Text

Post-Tensioning Sys,First Tendon Surveillance Program.
	ML19256D536
Person / Time
Site:	Three Mile Island
Issue date:	07/31/1975
From:	Chadha G; PRECISION SURVEILLANCE CORP. (FORMERLY INRYCO, INC.)
To:	;
Shared Package
ML19256D535	List: ML19256D534; ML19256D536;
References
	NUDOCS 7910180846
	Download: ML19256D536 (36)
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{{#Wiki_filter:m Our New Name: l INRYCO, Inc. 1 APPENDIX I INRYCD en SNLA8so STEEL m i METROPOLITAN EDISON COMPANY THREE MILE ISLAND NUCLEAR POWER STATION POST TENSIONING SYSTEM FIRST TENDON SURVEILLANCE PROGRAM Prepared By: G. Chadha, P. E. , S. E. Chief Engineer Inryco, Inc. July 31,1975 1451 193 5910,gg

TAB LE OF CONTENTS SECTION PAGE Introduction 1

1. 0

2. 0 Summary and Conclusions 2 2.1 Summary 2

2. 2 Conclusions 3

3. O Results 3 3.1 Sheathing Filler 3

3. 2 End Anchorage Components 3-4

3. 3 Lift-Off Forces 4

3. 4 Wire Surveillance and Testing 4-5

3. 5 Retensioning and Filler Replacement 5 Data Sheets 6-19 Appendix I-A Test Results From Independent Testing Laboratory (WJE) 1451 194

e LicT OF DATA SHEETS Data Sheet No. 1 Anchorage Assembly Surveillance Inspection - Dome Tendons 2 Anchorage Assembly Surveillance Inspection - Vertical Tendons 3 Anchorage Assembly Surveillance Inspection Hoop Tendons 4 Tendon Wire Inspection Data 5 Tendon Wire Test Results 6 Prestress Force Confirmation Test - Dome Tendons

         ?        Prestress Force Confirmation Test - Vertical Tendes :

8 Prestress Force Confirmation Test - Hoop Tc;Jons 9 Tendon Anchorage Area Concrete Crack Inspection - Dome Tendons 10 Tendon Anchorage Area Ocncrete Crack Inspection - Vertical Tendons 11 Tendon Anchorage Area Concrete Crack Inspection - Hoop Tendons 12 Laboratory Analysis of Bulk Filler Grease 1451 195

1. O INTROD UC TION The purpose of this surveillance program is to obtain data to assess the continued quality and structural performance of the reactor building post tensioning system including its major components. The program consists of periodic inspectiori of twenty-one (21) pre-selected tendons, six (6) dome tendons, five (5) vertical tendons and ten (10) hoop tendons for symptorns of material deterioration or force reduction. The surveillance assesses the condition and functional capability of the system and, therefore, verifies the adequacy of the system and provtces an opportunity to take proper ,

corrective action should adverse conditions be detected. The requirements for the program are detailed in the Metropolitan Edison Company's proposal for tendon surveillance program and in accord-ance.with the Specification - Reactor Building Structural Integrity, Three Mile Island Nuclear Station Unit I. The procedure is essentially in agree-ment with the U. S. Atomic Energy Commission regulatory guide No. 1.35, issued June, 1974. The surveillance program was conducted May through July, 1975 in accordance with the approved test procedure. Reactor Building Surveillance Program and the results of inspection and testing are reported herein. 1451 196

- 2. 0 SUhihiARY AND CONC LUSIONS 2.1 SUhihiA RY No significant discoloration of the sheathing filler was observed. Lab-oratory analysis of sheathing filler samples revealed no detectable amounts of impurities to be present. The end anchorage compone'nts were found to be in excellent condition with no sign of the development of adverse conditions such as cracking or exces-sive corrosion, or missing or deformed buttonheads. The lift-off forces for all surveillance tendons were within the range of predicted values, considering the effects of concrete creep and shrinkage, steel relaxation and initial structural deformation. However, due to the too high ambient temperatures the losses due to relaxation of wire are likely to be higher in the future in locations where temperatures of the order of 132 F have been observed; whereas, a design temperature of 68 F was assumed for relaxation losses. The tendon wires were in excellent condition and no corrosion along the length of the wires was observed. It was determined that no wire breaks had occurred during the interval since the initial Reactor Building tendons were stressed except for one wire found broken due to a possible manu-facturing defect as observed by visual inspection, performed by Inryco's Chief Engineer, G. Chadha. hiechanical tests of specimens showed no significant changes in the ultimate strength of the wire as compared to results obtained during initial acceptance tests. The results of independent testing laboratory are attached at the end of this report. 1451 197

2. 2 C ONC LUSIONS Based on the tests and inspections described herein, it is concluded that the post tensioning system for TMI Nuclear Station, Unit I, is in excellent condition, that the functional capability of the system has not dimin'ished, and that the system shows no detectable evidence of the occurrence of any adverse deterioration.

3. 0 RESULTS 3.1 SHEATHING FILLER The sheathing filler at the ends of the twenty-one (21) surveillance ten-dons was visually examined. The filler coating on the end anchorage com-ponents, and the color and consistency of the filler, were found to be ac-ceptable, with no evidence of water being present.

Samples of sheathing filler were obtained from each of three (3) tendons from which a wire was removed. This filler was visually examined and no signs of water nor any discoloration of the sheathing filler was evident. Laboratory analysis of the filler samples revealed no detectable amounts of impurities to be present.

3. 2 END ANCHORAGE COMPONENTS The results of the end anchorage component inspections are given in data sheets 1 thru 3. Buttonheads were inspected for acceptable shape, general appearance, cracks and corrosion. No buttenhead defects or

missing buttonheads were observed. Anchor heads, shims and bearing plates were visually inspected for cracking and corrosion. (Some millscale and minor surface corrosion were present on the edges and faces of shims _3 1451 198

3. 2 END ANCHORAGE COMPONENTS - (Cont. ) .

and bearing plates. However, this condition existed at 1.he time of installation and no deterioration has occurred in the interval since installa-tion. )

3. 3 LIFT-OFF FORCES Lift-off forces were obtained for each surveillance tendon. Lif t-off forces were within the range of predicted ralues, considering the effects of concrete creep and shrinkage, steel relaxation and initial structural defo rmation.

