ML102720170
| ML102720170 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 10/29/2009 |
| From: | Precision Surveillance Corp |
| To: | Office of Information Services |
| References | |
| FOIA/PA-2010-0116 | |
| Download: ML102720170 (98) | |
Text
PCHG-DESG ENGINEERING CHANGE ATTACHMENT 2 Sheet 1 of 1 Record of Lead Review 000063016R0 Document #CR-N1009-503 (PSC-Tendon Fab lengths)
Revision 0 The signature below of the Lead Reviewer records that:
the review indicated below has been performed by the Lead Reviewer; appropriate reviews were performed and errors/deficiencies (for all reviews performed) have been resolved and these records are included in the design package; the review was performed in accordance with EGR-NGGC-0003.
-- Design Verification Review E-Design Review F-- Alternate Calculation F-1 Qualification Testing S-special Engineering Review
-- YES E-N/A Other Record!
[I Engineering Review 0
Owner's Review 3are attached.
,W-, 4zk, A
Civil John Holliday Lead Reviewer 8101108 YJ (print/sign)
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Discipline Date Item Deficiency Resolution No.
NONE FORM EGR-NGGC-0003-2-10 This form is a QA Record when completed and included with a completed design package.
Owner's Reviews may be processed as stand alone QA records when Owner's Review is completed.
rEGR-NGGC-0003 T
Rev. 10 Z18R0 Page 1 of 3
PCHG-DESG ENGINEERING CHANGE 000063016RO PCHG-DESG ENGINEERING CHANGE 00006301 6R0 DOCUMENT TRANSMITTAL Transmittal Number: N1009-002 (E
Precision Surveillance Corporation 3468 Watling Street East Chicago, IN 46312 Phone: (219) 397-S826 Fax:
(219) 397-5867 Email: info@psctendon.com http://www.psctendon.com Crystal River Nuclear plant 3 TO:
15760 West Power line Street Crystal River, FL 34428-6708 ATTN:
JOHN HOLLIDAY PO/SUBCONTRACT NUMBER:
CONTRACT # 270269/ADDENDUM 4 SUBMITTED BY:
PAUL C. SMITH SIGNATURE:
TITLE:
PRESIDENT DATE SUBMITTED:
January 9, 2008 DOCUMENT TRANSMITTAL INFORMATION DOCUMENT NUMBER REVISION DESCRIPTION PAGES FORMAT CR-N1009-503 0
TENDON FABRICATION LENGTHS I
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4 REMARKS:
Z18RO Page 2 of 3 Z18R0 Page 2 of 3
PCHG-DESG ENGINEERING CHANGE 000063016RO DOCUMENT NO:
N 1009-503 ENGINEERING DOCUMENT REVISION NO:
0 PLANT: CRYSTAL RIVER JOB #: N-1009 SAFETY RELATED:
DATE: FALL 2009 NON-SAFETY RELATEDL PAGE NO:
I OF I PREPARED BY:
PCS DATE: 1/9/08 REVIEWED BY: CEC DATE: 1/9/08 CRYSTAL RIVER TENDONS FABRICATION LENGTHS Verticals 34V8 34V9 34V10 34V1 1 34V12 34V13 34V14 34V15 34V16 34V17 ft inch 189-0.25 189-4.5 189-11.25 190-10 191-10.75 191-9 190-9.5 188-11.5 189-2.75 188-10.75 Spare TBD Horizontals 42H27 42H28 42H29 42H30 421H31 42H32 42H33 42H34 53H27 53H28 53H29 53H30 53H31 53H32 53H33 53H34 53H35 155-7 155-6 155-7 155-6.25 155-7.25 155-6 155-8 155-6 155-6.75 155-7.5 155-7.5 155-7.5 155-7.5 155-7.5 155-6.75 155-6 155-8 Spare TBD Verify tendon numbers and fabrication lengths outlined above. Suggest spare tendons to be equal to longest tendon and shortened in field as necessary.
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PCHG-DESG ENGINEERING CHANGE ATTACHMENT 3 Sheet 1 of 1 Record of Concurrent Revibw 000063016R0 Document
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i Design Verification Review
-] Engineering Review Z
Owner's Review
-I Design Review r-Alternate Calculation i Qualification Testing
] Special Engineering Review: Engineering Co current Reviewer (pDint/sicn)
Discipline Date Item No.
Deficiency Resolution NONE 4
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FORM EGR-NGGC-0003-3-10 This form is a QA Record when completed and included with a completed design package.
Owner's Reviews may be processed as stand alone QA records when Owner's Review is completed.
EGR-NGGC-0003 Rev. 10 Page 21 of 13 Z1 7R0
,Page 1 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 ATTACHMENT 3 Sheet 1 of 1 Record of Concurrent Review Document 7-5C 6
iL Pe~cr~~\\rr Revision M Owner's Review El Design Verification Review F-1 Design Review F-1 Alternate Calculation Fl Qualification Testing F-1 Special Engineering Review El Engineering Review Concurrent Reviewer (prinflsiqn)
Discipline Date Item No.
Deficiency Resolution FORM EGR-NGGC-0003-3-10 This form is a QA Record when completed and included with a completed design package. Owner's Reviews may be processed as stand alone QA records when Owner's Review is completed.
EGR-NGGC-0003 Rev. 10 Page 1 of 1 Z1 7R0 Page 2 of 95
PCHG-DESG ENGINEERING CHANGE ATTACHMENT 3 Sheet 1 of 1 Record of Concurrent Review 000063016R0 Document F-- Design Verification Review F-- Design Review El Alternate Calculation 0- Qualification Testing Revision L-Engineering Review Z
Owner's Review Special Engineering Review: Engineering lj 4
Co current Reviewer (print/sign)
Discipline
.4 li -S 6 S Date Item No.
Deficiency Resolution NONE FORM EGR-NGGC-0003-3-10 This form is a QA Record when completed and included with a completed design package.
Owner's Reviews may be processed as stand alone QA records when Owner's Review is completed.
EGR-NGGC-0003 Rev. 10 Page 21 of 13 Z1 7R0 Page 3 of 95
PCHG-DESG ENGINEERING CHANGE ATTACHMENT 3 Sheet 1 of 1 Record of Concurrent Review 000063016R0 I I Document Post Tentioning System Fabrication Manual Revision 0
FI Design Verification Review
-- Design Review I Alternate Calculation l Qualification Testing EI Engineering Review r-Owner's Review SpeciaI Engineer~ig Re iewfl Procurement Eng-ineering Date 41 _
Concurrent Revievier"
( J lpfint/sign)
Discipline Item No.
Deficiency Resolution 1
Our approved suppliers list (ASL) requires,"
All material commercial graded dedicated Materials provided under this Purchase by PSC. Vendor E&Q notified of ASL Order/Service Contract shall be from restriction disparity by procurement subsuppliers of PSC who have been qualified engineering.
through an on-site audit which verified I OCFR50 App. B Compliance". This does not appear in any of the specs. One spec is for non domestic material, which will likely mean their subsupplier will not have a I OCFR50 App. B QA program.
FORM EGR-NGGC-0003-3-10 This form is a QA Record when completed and included with a completed design package. Owner's Reviews may be processed as' stand alone QA records when Owner's Review is completed.
EGR-NGGC-0003 Rev. 10 Page 1 of 2 Z1 7R0 Page 4 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO ATTACHMENT 3 Sheet 1 of 1 Record of Concurrent Review Design : 1009-TFAB TENDON FABRICATION MANUAL Revisior Design Verification Review i
Engineering Review Z
Owner's F
-I Design Review EI Alternate Calculation nI Qualification Testing Z Special Engineering Review Contract Administration Review; no comments Cnoki 4WCT I
tIERBI~Ao WA 1/fi3(42~
Joe~
leview Concurrent Reviewev (orint1sian)
DiSCiDline Date Item I/Si lo No.
I/_ _
_Resolution FORM EGR-NGGC-0003-3-10 This form is a QA Record when completed and included with a completed design package.
Owner's Reviews may be processed as stand alone QA records when Owner's Review is completed.
EGR-NGGC-0003 Rev. 10 Page 21 of 13 Z1 7R0 Page 5 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0
.............. ATTACHMENT 3 Sheet 1 of 1 Record of Concurrent Review 1 009? -
T- /,ý14I/3 Documentt Revision 0
t MI Design Verification Review EI Design Review
-I Alternate Calculation
[I Qualification Testing I-Engineering Review Owner's Review
'- Special Engineerin ew Concurrent Reviewer (print/sign)
Discipline
//3 z
a;.c' Date Item No.
Deficiency Resolution FORM EGR-NGGC-0003-3-10 This form is a QA Record when completed and included with a completed design package. Owner's Reviews may be processed as stand alone QA records when Owner's Review is completed.
I EGR-NGGC-0003 Rev. 10 Page 1 of 2 Z1 7R0 Page 6 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PCHG-DESG ENGINEERING CHANGE 00006301 6R0 DOCUMENT TRANSMITTAL Transmittal Number: N 1009-001 Precision Surveillance Corporation 3468 Watling Street East Chicago, IN 46312 Phone: (219) 397-S826 Fax:
(219) 397-5867 Email: info@psctendon.com http://www.psctEndon.com Crystal River Nuclear plant 3 TO:
15760 West Power line Street Crystal River, FL 34428-6708 ATTN:
JOHN HOLLIDAY PO/SUBCONTRACT NUMBER:
CONTRACT # 270269/ADDENDUM 4 SUBMITTED BY:
PAUL C. SMITH SIGNATURE:
,/&& 6.
--/
TITLE:
PRESIDENT DATE SUBMITTED:
DECEMBER 12, 2007 DOCUMENT TRANSMITTAL INFORMATION DOCUMENT NUMBER REVISION DESCRIPTION PAGES FORMAT 1009-TFAB 0
TENDON FABRICATION MANUAL 89 Pdf.
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REMARKS:
ZI7RO Page 7 of 95 Z1 7R0 Page 7 of 95
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- - - r W ý Precision Surveillance Corporation 3468 Watling Street East Chicago. IN 46312 Email: info@psctendon.com Phone: (219) 397-5826 Fax:
(219) 397-5867 http://www.psctendon.com CONTROLLED MANUAL NO:
POST TENSIONING SYSTEM FABRICATION MANUAL FOR PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT CONTAINMENT BUILDING TENDON FABRICATION REVISION REVISION REVISION REVISION A
A~
NOVEMBER 27, 2007 LEVEL II Q. C.
11/27/07 Date Prepared by aA-'pr~ove'd d A5 b
Title PROJECT MANAGER, P.E.
11/27/07 Date Title rý /' '- ///
PRESIDENT Title 11/27/07 Date
-- 7Approved by`
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PCHG-DESG ENGINEERING CHANGE 000063016R0 TENDON FABRICATION MANUAL ACKNOWLEDGEMENT OF RECEIPT FORM November 27, 2007 Page 1 of 1 Revision 0 This page shall be removed, and mailed or faxed to:
Precision Surveillance Corporation Phone: 219-397-5826 Quality Assurance Fax: 219-397-5867 3468 Watling Street East Chicago, IN 46312 The return of this Acknowledgement form from Control Manual Number:
will indicate acknowledgement-of-receipt for document control purposes. Failure to return this page or otherwise provide similar acknowledgement, SHALL be just cause for terminating the controlled status of this manual.
RETURN OF THIS FORM DOES NOT CONSTITUTE APPROVAL OF THE CONTENTS HEREIN.
If this page is stamped "UNCONTROLLED MANUAL", it is not necessary to return.
Date of Submittal:
Date of Receipt:
The individual acknowledging Name:
receipt will be considered the Name:
permanent holder of this manual.
Signature:
For more information regarding
Title:
responsibility of the attendant of this manual, refer to the Manual Company:
Control Policy Statement.
Project:
Contract:
Tendon Fabrication Manual Issue Date 11-27-07 Revision 11-27-07 ZI7RO Pae 9/of,9 Z1 7R0 Page 9 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO TENDON FABRICATION MANUAL MANUAL CONTROL POLICY November 27, 2007 Page 1 of 2 Precision Surveillance Corporation Revision 0 PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE MANUAL CONTROL POLICY LEVEL II Q.C.
11/27/07 Date e
Prepared by Title Ap'proved by PROJECT MANAGER, PE.
Title PRESIDENT Title 11/27/07 Date 11/27/07 Date ZI7RO Page 10 of 95 Z17RO ManContPIcy.CR3.SGR.doc Page 10 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 TENDON FABRICATION MANUAL MANUAL CONTROL POLICY November 27, 2007 Page 2 of 2 Revision 0 1.0 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.
2.0 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.
3.0 The person acknowledging receipt of the Controlled Manual shall be responsible for keeping any uncontrolled Manuals or copies up to date.
4.0 Reproduction of the Manual IS NOT AUTHORIZED, 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.
5.0 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.
6.0 INTERNAL 6.1 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 Program/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.
ManContPlcy.CR3.SGR.doc Z17R0 Page 11 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO Precision Surveillance Corporation TENDON FABRICATIONMANUAL INDEX STATUS SHEET November 27, 2007 Page 1 of 2 Revision 0 ORIGINAL ISSUE REVISED STATUS SECTION PAGES REV.
DATE REV.
DATE PREFACE Title 1
0 11-27-07 Receipt - To be returned 1
0 11-27-07 Manual Control Policy 1 -2 0
11-27-07 Index Status Sheets 1 -2 0
11-27-07 Revision Control Sheet 1
N/A N/A SPECIFICATIONS PSC Spec. D901 1 - 3 0
111-27-07 (Manifesting, Billing and Material Certification)
PSC Spec. D902-F 1 -3 0
11-27-07 (Import - Manifest & Billing)
PSC Spec. D903 1 -3 0
11-27-07 (Mark, Pack & Ship)
PSC Material Spec. 1421.C.7mm 1 - 6 0
11-27-07 (Raw material for tendon wire ASTM A421, Type BA Low-Relaxation Wire)
PSC Material Spec. A514 1 -3 0
11-27-07 (Raw material for 163 Wire Anchor Head ASTM A514, Grade Q)
PSC Material Spec. 1601 AMBER 1 - 3 0
11-27-07 (Visconorust 1601 Amber material for tendon temporary corrosion protection)
PSC Material Spec. 2090P-4 1 - 3 0
11-27-07 (Visconorust 2090P-4 Casing Filler Nuclear Grade material for tendon corrosion protection)
[
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Effective Date: 11-27-07 Previous Revision: N/A Revision:Ao 11-27-07 Z17RO Page 12 Of 95 Z1 7R0 INDEX.CR3.SGR.doc
PCHG-DESG ENGINEERING CHANGE 000063016RO TENDON FABRICATIONMANUAL INDEX STATUS SHEET November 27, 2007 Page 2 of 2 co r
c
, C o
Revision 0 Ppecision Surveillance: Coppopation Original Issue Revised Status SECTION Pages Rev.
Date Rev.
Date FABRICATION PROCEDURES Procedure PT 1.OT 1-16 0
11-27-07 (Tendon Fabrication)
0 11-27-07 B.H. Mach/Oper. Qual Sht.
1 0
11-27-07 Procedure PT 2.0 1-5 0
11-27-07 (Anchorage Fabrication - General)
Procedure PT 2.1 1-4 0
11-27-07 (Receiving Inspection -Anchorage)
Form PT 2.1.A 1
0 11-27-07 Form PT 2.1.B 1
0 11-27-07 Procedure PT 2.1.2 1-3 0
11-27-07 (Identification-Bars/Tubes/Plates)
Procedure PT 2.3 1-6 0
11-27-07 (Fabrication-Anchorages)
Form PT 2.3A 1
0 11-27-07 Form PT 2.3B 1
0 11-27-07 Drawing CR-N1009-502 1
0 11-15-07 Procedure PT 2.7 1 -6 0
11-27-07 (Ultrasonic Examination - Anchor head)
Procedure PT 3.0 1-3, 0
11-27-07 (Thread Measuring -Anchorages)
Appendix 1 1
0 11-27-07 Thread Table 1
0 11-27-07 Data Sheet PT3.0 1
0 11-27-07 Procedure TTT.CR3 1 -6 0
11-27-07 (Tendon Tensile Test)
Previous Revision: N/A Effective Date: 11-27-07 Revision: Ao.11-27-07 INDEX.CR3.SGR.doc Page 13 of 95 Z1 7R0
PCHG-DESG ENGINEERING CHANGE 000063016R0 REVISION CONTROL SHEET Page __ of__
Revision Date:
Project:
CRYSTAL RIVER UNIT 3 SGRP Revision #
REVISION CONTROL SHEET Revision/
Submitted Revision/
Submitted Procedure #
Page #
Date Date Procedure #
Page #
Date Date t ___
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4 Revision T Date Revision Description Revision By:
Date Approved No.
