ML102870910
| ML102870910 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 01/16/2010 |
| From: | Chris Miller Progress Energy Co |
| To: | Robert Carrion, Lake L, George Thomas Office of New Reactors, NRC/RGN-II |
| References | |
| FOIA/PA-2010-0116 | |
| Download: ML102870910 (33) | |
Text
Sengupta, Abhijit From:
Sent:
To:
Cc:
Subject:
Attachments:
Miller, Craig L [Craig.Miller@pgnmail.com]
Saturday, January 16, 2010 12:53 PM Portmann, Rick; Lake, Louis; Thomas, George; Ghosal, Partha S.; Carrion, Robert;
'nausdj@ornl.gov' -
Williams, Charles R.
-- Ic' f$,
Failure Mode 6.2 for Review and omment/
I xhbi "W
FM 6.2.pdf; FM 6:2-Exhibit 1 Suksectio,ýn L.pdf; FM 6.2 Exhibit 2 Wire Mate, rcI from
,o, DBD1 1-2-'1.pdf; FM 6.2 Exhibit 3 Strairfalong Wire.pdf; FM 6.2 Exhibit 3-Strafinalong XpO,& Wire.pdf; FM 6.2 Exhibit 4 Wire Surveij lances.pdf; FM 6.2 Exhibit 5 Wire Testing-i.pdf; FM 6.2 Exhibit 6 atlas 947613_0001.pdf I 1
k,I e&V-10 P r-t" Mr. Lake and others, Attached for your review is the draftof FM 6.2 and its exhibits. If you have any questions, please contact Charles Williams or myself.
Thank you, Craig Miller I
FM 6.2 Exhibit 1 Page 1 of 14 IWL-1000 IWL-l100 JWL-l 200 IWL-l 210 IWL-1220 IWL-2000 IWL.-2 100 IWL-2200 IWL-2210, IWL-2220 IWIL-2220. 1 IWL-2220.2 IWL-2230 IWL,-2300 IWL-23 10 lWL-12320 IWL-2400 IWL-2410 IWL-2420 IWL-2421 IWL-21500 IWL-2510 IWL-2520 IWL-2521 IWL-252 1.1 IWL-2522 IWL-2523 I.WL-2523. I IWL,-2523.2 IWL-72523.3 IWL-2524 I WL-2524. I JWL-2524.2 IWL-2525 IWL-2525. I IWL-2525.2 IWL-2526 SUBSECTION IWL REQUIREMENTS FOR CLASS CC CONCRETE COMPONENTS OF LIGHT-WATER COOLED PLANTS Scope and Responsibility..................................................
Scope...................
Items Subject to Examination..............................................
Examination Requirements Items.Exempt From Examination...........................................
Examination and Inspection......................
Inspection Preservice Exam ination Exam ination Schedule Examination Requirements C oncrete Unbonded Post-Tensioning Systems.........................................
Preservice Examination of Repairs and Modifications.......................
Visual Examination, Personnel Qualification, and Responsible Engineer..........
Visual Examination and Personnel Qualification Responsible Engineer Inservice Inspection Schedule..............................................
Concrete Unbonded Post-Tensioning Systems.........
Sites With Two Plants Examination Requirements.................................................
Examination of Concrete..................................................
Examination of Unbonded Post-Tensioning Systems...........................
Tendon Selection.............
Exemptions................
Tendon Force Measurements...............................................
Tendon Wire and Strand Sample Examination and Testing...................
Tendon Detensioning and Sample Removal Sample Examination and Testing...........................................
Retensioning............................................................
Examination of Tendon Anchorage Areas....................................
Visual Exam ination..............................................
Free Water Documentation Examination of Corrosion Protection Medium and Free Water..................
Sam ples....................................
Sam ple A nalysis..........................................
Removal and Replacement of Corrosion Protection Medium....................
251 251 251 251 251 252 252 252 252 252 252 252 252 252 252 252.1 252.1 252.1 252.1 253 253 253.
253 253 253 255 255 255 255 255 255 255 255 255 255 256 256 249 A92
FM 6.2 Exhibit 1 Page 2 of 14 IWL-3000 1 WL-3 100 IWL-3,1 10 IIWL-3 I I I IWL-31-12
.IWL-3.1 3 IWL-31 20
.IWL-3200 IWL-3210 IWL-32111 JWL-3212
'IWL-321 3 IWL-32.20 IWL-322 I
.IWL.322.I IWL-3221 IWL-3221 JWL-3221
[WL.-3222 IWL-3223 IWL-.3300
.IWL-3310 IWL-3320 IWL-4000 rWL-41 00 IWL-41 10 IWL-4120 IWL-,4200
.IWL-4.210 IWL-4220 JWL-4230 IWL-4-300 IWL-5000 IWL-5 100 IWL-5200 IWL-5210 IWL-5220 IWL-5230 IWL-5240 IWL-5250 IWL-5260 IWL-5300 IWI-7000ý MWL7.100 IWL-71 10 TWL-71 20 Tables MW-250J0-1[
IWL-252]- I IWL-27525-I Acceptance Standards...................................
25 Preservice Examination..
25 Concrete Surface Condition...........................................
25 Acceptance by Examination...............................................
25 Acceptance by Evaluation.....................................
25" Acceptance by Repair.......................................
25*
Unbonded Post-Tensioning System...........................................
25" Inservice Examination....................................................
25.
Concrete Surface Condition................................................
25' Acceptance by Examination.....................................
.25 Acceptance by Evaluation.............................................
25*
Acceptance by Repair....................................................
25 Unbonded Post-Tensioning Systems..........................................
251 Acceptance by Examination 25Y
.1 Tendon Force..............................................................
257
.2 Tendon Wire or Strand Samples 257
.3 Tendon Anchorage Areas..............................................
258
.4 Corrosion Protection Medium...........................................
258 Acceptance by Evaluation..................................................
258 Acceptance by Repair or Replacement 258 Evaluation 258 Evaluation Report........................................................
258 Review by Authorities..................................................
258 Repair Procedures...................
259 General 25.
scope 259 Repair/Replacement Program...............................................
259 Repair Plan..............................................................
259 Concrete Repair............................................................
259 Repair of Reinforcing Steel 259 Repair of the Post-Tensioning System.......................................
259 Exam ination 259 System Pressure Tests..........
260 Scope................................
260 System Test Requirements
.260 G eneral...............
260 Test Pressure..
260 Leakage Test...........................................
260 Schedule of Pressure Test.....................
260 Test Procedure and Examinations........................
260 Corrective Measures..........................................
260 Report..................
260 Replacements........................................................
261 General Requirements 261 Scope..............
261 Replacement Program 261 Examination Categories.......................................
.254 Nunbe-r of Tendons ibr Examination 255 S
Corrs*ion Protection Medium Analysis.................
256 7
7 7
7 7
7 7
7 7
7 7
PA(2 2_5{
FM 6.2 Exhibit 1 Page 3 of 14 ARTICLE IWL-1000 SCOPE AND RESPONSIBILITY IWL-1100 SCOPE (a) This Subsection provides the rules and require-ments for preservice examination, inservice inspection and repair of the reinforced concrete and the post-tensioning systems of Class CC components, herein re-ferred to as concrete containments as defined byCC-1000.
(b) The rules and requirements of this Subsection do not apply to the following:
(1) steel portions not backed by concrete; (2) shell metallic liners; (3) penetration liners extending the containment liner through the surrounding shell concrete.
IWL-1200 ITEMS SUBJECT TO EXAMINATION IWL-1210 EXAMINATION REQUIREMENTS The examination requirements of this Subsection shall apply to,concrete containments.
