ML17254A698

Rev 1 to Repair of Tendon V-75 for Re Ginna Nuclear Power Plant,Repair Rept.

ML17254A698
Person / Time
Site:	Ginna
Issue date:	12/29/1983
From:	Felder A PRECISION SURVEILLANCE CORP. (FORMERLY INRYCO, INC.)
To:
Shared Package
ML17254A696	List: ML17254A695 ML17254A697 ML17254A698
References
NUDOCS 8512310227
Download: ML17254A698 (62)

Text

ENGINEERING FILE NUMBER:

E!nvyco an Inland Steel company t1ain REPAIR OF TENDON V-75 FOR Ti tl e R.E. GINNA NUCLEAR POWER PLANT Sub-Title'EPAIR REPORT BY ANTHONY L. FELDER, P.E. ASSISTANT CHIEF ENGTNEER ENGINEERING DEPARTNENT CONCRETE SYSTENS DIVISION ABSTRACT This report presents the results of repair work conducted on tendon V-75 of the Ginna Power Plant. This tendon had been damaged duripg the 3rd Year Surveillance and Inryco was called upon to provide a repair procedure and technical assistance.

REVISION .CONTROL LOG

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RevisIon Approved Rev.. Date By By Pages Affected ll/l7/83 Z.g. 1 thru vt 1 thru 10, A-1 tht'u A-7, B-1 thru B-9, C-l thru C-8 12/29/83 zQ: i,iii thru v,l',3,6,8,10;B-7,B-9,C-3 thr'u C-7 gy22P2A4 8pN3ppp p22~

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Repair of Tendon V-75 for R. E. Ginna Nuclear Power Plant

SUMMARY

Tendon V-75 of the R.E. Ginna Nuclear Power Plant was damaged during the course of the 3rd Year Surveillance. Inryco was called upon to provide a repair procedure and technical assistance.

Of special concern was the fact that V-75 was not in an idea~ondition.

The shim halves, which the anchorhead rests upon, were of unequal heights causing the anchorage to be "cocked" by roughly 7 degrees from the vertical.

Some of the tendon wires were either broken or protruding above the anchorhead.

Repair work consisted mainly of the following:

1. Tendon destressing.

2. Inspection of the tendon and anchorage for any

'necessary.

damage and repair if

3. Restressing the tendon back to a stress level corresponding to the shim stack height existing at the original installation.

The repair work proceeded successfully during all phases and the following recommendations are made:

1. The tendon should be stressed'to a level of 70% GUTS (544 K) + 5%-

A visual reinspection of V-75 should 4'.

be conducted at a later date. ~

3. The repaired pull rod and coupler should be replaced.

4. To prevent any similar incidences from happening again, full en a ement of all threaded ieces must be enforced durin all further tendon o erations.

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INRYCO, Inc.

Repair of Tendon V-75 For R.E. Ginna Nuclear Power Plant TABLE OF CONTENTS'ist of Figures Introduction ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 0 ~ ~ ~ ~ t ~ ~ ~ ~ ~ ~ ~

iV Repair of Pull Rod and Coupler'..... ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

D estressing r Tendon and Anchorage Inspection .................. ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ . 3 IV. R estressing 0 ~ ~ ~ ~ ~ ~ ~ ~ ~ ot ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Recommendations 10 Appendix A. Inryco Repair Procedure QA 8309 A-1 B. R.G.GE. Repair Procedure .EM 376 B-1 C-1 C. Repair Work Data Sheets ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

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Repair of Tendon V-75 "or R.E. Ginna Nuclear Power Plant LIST OF FIGURES

@ 1. ,Shims Protruding From Under Adaptor.......................... v

2. Special Tapered Shims............... ~ ~ \~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 2 I

3I Tendon Being Destressed............. ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 0 ~ ~ ~ ~ ~ ~

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4.. Side View of 8 Inch Shim.....................................

5~ Top View of 8 Inch Shim......................................

6. S him Deformation ...

7~ Shims Removed From Tendon.....................................

A 8. Anchorhead Prior To Wire Continuity Test..................... 6

',. 'ire Continuity Test......................................... 6

10. R aised Anchorhead.........................................;.. 7 Restressed Tendon................................

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Repair of Tendon V-75 for R.E. Ginna Nuclear Power Plant Introduction The R. E. Ginna containment vessel tendons were retensioned in 1980.

