ML20064C927
| ML20064C927 | |
| Person / Time | |
|---|---|
| Site: | Byron, Braidwood, LaSalle, 05000000 |
| Issue date: | 06/02/1982 |
| From: | Reed C COMMONWEALTH EDISON CO. |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| Shared Package | |
| ML20064C876 | List: |
| References | |
| 4228N, NUDOCS 8301040516 | |
| Download: ML20064C927 (22) | |
Text
.
y 7
r-t f
f/Cf e
/'p/N,-
Mf Commonwealth Edison h
O g One First N:tionsi Piara, ChiCEgo, lihnois C'
'Alfdrsss Rip *y to: Post Office Box 767 Y
Chicago, litinois 60690
$j u[JL
'.D FC D.E STilm
-- (
x,P
]
y Iryc l}s
{
lln f.',90
.m Un An l t
t j
Jun e 2, 1982 i
l
/t' 2.
d.__ J.
i UA
.m l
,?
^#l 2W1 l
Mr. James. G. Keppler, Regional Administrator 1 'O I#"
b i
Directorate of Inspection and U
l Enforcement - Region III i
U.S. Nuclehr Regulatory Commission 799 Roosevelt Road 1
4 i
Glen Ellyn, IL 60137
.[ '
{
Subject:
Systematic Assessment of Licensee Performfrice (SALP) j i
Commonwealth Edtson Ccmpany Comments LaSalle County Station Units.1 and 2; Byron Staton Units 1 and 2; andf j
Braidwood Station Units 1 and 2 r
l HRC Docket Nos. 50-373/374, 52-454/455, and 50-456/457 j
References (1):
47 FR 12240, dated March 22,,1982 (2):
J. A. Hind letter to Cordell Reed date&
4 May'6, 1982 (LaSalle County Station) 4 r
a (3):
J. A. Find letter to Cordell Reed dahed l
May 7, 1982 (Byron Station)
(4):
J. A. Hind letter to Cordell Reed dated May 5, 1982 (Braidwood Station) p s
Dear Mr. Keppler:
x i
The purpose of this letter is to transmit commeats as i
allowed in Reference (1) in response to the Systematic Assessment o f i
i Licensee Performance ($ ALP) reports provideo in Re ferences (2), (3),
I 4
and (4).
Specific detailed comments for each of the, subject sites were presented to your staf f at the public meeting on May 18, 1982, and are documented in the enclosures to this letter.
l There are two general observations that we believe need to I
be made relative to the SALP process which are evidenced by our i
f specific comments.
First, it is very dif ficult f or this licensee to understand how the evaluation criteria are applied to categorize i
activities.
We are unable to understand what constitutes the threshhold for any of the categories; but most importantly, we see no objective standard for a finding that an area is Ca tegory 1 i
(Reduced NRC attention may be appropriate).
Although functional area 2 at Byron Station was identified as Category 1, our review of j
your bases for that finding as opposed to the findings for i
1 Vi DON d 8301040516 B21229 PDR ADOCK 05000456 G
,r,
, ?
7
./ _ p x
- q. q n
[ ' j }*
1, J
l 9
/
l.d3
'. l.
O'
}
e
~
functional ' area's 4, 9 ind 13 at LaSalle County (all Category 2)
L' mf[#
provided no basis for distinction.
If we are to devote the rescucces to improve our performance, as evaluated by your staff, we must have a better understanding not only of the criteria you use but also of the way in which these criteria are applied to reach decisions.
It is not enough to say that Category 2 performance is acceptable.
We< dre firmly committed to improve our performance and 4
feel justified in this request for clarification of the bases upon which we will be judged.
Second, the application of the Category 3 designation in at leas t two instances - LaSalle County Area 17 and Byron Area 6 - does not appaar consistent with the definition of this category provided in Stction II of Enclosure 2 of the SALP Reports.
Specifically, the definition indicates that both NRC and licensee attention should be increased,; presumably, beyond that attention then being applied at
~
the time the SALP report is issued.
In the case of the two referenced areas, performance at the time of the SALP report was categorized as "more than adequate" and improved from early in the evaluation period.
It is our understanding, based on comments by your staff, tha't our performance at the time of the SALP report for both stations and, in the case of Byron Area 6, at the time the SALP 1
period ended, would have been acceptable.
In both instances, we know of no increased licensee attention that could or necessarily should be applied in these areas.
We request that you clarify your position relative to any future action on our part judged necessary by your o f fice.
You will also see in reviewing our specific comments on the Category 3 designation for Braidwood Functional Area 9, that we believe this finding is not justified by the f acts, which we have attempted to summarize in the enclosure.
We would greatly appreciate any adoitional attention you may devote to this area.
At
[
a minimum, we request a more comprehensive discussion of the bases upcn which the SALP finding was made.
We are available at your convenience to discuss these comments.
Should you have any questions, please direct them to this o f fice.
Very truly yours,
([
h er_ M Cordell Reed Vice President 4228N vii
ENCLOSURE 1 Comments on Byron and Braidwood SALP Reports 1.
Functional Area 8 - Licensing Ac tivities The analysis f ails to note that NRR's review of the Byron /
Braidwood SER was conducted on a very short schedule because NRR resources were devoted to other projects.
The bulk of the work done in this eighteen month reporting period was done in the last four months.