3. 4 WIRE SURVEILLANCE AND TESTING As per surveillance requirement, a total of twenty-one (21) tendons were selected. Six (6) tendons were selected from dome, ten (10) from .

horisontals and five (5) from verticals. For eighteen (18) of these tendons only lift-off tendon force was measured. For the remaining three (3) tendons con-stituting the three groups in addition to recording of lift-off force one (1) wire and a grease sample was removed for the purpose of tensile testing and testing of grease samples for impurities. The wires removed were visually checked for corrosion and pitting and to determine their general condition. The tendon wires were found to con-tain minor surface scratches, resulting from insertion of the tendons into their sheaths at the time of installation. The general condition of the wires was determined to be equivalent to their condition at time of initial installa-tion. 1451 199 4_

3. 4 WIRE SURVEILLANCE AND TESTING - (Cont. ) ,

Three (3) specimens were cut from each of the extracted wires for tensile testing. The samples were taken from the ends and the middle of each of the wires. The ultimate strength of each of the specimens was de-termined by tensile testing by Wiss, Janney, Elstner and Associates, Inc. , Northbrook, Illinois. These tests are summarized in data sheet 5 and re-vealed no significant changes in the ultimate strength of the wire as com-pared to results obtained during in:tial acceptance tests.

3. 5 RETENSIONING AND FILLER REPLACEMENT Following wire removal the tendons were retensioned to approximately the same stress level indicated by the lift-off force data obtained during this surveillance. The sheathing filler which was removed during the sur-veillance process was replaced with new filler.

1451 200 D DATA SEEET 1 . ANC1f0PACC ASSEM3tf SURVE1ILA:#CE INSFECTION Field Report DoxE Trie as INSrECTson rERioD One DATE INSFECfD STRESSING WASHER BT SHIMS BEARINC FIATE INSP. 00'NENTS END StfTT0!.* HEADS & Ntf7 tin]D0 NO.0F PGS$1NC. BROKEN AND/OR CORA. PROPERLT CORA. CORR. CORR. DAMAGED 1NITIAL I.D. IJ0 CATION CAT. WIRLS CRACKS FORFID SKETCIED CAT. CRACKS SKETC1 FED CAT. CRACKS SKETC1tED CAI. CRACKS SKETCHED 13 15 15 16 17 18 19 6 7 8 9 10 11 12 1 2 3 4 5 N N Y N I N N 1 N N 1 N N 5/30/75 N W F.W

1. D- 101 5- 6(S) i N N JL N _N,, Y N N N 1 I _N _

1 6( F) 1 1 2.D- 201 1 6(S) I N_ N Y _N 1 N N I N _N __1_ 1 N_6 /lf)l751 IISG 1-2f F) 1 M N Y N 1 __N_ N 1 N. N _L_ 1 1 N N Y N I N N 2 N_ 1 l_ N 1 5/23175 1 _WEW 3.D- 301 l_- 2(S) i N N N N Y N 1 N N 2 N N 2 y- Z_- l{ F) i N N Y N I N N 1 N N I N 'N 6/10/75 N 11S_G s.D-220 5-6(S) 1 N N N N N N Y N N N I 1 2- 3( F) i 1 N N Y _N I N N _L N JL 1 1 JLS/1Ll751 _WEW 5.D-316 Id(S) ! N N N N 6/2/75 3-djF) 1 N N Y N I N 1 1 I N N Y N 1 N N I N N 2 N N 5/31/75 N WFW

6. D- I l 6 1- 5(S) i N N I N N 6/2/75 N N Y N 1 N N 1 1 - 2( F) 1 .

I.! ct:rD CI:NERAL TENDON END T = TES 1-6 Ilumber of buttress nearest Pt - H0 to end of tendon. . w b 15 E.' LT1 See Table 4 for corrosion categories. See Table 5 f or criters. for =t stna, broken. and/or danaced wires '

/.

and Table 5 wate c tur acceptance criters. for buttonheads. Reviewed by: -r Dates

                                                                                                                                                    *      'b Approved by: N/[ <    (            Date [ -/ Y - 7 S

DATA SHEET _2_ ANot0 RACE ASSDCLY StmvElt.1MCE INSPECTION FIELD REPORT vEatiCAL Ter:mS

INSFECTION FERIOD One DATE INSFECTED STRES$1NG WA$ltER SHTMS BFJtst1NG PLATE THSP. COMMENTS SY TENDON END BtlTTON1tEADS & NUT NO.0F MISSING. EROKEN. A.ND/OR DAttACED CORA. CORR. CORA. CORA. PROPERLY INITIAL 1.D. LOCATION CAT. WIRES CRACKS FOPM D SKETOi!2) CAT. CRACKS SKITOLED CAT. CRACKS SKITCF.ED CAT. . CRACKS SKETOtED 10 11 12 13 4 15 16 17 18 19 1 2 3 4 5 6 7 8 9

1. V - 16 T 2 N N Y N 2 N N 2 N N _2 E. E_. 5 _23_-7 5_ A. _IISG 11 1 N N Y N 1 N N 2 N N 2 N .Ji_

T 2 N Y N 2 N N, 2 N N 2 N N 5-l)._-7 5_AA B ESG

        . V - 27                              1 B         1           1        N         Y         N        1        N        N     2      N         N      2            N        N

3. V T 2 N N Y N 2 N N .2_ lL J L. _2_ _ tL _BL. 5 .2.2,7 5 ^ IISG N N N N 2 N N i' H 1 N N Y N 1 1 N N 2 N N 5-28-75 A IISG T 2 N N Y N 2 N N 2 4 M6 N 2 N N 2 N N H I N N Y N I N N N N 2 N N 2 N N 5-22-75 A IISG

