ML102870291

6.5 Inadequate RetensioningT1

ML102870291
Person / Time
Site:	Crystal River
Issue date:	02/02/2010
From:	- No Known Affiliation
To:	Office of Information Services
References
FOIA/PA-2010-0116
Download: ML102870291 (75)

Text

6.5 Inadequate Tendon Re-tensioning in a Surveillance Activities'

Description:

The NRC requires periodic inspections of the containment concrete and post-tensioning system following ASME Code Section X1, Subsection IWL (FM 6.5 Exhibit 1). The subsection requires lift-off measurements of a subset of the dome, vertical, and hoop tendons.

The criteria established for tendons "passing" or "failing" are described in NRC RegGuide 1.35 (FM 6.5 Exhibit 2) for surveillances 1 through 5, and in NRC RegGuide 1.35.1 (FM 6.5 Exhibit 3) for surveillances 6 through 8.

The predicted tendon force loss curves which establish acceptance criteria "base" values, are calculated for each tendon using known force loss mechanisms (FM 6.5 Exhibit 4, FM 6.5 Exhibit 5-w/o attachments, and FM 6.5 Exhibit 6) and design basis data taken from the plant's Design Basis Documents (FM 6.5 Exhibit 12).

The CR3 containment has a history of measured tendon forces being below the RegGuide 1.35.1 requirements applied to the established "base" values (FM 6.5 Exhibit 7 and FM 6.5 Exhibit 8). This has resulted in periodic re-tensioning of numerous hoop tendons to -0% +6% of the "base" value (FM 6.5 Exhibit 2). These re-tensioning activities could potentially lead to excessive or uneven stressing of the containment concrete.

Data to be collected and Analyzed:

1. Review ASME Code Section X1, Subsection IWL (FM 6.5 Exhibit 1);

2. Review NRC RegGuide 1.35 (FM 6.5 Exhibit 2) and RegGuide 1.35.1 (FM 6.5 Exhibit 3);

3. Review tendon force loss mechanisms (FM 6.5 Exhibit 4) and tendon force loss calculations (FM 6.5 Exhibit 5);

4. Review input parameters to force loss curves (FM 6.5 Exhibit 12);

6 2/2/10 _R11ppap"i-es. y @a fide 'M*,=ý Page 1 of 3 Draft 1

5. Review tendon surveillance lift-off data (FM 6.5 Exhibit 7 and FM 6.5 Exhibit 8);

6. Review regression analysis done by PSC and Progress Energy to explain tendons "failing" (FM 6.5 Exhibit 9);

7. Draw tendon force curves for hoop tendons tested multiple times in bay 34 (FM 6.5 Exhibit 10);

8. Look for NCR for over-tensioning data;

9. Calculate stresses in the concrete from tendon re-tensioning (FM 6.5 Exhibit 11);

Verified Supporting Evidence:

a. Examination of the tendon surveillance records indicate "runs" of hoop tendons that did not meet the requirement of >95%

predicted value (FM 6.5 Exhibit 7 and FM 6.5 Exhibit 8);

b. Tendon force loss curves show a force loss with time that is faster than predicted values (FM 6.5 Exhibit 10);

Verified Refuting Evidence:

a. No NCRs were found indicating re-tensioning above predicted value +6% force;

b. The four components going into the tendon force loss prediction are the elastic shortening, concrete shrinkage, concrete creep, and wire relaxation (FM 6.5 Exhibit 4). The regression analysis performed by PSC and Progress Energy on measured tendon forces show a better correlation than the predicted curves (FM 6.5 Exhibit 9). It also indicates that RegGuide 1.35.1 used with the CR3 DBD numbers may have underestimated the expected force loss, particularly for the horizontal tendons, resulting in overly conservative acceptance criteria, additional testing expansion, and re-tensioning activities to a higher than necessary base predicted value (-0%,+6%). Re-tensioning was conservative in ensuring that sufficient compressive pre-stress was maintained above the minimum required level, and well below the 1,635 kips original tensioning value;

c. Re-tensioning above the predicted value but below the original tensioning of 1,635 kips would not lead to additional stresses in the containment wall (FM 6.5 Exhibit 11);

2/2/10 'p R Page 2 of 3 Draft 1

Discussion:

The issue of tendon force losses being larger than the "predicted" values has been present at CR3 for the last three surveillances. It has been explained by CR3 and PSC by the use of a wrong "yardstick" as calculated in the tendon force loss prediction curves. A regression analysis was used instead to approximate tendon force losses that match better with measured lift-off forces.

Our analysis of the data agrees with the CR3 and PSC assessment that the "yardstick" by which a tendon is said to "fail" is not correct.

Therefore the tendon force losses are systematically under-estimated and the tendons "fail" to meet the predicted lift-off forces. The lift-off values are however much higher than the minimum values required for safe operation of the containment.

==

Conclusion:==

Tendon re-tensioning during surveillance activities did not contribute to the delamination.

2/2/10 . Page 3 of 3 Draft 1

FM 6.5 Exhibit 1 SUBSECTION IWL REQUIREMENTS FOR CLASS CC CONCRETE COMPONENTS OF LIGHT-WATER COOLED PLANTS IWL-1000 Scope and Responsibility ....... ..................................... 251 IWL- 1100 Scope .................................................................. 251 IWrL-1 200 Items Subject to Examination .............................................. 251 IWL-1210 Examination Requirements ................................................ 251 IWL-1220 Items Exempt From Examination ............................................ 251 IWL-20 00 Examination and Inspection .................... ........................ 252 IWL-2 100 Inspection .... ........................... ............................ 252 IWL-2200 Preservice Exam ination ................................................... 252 IWL-2210 Exam ination Schedule .................................................... 252 IWL7~2220 Examination Requirements .. ........... ........................ ........ 252 IWL-2220. I C oncrete ............................................................... .252 IWL-2226.2 Unbonded Post-Tensioning Systems ......................................... 252 IWL-2230 Preservice Examination of Repairs and Modifications .......................... 252 IWL-2300 Visual Examination, Personnel Qualification, and Responsible Engineer .......... 252 IWL-23 10 Visual Examination and Personnel Qualification .............................. 252 IWL-12320 Responsible Engineer ..................................................... 252.1 IW1,2400 Inservice Inspection Schedule .............................................. 252.1 IWL-2410 Concrete ......................................................... 252.1 IWL-2420 Unbonded Post-Tensioning Systems ......... ............................... 252.1 IWL-2421 Sites With Two Plants ............................................. 253 IWL-2500 Examination Requirements ........................ 253 lWLý25 10 Exam ination of Concrete .................................................. 253 IWL-2520 Examination of Unbonded Post-Tensioning Systems ........................... 253 IWL-2521 Tendon Selection ......................................................... 253 IWL-252 1.1I Exem ptions .... ......................................................... 253 IWL-2522 Tendon Force M easurements ............................................... 255 IWL-2523 Tendon Wire and Strand Sample Examination and Testing................... 255 IWL-2523. I Tendon Detensioning and Sample Removal .................................. 255 IWL-2523.2 Sample Examination and Testing ........................................... 255 IWL-2523.3 R etensioning ............................................................ 255 IWL-2524 Examination of Tendon Anchorage Areas ................................... 255 IWL.-2524. I Visual Examination ..............................................  : ....... 255 IWL-2524.2 Free Water Documentation .......................................... 255 IWL-2525 Examination of Corrosion Protection Medium and Free Water .................. 255 IWL-2525.1 Samples ................................................................ 255 IWL-2525.2 Sample Analysis ................................... 256 FWL-2526 Removal and Replacement of Corrosion Protection Medium .................... 256 249 A92 Calculation S07-0033 Revision 0 Attachment 2 Page 29 of 325

FM 6.5 Exhibit 1 page 2 of 14

,IWL-3000 Acceptance Standards ................................................... 257

[WL-3 100 Preservice Examination ............................................. 257 IWL-3.1 1o Concrete Surface Condition ............................................... 257 IWL--31 JI Acceptance by Examination,. ...................................... ........ 257 IWL-3lI 12 Acceptance by Evaluation..................................... ...... 257

.[iWL-3.1 13 Acceptance by Repair ..................................................... 257 IWL-31.20 Unbonded Post-Tensioning System ............... ................... ....... 257 IWL-3206 Inservice Examination ................. ............................. 257 IWL-32 10 Concrete Surface Condition ................................................. 257 IWL-3,2l1 Acceptance by Examination ............................................... 257

[IWL-32112 Acceptance by Evaluation ........................................... 257 257

ýIWL-321 3 Acceptance by Repair .....................................................

.IWL-3220 Unbonded Post-Tensioning Systems ........................................ .257 IWL-3221 Acceptance by Examination ............................................... .257 IWL-322 I.1 Tendon Force ......... .................................................... :257 IWL-3221 .2 Tendon Wire or Strand Samples ..................... ..................... 257

[WL-322 I.3 Tendon Anchorage Areas ........................................... 258

[WL-322 I .4 Corrosion Protection M edium .............................................. 258 IWL-3222 Acceptance by Evaluation ................. ......................... 258 IWL-3223 Acceptance by Repair or Replacement.................................. 258

[WL-.3300 Evaluation .... ...... ................................................... 258

.IWL-3.310 Evaluation Report................................................. 258 I.WL-3320 Review by Authorities.............................................. 258 IWL-4000 R epair Procedures .................................................. 259 IWL-4.100 General ................................................................ 259

IWL-41.10 Scope 259

..IWL-:4l20 Repair/Replacement Program .... ................... ...................... 259 IWL-4200 Repair Plan ....................... ................ . . .. 259 JWL-4210 Concrete Repair .................................................. ........ 259

!wL-4220 Repair of Reinforcing Steel ............................................... 259 IWL-42-30 Repair of the Post-Tensioning System 259

.IWL-4-100 Exam ination ......... . . ............ .................................. 259 IWL-5000 System Pressure Tests ...................................... .............. 260 IWL-5.l00 Scope .......................................................... ...... 260 IWL-5200 System Test Requirements .............. ...... ............ ............. 260 lWL-52,10 General ........... ...... .............................................. 260

.IWL-5220 Test Pressure .................................................... 260

.IWL-5230 Leakage Test............... ..................................... 260 IWL-5240 Schedule of Pressure Test ...... : .......... ........................... 260 IWL-5250 Test Procedure and Examinations ................... .................. 260

.TW.L-_5260 Corrective Measures .................. . .......................... 260

]W.L-5300 R eport .......... .. .......... ............. ........ .... ........... 260 JWL-7000 .Replacements .......................... ........ 261 IWL-7100 General Requirements ................ . ...................... 261 IWL-71 10 Scope .......................................................... 261 Replacement Program . .................................... ............... 261 lWL-7120 Tables IWL-,2500-1 Examination Categories .............................. ............ 254 (WL-2521 - I Nunber of Tendons Rkr Examination ...................... 25.5 (WL-25 25-! Conresion Protection Medium Analysis ................................. 256 A.92 250)

Calculation S07-0033 Revision 0 Attachment 2 Page 30 of 325

FM 6.5 Exhibit 1 page 3 of 14 ARTICLE IWL-1000 SCOPE AND RESPONSIBILITY IWL-1100 SCOPE IWL-1200 ITEMS SUBJECT TO (a) This Subsection provides the rules and require- EXAMINATION ments for preservice examination, inserv~ice inspection IWL-1210 EXAMINATION REQUIREMENTS and repair of the' reinforced concrete and the post-The examination requirements of this Subsection tensioning systems of Class CC components, herein. re-shall apply to concrete containments.

ferred to as concrete containments as*defined by CC-1000.

(b) The rules and requirements of this Subsection do not apply to the following: IWL-1220 ITEMS EXEMPT FROM (1) steel portions not backed by concrete; EXAMINATION

('2) shell metallic liners; The following items are exempt from the examina-(3) penetration liners extending the containment tion requirements of IWL-2000:

liner through the surrounding shell concrete. (a) tendon -end anchorages that are inaccessible, sub-ject to the requirements of IWL-2521. 1; (b) portions of the! concrete surface that are covered by the liner, foundation material, or backfill, or are otherwise obstructed by adjacent structures, compo-nents, parts, or appurtenances.

25 1 Calculation S07-0033 Revision 0 Attachment 2 Page 31 of 325

FM 6,5 Exhibit 1 page 4 of 14 ARTICLE IWL-2000 EXAMINATION AND INSPECTION

. 'IWL-2100INSPECTION of a plant, the preservice examination requirements shall be met for the repair or modification.