IWL-1220 ITEMS EXEMPT FROM EXAMINATION The following items are exempt from the examina-tion requirements of IWL-2000:
(a) tendon end anchorages that are inaccessible, sub-ject to the requirements of IWL-252 1.1I
"(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.
251
FM 6.2 Exhibit 1 Page 4 of 14 ARTICLE IWL-2000 EXAMINATION AND INSPECTION IWL-2100 INSPECTION Examinations shall be verified by an Inspector.
IWL-2200 PRESERVICE EXAMINATION Preservice examination shall be performed in accor-danee with the requirements of IWL-2500.
IWL-2210 EXAMINATION SCHEDULE Preservice examination shall be completed prior to initial plant startup.
IWL-2220 EXAMINATION REQUIREMENTS IWL-2220.1 Concrete (a) Preservice examination shall be performed in ac-
- i.cordance with IWL-2510.
(b) The preservice examination shall be performed following completion of the containment Structural In-tegrity Test.
.IWL-2220.2 Unbonded Post-Tensioning Systems.
Thefollowing information shall be documented in the preservice examination records. This information may be;:extracted from construction records.
(a) Date on which each tendon was tensioned.
"(b) Initial seating. force in each tendon.
(c) For each tendon anchorage, the location of all missing or broken wires or stands and unseated wires.
(d) For each tendon anchorage, the location of all missing or detached buttonheads or missing wedges.
(e) The product designation for the corrosion pro-tection medium used to fill the tendon duct.
IWL-2230 PRESERVICE EXAMINATION OF (a).When REPAIRS AND MODIFICATIONS (a) When a concrete containment or a portion there-of is repaired or modified during the service lifetime of a plant, the preservice examination requirements shall be met for the repair or modification.
(b) When the repair or modification is performed while the plant is not in service, the preservice ex-amination shall be performed prior to resumption of service.
(c) When the repair or modification is performed while the plant is in service, the preservice examination may be deferred to the next scheduled outage.
IWL-2300 VISUAL EXAMINATION, PERSONNEL QUALIFICATION, AND RESPONSIBLE ENGINEER IWL-2310 VISUAL EXAMINATION AND PERSONNEL QUALIFICATION (a) VT-IC visual examinations are conducted to de-termine concrete deterioration and distress for suspect areas detected by VT-3C, and conditions (e.g., cracks, wear, or corrosion) of tendon anchorage and wires or strands. Minimum illumination, maximum direct ex-amination distance, and maximum procedure demon-stration lower case character height shall be as speci-fied in IWA-2210 for VT-1 visual examination.
(b) VT-3C visual examinations are conducted to de-termine the general structural condition of concrete sur-faces of containments by identifying areas of concrete deterioration and distress, such as defined in ACI 201.1 R-68. The minimum illumination, maximum direct ex-amination distance, and maximum procedure demon-stration lower case character height shall be as speci-fied in IWA-2210 for VT-3 visual examination.
(c) The Owner's written practice shall define qual-ification requirements for concrete examination person-nel in accordance with IWA-2300. Limited certification in accordance with IWA-2350 may be used for ex-aminers limited to concrete.
A92 252
FM 6.2 Exhibit 1 Page 5 of 14 IWL-2320 REQUIREMENTS FOR CLASS CC COMPONENTS IWL-2420 IWL-2320 RESPONSIBLE ENGINEER The Responsible Engineer shall be a Registered Professional Engineer experienced in evaluating the in-service condition of structural concrete. The Respon-sible Engineer shall have knowledge of the design and Construction Codes and other criteria used in design and construction of concrete containments in nuclear power plants.
The Responsible Engineer shall be responsible for the following:
(a) development of plans and procedures for ex-amination of concrete surfaces; (b) approval, instruction, and training of concrete 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-2400 INSERVICE INSPECTION SCHEDULE IWL-2410 CONCRETE (a) Concrete shall be examined in accordance with
'IWL-2510 at 1, 3, and 5 years following the comple-tion of the containment Structural Integrity Test CC-6000 and every 5 years thereafter-(b) The 1, 3, and 5 year examinations shall com-mence not more than 6 months prior to the specified dates and shall be completed not more than 6 months after such dates. If plant operating conditions are such that examination of portions of the concrete cannot be completed within this stated time interval, examination of those portions may be deferred until the next reg-ularly scheduled plant outage.
(c) The 10 year and subsequent examinations shall commence not more than 1 year prior to the specified dates and shall be completed not more than 1 year after such dates.
IWL-2420 UNBONDED POST-TENSIONING SYSTEMS (a) Unbonded post-tensioning systems shall be ex-amined in accordance with IWL-2520 at 1, 3, and 5 years following the completion of the containment Structural Integrity Test and every 5 years thereafter.
(b) The 1, 3, and 5 year examinations shall corn-252.1
FM 6.2 Exhibit 1 Page6
- of.4
[WL-2420:-
REQUIREMENTS FOR CLASS CC COMPONENTSIW-5L mence not mor than 6 months prior to the specified 201.1 R-68, in accordance with IWL-2310"). Selected dates. and- 'shall.be completed not more than 6 months areas, such 'as those that indicate suspect conditions, a4ter suciih.daites"'.1 lfplant operating conditions are such shallI receive aVT-IC examination in accordance with
- thateaikino portions of tlhe post-tensioning sys-JWL-2310(d).
ltern canno be' copeed within this' stated time inter-(b): The" ex)ianunation shall be petforined by, or under,,
val, examinati,on" of those, portions may be d efertred the direction of,Lýthe Responsible Enginieer.
until th etrglarly scheduled plant outage-st (c
isll examinain ayb efondfo (C.
.e It0 year ýand susequent examinations shal floors roofs platformns,'walkways, ladders, ground
-. commnence not-more than* 1, year prior ;to, the specified' surface', or other pem nennt vantage points, unless tem-'
-- dates-and shall be completed not more than I year after porary close-in ac Icess. is required by, the in~sp-ection
. uch.date...an
[1WL-242 11, Sites, With, Two Plants,,.-
(a) For, sites with two plants,. the examination re-,
quirenients f r the cfiicrete' containments ma~y be ~mod-A92 ified if both coitainents utilize the same prestressing system 'and' are essentially, identical in design', it' post-IL ensioning. operations. -for~ the ~two containments were250EXMNTO'OFU ODE) completed not Tnior' tihan 2 years apart, and if-both.,
.PS~ENINN YTM containments are simfilarly exposed to'or pr-otected fromi W-51'eno eeto the' outside e vironinet' WL22 TndnSltin (b)W~i~i~thc(
diins of I W1-2421 (a), are,, m et, (a) Tendonis to. tiexatruned dni niseto~
the inspectin'dates and&examination requirements, ma~y shall' be,selected-on A mandom-basis excepit'as noted in be'as follows.'
IWL 2521(b)iiiid.(4 Th population front. which, the (1)'For'the: containment With the first, Structuiral random Sample' is drawn Shall consist of all tendonis Integrity Test, all,'ex~aninations required by, IWL-2500-.
whih K;ha'ye:not benexamiineddurirg, earliri' shall be performed a'.3, 10, '20, and 30 yetars_ýOnly tiofls.,1'he number of tednvto, be, examine diiirng\\,
'the exainin~itions' required'by IWL-2524 and IWL-2525 an ins pection shall be asýspecified i Table 1WU2521 I need be perfor med it'5, 15,1 25, a nd 35' years..