Continuity in this period was poor because the NRR Licensing Project Manager was changed at least six times.
Most of the review work was completed in accordance with a new Standard Review Plan that wasn't issued until September, 1981.
Given these circumstances, the conclusions regarding responsiveness to NRC initiatives seem unwarranted.
2.
Byron Functional Area 10 - Quality Assurance Four problems were identified in the discussion o f the April, 1982 special team inspection at Byron.
The fourth item listed contains an unnecessary broad characterization of the deficiency found in discrepancy tracking.
Based on the information given to us in the exit meeting, only two contractors were involved.
3.
Braidwood Functional Area 9 - Quality Assurance The conclusion regarding our performance in this area is based upon an unfair expansion of a single auditor's findings.
Most of those findings are in dispute.
Reconsideration o f this rating is requested.
The following comments address specific concerns highlighted in the analysis:
Concern (1):
Failure to plan ahead for corrosion inspection of post tensioning tendons, and to provide written l
procedures and checklists in accord with the policies established by the Quality Assurance Topical Repart.
Comment:
At the time o f the NRC inspection (11/18-20/81) tendons which had been (or were soon to be) installed over 90 days were inspected for corrosion in accord-ance with NSCI procedure 78, Rev.
5, Appendi x " A" (attached).
The inspections were documented in the form o f memos to file.
Concern (2):
Failure to understand and currently interpret previously established inspection requirement terms such as random sample, monthly, withdrawn, signs of corrosion, and rejected.
When an inspec-tion procedure for inspecting tendons installed I
over 90 days was prepared, the actual inspection included no tendons installed over 90 days, indicating that the most convenient sample was chosen rather than a representative sample.
l viii
O, Commen t :
Site personnel understood previously established inspection requirements terms such as random sample, withdrawn and signs of corrosion.
To minimize the possibility of misinterpretation NSCI's procedure 78, Rev.
6, (attached) was revised to define these terms.
This was done at the NRC Inspector's request.
However, when this was done the Inspector implied that the inspection requirements had been reduced to suit field practices.
The inspections that were performed on ungreased, horizontal tendons installed over 90 days are shown below.
It should be noted that of 191 inspections performed, no detrimental corrosion was observed.
The 10% inspection requirement was achieved as shown below; a) O f the 199 ungreased tendons that were installed over 90 days 29 were inspected for corrosion between the 74th day and the ll8th day.
21 tendons were inspected after the 90th day with 20 (10% o f 199) being required to be inspected, b) O f the 199 ungreased tendons that were installed over 120 days 47 were inspected for corrosion between the 121st day and the 149th day.
20 tendons (10% o f 199) were required to be inspected.
c) Of the 176 ungreased tendons that were installed over 150 days 80 were inspected for corrosion between the 151st day and the 180th day.
18 tendons (10% o f 176) were required to be inspected.
d) O f the 98 ungreased tendons that were installed over 180 days 35 were inspected for corrosion between the 181st day and the 200th day.
10 tendons (10% o f 98) were required to be inspected.
The above inspections are a combination o f those inspections that were performed on tendons prior to l
stressing and during stressing, They are documented i
on NSCI's Fo rm NS-19 and the In stallation Cards.
l l
Concern (3):
Failure to respond in a timely way as the 90 day inspection was reached and exceeded for tendons that had not been greased.
Comment:
It was anticipated by Braidwood Site that the ungreased tendons would be in place for over 90 days.
This condition was and is accounted for in the tendon installation specification F/L-2722, para.13-508.2 (a ttached).
Consequently the inspections listed in (2) above were performed as required.
ix
., Concern (4):
Failure to get advance approvals of inspection activity actually conducted on tendons and on the acceptability of the inspection records.
Comment:
As stated in (1) above, corrosion inspections were performed in accordance with NSCI procedure 78, Appendix "A".
This procedure was reviewed and approved by the Project Construction Department, the Site Q.A. Department, and by Engineering.
Concern (5):
Failure to recognize that they had exceeded the 180 day limit of the specification for tendon greasing and to consider the 50.55(e) implications a f ter exceeding the limit.
An extensive review of the results is not yet complete.
Comment:
Failure to recognize that some tendons exceeded the 180 day limit was due to NSCI misinterpreting the specification requirements.
It was NSCI interpreta-tion that the 28 day limit on stress-to-grease was additive to the 180 day limit on place-to-grease.
Contractor personnel have been made aware of the correct interpretation.
The requirements of 10 CFR 50.55(e) have been considered and found not to be applicable to this situation.
Concern (6):
Failure to follow a controlled approach to changes to an audit checklist.
Commen t :
When the audit checklist for CECO audit #20-81-31 was developed, only part of the acceptance criteria was included in one of the questions.
This situation was identified during the conduct of the audit.
The auditor added the omitted criteria to the checklist and referenced the design document from which it came.
Such corrective measures are permitted by an I
auditor and are subject to approval o f the lead auditor and the supervisor, where applicable, who review the objective evidence of the audit checklist and approve the audit report.
The entire audit report was later reviewed and accepted by the lead auditor and the Q.A. Superintendent before issuance.
Concern (7):
In addition, the licensee's approach to resolving some o f the problems identified was to propose and attempt to change the specifications and procedures to reflect the work as completed rather than pursue the overall Q.A. program objective of corrective action to bring the work and results into conform-ance.