3. V_-158 'l 1 N N Y 1 N Y N I N N 2 N N 2 N N H I N I FCDID

 --*        CFNERAL                        TDIDON IND A                                         T or 5 - Top or bottom of tendon g          Y - YES H - 14

_NO_T E : See Table 4 for corrosion c.tegorie.,

Q g See Table 5 for criters. ror .t.. sos, broken' ond/or dar sed wires: j,-

and Table 5 trate C for acceptance ersters for buttonheads. ' A. Cat. 2 corrosion appears to have developed before Reviewed by f I- '

                                                                                                                                        ./<
                                                                                                                                         - */*      'D te        " 8 * ~[>-

g rea sing. All above a reas were well coated witit gresse. f Approved 7by8 ///e /!N / D.tet. I'/Y ~ b . D. Broken wire. Itemoved 2 pcs, approx. 90'0" long. In-spection revealed manufacturing s defect in wire. -

DATA surrT 3 . ANCHORACE ASSEMI.Y SURVElf IANCE INSPFCTIOff FIE I.D It E P O R T ,, ,3, IllSFFCTION Ft2IOD One DATE INSPECTED STRESSING WASHER INSP CO?ttENTS BY SHIMS 2 FARING PIATE BtTITOSHEADS & Ntff TENDON I ND __ NO.0F MIS $1NG. BROKEN. AND/OR COPJt. 'CORA. CORR. DAMACt.0 PROPERLY CORJt . INITIAL 1.D. thCATION CAT.* WIRES CRACKS IURf'.1D SKETCHED CAT. CRACKS SKETotED CAT. CRACKS SKETOlED CAT. CRACKS SKETCitED 15 16 17 18 19 8 9 to , 11 12 13 14 4 5 6 7 1 2 3 2 N N N N 6/4/75 N WEW N Y N 1 N N 1 1.13-046 3- F I I N N N N N N Y N 1 N N 1 1 1-S I l N N I N N I N N_ 616f75 N t JIf_Il 2.ll_n34 3- F 1 N N _Y __N_ N N N N I N N , I-S I N N Y N 1 1 N_ N N N 6/13/75 N IISG N Y N 1 N N_ 1 1 3.62-016 2- F I _1__ N N_ 2 N_ N 6-S I N_ N Y N I N N , 1 N N Y N 1 N N 1 N N I_ N- N 6/_Ls/7'L_H .11S.G 4.62-010 2- F 1 N N N N Y l N N I N I 6-S ,_L N_ _N_ IISG Y N I N N I N N I N N 6/17/75 N N N

   , 5.35-010 3- F                1

_lL. _H. _H. 6-S N N Y_ _[L. __1_ H__ .H-. __1_ _1L _1__ 7 1 N I N N_ _I_ N N 1 N N 6/ll/7'L_H llSO 6.35-028 3-F 1 N N Y N N N I N N 2 N N 5-S I N N Y 1 N I N N N N 6/25/75 N lISG N N Y N 1 N 1 7.13-028 3-F 1 N N I N N l' N N l-S' 1 N N Y N 1 N Y N N N 1 .N_ N _L. _H_ N 6/11/75._H llSD

8. 51 - 012 _l -S 1 N 1 N N N N 1 N N -

5-F 1 N N Y ,fj4__ 1 1

                                                                                                                            .H_                    N      _N_ 612ft/ 75__N            IISG 9 21_Hal __Z _F _ 1                   _.1L       _IL      __X.       .11_.        I    _H_     .lL.       I   _rL_            _1__

N_ Y I N .N_ 1 N _lL_ _1 _H_ _H_ S _ L N _N N I N N N N I N N 7/.1125 __N JISD A 1021-047 2-F I N N Y 1 N N N N N 1 N N W 4-S 1 N N Y . 1 1 1.ECf3D GENERAL TENDON l'ND CD 1-6 Number of buttrese nearest g Y - YES . N - NO to end of tendon. . NOTE: See Table 4 for corrosion catesories. .

See Table 5 for criteria for =tastas.%roken. and/or damazed wires; W

                                                                                                                                              /.                   .

and Table 5 Note C f or acceptance criteria for buttonficade. Reviewed by: b h- > _ Dates '>~ Approved byt // N Dates 9-) d" Y ,

DATA SHEET 4 (Sheet 1 of 3) * ,' _ TENDON WIRE INSPECTION DATA , INSPECIION PERIOD One Tendon Identification: H-35-010 ' O C'o rrosion Category 1 25' . . 25' Corrosion Category I' 50' 50 Corrosion Category I 75' 75 i corrosion Category 1 100' . 100' Corrosion Categorv i 125'

125 Corrosion Catecory 1 150' ,

            ' 150'                          Corrosion Categorv 1                            (155'7")              175' 175' 180'                        .

Samole for Tensile Test . S' ample 1: 2 ft to 4 ft . Sample 2i* 76.5 fe to 78.5 ft , Sample 3: 151. 5_ f t to 153 f t - 6"

NOTE: Corrosica Categories (See Table 4), or any signs of deterioratica shall be indicated full length as she.cn on the above chart. Let the end of zero length be tagged per Section 7.3.2.cc.

s t- . Inspected by: H. G. Date: Reviewed by: k[ / Date: 'I' Approved by: % M'd /Date: fr-N d[ _5_ 1451 204 -

DATA SHEET 4 (Sheet 2 of 3) *

                                                                                                                        ..'4      ,

TDTDON VIRE INSPECT!ON DATA , INSPECTION PERIOD One - - Tendon Identification: V-27 ' -

O Corrosion Catecorv 1 25' . . 25' Corrosion Cateeorv 1 ,50' 50' Corrosion Category 1 75' ' - 75 i corresion Catecorv 1 10C' . 100' Corrosion Catecorv 1 125' 125" Corrosion Cateeory 1 150' ,

                     ' 150'                 Corrosion Category 1                                                          175' 175'                 Corrosien c,t,70-y 1                180' (184'-8")                  .