Z17RO Page 14 of 95 Zl 7R0 Page 14 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC SPECIFICATION D901 November 27, 2007 Page 1 of 3 rRevision 0
Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE MANIFESTING, BILLING AND MATERIAL CERTIFICATION
-rpred by Ap roved by z
r
/
LEVEL II Q.C.
Title 11/27/07 Date PROJECT MANAGER, PE.
11/27/07 Date Title PRESIDENT 11/27/07 Date Title Z17R0 D901 MATERIAL SPECIFICATION.doc Page 15 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC SPECIFICATION D901 MANIFESTING, BILLING AND MATERIAL CERTIFICATION November 27, 2007 Page 2 of 3 Revision 0
1.0 INVOICING
1.1 Mail invoice in duplicate to:
Precision Surveillance Corporation 3468 Watling Road East Chicago, Indiana 46312 1.2 All invoices shall show material description, pieces or weight, PSC Purchase Order Number, destination and date.
2.0 FREIGHT
2.1 All inbound shipments shall be sent prepaid in protected trailers. The freight charges shall be shown on the material invoice or attached to the shipping documents.
3.0 SHIPPING NOTICES:
3.1 Mail one copy of the shipping notice to the address shown above.
3.2 Send three copies of the shipping notice with the truck delivery. Mail three copies to the address shown above for all rail shipments.
4.0 MATERIAL CERTIFICATION:
4.1 Furnish three copies of the type of material certification document specified by the PSC Purchase Order and/or PSC Material Specification, indicating that the material supplied has been produced to the requirements of the PSC Purchase Order and/or PSC Material Specification.
4.2 At least one copy of the certifying documents should accompany the shipment, attached to the shipping documents. The shipping documents shall bear the PSC Purchase Order Number, point of origin and destination 4.3 At least two copies of the certifying documents should be sent to the address shown in Section 1.1 above, to the attention of: QUALITY ASSURANCE SECTION.
5.0 TEST REPORTS:
5.1 All certified test reports shall show the mill name, mill heat number, size, grade, quality and any additional requirements, specified by the PSC Purchase Order and/or PSC Material Specification.
5.2 All mill test reports shall be certified and signed by authorized personnel.
Z1 7R0 D901 MATERIAL SPECIFICATION.doc Page 16 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 I PSC SPECIFICATION D901 MANIFESTING, BILLING AND MATERIAL CERTIFICATION November 27, 2007 Page 3 of 3 Revision 0 5.3 Test reports shall be provided from the mill of origin, for any material not produced by the vendor of record on the PSC Purchase Order.
5.4 All certified test reports shall be legible and where possible of an original nature.
Copies of certified mill test reports are acceptable provided that all information is visible and capable of being reproduced by standard facsimile copiers and capable of being microfilmed.
Z1 7R0 D901 MATERIAL SPECIFICATION.doc Page 17 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC SPECIFICATION D902-F.
IMPORT - MANIFEST & BILLING November 27, 2007 Page 1 of 3 PPage 1 ofRevision 0
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Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE SPECIFICATION FOR IMPORTED SHIPMENTS MANIFESTING, BILLING & MATERIAL CERTIFICATION, MARKING, PACKING LEVEL II Q. C.
11/27/07 Date Prepared by Approved by Approved by' Title PROJECT MANAGER, PE.
Title PRESIDENT 11/27/07 Date 11/27/07 Date Title ZI7RO Page 18 of 95 Z17R0 D 902 F.doc Page 18 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC SPECIFICATION D902-F IMPORT - MANIFEST & BILLING November 27, 2007 Page 2 of 3 Revision 0
1.0 GENERAL
1.1 All test reports, invoices, packing lists, or shipping documents shall be in English, with measurements or dimensions in United States equivalents.
2.0 INVOICING
2.1 Mail invoice in duplicate to:
Precision Surveillance Corporation 3468 Watling Road East Chicago, Indiana 46312 2.2 All invoices shall show material description, pieces, weight, PSC Purchase Order Number, destination and date.
2.3 Terms of purchase are net 30 days after receipt of material and test reports or certifying documentation in acceptable condition. All purchases are for resale unless otherwise indicated.
3.0 PACKING LISTS:
3.1 Each shipping container shall have a packing list attached or inside.
3.2 A copy of each packing list shall be mailed to PS.C at the time of shipment.
4.0 MATERIAL CERTIFICATION:
4.1 Furnish two copies of the type of material certification document specified by the PSC Purchase Order and/or PSC Material Specification, indicating that the material supplied has been produced to the requirements of the PSC Purchase Order and/or PSC Material Specification.
4.2 At least one copy of the certifying documents should accompany the shipment, attached to the shipping documents.
4.3 At least one copy of the certifying documents should be sent to the address shown in Section 2.1 above,-to the attention of: QUALITY ASSURANCE SECTION.
5.0 TEST REPORTS:
5.1 All certified test reports shall show the mill name, mill heat number, size, grade, quality and any additional requirements specified by the PSC Purchase Order and/or PSC Material Specification.
5.2 All mill test reports shall be certified and signed by authorized personnel.
D 902 F.doc Z17R0 Page 19 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC SPECIFICATION D902-F IMPORT - MANIFEST & BILLING November 27, 2007 Page 3 of 3 Revision 0 5.3 Test reports shall be provided from the mill of origin, for any material not produced by the vendor of record on the PSC Purchase Order.
5.4 All certified test reports shall be legible and where possible of an original nature.
Copies of certified mill test reports are acceptable provided that all information is visible and capable of being reproduced by standard facsimile copiers and capable of being microfilmed.
6.0 MARKING
6.1 Identify materials as required by the PSC Purchase Order and/or PSC Material Specification.
7.0 PACKAGE AND SHIP:
7.1 As required by the PSC Purchase Order and/or Material Specification.
ZI7RO Page 20 of 95 Z1 7R0 D 902 F.doc Page 20 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC SPECIFICATION. D903 MARK, PACK & SHIP November 27, 2007 Page 1 of 3 Revision 0
(~N~J Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE MARKING, PACKAGING AND SHIPPING FOR DOMESTIC SHIPMENTS F~-epaedby Approved by LEVEL II Q.C.
Title 11/27/07 Date PROJECT MANAGER, PE.
11/27/07 Date Title PRESIDENT 11/27/07 Date Title Z17RO D9 Q 1
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC SPECIFICATION. D903 MARK, PACK & SHIP November 27, 2007 Page 2 of 3 Revision 0 1.0 MARKING 1.1 GENERAL 1.1.1 Where more than one heat number exists for material in a shipment of lot, each heat number in that shipment or lot shall be packaged separately and identified as to heat, so as to be able to identify each upon receipt. Material shall be tagged or marked with the PSC Purchase Order Number.
1.2 CUTSTOCK 1.2.1 Material that has been cut shall have the heat number applied by marking, tagging or stamping so as to retain the identity or traceability of that item to the original material or test report.
1.3 UNCUT STOCK 1.3.1 The heat number shall appear on each piece at all times by marking, tagging or stamping.
2.0 PACKING 2.1 Each item ordered shall be packaged separately.
2.2 Band each bundle together in a maximum of 10,000-pound lifts; no wrapping is required.
2.3 Plates shall be banded to wooden skids, if less than 36" x 36".
2.4 Smaller items may be packed in drums, boxes, or crates. Information regarding the PSC Purchase Order Number, size and quantity shall be marked on the outside of the container, with tags attached inside the containers.
2.5 Comply with any special requirements of the PSC Purchase Order and / or PSC Material Specification.
3.0 SHIPPING
3.1 TRUCK
3.1.1 Ship in protected trailer. Loads shall be blocked with 4" x 4" lumber for overhead crane or forklift unloading. All material shall be vertically blocked to prevent shifting.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC SPECIFICATION. D903 MARK, PACK & SHIP November 27, 2007 Page 3 of 3 Revision 0 3.2 RAIL:
3.2.1 As noted on the PSC Purchase Order; ship covered gondolas on 4" lumber blocking. Each lift of the load shall be separated by 4" x 4" blocks and shall be vertically blocked to prevent shifting.
4.0 SHIPPING DOCUMENTS 4.1 AT LEAST ONE COPY OF THE MATERIAL TEST REPORTS OR CERTIFICATION SHOULD ACCOMPANY THE MATERIAL, attached to the packing list, shipping notice, manifest or bill of lading.
ZI7RO Page 23 of 95 Z1 7R0 D903 MATERIAL SPEC.doc Page 23 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION 1421-C-7MM WIRE SPEC November 27, 2007 Page 1 of 6 Precision Surveillance Corporation Revision 0 IL PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE MATERIAL SPECIFICATION FOR IMPORTED 7 mm ASTM A421, TYPE BA UNCOATED LOW-RELAXATION STRESS RELIEVED STEEL WIRE FOR PRESTRESSED CONCRETE LEVEL I/ Q.C.
11/27/07 Date Pipared by Approved by A~ppr~ov~e~d by Title PROJECT MANAGER, PE.
Title PRESIDENT Title 11/27/07 Date 11/27/07 Date ZI7RO l-~age 24 oT~
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC MATERIAL SPECIFICATION 1421-C-7MM WIRE SPEC November 27, 2007 Page 2 of 6 Revision 0 1.0 ORDER DESCRIPTION:
1.1 7 mm (0.2756 in.) ASTM A421-98a (may be supplied to a later revision, provided that the later revision meets or exceeds the requirements of the year cited), Type BA Uncoated Low-Relaxation Stress-Relieved Steel Wire For Prestressed Concrete and PSC Material Specification 1421-C-7MM.
2.0 SCOPE
2.1 This specification is to be used to furnish tendon wire to ASTM A421-98a (may be supplied to a later revision, provided that the later revision meets or exceeds the requirements of the year cited), Type BA Low Relaxation Wire Supplement I, and as supplemented by this specification for Nuclear Grade Quality and traceability.
3.0 MANUFACTURE
3.1 Material may be supplied from a source located outside of the United States.
3.2 Shall conform to ASTM A421-98a (may be supplied to a later revision, provided that the later revision meets or exceeds the requirements of the year cited).
4.0 PROCESSING
4.1 Wire shall not be made from rusty rods whose pits and scale can result in surface imperfections on the wire.
4.2 The presence of laps or seams that affect the quality of the wire shall be cause for rejection of the wire.
4.3 The wire shall be capable of acceptably cold forming of buttons for anchorage.
4.4 Stress Relaxation characteristic shall not exceed 4% over 40 years when initially loaded to 70% of specified minimum tensile strength.
4.5 The diameter of the wire shall not vary from the nominal diameter specified by more than + 0.002in. (_ 0.05mm).
5.0 HEAT TREATMENT:
5.1 Do not supply oil tempered wire.
6.0 COATING
6.1 No coating shall be applied after the wire drawing process.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION 1421-C-7MM WIRE SPEC November 27, 2007 Page 3 of 6 Revision 0
7.0 SURFACE
7.1 The wire shall be substantially free of rust on delivery. Any rust present must be capable of being wiped clean with a rag. Under no circumstances will pitted wire be acceptable. No welds or joints shall be present in the finished wire.
8.0 COIL SIZE:
8.1 Furnish wire in approximately 1000 to 2500 pound coils. Aiming for 1000 pounds or above. Coil on about a 67 inch minimum inside diameter, with a maximum outside diameter of 84 inches.
9.0 IDENTIFICATION
9.1 Coils shall be sequentially numbered from each heat without duplicating coil numbers within a heat. A tag shall be attached to each coil showing the mill name, ASTM specification number, heat identification number, size, weight, coil number and order number as a minimum. A separate tag shall be attached to designate the starting end of the wire for uncoiling.
10.0 MECHANICAL PROPERTIES:
10.1 Elongation in a gauge length of 10 inches shall not be less than 4%. Relaxation losses shall be determined by a minimum of three 1000 hour0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> tests conducted in accordance with the latest revision of ASTM E328. There shall be a sufficient number of data points in each of the 3 tests to extrapolate the 1000 hour0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> relaxation data to the 40 year life. All other mechanical properties will be as specified in ASTM A421.
11.0 INSPECTION:
11.1 The Quality Program and testing practices of the supplying mill may be subjected to a review or audit at any time before, during or after any wire is processed. Outside source inspection may be specified at the time of ordering or at any later time for the unprocessed portion of the order.
12.0 STRESS/STRAIN CURVE CHARTS:
12.1 A stress/strain curve chart bearing the modulus of elasticity shall be provided with each test report. The modulus of elasticity for the wire shall be established and controlled to a tolerance of plus or minus 2%. Only one heat number shall appear on a chart. As a minimum, the chart shall contain the order number, size, heat number and coil number.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION 1421-C-7MM
. WIRE SPEC November 27, 2007 Page 4 of 6 Revision 0 13.0 TEST REPORTS:
13.1 A document, separate from the above chart, shall be provided containing data for one heat number only. As a minimum, this report shall show the heat number, the order number, size, coil number, mechanical properties, ladle/chemical analysis and the results of all the tests specified in Section 15, TESTING.
14.0 MANIFESTING AND BILLING:
14.1 Refer to PSC Specification D902-F.
15.0 TESTING:
15.1 All requirements below shall be reported as minimum for the frequencies specified.
15.2 Each coil from front and rear:
15.2.1 Wire diameter, measure and report.
15.3 Every tenth coil or fraction thereof shown on the test report:
15.3.1 Tensile Strength, test and report: once for the breaking strength of the sample in pounds and then converted to the ultimate tensile strength.
15.3.2 Yield Strength, test and report in pounds for the sample and then converted to the yield strength, as measured by the 1% extension under load method, and shall not be less than 90% of the specified minimum breaking strength.
15.3.3 Elongation, test and report from a 10 inch (250mm) gauge length.
15.3.4 Straightness or cast, test and report; A wire sample having a chord length of 60 inches (1524 mm) shall have an offset at the center of the chord of not more than 3 inches (76 mm). This is equivalent to a chord of an arc of a circle not less than 25 feet (7.6 m) in diameter.
15.4 The test data necessary to satisfy the quantities of tests shown above shall appear on the test report.
16.0 LOADING AND SHIPPING:
16.1 Coils to be wrapped with polypropylene bag or equivalent. For overseas shipments coils to be loaded in container of approximately 18 tons each. For any subsequent rail or truck shipments the containers or coils are to be protected from excessive exposure, environmental damage, tie down failure or rough handling.
2 SPEC 1421-C-7MM.doc Z17RO Page 27 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION 1421-C-7MM WIRE SPEC November 27, 2007 Page 5 of 6 Revision 0 17.0 GUIDE FOR PREPARATION AND CERTIFICATION OF TEST INFORMATION ORDER DESCRIPTION:
17.1 7 mm (0.2756 in.) ASTM A421-98a (may be supplied to a later revision, provided that the later revision meets or exceeds the requirements of the year cited), Type BA Uncoated Low-Relaxation Stress-Relieved Steel Wire For Pre-stressed Concrete.
