ML19347D377

Procedure TSS 13, Tendon Surveillance Test Procedures

ML19347D377
Person / Time
Site:	Zion  File:ZionSolutions icon.png
Issue date:	07/29/1980
From:	COMMONWEALTH EDISON CO.
To:
Shared Package
ML19347D376	List: ML19347D375 ML19347D377
References
TSS-13, NUDOCS 8103170512
Download: ML19347D377 (16)

Text

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l TENDON SURVEIII.NCE TEST PROCEDL~ DES TSS 13 TABLE OF CCNIH7tS SIITION TITLE PAGE DATE REVISICN Table of Centents 1

JUL 29 580 3

Procedure il 2

JUL : 8 588 3

Procedure #2 3

10-24-79 1

4 10-24-79 1

Procedure 43 5

10-24-79 1

6 10-24-79 1

Procedure #4 7

10-24-79 1

8 10-24-79 1

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Procedure 05 9

10-24-79 1

10 10-24-79 1

Procedure 46 11 10-24-79 1

Procedure #7 12 10-24-79 1

Procedure 58 13 10-24-79 1

Procedure 19 14 10-24-79 1

Procedure #10 15 10-24-79 1

16 10-24-79 1

Date Surveillance Perforned Surveillance Performed en Unit i

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APPROVED ff M DATE Y~M~D This procedure <;entains 16 pages.

1 810 317 051 L

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ISS 13 Fav. 3 JUL se m

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Procedures Procedure f1 Selecticn of tendons 1.1 Per Containment structure a total of 21 tendens shall be inspected.

1.2 In accordance with statistical sanpling methods 6 of these tendens shall be selected frm the Dee,10 frm the hoop teJx$cns, and 5 frm the vertical wall tendens.

1.3 Per NRC letter dating 6/16/76, the following tendens will be inspected during all subsequent surveillances:

Unit 1:

D1-7, 9; D2-13, 15; D3-7, 13 BF-21, 22, 27, 28, 29, 34, 35, 89, 90, 91 V-42, 43, 44, 176, 177 Unit 2: Dl-219, 221; D2-201, 203; D3-201, 203 GI-14, 15, 16, 42, 43, 76, 79 GL-21, 28, 35 V-303, 404, 376, 380, 513 1.4 Ccaplete surveillance test shall be performed en cne containment. The second ccntainment shall be subjected to visual inspc<: tion cnly.

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TSS 13 Rev. 1 10-24-79 Procedure #2 Collect tendon filler samples out of grease cans 2.1 Collect tendon casing filler samples out of cans of all 21 Unit 1 and 21 Unit 2 'Dmdons. Remove enough grease to allow for visual inspection and lacoratory analysis. Samples to be sent to a '.cboratory should be properly marked to prevent confusion and also should oe transported in clean, dry and tightly closed chenically inert containers to render laboratory results reliable. Sangles should be taken within the first 30 minutes after opening of the grease cans.

2.2 Remove endplug frca grease can if necessary, open cock valve (if provided) for venting and collect a representative sample.

2.3 If ambient tenperature is such that the tendon casing filler is liquid, this grease inside of the trunget might leak thru the anchor head into the grease can c ea. 'Iterefore, tenporary cooling may be used. Do not cool anchor head w.nts to below 30 F.

e 2.4 Remove grease can and insert the lis" plug (which is to be removed fran the grease can) into the anchor head hole.

• 2.5 Visually examine this tendon filler, ccmpare color and consistency with a sangle of new tendon casing filler (Visconorust 2090P), and check for the presence of water. Record findings.

• 2.6 Analize tendon casing filler sanple with respect to the following acceptance criteria:

physical properties:

Weight per gallon 7.3-7.6 Specific gravity @ 60 F

.88.91 per AS'IM-D-287 Melting point F 125-135 per AS'IM-D-938 Flash point F 385 min.

per AS'IM-D-92 Viscosity SUS @ 210 F 53-63 AS'IM-D-88 Viscosity SUS @ 152 F 100-120 ASDt-D-88 AS'IM consistency (cone penetration @ 77 F) 330-370 ASDt-D-937 chemical properties:

Water soluble Chlorides 2 ppa max.

ASDt-D-512 l

Water soluble Nitrates 4 ppa max.

ASDt-D-992 Water soluble Sulfides 2ppn max.

HACH chemical or APHA l

moisture catrent:

Water ocntent to be measured in ppm.