(bi) One tendon of.,each type.-(as definied ' iniTable.,,
7 (2) For the, containment Iwith the secoind Structur~al 1Wli,2521-01) shall be' selected froni the firsti'year-Jl" Entegrity, Test, 'all examninations required, by IWL-2500) specti'on Sam cp. and designated. as acommnon iteiidon.
shall be ptm6ribrnd' at L<'5, 45, 25, anid 35 years'. Only, Ech, commnoni tendon, shafl, be, examinied during ~each the examinations requited by 1WL-~2524 and IWL-2525
'fispection.
A commnoni tendonwshall. not be detetiSioned,
'need be performed at 3,.10, 20, and 30 ye'ars,>'.
unless required by IWLI.3300. If a comimon tendon is detesioned,
)nther comrn on~tendon of the same type (c) if aa contai-inenuwith a, stranded S~ystem' 'is consttucted ~withi 'a:prtxtesignated number of.
detensionable
- tedonti one tendon,of e ypeshA be selectwd from amnong thos'e.which are deternsion~able IWL-200 EAMIN TIONtbe remaining ziendons' shali' be' selected from aliong REUIEMNT those which canno(
detensioni~d.,
Examination shall be performed in accordance wth W-5 xmtos h
olwn ewe
.. :. '::+. -nthe realquirents o,0f oTable:
I..-'
s.;.-y-tendon, anchorageS bat are. not..
'-- -'accessibler for examnination becaduse of sfety (w radio--
logicail hazards or because' of structural obstCiiicMoS.
A92 [WL251 EX MINTIO OFCONRET to(4) After the process of randomly selecing tendons tobe e xamined,, any. incessible tendons shall be des-(1 Cncet srfceareas, including coated areas, ignated a's exempt 'antd.removed from the sample.,
e iepitoseiexemted by BWL-1200(), shall be, VT-(b) Substitute" tenon shatll be Selected for all -ten-tCviual: exaimined :for ýevidence of 'conditions indic-dons designated as exempt. Each Substitute tendon -shall ative of damnage or degradation, such as defined in ACI he selected so that it is located as close as possible to
- ..3
'-1
-n M
A92 TABLE IWL-2500-1 EXAMINATION CATEGORIES.
EXAMINATION.CATEGORY L-A, CONCRETE Item Test or Examination Test or Examination Acceptance Extent Frequency Deferral No.
Parts Examined Requirement Method Standard of Examination of Exapination of Examination L1.10 Concrete Surface L1.11 All Areas IWL-2510 Visual, VT-3C IWL-3210 IWL-2510 IWL-2410 NA L1-2 Suspect Areas IWL-2510 Visual, VT-,iC
.,IWL-3210 IWL-2510*
IWL-2410 NA 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 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
[WL-3221.2 IWL-2523,1 IWL-2420 NA L2.30 Anchorage Hardware and Surrounding IWL-2524 Visual, VT-1 IWL-3221.3 IWL-2524.i 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 Ci, 0z 0
z
-U (D
CD 0
FM 6.2 Exhibit 1 IWL-2521.1 Page 8 of 14 REQUIREMENTS FOR CLASS CC COMPONENTS IWL-2525.1 TABLE IWL-2521-1 NUMBER OF TENDONS FOR EXAMINATION Required Maximum Percentage1.2 Minimum1 Required Inspection of all Tendons Number of Number of Period of Each Type' Each Type Each Type 1st year 4
4 10 3rd year 4
4 10 5th year 4
4 10 1Oth year 2
3 5
15th year 2
3 5
20th year 2
3 5
25th year 2
3 5
30th year 2
3 5
35th year 2
3 5
NOTES:
(1) Fractional tendon numbers shall be rounded to the next higher integer. Actual number examined shall not be less than the minimum required number and need not be more than the maximum required number.
(2) The reduced sample size listed for the 10th year and subsequent inspections Is applicable only if the acceptance criteria of IWL-3221.1 are met during each of the earlier inspections.
(3) A tendon type is defined by its geometry and position in the containment; e.g., hoop, vertical, dome, helical, and inverted U.
,the exempted tendon, and shall be examined in ac-
.'ordance with IWL-2520.
(c) Each exempted tendon shall be examined in ac-cordance with IWL-2524 and IWL-2525 to the extent that the end anchorages of the exempt tendon are ac-cessible either during operation or at an outage.
IWL-2522 Tendon Force Measurements (a) The prestressing force in all inspection sample tendons shall be measured by lift-off or an equivalent test.
(b) Equipment used to measure tendon force shall be calibrated in accordance with a calibration procedure prior to the first tendon force measurement and fol-lowing the final tendon force measurement of the in-spection period. Accuracy of the calibration shall be within 1.5% of the specified minimum ultimate strength of the tendon. If the post-test calibration differs from the pretest calibration by more than the specified ac-curacy tolerance, the results of the examination shall be evaluated.
IWL-2523 Tendon Wire and Strand Sample Examination and Testing IWL-2523.1 Tendon Detensioning and Sample
'emoval. One sample tendon of each type shall be completely detensioned. A single wire or strand shall be removed from each detensioned tendon.
IWL-2523.2 Sample Examination and Testing (a) Each removed wire or strand shall be examined over its entire length for corrosion and mechanical damage. The examination shall determine the location of most severe corrosion, if any. Strand wires shall be examined for wedge slippage marks.
(b) Tension tests shall be performed on each re-moved wire or strand: one at each end, one at mid-length, and one in the location of the most corroded area, if any. The following information shall be ob-tained from each test:
(1) yield strength (2) ultimate tensile strength (3) elongation IWL-2523.3 Retensioning. Tendons that have been detensioned shall be retensioned to at least the force predicted for the tendon at the time of the test. How-ever, the retensioning force shall not exceed 70% of the specified minimum ultimate tensile strength of the tendon based on the number of effective wires or strands in the tendon at the time of retensioning.
IWL.2524 Examination of Tendon Anchorage Areas It1f IWL.2524.1 Visual Examination. A VT/visual examination in accordance with IWA4DIr hall be performed on the tendon anchorage hardware, includ-ing bearing plates, anchorheads, wedges, buttonheads, shims, and the concrete extending outward a distance of 2 ft from the edge of the bearing plate. The fol-lowing shall be documented:
(a) concrete cracks having widths greater than 0.01 in.;
(b) corrosion, broken or protruding wires, missing buttonheads, broken strands, and cracks in tendon an-chorage hardware; (c) broken wires or strands, protruding wires and detached buttonheads following retensioning of tendons which have been detensioned.
IWL-2524.2 Free Water Documentation.
The quantity of free water contained in the anchorage end cap as well as any which drains from the tendon during the examination process shall be documented.
IWL-2525 Examination of Corrosion Protection.
Medium and Free Water IWL-2525.1 Samples (a) Samples of the corrosion protection medium shall 255
- FM 6.2 Exhibit 1 IWL-2525.1 Page 9 of 14 1992 SECTION XI -
DIVISION I IWL-2526 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 0 512 [Note (1A 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. 0 105 mm, height 145 mm; is thoroughly coated with 100 t 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 100°F (37.8°C) +/-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 2S04.
Place solution on a steam bath for 1/2 hour. 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 IN, 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) (N,) -
(8) (N,)] 56.1 W
where B=milliliters NaOH N.4=normality of H2S0 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 water shall not be included in the samples.
(b) Samples of free water shall be taken where water is present in quantities sufficient for laboratory anal-
.ysis.
IWL-2525.2 Sample Analysis (a) Corrosion protection medium samples shall be thoroughly mixed and analyzed for reserve alkalinity, water content, and concentrations of water soluble chlorides, nitrates, and sulfides. Analyses shall be per-formed in accordance with the procedures specified in Table IWL-2525-1.
