ML20086C372
| ML20086C372 | |
| Person / Time | |
|---|---|
| Site: | Robinson  |
| Issue date: | 07/31/1968 |
| From: | CAROLINA POWER & LIGHT CO. |
| To: | |
| References | |
| NUDOCS 8311230218 | |
| Download: ML20086C372 (211) | |
Text
{{#Wiki_filter:, N/w.v/]k/JI.l7//l.)t,f 4 REPORT ON INCIDENCE OF CORROSION ON PRESTRESSING STEEL TENDONS AT H. B. ROBINSON STEAM ELECTRIC PLANT 1970 - 700,000 KW EXTENSION - UNIT NO. 2 OF Carolina Power & Light Company 5e *** "' 46 '
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F l L CONTENTS F Page I-
SUMMARY
l A - Synopsis B - Findings 1 2 C - Revised Procedures . . . . . . . . . . 3 II - DESCRIPTION OF PRESTRESSING . 1 STEEL TENDONS A - Basic Tendons . . . . . . . . . . . . 5 G - Corrosion Protection Provisions . . . . . 6 C - Corrosion Monitoring Provisions . . . . . 6 III - INCIDENCE OF CORROSION I I A - Histor; . . . B - Telltale Inspection C - Control Tendon Inspection 8 8 10 D - Tendon Inspection . . . . . . . . . . 11 IV- INVESTIGATIONS A - Laboratory Analyses I B - Rope . . . . . . 12 13 C - Vapor Phase Inhibitor . . . . . . . . . 14 D - Strength Tests 14 I E - Microscopic Analys es . . . . . . . . . 15 F - Accelerated Corrosion Tests . . . . . . . 15 V- DISCUSSION A - Basic Clauses of Corrosion on I Ferrous Metals . . . B - Probable Causes of Corrosion on
. . . . . . . . 19 P/S Tendons . . . . . . . . . . . 20 C - Substantiating Data 21 I
D - Magnitude of Corrosion on P/S Tendons . . . . . . . . . . . 24 E - Corrective Procedures . . . . . . . . . 25 I I I I t
5 APPENDIXES A - Description of Prestressing Steel Tendons s 1 - Ebasco Drawing G-190353 2 - Ebasco Specification 5379-CH-4, Rev. 2 3 - Stressteel Drawings S-1, S-2
, 4 - Extracts From Shell Oil Company Study (Report L-9) 5 - Photographs B - Incidence of Corrosion s
1 - Memos of Initial Inspection 2 - Telltale Inspection - January 3,1968 a - Notes on Inspection b - Photographs
, 3 - Control Tendon - January 9,1968 a - Initial Report - January 1967 s
b - Report of June 1967 c - Memorandum Report - January 1968 d - Photographs s 4 - Tendon Inspection - January 30, 1968 a - Notes on Inspection b - Photographs C - Investigations 1 - Chemical Analyses s a - Report of Chem-Bac Laboratories b - Report of Allentown Laboratories c - Report of Electrical Testing Laboratories d - Report of New York Testing Laboratories 2 - Physical Tests a - Report of Pittsburgh Testing Laboratory - Tensile Tests b - Report of Pittsburgh Testing Laboratory - Chemical Analysis c - Photographs 3 - Tendon Material Tests 4 - Report of Schupack & Associates - Manila Rope 5 - Report of Shell Oil Company 6 - Visual Microscopic Analysis 7 - Sublimation Tests of "VPI" 8 - Accelerated Corrosion Tests a - Data Sheets b - Photographs 9 - Report Dated January 31, 1968, From L. P. Sudrabin, Consultant, to Stressteel Corporation 10 - Report dated February 14,1968, From L. P. _ Sudrabin, - Consultant, to Stressteel Corporation-- r D - Report on Quality Control for the Manufacture of Prestressing Steel Tendons:
L e l - I -
SUMMARY
- A - SYNOPSIS L The H. B. Robinson Unit No. 2 will utilize a pressurized water - reactor type steam supply system. As such, a containment system is , required as the primary safeguard to prevent release of radioactive contamination to the atmosphere in case of an accident.
s The containment system for H. B. Robinson features a concrete cylinder and dome structure designed to adequately resist the pres-sure and temperature loads imposed by a complete rupture of the primary coolant system piping plus an earthquake of a higher mag-nitude than ever experienced in the area. The concrete cylinder por-tion of the structure is reinforced with normal reinforcing steel in the horizontal direction. In the verticci direction the uplift imposed on the wall by the hemispherical dome is resisted by prestressed steel tendons composed of high strength steel bars which are stressed
- at the time of construction to a value greater than the imposed stress , at the time of accident thereby reducing the vertical strain of the cylinder wall due to an accident. - The prestressing steel tendons are being installed during'erec- , tion of the wall and will be stressed sometime later. As a result of -
this time sequence it was necessary to provide a temporary corrosion protection system to the tendons to assure that their condition at time s of stressing and grouting will be such that they have not lost any
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strength due to corrosion. This system consisted of a length of manila rope, saturated with { a solution of "VPI" in alcohol, hung inside of the t'endon assembly dur ' ing transportation and erection followed by application of dry "VPI"- crystals in a container at the top of the tendons after erection. w During the course of construction corrosion was detected upon several of the tendons and an inspection and investigation of the reason for corrosion was immediately started with the aim of stopping any further corrosion and' determining the severity of the corrosion which 1 had already occurred.- - I i d
2 This report summarizes the results of the inspection and subsequent investigations along with the recommendations made to halt and prevent further corrosion, B - FINDINGS The investigations indicate that the corrosion was a result of four contributing causes neither of which was capable of creating the amoun't' of corrosion found but which in cumulative combination made the cor-rosion protection system used less effective than it properly should have been. The four contributing causes were:
- 1) Abrasion of the bars in transitand handling removed some of the oxide film on them thereby allowing a natural anode-cathode couple between the oxide film and the bright steel which in the presence of moisture vapor and condensation led to an active galvanic cell.
- 2) The rope was saturated with alcohol at the time of insertion between the tendon bars in 6 inch diameter galvanized pipe. Alcohol vapor lowers the effective-ness of "VPI" to inhibit corrosion probably due to maintaining "VPI" in a vapor state and preventing its recrystallization on steel surfaces.
- 3) The presence of oil in the manils rope lowers the effectiveness of "VPI" crystals probably due to partial encapsulation of the crystals by the oil.
- 4) Once a rust bloom forms it is difficult for tite "VPI" vapors to penetrate through it to the base metal and therefore the "VPI" is less effective in inhibiting further corrosion. Mill scale could have a similar etfect.
The severity of corrosion was not considered significant. Those sample telltale bars from the same " heat of steel" as the tendon bars showed no loss of strength. One telltale bar (No. 61 sampled showed a lower strength but this has been demonstrated as described in Appen-dix D to be from a different heat of steel than the tendon bars.- The chemical analyses of the telltale bars and 10 selected tendon bars f indicate that the bar substituted for the original telltale bar 6 was not f i from mill heat 110. All sample bars retained ductility properties in ! excess of specification requirements signifying no detrimental effect due to corrosion. It has been shown that sufficient quantity, proper size and an ac-ceptable grade of steel was purchased and processed into tendons by-Stressteel Corporation for the first phase wall construction at the I
3 Robinson Project. This is corroborated by the Ebasco inspection re-ports issued during fabrication. Additional information shows that shipment and delivery schedules correlate with each other. The docu-mentation is consistent with minor explainable exceptions. Plant in-spections showed that the type of documentation is maintained routinely by the Stressteel Corporation. The fabricator's facilities consist of a well run plant staffed by technically campetent personnel. It is concluded that the subject tendons at the H. B. Robinson site contain bars frem heat 110 which meet the strength requirement of the applicable specification. This is based on the following evidence:
- 1) The proper number of bars were observed to be physically in the fabricating plant.
- 2) The quality control records indicate that only one steel heat was used in the fabrication of the H. B.
Robinson tendons except for one of the telltale bars.
- 3) Stressteel's fabrication technique minimizes the possibility of intermixing bars from different mill heats.
- 4) The chemical analyses of the telltale bars and 10 selected tendon bars indicate that the bar substi- {
tuted for the original telltale bar 6 was not from mill heat 110. C - REVISED PROCEDURES Plans are to abandon "VPI" as the primary corrosion prevention 3 system for the prestressing steel system for containment walls. This ; corrosion prevention system will be replaced by a nitrogen inert gas system which has an excellent record for similar use. The "VPI" will be used as a backup for the inert gas system by depositing "VPI" crystals directly upon the surfaces to be protected. A.dditional telltale bars will be installed in selected tendon assem-blies to monitor corrosion rate while the inert gas system is in use. Upon entering the second stage of fabrication, a reevaluation of the quality control procedures is appropriate in light of experience gained during the first stage. This experience exposes both strengths and weaknesses in the present procedure. Strengths are seen in the weighty accumulation of evidence which could be reconstructed upon demand. The quality control requirements will be revised.
i 4 , 1 l Sample bars will be extracted from bundles prior to assembling of I the tendons. This will give a random sample of the output. Current ; procedure is a random sample of the input with controlled processing. Predetermined areas within the shop will be devoted exclusively to the storing of bars for the H. B. Robinson project. l l l 1
5 ; II - DESCRIPTION OF PRESTRESSING STEEL TENDONS A - BASIC TENDONS The typical lower section for the prestressing steel tendons for the H. B. Robinson No. 2 containment structure consists of six 1 -3/8 inch diameter high strength steel bars anchored at their bottom by threading l into a 4 inch thick carbon steel plate and enclosed within a 6 inch diameter Schedule 40 galvanized steel pipe. (See Appendix A-3.) A 1 -1/2 inch diameter galvanized steel grout pipe is threaded into the bottom of the anchorage plate. The six bars are placed at equal spacing around a 2-1/4 inch radius circle inside of the 6 inch pipe. The lower tendon assembly measures 33 feet overall length with the lower 8 feet em-bedded into the concrete base slab of the reactor containment. 'The tops of the high strength bars are threaded and protected with seal peal (a plastic coating applied hot) against corrosion and mechanical damage. The tops of the bars are set at two elevations, 1 foot apart, three being low and three being high and being staggered high and low around the circumf er ence. A 6 inch Schedule 40 black steel pipe is coupled onto the galvanized steel pipe enclosing the top 18 inches of tendon. A 1/4 inch plate is welded to the top of this black steel pipe making the assem-bled tendon a completely enclosed assembly. A 1-1/2 inch diameter plug is screwed into a hole in the top plate and a 16 gage perforated inetal container is welded to the bottom of the 1/4 inch plate. To this container is attached a small eye bolt for hanging a length of rope. The bars when threaded into the anchorage plate were secure'dwith epoxy to assure a vibration-proof mounting during transportation. To further assure no damage from vibration to the assembly during trans-portation a temporary spacer plate was inserted in the coupling between the galvanized steel pipe and black steel cap section. The entire lower tendon assembly was assembled at the Stresssteel
. Plant in Wilkes-Barre, Pennsylvania with the exception of the grout pipes. The hole for the grout pipes was plugged at the plant. The tendons were shipped by rail to the project site and placed in storage off the ground in a horizontal position until erected into the structure. (See Appendix -5.) After erection and alignment of tendons was completed the plug in the anchorage plate was removed and the grout pipes installed.
6 B - CORROSION PROTECTION PROVISIONS Since the prestressing steel tendons were to be encased in the con-crete base slab and not coupled, stressed and grouted for a period of nearly two years, considerable effort was expanded in attempting to provide an environment nonconducive to corrosion. The application of "VPI 250" a volatile corrosion inhibitor consist-ing of 90 percent "VPI 260" (dicyclohexyl nmmonium nitrite) and 10 per-cent "VPI 220" (diisopropyl ammonium nitrite) was selected as meeting all of the requirements. This product manufactured by Shell Oil Company, has a history of satisfactory use for many kinds of applications for cor-rosion protection. It is a fine, milky white powder which slowly subli-mates at normal temperatures. Its vapors are heavier than air and will recrystallize on metal forming a thin film which inhibits corrosion as any nitrite does. (See Appendix A-4. ) To take advantage of the property of vapor heavier than air it was decided to place the "VPI" in a small container (only a very small amount is needed for each tendon) in the top cap piece with a provision for inspecting and refilling the container periodically. To provide corrosion protection for the tendons during transporta-tion, when they would be in a horizontal position, and during erection, when vibrations would shake the "VPI" from the container a system was evolved whereby a manila rope saturated with a "VPI" - alcohol solution was hung from the eye bolt for the entire length of each tendon inside of the tendon at the time of fabrication. This provided a close proximity of "VPI" crystals to the prestressing steel until the containers at the top could be filled conveniently. It was felt that the combined use of the "VPI" rope system and the "VPI" container system in the sealed-in-a-pipe environment would pro-vide a corrosion protection system entirely adequate for the tendons. C - CORROSION MONITORING PROVISIONS As the prestressing steel tendons were threaded into the bottom anchorage plates and epoxy used to assure the vibration-proof mounting, no bars can be removed for inspection. Tests had shown that the epoxy 1
7 i virtually welded the bars to the plate and to unscrew and remove the bars was impossible. Therefore for the purpose of monitoring corrosion or the lack of it on typical tendons, four tendons in the initial 119 tendons to be placed were selected and a seventh 1-3/8 inch diameter high strength-steel bar inserted into the four tendons to act as a corrosion telltale. These bars were threaded into the top portion of the grout hole in the bottom anchorage plate. The corrosion telltale bars were wiped clean of all heat treating residue leaving a black bar prior to insertion in the tendon. This was necessary since the bars after heat treating have a dark red residue left on them which might confuse any judgment j as to the occurrence and severity of corrosion. Only the telltale bars j were wiped clean of this residue, all other bars being used in their as-received conditicn after heat treating. The telltale bars were not sealed with epoxy and were therefore removable at any time. It was also possible to inspect the bars in the tendon by means of-specialized equipment. - i i l r I
l 8 t III - INCIDENCE OF CORROSION l A - HISTORY The prestressing steel tendons were erected in September 1967. The tops of the assemblies were then protruding about 25 feet into the air and were relatively inaccessible until December by which time scaffolding had been erected in the portion of the containment wall from the equipment hatch to personnel lock at about the top of tendon elevation. On November 10 instructions were issued to initiate the program of placing "VPI" powder in the containers provided in the cap piece of the tendon. This work was actually started on December 20, 1967. As part of a normal procedure, the plugs were removed from the top plate and a visual inspection was made of the container to check for the occurrence of moisture. Several of the baskets were found to contain some moisture, however, four of the baskets were reported as containing a slight amount of rust. This was reported to Quality Control and thence to the New York design group. Instructions were forwarded to sound the grout pipes for water in an attempt to see if an excessive amount of moisture had collected in the tendons. All of the 119 tendons then in place were sounded and a total of 44 contained a measurable amount of water. The average depth of water was less than 1/2 inch with one tendonhaving 6-3/4 inches. Results of this investigation are shown in Appendix B-1 -1. No correlation could be found between the condition of the top of the tendon, whether it was somewhat loose or damaged, and the tendons which had water in the grout pipe. Three samples of the water from grout pipes were checked for pH, two of them being found slightly acidic and one being found highly alkaline. B - TELLTALE INSPECTION As a result of the reports from the Quality Control group and the preliminary laboratory tests run on the water, an inspection team from the manufacturer and the design engineering group visited the site and removed three of the four telltale bars to inspect them for corrosion. l The first bar removed was from Tendon No. 6 and it was found to have a large area of corrosion, dark brown in color, extending from approxi-mately 5 feet from the top to approximately 4 feet from the bottom. (See photographs, Appendix B-2.) There was some corrosion in spots
9 above and below these levels. It was noted that the corrosion tended to be concentrated on one side of the bar with the other side being uncor-roded in these areas. The line of corrosion tended to spiral somewhat down the bar. The area of heaviest corrosion was scraped with a knife blade to remove the products of corrosion. This was about 8-1/2 feet from the top and a 1" x 5" strip was scraped. In this area, numerous small pits estimated at I to 3 mils deep (later measured at a maximum of about 7-1/2 mils) were found. The bar was removed to the project warehouse and placed on the wall in temporary storage. A piece of rope about 3 feet long from the top end of the rope in Tendon No. 6 was removed for inspection. The cap of the tendon was inspected and found to be generally free of any corrosion products. Likewise the tops of the six tendon bars did not show any significant corrosion but a few incipient rust spots were noted. The telltale on Tendon No. 6 was then scraped and the corrosion products collected and sent to a laboratory for analysis. Likewis e water samples from three grout pipes, a section of the rope and a sample of the "VPI" was sent for chemical analysis. Es s entially, this chemical analysis showed that the corrosion products were iron oxide with nitrites present. The complete laboratory analysis is in-cluded in Appendix C. As a result of the inspection of telltale from Tendon No. 6, the te11 tales from Tendons Nos. 40 and 74 were removed and inspected. They were found to be corroded in the same way as Tendon No. 6 tell-tale but not as heavily. No pits were found on either of them. Photos of these telltale bars are included in Appendix B-2. A 5 foot length from the most heavily corroded sections of tell-tales 6 and 74 were cut and sent to a laboratory for tensile testing Telltale 74 matched almost identically the results of the tests made I i on the heat of steel used for the lower section of tendons. Telltale 6 did not match the original tensile test. Ductility of both of the bars l was equal to or better than the original tests. A chemical analysis was run on both te11 tales 6 and 74 and from these it was determined that telltale 6 was from a different heat of steel slightly different in physical properties from that used for the tendon bars. This has been found to be a unique situation resulting from a unique and specific occurrence in fabrication and has no further bearing on the corrosion study. It is dis-cussedin the report on " Quality Control for the manufacture of Prestresa Steel Tendons" which is included on page D-10 of Appendix D.
