ML18046B081

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Surveillance Procedure for Containment Bldg Post-Tensioning Sys
ML18046B081
Person / Time
Site: Palisades Entergy icon.png
Issue date: 06/24/1981
From:
BECHTEL GROUP, INC.
To:
Shared Package
ML18046B079 List:
References
TSFT-2(Q), NUDOCS 8111230494
Download: ML18046B081 (23)
v • d • e


Text

SURVEILLANCE PROCEDURE~

FOR CONTAINMENT BUILDING POST~TENSIONINC SYSTEM FOR CONSUMERS POtJn COMPANY PALISADES NUCLEAR PLANT

  • SOUTH HAVEN 1 MICHIGAN BECHTEL ASSOCIATES PROFESSIONAL CORPORATION REVISED AS NOTED*

REVISED AS NOTED INCORPORATED PRC '.2 COMMENTS AND REVISED DOC

  • COMMENTS AND REV SE DATI llVlllONS OllllllN CPCo - GW0-5158 CH'K CONSUMERS POWER COMPANY PALISADES. NUCLEAR PLANT SOUTH HAVEN, MICHIGAN J08"o. 12447 /066 SPECtOIES GUIDE Mo.

. REV.

4

. 8111~:94 811:1~

TSFT-~(Q)

PDR ADOCK 05000255~

1 --------------------.-..----==--=---~!.zz::..,,_.._......,....,. __ _. __ _

P, PDR I SHEET_..___ o*----

SURVEILLANCE PROCEDURE FOR TSFT~2(Q) 0 Rev 4 Job 12447/066 CONTAINMENT BUILDING POST-TENSIONING SYSTEM CONTENTS

l. *GENERAL Ae Purpose B.

Nomenclature

2.

SCOPE

3.

PRECAUTIONS AND NOTES

4.

INSTRUMENT CALIBRATION

5.

SURVEILLANCE TENDONS

6.

INITIAL INSTALLATION AND PREVIOUS

  • SURVEILLANCE DATA
7.

DETENSIONING AND INSPECTION A.

Sheathing and _Filler B.

Inspection of Anchorage Components and

  • Surrounding Concrete C.

Tendon Detensioning Procedure

  • D.

Surveillance Wire Removal E.

  • Wire Testing
  • 8.

RE'l'ENS ION ING TENDONS

9.
  • RESEALING TENDONS
  • 10.
  • EVALUATION AND CORRECTIVE ACTION
11.

ACCEPTANCE CRITERIA

12.

DATA REPORTING AND RECORDING i

PAGE 1

2 3

3 4

4.

4 10 11 12 12 13

APPEUDIXES A.

c.

Procedure for Calibration of Hydraulic Rams and Pressure Gages Procedure for Testing Wire Specimens Surveillance Data Forms TSFT=2(Q), Rev 4 Job 12447/066 Al Bl Cl Procedure for Laboratory Testing of _Sheathing Filler Dl El Corrosion Level Definitions F.

Required Submittals Fl FIGURES

. 1.

Go, No-Go Gage 14 2

  • Wire Puller 15 c!JO
3.

Wire Puller - Details 16 C-1 Sheathing Filler Removal and Installation C2 C-2 De tensioning and Re tensioning Data C3 c-3 Tendon Wire Anchorage Sketch C4 C-4 Tendon Wire Inspection cs c-s *Tendon Wire Test C()

c-6 Calculation Sheet C7 ii

lo GENERAL A.

Purpose TSFT=2(Q)

  • Rev 4 Job 12447/066 This procedure specifies the items to be performed to obtain data to assess the quality and structural performance of the containment post-tensioning system.

Bo Nomenclature Anchor assembly Anchor head Bearing plate Bushing Buttonhead Jack Sheathing filler Tendon 1

The end anchorage hardware for tendon wires.

Anchorage hardware includes shop or field anchor, grease cap gasket, grease cap gasket retainer, and grease cap.

The round, machined steel piece at the end of tendon through which 1/4-inch diameter wires pass and upon which the buttonhead bear.

A steel plate used in.conjunction with a trumpet.

