ML20084K350
| ML20084K350 | |
| Person / Time | |
|---|---|
| Site: | Turkey Point, 05000000 |
| Issue date: | 10/02/1970 |
| From: | FLORIDA POWER & LIGHT CO. |
| To: | |
| Shared Package | |
| ML19289B371 | List: |
| References | |
| NUDOCS 8305190321 | |
| Download: ML20084K350 (19) | |
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b W-FLORIDA POWER & LIGHT COMPANY TURKEY POINT UNIT 3 INTERIM REPORT CONTAINMENT DOME CONCRETE INVESTIGATION b
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Turkey Point, Unit #3 INDEX I.
Introduction II.
Summary III. Construction of Containment Dome IV.
Extent V.
Investigation of Potential Causes 1.
Materials Investigation a)
Petrographic Analysis of Concrete b)
Water & Ice Analysis c)
Cement Mill Test & User Test Results d)
Tensile Strength e)
Tensile Strain Capability 2.
Stresses & Strains a)
Caused by Pre-stressing b)
Effects of Stressing Sequence c)
Grease Pressure & Temperature d)
Expansion of Concrete e)
Truck Crane VI.
Miscellaneous Observations a.
Dome Deflection b.
Tendon Relaxation
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I.
Introduction On June 17, 1970 it was observed that the casing filler had begun to ooze out of the concrete surface of the Unit 3 Containment Dome in a spot at about 216 degrees azimuth and 35 feet radius from the center of the dome. At the close of the previous day, 110 out of 165 dome tendons had been stressed. One tendon was stressed on June 16, 1970 and two on June 17.
Basically the tendon stressing activity had been halted on June 16 to pump sheathing filler into the tendons already stressed. Nine tendons had been greased on June 16, 1970 and
- Jere greased on June 17.
In order to investigate the source of Icakage, a small area of concrete was chipped and a layer of separation in concrete was found a few inchen below the surface, with evidence of grease flow on the surface.
On June 22, 1970, a small bulge in the dome surface was noticed at approximately azimuth 290 degrees and radius of 25 feet. The concrete was broken through in one small spot with a hammer and separation layer was discovered at about %" depth. The exploratory chipping was expanded laterally and towards the center of the dome, revealing that the separated layer became thicker towards the center. This stage of chipping was stopped at about 15 feet radius, at which point the separated layer was about 4" thick, same as concrete cover above the upper layer of reinforcing steel in this area.
A detailed investigation is underway to ascertain the extent and the causes of this prob 1cm, and to arrive at a suitabic method of repairing the damaged concrete. The investigation is being conducted by the Bechtel Corporation with consultant services provided by T. Y. Lin, Kulka, Yang 1
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and Associate; Mr. George Nelson, Chairman of Law Engineering; Mr. Lewis H. Tuthill, retired, formerly of California Department of Water Resources, Division of Design and Construction; and Dr. Richard C. Mielenz, Vice President, Master Builders Company.
A verbal presentation on this subject was made to representatives of the Divisions of Reactor Licensing, Compliance, Reactor Standards and staff of ACRS in Bethesda on September 16, 1970. While the investigations are still incomplete, this interim report presents progress to date.
II.
Summary To determine the extent of concrete separation, the primary tools of investigation have been (i) soundings uith a steel hammer, and (ii) core borings. The sonic pulse velocity technique does not lend itself to this type of structure. The sonic vibratory resonance technique was tried at site, but was found unworkable. 43 core horings had been completed by September 29, 1970, and the program is still in About 50 core borings are planned.' The core holes are progress.
examined with a boroscope for existance of concrete separation.
The deepest separation noticed so far is about 15 inches below the dome surface. While a meaningful pattern has not yet emerged from the concrete separation detected by hammering and core boring, no separation has been discovered in the north quadrant of the dome.
The investigation into the causes encompasses the construction procedures, the testing of concrete and its constituents, as well as the stresses and strains imposed by the various loads.
Petrographic analysis indicates sound concrete with no signs of aggregate 2
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l reactivity, or microcracking and no chlorides, or other chemical impurities.
Since the investigation covering all aspects of the prob 1cm is still Choice underway, no conclusions have been drawn as to the causes.
of repair method will depend upon a determination of the causes.
III.
Construction of Containment Dorac The sequence of concrete placement for the dome is shown in Appendix A.
The lower half of the ring girder was placed in Lif t (A), in 60 degree segments like a typical wall pour. Lift (B) consisted of 2-180 degree segments and covered the 8" thick structural slab which provides a work platform for installation of the tendon sheathing, and a support for the dead weight of the remaining 31 inches of the d ome concrete.