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i 10 ; i i ! C - CONTROL TENDON INSPECTION I On February 8,1967 four tests were initiated at the Stressteel plant j in Wilkes-Barre, Pennsylvania to determine the effectiveness of dif-ferent naethods of corrosion control on the Stressteel bar tendon enclosed ] within a 6 inch steel pipe. One specimen tendon was a control with no I corrosion protection other than being within a sealed 6 inch pipe. A second specimen had a slurry of "VPI" and alcohol poured through it before being sealed, a third specimen had a rope saturated with a "VPI" alcohol solution inserted in it and the fourth specimen was filled with nitrogen. All four specimens were placed outside the plant in a vertical position and exposed to the elements. On June 16,1967 prior to assembly I of the tendons for H. B. Robinson, these specimens were opened for an
' inspection to determine if the corrosion control adopted for Robinson ; would be sufficient. All four specimens at this time were in excellent !
l condition with no signs of rust on any of the bars. The specimens rep-1 l resenting the control, the "VPI" slurry and the "VPI" rope were resealed and placed upright once more. I On January 9,1968 these three specimens were reopened to com-
! pare their condition with the condition of the three telltale bars in- i spected in the tendons in the structure. The control _ bar had_ general- ! rusting of about the same magnitude as observed on the te11 tales from 4
TMns Nos. 40 and 74 except that the rusting was on a greater area of the bar surfaces. The specimen with the alcohol "VPI" slurry had virtually no rust. The assembly with the "VPI" rope was generally rusted, however, the overall rusting was not considered as severe as t in the control specimen. When the assemblies were first opened, the control assembly and the one with the "VPI" rope had. substantial water in the bottom. The one with "VPI" alcohol slurry had none. Scrapings
- were taken from the control and the "VPI" rope specimen of both the ]
I corrosion products, the water and the rope. The results of the chemical , analysis on these specimens is included in Appendix C, photographs of the bars are included in Appendix B-3. These chemical tests showed , nothing radically _different than the tests on the specimens from the site. I e f
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^ 11 1 ] D - TENDON INSPECTION l During the week of January 29,1968, an inspection team visited the i site to inspect the bars in the prestressing tendons themselves and compare them with the telltale bars to determine the extent of corrosion ~ on the tendon bars. This was done using a borescope with a maximum ) extended length of 24 feet and a magnification factor of 5X and an in-I spection mirror. j . The three tendons with telltale bars previously inspected were in-l spected with the inspection mirror along with several other tendons. e The borescope was used to check minutely a few tendons but was found to be somewhat cumbersome and restrictive due to its narrow field of view. This inspection revealed that the tendon bars exhibit approximately the same pattern and degree of corrosion as the telltale bars. i 6 i i I l i t I __ _ _ _ . . _ . . _ . _ , . . . - . - .. .. Z
y l 12 I V - INVESTIGATIONS l ! A - LABORATORY ANALYSES Chemical laboratory analyses were made on samples collected from telltale bars, rope and water in the tendons at the site; on water, corrosion products and rope from control tendon assemblies at the Stressteel Corporation plant in Wilkes-Barre, Pennsylvania; on samples of "VPI" and alcohol used in the fabrication of the prestressing tendons; j on samples of cotton rope considered for "VPI" carrier; and on samples j of corrosion product from accelerated corrosion laboratory tests. The various analyses were made by the following laboratories:.
- 1) Chem-Bac Laboratories, Inc. , Charlotte, N.C.
- 2) Allentown Testing Laboratories , Inc. , Bethlehem, Pa.
- 3) Electrical Testing Laboratories, Inc. New York, N.Y.
- 4) New York Testing Laboratories, Inc. Westbury, Long Island, N. Y.
The laborr. tory reports are included in Appendix C-1. Some of the conclusions derived from the various tests were as follows:
- 1) That corrosion product from telltale bar from Tendon No. 6 at plant site was predominantly iron oxide, contained a high proportion of nitr_ites (indicating "VPI" activity), and was not acidic.
- 2) That the Manila rope "VPI" carrier from Tendon No. 6 contained over 9 percent "VPI" by weight and that it was nonacidic_indi_cating that sufficient "VPI" was present in a favorable pH environment for rust prevention.
- 3) That water samples (three) removed from tendon grout pipes at plant site ranged from pH 5.7 to 12.4_withyaryi.ng chemical content indicating that-the variation was influenced more by outside sources (such as wet concrete when pouring base slab) than by condensation from inside tendon containment pipes.
- 4) That Manila rope "VPI" carrier in control tendon assembly at Wilkes-Barre, Pennsylvania contained .
only a trace of "VPI" after approximately 10 months.
- 5) That alcohol and "VPI" used in tendon fabrication
- were as specified. An initial test of the "VPI" indi-cated high chlorides but this was later stated to be in error .by the chemist who conducted the test and two independent confirming tests showed that the chlorides were within specifications. (See Exhibit C-1 -d and C-5.)
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- 6) That Manila rope used to carry "VPI" in tendons (by i soaking it in a saturated solution of "VPI" and methyl alcohol) contained oil to varying degrees - ranging from 3.5 percent to 14.6 percent - indicating that this
- may have been a function of the length of time the rope was in the alcohol bath as well as the amount of rope that had been processed previously in the same solu-tion.
- 7) That samples of cotton rope considered as a substi-tute "VPI" carrier were low in oil content and in chloride content but were slightly acidic.
- 8) That white corrosion product observed on the interior of 6 inch galvanized pipe used in accelerated corrosion tests was predominantly zinc oxide with a minor nitrite content (from "VPI").
- 9) That corrosion products from telltale from Tendon No. 40 at the plant site had only 43.7 ppm nitrites whereas the same lab had reported 1 percent (10 000 ppm) nitrites
- in corrosion products from telltale from Tendon No. 6. Similarly, marked differences were noted in calcium and sulphate content. Chlorides were not present in either case.
B - ROPE The nature of the corrosion and its physical appearance, following a rather straight line down the te11 tales, along with the evidence from the control tendons at Wilkes-Barre which showed that a "VPI" alcohol solution was completely effective in corrosion prevention but that when the rope was introduced, the protection was reduced, led to a suspicion i that some material in the rope was having a detrimental effect on the "VPI. " Therefore a study was made of ordinary Manila rope to deter-mine what was in it and what effect these various materials could have on "VPI " The complete results of this study are included in Appen-dix C -4. In summary, the rope was manufactured to meet Federal Specification T-R-605 Rope, Manila and Sisal. It was manufactured by the American Manufacturing Co. in Brooklyn, New York. It was found that generally all the material in the rope is . inert and nonacidic consisting of ash, water, aqueous extract, fat and wax cellulose, encrusting pectin whichis the basic hemp fiber mixed with mineral oils and waxes 4 commonly called cordage oil.
- Appendix Item C-1 -a-1, a Chem-Bac Laboratories, Inc.- report, covers determinations made on a crash basis when the corrosion problem was first uncovered. Subsequently an. error was determined in "VPI" chloride content as noted on the copy of the report. Although the chemist who did.
.the work did not admit to other errors, the possibility of their. existence
' is recognized.
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-. 4 In discussing "VPI" with representatives of Shell Oil Company, the developers and distributors of "VPI," it was found that "VPI" is inc.om-
. ,f
. patible with - -
oil in tliat the oil may encapsulate the "VPI" crystals which will prevent the "VPI" from sublimating. This does not require much t oil, apparently, since Shell personnel indicated that a rnonomolecular film of oil may be sufficient to prevent the sublimation. C - VAPOR-PNASE INHIBIjOR In addit [on to'chenucal tests to check the "VPI" powder used (see ' Section I V-A), t'ests were made in the Ebasco Materials Engineering Laboratory to check the physical aspects of the "VPI" sublimation phenomenon.
- , l, Tests were made to-compare the sublimation rate of "VPI" in
< open air with the sublimation rate of "VPI" which was coated with cordage oil. Sublimation rates were essentially similar indicating
, that any retardation of "VPI" effectiveness caused by the presence of
. oil as demonstrated by other tests (see Section IV-F), must have been
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a result of reasons other than reduction in sublimation rate.
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Tests were made to compare the sublimation rate of "VPI" in s, open air with that in an alcohol vapor environment. The tests demon-
- strated that the presence of the alcohol vapor did not retard the sub-r, ' [' limatios of the '"VPI. "
^
/
Since other tests,(see Section IV-F) demonstrated that the pres-en'ce mf alcohol did have an adve*se on "VPI" effectiveness, this adverse
^
effect appears to have been a re'sult of reasons other than reduction in "VPI" sublimation rate. Laboratory data on'the foregoing sublimation [,, rate tests are contained in AppendirC-7. , D - STRENGTH TESTS , i
- Strength tests were performed on samples of two telltale bars. The results of these tests are included in Appendix C-2. For telltale 74 which was from the same heat of steel as the tendon bars, the strength y .of the slightly corroded telltale bar was the same as the original tests performed on the sa%.mple bars from the heat used for the prestressing tendons. In addition the ductility of both of the telltale samples was
- within specification. The fracture surfaces show that the break initiated
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15 at the center of the bars. It is generally accepted that corrosion of a severe degree on this type of steel will initially show its effect on mechanical properties of the steel in the ductility rather than on the strength of the material. Severe pitting will create stress raisers and fractures will start at a pit. The strength tests show then that the corrosion is of a minor degree and has had nc, detrimental effect on the strength or ductility of the bars. E - MICROSCOPIC ANALYSES In an attempt to determine whether the oil in the rope had been dis-solved in the alcohol "VPI" solution and then plated on the "VPI" crystals as they came out of solution as the alcohol evaporated, severa1 microscopic analyses were made under high power magnification. Initially a control of "VPI" alcohol was made and the alcohol allowed to evaporate as a con-trol. Secondly,a "VPI" alcohol cordage oil solution was made and the alcohol allowed to evaporate and the residue examined under bothwhite light and polarized light and the results compared to the control. No dis-cernible oil was found on the "VPI" crystals. This cannot be construed to verify that some of the crystals were not encapsulated since the great-est magnification used (approximately 1000X) was not great enough to de-tect a film only a few molecules thick. F - ACCELERATED CORROSION TESTS Tests made in the Ebasco corrosion laboratory were conducted under accelerated conditions (specimens exposed to continuous 100 percent humidity at above ambient temperature) to develop the follow-L ing information to determine reasons for failure of the "VPI" tendon protective system to perform as expected:
- 1) The effect of oil in Manila rope on the protective I action m >'PI." This was done to check the opinhn of shell Oil Company specialists that the
! eh rM .tcapsulate the "VPI" and retard its l s ..h ,m y . .
- 2) The effect of alcohol vapor on the protective h' l action of "VPI." This was done since Manila ropes saturated with "VPI" and methyl alcohol were not I allowed to air dry prior to placing them in tendon containment pipes.
- 3) The effect of galvanized pipe pn the protective ac \
./ g tion of "VPI." This was done since the tendon con \
.[ < 'tainment pipes are galvanized steel. k i
- r. s
16 The basic procedure used in conducting the accelerated tests con-sisted of placing test specimens in inverted containers of tinned steel or galvanized steel in shallow pans of warm water to subject the speci-mens to a 100 percent humidity corrosive environment. Both control specimens (with no "VPI" protection) and specimens with various "VPI" protective methods were exposed. In addition, a galvanized steel com-I pletely sealed container was used to permit exposing specimen to a humid atmosphere with trapped alcohol vapor. Laboratory notes on the 24-test series conducted are contained in Appendix C a. Pertinent results obtained from the tests conducted are summarized as follows:
- 1) Without "VPI" protection, test specimens corrode freely under the accelerated environment used.
Photographs on Appendix page C-8-b-1 illustrate the initial condition of a typical test specimen and the condition of such a specimen permitted to cor-rode freely for 26 days. The corroded specimen serves as a basis for evaluating the degree of pro-tection afforded by the various "VPI" protective conditions tested.
- 2) Good results were obtained with "VPI" applied prop-erly (either by (1) applying a solution of "VPI" and alcohol directly to the surface to be protected and air drying or by (2) using a rope saturated with "VPI"-
alcohol solution and air drying alcohol-free before us e). Results of such tests are shown by photographs on Appendix page C-8-b-2. Protection is excellent compared with the corrosion suffered by the control specimens under similar conditions.
- 3) The presence of alcohol vapor in a test vessel was shown to retard the protective action of "VPI."
Photographs on Appendix page C-8-b-3 show a minor corrosive effect observed on a specimen protected with a rope saturated with "VPI"-alcohol solution and placed in a standard test container without allowing the alcohol to air dry from the rope before placement. Although the standard test container (open-bottomed placed in water tray) allowed the alcohol vapor to dissipate rapidly, corrosion started before the dissi-pation could be completed. The upper pair of photographs on Appendix page C-8-b-4 show much more severe attack experienced by a speci-men using a completely sealed container and a non-air-dried "VPI"-alcohol saturated rope such that alcohol vapors could not escape. After the corrosion had occurred, i
.z 17 the container was vented to remove the alcohol fumes and a properly prepared protective rope installed. As shown by the lower pair of photographs on Appendix page C-8-b-4, further corrosion was minimal upon continued exposure to the 100 percent humidity test environment.
- 4) Excess oil and wax in the Manila rope used as a carrier for the "VPI" was shown to also have a retarding effect upon the action of "VPI."
Photographs on Appendix page C-8-b-5 illustrate corrosion on a test specimen protected by a section of Manila rope saturated with a solution of "VPI" and alcohol to which oil . and wax as used in rope manufacture had been added. This test was made to simulate conditions possible during tendon manufacturing operations where batches of approximately 40 ropes were processed in a single container of "VPI"- alcohol solution. By the time the last ropes were removed, the solution had had an opportunity to pick up excess oil - and wax from the preceding ropes. The above effect was checked by testing the protective effect on steel specimens of pieces of "VPI"-bearing rope taken from Tendons Nos. 6 and 74 at the plant site. Tendon No. 6 was observed in the field to have more rusting than Tendon No. 74. The rope from Tendon No. 6 was shown by chemical . analysis to have 14.6 percent oil and wax while the rope frorr. Tendon No. 74 had 11.1 percent oil and wax. As shown 1 by the photographs on Appendix page C-8-b-6, the rope from Tendon No. 74 (with less oil and wax content) protected its steel specimen more effectively than the rope from Tendon No. 6 which had approximately 31.5 percent more oil and wax.
- 5) Protection by "VP1" on previously rusted steel was reason-ably effective, although not perfect, under the 100 percent .
humidity test environment. - The upper pair of photographs on Appendix page C-8-b-7 show a portion of prestressing bar (taken from the telltale from Tendon No. 40 at the plant site) which had been split
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lengthwise to expose both a bright cut surface and the normal as -manufactured oxide surface. The photographs were taken after the specimen had been allowed to corrode freely (with-out "VPI" protection) in the 100 percent humidity test environ-ment to establish an obvious corrosion pattern. .. Tne lower pair of photographs on Appendix page C-8-b-7 are of the same bar specimen after coating the initially corroded surfaces with a "VPI"-alcohol solution and returning the specimen to the 100 percent humidity test environment. The photographs show no obvious increase in the corrosion pattern. Although not great enough to be readily apparent on photo-graphs, day-to-day observations during progress of this and other tests did indicate that there was some increase in cor-rosion at previously rusted spots. This tended to be greater dur-ing early stages of exposure and tobecome less obvious with time as the "VPI" established protection under the rust films
l 18
- 6) The presence of the galvanized pipe (used as the tendon containment tubes) was not found to detectably affect the protective action of "VPI." There was no apparent dif-ference in the protective action of "VPI" on specimens exposed in galvanized steel test containers (6 inch gal-vanized pipe was used for this p! _ pose) compared with the protection afforded specimens exposed in tinned steel container s. The only difference was the effect on the containers themselves; tinned steel is unaffected where galvanizing is not protected effectively by the "VPI" and suffered corrosion in the form of a zine oxide layer (white rust) on the inside of the galvanized containers.
[ t l l
19 V - DISCUSSION A - BASIC CAUSES OF CORROSION ON FERROUS METALS Corrosion as encountered normally on ferrous metals is basically - y an electrochemical mechanism. For corrosion to occur, four conditions must be satisfied. These are:
- 1) There must be anodic areas (where corrosion occurs) '
and cathodic areas (where there is no corrosion).
- 2) There must be an electrical voltage difference between the anodic area and the cathodic area.
- 3) There must be a metallic conductor connecting the anodic area to the cathodic area.
- 4) The anodic area and the cathodic area must both be in contact with an electrically conducting ionized en-vironment (such as soils, waters, and condensed moisture which are normally ionized - containing positively charged hydrogen ions and negatively charged hydroxyl ions).
There are a number of conditions which will satisfy the require-ments for corrosion to occur on steel. These include the following:
- 1) Dissimilar metals. Metals having different electro-chemical potentials (such as steel and copper) when in electrical contact with each other in a conducting en-vironment will permit corrosion current to flow. Steel will be the anode in the couple (and corrode) when the _
other metal is a less active material. As an example, - such materials include copper, brass and cast iron.
- 2) Dissimilarities in the surface of a single metal. The voltage between any point on a structure and a conduct-ing environment will depend on the condition of the metal surface. On steel, for example, bright metal exposed through handling scars or abrasion will be anodic (and corrode) when adjacent areas are in the normal as-received-from-mill condition.