Examinations shall be verified by an Inspector.

(b) When the repair or modification is lierformed while the plant is not in service, the preservice ex-IWL-2200 PRESERVICE EXAMINATION amination Shall be performed prior to resumption of service.

Preservice examination shall be performed in accor- (c) When the repair or modification is performed dance with the requirements of IWL-2500. while the plant is in service, the preservice examination may be deferred to the next scheduled outage.

I WL-2210 EXAMINATION SCHEDULE Preservice examination shall be completed prior to initial plant startup.

IWL-2300 VISUAL EXAMINATION, A92 IWL-2220 EXAMINATION REQUIREMENTS PERSONNEL QUALIFICATION, AND RESPONSIBLE ENGINEER J.WL-2220.1 Concrete (a) Preservice examination shall be performed in ac- IWL-2310 VISUAL EXAMINATION AND

.Cordance with IWL-2510. PERSONNEL QUALIFICATION (b) The preservice examination shall be performed (a) VT-IC visual examinations are conducted to de-following completion of the containment Structural In-termine concrete deterioration and distress for suspect tegrity Test.

areas detected by VT-3C, and conditions (e.g., cracks, IWL-2220.2 Unbonded Post-Tensioning Systems. wear, or corrosion) of tendon anchorage and wires or The following information shall be documented in the strands. Minimum illumination, maximum direct ex-preservice examination records. This information may aminaition distance, and maximum procedure demon-be-extracted from construction records. stration lower case character height shall be as speci-

.. (a) Date on which each tendon was tensioned. fied in IWA-2210 for VT-1 visual examination.

(b) Initial seating force in each tendon. (b). VT-3C visual examinations are conducted to de-(c) For each tendon anchorage, the location of all termine the general structural condition of concrete sur-missing or broken wires or stands and unseated wires. faces of containments by identifying areas of concrete (d) For each tendon anchorage, the location of all deterioration and distress, such as defined in ACI 201.1 missing or detached buttonheads or missing wedges. R-68. The minimum illumination, maximum direct ex-

• .(e) The product designation for the corrosion pro- amination distance, and maximum procedure demon-tection medium used to fill the tendon duct. stration lower case character height shall be as speci-fied in IWA-2210 for VT-3 visual examination.

IWL-2230 PRESERVICE EXAMINATION OF (c) The Owner's written practice shall define qual-ification requirements for concrete examination person-REPAIRS AND MODIFICATIONS nel in accordance with IWA-2300. Limited certification (a) When a concrete containment or a portion there- in accordance with IWA-2350 may be used for ex-of is repaired or modified during the service lifetime aminers limited to concrete.

252 Calculation S07-0033 Revision 0 Attachment 2 Page 32 of 325

FM 6.5 Exhibit 1 page 5 of 14 IWL-2320 REQUIREMENTS FOR CLASS CC COMPONENTS IWL-2420 IWL-2320 RESPONSIBLE ENGINEER tion of the containment Structural Integrity Test CC-6000 and every 5 years thereafter.

The Responsible Engineer shall be a Registered (b) The 1, 3, and 5 year examinations shall com-Professional Engineer experienced in evaluating the in-mence. not more than 6 months prior to the specified service condition of structural concrete. The Respon- dates and shall be completed not more than 6 months sible Engineer shall have knowledge of the design and after such dates. If plant operating conditions are such Construction Codes and other criteria used in design that examination of portions of the concrete cannot be and construction of concrete containments in nuclear completed within this stated time interval, examination power plants. of those portions may be deferred until the next reg-The Responsible Engineer shall be responsible for ularly scheduled plant outage.

the following: (c) The 10 year and subsequent examinations shall (a) development of plans and procedures for ex-commence not more than 1 year prior to. the specified amination of concrete surfaces; dates and shall be completed not more than 1 year after (b) approval, instruction, and training of concrete such dates.

examination personnel; (c) evaluation of examination results; (d) preparation of repair procedures; (e) submittal of report to the Owner documenting

,,results of examinations and repairs.

IWL-2420 UNBONDED POST-TENSIONING SYSTEMS IWL-2400 INSERVICE INSPECTION SCHEDULE (a) Unbonded post-tensioning systems shall be ex-amined in accordance with IWL-2520 at 1, 3, and 5 IWL-2410 CONCRETE years following the completion of the containment (a) Concrete shall be examined in accordance with Structural Integrity Test and every 5 years thereafter.

IWL-2510 at 1, 3, and 5 years following the comple- (b) The 1, 3, and 5 year examinations shall com-252.1 Calculation S07-0033 Revision 0 Attachment 2 Page 33 of 325

FM 6.5'Exhibit 1 page 6 of 14 IWL,2420 REQUIREMENTS, FOR CLASS CC COMPONENTS IWL-252L1 mence not more than 6 months prior to the specified 201.1 R--68, ini accordance' with IWL-23.10(b). Selected dates and shall be completed not more than 6 months areas, 'such as those that indicate suspect conditions,

• ter such dates. If plant operating conditions are such shall receive a NT- IC examination in accordance with thati examination of portions of the post-tensioning sys- IWIL-2310(a).

, ten cannot be completed within this stated time inter- (b) The exami nation shall be performed by, or under val, examination of those port*ions may be deferred the direction of, the Responsible Engineer.

until the next ~regularly scheduled plant outage- (c) Visual examinations may be performed from

. c).The 10 year and subsequent examinations shall floors, roofs, platformsi, walkways., ladders, ground commnence not more than I year prior to the specified' surface, or other per'manent vantage points, unrless tern-dates and sihall, be comipleted not miore than 1 year after -porary close-in access is required by the inspection ssuch dates- plan.~-

[WL-2421 Sites With Two Plants, A92

(.a) Forsites with two plarns, the examination, re-quirements for e those crete containments[ shaybe mod- A92 ifid ifabothecontainments utilize the s'.anedprestressing system and are essentiall identical in design, if post- IWL-2520 EXAMIENATION OF IJNBONDED' tensioning operationls foir the two containments were completed not more than 2 years apart, and if both PO(ST-TENSIONING SYSTEMS containments are similrl exposed to or prtce froin [WL-25111 Tendon Selection the outside environquent.'

- b) When the conditions of IWL-242 1(a,) are met, (a) Tendons, to be examined during an inspection the inspection dates and examin~ation requiremients may shl eselected oni a random basis except;'as notedin be -as follows. BWL-2521(b) 'and -(c). The population from, which the'

• (/) For the containmnent with the first Structural random -sample is drawn shall consist of al tendonis integrity Test, all1 examinations required by -IWL-2500 which "have not been examined~ during earlier ispec-shall be performned at 1, 3, 10, 0, and 30 years. Only tions,. The number ~of tendons to bie examined during the examiinations required by DIWL-2524 and [WL-2525 an. Inspection shall be as specified in Table TWL-2521-A need be performed- at 5, 15, 25,, and 35 years. (b) One tendon~ of each type. (as defined in, Table, (2) For the contaminent with the second Structural EWL-2521-l) shall be selected froin the first vear in-tntegrity 'Test,, all examninations required by~IWL-2500) -spectioni samiple and designated as a ~commnon, tendon.

shall be performed at 1, 5, -15, '25, and 35 years, Only -Eadich(oninion tendon shall 'be~ examined during each the examinations required by TWL-2524 ~and~IWL-'2525- inspection. A conimon tendon shall not, be detensioned need be performed at 3-, 10; 20, 'and 30 years.- unless required by' IWL-330(' ~If a coiiimon tendon is detensioned, another commuon, tendon of the sa'in type shafl be selected from 'the first year inspection sainple.

(c) If a containment with a stranded porst-tenslo1Iing systein ms constructed with; apreoesignated number of

-detensionable tedos one tendon of each type shallJ he selected fromn among those, which are deten~sionable.

The remaining tendons shall be selected fromi among IWL-2500 EXAMINATION those which cannot be detensioned.

REQUIREMENTS IWL-252 1,1 Exemptions. The following require-Examination shall be performed in accordance with

- meats shall apply to tendon anchorages, that are not the requirements of Table IWL-2500- I.

accessible for examination because oif safety or radio0-logical hazards 'or because of structunal obstructions.

(a) After the process of randomly selecting tendons A92 IWL-2510 EXAMINATION OF CONCRETE to be examined, any inaccessible tendons shall be des-(.1) Concrete surface- areas, including coated areas, ignated as exempt and removed from the -sample.

e~x-cept those exempted by TWL-1200(b), shaU be VT- (b.) Substitute tendons shall be selected for all ten-3C visual'examinted forevidence of conditions indic.- dons designated as exempt. Each substitute tendon shall

.atiweof,damage or degradation, such as defined in ACI be selected so that it is located as close as possible to 253 Calculation S07-0033 Revision 0 Attachment 2 Page 34 of 325.

Pq M

X.

A92 TABLE IWL-2500-1 EXAMINATION CATEGORIES EXAMINATION CATEGORY [-A. CONCRETE Item Test or Examination Test or Examination Acceptance Extent Frequency Deferral No. Parts Examined Requirement Method 'Standard of Examination of Exampination of Examination L1.1o Concrete Surface

[1,11 All Areas IWL-2510 Visual, VT-3C IWL-3210 IWL-2510 IWL-2410 NA L1,12 1 Suspect Areas IWL-2510 Visuali VT-IC IWL-320 IWL-2510 IWL-241,0 .NA 0

I z

EXAMINATION CATEGORY L-B, UNBONDED POST-TENSIONING SYSTEM Item Test or Examination Test or Examination Acceptance Extent Frequency Deferral No, Parts Examined Requirement Method Standard of Examination of Examination of Examination C; L2.10 Tendon IWL-2522 IWL-2522 IWL-3221.1 IWL-2521 IWL-2420 NA L2.20 Wire or Strand IWL-2523 IWL-2523.2 IWL-3221.2 IWL-2523,1 IWL-2420 NA L2.30 Anchorage Hardware and Surrounding IWL-2524 Visual, VT-1 IWL-3221.3 IWL-2524.1 IWL-2420 NA Concrete and VT-IC L2.40 Corrosion Protection Medium IWL-2525 IWL-2525.2(a) IWL-3221.4 IWL-2525.1(a) IWL-2420 NA L2.50 Free Water IWL-2525 IWL-2525.2(b) IWL-2525.1(b) IWL-2420 NA (00) CD0 CD 0 -.1 c 0 0-h CD)

CD)

IWL-Ufr.0.5 Exhibit 1 REQUIREMENTS FOR CLASS CC COMPONENTS page ifAA,.

TABLE IWL-2521-1 completely detensioned. A single wire or strand shall NUMBER OF TENDONS FOR EXAMINATION be removed from each detensioned tendon.

Required Maximum IWL-2523.2 Sample Examination and Testing Percentage 12, Minimum, Required (a) Each removed wire or strand shall be examined Inspection of all Tendons Number of Number of over its entire length for corrosion and mechanical Period of Each Type3 Each Type Each Type damage. The examination shall determine the location 1st year 4 4 10 of most severe corrosion, if any. Strand wires shall be 3rd year 4 4 10 5th year 4 4 10 examined for wedge slippage marks.

(b) Tension tests shall be performed on each re-10th year 2 3 5 moved wire or strand: one at each end, one at mid-15th year 2 3 5 length, and one in the location of the most corroded 20th year 2 3 5 area, if any. The following information shall be ob-25th year 2 3 5 tained from each test:

30th year 2 3 5 (1) yield strength 35th year 2 3 5 (2) ultimate tensile strength (3) elongation NOTES:

(1) Fractional tendon numbers shall be rounded to the next higher IWL-2S23.3 Retensioning. Tendons that have been integer. Actual number examined shall not be less than the minimum required number and need not be more than the detensioned shall be retensioned to at least the force maximum required number. predicted for the tendon at the time of the test. How-(2) The reduced sample size listed for the 10th year and subsequent ever, the retensioning force shall not exceed 70% of inspections is applicable only if the acceptance criteria of IWL-3221.1 are met during each of the earlier inspections. the specified minimum ultimate tensile strength of the (3) A tendon type is defined by its geometry and position in the tendon based on the number of effective wires or containment; e.g., hoop, vertical, dome, helical, and inverted U. strands in the tendon at the time of retensioning.