One example of this was the attempt to resolve a Q.A. audit finding regarding safety-related equipment lifting procedures by eliminating X
. Concern (7):
the procedure.
After complete review and approval (Cont'd) by station construction, Sargent & Lundy and Station Q.A. to eliminate the procedure, the identifying auditor pointed out that this procedure is required by ANSI.
Comment:
CECO Audit #20-81-22 o f PGCo. found that the contractor did not generate special lift procedures for equipment which weighed in excess of 20,000 lbs.
In response to this deficiency the contractor submit-ted a revised procedure eliminating the requirement of having special lift procedures for large equip-ment. The weight of a piece of equipment was not thought to be reason enough to generate special procedures.
This procedure went through the review and approval cycle.
When the auditor performed a follow-up surveillance on this audit deficiency, he found the corrective action to be inadequate.
As a result, PGCo. withdrew the revised procedures and re-committed to generate special lif ting procedures for lif ts over 20,000 lbs.
This is an example of the e f fectiveness o f Commonwealth Edison's Q. A. program, not a deficiency.
i t
l r
4228N xi
C C
..~
Q hn,fl fT REINFORCING & STRUCTURAL ERECTORS M
m hc L
Crane and Equipment Rental
.- M ser7
,I j
't '
Route 1, Box 84 14080 N.W. 20th Court St.
s544 Fairlane Drive
/
Braceville. Ill. 60407 opa Locka. Fla.33054 Cincinnati, ohio 45227 (sis) 5s8 2131 -
(30s: sas.3ses (stai 2717380 CONTR ACTORS, INC. OF ILL.
f Braidwood Station Procedure -7B Unita 1 &2 Approved 6-% eda-/
Post-Tensioning Tendons.
Quality Control Procedure Revision 5u Date-November 10, ~1980 i
e 1
1 POST-TE!!SIOtJIl1G TEIJDON I?!ST ALLATION ~
'~
~ ~
~ ~
7B-1.0 - SECTIOJ SCOPE 7B-1.1 - This procedure implements the IJSCI Quality Assurance Manual, Sections 1.0 and 4.8 for the control of post-tensioning tendon installation.
Reference S & L Specification L-2722, Division 13.
7B-2.0 - GE!!ERAL 7B-2.1 - The purpose of this procedure is to insure that post-tensioning tendon installation is done in accordance with approved plans, specifications, and applicable codes and standards.
7B-3.0 - GROU.'JD PREPAR ATIO:1 PROCEDURE 7B-3.1 - The tendon bag shall be removed and the tendon checked for the following conditions:
(If any irregularities are found, proceed as in 7A-4.3.
7B-3.1.1 Broken or damaged wire.
7B-3.1.2 Corrosion of wire and anchorhead (See Appendix A for
)
wire criteria).
7B-3.1.3 Presence of foreign matter, water, or sand.
7B-3.1.4 Identification Tags.
7B-3.2 - Place the pull back sleeve on the shop anchor head.
7B-3.3 - Remove only the necessary bands to free about six feet of e
,. =
k
P
(
{'
the unbutton headed end from the coil.
Remove Rack uprights as necessary.
7B-3.3.1 Remove bundle bands in this six foot length.
7B-3.3.2 Clean the grease from about f'our feet of this end using industrial solvent #16 or equal.
Wipe dry.--
7B-3.3.3 If the nose cone will enclose all 170 wire ends, bundle the wires, put nose cone on end, and tape nose cone in ~
~~.
~
~~
~~
place.
7B-3.3.4 If the nose cone will not-enclose-all-470-wire-ends,-make - Zi-a sheet metal sleeve to completely enclose all 170 wire m
ends.
Place the sleeve inside the nose cone and place over the wire ends.
Tape all joints securely.
Tape the~
nose cone-sleeve combination to the wires.
7B-3.4 - Tightly wrap this end of the tendon with about five feet of rubber material.
Use a 50 per cent overlap on each turn.
Tape securely start and finish end of the rubber material.
7B-3.5 - Place Kellums grip over the tendon end.
Insure that the nose cone is firmly in the head of the Kellums grip.
Secure tail of Kellums grip with two or three individual bands.
Cover bands with tape, especially any rough or jagged edges.
7B-3.6 - Steps 7B-3.3.2 through 7B-3.5 shall apply to horizontal, dome, and vertical tendons which require the use of the tugger.
Vertical tendons installed without the aid of the tugger will be prepared with steps 7B-3.3.3 and 7B-3.3.4 only.
7B-3.7 - Big tendon with NYLON sling for hoisting.
Sling shall be rated for 10,000 pounds for horizontal tendons and 7,000 pounds for all others.
7B-4.0 - INSTALLATION 7B-4.1 - As the tendon is lifted free, the bottom side of the tendon shall be checked for damage or corrosion.
If any damage is found, proceed as in 7A-4.3.
7B-4.2 - The tags attached near the shop head indicate the tendon mark number or location and the tendon length.
After the tendon is in the uncoiler, the tags shall be removed and their information recorded on the Tendon Pulling Card, Form 780.64-60.
(2)
'-4=
(
~
7B-4.3 - The tendon mark or number location shall be verified against the tendon number on the concrete next to the trumplate to insure proper placement.