During the 3rd Year Surveillance after retensioning, it was noticed that the shims for vertical tendon V-75 were slightly out of line after the tendon had undergone a Liftoff test. The decision was made to take a final. liftoff of the tendon, during which the shims were to be-placed more in line.

I However, the pull rod had not been completely engaged into the stressing adaptor.. This led to the pull rod stripping out of (he adaptor during liftoff operations, thereby damaging the anchorage and tendon. When the pull rod stripped from the adaptor, the adaptor struck the shims with enough force to expel some shims from the stack (Fig. 1) as well as break sev'eral wires in the tendon. The final result was that the adaptor (with the field anchorhead inside) was now "cocked" at an angle of roughly

7. degrees from the vertical.

Rochester Gas and Electric, called upon Inryco to provide them with the following:

1. A repair procedure

2. Technical assistance iv an Inland Steel company

INRYCO, Inc.

Repair of Tendon V-75 'for

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Shims Protruding From Under Adaptor (Note that shims had to be cut with a torch so that jack chair could be placed.)

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S Repair of Tendon V-75 'for R.E. Ginna Nuclear Power Plant I. Re air of Pull Rod and Ada tor The threads on the pull rod and adaptor were refinished to allow proper thread engagement,. Enough threads were left as to permit a maximum engagement of 3-1/4 inches, The threads were inspected and approved by the Inryco representative (Russell Thompson). Marks'were made on the pull rod to assure that maximum engagement was made once the stressing jack was in place.

Because of the cocked nature of the adaptor, special tapered shims were fabricated (Fig. 2). The jack chair bore'directly on these shims which

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permitted the jack to lie in parallel with. the centroid of the adaptor, allowing engagement of the pull rod and adaptor. It should be noted that before the jack chair could be placed over the adaptor, some shims

'protruding from the shim stack had to be trimmed away with a torch to allow sufficient clearance (Fig. 3). The equipment was reinspected once more before destressing actually began.

Provisions were made for destressing the tendon in stages. This was to allow for the eventual removal of the tapered shims. However, due to sufficient slack in the tendon, it was possible to completely destress in one stage. Liftoff was achieved at about 3950 psi or 504 Kips. Due to the tendon's condition, an actual liftoff test could not be performed.

Appendix C contains the data sheets documenting the destressing operation.."

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Repair of Tendon V-75 for R.E. Ginna Nuclear Power Plant III. Tendon and Anchora e Ins ection The shims had indentations in them due to the tendon wires (Fig. 4,5).

This was due to a collision between the shims and wires which also caused several wires to be sheared as the anchorhead shifted over the shim stack. The thinner shims were also slightly deformed due to the impact (Fig. 6,7).

After detensioning, ll protruding wires were identified (Fig. 8).

These wires were removed with a wire puller. A wire continuity

~ test was conducted on every wire (Fig. 9). All told, 24 wires were found broken and removed. The anchorhead was raised 3 inches to visually inspect for any more broken wires (Fig. 10), 66 wires remained intact in the anchorhead and were in good condition.

The field anchorhead was found to be in excellent condition. Appendix C'contains the data sheets documenting the. inspection process.

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A Repair of Tendon V-75 for R.E. Ginna Nuclear Power Plant The original 8 inch shims were milled at both ends to make them square and remove'the indentations due to the wires. As a result, the shims were now 7 inches in height.

In accordance with the restressing procedure, the tendon was restressed in stages until it was possible to insert the original 8 374 inches of shims. Measured elongations were Less than predicted elongations; giving evidence that no other wires were broken. After retensioning, the tendon was inspected once more and found in good condition (Fig.ll).

Appendix C contains the data sheets documenting'the restressing process.'he final tendon lockoff force was 386 Kips.

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Repair of Tendon V-75 for

.R.E. Ginna Nuclear Power Plant Recommendations The following recommendations are made concerning tendon V-75 or future tendon operations.

I. Tendon V-75 sheuld be restressed to a level of 70% GUTS (Guaranteed Ultimate'Tensile Strength) + 5%. As it was, this tendon was restressed to only 50% GUTS.

Az. A visual reinspection should be performed 'for tendon V-75 as a final measure of resolution of this tendon.

'3. As a safety precaution, the repaired pull rod'nd adaptor should be. replaced.

