ML19276H112
| ML19276H112 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 12/31/1977 |
| From: | Hansken R VSL CORP. |
| To: | |
| Shared Package | |
| ML19276H113 | List: |
| References | |
| GQL-0204, GQL-204, NUDOCS 7910100511 | |
| Download: ML19276H112 (44) | |
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s s IncI:sure OQL 020h THREE MILE ISLAND NUCLEAR GENERATING STATION UNIT NO. 1 SECOND TENDON SURVEILLANCE TEST OF REACTOR CONTAINMENT BUILDING THREE YEARS AFTER S.I.T. METROPOLITAN EDISON COMPANY SOBSIDIARY OF GENERAL PUBLIC UTILITIES CORP.
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- 1415 21-3 yrevel by: i w si . uts B. M. KIinge% / &</ ? fir hnager-94neration. Ingineering Prepared by: Rick Hansken VSL Corporation Los Gatos, Calif.
December 1977
SYNOPSIS The post-tensioning system of the concrete reactor building at Three Mile Island Nuclear Generating Station Unit #1 was sub-jected to an in-cervice surveillance test and inspection during the period frem August 8, 1977 to November 11, 1977. The purpose of this surveillance was to verify the structural integrity of the post-tensioning system three years after the initial contain-ment Structural Integrity Test (S.I.T.). The post-tensioning force for all twenty-one surveyed tendons was verified to be within acceptance limits by testing of the tendon lift-off force. Inspection of the tendon anchorage assemblies found them to be free of any excessive corrosion. The corrosion prevention system wa3 found to be functioning properly. Laboratory analysis of filler material samples revealed inpurities to be within accept-able limits. The concrete surrounding the bearing plates was found to be free of any significant defects. Three wires were removed from three selected tendons (one frcm one tendon in each directional group) and inspected for physical condition. Each sample wire was subjected to tensile tests; results demonstrated strengths above the guaranteed ultimate strength of 240,000 psi. These observations indicate that the containment post-tensioning system is in good condition and is fulfilling the design criteria. Collection of data, quality assurance and construction management were performed by VSL Corporation, Los Gatos, California, under contract to The Metropolitan Edison Company. INTRODUCTION The objective of the tendon surveillance program is the evaluation of data obtained from the testing and inspection of twenty-one randomly selected tendons: ten hoop tendons, six dome tendons and five vertical tendons. Each tendon was evaluated on the following: a) Tendon lift-off force b) Tendon anchorage assemblies c) Tendon physical condition d) Tendon corrosion prevention system Tae purpose of the tendon surveillance is to assess the condition and functional capability of the system, thereby verifying the adequacy of the system and providing an opportunity to take cor-rective action should adverse conditions be detected. The surveillance test conforms to the U. S. Nuclear Regulatory Commission's Regulatory Guide 1.35, Revision 1. 1415 216
RESULTS (1) Inspection of corrosion protection system The grease filler found in the end caps of the twenty-one tendons was visually examined for color and consistency; no evidence of water was discovered. No discoloration of filler material was evident. Filler material was removed from the surveillance tendons and placed in clean 55-gallon containers. When g the con-tainers were near full, they were heated tc 150 F, to ensure a homogeneous mixture. Samples were then taken and sent to a lab for testing before the filler grease was returned to the tendons. All new containers of grease were subjected to the same procedure of sampling and testing before being pumped into the tendons. As part of this surveillance, three tendons were scheduled for a physical test; part of this physical test was the laboratory an. lysis of the filler grease found in the end caps of the tendons. Collection of a grease sample from both end caps of V-119 was impossible due to the highly liquid state cf the grease at the time of inspection. The grease samples for V-119 were taken from the filler grease that wos drained into two 55-gallon containers. Subsequent testing found these samples to be within acceptable limits. (2) Anchoraae assemblies Anchor heads, shims and bearing plates were visually exam-ined for cracking and corrosion; buttonheads were inspected for acceptable shape, cracks and corrosion. No significant deletericus conditions were found in the buttonheads of the tendon system with the exception of sur-veillance tendon H51-013 and tendons H51-012 and H51-01h The condition of the buttonheads of H51-013 was brought to the attention of Metropolitan Edison