7B-4.4 - The trumplate and bearing pla,,te shall be clean of rust and loose scale prior to the installation of the tendons.
7B-4.5 - Prior to the installation of the tendons, a cloth " rabbit" i
shall be pulled through the void to check for moisture.
This shall be repeated until the " rabbit" comes out pry.
7B-4.6 - The uncoiler shall be postioned to provide a fairlead from the exit' hole of the uncoi-ler-to-the-tendon-void -
1-
~
This is to avoid pulling the tendon on sharp edges and damaging the wire.
7B-4.7 - The bands shall be removed while tendon is being pull ~ed' into the void.
The quadrant and bundle bands should be cut last.
As necessary, all bands shall be removed before the tendon enters the void except those bands that pro-trude far enough to be removed after installation.
These bands will be removed during installation of the field anchor head.
Rev. 4 7D-4.8 - Before the tendon installation, the tendon shall be inspected for any signs of damage or corrosion, as noted in Section 7B-3.1.
If any damage or corrosion is found proceed as in Section 7A-4.3.
7B-4.9 - The initial protrusion of the unbutton headed wires exit-ing from the tendon void shall be recorded in the Comments section of the Tendon Pulling Card.
This measurement is taken when the front face of the shop anchor head is flush with the bearing plate.
7B-4.10- Any significant occurrences, such as bent or broken wires, l
during tendon installation shall be noted on the Tendon Rev. 4 Pulling Card.
l 7B-5.0 - END PROTECTION 7B-5.1 - VERTICAL TENDOMS 7B-5.1.1 Louer shop head with pull back cap into bottom of trum-l plate.
Disconnect cable.
Seal void with temporary covers with rubber gaskets, or install grease cans as doncribed in Section 7C-13.0.
7B-5.1.2 When necessary renove Kellums grip, nose cone, tape and rubber from tendon.
Recoat the bare wires with Viscono-rust 2090P4, 1601, 1702 or an approved equal.
(3)
~,
(
[
~
78-5.1.3 The end shall be covered uith a plastic bag which is of adequate thickness to prevent vind damage.
The bag must be placed and taped to the bearing plate to seal the void completely.
70-5.1.4 These temporary covers can rema-in in place in the tendon tunnel until grease cans are installed as described _in Section 7C-13.0.
7B-5.2 - D OME AND HOR IZ ONT A L TEND ONS 7B-5.2.1 The shop end of the tendon'shall be protected as soon as possibic by installing temporary co_ vers with rubber. gaskets.l :_.-
These covers to remain in p~1 ace until installation of grease.
cans as described in Section 7C-12.0.
70-5.2.2 The Kellums grip, nose cone, tape and rubber stripping shall; -
be removed from the field end of the tendon, and the bare i
uires recoated uith Visconorust 2090P4, 1601, 1702, or an, approved equal.
5 7B-5.2.3 The end shall be covered uith a plastic bag which is of l
adequate thickness to prevent vind damage.
The bag must i
be placed and taped to the bearing plate to seal the void l
completely, i
70-5.2.4 These temporary plastic covers shall be utilized for a per-iod of thitty (30) dayr until buttonheading is comp 1.eted and grease cens installed as in Section 7C-13.0.
70-5.3 D OCUME NT AI 10N 70-5.3.1 Record all data as listed on the Tendon Pulling Card, form 780.64-60 plus in the comment section note the protrusion length, if the tendon was installed uithout the use of the Rev.4 tugger, if any vires vere bent or broken during installation, and if the tendon uns placed on hold and action taken as in Section 7A-4.3.
7B-6.0 - S PE C I A L INSTRUCTIONS 7B-6.1 - Uhere job site conditions prevent immediate placement of the uncoiler next to the trumplate, i.e.
horizontal tendons in lover buttresses, special care must be taken to provide a systen to install these Londons.
7B-6.2 - The tendon must never be allound to drag over a sharp edge.
Some form of roller or guide must be used to insure a gentle sucep or curve to the hole uith caution taken not to remove grease from tendon.
70-7.0 T E ND ON RE ST OR AGE 7B-7.1 - Tendons removed from storage rack to gain access to other (4)
(
tendons underneath shall be placed in an empty shipping rack or preparation rack.
78-7.2 - Any tendons that must be returned to storage shall be covered completely, similar.t.o original storage condition.
They shall be stored only in racks.,
7B-8.0 - SPECIFICATION 7B-8.1 - The tendon nust be greased within ninety (90) days fr_om installation or within seven (7). days af ter -stressing.---
Time from stressing to Greasing may be extended from R*V' 4
seven (7). days to twenty-eight (28), days provided'the--
tendon grease caps are installed immediately af ter stressing to keep out moisture and prevent corrosion.
(5)
(/
(.
e APPENDIX "A"
ACCEPTANCE / REJECTION CRITERIA 0F WIRE 4
INCPECTION All wire will be visibly inspected for rust.---Acceptance or rejection will be based,on the follwing criteria:
A wire in categories A, B[ orc.is.~ acceptable.-
_ -.- ZI.- J_
A wire in categories-D or E-is-rejected.
Check for wire identification.
i LEGEMD:
VISUAL CHECK OF DEGREES OF CORROSION CRITERIA FOR ACCEPTABILITY:
A.