IWL-2524 Examination of Tendon Anchorage Ithe exempted tendon, and shall be examined in ac- Areas -L cordance with IWL-2520.

(c) Each exempted tendon shall be examined in ac- IWL-2524.1 Visual Examination. A VT,/visual cordance with IWL-2524 and IWL-2525 to the extent examination in accordance with IWA(4_4. hall be that the end anchorages of the exempt tendon are ac- performed on the tendon anchorage hardware, includ-cessible either during operation or at an outage. ing bearing plates, anchorbeads, wedges, buttonheads, shims, and the concrete extending outward a distance IWL-2522 Tendon Force Measurements of 2 ft from the edge of the bearing plate. The fol-lowing shall be documented:

(a) The prestressing force in all inspection sample (a) concrete cracks having widths greater than 0.01 tendons shall be measured by lift-off or an equivalent in.;

test. (b) corrosion, broken or protruding wires, missing (b) Equipment used to measure tendon force shall buttonheads, broken strands, and cracks in tendon an-be calibrated in accordance with a calibration procedure chorage hardware; prior to the first tendon force measurement and fol- (c) broken wires or strands, protruding wires and lowing the final tendon force measurement of the in- detached buttonheads following retensioning of tendons spection period. Accuracy of the calibration shall be which have been detensioned.

within 1.5% of the specified minimum ultimate strength of the tendon. If the post-test calibration differs from IWL-2524.2 Free Water Documentation. The the pretest calibration by more than the specified ac- quantity of free water contained in the anchorage end curacy tolerance, the results of the examination shall cap as well as any which drains from the tendon during be evaluated. the examination process shall be documented.

IWL-2523 Tendon Wire and Strand Sample IWL.2525 Examination of Corrosion Protection Examination and Testing Medium and Free Water IWL-2523.1 Tendon Detensioning and Sample IWL-252S. 1 Samples

'emoval. One sample tendon of each type shall be (a) Samples of the corrosion protection medium shall 255 Calculation S07-0033 Revision 0 Attachment 2 Page 36 of 325

IWL-25M 6.5 Exhibit 1 1992 SECTION XI - DIVISION I pagelpý TABLE IWL-2525-1 CORROSION PROTECTION MEDIUM ANALYSIS Characteristic Test Method Acceptance Limit Water content ASTM .D 95 In course of preparation Water soluble chlorides ASTM D 512 [Note (1)] 10 ppm maximum Water soluble nitrates ASTM D 992 [Note (1)] 10 ppm maximum Water soluble sulfides APHA 427 [Note (1)] 10 ppm maximum (Methylene blue)

Reserve alkalinity ASTM D 974 (Note (3)]

(Base number) Modified [Note (2)]

NOTES:

(1) Water Soluble Ion Tests. The inside (bottom and sides) of a one (1) liter beaker, approx. OD 105 mm, height 145 mm, is thoroughly coated with 100 +/- 10 grams of the sample. The coated beaker is filled with approximately 900 ml of distilled water and heated in an oven at a controlled temperature of 1O0*F (37.8°C) -t 2°F for 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />. The water extraction is tested by the noted test procedures for the appropriate water soluble ions. Results are reported as PPM in the extracted water.

(2) ASTM D 974 Modified. Place 10 g of sample in a 500 ml Erlenmeyer flask. Add 10 cc isopropyl alcohol and 5 cc toluene. Heat until sample goes into solution. Add 90 cc distilled water and 20 cc 1NH 2S0 4.

Place solution on a steam bath for 1/2hour. Stir well. Add a few drops of indicator (1% phenolphthalein) and titrate with 1NNaOH until the lower layer just turns pink. If acid or base solutions are not exactly 1N, the exact normalities should be used when calculating the base number. The Total Base Number (TBN), expressed as milligrams of KOH per gram of sample, is calculated as follows:

TBN [(20) (NA) - (B) (N,)] 56.1 W

where B=milliliters NaOH N.--.normality of HzS0 4 solution N-=normality of NaOH solution W=weight of sample in grams (3) The base number shall be at least 50% of the as-installed value, unless the as-installed value is 5 or less, in which case the base number shall be no less than zero. If the tendon duct is filled with a mixture of materials having various as-installed base numbers, the lowest number shall govern acceptance.

be taken from each end of each tendon examined. Free (b) Free water samples shall be analyzed to deter-water shall not be included in the samples. mine pH.

(b) Samples of free water shall be taken where water is present in quantities sufficient for laboratory anal- IWL-2526 Removal and Replacement of

.ysis. Corrosion Protection Medium IWL-2525.2 Sample Analysis The amount of corrosion protection medium removed (a) Corrosion protection medium samples shall be at each anchorage shall be measured and the total thoroughly mixed and analyzed for reserve alkalinity, amount removed from each tendon (two anchorages) water content, and concentrations of water soluble shall be recorded. The total amount replaced in each chlorides, nitrates, and sulfides. Analyses shall be per- tendon shall be recorded and differences between formed in accordance with the procedures specified in amount removed and amount replaced shall be docu-Table IWL-2525-1. mented.

256 Calculation S07-0033 Revision 0 Attachment 2 Page 37 of 325

FM 6.5 Exhibit 1 page 10 of 14 ARTICLE IWL-3000 ACCEPTANCE STANDARDS IWL-3100 PRESERVICE EXAMINATION IWL-3212 Acceptance by Evaluation IWL-3110 CONCRETE SURFACE CONDITION Items with examination results that do not meet the acceptance standards of IWL-3211 shall be evaluated IWL-3111 Acceptance by Examination as required by IWL-3300.

The condition of the surface is acceptable if the Re-sponsible Engineer determines that there is no evidence IWL-3213 Acceptance by Repair of damage or degradation sufficient to warrant further evaluation or repair. Repairs to reestablish the acceptability of an item shall be completed as required by IWL-3300. Accept-able completion of the repair shall constitute accept-IWL-3112 Acceptance by Evaluation ability of the item.

Items with examination results that do not meet the acceptance standards of IWL-3111 shall be evaluated as required by IWL-3300. IWL-3220 UNBONDED POST-TENSIONING SYSTEMS IWL-3113 Acceptance by Repair IWL-3221 Acceptance by Examination Repairs required to reestablish acceptability of an IWL-3221.1 Tendon Force. Tendon forces are ac-item shall be completed as required by IWL-3300. Ac- ceptable if:

ceptable completion of the repair shall constitute ac- (a) the average of all measured tendon forces, in-ceptability of the item. cluding those measured in IWL-3221. 1(b)(2), for each type of tendon is equal to or greater than the minimum required prestress specified at the anchorage for that IWL-3120 UNBONDED POST-TENSIONING type of tendon; SYSTEM (b) the measured force in each individual tendon is The condition of the unbonded post-tensioning sys- not less than 95% of the predicted force unless the tem is acceptable if it met the requirements of the con- following conditions are satisfied:

struction specification at the time of installation. (1) the measured force in not more than one ten-don is between 90% and 95% of the predicted force; (2) the measured forces in two tendons located IWL-3200 INSERVICE EXAMINATION adjacent to the tendon in IWL-3221. I(b)(1) are not less than 95% of the predicted forces; and IWL-3210 CONCRETE SURFACE CONDITION (3) the measured forces in all the remaining sam-IWL-3211 Acceptance by Examination ple tendons are not less than 95% of the predicted force.

The condition of the concrete surface is acceptable if the Responsible Engineer determines that there is no evi- IWL-3221.2 Tendon Wire or Strand Samples. The dence of damage or degradation sufficient to warrant condition of wire or strand samples is acceptable if:

further evaluation or repair. (a) samples are free of physical damage; 257 Calculation S07-0033 Revision 0 Attachment 2 Page 38 of 325

IWL-322F4A 6.5 Exhibit 1 1992 SECTION XI - DIVISION I page t*4LqfJ3Ja (b) sample ultimate tensile strength and elongation pair or replacement shall constitute acceptability of the p not less than minimum specified values. item.

IWL-3221.3 Tendon Anchorage Areas. The con-dition of tendon anchorage areas is acceptable if:

(a) there is no evidence of cracking in anchor heads, IWL-3300 EVALUATION shims, or bearing plates; (b) there is no evidence of active corrosion; IWL-3310 EVALUATION REPORT (c) broken or unseated wires, broken strands, and Items with examination results that do not meet the detached buttonheads were documented and accepted acceptance standards of IWL-3100 or IWL-3200 shall during a preservice examination or during a previous be evaluated by the Owner. The Owner shall be re-inservice examination; sponsible for preparation of an Engineering Evaluation (d) cracks in the concrete adjacent to the bearing plates do not exceed 0.01 in. in width. Report stating the following:

(a) the cause of the condition which does not meet IWL-3221 .4 Corrosion Protection Medium. Cor- the acceptance standards; rosion protection medium is acceptable when the re- (b) the acceptability of the concrete containment serve alkalinity, water content, and soluble ion con- without repair of the item; centrations of all samples are within the limits specified (c) whether or not repair or replacement is required in Table IWL-2525-1.

and, if required, the extent, method, and completion IWL-3222 Acceptance by Evaluation date for the repair or replacement; (d) extent, nature, and frequency of additional ex-Items with examination results that do not meet the aminations.

acceptance standards of [WL-3221 shall be evaluated as required by IWL-3300.

IWL-3223 Acceptance by Repair or Replacement IWL-3320 REVIEW BY AUTHORITIES Repairs or replacements to reestablish acceptability The Engineering Evaluation Report shall be subject the condition of an item shall be completed as re- to review by the regulatory and enforcement authorities

,red by IWL-3300. Acceptable completion of the re- having jurisdiction at the plant site.

258 Calculation S07-0033 Revision 0 Attachment 2 Page 39 of 325

FM 6.5 Exhibit 1 page 12 of 14 ARTICLE IWL-4000 REPAIR PROCEDURES IWL-4100 GENERAL post-tensioning system shall be in. accordance with IWL-4230.

IWL-4110 SCOPE (d) Repair material, shall be chemically, mechani7 This Article provides rules and requirements for re- cally, and physically compatible with existing concrete.

pair of concrete containments. (e) When detensioning of prestressing tendons is re-quired for repair of the concrete surface adjacent to the tendon, the Repair Plan shall. require the following:

IWL-4120 REPAIR/REPLACEMENT (1) selection of repair material to minimize stress and strain incompatibilities between repair material and PROGRAM existing concrete; (a) Repairs shall be performed in accordance with (2) procedures for application of repair material; the Repair/Replacement Program required by IWA- (3) procedures for detensioning and retensioning 4140. of prestressing tendons.

(b) Repairs shall be completed in accordance with (f) The Repair Plan shall specify requirements for the Repair Plan of IWL-4200. in-process sampling and testing of repair material.

(c) The Repair/Replacemen.t Program shall address concrete material control.

IWL-4220 REPAIR OF REINFORCING STEEL Damaged reinforcing steel shall be repaired by any IWL-4200 REPAIR PLAN method permitted in the original Cpnstruction Code or in Section IlII, Division 2, with or without removal of The Repair Plan shall be developed under the di-the damaged reinforcing steel.

rection of a Responsible Engineer (IWL-2500).

IWL-4230 REPAIR OF THE POST-IWL-4210 CONCRETE REPAIR TENSIONING SYSTEM (a) The Repair Plan shall specify requirements for (a) Weld repair of bearing plates and shim plates of removal of defective material. the post-tensioning system shall meet the applicable re-(b) The affected area shall be visually examined to quirements of LWA-4000. The corrosion protection me-assure proper surface preparation of concrete and rein, dium shall be. restored following the repair.

forcing steel, prior to placement of repair material. (b) Procedures for detensioning and retensioning of (c) When removal of defective material exposes prestressing tendons shall be specified in the Repair reinforcing steel., the reinforcing steel shall receive a Plan.

VT-I visual examination. Reinforcing steel is accept-able when the Responsible Engineer determines that IWL-4300 EXAMINATION there is no evidence of damage or degradation suffi-cient to warrant further evaluation or repair. When re- The repaired area shall be examined in accordance quired, reinforcing steel shall be repaired in accordance with IWL-2000 to establish a new preservice record with IWL-4220. Repair of exposed-end anchors of the and shall meet the acceptance standards of IWL-3000.

