ML19319A741
| ML19319A741 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 03/25/1970 |
| From: | Kelley W, Murphy C, Seidle W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319A740 | List: |
| References | |
| NUDOCS 7911280714 | |
| Download: ML19319A741 (17) | |
Text
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alvf:;uMI c/ '>;ir/M:: Vi'.imo't 1:..i im' G r ! 0:1 Tf'tT Tendonc for Post-Tranional Cnnerrte Centisin:.e ut a u ild bif'. Vendor: The Prescon Corporation Pir.nt 5 1 i: p u o.n t.110 :l/ 1 :m t. h C.2 r o l ina .a zi'/1 'cport No : . +, e j cy j Co:.7-a c. a t s T a p. c t e d l'e c : r e l' I 1, .4 3 3 1 1 n: A C t cv la,
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U. D. r (T.n Ch.ir o) j o g l '".~-[ N ( p. f y s / gv i C. F.. o t p ?.y, { # :ct(c T.c;p ecto c 'O de ideen. o 'epte, a t :, t i v c. ; : G. i,. ,,m ic ;f t, l'ald 'n t r (Civ i t ), FMC R. U. Si'cu'ns, in:.p. c tor, DFC ,. <,n i ng 1', Cther 2. e ans Contc.cted: G. T..Toim:en, newtoc M 1 I' 1 scen Cm: p o r e t t.1, n, C..r p ; Ci. + of f f c n D. ",att, C i 41 1 t y C.:m r. r ol h e > <.. > c, t C mpo ntion, 1:l a nt 5.i i ; av i 110, 3 t,a <,.;ol a.na ./.fb../p*oor. ,/ i s/ s .. / J 'I f J /,o '..._.._._._c.i i' hport raie.eed By: w to c L p e r. t o r '-te S e idl.c ). a n i e r W. C.
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et A h. Pr'.' /': G. W. Rebauth, iWctor Ir s> ' tor Date (Fcogrm Sta.uhrds) Picp ri.etary In f' >n at ica : Entita 1, 4rt .R_O P_E. un Cm c.c:tfan, Plant 5, A rpecial m me.:t, cod visit - 'd' o f Ite ' ; h C.:tol h o,.a ~ e i, c " rf LS, t '! 7 0. '; h.:P o,n v il l e, ..... -....... ~...... -. -. l
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i 1 ! VILPpt.11% FC.,70-1 /2-I. .L [ <!I t .The visit $as stranged thtough Ruhe power.Ce mpany and had as its specific [ objective the comination of Prescon Corporat. ion's quality assurance pro - +
- gtam and qudity control' in the manufacturing of tendons for post-to.nstaned concrete containment buildings and "a review of the available' recx ds pcc--
E - *a bing to the *erhus for: Oconee W f t No, 1 contein"ent faildinq. i SUISt\\RY
- 1. 'Fiescon specialf acs in"the manufacturo and installation of tcodcas for j
post-tension concrete. (See Sectien A.) .l r 'l 2., The tendons.for nuclear applications : re a-se M ed at a new plcut at Singsonville, South Carolina. (Gee Sect Lou H.) l + j' j. '3. Aduality control uanual has been ucitten and its und by Prescoa which '{ outlines its quality assurance program. It contains fabt icar.Ioa and manufceturing proceduces, and specifies quality control ched points l and ' records that =mst be kept. (See Sec tion C.).
- 4. ?The quality assurance prograra is it;gler :nted by a cabinat ion of lino and staf f organizations with a quality Assm ance Camittee that is the j
- final authority. for the revicv of the quality as.nuranca prurams and [ .( - proposed changes to the program. (See Section D.) I [
- 5. - The ntil test data en natorial for wire and stressing washets vece j
i [ xcadily. available nr.d confor.ncd with t he specific ations. (See Sections j-
- E 6nd F.)
4 l I folicsed by an insp ction
- 6.. :Each step in fabrication and canufactur ing is check point that is described in the quality control n.anual. Each inspection point aust be recorded on a QC fom.