Temporary Corrosion Material in tact, no visible oxidation.
B.
Light, thin, removable oxide on wire.
C.
A heavy red oxide dust, still removable by wiping.
CRITERIA FOR REJECTION OF WIRE:
D.
Patches of red oxide, not removable and/or leaving noticeable pits.
E.
Heavy rusting, dark red which when removed leaves very noticeable pitting.
MOTE:
If other conditions from the above appear, please indicate in the comments section of the Tendon Pulling Card.
y c.
i.
/
t t
i
?
l s
4 r
-. ~.
m I'i i
l
~
- - JOB Noir- '~ ~ ~ ~ -
~ ~ ~~-~~~~'~ 7 ~
~~~
. : _. l - -.
TEND 6N PULLING CARD I
i.
JOB:-
i l-l TENDON LOCATION DATE:
l C TENDON MARK NO. (FROM TAG)
.,I
-)
I TENDOt1 LENGTH (FROM TAG) a l
{
I(
-l l
WIRE CONDITION A
B C
D E
tu sett.or4u l (
l TENDON ENDS PROTECTED (CHECK) l l C i
l I
COMMENTS I (.
I
^l f. C.
4'
.s
_I I
,! C.
FOREMAN
' I O.C. INSPECTOR nATE
] $
i i
FOHM mom 60 F ED.1979
(
InryCO
~l M Ifddnd Steel Company 1 s I
i
- ~.
=-. _:...
... ~...
.., h.- -
h-.
. - -. - ~ - - -
~
L-)
l 6
i 1
4
- ~
_.3
.~.
.m
.~,a
- , ~ ;
i
-%.=.--.
-m ~~wc*
- - ~. - -
. se
[
\\
g)
REINFORCING & STRUCTURAL ERECTORS U %'d-l v.$4h Crane and Equipment Rental
,_a,;.p y 6 g[j 4f, Q I
Route 1, Box 84 14080 N.W. 20th Court St.
5544 Fairfano Drive erace<isie. ::. 60407 Opa Locka. Fla.33054 Cincinnati, ohio 45227 C T4TR ACTORS, INC. OF ILL.
.(815:458 2131 (305) 685-3595 (513) 271 7380 f
Braidwood Station Procedure. 7B Units 1 &2 1_ A p pr oved _('-hdo-/
Post-Tensioning Tendons Revision 6u Ouality Control Procedure.
Date-Nove mb e r 30,- 1981 ~
POST-TEllSIONIIIG TENDON ITISTALLATION
.. ~ ~
7B-1.0 - SECTION SCOPE 78-1.1 - This procedure implemcnts the NSCI Quality Assurance Manual, Sections 1.0 and 4.8 for the control of post-tensioning tendon installation.
Reference S & L Specification L-2722, Division 13.
7B-2.0 - GENERAL 7B-2.1 - The purpose of this procedure is to insure that post-tensioning tendon installation is done in accordance with approved plans, specifications, and applicable codes and standards.
7B-3.0 - GROUND PREPARATION PROCEDURE 7B-3.1 - The tendon bag shall be removed and the tenden checked for the following conditions:
(If any irregularities are found, proceed as in 7A-4.3.
l 7B-3.1.1 Broken or damaged wire.
I l
t 7B-3.1.2 Corrosien of wire and anchorhead (See Appendix A for l
wire criteria).
t 7B-3.1.3 Presence of foreign matter, water, or sand.
7B-3.1.4 Identification Tags.
7B-3.2 - Place the pull back 31eeve' on the shop anchor head.
I 7B-3.3 - Remove only the necessary bands to free about six feet of s.._
n.
(
(
t
.the unbutton headed Tend from the coil.
Remove Rack uprights as necessary.
7B-3.3.1 Remove bundle band's in this six foot length.
7B-3.3.2 Clean the grease from about four feet of thi.s_end using industrial solvent #16 or equal.
Wipe dry.
78-3.3.3 If the nose cone will enclose all 170 wire ends, bundle the wires, put nose cone on end, and tape nose cone--in place.
-~
~~
' - - - ~ ~ -
7B-3.3.4 If the nose cone'will not enclose all 170 wire ends, make a sheet actal sleeve to completely enclose all 170 wire'
~
ends.
Place the sleeve inside the nose cone and place over the wire ends.
Tape all joints securely.
Tape the nose cone-sleeve combination to the wires.
7B-3.4 - Tightly wrap this end of the tendon with about five feet of rubber material.
Use a 50 per cent overlap on each turn.
Tape securely start and finish end of the rubber material.
7B-3.5 - Place Kellums grip over the tendon end.
Insure that the nose cone is firmly in the head of the Kellums grip.
Secure tail of Kellums grip with two or three individual bands.
Cover bands with tape, especially any rough or jagged edges.
o 7B-3.6 - Steps 7B-3.3.2 through 7B-3.5 shall apply to horizontal, dome, and vertical tendons which require the use of the tugger.
Vertical tendons installed without the aid of the tugger will be prepared with steps 7B-3.3.3 and 7B-3.3.4 only.
7B-3.7
. Rig tendon with NYLON sling for hoisting.
Sling shall be rated for 10,000 pounds for horizontal tendons and 7,000 pounds for all others.
l 7B-4.0 - INSTALLATION l
7B-4.1 - As the tendon is lifted free, the bottom side of the tenden l
shall be checked for damage or corrosion.
