~ 4vp 7 Date 7_ , Approved by At P,
'e zks+ Title Date 7- A' -y qa7-O .TMI .04isi
PSC PROCEDURE QA 7.0 FIELD CHANGE REQUEST JULY 23, 2004 Page 2 of 3 REVISION 0
- 1. FT.TTT CIHANGE.RQITST..
The Field Change Request (FCR) shall be the mechanism for requesting rapid evaluation and approval for those operations that must be changed to accommodate field conditions. The FCR shall be approved by the Owner or his agent prior to that change being put into effect. 1.1. Field Changes that take place prior to the approval of 'the FCR shall be documented by a Nonconfonnarice Report and subject to a "STOP WORK'" order, depending on the magnitude of the change and the impact on the quality, program. It shall not be necessary to generate an NCR where it has become necessary to return or move to a safe condition of the tendon or personnel. 1.2. Revisions to this manual shall be performed according to the Revision Control procedure found in the prologue of the Surveillance Manual. The following information will supplement those procedures for Field Change Request Activity. 1.2.1. When field operating procedures, as stated in this manual, become impractical to follow exactly for any reason, that portion and any other affected portion of the manual shall be'revised to provide the appropriate procedures. Where possible, revisions shall be made prior to performing the work. 1.2.2. When revisions become necessary, they shall be formally drafted by the PSC Quality Assurance Section and submitted to the Owner or his agent for formal approval. Where applicable, the responsible PSC Field Quality Control Personnel shall prepare a Field Change Request document to expedite approval from the Owner's Field Quality Organization, Maintenance Engineer or such other authority as designated by the Owner, in order to continue operations without extraordinary delays. The change document may then be transmitted to the Owner or his -agent for formal approval or to issue a change order notice type of document. 1.2.3. Approval of the Field Change Request or emergency revision shall be obtained from the appropriate Site Quality Assurance Authority representing the Owner, if applicable, before starting any Field Changes or Revisions. 1.2.4. Copies of the Field Change Request shall be submitted to the PSC Quality Assurance Section for review 'and where necessary for development of formal procedures to be included in the Surveillance Quality Control Manual. 1.2.5. The approval of the FCR shall be considered as the acceptance for the Revised Procedures unless gross changes occur during the Revision drafting, that affect other portions of the Surveillance Manual. 1.2.5.1.If gross changes occur, the Surveillance Quality Control Manual affected procedures shall be submitted for formal review and approval. Otherwise, the FCR Revision shall be considered as approved and submitted on a controlled basis for inclusion in the Surveillance Manual. qa7-O.TMI . 04isi
PSC PROCEDURE QA 7.0 FIELD CHANGE REQUEST JULY 23, 2004 Page 3 of 3 REVISION 0 1.2.6. As the PSC Quality Assurance Section and the Engineering Department are responsible for drafting Revisions, whether a result of the FCR process or Specification Changes, it shall not be necessary for either function to provide a formal review and signoff. It shall be necessary for the Originator or PSC Field Quality Control personnel to call the PSC Home Office to acquire agreement and acceptance of the FCR before submitting it to the Owner's agent. This way Quality Assurance and Engineering can evaluate the impact of the FCR on Quality Control, Engineering features and other subsequent Surveillance activities. 1.2.6.1.The Originator or PSC Quality Control personnel shall document the review and acceptance of the PSC Home Office personnel by printing the name of the person accepting that FCR and the date of acceptance at the bottom of the Recommended Change area on the FCR form. 1.2.7. The original FCR shall be maintained with the Field Quality Control records. 1.2.7.1.The remaining distribution shall be completed using the Distribution Listing shown at the bottom of the FCR form once the FCR is formally approved byPSC and the Owner. 1.2.7.2. The FCR shall be entered into the FCR Index Log for
- 1. For Number
- 2. Brief Description
- 3. Date Written
- 4. Date Approved
- 5. Date of Revision (to Surveillance Manual, if applicable) 1.3. D1CITMENTATT[N Included with this procedure are the various forms and control sheets described-in this-procedure.
- 2. ATTAGM rE.NTS 2.1. Field Change Request Form 2.2. Field Change Request Index Form qa7-0 .TMI . 4isi
fa6/Pk"PROCEDURE QA 7.0 SPECIAL FIELD REVISION CONTROL I PSC Precision Surveillance Corporation
'1._---
.:- FIELD CHANGE REQUEST NO. FCR .
Requested By:
Title:
Date: Originator: PROCEDURE NUMBER: REV. NO.: PROCEDURE TITLE: AFFECTED SECTION: Revision to Manual Required Yes [ I No NCR REQUIRED: Yes [ No [ 3 NCR. No. Hold Tag No. DETAILED DESCRIPTION OF EXISTING CONDITION: (use -extra pages or write on back) RECOMMENDED CHANGE: psC .Approval: Quality Assurance Quality Control Engineering Sign & Date - . ON SITE OWNER/AGENT, APPROVAL OR COMMENTS: ____ APPROVED -SITE QA AUTHORITY: TITLE; DATE: DISPOSITION pSC QC:- HOLD TAG APPLIED _ HOLD TAG REMOVED'. Q.C. INSPECTOR: DATE: i i Distribution: Quality Assurance Owner Quality Control Owner L: Quality Assurance PSC Quality Control pSC Engineering Owner _ Engineering PSC -_-___.- Project-Manager PSC -_- i "I Page o
f t7/0PR/O C E D URE QA 7.U I FIELD CHANGE REQUEST . I P cC Pre-ision Surveillanc-Corporadon Ii -I INDEX LOG Date - Date Date I II f-IFCRNO.' Item Written Approved Rev. F ___ f __ .1 __ I ____________ ____________ ____________ Ii. __________ I ______________ _______________ I I I ____ I ___ ___ ______ .1. P 1 _____ M-o *5f .5. jA- . I I I ____ 4 _____________________
. I ____ ____
___________ [ ... Iii i i i i
. I I
. I I
___ I___________________ i j i I ____ ___ I i I. T___ II ________________________________________ i k t 4 I I j I _____ ____ F j i Ii IPAGE i I
1-1,I,VII , i II PSC PROCEDURE QA 8.0 i DOCUMENT CONTROL JULY 23, 2004 Page 1 of 3 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1(8TH INSPECTION PERIOD) (30TH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE DOCUMENT CONTROL Prepared by ' . V/- 9.( Title /ieC, (j 4.- Date 9?-2L7my Approved by A C /e Title 7A pen Date 7,t ->-r c, Approved by Title r mc De, 7-,?- 3-,,g Date qa8-0, TMI .04isi
PSC PROCEDURE QA 8.0 v-9?),Jof jDOCUMENT i CONTROL JULY 23, 2004 Page 2 of 3 REVISION 0
- 1. no)CTJMPNT rNTTW)T.
The responsibility for control and retention of all documentation and records, related to the quality control functions for the project within the limitations of the contract documents shall be incumbent on those organizations performing that portion of the work and as further stated in PSC Procedure QA 3.0. 1.1. All documentation, which includes inspections, tests, certifications, drawings, purchase orders, specifications, procedures, correspondence and audits, etc. shall.be prepared in accordance with the procedures as described in the applicable job related manuals and procedures. 1.2. All inspection records shall be reviewed, initialed or signed and dated by the personnel responsible for the quality control functions. 1.3. All quality related documents pertaining to the project shall be retained in the field office file, jobsite vault, or both and maintained in such a manner so as to permit retrieval and prevent loss. 1.4. Document distribution or retention shall be in accordance with the requirements of the project specifications, or as agreed to in the contract documents. 1.4.1. All documents such as Data. Sheets, Nonconformances, verification records, calibration records, certified mill test reports, engineering analyses, etc. generated during the course of the In-Service Inspection, shall be included in the Final Report for that Nuclear Generating Station being surveyed, or appended to that Final Report. 1.5. Copies of Nonconformance Reports shall be distributed in accordance with.. the project specifications or as noted on the Nonconformance/Corrective Action form; refer to PSC Procedure QA9.0. 1.6. All records shall be sent to the responsible Quality Control Section for further distribution in accordance with the project specifications, or as agreed to in the contract documents, or the PSC Quality Assurance Manual.. qaB-O.TMI.04isi
C' , PSCPROCEDUREQA8.0 3 ' {f DOCUMENT CONTROL JULY 23, 2004 Page'3 of 3 REVISION 0 1.7. The following numbering system, as extracted from the Quality Assurance/Quality Control filing index may be used to control the Field Quality Control Files. 1201 Q.A. Manual 1202 Q.C. Manual 1204 Field Manual 1205 Project Specs. 1207 Inspection Field Records 1208 Audits 1209 Calibrations 1210 Q.C. Documentation (Receiving) 1213 Nonconformance/Corrective Action 1214 Purchase Orders 1215 Training/Qualifications 1216 Testing 1218 Miscellaneous -qa8-O.TMI.04isi
PSC PROCEDURE QA 8.1 lAwlV / REVISION CONTROL JULY 23, 2004 Page 1 of 5 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TH INSPECTION PERIOD) (30' YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE REVISION CONTROL Prepared by_ 24 r - w
- S T t V t _
Title A4. : 4, Date *-23.ot
-I Approved by ._Title / s c9 Date -2 Approved by. R I )i /A Title (- Y Date 7-2-3-o 'y 6/1 qa8-1 .TMI .04isi
PSC PROCEDURE QA 8.1 l1 . t GilREVISION CONTROL JULY 23, 2004 Page 2 of 5 L: --- REVISION 0 L
- 1. FNFR AT.
The statements within this Manual are representative of the Precision Surveillance Corporation quality program activities in effect at the time of issue. The construction phase of the project and other delays have a direct influence on the amount of time that will transpire between the actual startup of fabrication and termination of the construction life of the contract. It may therefore become necessary to review and - upgrade or revise the various quality procedures or manuals, as a means of accommodating changes in the specifications, codes; operating procedures, material procurement, or as a means of transmitting intent; information or clarification. Correction of misspelled words or typographical errors that do not affect intent, shall not be considered as revisions.
- 2. TRANSMTT7AT.
Submittal of revisions to the Owner or his agent, shall be in conformance with Criteria VI, Document _ Control, of the Quality Assurance Manual.
- 3. RPV sTOcN mONTROT.
3.1. If a revision is submitted where a Quality Control Manual has been issued, only those procedures l Wbeing revised shall be affected for approval status. The remainder of the Quality Control Manual shall still remain approved. The original or previous revision of the affected procedure shall remain in effect, unless unworkable, until the revised procedure has been approved. 3.2. When a revision is submitted, the entire, manual shall then become "Revision One" for example. Included in the revision package are all .those documents required to bring the original-version of that manual to "Revision One" status. 3.3. A Revision Control Sheet shall show all the documents being submitted, with the correct revision status of each page. The Revision Control Sheet provides a chronological history of development for the manual while the Index Status Sheet indicates all the original documents contained within the original submittal of the manual. 3.4. The Index Status Sheet shall not be revised to any extent greater than to show a date and revision number in the Revision Status column on the Index Status Sheet. 3.5. It is unlikely that any document within any PSC Quality Manual shall be of an unrevised status or
*of the same revision status as the Manual itself. Therefore, the document and manual revision L2 numbers will not be the same. The Index Status Sheet will establish the revision status of each Manual or document issued.
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PSC PROCEDURE QA 8.1 REVISION CONTROL JULY 23, 2004 Page 3 of 5 REVISION 0 3.6. When a revision is made to a procedure, the entire procedure will revert to that revision number, even if there are no editorial or format changes to that procedure. Unaffected pages will be marked at the bottom of the page with a triangle (delta), with the revision number and comments as to the status of that page. 3.6.1. Revision to a Section/Paragraph of a procedure will be identified with a triangle appearing at the
.left edge of the page near the Section/Paragraph which has been affected and revised. Inside the triangle will appear the revision number for that current change. The triangle will appear only for those Sections/Paragraphs that have changed.
3.6.2. It will not be necessary to delete the triangle from the previous revision, even though it is generally recommended that signs of a previous revision be removed to avoid confusion. It will be acceptable to erase, white-out, or tape over signs of the previous revision, where that page has not been revised and is not being reproduced as a new document. 3.6.3. It will not be necessary to apply a revision number to the top of each of those pages that comprise the body of the procedure. The revision number and date need only appear at the top of the Title Page and Data Sheets. 3.6.4. No Change will be taken to mean, that no changes have occurred to that page and that the revision number indicates the current status of that page. No dates other than the original effective date will appear on individual pages. Only the Title Page and Data Sheets shall show revision status and date of that revision, along with the triangle at the bottom of the page. 3.6.5. No Editorinl Change or Foimnt Chhnnge will be taken to mean, that the text of that procedure has not changed and -that the change affects the page number, section/paragraph number or that
-information has shifted from one page to another. This will be noted along side the triangle at the bottom of the page.
3.7. Where drawings are included in the manual, such as post-tensioning fabricated components, these drawings shall be controlled through the quality manual for that product, except where otherwise. agreed to in writing. This system utilizes the drawings and procedures from a controlled quality manual for fabrication and inspection control of that component and shall accompany the purchase order to the vendor, where applicable.
- 4. O)WNFR RPF.SPONS.,
4.1. Once the revision is received by the -Owner or his agent, the Acknowledgement of Receipt or a facsimile, shall be returned to the Precision Surveillance Corporation, Quality Assurance Section. 4.2. Owner comments shall be referred to the PSC Quality Assurance Section or those personnel
- responsible for contract coordination.
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PSC PROCEDURE QA 8.1
/ally;REVISION CONTROL JULY 23, 2004 Page4of5 REVISION 0 4.3. Owner approval without comments shall be transmitted in writing to either party noted in Section 4.2 above, however verbal approval shall be sufficient to start work using the approved revision.
4.3.1. Section 4.2 or 4.3 above, may be replaced by other means of control which have been established and formally agreed to by PSC and the Owner.
- 5. OWNER CONTS OT. (ST TGGFSTI=D)
As a means of maintaining the controlled manual and revisions at the Owner or his agents facility, it is recommended that the submitted documents be verified for accuracy of inclusion, by comparing them to the Revision Control Sheet. PSC is not immune to errors, regardless of the amount of controls imposed or implied.
- 6. EXPDTTINCThCONSTRI CTTIQN 6.1. In order to expedite the construction schedule and with the Owner's approval, it may become necessary or advantageous to fabricate materials prior to the approval of the revision. All materials fabricated in this situation shall be tagged "Hold" and retained on that status until approval of the revision. At the time of approval the "Hold" tag shall be removed. Also see Criteria II Quality Assurance Program, Section 3.4.
6.2. If, for some reason, the revision is not approved, the material fabricated or installed under the controls of the revised procedure shall be maintained on Hold status until the revision is approved. Adjustments to the material shall be made, where required, after approval.
- 7. VOIDMDCCTTMFNTS Once approved, the document being revised shall be marked void and -dated to reflect the revision date.
This void copy will be removed from the manual and placed into a dead or void file for retention as part of the Quality Assurance records. 7.1. As a temporary measure, the void copy may be turned backwards in the manual, until removal to the file. 7.2. Items fabricated or installed with the use of the previous revisions will not require any subsequent change once fabricated or installed. The date of the document approval shall determine the point of fabrication changeover and therefore, the applicable quality requirements. 7.3. PSC does not require that void documents be returned. qa8-1.TMI.04isi
PSC PROCEDURE QA 8.1
-alx REVISION CONTROL JULY 23, 2004 LI Page 5 of 5 REVISION 0
- 8. FORMSM'ATA SUPPT-S Any of the forms contained in this Manual or any Quality Control Procedure used as a means of providing quality control or inspection documentation, are subject to change at any time without prior approval of the Owner or his authorized agent, providing that the amount of information shown on the original form is not diminished in any way.
8.1. These revised. forms shall be submitted for approval at the convenience of PSC with the next revision of that procedure that effects the change, but in no case later than 30 days from the first use of that form. 8.2. If the information required of the original or previous revision of that form is to be diminished in any way, that form shall be submitted for approval prior to use. 8.3. Forms may be provided at any time where. not shown in any procedure in order to provide the required quality control or inspection documentation, without prior approval and at the option of the PSC Quality Control or Quality Assurance Sections.
- 9. ATTACNMFNT5S 1ii I ;- 9.1. Sample Revision Control Sheet qa8-1. TMI . O4isi
PSC PROCEDURE QA 8.1 REVISION CONTROL REVISION CONTROL SHEET Page 1 oF 1 REVISION CONTROL SHEET Shown below is a reduced size sample of the Revision Control Sheet. REVISION CONTROD SE PSC .Surveillance Rev./ Date
- _ Pe,,e ___ of _Corporation REVISED PROCE URES/CRIIERZA Procedure l Pg. Rev. Sub. Procedurel Pk. Rev. Sub. Procedure PS. Rev. Sub.
No. No. D t. No. I No. Date Dt. IoNo. Date IDt.
._l_Revis__ V A, A
1\' uhiated at\ being a i Pagec Number of Rv o.Shee I
\ j A
A Procedure/Criteria Date of subrmittal . nuber'being revised of this revision Page number of revision - A Revision number (Current Status) Date of revision - A '_ A1
£TA A-D Eo 11
PSC PROCEDURE QA 9.0 NONCONFORMANCES JULY 23, 2004 Page 1 of 7 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8T INSPECTION PERIOD) (30T YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE NONCONFORMANCE REPORTING Prepared by Title .Date %-Z3- r_ Approved by ,j / - Title 4&- , Date Approved by , ~, q - Title A,_ 7 - Date 7-2)-ey qa9-O . TMI. 04isi
PS(C PROCEDURE QA 9.0 NONCONFORMANCES JULY 23, 2004 Page 2 of 7 REVISION 0
- 1. NONCONFQRMANQK REPORTHN&1 1.1. Any item, serv~ice, activity or procedure not conforming to the approved drawings, specifications, instructions or other project requirements as related to the PSC contract for the project, shall be documented as a nonconformance. A nonconformance report shall be written by the authority responsible for quality, discovering the nonconformance, regardless of the location where the deficiency was discovered or the source of origin.