259 Calculation S07-0033 Revision 0 Attachment 2 Page 40 of 325

FM 6.5 Exhibit 1 page 13 of 14 A92 ARTICLE IWL-5000 SYSTEM PRESSURE TESTS IWL-5100 SCOPE placement is performed with the plant in operation, the pressure test may be deferred until the next scheduled This Article provides requirements for pressure test-integrated leak-rate test.

ing concrete containments following repair or replace-ment.

IWL-5250 TEST PROCEDURE AND IWL-5200 SYSTEM TEST REQUIREMENTS EXAMINATIONS IWL-5210 GENERAL The pressure test shall be conducted in accordance with a detailed procedure prepared under the direction A Containment pressure test, shall be performed fol- of the Responsible Engineer. The surface of all con-lowing repair or replacement unless any of the follow- tainment concrete placed during repair or replacement ing conditions exist: operations shall be examined by VT-I examination (a) The Engineering Evaluation Report (IWL-3310) prior to start of :pressurization, at test pressure, and demonstrates that the structural integrity of containment following completion of depressurization. Extended

.in the existing unrepaired condition has not been re- surface examinations, additional examinations during duced below that required by the original design cri- pressurization, other examinations, and measurements teria. of structural response to pressure shall be conducted as (b) The repair or replacement affects only the cover specified by the Responsible Engineer.

concrete external to the outermost layer of structural reinforcing steel or post-tensioning tendons.

IWL-5260 CORRECTIVE MEASURES (c) The repair or replacement involves only ex-change of post-tensioning tendons, tendon anchorage If the surface examinations of IWL-5250 cannot sat-hardware, shims, or corrosion protection medium. isfy the requirements specified by the Responsible En-gineer, the area shall be examined to the extent nec-IWL-5220 TEST PRESSURE essary to establish requirements for corrective action.

Repairs shall be performed in accordance with IWL-The pressure test shall be conducted at the design 4000, and pressure testing shall be repeated in accor-

'basis accident pressure, Pa. dance with IWL-5200, prior to returning the contain-ment to service.

IWL-5230 LEAKAGE TEST If the repair or replacement penetrated the contain- IWL-5300 REPORT ment metallic liner, or otherwise breached containment leak-tight integrity, a leakage rate test shall be con- A pressure test report shall be prepared under the ducted as required by IWE-5000. direction of the Responsible Engineer. This report may be an addition to a previously-prepared Engineering Evaluation Report (IWL-3310). The report shall de-IWL-5240 SCHEDULE OF PRESSURETEST scribe pressure test procedures and examination results If the repair or replacement is performed with the and shall state whether or not the repair or replacement plant shutdown, the pressure test shall be conducted is acceptable. If the repair or replacement is not ac-prior to resumption of operation. If the repair or re- ceptable, the report shall specify corrective measures.

260 Calculation S07-0033 Revision 0 Attachment 2 Page 41 of 325

FM 6.5 Exhibit 1 page 14 of 14 ARTICLE IWL-7000 REPLACEMENTS IWL-7100 GENERAL REQUIREMENTS (a) requirements for removal of items that are to. be IWL-7110 SCOPE replaced; (b) surface preparation required prior to installation (a) This Article provides rules and requirements for of replacement items; reinstallation and replacement of post-tensioning sys- (c) examinations required prior to installation of re-tem items for concrete containments. placement items; (b) Grease caps and installation screws are exempt (d) detensioning and retensioning requirements for from the requirements of this Article. tendons affected by installation of replacement items; (e) requirements and procedures applicable to in-IWL-7120 REPLACEMENT PROGRAM stallation of replacement items; (f) in-process sampling and testing requirements to The following items, as applicable, shall be con- be performed during installation of replacement items.

tained in the Replacement Plan:

261 Calculation S07-0033 Revision 0 Attachment 2 Page 42 of 325

FM 6.5 Exhibit 2 page 1 of 7 U.S. NUCLEAR REGULATORY COMMISSION Revision 3 July 1990 REGULATORY GUIDE OFFICE OF NUCLEAR REGULATORY RESEARCH a

REGULATORY GUIDE 1.35 (TASK SC 810-4)

INSERVICE INSPECTION OF UNGROUTED TENDONS IN PRESTRESSED CONCRETE CONTAINMENTS A. INTRODUCTION 810-4) and of the accompanying proposed Regula-tory Guide 1.35.1 (Task SC 807-4) in April 1979, General Design Criterion 53, "Provisions for the NRC Office of Research awarded a contract to Containment Testing and Inspection," of Appendix Oak Ridge National Laboratory (ORNL). The con-A. "General Design Criteria for Nuclear Power tract work included evaluating actual inspections per-Plants," to 10 CFR Part 50, "Domestic Licensing of formed by licensees, the methods of implementing Production and Utilization Facilities," requires, in Revision 2 of this guide, and the opinions and prob-part. that the reactor containment be designed to per-lems of utilities, A/Es, vendors, etc., related to Revi-mit (1) periodic inspection of all important areas and sion 2 of this regulatory guide. The contractor also (2) an appropriate surveillance program. This guide considered the pertinent portion of the January 1982 describes a basis acceptable to the NRC staff for draft version of "Inservice Inspection of Concrete developing an appropriate inservice inspection and Pressure Components," developed by a Working surveillance program for ungrouted tendons' in pre-Group of ASME Section XI, in making final sugges-stressed concrete containment structures of light-tions for modifying this guide. These suggestions were water-cooled reactors.

published in NUREG/CR-2719.2 The Advisory Committee on Reactor Safeguards This guide has been revised to reflect public com-has been consulted concerning this guide and has ments, suggestions from ORNL, and additional staff concurred in the regulatory position.

review.

Any information collection activities mentioned Regulatory Position 1 provides general informa-in this regulatory guide are contained as requirements tion. on the applicability of the guide, frequency of in 10 CFR Part 50, which provides the regulatory ba-inservice inspections, and inspections when there are sis for this guide. The information collection require-two containments at a site.

ments in 10 CFR Part 50 have been cleared under OMB Clearance No. 3150-0011. Regulatory Position 2 delineates the method of determining sample size and emphasizes random B. DISCUSSION sampling. If random sampling can not be assured, it is acceptable to select representative samples from Following the issuance for public comment of the 2

proposed Revision 3 of this regulatory guide (Task SC NUREG/CR-2719, "Evaluation of Inservice Inspections of Greased Prestressing Tendons." by J. R. Dougan, Nuclear Regulatory Commission. September 1982. Available for sale

'For the purpose of this guide, a tendon is defined as a from the U.S. Government Printing Office, P.O. Box 37082.

separate continuous multiwire or multistrand tensioned ele- Washington. DC 20013-7082, or from the National Technical ment anchored at both ends to an end anchorage assembly. Information Service. Springfield, VA 22161.

USNRC REGULATORY GUIDES The guides are issued in the following ten broad divisions:

Regulatory Guides are issued to describe and make available to the pub-lic methods acceotable to the NRC staff of implementing specific 1arts . Reactors 6. Products of the Commission' s regulations, to delineate techniques used by the 1. RePear T Reactors 7. Transo*rtation staff In evaluating Specific Problems or postulated accidents, or to 0O' 3. Fuels and Materilst Facilities 8. Ocacupational Health vide guidance to applicants. Regulatory Guioes are not substitutes for regulations, and compliance with them is not required. Methods and 4. Environmental and Siting 9. Antitrust and Financial Review solutions different from those set out in the guides will be acceptable if S. Materials and Plant Protection 10. General they provide a basis far the findings requisite to the issuance or continu-ance of a permit or license oy the Commission. Copies of Issued guIdes may be purchased from the Governrmet Printing This guide was issued after consideration of comments received from Office at the current GPO price. informatlon on current GPO prices may the public. Comments andi suggestions for improvements in these be obtained by contacting the Superintendent of OocuuentS. U.S.

guides are encouraged at all times, and guides will be revised, as aso Govemrment Printing Office. Post Office Box 37082. Washington. 0C propriate. to accommodate comments and to reflect new information or 20013-7082. telephone (202)275-2060 or (202)275-2171.

experience.

Written comments may be submitted to the Regulatory Publications Issued guides may also be purchased from the National Technical Infor-Branch. OFIPS. ACM. U.S. Nuclear Regulatory Commission. Washing- mation Service on a standing orde basis. Oetails on this service may be ton. DC 20555. obtained by writing NTIS. 5288 Port Royal Road. Springfield, VA 22161.

Calculation S07-0033 Revision 0 Attachment 2 Page 44 of 325

t-etweenF p]oe6 ixfhbW'Jvresses and from variou:s the same tendon or tendons in a group. flgis heights. The samples for each inspection may be se - the trend line, one can determine when the effective lected any time prior to the inspection. Since inspec - tendon force will be below the minimum required.

"ions can be performed when the plant is operating Regulatory Position 7.2 provides a means of iere may be certain areas where inspection of a ran - tracking elongations during lift-off testing. The 10%

domly selected tendon might result in some radiologi - tolerance in elongations at specific loads of reten-cal exposure to the inspecting personnel. The posi " sioned tendons should include the effect of differen-tion provides for substituting a readily accessibl4 tial friction (from fully greased vs. coated tendons) tendon for such a tendon. and errors attributed to calibration, measurement Regulatory Position 3 describes the areas and ex . procedures, and equipment.

tent of visual examinations during each inspection. Regulatory Position 7.4 provides detailed guid-Regulatory Position 4 presents the criteria foir ance on the results of the grease examination.

performing prestress monitoring tests. The incident of tendon anchor head failures at Farley demonstrated that the free water in grease was Regulatory Position 5 states the extent and scop( the main source of hydrogen for, hydrogen stress of tendon material testing. cracking of high-hardness anchor heads. High-Regulatory Position 6 lists items that should b4e hardness anchor heads are used in large-size tendon considered in the inspection of sheathing filler grease systems (i.e., 2t750 tons). Since the small-size (<_750 In order to assess the potential grease leakage, a rec - tons) tendons have not exhibited such characteristics, ommendation is made to compare the amount o f two limits for water are provided. It should be recog-sheathing filler grease removed with that being re - nized that these limits are not the threshold limits for placed. distress in anchor heads. When these limits are ex-ceeded, it is advisable to detension the tendon and Regulatory Position 7 discusses the individual cri - look for cracks on the shim side of the anchor heads.

teria for evaluating inspection results as follows:

An assessment of a base number for filler grease In Regulatory Position 7.1, prestress monitoriniI has been proposed for new grease in ASME Sec-criteria have been developed to ensure that any sign s tion III, Division 2, and for new and old grease in of systematic tendon force degradation are detectecI ASME Section XI. The grease used in many operat-and investigated. Acceptance of 95% of the predicteci ing plants tends to have a low base number (<S5). The

)orce for two tendons out of three in Regulatory Posi - newer grease formulations tend to have base numbers tion 7.1.3 is a slightly relaxed criterion from Revisiorn in excess of 20. Hence, two acceptance limits have 2 of the guide. It should be recognized, however, that been provided.

the primary objective is to compare the measure( At least two plants that implemented the detailed tendon forces against the predicted forces at the timi grease examination criteria experienced problems of the lift-off testing. Regulatory Guide 1.35.1 pro with the void limit of 5%. Further inquiry into the vides guidance on establishing the predicted forces. matter revealed that when the injection pressure was A provision has been added to check the averagq* very high (twice the pressure used during installation of measured forces against the minimum requirecj of grease), the amount of grease replaced was 10 to force in an average (hypothetical) tendon in a group 155% higher than that removed. The staff discourages This provision is added as a result of a suggestiorn this practice, as there is a likelihood of tearing the from the contractor (ORNL) and public comments. I t sheathing joints at such pressures, opening a way for should be recognized that each individual tendorI grease to seep into the concrete. Hence, Regulatory force (measured) will have to be modified to reflec t Position 7.4 has been revised to reflect this consid-the condition of an average tendon. The contributiný9 eration.

modifying factors would be the difference in installa - The NRC staff encourages operating plant licen-tion forces and in the elastic shortening losses, as - sees to review their existing tendon inservice inspec-suming the time-dependent characteristics remain es - tion programs and evaluate them from the standpoint sentially the same for the group of tendons. of operating convenience, safety improvements, and cost reduction potential.