4. For all future tendon operations,'ull en a ement of all threaded com onents must be enforced at all times.

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Repair of Tendon V-75 for R.E. Ginna Nuclear Power Plant APPENDIX A Inryco Repair Procedure QA 8309 an Inland Steel comoanv

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INRYCO QUALITY PROCEDURE QA 8309 Inryeo REPAIR FOR FIELD SURVEILLANCE R. E. GINNA en lnlsnd Steel company I. SCOPE This procedure will establish the requirements to complete the repairs for post-tensioning tendon V 75 of the Robert E. Ginna Nuclear Power Plant.

2. RESPONSIBILITY ht this time this procedure considers that Inryco shall only provide the repair procedure and field technical assistance to affect tha ropairs.

l ~ R.E, Ginns personnel shall provide the necessary Quality Control, Quality Assurance, Construction Management and Field .Labor. l 2s R.E. Ginna shall provide all necessary tools, aquipmant, scaf folds, cranes, repair items, etc. which are essential for the repair and retensioning of the tendon.

3. Inryco shall provide wire gripper for Tendon Wire Continuity Check.

i 3 PRERE UISITES 1~ R.E. Ginna its shall. provide a shim tapered to match the tilt of the anchorage in present position. This shim will be used under .the jack chair in order to permit a parallel alignment between the ram and the anchorage. This shim shall fully support both legs of the jack chair to prevent gouging the bearing plate.

2. R.E. Ginna shall repair the pullrod and ~ trassing adaptor.

4, TRAINING hll personnel involved in this repair shall be trained, with appropriate documenta" ti'on to be provided, in the requirements of this procedure.

5 PRECAUTIONS Care shall be exercised during all the following operations, to avoid personal injury or additional damage to the tendon. Remember that this tendon is still in a stressed condition and shall remain so, until all the shims are removed.

DETENSIONING OF TENDON Before det'ansioning, a partial inspection (without Wire Continuity Tests - Saa Section 7.) shall. be conducted. Number of effective wires will determine maximum allowable force (80X GUTS) ~ Care shall be axarcioad during all tho following operations, to avoid personal injury or additional damage to the tendon. Remember that this tendon is still in a stressed condition and shall remain so, until all th shims are removed.

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INRYCO QUALITY PROCEDURE QA 8309 Inl yco REPAIR FOR FIELD SURVEILLANCE - R. Ee GINNA an Inland Steel company

6. 1. Grind off or otherwise cut away any excess shim material protruding from the shit- stacks, that would interfere vith the .placement of the ram over the anchorage.

2. Place the tapered shim noted in Section 3.1, onto the bearing plate in the correct direction, to provide parallel alignment of the jack chair with the anchorage.

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3. Place ram over the anchorage onto the tapered shim. Adjust as necessary to provide acceptable alignment.

4. Couple pull-rod to stressing adaptor vhich is connected to the anchorage.

Check to ensure full thread engagement.

5. Pressurize the ram to effect a lift-offof the anchorage from the shim stack.

This should be only a small lift above the shims to permit remova'1 of the smallest shims. Care should be exercised during this lift-offas this is not a straight line pull on the tendon. Document the lift-off forces on the Dat'a Sheet.

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1. Pressurize ram at about 100 psi/min.

2. If liftoff is not achieved prior to reaching a gauge pressure delivering a force of 80X GUTS of tendon, pressurization shall discontinue and an evaluation conducted.

3. When possible; an effort shall be made to re-align the shims so that they bear more completely on each other while allowing the anchorhead to bear completely on the shims.

6. Depressurize the ram, allowing the load to be transferred to the shim stack and to permit the anchorage to begin centering itself over the tendon void.

Document the transfer load on the Data Sheet.

l. Once again, care must be exercised during transfer to make sure the load ia ~securel placed on the shin stack, chile the ~ tack retsains intact.

7. Repeat Sections 6.5 and 6.6 as many times as necessary .until the shim stacks are of equal height. At this time it will be necessary to remove the tapered shims under the jack chair to permit the anchorhead to center itself and allow a straight line pull. It now will be possible to completely destress the tendon in one operation, so long as visual inspection of the location of the anchorhead relative to the tendon void indicates that damage to the tendon will not occur.

8. Remove all equipment.

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rat A-8 INRYCO QUALITY PROCEDURE QA S309 Ieryco REPAIR FOR FIELD SURVEILLANCE - R. E. GINNA an Inland Steel company 7~ INSPECTION (TO BE CONDUCTED BY GAI/INRYCO) h,full inspection shall be conducted vhen the tendon is completely detensioned.

l. Inspect the anchorage for damage. Document results on Data Sheet.

