ML102930613

Email from: Carrion, Robert to: Lake, Louis Dated Wednesday, November 18, 2009 3:53 PM Subject: Extra Files

ML102930613
Person / Time
Site:	Crystal River
Issue date:	11/18/2009
From:	Robert Carrion NRC/RGN-II
To:	Lake L NRC/RGN-II
References
FOIA/PA-2010-0116
Download: ML102930613 (19)

Text

Sengupta, Abhijit From: Carrion, Robert Sent: Wednesday, November 18, 2009 3:53 PM To: Lake, Louis

Subject:

Extra Files Attachments: Status (11 Nov09).doc; 2009 Oct 29_NRC Copy- Containment Delaminaton.pptx; Bob Carrion Exp.doc; CR Containment Comm Plan.doc; GThomas - SIT 11-13-09.doc; PHONE NUMBERS.doc

Lou, These are the extra files not associated with a folder.

Bob 1

Gll':ý- /.2-

Construction Opening Removal Sequence (cont)

.,.-.,.,91 ION ZINN, 1

Construction Opening Removal Sequence (cont) 2

Construction Opening Removal Sequence (cont)

External Visual Observations Buttress Span Buttress I

I 3

Plan View Buttress #

(typical)

¶ b

Source Drawing:

101-112 SHOW0 4

Horizontal Tendons Buttress 2 - 4 I Additional Tendons to be Detensioned Tendons Removed Additional Tendons to be Detensioned Source Drawing:

0425-006 SH001

- SH 000 9Tý Progress Energy 5

Horizontal Tendons Buttress 3 - 5 Additional Tendons to be Detensioned Tendons Removed Additional Tendons to be Detensioned Source Drawing:

0425-007 SH001

- SH 000 6

jProgress Energy

CR3 Typical Tendon Schematic and Photo (for horizontal tendon # 53H27) 7 h0 Progress Energy

Recent Tendon Surveillance History

• 6th Surveillance Interval - Oct 1997 to Jan 1998 (20th Year)

• 9 Tendon Failures (i.e. < 95%)

• 42H30 to 42H36 (inclusive) and 51 H26 & 51 H27 (inclusive),

• 42H35 and 51 H26 were below 90%.

• 7th Surveillance Interval - 2001 (25th Year)

• 9 Tendon Failures (i.e. <95%)

• 12V01 and 46H30 to 46H38 (inclusive)

• 46H36 below 90%

• 8th Surveillance Interval - Oct 2007 to Nov 2007 (30th Year)

• 12 tendon failures (i.e. <95%)

0 46H20 to 46H23 (inclusive), 62H30 to 62H33 (inclusive), and 13H34 to 13H37 (inclusive)

• 4 tendons were below 90%

a 0* Progress Energy U

Containment "Unfolded" - Buttress 2 to 5 Buttress #2 Buttress #3 Buttress #4 Buttress #5 r T

- ----- EL 250' A B C A B C A B C Pour 16 EL 250' EL 240' D E F D-o E F D E F Pour 15 230' G H G H I G H. Pour 14

---

EL 220' J K L K L J K L Pour 13

---

EL 210' M N 0 M N 0 Pour 12 0 SG0R ------- EL 200' P Opening R P .- Q R P Q R Pour 11 EL 190' S .T U S T U Pour 10 EL 180' X V W X X Pour 9 V W V W0 ------------EL 170' Y Z AA Aux Bldg Ro Of Pour 8 y Z AA Y EL 167' 8" --- EL 160' AB AC AD z Pour 7 EL 150' Intermediate AA Pour 6 AE Bldg Roof EL 140' EL 149' 0" AF AB Pour 5 EL 130' AG AC Pour 4 EL 120' Equipment Hatch Pour 3 EL 110' Pour 2 EL 100' Pour 1 I - L-.J------ ---EL 90' 9 0C)re Bore IR Scans Complete Progress Energy

Containment "Unfolded" - Buttress 5 to 2 Buttress #5 Buttress #6 Buttress #1 Buttress #2

-I-.. f-'Y--I- - ________ - r EL 250' A B C A B C A B C Pour 16 240' D E F D E F D E F Pour 15 230' G H I G H G H I Pour 14 EL 220' K L J K L J K L Pour 13

---

EL210' M No O M N 0 M N 0 Pour 12 1 0 1O0 -------- EL 200' P Q R P Pour 11 P Fuel Transfer Q R EL 190' Q

Bldg Roof S T U S T U Pour 10 EL 200' 4" EL 180' R V W X V W X Pour 9 EL 170' S y Z AA Pour 8 y Z AA

--- EL 160' AB AC AD AB AC AD Pour 7 EL 150' Intermediate Intermediate Pour 6 Bldg Roof Bldg Roof EL 140' EL 149' 0" EL 149' 0" Pour 5

-- - - - - EL 130' Pour 4 EL 120'.