The loss of prestress from creep and shrinkage o f concrete and stress relaxation of the tendon steel arne The NRC staff recognizes that in some older time-dependent and are predicted on such a basis plants (plants operating before the initial issuance of The predicted tendon force may be represented by a Regulatory Guide 1.35 in 1974), adopting all provi-sloped line in a semi-logarithmic graph. The trend o f sions of this revised guide may not be feasible without the actual effective tendon force is obtained by join - extensive retrofitting. In such cases, licensees are ad-ling the points on the graph representing the meas - vised to present their revised inservice inspection pro-ured tendon forces in two or more surveillances o f grams with any necessary exemptions from the 1.35-2 Calculation S07-0033 Revision 0 Attachment 2 Page 45 of 325

spe4O$* .r v@AA~f2*his guide. If licensees adopit randomly with a minimum of four te ach this Revision 3 to Regulatory Guide 1.35. it should b,* group. The sample size from any r e dflof ex-adopted in its entirety, not just segments of the guide ceed ten.

2.2. If the inspections performed at 1. 3, and 5 years indicate no abnormal degradation of the post-C. REGULATORY POSITION tensioning system, 2% of the population of each group (vertical, hoop, dome, and inverted U) of ten-dons or five tendons, whichever is less, may be se-

1. GENERAL lected for the subsequent inspection with a minimum

1. 1. The inservice inspection program de - of three tendons for each group.

scribed in this guide should be used with the followin g 2.3. The fraction obtained as a percentage of a types of prestressed concrete containment structures tendon population should be rounded off to the near-

a. Prestressed concrete containment s est integer.

having a shallow-dome roof on cylindrical walls wit] 2.4. The tendons to be inspected should be the cylinder prestressed in hoop and vertical direc randomly selected from each group during each in-tions and the dome prestressed by three families o }f spection. However, to develop a history and to corre-tendons at 600.

late the observed data, one tendon from each group

b. Prestressed concrete containment s should be kept unchanged after the initial selection, having a hemispherical-dome roof on cylindrical wall s and these unchanged tendons should be identified as with two families of inverted U tendons placed at 90 control tendons.

to each other and hoop tendons located in the cylin

" 2.5. If, owing to plant operating conditions, a der and dome. randomly selected tendon from a group cannot be 1.2. For containments that differ from thes e inspected during a scheduled inspection, another two types, the program described should serve as th e sample from the group should be randomly selected.

basis for the development of a comparable inservic,* The tendon that was selected but not inspected inspection program. should be inspected during the following plant shut-down and accepted (or rejected) on an individual 1.3. The inservice inspection should be per formed 1, 3, and 5 years after the initial structuraJ- tendon basis.

integrity test (ISIT) and every S years thereafter. 2.6. Tendons, except the control tendons, that had been inspected and found intact during previous 1.4. Containments should be designed and con t- inspections should be excluded from the group popu-structed so that the prestressing anchor hardware i S lation during subsequent inspections.

accessible for inservice inspection.

1.5. All containment structures with ungroute,d 3. VISUAL INSPECTION tendons should be inspected in accordance with thi s 3.1. The exterior surface of the containment guide. However, the liftoff force comparison may b,e should be visually examined to detect areas of large performed as shown in Figure 1 if any two contain - spall, 3 severe scaling, D-cracking in an area of 25 ments at the same site are shown to satisfy all three o f square feet or more, other surface deterioration or the following conditions: disintegration, or grease leakage.

a. The containments are identical in a]11 3.2. Tendon anchorage assembly hardware aspects such as size, tendon system (such as bearing plates, stressing washers, shims, design, materials of construction, an d wedges, and buttonheads) of all tendons selected as method of construction. described in Regulatory Position 2 should be visually

b. Their ISITs were performed within tw4 examined. For those containments for which only vis-years of each other. ual inspections need be performed, tendons selected as described in Regulatory Position 2 should be visu-

c. There is no unique situation that ma Y ally examined to the extent practical without disman-subject either containment to a differ tling load-bearing components of the anchorage or ent potential for structural or tendoia removing grease caps.

deterioration.

3.3. Bottom grease caps of all vertical tendons For both containments, the visual and file r should be visually inspected to detect grease leakage grease inspection should be performed according tiD or grease cap deformations. Removal of grease caps is Regulatory Positions 3 and 6 at frequencies describeid not necessary for this inspection.

in Regulatory Position 1.3.

Mrhe terms "large spall," "severe scaling," 'D-cracking,"

"deterioration" and "disintegration" are as defined in the

2. SAMPLE SELECTION American Concrete Institute publication, ACI 201.1R-68.

2.1. For the inspections at 1. 3, and 5 years "Guide for Making a Condition Survey of Concrete in Serv-ice." The publication can, be obtained from the American 4% of the population of each group (vertical, hoop" Concrete Institute, Redford Station. Detroit, Michigan dome, and inverted U) of tendons should be selecteid 48219.

1.35-3 Calculation S07-0033 Revision 0 Attachment 2 Page 46 of 325

-W 6&1 Itrrounding visually inspected zation Number by Color- "gtd-Ota-tendon anchorages should also be checked visually tion. "4 .

for indications of abnormal material behavior. 3. To determine the concentrations of water-soluble chlorides. ASTM D512, "Standard

4. PRESTRESS MONITORING TESTS Test Methods for Chloride Ion in Water."4 Tendons selected as described in Regulatory Po- 4. To determine nitrates, ASTM D3867, "Stan-sition 2 should be subjected to liftoff or other equiva- dard Test Methods for Nitrite-Nitrate in Water"4 (formerly ASTM D992).

lent tests to monitor their prestress. Additionally, the tests should include the following: 5. To determine sulfides, APHA 428. "Stan-dard Methods for Examination of Water and 4.1. One tendon, randomly selected from each Waste Water."8 group of tendons during each inspection, should be In addition, the amount of sheathing filler grease subjected to necessary detensioning in order to iden-removed and replaced should be compared to assess tify broken or damaged wires or strands.

grease leakage within the structure.

4.2. The simultaneous measurement of elonga-tion and jacking force during retensioning should be 7. EVALUATION OF INSPECTION RESULTS made at a minimum of three approximately equally 7.1. The prestressing force measured for each spaced levels of force between zero and the lock-off tendon in the tests described in Regulatory Position 4 force. should be compared with the limits predicted for the time of that test. Regulatory Guide 1.35.1 provides S. TENDON MATERIAL TESTS AND further information on the determination of these INSPECTIONS limits.

7.1.1. If the measured prestressing force 5.1. A previously stressed tendon wire or strand of the selected tendon in a group lies above the pre-from one tendon of each group should be removed scribed lower limit, the liftoff test is considered to be for testing and examination over its entire length to a positive indication of the sample tendon's accept-determine if evidence of corrosion or other deleteri- ability.

ous effects is present. At each successive inspection.

the samples should be selected from different ten- 7.1.2. If the measured prestressing force dons. The tendon selected may be the same as that of a selected tendon in a group lies between 95% of selected for detensioning. In addition, all wires or the prescribed lower limit and 90% of the prescribed strands identified as broken should be removed for lower limit, two additional tendons, one on each side tensile testing and visual examination. of the first tendon, should be checked for their pre-stressing forces. If the prestressing forces of each of 5.2. Tensile tests should be made on at least the second and third tested tendons are above 95%

three samples cut from each removed wire or strand, of the prescribed lower limits for the tendons, all one at each end and one at mid-length. The samples three tendons should be restored to the required level should be the maximum length practical for testing of integrity and the tendon group should be and the gauge length for the measurement of elonga- considered acceptable.

tion should be in accordance with the relevant ASTM 7.1.3. In Regulatory Position 7.1.2, if the specification. The following information should be prestressing force of any two adjoining tendons falls obtained from each test: below 95% of the prescribed lower limits of the ten-

1. Yield strength dons, additional lift-off testing should be done to de-tect the cause and extent of such occurrence. The

2. Ultimate tensile strength condition should be considered reportable.

7.1.4. If the measured prestressing force

3. Elongation at ultimate tensile strength of the selected tendon lies below 90% of the pre-scribed lower limit, the defective tendon should be

6. INSPECTION OF FILLER GREASE fully investigated and a determination should be made as to the extent and cause of such occurrence.

A sample of sheathing filler grease from each of Such an occurrence should be considered a report-the sample tendons should be taken and analyzed ac-able condition.

cording to the following national standards.

1. To determine water content, ASTM D95, OASTM Standards can be obtained from the American So-ciety of Testing and Materials, 1916 Race Street. Philadel-

"Standard Test Methods for Water in Petro- phia. PA 19103.

leum Products and Bituminous Materials by 5 Modifled by Note 3 of Table CC-2422-1 of the ASME Distillation."' B&PV.Section III. Div. 2. 1982 Winter Addenda.

2. To determine reserve alkalinity, ASTM 6APHA Standards can be obtained from the American Pub-lic Health Association. 1015 Eighteenth Street NW., Wash-D974. "Standard Test Methods for Neutrali- ington. DC 20036.

1.35-4 Calculation S07-0033 Revision 0 Attachment 2 Page 47 of 325

• ' FM 6.5 EXUDli*.t1Pthe average of all measured ten- f. Amount of grease repLQ@,@EedAn %of don forces for each group (corrected for average the net duct volume, when injected at the

, condition) is found to be less than the minimum re- original installation pressure.

quired prestress level (as defined in the plant's Tech-

g. Grease leakage detected during general visual nical Specifications) at anchorage location for that examination of the containment exterior sur-group. the condition should be considered report-face.

able.

h. Presence of free water.

7,1.6. If from consecutive surveillances the measured prestressing forces for the same tendon 8. REPORTING TO THE NRC or tendons in a group indicate a trend of prestress loss larger than expected and the resulting prestress- The reportable conditions listed in Regulatory ing forces will be less than the minimum required for Positions 7.1.3, 7.1.4, 7.1.5, 7.3, or 7.4 could indi-the group before the next scheduled surveillance, ad- cate a possible abnormal degradation of the contain-ditional lift-off testing should be done to determine ment structure (a boundary designed to contain ra-the cause and extent of such occurrence. The condi- dioactive materials). Any such condition should be tion should be considered reportable. reported to the NRC in accordance with the recom-mended reporting program of Regulatory Guide 1. 16, 7.2. During detensioning and retensioning of tendons (Regulatory Position 4.2), if the elongation "Reporting of Operating Information-Appendix A corresponding to a specific load differs by more than Technical Specifications."

10% from that recorded during installation of the ten- The NRC staff recognizes that for some contain-dons, an investigation should be made to ensure that ment designs, adoption of all provisions of this guide the difference is not related to wire failures or slip of may not be feasible. In those cases, licensees should wires in anchorages. A difference of more than 10% present alternatives for those provisions of the guide should be considered reportable.

they are unable to implement.

7.3. Failure in the tensile test at a strength or elongation value less than the minimum requirements D. IMPLEMENTATION of the tendon material should be considered report-able. Other' conditions that indicate corrosion (metal The purpose of this section is to provide informa-reduction) found by visually examining wire or tion to applicants and licensees regarding the NRC strands should be considered reportable. staff's plans for using this regulatory guide.

7.4. Reportable conditions for sampled sheath- Except in those cases in which the applicant or ing filler grease include:

licensee proposes an acceptable alternative method

a. Water content Exceeding 10% by wt for complying with specified portions of the Commis-sion's regulations, the methods described herein will

b. Chlorides Exceeding 10 ppm be used in the evaluation of inservice inspection and

c. Nitrates Exceeding 10 ppm surveillance programs for the following ;.uclear power plants using prestressed concrete containments with

d. Sulfides Exceeding 10 ppm ungrouted tendons:

e. Reserve alkalinity Less than 50% of the 1. Plants for which the construction permit or (Base numbers) installed value or less Lhan zero when the design approval is issued after July 31, 1990.

installed value was less 2. Plants for which the licensee voluntarily than 5 commits to the provisions of this guide.