(See Gect. ion G.) y 7. Plant 5.has a labnatory well equipped-for perComing the: tests designated l in the quality control-rannal. (See Section G.4.) [ 8.. There is a difference in the allovable width of a button head split permitted by Prescon's quality corttoi manual and the licenscets FSAR. p F -(See Sect ion II.) - t I-l- [!anajgent~ Intervin w At' the complet. ion of the visit, an intervicu was held [ uith -10.tnnicutt; Simons, Johnson and Hyatt. V l} Thef followin3 points were discussed: Lt. Prese.2n has;a very coniprehensive quality ustwnrxic progran that is . structured as outlined 'in..their. quality control' manual. ,l' ' J t 1 it - e . J i. p-I' Ne'ur.*e ...L'Phe;m.rge.%he.gigg-.,,, ..pg.,,4
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~l f g y; E - 2. 'The quality control manual did not define a tOden wire bec.d or kiuk arni L . it ' docs ~'nbtiplace a limit ca.their acceptance. Jcimson utated a l bit h
- would be'epccified.-
m L '3; Detf g f@ fcaf f en of s t m'm far 0-nnco W i t: 1, th* Pe p n II intpertor y ahucceed a.t'ci,3 cal;irc which had' bcen bent. Johnson pine.1d the P s tion i k -in quarantine pending the establishment of an acceptance criterien. s [ [
- 4. EPnir, con was; inspect ing L'at ton heads on the bas is set forth fu thctr qaality control wnual yhich penitt ed splits-1060er x o,23a m g ym,
I' 'Gie ESAR has a' limit of two splits cf 1/64 foch. INnnfc.ut had p revic us ly stat 4d that the 1/64-Inch II61t Ws a typographical i. rxec sd that the I FSAR:Ws bt the process of b 'i 3 corrected to 3 cad 0, T.0 inch. This cor,rection was confined 'by 6 C. Dail, the lic e nseds p rim (pal clv t.1 cugineer, the following ddy. F i: f [ .) iz (- -. T_A._J LS-DE + M E +l A. -- peg;ription of Prescon Corp 3 ration [ Prescon.has been in the post-tr.usioning ficid s ince ita luc %poratian In April-1956. It eperates fabricating plants in various parts of the F United States and has sales representat.ives =in' major cities. For che [ 4 - specialized work ihvolved in post-tcasioning for nucicar applicatiens, }. ~ [ Prescon has established modern production f acilitics for auchorage mam ficture (uashers,_ spacers, and trumpets) in Covptn Christi, Texas, [ and tendon asumbly in Sirosonvilla, South Cnolina. In addition, ic i, has organized a_ field services group and aa cngineering gro:q in Cnpus j 7 j i Christi, Twas, to hand 1.c the technical phases of prods;ct design, detait j }. drawings, testing, equipment developncut, and jobs ite technical assistance. i [ A company organization chart for the canufacture of t enhns t'or nuclear. j, appifcationa-is shwa :in D.hibit A, and a list of pmonnel locctions -- .and functions. for nuclear applications.may be found in hbtbit B.
- B. IDercriptioniof Prescon Corporation Plantj h
..Pecscon has1ere6ted a' 40,000 square foot of fice, laboratory, and tendon i [ 'assenbly area for post-teasion applications. The platt his been identified ' t i.
- by Prescon as Plant 5.