- 3) Dissimilarities in the environment. Differences in concentration, from point tc point, of the conducting environment contacting a metal surface can result in differences in the voltage difference between the en-vironment and metal. This will permit establishing anodic and cathodic areas with corrosion resulting.
- 4) Differential aeration. With metal in contact with a con-ducting environment and if oxygen is more readily avail- .
able to some portions of the surface than to others, those areas having an oxygen deficiency will be anodic and corrode.
20 The severity of corrosion experienced will depend on the type of condition (corrosion cell) causing the corrosion and the electrical re-sistance of the environment in contact with the metal surface. An oxygen supply is also essential as once the dissolved oxygen in the environment is consumed, the c.ctivity of the corrosion cells will be stifled. Where the electrical resistivity of the environment is high (such as relatively pure water - rainwater, condensation from the air, etc.), considerable resistance to the flow of corrosion current is interposed. This reduces the amount of actual corrosion current flowing and re-duces the amount of metal loss. Metal consumption is a direct func-tion of the amount of current flowing. With a given type of corrosion cell, the greatest degree of corro-sion is encountered where the environment has low electrical resis-tivity and a free access to oxygen. Waters with high total dissolved solids content and acid solutions constitute typical corrosive environ-ments. Although stray direct currents from outside sources can be a factor in corrosion problems, the conditions within the tendon con-tainment pipes at the plant site are such that the rusting observed on the tendon bars could not have been a result of their presence. B - PROBABLE CAUSES OF CORROSION ON THE PRESTRESSING TENDONS The corrosion which has been observed on the telltale prestress-ing tendons at the Robinson plant are believed to have been a combina-tion of two factors:
- 1) Failure of the vapor phase inhibitor system which was intended to fully inhibit development of cor-rosion cells by depositing protective nitrite films.
- 2) Corrosion of the tendon surfaces resulting from dissimilarities in the metal surfaces and from dif-ferential aeration as described in the preceding s e ction.
l l Observation of the tendons inspected at the plant site indicate the probability that the greater degree of corrosion was in those areas where the tendon surface, were subject to abrasion during transporta-tion.
21 Since the conducting environment is necessary for corrosion to proceed, the rusting observed could have occurred only when the tendon surfaces were moistened by condensation from the air within the tendon containment pipes. This condition would exist when temperature and trapped air humidity were favorable to condensation on the tendon sur-faces. Moisture beads or films will not couple anodic and cathodic areas of substantial size (as is possible when a steel structure is sub-merged in a large volume of conducting water). Anodic and cathodic areas can, however, be extremely small in size which permits all conditions necessary for corrosion to exist within an area the size of a pinhead. The differential aeration condition can exist at moisture droplets forming on the metal surface. Oxygen from the surrounding air is more readily accessible at the edges of the water drop than at the c ent e r. The metal under the center of the water droplet will be anodic with respect to that covered by the edges of the drop. This type of corrosion cell is relatively weak and will be most apparent on clean steel surfaces free of films resulting from manufacturing processes. Corrosion of this type would be most apparent, in the case of the tendons, at surfaces which had been abraded. With the thin film moisture environment at the tendon surfaces, a general surface. rusting attack is to be expected rather than a highly localized and more intense penetrating attack as is possible with other types of exposure. There is a significant possibility that the rusting observed on the telltale tendons at the plant site had been at least partially arrested through delayed action of the vapor phase inhibitor ("VPI") action. This is possible if the method used to apply the "VPI" (Manila rope saturated with a solution of "VPI" and methyl alcohol) resulted in a temporary retardation of the sublimation of the "VPI" crystals as is necessary to lay down protective nitrite fil m s. C - SUBSTANTIATING DATA 1 - Corrosion at Abraded Areas The field observations on three telltale tendons at the plant site revealed that the rusting observed tended to be in a streak formation through the central portion of the tendons with no significant attack on
22 the tendons near either end. The construction of the tendon bundle and containment pipe was such that coincidence of rust streaks with abrasion during transportation is entirely possible. Those containment pipes containing telltale tendons held seven 1 -3/8 inch diameter tendons within a 6 inch diameter pipe. Clearance between tendons is less than an inch. The tendons were supported only at the ends with the distance between supports being approximately 31 feet. During transportation (in a horizontal position) between the tendon manufacturing plant at Wilkes-Barre, Pennsylvania, and the Robinson plant site at Hartsville, South Carolina, normal traffic vibration and jarring would cause rubbing between rods through the central portion of the tendon bundle but none near the ends where the tendons were sup-po rt ed. Rubbing between tendons would tend to be in a streak forma-tion. Rusting at areas where abrasion occurs on tendon surfaces would be expected as described previously if the "VPI" provided for protec-tion were ineff ective and provided moisture was present. Since "VPI" was provided, no attempt was made to use dry air with-in the tendon containment pipes before closing with pipe caps. With an effective "VPI" application, dry air would not be necessary. With ineffec-tive "VPI," however, corrosion was possible during those periods when climatic conditions were favorable to moisture condensation on tendon bar surfaces. With cyclic warming and cooling during outdoor storage, a certain amount of breathing action through the threaded pipe joints in the assembly, where not perfectly tight, permits entry of additional moist air and helps to keep the oxygen supply replenished. There is no evidence to indicate that all joints were completely airtight ar.d there is no need for them to be if "VPI" protection is effective. 2 - Delayed Action of Vapor Phase Inhibitor The possibility of delayed action in the effectiveness of the "VPI" is supported by the findings of an analysis of rust removed from one of the telltale tendons inspected at the plant site. The analysis revealed that the corrosion product was iron oxide (rust) with a heavy concentra-tion of nitrites as would be expected f rom the action of "VPI." The analyt,t expressed the opinion that the rusting must have occurred before
23 the nitrites were deposited from the "VPI." Had the nitrites been de-posited first, the corrosion should not have occurred under the condi-tions within the containment pipe. There are two reasons to believe that the "VP1" may have been delayed in its action. Normally, a carrier (such as the Manila rope used in this instance) is saturated with a solution of "VP1" and methyl alcohol and allowed to air dry prior to insertion in the space where protection is desired. By allowing the methyl alcohol to evaporate first, the "VP1" crystals re-form on and within the rope structure and are then available to perform their normal function. In the case of the tendon containment pipes, however, the saturated rope was placed inside the pipe and the pipe closed without allowing the alcohol to evaporate. Although the alcohol vapor could ultimately be dissipated through non-airtight pipe joints, the alcohol vapor could have a retarding effect on the reformation and subsequent sublimation of the "VPI" crystals. Once the alcohol vapor is dissipated, however, the "VPI" would be free to assume its normal protective function. A second reason for retardation of the "VPI" action is the use of Manila rope as the "VPI" carrier. Advice f rom the Shell Oil Company indicates that oil and waxes may encapsulate "VPI" crystals and render them ineffective. Manila rope does contain oil and wax in its normal manufacturing process. Formation of an oil film is then possible when the "VPI" crystals reform after evaporation of the alcohol from the "VP1"-methyl alcohol solution. The facts of the case, as indicated ~oy the chemical analysis of corrosion products, suggest that any inhibition of the "VPI" crystals by oil may have been temporary. Where there is existing rust on a steel surface prior to application of "VPI," there is evidence that further rusting at these locations is not stopped immediately. The rust layer would appear to act as a barrier preventing the nitrites (from the "VPI") from reaching the steel surface. With time and an effective "VPI" application, however, rusting tends to be at least reduced to a very low rate (if not stopped) under preexisting rust films.
24 D - MAGNITUDE OF CORROSION ON PRESTRESSING TENDONS The corrosion observed on three telltale tendons inspected at the plant site on January 3 and 5,1968 was not of a severe nature although at first inspection it looked to be so. The corrosion, for the most part, took the form of uniform rusting along streaks through the central part of the tendons. The rust was a loose powdery formation which could be readily scraped away. The rust was scraped away to observe the condition of the under-lying steel. In most cases, the exposed steel was as smooth to the eye as steel similarly scraped in adjacent areas where no corrosion at all had developed. This indicates a superficial rusting attack with no sig-nificant reduction in steel strength. On one bar, telltale from Tendon No. 6, small pits were observed. These were, however, only an estimated one to three mils deep for the most part. Subsequent laboratory tests revealed that the deepest pit found was 7-1/2 mils (substantially thicker than the layer of base metal lost). The rust film was estimated to have a maximum thickness of 10 to 15 mils. Of the three telltale tendons inspected, that removed from tendon containment pipe No. 6 had the heaviest rust film. All rust streaks on this tendon were carefully scraped in order to remove as much of the rust as possible to gather a sample of the material for analysis. The total weight of rust so removed amounted to only 1.2 grams. Visual inspection indicated that the majority of the rust film had been removed and collected. If we assume for conservatism that only 20 percent had been removed and collected, the total weight of rust would be about 6 grams. The telltale bar was 32'-5-1/4" long weighing approximately 5.05 pounds per foot or a total of approximately 164 pounds or 74 390 grams. The 6 gram loss represents only 0.00807 percent of the tendon weight. This is after a 4 month exposure. The metal loss at this time is negligible and well within any prac-tical manufacturing tolerance applicable to the manufacture of the tendons.
. - . , . , . . . - <. , , , , - . .~ _ . . , - _. ,. .-
25 Physical tests on samples of telltale bars removed from the plant site gave no indication of loss of ductility (all ductility determinations were better than specification) as would be expected if corrosion were affecting bar strength to a detectable degree. On bar break tests, . f.g
- j4 ,yp fractures were initiated, in each case, inside the bar rather than at b.IU ~!
;ya h"if n? J the bar surface as would be probable if surface corrosion were serious enough to be a problem. .l, .
E - CORRECTIVE PROCEDURES WM'V ."--
- p &s.r-There are several methods that may be used to ensure arresting f:;f-5 % ;. ;
' g ~ w . ',. . f any further progression of the rusting that has been observed. The y j following sections discuss the relative merits of some of these pro- .I.y 37 4 cedures. Any one of these could be expected to prevent continuation -
of rusting in case it has not been stopped already as suggested earlier. FMW$- t. % 1 - Continued Use of Vapor Phase Inhibitor
&.Q~h ~Q.~ '
Complete stopping of corrosion can be accomplished in the case @4 w<,.Q Q D-of the tendona (on which rusting has already started), by using "VPI" C* , . y;%;< in conjunction with a controlled atmosphere having less than 50 per- Q)f. ; E e ,$.1. c . s . - cent relative humidity.
&rT"1 :M Application procedure would include the following: d. i %, ,.y. Y
- 1) Remove present "VPI" carrier rope.
- 2) Fill tendon containment pipe with a saturated solu- M ' h.
tion of methyl alcohol and No. 250 "VPI. "
- 3) Drain solution out of containment pipe leaving a
%..ff.-[:" .
layer of "VPI"-alcohol on all metal surfaces. .h. 7 p?h".
. bk~
- 4) Allow all alcohol to evaporate completely leaving a layer of "VPI" crystals on all surfaces to be p rote cted. p[ 3..(} n -:
- 5) Displace all air in containment pipes with dry air L' 'p. 'l$' d.
having less than 50 percent relative humidity. : 'f. a .f e. Seal containment pipe airtight. VdM
.k e.,a2. .c -.
A particular disadvantage of this system is the surveillance problem 3..d. :y,,,7.
.s- . . .;
to be assured that the environment within the tendon containment pipes is N'%r. J c ;.' w.m , ;.; , at all times less than 50 percent relative humidity. Therefore this system 4 46,'./ is considered to be unsatisfactory.
26 ( i l 2 - Use of Nitrogen f Replacing the air within tendon containment pipes with dry nitrogen ! maintained under positive pressure will remove the conditions neces-sary for corrosion to proceed. This is an effective method of corrosion control. Although effective, if nitrogen is used as the only method of corro-sion control, a monitoring system will be required to be assured that positive nitrogen pressure is maintained on all tendons at all times. This will be done. 3 - Nitrogen and "VPI" Protective System To Be Used This corrective procedure involves the use of a simplified pres-surized nitrogen system as the principal means of corrosion control with "VPI" as the second line of defense to supplement the nitrogen s yst em. By using the two in conjunction, nitrogen pressure can be -
/ _
checked on a routine periodic basis. The intervalTan be made short enough so that if, for any reason, nitrogen pressure should be lost, the "VPI" would provide interim protection which should be completely l effective on a short-term basis. l l Nitrogen pressure checking would be performed, on a routine basis, by using a portable quick-connect gage to measure the pres-sure at each groutpipe. This would be expected to take 1 to 2 hours to check all tendons. The order of installation for such a system is as follows:
- 1) Remove existing "VPI" carrier ropes.
l
- 2) Add new telltale bars where required.
- 3) Fill tendon containment pipe to the top with a saturated solution of methyl alcohol and No. 250 "VPI. "
- 4) Drain all "VPI"-alcohol solution from the pipe leaving a wet film on all metal surfaces to be p rote cted.
- 5) Install retainment valve at grout pipe.
- 6) Using warm dry nitrogen, purge all air from the
- _ containment pipe leaving a-layer of "VPI" crystals I 'on metal surfaces to be protected.
- 7) Seal containment pipe nitrogen tight.
- 8) Pressurize nitrogen in containment pipe. Check for leaks and correct as necessary. Leave residual-pressur'e of 10 psi, minimum-a
27 4 - Shipping and Storage To protect the tendon assemblies during shipment and prior to installation, the assemblies will be prepa red for shipment by flush-ing with an alcohol "VP1" slurry and pressurized with nitrogen as the assemblies are completed. During storage at the site, the nitrogen blanket will be main-tained until the assembly is rigged for installation. Immediately following installation, the assembly will be purged with nitrogen and repress.urized, the pressure being maintained on the assembly until it is grouted with cement.
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A-2 -1 Purchaser's Identification No. WElr 5379-CH-4 Issue Date October 5, 1966 Order No. El October 26, 1966 l i i l EBASCO SPECIFICATION PRESSESSING S M L TENDONS HIS DOCUMENT IS HE PROPERTY OF EBASCO SERVICES INCORPORATED. IT IS PROVIDED IN CONFIDENCE AND UPON HE CONDITION MAT NEINER IT NOR THE IIGORMATION IN IT WILL BE REPRODUCED, COPIED, DISCIDSED OR USED IN WHOLE OR PART EXCEPT POR HE PURPOSES SPECIFIED IN WRITING BY EBASCO SERVICES INCORPORATED. PURCHASER EBASCO SERVICES INCORPORATED STATION H B ROBINSON' S'5!lAM ELECEIC PIANT 1# ~ 700'000 * "" UNIT 2 PROJECT SELLER Issue No. DalR Prenared Bv: Reviewed By: Pages Affected orioinal Oct 5, 1966 A H Wern JAS/CPW Revisions. Ri Oct 26, 1966 A H Wern JAS/CFW R2 ESASCO SERVICES IpCORPORATED
l A 2 Purchas;r's Identification Spee No. WELC 5379-CH-4 ) i Issue Date: October 5,1966 ' EBASCO SPECIFICATION PRESSESSING STEEL TENDONS l CONTENTS Section Title Page I SCOPE 1 II PROJECT DESCRIPTION 1 III WORK BY SELLER AND BY OTHERS 3 IV CONSTRUCTION SCHEDULE 4 V MATERIAL 5 VI DESIGN CRITERIA 7 VII DEMIIB AT IAME PENESATIONS 8 VIII CORROSION PROTECTION 8 IX TENSIONING OPERATIONS 9 X GROUTING OPERATIONS 10 XI QUALITY CONTROL 10 XII INMRMATION AND DETAILS REQUIRED FROM SELLER 11 1-
A-2 -3 . Purchascr's id ntirication EBASCO SPECIFICATION. Spec No. WELC 5379-CH-4 i PRESTRESSING STEEL TENDONS Issue Date October a R1 October 26, 1966 II PROJECT DESCRIPTION (Cont'd) The prestressing steel tendons shall be placed with and.within a rigid steel pipe sheath and the pipe filled with grout after the tendons are stressed and anchored. The structure _is shown on Ebasco Sketch 5379-- 1 -CH-28, Appendix A. ! Construction scheduling requires the placing of the first 20 ft of the cylindrical vall concrete starting in September of 1967 and completed by November of 1967 A construction joint.will be made in the wall at the j 20 ft level and the remainder of the wall concrete will be placed starting in September of 1968 and completed by January of 1969 A coupling will be 1 necessary in the prestressing tendon at this. construction joint and corrosion protection required on the tendon sufficient to insure that no. corrosion will occur during the long period in which work will be done on the wall. The tendon coupling may project a short distance above the top of the concrete at the construction joint provided it is satisfactorily protected - Rl ' j against corrosion and physical damage. The tendon will be embedded in the base slab for a distance of 8 ft including anchor. During the placing of
-the concrete for the base slab, it will be necessary to support the tendons a ; in their proper positions and alignment. No' structure will be available I ~
at this time to support the tendon' and the Seller is required to supply a support design detail. Purchaser will' evaluate and estimate cost to himself to i .
.R1 fabricate and erect and apply against Seller's price for analysis of proposal.
The section of the tendon placed above the 20 ft level may be supported,from I the containment liner. If such support is required, the Seller's details
- will be reviewed. The top tendon anchorage will.be supported on a concrete-ledge 13 ft above the spring line of the dome' (139 ft above top of the base slab)..
'Because of the critical function of the: containment, the highest degree-of integrity is require'd of the containment structure. To this end~the:
{. quality of the materials used to construct the structure must be to-the-highest standards available.