Company for consider-ation. The decision was made to visually inspect H51-012 and H51-014 for the condition of the buttonheads. Af ter visual examination of these two tendons (the condition of the buttonheads was found to be similar to H51-013 but not as severe), Gilbert Associates were called in to ascer-tain the physical condition of the buttonheads of the three tendons, H51-013, H51-012 and H51-014. The condition of the buttonheads of the three tendons was found to be acceptable. (Ivaluation of the tutten head 0:niitions as per.'e=ed by Gilbert Assceistes, is reported in their letter, copy included as Attachment Ho.1. ) 1415 217 Tendon installation cards do not indicate that this condi-tion occurred during installation. See Diagrams 1 through 6 for graphic condition of the buttonheads of H51-013, H51-012 and H51-014. The results of the visual inspection are given in Data Sheets 1, 2 and 3. Some millscale and minor surface corrosion were found on the edges and face of some of the shims. Due to total coverage of the anchorage assemblies with grease, this condition probably existed at the time of installation. (3) Tendon lift-off force Lift-off force was obtained from each end cf the ten hoop and six dome tendons; the average value of these forces was within the upper and lower bounds of the predicted value. The five vertical tendons were single-end stressed so that the lift-off force need only be recorded from one end. Here, too, the force was within the upper and lower bounds of the predicted value. The results are given in Data Sheets 6, 7 and 8. It was necessary to add shims to various tendons during re-tensioning in order to obtain the required final lift-off force. This was due to anchor head rotation during deten-sioning which caused a relaxation in the twist of the tendon, thus showing a decrease in the force when the original shims were replaced. The tendon force after retensioning in all cases is equal to or greater than the initial tendon lift-off force. The concrete surrounding the bearing plate area of the ten-dons was examined for any signs of cracking. No evidence of cracking was found in the concrete around the hoop and vertical tendon bearing plates. Cracking patterns were found in the concrete surrounding the bearing plates of some of the dome tendons; none of the cracks in these areas were found to be greater than 0.009" (see Diagram 7 and Data Sheets 9, 10 and 11). (4) Tendon physical condition Of the twenty-one surveillance tendons, three were chosen for physical testing. This included laboratory analysis of the filler grease samples from the end caps for traces 1415 218 4 of chlorides, nitrates, sulfides and percent of water con-tent. Analysis results of the grease samples are shown on Data Sheet 12 and separate data sheets from Allentown Testing Laboratories, Inc., Bethlehem, Pennsylvania. All of the samples meet the acceptance criteria. Part of the physical condition inspection is the tensile testing of a single wire pulled from each of the three tendons. The removed wires were wrapped to protect them from a change in condition and sent to a testing facility for evaluation. Three tensile test samples were cut from each wire, one from each end and one from the center. The ultimate strength of each sample was determined by the testing facilities at Fritz Labs of Lehigh University, Bethlehem, Pennsylvania. The results are summarized on Data Sheet 5, reve-ling no significant change in the ulti-mate strength of the wire as compared to results of the initial acceptance tests. (5) Eculpment calibration Two stressing jacks were used to complete the surveillance: The Metropolitan Edison's ram (1650 kips) and General Atomic's ram (2000 kips). Both rams were calibrated at Fritz sacs, of Lehigh University. The equipment used for calibrations is traceable to the National Bureau of Standards. Calibration data is given on data sheets from Fritz Labs. 14i5 219 l 2'/ A<52/-- M # / _ r 7,&fffl //MZfff CFM'sd*/73/ (_)
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200./7.53t FRITZ ENG!llEERil!G LADORATORY f13 ' VSL Corporation Field Report CEDRO E 'l E fila 18015 DATA SHEET 411 TENDON WIRF INSPECTION DATA INSPECTION PERIOD 2 TENDON IDEt!TIFICATION 11-62-047 O category 1 25' 25' category 1 50' 50' category 1 75' 75' category 1 100 100' category 1 _125 125' caten ry 1 150 categ ry 1 175 150' 175' E rY l 180' Sample for Tensile Test Sample 1: 0 ft. to 5 ft. Sample 2: 90 ft. to 95 ft. Sample 3: 175 ft. to 180 f 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 zero length be tagged per Section 7.3.2.cc. Inspected by: #4, !tt > Date: // '2 2 -77 Reviewed by: - f N '/ , iu