The tendens for Oconee Unita1 are the first tendons [ i for nucicar application to be produced at this f acility. h is'i 'TEF. chaped alth, the cross hay bein3 500 feet long and.-50 p , The plant [ feet wide and ackved by tror avechecd crancs. The icg is 250 fecte long andL50 feet wid,e: and 'is used to uaco tt, cut, and e secble the tdak n. h Thojbuildingjis layed out far' onecathrcogh pteduction with mterint [.~ (being' received-at one.crat of the 500-f at bay and finished itanjcus 9 p ~ being: shipped, from the oppgsite ond.. 4 tp 4 I p ,( -z u% ) _a- ' dh m ;. ad-_,.. J., 6. A-L ~.. ' ^
3- ~ -- h - ~ Vi fpt.'No.,-EC 20 1^ g s 'J -C. Quality Control Manual in detall its Prescan has turitten a quality control manual that describr ; i ? qutlity assurance program, material control procedur'es, anchc" manufacture L : c w rs ? n n, dad: tin A n-w bly ; nc *es. This &anual has been written to guide Prescon's personnel in fabricating [
- and ~mdnuf acturing ptocedures and to specify those quality control checks for the iffe of 1
and vicords that are required to assure a quality product - the post-tens ioned structuro. ~ D. Quality 3surance Pr<gry3 Precon bus developed a. qvality e utence p wgc.ua for the fabrication of its pont~ tensioning systens furnf ahed for structures like seconduy con-taintmnt vacscls for nuclear rc ictors. Tbc progrtA was developcd to l assurc:lth customers and ellents that its praducts met or exceed the specifications set forth -in :ach coat;ct. o Prescon has ef fected a combined line cud staf f organization for irclementing This type of ccc,anization places.line its quality rssurance prograr.s. responsibility for developing and cait.taining the quslity assurance pr.c- 'graus on the ecmpany's Engineering Dcpartncnt hsudling teactor cont e:. cts. l At the smcc time, the company has Con ed a quality annurance camit ' ce 7 .uhich functions as the final authority revieu group for all quality l r j. The concept of this organization is to fix tesponei-assursrec programs. an operating l bility for' devalupnent of quality anaurance progems at ,1 cycl. An organization chart' dcp icting this c mcept is fouad in Exhibit' C. The Quality Assurance Comnittee is composed of fiva nanagers throughout - It neets nonthly the company appointed annually by the 3cncral manager. l- ~ to review existing progran r ed suggested revisions, and to discuss general E quality assurance probicas.. Cue acmber of the exuittee is selected to ; . conduct an' annual audit of the quality 2ssurance programs. The reactor. engineering manager is respcasible for develeping and- ~ inglementing-the ' quality assutance p regrams., ' He' is re sponsible for formplating the necessary p'rocedures, checks, and~ controls that util-Such p ro- _ - result 'in a_ quality product meeting all job specificaticas. cedures,. checks, and controls 1 are then submitted to the Quality Assurance Cwmittee for' final review and approval. - He' also selects ~ a project engineer to conduct a quax_terly audit of-the quality assura..ce programs. The hpiementation.of the quality, assurance progran is the repon$ibility~ . The lotpectors are selected by the of.the4 quality condrol f nspectors. generalsnsgcr and they c2erate at nach' prodection facility and carry - out the ; quality contr.ol checks _ and 'staintain?the quality control ' records k.- ? .~ J R