1.35-5 Calculation S07-0033 Revision 0 Attachment 2 Page 48 of 325

-n CT) mn M

X~

Sample Size Criteria (See Regulatory Position 2) N) 4% 2%

01 5 10 20 30 II  ! I 1 I Time after Initial Structural Integrity Testing.of Containment, Years (Uft-off Testing Schedule. Containment No. 1)

CA 2 Years (Maximum)

I-0 1 5 15 25 35 II 1 1 1 1 Time after Initial Struclural Integrity Testing of Containment, Years (Lift-off Testing Schedule, Containment No. 2)

Figure 1. Schedule of Lift-off Testing for Two Containments at aSite (See Regulatory Position 1.5) o 0'

FM 6.5 Exhibit 2 page 7 of 7 REGULATORY ANALYSIS A separate regulatory analysis was prepared for copying for a fee in the Commission's Public Docu-this Revision 3 to Regulatory Guide 1.35. The regula- ment Room. 2120 L Street NW.. Lower Level.

tory analysis is contained in NUREG/CR-4712, Washington. DC. NUREG/CR-4712 is also for sale at "Regulatory Analysis of Regulatory Guide 1.35 (Revi- the U.S. Government Printing Office, P.O. Box sion 3. Draft 2)-In-Service Inspection of Ungrouted 37082, Washington. DC 20013-7082, and at the Na-Tendons in Prestressed Concrete Containments" tional Technical Information Service, 5285 Port (February 1987). and is available for inspection or Royal Road, Springfield, VA 22161.

1.35-7 Calculation S07-0033 Revision 0 Attachment 2 Page 50 of 325

FM 6.5 Exhibit 3 page 1 of 12 U.S. NUCLEAR REGULATORY COMMISSION July 1990 REGULATORY GUIDE OFFICE OF NUCLEAR REGULATORY RESEARCH REGULATORY GUIDE 1.35.1 (Task SC 807-4)

DETERMINING PRESTRESSING FORCES FOR INSPECTION OF PRESTRESSED CONCRETE CONTAINMENTS A. INTRODUCTION B. DISCUSSION The inspections of prestressed concrete contain-General Design Criterion 53, "Provisions for ment structures (with greased or grouted tendons) are Containment Testing and Inspection," of Appendix performed with the objective of ensuring that the A, "General Design Criteria for Nuclear Power safety margins postulated in the design of contain-

-Plants," to 10 CFR Part 50, "Domestic Licensing of ment structures are not reduced under operating and Production and Utilization Facilities," requires, in environmental conditions. Of particular concern in part, that the reactor containment be designed to per- the case of prestressed concrete containment struc-mit (1) periodic inspection of all important areas and tures is the possible degradation of the prestressing (2) an appropriate surveillance program. Regulatory tendon system by corrosion. The recommended in-Guide 1.35, "Inservice Inspection of Ungrouted Ten- service inspection programs of Regulatory Guides dons in Prestressed Concrete Containment Struc- 1.35 and 1.90, "Inservice Inspections of Prestressed tures," describes a basis acceptable to the NRC staff Concrete Containment Structures with Grouted Ten-for developing an appropriate inservice inspection dons," are formulated to achieve this basic objective.

and surveillance program for ungrouted tendons in The extent to which the programs can perform their prestressed concrete containment structures of light- intended function depends on the method of their water-cooled reactors. This guide expands and clari- implementation.

fies the NRC staff position on determining prestres- Review of reports of some of the inspections per-sing forces to be used for inservice inspections of formed by licensees on greased tendons indicates that prestressed concrete containment structures. there are various ways (simple but imprecise) of com-bining the losses in prestressing forces, giving a wide The Advisory Committee on Reactor Safeguards band of tolerance in comparing the measured results.

has been consulted concerning this guide and has Such a practice is not acceptable to the NRC staff concurred in the regulatory position. because a real and substantial degradation of the ten-don system may remain undetected.

Any information collection activities mentioned Regulatory Guide 1.35 recommends the compari-in this regulatory guide are contained as requirements son of measured prestressing forces with the predicted in 10 CFR Part 50, which provides the regulatory ba- forces of randomly selected tendons. The predicted sis for this guide. The information collection require- forces at a given time are based on the measurement ments in 10 CFR Part 50 have been cleared under of prestressing forces during installation minus the OMB Clearance No. 3150-0011. losses in the prestressing forces that were predicted to USKNIC IREGUIATORY GUIDES The guides are Issued In the following ten broad divisions:

Regulatory Guides are issued to describe and make available to the pub-Ile methods acceptable to the NRC staff of Implementing specific parts of the Commission's regulations, to delineate techniques used by the 1. Power Reactors 6. Products staff In evaluating specific problems or postulated accidents, or to pro- 2. Research and Test Reactors 7. Transportation vide guidance to applicants. Regulatory Guides are not substitutes for 3. Fuels and Materials Facilities 6. Occupational Heah regulations, and compliance with them Is not required. Methods and 4. Environmental and Siting 9. Antitrust and Financial Review solutions different from those set out In the guides will be acceptable If S. Materials and Plant Protection 10, General they provide a basis for the findings requisite to the Issuance or continu-ance of a permit or license by the Commission. Copies of issued guides may be purchased from the Government Printing This guide was Issued after consideration of comments received from Office at the current GPO price. Information on current GPO prices may the public. Comments and suggestions for Improvements In these be obtained by contacting the Superintendent of Documents, U.S.

guides are encouraged at all times, and guides will be revised, as ap- Government Printing Office, Post Office Box 37082, Washington, DC proprlate, to accommodate comments and to reflect new Information or 20013-7082, telephone (202)275-2060 or (202)275-2171, experience.

Written comments may be submitted to the Regulatory Publications Issued guides may also be purchased from the National Technical Infor-Branch, DFIPS, ADM, U.S. Nuclear Regulatory Commission, Washing- matlon Service on a standing order basis. Details on this service may be ton, DO 20565. obtained by writing NTIS, 5285 Port Royal Road, Springfield, VA 22161.

FM 6.5 Exhibit 3 page 2 of 12 have occurred since that time because of material During an inservice inspection, the liftoff (or and structural characteristics. load cell) measurements are compared against the in-itially measured forces. If the equipment used to As various, complex interacting phenomena are make the measurements during the tensioning opera-involved in the prediction of these losses, the chance tion and during an inservice inspection have identical is small that the measured prestressing force will characteristics, the errors introduced by contributing agree quite closely with the predicted value. Hence, factors such as reading accuracy or friction .in the Regulatory Position 2.2 of this regulatory guide rec- jacking system can be reduced to a minimum. The ommends the determination of limits (upper and objective should be to use well-calibrated, accurate lower) of prestressing force as a function of time. measuring equipment with sufficient sensitivity during Revision 1 of Regulatory Guide 1.90 discusses this as- both construction and inservice inspections to reduce pect briefly, as it is also relevant to the recommended the comparative errors caused by measurement to a inspection alternatives in that guide. negligible amount.

This supplementary guide is intended to clarify 2. DETERMINATION OF PRESTRESSING the NRC staff's position on the construction of toler- LOSSES ance bands for groups and subgroups of tendons so The losses in prestressing force after the applica-that the small-sample inspection program of Regula- tion of the force can be classified as follows:

tory Guide 1.35 can provide better confidence in the integrity of prestressing tendons. The regulatory posi- 1. Initial losses caused by:

tion of this guide recommends the factors to be evalu-ated and a method of using these factors in the con- " Slip at anchorages

" Friction between the tendon and the tendon struction of a tolerance band for a group of tendons duct at areas of contact having approximately the same time-dependent char-

• Elastic shortening and effect of sequence of acteristics. The methods for evaluating the effects of stressing the various tendons.

these factors are discussed in this section of the guide. 2. Time-dependent losses caused by:

The "Code for Concrete Reactor Vessels and 0 Shrinkage of concrete Containments" (Ref. 1) enumerates the factors to be a Creep of concrete considered in determining the effective prestress (see 0 Relaxation of prestressing steel.

Section CC-3542 of Ref. 1). However, it does not 3. Other losses caused by:

provide detailed consideration of these factors.

• Failure of tendon elements from corrosion The methods suggested here are based on a or material deficiency search of relevant literature and on information pro- " Effects of variations in temperature.

vided to the NRC staff by applicants and their con- These losses are discussed in Regulatory Position tractors. However, the listing of references in this 2 together with the methods of determining their guide does not constitute a blanket endorsement of magnitude. Regulatory Position 2 pertains only to the the content of these references by the NRC staff. prestressed concrete containment structures typically used for light-water reactors. For containments that

1. MEASUREMENT OF PRESTRESSING operate at sustained high temperatures, the time-FORCE dependent characteristics need to be evaluated at correspondingly high temperatures.

In general, the requirements of Section CC-4464 of the Code (Ref. 1) are adequate for measuring and C. REGULATORY POSITION verifying the seating force. However, the allowable discrepancy of +/-10% of the force calculated from the The following minimum standards should be fol-measured elongation and that obtained by a dyna- lowed in the design and construction of prestressed mometer or a pressure gauge is excessive. If the load/ concrete containment structures for the inspection elongation curve for the tendon system is based on a programs described in Regulatory Guide 1.35 (Revi-thorough evaluation of the prior tests .using tensioning sion 3).

and measuring equipment similar to that proposed for use in construction, such a high discrepancy level is 1. MEASUREMENT OF PRESTRESSING unwarranted. The NRC staff believes that this dis- FORCE crepancy level should not exceed +/-5%. This recom- The procedure of Code Section CC-4464 (Ref.

mendation is in*agreement with the practice adopted 1) should be followed in measuring loads and exten-by the American Concrete Institute (Ref. 2) and the sions during tensioning, as supplemented by the fol-Post-Tensioning Institute (Ref. 3). lowing:

1.35. 1-2

FM 6.5 Exhibit 3 page 3 of 12 I. A minimum of three readings of loads ai If all tendons in a specific direction (hoop, verti-extensions at approximately equally spaced levels cal, etc.) are prestress'ed simultaneously, the loss of load should be recorded before the final seating prestressing force from elastic shortening (FLES) can the tendon.

be given by:

2. If the discrepancy between the measured e Fo

-J tension at the final seating force and the extensi, FLm. = x EpAp AcnEc + AsE, + ApEp + AIE] + AdEd determined from the average tendon force along t length of a tendon exceeds 5%, the cause of su discrepancy and the corrective actions taken shoiý where be recorded. The extension corresponding to the a erage tendon force may be determined by calculatii F0 is the initial seating force or from a tendon load-extension diagram provided Acn is the net concrete area the tendon manufacturer.

As, Ap, Al, Ad are the areas of reinforcing steel, The objective should be to use well-calibrate prestressing steel, liner, and duct, accurate measuring equipment with sufficient sensit]

respectively ity during both construction and inservice inspectio to reduce the comparative errors caused by measuz Ec, Es, Ep, E1, Ed are the moduli of elasticity of con-ment to a negligible amount.. crete, reinforcing steel, prestres-sing steel, liner, and duct, respec-

2. DETERMINATION OF PRESTRESSING tively.

LOSSES However, the number of tendons to be pre-The following regulatory positions apply only to stressed is large, and the prestressing operation is per-the prestressed concrete containment structures tylpi- formed in a systematic sequence so that the structure cally used for light-water reactors. For containmer its is more or less symmetrically prestressed during the that operate at sustained high temperatures, the tim.e- process. Thus, the first tendons that are tensioned dependent characteristics need to be evaluated at undergo a full loss from the subsequent elastic short-correspondingly high temperatures. ening of the structure, while the tendons that are ten-sioned last undergo almost no loss from elastic short-2.1 Initial Losses ening. For all practical purposes, the loss of prestressing force from elastic shortening can be esti-The initial seating force (F0 ) should be modifiied mated and accounted for by using the following linear

-'* to allow for the following influences: relationship:

1. A known amount of slip at anchorage (if Fn = FLES any) LES N

2. A loss caused by elastic shortening of t]he where N represents the total number of tendons in a structure, including the effects of sequence of particular direction, n represents the sequential num-tensioning by the method discussed here or ber of a randomly selected tendon to be tensioned in by any other appropriate method. that direction, and nr represents the number of ten-

3. Influence of wire breakage during constru 1c- dons to be tensioned after the nth tendon, i.e., nr =

tion. The extent of wire breakage should n ot N-n.

exceed the allowance made in the design. If the sequences of tensioning tendons in differ-Loss from slip at anchorages should be detEer- ent directions are intermingled, the stresses produced mined based on prior experience and the testing hIis- in one direction by the tendons tensioned in the tory of the prestressing system to be used. The influ- other directions must be considered.

ence of slip at anchorages should be allowed for in Thus it is essential that the complete history of the computation of initial prestressing forces. tensioning a tendon be recorded, including its seating Coefficients for determining the losses from friic- force F0 , the number of tendons tensioned before tion should be determined before the start of the in- and after it, and any provision to account for the slip stallation and should be verified and modified (if at anchorages. The modified initial prestressing force necessary) during the construction. In comparing tlhe Fi at the tensioned end can be calculated and re-liftoff (or load cell) forces for ungrouted tendor is, corded as:

friction loss need be considered only for the fixi Fn=n Fn ends of tendons that have been tensioned from oene lg) F i =F 0 LES - FLSA end. For the purposes of inspecting (or monitorin ungrouted tendons, consideration of this loss can 1be where FLSA is the loss of prestressing force due to avoided by comparing forces at tensioned ends. slip at anchorages.