17.2 PSC Material Specification 1421-C-7mm.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC MATERIAL SPECIFICATION 1421-C-7MM WIRE SPEC November 27, 2007 Page 6 of 6 Revision 0 SOURCE MUST REPORT TESTS ON TEST REPORT WITHIN THE FOLLOWING LIMITS:
CHEMICAL REQUIREMENTS Phosphorus Sulfur Maximum 0.040%
0.050%
MECHANICAL REQUIREMENTS Tensile Strength Yield Strength psi
% Elongation in 10 Straightness or Cast psi MINIMUM inches (250 mm)
MINIMUM MINIMUM 240,000 psi 216,000 psi 4.0%
OK per 15.3.4 (1655 Mpa)
(1490 Mpa)
OTHER REQUIREMENTS Manufacturer Wire Diameter Heat Number/Coil Number SHOW SHOW SHOW DATE Mill Order Number Customer' Number SHOW IF NECESSARY PSC P.O. NUMBER 18.0 OTHER REQUIREMENTS:
18.1 A stress/strain curve chart shall accompany each test report.
18.2 Test reports must specify Low Stress Relaxation Wire.
18.3 Date, PSC Purchase Order Number, Mill Order Number shall be shown where applicable.
18.4 Order Description shall be included/reported.
18.5 Wire diameter, shall be reported from the front and back of each coil.
18.6 Elongation, straightness, tensile strength in pounds and converted to ultimate tensile strength, and yield strength in pounds and converted to yield strength, shall be reported from every tenth coil or fraction thereof.
18.7 All mill test reports shall be certified and signed by authorized personnel.
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PCHG-DESG ENGINEERING CHANGE 0000630116RO PSC MATERIAL SPECIFICATION. A514 MATERIAL-ASTM A514 GRADE Q November 27, 2007 Page 1 of 3 Precision Surveillance Corporation Revision 0 PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE MATERIAL SPECIFICATION - ASTM A514 GRADE Q FOR ANCHOR HEADS Prepared by Apbproved by Approved-~y' LEVEL II Q.C.
Title PROJECT MANAGER, P. E.
Title PRESIDENT Title 11/27/07 Date 11/27/07 Date 11/27/07 Date ZI7RO of 95 Z17R0 Material pecific tdns A514.doc
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC MATERIAL SPEC. A514 MATERIAL-ASTM A514 GRADE Q SEPTEMBER 21, 2007 Page 2 of 3 Revision 0 1.0 ORDER DESCRIPTION:
1.1 High-yield-strength quenched and tempered alloy steel plate: conforming to the requirements of ASTM A514-latest; fine grain and fully killed.
2.0 SCOPE
2.1 Furnish to ASTM A514-latest, and as supplemented by this material specification.
3.0 MANUFACTURE
3.1 Steel shall be from heats melted in the United States unless otherwise specifically approved in writing by PSC. Open access for purposes of inspection, audit and qualification shall be provided by the manufacturer.
4.0 COATING
4.1 May be coated with a rust retarding oil on the outside at the option of the manufacturer.
5.0 IDENTIFICATION
5.1 Each plate shall have at least one end steel stamped with the heat number and any other identifying codes.
6.0 MECHANICAL PROPERTIES:
6.1 Tensile, yield and elongation may be shown. Grain size shall be shown. Final condition of product shall be shown; annealed, quenched and tempered, etc.
7.0 MANIFESTING AND BILLING:
7.1 Refer to PSC Specification D901.
8.0 SHIPPING AND PACKING:
8.1 Refer to PSC Specification D903.
9.0 SPECIAL REQUIREMENTS AND QUALITY ASSURANCE:
9.1 Refer to PSC Purchase Order. Certified mill test report required and it must be signed by authorized personnel.
10.0 GUIDE FOR PREPARATION AND CERTIFICATION OF TEST INFORMATION 10.1 ORDER DESCRIPTION:
10.1.1 High-yield-strength steel plate: conforming to the requirements of ASTM A514-latest; fine grain; fully killed.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC MATERIAL SPEC. A514 MATERIAL-ASTM A514 GRADE Q SEPTEMBER 21, 2007 Page 3 of 3 Revision 0 10.2 SOURCE MUST REPORT TESTS ON TEST REPORT OR SHIPPING NOTICE WITHIN THE FOLLOWING LIMITS:
10.2.1.
10.2.2 10.2.3 10.2.4 10.2.5 Material shall be fully killed.
Mechanical properties may be shown for product.
Order Description.
Product analysis tolerance of ASTM A514-latest shall apply.
All mill test reports shall be certified and signed by authorized personnel.
Z17R0 Material Specifications A514.doc Page 32 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PCHG-DESG ENGINEERING CHANGE 00006301 6R0 Precision Surveillance Corporation PSC MATERIAL SPECIFICATION 1601 AMBER VISCONSITY 1601 AMBER November 27, 2007 Page 1 of 3 Revision 0 11 PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE MATERIAL SPECIFICATION FOR VISCONORUST 1601 AMBER TEMPORARY TENDON CORROSION PROTECTION LEVEL I/ Q.C.
11/27/07 Date Prepared by Approved by ApproveU-15Dy Title PROJECT MANAGER, PE.
Title PRESIDENT Title 11/27/07 Date 11/27/07 Date Z17RO age 3 of 95 Z17R0 EC 16QAM BERdoc
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC MATERIAL SPECIFICATION 1601 AMBER VISCONSITY 1601 AMBER November 27, 2007 Page 2 of 3 Revision 0 1.0 ORDER DESCRIPTION:
1.1 Visconorust 1601 Amber-latest 2.0 END USE:
2.1 Post-tensioning tendon temporary corrosion protection.
3.0 MANUFACTURE
3.1 Material as manufactured by Viscosity Oil Company.
4.0 PHYSICAL PROPERTIES:
4.1 Report on physical properties as required for Visconorust 1601 Amber-Latest, for Wt.
Per Gallon, Specific Gravity, Flow Resistance, Flash Point.
5.0 CHEMICAL PROPERTIES:
5.1 Report on chemical properties as required for Visconorust 1601 Amber-Latest, for Water Soluble Chlorides, Water Soluble Nitrates, Water Soluble Sulfides.
6.0 GENERAL REQUIREMENTS FOR DELIVERY:
6.1 Material to be furnished in 55 gallon drums.
7.0 SPECIAL REQUIREMENTS AND QUALITY ASSURANCE:
7.1 Refer to PSC Purchase Order. Viscosity Oil Company Quality Control Certificate of Tests required, signed by authorized personnel.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC MATERIAL SPECIFICATION 1601 AMBER VISCONSITY 1601 AMBER November 27, 2007 Page 3 of 3 Revision 0 GUIDE FOR VERIFICATION OF TEST INFORMATION ORDER DESCRIPTION: Visconorust 1601 Amber-latest.
VISCOSITY OIL COMPANY MUST REPORT TESTS ON QUALITY CONTROL CERTIFICATE WITHIN THE FOLLOWING LIMITS:
PHYSICAL PROPERTIES:
PHYSICAL PROPERTIES TEST REQUIRED Wt. Per Gallon 7.1 - 7.4 lbs.
Specific Gravity ASTM D-1298 0.85-0.89
@ 60°F (15.6 C)
Flow Resistance OF (OC) 1 175 (80) min.
Flash Point OF (0C)
ASTM D-92 102 (38.9) mr.
CHEMICAL PROPERTIES: (Note: Special ASME sample test preparations and reporting required.)
CHEMICAL PROPERTIES TEST REQUIRED Water Soluble Chlorides ppm ASTM D-512 2 max.
Water Soluble Nitrates ppm ASTM D-992-78 4 max.
Water Soluble Sulfides ppm APHA 4500 S2 (17TM ed) 2 max.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION. 2090P-4 MATERIAL-VISCONORUST 2090P-4 CASING FILLER November 27, 2007 Page 1 of 3 I
Precision Surveillance Corporation Revision 0 PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION MATERIAL SPECIFICATION FOR VISCONORUST 2090P-4 CASING FILLER NUCLEAR GRADE FOR POST TENSIONING TENDON CORROSION PROTECTION LEVEL II Q.C.
11/27/07 Date
<Prepared by Apprloved by Approveffby-Title PROJECT MANAGER, PE.
11/27/07 Date Title PRESIDENT 11/27/07 Date Title Z1 7R0
' sconorust2O90P-4.doc Zage 36 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION. 2090P-4 MATERIAL-VISCONORUST 2090P-4 CASING FILLER November 27, 2007 Page 2 of 3 Revision 0 1.0 ORDER DESCRIPTION:
1.1 Visconorust 2090P-4 casing filler nuclear grade-latest.
2.0 END USE:
2.1 Post-tensioning tendon corrosion protection.
3.0 MANUFACTURE
3.1 Material as manufactured by Viscosity Oil Company.
4.0 PHYSICAL PROPERTIES:
4.1 Report on physical properties as required for Visconorust 2090P-4 Casing Filler Nuclear Grade for Density, Specific Gravity, Congealing Point, Flash Point, Viscosity SUS, Consistency (Cone Penetration), Total Base Number, Water Content.
5.0 CHEMICAL PROPERTIES:
5.1 Report on chemical properties as required for Visconorust 2090P-Casing Filler Nuclear Grade-Latest, for Water Soluble Chlorides, Water Soluble Nitrates, Water Soluble Sulfides.
6.0 GENERAL REQUIREMENTS FOR DELIVERY:
6.1 Material to be furnished in 55 gallon drums or by bulk tanker truck as applicable.
7.0 SPECIAL REQUIEMENTS AND QUALITY ASSURANCE:
7.1 Refer to PSC Purchase Order. Viscosity Oil Company Quality Control Certificate of Tests required, signed by authorized personnel.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC MATERIAL SPECIFICATION. 2090P-4 MATERIAL-VISCONORUST 2090P-4 CASING FILLER November 27, 2007 Page 3 of 3 Revision 0 GUIDE FOR VERIFICATION OF TEST INFORMATION ORDER DESCRIPTION: Visconorust 2090P-4 casing filler nuclear grade-latest.
VISCOSITY OIL COMPANY MUST REPORT TESTS ON QUALITY CONTROL CERTIFICATE WITHIN THE FOLLOWING LIMITS:
PHYSICAL PROPERTIES:
PHYSICAL PROPERTIES TEST REQUIRED Density (1 lbs/gal)
ASTM D-1298 7.3 - 7.8 lbs
@ 60-F (15.68C)
Specific Gravity ASTM D-1298 0.88 - 0.94
@ 60°F (15.6-C)
Congealing Point OF (°C)
ASTM D-938 135 (57) min.
Flash Point OF (°C)
ASTM D-92 420 (215) min.
Viscosity SUS ASTM D-88 130 min.
@ 210°F (98.8°C)
Consistency (Cone Penetration)
ASTM D-937 170 - 200
@ 770F (25 0C) dmm Total Base No. (Modified)
ASTM D-974 35 min.
Water Content (wt. %)
ASTM D-95 0.4 max.
CHEMICAL PROPERTIES: (Note: Special ASME sample test preparations and reporting required).
CHEMICAL PROPERTIES TEST REQUIRED Water Soluble Chlorides ppm ASTM D-512 2 max.
Water Soluble Nitrates ppm ASTM D-992-78 4 max.
Water Soluble Sulfides ppm APHA 4500 S2 17' ed.)
2 max.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 1 of 16 Revision 0 Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE FABRICATION OF POST-TENSIONING SYSTEM TENDONS 6
Prepared by Al proved by
-Approved by LEVEL II Q. C.
Title PROJECT MANAGER, P.E.
Title 11/27/07 Date 11/27/07 Date 11/27/07 Date PRESIDENT Title Z17R0 Page 39 Of 95 Z17R0 PT1-OT.CR3.SGR.doc Page 39 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 2 of 16 Revision 0 1.0 PURPOSE 1.1 This procedure will establish the requirements for the fabrication of tendons for the Post-Tensioning Tendon System of Crystal River Unit 3 SGRP.
2.0 SCOPE 2.1 This procedure is to be used to fabricate tendons from new coils of ASTM A421, Type BA, Low Relaxation, 0.2756 inch diameter wire. As this PSC Quality Control procedure has provisions for evaluations of the wire prior to use and during fabrication, it will not be necessary to provide any other documentation or inspections prior to the actual use of the tendon wire.
3.0 RESPONSIBILITY 3.1 PSC shall be responsible for the Quality Assurance and Quality Control activities required for the fabrication of a post-tensioning tendon. PSC shall be responsible for assembling the wires into a tendon configuration, in accordance with the requirements of this Procedure.
3.2 PSC Quality Control Personnel shall provide the Quality Control actions, 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.
3.3 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.
3.4 The items or services provided under this Procedure shall be in accordance with the Precision Surveillance Corporation Quality Assurance Program accepted by the Owner or his authorized agent.
4.0 QUALIFICATIONS 4.1 QUALITY CONTROL INSPECTOR 4.1.1 Quality Control Inspectors performing Inspections, Tests, and/or Evaluations shall be qualified to a minimum of Level II capability in accordance with the requirements of ANSI N45.2.6-1978.
4.1.2 Quality Control Inspectors shall be certified to specific skill levels by a Quality Control Inspector who has been qualified as Level III in accordance with the requirements of ANSI N45.2.6-1978.
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PCHG-DESG ENGINEERING CHANGE 000063016KO PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 3 of 16 Revision 0 4.2 AUDITORS 4.2.1 PSC Personnel performing audits shall be qualified as auditors in accordance with the requirements of ANSI N45.2.23-1978.
4.3 DOCUMENTATION 4.3.1 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.
5.0 EQUIPMENT 5.1 FABRICATION 5.1.1 Tendon Uncoiler/Coiler.
5.1.2 Comb and Twist Unit.
5.1.3 Tendon fabrication line.
5.1.4 Miscellaneous tools and banding equipment.
5.1.5 PSC BBRV Button heading Machine.
5.2 QUALITY CONTROL 5.2.1 Those devices requiring calibration shall be in a currently calibrated condition when being used.
5.2.2 Button head (Drg. CR-N 1009-501) Go, No-Go Gauge.
5.2.3 Eccentricity Gauge.
5.2.4 Feeler Gauges.
5.2.5 PSC Wire Tensile Test Device and Test Blocks.
5.2.6 0-1 inch Micrometer.
6.0 PRECAUTIONS 6.1 Use care when uncoiling and coiling a tendon or coils of tendon wire. It tends to be quite springy and can cause injury if not properly restrained.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 4 of 16 Revision 0 7.0 QUALITY CONTROL 7.1 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 release from the Inspector. The required information or evaluative data shall be documented on Data Sheet PT 1.OT (DS PT 1.OT).
7.2 Inspection of the shop tendon fabrication operations shall be performed on a continuous basis by a PSC Quality Control Inspector. The inspections shall be documented for each tendon fabricated and entered onto Data Sheet PT 1.OT, for that tendon. The Inspector shall witness the tendon fabrication operation for conformance to the fabrication procedure.
7.3 The Inspector shall be responsible for accepting or rejecting the material, the removal of Hold Tags from material placed on hold status and to release that material for further fabrication or shipping. The Inspector shall also be responsible for the disposition of material, whether hold, reject or non-conforming status, to comply with the approved corrective action, or where the material has failed to pass the inspection requirements.
7.4 Tendons are inspected continuously throughout fabrication. Tendons may be rejected at any point during fabrication if the acceptance criteria is not met, if damage is suspected or observed, or there is objective evidence of loss of control during the fabrication process.
7.5 Incidents of repetitive rejected inspections that show evidence of loss of control shall be just cause for stopping work, until corrective action can be determined through the medium of a nonconformance report.
7.6 A tendon failing to pass inspection shall be tagged Hold and removed from' production status. Immediate correction of the deficiency shall allow further processing of that tendon. Tendons may be corrected at any point during fabrication and shall be re-inspected for the same criteria as the original tendon, after the correction has been completed.
7.7 Historically, the nature of deficiencies noted during tendon inspection do not require nonconformance reporting. However, a nonconformance may be written at any time for any deficiency, over which the Quality Control Inspector intends to exercise a greater degree of control.