(b) Free water samples shall be analyzed to deter-mine pH.
IWL-2526 Removai and Replacement of Corrosion Protection Medium The amount of corrosion protection medium removed at each anchorage shall be measured and the total amount removed from each tendon (two anchorages) shall be recorded. The total amount replaced in each tendon shall be recorded and differences between amount removed and amount replaced shall be docu-mented.
256
FM 6.2 Exhibit 1 Page 10 of 14 ARTICLE IWL-3000 ACCEPTANCE STANDARDS IWL-3100 PRESERVICE EXAMINATION IWL-3110 CONCRETE SURFACE CONDITION IWL-3111 Acceptance by Examination The condition of the surface is acceptable if the Re-sponsible Engineer determines that there is no evidence of damage or degradation sufficient to warrant further evaluation or repair.
IWL-3112 Acceptance by Evaluation Items with examination results that do not meet the acceptance standards of IWL-3111 shall be evaluated as required by IWL-3300.
IWL-3113 Acceptance by Repair Repairs required to reestablish acceptability of an item shall be completed as required by IWL-3300. Ac-ceptable completion of the repair shall constitute ac-ceptability of the item.
IWL-3120 UNBONDED POST-TENSIONING SYSTEM The condition of the unbonded post-tensioning sys-tem is acceptable if it met the requirements of the con-struction specification at the time of installation.
IWL-3200 INSERVICE EXAMINATION IWL-3210 CONCRETE SURFACE CONDITION IWL-3211 Acceptance by Examination The condition of the concrete surface is acceptable if the Responsible Engineer determines that there is no evi-dence of damage or degradation sufficient to warrant further evaluation or repair.
IWL-3212 Acceptance by Evaluation Items with examination results that do not meet the acceptance standards of IWL-3211 shall be evaluated as required by IWL-3300.
IWL-3213 Acceptance by 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-ability of the item, IWL-3220 UNBONDED POST-TENSIONING SYSTEMS IWL-3221 Acceptance by Examination IWL-3221.1 Tendon Force. Tendon forces are ac-ceptable if:
(a) the average of all measured tendon forces, in-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 type of tendon; (b) the measured force in each individual tendon is not less than 95% of the predicted force unless the following conditions are satisfied:
(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 adjacent to the tendon in IWL-322 1. 1 (b)(1) are not less than 95% of the predicted forces; and (3) the measured forces in all the remaining sam-ple tendons are not less than 95% of the predicted force.
IWL-3221.2 Tendon Wire or Strand Samples. The condition of wire or strand samples is acceptable if:
(a) samples are free of physical damage; 257
- FM 6.2 Exhibit 1 IWL-3221.2 Page 11 of 14 1992 SECTION XI -
DIVISION I IWL-3320 (b) sample ultimate tensile strength and elongation
'e not less than minimum specified values.
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, shims, or bearing plates; (b) there is no evidence of active corrosion; (c) broken or unseated wires, broken strands, and detached buttonheads were documented and accepted during a preservice examination or during a previous inservice examination; (d) cracks in the concrete adjacent to the bearing plates do not exceed 0.01 in. in width.
IWL-3221.4 Corrosion Protection Medium. Cor-rosion protection medium is acceptable when the re-serve alkalinity, water content, and soluble ion con-centrations of all samples are within the limits specified in Table IWL-2525-1.
IWL-3222 Acceptance by Evaluation Items with examination results that do not meet the acceptance standards of IWL-3221 shall be evaluated as required by IWL-3300.
IWL-3223 Acceptance by Repair or Replacement Repairs or replacements to reestablish acceptability the condition of an item shall be completed as re-
-red by IWL-3300. Acceptable completion of the re-pair or replacement shall constitute acceptability of the item.
IWL-3300 EVALUATION IWL-3310 EVALUATION REPORT Items with examination results that do not meet the acceptance standards of IWL-3100 or IWL-3200 shall be evaluated by the Owner. The Owner shall be re-sponsible for preparation of an Engineering Evaluation Report stating the following:
(a) the cause of the condition which does not meet the acceptance standards; (b) the acceptability of the concrete containment without repair of the item; (c) whether or not repair or replacement is required and, if required, the extent, method, and completion date for the repair.or replacement; (d) extent, nature, and frequency of additional ex-aminations.
IWL-3320 REVIEW BY AUTHORITIES The Engineering Evaluation Report shall be subject to review by the regulatory and enforcement authorities having jurisdiction at the plant site.
258
FM 6.2 Exhibit 1 Page 12 of 14 ARTICLE IWL-4000 REPAIR PROCEDURES IWL-4100 GENERAL IWL.4110 SCOPE This Article provides rules and requirements for re-pair of concrete containments.
IWL-4120 REPAIR/REPLACEMENT PROGRAM (a) Repairs shall be performed in accordance with the Repair/Replacement Program required by [WA-4140.
(b) Repairs shall be completed in accordance with the Repair Plan of IWL-4200.
(c) The Repair/Replacement Program shall address concrete material control..
IWL-4200 REPAIR PLAN The Repair Plan shall be developed under the di-rection of a Responsible Engineer (IWL-2500).
IWL-4210 CONCRETE REPAIR (a) The Repair Plan shall specify requirements for removal of-defective material.
(b) The affected area shall, be visually examined to assure proper surface preparation of concrete and rein-forcing steel. prior to placement of repair material.
(c) When removal, of defective material exposes reinforcing steel.,.the reinforcing steel shall receive a VT-i visual examination. Reinforcing steel is accept-able when, the Responsible Engineer determines that there is no evidence of damage or degradation suffi-cient to warrant further evaluation or repair. When re-quired, reinforcing steel shall be. repaired in accordance with IWL-4220. Repair of exposed-end anchors of the post-tensioning system shall be in. accordance with IWL-4230.
(d) Repair material shall be chemically, mechani-cally, and physically compatible with existing concrete.
(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:
(1) selection of repair material, to minimize stress and strain incompatibilities between repair material and.
existing concrete; (2) procedures for application of repair material; (3) procedures for detensioning and retensioning of prestressing tendons.
() The Repair Plan shall. specify requirements for in-process sampling and testing.of repair material.
IWL-4220 REPAIR OF REINFORCING STEEL Damaged. reinforcing steel shall be repaired by any method permitted in the original Cpnstruction Code or in Section 11, Division 2, with or without removal of the damaged reinforcing steel.
IWL-4230 REPAIR OF THE POST-TENSIONING SYSTEM (a) Weld repair of bearing plates and shim plates of the. post-tensioning system. shall meet the applicable re-7 quirements of LWA-4000. The corrosion protection me-dium shall be-restored following the. repair.
(b) Procedures for detensioning and retensioning of prestressing tendons shall be specified in the Repair Plan.
IWL-4300 EXAMINATION The repaired area. shall be examined in accordance with TWL-2000 to establish a new preservice. record and shall meet the acceptance standards of IWL-3000.
259
FM 6.2 Exhibit 1 Page 13 of 14 A92 ARTICLE IWL-5000 SYSTEM PRESSURE TESTS IWL-5100 SCOPE This Article provides requirements for pressure test-ing concrete containments following repair or replace-ment.
I*WL-5200 SYSTEM TEST REQUIREMENTS IWL-5210 GENERAL.
A containment pressure test shall be performed fol-lo. wing repair or replacement unless any of the follow-ing conditions exist:
(a) The Engineering Evaluation Report (IWL-3310)
- ','*: ' :.demonstrates. that. the. structural, integrity of containment.
in the existing unrepaired condition has not been re-duced below that required by the original design cri-teria.