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TSS 13 Rev. 1 10-24-79 2.7 hten the appropriate work phases have been carpleted, refill grease can with new, unused tendon casing filler (visconorus 2090P).

Before new grease is brought on site subject each batch to the same laboratory analysis as under "2.6".

(Provide owner with a certified ch=ical analysis before bringing on site, see. paragraph 12.4 of the specification.)

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4 TSS 13 Rev. 1 10-24-79 Procedure #3 visually inspeedt the 21 Anchorage Ccaponents

• 3.1 Remove grease can and screw plug into ancMr head hole. RMord the j

amount of tendon casing filler removed frca the trumplate space.

If needed cool ancnor head, but not below 30 F.

3.2 Renove all visible tendon casing filler, and thcroughly clean the anchorage caponents with Vismaity oil Capany's Industrial Solvent No.

16 in accordance with manufacturer's instructions, Chlorinated hydrocarbon solvents shall not be used (Provide a certified chemical analysis before bringing on site, see paragraph 12.4 of the specifications).

• 3.3 visually inspect the caponents, and check for, and record bronen wires. In the stressed tendons, these may be detected by finding button heads on shop end, or field end not in contact with anchor head.

• 3.4 Inspect the buttenheads for general appearance, for cracks, for corrosion, and any other deterioriation. Identify missing cuttenneads and any buttenhead defects cm a sketch of the shop and field anchorheads using the forms shown in attachment "A".

• 3.5 Inspect the shop and field anchorheads for corrosica status, ciretanferent al cracking, or cracks between but*a teads. If cracks are coscrved, sA their location and size on the shop and field anchorhead sketches.

• 3.6 Inspect shims t 1 formation and cracks. If cracks are observed, prepare a sketch (

' heir location, including location in the shim pack.

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• 3.7 Inspect the bearing pt e at the contact surface with the shims for deformatica and cracks.

Prepare a sketch describing any cracks observed.

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3.8 Subject the shop and fielo W ebeads and shims of the six tendons, selectel under 5.1 to a mort v ensive inspection as follows:

3.9 Clean anchorheads and shims wi u = -hloride free solvent.

(Provide certification)

• 3.10 Inspect stressed surfaces for signs of localized ccupression, cracking, yielding or eccentricity. Map ant record results.

• 3 11 Inspect anchorheads and shims for u dn ue and/or progressive corrosion.

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TSS 13

%v. 1 0-24-79 l

3.12 If any tr mptable defects (such as the ones listed above) are found, the owner should be notified imediately.

3.13 During reassembly after stressing cperations have been cor@leted reinstall all shims in the same position and sequence as they can out.

U m additicnal installation of extra shims may be required due to yielding of the tendons. Supply and install additicnal shims to the nearest 1/8" required.

(Provide material certification before bringing on site.)

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TSS 13 Rev. 1 10-24-79 Procedure #4 Measure Tendon Force (Lift-off Reading) of the 21 Tenoons.

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• 4.1 For the horizontal and d me tendons use two hydraulic jacks simultaneously to be applied at shop and field end. The hydraulic jack will be applied to the top end of the Vertical tendons only. We stressing units, pressure and elongation gauges for all jacks being used shall be calibrated before the test program is resumed. Pressure gauges should be calibrated at last once every 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, provided the jacx has been used during the past 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.

• 4.2 Before application of the lift-off force checx for, md record broken wires. In the stressed tendens, these may be detected by finding buttonheads on shop and/or field end, not in contact with the anchorhead.

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• 4.3 With the hydraulic jack, measure and record the lift,2ff force and elongation. Do not stand behind the jacks while t W/ are pressurized.

Se anchorheads must be lifted nere than 1/32" of'. the shims before recording the lift-off force. Measure and record trtmplate tenperatures l

at shop and field end before and after stressing operatims (i.e. at least four readings).

• 4.4 Take into consideration the proportionally lower force for thi tendons that had a wire removed and/or showed broken wires. Rese are:

Dl-7, Dl-9, D2-13, D2-15, BF-21, BF-22, BF-34, BF-35, BF-91, V-42, and V-176.

• 4.5 Se lift-off force for the tendons shall equal or exceed the following values: For the dme tendons: 142KSI; for the horizontal tenoons:

143.3 KSI for the vertical tendons: 147.1 KSI. Due to the accuracy of the stressing equignent, a measured load of 24 less than the minimum predicted load is acceptable.