1.1.1. This reporting shall be completed on a timely basis, preferably the Owner is to be verbally notified immediately upon discovery and consultation, with a written NCR within 24 hours. 1.2. All nonconforming items shall be suitably identified or tagged as "HOLD", and where physical segregation is practical, that item shall be removed to a segregated area. Where size or quantity do not permit segregation, the nonconforming items shall be identified so as to prevent that item from being incorporated into the production or process flow. 1.3. The nonconformance report shall be distributed to the appropriate parties noted on the distribution list shown on the PSC Nonconformance/Corrective Action Report Form, which is shown at the end of this procedure. A typical Nonconformance Report Index shall also be seen. 1.3.1. The Owner or his agent shall receive copies of those nonconformance reports that indicate a loss of control for the manufacturing process, field construction, or quality control system and where it has been determined by PSC Quality Assurance, Quality Control, and/or possibly the Owner, that a measure of input shall be required by the Owner or his agent to resolve the deficiency. 1.3.1.1.The Recommended Corrective Action for the nonconformance reports noted in Section 1.3.1 above, shall b& submitted to the Owner or his agent for review and approval prior to the execution of that action, for all items to be dispositioned as "Repair" or Use-As-Is. 1.3.1.2.There is no intention to submit all nonconformance reports to the Owner or his agent, whether for review and/or approval where these deficiencies do not impact on the quality of the product being supplied and are generated as a matter of additional control or to report internal administrative deficiencies. 1.4. Acceptance of the nonconforming item, after completion of the corrective action, shall be by inspection. 1.5. Once the corrective action has been detennined, the Quality Control or Quality. Assurance personnel shall make arrangements for the completion of the nonconformnance, including verification. The completion of this action shall be documented in the Disposition area provided on the NC/CA Report Form. qa9-O.TMI.04isi
PSC PROCEDURE QA 9.0
- NONCONFORMANCES JULY 23, 2004 0 Page 3 of 7
( 'REVISION 0 1.5.1. Once the nonconformance has been corrected and the disposition completed on the NC/CA Report Form, the formal close-out of that report shall be documented in the NCR Index Log. All nonconformance reports shall be closed-out. 1.5.2. In some circumstances, the corrective action may be completed on another document, such as an Owner nonconformance report. In that case, the PSC NC/CA Report may be closed-out immediately as a result of the Owner's document, and shall be so noted in the Index Log. 1.6. Only Quality Control or Quality Assurance personnel shall have the authority to remove the L "HOLD" tag or other identifying marks from the nonconforming item, once disposition of the corrective action has been completed and accepted by that Quality authority. 1.7. In addition to the normal reporting system for Nonconforming Material and Services, supplemental reports shall be submitted for deficiencies whether a result of design, conformance, fabrication, or performance, that represent a significant breakdown in the Quality Assurance Program and, were they to remain uncorrected, could adversely affect the operation of the item at any time throughout the expected lifetime of the item. These written reports shall be prepared by the PSC Quality
! W Assurance, Quality- Control, and/or Engineering Department and submitted to the Owner or his agent documenting the cause of the deficiency and the formal corrective action to prevent repetition.
1.8. The Nonconformance Reports shall be retained in the appropriate Quality file on site.
- 2. DR AAFTTNfr THE REPORT The following outline shall be used as a guide for developing the Nonconformance Report. Refer to the example at the end of this procedure.
2.1. The Nonconformance Report shall indicate the identification of the nonconforming item, the deficiency noted, preferably with reference to the requirement in violation, in the area marked Nonconformnance on the NC/CA Report Form. 2.2. The Apparent (anuse Known shall be entered onto the form, if it can be readily discerned. Overly restrictive or unworkable procedures or specifications may be listed as the cause, as well as changes. in working conditions not considered by the procedures or specifications. If this cannot be satisfactorily resolved by the initiator of the report, then it shall be completed by Quality Assurance, Quality Control or the Engineering Department. 2.3. The area marked Reconimeinded Corrective Action on the NCiCA Report Forn shall indicate the action necessary to immediately correct the deficiency. Usually noted as Use-As-Is; Repair; Rework; Scrap; and any appropriate commentary to substantiate that action. qa9-0 .TMII. 04isi
Sz<23: /i>~3PSC PROCEDURE QA 9.0 NONCONFORMANCES JULY 23, 2004 Page 4 of 7 REVISION 0 2.3.1. Where nonconforming items are to be corrected by repairing the stated deficiency, tlie repairs shall be. accomplished through the use of an approved repair procedure. Thlis may be shown directly on the NC/CA Report Form or attached to it as a separate document. 2.3.2. Nonconforming items shall be rejected, repaired, reworked or 'accepted for corrective action after evaluation by the PSC Quality Assurance, Quality Control, Engineering and/or the Owner or his a agent. 2.4. Where possible, the Corrective Action to Prevent Recurrence area of the NC/CA Report Form, L; shall provide the long range action that may be instrumental in preventing recurrence of that deficiency entered onto the form. 2.5. The determination of S.ignifirant Condition status shall be performed by the Quality Assurance, Quality Control and/or the Engineering Department. The identification of significant conditions adverse to quality, their cause and the appropriate corrective action to resolve the condition shall be documented on the NC/CA Report Form or in a separate report as noted in Section 1.7 of this procedure. 2.5.1. A significant condition adverse to quality shall exist if one or more of the following elements are required: 2.5.1.1 .A significant investigation is necessary to determine the cause. 2.5.1.2.Significant redesign, repair or rework ofthe item. 2.5.1.3.A significant evaluation of the QA/QC Program implementation. 2.5.1.4. Significant evaluation for determining generic implication. L 3. NONC(ONFORMANCP RPPORTNTT M1BR TNC 3.1. All Nonconformance Report Numbers shall be prefixed with the PSC Project Contract Number. 3.2. All Field originated NCRs shall prefix the Project Contract Number with the letter "F".
, I L 3.3. Non-project oriented NCRs shall be prefixed with QA and shall only be issued through the Quality Assurance Section.
3.4. All NCRs shall be assigned a sequential control number, to follow the prefix number, which shall X - be applied in ascending order from the previous report and originating with the number "I ". qa9-C .TMI. 04isi
PSC PROCEDURE QA 9.0 NONCONFORMANCES JULY 23, 2004 Page 5 of 7 REVISION 0
- 4. PROCPSRShCT NONCONFORMANCWF PPPOTR This is intended to provide PSC Field Quality Control personnel with the means of approving processing or i_asclosing out NCRs where they are not in close proximity to the home office.
4.1. The report may be drafted by independent action or with the assistance of the Engineering or ,_ - Quality Assurance Sections. Where input has been provided by the assistance of others, the Quality Control person drafting the report shall print the name of that person assisting and the date in the respective area of that Section of the Nonconformance/Corrective Action Report Form. The report L should be distributed as soon as it is drafted, unless the disposition of the corrective action takes place within 5 days after discovery of the deficiency; -in this instance, the distribution may take L: place after the disposition is complete. 4.2. The PSC Approval for QA, QC and/or Engineering may be communicated by telephone to expedite corrective action. In which case the Quality Control person on site would print the name of the person approving that action and the date. Those NCRs could be initialed at a later date to formally ( complete the approval actions., lI - 5. HOLTD &R EFTFWCT TA GS - CONTRO TITR The following procedures shall explain the operation of the controlled Hold or Reject tags. 'The application - of a Hold or Reject tag may be the result of the action of a NCR. Tags may be removed and replaced by other tags prior to the disposition of corrective action should it be determined that an incorrect tag has been
-applied. A Hold tag may also be used 'where a nonconformance is not indicated or warranted to control any item or condition, where Quality Control personnel determine that need. This system shall be controlled by Quality Control personnel.
5.1. The two-part sequentially numbered tags shall be issued in a controlled manner, so that traceability and control can be exhibited through the respective Control Log. The tags shall also be issued sequentially so that significant gaps do not appear in the Control Log. 5.2. Two-part numbered tags shall be used to control those items that are to be placed on Hold or Reject Lo. -status. The tag shall be written to explain the condition and attached to the discrepant item, by'the Quality Control or personnel discovering the condition. 5.3. After the tag has been attached to the item identifying the condition, the face portion of the tag shall be detached and returned to Quality Control. 5.4. The discrepant items shall be moved to the segregated area or otherwise appropriately identified, if it is too large to. be placed in the segregated. area, so as to prevent its inadvertent use in the production flow. qa9-O .TMI . 4isi
- l3L l /PSC \ PROCEDURE QA 9.0 NONCONFORMANCES JULY 23, 2004 Page 6 of 7
- .REVISION 0 5.5. The face portion of the tag shall be used by Quality Control personnel, to post the appropriate information into the respective Control Log Sheet, to best describe the condition of the discrepant item.
5.5.1. It shall not be necessary to enter an elaborate description into the Reason Held area of the log if detailed information has already been presented in any other controlling document such as a Nonconformance Report. 5.5.2. A copy of a typical log sheet is included in this procedure. These are interchangeable for either system, the only difference being the heading or title of the sheet. 5.6. Upon approval or acceptance of a held item, Quality Control personnel shall remove the Hold tag and place an Accepted tag on the item. That item may then be moved into the production or construction process. 5.6.1. In the event that the held item is rejected, the Hold tag shall be removed and -aReject tag placed on the item, where disposition of the reject is not immediate. ! 5.6.2. When a held item has been placed into Reject status, a Nonconformarice Report shall be written to detail the control and disposition of that item. It shall not be necessary to re-enter the -Reject/Hold item information into the Reject Log if that item has already been entered into the Hold Log. It
' -- shall be necessary to indicate the disposition of the Hold to Reject status, in the Hold Log.
5.7. If the original condition of the discrepant item was entered as a reject into the-Reject Log, -then the date of disposition of that item shall be noted in the Reject Log. This-will be the result of clearing the Nonconfonnance Report. L 5.8. The date of the tag removal shall be entered into the respective log along with the initials of the Quality Control personnel performing that activity, to close out the condition of that item. 5.9. Once the disposition of the Hold or Reject item has been completed and documented in the respective log, then the face portion of the tag may be disposed of. 5;10. A Nonconformance Report can be written by Quality Control personnel any time that it is desirable to exercise a greater degree of control over any item or material on Hold status. 5.10.1. A Nonconfornance Report shall be mandatory to control or disposition a reject item or any item changing from Hold to Reject status. qa9-O .TM1 .04isi
PSC PROCEDURE QA9.0 NONCONFORMANCES JULY 23, 2004 Page 7 of 7 REVISION 0
- 6. D)OMT TFNTATION Included with this procedure are the various tags and control sheets described in this procedure.
- 7. ATTACIHIMiNTS 7.1. Tags and Sample Logs 7.2. Sample NC/CA Report 7.3. NC/CAR Formn 7.4. NCR Index Form 7.5. Hold Tag Log Form
*7.6. Reject Tag Log Form I qa-.TM . O.s , a-
PSC PROCEDURE QA 9.0 NON, C"JFORMANCES TAG;. ? SAMPLE LOGS
-Pag-. of 1 NONCONFORMING MATERIALS, PARTS OR COMPONENTS TAGS Shown below are typical examples of the various types of tags used in the-Hold and Reject Tag System. These may vary in appearance-from the devices actually being used but are generally representative of the format and information to be provided. All but the Accepted tag, are two-part tags.
I tROMHOLD d -<mfcA.REJECTED
}1 'm ' , .g jt~ _ rl Tvdiir~)tr, ACCEPTED L Om" ti.:r - ! e -~ rus 10167 l lo-It._. 104.c>t' IC.
SAMPLE LOG ENTRIES-into te. -- ' iShown below are reduced size examples of entries respective log. Note that some are crboss-referenced such as: Hold 1100 to Reject 1700; Hold 1103 to Reject 1701.
PSC PROCEDURE QA 9.0 NONCONFORMANCES i /. :
- f. ; SAMPLE NC/CA REPORT I 1a Page 1 of 1 NONCONFORMANCE/CORRECTIVE ACTION REPORT FORM - SAMPLE
'I IVE ACION 'REPORT FORM.Pre PSC on Surveiaact Enter Control Number NOLD TAO HO. \NC/CA NO. Corporador and into NCR Index Log.
NONCONFOR1UANCS: - jPrefix with project Enter the nonconformance preferably ferencing the quality program r t irenent Contract Number. that his been violated. Field NCRs will be er.-
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APPARENT CAUSE gNOWY C3YZS O NO- If yes, describe: Hold tag number, if May require consultation with QA, QE and/or Engineerwrkg o applied will be entered Refer Section 5 ..3. here. If a tag was RECORCECIVE ACTION ACTIOE EN:ECR applied, note the .removal The i= ediate corrective action that will be taken to correct the sted of that tag in the nonconformance. One of the following disposieions shall be noted for the-Disposition' Completed. (-,
, deficiency as Ref er S ec tion 7r3 it applies: "Use As Is"; "Repair" "Rework" or "Scrap.
Anv nonconfoering Item to be roottred shall To be entered and have an agoroved repaik ceocedure. CORRECTlVE ACSION TO PREVENTS RECURBENCE: evaluated only-by or with consultation of QA, QE The long ranee corrective 2Ction that rev be useful 'in eltianrtlnz the detfe
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and/or Engineering. Refer Section 2.1+. Initistor Refer Scction .. 7. 7 Date SIGNIFICANT CONDITION:, OYES-----INO - If yes. refer QAR Section A Criteria XY. - To be signed by bept; shown. Hay be signed by APPROVAL COMMENTS: Enter any cowants that' might be percinent to effecting the approval of ;initiator only if the the corrective action. Dept. designated was
. Refer Section 2 S. _ _ _ notified of NCR and P5C ~QC Q approved action.
APPROVAL __ _ __ SIGN & DATS l _ CYNER/AGENT APPROVAL Engineer R E Q U IR ZO Qlyt S QuNO a e _ _ _ _ _ _ _ _ _ _ _ _ _ V e __ _ _ _ _ _ _ _ _ _ To be entered upon
-Date Date completion of Corrective CO~tNENS: This area to be Input only by the Owner or his arent. Action to close-out NCR.
Refer Section ).I.I. Also close-out in NCR Index Log. DISTRIBUTION DISPOSITION COMPLESED
- QA Section QVice President vendor Signed BQe Section [QContr. ngmt. TTitle __
Qsnsineering Q Owner/Agent Da ____te _ -
7V11\ PSC PRODCEDUJRE OA~ 9.0
- I
-NONCONFORMANCE/CORRECTIVE ACTION REPORT FORM Corporation f-.e -IHOLD TAG- NO. NC/CA NO.
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APPARENT CAUSE KNOWN LIYES []NO -'If yes, describe: _____________
- ^v ^ tvs vnr1,r. Aflwtlt .~ ' ll ThTI l'fIf l~I#f RECOMMENDED CORRECTIVE ACTION:
Any nonconformihg item,to be repaired shall have an approved repair procedure: {--.:*J1%.LmrA~-LL.Vr. A%%1L.JUA~ .LV rLU.VZ1-.L r~~1rrLLd1-Initiator Title Date SIGNIFICANT CONDITION: [:YES UNO - If yes, refer QAX Section 4 Criteria XV. APPROVAL COMMENTS:
!/ PSC QA Engineering APPROVAL SIGN & DATE OWNER/AGEENT APPROVAL Engineer QA L REQUIRED OIYES OII NO. -
Date . . . _ . _ . _ . . Date . COMMENTS: i.;~ I DISTRIBUTION DISPOSITION COMPLETED I [QA Section EVice President M Vendor Sirgn( ed - 8 I EQE Section []Contr. Mgmt. O. Title _r
' - -MEngineering a Owner/Agent cii Date
PSC PROCEDURE, OA 9.0 QUALITY ASSURANCE PROGRAM f-9 id.,Precision
.PS(4Surveillance NONCONFORMANCE REPORT INDEX Corporation Date Date Date Date NjCR No. Item Written Submitted Approved Complete iA I~ . . . A, Page
PSC PROCEDURE QA, 9.0 Precision QUALITY ASSURANCE PROGRAM faL kI,, / f? rea PSC Surveillance L; IK-- - Date REJECT TAG LOG Corporation Date C Q.C. XT- IT-qAiiDA nTVrRTPTTrnM OF r'nA TTTnI Removed I iznnffr ___ I I-I_____ ___ .1 F___ ___ __ F I __ 1 _____ ______ _____
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PSC PROCEDURE QA 9. O Precision 1 QUALITY ASSURANCE PROGRAM I i PsC Surveillance Corporation Li. hi. HOLD TAG LOG
.. Date l .- l Date Q. C. -
iTag No. Issued DESCRIPTION OF CONDITION - Removed ISi gnoff _ _ -f------ -- -- _ _ . I i K - i -i .__..- Page I.
PSC7PROCEDURE QA 10.0 6 01 /~
~_A CALIBRATION JULY 23, 2004 Page 1 of 6 REVISION 0 REVISION 1, 8/25/04 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8TTH INSPECTION PERIOD) (30TH T YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE CALIBRATION OF MEASURING AND TEST EQUIPMENT A Prepared by - .. .. . . Title .; _ !. ... -Date 'S- ay A Approved by ZA/ C-L,/ Title cow- Date Ai Approved by R- 0/LAz
. . ta Title C, 22,. Date -g >- lqal-O.TMI.04isi
4 lPSC PROCEDURE QA 10.0 CALIBRATION aJ`LY 23, 2004 Page 2 of 6 REVISION 0 REVISION 1, 8/25/04
- 1. This procedure will establish the requirements for calibration of the Quality Control Test and Measuring Equipment to be used for inspection, testing and evaluation, during In-Service Inspections (surveillance) of the Post-Tensioning System Tendons.
- 2. CONTROLS All calibrated test and measuring equipment shall be controlled for issue by the PSC Quality Control or Quality Assurance Section. The area of issue shall be indicated on the calibration records. The calibration records shall be maintained by the PSC Quality Control or Quality Assurance Section.