Sample for Tensile Test . . S' ample 1: 2 ft to 4 ft . Sample 2i- 88 ft to 90 ft , Sample 3: 180.5 ft to 182.5 ft . . NOTE: Corrosion Categories (See Table 4), or any signs of deterioration shall be indicated full length as shova on the above chart. Let the end of zero length be tagged per Section 7.3.2.cc. t- .. Inspected by: Date: M. G. Reviewed by: [ v Date: $.93 Approved by: % 4/#d Date: 9-/ / -Y C 1451 205

DATA SitEET 4 (Sheet 3 of 3) .

TENDON WIRE INSPECTION DATA INSPECTION PERIOD One Tendon Identification: D-301 , . O Corrosion Category 1 25' , s 25' Corrosion Category 1 50' 50' Corrosion Categorv 1 75' 75' Corrosion c ateoory i 100' 100' Corrosion Catecorv 1 (104) 125' 125' 150' 150' 175' 175' 180' Samole'for Tensile Test Sample 1: 2 ft to 4 ft Sample 2: 50 ft to 52 ft Sample 3: 100 ft to 102 ft NOTE: Corrosion Categories (See Table 4 ), or any signs of deterioration shall be indicated full length as shown on the above chart. Let the end of =cro length be tagged per Section 7.3.2.cc. Inspected i:' HSG Date: [.

                .                                  Reviewed' by :          . _
                                                                                       - Date: (d' ':'

Approved 5f: 7//o !/,////<[k Date: F-/v I 1451 206

DATA Sl8tTTS . TENDON WIRE TEST RESULTS Fit. LD REl>OltT INSPECTION PERIOD One ULTIMATE PERCENT LOCATION (2) YIELD ( COMMENTS TENDON WIRE (1) STRESS (ks t_)_ STRESS (ksi) ELONGATION SAMPLE NO. FROM END OF WIRE DOM ' 254.08 4.5 O. K _ 2' to 4 ' 227

1. h3RQ11p) 4.5

O.K_ 221 252.55 50' to 52'

2. O K.

100' to 102' 22l 251.02 5.1 3. VERTICAL

255.10 O.K.

2' to 4' 221

1. V-27 ( 184'8") O K.

219 254.59 5. O

2. 88' to 90' 255.61 5.O O.K_

180'6" to 182'6" ' 217

  ;    3.   ,
              !!OOP         ,

252.55. 5.I O.K. 2' to 4' 219

1. 11-35-010 (155'7") O. K .

223 255.61 5.I - 2. 76'6" to 78'6" 253.57 5. I O.K. A

151'6" to 153'6" 223 Ln 3.

N NOTES: (1) See Sections 7.3.2.cc. & 7.3.2.ce. ' O (2) The end starts from the end of zero length as indicated on Data Sheet 4. i.e., N (3) The yield stress is defined as the stress at 1% elongation, 192,000 psi minimum. Prepared by: 11. S. Gorawsk,1 Date: 7/2/75 D-301 - Button cut off at fiehl end '-

                                                                                                     / 2 // /    ,

Date: 6 5 D, V Button cut off at field end (bottom) Received by: _)$'.C[/. b ./{ 1,1-35-010 - liutton cut off at shop end - # 5 Approved by:7#x- <[//al< / Date: f- / )' 'h~

                            .                                                                                                                r y                  /
                                                                                                                                                           \ fi DATA SHEFT 6 FRESTRESS FCPCE CONFIRMATTON TES1 -

FIELD REl'OltT Dore TC: DONS INSFt.CTION PLRIOD Osie REACTOR DATE RETFNSIONINC BIDC TEMP INSF. INSF. SY TIND0td LIFT-M F CO!3)tTION IWCE EAFLCTFD CACE AVC .0 F SHitt CACE FINA1. $H N 1YPE OF FF.EVIOUS 'T 2 1305 TUIC r.NT S S (in.)__ FRESS FORCE Tit!CKNESS L:O IOPCE LITT-CFF FORCE PRESS. FORCE F.XT. INITIAIS I.D. 1.0 CATION L'A5!fl R (k t y) (bips) (Est) (ktps) (> fps) FRIVIOUS CH I C_I N A!. (Wil) (klpi) (i n .) INT. 9 to 11 !? I) 14 15 16 17 1 2 3 4 5 6 7 8 o 1.D-101 5-6 s 1406 1250 5930 1250 1252 4-1/2 4-1/2 6000 1 z63 5 91 80 5/30/75 wEW 1-6 F_ 1416 5950 1254- _4-3/4 4-3/4 6030 .1275 -1 114 2.D-201 1-6 S 1394 1250 6150 _1236 1278 4-3/4 4-3/4 6300 1327 5-3/8 109 74_6]_L0/ 751]SG - l-2 F 1416 5975 1259 4-3/4 4-3/4 6250 1317 4 3/4 3.D-301 1-2 S 1394 1250 6000 'i263 1269 4-1/2 4-1/2 6050 r275 4-1/2 97 82 5/29/75 wEW 2-3 F 1432 6050 1275 4 4 6100 1285 4 3/4 4.1)-220 5-6 S 1447 1250

5850 1232 1253 6 6 6100 .1235 6-3/4 109 _216110/ 75.11SG 2-3 F 1437 '
6050 1275 6 6 6075 1280 6-1/8 H o

    'j' 5. D - 316 l6               S        1454           1210      6000 _LM3 ES9 M/4 5_114 !2nDO .1263 (t-1/8                                          _92._ .&Q_ SI11/ 75 ME W 3-4         F        1463                      5950    1254               1/2 5-1/2 5950 a254 6                                 -

6. D- I l 6 4-5 S 1458 1250 5950 1254 1259 5-1/4 5-1/4 6000 1263 5-7/8 92 78 5]_ll/75_lySW l-2 F 1458 6000 1263 6-5/8 6-5/8 6050 1275 6-5/8 1rcFND

~                                                                           .