• 4.6 If the lift-off reading for one tendon shows a load ena11er than indicated above, two adjacent tendens, ~ene cm each side of the tendon in que:; tion shall also be checked. If both of these tendons are acceptable l

based m the acove criteria, the tendon in question shall also be acceptable. W e owner should be notified if any deviations are encountered.

(See paragraph 10.1 of the specification)

• 4.7 9 % mntly overstress (D e e and Horizontal tendons only) the tendon (704, 754, and 80% of the U.T.S. = 240 KSI, but never to exceed 192 KSI) in three steps, and record force and elongation at each step.

Overstressing of the six tendens selected under procedure 95, snall be done afte-the test wires have been removed.

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TSS 13 Rev. L 10-24-79 Ccmtractor shall subnit for owner's review and approval the calculations of, and the predicted pressure and elongation gauge readings before ocenencement of the stressing operaticns. Record the serial numbers, and pisten areas of the hydraulic jacxs used for either anchcrhead.

• 4.8 Seat the anchcrhead back on the original shims and make a second lift-off reading and record. Added shims may be required to bring the lift-off force to the minima as stated under procedure item #4.5 above.

• 4.9 If additional shims are added, a second set of lift-off readings shall be taken for future reference.

• 4.10 Inspect for and record any broken wires, or buttenheads and notify the owners representative.

• 4 11 Apply tenden casing filler to the anchorhead and replace grease can filled with new tenden casing filler to the extent possible. Record the amount required. Do not reuse tendon casing filler removed fran tendons.

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TSS 13 Rev. 1 10-24-79 Procedure 45 Remove one wire out of six ten 3cns

• 5.1 Select a rand a three dme, two hoop, and one vertical wall-tendons.

Avoid removing wires fr m anose tendons that have had a wire removed during previous surveillances.

5.2 After taking the first set of lift-off readings in acccrdance with items 4.1 thru 4.6 keep tendon under lift-off stress and remove shims.

5.3 Destress tendon ccupletely and detach hydraulic jacks. Record the configuration of the shims.

• S.4 Visually inspect anchor heads for broken wires. They may be detected by being able to pull out wires fr m the tendon. Suspect are the wires which protrude the furthest fr m the anchorheads.

5.5 If any broken wires are found, remove this wire, make test coupons and test as under procedure 6.

• 5.6 Remove one wire by cutting the buttonhead off on one end and by pulling out this wire fr a the other end. Record on which end the buttcohead was removed. Identification of the buttonhead on the other side may be made by tapping the buttenhead and feeling the vibration on the other end, or by pushing the cut off wire in and seeing on the otner side which one caos out. Map and record location of removed wire on anchor head sketch.

• S.7 After removal of a grease sample in accordance with procedure 47, restress the tendon in at least 6 steps (oil pressure increnunts, matching a wire tension of 34.19768 KSI) to overstress at 80% ( = 192 KSI) of the ultimate strengths of the tendon, and record force and elongation at each step. Do this for both ends simultaneously.

Contractor shall sutait for owner's review and approval the calculaticns of, and the predicted pressure and elongation gauge readings before ccsunencement of stressing operation. Record the serial numbers, and piston areas of the hydraulic jacks used for either anchor head.

Measure and record tenperatures of the trunplates at shop and field ends before and after stressing operations (i.e. at least four readings).

5.8 Release the load (on both ends simultaneously) to the under procedure item 4.5 measured lift-off force (adjusted for the removed wire) and seat anchorhead on shims.

5.9 Restack shims in the same configuration as before destressing, and as recorded under 5.3.

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'ESS L3 Rev. 1 10-24-79

• 5.10 Recheck lift-eff force as under item 4.3 and 4.4 and record findings.

5.11 Overstress tendons as under "4.7".

• 5.12 Lw for, and record any broxen wires.

• S.13 Apply tendon casing filler to the anchorheads and replace grease can b1 YhirT.

nofuse

'casikfI fee rN Ifcan 10

TSS 13 Rev. 1 10-24-79 Procedure 16 Inspect and test wires removed under procedure 5.

• 6.1 Inspect each wire visually over the full lengths and all around for any signs of corrosion, pitting or other surface inperfections, and record findings.

6.2 1he acceptance criteria shall be the same as for accepting the wire frm the mill as stated in the AS7M specification A 421 paragraph 13. Any signs of corrosion with pits visible to the naked eye shall be cause for additional tensile tests to be performed on the corroded and pitted areas.

• 6.3 A minimum of three wire sanples, one frcm each end, one frm the middle and one of each corroded area as described L'xier item "6.2", of each removed wire, shall be tensile tested in acmrdance with ASIM A-421 (paragraph 6, 7, and 8) by an indepas3ent testing laboratory, and the results shall be reported.