A(b)
The repair or replacement affects only the cover concrete external to the. outermost layer of structural reinforcing steel or post-tensioning tendons.
(c) The repair or replacement involves only ex-change of post-tensioning tendons, tendon anchorage hardware, shims, or corrosion protection medium.
S. IWL-5220. TEST PRESSURE The pressure test shall be conducted at the design basis accident pressure, Pa.
I. WL-230 LEAKAGE TEST If the repair or replacement penetrated the contain-ment metallic liner, or otherwise breached containment
.leak-tight integrity, a leakage rate test shall be con-ducted as required by IWE-5000.
IWL-5240 SCHEDULE OF PRESSURETEST If the repair or replacement is performed with the plant shutdown, the pressure test shall be conducted prior to resumption of operation. If the repair or re-placement is performed with the plant in operation, the pressure test may be deferred until the next scheduled integrated leak-rate test.
IWL-5250 TEST PROCEDURE AND EXAMINATIONS The pressure test shall be conducted in accordance with a detailed -procedure. prepared under the direction of the Responsible Engineer. The surface of all con-tainment concrete placed during repair or replacement operations shall be examined by VT-I examination prior to. start of pressurization, at test pressure, and' following completion of depressurization. Extended surface examinations, additional examinations during pressurization, other examinations, and measurements of structural response to pressure shall be conducted as specified by the Responsible Engineer.
IWL-5260 CORRECTIVE MEASURES If the surface examinations of IWL-5250 cannot sat-isfy the requirements specified by the Responsible En-gineer, the area shall be examined to the extent nec-essary to establish requirements for corrective action.
Repairs shall be performed in accordance with IWL-4000, and pressure testing shall be repeated in accor-dance with IWL-5200, prior to returning the contain-ment to service.
IWL-5300 REPORT A pressure test report shall be prepared under the direction of the Responsible Engineer. This report may be an addition to a previously-prepared Engineering Evaluation Report (IWL-3310). The report shall de-scribe pressure test procedures and examination results and shall state whether or not the repair or replacement is acceptable. If the repair or replacement is not ac-ceptable, the report shall specify corrective measures.
260
FM 6.2 Exhibit 1 Page 14 of 14 ARTICLE IWL-7000 REPLACEMENTS IWL-7100 GENERAL REQUIREMENTS IWL-7110 SCOPE (a) This Article provides rules and requirements for reinstallation and replacement of post-tensioning sys-tem items for concrete containments.
(b) Grease caps and installation screws are exempt from the requirements of this Article.
IWL-7120 REPLACEMENT PROGRAM The following items, as applicable, shall be con-tained in the Replacement Plan:
(a) requirements for removal of items that are to. be replaced; (b) surface preparation required prior to installation of replacement items; (c) examinations required prior to installation of re-placement items; (d) detensioning and retensioning requirements for tendons affected by installation of replacement items; (e) requirements and procedures applicable to in-stallation of replacement items; (f) in-process sampling and testing requirements to be performed during installation of replacement items.
261
FM 6.2 Exhibit 2 Page 1 of 2 K, Prgress Energy CRYSTAL RIVER UNIT 3 Page 5 of 44 Rev. 6 DESIGN BASIS DOCUMENT SYSTEM NAME:
SYSTEM CODE:
CONTAINMENT - GENERAL N/A PARAMETER Flexible Conduit -
Used around penetrations in wall of containment.
- Minimum 22 gauge
-5 1/4" O.D.
- 5" I.D.
Schedule 40 Conduit Used in foundation mat and containment dome.
- ASTM A53-70, Type E or S Steel pipe Grade A for mat Grade B for dome SOURCE See "Conduit (General)" on Page 5 for the Source of requirements cited on this page.
REASON Flexible conduit specified in order to permit economical and efficient field fabrication and fitting.
Structural design material to ensure that dome conduit system is capable of supporting the dome liner under concrete placement loads. This conduit is, therefore, load carrying such that Grade B material (fy = 60 ksi) is specified.
In the base mat the schedule 40 conduit (pipe) is the transition material between the trumpet in the base mat and the rigid conduit in the cylindrical wall.
This pipe is not required to carry structural load, such that Grade A material (fy = 48 ksi) is considered adequate.
Steel conforming to ASTM A421 is the standard material specified throughout the industry for use as a buttonheaded tendon wire.
The steel used for this project is the Japanese equivalent of that material.
Exceptionally high strength is required in order to develop the required level of prestress.
Relaxation is a loss of stress when a wire is prestressed and maintained at a constant strain for an extended time. The degree to which this happens varies with the steel and is, therefore, specified by the steel supplier. That value must be known in order to evaluate the effective prestress over the life of the plant.
Tendon Wire ASTM A421-65 Type BA Tendon wire is specified in G/C, Inc. Specification SP-5583 and is listed here for reference only.
fy = 240 ksi
- Relaxation = 4%
See "Tendon Wire" on Page 6 for the Source of the requirement cited on this page.
Tab 1/1, Revision 6
FM 6.2 Exhibit 2 Page. 2 of 2
, Progress Energy CRYSTAL RIVER UNIT 3 Page 6 of 44 Rev. 6 DESIGN BASIS DOCUMENT SYSTEM NAME:
SYSTEM CODE:
CONTAINMENT - GENERAL N/A PARAMETER Tendons
- 163 wire Area - 9.723 in2 SOURCE G/C, Inc. Specification SP-5583 (for reference only).
REASON The tendon comprised of 163 -
7mm wires is approximately equivalent to the 170-0.25 in.
wire tendons typically being utilized in the industry at the time of plant design.
See page 19 for a summary of prestress forces in each of the three tendon groups.
Utilized on the basis of recommendations from Prescon Corp., the supplier of the prestressing system.
Anchorage Components Prescon Shop Drawings.
Bearing plate
- ASTM A533
- Grade B
- Class 2 Shims
- Modified Armco VNT or like material PEERE # 0987 Stressing End Washer
- Alloy steel forging Tendon Grease Shop application:
Visconorust 3001A Field application:
Visconorust 2090P Visconorust 2090P-2 G/C, Inc. Specification SP-5583 (for reference only).
Visconorust 3001A was the state-of-the-art tendon grease for the prevention of corrosion of prestressing wires. The 3001A material was used as a shop-applied coating. The 2090P and 2090P-2 were used to field coat the inside of the conduit as well as to serve as a bulk filler after tendon installation.
Other Visconorust formulations compatible with those noted are used during outages when tendon surveillance is carried out.
Foundation Bearinq Material The basic source for all criteria relating to foundation design parameters is:
Woodward-Clyde & Assoc.,
"Summary of Foundation Investigation Evaluation and Construction for Crystal River Unit 3."
Tab 1/1, Revision 6
FM 6.2 Exhibit 3 Page 1 of 1 Tendon Force and Wire Strain along the Tendon Hoop Tendon Force (kips) and Wire Strain (pin/in)
Going directly from 0 to 1,635 kips "4
Cj 1800 1500 1400 1200 1000 800 600 400 200 0
- ~ ~
~
~
~
~
of caa iS mi ilh saa
_ _--I....
10 9
8 7
5 S
4 3
2 1
0 L
.0 ix 0
20 40 60 80 Angular Position from left buttress (deg) or Distance from left buttress (ft) 100 120
FM 6.2 Exhibit 4 TENDON WIRIE 'TEST RESULTS Page 1 of.lO
'U C')
a L.h 1.
2.
3.
INSP'ECTION PELRIOD TENDlON W4IRE(1 SAMtPLE N40.
VERT ICAL.