The spacers bear directly on the bearing plate which in turn transmits the load to concrete**

The steel ring, threaded on both inside dimension and outside di-mension which. threads onto the small anchor head to provide bear-ing for the shims.

The upset portion at the end of the wire.

A.device to stress the tendon.

A corrosion protection agent, Visconorust 2090P-4, to b~ pumped into the* sheathing after tendon is stressed.

A strand of 90 high strength steel wires, 1/4-inch in diameter, used for.prestressing reactor contain~

ment building.

l

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  • ~

I' I

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f,

/,.

~

2.

SCOPE TSFT=2(Q) 6 Rev 4 Job 12447/066 A.

This procedure satisfies the requirements of Technical Specifications for.Palisades Plant FSAR, Section 4.5.4 (Licensing Amendment 31).

Each surveillance shall consist of the following:

1)

Visual and laboratory examination of sheathing filler

2)
r:nspection of anchor assembly for* deleterious conditions such as corrosion, cracks, missing wires, or Off-si~e buttonheads
3)

Measuring the height of the existing shim stack (clearance distance between the bearing plate and ~nchor head on the field end or the bushing on the shop end)

.4)

Measuring lift-off force

5)

Detensioning the tendons and inspecting for damaged or broken wires

6)

Removal of a minimum of one wire from three selected surveillance tendons, one from each group:

hoop, vertical, and dome, for examination and testing (Consumers Power Company shall select the three tendons from which ~ires are to be removed. )

7)

Visual inspection of. the concrete surrounding the bearing plates of all surveillance tendons

8)

Re tensioning the tendons to the lift-off force measured. in Item 4 above,

  • less the effect of any.wires removed and measuring*

corresponding* tendon elongatiori

9)
  • Visual inspection of wires removed from tendons.
10)

Testing* of wires.removed from tendons. for yield, ultimate str~ngth, and percent of elongation

. ~. *..

ll). £valuation of test and insp~ctiori results to

'assess the general condition of the post::..

tensioning system and to evaluate time-dependent

. factors such a.s prestress losses* and corrosion 2

3 0 PRECAUTIONS AND NOTES TSFT=2{Q), Rev 4 Job 12447/066 A.

During the time between removal or loss and replace-ment of sheathing filler from each tendon, the tendon end anchors shall be protected with Visconorust 2090P-4, manufactured by Viscosity Oil Company.

B.

If tendon surveillance is conducted at anytime other than cold shutdown, no more than one surveil-lance tendon shall be detensioned at any time.

If adjacent tendons must be checked, the original surveillance tendon shall be retensioned.

c.

Shims must be centered within 1/4 inch of center of bearing_ plate to accommodate the gr.ease cans.

D.

Any indication of abnormal degradation of the post-tensioning system shall be reviewed with CPCo.

E.

Drawing location for all tendons is shown in CPCo's document file C-51. -

F.

  • The elapsed time between removal and replacement of sheathing filler from each tendon shall not exceed 3 weeks.
4.

INSTRUMENT CALIBRATION A.

All instrumentation used for the tendon surveillance

_shall be calibrated. - The instruments to be calibrated according to industry standards include:

1)
  • "Go" -

"No""".Go'_' gages {Figure l)

2)
3)

Imme~sion dial thermometers or bulb thermometers

4)

Optical comparators

  • S.)

Surface thermometers The. following instrum~nts shall. be **calib_rated by the calibration procedure contained in Appendix A:

Hold point for Bechtel witness f)

Rams

2)

Pressure gages 3

TSFT-2(0) w Rev 4 Job 12447/066

5.

SURVEILLANCE TENDONS

6.

A.

Consumers. Power Company and/or its technical representative shall select three hoop, three dome, and three vertical tendons from the following tendon list for the 10-year surveillance.

If interferences are found from a surveillance standpoint, substitutions may be made.

CPCo-approved tendons are circled in the fpllowing list:

1)

Hoop Tendons: (Select one from each column for a complete circle of the containment. )

  • 4SBD*

( 67BF )

42DF 54BD 73BF 51DF

( f2ZBQ )

78BF 64DF 72BD

( 73DF )

2)

Vertical Tendons: (One group of three at 120-degrees spacing)

V-38 V-46

( :!l-!H2

)

V-158 V-168

( :!l-l 2g )

V-284 V~294

( Y-306 )

3)

Dome Tendons: (One from each group)

( Dl-32)

  • D2-35

( 03-35)

Dl:--45.