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~ _..,.. _. _,. _. _,,. _,,. _ _ _ _, _ _, _ _ _ _ _ ~ { 7 3 r. ..VI itet. lio. : PC 70-1 . 5 '- ? t .i: i f' as t rcquired jin the QA remntal. They ace responsibic directly to the [ i [ - cngineering. manager for-the adaioistrat ton o f the quality assurance l - program ind work clocely with production percounct in order to assure l h comp 11ance with quality control requirements. - The quality control inspector at l'lat 5, D. Hyat.t, has bu.u >.wley.:d J l l for :six months by Prescon.. He..h'as a B.S. degree ' in Business Industrial' } ' A1.ts.' Two additional upicyces, A. Eolt and.J. C. Tayor, are training j U i i~ to be incpectors. i 4. L .In_or der to prevent the quclity assurance Progra fron becoming stum.nt, 'j i' o d tng l thejyality control muaual proviks the folic Ag dethods for s 'l and revising the p3 ogrun: s V '1.. Isny czployee aho fuels a ev t alon should be cade to an existing its a let ter to the engine ving mnager quality assurcnce progran i. . i. cetituing the arggasted revi= 'nn, how and uhy it abould be ' cp imc ated, - tuid attaches' support ing evis te that cuch revision will not ac t ific e l j b quality. r '2. 1hc engineering uanager and quality centrol inspector review and l evaluate the nuL:itted revision. If the revision has nerit, it is 1 dir cded in detail with the employce who cubaitted it. If the l I revision is rejected, it is answered in ucit Ing by the quality l control inspector vit.hin four wecks after receipt. . On revisions accceted by cuginecring manager, the quality cont ro1 l 3 '. inspector-drafts a proposed revision to' the quality assurance pro - t In addition, a cover letter is prepared outlining the support fug L gram. evidence indicating there is no cacrifice of quality. r The propesed pality:nssurance progran unrision and the cover letter j 4. are present(d at the next c.cnthly uceting of the Quality Assurance i Connittcc = fo r review and approval. i i [ 5. Any revision requirgi by the Quality Assurance Corunittee must be F rade. The revision is then finalized and the quality-control Inspector }
- sees to it that all ontstanding copics of the quality assurcace pro-l~
grna receive the revic. ion. A ccpy of the cover letter is sent to the 1 [ 1: customers. Involved for Nerification of the tevision. 1. I. k? E. ' Purchase of Utre by, Pecscon l r l Johncon stated that ?reccon had investigated all potential.dcmectic, vl' EuropeanJ dnd Jhpanes'c suppllors of wire conforming to ASTM A471 -65. l Uc atated that only -the Japanese wire met Prescon requircments for ' corrosion 1 resistanch, 'ducti1Ry. without splitting, heading and cleanliness. o ( h I' [^ -L-+M-s--.ecE.a,as,4.,'--w.c',m.m,,.;j._
c- ~ 'VIdet, No.- FC ;10-1-' . f3 Ji. . The wire-is purchace.ll by the. Preccon, Corpus Christi, Texas, office Ethrop h thel Swift Train Coepany, Corpus Chricti, frca Suzuki. Itetal g Indust ry Company, Ltd., with an of fice at No. 1-18ATADANE '- TA, KITA-K, Tokyo, Japan. y A rc'fm > e c Q :;- m. 2$9 to C -ift Train A pany for 2,200 t ws . of : quarter-inch diameter, cold drawn, stress relieved, PC wire in cccordance with ASTM Specification A421-65 for Oconce Units 1 and 2 tendons was ' audited. The purchase order required cich coil to be ruked with purchase order.ncaber, coil nrmber, and heat.naber ; stress-strain cutves and y.odules of cicaticity for cach - heat ; wire to lay stra ight ind lhave uo ' tendencies to seck an are yhen laid on ground; and each coil La ~ - one continuous wiro without velds. The catecial was shipped.frcn Japan to Charleston, South Carolina, Scre j .it was loaded onto t tuck for chipuent to Prescen's Plant 5. TAspection cdttificates from Suzuki 1:etn1 Industry were audf Led. It "as ? speciflod as uncoated, stress relieved for prcutressed e nc rete. The inspection certificate gave the -:artcu, silicon, rangancoe, phocphorus, sulphur, and copper content. A stress otrained. curve was scN11ed eith -cach inapection certifiedte for. nach. heat. In addit ion, the re c.n de d test data frca which the curve was derivnd was attached. -1 F. Strassing p thers Thc. stressing washers are manufactured at Picacon's Plant 1, Corpus Chr ist i, Texas. Johnron bciofly c:01ained some of the manufacturing puc sses cnd quality control checks involved.
- To attempt will he nade to describe thue as they were:not witnessed by the inspector.