Pour 3 Pour---- EL 110' Pour 2 Pour-2 - EL 100' Pour 1 EL 90' Progress Po ss Enry Energ 10 C,wre Bore IR Scans Complete

Summary of Other Utility Experience Survey documents are work-in-progress Total # of PWR Plants 42 Plants, 69 Units Total # of Units With 3-D Post-Tensioned Concrete Containment 18 Plants, 32 Units Data Collected From Total # of Plants and Units 16 Plants, 28 Units

1. of Plants that have replaced Steam Generators 14 Plants, 22 Units CR3, ANO 1&2, Byron 1, Braidwood 1, TMI

1. of Plants and Units Made Opening in Concrete 8 Plants, 11 Units 1(2), Oconee 1,2,3; San Onofre 2, Palisades

1. of Units Used Hydro-demolition 6 CR3, ANO 1, TMI 1, Oconee 1,2,3

1. of Units Used Other Methods (Chipping, Impact 4 ANO 2, Byron 1, Braidwood 1; San Onofre 2 Hammer, etc.)

1. of Units With 3 Buttresses 20

1. of Units With 6 Buttresses 8 CR3, Oconee 1,2,3; TMI 1, Calvert Cliffs 1&2; Palisades

1. of Plants and Units Having Continuous Reinforcement 10 Plants, 18 Units on Both Faces of Containment Wall 10_Plants_18_Unit

1. of Units Not Having Continuous Reinforcement on Inside 7 Plants, 12 Units CR3, ANO 1&2; Byron 1&2; Braidwood 1&2; Face of Containment Wall TMI 1, Oconee 1,2,3; Palisades Farley 1&2; Vogtle 1&2; Summer; STP 1&2;

1. of Units Having Ties/Stirrups Connecting Both Faces 7 Plants, 12 Units Wolf Creek, San Onofre 2&3; Calvert Cliffs 1&2

1. of Units that detensioned all tendons within cut out CR3, ANO 1&2, Byron 1, Braidwood 1, TMI 1, area prior to cutting concrete 10 Oconee 1,2,3; San Onofre 2

1. of Units that detensioned additional tendons beyond the 8 ANO 20), Byron 1, Braidwood 1, TMI 1, cut out area prior to cutting concrete Oconee 1,2,3; San Onofre 2&3 (1) For ANO Unit 1: The additional tendons around the construction opening were detensioned during or after the creation of the construction opening (2) TMI 1 Steam Generator Project is in progress.

• 11 Progress Energy

Sample of Utility Experience Being Collected (work-in-progress)

COMPARISON OF Pif 3D POST-TENSIONED CONCRETE OONTAINE ITEM CRYSTAL RVER3 FARLEY 1 &2 VOGTLE 1 8 2 ARKANSAS ONE U2 ARKANSAS ONE UI SUMMER BYRON 1 2 BRAIDWOOD 182 3 MLE ISLAND 1 OCONEE 1.2 &3 Prowess SOUtlern SouRhen Entergy Entergy SCEG Exelon telm ExSelon Duke Type of CTMT 3D Post-Tensinsed Post-Tensioned Coacrete Post-Tensionee Concrete Post-Tersioned Cocrete Post-Teesioned Concrete Post-Tensioned Pst-Tensioned Concre-e Post-Tensioned Concrete Post-Tensiorred Concrete Post-Tensioned Concrete Concrete Cyliner wirth Cylinder with Stee Liner Cyinder with Steel Liner Cylinderwith Steel Lne Cylir6derwire Steel Liner Concrete Cylinder-wd Cyincerwith Stel Cylinderwith Steel Liner CliderwithStee Line iLinne Cyl with Steel Line Steel Liner Steel Liner, Design Pressure 55 psig 54 psig -52 psig 59 psig -59 psig 50 psig 50 psig 55 psig 59 psrg Nunmberof Buttress 6 3 3 3 3 3 3 3 6 6 Hoop Tendeonorangemert Honzoutal tendons placed Horizontal tendons placed Horizontal tendons placed Horizonstaltendons placed in Horizntal tendons placed in Honzral tendons Horzontal tendons paaced in Horizontal tendons Iaced in Holizontta tendons placed in Honzortal tendo-s placed in six 120 degree segments inthree 240 degree inthree 240 degree thrree 240 degree segrents three 240 degree segnents placed inthree 240 three 240 degree segmerlts three 240 degree segments sn l20degree segmets in six120 degree segmerts segments segmoents degree segmerts Concrete (rc) 5000 psi 5000 psi 5000 psi 5000 psi 5000 psi 500D psi 5500 psi 5500 psi 5t00 psi 5000 psi Internal Dia 130fT 130 If 14001t 116 t 116 it 126fl 1401t 140ft 130 It 116 ft InteiorH-eight 1890 183 it 232-6" 201B1-6" '209-6" 183 f0 222 ft 222 t 189 It 208'-55."