7.7.1 Nonconformance Reports shall be written and distributed in accordance with the requirements of the Precision Surveillance Corp. Quality Assurance Manual, to document and control nonconforming materials, services or activities.
7.8
- Production personnel shall notify the Inspector of corrected deficiencies for purpose of re-inspection.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 5 of 16 Revision 0 7.9 All inspections shall be documented on the Data Sheet PT 1.OT for the items and quantities specified. Acceptable Inspections shall be signified by marking "OK" for that item in the space provided or by posting the required data.
7.9.1 QCD-Document the required calibration data for the devices used.
7.10 Tendons shall be fabricated and inspected as required of the following procedures.
8.0 GENERAL 8.1 Where required, PSC shall submit test reports to the Owner or his agent for approval and at a point in time previously agreed to in the contract documents. Otherwise, the PSC Quality Assurance Section personnel will approve the material prior to fabrication when possible, but reserves the right to approve the test reports or certifications at any point during fabrication, but before final inspection.
8.1.1 Tendons fabricated with unapproved wire shall be tagged Hold until the test reports are received and approved by the PSC Quality Assurance Section. The PSC Quality Control Inspector shall be responsible for the removal of Hold Tags and subsequent release of the material.
8.2 If the material is not acceptable, the rejected wire shall be scrapped.
8.3 TENDON LENGTH 8.3.1 The tendon length will be provided by the Owner or his agent. This length will be forwarded to the PSC Engineering Section for review and conversion to tendon fabrication length or Cutting Length of Wire (CLOW).
8.4 ORDER ENTRY 8.4.1 PSC contract coordinating personnel will initiate the fabricating, stacking and shipping sequence, coordinating these items to meet the requirements of the Project specification, the Owner or his agent.
8.4.2 For fabrication a fabrication ticket will be provided showing as a minimum, tendon identification, the cutting length of the tendon, the number of wires in the tendon, the anchorage device required and where necessary, any special instructions for packaging and shipping.
PT1-0T.CR3.SGR.doc Z1 7R0 Page 43 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 6 of 16 Revision 0 8.5 SHOP ACTIONS 8.5.1 TENDON ASSEMBLY - GENERAL 8.5.1.1 After receiving the fabrication ticket, the shop will prepare to fabricate the tendon. A tendon consists of the proper number of individual wires. Tendon fabrication includes the cutting to length of the individual wires, applying the anchor head and button heading the wires on one end, twisting and banding the tendon, coiling the tendon, coating it with a corrosion protection material and placing the entire assembly in the specified shipping/storage container.
8.5.2 TENDON ASSEMBLY 8.5.2.1 Production may begin only on material that has been accepted in accordance with Quality Control Receiving Inspection.
8.5.3 CLEAN TENDON FABRICATION AREA 8.5.3.1 Fabrication areas are to be kept in a clean condition to prevent dirt or grime from contaminating the tendon being fabricated.
8.5.4 WIRE SELECTION 8.5.4.1 For fabrication a coil of wire shall be selected. Wire identity shall be maintained throughout the fabrication process to allow the wire to be traced to the original test reports.
8.5.5 All wrapping is to be removed.
9.0 MATERIAL EVALUATION 9.1 Tendon wire shall be visually checked for evidence of surface corrosion or defects, in accordance with the requirements of PSC specification EW101, Evaluative Criteria for the visual inspection of wire, Section 9.6, of this Procedure.
9.2 Normally, only wire in Condition Rating "A" will be used for fabrication of nuclear tendons. However, if this grade of material is not available, then materials of Condition Rating "B" or "C" may be substituted in descending order of rating, according to availability if they are cleaned.
9.3 Wire in Condition "B" or "C" will be wiped clean with a dry rag for purposes of evaluation. Wire in Condition "D" or "E" shall not be used.
9.4 Any tendon wire which is unacceptable because of some defect or deficiency, will be tagged as rejected by the Inspector and removed from production status.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 7 of 16 Revision 0 9.5 UNCOILING OF TENDON/WIRE 9.5.1 Wire coils are placed in the uncoiling rack, uncoiled, and cut to the finished tendon length. If needed, wire wheel brushes may be used during the uncoiling process to remove any foreign matter or light rust.
9.5.2 QCD-Document the Wire Condition Rating of that wire. The Inspector shall verify the condition of that wire observing the requirements of PSC Specification EWl01 below. Also, document on DS PT 1.OT the Wire Heat Number and Coil Number. During the course of wire uncoiling and cutting, the Inspector shall verify the condition of each wire cut to assure that only wire in Condition "A", "B", or "C" are in the tendon.
9.6 SPECIFICATION EW101 - EVALUATIVE CRITERIA 9.6.1 The following criteria shall be used for evaluation during visual inspection of tendon wire. Wire in Condition Rating A, B, or C is considered acceptable.
Sandpaper cleaning, as noted below, is only a means of evaluating the true condition of the wire before fabrication and will be done only at the discretion and approval of the PSC Quality Control Inspector. Wire sections that have been sanded and found unacceptable as noted below, shall not be used in tendon fabrication.
9.6.2 A = EXCELLENT CONDITION 9.6.2.1 Bright, uniformly colored wire; no foreign matter, visible rust or pitting. No cleaning for inspection is required. One to two heavy passes with 100 grit sandpaper to bright metal.
9.6.3 B = GOOD CONDITION 9.6.3.1 Partial loss of color; little foreign matter and a small quantity of light rust may be present; no pitting. The oxide coat will be more discernable when viewed parallel to the length of the wire. Rag wipe cleaning may be required for inspection. Three to five heavy passes with 100 grit sandpaper to bright metal.
9.6.4 C = FAIR CONDITION 9.6.4.1 Major loss of color; some foreign matter and a large quantity of light rust may be present; no pitting. Rag cleaning or steel wool may be required for inspection.
Six to ten heavy passes with 100 grit sandpaper to bright metal.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 8 of 16 Revision 0 9.6.5 D = UNUSABLE CONDITION 9.6.5.1 Almost total loss of color; much foreign matter and small quantities of heavy rust in the form of red oxide dust; no pitting. Rag wiping, steel wool and sandpaper cleaning will be required for inspection. Eleven to twenty heavy passes with 100 grit sandpaper to bright metal.
9.6.6 E = REJECTED CONDITION 9.6.6.1 Areas of hard, crusty, scaly red oxide, when cleaned show definite signs of pitting. Pits are defined as indentations of a depth of 1/64" or deeper and a minimum of 1/32" in diameter. Anytime pitting is in evidence, the material shall be graded as rejected and removed from production status. Heavy sanding or scraping will be required for inspection cleaning. Twenty one to thirty or more passes with 100 grit sandpaper to bright metal. Wire that is nicked, gouged, cracked or otherwise damaged shall not be used, unless the defective sections can be removed, without impairing the quality integrity of the tendon.
9.7 Sample wires from each coil of wire shall undergo a series of tests to verify the acceptability of each coil of wire prior to use.
9.8 WIRE TESTING 9.8.1 One or more samples of wire from the front and back of the wire coil shall be cut for the button head/tensile test. Each sample shall be tested as described below and the results documented on Data Sheet PT 1.OT.
9.8.2 DIAMETER MEASUREMENT 9.8.2.1 The diameter of the sample wire shall be measured with a micrometer and the dimension recorded on DS PT 1.OT. This shall be performed for the sample cut from the front and back ends of each wire coil and shall not exceed the range of 0.2736 to 0.2776 of an inch.
9.8.2.2 QCD-The Inspector shall document the dimension measured for the front and back of the wire.
9.8.3 BUTTON HEAD QUALIFICATION AND WIRE TENSILE TEST 9.8.3.1 This test, performed on the sample wire, will be used to evaluate the ability of the button head to withstand the tensile force required to break the wire and to verify that the wire will meet the specified ultimate tensile strength. The tensile test shall be performed on the sample cut from the front and back end of each wire coil. The button heading machine will have been previously qualified, in accordance with the requirements of Section 10, of this Procedure, Button head Machine Qualification.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 9 of 16 Revision 0 9.8.3.2 Two tensile test blocks shall be placed on the sample wire and each end of the wire shall be button headed. The sample shall be placed into the PSC test device and tested to failure.
9.8.3.3 Tensile Samples shall not be less than the Breaking Strength fdr the wire diameter shown below or that tendon wire shall be rejected 9.8.3.3.1 Diameter 0.2736"; Break Strength = 14,110 lbs 9.8.3.3.2 Diameter 0.2746"; Break Strength = 14,214 lbs 9.8.3.3.3 Diameter 0.2756"; Break Strength = 14,317 lbs 9.8.3.3.4 Diameter 0.2766"; Break Strength = 14,421 lbs 9.8.3.3.5 Diameter 0.2776"; Break Strength = 14,526 lbs 9.8.3.4 QCD-Document the Break Strength of the wire sample. This will be a ram area times pressure calculation, where the PSC wire tensile device and test blocks are being used.
9.8.3.5 The wire break shall occur in the shaft of the wire not less than one half the wire diameter in distance from the base of the button head to the break. The length of wire, from the base of the button head to the break, shall be measured and recorded on DS PT 1.OT.
9.8.3.5.1 QCD-Document the Button head Break dimension, wire breaks of a nature other than ductile failure shall be noted. Non-ductile failure at the site of break will be observed to be dull, silky, and not necked down or reduced in area.
9.8.3.6 If sample failure occurs lower than the Break Strength specified in Section 9.8.3.3, above, two additional sample wires will be cut and tested. These two samples shall pass the tensile test before that wire can be used.
9.8.3.6.1 If one of the two above samples fails the force/pressure requirement or fails within the button head, two more samples shall be cut and tested. If one of these samples fails, the mode of failure shall be investigated for cause. If the failure is traceable to the button header or test equipment, that device shall be repaired or replaced. Section 9.8.3.6, shall be repeated to acquire two consecutive acceptable test results.
9.8.3.6.2 If the failure is attributable to the wire, that wire shall be tagged as rejected and removed from production status.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 10 of 16 Revision 0 10.0 BUTTONHEADING MACHINE/OPERATOR QUALIFICATION 10.1 Prior to forming any button heads on a tendon, the button head machine and operator will be tested for the ability to form acceptable button heads, observing the requirements of this procedure.
10.2 As a minimum, the machine and operator shall be qualified at the beginning of each shift; whenever another machine or operator is substituted; whenever the machine has had mechanical repairs or parts replacement that would influence the forming of the button head; or whenever the machine is determined to be responsible for forming unacceptable button heads.
10.3 The machine operator shall form button heads on each end of three sample wires about 12 inches in length.
10.4 The button heads shall be inspected for acceptability observing the requirements of Section 11 of this Procedure. The button head diameter and shall be checked with a Go No-Go Gauge or micrometer, with visual inspection for splits, slips and eccentricity. If the visually inspected button heads appear to exceed the acceptance criteria, they shall be mechanically checked with the appropriate gauge for the suspect deficiency.
10.5 If all the button heads are acceptable, that machine and operator is therefore qualified for the manufacture of button heads.
10.6 Machines or operators that do not form acceptable button heads, excluding problems with the wire, shall not be used in the production of button heads until that machine is repaired and qualified or replaced by a qualified machine or operator.
10.7 The qualification of each machine and operator tested shall be documented on the Button Heading Machine Qualification Sheet and on DS PT1.OT.
10.7.1 QDC-Document machine, date, shift and operator data.
10.7.2 QDC-Document buttonhead Go-NoGo acceptability.
10.7.3 QDC-Document buttonhead eccentricity acceptability.
10.7.4 QDC-Document buttonhead split/crack criteria acceptability.
10.7.5 QDC-Document any comments or observations.
10.7.6 QDC-Document calibrated equipment used including cal due date.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 1.0T TENDON FABRICATION November 27, 2007 Page 11 of 16 Revision 0 11.0 11.1 11.2 11.2.1 11.3 11.3.1 11.4 11.4.1 PSC BUTTONHEAD SPECIFICATION ACCEPTANCE CRITERIA The following sections describe the characteristics and acceptance criteria that have been established for Buttonheads on stress relieved wire corresponding to ASTM A421 Type BA, to 0.2756 inch diameter. To develop the ultimate strength of wire, the following standards must be met.
Dimensions of Wire Hole For the most effective performance of the button head, the bore through the base material must be approximately.290" for the 163 wire system.
Buttonhead Dimensions Diameter:
0.410 inch minimum to 0.450 inch maximum Buttonhead Defects (Ref. Crystal River Procedure SP182)
Fissures in Buttonheads 11.4.1.1 11.4.1.1.1 11.4.1.1.2 11.4.1.1.3 11.4.1.1.4 11.4.1.1.5 11.4.1.1.6 11.4.2 11.4.2.1 11.4.2.2 Splits are defined as fissures with their larger dimension oriented within +/-500 to the wire axis. Split width is the dimension perpendicular to larger dimension.
Maximum admissible number per buttonhead: 4 Maximum split width allowed for any one split: 0.060 inches.
Maximum split length allowed for any one split: 0.350 inches Buttonheads with splits, which bisect the button head, shall be rejected.
Splits shall not intersect.
Splits shall not penetrate the root of the buttonhead.
Eccentricity of Buttonheads Buttonhead eccentricity is defined as a lack of alignment between the axis of the buttonhead with the axis of the wire.
Maximum allowable eccentricity: 0.010 inches.
12.0 12.1 12.1.1 TENDON FABRICATION UNCOILING Wire Coil The wires from wire coils are uncoiled into the tendon trough and cut to the finished tendon length. If needed, wire wheel brushes may be used during the uncoiling process to remove any foreign matter or light rust.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 12 of 16 Revision 0 12.1.2 A twisting plate with 6 holes and an anchor head are to be installed by button heading the anchor head on the end of the wires.
12.1.3 QCD-Document the I.D. of the anchor head installed and the acceptance of buttonheads formed (using Section 11.0).
12.2 CUTTING LENGTH SET UP 12.2.1 The cutting length as given on the tendon fabrication ticket, is measured from the wire shear cutting face to the appropriate length along the tendon line/trough.
12.2.2 The wire end clamp is then locked off at the appropriate location measured. The wire end clamp is used to secure the loose end of the wire so that it can be stretched to remove slack and cut.
12.2.2.1 The wire end clamp shall be placed according to the required cut length on the tendon fabrication ticket to within the following tolerances.
12.2.2.1.1 Plus or minus 1/16 of an inch for tendons up to 100 feet in length 12.2.2.1.2 Plus or minus 1/8 of an inch for tendons up to 200 feet in length 12.2.2.1.3 Add plus or minus 1/8 of an inch for each 100-foot increment of tendon length after 200 feet. (i.e. plus or minus 3/8" over 300 feet to 400 feet) 12.2.3 A laser-measuring device shall be used to assist in verifying the placement of the wire end clamp for each tendon fabricated.
12.2.4 QCD-Document the verified measured cutting length of each tendon.
12.3 WIRE CUTTING 12.3.1 Each tendon wire will be fed through the trough until it reaches a length at which it can be secured into the wire end clamp.
12.3.2 The wire will be secured into the wire end clamp and pulled tight to remove any slack and provide an accurate length. Once the slack is removed the wire will be cut.
12.3.3 The variation in wire length between wires in a single tendon will be minimized because each wire is secured at the same location and its slack is removed through tightening.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 13 of 16 Revision 0 12.4 COMBING-TWISTING-BANDING 12.4.1 The self-propelled comb and twist unit is to be located approximately 10 feet from the anchor head, and the combing plate will be attached to the rotating part of the unit. The anchor head on the tendon is attached to the coiler or jig. At this point the combing plate is rotated 1/4 turn, and a dolly placed under the tendon. As the comb and twist unit moves away from the anchor head, the combing plate is rotated 1/4 revolution at 10 feet intervals, and dollies are placed under the tendon at these points.