IVRCE CALCULATION: Force 6 Lif t 4)f f - Jack Pressura a Jack Fiston Area 'A t.0 CATION: 1 to 6 - liumber of buttrees nearest to end of tenJon. . Inryco Jack No. 1 R. A. = 210. 657 Sq. In. : W TYFE OF WASHER: F - Field Inryco Gauge No. 20 - - . s - Shop ' U SittM T111CKNLSS: ' Clear distance between bearing plate and stressing washer. PkLVIOUS3 At time of installation or previous surveillance. - g ORIGINAL: At time of starting current surveillante. See TenJon force (col m n 8) required to achieve lift-off conj 1 tion shall fall between the upper and lower bounds of prestrees forces. Figure 10. j f .

Note: D-220 Field end rotated approx. 3/4 turn Reviewed by: 37< S c.# o e: 44W during lift-off. Therefore reducing lift- gggg 7., g

                . off at shop end.

O

                                                    . s                               .

DATA SHEET 7 FRESTRESS FORCE CONFIRMATION TEST FIELD REPORT ~ ~ ' VERTICAL TF!OO L INSFLCTION FERIOD One RZACTOR DATE RETENSIONING BLDC TD9 INSP. INSP. BT_ TDmON !.IFT-OFF CO:fDITION_ IUHCE CACE AVC.0F Sitiff CACE FINAL SillM TYPE OF FPEVIOUS E.XFECTED 2 ENDS _ pf!CKNFSS_{f Q FRESS FORCE THICKNESS 'F UfD FORCE LIFT-OFF FORCE PRESS. FORCE (In.) INT. EXT. INITIALS T .D. 10 CATION VASilFR (htps) (b i pe) (Est) (k t g) (htps) PH VIOUS ORIGINAL (Kgl) (ktpe) 13 14 15 16 17 8 9 10 11 12 1 2 3 4 5 6 7 63 !19 1118 1118 - 14 6425 1353 12-1/2 125" 90 'S/23/75 llSG

1. v_=.IL _I_ .S._. LL17 1280 6100 1785 1285 - 15-1/4 6175 1301 16-1/4 125 94" 5 / 23 /7511SG

2. v.d3 T S 1437 12J10 1280 6200 1306 1306 - 13-3/4 6300 1327 14-3/4 100" 89" 5/27/75 llSG

3. v_-lj T s 1426 0 s 1426 1280 6100 1285 1285 - 14-1/2 6100 1285 16-1/2 _96" 79 5/28/75 IISG

4. v-86 T s 1458 1280 6200 1306 1306 - 14-1/2 6275 1322 15-3/4 115" 90 5/22/75 lisc

3. vm3T e I tcDro IDRCE CALCULATION: Force O Lift-Off = Jack Pressure a Jack Fleton Area toCATION: T or 5 - top or bottom (eertical tendon). Inryco Jack No. 1 R. A. = 210. 657 Sq. In.

TTrE oF WASRER: F - Field InryCo Gauge No. 20 R. A. a 208,26 'Sq. In. (Previous) S - Shop SilIH nt!CKNESS: Clest distance between beartm9 plate and stressing washer. I p tY!OUS a At time of installation or previous surveillance. A Ot!GINALs At time of starting current surveillance. . W TenJon force (column 8) required to achieve lift-off condition shall fall between the upper and louse bounds of prescress forces. See Figusc 11. N Column 7 - Column 8

Due to untwisting of tendon wires during lift-off Reviewed bys [ N . <s* J- Dat.2 f 4 f f Note: Mk/Ml M Dates , $ / p [

f and retensioning, additional shims were required Approved by: to inaintain lift-off force. ,

n DATA SitTET 8 FIMI.D 11FPOltf- rarSTarSS roRcE Courn rATroa TEST noor Tr::te:3 IuSrEctrow PERIOD One REACTOR DATE TE!OON I I FT-Of F, CONDI T ION PETENS10 Nit:C _ Bt.DC TIMP INSP. INSP. EY luru. TYRE or rRrvrouS EXPECTID CAcE Avc.c F Sl!!N CACE FINAL SilD1 l'ND FORCE LIFT-OFF FORCE PRESS. FORCE 2 INDS 11t!CKNESS 111 t Cr.NI.S S Qni FRESS FORCE F I.D. I.OCATION WA{IlfR (ktpn) (bQs) (kst) (ktps) QQs) ra t7IOt:S ORIGINAL. (Kst) (klps) (In.) INT. FIT. INITIAt.S 1 2 1 4 5 6 7 8 9 10 la 12 11 la 15 16 17

1. 11-016 1 S 1416 1250 6050 1275 1260 6-3/4 6-3/4 6050 1275 6-3/4 84" 68" 6/4/75 WEV 3 F 13'J l 7600 1245 7-I/8 7-I/8 7600 1245 7-5/8

2. 13-034 i S 14 17 1250 6100 1285 1273 6-5/8 6-5/8 6200 1306 6-3/4 84" 70" 6/6/75 llFil 3 F 1391 7700 1261 7 7 7700 1261 7 o o

3. 64-016 6 S 13 0!) 1210 5')50 1254 1253 6-3/4 6,__}/4 6215 1311 6-3/4 118 H3 6/13/1111SG 2 P 1 l')-) 7650 1253 7 7 7700 1261 7-3/4 4 62-010 6 S 1368 1250 6075 Uito 1272 6-3/8 6-3/8 6300 1327 6-1/4 123 82 6/16/75 llSG 2 F 14M 7725 1265 7-1/4 7-I/4 7800 1278 7-7/8 0 0

5. 3 bili 0.- 'i_ _S__ 13SB LZ5.0 S'H_0 1257 1259 6 d/4 (tdl4 (IllE) L}27 7W2 12L 73 6 /17 /l11ISG

_J_ _E_ 13 06 7))LO J26I 2d/2 7-l /2 7H00 1278 7 g

6. 36-028 5 S IJ '1H 1250 6250 1316 1282 6-I/2 6-I/2 6350 1337 6-Il2 128" 84 6/23/75 IISG 1 F I;11H 7625 12I') 6-1/2 6-1/2 7800 1278 6-3/4