Cylindrical Wall Thickness 3-6" 3-9" .3'-" 3-9" 3-9" . 4'-0" 3-6" 31*6" 3-6" 3-9' Dome Thickness 3-6" 3-3" 3'-9" 3*-3" 3-3" 3-0" 3'-0" 3-0" 3-0" 3r-3" Tendons: 163 wires 170 wire of '/,"dia St s-ands per tendon 18 wire or W"aia 186 wire ofW"dia 170 wire o'/." t7wire or/"

1a 1Wia s 170 wire of dia 169 wire of/""

1ia 90 wire of /.dia Vertcal V= 144 V= 130 Inrted U = 74 V= 115 V= 102 V= 115 V= 162. V= 162 V= 166 V= 176 Hoop H = 282 H = 135 H (wall)= 141 H = 159 H = 171 H = 150 H = 201 H =201 H = 330 H (wall) 632 Done D= 123 D=93 D (Hoop) - 27 0=84 ASTM AD.90 ASTM A- 0=99 D= 120 D= 120 D= 147 r (hoop) = 162 ASTM A416 421 421 Uner Plate Thickiress 0,375" 0 25" 0.25" 0.25' 0.25" 025" 025" 025" 0375" 025" Bothacevt#14orOutside 8 1 adp face vert:#11 or 18 Outside face: vaet #11 or 18#10 @12ccverta

1. 8 12"rclc*rate hopSt Botnface:vert #rS@9" Bsoltacs;vert#1@ "#0-. #1So§12"clcsouterfaceeiorr"

1. 18 @12" 12U eta h°p Bot fae:

De*L#14or@12" Stp c/c; hoop co 12"#10@ 90- @12"U6./c; oop r f #!0@ #@28 yentand Smpso ceanhoo 9"- #8eo2utcfaned1.

ceot l 6 1@12"c/c S~etn hoopieacse Reirtorcemert on Me outer face only cc Sehoop #18@12"cI Lc;hOp: #18 "cc.

' #10 @ 12"c/c vert and hoop the outer f:e only. Some #14 @ 1C12'coutefacerdy. 12' cnc er faceonly, eoutwae Sores .

insidefacesteelattop #7 U-s1aped Ties@ 12- Some inside face steelato  : Some insiefaceseeat inside rae steel attop and So- and fcsteel at Some insideface steel a #8 C-snaed Ties @12"' ct #8 C-snaped Ties @ CC onsthee uteraceonlly 5botom. and bo-toT. Ties at top and top arid bottm. Ties at top botom near open top and bottom. proeided provided cit Provided b and I=bnear opening oG REPLACED? INPROCESS YES NO YES ES YES YES(U-i) YES(U-I) INPROCESS YES YES NO NO YES YES NO YES(U-l) YES(L-1) INPRC-ESS YES CooeteOpenirg Made?

Cole-eteHycorBlastirngused?. YES NO NO NO;By Chipping YES NO NO ByChipping, NO;ByChipping INPROCESS YES Hydro blasting done by Hyciroblastng soneby larrlr-c avirorl et)i Miredlaneousllnfo Mac & Mac American Rydro (410-574- CoisacIt BuorNeleI ir T, I.