( D2-45 )

D3-45 Dl-55 D2-55 D3-55 INITIAL INSTALLATION AND PREVIOUS SURVEILLANCE DATA A.

Original records of tendon installation and subsequent

. surveillance are stored and maintained by CPCo.

These records are stored at the Palisades plant.

The initial installation data for the surveillance tendons and sheathing.filler are given in the form of tendon pulling, buttonheading, tensioning, and

. sheathing filler cards.

Surveillance data are giv:en in the form of surveillance reports and data recorded during surv~illance.

7.

DETENSIONING AND INSPECTION A.

Sheathing Filler

1) * *Record all data.in Figure C-1.

The sheathing filler, Visconorust 2090P-4, may be in liquid, gel, or solid form.

Complete removal of 4

TSFT-2{Q), Rev 4

.,Tob 12447/066 sheathing filler is not required, provided that all filler which has drained out or been removed during surveillance is replaced.

Provisions shall be made to collect all filler which is removed in such a manner that the volume removed at each tendon is knowno The sheathing filler removal and sampling procedure shall be as follows:

a)

Record the containment exterior concrete temperature near the tendon using surface thermometer.

b)

Open the tendon end cover fill plug and drain filler into a container.

cJ When flow through the fill opening is very s.low or in termi t tent, remove cap.*

d).

Observe and record in Figure C-3. the completeness *of sheathing filler.. coverage on the inside of the end cap, bearing plate, buttonheads, anchor head, bushing, and shims immediately after removal of the filler cap.

e)

Obtain two. 1-quart samples of sheathing filler from each surve~llartce tendon*

(one from each end) for analysis per Appendix D.

Identify each sample appro-priately..

The containers shall be fre.e

  • from contamination or foreign* agents.

d)

Measure and record the volume of sheathing filler removed.from each tendon.

B.

Inspection of Anchorage Components and Surrounding Concrete 1). *The tendon and anchorage components shall be thoroughly cleaned. with Viscosity Oil Company Indus.trial Solvent.Number 16, after cleaning,*

the. componen'ts snall be inspected as *follows:

a)

Inspect the stressing washe.r, *bushing, buttonheads, shim~, and bearing plate.

for corrosion (corrosion levels defined in Appendix E) and cracks (splits) and record in Figure.C-3.

5 I

TSFT-2 ( Q), Rev l:

Job 1.2447/066 b)

Record any missing, corroded, or unusual buttonheads in Figure C-3.

c)

Prepare a sketch of the concrete surrounding the bearing plates of all surveillance tendons.

Cracks exceeding 0.01 inch in width shall be recorded on a sketch.

The crack size is determined with an optical comparator and recorded in 0.005-inch increments.

The concrete surveillance area included in the sketch covers an area approximately 4 feet-long by 4 feet wide.

c.

Tendon Detensioning Procedure

1)

Detensioning shall be done from the same end{s) as done in the original tendon tensioning.

All data and events which occur during detensioning shall be recorded in Figure c-2.

The detensioning procedure shall be as follows:

a)

Record the containment exterior concrete temperature. near the tendon anchorage b)

Measure the existing shim stack to within 1/16 inch

  • c)

Attach-the ram to the stressing washer d).

Attach the pressure gage to* the ram e)

During detensioriing of dome and hoop tendons, an approximately equal force level shall be maintained on each tendon end at all tii:nes.

Use the ram/gage combination for which a corrected pressure versus force curve has been prepared.

  • f)
  • Lift-off is that point where stress is transferred from the shim stack to the jack.*

Three lift-off measurements* shall*

be made for each tendon (see Figure c-2).

Lift-off' shall be determined by the following method:

(l)* "Ring" the stack of shims by striking both sides of _the stack with a 6

g) h)

i)

TSFT~2(Q), Rev 4 Job 12447/066 metal hammer (approximately 24 ounces) and listening for the sound change.

When the shims are under compressive stress, they will make a ringing sound when struck.