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200. 53C.. FRITZ ENGINEERING ,.,aon.you g;3 . LE!ilG!i Ui!jiE,tiry EETillE!iEP1, PEtigsyLVANIA 18015 VSL Corporation Field Report DATA SHEET 4V TENDON WIRE INSPECTION DATA INSPECTION PERIOD 2 TENDON IDENTIFICATION V-Il9 category 1 25' 25' Category 1 50' 50' category 1 75' 75' categ ry 1 100' 100' category 1 125' 125' catenory i 150' 150' category 1 175' 175' ' category 1 180' Sample for Tensile Test Sample 1: 0 ft. to 5 ft. Sample 2: 90 ft. to 95 ft. Sample 3 175 ft. to 180 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 zero length be tagged per Section 7.3.2.cc. Inspected by: $1 t Date: // -2 2.~77 Reviewed by: / [n //, r.y / , - Date: / 27 7 N . 1 ~Y ' " ' t M Approved by: / )v h Date: 2A 7F
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New York D.Ws.on New Jersey, Ma.n Offecs Central Pennsylvania Civision C f. L. INC. CERTJIED TEST;NG LABORATORIES, INC ASTROTECH INC. 2525 Ma:perin Avne Brona 61, N. Y. 155 U. S. Route 130, Bordentown, N. J. 7801 Al'entown Blvd. U. 5. 22 Hwris'o urg. Pi (Area Code 2:2) 824 1516 (Area Code 609) 299 3255 (Area Code 717) 652 1750 ALLENTOWN T 5 L T ! M G !. A B O R A T O R Y , i ' c Civision d Cer Jied Testing Laboratories, Inc. Inspection - Testing Resear:h - Chemical Analysis -- Indus! rial Radiology -- Soils - X-Ray - water - Steel 754 East Fairview Street Bethlehem, Pennsylvania Phone 215-865-2674 Certificate of Test and Analysis Client: V S L Corporation Date: Sept. 3, 1977 P. O. Box 412 Middletown, Pa. 17057 Attn: Rick llansken Lab. No. 77486 On sa=ple of: Twelve (12) Greases (A 2202 Ch) Received: August 31, 1977 Marked: as below (Part 1) Examined with the following results: Chlorides (D878) Nitrates (D878) Sulfides (D878) % Uater (D95)
#1 New Barrel Lot #63813 less than one less than five less than one less than 0.1
#2 New Barrel " " "
Lot #63813
#3 New Barrel Lot #63813 " " "
V-24 Barrel #1 " " " " V-24 Barrel #2 " " " " V-48 Barrel #1 " " " " V-72 Barrel #1 " " " " V-72 Barrel #2 " " " " V-97 Barrel #1 " " " " V-97 Barrel #2 " " " " V-119 Barrel #1 " " " " V-119 Barrel #2 " " " " Reported to: aboire Respectfully sibcitted, 415 240 ALLENTdWNTESTINGLABORATORIOS,INC.
- 3 y' ,A ;- I
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John J. Destiond
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ALLENTOWN TESTING LABORATORIES, INC. olvistoN cr ctRTirito TEstiNo L.AeonAromics. INC.
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754 EAST FAl2 VIEW STREIT - liiHLEHf4 PA. PHON!315}.365 2574 hspection . Testing . Research . chamkal . Analysis . ladafrial Raioto 3y
- Soils
- X-Ray
- Water . SW Certificate of Test and Analysis Date November 8, 1977 For: V S L Corporation P. O. Box 412 LA No. m86J-Middletown, Pa. 17057 Attn: Rick Hansken On sample of: Twelve Greases Received: August 31, 1977 Marked: as below Examined with the following results:
Flash Point D92 Drop Melt. Point D-127 Sample #1 New Lot #63813 */480* F 149' F Sample #2 New Lot #63813 > 480' F 147' F Sample #3 New Lot #63813 > 480* F 148' F V 24 Barrel #1 r 480* F 146' F V 24 Barrel #2 7480* F 147' F V 119 Barrel #1 >480* F L40' F V 119 Barrel #2 7 480' F 140' F V-72 Barrel #1 7480' F 138' F V-72 Barrel #2 >480' F 139' F V-97 Barrel #1 7480* F 147' F V-97 Barrel #2. 7480* F 145' F V-48 Barrel #1 7480' F 140' F Respec: fully submitted, 1415 241 Repcrted to: ALLENTOWN TESTING LABORATORY, INC. John J. Desmond
.~ ., iC ,r.,
o
..a orm No. .\3 102 '
Att Reports are the coal.dearial property of cl. eats, and informat.on conta.eed may not be pubbs%ed or reproduced, pend'ag owr wret'ea acD J'*;
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ALLENTOWN TESTING LABORATORIES. INC. DIVISION CF CERTIFIED TESTING L. ABOR 70 RIES. W C, 754 EAST FAIRVIEW STREET . BETHLEHiM. PA. PHONE (2151965 2674 Inspection . Testing . Research . Charnical . Analysis . Industris! Radio:ogy . Soils X-Ray Wa:er
. . . Sf **!
Certificate of Test and Analysis Date Nove=ber ll,1977
.~o r: V S L Corporation P. O. Box 412 Lab. No. 77554 Middletown, Pa. 17057 (A 2202 Ch)
Jn sample of: Three greases Received: September 23, 1977 warked: as below xamined with the following results:
#4 #5 #6 Used Fresh Lot #7-2762 Fresh Lot (!7-2763 Flash Point (D92) 7 480*F 7480*F 7480*F Drop Melting Point (D127) 144*F 144*F 145'F Chlorides 41 ppm 41 ppm 41 ppm Nitrate, 4.5 ppm 4 5 ppm 45 ppm Sulfides 41 ppm 41 ppm 41 ppm Water 4.0.1% 40.1% (0.1%
1415 242 Reseectfully submitted,' deported to. above ALLENTOWN TESTING LABORATORY, INC. John J. Dest::end
, c s
.orm No. A3102 All Reports are the coal.deae.e4 croperty of cheats. and ialoemation conta.aed may not be pubbshed of reproowced, peadrag owt wrrteaaopro.*
~
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/\ \ / _[/ /l ALLENTOWN TESTING LABORA TORIES, INC.