45V3 45V3 MOP_____
I.OCATION (2)
_TROM END OF WITRE YI0.1)(3 ULT IMATE rERCENT STRESS~-
f..--,
STRSS(ks..-I,...
TN OM-."T rnrv~r-I.
2.
3.
Cn Co 6-12 Ft-30-37 FT 75-3RI 220.2
_._227.8 251.7 252.1-255.0 Over Over Over Ac cept Acctont 2.
3.
'.4 I-S I-
-S
'-I NOTES:
'(1) See Steps 6.2.5.1 and 6.2.5.3.
(2))
The und sLarts (roni the end of (3)
TheIL Yield SLreNS i.% tlefiiad as 102,00O PSI 1111111,111111.
zero lentLhi as indicated on Data Sheet. 4.
the stress at 17% elonCaLion. I.e.,
Prepared by:
Co;aLraCtor reVieLV by:
F.P.C. Appruvil by:
- %J h~
~
u';u 1*
Date:_____
Date:
DusLe:___
F-M 6.2 Exhibit 4 C
C DATA 51IEET 5 TENDON *WiRE TEST RESULTS Page 2-of 10 C,
I U
to 04M 1.
2.
3.
INSPECTION PERIOD TENDON WIRE (I)
SAHPLE NO.
n0O__E 07Zo8 DME VERrICAL 5(# 1/
11o0i,/.AM3 2.
saoe*..2 _
LOCATION (2)
MOM END OF WIRE YIELD (3)
STRESS (kal)
ULTIHATE STRESS (ksi)
PERCENT ELONGATION I.
2.
- 3. 40 i____
0 S.oT_
COMtII.NTS
_Z I/
z2.5.*
,,Z14 Z.1 zi'.
?.L.
Z52
_ZS-3
.815-
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_.46r
_,v
- -W
,,//Q ej~
"0 I.
2.
3.
0a rt 0
I-s
'-a
-,4 NOTES:
(I)
See Steps 6.2.5.1 and 6.2.5.3.
(2)
The end starts from the end of (3)
The yield stress is defined as 192,000 psi millium.
zero length as indicated on Data Sheet 4.
the stress at 1%. elongation, i.e.,
Prepared by:
£e_ 2_.,i.
Date: Z..
_41E,0.
Contractor Review by:
Date:
07__
F.P.C. Approval by:
Date:
M
FM 6.2 Exhibit 4 Page 3 of 10
- 3.
Laboratory analysis on twenty-two samples of the filler grease disclosed that the grease was free of unacceptable nitrate, chloride, sulfide or water contamination.
3.4 Tendon Lift-Off Force
- 1. Lift-off force measurements were made on ten hori-zontal, plus six dome, plus three upper vertical tendon ends.
All lift-off measurements were within the procedure specified acceptance criteria.
Refer to Table 1.
One end lift-off measurement was used for the ver-tical tendons.
3.5 Tendon Detensioning/Retensioning and Wire Tests
- 1. Broken, damaged or slipped wires were not noted during wire inspection operations on surveillance tendons 13H40, 56V2 and DI05.
None of the sur-veillance tendons exhibited lift-off forces above or below the procedure specified maximum or mini-mum.
The +3% (of initial) lift-off criteria was met and was deemed acceptable.
- 2.
The visual inspection of the three removed tendon wires showed no significant signs of corrosion or damage.
There were minor handling marks from the extraction tool.
- 3.
Three wire samples were removed.
The samples were measured, tagged and wrapped.
They were then sent to Professional Service Industries, (PSI),
Pittsburgh, Pennsylvania for testing.
The samples were cut into three coupons (one at each end and at mid-length) and subjected to breaking tests per ASTM 421.
The wire coupons showed tensile strengths in excess of 240 ksi minimum required.
- 4.
The "as found" elongation for the three sur-veillance tendons differed from the "proportioned" original elongation.
Horizontal tendon'13H40 "shop-end" was 7.2% above; dome tendon D105 "field-end" was 17.8% above; and vertical tendon 56V2 was 9.5% below the respective proportioned original elongations.
The.procedure specified acceptable criteria is + 5%.
See Table 2.
--5--
TP415ds
FM 6.2 Exhibit 4 Page 4 of 10 Crystal-"River Unit 3 Post-Tensioning System:
5th In-Service Tendon Surveillance Test Report: Revision 0 TABLE 71 SUMMKARY OF TENDON WIRE TENSILE TEST RESULTS WIRE YIELD ULTIMATE LOCATION TENDON SAMPLE STRENGTH TENSILE PERCENT OF WIRE NUMBER LOCATION (ksi @ 1% Ext)
STRENGTH (ksi)
ELONGATION FAILURE (in)
D231 SHOP 219.0 243.0 6.3 1.0
- RANDOM CENTER 219.0 239.0 6.4 5.3
- WIRE FIELD 221.0 244.0 6.2 0.5
- 46H47 SHOP 226.0 251.0 8.5 0.3
- RANDOM CENTER 225.0 252.0 7.8 0.3
- WIRE FIELD 227.0 253.0 8.1 4.5
- 56V15 SHOP 212.0 244.0 7.8 8.5
- RANDOM CENTER 216.0 243.0 6.5 2.0
- WIRE FIELD 212.0 243.0 8.7 8.5
- 56V15 NON SHOP 220.0 245.0 8.5 7.5
- TENSION CENTER 216.0 243.0 7.9 1.6
- WIRE FIELD 215.0 243.0 8.6 2.0
- 46H29 SHOP 227.0 253.0 7.4 0.2
- RANDOM CENTER 226.0 253.0 7.1 0.2
- WIRE FIELD 229.0 254.0 7.5 3.0
- 46H29 BROKEN SHOP 217.0 242.0 8.3 7.8
- WIRE CENTER 217.0 242.0 8.7 0.5
- 1 OF 3 FIELD 214.0 242.0 8.5 8.5
- 46H29 BROKEN SHOP 221.0 253.0 8.5 8.8
- WIRE CENTER 227.0 252.0 8.5 8.9
- 2 OF 3 FIELD 227.0 252.0 8.5 3.3
- 46H29 BROKEN SHOP 222.0 245.0 7.8 8.5
- WIRE CENTER 219.0 242.0 8.7 8.5
- 3 OF 3 FIELD 215.0 240.0 7.5 0.5
- ACCEPTANCE 204.0 240.0 4.0 CRITERIA (min)
(min)
(min)
N/A Distance From Moving Jaw 19
FM 6.2 Exhibit 4 Page 5 of 10 Crystal-"River Unit 3 Post-Tensioning System:
5th In-Service Tendon Surveillance Test Report: Revision 0 TABLE 7:
SUMMARY
FTENDON WIRE TENILE TEST RESULTS K
WIRE YIELD ULTIMATE LOCATION TENDON SAMPLE STRENGTH TENSILE PERCENT OF WIRE NUMBER LOCATION (ksi @ 1% Ext)
STRENGTH (ksi)
ELONGATION FAILURE (in)
D231 SHOP 219.0 243.0 6.3 1.0
- RANDOM CENTER 219.0 239.0 6.4 5.3
- WIRE FIELD 221.0 244.0 6.2 0.5
- 46H47 SHOP 226.0 251.0 8.5 0.3
- RANDOM CENTER 225.0 252.0 7.8 0.3
- WIRE FIELD 227.0 253.0 8.1 4.5
- 56V15 SHOP 212.0 244.0 7.8 8.5
- RANDOM CENTER 216.0 243.0 6.5 2.0
- WIRE FIELD 212.0 243.0 8.7 8.5
- 56V15 NON SHOP 220.0 245.0 8.5 7.5
- TENSION CENTER 216.0 243.0 7.9 1.6
- WIRE FIELD 215.0 243.0 8.6 2.0
- 46H29 SHOP 227.0 253.0 7.4 0.2
- RANDOM CENTER 226.0 253.0 7.1 0.2
- WIRE FIELD 229.0 254.0 7.5 3.0
- 46H29 BROKEN SHOP 217.0 242.0 8.3 7.8
- WIRE CENTER 217.0 242.0 8.7 0.5
- 1 OF 3 FIELD 214.0 242.0 8.5 8.5
- 46H29 BROKEN SHOP 221.0 253.0 8.5 8.8
- WIRE CENTER 227.0 252.0 8.5 8.9
- 2 OF 3 FIELD 227.0 252.0 8.5 3.3
- 46H29 BROKEN SHOP 222.0 245.0 7.8 8.5
- WIRE CENTER 219.0 242.0 8.7 8.5
- 3 OF 3 FIELD 215.0 240.0 7.5 0.5
- ACCEPTANCE 204.0 240.0 4.0 CRITERIA (min)
(min)
(min)
N/A Distance From Moving Jaw 19
FM 6.2 Exhibit 4 Page 6 of 10 20TIl YEAR SURVEILLANCE OF TIHE POST-TENSIONING SYSTEM AT THE CRYSTAL RIVER NUCLEAR PLANT UNIT 3 Florida i Power CORPORATION
.J VI.