When there is no longer any load on the shims, the sound will change to a dull thud.

The lift-off is determined by continuously striking the shims with the hammer and noting the gage reading when the sound changes.

It is the minimum force at which all shims can be moved laterally by pounding with a hammer while three consecutive measurement.s fall within a 100 psig ram pressure range.

Reduce the jack force to zero after the first lift-off measurement so that the prestressing

  • force is transferred back to shim stacks.

Repeat *the same procedure for the second and third lift-off measurements and record onFigure*C-2

  • NOTE:

Both sides of the shim stack must be loose to establish the lift-off reading.

If lift-off occurs at different times from one side to the other and the gage difference is more than 200 psi, measure and record the difference in shim stack heights (verify that the heig~t of each shim stack is within 0.030 inch of the other).

The higher gage reading of the two shall be the lift-off pressure recorded on Figure C-2.

After the lift-off force is determined, and recoraed on Figure c-2, the tensioning force can be increased to allow removal of shims, but shall not exceed 80% of the specified minimum ultimate strength of.~he wire (0.8 x 240 ksi or 9.43 kips per effective wire on Figure C-2).

Record maximum gage reading prior to detensioning.

Remove all shims Reduce the ram force to zero and remove the ram 7

TSFT=2(Q) 8 Rev 4 Job 12447/0~6 j)

Tendon wire shall be checked for continuity by pulling or rotating each wire and observing the movement at the other end.

The tool for pulling individual wire is shown in Figures 2 and 3.

The discon-tinuous wires shall be shown on Figure C=3, Appendix c.

These wires should not be considered as surveillance wires.

k)

Inspect buttonheads for shape and size, using the go, no-go gage shown in Fig.ure 1, and for corrosion and general appearance.

Record any off-size buttonheads in Figure C-3.

2)

Pressure gage shall be checked against master gage before and after each daily use *

.

  • D.
  • surveillance Wire Removal 1).

The surveillance wires shall be removed as follows.

a)

CPCo and/or its technical representative

  • shall have selected the vertical, hoop, and dome tendons *from which one sur-veillance wire is to be* removed.* for inspection and testing.

Select and. mark

  • both ends of the surveillance wire and record its location in Figure C-3.

The

.corresponding wire 'ends are identified by pull.ing or rotating at one* end and observing which.buttonhead moves* at the

  • .other end.

The surveillance wire shall not be removed from tendons from.which a surveillance wire was pulled in an earlier test~

b)

Pull the wire toward the end.to be cut and cut the wire as close to buttonhead as possible.

c)

Remove the remaining. *portion of *wire and clean it with Viscosity Oil Company Industrial Solvent Number 16 or approved *

  • *.equal. *Inspect and sketch* the wire, showing the.location of any*corrosion or damage and note corrosion level using the definitions given in Appendix E using Figure c-4.

8

TSFT-2(Q), Rev 4 Job 12447/066 d)

If the corrosion level exceeds Corrosion Level 4 (Appendix E), an additional wire shall be removed and inspected in accordance with Subparagraph 7.D.c above.

E.

Wire Testing

1)

Strength and elongation tests shall be performed on the removed wires.

One tensile test specimen shall be taken from each end of the wire and one at mid-length.

Length of wire specimens shall be a minimum of 101 inches.

Additional specimens shall be taken from areas which have a corrosion rating two or more levels greater than the average corrosion level of the wire.

In any event, a specimen shall be taken in the area exhibiting the greatest corrosion of any surveillance wire removed.

Tensile tests shall also be made on at least two specimens from each broken wire removed, one from each broken segment.

The test specimens shall be taken from near the wire break and shall be 101 inches long, unless the break is less than 101 inches from the wire end.

Tag and identify.the specimen imme<M.ately before cutting using Figure C-4 as a guide.

The wire test shall be in accordance with Appendix B.

Surveillance wire material not used for test specimens shall be protected from corrosion until tensile test results are found acceptable.

8..

RETENS IONING TENDONS A.

Retensioning shail be donefro~the same end(s) as the original tendon tensioning.

All data and events which occur during retensioning shall be recorded. (*Appendix C).