If any damage is found, proceed as in 7A-4.3.
l 7B-4.2 - The tags attached near the shop head indicate the tendon i
nark number or location and the tendon length.
After the
(
tendon is in the uncoiler, the tags shall be removed and their information recceded on the Tendon Pulling Card, i
Forn 780.64-60.
(2)
(
(
7B-4.3 - The tendon mark or number location shall be verified against the tendon nu.~bcr on the concrete next to the trumplate to insure proper placement.
7B-4.4 - The trumplate and bearing plate shall be clean of rust and loose scale prior to the installation of the tendons.
7B-4.5 - Prior to the installation of the tendons, a cloth " rabbit" shall be pulled through the void to check for moisture.
This shall be repeated until~the " rabbit" comes out_ dry.
7B-4.6 - The uncoiler shall be postioned to provide a fairlead from the exit hole of the uncoi-ler to-the-tendon-void.
This is to avoid pulling the tendon on sharp edges and -
damaging the wire.
7B-4.7 - The bands shall be removed while tendon is being pulled into the void.
The quadrant and bundle bands should be cut last.
As necessary, all bands shall be removed before the tendon enters the void except those bands that pro-trude far enough to be removed af ter installation.
These bands will be removed during installation of the field anchor head.
7B-4.8 - Before the tendon installation, the tendon shall be inspected for any signs of damage or corrosion, as noted in Section 7B-3.1.
If any damage or corrosion is found proceed as in Section 7A 4.3.
7B-4.9 - The initial protrusion of the unbutton headed uires exit-ing from the tendon void shall be recorded in the Corments section of the Tendon Fulling Card.
This measurement is taken when the front face of the shop anchor head is flush with the bearing plate.
7B-4.10- Any significant occurrences, such as bent or broken wires, during tendon installation shall be noted on the Tendon Pulling Card.
7B-5.0 - END PR OT ECT ION 7B-5.1 - VERTICAL TENDONS 7B-5.1.1 Lower shop head with pull back cap into bottom of trum-plate.
Disconnect cable.
Seal void with temporary covers with rubber gaskets, or install grease cans as described in Section 7C-13.0.
7B-5.1.2 'dhen necessary remove Kellums grip, nose cone, tape and rubber from tendon.
Recoat the bare wires with Viscono-rust 2090P4, 1601, 1702 or an approved equal.
(3)
~.
70-5.1.3 The e*nd shall be covened uith a plastic bag uhich is of adequate thickness to, prevent vind damage.
The bag must be placed and taped to the bearing plate to seal the void completely.
70-5.1.4 These temporary covers can remain in place in the tendon tunnel until grease cans are installed as described _in Section 7C-13.0.
7B-5.2 - D OME A ND HORIZONTAL T E ND ONS 7B-5.2.1 The shop end of the tendon shall be protected ~as^soon 'as ~ ~ ~
possible by installing temporary covers vith rubbc.r__ gaskets.__ -
These covers to remain in place until in_stallation of,grea_se cans as described in Section 7C-12.0.
70-5.2.2 The Kellums grip, nose cone, tape and rubber stripping shall-be removed from the field end of the tendon, and the bare wires recoated with Visconorust 2090P4, 1601, 1702, or an approved equal.
7B-5.2.3 The end shall be covered with a plastic bag which is of adequate thickness to prevent vind damage. -The bag must be placed and taped to the bearing plate to seal the void completely.
78-5.2.4 These temporary plastic covers shall be utilized for a per-iod of thirty (30) dayr until buttonheading is como10ted and grease cans installed as in Section 7C-13.0.
o 7B-5.3 D OCUME NT AT 10N 7B-5.3.1 Record all data as listed on the Tendon Pulling Card, form 780.64-60 plus in the comment section note the protrusion length, if the tendon was installed without the use of the tugger, if any uires vere bent or broken during installation.
and if the tendon was placed on hold and action taken as in Section 7A -4. 3.
70-6.0 - SPECIAL INSTRUCTIONS 7B-6.1 - Where job site conditions prevent immediate placement of the uncoiler next to the trumplate, i.e. horizontal tendons in lover buttresses, special care must be taken to provide a system to install these tendons.
7B-6.2 - The tendon must never be alloved to drag over a sharp edge.
Some form of roller or guide must be used to insure a gentle sveep or curve to the hole uith caution taken not to remove grease from tendon.
70-7.0 TE ND ON RE ST OR ACE 70-7.1 - Tendons removed from storage rack to gain access to other (4)
(
(~
i
. tendons underneath shall be placed in an empty shipping rack or proparation rack.
70- 7. 2 - Any tondons that must be returned to storage shall be covered completely, similar to original storage condition. They shall be stored only in racks.
70- 8. 0 - SPECIFICATION
~~
~~
~~~
~-
70- 8. 1 - The tendon must be greased within ninoty (90) days from installation or within seven (7) days af tor stressing. -Time f rom stressing to-
"1--
greasing may be extended from seven (7) days'to t~went'y-eight'~(28) ~'
days provided the tendon groasa_ caps,a_r_c_ installed _immediately_arter stressing to koop out' moisture and provent corrosion.-
70- 8. 2 - Time f rom initial placement of tendons to greasing may be increased to 180 days provided a random sample of 10% of the tondons are with --
drawn monthly betwoon the 90 and 180 day period inspected for corrosion.