- WIRE INSPECTION AND TESTING One wire was scheduled for removal from each detensioned tendon for visual inspection and tensile testing. PSC Procedure SQ 10.3 outlines the details involved with the wire testing and the data was recorded on Data Sheets SQ 10.2 and SQ 10.3 with the results summarized in Table X.
All wire diameters were within the acceptance criteria of 0.27559 +/- 0.002". The corrosion condition of all samples was level I - "bright metal; no visible oxidation" and the Ultimate Strength exceeded the minimum strength criteria of 240,000 psi (240 ksi) for all wire samples tested.
- 1
!l
./
\\-
I
.1 40
- FM 6.2 Exhibit 4 C.
C 20T11 YEAR SURVEILLANCE OF TIlE POST-TENSIONING SYSTEM AT THE CRYSTAL RIVER NUCLEAR PLANT UNIT3 Page 7 of 10
(-
Florida Power CORPORATION TABLE X:
SUMMARY
OF DATA SHEETS SQ 10.2 & 10.3 - VISUAL INSPECTION AND TENSILE TESTING OF WIRE TENDON SAMPLE CORROSION SAMPLE DIAMETER YIELD ULTIMATE
- ACCEPTABLE No.
LEVEL LOCATION (IN)
STRENGTH STRENGTHI (FT)
(PSI)
(PSI) 61V21 I
1 20-29 0.275 210,770 249,197 YES 2
1 90-99 0.275 210,251 251,793 YES 3
1 170- 179 0.275 209,212 242,966 YES D304 1
1 20-29 0.2755 213,614 244,138 YES 2
1 60-69 0.2755 21 3,614 241,552 YES 13 1
100-109 0.2755 217,236 250,864 YES 421135 1
1 20-29 0.276 210,286 241,219 YES 2
1 70 - 79 0.276 210,802 246,375 YES 3
1 140-149 0.276 212,864 253,077 YES S1H26 1
1 10-19 0.2745 210,512 254,293 YES 2
1 70-79 0.2745 209,990 248,560 YES 3
I 140- 149 0.2745 216,766 243,869 YES 511126 IA 1
10-19 0.2745 215,202 250,645 YES 2A 1
70-79 0.2745 214,160 253,251 YES 3A 1
146-155 0.2745 220,415 257,942 YES 621141 1
1 20 - 29 0.2755 211,545 247,760 YES 2
1 70-79 0.2755 213,614 245,173 YES 3
1 140-149 0.2755 214,390 241,552 YES
FM 6.2 Exhibit 4 Page 8 of 10 25TI1 YEAR SURVEILLANCE OF TIlE POST-TENSIONING SYSTEM AT THE Florida Power CRYSTAL RIVER NUCLEAR PLANT A
r gC UNIT 3 A Progress Energy Company VI.
WIRE INSPECTION AND TESTING One wire was scheduled for removal from each detensioned tendon for visual inspection and tensile testing. PSC Procedure SQ 10.3 outlines the details involved with the wire testing and the data was recorded on Data Sheets SQ 10.2 and SQ 10.3 with the results summarized in Table X.
All wire diameters were within the acceptance criteria of 0.27559" +/- 0.002". The corrosion condition of all samples was level 1 - "Bright metal, no visible oxidation", or level 2 - "Metal reddish browna color, no pitting". Also, the ultimate strength exceeded the minimum strength criteria of 240,000 psi (240 ksi) for all samples tested.
31
FM.6.2 Exhibit 4 C...
Page 9 of 10 25T11 YEAR SURVEILLANCE OF THE POST-TENSIONING SYSTEM AT THE Florida Power CRYSTAL RIVER NUCLEAR PLANT Prgress Energy Company UNIT 3 TABLE IX:
SUMMARY
OF DATA SHEETS SQ 10.2 & 10.3 -VISUAL INSPECTION AND TENSILE TESTING OF WIRE TENDON SAMPLE CORROSION SAMPLE DIAMETER YIELD ULTIMATE ACCEPTABLE No.
LEVEL LOCATION (IN)
STRENGTH STRENGTH (Fr)
(PSI)
(PSI) 45V14 1
2 20-29
.275 226,477 267,691 YES 2
2 90- 99
.275 224,249 266,020 YES 3
2 170-179
.275 228,148 265,184 YES 531116 1
1 10-19
.275 227,312 272,146 YES 2
1 70-79
.275 231,211 266,298 YES 3
1 140-149
.275 233,160 272,703 YES D339 I
1 20-29
.275 230,097 265,463 YES 2
1 50-59
.275 231,489 257,944 YES 3
1 90-99
.275 230,097 265,184 YES tw
I I
I I
I I
I I
I 1 4' FM 6.2 Exhibit 4 Page 10 of 10 DOUMENT NUMBER.
CR-N1002-504 REVISION:
0 PAGE:
42 DOUMENT TITLE.
FINAL REPORT FOR THE 30'" YEAR CONTAINMENT IWL. INSPECTION<
PROJECT TITLE:
30'" YEAR TENDON SURVEILLANCE AT CRYSTAL RIVER DATE:
014/208 Purs 9.0 WIRE INSPECTION AND TESTING 9.1 One tendon from each group (Vertical. Hoop, Dome) was completely detensioned. A single wire was removed from each detensioned tendon for inspection and testing. Each removed wire was examined over its entire length for corrosion and mechanical damage. Three samples from each wire were tested for diameter, yield strength, ultimate tensile strength and elongation. PSC Procedures SQ 10.2 and SQ 10.3 outline the details and acceptance criteria pertaining to the wire removal and testing. All data was recorded on Data Sheets SQ 10.2 and SQ 10.3 and the results summarized in Table 48.
9.1 1 All wire diameters were within the acceptance criteria of 0.2756 + 0.002".
9.1.2 The corrosion level for all of the test wires were:
I - Bright metal; no visible oxidation.
9.1.3 No mechanical damage was noted on any of the wires.
9.1.4 The yield strength of the wires tested exceeded the minimum acceptance criteria of 192,000 psi at 1%
elongation. The lowest recorded yield strength was 225.678 psi.
9.1.5 The Ultimate Strength of the wires tested exceeded the minimum strength criteria of 240,000 psi on all samples. The lowest recorded ultimate strength was 257,305 psi.