1. Documentation to include: Condition of threads, damage to surfaces of stressing head,,and photographs of stressing head and shims.

2. Inspect the wires and buttonheads for orpull damage. Document results on the Data ~

Sheet.

l. Using the tendon wire gripper, each vire vith sufficient force to expose 4" of wire abave top of vire of stressing head. Visually inspec't exposed portion of wire and document nicks, gouges, scratches, etc.

Photograph each vire which shovs abnormal conditions. Again, 'mark a 'copy of the stressing head drawing (Figure 1) shoving locations and degree of damage for all continuous wires and locations of missing vires.

'2. Documentation to include: Visual inspection of condition of buttonheads and the visible portion of vires between stressing head and bearing plate vith locations of known broken or damaged vires being marked on stressing head draving.

3. 'nspect the bearing plate for damage. Document results on the Data Sheet.

1. Documentation to include aise and location'of any ridges, depressions or other unusual conditions.

8. EVALUATION (TO BE CONDUCTED BY GAI/INRYCO) 1'he results of the inspections .shall be evaluated for impact on that tendon and possibly the adjacent tendons.

2. Damage'o the anchorage and/or bearing plate i'f any, shall bo corrected prior to undertaking retensioning operations.

3. Once the effective number of vires is knovn, calculations shall be performed to control the lockoff force for retensioning and shim stack height.

1. The tendon shall be stressed just enough to install the original height of shims incremental'g

.(vhich is from the original strassing records, 8-3/4") For the ~

purposes of accomplishing the retensioning, calculate the theoretical elongation of the tendon from 1000 psig to 6000 psig in 500 psig rrecttve Date:

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I INRYCO QUALITY PROCEDURE QA 8309 Inryco REPhIR FOR FIELD SURVEILLANCE R. E. GINNA an Inland Steel company

8. 3. 2. Construct a table having columns for Gauge Pressure, Tendon Force, Theore-tical Elongation, Ram Position, Measured Elongation. Prior to retension<<

ing, complete columns for Gauge Pressure, Tendon Force, and Theoreti'cal Elongation. Gauge Pressures entered in the table shall be from 1000 to 6000 psig in 500 psig increments. Theoretical Elongation is 0 at 1000 ps Lge NOTE: THE TENDPN.WILL NOT BE STRESSED TO 6000 PSIG. IT WILL BE STRESSED TO h LEVEL NECESSARY TO INSERT THE 8-3/4" SHIM STACK HEIGHT.

RETENSIONING The pull-rod shall be attached to'. the stressing adaptor.

2. The stressing equipmont, ram, gauges, otc. shall ba in a current calibrated condition.

3. The ram shall be placed over the tendon and coupled to the anchor.

4.. The tendon shall be stressed to the level only necessary to install the 8-3/4" shim*stack height. During this stressing at 500 psig increments, the gauge pressure, ram position and measured olongation (starting at 1000 paig) are to be. recorded in the table prepared in item 8.3.2 above. During this ~

stressing operation, the measured and c'alculated values of gauge pressure ond

. elongation shall be compared.

1. With the tendon elongated 8-3/4", before shim installation, visually inspect tendon through tPindows in jack chair. Document condition, parti-cularly looking for damage to perimeter tFiros.

5. The shim stack shall be placed to provide the specified height.

1. The shim stack shall be controlled for'niformity of tho height of each stack, 2v The shim stack shall be placed so that the gap between stacks is not eXCOS S LVev II

3. The shims shall be placed in such a manner as to control the centering of the load on the bearing plate to the. anchorage and over the tendon void, 4., Document the results 'of the required shim alignment controls on Data Shoot 6~ Seat anchor head'n the shim stack and decrease proasuro to 2000 paig. Not necessary to specify rate of depressurixation of ram.

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A-7 INRYCO QUALITY PROCEDURE QA 8309 4nm yco REPAIR FOR FIELD SURVEILLANCE R. E. GINNA an Inland Steal company

9. 7. Pressure the ram to verify the lift-offpoint. The lift-offmay be taken by placing, about .035", shim stock into each shim stack. When pressure is applie and the shim stock can be removed, that point is lift-off.

1. The lift-offforce shall be documented.

8. Transfer the load on to the shim stack by deprossuriaing the ram.

9~ Uncouple and aside all equipment.