The retensioning procedure

. shall be as follows:

l)

Attach the ram to** the tendon *anchorage

2)

Attach the. pressure gage to the ram after.

checking it for damage

3)

During retensioning of dome and hoop tendons, an approximately.equal force level shall be maintained on each tendori end at any time

  • 9
4)

TSFT=2 (Q}, Rev 4 Job 12447/066 Record the containment exterior concrete temperature near the tendon anchorage (Figure C-1)

5)

Increase tensioning force until average wire force is 1,000 pounds per wire, and measure the tendon force and the distance from the bearing plate to the inside face of the stressing washer at the field end, and the distance from the bearing plate to the inside

  • face of the bushing at the shop end 6).

Increase tensioning force until average wire stress is*80% of the specified minimum ultimate strength of the wire co.a x 240 ksi or 9.43 kips per effective wire per Figure C-6, Appendix C)

7)
8)

. 9)

10)
11)

NOTE: Do not exceed a total elongation (distance from bearing plate to stressing washer) of i.5 times the original shim stack height at either end of the tendon without an engineering

.evaluation.

Record on Figure C-2 the maximum tensioning force. and the corresponding d.istances between the bearing plate and stressing washer

  • Reduce tension back to original lift-off plus 5%
  • Install sufficient shims to obtain lift-off -
  • force equal to that* measured in Subparagraph* 7.C.!.f

. (tolerance plus 5%, minus 0%), less the.

effect of any reduction in the number of effective wires.

Reduce the ram pressure to permit ram removal. *Lift-off force shall be determined as described in Subparagraph 7.C.!.f

  • Detach the ram Measure and record the new shim stack within 1/16 inch Apply a _coating of Visconorust 2090P-4 to the tendon end anchorage
9.

RES*EALING TENDONS.

A.

The tendon *resealing procedure shall be as follows *

1)

Install tendon filler.caps using new gaskets and gasket sealant as used during original

._10

2)

TSFT-2(Q), Rev 4 Job 12447/066 construction.

Gaskets shall be closed cell neoprene sponge complying with ASTM SCE 430 1056 65T or approved equal.

Refill the tendon system with Visconorust 2090P-4 sheathing filler.

Measure the temperature of the sheathing filler in the container and record on Figure c-1.

The filling procedure shall be similar to that used during initial installation or approved equivalent, utilizing all accessible valves, vents, and drains.

Pumping shall*coritinue until the amount of

.grease removed at each end is replaced.

Pumping may be necessary at each end.

  • Each end shall be vented to bleed out air and 1 gallon of filler without air bubbles.

NOTE* 1: The temperature of the filler in the container shall be between 150 and 200F.

NOTE 2: Do not reuse filler which has been removed from a tendon.

3)

Determine the volume of sheathing: filler installed in each tendon and ensure that the amount* removed is replaced and recorded in.

  • Figure.c-1.

, 10. - EVALUATION AND CORRECTIVE ACTION A.

.*.Lift-Off Forces

. 1)

If one-of' the nine surveillance tendons fails tomeet the minimum and maximum forces in the acceptance criteria, an adjacent tendon on*.

each side of that tendon shall be tested and considered as surveillance tendons.

If both*

of these tendons meet the criteria,* then the tendon surveillance program shall proceed considering the single deficiency as unique

, and acceptable.

However, if-either adjacen_t

  • tendon fails to meet the acceptance criteria,
  • or.ifmore than one of the* nine surveillance*

tendons fails to meet the acceptance criteria, the findings.shall be reported immediately to CPCO.

B.

  • Wire.* Tensile Strength
1)

Failure of any of the test samples according to the acceptance criteria shall be reviewed with CPCo

  • 11
c.

Anchorage and Wire Hardware Corrosion TSFT-2(Q), Rev 4 Job 12447/066

1)

Significant deterioration and/or corrosions greater than Level 4 shall be reviewed with CPCo.

o.

Sheathing Filler

1)

If any chemical analysis exceeds the acceptance criteria, it shall be reported to CPCo.

E.

A final report documenting the results of all tests and inspections performed during the surveillance and conclusions made from these shall be submitted to CPCo within 30 days.

11.

ACCEPTANCE CRITERIA A.