9.1.6 The percent elongation at sample failure exceeded the required minimum of 4.0% on all samples tested.
The recorded elongation on the samples varied from 4.5% to 5.3%.
I I
I I
I I
I I
I I
I I
-1 TENDON U111 SW 08
-j d
I-ii,id U
1 1
10'-20' 278 227.805 259.164 4.6 YES 51 H34 2
1 70-60T
.276 226.210 262.353 5.1 YES 3
1 140%.150
.276 225.678 260.227 4.8 YES 1
1 10'-20'
.275 230.535 263.194 4.6 YES 61V1?
2 1
90g.100'
.275 229.464 263.194 5.0 YES 3
1 170'-180'
.275 230.000 265.871 5.3 YES 1
1 10'-20'
.275 230.000 260.517 47 YES D238 2
1 50"-60'
.275 229-464 257305 4.5 YES 3
1 100'-110
.275 228393 263.194 50 YES
FM 6.2 Exhibit 5 Page 1 of 1 Wire Testing All tested wires passed the Ultimate Tensile Strength requirement of 240ksi UTS (ksi) 280 270 260 250 240 230 220 i I I
II.-
I I
I I
M n
I a
II II I
I1 I
I I
-- *'rli--l*--I'--'I*I,-H-H -*I-
-*J--m'-I
- lg-*
mUTS (ksi)
FM 6.2 Exhibit 6 TEST REPORT "SAMPLE (S): CUSTOMER SUPPLIED" AM Page 1 of 1 AVAM APR
^TL-AtN TESTING LABORATORIES, INC.
-M ATLASLABStATF.NET 9820 SIXTH STREET RANCHO CUCAMONGA, CA 91730 909-373-4130. FAX 909-373-4132 WF PERFORMANCE IMPROVEMENT INT'L ATTN: DR. MOSTAFA MOSTAFA 2111 S. EL CAMINO REAL ST.302 OCEANSIDE, CA. 92054 PAGE I OF I DATE 12/09/09 ATL# 947613 PO# 5718 MAT'L: STEEL ID: #12 & #13 MECHANICAL PROPERTIES:
YIELD STRENGTH Actual Load/
Pounds
- Size, Area Pounds Sq. inch TENSILE STRENGTH Load/
Pounds Elongation Pounds Sq. inch in.64" 12-1.160 12-2.161 13-l1.162 13'2.16l
.0201
.0204
.0206
.0204 4,720 4,680 4,900 4,700 234,800 229,400 237,900 230,400 5,280 5,220 5,420 5,200 262,700 255,900 263,100 254,900
.09
.10
.10
- 08 14.1 15.6 15.6' 12.5
'Reduced Dimensioi
.118
.117
.125
.125 Reduction of Area 45.6 47.2 40.5 39.7 YIELD STRENGTH.2% OFFSET METHOD: ASTM-E8/08 ATE# 503 CHEMICAL ANALYSIS: (% BY WEIGHT)
ELEMENTS 12-A 12-B 13-.A 13-B Carbon 0.82 0.80 0.81 0.79 Manganese 0.84 0.84 0.84 0.84 Phi6sphoius 0.018 0.018 0.018 0.018 Sulfur 0.015 0.014 0.015 0.014 SilicOn 0.21 0.21 021 0.21 Chl-omium 0.05 0.05 0.05 0.05 Nickel 0.03 0.03 0.03 0.03 Molybdenum 0.01 0.01 0.01 0.01 Copper 0.08 0.08 0.08 0.08 Aluminum 0.032 0.031 0.030 0.030 METHOD: ASTM-E415/08, E1019/08 STDS: IARM 31C, NBS 1262B, 63A, ATE# 202, 204 64A, LECO501-502 ANALYSIS IDENTIFIED MATERIAL AS: 1080 C/STEEL REMARKS: Samples tested for information only.
4 ect Sub~mi, ALI A.
Quality 41troIl "Atlas testing submits this report as the confidential property of our client. Reproduction is authorized, but only if In full.
"-.Thce rcordingof falsefictitious-or fraudulentinforriation to-this report maybe punishable uhder federal law."-.-
FM 6.2 Exhibit 3 Page 1 of 1 Tendon Force and Wire Strain along the Tendon Hoop Tendon Force (kips) and Wire Strain (pLin/in)
Going directly from 0 to 1,635 kips
-i 2I 1800 1600 1400 1200 1000 800 600 400 200 0
I I
II I
4 4
Force (kips) (left soale)
I -Strain (rj&ht scale) 10 9
a 7
6 5
4 3
2 0
I M
C*1 VI 0
40 60 8o Angular Position from left buttress (deg) or Distance from left buttress (ft) 100 120
6.2 Inadequate Tendon Wires
==
Description:==
The tendons in a concrete post-tensioned system are made of steel wires. The wires must have a very high tensile strength and must sustain high stress levels for long time periods with minimal stress relaxation. Cold-drawn steel wires are typically used. The wire quality, strength, uniformity, and corrosion are tested during regular surveillances, as described in the ASME Code Section XI, Subsection IWL (FM 6.5 Exhibit 1). Relaxation of the tendon wires leads to reduced pre-stress levels in the concrete. Local strain-hardening (work-hardening) leads to non-uniform force along the tendon and non-uniform pre-stress levels. Tendon wires are ASTM A421-65 high-strength steel with a guaranteed ultimate tensile strength (GUTS) of 240ksi (FM 6.2 Exhibit 2).
Data to be collected and Analyzed:
- 1. Draw wire elongation variation along the tendon due to friction (FM 6.2 Exhibit 3);
- 2. Review surveillance data on tendon wires (FM 6.2 Exhibit 4);
- 3. Analyze wire surveillance data (FM 6.2 Exhibit 5);
- 4. Test wires recovered from removed tendons (FM 6.2 Exhibit 6);
Verified Supporting Evidence:
- a. The strain in the wire is not uniform because the tendon force is not uniform (due to friction) (FM 6.2 Exhibit 3).
Verified Refuting Evidence:
- a. Wire material ASTM A421 high-strength steel is the standard material specified in the industry. It is low relaxation and it is not subject to strain hardening / work hardening (FM 6.2 Exhibit 2);
- b. Surveillance data on tendon wires show expected strengths and ductilities (FM 6.2 Exhibit 4 and FM 6.2 Exhibit 5);
1/4/2010 10:08 AM Pt-Pre~iecaidentaI.2OO9-Page 1 of 2 Draft 1
Discussion:
- a. The strain of 5,000 pin/in on a 120 ft wire leads to a displacement of 7.2in. This is consistent with observations made by PSC personnel;
- b. There are no cyclic stresses imparted to the tendon wires so that the effects of strain hardening / work hardening are further limited;
- c. ASTM A421 has chemical requirements on Sulfur (0.050% max) and Phosphorus-(0.040 % max) only for carbon steel alloys. The wire material is left to the discretion of the manufacturer to provide the wire physical requirements such as tensile, yield, and elongation. Therefore, a wire chemistry of 1080 carbon steel falls within the ASTM A421 specifications. Based on Atlas Laboratories analysis, the wire meets chemical and mechanical properties of the ASTM A421 requirements;
- d. The tendon wires are stretched to 70% GUTS in service. Therefore the maximum possible over-stressing in a local area of a wire is only 30% (above that we would reach the GUTS and the wire would break). There are very few instances of broken wires and all are explained by other factors than over-stressing;
==
Conclusion:==
There are no indications the tendon wires used in CR3 tendons generated the delamination.
1/4/2010 10:08 AM Page 2 of 2 Draft 1
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