' Quality control procedures will be' established in collaboration ~ be-tween Purchaser and Seller to insure.that this required ~ quality is'obtained-on all of the tendons placed within.the wall.
n . .. L- _ _ _ . _ '3
l A 4 Purchaser's Identification EBASCO SPECIFICATION Spec No. WELC 5379-CH-4 PRESTRESSING STEEL TENDONS Issue Date October 5, 1966 R1 October 26, 1966 II PROJECT DESCRIPTION (Cont'd) l Several details will be closely reviewed as they are of critical importance to the integrity of this structure. The Seller's recommended procedures for preventing corrosion on the tendons and anchorages before grouting vill be subjected to detailed review. Anchorage details will be subjected to detailed review in light of the recent and continuing discussion in the industry on anchorage requirements for earthquake re-cistant structures. The Seller vill be obligated to supply a considerable amount of engi-neering det ign to justify the system proposed by him. The Seller will, in addition, be expected to supply as much aid and assistance to the Purchaser as is necessary to gain the approval of the US Atomic Energf Commission for the use of this system. The Seller shall be expected to supply knowledgeable personnel, results of past projects, results of past laboratory tests and a reasonable test program if such is required by the Atomic Energy Commission, R1 to grant approval of the Seller's system. Unreasonable and extra-ordinary test procedures vill be subject to negotiation between Seller and Purchaser. The Seller vill be expected to make any nominal changes to his system, at his expense, which the USAEC requires before approving his system. III WORK BY SELT1% AND BY CrfHERS The work by the Seller vill include all or part of the following:
- 1) Design of the tendons and anchorages
- 2) Detailed recommendations as to system capabilities
- 3) Recommendations as to system layout
- 4) Furnishing all material with certain exceptions as noted below for tendons, couplings and anchorages
- 5) Fabricating tendons and anchorages
- 6) Delivering tendons and anchorages
- 7) Supervision of storage of tendons and anchorages
- 8) Supervision of the placing of tendons and anchorages in the structure
- 9) Supply of all material, equipment, labor and supervision necessary for tensioning of the tendons
- 10) Supply of all material, equipment, labor and supervision necessary ;
for grouting of the tendons j 1
A-2 -5 Purcha:Gr's Identifiention Spec No. WELC 5379-CH-4 EBASCO SPECIFICATION Issue Date: October 5, 1966 PRES'!RESSING STEEL TENDONS R1 October 26, lQ66 III WORKBTSELLERANDBTOTHERS(Cont'd) Work by others vill include at least:
- 1) Final layout and dimensioning of the tendon and anchorage l system
- 2) Rtrnishing of anchorage at steel rings around large penetra-tions in structure
- 3) Unloading and storing of tendons and anchors at jobsite
- 4) Placing of tendons and anchorages in structure IV CONSTRUCTION sun The sequence of constniction for the project vill require the following as regards the prestressing steel tendons.
'Ihe lower 28'I of the tendons along with the stee3 sheathing will be placed in position and securely held, while the 10' concrete base slab is placed. The tendons, including anchors, will extend 8' into this slab.
Following the slab construction', the steel liner will be erected to a height of 20' (level with the top of the tendons) and the reinfore-ing steel and concrete for the vall placed. On completion of the lower 20 ft of wall, construction vill proceed on internals of the building for approximately one-half year, at which time the steel liner will be erected to the spring line of the dome and' beyond. Upon the liner reaching the spring line of the dome, erection of the reinforcing steel and prestressing steel vill resume, followed R1 by concating operations. Tensioning and grouting operations vill be performed during February of 1969 A bar chart for this is shown in R1 Appendix B. It must be noted that this is an approximate construction schedule subject to modification and change as the project progresses. During construction Purchaser vill have available for erection on the tendons a Manitowoc 4000 v crane'with 230 ft boom and a 60 ft jib with 5 ton R1 capacity. Scaffolding at the top tendon anchorage sufficient to safely support several men at one spot will be supplied by Purchaser. l Wrenarr's laenuncmuvu A-2 -6 ' 8pec No. WEIC 5379-CH-4 EBASCO SPECIFICATION Issue Dater - October 5,1966 PRESTRESSING STEEL TENDONS V MATERIAL ! A. Tendons - Prestressing steel tendons may be either high ,rength' steel bars or cables made up of parallel 1/4" high strength steti wires.
- 1. Steel bars shall be fabricated from steel conforming to AS'IM A322 " Hot Rolled Alloy Steel Bars" and AS'IM A29
" General Requirements for Hot Rolled and Cold Finished Carboa and Alloy Steel Bars." 'Jhe bass shall be cold stretched before fabrication into tendons to 87 5% of their minimum ultimate strength and then stress relieved to produce the following minimum physical requirements:
Ultimate Strength: 160,000 psi Yield Strength: 140,000 poi (at07% elongation)
- 2. Parallel wire cables shall consist of wires conforming to AS'IM A421, Type BA "Unconted Stress Relieved Wire for Prestressed Concrete." Oil tempered wire will not be permitted. The wire shall meet the following physi-cal requirements:
Ultimate Strength: 240,000 poi Yield Strength: 204,000 poi (at 0.2% offset) Seller shall be required to supply to, Purchaser, samples from each heat of steel used or from each coil of wire for testing by a testing laboratory retained by Purchaser. B. Anchorages and Couplings - Anchorages and couplings shall be carbon steel of a type which will create no galvanic action with'the prestressing steel tendons when in placs.
- 1. Anchorage for the parallel wire cables shall be by means of cold formed button heads bearing against a steel plate.
- 2. Anchorage for the steel bars shall be by means of threaded connections or other means sufficient for the seismic loading to which it will be subjected.
4. A 7 htrehaser's Identiricar,1c': EBASCO SPECIFICATION Spec No. WELC 5379-CH-4 t PRESTRESSING STEEL TENDONS Issue Date October 5, 1966 - R1 October 26, 1966 V MATERIAL _(Cont'd) B. Anenorages and Couplings (Cont'd) Design of the anchorages for seismic loading shall account for the cycling of load caused by the rocking of the structure. Stresses computed El by g analysis at the spring line and base of the cylinder due to the two I seismic loading conditions are as follows : 8 888 Earthquake Acceleration Position 0.1 g 0.2 g Spring Line i 11 3 klf 1 22.6 klf 4 Base 1 80.0 klf I 160 klf Me The I stresses shall be assumed as varying on a straight line basis between these two levels. The tendon anchorages and couplings shall be shown to be capable of withstanding the cyclic loading due to seismic loading with a frequency of 6 cycles per second. Verification of anchorage capability may be by means of full scale tests, model tests or computations. Celler shall be required to furnish stress-strain data and a full chemical analysis of each heat of steel used for the anchorages and couplings. Seller shall be required to supply Purchaser with Samples from each heat of steel for testing by an independent testing laboratory. C. Protective Sheathing - The protective sheathing shall be rigid galvanized si, eel pipe. It shall be designed to support itself and any loads which the prestressing steel tendon exerts upon it. It shall be designed w. for a heat of 250 ft of water and seams shall be watertight against such a head. The minimum internal diameter of the sheath shall exceed the maximum external diameter of the tendon by at least 1/4 inch or shall be such as to produce an internal area at least twice the gross area of the tendon, whichever is the larger sheath diameter. I
-8 Purchassr's IdIntific tica EBASCO SPECIFICATION Spec No. WELC 5379-CH-4 PRESTRESSING STEEL TENDONS Issue Date October 5, 1966 ,
R1 October 26, 1966 I V MATERIAL (Cont'd) l D. Grout - Grout shall consist of fine sand, Type Il Portland cement and water. Suitable admixtures known to have no injurious effects on the steel or concrete may be used to increase workability and reduce shrinkage. Use of any admixture vin be subject to approval of Purchaser. Calcium chloride shall not be used. Sand may be omitted frein the grout upon justification of such action by Seller. 4 Proportions of grouting materials shall be based on the results of adequate tests made prior to the commencement of work. Grout shall be of a consistency similar to thick cream. When the grout is permitted to stand at a temperature of 70 - 75 F, the sepe. ration of watgr from the grout shall not exceed 4 percent of the volume at any time and the separated water shan be entirely reabsorbed within 24 hours. Grout shall not segregate when allowed to stand until set. The water content shall not exceed 5-1/2 sellons Per sack of cement. The grout, shan be designed for no shrinkage and shall be of sufficient strength to withstand at least twice the magnitude of stress to which computations show it win be subjected to due to shrinkage of the van concrete and seismic loading. VI DESIGN CRITERIA j The following information shan be used hy the Sener in developing the design of the tendons and anchorages. A. Applicable Provisions of Chapter 26, " Prestressed Concrete" of ACl 316-63 "ACl Standard Building Code Requirements for Reinforced concrete" shall apply with the fonowing exception. The tendons may be stressed to a value beyond 70 percent of the ultimate strength but less than 80 percent of the ultimate strength immediately after anchoring. This will be accepted so long as the stress in the tendon one R1 year after stressing is equal to or less than 70 percent of the ultimate strength and the effective prestress during the life of the structure is in accordance with ACI 318-63 . Slip at the anchorage must remain in accordance with Section VI-E. 7
A 9 Purchasar's Identification EBASCO SPECIFICATION Spec No. WELC 5379-CH-4 PRESTRESSING STEEL TENDONS Issue Date October 5, 1966 R1 October 26, 1966 VI DESIGN CRITalIA (Cont'd) B. The total vertical force required in the concrete vall after all prestressing force losses including loss of tendons have been accounted R1 for is 275,000 lb per foot (measured at the centerline of the vall). C. Concrete Properties:
- 1. Minimum 28 day test cylinder compressive strength: 4000 psi
- 2. Shrinkage: 0.0003 inches / inch 6
3 Modulus of Elasticity: 3 6 x 10 psi
- 4. Coefficient of Creep: 2.25 D. Temperature of Tendon - The temperature of the tendon vill remain at ambient temperature (70 F) for a period of one year after vnich it will El be a time dependent variable varying with both external and internal tempera-tures on the vall. For purposes of this design, a constant internal vall temperature of 110 F vith a variable external vall temperature of from 90 F to 40 F vill be used. The tendon temperature vill then vary from 75 to 100 F on a sinusoidal curve with a period of 12 months.
E. Anchorage Requirements - Anchorages shall develop the minimum ultimate strength of the tendons without slip and without excessive de-fonnation. Bearing plates shall be sufficiently rigid to assure reason-ably uniform pressure distribution to the concrete beneath the plates. At least one anchor shall be tested to failure to verify the adequacy of the design. Bond of the prestressing steel tendon shall not be accounted for in the design of the anchorages. Bond of portions of the anchorage assembly may be used upon proof that such action occurs and has no adverse effect upon the bursting stresses beneath the anchorage assemblies. Anchorages chall remain effective during seismic loading. F. Coupling Requirements - Couplings in the tendon shall develop the minimum ultimate strength of the tendons without excessive deformc. tion and without slip. At least one coupling shall be tested to failure to verify the adequacy of the design. G. Broken Tendons - The total loss of prestress due to unreplaced broken tendone shall be assumed as 2 percent of the total prestress.
Purchaser's Identification A 10 EBASCO SPECIFICATION Spec No. WELC 5379-CH-4 PRESTRESSING STEEL TENDONS Issue Date October 5, 1966 1 R1 October 26,1%6 VI DESIGN CRITERIA (Cont'd) H. Tendon Location - Prestressing steel tendons shall be located ' at the center 11ng of the vall. Spacing around the vall affects the location and orientation of the many penetrations through the vall at various levels. A spacing of about 3' - o center to center of tendons is desirable. . $ VII DETAILS AT LARGE PENETRATIONS, At present two large diameter penetrations pierce the containment and interrupt the normal layout of the prestressing steel tendons. An equipment batch, 20'I in diameter and a personr.el lock 7' - 3 in diameter penetrate with their inverts about 5' above the base slab. These pene-trations are surrounded by heavy steel rings and sleeves (see Appendix C). . The prestressing steel tendons shall be anchored to these rings. The lover prestressing steel tendons vill be tensioned through holes in the steel sleeves. Purchaser will allow slight respacing of tendons at the g large penetrations to allow some to be carried past the penetration or to -- be more closely grouped toward the centerline of the penetration. Seller and Purchaser shall jointly develop the final details of the anchorage at - these penetrations and the method of tensioning the lower tendons. Seller i shall supply a workable scheme in conceptual fom for analysis with the ? proposal. , VIII CORROSION PROTECTION , Prestressing steel tendons and anchors shall be free of any products zl . of corrosion at the time of grouting. Tendons and anchors shall further remain free of corrosion for the life of the structure. Purchaser vill accept proposals which include adherence to this section plus an alternate which takes exception to this section. The exception must provide that all 1 surfaces of the prestressing steel tendons and anchors shall be free from visible rust or other results of corrosion at the time of placing within El the sheath within the vall. Methods of protecting against corrosion until
~
grouting and the amount of type of corrosion proposed as acceptable must be fully stated and evidence presented to justify the acceptability. A positive method of inspecting the tendons iranediately prior to grouting must be included as part of the exception along with positive proof that
, the corrosion will not continue after grouting.
9
A 11 Purchancr's Id:ntification Spec No. WELC 5379-CH 16 EBASCO SPOIFICATION Issue Date: October 5, 1966 PRESTRESSING STEEL TENDOUS VIII CORROSION PROTECTION (Cont'd) In light of the long period between placing of tendons and grout-ing, precautions must be taken to assure that the tendons remain free of corrosion. Seller shall be required to develop and present a method whereby this criteria is met. Seller's lower anchorage embedded 8 ft in the base slab will be reviewed to determine the possibility of corrosion due to intrusion of groundwater through cracks induced in the concrete at the time of pressure testing of the containment structure and later in the life of the structure. IX TENSIONING OPERATIONS All tendors with the exception of those below the two large penetrations, shall be post-tensioned from the top of the contain-ment. At this level, a flat area 2 ft 6 in. vide is provided for bearing plates and jacking operations. Post-tensioning of the ten-dons shall be by means of physical elongation and anchoring at the elongated length. Seller shall develop the method, procedure and sequence for tensioning and shall supply computations showing the amount of overstressing required to accomplish his method of tensioning along with details of jacking equipsent and local stresses be-neath this equipment during stressing operations. l l L
,-----7 _ - __ l n y ,. A 12
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- .y Spec no. Wau: 5379-CH-4 EBASCO SPECIFICATION Issue Date October.$,1966 a R1 October 26, 1966
~ PRESTRESSIRL STEEL TENDONS 7- - - -
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! X GR0hfING_0PEi&TIONS Grout shan be introduced into the sheathing at the bottom and be force 2. to flow up through the sheathing and out the top. Seller shan develop details of a grouting system which win meet this criteria and j casure a completely filled sheath with no cavities and submit his speci- ' fications with the proposal. XI QUALITY COFfROL Due to - the function'of the structure in which the prestressing steel h
, tendons win be used, care must be taken to ensure that an. components of the prestressing system are of high quality. To this end the work , and naterial covered by this specification shan be subject to inspection l by the Purchaser's Quality Control Engineers in addition to the Purchaser's , , construction force. Purchaser's inspectors shan have fue access at an times to all parts of the shops where the material is being manufactured and the Seller shan provide Purchaser with au reasonable facilities for inspection'and tests. Inspection by Purchaser shall not relieve the Seller from the responsibility for t$e material and workmanship conforming to tho' requirements of this specification.
She fonowing miniana tests win be required for quality control. A complete fabrication history of the steel used including the source of supply, method of annufacture and results of an mill tests. Ekch heat of steel.must'have at least four sets of stmas-strain data taken on it prioi- to cold working and after stress relieving along with a complete chemical analysis. She stress-strain data resulting from cold stretching . 6f each har shan be recorded. Strese,-strain data resulting from cold stretching of each bar shall not be required providing a sample of each bar as cold stretched is R1' retained for ftiture testing if necessary. Care shan be taken to assure that no portions of the tandana are nicked or scratched, and that an wires or bars are smooth. l m
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l ! A 13 Purchas:r's Identification Spec No. WFLC S379 bH-4 EBASCO SPECIFICATION Issue Date: October 5, 1966 PRESTRESSING STEEL TENDONS R1 October 26,1%6 l i , , XI QUALITY CON'IROL (Cont'd) ! _ Tendons shan.be inspected-for ectrostett WfoWfabrication, after fkbrication, before shipping, upon arrival at jobsite, throughout storage and insediately before placing in the wall. Evidence of corrosion will be sufficient cause for rejection of the tendon. Seller shall submit procedures whereby he vill demonstrate that tendons are not corroded prior to grouting. XII INFORMATION AND DETAIIB REQUIRED FROM VENDOR A. Recommended tendon detail. B. Recommended anchorage detail: ,
- 1. In slab 3 At top of penettstions R1
- 2. At top of wall 4. At bottost of penetrations C. Reconmended coupling detail.
j D. Recomumended sheathing detail. E. Recosamended tendon layout. F. Recosusended erection procedure. G. Losses in prestressing force due to relaxation of steel at elevated temperature H. Losses in prestressing force due to friction R1 i I. Method of supporting tendon at:
- 1. Lower construction joint
;e .., 2. Top of wall J. Decomunended grout mix and experience to justify use.
K. Method and equipment for grouting. L. Grouting details. M. Quality Control Procedures for tendon and anchorage components to assure capability of completed system frost time steel is rolled until it is placed in structure. N. Cearputations to show adequacy of anchorages and couplings.