 ,L 1. I.ldl2H_ L           _li_.      13 16          1210       7750 1269 12fgi 6                             6         7875 1 2'10          6 _3/ 8 126 (1)l32 6/25/75 IISG Y'                    3         P       l121                      7660 1253                      6-3/4 6-3/4 7775 1274                         6-7/8            (3) 88

e. 51-012_I_ S 1116 1250 7625 124') 1293 7-1/2 7-1/2 7750 1269 6-1/4 127"(1) 92" 6/26/75 llSG S P 1137 6350 1338 5-5/8 5-5/8 6500 1369 7-1/4 (5) 67

9. 2-hD 21 4 .li 1168 1250 6200 l'106 1267 6-5/8 63 /8 6150 13'd 7-7/8 128" 80" 6/28/75llSG 2 F 1111 7500 122') 7 7 7825 1282 6-5/8 10 2d2D 17 l ._S__ 13 16 12'LO 6113 11D 1 1280 6_-1/4 6_d14 f 2'i0 UJ6 1 7dl 2 125" 84" 7 /1/15___ IISG l _I 13 06 5975 12%9 (__ 7 67.50 1316 7-l/4 IFCFMD IVRCE CA!.CU \ TION A Force G Lift-Off = Jask Pressure a Jack Piston. Area IOCATION: 1 to 6 - Ilumber c' uttress nearcot to end of tendon.

In ryc0 .Iack Il. A. 210. 6 57 Sq. In. TYt'E OF WASHER: F - Field MeM R A. ; 161.832 % Im SHlit1HIUNESS: Clear distance between bearing plate and streesing was . (l. Iti. (I reviotas) N I I(t v!Oos: At time of installation or previous surveillance. ~ ott !G t HAI. : At tice of st.arting current eurycillance. O icn.l..n force (culumn 8) seguired tq athieve lif t-of f condition ohell fall between the upper and lower boundaries of prestress force. See ricurc 12 . , lte m # l -8 uneil issuge # 20, 24 Reviewed by: .ChLV ,Date: [8/D_ ltem #9-10 useil gauge #4, 10 Approved by: 7/ S w / N ()) M / o,te: p -f 4/. / 5'

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W 2ll 1451

r DATA SHEFT 10 TENDON ANCHORACE AR'A CONCPETE CRACK INSFECTION FIE LD ILEI)OltT VTRTICAI. TENDONS INSFECT10tl FERIOD One CRACE" 'JIT" -.~ 5 '.01" DATE INSF BY TctDON TYPE OF 41 3 .*3 *in.) INSF. (INITIALS) Rfv. ARKS ABot!T CRACK!$C FATTERN IOC.tT!?N NO. END UASHER None None 5/23/75 IISG

1. V - 1 6' S None F None . Nonq. _None. .

N on e, None 5/23/75 IISG

2. V - 27 S None

                                                                       *None                            N o_n e            None' V

None None None 5/27/75 IISG

3. V-61 _S None None None .

F M ont. None- 5/28/75 IISG

4. 1,86 S None None _ N.in e_ None e

F - s. None None None 5/22/75 IISG i' 5. V-158 S F None None None NOTE: Type of end washer , F = Field S . Shop Reviewed by: . < r # Datesffs.W.'.i m A .....d ,,. r e a m w D. .. t- ~ < , _ e N . ~ iL t B

DATA SHEET 11 . FIE l,D lt E P Oll T . TENDON ANCHORACE AREA CONCRETE CRACE INSFECTION HOOP TEt: DOSS INSFECTION PERIOD Gne T!]fDON TYPE OF NO. 27m VASHER CRACXS VITH VTDTM > 0.01** DATE INSF ST RFNAuKS ABOOT CRACXING PATTERN lDCATION U1DTH in.) INSP.

1. 13-046 F-3 None (INTTIALS)

N N 6/4/75 _ WEW S-1 None N

2. 13-034 N

F-3 None N N 6/6/75 __ II FII b-1 None N 3.26-016 N F-2 None N N 6/13/75 IISG S-6 None N N

4. 26-010 F-2 None N N S-6 None 6/16/75 IISG 3,35'010 N N F-3 None N N 6/17/75 IISG S-5 None N N 6.35-028 F-3 None N N S-S -

None 6/23/75 IISG N N

 /. 7.13-028                       F-3                          None Y                                                                                                 N             N S-1                          None                                                    6/25/75      IISG N             N a.51-012                       F-5                          None                            N             N         6/26/75     IISG S-1                          None                            N              N p.24-021                       P-2                         None                            N              N S-4                          None 6/28/75     IISG N              N 10.24-047                      P-2                          None                            N           _N           7/1/75       IISG S-4                          None                            N              N NOTE: Type of end washer F = Yield

. S - Shop Reviewed by: _>

                                                                                               / # Date: _ ['[~7 Approved by 9/     4/ hi          Datea h-/'/"

N u

r

                                                                                                                                     ~
                              .                         DATA SilEET 12 FIEI.D ILEPORT                       LABORATORY ANALYSIS OF BULK FILLER GRFASE INSPECTION PERIOD           One SAMPLE                  TENDON           CIILORIDES(I)     NITRATES (1)    SULPilIDES(I}      WATER / DRY WEIGIIT(2)

IDENTIFICATION END (ppm) (ppm) (ppm) % less than less than less than e DOME D-301 F 4 1 0. 0

1. 1 S I 4 1 0. 0 VERTICAI.