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Provide a final visual inspection of the completed tendon.

ll. Apply sufficient quantities of corrosion protection compound to I

the anchorage, the wires and the void.

12. Replace the tendon cap.

13. Pill the void with corrosion protection compound.

10 'INAL REPORT Develop final report snd submit for approval within 30 days after completion of 'wor 11 'ONTINGENCY In the event that unforeseen problems develop during the repair operati.on, i.t CD suggested that the tendon remain detensioned until such'.time that those problems may be corrected.and documented.

I. In the event that this procedure becomes unworkable at some point due to the unforeseen problems, an addendum to this procedure shall be developed by Inryco to control that situation.

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Repair of Tendon V-75 for R.E. Ginna Nuclear Power Plant APPENDIX B R.G.&E. Repair Procedure &i 376 an Inland Steel company

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UNIT g1 COMPLETED DATE: ~

ROCHESTER GAS AND ELECTRIC CORPORATI RIME:-

GINNA STATION CONTROLLED COPY NUMBER PROCEDURE NO. EH-376 REV. NO. 8 TENDON REPAIR FOR TENDON V-75 TECHNI-AL REVIEif PORC REVI EW DATE t 0 I - 3 QC REVI Et$ PLANT SUPER NTENDENT EFFECTIVE DATE QA K. NON QA CATEGORY 1.0 REVIEWED BY!

THIS PROCEDURE CONTAINS 7 PAGES

+ 6 ATTACHMENTS

EH-376:1 EN-376 TENDON REPAIR FOR TENDON V-75 AD PURPOSE:

This procedure will establish the requirements to complete "the repair for post tensioning tendon V 75 o f the Rober' E. Ginna Nuclear Power Plant.

2.0 REFERENCES

2 ' None 3 ' INITIAL CONDITIONS:

3.1 At thxs tame thxs pro" edure considers that -Inryco shall only provide the repair proceDure and field technical assistance to effect the r pairs.

3 ' RG6 E personnel shall provide the necessary Quality Control, Quality Assurance, Construction tlanagement and FielD Labor..

3-3 RG&E shall provide all necessary tools, equip:nent, scaffolds, cranes, repair items, etc., which are essential for the repair and retensioning of the tendon.

3e4 Inryco shall provide wire gripper for tendon wire continuity checks.

3 ' R ~ E ~ Ginna shall provide a shim tapered to match the .tilt of the anchorage in its present position. This shim will be used under the jack chair'n order to permit a parallel alignment between the ram and the anchorage. This shim shall fully support both legs of the jack chair to prevent gouging the bearing plate.

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RG&E shall repair pullrod and stressing adapter.

EH-376:2 Before detensioning, a partial inspection shall be conducted.

Inspection shall determine the number of effective wires to d'etermine maximum allowable force at 88% Guaranteed Ultimate Tensile Strength (GUTS).

~r 3 ' All personnel involved in this repair shall be trained, with appropriate documentation to be provided, in the requirements of this procedure.

4' PRECAUTIONS:

4 ' 'Care shall be exercised during all the. following operations, to avoid personal injury or additional damage to the tendon.

Remember that this tendon is still in a stressed condition and shall remain so, until all the shims are removed.

5.0 INSTRUCTIONS

5 ' DETENSXONjNG OP TENDON:

5 ~ 1 ~ 1 Use a torch to remove any excess shim material protruding from the shim stack, that would interfere with the placement 3r, 5.

of the ram over the anchorage.

5.1.2 Place the tapered shim noted in Sectiop 3.5, onto the bearing plate in the correct direction, to provide parallel alignment of the jack chair with the anchorage.

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5-1 ~ 3 Place ram over the anchorage onto the tapered shim. Ad just as necessary to provide acceptable alignment.

5 ' ~ 4 Couple pull-rod to stressing adaptor which is connected to the anchorage. Check to insure full thread engagement.

5-1 Pressurize the ram to effect a lift-off of the

~ 5 from the shim stack. This should be only a smal 1 the shims to permit removal of the shims. 'Care lianchorage f t above should be exercised during this lift-off as this is not a straight line pull on the tendon.

the data sheet.

Document the lift-off forces on

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EN-376:3 5.1.5.1 Rate of ram pressurization shall not exceed 180 psi/sec.

i..l-5.1 ~ 5 ' If 1'ift-off is not achieved prior to reaching a gage pressure delivering force of 80% guts of tendon, pressurization shall discontinue and an evaluation conducted. SV04 P>lG~

5~1~5~3 llhen possible, an effort shall be made to re-align the shims so that they bear more completely on e'ach other while allowing the anchorhead to bear completely on the shims.