Material for the stressing vashers e.s purchased from Earl M. Jorgensea Cempeny. and specified as C104511R. A certified test report was audited for street,fug washer pieces 23 and 29. (Pieco 29 has been shipped to the 0conce Uait No..I site.) The certification gave the chemical and mechanical prepcrties uhich 2ndicated that the two heat; involved met the requirements for C1045 steel. The strosting wachers are shipped from Plant 1 to Plant 5 in the es-nachined Jenndition, in 2 rates without a tust.- inhibitt r coat ing. When the washers are received at Plant 5, they are. st ared inside the plant unit u'iere the tendons. are assembled..
- G,= Qualit { Control 1.
Recciying '.The coils of{ wire are received from Suzuki IIetal Industry % Pay, Ltd., J y with three mrappings..The coil.is first wrapped in a vapor phase v ,e u ~.i.A
g. -. __ _ ,1 VW nytj No; NG m-I [_ r ? h iah1bitar' impregnated papec, thett.f.n polyethylene, end fh ;I by a f } Pestccti9c burirq dapping. One wtal and one papec i&ntification [ tag is on the citerior of ecch coil and one u.etal tag nd one peper tag 'is :Inside of the burlap wrapping. Should the natal tags nat be W -M-ed on the coils when receiwd, Hm en11s -re y M e c s. j t' q h tie u b u *ol L. J i d i et, m, =. ' one. heat' is assigned a PCU rr',er and each coil in that hcat receives i-. an -individud nwnber. htat id is uemrepped and innp<uted just before ( it li'phced in productica cud the in cpection is i.eco1&d on Po' scot l l Wim T.w pc.etion hco:d QC rom %, 3 (Whlbit D) f n..r cent m citn the re.pt tements of their 'QC a:enul, Check Na. 1, 3 0, 81 d '3 2 I l OC C%ck.No.1 Is the data :ecc Wd and coil nrxber, i.e., t. 5 Fu.scsa's a d tt.c m rafect m t.% mber. QC C'm'nk h, 30 h fr eba j: vrpping conditions and storge : req. QC check W. 81 wp ' 3 ti e ado: A t ha gh 7 Cr & t & Oc 3h j taticg of the r se conditioa fx va i D are accep table - for u3e in. nucier unk Nie O A C is 1Uc'ed. The ufre is alco d cked for any beat-or kinked of n.
- m. ' t u.e cut ont of the colla.
The pun d QC mm 31 da ;
- .t defJna a b> ud
' j or a kink; ho wier,.ha QC n..:ual util be . zi; d '.o '.fo H-cc it. m. l QC Chcck No. 82 is to indierto that icbocatoty spplcs hoa bu a tek o.. I The:,e semples are cut, placed in plastic tubes ma:kcd oith the ICil trnScr and coll n nb<r, and sent to the lab for heading :ad t easile { test. Rejteted wire is naavad frora the building to a salvge yaed in back cf the building. A salvage dhpositian fo:m is filh d nt mt is suht.itted to the,Caepus C'iristi ef fice uecily,. A crom u feerce ' of Prescon s PCW nv aber and the supplier's heat nutr e is m ixaia.d t ' t 1Q, on the PCU Material number Ne vrds (Wire) QC scrn Moe 2 (F This fom gives the FCU materbl m.mber, type, pu:chsse 0,dct r. 'cr, date deliured, dato ce.r tificct bn tecnived,.tra w plier, site description and size, heat omber job. ec.de, &.to ingscted, ad h#4 4 7 bleck for the in;pector% taitials. ?- protective x apping s a muld be Only enovah Oire Is stripped of 15 3 4 required for 3-4 days of product 0 n. at r.be mt, an enrgle is the Florida Pwer and Licht Cxpar.y s u ike vbere wire for I n. key Faint i Units 3 and 4 vore uavrappcd md nody for pudection wher. uork va3 i received at Prcscon of the strike. The mt nial wa s then routed to the cocmreiai s ide of th e op ent ions. j 2. . U.. n u f.m e t ur_a ino i f 1The coils sre leaded ihto baskets and thstr FCU wwher and call ebers -are recorded onDa tag shich is attached to e.mch coil. Nar mily, r,31y i On.3-halt Of WI.IC {S 104ded Ir,to 3 h h ;I A t. Occ ? 40MS c?Q ' L D C 'l h) CG f. laixed heits-will ba embined In ana.buket, by ch call tr, ragged l; si'th-its FCil number a l c yl c aber, /my coil i f.edily t:uceable t o F -the supplier's heat nmbu W:augh ;he QC rop No. 7. Indbedual wires
