ML19341D028
| ML19341D028 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 02/27/1981 |
| From: | Shields S PSI ENERGY, INC. A/K/A PUBLIC SERVICE CO. OF INDIANA |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, S79-03, S79-3, NUDOCS 8103040725 | |
| Download: ML19341D028 (17) | |
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PUBLIC SERVICE INDIANA S. W. Shields Senior Vice President - Nuclear Division - February 27, 1981 S79-03 Mr. James G. Keppler, Director Docket Nos.: STN 50-546 U. S. Nuclear Regulatory Co=missica STN 50-547 Region III Construction Permit Nos.: 799 Roosevelt Road CPPR - 170 Glen Ellyn, Illinois 60137 CPPR - 171 Marble Hill Nuclear Generating Station - Units 1 and 2
Dear Mr. Keppler:
On April 16, 1979, Mr. F. R. Hodges of Public Service Company of Indiana, Inc. (PSI) notified your of fice of a potentially reportable incident in-volving two containment post-tensioning trumplates. Propane fired torches were applied to these trumplates at opposite ends of a tendon duct in order to heat the pour above the trumplates in question. Heat was applied for a period of approximately 6 hours; this practice allowed overheating of the trumplates and surrottnding concrete to occur. Subsequent examination and testing of a series of cores in the area of concrets .,verheatii.g has reveal 1 a decrease in the c-: crete compressive strength. Some dr. mage to the trumplates has also occurred. Had this deficiency remained uncorrected it would have reduced the effectiveness of the contairment post-tensioning tendons which passed through the damaged trumplates. The contractor responsible has been instructed not to repeat this procedure and will repair the damaged trumplates a- '
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1 8103040725 N f,;,g A/ P. O. Box 190, New Washington, Indiana 47162 812. 289 .1000 L --
5 2d PUBUC SERVICE INDIANA O2278140;03 Letter: James G. Keppler February 27, 1981 S79-03 This letter is intended to fulfill the requirements of a final report as defined by 10 CFR 50.55(e) . If you have any questions on this matter, please feel free to contact me. Sincer ly,
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S. W. Shields TDG/mj g cc: / Director of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C. 20555 E. R. Schweibins, P. E. J J. lTarriso. bec: W. M. Petro T. R. Burns J. U. Bott L. O. Ramsett J. R. Pope G. A. Troxell S. J. Brewer C. S. Togni R. H. Porter K. Hinkle C. G. Beckham
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CONTRACTOR NEWBERC PROCEDURE NO. WPN 25.01 REV. NO. O DAT, APPROVED A // 9 ///
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PROCEDURE TITLE UNIT 1 CONTAINME'4T TRLS' PLATE REPAIF PER NCR 6325 This procedure has been reviewed and approved for Construction with restrictions / remarks, if any, as noted below. RESTRICTIONS / REM AR KS APPROVED BY PRB Chairman--- Date J. ,[ a e f[MOlMM_ Quality Engineering Mgr. a -2 " Date U / C 1 l 5- 1 R
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.The purpose of this pre ecedure is to provide the methods and controls fc repair of damaged Containment Building post tensioning trum-plcuas as dispositioned on N-MH NCR #325.
2.0 SCOPE This procedure applies to the Buttress 1 and 2 trumplates of Unit #1 Tendon 7BA. 3.0 REFERENCE DOCUMENTS NCR #325 WPN 25, " Concrete Patching" WPN 41, " Curing Concrete" WCWP-1, "Cadwelding" WCWP-2, " Reinforcing Steel Erection" WCWP-3, " Post-Tensioning" ,' QCP 7.03, " Surveillance" QCP 10.02, " Concrete Preplapement Inspection" ' QCP 10.03, " Concrete Placement Inspection" QCP 10.04, " Concrete Curing Inspection" QCP 10.05, " Concrete Production Inspection" QCP 10.06, " Post Placement.and Patching Inspection" 1.0 RESPONSIBILITY '- - ~ . :i ' " ' " " " " ' ~ ~ ' ' ~ '- ~ '
,4.1 Assistant. Project ~ Manage ~r - General The Assistant Project' Manager - General is responsible for the implementation and coordination of the work for this procedure and for observation of Hold points as delineated in this proce-dure and applicable WPN's.