1. V-27 Ton (S) 1 . 4 1 0. 0 B o t. (F) 1 4 1 0.0

        . IIGOP                                                                                         ,

F (3) 4 1 0, O

l. 11-35-010 1 S (5) 1 4 1 0, 0 FRES11 SAMPLE

1. 10 pcs. Batch #5015 1 4 1 0.0

2. 11 pcs. Batch I/1138 1 4 1 0. 0

 -   (1) Acceptance criterion is 10 ppm maximum A  (2) Acceptance criterion is 5% maxitcum LD                                             .
 ~

Tendon End : T or B - Top or bottom vertical tendons 1 to 6 - Number of buttress nearest to tendon end. 4 Prepared By: II. S. Goraweki Date: 7/1/75 g ReviewedBy:] Cf Date: [ G 75 , / . U Approved By: "781 a/!N/ /g Date: ?-/ v -I

APPENDIX I-A TENDON SURVEILI.ANCE W THREE MILE ISLAND {s, NUCLEAR POWER STATION y g FOR v. INLAND RYERSON CONSTRUCTION PRODUCTS E 1 s n WJE JOB No. 75355 a 2 A 8 i a July 29, 1975 1451 215

TENDON SURVEILLANCE w THREE MILE ISLA'iD 1 s, NUCLEAR PO'JER STATION J a g FOR e Y' INLAND RYERSCN CCNSTRUCTION PRODUC~S E I s t

 $                                                               July 29, 1975 r

a h INTRODUCTION A Wiss, Janney, Elstner and Associates, Inc. recently co=pleted a series s 5 e of tests on 1/4 inch diamster wire tendons from the above-captioned a o p roj e ct.' The tendon surveillance program consisted of testing three a tendons which had been re=oved from the structure. The testing program consisted of the following tests:

1. Bend Test

2. Tensile Test

3. Grease Test TEST DESCRIPTION The individual tests were perfor=ed as follows:

1. Bend Test: All tendon wires were visually inspected and sa=ples were cut from the shop end, field end, and the =iddle, respectively. Each speci=en was properly identified and subjected to a bend test. All speci-mens =et the Inland Ryerson criteria of 6 bends before fracturing. The 1451 216 results of the bend tests are as follows:

Tendon W Identification Location No. of Bends , a

s. D 301 Shop end 11 J liiddle 10 g .

Field end 11 n y, H 35-010 Shop end 11 Middle 10 f5 Field end 10

     $        V 27                         Shop end                     10 1/2 y                                     Middle                       10
     ,                                     Field end                    10 h

A 2. Tensile Test: From the same tendon wir'es used for the bend tests, i g 24 icch companion sa=ples were cut and subjected to a tensile test. The i samph - were rested in compliance with the applicable req: tire =ents of ASTM s A421-65, " Uncoated Stress-Relieved 'Jire for Prestressed Concrete". The elongation of wire was measured over the gage length of 10 inches. The extensometer was placed on the test specimen after a load corresponding to 29000 psi stress vns reached. The load was increased gradually and a stress-strain curve was plotted on the analog recorder. The extensoceter was re=oved at an approx 1= ate elongation of 4 1/2 percent to prevent possible damage due to breakage. The loading was continued until failure occurred The following data were recorded and are shown on the attached curves:

1. Stress-strain curve

2. Ulti= ate strength

3. Elongation after failure over 10 in. gage length Of the 9 specimens tested, only one broke outside the 10 inch gage length.

1451 217

Section8.1ofASTMA421-65allowstheresultsofthistheofbreak (outside of gage length) to be considered a valid test, provided the y mini =us elongation require =ent of 4 percent within the gage length is a

s. meg, J .

a A 500,000 lb. Riehle TH-500 =achine was used to perform the test. A n y, certificate of calibration is enclosed herewith.

}a

3. Crease Test: Ten sa=ples of grease vere subjected to a grease test

     $  according to t:ie procedure of the Viscosity 011 Company. The sa=ples were found to be satisfactory. The results of the test are as fo11cus:

b . A SAMPLE PPM PPM PPM 8 NITRATE SULPHIDE CHLORIDE 8 * <4 <1 <1 i D 301 Shop End 8 D 301 Field End <4 <1 <1 e U 35-010 Shop End 44 <1 <1 H 35-010 Field End <4 <1 <1 V 27 Shop End <4 <1 <1 V 27 Field End <4 <1 <1 6-9-75 Lot 5-1138 <4 <1 <1 5015 <4 <1 <1 Grease Drus 420-48 Batch 5015 <4 <1 <1 Batch 1138 <4 <1 <1 Respectfully submitted, WISS, JANNEY, ELST::ER AND ASSOCIATES, INC. es'Pi,$iOm . Suresh G. P'injarkar, Reg. Strue. Engr. Illinois - 3678 Dated this 29th day c? July, 1975 SGP:11 1451 218 wiss, ann:c,ct.stura t assac. INLRND RYERSON CD. na enam c. enuer,itunis can TENDON SURVEILLfiNCE I

 ;pn          escro n     me        THREE MILE 15LRND           -

r8= =o HNF 7/lB/7E V 27 FIELD END 7E3EE ULTIMRTE STRENGTH 2EE.10 K51 ELONEAT10N E.8 7 300 - E t2 200 - b C1., I M laa - - 2B ' 0 : : : : : 0 1 2 3 4 E STRR I N - I N/ I N

I B-?[,

1451 219

unss,Jaxer,ct.snxa t assac. INLRND RYEREDN CD. " *** m enena o. cnmu=r,iutais c=n 2 TENDON SURVEILLRtKE xac n occo n one THREE MILE 15LRND . roxa Eam HNF 7/lB/7E V 27 MIDDLE 7E3EE ULTIMRTE STRENETH 2E4.ES X51 ELDNERTION E.8 5 300 - E tS 200 - u; a. IR M 100 - - 29 0 : : : : : 0 1 2 3 4 E ETRRlN-IN/lN*10( 145l 220

utss,Jasney,et.sista t assac. INLRND RYEREON CD. n enem u. enr.-- .aucis c=n TENDON EURVElLLRNCE 3 men arco n one THREE MILE ISLRND resa ese HNF 7/18/7E V 27 EHOP END 7UEE ULTIMRTE STRENGTH 2EE.51 K51 ELONERTION E.B 5 7 300 - E E 200 - G a I

          !E d
          $    100        -

29 0 . :. : 0 1 2 3 tl E STRRIN-IN/IN*IB-Y 1451 221

wiss,aasscy,ctsista t assac. INLRND RYER50N CD. m incno c. enura aunts an TENDON EURVEILLRNCE 4 men accro a me THREE MILE 15LRND - resa me HNF 7/18/7E H 3E-010 FIELD END 7E3EE ULTIMRTE STRENGTH 2E2.EE K51 ELONGRT10N E.1 %

 '              300    -

E 5 200 - m j . 1 in . d m . 100 - 29 0 : : : : : 0 1 2 3 4 E

                                                                 . 2.