12.4.2 After the tendon has been twisted two full revolutions or more, it may be combed out by moving the comb and twist unit over the full length of the tendon. After combing, the comb twist unit returns to the position where the last 1/4 revolution was made, and the process may be repeated until the entire tendon is combed and twisted. During this operation the tendon is banded approximately every 5 feet.
12.4.3 If, during the combing and twist process, any wires are bent or kinked beyond the specified tolerance, these wires must be removed and replaced by new wires.
12.5 QUALITY CHECK - COMBING AND BANDING 12.5.1 The purpose is to insure that the tendon has been twisted to proper pitch, that the differential wire lengths at the free end are within tolerance and no wires kinked or bent during combing. Any wire with nicks, pits, gouges, is to be replaced.
12.5.2 A QC Inspector is to be present at all times during combing and banding.
12.5.3 Section 9.6 of this procedure shall be used for Inspection and Evaluation of wire corrosion condition.
12.5.4 CRITERIA 12.5.4.1 Tendon pitch shall be one (1) twist per every 40'-0" (plus 2'-0"; minus 4'-0").
Differential lengths between individual wires at the free end of the tendon should not be greater than 3". Kinks or bends in the tendon wire which have a permanent set tighter radius than the bend template (6" radius) shall be rejected. The maximum number of bends meeting the limit of this criteria per tendon shall be 10. Nicks, pits and other local wire damage that is visible to the naked eye will cause those wires to be replaced.
12.5.4.2 QCD-Document the amount of bent wires and the acceptability of the tendon twisting.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 14 of 16 Revision 0 12.5.5 WIRE DIFFERENTIAL 12.5.5.1 After combing and banding of the tendon and before coiling the tendon, wires will appear to be at different lengths at the free end. Differential lengths between individual wires at the free end of the tendon should not be greater than 3". Leave combing plate on the wires if differential exceeds 3".
12.5.5.2 In the event that the differential lengths exceed 3", the apparent short wire(s) may be pulled using a come along attached to a wire grip chuck. Maximum load on the wire not to exceed 1,000 lbs. using a come along rated at 1,000 lbs. or less.
12.5.5.3 In the event the differential still exceeds 3", the tendon is to be re-twisted In order to re-twist the tendon, remove all bands, and return comb-twist unit to 10 feet from the anchor head. During this return travel the twist unit is rotated 1/4 turn every 10 feet so that the twist of 1 turn per 40 feet remains in the tendon.
The comb and twist process is repeated with the exception that the tendon does not have to be combed out after every 2nd turn.
12.5.6 QCD-Document the final observed Differential Length on the Data Sheet.
12.6 COILING 12.6.1 Before coiling if excessive dirt and grime is present, production is to remove it with a soft cloth. Dust is to be removed by the application of air pressure as the tendon is coiled.
12.6.2 The tendon is to be coiled in the coiling tub. As the tendon is coiled, it will be banded a minimum of 1 band for every 1-1/3" revolutions. The completed coiled tendon is banded with a minimum of 10.
12.6.3 The tendon is removed from the coiling tub using a nylon sling or a metal sling with protection applied to prevent the metal of the sling from contact with the tendon, single point lift.
12.7 QUALITY CHECK - TENDON CLEANLINESS INSPECTION 12.7.1 To assure that the tendon does not contain excessive amounts of dust, dirt, grime, etc., which might prevent the corrosion protection from being effective; Quality Control is to inspect the tendon at various points. Although this is a specific signoff point, this should be an ongoing check. If QC detects any of the above conditions on the tendon, notify Production and verify general cleanliness of tendon.
Conditions may be removed with soft cloth or air pressure. This will be signed off at coiling completion.
12.7.2 QCD-Document the acceptance of the tendon cleanliness.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 15 of 16 Revision 0 12.8 CORROSION PROTECTION 12.8.1 After coiling, banding and acceptance for cleanliness the tendon will be either dipped in or sprayed with Visconorust 1601 Amber for corrosion protection.
12.8.2 QCD-After the tendon is coated, QC shall inspect and document for complete corrosion protection coverage prior to packaging 12.9 TENDON IDENTIFICATION 12.9.1 A tendon identification tag shall be attached to the tendon at any time after coating with grease, but before packaging. The tag carries the tendon mark and tendon length. The tag is attached near the button headed end.
12.10 TEMPORARY PLANT STORAGE to meet ANSI N45.2.2, level C requirements.
12.10.1 The tendons can be placed in horizontal position on plastic wrapped dunnage to prevent contact with the floor and provide circulation. The tendons may be stacked a maximum of 4 high with minimum 2" thick plastic wrapped lumber between layer to allow for placement and removal of slings.
12.11 PACKAGING 12.11.1 The completed tendons may be placed into a steel shipping container with a gasketed joint, which effectively excludes dirt and environmental conditions which could adversely affect the tendon. Plastic coated dunnage should be placed on the bottom and between tendons. One to three tendons may be placed inside the container on the dunnage and blocked or otherwise secured to prevent excessive shifting during shipment. The cover shall then be attached.
12.11.2 As an alternate to placement into the steel shipping container each tendon may be hand wrapped with reinforced plastic or completely encased in a reinforced plastic bag and then placed on wooden shipping rack/pallets with plastic coated dunnage between the tendons.
12.11.3 The Inspector shall check to see that the tendon has been properly packaged and verify that no damage has occurred to the tendon.
12.12 FINAL INSPECTION 12.12.1 The Inspector shall verify that the information documented on the Data Sheet is complete and correct. Obvious errors or omissions shall be corrected before the tendon can be finally tagged as acceptable for shipping release.
12.12.2 After the inspections and documentation are complete, the Inspector shall apply the final inspection tag to the tendon.
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PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 1.OT TENDON FABRICATION November 27, 2007 Page 16 of 16 Revision 0 12.12.3 The tendon inspection tags shall be taped to the tendon shipping container or rack/pallet. These inspection tags identify the tendons within the container or on the rack/pallet, so that the container or rack/pallet does not have to be opened when it gets to the jobsite.
12.12.4 QCD-Document the acceptance of the Final Inspection.
12.12.5 QCD-Document any comments that may be pertinent to the fabrication of this tendon to include NCR number, Hold Tag Number, etc.
12.13 SHIPPING 12.13.1 Location of shipping container or rack/pallet on the trailer to be determined at time of shipping depending on weight of tendon and other items that may be shipped at the same time. Each shipping container or rack/pallet shall be secured to the bed of the trailer and tarped.
13.0 ATTACHMENTS 13.1 Data Sheet PT 1.OT 13.2 Button Heading Machine/Operator Qualification Sheet ZI7RO Page 54 of 95 Z1 7R0 PT1-0T.CR3.SGR.doc Page 54 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO Precision Surveillance Corporation PSC PROCEDURE PT 1.OT TENDON FABRICATION B.H. MACH/OPERATOR QUAL SHEET November 27, 2007 Page 1 of 1 Revision 0 BUTTON HEADING MACHINE/OPERATOR QUALIFICATION SHEET (10.7.1)
BUTTON HEADING MACHINE ID:
(10.7.1)
DATE:
(10.7.1)
SHIFT:
(10.7.1)
OPERATOR:
(10.7.1)
INSPECTOR:.
INSPECTION CHECKS:
Indicated in-tolerance dimension by check mark.
Wire #1 Wire #2 Wire #3
- 1. (10.7.2) Head diameter:
- 2. (10.7.3) Head eccentricity:
- 3. (10.7.4) Split/Crack criteria:
(10.7.5) Remarks of general appearance check (Visual):
(10.7.6)
BH GO-NOGO GAUGE NO.:
RECAL. DATE:
(10.7.6) ECCENTRICITY GAUGE NO.
RECAL. DATE:
(10.7.6) FEELER GAUGE NO.:
RECAL. DATE INSPECTOR Q.C. SIGNOFF:
LEVEL:
DATE:
Q.C. REVIEW:
LEVEL:
DATE:
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PCHG-DESG ENGINEERING CHANGE 000063016RO Precision Surveillance Corporation PSC PROCEDURE PT 1.OT TENDON FABRICATION DATA SHEET PT 1.0T November 27, 2007 Page 1 of 1 Revision 0 TENDON (9.5.2)
(9.5.2)
(9.5.2)
(9.8.2.2)
(9.8.3.4)
(9.8.3.5.1)
TYPE OF WIRE WIRE DIAMETER WIRE BREAK WIRE BREAK WIRE BREAK MARK WIRE HEAT COIL RATING
.2736 to.2776 STRENGTH DIMENSION (DUCTILE/
QC Signoff/Date MAK NUMBER NUMBER RAIG
.76t 27 TEGHDMNINNON-A, B or C FRONT BACK FRONT BACK FRONT BACK DOW DUCTILE)
(10.7)
(12.1.3)
(12.1.3)
(12.2.2)
(12.5.4.2)
(12.5.4.2)
(12.5.6)
(12.7.2)
(12.8.2)
(12.12.4)
BUTTONHEAD INSTALLED ACCEPTABLE TENDON BENT TWISTING WIRE TENDON CORROSION FINAL MACH/OPER ANCHORHEAD BUTTONHEADS LENGTH WIRES DIFFERENTAL CLEANLINESS PROTECTION INSPECTION QUALIFIED I.D.
LENGTH COVERAGE QC QC QC QC QC QC QC QC QC QC Signoff/Date Signoff/Date Signoff/Date Signoff/Date Signoff/Date Signoff/Date Signoff/Date Signoff/Date Signoff/Date Signoff/Date (12.12.5) COMMENTS:
(7.9.1)
CALIBRATION:
MICROMETER NO.:
RECAL. DATE:
BHGO-NOGO GAUGE NO.:
RECAL. DATE:
FEELER GAUGE NO.:
RECAL. DATE:
ECCENTRICITY GAUGE NO.
RECAL. DATE:
RAM NO.:
AREA:
K:
RECAL. DATE:
PRESSURE GAUGE NO.:
RECAL. DATE:
QC SIGNOFF/DATE:
QC REVIEW:
TITLE:
DATE:
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.0 77!
ANCHORAGE FABRICATION-GENERAL November 27, 2007 Page 1 of 5 Revision 0 Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE GENERAL REQUIREMENTS FOR FABRICATION OF POST-TENSIONING ANCHORAGES Prpred by Ap roved by A-ppiuVW by__
LEVEL II Q. C.
11/27/07 Date Title PROJECT MANAGER, P. E.
11/27/07 Date Title PRESIDENT Title 11/27/07 Date Z17RO Page 3~o95 Z17R0 PT2.0 3SGR.doc Page 57of9
PCHG-DESG
.CENGINEERING CHANGE
. 000063016RO PSC PROCEDURE PT 2.0 ANCHORAGE FABRICATION-GENERAL November 27, 2007 Page 2 of 5 Revision 0 1.0 PURPOSE 1.1 This procedure will establish the General Requirements for the Fabrication and Inspection of Anchorage Components for the Post-Tensioning Tendon System of Crystal River Unit 3 SGRP.
2.0 SCOPE 2.1 This procedure will be the preface for the other Procedures which control the various operations which are involved in the Fabrication, Inspection and where specified, the Testing of post-tensioning anchorages.
3.0 RESPONSIBILITY 3.1 PSC shall be responsible for the Quality Assurance and Quality Control activities required for the fabrication of the post-tensioning tendon system anchorages. The various Vendors shall be responsible for performing the specified activities cited in the governing procedures for their respective operations and in accordance with the requirements of this Procedure. The responsibility for the final acceptance of any anchorage, regardless of the operation being performed shall rest with the PSC Quality Control Inspector 3.2 PSC 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.
3.3 PSC and its Vendors and the Sub-Tier Suppliers of those Vendors shall maintain open access for Inspection, Survey and Audit by the Owner or his authorized agent for any or all portions of the work being performed for the project.
4.0 QUALIFICATIONS 4.1 QUALITY CONTROL INSPECTORS 4.1.1 All Quality Control Inspectors performing Inspections, Tests, and/or Evaluations shall be qualified to a minimum of Level II capability in accordance with the requirements of ANSI N45.2.6.
4Property "ANSI code" (as page type) with input value "ANSI N45.2.6.</br></br>4" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..1.2 All Quality Control Inspectors shall be certified to specific skill levels by a Quality Control Inspector who has been qualified as Level III in accordance with the requirements of ANSI N45.2.6.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.0 ANCHORAGE FABRICATION-GENERAL November 27, 2007 Page 3 of 5 Revision 0 4.2 AUDITORS 4.2.1 PSC Personnel performing audits shall be qualified as auditors in accordance with the requirements of ANSI N45.2.23.
4Property "ANSI code" (as page type) with input value "ANSI N45.2.23.</br></br>4" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..3 DOCUMENTATION 4.3.1 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.
5.0 EQUIPMENT 5.1 The Equipment to be used for the fabrication and inspection of the Anchorages shall be specified, where necessary, in the Procedure for the operation being performed.
6.0 PRECAUTIONS 6.1 Where Precautions are to be observed, they will be described in that procedure where they are expected to occur.
7.0 QUALITY CONTROL 7.1 All Quality Control Documentation (QCD) points noted in procedures are Hold Points.
The work shall not progress past or through a QCD without a release from the Inspector. The required information or evaluative data shall be documented on the Data Sheet for each specific inspection.
7.2 Inspection of the various anchorage fabrication Operations shall be performed on a continuous basis by a PSC Quality Control Inspector. The inspections shall be documented for each anchorage and entered onto the respective Data Sheet. Where specified, the Inspector shall witness the anchorage fabricating operations for conformance to the fabrication procedures.
7.3 The Inspector shall be responsible for accepting or rejecting the material, the removal of Hold Tags from material placed on hold status and to release that material for further fabrication or shipping. The Inspector shall also be responsible for the disposition of material, whether hold, reject or non-conforming status, to comply with the approved corrective action, or where the material has failed to pass the inspection requirements.
7.4 Anchorages may be inspected at any time or continuously throughout fabrication for specified criteria. Usually, the Inspections will take place after the completion of machining. Anchorages may be rejected at any point during fabrication if the criteria for acceptance is not met, if damage is suspected or observed, or there is objective evidence of loss of control during the fabrication process.
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PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.0 ANCHORAGE FABRICATION-GENERAL November 27, 2007 Page 4 of 5 Revision 0 7.5 Incidents of repetitive rejected inspections that show evidence of loss of control shall be just cause for stopping work, until corrective action can be determined through the medium of a nonconformance report.
7.6 An anchorage failing to pass inspection shall be tagged Hold and removed from production status. Immediate correction of the deficiency shall allow further processing of that Anchorage. Anchorages may be corrected at any point during fabrication and shall be re-inspected for the same criteria as the original Anchorage, after the correction has been completed.
7.7 Historically, the nature of deficiencies noted during Anchorage inspection do not require nonconformance reporting. However, a nonconformance may be written at any time for any deficiency, over which the Quality Control Inspector intends to exercise a greater degree of control.
7.7.1 Nonconformance Reports shall be written and distributed in accordance with the requirements of the PSC Quality Assurance Manual to document and control nonconforming materials, services or activities.
7.8 Production personnel shall notify the Inspector of corrected deficiencies for purposes of re-inspection.
7.9 All inspections shall be documented on the respective Data Sheet for the items and quantities specified. Acceptable Inspections shall be signified by marking "OK" for that item in the space provided or by posting the required data.
7.9.1 All calibrated devices used shall have calibration data documented on respective data sheets.
7.10 Anchorages shall be fabricated and inspected as required of the Procedure for that operation.
8.0 GENERAL 8.1 Where required PSC shall submit test reports to the Owner or his agent for approval and at a point in time previously agreed to in the contract documents. Otherwise, the PSC Quality Assurance Section personnel will approve the material prior to fabrication when possible, but reserves the right to approve the test reports or certifications at any point during fabrication, but before final inspection.
8.1.1 Anchorages fabricated with unapproved material shall be tagged Hold until the test reports are received and approved by the PSC Quality Assurance Section. The PSC Quality Control Inspector shall be responsible for the removal of Hold Tags and subsequent release of the material.