4.2 Quality Control Supervisor.- Special Projects The Quality Control Supervisor - Special Projects is responsible for inspection and subcontractor surveillance of the work per applicable QCP 7.u3, 10.06, 10.02, 10.03, 10.04, 10.05 and the requirements of this procedure. PREPARED BY: DATE: N-MH POAM APPROVAL: DATE:
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MWhr-- _ n REPAIR PER NCR #325 5.0 GENERAL 5.1 Sketches 1 through 8 (Attachment 1 through 8) indicate the approximate limits of concrete to be removed at each buttress and also illustrate the affected reinforcing steel, tendon sheathing and trumplates. These sketches shall be used to direct the concrete removal and coring operations. 5.2 Replacement trumplates, funnels, and sheathing material will be supplied by PSI. 5.3 Reinforcing steel, cadweld material, etc., needed for replace-ment shall be used from stock supplies of Category I material on site. 5.4 Ins,ection special to this procedure sha.'.1 he performed and documented on.the attached NCR #325 Checklist (Attachment 9). These inspections do not preclude any inspections required by the referenced Preplacement Inspection Checklist (QCP 10.02) ,, prior to " release for placement". . E.0 CONCRETE REMOVAL 6.1 Reinforcing steel on the face of each repair area e.til be located with a metal detector (James-R Meter) and the pattern drawn on the surface prior to concrete removal. 6.2 Concrete removal and preparation of the area shall be in accordance with WPN 25, " Concrete Patching" and the following. 6.3 The surface of the concrete shall be saw cut along the limits as shown on Sketches 1-through 8 to a depth of lk" using a carborundum blade. 6.4 The concrete shall be removed to the excavation divisions shown on the Attachments using pneumatic chipping hammers, jack hammers or hand chisels and chippers as most appropriate for eact area. 6.5 Concrete shall be removed from around the reinforcing steel and the steel thoroughly cleaned of all concrete using wire brushes, water blasting, chipping hammers, etc., as required. 6.6 In order to provide access to the interior of the area, some reinforcing steel may require removal. The removal and subsequent replacement of this steel shall be approsed by the PSI Contract Manager before proceeding. This is a MHP. This request shall be documented on the Supplemental Owner Approval Sheet (Attachment 10). The bar shall be flame cut and replace-ment shall be per WCWP 1 and 2. The temperature of the steel at the concrete surface shall be maintained below 5000F as -
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m[@g u .. w w e s . E M REPAIR PER NCR #325 monitored with a temperature indicating crayon. 6.7 The bottom surface of the repair area shall be level ( " per foot), and the top surface a one in four slope. The inside face shall be vertical (th" per foot). See Attachments 2, 3, 6, and 7). 7.0 CONCRETE AND REBAR TESTING 7.1 Upon completion of concrete removal, three (3), 2" x 12" core samples shall be taken from the locations indicated on Attach-ment Sketches 1 and 5. A rebar detector (James-R Meter) shall be used to locate any reinforcing steel in the area of the cores. The Supplemental Owner Approval Sheet shall be used tt document relocating the holes to miss any such rebar. This would be a MHP if required. 7.2 The cores shall be drilled and prepared in accordance with the applicable section of ASTM C42-77, " Obtaining and Testing ,, Drill Cores and Sawed Beams of Concrete". The cores shall be identified per Attachment 1 and 5 with an indelible marking pen and delivered to a testing laboratory selected by PSI for com-pressive strength and petrographic testing. The test reports generated shall be evaluated by the Owner /A-E to show that the concrete in the area o2 the cores is acceptable.
. 7.3 One piece of rebar, a minimum of 24" long, shall be removed (flame. cut) from each repair area, identified per Attachment Sketches.3 and 7 with tags and be delivered to the owner's Testing Laboratory for tensile strength and elongation testing.
Results of the tests shall be evaluated by the Owner /A-E for acceptability of steel within the repair area. 3.0 EMBEDMENT REPAIR 8.1 Nicks in transverse deformations of reinforcing steel may be left as is. Nicks in longitudinal deformations less than 1/32" deep, and those nicks less than 1/16" deep, other than on deformations shall be smoothed out with a grinder or file. Bars with nicks on longitudinal deformations greater than 1/32" deep, or greater than 1/16" deep, other than on deformations, shall be removed (flame cut) and replaced as per WCWP-2, " Rein-forcing Steel Erection", using cadweld splices per WCWP-1 " Cad-welding". Bars removed for testing shall be replaced per those procedures also. 8.2 Trumplates, funnels and tendon sheathing shall be removed and replaced with new material installed in accordance with WCWP-3, Post-Tensioning". When removing sheathing, care shall be taken to provide for enough material to allow proper reinstal-lation during concrete removal. Removed items shall be tagged -
" Reject" and removed from the jobsite.
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ame J REPAIR PER NCR #325 9.0 CONCRETE PLACEMENT 9.1 Upon notification from the PSI Contract Manager that the con-crete core and rebar test results for each repair area have been evaluated and accepted by the A-E, the respective repair area shall be prepared and filled using the pour back method per WPN 25, and in accordance wi.th the applicable paragraphs and Hold Points. referenced ther.in. This is a MHP. 9.1.1 The pour shall be made in two lifts. The first lift in each repair area shall be made to within approxi-mately 6" of the top at the back of the~ void area using an approved 5500 psi, Size 67 coarse aggregate concrete. 9.1.2 The surface of the first lift shall be " green cut" per hPN 9, prior to placement of final lift. The final lift shall be made with Master-Flow 713 Grout. A form chimney shall be used in accordance with WPN 25 to ,, assure that the repair area is completely filled. . 9.1.3 Concrete and grout shall be cured in accordance with WPN 41, " Curing Concrete". 10.0 DOCUMENTATION
, Documentation produced by this procedure and all supporting proce-dures (including Whalen-Chilstrem and the Owner's Testing Laboratory) shall be submitted to the N-MH Quality Control Supervisor. All docu-mentation shall reference NCR #325. . it.