STRR I N - I N/ l N

10-3 L

222 1451

                                                                        "' N "~

wiss,Jaxxa,ctsTxta t assac. INLRND RYERSON CD. zu enesia u. emu =r,aucis c:n TENDON EURVEILLRNCE E rm: n arco n mc THREE MILE l5LRND . rexc mo HNF 7/18/7E H 3E-910 MIDDLE 7E3EE ULTIMRTE STRENETH 2EE.El K51 ELD.NGRT10N E.1 % 300 - 4 - E 5 200 - m Gi EL. I

         !E s
         $     199  --

29 0 : : : : : B l 2 3 4 E STRRIN - IN/IN

1946 "

1451 223

Wtss,Jann,et. sura t assac. 1NLRND RYEREDN CD. am cuo m ens:no n. enemitticis cza TENDON EURVEILLEIKE E

 "*' "      "o"                   THREE MILE 15LRND         .

Icxa eus HNF m' 7/le/.,E. 7E3EE H3E-010 5HDP END _ ULTIMRTE STRENETH 2E3.E7 X51 ELDNEAT1DN E.1 5 300 - E 1 E 200

G a. I s 5 100 -- 29 0 : : : : : 0 1 2 3 4 E STRR I N - IN/ I N

10-{'

451 ??4

wiss,asssa,ctsTsca t assac. INLRND RYER5DN CD. na ennum a. ema=t, aucis mn TENDON SURVEILLRNCE 7 me av acao si me THREE MILE 15LRND - emac ma HNF 7/18/7E D 301 MIDDLE 7E3EE ULTIMRTE STRENETH 2E2.EE K51 . ELDNGBTIDN 4.E T 300 - E E 200 - G Q I Ol u 5 100 - 29 0 : : : : : B 1 2 3 4 E STER I N - IN/ I N

10-3[

1451 225

wiss,anm:n,a.snxa t assac. INLR!lD RYER5E'.' CD. m erinna n. enu;=x,itunis t=n TENDON SURVEILLRNCE B roc n accxo u ont THREE MlLE 15LRND . reca n:wq HNF 7/IB/7E D 301 FIELD END 7E3EE ULTIMRTE STRENETH 2E4.08 K51 ELONERTION 300 - E 5 200 - Gi a 4

        $                f d
        ~              l m     100   -

29 0 0 1 2 3 4 E STRRIN - IN/IN

10-P L F

1451 226

uiss,dann etsuta t assac. INLRND RYER50N CD. m enana c. cne=2,itucts c:n! TENDON EURVE!LLRtKE 9

nc THREE HlLE 15LRND re xa nasa men cicao n .

7/18/7E D 301 5 HOP END 7E3EE HNF ULTIMRTE STRENGTH 2El.02 K51 ' ELONGRTION E.1 % 300 - E

= 200 --

Gi c I

         !S s

5 100 29 0 0 1 2 3 tl E STRRIN - IN/lN

IBf' &

145l 227

t .>. ates.'.e - f,[..,Q

'3 lli.1 )

Wilson instrument Division SM CONNECTICUT AVENUE. eRioCEPoRT. C'JNNECflCUT 06602. {203) *05 2$11

                                                                                                                                         **"8"#'"'^
             .d            AMERiCAN CrtAIN & CABLE CCMPANY. INC.

D"D D T M woJ o ] /fd. 1 J1 _a Certificate o" Caibra: ion Calibration Date January 10,1974 Machine Description aiehle m _300 Customer Wiss,Janney Ilstac & Assoc. Serial No. 3A_47247 330 Pfings-en Road Northbrook, Ill. 60062 Attn: Mr. Sob liansen Wilson Instrument Division of Acco certifies that the rnachine described above has been calibrate designatien E4 using cabbrated weights and/or proving rings calibrated to National Eureau cf Standacts Speci'ication. Machine Range Machine Range 100,cco in nnn Macn no reas.n; j % Error Macnine reasing l % Error

                                              ,' )OO            I                                                       20000              1         0 O

20000 1 0 2000 1 0 1 .14 60C00 I 'O 6000 80000 i +.1^ 8000 l .11 l iccco I .11 100000 I + . 2,1 i ! I Machine Range 25, COO Machine Range 250,000 Ma:nine reading l % Error Machine rea ing l % Err:r l 5000 0 c.'na" I + "Ac I 0 isanmn ! . c oi i 100cc n i 1cc.--a I ic0cc _.i1 SAnnan f . a i panaq l na? f_ q10 ocenen I . *:- !

                                               ?cyn t

I ~l Machine Range :00,000 Machine Range an , n.,n

              ) Ma:n.re reso n;                                   i % Error                      Machine rescing                             i '. Errer l
                                                                                                                          '0000]             I     .042 l 10000             l        a                                                                     -r . i ;

200,n l_, m 2000JJ i l

                                                 . .v s n. 3       i _ , i.;                  i                           300%J                    . 02 i 2000 ',            i      ...
              )                                  . ann             I..to      _

ssna t n i 5000') .. i i 1

I i I Canbr: ting r.:carstus uscc s fM.'[J Ca" 'JW" " - ' ~ [ ~ ~~ ^ '

e N

i C::44.: < l Se is, so. l Cal. d:te ! L:3. r o. ca . . Af ..q 22 j 60,0'O

                                .s          v.;

632

                                                                    ;-; ea 1-29-73            SJr.01/100gi                M,py.d ,,,g q -       ;
                                                                                                                                                          ~

MD,000 24'c 3-23-72 wa .:a-ca v-wr I SJ-' . 01/lC'4., , , r , , _ '1 :. 3

                      .., , ,               o
                                            ,-                 ,,                     ...,--..3
                  -*w - -
                                                                                   -                   a 1451          228}}

ML19256D536

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