8.1.2 If the material is not acceptable, the rejected items shall be scrapped.
PT2.0 CR3.SGR.doc Z17RO Page 60 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.0 ANCHORAGE FABRICATION-GENERAL November 27, 2007 Page 5 of 5 Revision 0 8.2 Quality Control inspections or surveillances may occur at any time during fabrication.
Final inspection will always be performed upon completion of the fabrication of an anchorage or group of Anchorages, observing the requirements of the Procedure.
8.3 ORDER ENTRY 8.3.1 PSC contract coordinating personnel will initiate the fabricating, stacking and shipping sequence, coordinating these items to meet the requirements of the project specifications, the Owner, or his agent.
8.4 CONTROL DOCUMENTS 8.4.1 The fabrication of anchorages will be in accordance with these Procedures, anchorage drawings, material specifications, the PSC Purchase Order and the regulating codes for the work being performed.
8.5 RECEIVING INSPECTIONS 8.5.1 The PSC Quality Control Section shall be responsible for the performance and documentation of all Receiving Inspection. Work shall not be performed on Raw Material or partially completed Anchorages until a Receiving Inspection has been performed and documented. The requirements for a Receiving Inspection will be noted in each Procedure.
8.6 CALIBRATION 8.6.1 The Procedures for the various fabrication operations will detail the requirements to be observed for the calibration and control of test and measuring equipment.
Cutting or semi-finishing operations require only commercial tolerances and will not require the imposition of a calibration control system by the Vendor. Final Inspections by PSC Quality Control Inspectors will require calibrated and controlled test and measuring equipment.
8.7 NONCONFORMANCE REPORTS 8.7.1 Where evidence of a loss of control is indicated, a Nonconformance Report shall be drafted by PSC personnel after notification by the Vendor of such a deficiency or where a deficiency is noted by PSC personnel. Refer to the PSC Quality Assurance Manual.
8.8 DOCUMENT CORRECTION 8.8.1 Any errors of posted data to any documentation form shall have a single line drawn through the error, the correct information inserted and each such correction initialed and dated by the person making the correction.
8.8.1.1 Cross outs, blackouts, whiteouts or correction tape will not be acceptable on original documents being submitted to PSC.
PT2.0 CR3.SGR.doc Z17RO Page 61 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.1 RECEIVING INSPECTION-ANCHORAGE November 27, 2007 Page 1 of 4 Revision 0 Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE RECEIVING INSPECTIONS FOR POST-TENSIONING ANCHORAGES AS RAW OR PARTIALLY COMPLETED MATERIAL Prepared by A provedl by,,
41lr /'
Apprved by-LEVEL II Q. C.
11/27/07 Date Title PROJECT MANAGER, P. E.
11/27/07 Date Title PRESIDENT 11/27/07 Date Title Z17RO Pa~ b~R3 ~P~doc Z1 7R0 PT2. ffd bdoc Page o
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.1 RECEIVING INSPECTION-ANCHORAGE November 27, 2007 Page 2 of 4 Revision 0 1.0 PURPOSE 1.1 This procedure will establish the requirements for the various Receiving Inspections for post-tensioning tendon system anchorages whether as raw material or partially completed anchorages.
2.0 RESPONSIBILITY 2.1 As stated in PSC Procedure PT 2.0. The Vendor or PSC Shop shall be responsible for notifying the PSC Quality Control Section that material has been received.
3.0 QUALIFICATIONS 3.1 As stated in PSC Procedure PT 2.0.
4.0 QUALITY CONTROL 4.1 As stated in PSC Procedure PT 2.0. All Quality Control Documentation (QCD) points noted in this Procedure are Hold Points. The work shall not progress past or through a QCD point without a verbal release from the Inspector. The required information or evaluative data shall be documented on the appropriate Receiving Form PT 2.1.A or PT 2.1.B. For purposes of this Procedure the PSC Quality Control Inspector shall be known as the "Inspector".
5.0 EQUIPMENT 5.1 The following items may be needed to perform the Receiving Inspection.
5.1.1 Flashlight.
5.1.2 Tapeline/ruler.
5.1.3 Mark.ing paint or Paintstick.
6.0 PRECAUTIONS 6.1 Observe the Safety Requirements of that location at which the Receiving Inspection is being performed. Care should be exercised during the Receiving Inspections of Machined Anchorages, to avoid damaging threads or inducing fractures.
7.0 RECEIVING 7.1 The Vendor or PSC Shop shall be responsible for those physical actions required for the receiving of Raw Material, Partially Completed or Completed Anchorages. Work shall not be performed on any Anchorage Material regardless of status, until that Material has been released by the Inspector.
PT2.1 CR3.SGR.doc Z17RO Page 63 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.1 RECEIVING INSPECTION-ANCHORAGE November 27, 2007 Page 3 of 4 Revision 0 7.2 RAW MATERIAL 7.2.1 Raw Material for Anchorages will most likely be received in a Vendor Shop. Work shall not begin on any Raw Material until a fully documented Receiving Inspection has been performed for each original received piece of material. This Inspection shall be documented on Form PT 2.1.A.
7.2.1.1 QCD-Verify that the steel stamped Heat Number (painted or tagged with Heat Number acceptable) appears on at least one end of each tube, bar, billet or plate of material received. Document the existence of the Heat Number and enter the other required information on to Form PT 2.1.A.
7.2.1.2 QCD-Each tube, bar, billet or plate shall be measured for size and length and documented on Form PT 2.1.A. The size and/or quantity shall agree with the requirements of the PSC Purchase Order.
7.2.1.3 QCD-Visually inspect the material for signs of damage that could affect the use of that material for Anchorages such as, severe dents or gouges, cracks, excessive corrosion, etc. Document any damage or the Acceptance of that material.
7.2.2 The Heat Code for the Received Material shall be assigned by the PSC Quality Assurance Section and will be available once the Mill Test Reports have been acquired.
7.2.3 Any material not meeting the Inspection and Purchase Order requirements shall be controlled for Hold or Reject action as cited in the PSC Quality Assurance Manual. Nonconformance Reports shall be generated at the control and discretion of the Inspector. Post the Nonconformance Report Number and/or the Hold or Reject Tag Number in the Comments Area of Form PT 2.1.A, when applicable.
7.2.4 The Heat Code and the Tube, Bar, Billet or Plate Code shall be marked, painted, stamped or tagged onto each original piece received. The Tube, Bar, Billet or Plate Code will be described in PSC Procedures PT 2.1.2 and PT 2.3.
7.2.5 QCD-Document the Heat Code and the Tube, Bar, Billet or Plate Code on Form PT 2.1.A as it applies for each Received original Tube, Bar, Billet or Plate. The application of these Codes will signify acceptance of that piece for subsequent processing.
Z17RO PT2.1 CR3.SGR.doc Page 64 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.1 RECEIVING INSPECTION-ANCHORAGE November 27, 2007 Page 4 of 4 Revision 0 7.3 PARTIALLY COMPLETED OR COMPLETED MATERIAL 7.3.1 Partially Completed or Completed Material will be received in a Vendor Shop or the PSC Shop and shall be subject to a Receiving Inspection or Waiver of Inspection, depending on the subsequent operation. The inspector shall retain the option and discretion of performing this inspection. When a receiving inspection is waived, the inspector shall document on Form PT 2.1.B the reason for acceptance without inspection. Work shall not be performed on this material until released from the Receiving Inspection. This inspection shall be based on sampling at least 10% of the pieces received and verify that the quantity received is correct.
Inspection shall be documented on Form PT 2.1.B.
7.3.1.1 QCD-Verify that the material is still identified. Document the method of marking the material and the Code Numbers for identifying those pieces that were inspected. Document the information required by Form PT 2.1.B.
7.3.1.2 QCD-Visually inspect the material for signs of damage that could affect the use of that partially completed or completed anchorage.
7.3.1.3 Any material not meeting the inspection requirements shall be controlled for Hold or Reject actions as cited in the PSC Quality Assurance Manual.
Nonconformance Reports shall be generated at the control and discretion of the inspector. Post the Nonconformance Report Number and/or the Hold or Reject Tag Number in the Comments Area of Form PT 2.1.B, when applicable.
7.4 LOST IDENTIFICATION 7.4.1 Any Partially Completed or Completed Anchorage which has been determined to have lost identification or trace ability to the Heat Number or Heat Code shall be removed from the production flow and segregated. A Nonconformance Report shall be generated to control that anchorage.
8.0 DOCUMENTATION 8.1 The items requiring documentation in this Procedure shall be documented on Form PT 2.1.A or PT 2.1.B as each might apply. These documents shall be subjected to a final Quality Control Review for content and accuracy.
9.0 ATTACHMENTS 9.1 Receiving Documentation Form PT2.1A -Bars, Tubes, Billets and Plate (Raw Material).
9.2 Receiving Documentation Form PT2.1 B - (Partially completed or completed anchorages).
PT2.1 CR3.SGR~doc Z17R0 Page 65 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT2.1 RECEIVING INSPECTION - ANCHORAGE BARS, TUBES, BILLETS, PLATE (RAW MATERIAL)
FORM PT2.1A November 27, 2007 Page 1 of 1 Revision 0 HEAT NUMBER:
MILL:
MATERIAL (Circle one): BARS - TUBES - BILLET - PLATE (7.2.1.1)
(7.2.1.2)
(7.2.1.2)
(7.2.1.3)
(7.2.5)
COMMENTS HEAT NUMBER SIZE LENGTH VISUAL HEAT (Steel stamped, CHECK CODE/COLOR painted or (Damage, CODE tagged)
- rust, other) 4 4
6 I
I.
4 4
I I
4 4
4 I
I 4
4 4
I I
4 4
4 I
I 4
4 4
I I
4 RECEIVING INSPECTION PERFORMED AT (Vendor):
RECEIVING INSPECTOR Q.C. SIGNOFF:
LEVEL:
DATE:
Q.C. REVIEW:
LEVEL:
DATE:
Z1 7R0 FORM PT2.1.A-CR3.SGR.doc Page 66 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT2.1 RECEIVING INSPECTION - ANCHORAGE PARTIALLY COMPLETED OR COMPLETED ANCHORAGES FORM PT2.1B November 27, 2007 Page 1 of 1 Revision 0 RECEIVING INSPECTION PERFORMED AT:
DESCRIPTION OF MATERIAL INSPECTED:
NUMBER OF PIECES RECEIVED:
(At least 10% of the pieces received are to be inspected)
(7.3.1.1)
(7.3.1.1)
(7.3.1.2)
COMMENTS IDENTITY CODE METHOD OF VISUAL CHECK OF PIECE MARKING (Damage, rust, other)
INSPECTED IDENTITY ACCEPT or HOLD 9.
.9
.9 9.
.9 9.
9
.9 1~
.9
.9 1~
RECEIVING INSPECTION PERFORMED AT (Vendor):
RECEIVING INSPECTOR Q.C. SIGNOFF:
LEVEL:
DATE:
Q.C. REVIEW:
LEVEL:
DATE:
Z17RO Page 67 of 95 Z1 7R0 FORM PT2.1.B-CR3.SGR.doc Page 67 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.1.2 IDENTIFICATION-BARSITUBES/PLATES November 27, 2007 Page 1 of 3 Precision Surveillance Corporation Revision 0 PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE APPLICATION OF HEAT AND COLOR CODE IDENTIFICATION TO BARS, TUBES OR PLATES TO BE CUT INTO POST-TENSIONING SYSTEM ANCHORAGES LEVEL // Q. C.
11/27/07 Date
- "Prepared by Title A proved by PROJECT MANAGER, RE.
Title PRESIDENT 11/27/07 Date 11/27/07 Date Title Z17RO Page 68 of 95 Z1 7R0 PT2.1.2 CR3.SGRAdoc Page 68 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.1.2 IDENTIFICATION-BARS/TUBES/PLATES November 27, 2007 Page 2 of 3 Revision 0 1.0 PURPOSE 1.1 This procedure will establish the requirements for the assignment and application of Heat Code and Color Code Identification to bar, plate or tube stock which will be used for the fabrication of post-tensioning anchorages.
2.0 RESPONSIBILITY 2.1 As stated in PSC Procedure PT 2.0.
3.0 QUALIFICATIONS 3.1 As stated in PSC Procedure PT 2.0.
4.0 QUALITY CONTROL 4.1 As stated in PSC Procedure PT 2.0.
5.0 PRECAUTIONS 5.1 Observe the safety requirements of that location at which the work and inspections are being performed.
6.0 CODE IDENTIFICATION 6.1 In order to maintain heat number, bar, tube or plate and adjacent piece traceability, special codes will be applied to each bar, tube or plate as early as practical after receiving.
6.2 HEAT CODE 6.2.1 This will be a two letter code that represents the heat number and will be assigned by the PSC Quality Assurance Section. The letters I, 0, Q and Z will not be used because of their possible appearance as numbers. The Heat Code may be initially painted onto the bar, tube or plate, or accompany the material with a tag.
6.3 COLOR CODE 6.3.1 This will consist of one or more stripes of the same or multiple colors, depending on the quantity of bars, tubes or plates to a heat number, that will be used to represent each bar, tube or plate. This color code will also be assigned by the PSC Quality Assurance Section, once the quantity of bars, tubes or plates per heat number is known. The Color Code will be painted along the entire length of the bar, tube or plate and both bar, tube or plate ends.
Z17RO Page 69 of 95 Z1 7R0 PT2.1.2 CR3.SGR.doc Page 69 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.1.2 IDENTIFICATION-BARS/TUBES/PLATES November 27, 2007 Page 3.of 3 Revision 0 6.3.2 6.3.3 With the advent of larger heats, it becomes necessary to plan for the Color Code system to prevent duplication of Color Codes per heat number. It is not advisable to put more than 3 stripes on a bar, tube or plate nor is it advisable to have these 3 stripes be of the same color.
As shown in the chart below, 27 separate Color Code combinations can be provided with only 6 colors and only 2 stripes per bar, tube or plate. A seventh color would provide 35 combinations and an eighth would make 44 combinations.
A caution should be observed here, be sure that there is adequate distinction between colors to avoid problems in distinguishing one from another. For example, purple and dark blue could be seen as blue-blue or purple-purple. Avoid dark colors such as black and dark brown. Each bar, tube or plate shall have a color code applied.
Color Red White Blue Yellow Green Orange One Stripe Red RR RW RB RY RG RO R
White WW WB WY WG WO W
Blue BB BY BG BO B
Yellow YY YG YO Y
Green GG GO G
Orange 00 0
6.4 QCD-document the Heat Code and Color Code on Form PT 2.1.A by Section 7.1.7 of PSC Receiving Inspection Procedure PT 2.1.
as required Z17RO Page 70 of 95 Z1 7R0 PT2.1.2 CR3.SGR.doc Page 70 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.3 FABRICATION -A NCHORAG ES November 27, 2007 Page 1 of 6 soce Revision 0 Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE FLAMECUTTING, TURNING AND FACING, DRILLING AND THREADING OF POST-TENSIONING ANCHORAGES LEVEL II Q.C.
11/27/07 Date
'/-*J Prepared by Title Allroedby
-Apprvluv1d o PROJECT MANAGER, PE.
Title 11/27/07 Date PRESIDENT 11/27/07 Date Title Z17RO Pa~ %Rg~~doc Z1 7R0 PT2.ýýRolf bý.Ioc Page
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.3 FABRICATION-ANCHORAGES November 27, 2007 Page 2 of 6 Revision 0 1.0 PURPOSE 1.1 This Procedure will establish the requirements for flame cutting, identification, turning, facing, drilling and threading of post-tensioning tendon system anchorages.
2.0 RESPONSIBILITY 2.1 As stated in PSC Procedure PT 2.0. In addition, the PSC Quality Control Inspector shall be responsible for the receiving inspection, assignment of heat codes, the inspection of all material at the designated Hold Points and the shipping release of that material.