1.35.1-3 S.

FM 6.5 Exhibit 3 page 4 of 12 2.2 Time-Dependent Losses of several plants' indicate that a 40-year shrinkage Limits (high and low) on expected time- value of lO0x 10-B has been used by the applicants.

dependent losses at the end of the service life of the This value, however, needs to be modified to ac-structure (generally 40 years), as well as those at one count for the significantly higher shrinkage in a low-year after prestressing, should be established consid- humidity environment and the significantly lower ering the variations in the following factors: shrinkage in a high-humidity environment. Table 1 provides typical shrinkage values that could be used

1. The extent of shrinkage of the structure con-for computation of prestressing losses caused by tributing to the prestress losses. Table 1 may be used in the absence of specific data. shrinkage.

2. The effect of creep deformation on prestres- 2.2.2 Effect of Concrete Creep sing force. The method given in Appendix A One of the most significant and variable factors of this guide or a similar method may be used in the computation of time-dependent losses in to determine the creep deformation. prestressed concrete containment structures is the in-

3. The effect of relaxation of stress in prestres- fluence of concrete creep. Creep is thought to consist sing tendons. Reference I states that a mini- of two components: basic creep and drying creep.

mum of three 1000-hour relaxation tests Drying creep, also sometimes termed stress-induced should be performed for the prestressing steel shrinkage, is thought to be due to the exchange of proposed for use. moisture between the structure and its environment.

Its characteristics are considered to be similar to those of shrinkage, except that they represent an ad-Table 1. Variation of Shrinkage Strain With ditional moisture movement resulting from the Relative Humidity stressed condition of a structure. The amount of dry-Mean Daily Relative 40-Year Shrinkage Strain 2 ing creep depends mainly on the volume-to-surface ratio of the structure and the mean relative humidity Humidity,' Annual % of the environment. For prestressed concrete con-tainment structures having a volume-to-surface ratio Under 40% 130 x 10-e in excess of 24 in. (60 cm), the relative influence of drying creep (compared to basic creep) is negligible 40 to 80% 100 x 10-e as indicated by Figure 9 of Reference 5.

Above 80% 50 x 10-6 The significant parameters that influence the magnitude of basic creep can be summarized as 1

Mean daily relative humidities for various areas in the U.S. follows:

can be found on Map 46 of Reference 4.

2 1. Concrete mix-cement and aggregate type; These values are applicable to containments in which inside operating temperatures do not exceed 120*F (490C) and that proportion of cement, water, and aggregates; are subject to the ambient outside environment. The maxi- and the influence of admixtures.

mum value of 130 x 10-e may be substantially increased if the con- 2. Age at loading-The basic creep value is a tainment is exposed to a controlled dry high-temperature environment after completion of prestressing. function of the degree of hydration that has taken place at the time of loading.

3. The magnitude of the average sustained 2.2.1 Effect of Shrinkage of Concrete stress.

The schedule of construction of a typical 4. Temperature.

prestressed concrete containment is such that a sub- Almost all investigators support the assumption stantial portion of the expected long-term shrinkage that basic creep varies linearly with the intensity of will have taken place before the structure is pre- sustained stress, as long as the average stress level in stressed. Reference 5 presents formulas for predicting the concrete is not greater than 40% of the ultimate the long-term shrinkage based on the assumption that strength of the concrete. The specific creep is thus the shrinkage approximately follows the laws of diffu- defined as the ratio of total creep to the average sion and supports the formulas by experimental in- stress intensity.

vestigation. An appropriate extrapolation of these formulas (for the volume-to-surface ratio of the struc- A literature review of the effect of temperature ture in excess of 24 in. (60 cm) and the contributing on basic creep (sealed or water-stored concrete speci-shrinkage as that occurring 100 days after the average mens) is compiled in Reference 6. The average tem-time of construction of the structure) would yield a perature of a prestressed concrete containment struc-value of 100 x 10-6, which is considered to be a rea- ture could vary between 40'F (50 C) and 100 0 F sonable value at a temperature of 70 0 F (21 C) and a (38*C). Basic creep is shown to vary linearly with relative humidity of 50%. The safety analysis reports 'Turkey Point, Midland, Bellefonte, Three Mile Island.

1.35.1-4

FM 6.5 Exhibit 3 page 5 of 12 temperature in this range of temperatures. Hence, if construction without need for replacing these wires.

the basic creep is evaluated at approximately 70 0 F7 For a tendon with a few broken wires, care should be (21 0 C), it should represent overall deformation taken not to overstress intact wires to bring the ten-caused by creep of concrete. don force to a prescribed value. Instead, the tendon should be extended to the same level as other similar An acceptable method of determining basic creep at various times for a 'given concrete mix as a tendons (without broken wires). The procedure will leave the tendon at a prestress level lower than the function of age at loading is provided in Appendix A prescribed (generally 70% of the guaranteed ultimate to this guide. The method is.based on concepts and equations derived by Hansen (Ref. 7) from a tensile strength (GUTS)) level. This is acceptable provided the design includes an allowance for the rheological model representing creep of concrete. breakage of wires.

Reference 8 uses the method of Reference 7 in deter-mining long-term creep for a given concrete mix. 2.4 Effects of Variations in Temperature Most investigators agree that there is no one formula that can be generally applicable in determining the Of particular importance for the purpose of com-long-term creep for various concrete mixes. Hence paring the prestress forces is the effect of differences between the average temperature of the structure Appendix A recommends a method of predicting the long-term basic creep from the results of short-term during installation and that during inspections. Local-ized hot spots and temperature variations along the creep tests. Other methods such as those described in References 9, 10, and 11 may be used if demon- length of a tendon can cause variations in the force strated to be appropriate for predicting long-term ba- along the length of the tendon. The differences be-tween the coefficients of expansion or contraction of sic creep.

concrete and steel can also cause modifications of Short-term creep tests are generally performed tendon forces. These effects, as appropriate, should during the construction of a nuclear power plant. The be considered in comparing the measured prestres-extrapolated creep values consistent with the average sing forces with the predicted forces.

time of the loading of the structure may not be avail-able during the preliminary design stages. A conserv- 3. GROUPING OF TENDONS ative estimate of creep values may be obtained from 3.1 Basic Grouping of Tendons previous experience or from creep tests on similar concretes. However, these values should be modified The basic grouping of tendons for the purpose of to estimate the tolerance band for the prestressing developing tolerance bands should consider:

force to be used for comparison of the measured pre- 1. The geometric configuration of tendons with stressing forces during inservice inspections. The respect to the structure, e.g., vertical, hoop, modifications should include the extrapolated creep dome, inverted U, and values in light of the actual average age of the con- 2. The similarity in time-dependent characteris-crete at the time the containment is prestressed. tics. This may involve dividing the above con-figuration group (e.g-., vertical, hoop, dome, 2.2.3 Effect of Relaxation of Prestressing and inverted U) into additional groups.

Steel The significant Variable affecting the time-The stress relaxation properties of prestressing dependent prestressing force of tendons would be the steel vary with its chemical composition and thermal/ effect of concrete creep. If the concrete mix charac-mechanical treatment. Manufacturers should be able teristics and the curing conditions are assumed to be to provide data on the long-term loss in prestressing about the same during the entire period of construc-steel stress from pure relaxation. Section CC-2424 of tion of a containment structure, the parameters intro-Reference 1 requires a minimum of three 1000-hour ducing variations in. creep are (1) average compres-relaxation tests for the prestressing steel proposed for sive stress and (2) age of concrete at the time of use. There should be a sufficient number. of data prestressing. For example, in a shallow-dome con-points in each of the three tests to extrapolate the tainmenit structure, if the design requires that the 1000-hour pure relaxation data to the life of the meridional compressive stresses in the cylinder be structure. An appropriate model (Refs. 12, 13, 14) half those in the hoop direction, the creep strains should be selected for the determination of the 'best- affecting the losses in prestressing would be propor-fitting" line for the purpose of extrapolation. tional to their compressive stresses. Similarly, at the time of prestressing, the dome concrete might have 2.3 Losses Caused by Tendon Degradation aged three months, while the cylinder concrete might Most applicants make allowance for breakage of have aged six months or more. These parameters wires on an overall basis as well as on a localized ba- would affect the losses in prestressing forces in sis. Such an allowance in the design of the contain- tendons and should be considered in grouping

~-ment would allow a breakage of a few wires during the tendons according to the similarity of their 35.1-5

FM 6.5 Exhibit 3 page 6 of 12 time-dependent characteristics and in prescribing the The first inservice inspection needs to be per-tolerance band for prestressing forces in these formed one year after the Initial Structural Integrity tendons. Testing (ISIT) of the containment. Hence, the period of interest from the point of view of inservice inspec-3.2 Subgroups of Tendons tion is nominally between 1 year and 40 years after The basic groups may be divided further into prestressing.

subgroups to account for the differences in instanta- The upper and lower bounds for prestressing neous elastic shortening during the transfer of pre- forces at 1 year and 40 years after prestressing can be stressing force and to account for the differences in found by adding up the low and high losses and sub-initial prestressing forces (Fi) caused by differences tracting them from Fi. For the purpose of construct-in instantaneous elastic shortening during transfer. To ing tolerance bands for various groups of tendons, it account for the differences in initial prestressing is sufficiently accurate to consider prestressing force forces Fi, a tabulation of Fi for each tendon in a to vary linearly with the logarithm of time.

group may serve the same purpose as subgrouping.

In lieu of the variations indicated above, the de-In short, the intent of any adopted procedure signer may use the conservatively estimated design should be to track the individual prestressing forces values as the base values for the time-dependent fac-as precisely as possible with the current state of the tors. In that case, the individual predicted tendon art in predicting these forces, so that when a tendon prestressing force at 1 year and 40 years can be de-is selected randomly during an inspection its meas- termined using the base value as illustrated in Appen-ured values can be compared with its prescribed tol- dix B. The line drawn using these values should be erance band. considered as the lower bound. The upper bound can be arbitrarily drawn by plotting a line parallel to the

4. CONSTRUCTION OF TOLERANCE BANDS lower bound and starting at 0.93F1 i at 1 year. This Tolerance bands for groups and subgroups of method can be used for the operating plants.

tendons should be constructed and should be used for comparison of measured prestressing forces with The upper line of the tolerance band is not criti-the forces predicted for the time of inspection. cal from a safety point of view. However, this line allows the designer to establish a maximum variation It is recognized that each of the factors affecting line. If the prestressing of a tendon lies above this the time-dependent characteristics of tendon forces line, it is prudent to investigate the measurement are subject to variations. To account for these vari- technique and the pattern of losses in adjoining ations in prescribing the tolerance band, the following tendons.

method is recommended:

1. Determine Shrinkage. Table 1 provides the D. IMPLEMENTATION 40-year shrinkage strains in relation to the humidity level at the location of the structure. To allow for the The purpose of this section is to provide informa-associated uncertainty in the assumed values, strain tion to applicants and licensees regarding the NRC should be varied by +/-20%. The shrinkage strains at staff's plans for using this regulatory guide.

any time between the time of prestressing (consider Except in those cases in which the applicant or zero shrinkage at t = 10 days) and 40 years can be estimated by considering shrinkage strain to vary line- licensee proposes an acceptable alternative method arly with the logarithm of time. for complying with specified portions of the Commis-sion's regulation, the methods described herein will

2. Determine Creep. The creep strains at any be used in the evaluation of inservice inspection and time after prestressing can be determined by the surveillance programs for the following nuclear power method of Appendix A. The high and low creep plants using prestressed concrete containments with strains can be determined by increasing the extrapo-lated creep values by 25% and decreasing them by ungrouted tendons:

15%, respectively (see Appendix B for illustrative ex- 1. Plants for which the construction permit or ample). design approval is issued after July 31, 1990.

3. Determine Relaxation of Prestressing Steel.

Provide a +/-15% variation in relaxation values ob- 2. Plants for which the licensee voluntarily commits tained by extrapolation of 1000-hour tests. to the provisions of this guide.