Lift-Off Forces

1)

The measured lift-off force (lof) per tendon shall be:

Dome Hoop

}

vertical. *.

584 ~ lof < 815 kips

~15 < lof < 815 kips

. 2)

Three consecutive measurements shall fall within a 100 psig r.am pressure range~

B.

Wire Tensile St+ength 1).

Surveillance wire test ultimate strength shall be equal to or greater than 11.78 kips.

c.

Anchorage arid Wire Hardware Corrosion'.

1)
  • Anchorage and. Wire Hardware *components shall have a corrosion level less than 5 as defined in*. Appendix E.

D.

Sheathing Filler

1)

The concentration of impurities shall not exceed the following:

o Chlorides o

Nitrates o

Sulfides 12 10.ppm 10 ppm 10 ppm

Neutralization Number:

TSFT-2(Q), Rev 4 Job 12447/066 Base number >0 mg KOH/gm 2090 P grease sample Base number >0.07 mg KOH/gm 2090 P-2 or 2090 P-4 grease sample Water 10%

dry weight

12.

DATA REPORTING AND RECORDING

a.

. C~

D.

E.

Any indication of abnormal degradation of the post-tensioning system shall be reported to the Nuclear Regulatory Commission (NRC) wi.thin 14 days of the completion of the tests.

This report shall be in conformance with NRC Regu.latory Guide 1.16, Reporting of Operating Information.

  • A summary of all surveillance data obtained during any working day shall be submitted to Consumers Power Company or its agent on the same day
  • A daily field report shall be prepared and submitted to CPCo *.

A final report documenting the results of all tests and. inspections performed during surveillance and the conclusions gained from these results

  • shall be submitted to the NRC within 90 days of the*completion of the tests (by Consumers Power-

.

  • Company or oth~r designated party).

The. original raw data of the surveillance shall be

  • maintained by Consumers Power Company in the plant records
  • 13

)

FIGURE 1 GO, NO-GO Gl\\G E Pl\\I.ISJ\\DES PLANT TENDON SURVEILLJ\\NCE t0t::NT1 FICATlON r*iUMClER TSFT-2(Q), Rev 4 Job 12447/066 s

~g g 8

~

--=-= - -*- --* -

-~---~~~----~---1='="""""""'~'.!+,*

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*-to---~

)

---= =* -*- -- --.. _I

~*

g~

..., OQ a oa q..

+I + I tn tn

~

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,.. ! 1/8 5/S +/-. 1/16 0 BAR 3}S";t %

1" + 1/8

--**---**-***.*****o--------------

'Notes:

1.

Gage shall be heat treated to Rockwell C62~67.

2.

Holes sh~ll be sized after heat treating.

3~

Each hole diameter shall be certified p~jor to e~ch surveillance.

4.
  • Each gage shall have an identifying number.
5.

"Go" *end shall be identified with red label and stamped with dimension 0. 395"

  • 6.,

"No Go" end shall be identified with green. label and stamped with dimension 0.366".

. 14

Notes:

FIGURI~ 2 WIRE PULLER TSFT~2(0)~ Rev 4 Job 12447/066 PALISJ\\DES PLANT TENDON SURVEIT~LANCE SLEE.Vt:, sr;e DETAIL 0.

See Figure 3 1'*0" HEAD. SEE DETAlLQ).

See Figure 3

*--------4

  • o*-0---------------~

,.4-"

1.

The nut with the pulling ring welded to it may be

  • replaced with an eye nut.
2.

The anchor head must be pushed into. the trumpet to give a clear distance of at least 1 foot between

. buttonheads and the anchor head to use this tool.

Thts permi t*s the wires -to move. apart so that the tool shall slip over the buttonheads.

3.

The hardness of this* tool shall not-exceed Rockwell C40

  • 15

.~

-J FIGURE 3 WIRE PULLER -

DETAILS PALISADES PLANT TENDON SURVEILLANCE REAM TO SUIT BUTTON HEAD

.39s** +.OOSDIA "!

-.ooo TSFT-2 ( Q), Rev la

,Tab* "1~447/066

+.06

.75".!. 12*

  • HEAD DETAIL()

.375

+/-.12

... _ (SEE FIGURE 2).