2.1. PSC Quality Control personnel shall maintain a file or list of in-service devices requiring calibration, and periodically review those records to prevent any lapse in calibration. 2.2. The Quality Assurance Section shall review calibration records during audits of that operation being audited. 2.3. All calibrated equipment shall be documented and identified by a label, tag, or log sheet indicating the status of calibration. The control device -shall identify the equipment, the date' of calibration, date due for recalibration and the signature or initials of the person performing or verifyring the calibration. 2.4. The identification control of the calibrated equipment shall be of such a nature so that the specific traceability of that device will not be lost; usually engraved or marked with a Quality Control code number. 2.5. Any calibrated device that has been damaged, adjusted or repaired before the recalibration due date, shall be recalibrated before initial use, to assure the prescribed accuracy. 2.6. There is no intent to apply calibration requirements on those devices such as rulers,- tapelines, levels, etc. where normal commercial practices provide adequate accuracy, or where there is no need for accuracy. 2.7. Procedures shall be provided for the calibration of special testing, measuring, inspection devices or bther equipment requiring calibration and shall be controlled by the Quality Assurance Section or included in the Quality Manual for the project. 2.8. The Rams which have been used for Monitoring Force, Detensioning or Retensioning operations for the In-Service Inspection of the Post-Tensioning System Tendons shall be verified for calibrated status after the completion of the work. lqalO-O.TMI.04isi A) Ftv/Jf -e crRLA'-F
Acxi/,< .,\ PSOPROCEDUREQA 10.0 CALIBRATION JULY 23, 2004 Page 3 of 6 REVISION 0 REVISION 1, 8/25/04 2.9. The documents for the calibration of Rams prior to starting the work and after completing the work shall be included with the Final Report for the In-Service Inspection.
- 3. OUTJTOFCATLRATTMN 3.1. Devices out of calibration shall be processed as nonconformances. Devices out of calibration that are determined to have an adverse effect on quality shall have copies of that nonconformance report
- submitted to Executive Management for review, and comments where applicable.
3.1.1. Nonconformance Reports shall be drafted, submitted and distributed in accordance with the L .requirements ofPSC Procedure QA 9.0. 3.2. Instruments that are found to be out of calibration shall be re-calibrated and a comparison made of the results of the new calibration and the out-of-calibration variance, if any. If no significant variation exists, the instrument shall be put back into service. In the event that a discrepancy exists, then the Engineering and/or Quality Assurance and Quality Control Sections shall make an evaluation of the discrepancy and the possible effect on the items processed with the out-of-calibration device, with regard to quality, accuracy or reliability. If it is determined that a serious problem exists, then the Quality Assurance Section shall determine what items checked with the out-of-calibration device shall be rechecked with an effective calibrated device. 3.3. Instruments that are found to be in excess of the required accuracy or tolerance band after being returned from Field Service, shall 'be controlled with Nonconformance Reports as required of Sections 3.1 and 3.2 of this Procedure.
- 4. TOnT. ANF) GACTAJG CC)NTT)OT 4.1. The calibration standards used to calibrate measuring and test equipment shall be traceable to the National Institute of Standards and Technology (NIST) formerly National Bureau of Standards (NB S) and shall be controlled to an accuracy not to exceed a limit of 0.25% of the tolerance of the
- equipment being calibrated or the smallest used division of that instrument's scale, unless otherwise limited by "State-of-the Art" conditions. Pressure Gauges used for Post-Tensioning System operations shall be excluded from this requirement and shall be defined for accuracy in separate procedures.
4.1.1. For example, a micrometer that has a smallest scale reading of 0.001" shall be calibrated with a standard or device that has been calibrated to an accuracy or 0.00025" or less. 4.2. All measuring and test equipment used for Quality Control Inspections shall have subdivisions or increments for measurements that are equal to or smaller than the tolerance .ofthe parameter being measured. A) t{i1J?S~ AJ,5.GWk9£ lqalO-O.TMI. 04isi
PSCPROCEDURE QA 10.0 CALIBRATION JULY 23, 2004 Page 4 of 6 REVISION 0 REVISION 1, 8/25/04 4.2.1. For example, a part needs to be controlled to a dimension of 9.365" with a tolerance of plus or minus 0.001". It would therefore be acceptable to perform that measurement with a device that is capable of measuring to 0.001" or smaller. 4.3. Calibrated Devices may be extended for the stated period of frequency, where that device has been calibrated and placed into storage, rather than into service. The original frequency period stated in Section 5.2, Equipment List, shall always be observed.
- 5. FQITIRMFNT 5.1. The Equipment List shown in Section 5.2 of this Procedure contains those devices that are required
- for the In-Service Inspection or are used to calibrate devices that will be used during the In-Service Inspection. The required accuracy and frequency of calibration are stated for each device. It should be noted that the accuracy requirement is meant to- be the tolerance band to which the device is being calibrated and not the original accuracy or the accuracy between calibration frequencies.
5.1.1. The term "DISS" in the Accuracy Column is defined as "Division of that Instrument's Smallest Scale". 5.1.2.- Where an asterisk "" follows the accuracy dimension, this is meant to be that the dimension shown shall be verified with a Micrometer that reads to 0.0001". 5.1.3. The procedures that are used to calibrate the various types of equipment, gauges or instruments used during the In-Service Inspection, will accompany this procedure in the Surveillance Program Quality Control Manual. These procedures provide information relative to the calibration of each device and may be used for purposes of calibrating these devices in the field, should that become necessary. lqalO-O.TMI.04isi
/ 14 1 PSC PROCEDURE QA 10.0 k,
CALIBRATION JULY 23, 2004 Page 5 of 6 REVISION 0 REVISION 1, 8/25/04 5.2. POTJTPM\FNT TTST DEVICE FREQUENCY ACCURACY Load Cell (2000 Kips) 5 Years + .1% Entire System Load Cell (Approx 50 Kips) 8 Years + .1% Entire System Rams/Jacks Beginning & End - Calculated to within (Stressing, Testing, etc. (B & E) of Project + 0.01" for Ram Area Dead Weight Tester 5 Years + 0.10% Heise Digital Gauge 3 Years + 0.10% A Pressure Gauge-Master (114%) B & E of Project + 30 psi Pressure Gauge-Stressing (1/4%) B & E of Project + 30 psi of Heise Pressure Gauges (1/2%) 1 Year + 55 psi of Heise (Not used for Stressing) The 3 items above include reading accuracy. Micrometer 6 months + I DISS Micrometer-Checking + 0.0001" Bar Standard Thickness (Feeler) Gauge Under 0.005" 6 months + 0.0005"* 0.005" and Over 6 months + 0.0010" (* Verified with a 0.0001" -micrometer) Steel Ruler 1 Year + 0.0100" Steel Tapeline 1 Year + 1/16"/l00' of Igth. Thermometer 1 Year + I DISS Zl Optical Comparator 1 Year + 0.0010" Dial Indicator I Year + 1 DISS 3 Wire Thread Gauges
+ 0.0005 Roundness Hardened (HRC50 or Over) 1 Year + 0.0001 Diameter PD Type (less than HRC50) 6 months + 0.0010 Diameter
- -THREAD PLUG GAUGE (Stressing Adaptor Pitch Dia.) No-Go Gauge 3 Years + 0.0000"
- 0.001 1" Go Gauge 3 Years + 0.0020"
- 0.0030" ZL ?/V/oy 10,V rjljlrz.
lqa1O-O .TMI .04isi
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PSC PROCEDURE QA 10.0 CALIBRATION JULY 23, 2004 Page 6 of 6 REVISION 0 REVISION 1, 8/25/04
- 6. DOCITJMPNTATTIN The various types of documents generated for calibration, and/or status of calibrations will be described in the General Procedures for Cajibration or contained within that procedure for a particular device. Others may be added as the need arises. Quality Control personnel shall prepare or assist in the preparation of these records. A copy of the calibration record shall accompany the calibrated device to the field.
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(. I PSC-PROCEDURE QA 10.1 CALIBRATION VERIFICATION JULY 23, 2004 Page 1 of 5 REVISION 0 t AMERGEN ENERGY THREE MILE ISLAND I TH TH I UNIT 1 (8 INSPECTION PERIOD) (30 YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE VERIFICATION OF CALIBRATED STATUS Ii OF HYDRAULIC PRESSURE GAUGES ! 11 Prepared by Title AGE . 4, Date Q.>- ,y Approved by. . _ Title- Date 7-___,_,_ Approved by Title_ Date qa1C-1.TMI.04+/-isi
PSC PROCEDURE QA 10.1 CALIBRATION VERIFICATION JULY 23, 2004 Page 2 of 5 REVISION 0 FMTT) VFRTFTCATTON OF PRFSSUTRFP GTATGEPS The following procedure shall be used to verify the calibration of hydraulic pressure gauges during field operations. These gauges may be used in stressing operations with the rams or other devices that require a measure of accuracy to produce quality results. Frequency and Accuracy of Calibration shall be controlled as stated in Section 5.2 of Procedure QA 10.0, Equipment List. The Verification frequency shall be controlled as stated in Section 1.5 of this Procedure, while the Verification Accuracy shall be controlled as stated in Sections 2.6.or 2.7.
- 1. CTiNFR AT 1.1. Prior to being used for any work, all gauges shall be calibrated with the use of a Dead Weight Tester or the Heise Digital electronic pressure indicator.
1.2. In addition to the pressure gauges used during the surveillance, one gauge, designated as the Master Gauge or a Heise Digital Gauge, shall be set aside for purposes of Calibration Verification during the process of the work. 1.3. PSC Quality Control personnel shall maintain the controls for distribution and recall of each Pressure Gauge being used on site. 1.4. A Pressure Gauge may be verified for calibration or accuracy at shorter frequencies than stated in Section 1.5 of this procedure. It is important that verification be performed any time that the gauge has been damaged, subject to some physical abuse or there is some reason to suspect its accuracy. 1.5. Pressure Gauges used for Monitoring of Force, Detensioning or Retensioning (Stressing) tendons of Post-Tensioning Systems during In-Service Inspections of Nuclear Power Plants, shall be Verified for Calibrated status at least once a day during the operational use of those gauges.
- 2. VF.RTFTC(ATTON OF CATBTRATTON 2.1. Clean and remove any dirt, grease or residue that could affect the accuracy of the calibration or use of the pressure gauge.
2.2. At the option of the PSC Quality Control Section it shall be acceptable to use a Heise Digital Pressure indicating Gauge for Calibration Verification or Pressure Gauges, rather than a Master Gauge. 2.3. Attach the Pressure Gauge to the Calibration Pump of the Heise Indicator or Master Gauge. 2.4. Close the back pressure valves before pressurizing the system. qa10-1.TM1.04isi
PSC PROCEDURE QA 10.1 CALIBRATION VERIFICATION JULY 23, 2004 Page 3 of 5 REVISION 0 2.5. Increase the hydraulic pressure to the point of the desired reading on the Pressure Gauge, usually 1,000 psi plus or minus 100 psi increments. Take a reading of the Pressure Gauge and the Heise Indicator or Master Gauge and document both on the Pressure Gauge Calibration Form. 2.6. MASTER (GTATTC TP,(1/4% Accuracy) 2.6.1. Where a Master Gauge is used for verification of calibration the master gauge and field gauge to be calibrated shall be connected to a common line (manifold) on a hydraulic pump. The pump shall be pressurized in no greater than 1,000 psi increments, plus or minus 100 psi, to the highest overstress pressure that shall be encountered during stressing activities; for example, 7,600 psi overstress will require calibration on that gauge to at least 7,600 psi. It shall be acceptable to go to 8,000 psi. 2.6.2. The -accuracy of a gauge verified in this manner shall be acceptable, if it reads to within 50 psi of any reading on the Master Gauge. 2.7. T-TEFI DICTITAT, ('TAT T(T-2.7.1. A Pressure Gauge may be verified for calibration by connecting that gauge and the Heise Digital Gauge to a common line, which is in turn connected to a hydraulic pump and pressurized to the same values noted in 2.6.1 above. 2.7.2. The verification accuracy of that Pressure Gauge shall be acceptable if it reads within 30 psi of the Heise Digital Gauge reading for a 1/4 percent accuracy gauge or 55 psi for 1/2 percent accuracy gauge. As a 1/2 percent gauge cannot be accurately interpolated to increments of 5 psi it will be acceptable to take the reading to some point equal to or above 50 psi but not to exceed 60 psi. - 2.7.3. Pressure Gauges with antaccuracy of 1/2 percent or greater shall not be used for Monitoring Force, Detensioning or Retensioning operations of the Post-Tensioning Tendon System during In-Service Inspections. 2.8. With the Verification and Documentation of the Pressure Gauge being acceptable, the pump and gauge shall be depressurized and disassembled.
- 3. TNACCEPTABLE (X)NF)TDTONS If a Pressure Gauge fails to meet the accuracy requirements of Section 2.6.2 or 2.7.2 after being used for Monitoring Force, Stressing or Detensioning operations, it shall be necessary to draft a Nonconformance Report in accordance with the requirements of Section 3 of Procedure QA 10.0, to control the Gauge and any Tendons worked with that Gauge.
qa1O-1 .TM1. 04isi
PSC PROCEDURE QA 10.1 CALIBRATION VERIFICATION JULY 23, 2004 Page 4 of 5 REVISION 0 3.1. Any Pressure Gauge not capable of meeting the stated accuracy requirements of Section 2.6.2 or 2.7.2 for the method of calibration being used, shall be returned to the PSC shop for adjustment or repair. Any repaired or adjusted Gauge shall be recalibrated before use. 3.2. 7FRQ AT TGNN{PNT (Zero Renting)- On occasion, the Pressure Gauge Indicating Needle'may not be in precise alignment with the Zero mark on the Gauge Face, necessitating realignment. Before realignment takes place, a complete Verification shall be performed and documented on the Gauge Calibration Record. Then, the Inspector shall perform the realignment. With the realignment completed, a new Verification shall be performed and dociuiented. This realignment shall not be considered an adjustment or repair, as long as that gauge meets the stated accuracy requirements of Section 2.6.2 or 2.7.2.
- 4. ACCI RACY VARITATONS Even though Pressure Gauges that have been calibrated or verified for calibration, variations in excess of the requirements of Sections 2.6.2 and 2.7.2 may be detected between calibration or verifications. In an effort to explain and control this deficiency, this Section shall be reviewed before the Verifications of any Pressure Gauges.
4.1. The accuracy of the calibration of Pressure Gauges or the verification of calibration is highly dependent on the accuracy of the reading of the location of the Pressure Indicating Needle on'the Gauge Face. While there is an attempt to precisely align the needle with the Gauge Face Indicating Line, it is nearly impossible to maintain that control. In an effort to explain any variations that could be noted between calibrations or verifications, it is recommended that a notation be added to the Calibration Document to signify that the intended increment was riot precisely obtained. At that increment it would be noted that the value actually achieved was plus or minus an extrapolated pressure noted during the calibration. 4.1.1. For example: If the target increment on the gauge face was intended to be 2,000 psi and the Indicating Needle was somewhat over the 2,000 psi line, perhaps enough to interpret as 10 psi, the notation on the Calibration Record would read: 2,000 psi +10 4.1.2. The requirements for Monitoring Force, Stressing or Detensioning tendons do not requirelife' pressure to be read any' finer than 10 psi during In-Service Inspections. The Hydraulic Ram Calibration Procedure takes the reading error into account for Monitoring Force, Stressing or Detensioning along with any other errors that may occur as a result of calibration or gauge reading, thereby maintaining the accuracy or integrity of the work being perfonned. It is therefore necessary to document any minor variations 'during calibration or verification activities, so as to maintain the integrity of the accuracy of the Pressure Gauges. qalO-J.TMI.04isi
XiF1 (-61\ PSGPROCEDURE QA 10.1 CALIBRATION VERIFICATION JULY 23, 2004 Page 5 of 5
. REVISION 0
- 5. DpQLNruMNTAT-lQ1 A Gauge Calibration Record form shall be prepared for each gauge being calibrated or verified. All pertinent information as required by the form shall be posted during calibration or verification.
5.1. Calibration or verification documents shall be retained in the appropriate jobsite Quality file.
- 6. ATTACHRM NTS 6.1. Gauge Calibration Record form L
qa10-1.TMI.04iSi
I 0, PSC Formerly Inryco Surveillance MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: . ... JACK GAUGE NO.:_ MASTER GAUGE NO.: . . DATE CHECKED: CHECKED BY: . . _ . . _ REMARKS: I i FMASTER GAUGE (PSI) I JACK GAUGE (PSD I I I-PRESSURE GAUGE CALIBRATION RECORD JOB: JACK: GAUGE NO.: MASTER GAUGE NO.:-. DATE CHECKED: . iI i I CHECKED BY: I I I REMARKS: I I
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fQ 0/19;) PSC-PROCEDURE QA 11.0 INSPECTIONS JULY 23, 2004 L t-s; I Page 1 of 3 REVISION 0 AMERGEN ENERGY THREE MILE ISLAND TH UNIT 1 (8THINSPECTION PERIOD) (30 TH YEAR) REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE QUALITY CONTROL INSPECTION
.1; Prepared by Title W, 4'.A, WtM Date %z3-6r Approved by , - /:=Z- Title Gu F° . Date 7 Approved by R.P. Title G -ro Date 7-_ __
qall-O.TMI.04isi
PSCPROCEDURE QA 11.0 _hINSPECTIONS JULY 23,2004 Page 2 of 3 REVISION 0
- 1. Q(TIAT TTY CONTROT, TNSPECTTIDNE 1.1. Where Precision Surveillance Corporation (PSC) is not acting as the General Contractor for the Post-Tensioning operations, Quality Control Inspections shall be performed by the organization responsible for the quality control function of that portion ofthe work they are perfonning, as stated in PSC Procedure QA 4.0 of this manual, or as agreed to in the contract documents.