- ' 12 -
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i I A 14 Purchaser's Identification. Spec No. WEIC 5379-Cs-4 ERASCO SPECIFICATION Issue Date October 5, 1966 PRESIRESSING STEEL TENDONS XII INFORMATIONANDDETAIISREQUIREDFROMVENDOR(Cont'd) O. Computations to show sdequacy of tendon details and layout to meet criteria for prestressing force. P. Reconenended procedure to assure no corrosion on tendons at time of grouting. Q. Method sequence and procedures for tensioning tendons, including computations on overstress. l
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l l A VOLATILE CORROSION INHIBITOR CONFIDENTIAL REPORT L-9 Prepared By H. E. Sipple - Products Application Department L. P. Haxby - Products Application Department E, J. Colerick - Industrial Products Department SHELL OIL COMPANY INDUSTRI AL PRODUCTS DEPARTMENT Lubricants Division New York, N. Y. May 1957 R*01stered Trademark
A 2 VPl* A VOLATILE CORROSION INHIBITOR l l THE NATURE OF "VPl" It is known that any salt liberating nitrite ions in neutral or alkaline solutions will act to inhibit corrosion. There are a great many nitrogen-containing organic compounds that react as bases in aqueous solu- ; tion whose salts of nitrous acid have been shown to be excellent corrosion inhibitors for ferrous metals. The "VPI" products are a family of such compounds which combine this inhibiting action with controlled volatility. These are available in various volatility ranges. Where long term protec-tion is required the "VPI" 260, dicyclohexyl ammonium nitrite is used. This material has a vapor pressure approximately one tenth that of mercury and since it is not readily dissipated from an enclosed area it provides long lasting protection. When rapid initial protection is desired "VPI" 220, diisopropyl ammonium nitrite is used. The vapor pressure of "VPI" 220 is cpproximately four times that of mercury and forty times that of "VPI" 260. Since this material is much more volatile than "VPI" 260 its service life is much shorter.
"VPI" 250 (90% "VPI" 260 + 10% "VPId 220) incorporates the de-airable features of both nitrites, namely, rapid early protection with a long service life.
"VPI" 270 ("VPI" 250 plus basic neutralizer) is used for corro-sion inhibition in the presence of acidic conditions. It utilizes the combined volatility features of "VPI" 250 and an added neutralizing agent.
The product was designed to combat the acid condition aricing from the hydrolysis of lead deposits formed during combustion.pf leaded fuels in spark ignited reciprocating engines. THE ACTION OF "VPl" These solid amine nitrites are slightly volatile at atmospheric tsmperatures which makes possible prevention of atmospheric corrosion of farrous metals in containers or packages. In application, "VPI" vapors are transported by convection and diffusion to all surfaces of the metal where they condense giving a thin layer of crystals. 'In the presence of sven minute quantities of moisture, these crystals dissolve, giving their nitrite ions to the condensed or adsorbed moisture, thereby protecting the metal. The volatility of the inhibitors is merely a means of transport.
- Registered tradewark
A-4-3 1 EFFECTIVENESS OF "VPl* Effect on Ferrous Hetals Laboratory cycling tests at 100% relative humidity over a two-month period showed "VPI" traveled over a considerable distance in a con-fined space and provided complete protection. Tests of steel specimens under conditions simulating punctured packaging and allowing fair sized openings for escape of vapors, showed perfect protection after a six-month period at 1500F. in the presence of saturated water vapor. Other labora- ; tory tests have demonstrated that the vapors will effectively protect com-plex parts or assemblies normally difficult or impossible to treat with j other types of protectives. The vapor also permeates into remote corners J and small recesses giving uniform protection within the interior of a vrap. The ability of "VPI" to prevent further rusting of rusted steel has been demonstrated in the laborato'ry. Weight loss corrosion tests l with prerusted steel showed the inhibitor capable of preventing further rusting both in aqueous solution and in the vapor phase (see Appendix 1). Corrosion tests were made under stagnant conditions to determine the minimum concentrations of "VPI" in water for rust prevention on steel totally immersed in the water, on steel partially immersed, and on steel in the vapor above the water. The test strips after 500 hours at 100 F. 0 4 showed complete protection obtained at all strip locations with a concen-tration of 4% by weight. Totally immersed steel was protected perfectly at concentrations down to 0.1% and showed only slight signs of corrosion at 0.01%. Increasing tendency to rust was observed in the vapor space as the concentration of "VPI" in the water was decreased to 2% or lower. In no case was localized corrosion observed at the water-air interface. Other tests have illustrated the ability of "VPI" to protect effectively at sustained low temperatures. Steel strips suspended in 250 ml glass bottles containing 0 5 ml water.were stored for 14 days at -300F. then 4-
-hours at room temperature. This cycle being-repeated four times. Excellent protection' was obtained 'with "VPl'* while control samples showed considerable corrosion.
The presence of an oil or other preservative film on the part to-be protected does not impair protection afforded by the Napore. The vapors will not penetrate the oil film, but will protect where the film has been ruptured or removed. Effect on Nonferrous Metals Tests on nonferrous metals indicate that varying degrees of pro-tection are cbtaincd. These.are graphically illustrated _in_ Appendices 2 and 3 Surfaces with very slight or even moderate amounts of dulling,- stain or tarnish, would not be considered impaired unless surfac(finish is extremely critical.' Controls were used in each test under identical O
A 4 3 conditions of storage except that "VPI" was absent. A comparison of the control results with the "VPI" vapor results illustrated the effects of
" VPI" . The deleterious effects of direct contact on nonferrous metals are often reduced or do not occur when the metal is exposed only to the vapors.
The results were variable as shown by the chart. Under most actual use conditions the effects would also be variable and far less severe than illustrated. "VPI" protection on assemblies with components of copper and magnesium has been used by one large manufacterer for several years with no effect on the metals. This experience has been repeated many times in the preservation of aircraft engines. Effects on Nonmetallic Materials The effects of "VPI" on nonmetallic materials have been studied Examination of test specimens involved comparison with specimens which had been exposed to duplicate conditions in the absence of "VPI" . Results were recorded on the basis of difference between normal storage and storage in I the presence of "VPI" . Examinations were qualitative and involved such criteria as color change, scratch resistance, stiffness, tear resistance, etc. The recults are recorded in Appendices 4, 5 and 6. " Slight effect" indicates primarily minor changes in color. " Mild effect" indicates changes other than color which might be progressive with time. " Serious effect" indicates marked deterioration. White deposits, generally slight, and readily removed with a damp cloth, were found on most plastics and rubbers tested. Effects on Fingerprints Vapors of "VPI" tend to reduce the tendency for unclean finger-printed parts to corrode. The degree to which this can be achieved will depend on corrosiveness of the fingerprints and severity of subsequent etmospheric conditions. Better protection can be achieved by "VPI" powder. This pro-cedure is considered especially useful in a manufacturing plant for pro-tection of parts between manufacturing steps since an appreciable coating of "VPI" crystale tends to prevent subsequent damage by fingerprints. HovcVer, when a bare steel part has been fingerprinted, complete assurance of corrosion prevention by any rust preventive requires first that the fingerprints be removed by the cleaning step. An alcohol-water solution containing "VPI" effectively removes fingerprints when used as a dip. Inclusion of water improves the action of alcohol to remove fingerprints and "VPI" offsets the corrosive tendency of the added water. The suitable solution is approximately 88% (by weight) isopropyl alcohol and 12% water (this mixture is comunercially available),
.containingabout2%"VPI". Use of this solution as a dip performs a double
A-4-5 i l % l l l function of removing fingerprints and providing a residue of "VPI" which will afford temporary protection against subsequent corrosion. However, before packaging or storage it is necessary to remove the liquid phase by accelerated air drying. If this step is followed by "VPI" packaging, long term protection will be insured. Duration of Protection by "VPl* Since the vapor pressure of "VPI" is low, the material is not lost rapidly through vaporization if it is not subjected to free circula-tion of air. Even when exposed directly to outdoor air at normal tempera-tures its retention is remarkable. Since "VPI" is slightly water soluble, it is necessary to provide waterproof barriers to packages adbject to rain or any leeching action of liquid water. Rate of loss of "VPI" as vapor from a given package vill be a function of a nurJber of factors which include ambient temperature, nature of the outer barrier and rate of circulation of air through and around the package. From this it can be seen that a definite indication of duration of protection is difficult. Short term protection is very easily achieved. Using reasonable care, protection periods of several years are possible. For ordinary paper packages, cardboard containers, and wooden cases at normal temperatures, loss of "VPI" by vaporization vill be the controlling factor in the service life. For containers stored at very high temperatures another factor is involved. This is discussed under the sub-ject of " Stability" . i
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A-4-6 5 PROPERTIES OF "VPl" PHYSICAL CHARACTERISTICS All grades of "VPI" are white crystalline solids. The crystals are small, soft and have melting points ranging from 2ko0F. to 390 F. (capillary tube) with decomposition. They are practically odorless. The pH values of aqueous solutions of "VPI" 260, 250 and 220, vary from 7 2 to 7.0, with "VPI" 270 approximately 11. It has been determined that "VPI" 220, 250 and 260 have a Moh hardness of about 1 and vill not scratch aluminum, lead or copper. " VPI" 270 has a Moh of 2 and vill scratch lead but not copper, magnesium or alu-minum and is not abrasive to iron and steel. Vapor pressures of these materials are listed in Appendix 7 At room temperature the vapor pressure of "VPI" 220 is about 40 times that of "VPI" 260. Vapor pressure of "VPI" 220 is equivalent to about four times the vapor pressure of mercury. This lov vapor pressure accounta for the action of "VPI" and its prolonged effectiveness. "VPI" 250 uses the .yapor pressures of both "VPI" 220 and "VPI" 260 to give imediate and prolonged l protection. Vapor pressure of 270 approximates thet of 250. Solubility data are contained in Appendices 7 and 8. 3TABILITY
- 1. Light atabi1ity. Samples of pure white crystals of "VPI" J60 stored in clear glass bottles when exposed to diffused daylight slowly darkened superficially. Small quantities of inhibitor in sealed glass tubes when exposed to direct sunlight for 60 days-show marked decomposition (20% to 50%).
- 2. SoIution atabIIity. Excellent stability has been shown with aqueous solutions of "VPI" 260 stored at 1000 F. and with identical solutions maintained in contact with steel.
There have been indications that the stability of "VPI"' 260 solu-tions decreases in solvents less polar than water. However, the presence of a low concentration (0.1% to 0.01%) of dicyclohexylamine in such solutions exerts a strong stabilizing influence. 3 Temperature stability. When packages and containers are stored at very high temperatures, "VPI", although completely stable at normal temperatures, undergoes a slow conversion into a less. active compound. Practical upper limits- on the use of "VPI" (sustained temperature) have been shown to be about 150 F. Above this
A 7 6 temperature decomposition increases rapidly. If used above this temperature the effect of decomposition must be considered and if used below this temperature the only consideration in the package life is vaporization.
- 4. Envi ronmen tal Stabil i ty. The ideal operating range of "VPI" 260, 220 and 250 is from a pH of 7 to 9 "VPI" 270 vill function in the presence of acids by neutralizing them and allowing subsequent protection.
l l T0 X I C I TY Toxicity studies with small animals have shown that "VPI" is similar in its properties to sodium nitrite (a commonly used food preser-vative), and would have about the same degree of hazard. Sufficiently large quantities taken orally would be poisonous (LD 50 equalled 2051 15 mg per kg of animal weight in mice).* No cumulative toxic effects could be detected nor were local irritant effects on the skin noted. These re-sults and extensive commercial experience indicate that undue hazards are not introduced under normal handling and use conditions. If the fine "VPI" crystals themselves are breathed, the nose and throat may be irritated and/orabittertasteresult. However, owing to its very low vapor pres-sure, constant inhalation of air saturated with "VPI" vapor vill not be expected to exert a detectable effect. APPLICATION OF "VPl*
"VPI" should, in general, be evenly distributed within the pack-age or container. Its vapors are heavier than air and when fairly even distribution is impossible the diffusion-convection process can be speeded up by a location to favor downward movement of the vapors. It is not necessary to have a hermetic seal to retain "VPI" adequately. Where the "VPI" vrapped item is placed in an outer wrap, no special sealing of the outer wrap is required. A puncture of the outer wrap does not destroy the function of "VPI", but merely reduces the effective life of the protection afforded. This will be in proportion to the size of the puncture or tear, a small puncture having little or no effect. With tighter less permeable wraps having protection against puncture, the amount of "VPI" used can be reduced.
In addition to mechanical methods of application of the crystals, spraying of concentrated alcohol solutions, particularly in protection of complex internal surfaces, is sometimes convenient provided the alcohol is removed by air drying. Dipping of parts into solution has also been shown to be practical. l
*LO So indicates the awount in milligrams per kilogram animal weight which when ingested would prove fatal to 50% of the test animals.
A-4-8 15 GUIDES TO PROPER USAGE OF "VPl" l
, 1. In many cases the items to be protected can be put into containers in which the "VPI" has been introduced previously and given time to form protective vapors. If this is the case, care should be used not to blow out the vapors when inserting the part in the package.
- 2. Although "VPI" vapors have been shown to travel a considerable distance, field results indicate that it is best to consider the practical limits of travel as approximately one foot. Crystals or coated paper should be within about 12" of all surfaces protected.
3 When a part is removed from a "VPI" protective package, it may be re-turned and protection will continue. However, parts removed from the protective vapors have no enduring protection.
- 4. Certain packaging materials are acidic in nature - some green woods and certain papers and cardboards. Contact with these by "VPI" 220,~250 and 260 crystals or paper will cause gradual deterioration, particularly if moisture is precent, appreciably shortening the protection per'iod.
It is more desirable to use "VPI" 270 under these conditions, although use of known neutral packaging materials should always be used if pos-sible, i 5 To protect one cubic foot of space, the use of about 2 to 3 grams of "VPI" 250 is recommended as satisfactory for average conditions. When using "VPI" 270 for engine preservation, one gram per 10 to 15 cubic inches is recommended.
- 6. "VPI" can be shut out or shielded off from areas within a package.
Always try to keep distribution as uniform as possible. A package partitioned internally will require "VPI" in all sections. The vapors will not effectively penetrate cardboard div1derc or paper wrapping.
"VPI" should be on the inside of any wrap..
7 The packages should be kept as tight as practicable, but the wrappers need not be airtight. The purpose is to prevent air circulation through a package, thereby increasing the duration of Protection.
- 8. Since "VPI" paper is simply a carrier for the inhibitor, it does not necessarily have to cover completely the part being protected. It anast, however, be inside any other wrap with the coated side inward.
- 9. _ If "VPI" is used in a water solution for dipping parts, a super satu-rated solution is required. - Water will evaporate faster than "VPI".
Therefore, control of concentration of such a solution is not diffi-cult.
i A-4-9 16 1
- 10. "VPI" is intended primarily for prevention of corrosion due to the action of oxygen and water, especially in regard to ferrous metals I '
l and to a certain extent aluminum.
- 11. Cast iron is sorretimes difficult to protect with "VPI". A pre-dip of an oil base rust preventive is recommended before "VPI" application.
l l 12. Ingenuity and common sense can result in applications where "VPI" protection which will save time and money and provide superior protec-tion against corrosion. i t 1 t l
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A 10 i APPEllDI X l PREVENTION OF FURTHER CORROSION BY "VPl" WATER SOLUTION l l h m . 60 - STEEL RUSTING IN D . DISTILLED WATER c: $ (7 MILS PER YEAR)
$ g 120 -
to g - E :o vi Wg 80 -
"VPI" 260 ADDED TO WATER o" ~ t(AFTER STEEL HAD RUSTED g 6- - - - L -- - u--o- - --4 x 40 -
g "VPI' 260 ADDED 3: TO ONE SET
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0 2 4 6 8 10 12 DAYS Prevention of furtner corrosion of prerusted steel. Polished steel strips p/4 by 3 in.) wre rusted by rotating theti in jars containing 100 mi of distilled water at 150 F. (air temperature). Some strips were removed af ter 2 and 3 days to esta01ish the corrosion rate in water. After 3 days the strips were heavily rusted and solid *vPl*-260 was added to the water in some jars to a concentration of 2 percent. The tests were continued and strips were renoved from water and the
'VPl*-260 solutions at intervals to determine weight loss.
PREVENTION OF FURTHER CORROSION BY "VPl" Vt.POR 25
*E STEEL IN PLAIN g 20 -
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z 9 A SET OF STRIPS REMOVED W ~ AND RE-WRAPPED IN 'VPI" PAPER 0 0 2 4 6 8 10 12 NO. OF CYCLES Prevention of further corrosion of prerusted steel. Polished steel strips (1/2 by 2 in.) wrapped in a single fold of 60-1b. hraf t paper were suspended over 1 m10water in a stoppered 500 m1 flask. The flasks were heated to 150 0 F. for 30 minutes ar.d cooled to 0 F. for 15 minutes. This tempere-ture treatment constituted 1 cycle. After the second Cycle the strips were Covered with rust. Several of these strips then were removed and wrapped in 60-10. kraf t paper containing 1.8 g.
'VPI'-260 per sq. f t., and cycle treatment continued with both groups. Triplicate strips were re-moved at intervals and their weight loss determined.
I
A I l hPPEN0lX 7 PHYSICAL PROPERTIES VAPOR PRESSURE OF "VPl"-260 AT VARIOUS TEMPERATURES
*F. Vapor Pressure, as. Hg 30 0.000007 50 0.00003 70 0.0001 90 0.0004 110 0.001 130 0.003 150 0.012 Vapor pressure of "VPI"-220 at 7o*F. is o.co4 mm. of Hg.