5.1.6 Depressurize the ram, allowing the load to be transferred to the shim stack and to permit the anchorage to begin centering

,itself over the tendon void. Document the transfer load on the data sheet.

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again, care must be exercised during trans'. r to make the stack remains I erg~ ~

5 '.7 Rep until at Sections 5. l. 5 and 5. 1;6 as many times as necessary th'e shim stacks are of equal height. At this time, it will be n cessary to remove the tapered shims jack chair to permit the anchorhead to center itself and under the ~

allow a straight line pull. It now will be possible to P

y completely destress the tendon in one operation so long as visual inspection of the location o f the anchorhead relative to the tendon void indicates that damage to the tendon will not occur.

5~1~0 Remove all equipment.

5.2 I:INSPECTION (To be conducted by GAI/INRYCO):

5. 2. 1 '

full inspection shall be conducted while tendon is detensioned.

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' ' Inspect the anchorage for, damage. Document'esults on the data sheet.

0 EM-376:4 5.2.2 ' Documentation to includez condition of threads, any damage to surfaces of stressing head, and photographs of stressing head'nd shims.

5~2~3 Inspect 'the wires and buttonheads for damage. Document results on the data sheet.

5.2.3 ' Documentation to include: visual inspection of condition buttonheads and the visible portion of wires'etween

'f stressing head and bearing plate with locations of known

. broken or damaged wires being marked on stressing head drawing.

(Figure 2.8) 5 ' '.2 Using the tendon wire gripper pull each wire with sufficient force to expose 4" of wire above top of stressing head.

Visually insp ct exposed portion of wire and document nicks, gouges, scratches, etc. Photograph each wire which shows abnormal conditions. Again, mark a copy of the stressing and degree o f damage for all continuous wires andlocations head drawing showing locations of missing wires~

0 5~2~4 Inspect the bearing plate for dama je. document .results on the data sheet.

5~2~4~1 Documentation to include size and location, of any ridges, depressions or other unusual conditions.

5.3 EVALUATION (To be conducted by GAI/INRYCO):

5.3.1 The results of the inspections shall be evaluated for impact on that tendon and'ossibly the adjacent tendons.

P 5 '.2 'The effective amount of wires, once known, shall have calculations performed to control lockoff forces for retensioning and shim stack height.

EN-376:5 5.3.2.1 The tendon shall be stressed just enough to install the original height of shims (which is from the original stressing records, 8 3/4") For the purposes of accomplishing the

~

retensioning, calculate the theoretical elongation of th tendon from 1888 psig to'988 psig in 580 psig increments.

,5 ' ' ' , Prior to retensioning, complete columns on data sheet for

~

Gauge Press@re, Tendon Force, and Theoretical Elongation.

Gauge Pressures ntered in the table shall be from 8 t'o 6838 psig in 588 psig increments. Theoretical Elongation is 8 at 1808 psig.

0 h

NOTE= THE TENDON HILL NOT BE STRESSED TO 6080 PRIG.

IT NILL BE STRESSED TO A LEVEL NECESSARY TO 8 3/4" INSERT'HE SHIN STACK HEIGHT ~

5.3.3 Damage to anchorage and/or bearing plat , if i

be corrected prior to undertaking retensioning operations.

any, shall C'.

5.4 RETENSIONING

5~4 ~ I The pull-rod shall be attached to the new stressing adaptor.

5-4 ' The stressing equipment, ram, gauges, etc., shall be in a current calibrated condition.

E 5.4 ' The ram shall be placed over the tendon and coupled to the anchorage..

5.4.4 The tendon shall be stressed to the level only necesshry to install the 8 3/4" shim stack height. During thiq stressing at 5,88 psig increments, the gauge pressure, ram position and measured elongation (starting at 1888 psig) are to be recorded in the table. During this stressing operation, the measured and calculated values of gauge pressure and elongation shall be compared.

EM-376:6 5.4 ~ 4~1 '.lith the tendon elongated 8 3/4+", before shim installation, visually inspect tendon through windows in jack chair.

Document condition, particularly looking for damage to perimeter wires.

C4.'

5.4 ' The shim stack shall be placed to provide the specified height. Document the order and size of shims on the data sheet.