(Ulthjrawn in this case is as defined in 78-9.3, below.)
70- 9. 0 - IN PLACE TENDON INSPECTION (90 to 180 days) 70- 9 1 - Tho 10% of tendons which are to withdrawn within the 90 and 180 day period shall be grouped for inspection as follows:
- 1. First month-inspection group of tendons-91 to 120 days f rom date of installation.
- 2. Second month-inspection group to tendons-91 to 150 days from date of installation.
- 3. Third month-inspection group of tendons-91 to 180 days from dato of installation.
Tendon inspection for each group can be conducted at any time within the noted limits, 78-9. 2 - Tondons selected for the 10% random sample monthly inspection shall represent a cross section of m ntainment building olovations and/or azimuth locations. The random samplo shall be a simplo samplo of the RE V. 6 tondons applicable to the 90 thru 180 day critoria.
70- 9. 3 - Tendon inspection shall be conducted as follows:
- 1. Full back cap placed on shop ond.
- 2. The riold and of tho tendon pulled out as for as pull back cap protrudes inside trumplate.
' 3. Exposed tondon wires on field and cleaned with solvent end wires inspected for corrosion as por Appendix "A".
- 4. Af ter inspection is comploted ro-coat tendon uires with INRYCU approved groase and push tondon back into void.
S. If wiro is rejectablo, CECO P.C.D. will be notified immediately.
Tendon to be placed on " HOLD" pending C.E.C.O. resolution.
- 6. Documentation to bo completed on NSCI " Tendon in Place Inspection Card".
Form NS-19 70- 9. 4 - CECO P.C.D. Will be notified within two uoeks of the date when tendons' excond the 180 day limit.
I e
(
(
APPENDIX "A"
ACCEPTANCE / REJECTION CRITERIA 0F WIRE INSPECTION All wire will be visibly inspected for rust.
Acceptance or rejection will be based on the foll, wing criteria:
A wire in categories A, B, or C is acceptable.
~
~ ~~
~
A wire in cat'egories D or E is rejected.
~
~
Check for wire identification.
LEGEND:
VISUAL CHECK OF DEGREES OF CORROSION CRITERIA FOR ACCEPTABILITY:
A.
Temporary Corrosion Material in tact, no visible oxidation.
B.
Light, thin, removable oxide on wire.
C.
A heavy red oxide dust, still removable by wiping.
CRITERIA FOR REJECTION OF WIRE:
D.
Patches of red oxide, not removable and/or leaving noticeable pits.
E.
Heavy rusting, dark red which when removed leaves very noticeable pitting.
NOTE:
If other conditions from the above appear, please indicate in the comments section of the Tendon Pulling Card.
.. ~... - -
=
- - ~ -
=
e.i l
[.*[s.t %j*:!.'.-
.. n,.~.
Of,.. '- i
) * ;if.,i;...'....
~; :..,
- g. g.(t *
.#-==j e I'-
.A 9. f..
,7
- .s. ;
,g.Q..,,:5,U -t i,.[s... ; *.._,M,...-(,
7:
r.4
,u..
... ' C 3 N.'. ;,s 'i*-W' :'l:. "w, y-:. -
3 ;f:.* i ~~.. :#. :
."~..l'.'h.;'.
.,. q s.
- ...:.:,;s
...w
.. n.y m.
.i.. -:
. _. 4 '..; :~ -.,.
...., c..;v...
... ;. p. :.,......
r.
.a
...c t
1,
. v..
.,.~....
-. e:
..,a
-.... ~
t
- m....
.... r,'.
>o..:
- c... '.
..s n+..
- u..
.. y..
v.
,.,.?r.. ;.,..,
...,...,p w...
.~
.a
+
c.,.
..,...n.,
=+
... = >. -
.s.
y ne,
e
- 'e.,
.c.-
~
j..g '.',s.
,.; 3
., s
?{
- .;;. *,, i.. g 3. -.'s e.k,,,..
f, N..g? *,
~ ' ;
-Q;,'..,,,.p.-l* Q
).**...
.g. -
/ _
s e
.,.. f.- : q..
e ey :.,.. t x,.y
.s
+-
7
.....a...
m-I 4 r1;
._-..l.
JOB NO.:
TE N. D 6 N PULLING CARD
..l m
-- - -JOD:-
' - - +
1 l
TENDON LOCATION DATE:
(
l a
[
TENDON MARK NO. (FROM TAG)
~
~~
TENDON LENGTH (FROM TAG) l b i f
WIRE CONDITION A
R C
D E
t tcmutoNu
! (
TENDON ENDS PROTECTED (CHECK)
!(
f 8
1 COMf4ENTS
!(
v i
e
.s
?
s U.
t i
i c~.
s
'l FOREMAN O.C. INSPECTOR NATE r
FOH M 780.64 00 H O.1979 ItiryCO I (.
i
~
9 ~.
d
~
i
-- - = a - ]-..-. - - - -. - - - - -
o i
i.
s.s.
t i
r ;.
- s
- ..1
...i..
..r..,.,.
e
.i ma..
e
..., ~.
s.
. m......c,
.+.. *;
~
u.
e
+
. a.,..