- are.not idmtifiable by hr-at unebor7 ' A tendm assetbly, sheet (E:aibit ?),
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J A LVi%)t.f Na,00) [Ca t 3.. 1. b lasuc'd;byJengiriccing' for caeh tendon, -gives' the tendoa mf.k n: 3 n c,. cutting'. length, v!re supplier, hcat m&ber, ' stressing yac Mr rc Nr, and wire' FGT nw bar and coil humber. The tendon mark is kcyd to the tendon Idcation.. For exacple, in the case of Oconec tc9 on mk - d 14n99,- th a 9 A dn t e c)tbn ec + n <c fr m W rms 2 thro gh h, and tl w H M & s Q t itt. n th e t et u n N ' . :Imr is-99. The bay, mh6 tia cuttin'g of the vires 'is performed, has two cutting - tables along opposite hils; cue is for cenarcial applieut ha and the The cutting Obles first 100-foot nark ws
- other for realcar :
ained and a 100-foot stee1 race stat iros at the k.00-accunt:1y deu fect muk %3-f.wtcncd to _ it. liire is miGdr.pn f wm 60 b ukety a.ud rcHur decclerne the &ca to a v& city of "M f eet per uf ate dwa
' the cw t ing tame. - A & coh otor with no, dero wEtches located aa the table detcu 6 cs the cuttf,ng 1 mgth. The tu @Ms cme b.* the q ~
table' and sto. decelerated; Cn both.nicro vitches arc 6 pteas ed, t he
= cutting cp rat ion is ntta 3tically ya famid. Af t er tM cuttbg cpcz;-
t ion, a.pocoutic cy1 Mer.:utomt teally telenc s t ha t. ire to a ttough.
i.
Af ter tal wires for or.e tenN hue--bm cut, they m.e m ed to the lower side of the table for bJtton hid bg.
The e cs ue f ad through
-a ecobing ' late and a strening u +she r, then cold ira ton 5caded.
Quality oatrol of tha huMonehead wnat ton is perfou :d in three steps. A "go or no go" pj ge is u c d to ' us ure cht. d h " er of cach button b e.d.
The ecccatricity nament of the brtn %d is per-j '
Coned en a esmple made before and after the buttcu-hec.dba operat un for each tend >n.
Each button head is vicu.dly inspouted for 2plits, any (plit s found no measured acd rceorded. The QC Ch<.r.k List D e Tendan Fabrication (Exhibit G) requires in QC Check No. 33 that the tendon wrk nurber, cut length and eccentricity of the tutton be
. recorded. QC Check' No.
3'+ tequires that the stree sing nhar idc ot t-ficitton part nnber'be acorded, and the checking of the dister of -
the butten hesd for cplits be recot ded and tmed.
LAfter all utres hw icen butten headed and irspected for cplitting, the ceabibg p,1 to
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~ .5 r e' 4- - 11._ tstenn IIcad @ lits ~ rreacca's quality assurance raanual perv.its uplit butt 6n headn of a maxipuna: of.0.060.. inch. The FOAR pernits tuo splits of 1/64-inch
- . didth. Prescon' stated that this discrepancy will be resolved with
' t h e.1.L,w; n. J'A t t achment s :- -, Exhibits A thru.G 4 = i T 4 4 + 4 d a 4 I i .i m t h i, t s ,) . -- j. 3:x 4 .i. I A k-g _, :i-. .~ , ~ - .c...
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