.25"

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....... 06:r' +.005

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MOVAill.E Sl.F.EVE DET/\\11.

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l.
  • GENERAL APPENDIX A PROCEDURE FOR CALIBRATION OF HYDRAULIC RAMS AND PRESSURE GAGES TSFT~2(0)e Rev 4

Job 12447/066 A.

This document specifies the general procedures which shall be us~d for calibration of the hydraulic rams* and pressure gages under increasing tensile loads for various ram extensions.

This doc.ument does not relieve the supplier of responsibility for conducting this calibration in a manner consistent with industry standards.

B.

Calibration of the hydraulic ram shall be performed in accordance with Article 2.

Calibration of the gages shall be in accordance with Article J.

A report meeting the requirements of Article 4 shall be prepared.

C.

The following items shall be supplied:

1.

A load measuring device with calibration tracieable to the National Bureau of Standards

2.

Bearing plates, threaded* rods, and nuts required to transmit concentric loads to the ram

3.

Three hydraulic rams with corresponding pumps

4.

A minimum of three pressure gages, 0 to 10,000 psi, 1/4% atcuracy with 20 psi increments

s.

Dead weight tester

2.

RAM CALIBRATION PROCEDURE A *. *Calibration Setup

  • Center the load measuring device on the* rain to ensure that load transfer is the same as that occurring during calibration of the device.

Connect the hydraulic pump to the ram and attach a pressure ~age to a manifold which is connected to the ram through a port separate from the pressurizing port.

A-1

TSFT=2(Q), Rev 4 Job 12447/066 B.

Loading Sequence

1.

Rams shall be calibrated at 30, 60, and 90%

piston extension.

At each extension, one load cycle shall be completed according to the following sequence.

a.

Retreat piston approximately.s inches

b.

Extend piston to load the load measuring device

c.

Increase pressure and record'load and pressure indications on both gages at 500-psig incr.ements between 500 psig and a pressure corresponding to a load of 850 kip

c.

Acceptance Criteria Using all calibration data for 400-kip force through maximum force, calculate a least-square fit calibration line for each ram.

Calculate the standard deviation of the individual data point from the fitted line.

If the standard deviation is 10 kip or less, the ram is acceptable.

If the standard deviation exceeds 10 kip, the-ram is not acceptable for use* as is and will require* appropriate repair followed by recalibration. _

3.

PRESSURE GAGE CALIBRATION PROCEDURE A.

Pressure gages -shall, be deadweight calibrated for increasing pressures_ starting from zero in 1,000-psig increments up to a pressure equal to or greater than 900,000 pounds, divided by the effective ram area.

Three runs shall be performed for _each gage.

4.

CALIBRATION REPORT

_A.

A report shall be submitted within 1 week of completion of calibration.

B.

Report Contents

l.

The calibration report shall contain the following:

A-2

TSFT-2(Q), Rev 4 Job 12447/066

a.

The load measuring device calibration showing true versus measured load for the load range used for ram calibration (Calibration shall be traceable to the U.S. Bureau of Standards (NBS).)

be Data recorded for each run performed for ram and gage calibrations

  • Cc Corrected pressure versus fo.rce curves for each ram and matched set of gages
c.

Distribution

1.

Distribution of the calibration re.port shall be made in accordance with the requirements of Appendix F

  • A-3

APPENDIX B PROCEDURE FOR TESTING WIRE SPECIMENS

1.

GENERAL TSFTc..2(Q). Rev 4 Job 12447/066 A..

Wire specimens shall be tested at a qualified testing laboratory for yield strength, ultimate strength, and percent elongation at failure.

Wire specimens shall be tested in accordance with the detailed specifications of ASTM A 421 and the general specifications of ASTM A 370.

B..

Equipment used by the testing laboratory shall have current calibration traceable to the NBS.

c.

Figures showing wire specimen test setup shall be provided.

2..

REPORTS A.

A report shall be prepared by the testing laboratory for inclusion in the surveillance report.

The testing laboratory report shall include the following:

.1.

Copies of all equipment calibration documents verifying traceability to NBS

2.
  • Comparison of test results to ASTM A 421 requirements B-1
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