.se r.
- ...c %...r. *.
u.
. < ;y sis-** v;',,f.y ;,...,.,;- s
. :..1,n.
- . *,*.
- w %... r --*
)..o*,
. m.- 1. e.
s.
..s-.r.g.L.%nr ;... '
v~~=*...
.s,-
- s.,
~ -
%.,sn;..w=,.
y e... l..,' r *,.
,a y _.;-
ny
.s.
~
a M
b O
.a.
% 6
,,.g*
.,.hj
.k
- 3 8
g5.
g g.
- g g
g.
O S.,
-....s.....,c.--.._......,~'---~---
e g
W g
...- ~..
--c o. w...-.. v. %. ~......
. _ ~ - - - -, _. - -,.,. - -. - - - - -.
.=
r
s.
~
yr
. n.,i ~ t..
.r-
.i*.
-r
,.2
- .?.*~~
,"..~.#Df ; T: *..
.o * >.. + y.
.. ',.' p'.
,'~.; :. ;,...
- ~. *
..=
, r *. " l-....
. :.., i,,.. '
.. ~.
.s..
- ~,
.,.. ;..... n.;
. ~-
. '..},.. s -
(.
.w ~:
. y'.
. X *
. :.gr.
j
~,
.,^
- ~
..~
.. +.
~... ; ), s.
~-
..,.. ~..
.,........>.s
.w. c: x-..
/c
./
.7.
., : r
/
.-..,: :.v
. -~
.,;..,,.....<,g n.;.
..:.. 4 -
.,8 c.,,..-
s>
,.s n.
...,... =ja m...
-Q_
~
..t JOa NO.:
i.n:,;
Tendon In Place Inspection BR AIDWOOD POWER PL. ANT.
~
JOB:
TENDON LOCATION DATE:
~
TENDON M ARK NO.
TENDON LENGTH (IncpectoM WIRE COND! TION A
R C
D E
(As per Appendex "A" fjSCI Q.C.
(C664GLL ONL)
Procedurc #78)
TENDON ENDS PROTECTED (CHECK)
Date of Tendon Inctallation o
COMM ENTS FOREMAN O.C. INSPECTOR OATE NSCI Form NS 19 d
s, j
s..-
,. 4. ;.
t
- ~.
~
)
ej
./
- 7.
- ., -;;.. -
. y
,..g.
1 v... 7v.
....g.
.; e..,.
.. ~,..,s..,.
^
fQ. r m's.,~. :..a c. i.4.a.-,..k r :.,... ~ :. :...:u;...c. z -,xo ::.:m.q.,g.~;.. y,,,.p,m _. u...,. e,,..,, ;*.m..;,
.. -. ~. - ~. ~ ~ - -:- :.. - ;
.....-.......-..:.w...,..r...~
~. ~ - -
SARGENTn LUNDY E N C. I N I cHs F-2722 cnica.u.
L-272'1 Rev. 14, 05-18-79 Ax-13-507.7 Field button-heading shall conform to the following requirements:
R14 Button-heads shall be cold-formed after threading wires through a.
wire holes of anchor heads.
b.
Contractor shall submit for approval, procedures for field button-R14 heading based upon acceptance criteria established by Supplier and reviewed by Consulting Engineers.
~ ~ ~ ~ ~
c.
Button-heads shall be formed symmetrically about the axis of wires and shall be free from harmful seams, fractures or flaws.
No head-ing procedures shall be used that cause serious indentations in the wires; any wires so damaged will be rejected on inspection.13-508.
INJECTION OF CORROSION PREVENTATIVE GREASE 13-508.1 Prior to injecting grease, Contractor shall submit a detailed pro-cedure, including a list of proposed equipment, for approval, and shall not start work until approval is received.13-508.2 Each tendon shall be protected from corrosion within one week after RIO it is stressed by injecting grease into the sheathing.
In addition, each tendon which is not stressed within 90 days after it is in-stalled in its sheathing, shall be greased within that 90 day peri-(\\
od.
If grease is injected prior to stressing, any grease loss 1
during post-tensioning shall be replaced within one week after it is stressed.
Time from stressing-to greasing may be extended from seven days to 28 days, provided the tendon grease caps are installed
)
immediately after stressing to keep out moisture and prevent corro-sion (see 13-509).
Time from initial placement of the tendons to R14 greasing may be increased to 180 days, provided a random sample of 10% of the tendons are withdrawn monthly between the 90 and 180 day
,~
period and inspected for cerrosion.
Tendons which show signs of f
If corrosion during the 90 to 180 day period shall be rejected.
- 13-508.3 Inject grease into sheathing through the grease retainine cap under minimum pressure not to exceed 100 psi, as approved, measured at the anchorage inlet at an optimum placement temperature as recom-mended by grease manufacturer.13-508.4 Inject grease by circulation method from one end of each sheathing, and continue injecting until it flushes out at opposite end without air bubbles.13-508.5 Entire injection procedure shall be in accordance with grease manu-R14 facturer's recommendations, contained in Contractor's approved as procedures.13-508.6 Exercise ext reme care during all greasing operations to avoid con-(
-),
taminating concrete or other surfaces.
Any grease that is spilled on these surfaces shall be immediately removed, to complete satis-faction of Purchaser, at Contractor's expense.
13-5-4
.-.