Crtact 8470) Cacact Wayne YounTger 724-61-42009 TTenons Renoved InH= 18. Tendons Reeroved in Tendons Removed in Tendons Removed in Tendons Removed in

)erdeeg O Detail Ter-oroOs Removed in NA NA Opening Zone V=6. Opening Zonle: V=6. H=16 Opesing Zone:V=9,,H= 16. Opening Zone:V=9,H= 16 Tendons To Be Removed in pening Zone V=I 2H 3=28 Opening Zone. v=8 H=17 _perng Zone v = 11 PH=19 D3el oned byCuordg(burnirn) V = 6; H=17 NA NA None None

______________=

V= 11.H=19 12.8H=26 etensi-od byRar1tin V= 2 NA NA V= 9, H=16 9.H=16 NonesONE Yes: Addtonal tendes Yes; Addonal tendons Yes; Additional tendors Yes; AdIleon tentons Yes; Additional tendons A.dcitiereal3e~er~oning NA NA detessined:V=i6H=12 dtensioned V=30, H=18 detensioneeeV=29,H=14 detinsisone.V=293H=14 Yes;Addeion'lteensto be daensoned V=30. H= I1I denseioned V=4, H= 1I No cocraes crackng or No cocrele cracking ar No coc'ete cracadng or No cocrete cracdng or delamination observed defaminalion obser-ved delaminationobserved delaninantion observed The additonal tendons around the constuction Addtrinal IInformation opening were detensiored durng or after the creason of MhconsuOcton opening 12

Technical Approach Root Cause Analysis

• External Contractor - Performance Improvement International (P11) (Dr Chong Chiu)

• Develop potential failure modes

• Includes specialized RCA analysis to facilitate support/refute process

• PII internal peer review process of support/refute basis documents

• PGN Owner's review of support/refute basis documents

• Historical data gathering supported by PGN personnel

• Ongoing field data provided by Condition Assessment Team

• RCA Team directing additional field data to be taken

• As-found lift-off values for remaining tendons to be de-tensioned

• Installation of strain gauges to monitor detensioning I P Progress Energy I,3

Root Cause Analysis - PII Metrics Un-refuted FailureModes Yet to Be Dispositioned 80 mExternal Events 70 Operational Events 60

• Inadequate Containment Cuffing 50 U Inadequate Concrete - tendon interactions 40

• Shrinkage, Creep, and Settlement 30

• Chemically or Environmentally Induced Aging 20 Inadequate Use of Concrete Materials 10 Inadequate Concrete Construction

. .. .

• Inadequate Concrete Design due to 0 . .I. . . . . . . . .. . .. . . .. . . . .. . . .. . . . .. .. . . . .. . .. . . .

High Local Stress Progress Energy 14

Technical Approach Condition Assessment Team

• Contractor for NDT - Construction Technology Laboratories (C TL)

• Impact Response technique to "screen" for delamination

• Impact Echo technique to characterize depth of delamination

• NDT backed up by core bore samples & boroscopic inspection

" Special interest locations from IR

" Engineered locations

• Random locations

• Laboratory Petrographic Analysis by Mac Tec and CTL

• Containment external visual inspection (IWL process)

• Activities governed by Test Procedure(s)

I'.J

• j Progress Energy

Technical Approach .1 Condition Assessment - IR Scan in Buttress 3- 4 Area 30-25-20-15-Buttress #3 10-5-

0-16 1j Progress Energy 0.4 1 Average Mobility

Technical Approach Design Basis Analysis Team 0 External Contractor Support for DBA Modeling- MPR Associates, Inc.

o Build CR3 Finite-Element Model (per design)/

Analyze Impact of Delamination for Design Basis Events Dead Load, Live Load, Internal Pressure (LOCA and Accidental Containment Spray Actuation), Tornado Differential, Wind Loading, Tornado Missile Load, Seismic, Thermal Analyze Repair Alternatives to Restoring Design Margins Coordination between PII analysis and MPR analysis on geometry and concrete parameters 17 I I Progress Energy

Technical Approach Repair Analysis Team

• Investigating Repair Alternatives for Delaminated Areas Evaluating Bar Anchorage Options and Grout/Epoxy Options Viability is subject to analysis of radial stresses Example - Maxi-Bolt UndercutAnchor System

• Evaluatin Removal of Delaminated Areas and Re-Pouring of Concrete-(with additional radial rebar installation)

• Considerations for Repair Alternatives (not in order of priority)

• Ability to Restore Design Basis Margins

• Cost

• Schedule Impact

• Availability of Materials

• Ability. to Dedicate Materials for Nuclear Safety Use

• Product/Method Readiness for Implementation

• Constructability

• Future Monitoring and/or Maintenance Requirements

• Regulatory Acceptability CO ,,a,- I 18 ý1* Progress Energy