I. 1.2. It is PSC's intent to provide the Quality Control activities for the Surveillance Inspection of the Post-Tensioning Tendon System as agreed to in the contract documents and as stated in the L Surveillance Quality Control Manual. 1.3. Quality Control documents shall NOT RF SIGNED until all information for the inspections or tests for which that document is being generated have been entered onto that document.. 1.3.1. Partially completed inspections or tests, those where the operation cannot be completed on the same day, shall be initialed and dated by the Inspector for those items that have been completed and s: .3.2.require documentation. 1.3.2. Partially completed inspections or tests, those where the operation is interrupted by a temporary condition such as lunch or a break and where the operation shall be completed the same day, may
- S be initialed completed by the Inspector to that point,"for those items that have been completed and L require documentation.
1.4. Quality Control documents that are being reviewed for completeness but were not witnessed by the L reviewer shall be signed for that review ONL Y AFTER completion of the review and NOT BFFnR-E.E 1.5. A Quality Control document is defined as any document or record that contains a Quality Control Inspector signature requirement. 1.6. All inspections shall be documented on the appropriate inspection form for those operations witnessed on that day. All inspection documents shall be signed or initialed, dated and retained in the appropriate Quality file at the jobsite. 1.7. Quality Control Documentation shall be completed and turned in for review as soon as possible after. completion of that Inspection, Test or Evaluation.
- 1.8. Reviews of Quality Control Documentation should be completed within 24 hours of receipt or sooner to verify that the information is accurate and complete. Errors or deficiencies shall be X aresolved without delay.
qall-O . TMI . O4isi
'- PSCPROCEDUREQA11.0 INSPECTIONS JULY 23, 2004 Page 3 of 3 REVISION 0 1.9. There are a number of Quality Control Documents that may not be completed in one day or require posting to another document. It is advisable to make reproductions of these documents and use these to complete whatever actions are necessary, while retaining the original document, even.
though incomplete, in a Quality Control file. The additional information can be entered onto the original document until completed. Leave the reproduced copies attached to the back of that document until the review is completed, at which time the reproductions may be disposed of. 1.10. It may be necessary to generate more than one original copy of a Quality Control Document -for an Inspectionbr.oTest on a tendon. This shall be acceptable just so the total quantity of pages and the page number appear on each document.
- 2. INSP.ECTTON The term Inspection is meant to include:
2.1. The witnessing of an operation that generates Quality Control Data which is documented by the Inspector. 2.2. The performance of some operation by the Inspector, such as measuring or other Quality Control Data, which is documented by the Inspector. qall-O .TMI .04isi
-f JA (f a,\ PSC PROCEDURE QA 12.0 AUDITS JULY 23, 2004 Page 1 of 2 I 'k. -, REVISION 0 AMERGEN ENERGY THREE MILE ISLAND UNIT 1 (8 TH INSPECTION PERIOD) (3 0 TH YEAR)
REACTOR BUILDING STRUCTURAL INTEGRITY TENDON SURVEILLANCE PRECISION SURVEILLANCE CORPORATION IN-SERVICE INSPECTION QUALITY ASSURANCE PROCEDURE AUDITS Prepared by Title E. 4, Date r,7-2-Q Approved by </~ cA Title /:eca Date Approved by W D P. /O4,,, Title Date ?.A3-or I 7 qal2-0.TMI.04isi
PSC PROCEDURE QA 12.0 AUDITS JULY 23, 2004 Page 2 of 2 REVISION 0
- 1. ATUITS Surveillance operations shall be audited as required by the project specifications or as agreed to in the contract documents, to verify confonrinance with the approved job related manuals and procedures.
1.1. Audits shall be performed by qualified personnel of the Precision Surveillance Corporation Quality Assurance Section and who shall be independent of the area being audited. 1.2. Audits shall be performed using a checklist prepared prior to the audit, with the results documented on a Jobsite Audit Summary Sheet and a commentary noted on an Audit Finding Report form or similar type documents. 1.3. Audits shall be performed on a random basis and shall be scheduled when a variety of operations are being performed or as a specific activity occurs. L 1.4. Subsequent audits shall provide a review of previously noted deficiencies or program non-
- 15. compliance to ensure appropriate action has been taken to resolve those areas of concern.
)1.5. Copies of the audit report shall be maintained in the appropriate jobsite quality files and distributed in accordance with the project specifications or distribution list on the audit checklist.
1.6. The audits shall be performed as early in the life of the In-Service Inspection, as is practical, and must consider the limitations of the scaffolding or platforms. 1.7. The elements to be audited shall be commensurate with the status and importance associated with the In-Service Inspection activities. qa12- . TMI.0O4isi
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, Precision I PROCEDURE Q 12.2
.... PSCd Surveillance Corporation I4- Ci i ..- EQUIPMENT CALIBRATION - GENERAL GENERAL Calibrations of equipment.will be performed for the frequency and accuracy as described in the respective quality control manual for.those devices used for the control of the project materials or tests.
Calibrations are only provided for equipment in'service at any one time for any number of projects. Because of the quantity of original equipment as gauges, and measuring devices, and subsequent back up or replacement equipment, no attempt will be made to keep all the equipment calibrated at-one-time. IN-SERVICE EQUIPMENT: Equipment classified as "in-service", regardless of location, will be kept in a calibrated condition for the frequency and accuracy specified for that piece of equipment.'
'Vendor:' i Equipment will be calibrated for the frequency and-accuracy specified whenever-work is being performed for any PSC Post Tensioning component and prior to startup'of that work.' i i
i Shop - PSC i i I Equipment will be calibrated for the frequency and accuracy specified i whenever tendons are being manufactured and prior to the startup of the work.' Field PSC Equipment will be calibrated for the frequency and accuracy, specified whenever tendon-installation-operations are being performed and prior to the startup of that operation. Effective lprevious Revision: Page Date: %_ ;lRevision:i-i ; -.. If¢f Formerly "Inryco Surveillance"
( Irow I I1ItA¶ Precision I PROCEDURE n T2.2 I I FS.C Surveillance Corporation EQUIPMENT CALIBRATION - GENERAL L 7r OUT-OF-SERVICE EQUIPMENT When no operations are being perfoirmed for work of a post tensioned nature, components are not being manufactured, or equipment is classified as being in storage, no attempt will be made to keep the equipment in a calibrated condition. The calibration records may show gaps indicating non-continuity of calibration, but this should not be construed as a lapse of Quality Con-trol. Specific items in use will be used to verify continuity of calibra-tion and control. RECALL Equipment will be controlled for recall by the Quality Control Section of-the area responsible for calibrations and will generally follow the requirements
-of PSC Procedure Q 12.5.
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I (IV2CI/IU- - Precision I -PROCEDURE Q 12.5 SC: Surveillance CALIBRATION RECALL CONTROL Corporation
.1. CONTROL COLOR-FLAGS
- 1. As a means of porviding a control of items requiring calibration, after any device has been calibrated, a control color flag will be attached to the folder into which the calibration record has been placed.
.2. The following list is the monthly color code:
- 1. January Orange
- 2. February Red
- 3. March Blue
- 4. April Dark Red
'5. May Light Blue*
- 6. June Light Green
- 7. July Yellow 8 ! August. Dark Green
- 9. September Pink
- 10. October Black
- 11. November Brown
- 12. December White
- 3. The. color flag.will indicate, that a 'calibratio* is due for that month.
- 4. The following procedure will be followed when the color flag indicates that a calibration is due.
- 1. Remove and.store the control color flag.
- 2. Recalibrate the gauge.
- a. If the gauge is not to be put back into service Hat that time, it will be returned to storage and so documented on the calibration record. It will not be calibrated until it goes into active service.
.3. Document the calibration on the calibration record.
- 4. Return the-calibrated gauge to active service.
- 5. Attach the control flag to signal the new month for calibration.
- 5. At the end of a month, the files will be checked to determine what calibrations are due'.
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PROCEDURE Q 12.8.B-W s.. a-d Sur veill anece
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- -;-CALIBRATIO - IROMETERi IN MI 1 MICROMETER 0" to 2" The following procedures will be used as a means of calibrating micrometers.
1 1. Clean micrometer of all dirt, oil, residue, etc.
- 1. 2. Remove the old calibration sticker.
- 1. 3. A calibrated Surveillance Kit Step Block, traceable to the National Bureau of Standards will be used for calibrating small micrometers.
- 1. 3. 1. Take the various readings and enter them onto the Calibration Form -
Exhibit A.
- 1. 3. 2. The measurements on the current P5iC Surveillance Kit Step Block are:
.2430" . .... .3460" L .6550" I . .9640" I. ; i. 3. 2. 1. These measurements will vary according to the Step Block being used and . V) the final size of the micrometer; those capable of reading in excess of 2".
- 1. 3. 3. Record all actual readings on the reading column on the Calibration Form -
' Exhibit A, the accuracy shall be within + one division of. the smallest reading on that instrument to be acceptable.
- 1. 3. 4. Record any variations in the error column, provided that-the errors are within the acceptable tolerance band.
t11. 3. 4. 1. If the error-is outside the tolerance band, then the micrometer shall be adjusted following the instructions and using the tools for adjusting II the micrometer, by Quality Control personnel. Once adjusted the
. I micrometer shall be recalibrated in accordance with the requirements of I
this procedure. t1. 3. 5. Larger micrometers shall be calibrated by using larger Step Blocks or Bar Gauges in unison with the Step Block.. X 1. 3. 6. No less than three readings shall-be taken for a micrometer calibration. These readings should occur somewhere at the minimum, middle and maximum I spindle or measuring capabilities.
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PROCEDURE Q 12.8.B-W Precis ionC Corpolatc-n CALIBRATION - MICROMETER 0Cpaton
- 2. LARGE HICROMETERS 2 1. Micrometers larger than described in Section 1 above may be calibrated with the use of Step Blocks large enough to facilitate the size of the micrometer being calibra-ted or any one of the following options:
- 2. 1. 1. Use the calibrated standard supplied with that micrometer and combine that device with the calibrated master feeler gauges or a large calibrated Step Block.
- 2. 1. 2. Use a series of calibration standards or inidvidual gauge blocks.
- 2. 2. In any circumstance stated above, no less than three different measurements shall be taken and preferably at the low, middle, and high ranges of that micrometer.
l2. 2. 1. Each calibration standard stated above shall be calibrated and to an accuracy magnitude of 10 times finer, (0.10), than the device being calibrated is capable of measuring. For example, an 0.001" micrometer shall be verified for accuracy by another'device that is capable of being read to or is calibrated to 0.0001". Xr I~NSIDE MICROMETERS Inside micrometers shall be calibrated with a calibr'ated outside measuring micrometer _ capable of reading to 0.0001" and in general compliance with Section 2.2 above.
- 4. DOCUMENTATION AND CONTROL
- 4. 1. If all the readings are acceptable, they shall be documented on the Micrometer Calibration Record. The record shall be signed and dated by the person performing the calibration. i4. 2. Document the calibration on the Gauge Calibration Record and also note where that micrometer is being used. See Exhibit B attached.- Gauge Calibration Record.
- 4. 3. After all records have been filled out and are correct, including the correct date for re-calibration, fill'out the phi! Calibration Sticker and attach it to the micrometer and release it to its respective function in the shop.
- 4. 4. If the micrometer is to be put into field service, follow the procedures below:
- 4. 4. 1. Put the original calibration documents into the calibration file.
- 4. 4. 2. A facsimile copy of the documents shall'go to the Field Quality Control representative or respective p.c Agent, where that gauge is to be placed into service.
i 4. 4. -3. The Gauge Calibration Record shall also contain, in the Remarks column, the project name, contract number and date. 1 4. 5. Attach a control color flag as noted in Procedure Q12.5 as a means of controlling U 'calibration recall. i-. ... . l, ormerly '"lnryco Surveillancn"
CALITBRATION FORM Project : Contract . Date CALIBRATION DATA Recall Date 1-Gauge or Device Namre - Number MapnIacturer - Type or Model Range \ ! Master Calibration Device - J.Nurnber Master Device Calibration Date: L L i Method of Cali.bration (Procedure number or describe other) - - i I I;..... . i I II i I iComments: - i i I I
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PROCEDURE Q 12.8.C-W l e CALIBRATION - PRESSURE GAUGES Ccpc0raion
- 1. PRESSURE GAUGES The following procedures will be used as a means of calibrating pressure gauges to be used during stressing or detensioning operations.
- 1. 1. Clean and remove all dirt, oil, residue, etc.
- 1. 2. Remove the old calibration sticker.
- 1. 3. Put the gauge on the calibration pump of the Mansfield & Green Dead Weight Tester and follow the procedures below.
- 1. 3. 1. Remove the front glass or plastic from the face of the gauge, or remove the rubber grommet in the back of the gauge, to make any adjustment, if needed, but only after all 9000 lbs. have been gauged.
- 1. 3. 2. Place the gauge on the pump, fitting adaptors as needed to conform to the gauge outlets.
- 3. 3. Close the oil port by moving the lever forward.
i1. 3. 4. Place a dish type-weight onto the cylinder carefully (all weights are
) numerically marked 1 through 9) starting with Number One.
- 1. 3. 5. Push the button in for a fast build up of pressure on the gauge.
A 1. 3. 6. Pull the button out for a slow incline of oil being pumped into the gauge.
- 1. 3. 7. :Read-the gauge in 1000 psi graduations and record on the Calibratiofi'Record Sheet (Exhibit A).
- 1. 3. 8. Continue to add weights and pump pressure-into the gauge until all the weights have been placed on the cylinder, a total of 9 weights.
- 1. 4. If the gauge readings are not consistent with the required weights, the initial calibration shall be completed. If the gauge is reading uniformly over or under, an adjustment of thegauge is necessary.
- 1. 4. 1. GAUGE ADJUSTHENT-
- 1. 4. 1. 1. Place a screwdriver on the back of the gauge and into a small port hole or on the face of the gauge. ' -
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- 2. 4. 1. 2. Hatch the gauge reading with the amount of weights on cylinder by turning the screw.
- 1. 4. 1.- 3. If the gauge cannot be adjusted, it will be repaired or properly disposed of.
I .. 5. After the adjustments, if any, have been made, release the pressure by moving the Li lever back to the original position. The calibration will now be completed by checking all the required increments. L 1. 6. Take the dish type weights off one by one, and put them back into the box in their respective slots, taking care not to damage .the weights. 1 7.. Fill out a new p5d Calibration Sticker and attach it to the face of the gauge, making sure that the re-calibration date is correct.
- 1. 8. Put the glass or plastic back on the face of the gauge or install the rubber L grommet into the back of the gauge.
i 9. Document the calibration on the Gauge Calibration Record (Exhibit B) also noting where the gauge is being used.
- 20. -With the gauge now calibrated, it may be released to its area of intended use.
1 11.; If the pressure gauge is put into.field~service, follow the procedure below: 1 .1. 1. Put the original calibration documents into the Calibration File. 1 1-. 11. 2. A facsimile- copy of the documens will go to the Field Quality Control representative or.respective pS7- Agent where that gauge is to be placed into service.
- 1. 11. 3. The Gauge Calibration Record will..also contain, in the Remarks Column, the project name, contract number and date.
- 1. 12. Attach a control color flag as noted in Procedure Q12.5 as a means of-controlling calibration recall.
- 2. HEISE DIGITAL PRESSURE INDICATOR Rather than using the Dead Weight Tester for calibration, a Heise Digital Pressure Indicator may be substituted.
- 1. Close back pressure valves before pressurizing the system.
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- 2. 2. Increase the hydraulic pressure to the point of the desired reading on the pressure gauge, usually 1000 psi + 100 .psi increments. Take a reading of the pressure gauge and the Heise Indicator and document both on the gauge calibration form.
- 2. 3. Section 2.2 shall be repeated until all the required readings have been taken usually to a maximum of the next even 1000 psi increment above the highest overstress pressure-required for'the stressing operations, i.e., 7600 psi overstress will require calibration to,8000 psi.
- 3. GAUGE ACCEPTANCE The pressure gauge to be used for zstressing or detensioning of tendons will be acceptable if it meets the following requirements.
- 3. 1. A 1/4% (0.25). gauge shall read to no greater than plus or minus 30 psi for any scale face reading of the calibrating gauge.
- 2. A 1/2% (0;50) gauge shall read to no greater than plus or minus 50 psi for any scale face reading of the calibrating gauge. This type gauge shall not be used as a master gauge.
TEMPERATURE The ambient -temperature during calibration of the pressure gauge shall be documented on the Calibration-Record Sheet.
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. PROCEDURE Q 1.8.D-W rciion t~~~~~u M , a tuvelanfce h-ei Corporati1o01 CALIBRATION - THERMOMETERS 18
- 1. THERMOMETERS The following procedures will be used as a means of calibrating thermometers.
- 1. 1. Clean thermometer of all dirt, oil, residue, etc.
- 1. 2. Remove the old calibration sticker. -
- 1. 3. Master and test thermometer shall be immersed in an agitated liquid for at least!
3 minutes, and at least 3 inches of sensing or sending unit shall be submerged in the liquid. Comparisons will be made at 3 temperature variances in the range! of the temperatures expected to be used, but in no case less than 500 F. between variances. 1} 3. 1. Where temperatures below freezing apply, it shall be acceptable to place the' master thermometer and the thermometer to be calibrated into a freezer com'partment, such as that of a refrigerator, for no less than the required C time period.
- 1. 3. 2. The accuracy shall be within one graduation of the smallest reading oh the scale. If not, adjust-the thermometer to the same reading as the master and f continue to calibrate.
- 1. 3. 3. If no adjustment can be made, the thermometer shall be 'returned to Quality Control or Quality Assurance for repair or destruction.
_1. 4. If the readings are acceptable, complete the Thermometer Calibration Record (Exhibit A). The record-shall be signed and dated by the person performing the calibration. -
- 1. 5. Document the calibration on the Gauge Calibration Record (Exhibit B) and note where that thermometer is being used.
- 1. 6. After all records are filled out, including the correct date for re-calibration, fill out, the pse Calibration Sticker and attach it to the thermometer. _ -1. 7. If the thermometer is put into field service, follow the procedures below:
- 1. 7. 1. Put the original calibration documents into the calibration file.
-1. 7. 2. A facsimile copy of the documents shall go to the Field Quality Control representative or respective _p. Agent.