Div:s;os or CERTIFIED TESie'.G LABOR ATORIES. INO.
~
754 EAST TAIEVliW STREET . B EN'. ini M. F A. PHON!!215b565 2674 is:pecEon . Testeng . Reswch . Chemical Analys.s
. . Indestrist Radiology . Soils . X-Ray . Wa:er . S'**3 Certificate of Test and Analysis Dale November 21, 1977 For: , V S L Corporation tab. N -
P. O. Box 412 77700 Middletown, Pa. 17057 Attn: Rick Hansken On sample of: Six greases Received: November 10, 1977
/Aarked; as below Ixamined with the following results:
Fresh Sa=ple Fresh Sample D202 D202 H62-047 H62-047
#7 Lot #7-2762 #8 Lot #7-2762 End#2-1 End #6-1 End #2 End #6 w.dorides (ppm) 41 41 41 41 (1 41 Nitrates (ppm) 45 45 45 45 (5 45 Sulfides (ppm) 41 41 (1 (1 41 (1 Water % 40.1 40.1 40.1 (0.1 c 0.1 c0.1 Flash Pt. >480* F 7 480* F P480* F 7480* F 7480* F 7480* F Drop Melt. Pt. 146' F 144' F 132* F 136' F 143* F 142* F Respectfully submitted, 1415 243 Reperted to'
_ above ALLENTOWN TESTING LABORATORY, INC. John J. Desmond ' roem No. A3102 Ali Reports are the coal.dealeal property of O*a's and e alormahon contained may act be pwbbshed or eeproduced. gead'a'J w we+Hea aD0's.el
N 200.77.530.3
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FRITZ SNGlHEIRING LA3 ORATORY DEC Lahlgh Uninrsity 5 1977 33,,, 1 ., 1 subjen COMPRESSIVE STRENGTH OF 2" by 2" CROUT CUS S WapAT10*J Date .12/1/77 Specimen No. - Party.. .R..L ,. ygig - !. i .,. . . __ R.C.S.
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l ALLENTOWN TESTING E il6MAMORIESr INC. DIVISION OF CftRTIFIED TESTING L ABOR ATORIES. sNO. 754 EA$f FAIRYl!W sfRE! f . 8 E TH'.!H!M. PA FHON!l215) 865 2674 Inspect on . Test.as . Research . Chemical . Analysis . ladostrial Rad W ,;y . so;is . x_g.y . wre, . Si++6 Certificate of Test and Analysis Date 9/06/77 V S L Corporation For: P. O. Box 412 Lab. No. 77554 Middletown, Pa. 17057 Attn: Rick Hansken (^ On sample of: three (3) Greases Received. 9/23/77 Marked: as below (Pirt 1) ixamined with the following results: - Sample #5 Sample #6 Samule #4 Fresh lot #7-2762 Fresh lot #7-2767 Chlorides (ppm) 41 41 41 Nitrates (ppm) 45 45 45 Sulfide (ppm) 41 41 41 Water (%) 40.1 e 0.1 e.0.1
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.teported to: ALLENTOWN TESTING LABORATORY, INC.
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m o VISCOSITY OIL COM PANY Lubricants 3200 50. WESTERN AVE. TELEPHONE: CHICAGO, ILLINOIS 60608 AREA CODE 312 847 C225 O ER TO ' # # BATCH NO. 7-2762 OUALITY CONTROL SPECIFICATION SHEET VISCONORUST 2090P-4 CASING FILLER NUCLEAR-GRADE PHYSICAL PROPERTIES TEST RESULTS REOUIRED Weight per gallen 7.6 7.3-7.8 Specific Gravity @ 60 0F (15 C) ASTM D-287 0.92 0.88-0.94 (57.2-62.8) Congealing Point F (OC) ASTM D-938 139 135-145 Flash Point F ASTM D-92 430 420 Min. Viscosity SUS @ 2100F (99 C) ASTM D-88 163 150-225 ASTM Consistency (cone penetration @ 770F' (25 C) ASTM D-937 210 190-220 Total Base No. Modified ASTM D-974 50 35 Min. CHEMICAL PROPERTIES Water Soluble Chlorides ASTM D-512 Less then 2 ppm 2 com Max Water Soluble ~ Nitrates HACH CHEMICALLess than appm 4 com Max Water Soluble Sulfides HACH CHEMICAL T oce ei,m ?~,4 com Max BY / Contr61{hemijt4#/5 2$6 DATE o/16/77 112475
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