2.2 The Vendor (Machine Shop) shall be responsible for performing the required operations in accordance with the requirements of this procedure. Additionally, the vendor shall be responsible for notifying the PSC Quality Control Inspector when a hold point inspection is to be scheduled or is ready to be performed.
2.3 The inspection acceptance and release from a hold point by the PSC Quality Control Inspector does not mean that PSC waives the right to reject that material at a later time, where deficiencies may be detected. Furthermore, this acceptance does not relieve the vendor from his responsibility to provide a quality product which meets the requirements of this Procedure, the PSC Purchase Order and standard machine shop practices.
3.0 QUALIFICATIONS 3.1 As stated in PSC Procedure PT 2.0.
3.2 The Vendor (Machine Shop) shall be responsible for providing qualified personnel to perform the work.
4.0 PRECAUTIONS 4.1 Observe the safety requirements of that location at which the work and inspections are being performed.
5.0 QUALITY CONTROL 5.1 As stated in PSC Procedure PT 2.0. For purposes of this Procedure the PSC Quality Control Inspector shall be referred to as the "Inspector".
5.2 All Quality Control Documentation (QCD) Points noted in this Procedure are hold points. The work shall not progress past or through a QCD hold point without a verbal release from the Inspector. The required information or evaluative data shall be documented on the appropriate data sheet or form designated in this Procedure.
PT2.3 CR3.SGR.doc Z17RO Page 72 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.3 FABRICATION-ANCHORAGES November 27, 2007 Page 3 of 6 Revision 0 6.0 HOLD POINT - RECEIVING INFORMATION 6.1 The bar, or plate stock shall be inspected and documented, for receipt by the PSC Inspector in accordance with the requirements of PSC Procedure PT 2.1. Verify that the receiving documentation is available.
6.2 If more than one heat of material has been received, each heat number shall be segregated. Work SHALL NOT BEGIN on a second heat number until the first heat number has been completed. DO NOT INTERMIX HEAT NUMBERS.
7.0 HOLD POINT - MATERIAL IDENTIFICATION 7.1 The bar, or plate stock shall be provided with a Heat Code and Color Code identification by the Inspector before that material can be processed. The Heat Code and Color Code shall be assigned or marked by the PSC Inspector in accordance with the requirements of PSC Procedure PT 2.1.2.
7.2 The vendor shall be responsible for maintaining the identification of the raw material, cut material and/or blank slugs at all times.
7.3 If the material is not steel stamped immediately after cutting, the material shall be traceable for identity through the use of marking or tags, so that it is readily known which piece is being worked, with reference to the heat, color and sequence code.
7.4 The Heat Code identifies the raw material with reference to the heat number provided by the manufacturing (rolling) mill.
7.5 The Color Code identifies the raw material with reference to each specific bar or plate in a Heat Code.
7.6 The Sequence Code identifies the cut material with reference to a specific location of removal from a coded bar or plate of a heat code.
8.0 STORAGE - FABRICATION; TEMPORARY 8.1 It may be necessary to hold the material in storage temporarily, for any number of reasons. Heat Numbers shall not be intermixed during storage. Positive identification of the material shall always be maintained whether as raw stock, plates, or cut slugs, or partially machined parts.
8.2 Anchorage material as partially fabricated or as completed anchorages shall be stored indoors to prevent rusting or accumulation of undesirable coatings such as grease, dirt, oil, etc.
8.3 Anchorage material as raw bars, or plates may be stored outside if suitably protected.
Raw bars, or plates with excessive rust, grease, dirt, oil, etc. shall be acceptably cleaned prior to processing.
PT2.3 CR3.SGR.doc Z17RO Page 73 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.3 FABRICATION-ANCHORAGES November 27, 2007 Page 4 of 6 Revision 0 9.0 FLAME CUT 9.1 While the cut out is stated to be a flame cut, this is not intended to restrict the type of cutting device used to effect the cut out, just so that waste is minimized and accuracy is maintained. The cut out will be performed with due regard for maintaining heat number and bar or plate traceability, with consideration for being capable of reconstructing the original bar or plate at any time.
9.2 Each bar or plate shall be completely cut before starting another.
9.3 QCD-The steel stamped bar or plate heat number, the bar or plate length, the color code and the date of cutting shall be documented on Form PT 2.3A by the PSC Inspector.
9.4 Cut the bar or plate into slugs of~the required diameter, until completely consumed.
The next bar or plate may be cut only after the previous bar or plate has been completely cut and documented.
9.5 QCD-Document the amount of pieces cut and location on Form PT 2.3A by the PSC Inspector.
9.6 Each cut slug shall be marked with the Heat Code, Color Code and Sequence Code immediately after cutting or while it is being cut. This marking can be done with an indelible marking agent, such as steel stamps, paint or special marker. No more than one unmarked slug shall remain on the cutting table at any time.
9.6.1 The Sequence Code represents the location of removal from the bar or plate. The first usable slug cut from the bar or plate shall be identified as "1" with "2" and "3" following in order for the second and third slugs cut from the bar or plate. The entire bar or plate shall be cut into slugs, with each slug being identified in succession for its order of removal.
9.7 QCD-Form PT 2.3A has numbers printed on it which represent the Sequence Code. Any slug that has been scrapped shall have an "X" drawn through the Sequence Code number which represents that slug.
9.8 QCD-Draw a line through the Sequence Code numbers on Form PT 2.3A which remain unused for that bar or plate. The numbers which remain indicate the quantity of slugs removed from that bar or plate and which become available for machining.
9.9 QCD-A reconstruction of the bar or plate shall be performed after cutting identifying cut slug locations. This shall be documented on Form PT 2.3A.
9.10 The cut slugs of a plate shall be stress relieved (heated in a furnace to approximately 1,1500F) after flame cutting to reduce surface hardness.
PT2.3 CR3.SGR.doc Z17RO Page 74 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 2.3 FABRICATION-ANCHORAGES November 27, 2007 Page 5 of 6 Revision 0 9.11 The cut slugs of a bar or plate shall be placed into a suitable processing container for movement within the machining shop. Suitable supplementary identification shall accompany the slugs to the next work station, whether in the form of data sheets or shop work orders.
9.11.1 In the event that a bar or plate cannot be completely consumed, the dropoff (the remaining portion of the unconsumed bar or plate) shall be returned to the storage area. The cut end of the bar or plate shall be steel stamped or painted with the heat number or heat code of that bar or plate. The length of the dropoff shall be recorded on Form PT 2.3A.
9.11.1.1 QCD-Record length of any dropoff on Form PT 2.3A.
9.12 The Color Code and Sequence Code numbers are for purposes of PSC information.
As long as the traceability to the original heat number is maintained, no loss of control has been exhibited and a nonconformance shall not exist.
10.0 ULTRASONIC EXAMINATION (UT) 10.1 Parts will be batched by Heat Code and processed through UT examination.
10.2 Parts will be examined per PSC Procedure PT 2.7.
11.0 TURNING AND FACING (BAR/PLATE SLUGS) 11.1 Acceptable slugs shall be turned and faced to the diameters and thickness shown on the drawing attached to the PSC Purchase Order.
11.2 Vendor will machine parts by Heat Number and more specifically by bar or plate Color Code. That is, machine all of one color first, then all of another color, etc.
Vendor will Heat Code stamp each piece as it is machined.
11.3 Steel Stamp - 100% of anchorages will be steel stamped with the Heat Code as assigned by the PSC Quality Assurance Section and consecutively numbered.
Stamping will be of a low stress type 1/2" character height and allow maximum legibility without altering the life and effectiveness of the component. (NOTE: for bar/plate slugs this may be done after turning and facing or after drilling or threading at the option of the machine shop as long as positive identification of the material is maintained.)
11.3.1 QCD-The Color Code and Numbering sequence identification, if applicable, along with the Heat Code stamp number will be entered onto Form PT 2.3B with the PSC Inspector's initials and date of inspection.
11.4 Hold point for steel stamp.
PT2.3 CR3.SGR.doc Z17RO Page 75 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 2.3 FABRICATION-ANCHORAGES November 27, 2007 Page 6 of 6 Revision 0 12.0 DRILLING 12.1 Drill Wire Holes - Drill the number of holes to location as shown on the drawing.
12.2 Wire hole diameter - Drill holes to the diameter as shown on the drawing.
12.3 Break Corners - Break "chamfer" the corners of wire holes on the button head bearing surface. Wire holes are relieved "radiuses" on the rear face.
13.0 THREADING (MAY BE PERFORMED BEFORE OR AFTER DRILLING) 13.1 This Section is not applicable for dead end plates that are not threaded.
13.2 Thread parts in accordance with drawing and standard procedures.
13.3 Lead Thread - Interfering burrs to be removed. Thread is not necessarily in tolerance until part is rotated 360 degrees.
13.4 Turning, facing and threading may be one continuous operation.
13.5 PSC Q.C. Inspector will perform Thread Measurement Inspections per PSC Procedure PT 3.0.
14.0 PACKAGE AND SHIPPING 14.1 Package so threads of adjacent parts are separated and protected with impact absorbing material.
14.2 Package all parts in boxes on skids for shipment to PSC. Mark boxes with order number, quantity and part or drawing number.
15.0 DOCUMENTATION 15.1 The items requiring documentation in this Procedure shall be documented on Form PT 2.3.A or Form PT 2.3.B as each might apply.
16.0 ATTACHMENTS 16.1 Form PT 2.3A. (Flame cut anchorage cutting documentation form.)
16.2 Form PT 2.3B (Anchorage inspection form.)
16.3 Drawing: CR-N1009-502 (Anchorhead 163 Wire.)
PT2.3 CR3.SGR.doc Z17RO Page 76 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0
, iI-J PSC PROCEDURE PT2.3 FABRICATION - ANCHORAGE FLAME CUT ANCHORAGE FORM PT2.3A November 27, 2007 Page 1 of 1 Revision 0 FLAME CU'TING PERFORMED AT:
DESCRIPTION OF MATERIAL FLAME CUT:
(9.3) Heat Number:
Color Code:
Heat Code:
(9.5) Amount of Pieces and Location: :
(9.7) Sequence Code:
1 2
3 4
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 Mark an "X" through each sequence code number of a scrap piece.
Draw a line through those numbers not used for sequence code numbers.
(9.8) Sequence Layout f
(9.11.1.1)
Drop off length:
INSPECTOR Q.C. SIGNOFF:
LEVEL:
DATE:
Q.C. REVIEW:
LEVEL:
DATE:
FORM PT2.3.A-CR3.SGR.doc Z17RO Page 77 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT2.3 FABRICATION - ANCHORAGE ANCHORAGE INSPECTION FORM PT2.3B November 27, 2007 Page 1 of 1 Revision 0 Anchorage
Description:
Drawing No.:
Plate No.:
Heat Code:
(11.3.2) ID CODE UT TEST MACHINING & DRILLING Heat Color Sequence Q.C.
Indications Number Q.C.
Anchor Wire Flatness/
Wire Hole Q.C.
Code Code No.
Thickness Hole Parallel-Perpen-No.
Dia.
ism dicularity 100%
100%
100%
Initial/
100%
100%
Initial/Date 100%
10%
100%
100%
Initial/Date Date Q.C. REVIEW:
LEVEL:
DATE:
Z17RO FORM PT2.3.B-CR3.SGR.doc Page 78 of 95
N u Typical Hole Pattern o
for Quadrant Additional Hole for 3'
\\ \\
Surveillance Wire One Per Tendon C\\J4 00.290" Typ.
163 Required Drill & Tap 12"-l13 N.C. x 1" Deep 3 Places @ 1200 C-C c0) 0O co r-.
0-6" 0
(D U)
E
- !:-LL (D
Cd)
Cn
_0 CD 0
06 75 CD 0C)
C)
Thread Relief Diameter Shall Not be less than 10.137" Owner Approval This drawing has been approved by use by Progress Energy Florida by the individual listed below for use on the Crystal River Unit 3 Steam Generator Replacement Project psc MASTER COPY
- .mA*
RAýTE,,/D7 Notes
- 1.
Bottom Vertical Washers Unthreaded
- 2.
Material: SSS-100, ASTM A514 - Type Q
- 3.
Reference Dwg: Prescon Drawing 5EX7-003 Sheet A8 Rev 3 Wnature Date 0000o U n Project NameDIl Cd o
oPrjctNm Revisions Dsigned By:0 CD
!Crystal R"ate C_
v___os 0__
0 Ce ne o River.
Description Approved N/A NIA
,z,,0 P0C
,.ti0i0 11ISEOR OWNER APROVAL C,-C Drw Unit 3 Steam Generator Replacement Project P
Sreilla Corporation BAG 11/15/20*
0,.. 0 CD OD D'rawing Name a*
C' 163 Wire Stressing Washer 3468 Watling Street Phone (219) 397-5826 Checked/Approved By:
Cr1 rsn East Chicago. IN 46312 Fax.
(219) 397-5867 I
CEC 11/15/2007 Scale: NTS http://www.psctendon.com Email: info@psctendonacom M:
00..\\N109 Crystal River SGR Material\\CADýCR.N1009-502 163 Wir Stressing Washer.dvg
PCHG-DESG ENGINEERING CHANGE
. 000063016RO PSC PROCEDURE PT 3.0 THREAD MEASURING-ANCHORAGES SNovember 27, 2007 Page 1 of 3
,l Revision 0 Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE THREAD MEASURING OF POST-TENSIONING ANCHORAGES 7~K~
LEVEL II Q. C.
11/27/07 Date Pre-pared by A proved by Title PROJECT MANAGER, P.E.
Title 11/27/07 Date PRESIDENT 11/27/07 Date Title Z17RO PT3.0 CR3.SGR.doc Page 80 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE PT 3.0 THREAD MEASURING-ANCHORAGES November 27, 2007 Page 2 of 3 Revision 0 1.0 PURPOSE 1.1 This procedure will be used as the means of measuring 163 Wire Anchor Head external thread diameters to assure that they conform to American Standard Stub Acme Threads 2 threads per inch, (Class 2G) dimensions.
2.0 RESPONSIBILITY 2.1 A PSC Quality Control Inspector shall be responsible for taking thread measurements.
3.0 DOCUMENTATION 3.1 All measurements shall be recorded, signed and dated by the Inspector. The only hold point in this Procedure is the acceptability of the measurements.
3.2 QCD-Gauge identification and calibration status shall be documented on Data Sheet PT 3.0 as required.
4.0 MEASURING INSTRUMENTS 4.1 The following instruments shall be necessary for thread measurements.
4.1.1 Standard Outside Measuring Micrometer capable of reading to 0.001" or better.
4.1.2 A set of three hardened standard stub ACME thread wires.
4.1.3 Shims for wire measuring method 5.0 MEASURING THREAD DIAMETERS 5.1 Two readings in perpendicular directions shall be taken for each thread measured. A 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.
5.2 EXTERNAL MAJOR DIAMETERS 5.2.1 External Major Diameters shall be measured for the 3rd, 6th and 9th threads.
Measurements shall be made with an Outside Micrometer with needle points as shown in Figure 1 of Appendix 1.
5.2.2 The Major Diameter is given directly by the micrometer reading.
5.2.3 QCD-Document each reading taken for external major diameter on Data Sheet PT 3.0.
Z1 7R0 PT3.0 GR3.ScR.doc
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 3.0 THREAD MEASURING-ANCHORAGES November 27, 2007 Page 3 of 3 Revision 0 5.3 EXTERNAL MINOR DIAMETERS 5.3.1 External Minor Diameters shall be measured for the 3rd, 6th and 9th threads.
Measurements shall be made with an Outside Micrometer and three wires of equal diameter. Wire diameters 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 2 of Appendix 1.
5.3.2 The sum of twice the selected wire diameter and shim thickness shall be subtracted from the micrometer reading to give minor diameter.
5.3.3 QDC-Document each calculated minor diameter in the corresponding readings section of Data Sheet PT 3.0.
6.0 ACCEPTANCE 6.1 Acceptance of anchorages will be based on the dimensions given in the attached Thread Table provided that the average of the reading taken falls within the specified dimensions on a given type of measurement.