SOLUBILITY AT 77'F., IN GR ANS PER 100 GRANS OF SOLUTION Solvent "VPl"-260 "VPl"-220 Wat e r 3.9 __)4 Methanol 23, 47 Ethanol 9.2 55. Isopropyl alcohol 2.2 7.5 Acetone 0.2 1.2 Methyl ethyl ketone Less than 0.05 -- Isocctane Less than 0.05 Less than 0.05 Benzene -- Approx. 0.05 Toluene Less than 0.05 -- Dioxane 7.9 -- Ethylene glycol 5.6 21. Carbon tetrachloride 0.012 -- Isopropyl ether Less than 0.05 -- Trichloroet hy l ene 0.16 -- COC Flash and Fi re Point - 2400 F. with Decomposition Auto ignition Temperature - Greater than 4640F. l 1 I I
l r A 12 APPENDIX 8 PHYSICAL PROPERTIES SOLU 81LITY IN WATER AT VARIOUS TEMPERATURES IN GRANS PER 100 GRANS 0F SOLUTION Temperature, 'C. "VPl"-260 "VPl"-220 0 3.0 44 25 3.9 54 45 5.2 64 65 6.9 70 SOLUBILITY OF "VPl"-260 IN BIN ARY S0LVENTS CONTAINING WATER AS ONE COMPONENT Solubility of *VPl"-260 at 77'F. In Approximate Nazimum Grams /100 grams Solvent at Water Sol u bi l i ty Organic Content in Per Cent by Weight %H2 0 S o l . " V P l *, Consonent 0 25 50 75 in SoTvent s./100 s. Methyl alcohol 23.6 22.5 13.5 6.8 0 23.6 Ethyl alcohol 9.2 16.6 11.8 5.6 30 16.7 n-Propy l alcohol 5.4 17.4 14.4 8.2 30 17.4 isopropyl alcohol 2.2 11.5 10.2 5.4 35 12.8 tert-Butyl alcohol 0.8* 8.6 8.4 5.7 35 9.4 Diacetone alcohol 1.2 7.9 6.7 5.1 30 8.0 Ac etone 0.2 6.7 8.7 6.3 50 8.7
*o.7 6% water present SOLUSILITY 0F "VPl"-260 IN VARIOUS S0LVENTS Solubility of "VPl"-260. g./100 g. Solution solvent Saturated Water Saturated Solvent Pure Solven t With Water With Solvent n-Butyl alcohol 3.5 15.6 4.5 sec-8uty,1 alcohol I.7 13.3 4.6 Methyl ethyl ketone 0.08 4.3 7.0*
Methyl isobutyl ketone 0.05 0.9 4.2 Mesityl oxide 0.ll** 0.7 4.2 Dilsopropyl ether 0.007 0.001 4.3 l
- Solubility of methyl ethyl ketone is. 37 parts per hundred in water alone.
***VPI"-260 decomposes on standing.
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i l B-1-1 l M E M O R A'N D U M Hartsville, South Carolina December 27,1%7 TO: Quality Control H B Robinson Steam Electcic Plant Unit No. 2 FROM: J E Fries
SUBJECT:
Containment Tendon Inspection Tuonty grams of VPI pm1 der uas placed in 25 tendons in the wall of the containment building as per Tom Wyllie's memo of November 10, 1967. These tendonc ucre numbers 1-19 and 131-136. The baskets vere examined for moisture before the powder uas placed. Five baskets contained a cmall amount of moisture--(#3,
#7, #10, #133, #134) . The tops of tendonc 133 and 134 were depressed in the area of the plugo. The cap of tendon 134 was loose and could be turced by hand. The bashot in' tendon #6, #7, #8, #9 contained a slight amount of rust. Tendon #6 contained one (1) of the four (4) telltale bars. The plugs of tendon #2 vas stripped and una replaced.
TENDON NO. UATER CONTER/ TENDON NO. WATER CON 11 TNT 14 Moist 95 Moist 131 1/2" deep 93 11 134 2" deep 90 1/4"- 1 10 1/2" deep 89 1/8" 124 3/8" 85 Moist 123 3/8" deep' 80 .1/2" 121 1/16" deep 78 _ Moist 120 3/8" deep 74 11 119 3/8" deep 71 1/16" 117 1 3/4" deep 70 1/4" 116 Moirl 69 3/16" 113 3/8" dcop 63 3/16" 111 Moist 56 1/2" 110 3/8" deep' '55- 3/8" 109 3/8" deep 54 Moist 107 Moict '49 1/16 105 Moist 45- 1/16 104 Moist. 40 1/2 101 3/8" deep 34 1 3/8. 100 1/4" deep 33 1/16. 99 Moict 98 3/8". . 97 '6 3/41'
B 2 i Memo to Quality Control Page Two December 27, 1967 Forty-four out of a total of a 119 grout pipes contained water (407.) . The average depth of water was 0.4" (ateut 0.2 of a pint). All caps contained conderaation drops. A possible corrolation batween tendons with dished tops and tendons containing water was diccounted when i.: was found that of coven dish topped tendons only one centained water. The :heory that the loose tops of the tendons mado Icakage possible was d:scount.:d when only one of five tendons with loose tops contained unter. Three (3) sampics of wat2r were analyzied for Pil per A Ucrn's request. The findings vere as follows - Tendon #34 3 3/8 water PH 6.6 Tendon #97 2" uct.cr Pil 6.8 Tendon #134 6 3/4" water PH 12.2 The readings of 6.6 and 6.8 indicate the presents of acid. The reading of 12.2 is highly basic,(14 ociu3 the highest point on the scale. Mr. Al Ucrn was called at Nu York and informed of the existing condition. He stated that ue should stand Ly until he could get more information from Shell Oil Company as to what tests would be needed and what action might be taken. Ile also mentioned that a group f::om Neu York would probably come to the site to try and find out what the problun is, if any. Approximately five (5) grout pipes vere found to have partial vacuums uhen opened. One of those contained water. The plugs at the top of the tendons have only three (3) threads. This perhaps is not onough to prevent leakage into the tendons. Plcstic bags ucre tied to the top of each tendon in which the VP1 powder had been placed in order to prevent moisture from accumulating in the dished heads and possible entering the plugged canisters. These bags uere mutilated by ironuorkers during erection of this hoop steel.
B-t -3 Memo to Quality Control Pass Three December 27, 1967 New Plastic bags were put back over the seven (7) tendons which have dished caps as listed above. If at any time in the future, these i bags are torn off, they will be replaced with new ones. JEF/cs cc: Messrs D M Pulito (4) J A Klapper (2) A H Wern (2) T H Wyllie J E Fries Quality Control File Readers File
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B 4 I i i ! l l MEM0RANDUM Hartsville, South Carolina I January 10, 1968 TO: Mr. M A McDuffie PRGl: N J Chiangi
SUBJECT:
Report on Corrosion of Prestressed Tendons for Containment Building On December 20,1%7 inspection of the prestressed tendons to check for VPI powder was made, by N J Chiangi, Quality Control and J E Fries, Assi tant Engineer. It was noted that the baskets in these tendons had traces of rust on them as weli as slight traces of moisture. The VPI powder in these baskets also seemed to be overly moist. It was decided to take the cape off the grout plugs to see if ,. any uater was procent in them. It was found that there was water and/or < moisture in about 40 percent of thace plugo,varing from as much as 6 3/4" in tendon No. 97 to just moist in others. Mr. Al Wern in the N. Y. Office was then called and given our findings. He requested that we have water samples taken of the water we had removed from three of the different tendono. - This was done at the CP&L lab, Unit No. 1. The findings ucre as follows: Tendon No. 97 12yPH Tendon No. 134 6.8 PH Tendon No. 34 6.6 PH This information was then called back to New York to Mr. Wern. We were then informed by Mr. Wern to do nothing else until he could contact Shell Oil Company to see what other tents would be needsd. We were later informed that a 8roup from New York representating Ebasco, Stressteel, and a representative from the Shupac Associates would visit the site. On January 3,1968 Mr. Al Wern, Hr. A W Peabody, Mr. J J Gilmore, Ebasco Representatives and Mr. E Marlowe from Shucpec Associates and Mr. W Larson from Stressteel visited the site, to determine the extent of the corrosion and what could be done to stop it, as well as what was causing it.
B 5 Memo to M A McDuffia Page Two January 10,1%8 On January 4,1%8 tendon No. 6 uas opened, and the tell-tale bar was removed so that it could be examined. Upon removal, the bar indicated that corrosion had taken place quite extensively on about 80 - 90 percent of it. In areas the rust was approximately .010 .015 mills thick. This is not an exact measurement and use given as a rough gueco by Mr. A W Peabody. There uere also some evidences of pitting on the bar. This pitting was guessed to be in the area of .001 .002 mills. This again was only an educated guesa. At thic time it was decided that more lab tests would be needed. A sample of rope that had been saturated with VPI powder and alcohol was taken, rust scraped off the bar and VPI powder, also three (3) water camplea. These items were sent to a Charlotte, North Carolina lab for testing. This lab was " Chem Bac Lab" by name. The tests were performed by a Mr. C Cochran. The reports of his findings are enclosed along with this report. On January 5,1968 the two of the three remaining tall - tale bars were removed for examination. They were found to be rusted also, but not quite as bad as the previous one teken out of tendon No. 6. Af ter some discussion it was decided to take a five foot section out of number 6 bar and also a piece out of No. 74. These samples are to be sent to the Pittsburgh Testing Laboratory for tensile strengh tests. At a later date a new piece will be drilled and taped, or spliced (as shown on chetched included with this report), then put in the tendon with the remaining section of bars, (original piece) that it was removed from, placed along side a new tell-tale bar, that are being shipped to the site from Stressteel Company to be placed into the tendons they were retaoved from. The old bars are to be used so sort of a gauge to check on any new corrosion if any chould occur. Tendon.No. 110 has not been opened. It was felt that one tell-tale bar should be left in place as is, for any future examinations that might be needed at a later date. The three tendons that were oper:.d have now been resealed. Mr. R Kaenan and Mr. R Page Westinghouse Quality Control representatives, were present and witnessed all proceedings during the opening and removal of these tell-tale bars from the tendons. This is all the information available at this time, we will receive reports from Mr. Al Wern from New York on their findings and decisions as to what else will be done. NJC/cs . r! l > l r, l g l g 71 - gp M t-' 1 , {- .g.,. ,g cc: Messrs D M Pulito (4) p J A Klapper (2) ~; - - Quality Control y . T H Wyllie File - Readers File - - l S
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fores 584 Rtv s.s? EsASCO SERVICES INCORPORATtD B2a-1 FIELD TEST DATA SHEET ron H B ROBINSON SEP NO. 2, CAROLINA P&L CO D.S. NO. l CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT oATE 1-3-68 susJECT REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C AWP p_2s er The following field notes were taken during the period January 3 to January 5,1968 during inspection of telltale bars for evidence of corrosion. Inspection team: Mr Walter Larson, Stressteel Corporation Mr Gene Marlowe, Schupack Associates Mr J J Gilmore, Ebasco Services Inc Mr A H Wern, Ebasco Services Inc Mr a W Peabody, Ebasco Services Inc At plant: Ualt Larson had brought with-him one of VPI baskets from Wilkes-Barre. Tal Chiangi, who had' inspected baskets at plant, said that appearance of the basket Walt brought was about the same as those he had looked at in the containment pipes. Looked into plug hole at top of No. 6 pipe. Inside of basket, as much as could be seen, looked okay with only discoloration from basket welding. Basket had VPI in it which had been in for 10 days, so only a small part of basket surface could be seen. Some small beads of moistare in perforations on upper part of basket. Removed top cap from #6 pipe. Incipient rust spots along side of telltale bar. Sounded pipe from top for water. Pipe is essentially dry. Tops of tendons that show are black from machine oil, but a few incipient rust epots were noted. No significant amount of rust stain could be rubbed off with the fingers. Unscrewed the telitale,bar. Pulled it out with crane. Heavy rust noted along oides of bar as it was removed. Bar laid out on ground for preliminary inspection cud then taken inside the warehouse. Rod corroded most heavily, starting approximately 66 inches from top end (only cild corrosion in isolated spots above this point) to approximately 46 inches from bottom end. Some rusting in spots below the 46" point. Corrosion tends to be concentrated on' one side (heavy rusting on one side, unattacked on opposite side) through most of the heavily rusted area. Streak not; atraightl for the whole length- of rod -- tends to spiral somewhat.
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l Foans see RU s.57 ESASCO SERVICES INCORPORATE 3 FIELD TEST DATA SHEET ma H B ROBINSON SEP NO. 2, CAROLINA P&L CO D.S. NO. CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT gg 1-3-68 l AWP Q REACTOR CONTAINMENT BUILDING. HARTSVILLE. S C sy Area of heaviest scaling centered about 8-1/2 feet from top end. A 1" x 5" strip scraped in this area. Nueberous small pits estimated at 1 to 3 mils deep. Over 100 pits. Scale estimated at_ not over 10 mils. Rope suspended from one side in #6 pipe because of telltale rod in center. Rope is passed through one of side holes in spacer plate and secured by knot (instead of tying off to ring at bottom of basket). There may be some relation between rope position and corroded streak, but relative position of the two was not carked prior to unscrewing and removing telltale bar. Inside of the 6" stub cap, walls were not rusted as was the rod. There may have been a mild amount at one spot. Rope, however, did not extend up into the pipe cap as cpacer plate, from which rope is suspended, is just below the top of the main 6" pipe. Color of corrosion product is dark brown with light tan spots af ter drying. A piece of the rope from the top end was removed for inspection. Has a strong odor. Someone suggested similar to wet plaster. Walt Larson advised that the color of the rope has changed in the yellowish direction from the original lighter color. Now a dark straw color. Walt Larson's Comments on Method Thev Used To App 1v VPI Slurry of #250 VPI and methyl alcohol made in ratio of 2 pounds of VPI to 1 gallon of alcohol. The mixture was placed in a' plastic garbage can and the rope lengths immersed in this solution. Typically, rope was soaked for five minutes or so, minimum. No attempt made to dry alcohol-soaked ropes before pulling them into pipes. When a group of tendon-containing pipes-was ready for ropes (with wire pulled through for pulling rope in place), ropes were immersed in the VPI solution, soaked for the minimum period., As rope lengths were needed for pipes, they were taken out of can and pulled directly into pipe with no drying time. Regarding solution, VPI is supposed s to be very soluble in methyl alcohol yet Walt indicated thtt all of the VPI did not dissolve when used at~ the ratiop of 2 lb per 1 gallon of alcohol. / Par Wachter's paper, solubility of,.dicycl'ohexyl ammonium nitrite in methyl alcohol att 75 F is 23.6 grams per 100 grams of alcohol. Ratio = 4.24:1 (alcohol to VPI). i Alcohol weighs 49 lb/cu ft. . At 7.4805 gallons per cubic foot, 1 gallon of alcohol = ! 49 + 7.4805 = 6.54 lbs. VPI that would dissolve should be: 6.54 + 4.24 = 1.55 lbs. l So there should be some excess (2.25 excees in a 5-gallon batch which Stressteel l normally mixed up). l n
rems oss esv e.s, Esasco stavects INconronATt3 FIELD TEST DATA SNEET H B ROBINSON SEP NO. 2, CAROLINA P&L CO D.s. No. 3 sueJtcT CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT cATE 1-3-68 REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C ,y AWP g Called Atlanta office of Shell to see if could get someone to come to plant site
- to review the situation. Talked with Mr Andy Morrow. He is interested but has to be in St Louis tomorrow (Thursday,1-4-68) but will try to call me at plant
- Thursday af ternoon.
!' Morrow advised that he would get in contact with Mr J P Petree, area manager at Charlotte. Gave Morrow all of our observations to date. Later had a call from Shell's Mr J S Dick who works under Mr Petree but was on a job at Wilmington, N C. Dick could not come down Thursday. Might be able to on Friday or first of week. Discussed details of the problem with Dick. He couldn't offer any suggestions other than to have sampics of VPI and VPI-saturated rope checked at their Sewaren, New Jersey, Lab. Suggested that Stressteel arrange this through man from whom they got their initial dope (Shell's Mr Bob Maurer, Nutley, New Jersey) . Asked Dick if he knew of any similar cases of failure of VPI to protect. Says it works when properly applied. Mentioned only one instance of a phakaged steel product at Malden, S C, where the VPI was not so applied that it could get to the r; teel to be protected. Assembled the following samples which were sent for analysis to the Chem-Bac Laboratories in Charlotte, N C.
- 1) Corrosion product scraped from teiltale bar in #6 tendon pipe.
Requested qualitative and quantitative data (for this and other samples) on:
- Iron (identified by compounds - oxides)
- Nitrites
- Sulphates
- Chlorides Note: In getting scrapings from telltale, had to cover the whole bar at worst rusted location in order to get less than.1/2 cubic inch for test sample.
- 2) Water sample from Tendon #34. (This is not a telltale-containing pipe.
Lab had checked pH as 6.6. No VPI in basket.)
- pH
- Conductivity
- Presence of VPI (Shell #250 VPI, 90% dicyclohexyl ammonium nitrite, 10% dicsopropyl ammonium nitrite)
- Calcium
- Hydroxides
- Nitrites
- Sulphates
- Chlorides
Fons ese es7 s.s? ESASCO SERVICES INCORPORATED B2a-4 ! FIELD TEST DATA SHEET FOR H B ROBINSON SEP NO. 2, CAROLINA P&L CO D.S. NO. 4 i sueJECT CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT oxyg 1-3-68 g REACTOR CONTAINMENT BUILDING sy AWP
- 3) Water sample from Tendon #134. (This is not a telltale-containing pipe. Lab had checked pH as 6.8. VPI had been placed in basket 7 days prior to taking water sample.)