- 1. 7. 3. The Gauge Calibration Record shall also contain in the Remarks column, the project name, contract number and date.. - - }
- 8. Attach a control color flag as noted in Procedure Q12.5 as a means of -
C.- controlling calibration recall.
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LiS - SCR LIB RATION "EXHIBIT A" Inryco Surveillance Customer Project Contract I ! ": Namame: Number: ThermometerI.D. I: Date of calIbration: Manufacture: Recallbration due date: Type or model: Master thermometer I.D.: Range: Naster calibration due date: Location:- CALIBRATION DATA Calibration Method: Master Actual Temperature Test Reading Temperature 1aster and test thermometer to be Innersed In agitated liquid for at least 3'minutes. and at least 3 inches of sepsing or sending unit to be submerged in liquid. Comparison will
.be made at 3 temperature variances of no less than 50 degrees F.
-Accuracy must be witnin one graduation of the smallest reading on the scale.
If not, adjust to same reading as master. If there is no adjustment. thermometer ____ I _ will be.returned to-Quality Assurance for repair or destruction. - Z., LI -- T NOTE: Accuracy will be within 5: of the total guage face value or one unit of the smallest scale graduation whichever is smaller. l Condition: LI : l Remarks: CBI Ci - Ca8raey: Calibr...e..-. -. ". Date: - .Page of Pages l
c-C r 17=-. [71 [77^- r---- 1777- 77> F? [---^ =
. i~f~r; ,E;XHIBIITB\ t
! rycoSt, 'nc *GAU.GE CALIBRATION F rU..R. iRE-CAL 1ERROR . _ IDENTIt I DATE R£MARKS. GFICATION CAL .. DUE . ( PROJECT, PART NO.>,REPAltR, ETC. ) Ie 7 .-'.! . II4-
.. ! 7. ," : . .
X PROCEDURE Q 12.8.E-W H ii , Cf i ta -.Gtti-i CALIBRATION - FEELER GAUGES - Ads by 1 FEELER GAUGES The following procedures will be used as a means of calibrating feeler gauges or shim stock. Feeler gauges are described as metal strips of various lengths and/or L widths supplied or measured to a specific thickness. L . 1. Clean each strip to remove dirt, oil or other residue that may unduly affect the! calibration accuracy.
- 1. 2. Remove old calibration sticker.
L 1. 3. The means of calibrating each gauge strip shall be provided through the use of al calibrated micrometer capable of reading in units of 0.0001".
- 1. 3. 1. Place the feeler gauge strip between the micrometer spindle and anvil.
- 1. 3.' 2. Adjust the thimble and sleeve assembly, by using the barrel hub or ratchet, to the thickness of the gauge strip.
-1. 3. 3. Read the barrel and vernier to determine the thickness. Repeat the adjust-ment and reading to verify the thickness. If necessary use the. Instructions for Reading-a Micrometer, attached. - - l I 4. If the accuracy is within the specified tolerance, document the calibration on Li the Calibration Form provided. .(Exhibit C) .
1 4. 1. If the measured thickness of the gauge strip during calibration, is in excess of 0.0005" of the specified or required thickness, that gauge strip shall be re-marked to show the new dimension or that strip-may be scrapped. 1 5. After each gauge strip has been calibrated and all records are filled out and correct, fill out the Calibration Sticker and attach it to the gauge strip, the gauge holder, or the container in which the gauge is stored. 1 5. 1. Document the calibration on the Gauge Calibration Record (Exhibit B) and note where that device is being used. 1 6. If the gauge strip is to be put into field service, follow the procedures below:
- 11. 6.. 1. Place the original calibration documents into the calibration file.
- 6. facsimile
,1. 6. 2. A facsimile copy of the documents shall go to the Field Quality Control representative or respective ph . Agent.
- 1. 6. 3. The Calibration Form shall also carry in the Remarks columnnor'other suitable area, the project name, contract number and date.
. In: -2,- - _ - -
- . ~~For nvle;-xy "Inayco Surve i1a!!bet
Li- Survei lanc,
'-. CALIBRATION - FEELER GAUGES [ 'oGportioC '
- 7. Attach a color control flag as noted in Procedure Q12.5, as a means of controlling j calibration recall.
Instructions For Reading A Micrometer EXAMPLE: .375 + .070 = .335 Your reading is taken by FIRST-read the barrel including the last visible line-then-add the amount shown on the thimble. EXAMPLE-
.375 + .010 equals .. 5.
- _ ,A micrometer is a measuring gage operated by-a screw having 40 i , I 2, 3 " tS threads per inch. Therefore one complete revolution of the screw t .l ini _ advances one thread exactly or one fourtieth of an inch. 1104 equals l l S} _25thousandths of an inch or .025'. Thus each line on the barrel
___
- equals .025'. The beveled edge of the thimble is divided into 25 equal parts. Each line equals 1125of .025 or .001". (one thousandths of an inch.) One complete revolution of the thimble therefore equals
.25' 0- or one line on the barrel scale.
Instructions For ReadingA Micrometer to Ten-Thousandths of An Inch Thimble C tO 0. C\j -' V-11
!.'v-z Th-' -imb-e.
~Mm i 9 597 6 Si32 tOJ
- t- = w X 7My / }
Barrel
.igure I J.RAZi BUM'x 09876543210 Barre/
Readings in ten-thousandths of an inch can be obtained by use of a vernier scale. The vernier scale, marked on the barrel, has ten divisions which equal nine divisions on the thimble. Since each graduation on the thimble equals 11/100 of an inch, then each vernier division is 1/10 of 9110,000 of an inch. The difference between a thimble ARV-. division and a vernier division is 1/10,000 of an inch. There-fore, when the zero lines of the vernier exactly coincide with thimble lines (Figure 1). the number on the vernier lines is the difference between the vernier line and the next thimble line in ten-thousandths of an inch. Thus when "Aux the fifth line on the vernier coincides with a thimble line, taX { , -. the thimble has moved 5110.000 of an inch. Example- First determine the number of thousandths, as with an ordinary micrometer. Then rind a line on the vernier that exactly coincides with a thimble linecBy adding the vernier reading to the thousandths reading the actual read-ing in ten-thousandths of an inch is obtained. The reading shown in Figure 2 is 250 plus .0005 or .2505. Ti CVioum. ' - /en~siti j
..- orrneriv
.. ,cfnrvico .. . Surveillance"
K QUALITY CONTROL
<C Project Contracit - Date CALIBRATION DATA Recall Date Gauge or Device Name Number_
Manufacturer Type or.:Model : Range Master Calibration Device . Number L Master Device Calibration Date: Test Range - I Reading l Error I I i
. I I
i ~ . .- . I i i
.I.
.'I - I I
L L U hMethod of Calibration (Procedure number or describe other) - Li Comments - I LCalibrated By:
- FF
Title:
., Date:
I - -- - E--- -., F - r- -,- r .I F-7777 F - -I T.:;, !;o NkEXHIBIT Bi" IflrYcoSurvl.~ (A I(~ I CP(Al lIPA'rtCnf t .C.O... 11-%L-IL-JAIrNI 1will SIL 44 Q
-7I GAUGE/I NSTRUM ENT IDENTI-- DATE: RE-CAL ERROR REMARhKS
_______FICATION CAL DUE (PROJECT, PART NO., REPA.IR.,ETC.) lb
Precision PROCEDURE Q 12.8.F _ _ _PSC - Surveillance CALIBRATION - DIAL INDICATOR GAUGESCoprtn I1. DIAL INDICATOR GAUGES The following procedures will be used to calibrate Dial Indicator gauges. The gauge maybe used for a variety of measurements and may require that the gauge be dismounted from some other device before calibration.
- 1. Dismount the gauge where necessary.
- 2. Clean the gauge of any dirt, oil or other residue that may unduly affect the calibration accuracy.
- 3. Attach the Dial Indicator to the Indicator Stand, with the probe pointing down towards
'the stand base.
- 4. Adjust the Dial Indicator gauge so that it rests ofi the Indicator Stand base with no pressure exerted on the probe. Set the dial face to read zero on the gauge, with the rotating bezel.
- 5. Using calibrated feeler gauge strips, slide the gauge strips betveen the stand base and the probe and note the readings on the Dial Indicator..
- a. A range of four readings will be taken. These will be 0.002", 0.005", 0.010" and 0.015".
- 6. If the accuracy is within the specific tolerance, document the calibration on the Calibration Form provided. (Exhibit C)
- a. If the accuracy is in excess of plus or minus one division of the smallest reading on the gauge, the gauge will be adjusted, repaired or scrapped.
7.' After the Dial Indicator gauge has been calibrated and all records are filled out and correct, fill out the PSC Calibration Sticker and attach it to the gauge, gauge holder, or the gauge storage container. Effective Previous A Revision: A96a 4 Page: Date: r- I-c I Revision:,! AIN
'i[ .il<
Fonnerly "Inryco Surveillance" I-C. L, I -I - - 2d
Precio-n -
~aK2
-Precision PROCEDURE Q 12.8.F - PSC Surveillance I -
Corporation CALIBRATION - DIAL INDICATOR GAUGES
.8. If the gauge is to be put into field service, follow the procedures below:
- a. Place the original calibration documents into the calibration file.
- b. A facsimile copy of the documents will go to the Field Quality Control A representative or respective PSC Agent.
- c. The Calibration Form will also carry in the remarks column or other suitable area, the project name, contract number and date.
- 9. Attach a color control flag as noted in Procedure Q12.5, as a means of controlling calibration recall.
K U I'
/
Effective l PreviousA Revision: A 4crrYF i Page: Date: 2-7/?KC I Revision: Jo! 4-/4 l add 8 70? I Z t ii Fonnerly "Inryco Surveillance"
QUALITY CONTROL
),.
Ii Project Contrac _t _Date CALIBRATION DATA Recall Date il Gauge or Device Name Number Manufacturer _ Type or. Model , Range I L Master Calibration Device _ _ _ _ .-
. Number Master Device Calibration Date:
Test Rang e I Reading Error
-- I . rs_ _
L
.I.
.1 I L Method of Calibration (Procedure number or describe other)
Comments: . ( L F Calibrated By: _ . . _ .
Title:
. Date: H
Precision PROCEDURE QA 12.8.G-WI
!f_-PSC Surveillanlce]
CALIBRATION - STRESSING RAM/JACK
- 1. STRESSING RAM/JACK - HYDRAULIC The following procedures will be used as the means of calibrating or determining the area of hydraulic stressing rams.
- 1. 1. Clean the ram of excessive dirt, oil, or other residue that may unduly affect the calibration accuracy.
- 1. 2. The load cell or testing machine shall be set up so that the loads will be applied in a uniform accuracy.
- 1. 3. The ram shall be attached to the load cell or testing machine and centered so that the loads will be applied concentrically and uniformly.
- 1. 4. The ram shall be loaded to the target increments shown on Form 12.8.G. This will be in about 1000 psi increments for 1000 ton rams and about 500 psi increments for 1400 ton rams. This will also vary according to the size of the ram and accuracy requirements for a project.
. 1. 4. 1. Gauge pressures shall not be reduced to meet a target increment once a target
.. - increment has been exceeded. Readings will be acceptable when they are within 100 psi of the target increment.
- 1. 4. 2. A minimum of three runs shall be made for each of the required target increments.
- These runs shall occur at about 11/44,, '2, and 3/4 of the total ram extension for each
', - ram.
- 1. 4.: 3. The maximum ram pressure has been predetermined for each size ram to be calibrated and normally will not be exceeded, to avoid damaging the ram.
- 1. 4. 4. Readings of the load cell readout and the pressure gauge shall be taken at the L. same time.
- 1. 5. During ram calibration a calibrated hydraulic pressure gauge having the smallest reading equal to or less than 20 psi or a Heise Electronic Digital pressure indicator shall be used.
The hydraulic pressure reading to the nearest 10 or less psi or the actual digital readout shall be recorded on the calibration form. L 1. 5. 1. The load cell or testing machine readout shall also be entered onto the calibration record to the nearest 0.1 reading. . i I. 6. All other information areas of the calibration form shall be completely filled in by the ( calibration technician or the witnessing'agent. The form shall be signed and dated. The calibration record shall then be handed over to the Engineering Section for final computation. Effective Previous Revision AI-laS Page-l -Date: C l- Revision:Za C '?R8- Surveillae tC L . ~~~Formnerly "Inryco Sur veillance" °Aj/
PROCDUR QA 2.8G-WPrecision PRCDUEQA1.8GWPSC Surveillancel CALIBRATION - STRESSING RAM/JACK Corporation
- 2. COMPUTATION OF RAM AREA Regression analysis shall be used to compute the ram area once initial, raw data, infonnation has been documented on the Jack Calibration Record Form. The personnel performing the computation and verification checks shall sign and date the Calibration Form and the computer printout.
- 2. -1 - Computation shall be performed by the computer. All data entered into the computer will also be printed out. This data, as well as the-computer results, shall be verified by
- ~ someone other than the person operating the computer.
- 2. 2. In the event that the computer is temporarily unavailable, computations may be performed manually observing the same methods being used by the computer. These manual computations shall be verified and/or corrected by a computer computation as soon as practical. The manual computations shall only be performed by the Engineering Department personnel.
- 2. 3. Omitted readings, dropouts, are automatically considered by the computer. An explanation will be found in Appendix 1, Section 8.
- 3. STRESS CARD PREPARATION - APPLIES FOR ORIGINAL TENDON INSTALLATION ONLY The regression equation shall be used in the preparation of stressing cards for each jack. As a means of providing a uniform area calculation where 'more than one jack is used in simultaneous stressing operations, the following procedures will be used.
- 3. 1. The mean ram area of all the jacks being sent to the jobsite shall be calculated.
- 3. 1. 1. If any ram in a group of rams varies from the mean ram area by more than plus or minus 2 percent, those rams with variation in'excess of the specified tolerance shall be recalibrated or separate individual Stressing Cards shall be used for that ram.
- 3. 2. The mean ram area will be encoded into the PSC computer for use in preparation of the Stressing Cards for determining ram area. This will eliminate the need for manual calculation on the Stressing Cards.
- 3. 2. 1. Rams that cannot meet the plus or minus 2 percent control tolerance and are not to be recalibrated; will have separate Stressing Cards prepared based on that individual ram area.
- 3. 2. 2. In conditions of urgency, the Stressing Cards may be hand written.
Effective Previous A Revision: A-No 11ki4K l Page: Date: . Revision: L C-28,-o . g 8-2.-?? l Y7 Formerly "Inryco Surveillance" /-i./Q i
PROCDUR 8G-WPrecision QA 2 PRCEUR Q 1.8.G* PSC Surveillance CGCALIBRATION - STRESSING RAM/JACK
- 3. 3. It is therefore possible to have more than one set of Stressing Cards for use in the stressing operations. Each set of cards shall have the appropriate information documented, following the requirements of the fabrication and quality control procedures for that project.
I 4. CALIBRATION DOCUMENT DISTRIBUTION After completion of the verification check of the ram area calculations, the following distribution of the Calibration Record shall be made.
- 4. 1. The original Calibration Record shall be sent to Quality Control for retention in the L Calibration file.
- 4. 2. Quality Control shall prepare a Ram Calibration Shipping Document Package and submit L_ copies of this package for inclusion in the; L 4. 2. 1. Quality Assurance Contract File.
- 4. 2. 2. Project Management Files.
,,- 4. 2. 3. Engineering lack Calibration Files.
- 4. 3. Copies of the Calibration Record shall be distributed to:
- 4. 3. 1. Project Management or Coordinators/Project Managers.
- 4. 3. 2. Equipment Maintenance, Jack Number File.
L 4. 3. 3. Equipment Maintenance, Jack Calibration File.
- 4. 3. 4. Detailing/Engineering Departments, for preparation of field records.
- 4. 4. At least one copy will accompany the jack for shipment to the field. This copy shall be retained in the appropriate quality documentation file on site.
- 4. 5. RAM CALIBRATION DOCUMENT PACKAGE L Included in the Ram Calibration Document Package will be the NIST Calibration Data Sheet for the Load Cell; the Gauge Calibration Data Sheet traceable to the NIST, for the gauge used during calibration; Calibration Record Form 12.8.G and the Computer A-. HPrintout. Where required by the Contract Documents, a Certificate of Compliance shall be included attesting to the traceability of the various instruments to the NIST.
Effective I Previous A I Revision: A cV.Ae4i rv Y Pate: Date: ~ - 8 ?IRevision:At C-29B?6 l A - LA Formerly "Inryco Surveillance"
Precision PROCEDURE QA 12.8.G-W PSC Srrilac CALIBRATION - STRESSING RAM/JACKCoprtn
- 5. OTHER CONTROLS
- 5. 1. Calibration stickers or any other calibration information may or may not be applied to the rams. The nature of the jacks plus the constant handling make it very difficult, if not impossible, to retain any markings or temporarily attached devices.
- 5. 2. Calibration frequency and recall control shall be found in the appropriate Field
- Installation Manual, Surveillance Program Quality Control Manual, Fabrication Quality Control Manual or as separate Quality Control Procedures.
- 5. 3. Requirements for other conditions mandating recalibration shall be specified in the Quality Assurance Manual, Fabrication Quality Control Manual, Field Installation Manual, Surveillance Program Quality Control Manual or as separate Quality Control Procedures.
- 6. DOCUMENTATION The calibration of a ram shall be documented on the Ram/Jack Calibration Record Form 12.8.G or a similar document. The computation will be in the form of computer printout sheets.
- 7. APPENDIX Attached to this procedure are the following documents that will detail the computation of ram force as a function of gauge pressure using Linear Regression, computation of errors, examples and computer program used for calibration:
- 7. 1. Appendix I - Jack Calibration Using Linear Regression
- 7. 2. Appendix 2 - Examples I & 2: 2 pages
- 7. 3. Appendix 3 - Program Listing: 3 pages, dated 3-3-81 b"r
- tcaL0
- 7. 4. Appendix 4 -Definition of Variables: 2 pages, dated 3-3-81 *e 'h14W
- 7. 5. Appendix 5 - Program Operation & Flow Chart: 5 pages, dated 3-3-8
- 8. DEFINITIONS
- 8. 1. A ram is defined as the piston part of a force pump. It is the area of the piston which is to be measured as the means of calibration.