The upper part of the ring girder, Lif t (C) was placed in 3-120 degree segments, while the Lif ts (E) and (F) cach consisted of 2-180 degree segments. Known concretc separation exists in Lift (F) only.
Curing of Concrete For lifts (C), (E), and (F), the concrete was cured using a membrane curing compound. The compound was sprayed on after the finishing operation was complete and the surface moisture had disappeared. The coating was uniformly applied over the entire surface.
The product used was W. R. Grace's #2803-R white pigmented curing com-pound meeting ASTM specifications C-309. White pigment was selected for maximum reflection of solar heat and to permit visual inspection for thoroughness of application.
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O that the For lift (B), the method and compound was same as above except compound was sand blasted off just prior to placing concrete above joint.
For list (A) burlap bags were spread over the top of concrete and contin-ually water soaked.
IV.
Extent The initial investigation to determine the extent of the concrete separ-ation below the surface was performed by soundings with a Swiss hammer and a steel sledge hammer. The steel hammer was found to be more effective in finding separations deeper into the concrete, and is reliable up to a depth of about 10 inches. The ' hollow' sounding areas as indicated by hammering technique have been marked in the sketch in Appendix C.
Sonic investigations with a V-scope were considered. The pulse velocity technique does not lend itself to a concrete mass with large numbers of embedded conduits and a liner plate on the underside of the dome. Moreover, the presense of an intentional construction joint 8 inches from the liner plate further dominishes the reliability of the pulse velocity technique.
The reflection method cf ultrasonic examination used in metals has not been perfected for a hetrogeneous mass such as concrctc. A method of senic induced vibratory resonance of concrete surfaces was tried but proved un-successful.
, Core borings appear to be the only reliable method for locating separations at greater depths from the concrete surface. The program of core borings is almost complete. 43 core holes have b'een drilled out of the 50 planned cores. Due to the presence of 5 layers of tendons in the dor;c as shown in Appendix B, the likelihood of puncturing through tendons increases with the 4
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i depth of coring. In general, an attempt has been made to drill the holes to a 16 inch depth, this being supplemented by a few 29 inch deep core holes. The coring log and a sketch showing the location of core holes is included as Appendi:: B.
The deepest lamination found is in core hole #23 at a depth of 15 inches.
The holcs are exanined with a boroscope that permits a magnified view of the interior surface of the hole. Pictures have been taken of representative holes to record the nature of concrete ceparation. It has been detennined that frequently, air gaps in the order of 4." to (" exist at the level of separation.
No concrete separation has been found in an approximate 90 degrec area, between 316 degrees and 46 degrecs. In the southern portion of the dome, core holes revealed lamination even though hammer soundings did not indicate any separation.
V.
Investigation of Potential Causes An investigation is underway to determine the likely causes for the observed concrete distress. This investigation covers the materials uned, the stresses and strains generated by the various loads, and the method of construction used for the containment dome.
(1)
Materials Investigation:
(a)
Petrographic analysis of concrete has been performed by 2 independent laboratories, namely: Erlin Associates of Northbrook, Illinois through Pittsburgh Testing Laboratory and by Dr. Richard C. Mielenz, Vice President of Research & Development, Master Builders Company of Cleveland, Ohio. The reports indicate concrete of good quality and a high cement factor, low i
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water-cement ratio, and an air-void system characteristic of the inten-tionally entrained air.
There is no indication of aggregate reactivity nor of voids introduced by presence of aluminum in the concrete. No micro-cracking has been observed.
(b)
Water and ice used in the concrete have been subjected to a chemical analysis. The results of a few typical test reports are included as Ap-pendix D.
All chemical inclusions are within the specified limits.
(c)
The cement used for the dome concrete is Type Il Portland Cement. Mill Test Reports are regularly received from the supplier and grab samples have been tested by the user through Pittsburgh Testing Laboratory. A few typical user sample test reports are included as Appendix E.
The cement conforms to the requirements of Type II cement with the ex-ception that the combined limit of 58*/. on Tri-calcium silicate and Tri-calcium aluminiate has not been enforced on this project.
(The ASTM limit of 587. for Type II cement is optional and applies only when speci-fically so indicated by the user.) llowever, this non-enforcement is not considered to be serious in view of the strict control of concrete temperature at 70 degrees F. and the use of Retardwell for slowing down the rate of hydration of cement.
(d)
The concrete specified for the dome should have a 28-day compressive strength of 5000 psi. The actual values generally were over 6000 psi.
However, no limit has been specified for the tensile strength of concrete.
This is not generally done for concrete used in buildings, etc.