~

Cf-5 ~ 4. 5 ~ 1 The shim stack shall be controlled for unxformity, of the height of each stack.

r 5.4.5.2 The shim stack shall be placed so that the gap between stacks is not excessive.

5 4 '.3 The shims shall be placed in such a manner as to control the centering of the load on the bearing plate to the anchorage and over the tendon void.

C.

5.4.5.4 Document the results of the required shim alig'nment controls on the data sheet.

h 5.4.6 Seat anchor head on the shim stack and decrease pressure to 2888 psig. Not necessary to sp cify rate of depressurization of ram.

C'.d..4.7 Pressurize the ram to. verify the lift-off point. The lift-off

~ may be taken by placing, about .035",'him stock into each shim stack. i0hen pressure is applied and the shim stock can be removed, that point is lift-off. t".u.

5~4~7~1 The lift-off force shall be documented on the data sheet.

5 '.8 Transfer the load the ram.

on to the shim stack by depressurizing 5'F 9 Uncouple and aside all equipment.

t ~

EH-376:7 5 ' 10 Provide a final visual inspection of the completed tendon.

Cz..

5 '.11 Apply suffici'ent quantities of corrosion protection compound to the anchorage and the wires to. provide protection against moisture until testing is complete and the void can be filled.

5.4.12 Replace the tendon cap.

'I 5.5 FINAL REPORT:

5.5.1 Develop final report and,submit for approval within 39 days after completion of work.

5.6 CONTINGENCY

5.6.1 In the event that unforeseen problems develop during the repair operation, detensioned until it is suggested that the tendon rem'ain such time that those problems'may be corrected and documented. Otnerwise mark'N/A.

CO:DEPLETED BY:

DATE C04IPLETED:

Q- C ~ SUPERVISION:

R&T SUPERVISION:

PORC REVIE(l DATE:

<nn i iv, <nc.

Repair of Tendon V-75 for R.E. Ginna Nuclear Power Plant APPENDIX C Repair -Work Data Sheets an Inland Steel company

A'L'XAt;rma5'x' Tendon No. 75 Anchorage Repair C-Z Data Sheet 1 - Detanaioning Record Dace a /O// FZ i) Tendon Identification No.. 7W Anchorhead No. RG-d O

2) Hydraulic Jack No. 7-)4t7- 2 Pump No. &~ lfOg.

3) Pressure Gauge No. OO 0

4) Hydraulic Ram Calibration EquationsForce (Kivs)*~0.896+0.1274xGaP.(PS:

5) Initi.al Anchorage Conditions!

6) Pressurization/Depressu'rization Records Tabla 1.0 Mnnouvers Condition 1st 2nd 3rd 4th 5th

a. Lift-Off

- Pressure {PSI) Q

- Force (Kips)* SOS/

- Ram Position 7 J

(inches) 1,

b. Transfer

- Pressure (PSZ)

- Force (Kips)* 0

- Ram Position

. (inches)

c. Shim Removal et 4&au PCAe' Jg

d. Shim Addition '2 + 2 //a / dZ rdrC

e. Comments ompleted by>

( Date:

S)'c ceavesesscs,s c c Tendon No. 75 Anchorage Repair Data Sheet 2 Inspection Record gQjQQ g~~~~droM~my i7 ~ff'3 Date: dC r i/:3

1) Tendon Identification No. Anchorhead No. 8&

2) Hydraulic Jack No. - 5 00-/Z. Pump No'. ~~ f7~~/ ~/VQ Pgg

3) Pressure Gauge No. 00 l

4) Anchorage Inspection

a. Thread Condition: EK CC ZC Eiu

b. Surface Condition: Ddt

. A ~Q g~r or7 CAccfl u,~M

5) Mire and Buttonhead Inspection pre'rD)'>>)

a.',Comments: / 2Z ft cess r/lseX

~X l pcs'ss s~,.i, oMW 2.

It'ass . .l4

~ DM~+.