- 8. 2. A jack is defined as the entire force pump with the various attachments that permit it to pull or lift. For Post-Tensioning operations the applied force pulls one end of a tendon.
Effective revion: A Revision: A I<ofr Page: DateF Revision:/ely ("In-yo Sur-vellc V i
- ~~~Fornierly "Inryco Surveillance" (p$I'
Precision PROCEDURE QA 12.8.G-W PSC P ..C u Surveillance (. - CALIBRATION - STRESSING RAM/JACK Corporation
- 9. WITNESSING
-9. 1. Where the project documents require the witnessing of ram calibrations, raw data, PSC shall notify the Owner or his ageri~3o perform the witnessing.
- 9. 1. 1. If it is acceptable to the Owner, PSC shall have an independent i; inspection/laboratory source, who is acceptable to the Owner, perform the witnessing function.
- 9. 1. 2. If it is acceptable to the Owner, PSC shall have a PSC Level II Q.C. Inspector perform the witnessing function.
- 9. 2. Where the project documents do not specify a witnessing requirement, PSC may or may not provide witnessing, at PSC's option.
- 10. WITNESSING ACTIVITY The witnessing activity consists of a visual observation of those operations that are associated with the calibration of the ram.
l , 10. 1. The witness shall be a certified Level II Inspector per the requirements of ANSI N45.2.6-1978 from an independent inspection or laboratory source. The Owner shall retain the option of having a certified Level II Inspector from his Organization perform the
- -witnessing function.
- 10. 2. The witnessing function shall consist of:
- 10. 2. 1. -Verifying that the information posted on the calibration form is representative of
'the device being calibrated.
- 10. 2. 2. Verifying that the readings taken of the load cell readout and pressure gauge at each increment.
- 10. 2. 3. Signing the Calibration Record Form in the Witness Area attesting to the accuracy l and acceptance of the raw data being entered.
- 10. 2. 4. Rejecting any activity not in conformance with the accumulation of the raw calibration data or not in compliance with Section 1 of PSC Calibration Procedure QA 12.8.G-W.
- 10. 3. The witness does not verify the actual computation of the ram area as this is a computer controlled function based on the "JKCALNR9 Jack Calibration Program."
Effective Previous Revision: A CYvc9 Page: Date: cRevision. l,Forinierly e Surveill "Inryco Surveillance" y1>, Iyco
fq tY
.(7; C:me RAŽU/JACK CALIBRATION RECORD FORM 12.8.G I PSC Formerly Inryco Surveillance PROJECT - CONTRACT/PART NO. I Jack Description Size _ons Register No Theoretical Ram Area- _Max_ _ . Pressure PSI Calibrating Device Register No.__ Constant Calibrating Gauge _ . Register No. _ Date Raw Data By -__ WITNESS Mean Ram Area sq.in. I _ __ __gency _ Date .
Computed By QC Check., Title Date Title Date Tarzet PSI Gauze Readinz PSI LLoad Cell Readoutl COMMENTS RUNI POSITION _ _ _ I I A.i I. 1- 1 RUEN POSITION i I I __; I - l _ - _-- I RUN I --- I POSITION _
.11 __ _ _ _ _ _ _ __ _ _ _ _ _ -*
_ __ I .. I _ __ I___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ I. I. At I I I I I___ I. _I _! _ - - L IL I L I I I
K L....... APPENDIX 1 PROCEDURE QA 12.8.G-W x SC 3tlieIanci, JACK CALIBRATION USING LINEAR REGRESSION r 1. THEORY OF LINEAR REGRESSION The theory of Linear Regression, which uses the principle of Least Square to obtain' the line of best fit, will be used to determine the relationship between ram force
-and gauge pressure. The equation of such a line is y = a + bx = prediction ram forces,
.X, (y) - (Zx) (5y) where b n slope of the line of best fit (regression line) 2 ZX2- (Ex) n a = y - bx = y - intercept of the line, x (Sx)/n mean of all x-readings (gauge pressures)
L L y = (y)/n = mean of all y-readings (measured ram forces) n Number of pairs 6f x, y readings. All readings for all three' Iram positions.will be considered together.-
- 2. COMPUTATION OF RESIDUALS (ERRORS)
For each pair of readings, the residual quantity unexplained by regression, Y res. = y - y, will be..determined. The percentage residual will also be K I determined as El = (Y res./Y x 100). Note that y is the force computed from the Load Cell readout and the Constant (K).
- 3. OTHER ERRORS
'A All other errors due to calibration such as interpolation, accuracy and/or repeatability of the Standards certified by the National Institute of Standards and Technolojy repeatability of gauges used in calibration or in the field, etc. shall be listed. As a minimum, the following items will be considered.
- 3. 1. AT JACK CALIBRATION
' 3. 1. :1. Error in Standard (varies between repeatability of 3 psi to maximum guaranteed value of 10 psi) ..... use -S=(K+.003)ksi or actual value. '.3 1. 2. Interpolation error of calibration gauge against which the jack is compared with the standard ......use (Gc/4)ksi or actual value.
- 3. 1. 3. Accuracy and repeatibility of calibration gauge = 0, since the calibration gauge is adjusted to match the Standard each time.
;'7-)
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APPENDIX 1 PROCEDURE QA 12.8.G-W Prec1or l JACK CALIBRATION USING LINEAR REGPFESST ON
- - 1.
- 3. 2. AT GAUGE CALIBRATION
- 3. 2. 1. Interpolation error in Master ....... use (Gm/4)ksi or actual value.
- 3. 2. 2. Interpolation error in Field Gauge . us'e OGf/4)ksi or actual value.
- 3. 2. 3. Accuracy of Master .................. use M=(S/2+Am)ksi or act. value.
- 3. 2. 4. Accuracy of Field Gauge.; ........ ...use F=(M+Af+Arn)ksi or act. value.;
Note: It is expected that the various gauges can be interpolated to any one bf 4 division between incremental markings.
- 3. 3. AT FIELD USE OF GAUGE
- 3. 3. 1. Interpolation error .................. use (Gf/4)ksi or actual value.
- 3. 3. 2.' Accuracy............. - . ' .use E=(H+Af+Am)ksi or act. value.
i 4. -DEFINITIONS l K = Actual calibration value of Standard. S= Error in. Standard (traceable ..to rjipr), G Smallest Gauge scale face reading.. (Graduations.) I A = Manufactured guaranteed accuracy. M = Calibrated accuracy of Master Gauge. F = Calibrated accuracy of Field Gauge.' E = Calibration error in field. c = Calibration Gauge. m = Master Gauge. I = Field Gauge. i iv .. L .J . L i .5. 0 q Ii',* . s/ lrzI n: Al "I*'~ t ; .-v: . ,-...
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APPENDIX 1 PROCEDURE QA 12.8.G-W Ptecsion Surveillance JACK CALIBRATION USING LINEAR REGRESSION
- I Corporation 1 5. ERROR CALCULATION - EXAMPLE Let K - .007 ksi; G. = .010 ksi; Gm = .050 ksi; Gf = .050 ksi; H (.010/2 + .025) or .030 ksi; E or F = (.030 + .050 + .025) or .105 ksi.
S (K + .003) or .010 ksi; Am = .025 ksi; Af .050 ksi.
- 5. 1. From the above list of values the most probable sum of the "other" errors will
-be calculated as the square root of the sum of squares. For the stated values
+ (errors) + .1534 ksi
- 5. 2. The m~ost probable error will be input and calculated as a percentage of the
}maximum gauge pressure expected to be used for that ram at Overstress.
Example: Maximum gauge reading = 10 ksi (10,000 psi for a 750 T ram) t ' The most probable 'error as a percentage of the maximum gauge pressure to be used at Overstress for the above example would be:
.1534 x 100 1.534%
10
'6. COMBINED ERRORS The residuals from the regression (jack calibration errors) will be combined with the "other" errors to result in the most probable total error.
Most probable total error, E = VE 2 + 2
- 7. RECALIBRATION If the most probable total error, E is greater than 1.57,the 'jack will be recalibrated or more accurate gauges will be used to reduce the value of E to i.5%or.less. If the jack has any repairs performed that could affect the ram area then that jack will be recalibrated.
l- : (111 Prviu I\- ,q
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-- - rorrmetly "Inryco Surveii~anlce"
. ~Predsion APPENDIX 1 PROCEDURE QA 12.8.G-W Pesi1n I
. .... .. . Vei I nce
(. ` JACK CALIBRATION USING LINEAR REGRESSION Corporation i II I I
- 8. OMITTED READINGS (Computer Dropouts)
During the calibration of the ram using the Jack Calibration - Linear Regression Program - JKCALNR9 simultaneous readings of the gauge pressure and the load cell indicator are-taken. If plotted, these readings would form a scatter diagram from which a -"line of best fit" could be drawn. Most of these points will be- reasonably close to the "line of best fit", however, one or two may not be close enough and may be considered to be in error. Therefore these "error" points will be automatically discarded by the computer and recomputed as stated in the JKCALNR9 program. If more than one-third-of the points are eliminated in this manner, the data is considered unsatisfactory-and recalibration performed. ( (4L _ _ __ __ _ _ _ _ C~ _ _. ion I ( ar .1
* .~ ..-. Z LfXZ I AI -
I 2g~./r v I~ Formerly "Inryco Surveillance"
I -!r3,, L<T {....2 j7-G < G ERFZTX , 0 APPENDIX 2 - Example 1
-7
_ sc F F: F:SS Page 1 of 2 N PROJECT. V. C. SUMH.F: C -NT RA CT / PART NO. JAC14 DESCRIFTION. TON'S RE C IST ER NOtu. 9 _ Z6 THE-ORETICAL RAW AREA. MAY' PFRESSURE. PS I CALIERRATING DEVICE USED. REGIES)TER No. CONSTANT. 16 0 0 CALLIBR.ATING GAUGE DESCRIFTION. REGIS6TER NO. ACTUAL GAUGE LOAD CELL C5H PU TE5 READING (PtSI) READOUT F0 RCE ( tt )
. ~,I,~.. 79.-!5O 12'72. 000 71 C'0 14S56. 000 10.00
?900 . O7. 00 1645-. 000 4 248. 000 70 30 91.20 11462.-000 7Co'c - 101.s0 1628.-000 6080 "OS~
7 10' 0 1275 .2 '00 70 10 1470. 400
?770 101. s0 16_25 .6OO
-w- - THESE READ INGS HAVE B:EEN OMITTED FROMi THE FINAL CALCULATIONS
- ERF:ORS IN JACh' CALIE'RATI . -
.RF:OR IN STANDARD *** * -** 0. C' 00 HSI I----- I INTERPOLATION IN GAUGE ****-- 0. 0025 ACCURACY OF GAUGE
- 0. 0000 K S I ERRORS IN GAUGE CALI'F:ATION INTERPOLATION IN MASTER ** i* 0.0125 KSSI INTERFOLATION IN FIELD GAUGE
- 0.0125 KSSI ACCURACY OF MASTER
- 0.0300 (S I ACCURACY OF FIELD GAUGE - .O. 150.1<SI ERRORS IN FIELD UScr OF GAUGE INTERPOLATION ERROR **--* 0. 0125 K<SI ACCURACY ERROR * * -- :O . 1o50 1<S I MAXIMUM GAUGE READING USED * *** 10.0000 1<5I
***** FORCE(0)= 213.438 X GAUGE READING(R<SI) < .2.70G **=**
CORRELATION = O.-998227 N/NO 1.0000 (NOT < . o87 ) MAXIMUM ERROR RATIO IN -JAHU' 008
. oe MAXIMUM ERROR RATIO IN GAUGES **** * .01'3 MAXIMUMt; TOTAL ERROR RATIO * .01-77
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JACK CALIBRATION - LINEAR REGRESSION ANALYSIS PROJECT CAL PROCEDURE CONTRAC CT NO. EXAMPLE
. ATACK DESCRIPTION: PINE TONS: 1000 REGISTEER NO.: 9365 -( HEORETICAL RAM AREA (sq.in): .212.65 MAX PRESSURE (psi): 8440 CALIBRATING DEVICE USED: TELEDYNE REGISTER NO.: 4734 CONSTAlTT= 32991.2 CALIBRATING GAUGE DESCRIPTION:-HEISE REGISTE]R NO.: S9-271 L.. INPUT.
ACTUAL GAUGE LOAD CELL COMPUTED READING (psi) READOUT FORCE (k) 1013 8.44 278.446* 2116 12.84 423;607 3155 19.20 633.431 4007 27.60 910.557* L 5140 31.98 1055.059 6002 41.32 1363.196* l7107 44.64 1472.7.27 it L8016- 50.92 1679.912 1004 7.66 252.713* 2100 12.78 421.628 o L 3004 17.26 569.428* 4006 25.60 844.575 5088 31.00 1022.727
' 6005 41.58 1371.774* Q7 7255 44.88 i480.645 ,?
8002 51.28 1691.789 1010. K 6.34 209.164* L2009 . 12.78 421.628 3010 16.22 535.117* 4108 25.62 845.235 5300 - 38.46 1268.842* 6004 38.46 1268.842 7003- 41.86 -1381.012 8005 51.22 1689.809 L * - - THESE READINGS HAVE BEEN OMITTED FROM THE FINAL COMPUTATIONS ERRORS IN JACK CALIBRATION ERROR IN STANDARD ............... 0 . 01'00 -ksi INTERPOLATION IN GAUGE .......... 0.0000 ksi ACCURACY OF GAUGE ......... 0 .0000 ksi ERRORS IN GAUGE CALIBRATION INTERPOLATION IN MASTER ......... 0 .0000 ksi INTERPOLATION IN FIELD GAUGE 0.0050 ksi ACCURACY OF MASTER .............. 0.0100 ksi ACCURACY OF FIELD GAUGE ......... 0. 0275 ksi ERRORS IN FIELD USE OF GAUGE INTERPOLATION-ERROR ............. 0.0050 ksi ACCURACY ERROR .................- 0.0275 ksi MAXIMUM GAUGE READING USED .;.............. 8.0160 ksi CALIBRATION DEVIATIONS ARE NOT WITHIN 1.5% RECALIBRATE JACK (_b,- MPUTED EIY: DATE: CHECKED BY: DATE:
DUR~A Precision PROCEDURE-QA 12.8.K rcso R01 . Surveillance L' - -rA Trfl\TTn?, LA-LLltrMI1UINI - _J flJAFICtn 1.1TOF I JiFrLJL.iaL) L'M+/-\E. fniirce Um3L Corporation lI
- 1. THREAD MEASURING WIRE-GAUGES The following procedures will be used for calibrating Thread Measuring Wire Gauges. These wire gauges are commonly used for verifying the pitch diameter I i of threads. -
-1. MIL-STD-120 Section 8 and FED-STD-H28 Appendix A13 have been used as guides to preparing these procedures. While these documents propose five place decimal accuracy for diameter (0.00001"), roundness (0.00002" to 0.00005") and-dimensional-relationship of wires-to each other (0.00002"), this procedure will only require those accuracy requirements to be maintained to four decimal places, 0.0001", as measured with a micrometer that reads to 0.0001". As the acceptance controls for the thread measurement of anchorages is only required to three decimal places, 0.001", there is no need for greater accuracy.
- 2. Wire gauges are-obtained in sets of three pieces and will be acquired in a calibrated condition to at lhat four decimal places, within an-accuracy of 0.0001" for the specified diameter. This means that the roundness will also be maintained at' the same requirement.
- 3. Prior to calibration the wire gauge will be carefully cleaned of any surface residue that could unduly influence the accuracy of the calibration.
- 4. The previous calibration sticker will be removed from the wire storage container.
2.' DIAMETER 1.' Place the wire gauge between the anvil and spindle of the micrometer.
'2. Bring the spindle assembly into contact with the wire,-while the wire is in contact'with the anvil-, by rotating the rachet or the Thimble'cap.
The wire must be fairly placed between the plug and anvil to effect an accurate and true reading. It may be necessary to do this more than once for each reading in order to 'obtain correct results.
- 3. Document the reading to 0.0001".
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- PROCEDURE QA 12.8.K C TeiUSA\c< F
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P CALIBRATION - HARDENED WIRE GAUGES orporation
- 2. 4. Open the spindle slightly and move the wire to a new location. Repeat Step 2.2 to obtain a measurement at this location.' Document that reading.
- 5. The wire will be measured at no less than six locations, over no less than a L inch length near the center of the wire, to verify that the diameter is within the limits over that entire portion.
- 6. The diameter of that wire is acceptable if all six measurements are identical and that dimension will be used as the control dimension for the final size of that wire.
- 3. ROUNDNESS i The-condition of roundness for a wire may be measured with a 0.0001" micrometer or verified by rotating that wire under a dial indicator mounted on a test stand.
- 1. MICROMETER The roundness of a wire will be verified by measuring the wire as it rests in a "V" grove of a hardened and lapped surface. When the wire is rotated and measured at various points about its circumference, in
'the same general location as noted in Step 2.5 above, the dimensions will be documented.
- 1. At least three readings will be taken at each measuring location about 120 degrees apart.
- 2. The wire will be moved to a new location and measured. This will be performed at no less than four locations in the approximate center of the wire, a total of 12 readings.
- 3. FED-STD-H28 APPENDIX A13 recommends that the wire be rotated in an anvil with flank angles of 14 degrees 30', to approximate the condition of an actual Acme thread, while MIL-STD-120 Section 8 only requires a "VI' groove. Because the measurements are taken at 120 degree angles to each other at the same location, the "V" groove may be 29 or 60 degrees, just so 3 point contact is maintained and wedging conditions avoided:
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p-,ecision PROCEDURE QA 12.8.K [ at=xn CALIBRATION HARDENED WIRE GAUGES
- 3. 1. 4. Figure 1 shows the general configuration of this type-of measuring device.