- pH
- Conductivity
- Presence 'ci VPI (Shell #250 VPI, 907. dicyclohexyl ammonium nitrite, 107. dicsopropyl ammonium nitrite)
- Calcium
- Hydroxides
- Nitrites
- Sulphates
- Chlorides
- 4) Water sample from Tendon #97. (This is not a telltale-containing pipe. Lab hed checked pH as 12.4. No VPI in basket.)
Same tests as above
- 5) Sample of VPI impregnated rope taken from Tendon Pipe No. 6.
- pH
- Sulphates
- Presence of VPI
- Chlorides
- Nitrites
- 6) Sample of VPI #250 powder which is from the same 100-lb batch that Stressteel used in Wilkes-Barre.
- Impurities Note: Stressteel had a 5-lb container of #250 VPI used for the test samples at Wilkes-Barre.
A H Wern got preliminary report back from Mr Cochran in evening. Data as follows:
- 1) Corrosion products Iron oxide No sulphates No chlorides Much nitrites (suggested that may have developed af ter corrosion)
roam en no ..., tsasco scavicts twconeonarto D2n-5 l FIELD TEST DATA SNEET yon H B ROBINSON SEP NO. 2, CAROLINA P&L CO o.s. No. 5 I sueJECT __ CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT DATt 1-3 & 1-4-68 n= REACTOR CONTAINMENT BUILDING ey AWP Km m_n 2) to
- 4) Water samples Tendon Nitrites Chlorides Sulphates Calcium
#34 (Practically none) heavy none trace 25 parts / billion
#134 large amount heavy none fair amt
#97 large amount trace some small At plant - January 4, 1968:
Jim Gilmore found in literature reference to fact that use of alcohol solution
". . . is sometimes convenient provided the alcohol is renoved by air drying."
This was not done at Stressteel. Talked with Dick Richardson and asked him to (1) see if he could find out from Shell what the ef fect would be if alcohol is not allowed to air dry and (2) lime water mixture that should be used in containment pipe. Dick to look into (1) but suggested that dope on lime water would be in the State of California Division of Highways specs that I have. Specs indicate as follows:
"All water used for flushing enclosures shall be saturated with either quick lime (calcium oxide) or slaked lime (calcium hydroxide)."
This was with reference to enclosures for post stressing tendons. Specs also say, "Prestressing steel for post-tensioning which is installed in members prior to placing and curing of the concrete, shall be continuously protected against rust or other corrosion, until grouted, by means of a corrosion inhibitor placed in the enclosure or applied to the steel in the enclosure. The corrosion inhibitor shall conform to the requirements specified herein." The inhibitor mentioned is selected by contractor with approval of Division of Highways. Richardson called back to indicate that Shell people in New York have no dope on effect of not letting alcohol dry. They are, however, contacting Charlotte and Atlanta offices to have someone get in touch with us. I asked Dick to do some l core research on the lime water usage for corrosion prevention. Called Mr Cochran at Chem-Bac Laboratories. He should have full report before noon tomorrow. Discussed, with Cochran, following statement from Wachter's paper: i _ _ _ _ _ _ _ _. w
roam see nsv s.s, EsASCO SERVICES INCORPORATED FIELD TEST DATA SMEET FOR H B ROBINSON SEP NO. 2, CAROLINA P&L CO o.S. NO. CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT oxyg 1-4-68 wsJEcr g REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C eY ,
"It is known that amine nitrites are decomposed by acids or caustic alkalies in aqueous solution. The main products from reaction of Dichan with acid would be the nitrosamine and with caustic would be the free amine and sodium nitrite."
From what Cochran says, nitrosamine with acid and sodium nitrite with caustic would both be protective in nature but not for as long a tens or as effectively as the amine nitrites. Asked Cochran his opinion of the effect of not allowing the methyl algohol to evaporate from the VPI-saturated rope prior to placing in tendon pipes. Cochran felt that the alcohol vapor could have the effect of inhibiting the action of the VPI and also acting as a degreasing agent on the steel with the result that it would be more susceptible to corrosion from any moisture. He indicated that this would support the following action inside the tendon containment pipe:
- 1) Initially, while alcohol vapor pressure was high: Suppression of VPI action and degreasing of the steel allowing it to corrode.
- 2) Af ter alcohol vapor had worked its way out through pipe joints, start of VPI protective effect.
This would tend to explain his findings of high nitrite content in the iron oxide scrapings from the #6 telltale bar. Asked Cochran if he had any thoughts on the possible effect of the presence of galvanizing on the action of VPI. He had nothing to offer at this time. Walter Larson received report from Ed Schechter at Wilkes-Barre re inspection mtde of three test tendon containment vessels there which are now approximately 10 months old and last inspected in June 1967. The three samples inspected were: A) Control (no VPI treatment) B) Pipe through which a VPI slurry had been poured prior to placing tendons in position. C) Pipe in which VPI-saturated rope had been placed along with the tendons. Detailed results on separate sheets but general results are as follows: Sample A (Control) - Tendons were corroded. Water present. Sample B, (Slurry) - Tendons were not corroded. No water present.
reau saa esv s.s7 E:Asco SERVICES INc0RPORATED B2a-7 FIELD TEST DATA SHEET H B ROBINSON SEP NO. 2. CAROLINA P&L CO D. s. NO. 7 sron susJECT CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT oxyg 1-4 & 1-5-68 REACTOR CONTAIMiENT BUILDING, HARTSVILLEm S C AWP g ev Sample C (Rope) - Tendons were corroded at least as much as on control. Moisture present. In Samples A and C, it was no longer possible to distinguish, visually, between the three red (as heat treated) tendons and the three black (wiped) tendons. In Sample B, the color difference is still clear. At containment structure, checked present condition of steel for accessibility of tendon containment for possible cutting of f of upper section to expose tendons for examination.
#131 and #31 can be reached easily.
#66 - top 15 ft is exposed. More could be reached by cutting out some of the vertical re-bars. No horizontal re-bars at this location yet.
#91 and #92 could likewise be reached by cutting some vertical re-bars.
#110 (which has a telltale) could be cut out by taking out some vertical re-bars. No horizontal re-bars present yet.
January 5, 1968 Mcrked section, 5 feet long, between 6' and 11' from top end of telltale bar from #6 tendon containment pipe. This section to be cut out and given tensile test. I Removed top stub cap from #70 tendon. This does not have a tendon. VPI rope in place. Tops of tendons look good. No trace of rust. No. 40 Tendon -- Removed pipe stub cap. Tops of tendons looked good. May have been a few minute specks of rust but nothing significant. Rope was loaded with VPI powder (more so than at #6 tendon). Powder flaked off and flew as rope was being handled. Sample of rope removed and tagged. Removed the telltale bar. It was rusted but not as bad as the one from #6 tendon. First significant rusted streak 4 feet from top. The last one approx 6 feet from bottom of rod. In between are rusty streaks along side of rod. These not necessarily in line. Scraped what appeared to be the worst spot (approx 15 feet from top end). No definite pitting as was observed on the #6 telltale bar, but the surface appeared to be slightly roughened as compared to a nearby area scraped clean where the bar was in the non-rusted black state. This was actually on the opposite side of the bar from rusted section. Inside of stub, pipe cap was dry. Bottom of VPI basket dented by top of telltale bar. Telltale bar itself was dry. No moisture on bottom end of bar when removed. l
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.-sy-b.,u' No. 74 Tendon -- Removed pipe stub cap. Nothing significant on tops of rods in S N,y .s the way of rusting. Top of telltale rod had pushed hole through bottom of VPI ' %f.$)
basket. Pipe stub cap dry inside although oily in appearance. One area inside 3% stub looked like a mixture of rust and oil. 5
/j.(. y Rope had same smell as that from #6 tendon. Section of rope < 4, ,(
removed from top erd. VPI visible but did not flake off as readily as observed at Q'.1,q . Tendon #40. {'p3 p Rod removed. Completely dry. h.yG .' n Worst corroded area was in the section between 7' and 11' from the top end of the rod. Rusting was circumferential in parts of this area. The
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g' worst rust appeared about the same as that on #40. There were some other rust streaks but relatively large areas of unaffected surface. The last significant
@N Qf; rust streak approximately 8-1/2 feet from bottom end of rod.
h.nk.- s .h J Scraped section in the worst rusted area. Smooth. Appeared ;~C r: . ; somewhat smoother than area scraped on #40 rod (but see later notation). The R.7, scraped area was only slightly rougher than on area scraped on clean (uncorroded) ;% black oxide surface nearby, Marked section of #74 bar between 6-1/2' and 11-1/2' from top
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LZ r g.rt end to be cut out for tensile tests. 10 3. . Placed the scraped section of #74 bar alongside that of #40 bar -i (both scraped sections in rusted areas) to make direct comparison. Both appeared h(JE. I to have the same degree of roughness. p.f.yy;
- p. y 4 .4 No. 40 telltale bar was replaced. . f W:
.f:b Called Mr Cochran at Chem-Bac Labs Inc, 2500 W Blvd, Charlotte, N C (704) 392-5388. M.'I.
Cochran had not finished his calculations as yet but gave me the following data ~2' A ,.i which was ready. L, , Tendon 34 Tendon 134 Tendon 97 L.y.@ Rope
- Water Sample Water Sample Water Sample Rust VPI pH 5. 7~ 6,7 12.4 M(.[f ' T. 1
- Conductivity in 6.*g ? j '.t b equivalent of N fE" Nacl 329 ppm 100 ppm 304 ppm j,e y Calcium 1159 ppm 557 ppm 267 ppm "hN a D.h g -
Alkalinity as @. w. , L h bicarbonate ** 549 ppm 115 ppm 32,657 ppm d }// Sulphates --- --- 1265 ppm Chorides , 2234 ppm 1005 ppm 415 ppm --- 127 ppm 214 ppm . j (p..g sss
- Over 100 ppm VPI as nitrite in rope.
** No hydroxyl alkalinity.
.. B..
re== see as ,..., reasco scavices inconeonave B2n-9 FIELD TEST DATA SHEET i H B ROBINSON SEP NO. 2, CAROLINA P&L CO ,,,, ,,, 9 CORROSION OF PRESTRESSING TENDON TELLTALE BARS AT 347g 1-M SU NECT _ REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C ,y AWP Call from R B Richardson in New York. Trousard's article on protection of annular space between pipe and casing cites use of saturated solution of lime water. Dick mentioned the matter of freezing if lime water is used. He could find no data on the freezing point of the solution. Dick had found no data indicating a susceptib!11ty for stress corrosion cracking of steel in high alkaline solutions at low temperatures, i I
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Janua 26, 1967 B33-1 TEST TO INDICATE EFFECTIVENESS OF VARIOUS CORROSION PREVENTATIVE MEASURES FOR'STRESSTEEL BARS INSIDE OF 6" OALVANIZED PIPE. Re f: Our WO 66-213 l Four Specimens will be prepared each using: One - length of 6" galvanized pipe approximately 20' long Two - 6" galvanized pipe caps Three - 1 3/8" STRESSTEEL bars approximately 20' long in the As-Stress-Relieve Condition. Three - STRESSTEEL bars approximately 20' lon6, wiped cican with , solvent and rags. One - h" diameter X approximately 20' long cold-rolled bar with bright finish. Three - Bar spacers The six STRESSTEEL bars will be spaced and bundled inside the 6" pipe. The " diameter cold-rolled bar will be placed in the approximate center of the spaced bundle. The specimens will be prepared as further described below, and w'ill be placed out 6f doors in our yard in a vertical position. At any periodic interval, the specimens may be taken indoors, uncapped, and examined.
" Specimen A" - Control No corrosion control treatment will be used. The . ends of the pipe will be tightly capped.
" Specimen B" - VPI Slurry in pipe.
Same as " Specimen A", except that a slurry in a ratio of two pounds of VPI 250 crystals and one gallon of methyl alcohol, as recommended by Shell Oil Company, Will be poured throuch the pipe when it is in an approximately horizontal position.
" Specimen C" - VPI Slurry Coated Rope Same as " Specimen A:, except that a b" diameter manila roce soaked in slurry described in " Specimen B" wili be inserted through the center of the spaced 1. 3/8" diameter bars and .
arranged so that it will hang from one end when in vertical position.
" Specimen D" - Nitrogen under pressure Same as " Specimen A", except that after_ assembly, air in pipe
- will be purged with nitrogen and a positive pressure of 5 to 10-l PSI will be maintained in pipe throughout test period.
Walter H. Larson l
B 3a -2 STRESSTEEL CORP. soar Wo c, (,- 2, g3 **T8' I " 2 (*
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(--- ,s' j l February 13, 1967 B3a-3, CORROSION TEST NOTEE Re: Our WO 66-213
- 1. Photos taken 2/6/67 Close-up photos taken between 43" and 60" from bottom of each assembly.
- 2. Specimens placed in pipe 2/8/67 inside buildin6 Weather outside cold and clear.
3 Mixed alcoholslurty of 2 p(ounds very-thin DIPI 250 like water) and with 1 gallon stron6 of methyl tendancy of V.P.I. to precipitate.
- 4. Slurry in pipe "B" was poured through after bars
- were inserted. Pipe was sloped 6" in 20'2" len6th.
5 Approximately pound of slurry was retained in pipe.
- 6. nope for Test "C" was soaked for 5 minutes and approximately b pound of slurry was absorbed by rope. Hope was pulled through assembly with a lead' line previously inserted through center of bar group.
7 Specimen "D" was purged with nitrogen until gas escaping , from vent end would not support an open flame. It was necessary to disassemble 6" caps on "D" in order to reseal threads to stop. leaks. 10 PSI was selected as nominal pressure in "D". - Specimens placed outside 2/13/67
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8. 9 l[l b Walter H. Larson WHL/ra
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l Q W4 l I M / B3b-2 l SCHUPACK u.o ASSOCIATES "E?o","oio" S/"#f5 l C O N S U LT I N G ENGINEERS 5' H O N E 203 325 3578 June 22, 1967 % $ ,
%f@pfM l s w 4 s%r Mr. John A. Scarola Chief Concrete Hydraulic k gineer Ebasco Services, Incorporated Two Rector Street New York, New York 10006 Ref: Westinghouse Electric Corporation H.B. Robinson Steam Electric Plant 1970 - 700 000 KW h tension-Unit #2 Inspection of corrosion protection for Robinson Plant (66-M1)
Gentlemen: On Friday, June 16, 1967, I inspected the four sample bottom tendon assemblies which were reported on in Stressteel's meno of January 26, 1967 For your convenience a copy of the Stressteel meno by Walter H. Larson is attached. The specimens were fabricated on February 8, 1967 and placed outside in storage on February 13, 1967 The tendons were stored outside in horizontal position until March 17, 1967 b y then vore lifted in the vertical position and stored supported against the pole. On June 15, 1967 they were lowered to a horizontal position and disassembled on June 16, 1967 for inspection for corrosion. General observations of the four months of exposure of the tendons indicated no progressive corrosion in any of the systems. In specimen A, which had no treatment at all except a sealed tube, the indications were that no corrosion has taken place and that the performance were comparible to the specimens B, C, and D which had a secondary corrosion protection. It was particularly interesting to note that the 1/2-inch burnished control bars were completely free of rust and further the ends of the Stressteel bars, which were cut with an abrasive saw, were completely free of rust. It can be concluded from this examination based on the four month exposure, that a completely. sealed tube, which does not permit a change of atmosphere, will not permit corrosion of the Stressteel bars. It is recommended that the VPI powder be used in any case to insure a. second line of protection in case there is damage to the sheath in construction. However, there seems to be excellent assurance that an excellent protective media exists for the Streasteel bars in the 6" galvenized sheath.
Mr. John A. Scarolo B3b-3 Ebasco Services, Incorporated June 22, 1967 Streasteel has taken before and after photographs of the tendons and will send a copy to Ebasco in the near future. It may be of interest to Ebasco to have Stressteel continue the test toward the end of the Robinson project for specimens A and C. In this way a better understanding of the environment will be achieved and better knowledge obtained for making a decision for the next structure. Sincerely yours, j
/
/
OL e - 4r e ? M. Schupack SCHUPACK AND ASSOCIATES P.S. Enclosed is a copy of a memo describing the field observations. cc: Mr. Al Wern Enc. MS:SSA:ce)
COPY January 26, 1967 B3b-4 TEST TO INDICATE EFFECTIVENESS OF l j VARIOUS CORROSION PREVENTATIVE MEASURES FOR STRESSTEEL BARS INSIDE OF 6" GALVANIZED PIPE. Ref: OurM O 66-213 Four Specimens will be prepared each using: One - length of 6" galvanized pipe approximately 20' long Two - 6" galvanized pipe caps Three - 1 3/8" STRESSTEEL bars approximately 20' long in the As-Stress-Relieve Condition. Three - STRESSTEEL bars approximately 20' long, wiped clean with solvent and rags. One - h" diameter X approximately 20' long cold-rolled bar with, bright finish. Three - Bar spacers The six STRESSTEEL bars will be spaced and bundled inside the 6" pipe. The h" diameter cold-rolled bar will be placed in the approximate center of the spaced bundle. The specimens will be prepared as further described below, and will be placed out of doors in our yard in a vertical position. At any periodic interval, the specimens may be taken indoors, uncapped, and examined.
" Specimen A" - Control No corrosica control treatment will be used. The ends of the pipe will be tightly capped.
" Specimen B" - VPI Slurry in pipe.
Same as " Specimen A", except that a slurry in a ratio of two pounds of VPI 250 crystals and one gallon of methyl alcohol, as recommended by Shell Oil Company, will be poured through the pipe when it is in an approximately horizontal position.