6.2 QDC-Document the acceptance or rejection of the threads.
7.0 REJECTION 7.1 Any anchorage not meeting the above acceptance measurement tolerance shall be controlled for hold or reject action as cited in PSC Quality Assurance Manual.
8.0 DOCUMENTATION 8.1 The items requiring documentation in this Procedure shall be documented on Data Sheet PT 3.0 as each might apply.
8.2 QDC-Any remarks pertaining to the measurement and acceptability of the threads shall be documented.
9.0 ATTACHMENTS 9.1 Appendix 1 - Figures for Thread Diameter Measuirements 9.1.1 These figures are used to illustrate the manner of measuring thread diameters.
9.2 Thread Table 9.3 Data Sheet PT 3.0.
PT3.0 CR3.SGR.doc Z17RO Page 82 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0
=D PSC PROCEDURE PT 3.0 THREAD MEASURING-ANCHORAGES APPENDIX 1 November 27, 2007 Page 1 of 1 Revision 0 FIGURES FOR THREAD DIAMETER MEASUREMENTS Figure 1 External Major Diameter Figure 2 External Minor Diameter (Note wires rest on root of thread and protrude beyond crest)
Z17RO Page 83 Of 95 Z1 7R0 PT3.0 CR3.SGR.doc Page 83 of95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT'3.0 s
cc THREAD MEASURING-ANCHORAGES THREAD TABLE November 27, 2007 Page 1 of 1 Revision 0 163 WIRE ANCHOR HEAD THREAD MEASUREMENT THREAD TABLE BASIC 10.5" DIAMETER DIAMETER 2 THREADS PER INCH THREAD EXTERNAL COMPONENT 163 WIRE ANCHOR HEAD DIAMETERS MAX.
MIN.
MAJOR 10.5000 10.4750 MINOR 10.1800 10.1393 Z17RO Page 84 of 95 Z1 7R0 PT3.0 CR3.SGR.doc Page 84 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE PT 3.0 THREAD MEASURING-ANCHORAGES DATA SHEET PT3.0 November 27, 2007 Page 1 of 1 Revision 0 163 WIRE ANCHOR HEAD THREAD MEASUREMENT INSPECTION DOCUMENTATION Anchorage I.D.
EQUIPMENT IDENTIFICATION.
RECALIBRATION.
DATE MICROMETER WIRE SHIMS MEASUREMENTS THREAD AVG.
THREAD READ 3RD 6TH 9TH DIAM.
(5.2.3)
EXT.
1 MAJOR 2
(5.3.3)
EXT.
1 MINOR 2
(6.2)Disposition (Circle One)
Accept Reject Remarks:
Q.C. Inspector Signoff:
Level:
Date:
Q.C. Review:
Level:
Date:
ZI7RO Page 85 of 95 Z1 7R0 PT3.0 CR3.SGR.doc Page 85 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE TTT CR3 TENDON TENSILE TEST November 27, 2007 Page 1 of 6 Revision 0 Precision Surveillance Corporation PROGRESS ENERGY FLORIDA, INC.
CRYSTAL RIVER NUCLEAR UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT (SGRP)
TENDON FABRICATION PRECISION SURVEILLANCE CORPORATION QUALITY CONTROL PROCEDURE TENDON TENSILE TEST Prepared by Apl roved by Apjefebeebx-LEVEL II Q. C.
Title PROJECT MANAGER, P.E.
11/27/07 Date 11/27/07 Date 11/27/07 Date Title PRESIDENT Title Z17RO TTT.CR3 TENDON TENSILE TEST CR3SGR.doc Page 86 o 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PCHG-DESG ENGINEERING CHANGE 00006301 6R0 PSC PROCEDURE TTT CR3 TENDON TENSILE TEST November 27, 2007 Page 2 of 6 Revision 0
1.0 PURPOSE
1.1 The purpose of this procedure is to tensile test a full capacity (163 wire) straight tendon complete with anchorage hardware to obtain the following information.
1.1.1 Yield Strength 1.1.2 Ultimate Tensile Strength 1.1.3 Load-Elongation Characteristics 1.2 This procedure will be performed to satisfy the requirements of ACI-ASME Code Section III Division 2, paragraph CC-2452.1 and CC-2463.1 1.3 The tensile force shall equal or exceed the minimum guaranteed ultimate strength of the tendon.
2.0 SCOPE
2.1 The total number of tendon test specimens to be tested is one.
2.2 Sample wire and anchorage hardware shall be selected from material being processed for the work.
2.3 The tendon test specimen shall be long enough to ensure that elongation measurements can be taken on a 100" minimum gauge length.
2.4 The test will be conducted outdoors, under existing ambient conditions for weather and temperature at the time of the test.
2.5 QCD-The weather condition, sunny, cloudy, raining, etc. and temperature will be noted on the Tendon Tensile Test Form.
3.0 RESPONSIBILITY
3.1 Precision Surveillance Corporation shop personnel shall be responsible for the physical activities associated with this procedure.
3.2 Precision Surveillance Corporation quality control personnel shall be responsible for the data recording associated with this procedure.
3.3 Precision Surveillance Corporation engineering personnel shall be responsible for the computations associated with this procedure.
4.0 EQUIPMENT
4.1 Tendon test block.
4.2 Hydraulic pressure gauge, calibrated.
TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Z17RO Page 87 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 4.3 Hydraulic pump, hoses, and associated hardware.
4.4 Hydraulic ram (jack), calibrated.
4.5 Supporting devices.
4.6 Safety shields, if needed.
4.7 Electrical power source.
4.8 Various measuring devices; steel scale graduated in 0.02" increments.
4.9 Test tendon - wires, and anchorages.
5.0 QUALITY CONTROL:
5.1 The work shall not proceed or progress without a verbal release from the Quality Control Inspector responsible for the data recording associated with this procedure.
6.0 PROCEDURE
6.1 The test tendon may have been fabricated with the anchorages installed on each end or may have been fabricated with only one end installed depending on the test block used. If the test tendon was fabricated with the anchorage installed only on one end, the tendon will be feed through the test block and then the other end anchorage installed.
6.2 Once the tendon is placed in the test block, stressing shims will be placed between one of the anchorages and the test block plate.
6.3 Safety shields as needed are placed around the tendon ends.
6.4 The hydraulic ram will be positioned on the test tendon and test block and a slight pressure will be applied to stabilize the tendon.
6.5 Once the tendon is stabilized, the elongation measuring devices will be positioned and adjusted to provide a reference mark and the test will begin.
6.5.1 QCD-Document initial elongation measurement.on the Tendon Tensile Test Form.
6.5.2 A typical setup is shown in Sketch Q7.1.
6.6 The hydraulic pressure on the ram will be increased in increments of about 10% of the minimum Guaranteed Ultimate Tensile Strength (GUTS) of the tendon, to a maximum force of 80% of tendon GUTS.
6.6.1 QCD-Document the actual pressure achieved for each increment read to the nearest 50 psi. on the Tendon Tensile Test Form.
TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Z17RO Page 88 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PSC PROCEDURE TTT CR3 TENDON TENSILE TEST November 27, 2007 Page 4 of 6 Revision 0 6.6.2 QCD-Document the actual elongation measurement for each increment read to the nearest 0.02 inches on the Tendon Tensile Test Form.
6.7 After reaching 80% GUTS, the minimum Acceptable Elongation Scale Reading (AESR) will be calculated. The minimum value will be based on: SO, which is defined as "zero reference" scale reading plus 2% of the tendon length in inches. This translates to: SO plus 2.17 inches for a 108.5 inch tendon as an example (Refer Diagram Q7.1.1.).
6.7.1 QCD-Document the zero reference scale reading and the acceptable elongation scale reading.
6.8 After 80% is reached the test continues with the pressure increments reduced to about 5% of Tendon GUTS, to a maximum force of 100% of Tendon GUTS.
6.9 The test will continue with about 5% increments after 100% GUTS and the minimum AESR have been reached or until 10% of the wires are broken, or tendon failure has occurred.
6.10 Once the tendon has achieved 100% of tendon GUTS, the stressing will continue slowly and will be continuously monitored. The pressure and elongation readings will be recorded at 5% increments and/or at the point of each broken wire until the point of tendon failure. It may be necessary to momentarily hold the load at the point of each wire break to check the quantity of wires that have broken. This is normally done by listening for the wires as they break.
6.10.1 Each wire will be documented for the point of failure until the test is terminated. All elongation readings that are possible to record will be taken for each corresponding force reading. It may be necessary to use a visual aid to accomplish this. The test results will be determined from the graph. The graph may be extended for this purpose.
6.11 Upon termination of the test, the pressure will be reduced to a nominal pressure to prevent breaking any more wires and to allow the supports to be repositioned.
6.12 The setup may be disassembled, once the documentation has been entered onto the Tendon Tensile Test Form (TTTF).
7.0 CALCULATIONS
7.1 A "zero reference" scale reading will be computed as follows:
S80-S1O S10- G 10 -----------
= SO G80 - G10 7.1.1 S = Measuring scale reading at 10 & 80% of tendon GUTS TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Z17RO Page 89 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 7.1.2 G = Pressure gauge reading at 10 & 80% of tendon GUTS 7.2 Computed elongation:
7.2.1 The tendon gauge length is the overall length of the fabricated test tendon, anchorage to anchorage.
7.2.2 Inches - the measurement for each load increment will be the scale reading for the increment minus "zero reference".
7.2.3
% GA Length - the computed elongation in inches for each load increment, divided by the gauge length in inches and multiplied by 100.
7.3 Computed load:
7.3.1 Kips - the load for each increment will be the gauge reading multiplied by the ram area divided by 1000 plus the constant (K) of the ram.
7.3.2
% GUTS - the computed load kips, divided by tendon GUTS in kips and multiplied by 100.
7.4 A load elongation curve will be plotted and the 1% total extension yield strength obtained from the curve. Reference ASTM-A421 Sect. 6.2.1 and ASTM-A370 Sect.
13.1.3.
8.0 TEST RESULTS:
8.1 The following results are required by ASME Boiler & Pressure Vessel Code Section III - Division 2, 1998 Edition, no addenda:
8.2 Yield Strength - from the load-elongation curve. Refer Diagram Q7.1.2.
8.3 Ultimate Tensile Strength - this will be assumed to be equal to the highest load applied to the tendon before tendon wire failure divided by net tendon area and shall be at least equal to the Guaranteed Ultimate Tensile Strength (GUTS) of the tendon.
8.4 Elongation - at failure elongation will be assumed to be the maximum elongation achieved during the test or the elongation achieved at the highest applied load and shall not be less than 2% measured in a minimum gage length of 100 inches.
8.5 The number of broken wires will be shown on the record form under "Remarks".
8.6 Anchorage components - shall not show any visible signs of permanent deformation or fracture.
TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Z17RO Page 90 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO
9.0 ACCEPTANCE
9.1 Tendon achieving GUTS and 2% elongation with no permanent deformation of the anchorage components will be considered as acceptable for meeting the specification requirements.
10.0 DOCUMENTATION:
10.1 The following documents will be included in the Package to be submitted to the Owner or his agent.
10.2 Wire test reports with a stress/strain curve.
10.3 Anchorage test reports with fabrication and inspection documents.
10.4 Tendon fabrication and inspection documents.
10.5 Test tendon documentation form.
10.6 Engineering test analysis for acceptance.
10.7 Ram calibration record.
10.8 Pressure gauge calibration record.
10.9 Non conformance report or deviation request, where applicable.
10.10 Table of contents for entire package.
10.11 Cover letter or letter of submittal.
11.0 ATTACHMENTS:
11.1 Tendon Tensile Test Form 11.2 Sketch Q7.1 (Test Tendon Set Up) 11.3 Diagram Q7.1.1 (Method of Computing AESR) 11.4 Diagram Q7.1.2 (Determination of Tendon Yield Strength)
TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Z17RO Page 91 of 95
PCHG-DESG ENGINEERING CHANGE 000063016RO PCHG-DESG ENGINEERING CHANGE 00006301 6R0 PSC PROCEDURE TTT CR3 TENDON TENSILE TEST TENDON TENSILE TEST FORM November 27, 2007 Page 1 of 1 Revision 0 TENDON TENSILE TEST FORM PROJECT: CRYSTAL RIVER 3 SGRP 163 WIRE TEST TENDON #: TTT#1 TON RAM #:
Ram Area:
Date Cal.
Pressure Gauge #:
Date Cal.
Ruler ID:
Recal. Date:
(2.5) Ambient Temperature:
Therm. #:
Recal. Date:
Weather:
Wire Mill:
Wire Mill:
Wire Heat #:
Wire Coil #-:
Wire Heat #: _Wire Coil #:
TENDON GAUGE LENGTH:
TENDON CUTTING LENGTH:
GAUGE SCALE Pre-Computed Recorded Computed from Recorded
% of Load in Gauge Elongation (6.6.1)
(6.6.2)
LOAD REMARKS GUTS KIPS Press.
Inches Gauge Scale In In
% Ga.
PSIG Reading Reading KIPS GUTS Inches Length PSIG Inches 0
10 20 30 40 50 60 70 80 85 90 95 100 105 110 Actual Ranges ANCHORAGE DEFORMATION:
VISUAL INSPECTION:
80 Shop Anchor head ID:
100 Field Anchor head ID:
110 1
(6.7.1) Zero Ref. Calculation:
Recorded by:
Date:
Computed by:
Date:
(6.7.1) AESR =
in Reviewed by:
Date:
Z17RO TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Page 92 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PCHG-DESG ENGINEERiNG CHANGE 00006301 6R0 PSC PROCEDURE TTT CR3 TENDON TENSILE TEST SKETCH Q7.1 November 27, 2007 Page 1 of 1 Revision 0 TEST TENDON SET UP Elongatian 1vndfcaor Test Block
-Ten~don Begyfn~g Plate
-Andhorhead Z17RO TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Page 93 of 95
PCHG-DESG ENGINEERING CHANGE 000063016R0 PSC PROCEDURE TTT CR3 PrP TENDON TENSILE TEST DIAGRAM Q7.1.1 November 27, 2007 Page 1 of 1 Revision 0 METHOD OF COMPUTfNG AESR SI I
B' I
K ID I
.=
tu 8 40,0 - --- ---------
r ------------ --
------------ I I
al AER' I :
Minimum Accept63ble w o*-o -- ---
40&
30 S1G60 S-420350----------4-----
I-------------
.L
-i
~II I
IIP G10 D
4 5-MEASURED ELONGATION Method of Computing "AESR" If the plot between (S1, G1l0) and (S80, G80) is a straight line and by similar triangles:
so0=S10 --G1O( S80-S1O "G80-G1O)
Then add 2% of the actual tendon (gauge) length, (0.02L)
Example:
2 2.78 -2.03 -
S10 =2.03 SO =2.03 -500 1.92__
S80 =2.78 (4200-500)
G10 = 500 anured G80 = 4200 an L =108.5 AESR (0.02*108.5) +1.92 =2.17
+1.92 =4.09"1 TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Z17RO Page 94 of 95
II ENGINEERING CHANGE PCHG-DESG 000063016R0
, 74ý " ýO PSC PROCEDURE TTT CR3 TENDON TENSILE TEST DIAGRAM Q7.1.2 November 27, 2007 Page 1 of 1 Revision 0 DETER lMINATIONI OF TENDON YIELD STRENGTH 0
9C 0
2f W
110 CI C(
411-I i
E I
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- 0. 2 0,4 10.,
01-9*
1.2 1.4 U
ELONGATION AS A % OF TENDON (GAUGE) LENGTH Determination Plot the stress strain curve from the test data. Determine the 1% Elongation Load on the curve. Determine the stress value of this point. This diagram shows a yield of 94%
of Tendon GUTS.
Z17RO TTT.CR3 TENDON TENSILE TEST CR3.SGR.doc Page 95 of 95