I I i i I U Figure 1
- 2. DIAL INDICATOR The roundness of the wire will be verified by rotating the wire as it rests in a "VI' groove of hardened and lapped mat erial, with the opposite surface of the wire in contact with the contact point of the dial indicator. The dial indicator rests in a fixed position on-the test stand, while the device with the "V"'-groove may be fixed to the test stand base or may be movable.
- 1. Regardless of the mounting of the "V'"groove device, it will be necessary to be sure that the contact points of the "VI'groove are in nearly perfect alignment with the centerline of the indicator contact points, otherwise wide variations in readings will be noted.
- 2. Care shall be taken while rotating the wire to avoid tipping the wire up or down while resting in the "VV"groove as this will only result in incorrect readings. -
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PROCEDURE QA 12.8.K k J CALIBRATION - HARDENED WIRE GAUGES -,
- 3. 2. 3. Some care should be exercised to prevent moving the wire laterally while being rotated, in order to effect a correct reading at any one location. This would have a tendency to produce readings of a
', helical-nature rather than circumferential, while undesirable, these readings are still acceptable.
- 4. At least eight locations will be verified over no less than a I inch length near the center of the wire; l
- 5. The greatest variation in reading the indicator dial will be documented for each of the eight locations.
- 6. It should be noted that dial indicators are manufactured in a variety of dimensional controls, therefore, any dial face may be used, just so an increment reading no larger than 0.0001" can be discerned; a scale reading 0.00005. will be acceptable as this is finer than 0.0001". 005 '
- 7. Figure 2 below shows a typical dial indicator test stand.
Figure 3 shows typical dial indicator face graduations. 01.' Ls11 l pl/ D05= Z~z 0 - - - - Starrett Sarrett Starrett L 2 i Figure 2- Figure 3 5- - - r '- .cL ' . o
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; ~Preodsionl PROCEDURE QA 12.8.K PCluvelaie.
Surveillanxce K i CALIBRATION - HARDENED WIRE GAUGES l - 3. 3. ROUNDNESS ACCEPTANCE
- The roundness of a wire is unacceptable when any reading for roundness exceeds 0.0001" or if the roundness dimension is 0.0001" more or less than the calibrated dimension of that wire.
- 4. WIRE SETS Thread measurements require three wires, therefore a three wire set shall' be made of three wire gauges of the same dimensional measurement, accurate to the fourth decimal place 0.0001" for diameter and roundness.
- 5. WIRE HARDNESS Two-types of wire sets were available for use in measurements. The-"Pee Dee" type wire gauge are relatively soft, about-Rockwell C20 and they tend to wear faster. Therefore these wires will be calibrated every six months.
- 1. A hardened set of wires in excess of Rockwel-l C5O, .are also used. They are obtained, originally certified to 5 decimal places 0.00001". As A- ~ these wires are .harder than, the threads being measured, the calibration L + frequency will be established -at 12 months.
- 6. DOCUMENTATION -AND CONTROL
- 1. If the accuracy is within the specified tolerances, document the calibration on the Thread Wire Calibration Documentation Form 12.8.K.
- 1. If the measured diameter of the gauge wire varies from the previous calibration by more than 0.0001" of the stated diameter, that gauge wire will be re-marked to show the new dimension or that wire may be scrapped.
- 2. After each gauge wire has been calibrated and all records are completely posted, fill out the PSC Calibration-Sticker and attach it to the gauge wire, the gauge holder, or the container in which the gauge is stored.
3.. The original copy of the calibration form will be retained in the QC/QA files. ['rrcvin's' .6 of l 'j ;z i. esin 5!-51-87 C\{5 Of .IT~T 6 i.7/
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- *--X -... l-PROCEDURE QA 12.8( K l CALIBRATION -HARDENED
- WIRE C~kidlr
- 6. 1. 4. A facsimile copy of the calibration record will go to the Field Quality Control representative or respective PSC Quality Agent wherever that Wire Gauge shall be placed into service.
- 5. The calibration form will also carry in the remarks column or other suitable area, the project-name, contract number and date.
- 6. Attach a control color flag as noted in Procedure Q12.5 as a means of controlling calibration recall.
- 7. The Wire Gauges or its container will be marked to provide traceability to the individual calibration records for a set of wires.
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THREAD WIRE CALIBRATION - PROCEDURE QA 12.8.K i as- -, .I iryco DOCUMENTATION FORM 12.8.K GENERAL INFORMATION RECALL DATE Project Assigned -_- Date _ Gauge lD Supplier/Manufacturer Gauge Type: Hardened Pee Dee Original Diameter Calibrated Roundness Calibrated Diameter CALIBRATION DATA DIA+/-'ETER Micrometer No. Calibration Date LOCATIONS 1 2 3 4- 1 5 6
.. . Il-i.11 I ROUNDNESS Micrometer No. Calibration Date LOCATIONS ReadinRl 33 4 ._L ROUNDNESS
___ I ____ Indicator No. Calibration Date
. i
.LOCATIONS.- POST.TOTAL VARIATION i a
1 2 3 4 5 6 7 8 I _1_ I I -I - 1- 1I I i I i Comments i I i Calibrated by: - Title-- Date t i EFFECTIVE DATE PREV.REV./\ REVISION A PAGE-I of 1. - .. i
J . . - E CA II A T O -- R~ -i, _ _ I C I
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. .I . it EXHIIBIT B GAUGE CALI BRATI ON RECK~.." Q IDENTI- DATE RE-CAL ERROR FICATION CAL DUE
- l Precksior~
PROCEDURE QA 12.8.L iP i g,.. .. ance. CALIBRATION - Pee Dee WIRE GAUGES I . .. ..
- 1. WIRE GAUGES
.The following procedure will be used as the means of calibrating wire gauges, usually a type known as Pee Dee, which will be used in the measuring of the ii minor diameter of threads. These gauges are acquired in sets of three and normally used for taking various types of thread measurements. There is no I-need for great accuracy of the measurement of the diameter or for roundness as these dimensions are later deleted from the measurements to provide the
!ii actual root of the thread dimension. The wire diameter will be documented to -
four decimal places, 0.0001", as read with a micrometer that measures to 0.0001".
-1. Prior to calibration, the wire gauge will be carefully cleaned of any, surface residue that could unduly influence the accuracy of the calibration.
Io: I I
.L 2. The previous calibration sticker will be removed from the wire storage container.
- 2. DIAMETER MEASUREMENT
- 1. Place the wire gauge between the anvil and spindle of the micrometer.
- 2. Bring the spindle assembly into contact with the wire, while the wire is in contact with the anvil, by rotating the rachet or Thimble cap. The wire must be fairly placed between the spindle and anvil to effect an accurate and true reading. It may be necessary to-do this more than once for each reading in order to obtain correct results.
- 3. Document the reading to 0.0001".
- 4. Open the spindle slightly and move the wire to a new location. Repeat Step 2.2 to obtain a measurement at this location. Document the reading.
- 5. The wire will be measured at no less than four locations, over no less than a 2 inch length near the center of the wire, to verify that the diameter is within the limits over that entire portion.
- 6. The diameter of that wire is acceptable if all four measurements are within 0.0005" of one another. The most frequent occurring measurement will be used as the diameter of that wire. It may be necessary to take additional readings to establish a majority dimension.
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- ~Fornt.rly "Inryco Surveillance"
- PROCEDURE QA 12.8.L IL Surveillance CALIBRATION - Pee Dee WIRE GAUGES -
- 3. DOCUMENTATION All measurements, as well as other pertinent information, will be.posted on the Calibration Form Exhibit C, which includes signing and dating.
- 1. If the measured diameter of the gauge wire varies from the previous calibration by more than 0.0005" of the stated diameter, that gauge wire will be re-rharked to show the new dimension or that wire may be scrapped.
- 2. After each gauge wire has been calibrated and all records are completely posted, fill out the PSC Calibration Sticker and attach it to the gauge L >wire, the gauge holder, or the container in which the gauge is stored.
- 3. The original copy of the calibration form will be retained in the QC/QA files.
- 4. A facsimile copy of the calibration-record will go to the Field Quality I Control representative or respective PSC Quality Agent wherever that Wire Gauge shall be placed into service.
L~
- 5. The calibration form will also carry in the remarks column or other suitable area, the project name, contract number and date.
- 6. Attach a control color flag as noted in Procedure Q12.5 as a means of controlling calibration recall.
.7. The Wire Gauges or its container will be marked to provide traceability to the individual calibration records for a set of wires.
I 4. WIRE SETS Thread measurements require three wires, therefore a three wire set shall I be made of three wire gauges of the same dimensional measurement, accurate to the fourth decimal place 0.0001" for diameter. Li L,
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I4I QUALITY CONTROL
; .t Project - Contract _ __ Date CALIBRATION DATA Recall Date Gauge or Device Name Number Manufacturer Type or; Model : Range Master Calibration Device _
Number Master Device Calibration Date: L Test Range Reading -Error LK L I I
. .I -I . .
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4- + K Method of Calibration (Procedure number or describe other)
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,j / Commnents *- L-Calibrated By: Titl e: . D ate: _ _ _ _ _
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iU IPrecisioln A 1C Surveillance CALIBRATION - MICROMETER BAR CHECKING STANDARD ororation
- 1. MICROMETER - BAR CHECKING STANDARD CALIBRATION The following procedure will establish the requirements for the verification of the calibration of Bar Checking Standards that will be used for the purposes of- calibrating or verifying the calibrated status of outside measuring micrometers.
- 1. 1. The Bar Checking Standard will be used to verify or provide the means of calibrating outside micrometers where it is not possible to access a Master Bar Standard.
- 1. 1. 1. A micrometer capable of reading to 0.0001" will be calibrated with a
-Master Standard in accordance with the requirements of PSC Procedure Q12.8.B. This micrometer will then be used to verify or provide the means of calibrating the Bar Checking Standard.
- 1. 2. Remove the end cushions from the Bar Checking Standard to be calibrated and thoroughly clean the ends to be measured.
- 1. 3. Remove the old calibration sticker if one exists.
- 1. 4. Place the Standard between the anvil and the spindle of the micrometer.
It would be advantageous to use a micrometer stand-to assure accurate and correct alignment.
- 1. 5. Take at least 3 separate readings of that Standard; open the micrometer, remove the Standard and re-install the Standard for each reading. Be sure that the Bar Standard is fairly engaged between the anvil and spindle of the micrometer otherwise accurate-measurements will not be possible or repeatable. Unfair readings will be discarded immediately.
- 1. 6. Acceptability of the measurement will be based on the 3 readings not exceeding the smallest measuring division on the micrometer.
-1. 7. Record the actual readings and errors/variations on the Calibration Record Form. The Form shall be signed and dated by the person performing the calibration.
- 1. 8. Document the calibration on the Gauge Calibration Record and also note where that Bar Checking Standard-is being used. See Exhibit B attached -
Gauge Calibration Record.
- 1. 9. After all records have been-filled out and are correct, including the correct date for re-calibration, fill out the PSC Calibration Sticker and attach it to the Bar Standard or its Storage Case and -release it to its respective function.-
I ion Ng Ft ,: 5-1-87 jRevision- 1 of2 Formerly "Inryco Surveillance-
P ._. _- . , _................ 1L, L _. - Precisior PROCEDURE QA 12.8.N Surveillance Corporation
-I I.-
-- CALIBRATION - MICROMETER BAR CHECKING STANDARD
+ _I7
- 1. 10. If the Standard is to be put into field service, follow the procedure i below:
_ I t
- 1. 10. 1. Put the original calibration documents into the calibration file.
- 1. 10. 2. A facsimile copy of the documents shall go to the Field Quality Control representative or respective PSC Agent, where that gauge is to be placed into service.
- 1. 10. 3. The Gauge Calibration Record shall also contain, in the Remarks column, the project name, contract number and date.
- 1. 11. Attach a control color flag as noted in Procedure Q12.5 as a means of controlling calibration recall.
- 2. COMMENTS It should be noted that the Bar Checking-Standard-is only being verified to 0.0001" with a micrometer that only reads to 0.0001". The measurements being performed in the field will only be taken to 0.001" therefore the Bar Checking-Standard will meet the requirements of Criteria XII of the PSC Quality Assurance Manual under the Section entitled "Accuracy".
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\A-S- &,I QJALTY CONTROL PSC Formerly i Inryco Surveimance CALIBRATION FORM "-EXHIBIT C' Project . Contract - - Date
-CALIBRATION
. DATA Recall Date Gauge or Device Name ___Number Manufacturer _ Type or Model : Range Master Calibration Device -_: Number Master Device Calibration Date:
U Method of Calibration (Procedure number or describe other) - U-
. -- a Comments: _
( I / Calibrated By: .
Title:
, Date: U- EFFECTIVE- DATE IPREV.REV. A l EVISION /\ . PAGE 1 of I I _ I I
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G-I I ny o Sur-.' - s CLRI i Inryco Survei'L.;:.; c; Nk EXHIBIT B ' GAU.GE CALIBRATION 'RECb." ' GAUGEl N STRUM ENT . DENTI- DAATLE RE-CAL ERROR (ROEMT ARTKSRPIJ T. FIATO CAL... DUE ._-' (POET PAR NO I C--..
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Precision PROCEDURE XA 12A.8.P P.C Surveillance L- -. CALIBRATION - MAGNIFYING COMPARATOR RETICLES Corporation
- 1. MAGNIFYING COMPARATOR RETICLES I The following procedure will establish the requirements for performing the verifica-tion of the status of accuracy of those Reticles that will be used with Magnifying Comparators.
- 1. 1. Remove the old calibration label if one was applied.
1 1. 2. Remove the Reticle from the Magnifying Comparator and carefully clean it. Do not L use solvents or abrasives. Do not excessively rub the Reticle-during cleaning or calibrating. This could displace the scale graduations which are flash plated onto the glass or plastic.
- 1. 3. Remove the Precision Glass Reticle Calibration Scale from its case and plastic-bag. If necessary, carefully clean it in the manner described in Section 1.2 i above. As this is a glass device, do not use excessive force during cleaning; do not drop this scale, as it could break.
I k --4. Place the Calibration Scale onto a sheet of clean, white or otherwise-light colored paper. It is advisable to use a flashlight or other auxiliary lighting to assist in illuminating the Reticle and Scale. l 1. 5. Place the Reticle to be calibrated into the Magnifying Comparator. The Magnifying
- Comparator should be in a range of 5 to 10 power magnification.
L 1. 6. Adust the Magnifying- Comparator for focus after placing it onto the Calibration Scale. Adjust the auxiliary lighting as necessary.
- 1. 7. Align the Reticle on the Calibration-Scale so that the 0.005" graduations are l; between the 0.004" to 0.006" graduation lines on the Calibration Scale. This should be done in about the center of the magnified viewing area to avoid problems with parallax at the outer edges of the viewing area. It would be advantageous to L align a numbered 0.100" graduation line of the Calibration Scale with a numbered 0.100" graduation line of the Reticle. This would eliminate a need to count graduations between viewing areas of both devices. Refer to the sketches .of the Reticle and Scale shown in Section 2 of this-Procedure.
Formerly "Inryco Surveillance"
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Precision Ppnr(nipTR nA l) R P I PSC Surveillance CALIBRATION - MAGNIFYING COMAERATORRETICLES Corporation
- 1. 8. Align the Reticle on the Scale so that the 0.005" Reticle graduation lines are just. above the 0.004" to 0.006" graduation lines of the Scale. The 0.005" Reticle graduation.lines will appear to emanate out of the 0.004" to 0.006" Scale graduation lines, making it a simple matter.to. verify that the Reti'cle .has the correct dimensional spacing.
- 9. Continue to verify that the 0.005" Reticle graduations intercept the 0.004" to 0.006" graduation lines and the 0.010" graduation lines through'out the incremental 0.100" range being checked. -
1 1. 10. Verify the correct dimensional alignment of the remaining incremental 0.100" ranges that are to be considered for this calibration. It may be necessary to shift the Reticle on the Scale so that it becomes easier to perform the verifications. Ll11. 11.' it will not be practical to use those portions of the Reticle that are affected by parallax, those portions near the edges verified nor will they be used during IIcJ '.- inspections due to the parallax condition. Therefore only those portions'of the Reticle that are not affected by parallax shall be verified.
- 1. There are a number of different configurations for the 0.005" increment Ui l. 11. Reticle, varying from 0.500" to 0.800" in length. The 0.500" Reticle is not affected by parallax to a great extent, so it can be verified 'for full value across the 0.500" length.
- l. 11. 2. For those Reticles-with lengths over 0.500", it will only be necessary to verify the center portion of the Reticle, typically the range of 0.200" to about 0.600".
- 1. 11. 3. The intent here is to provide some latitude regarding the range to be verified. Whichever range is verified shall be documented on the Calibration Record Form. That portion of the Reticle not verified--shall be appropriately marked to prevent its accidental use. It would be.best to place a piece of tape on the unflashed (unmarked) side-of those portions of the Reticle ranges that were not verified and therefore not to be used.'
- 1. 11. 4. The Reticle shall be verified for each 0.005" increment within each of the
- 0.100" Test Ranges to be used.
f - - I . .- - - . I Page 1 _0_ Formerly "Inryco Surveillance"
Q K,: 1, V, _ ~t x PROCEDURE 7-QA 12.8 .PSreillan Precision i, '. - >S4C Surveillance V . . Corporation CALIBRATION - MAGNIFYING compARATng gv.TTpr _
- 1. 11. 5. Record the -actual readings for each Test Range on the Calibration Record Form. Due to the large amount of readings it will be acceptable to document these'as Test Range readings for the ranges being verified, with a notation to indicate the increments between the Test Ranges being checked.
- 1. 11. 6. Acceptability of the verification of the Reticle shall be based on the Reticle matching the O.010" graduations on the Scale throughout all the Test Ranges.
As the Reticle is primarily used to identify cracks in concrete which are not less than 0.010" in width, the 0.005" Reticle graduation is of less importance and could be in error, but not in excess of 0.001" for any one 0.005" Reticle graduation.