6.4 The acceptance criteria for the tensile test results shall be the same as for the wire purchased fr m the mill, which is essentially that the tensile strengths shall be equal or greater than 240 KSI, that the yield strengths at 1% extension shall be greater than 192 KSI and tnat the elongation shall be greater than 4% in a gauge length of 10".

Any failure of the wire sangles to pass the minimum ultimate strengths should irunediately be brought to the owner's attention.

(See paragraph 10.1 of the specification)

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l TSS 13 Rev. 1 10-24-79

. Procedure (7 Collect a tenden filler sangle out of the tendon cavities i

7.1 Collect a tendon casing filler sangle out of all the tendon cavities of the six tendcms, chosen under procedure 65 and inspect. Enough tendon casing filler should be removed to allow for a reliable visual and laborstory examination. Sanples to be sent to a laboratory should be properly labeled to prevent confusion and also should be transported in clean, dry and tightly closed, cWcally inert containers to prevent containation. All sangles should be taken within 30 :rinutes after opening of trungets.

• 7.2 Visually examine this tenden casing filler, n eare color and consistency with a sanple of new tendon casing fillar (Visccoorust 2090P), and check for the presence of water. Rewrd findings.

• 7.3 Proceed in accordance with procedure items 2.6 and 2.7.

Record all findings and notify owner imediately wnen deviations are found, i

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255 13 Rev. 1 10-24-79 Procedure 38 Surveillance of concrete surfaces.

8.1 Inspect the concrete surfaces around the two end anchors of all Unit 1 and 2 surveyed tendons over an approximate 3' X 3' area.

• 8.2 Map all concrete cracks wider than.01" and record pattern and widths.

Also record any signs of deterioration.

• 8.3 Measure and record the surface temperatures of the concrete and in the close vicinity of the end anchors, and the ambient air ternperature existing during the crack surveillance.

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r ISS 13 Rev. 1 10-24-79 Procedure 69 Caplete attachnents - B 9.1 Caplete the "attachnent B" form for eacn end of each tendon.

9.2 "At* h t B" is not intended as a rep 1 m t of above listed procedure 2 or vice-versa. The data collection as required in the various Procedures 1 thru 8 and not required according to Attac.W nt B, and vice-versa, are still needed and should be identified with the respective procedures and item d's.

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TSS 13 Rev. 1 10-24-79 Procedure #10 Submit an evaluatim report.

10.1 All procedure items marked with an asterisk require where applicaole at least:

a.

A field report mananting on the encountered conditions, written and dated the same day wtv, this item occurred and signed by the full-time field supervisor.

b.

And/or a data sheet containing the raw data in the same units as they were measured under the respective procedure items. This data sheet should be ocapiled and dated during the same day tney are measured.

Both reports should be referenced to their respective procedure items.

A copy shall be submitted to the owner the ext day.

10.2 All under 10.1== lated data shall be capared with the minimum acceptance criteria as set forth in procedures 2 thru 8.

This shall be the basis for contractor's final evaluation report.

10.3 Contractor's final evaluation report shall cement on the following topics:

a.

Sheathing in grease cans.

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Accounting for. broken wires before and after overstressing and wire removal.

c.

Visual inspecticn of all anchorage ocuponents.

d.

Lift off, overstress and restress readings.

e.

Visual inspection of renoved wires.

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Tensile test reports on renomd wires.

g.

Tenden casing filler samples.

h.

Surveillance of adjacent ocncrete.

10.4 At the end of the sorveillance test the ocntractor shall along with his evaluation report include another package of the reports listed under item 10.1.

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TSS 13 Rev. 1 10-24-79 10.5 the evaluation report shall have attached sheets cn wnich all surveillance results are capiled in tabular for=.

la. Grease can grease field ins p ion.

Ib. Grease can grease laboratory analysis.

2.

d anchorage inspection.

3a.1%ndon lift off forces and alongations (list ram area).

36. Overstressing elongations.

4a.14ndm lift off forces and elongations after wire renoval.

4b. Overstressing elcngatims after wire removal.

5.

14st results cm mechanical properties such as: stress / strain curves; Break force,1%nsil strength, it yield strength, Elcngation, bend test recuts.

6a. Tenden grease field inspection.

6b. Tenden grease laboratory analysis.

6c Replaced quantities of grease.

7.

Concrete inspection.

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