1.35.1-6

FM 6.5 Exhibit 3 pg page 7 off112 APPENDIX A DETERMINATION OF BASIC CREEP STRAINS FOR PRESTRESSED CONCRETE CONTAINMENT STRUCTURES Recommended creep formula t on a semi-logarithmic paper (see Figure 1). The value of B would essentially remain the same for all values of to. The value of A for various values of to

+

+Bloglo- can be determined as shown in Figure 1. For to val-ues greater than 365 days, the A value determined at where 365 days should be used.

t = time (after average time of concrete The short-term creep tests should be performed placement) when creep value is desired, according to the test method of Reference 15. To in days make the creep test results representative of creep deformations in a containment structure, the refer-to = time of loading after average time of con- enced test method should be used with the following crete placement, in days specific provisions:

=c average sustained concrete stress a. Section 3.1: The length of specimens should be 16 +/- 1/16 in. (40 +/- 0.16 cm).

Ecc creep strain at time t when the age of concrete at loading is to b. Section 3.2: The concrete mix should be the same as that proposed for use in the construction of A,B are constants to be determined from the containment.

tests.

c. Section 3.3: Companion identical specimens To determine the value of constants A and B, corresponding to each to may be used to observe the the following 'short-term creep tests are recom- deformations of unloaded specimens.

mended:

d. Section 4.2: Mass curing (sealed specimen)

Age at loading Minimum Observations at conditions should be used during storage and testing.

(The method used for the "as cast" condition in Ref-erence 16 is a good example.)

30 30 31 45 90 150 210

e. Section 5. 1: Load the specimens to maintain 90 90 92 110 150 210 270 a sustained stress of 30% of the design compressive 180 180 185 210 240 300 360 strength of concrete.

f. Section 6. 1: Subtract the instantaneous elas-The constants A and B should be determined tic strain taken at time to and the strain on the un-from creep strains at tj ,t 2 ,, t3, t4, and t5 for each to loaded specimen from the subsequent total strain by plotting the measured specific creep (cc) against measurements to arrive at creep strain (ce).

fc 1.35. 1-7

FM 6.5 Exhibit 3 page 8 of 12 0.4 (2.73) 0.3 (2.05) 0.2 (1.37)

.5 00 0.1 (0.68) B A

10 100 1000 10000 t (indays) 40 years Figure 1. Specific Creep Curves Note: The creep curves are plotted from actual short-term creep test data - Communication from J.F. Fulton, Gilbert/Commonwealth Associates.

( (

FM 6.5 Exhibit 3 page 9 of 12 APPENDIX B CONSTRUCTION OF TOLERANCE BAND (EXAMPLE)

Consider the following values for time-dependent influences:

Time-Dependent Base Value at 1 Year 40 Years Factors 40 Years High Low High Low Shrinkage (Cc) at 70% Relative Humidity x 108 100 72 50 120 80 Variation: +/-20%

Creep - x 106 for to = 180 days per psi 0.3 0.193 0.073 0.375 0.255 per kPa 2.05 1.32 0.50 2.56 1.75 Variation: +25%

-15%

Stress Relaxation of Prestressing Steel in % of Fj 7 5.8 4.2 8.1 5.9 Variation: +/-15%

Prestressing Losses in % of Fi Assume Bps = 28 x 103 ksi (193 x 103 MPa) fps = 168 ksi (i.158 x 103 MPa)

Shrinkage EsxEpsxl100 1.7 1.2 0.8 2.0 1.3 fps Creep for fc = 1500 psi (10350 kPa)

Ec Eps x fc x x 100 7.5 4.8 1.8 9.4 6.4 fps Stress Relaxation of Prestressing Steel 7 5.8 4.2 8.1 5.9 Total Losses 16.2 11.8 6.8 19.5 13.6 Remaining Prestressng Force in Tendon' 0.84 Fi 0.88 Fi 0.93 Fi 0.8 Fj 0.86 Fi 1

These values are used for constructing the tolerance band in Figure' .

1.35.1-9

FM 6.5 Exhibit 3 page 10 of 12 Fi - Initial Prestressing Force at an Anchorage Considering Losses Due to Anchorage Takeup, Instantaneous Elastic Shortening, and Friction FI Predicted Prestressing Force Considering High Time-Dependent Losses Predicted Prestressing Force Considering Low Time-Dependent Losses 0.9Fi U)

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FM 6.5 Exhibit 3 page 11 of 12 REFERENCES

1. American Concrete Institute and American So- Journal of the Engineering Mechanics Division ciety of Mechanical Engineers Subcommittee on of the American Society of Civil Engineers, De-Nuclear Power, "Code for Concrete Reactor cember 1977.

Vessels and Containments," ACI-359, 1986.

11. J. W. Chaung, T. W. Kennedy, E. S. Perry,

2. American Concrete Institute, "Building Code "An Approach to Estimating Long-Term Multi-Requirements for Reinforced Concrete," axial Creep Behavior from Short-Term Uniaxial ACI-318, Revised periodically. Creep Results," Union Carbide Report #2864-3, TID 25795, Department of Civil Engineering,

3. Post-Tensioning Institute, "Post-Tensioning University of Texas at Austin, June 1970.5 Manual," Phoenix, AZ, 1986.1

4. J. L. Baldwin, "Climates of the United States," 12. D. D. Magura, M. A. Sozen, C. P. Siess, "A U.S. Department of Commerce, Washington, Study of Stress Relaxation in Prestressing Rein-DC, December 1974.2 forcement," Prestressed Concrete Institute Journal, April 1964.

5. T. C. Hansen, A. H. Mattock, "Influence of Size and Shape of Member on the Shrinkage 13. T. Cahill, C. D. Branch, "Long-Term Relaxa-and Creep of Concrete," Journal of the Ameri- tion Behavior of Stabilized Prestressing Wires can Concrete Institute, Proceedings Vol. 63, and Strands," Group D, Paper 19 of Conference February 1966. Also published as PCA Develop- Papers on Prestressed Concrete Pressure Ves-ment Bulletin D103. sels, The Institution of Civil Engineers, 1968.6

6. H. G. Geymayer, "Effect of Temperature on

14. R. J. Batal, T. Huang, "Relaxation Losses in Creep of Concrete, A Literature Review," Paper Stress-Relieved Special Grade Prestressing 31 of ACI SP-34, "Concrete for Nuclear Reac-Strands," Fritz Engineering Laboratory, Report tors," Vol. 1, American Concrete Institute, No. FEL-339.5, NTIS PB200668, April.1971. 6 1972.

7. T. C. Hansen, "Creep and Stress Relaxation of 15. American Society for Testing and Materials, Concrete," Swedish Cement and Concrete Re- "Standard Test Method for Creep of Concrete search Institute, Stockholm, 1960.3 in Compression," ANSI/ASTM C512-76, 1976.

8. "Report on Recommended Concrete Creep and 16. A. Hijazi, T. W. Kennedy, "Creep Recovery of Shrinkage Values for Computing Prestressing Concrete Subjected to Multiaxial Compressive Losses," by Schupack and Associates. This non- Stresses and Elevated Temperatures," Research proprietary report is filed in the NRC Public Report 3661-1, TID-26102, Department of Document Room as Appendix 5J in Amend- Civil Engineering, The University of Texas at ment 2 of the "Preliminary Safety Analysis Re- Austin, March 1972.6 port for the Three Mile Island Nuclear Power Station, Unit 2," June 1968, Docket No. 'Co ie may be obtained from the Post-Tensioning Institute, 301 50-320.4 West &born, Suite 3500, Phoenix, AZ 85013.

2 Copies may be obtained from the Superintendent of Documents, U.S.

5 Government Printing Office, Washington, DC 20013.

9. 1. J. Jordann, C. L. England, M. M. A. Khalifa, Copies in English may be obtained from the Swedish Cement and "Creep of Concrete: A Consistent Engineering Concrete Research Institute, Royal Institute of Technology, Stock-holm, Sweden.

Approach," Journal of the Structural Division 4A copy may be obtained from the Public Document Room, U.S.

of. the American Society of Civil Engineers, Nuclear Regulatory Commission, 2120 L Street, NW., Washington, DC.

March 1977. SCopies may be obtained from the National Technical Information service, Springfield, Virginia 22161.

10. E. Cinlar, Z. P. Bazant, E. Osman, "Stochastic eCopies may be obtained from The Institution of Civil Engineers, Thomas Telford Ltd., 26-34 Old Street, London, ECIV, 9AD, Process for Extrapolating Concrete Creep," England, 1.35.1-11

FM 6.5 Exhibit 3 page 12 of 12 VALUE/IMPACT STATEMENT A draft value/impact statement was published guide has not been prepared. A copy of the draft with the draft of Regulatory Guide 1.35.1 (Task SC value/impact statement is available for inspection and 807-4) when the draft guide was published for public copying for a fee at the Commission's Public Docu-comment in April 1979. No changes were necessary, ment Room at 2120 L Street NW., Washington, DC, so a separate value/impact statement for the final under Task SC 807-4.

UNITED STATES FIRr LAS AIL1 NUCLEAR REGULATORY COMMISSION POSTAGES& FES PAID 1 USNRC 1 WASHINGTON, D.C. 20555

[ ERrr010.0 j OFFICIAL BUSINESS PENALTY FOR PRIVATE USE. $300 1.35.1-12

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FM 6.5 Exhibit 4 n~nnp.19 nf 'I Florida DESIGN ANALYSISICALCULATION Power Crystal River Unit 3 CoPK Page F1 DMCUMFT lDDMFFA'I0N NO. tREVtON Calculation S-95-0082 ATTACHMENT F WIRE STRESS RELAXATION REFERENCE DATA NOTE:

The following data was extracted from the Reference 10 and 1I calculations and included herein for reference.

fi~95 RET: Ldsof PlaN RESP Nuclear Ergmne.nng "S9 RET: Life of Plant RESP'.Nuleatr Erlineenng

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TELEPHONE AND CONFERENCE MEMORANDUM DATE January 18, 1980 BY: G. T.

_____________________________ DeMoss 04 4762-099 WORK ORDER NO._________

TELEPHONE CALLCE CONFERENCE E WITH:* Mr. Earl Cutler COMPANY Prescon Corporation, San Antonio, Texas Tel. 512-828-6264 SUBJECT : Prestress wire relaxation for CR #3 containment NOTES:

I asked Mr. Cutler several questions regarding prestress wire relaxation. The questions and his answers are as follows:

1. Qt-. The curves in the CR #3 FSAR (Figure 5-23) show the 40 year relaxation for the Shinko wire used in CR #3 to be about 1. 1!.

I asked if this appeared to be reasonable.

At Mr. Cutler feels the numbers reflect the average values of the tests, but feels that to be conservative, the curve should be shifted upward so that the 40 year period would give about 2.0%

relaxation.

2. Q: Since the interior of the containment building normally operates above 1000 F, and the structure is exposed to the Florida sunshine on the outside, I asked if we should not be assuming a higher temperature for the wire than the 200 C (680 F) on which the curve in the FSAR is based.

Copies. To:

FM 6.5 Exhibit 4 page 38 of*§ 0

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A: Mr. Cutler stated, that the selection of temperature criteria is not a Prescon responsibility but, if we wanted to use a higher lifttime temperature, the current Shinko catalog also gives a curve for 400 C (1040 F). This curve roughly parallels the 200 C curve. At 1000 hours0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> the 200 C curve indicates .75%

relaxation, while the 400 C curve indicates about 1.1 2.

3. Q: I asked Mr. Cutler if the wire used was considered as "stress-relieved" or "stabilized".

A: He replied that it was "stabilized".

4. Q: I noted that the left hand scale on the curve in the CR #3 FSAR (Figure 5-23) indicates "Relaxation-Loss % G.U.T.S.",

while the curves in the Shinko catalog indicate,for the same scale, "Relaxation-Loss in Per Cant". I asked Mr. Cutler if he felt our labelling was in error and what the relaxation was a percent of.

A: He replied that the percentages were given as a percent loss of original stressing value, which in our case is 70% G.U.T.S.

He said that our labelling appeared to be inaccurate.

Mr. Cutler agreed to send a copy of the more recent Shinko tables or catalog to me for our reference.

cc: J. Fulton J. Herr K. Nodland R. Eshbach F. Moreadith

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