The tests are now'being made to determine the tensile strength as indicated 6
t by cylinder splitting tests (ASTM C-496) and by third point load method for flexural tensile strength of concrete (ASTM C-78).
These tests are also being run on materials from a few other projects. The results available to date are shown in Appendix F.
Values for direct tensile strength are expected from tests arranged through the U. S. Army Corps of Engineers in Vicksburg, Mississippi. The results will be available by about October 10, 1970.
(e) Tensile strain capability of concrete can become an important property for dome concrete in view of the biaxial membrane compression in the dome which could cause radial tensile strain. Tests are now under-way at Vicksburg to simulate the actual load condition of the dome and to determine the tensile strain capability of the dome concrete for Turkey Point and a few other projects. The results will be available by about October 10, 1970.
(2) Stresses and Strains A detailed review and analysis is in progress to determine the stresses and strains expected f rom the various loads. In particular, the following loads are receiving attention:
(a) Stresses caused by pre-stressing tendons.
(b) Stresses developed during the various stages of prestressing in ac-cordance with the actual stressing sequence foll. owed at Turkey Point.
(c) Grease pressure and temperature are under evaluation. The shut-off head of the two pumps used for injecting grease into the tendon sheathing has been tested at jobsite and has been found to be 200 psi for one pump and about 250 psi for the second. Considering the static head of the vertical riser from the pump to the dome, the pressure in the tendon sheath-ing cannot exceed 150 psi.
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The pumping temperature ranges between 90 degrees F and 125 degrecs F.
(d)
The effect of weathering and curing like rain, solar heat and heat of hydration is being studied.
(c)
A truck crane is parked at the center of the dome to make light construction lifts. The maximum load hoisted by this crane is 5000#.
The lift load along with the dead weight of the truck crane has been studied for its effect on.the structural integrity of the dome. The stresses induced by the crane seem to be minimal.
VI.
Miscellaneous Observations (a)
The deflection of the dome has been measured by comparing the elevation of the liner plate at the time the dome liner was installed over the dome trusses, and the present elevation of the liner plate.
The observed deflection is 1-5/8".
The predicted deflectiondue to prestress of the dome alonc is about 1".
Allowing for the dead weight deficction of the dome and the shrinkage of the vertical cylinder, the dome deflection does'not indicate any unexpected movement.
(b)
Three dome tendons were relaxed to take the lif t off readings.
Appendix G comparcs the initial and the present lift off readings. The actual and predicted losses in stress are also compared. There is no indication of unexpected stress loss in tite tendons.
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TURKEY PO!NT UNITS 3 a 4 COMPAR1300 0F TEUS11.E SPl.lT Ti!Si CESULTS I
TURKEY POINT TENSILE COMPRESSIVE psi Age psi Age G" x 12 eyliadcrs 473 73 days 7060 90 days 100 20 days 5900 28 days 359 23 days 5820 28 dt.ys 2.2" Dia, cores from G51 G810 Dry Cores shipped concrete 718 G710 Dry Cores SG1 6270 Water cured 5570 Water Cured-5840 Water Cured OCCONEE 6" x :2" cylmders 500 29 days 5838 28 days 563 6013 28 days STRAIN G"'x 12" cylmdcrs '(Direct Tensile) 347' (tested 9 2170) 24.5 x 10 G
'345 (tested 9 2170) 70.5 x 10 6 f
POINT REACH 6" x 12" cyimdcrs 585,615 28 days SGO,620 28 days 515,595 28 days COMPRESSIVE 000 150 days 9730 psi 28 days 730 170 days U420 psi 28 days I
G30 170 days 0130 psi 28 days APPENDIX F
l TENDON LIST OFF READINGS COMPARISON OF ACTUAL V/S PREDICTED All values are in terms of jack pressure, psi, to obtain tendon force in kips, multiply by 0.1202 L
I
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AVERAGE INITIAL STRESSING DESTRESSING STRESS LOSS %
'ENDON DATE LIFT OFF READING DATE LIFT OFF READING END-1 END-2 AVERAGE END-1 END-2 AVERAGE BOTH ENDS CALCU-CALCU-CALCU-CALCU-ACTUAL LATED ACTUAL LATED ACTUAL LATED ACTUAL LATED 1D30 6-1-70 6800 6500 6650 10-1-70 5800 5630 5900 5320 5850 5475 12%
17.7%
2D37 6-15-70 6500 6300 6400 10-1-70 5700 5320 5900 5140 5800 5230 9.4%
18.2%
3D21 6-10-70 6450 6350 6400 10-1-70 5800 5260 5700 5420 5750 5340 10.1%
16.6%
NOTES: Assumptions for stress loss are as in FSAR Section 5.1.4.
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