- 1. 11. 7. Record any variations in the error column, provided that the errors are within the acceptable tolerance cited in Section 1.11.6 above.
- 1. 11. 8. If the Reticle does not meet the required acceptance criteria that Reticle shall be scrapped or destroyed.
'- 12. If all the readings are acceptable, they shall be documented on the Calibration Record Form. The record shall be signed and dated by the person performing the calibration.
- 1. 13. Document the calibration on the Gauge Calibration-Record and also note where that Comparator/Reticle is being used. See Exhibit B attached - Gauge Calibration
'Record..
- 1. 14. After all records have been filled out and are correct, including the correct date for re-calibration, fill out the pFcd Calibration Sticker and attach it to the Comparator or its Storage Case and release it to its respective function.
- 1. 15. If the comparator/reticle is to be put into field service, follow the procedure below:
- 1. 15. 1. Put the original calibration documents into the calibration file.
- 1. 15. 2. A facsimile copy of the documents shall go to the Field Quality Control representative or respective p9' Agent, where that gauge is to be placed into service.
- 1. 15. 3. The Gauge Calibration Record shall also contain, in the Remarks column, the project name, contract number and date.
- 16. Attach a control color flag as noted in Procedure Q 12.5 as a means of controlling calibration recall.
Formerly "Inryco Surveillance"
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Precision
-, PROCEDURE O 12.8P - -SC Surveillance CALIBRATION - MAGNIFYING COMPARATOR RETICLES Corporation
- 2. PRECISION GLASS RETICLE CALIBRATION SCALE Shown below are enlarged copies of the Scale and the ranges. Some of the ranges do not reproduce well on facsimile machines and other.Scale range examples are also shown. The Metric Scale is not used and therefore not shown or discussed.
RANGE 0.100" - Read as 1.600" INCH -0.050" - Read as 1.550"
.1 .23 .4 .5 -6 .7 .8 .9t 1.1 12 13 14 1.6 O.010 - Read as 1.560" l 1l 1 l 11 1 i ] e / 0.004'" & 0.006"z graduations,
~:i ii i1 li~Ir~lI 1111 i iiiiii ~ IrI! iir eading, in between for 0.00051 IIIIfflll I IIIIJ fIII I I ilflhil lIli~ III, iifl ItillI read as 1 .565'0 PRECISION INDUSTRIES, INC. 0.002" graduations. Did not CLEVELAND, OHIO U.S.A. reproduce, but are not-used during verification.
- 2. 1. ENLARGED GRADUATIONS OF RETICLE AND SCALE I '- Shown below are-enlarged portions of each graduation so as to provide a reference for purposes of comparison.
RETICLE 0.025" Graduations Reference Range 0.100" Graduation 0.005" Graduations I I PRECISION SCALE
,AliRnment of 0.005" within 0.010" Graduations 0.004" and 0.006" graduations - 0.050" Graduation 0.002" Graduations
/I 9-!,
I. . . 1I .I L ,-1 M. .I I. rIT Formerly "Inryco Surveillance"
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-- r7 QUALITY CONTROL PSC Formerly k.- Inryco Surveillance :
CALIBRATION FORM " EXHIIBIT C"
- .r Project Contract I Date CALIBRATION DATA Recall Date Gauge or Device Name . . _
Number Manufacturer . - Type or 'Model Range Master Calibration Device Number Master Device Calibration Date: Test Range Reading Error Method of Calibration (Procedure number or describe other) . _ Comments: Calibrated By: ;
Title:
. Date:. i i
.EFFECTIYE IEFFECTIVE DATE DATE I IPREV.REV.
jPREV.REV./\ A . 1REVISION jREVISION/\/\> , ., PAGE I of IIPAGEL of I1 - ij
J:F ra {7 [7 .1 [1 l-- [ C, [- [ r-_ [ F.---
..- 7 ^I--- - .7 [ -- , ro72 I :
17 PSC For,, I IT B. InrycoSurv;';.' ' GAU.GE [aIB IT B \7 CALIBRATION RE(.7;;1 GAU GEl I N STR U M ENT . FICATI ON CA L RE-CALE RRO R P E MA R KS . .
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SECTION :10 PSC Formerly
.c, Ic Inryco Surveillance MASTER GAUGE (PSI) I JACK'GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: i'p A1
;- 1 2; d,V- _
JACK GAUGE NO.: Zy !: -0006' MASTER GAUGE NO.: S 7 - SZ? 33 36* 2 93 DATE CHECKED: 9-CHECKED BY: . / 4
- ZI-0,9052o61 REMARKS:
j i i Iz MASTER GAUGE (PSI I JACK GAUGE (PSI) I i II PRESSURE GAUGE CALIBRATION RECORD JOB: 7;;g A LD v2 i Ii JACK GAUGE NO.: 4",9 .oooot j MASTER GAUGE NO.: S7-5.Z33 i I T DATECHECKED: 9- 7-01 4 i i CHECKED BY: __ _________ i REMARKS: i i i i i 7000 "2W47e i I
-OOO I
IxfxPSC Formerly (Cqc' wu1' Inyco Surveillance MASTER GAUGE (PSI) I JACK-GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7-Hg MThe- /00 oo . .. JACK GAUGE NO.: /a,2-y J d doom - evea MASTER GAUGE NO.: S 7 - £v233
.3000 : 3aeva DATE CHECKED: 9-P-6/
CHECKED B_________
- rooeg .. 117e0 REMARKS:
6,000 e00w 60010 zz040 rsoolo rZO-9 MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: , 'o/6_00 JACK GAUGE NO.: *,eAo-v 2 MASTER GAUGE NO.: s
-304oo 3044 DATE CHECKED: 9- 9-&
CHECKED BY:__ _ _ _ - cOoo 3 9f6f REMARKS:
. .__. 2 96 60010 600Q 76000n0
il C2 G h PSC Formerly Irryco Surveillance I MASTER GAUGE (PSI) I JACKGAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD
- /6Lo 616Oo JOB: fHR cF At4-e JACK GAUGE NO.: A1/2N- f d 000 --- S°° MASTER GAUGE NO.: S7-s-z33 3,000 i0 DATE CHECKED: 9-/ -f '
CHECKED BY: _ _ _ _ _ _ rooo6'- REMARKS: 650007S0 Yeeooonv 6 000 "Z~ ' MASTER GAUGE (PSI) JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7,Z , e'; JACK GAUGENO.: *z,*'. MASTER GAUGE NO.: .57-5.L33 DATE CHECKED: 9-,3-oV . 00 CHECKED BY: -coo. REMA:RKS:___________
. -~~6000 f
,7aon o764
, ' ' g00 Z~a-o
10 GPSCFormerly GI'UJl Illryco Surveillance l MASTER GAUGE (PSI) I JACK-GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: TR Ea A1,.:- 1 s JACK GAUGE NO.: ,gY Z MASTER GAUGE NO.: s 7 S- 33 4000 _ ft DATE CHECKED: 9-/Y-oi CHECKED BY: 6 X REMARKS: ' ~Zi 5a-,9 6000 i6oo g13yg,~' ?732V MASTER GAUGE (PSI) JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: s 9Lq . JACK GAUGE NO.: ?c-oso 1,- MASTER GAUGE NO.: s 7-5;.33 3 ooo 9 -DATE CHECKED: 9-/r--e*' CHECKED BY::c / S io REMARKS: _ _ _ _ _ _ _ _ _ _ _ _ _ _
.600
l- PSC Formerly
&-6 /Gvp¶ Inryco Surveillance o r T? . _ _ . . _ . .
MASTER GAUGE (PSI) l JACK-GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7R A1,t..e-1g e JACK GAUGE NO.: Fo* 'I L ) o c' MASTERGAUGENO.: 57-S33 DATE CHECKED: - -6 Y
- leq6 CHECKED BY: W, ,
.Wo226 e REMARKS:
,3oo 2o6 05oo MASTER GAUGE (PSI) JACK GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: 7A-/S ,'--, Z vw JACKGAUGENO.: Ptk,. o 2 0o 0 MASTER GAUGE NO.: S.723 -3 DATE CHECKED: -Z 3 __°Y_- CHECKED BY: 2( Z 9oo d REMARKS: _
~5- ( c'
_ _ _ _ __ _)e
._7o/
. ._ _7_ _6000
&CO r 0 PSC Formerly ka hlu-yco Surveillance
_ _ MSTERGAUGE (PSD l JACK-GAUgE(P-SI) PRESSURE GAUGE CALIBRATION RECORD I JOB: 7-R aE- A1,a- - JACK GAUGE-NO.: ,s-v"2 __L__ ___ MASTER GAUGE NO.: S7-,-1233 DATE CHECKED: 9-I 6 -eg CHECKED BY:__________________-- '9 9° REMARKS: _ J_0___7 _____
.'ooo Fuogo MASTER GAUGE (PSI) JACK GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: Z7Y, q, cooo - /ooAo JACK GAUGE NO.: wx: - sooO-_________ MASTERGAUGENNO.:_s________' _-
. ~~3000 . B DATE CHECKED: d>-O -- o CHECKED B .M - ______3___ ?
REMARKS: -
;5-666716yn 7000 oo kigoo paoon
. PSC Formerly c k Gq Inryco Surveillance MA STER GAUGE (PSI) JACK-GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: 7HqR 14, ze- 1gus JACK GAUGE NO.: r9v' Y' L dBooo o MASTERGAUGENO.: s7 -S-33 DATE CHECKED: - Ao o CHECKED BY: 1. REMARKS: 500e7 Jc2H! 900a1 -, 96 MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: ;Fi Xt.ZHz i, looe9 / C7 C. 6 JACK GAUGE NO.: *;50y Z .aooo zC0o MASTER GAUGE NO.: s7-5.33 3000 3c e0 DATE CHECKED: D z__o __ CHECKED BY:_ _ __ _ _ -/1000 ' 'q-660 REMARKS: t5rop6 Sc0 fo
.600.0 Go Cx o 700r 700 o 8000 - 80<
- Jtl PSC Formerly 30t 1 Imryco Surveillance MASTER GAUGE (PSI) I JACK GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: 73
-t'R&~ Ag1,- -- .. ... _
./ 0 _ /occ JACK GAUGE NO.: P41/4I C .Booo - o MASTER GAUGE NO.: S 7 -- 33
,3000 3t DATE CHECKED: //- C 4 CHECKED BY:
V /RE R
.oSl G
REMARKS:- 500rv 00 0
- 0ooo _ _ _ _ _
roooncCC
-__ 8000ea
_ _ _ O MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: ,iREs ,lzzo-oL~qtb JACK GAUGE NO.: AoYL-'-/ - MASTER GAUGE NO.: s 7-5233 DATE CHECKED: 5/ CHECKED BY: REMARKS: Fooo Oo S000 G Cc) _____________________________________________________________ L
k 9jAl( 9 PSC Formerly
- q Im-yco Surveillance MASTER GAUGE (PSI) I JACK GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: 7HEe Apia:
/6000 0a JACK GAUGE NO.: Cd - / z- / t, )
MLASTER GAUGENO.: s7-s33 DATE CHECKED: 1 o e ReoOe Z-e'C, - CHECKED BY: -i// / - REMARKS:
'70 '700--e
. S OO67 _ _ _ _ _ _ _ _
MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: ,qq Z ,t,
/ZO O O _ _ _ __ _ _ _
JACKGAUGENO.: _________ MASTER GAUGE NO.: S 7-5233 DATE CHECKED:__________ CHECKED BY: A-4. REMARKS: 76fo
~e~e~O_ _ _ _ _ _ _ _ _ _
G jjL
*PSC Formerly Inryco Surveillance MASTER GAUGE (PSI) JACK -GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: -hse 4
/M 1, - slz
/600.00 . 2. o l_O___O__.__.
JACKGAUGENO.: Fo 4,t ' F mooo Z O 0o MASTER GAUGE NO.: S7 - sj2 33
- 4. -o ' ,c, ,30,00 ~ -3 VOO DATE CHECKED: /f J-? B 001 -
CHECKED BY: % - 1/00rw So REMARKS: yooo - 6oso
- C0006o roo 70o0 -
-slooo : oo
;~
0S6a - Ro 0 MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD . JOB: r, 5,*loL qs iT JACK GAUGE NO.: Z S boo MASTER GAUGE NO.: s7-S.33 DATE CHECKED: ii-i - L CHECKED BY: . - .~c1.VOO 0 n2.O Lj o REMARKS:
-MOr0 -
5 a c5
O4\\ j(o PSC Fornerly Inryco-Surveillance MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 3 7 HqC-e /d,ze 1c,~ - v § _ /-----O-O-- laoooI O JACK GAUGE NO.: - CC- i/Lb CI MASTERGAUGENO.: DATE CHECKED: /1- /6s 4-
'S7-S3 3000 j 3 °ao CHECKED BY: -Y. .L 00 0 REMARKS:
500 . S'o oc)
- rooo
-~'r 5o 000 o0 8000
_ o0 _ _ __o 8__oo _
'S7 o MASTER GAUGE (PSI) I JACK GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: Zf,zli*4Aqb F1coc JACK GAUGE NO.: romvey g5y MASTER GAUGE NO.: S7-5.Z33 3ooo DATE CHECKED: I I-1-o f aonoS ao o D CHECKED BY: 74- r REMARKS: S0 ooo 7000 - 7ooo 7000O6 _ _ _ _ _ _ _ _
PSC Formerly (ti (;0%£)I nryco Surveillance I - -- - ___ MASTER GAUGE (PSI) I JACK-GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: Figg R CE A1,I- eczeb
- t5 JACK GAUGE NO.: _______ AM9O oc MASTER GAUGE NO.: 57- t-233 DATE CHECKED: -_I- IS- C )L *5'OcW~ Lf ,
CHECKED BY: 2-REMARKS: 6e9O>O
- 0nO,7_ _ _ _ _ _
MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7Z- Ai,5 _T-Lz Zfe , JACK GAUGE NO.: C, C:f, - 6G9 Acooo MASTER GAUGE NO.: s 7-519Z_33: a~OO6 7C>0~ DATE CHECKED: . I I - If 5, 1Lf, L. 0c0c CHECKED BY: __ __ REMARKS: 7c0 'O ____ ___ ___ ____ ___ ___ ____ ___ ___1 I
G l? PSC Formerly L &C , Inryco Surveillance MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD L- JOB: 7wHC- /Aflae = JACK GAUGE NO.: F-Ae'CY U
.B3ooo MASTER GAUGE NO.: s 7 - E 33 DATE CHECKED: 11- Ic.- '
CHECKED BY: ( . (,t 9 0 _ _ _ _ _ _ _ _ REMARKS: Z~9~9 _ _ _ _ _ _ _ _Cs
-y.oo 385et I MASTER GAUGE (PSI) I JACK GAUGE (PSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: 7,yr JACK GAUGE NO.: CC /Z. y1/f9 MASTER GAUGE NO.: S7-5.k33 'A o looo " _ to _._,_/_o_ __o DATE CHECKED: 1 } -i G-°Y CHECKED BY: 'W REMARKS: _____ 5 0 C2
- 00 - - 9 co gS'C>
I PSC Formerl 6/J5,(qi Iru-yco Surveillance MLASTER GAUGE (PSI) I JACK-GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7--R AliT Mire ZL,46vb ,CC JACK GAUGE NO.: j Ey..
,4&- 5 MASTER GAUGE NO.: 57 S- 33 DATE CHECKED: _-__ 4 _
-r-_
-CHECKED BY: -
-0 -7~,
REMARKS: voecb . +F
&900g 600§ + 'oe2
.cc'
-e06 rooocso
_ _ _ _ _ ' _ _ '6tO~ MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: r Zs pj7
-4 JACK GAUGE NO.: _ Fc-,.Z,4v- y -"'5 00 MASTER GAUGE NO.: s7-5.33 "400o -- Zooc DATE CHECKED:
CHECKED BY: A .60,~oqo REMARKS: ODc' 7~op a~ 6OeW 3 006
._ _ _ _ _ _ _ ;o L ____ ___
____ __________ ____ ___ ____ ___ ____ ___ ___ _ _ _ _ _ _ _ _ _ _ _ I _ _ 85fo c:z Ii
p1 1 I PSC Formerly
&,I IG( Inxyco Surveillance MASTER GAUGE (PSI) IACKGAUGE tPSI)
PRESSURE GAUGE CALIBRATION RECORD JOB: R 1elMta- Szqt A6cIo /0 JACK GAUGE NO.: Fe,__m _____S MASTER GAUGE NO.: S 7- 5d 33 8c26oom0 DATE CHECKED:___________ ~'c9OO CHECKED BY: A-REMARKS: 50nO, _ __ _ _ _ _ _ _ _6 . oc' __ _ _ _ _ _ _ _ & C)o C > . 'e - 8o9c I (9 50 MASTER GAUGE (PSI) JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: - /000 /00 JACK GAUGE NO.: saOOO zO 0 MASTER GAUGE NO.: S7-5.Z33 DATE CHECKED: / Zo 300 2 CHECKED BY: /00/*-4---- REMARKS: -_. MooO 50 0 700
- 7. 70C-O
. - ' soo dgoo3 (3
PSC Formerly ( it4O 1 Inryco Surveillance 1 MASTER GAUGE (PSI) l JACK-GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7',- AS M-0 JACKGAUGENO.-: ,*_ 0,50 MASTER GAUGE NO.: S 7- suz 33 DATE CHECKED: / Z CHECKED BY: _____ -___ REMARKS: -__ 0000 s 0] 609O0 t6-0Lc _ _ __ 0_ _ _ _ _ _0 (3' cgoto2 ecodlo MASTER GAUGE (PSI) I JACK GAUGE (PSI) PRESSURE GAUGE CALIBRATION RECORD JOB: 7 ,. A-z;2 ', /000 _ _ _ _ _ _ _ _ JACK GAUGE NO.:_ _ MASTER GAUGE NO.: S7-5733 300o DATE CHECKED: CHECKED BY: REMARKS: 6O00O C F ri_ _ _ _ _ _ _ _ _ _
- 4. ________________}}