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Attachment 1. - WPN 25-01,- Sketch 1 - Attachment 2 - WPN 25-01, Sketch 2 _ Attachment 3 - WPN 25-01., Sketch 3 "- . Attachment 4 - WPN 25-01, Sketch 4-Attachment 5 - WPN 25-01, Sketch 5 Attachment 6 - WPN 25-01, Sketch 6 Attachment 7 - WPN 25-01, Sketch 7 Attachment 8 - WPN 25-01, Sketch 8 Attachment 9 - NCR #325 Checklist Attachment 10- Supplemental owner Approvals for WPN 25-01
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;- ! EXCAVAT4CN LIMIIS WPN 25.01 CONTAcENT C' TRUKPLATE REPAIA Mr7 *1 PCA NcA " 315 (
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0 5.T.c.,.rgy.c_1 .,M is',hJ*i ATTACIDIENT 7 SKETCH 7 D P D I LlD }D'l~)N"A a _ A o TEST REBAR No. WPN 25012. MIN. 24" LONGI. (av1
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SECTION B-B BUTTRE SS 'I NOTE: SH ADED AREA DENOTES E XC AVATIO N LIMITS NEWSERS MAABLE Hilt. WPN 25 Cl CCNTA1N!MNT TRUMPLATE REPAIR burT*L FEB NCA " 32.5 SCALE I" t YC' SKETQ
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spr-s. ATTACHMENT 8 SKETCH 8 - 0 l D lD f yh a J h hd . ..I J I i P i w r,tss .
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1 SCCTION C-C BU TT RE SS " -2 NOTE' NEWBERG PARBLE HIL _ SiiAD c 3 /J CA CEWCTES wpy . 2 5.01 CCNTAJNMENT E AcN:kTICM LitAITS TRUMPt. ATE REPAIR EL'TT *2
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g- g g w ,'j ,i, CRGANISATIONe Newt, erg-karble Hill 14CATIONekarble 11111 - Unit 1 "7 q' .: Mr s 7 /.,7 ~ p a D. ACTIVITYa Inspections for WPN 25-01. Pavisten' 0* I Tr'ubplate' Pepa1*r. bar: hch 1325 4' [* M Y
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- ITEM REFERENCE SAT. UNSAT. N/A COMitf NTS The Inspector ehe11 perform the
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M 4 i _. J-e$ent Trureplete Pepair per NCR 8325e ,*b a ,' , g
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- 1. Verify rebar rattern le drawn Para..6.1
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; prior to conerate renovel. *8.'* MJ 1 ..
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- 8 >d *'# 2 2., H d N#fd Verify concrete cut with saw . .se
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- Para. 6.3 1i ,
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,' q .t. i .I *i 3a Verify any rebar to t>e renoved Para 6.6 '*
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',l Contract Manager on theha Supple- s been approved
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.. sented Cvner Arproval Sheet,.
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- 4. Verify tottom eurf ace of re elr Para. 6.7 I le level (+ S* per foot.
- E l,eresar.d top ourface on a one to 7 ; 3 3/ g 1; four slope. e l 'I (q r Inside fece la . * **
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(+ per foot). ' g f} vertical tr3 Ig , g .o. 4' 1* e . . e
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D.. Tr'u mplat o port r' rar Nem 185 AcTav Tre _ inen. ci inne int v n 25-01. Novtelen 0 '.' % e. l [. ' 17tM stErERENCE SAT. tJHSAT. N/A CLMMENTS* J'. &
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S. verif y reber detector was useo Pare. 7.1 4 , O '===. [ i' ! '{
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to locate robar prior to ob- <;-
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f". d w.t i talning cores. If cores must , ',f,g{. . *.4.
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y ,;, ' b. be moved teyond the 3* toler- , - ;. , ;-
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2 . ance given on tha sketches, the :).' ',- ', i d'1 ! y"'C
. -4 Sogplemental Owner Approval e g. .('s .\'i. ,4. '
i e' - Sheet must provide approved
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. locations (t,y PSI Contract Man- %.j f.,
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ager) prior to coring in these . , p g
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has locatione. This le an MitP. ; ,,,,o,.
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.,. . e* e O 8* 2, i n O 4 Verify nicke in longitudinal deformatione are lose than Para. 8.1 t.
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g O%g 1/32' deep and nicks on other C ,,j a o . ,: , g .;g g than Geform.ations, lees than ;., '. i
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Any nick e deeper than this re-
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- 1. Verif y cores ar.J rebar removed and te s t e.1 pe r Pa g e. 1.2 and Para. 7.2, 1.3 & 9.1
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Owner /AE as inIlcated on test reporte prior to release of . e {
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f bd [)- the repair area for further I trork per WrN 25. This le an o - ' 7') M H Hnr. l g
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