Z'+

ss' ss 7'6 s. XP E/4gscc~ 4S o~ .tl:YS +r.

b Complete Figure 2. 0:

6) Bearing Plate Inspection

a. Comments: 3/o Miscellaneous Comments:

gN

./,',0 p~S

~ ~ ~ +~ ~icR)

I

~

Completed by:

A/D ss jfdr J~ c 'ssssscrvcZ

/Guh'E 2 o )( (nj p0 l I

](1 9

g)l, 00 IP' 000000 Qq,)(((,'~

~i~

OOOOGOO 0 000000000(

QOOO 000" 000 000 Oc00 0" OQ 000 OG>0 80<00 SSG(000 000 000 000~'80000 00( 0(0 0G WoTpS:

80~ Oi I. MA,RK LocATloQ Gt= AACWGR-PEu D QOm6as IQ Pl (6 9 V<am, Q, 5HOM AQROV/ POlkl T lklCq TOWARD CLEAT'6R, oF PBACTOR, QLQQ, Z. P LACKS'lRE, HOLE TO lQtoK.ATE. BRoKEW wiREg.

Q, IQDICA,TE L-OCATlOhJ OZ D4M<QFD WlP,E5 4 GGC.UMEhlT QAMAQE /OR EACH Vll+4 .

p<IDA 7>8c i'EIIJslo<</i<~Cg ofjD>>

Co ~pl c Wc2 d'p.'

.>'t t.'il'.<<'X 8

/GUfs'E 2 g MTJ

/4 0

C3 QQG 0' o v u u

~

Oo 0~

'D O~ 0~'< 0" 8" '~'i Qu 0> 0< Q" S Q Qu Po Qv pup~

06 Qu 6 Qv Q:

4,Q Oo . Oo NO~0~ 0" 8 (Q Q ,Qo 0> OU r 6 0~ Q~ Qv 0~ 0' 0" "

8@6~ Ou Q 0~.0" 0 goTES:

SQ~ Q~ Q~,0~ 0>

~9 Qi )-.

~A,gg LOCA< IOW G~ A~<~<R pE<D Qu~6aw tQ PLAA V~B~

~ 5~~~ ~qua~ polQTlh3@ 'TowARD gg+TE.p, oP PBAcToR BLDG.

g.BLAcKBH &BARF Hot.E To lQotc.aTE. BRoKEA vliRES.

g, ~QD~<.+'Tp LocATIoQ oP u o o ~~

o Is 1

Q 'lt nemacec wtRe5 4 o><U~iAT "

~

4 I ~

pg~p,C F FoP E<cg vJ)RK ~

p~)y ~ m'DFFEiV~iowrn/Cr

'g

~

p~

~ e Date:

A ATTACR1ENT IV Tendon No. 75 Anchorage Repair Q- Co Data Sheet 3 Retensioning Record Date: / L5

1) Tendon Identification No. 7~ Anchorhead No. Ag hd

2) Hydraulic Jack No. +5 OO-/2 Pump No ~

9')

Pressure Gauge No. 00 P

4) Hydraulic Ram Calibration Equation Force (Kins) =0.896+0.1274xG.P.(PSZ.

5) Elongation Record: Table 2.0 Gauge Force* Calculated Ram Measured Pressure Elongation+ Position Elongation (PSI) (Kips) (inches) 'inches) (inches)

~

cf 5'00 /-~Is .

1000 IZS- 5 1500 /9Z.c ~s 0. P4 '3- aP /

2000 >55-7 ~/66r /. 72 / (.l' 2500 3ono 'J'~ ~ 5 7/a p~so 35oo 'N.SVIV. 0 4000 S /0-5' 5:K'500

+7/ w 5OnO C57 g 4-g7 5500 7u/. 0 ~ 7.7g 6000 . y &go g.SQ

6) Condition of Tendon: Ply

7) Steel shims added for 8-3/4" stick height,=

Size By Order from Base Plate '. 7 '//'

=

"<p ~~@~

~~ <iF~//ee <e- o<f//e>> 7o>>gM /5/o= ~KKF+

.'pg~~

'0747 ncaa'r w v~

I rt.

~XWuAr 4, .

ATTACHMENT V Tendon Ho. 75 Anchorage Repair 8-7 Data Sheet 3A Retensioning Record

(' Results of Shim Alignment: Complete Figure 3.0

]) ~~Jt<>

9) Ram Pressure and Force at Lift-Off: PSI 2 0 g Kips S P4-7 I

~) C I~) agoo (/).=2 *r q >

e / t .

p e "~p '>@-~/iz COmpleted by: ~* Z.

Date:

CAF/107,

F- /6 U8'8 ATTACHI".EHT VI A!lCl/ppb'EA'Orr'h ]m //IlL/Griuarrr l"god< r os/ rrou

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5:'Ah's~C IM 7 C proo. i > 'Cloth rosrtrous 7 ow~rcl Ce~7c'r oy !guise.

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