" Specimen C" - VPI Slurry Coated Rope Same as " Specimen A:, except that a %" diameter manila rope soaked in slurry described in " Specimen B" will be inserted through the center of the spaced 13/8" diameter bars and arranged so that it will hang from one end when in vertical position.
" Specimen D" - Nitrogen under pressure Same as " Specimen A", except tnat after assembly, air in pipe will be purged with nitrogen and a positive pressure of~5 to 10 i PSI will be maintained in pipe throughout test period.
l Walter H. Iarson i I
B 3b-5 Schapack sad Asseeietse l l l 3I510 TO: Bobinsen plaat (66-41) FROII: E Schupack i DATE: June 16, 1967 RN Field inspection of corrosion prevention measures of the lower tendon. Robinson Plant.
- 1. "8pecimen A" - Control The 1/2-inch control bar which was polished btight, showed absolutely no indication of rust. The six bar assembly which had three bars all clean, in the black condition, and three bars as it came from the furnace, indicated no progression of corrosion. The bars wiped clean indicated no evidence of corrosion.
- 2. " Specimen B" - VPI Slurry in pipe.
The control bar which was bright, still is bright and indicates no corrosion. The alcohol which was aimed with VPI was still present in the bottom of the sheath in a flat position. A coating of VPI sined with alcohol occured on the bottom bar of the B tendon. The bars which nave been wiped bright indicate no corrosion. There aw some rust marks on some of these bars, but it appears that these were not wiped clean completely initially since no rust is removed by rubbing your finger across these points. 3 "Specimes C" - VPI Slurry Coated Rope The 1/2-inch test bar was bright, no signs of corrosion.. Wiped bars did r.ot indicate any corrosion. . From end appearance of bars corrosion appears to be completely inhibited during l the storage period. The ends of bars where the bars are cut. are bright. i l
-1
._,,-.I
Home tot h Plant (66-441) June 16, 1967 33b-6 4 "Specimes D" - Ritrogen under pressure Se 1/2-inch test har was bright with no evidemoe of corrosion. Wiped bare indiented shoolutely no corrosion. h appearance of the bars which were left unwiped seem to indicate a greater amoest of eerrosion, though of no structural significance. One could wipe off rest on the unwiped bare quite easily. i Mis was general for N other specimens also but not to such ; a marked degree. h ends of these bars, where the eats are l exposed, did not indicate any corrosion. D e general appearance of the four models indicated that all schemes of protection were approximately equal. h sheath that did not have l any treatment and was just capped performed excellently. It would appear that a tightly sealed sheath of this nature, which does not permit the change of atsoephere, would oospletely inhibit corrosion. It was noted that where the WPI was used in the aheath a coating existed on the bare located at the loser portion of the aheath. This coating, which can be noen in the photographs, could possibly inhibit bonding. This, however, is not important for this particular structure. This should not occur, in actual use however, since the bars and sheath would be vertical. However, if the solution of VFI did find its way to the bottom of the sheath it any form a crust. This is probably of no significance since it is corrosive protective substance anyway.
.4$
M. Schupack M8:sel
- - d-- J B3c-1 January 11, 1968.
J A Scarola J J Gilnorc/ A H Wern V D Brown R H Cordon D M Pulito S Cunninghis/ W Wallace R B Richardson WESTINGHOUSE ELECTRIC CORPORATION CAROLINA POWER & LIGHT COMPANY H B ROBINSON SEP - UNIT 2 CONTAINMENT - PRESTRESSING STEEL TENDONS TENDON CORROSION PROBLD1 The writer attended a meeting at Stressteel Corporation offices, Wilkes-Barre, Pennsylvania, on January 9,1968 to (1) inspect sample tendon assemblies that had been on test since February 1967 and (2) review (with Stressteel Corp personnel and Shell Oil Co personnel who were present) possible reasons for tendon rusting observed at the plant site and at Stressteel Corporation's plant. Attendecs: For Ebasco: A W Peabody For Stressteel Corp: E Schechter W Larson M Suarez E Crinnion For Shell Oil Co: R Maurer C Seelbach Mr Campbell
- 1. Observations on Sample Tendon Assemblies-
- a. Assembly A (Control)
Consists of three as-stress-relieved 'l-3/8" tendons, three 1-3/8" tendons wiped after stress relieving, and one 1/2" bright' finish cold rolled steel rod all contained in 6" galvanized pipe, sealed. No corrosion control provisions.
i B3c -2 Concral rusting on all tendons and on 1/2" rod. Rusting on tendons appeared to be of about the same magnitude as observed on Tendons
#40 and #74 at the plant site except that a greater area of the tendon surfaces was affected,
- b. Assembly D (VPI Slurry)
Assembly same as (A) except that corrosion protection provided by passing a VPI - Methyl Alcohol slurry through the containment pipe at time of assembly to deposit VPI crystals. All tendons and 1/2" bright rod were in good condition with no significant rusting apparent. Protection judged excellent.
- c. Assembly C (VFI Rope)
Assembly same as (A) except that corrosion protection provided by including a length of Manila rope which had been soaked in a VPI - Methyl Alcohol slurry. Tendons and 1/2" rod were generally rusted. It was visually apparent, however, : hat the over-all degree of rusting uns not quite as severe as in Assembly A (Control) indicating that there was some degree of protection afforded by the VPI. Larger areas of the tendons appeared to be rusted than observed on Tendons #40 and #74 at the plant.
- d. Notes Relative to Sample Tendon Assemblics When assemblics were first opened (on January 4), moisture was found in Assemblies A and C in substantial quantity but none of significance in Assembly B.
I ^ In Assembly B (VPI Slurry), the red coloration of as-stress-relieved bars was readily apparent as compared to the black coloration of the wiped bars. This color difference could not be seen in Assemblies A and C.
- 2. Possible Reasons for Tendon Rusting at Plant
- a. ,Effect of Oil Mr Seelbach advised that if VPI crystals come in contact with l oil, the crystals may become encapsulated with a monomolecular film of l oil which could inhibit the evaporation of the VPI crystals as is necessary 1
i
B3c-3 for protection. He indicated that if the rope used contained oil, this might have been a contributing factor to the failure of the system used.
- b. Effcet of Moisture -
Mr Sec1 bach advised that any water that gets into the tendon containment pipes can absorb 3-1/27 of its weight in VPI crystals. The amodnt of VPI used should include enough to allow for such _ absorption in addition to the amount needed for protection af the steel,
- c. Ef fect of Presence of Methyl-Alcohol The fact that VPI - methyl alcohol soaked rope was not allowed to air dry prior to placing in tendon pipes was discussed. There was no posLtive statement that this would definitely inhibit tha action of the VPI.
- d. Effect of Presence of Galvanized Steel Mr Sec1 bach indicated that the presence of galvanizing on the internal surface of the 6" containment pipe should have no effect on the protective action of the VPI.
- 3. VPI Application Methods Mr Sec1 bach indicated that VPI should protect up to a maximum distance of three feet (onc foot is stated in Shc11 literature).
Mr Seelbach advised that he felt that the preferred method of applying the VPI to the tendons at the pl.cnt would be to spray dry crystals along the length of the 6" pipe interi*or and provide a reserve supply at the top. He suggested 3/4 pound of ' dry crystals flocked onto internal surfaces and 1/2 pound in a porous bag at the top. In a later contact (December 11) with Mr Sec1 bach, he was asked if spraying a VPI - Methyl Alcohol solution inside the pipe might not be a more workabic solution. He said he felt that in letting the alcohol dry out by ventilating the 6" pipe, an uncontrolled amount of the VPI would be carried away with the alcohol. He prefers dry application.
- 4. VPI #250 Contaminants
- Mr Scelbach was contacted December 11 to get information on bicarbonate and chloride content of VPI 250, since VPI analysis by Chem-Bac Labs of Charlotte indicated 6,597 'ppu of bicarbonate content
6 B 3c'-4 4 and 8,406 ppm of chloride content. Mr Sec1 bach says that the spec on VPI No. 250 permits the - j following in % by weight: Chlorides 0.05% (approx 500 ppm) Sulphates 0.1% (approx 1,000 ppm) Phosphates 0.2% (approx 2,000 ppm)
!!e saw no reason why bicarbonates should be present and said the chloride content sounded a "little high."
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roam saa nov e.st teAsco stavkzs inconeoaATro B 4'. - l FIELD TEST DATA SNEET H B ROBINSON SEP NO. 2, CAROLINA P6L CO o.s. No. 1 l ,,, ! CORROSION OF PRESTRESSING TENDON WORKING BARS AT oxyg 1-30-68 NECT REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C sy AWP The following field notes were taken during the period January 30 to February 1, 1968 during inspection of working bars in prestressing tendons to determine if they exhibit some pattern of corrosion as observed on telltale bars during inspection of January 3 to 5,1968. Inspection team: Mr Walter Larson, Stressteel Corporation Mr Morris Schupack, Schupack Associates Mr B R Mazo, Ebasco Services Inc Mr A H Wern, Ebasco Services Inc Mr A W Peabody, Ebasco Services Inc Borescope Inspection At Tendon 74 Telltale removed prior to inspection. Pulled rope. Heavily loaded with VPI crystals. Some dark gray-black streaks which appeared to be areas where rope bore against galvanized pipes. Some reddish streaks where rope apparently bore against tendons. One spot where rope had pinched between two tendons -- was flattened and red on each flat. Spreading rope strands and inspecting interior fibers with 3X glass showed small white crystals throughout rope. Resumed to be VPI. Lowered Borescope with inspection tip 6 feet below upper end of longest tendons. Tendon surfaces quite clean at this location; saw some small specs of rust. In the order of 1/5 to 1/10 of field diameter which is in the order of 0.3 to 0.5 inch depending on focus. Lowered Borescope tip to 12 feet below upper end of longest tendon. More rust in some areas with field mostly filled with rust but with black unrusted surface showing through between some rust specs. Some tendon surfaces at this level were quite clean. Lowered Borescope tip to 18 feet. Some tendon surfaces clean, but white crystals noted on the surface for the first time. On other tendons noted rust formation over partial viewing area surfaces. Noted white crystalt er the surface of the rust. Lowered Borescope tip to 24 feet. No area rusting observed. Surface of galvanized pipe interior noted to have a few white crystals. Inspected interior of #6 tendon with mirror and light. Corrosion streaks observed. Closest streak to top started 38 inches, from top of galvanized pipe and extended downward for 13-1/2 inches. , [ Noted streaks between bars Removed and saved ropes from Tendons 74 and 6. OQ O
ream saa new e.sr teAsco senveces INconeonATto B42-2
- FIELD TEST DATA SMEET
,,, H B ROBINSON SEP NO. 2, CAROLINA P&L CO o.s. No. 2 su JECT CORROSION OF PRESTRESSING TENDON WORKING BARS AT e47g 1-31-68 j
g REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C er AWP Tendon Containment Pipe #7 Found to have a considerable amount of condensed moisture inside pipe cap and on upper ends of tendons immediately af ter opening. Schupack estimated about 2 cubic inches. Mirror inspection shows rust streak as observed in #6. Some streak face center of pipe. Some on sides. Pulled rod bundle to one side of opipe to inspect side of rods toward pipe. Continuous rust streak, through area observed, on side of tendon toward pipe. Rust formation did not appear to be as heavy as in #6. This inspection on a cool cloudy morning following a warm (70) sunny day. Black marks on inside of galvanized pipe. On the #6, #7 platform, 3 loose pipe caps. No. 4 and 5 could be turned 180 by hand. No. 7 could be turned completely off by hand. Tendon #39 (Mazo & Schupack) Cap clean on inside. No moisture noted (this was opened yesterday). Rusting was in streak formation but not as heavy as in #6 6 #7. Random location of rust streaks starting below top of pipe as in others, i Tendon #40 (Mazo & Schupack) Cap clean on inside. No moisture noted (this was opened yesterday). Rusting was again in streak formation with random location. Rusting did not appear as heavy as in #39. Verified. I noted some circumferential dark marks on inside of pipe where tendons may have rubbed. At other locations, short vertical reddish-brown marks where rusted tendon may have lain against pipe. NOTE: At scaffolding at 39 and 40, found pipe caps at 38 and 41 hand loose (these were all that could be reached).
( rose esa nav o.st EeAsco sEnVICES INCORPORATE 3 B40-3 FIELD TEST DATA SHEET l Fon H B ROBINSON SEP NO. 2, CAROLINA P&L CO D.s. NO. 3 sueJEc7 CORROSION OF PRESTRESSING TENDON WORKING BARS AT ong 1-31-68 g REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C ,y AWP l i Test on telltale from Tendon 40 to determine sag when supported in horizontal position with supports near ends. O ' 2.- w 8 - 9
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0 3 6 9 12 15 le 21 24- 27 DIS TA NC E BETWEEN SUPPoR Ts - FEE T Tendon #73 (Mazo, Schupack, Peabody) Relatively light rusting. Same streak pattern as on others observed. Were able to observe rust streaks down to approx 20 feet below top of 6" pipe (limit of depth to which mirror could be lowered). Tendon #74 (Mazo, Schupack, Peabody) Relatively light rusting. Same streak pattern as observed on other tendons observed. On accessible side of galvanized pipe, noted circumferential oriented black marks on galvanizing which appeared to be from contact with tendons. Tendons #72 and #75 Pipe caps were tight in that they could not be moved by hand.
poem see nov e.e, EsAsco stavicts inconeonATao B4a-4 FIELD TEST DATA SMEET
,,, H B ROBINSON SEP NO. 2, CAROLINA P6L CD o.s, no, 4 MacT CORROSION OF PRESTRESSING TENDON WORKING BARS AT DATE 1-31 & 2-1-68 p REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C ,y AWP Notes on Additional Lab Tests That Should Be Made Try protecting coupons with rope samples from Tendon 74 (which has relatively light corrosion) and from Tendon 6 which had the heaviest corrosion noted on telitale bars inspected to date.
Get rope samples from Tendons 6 and 74 tested for oil content, presence of nitrites in powder from rope. Materials Lab
- 1) Compare crystals from rope with unused VPI crystals.
- 2) Complete parallel investigation of oil film formation on VPI crystals.
- 3) Meta 11ographic comparision of steel from #6 telltale with thac from #74.
February 1, 1968 (A H Wern & A W Peabody) Tendon #111 Inspected tendon bars with inspection mirror and light. No accumulation of moisture noted at top of rods. Pipe cap was tight. Inspected rods to a depth of approx 20 feet. Rods had characteristic rust. Streaks. Appeared to be predominantly between reds. Noted that interior surface of galvanized pipe appeared to be particularly bright at central portion of the bar bundle. Rope had plenty of VPI powder. l Issued instructions to John Fries to install corrosion indicator bar in Telltale #7 which has VPI in basket but has rope removed, l
rome sea es ,s.e, teasco sEnvicts inconPORAftO B43-5 l FIELD TEST DATA SHEET rom H B ROBINSON SEP NO. 2, CAROLINA DEL CO o.s. No. 5 l sueJECT CORROSION OF PRESTRESSING TENDON WORKING BARS AT ong 2-6-68 l ,, REACTOR CONTAINMENT BUILDING, HARTSVILLE, S C ,y LfP l Inspected bar used in Tendon 7 as corrosion indicator. Protection afforded by VPI in basket at top only. Rope had been removed. Bar size is 1-1/2" x .325" 43.5". Hole 1-1/2" + from one end suspended by bare iron wire from tendon bar top to point in central portion of bundle. One side: Quite clean with nothing more than tarnish. Other side: Streak of light rusting 0.45" wide centered along entire length of bar face. Sides of strip perfectly straight insofar as could be told by sighting along each side. This gives every indication of dissimilar metal corrosion attack between bright metal and rusted metal (tendon bar) . Condition would be set up by wire establishing electrical contact between tendon and sample and by bright mets 1 sample bar hanging so close to tendon bar that condensed moisture would form bridge between them. Each side of bar photographed in black and white by Morris Schupack and in color by Walter Larson. Bar was out of containment pipe from 8:30 AM to 3:30 PM, approx 7 hours. John Fries advises that VPI now in all tendons except the following 23 which could not be reached: Tendons No. 31 102 110 32 103 112 33 104 113 34 105 114 36 106 115 60 107 116 63 108 121 92 109 John has found 34 loose pipe caps out of 96 containment pipes checked. John noted that when pipe cap on Tendon 90 was removed, all six bars were all wet from condensation. Cap was handl loose. It was removed to inspect tendons when inside of basket showed moisture at the time VPI was being installed. y
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C~- la - 1' . , C H E M-B A C 4d=4tova, k 2500 WEST BLVD., CHARLOTTE, N. C. 28203 P. O. BOX 3114 (741) TEL 392-5388 January 8, 1968 LEFs N-111-1-A l Analysis of Water and other substances l EADE FORs IBASCO Services, Inc.
& & Robinson Power Plant Nepteville, South Cesgline Attention Mr. M. A. MoDurrie, Projoet super.
uRKsDs despLs 1 - Tendon "
#3413/8" Water 6.6 ph sangte 2 -
#134 2" water 6.8 pH dauple 3 - r97 6 3/4" Water 12.4 pH
., maple 4 - Rust Colored Corrosion Product 3 ample @ - VPI Impregnated Rope Jample 4 - VPI (3 hell e250) 90/, Dioyolchenyl Ammonium Nitrite 10% Diisopropyl Amenomium Nitrite
[emale -1 _2 3 4 - 5 6 S.7 6.7 12.4 --- --- --- cnductivity som 3390 1000 35000 --- --- --- cloium ppm 11$9 267 0 0 0 Ikalinity as c ppm) HydroxyL (Oh) aleitas T castemete o (5570 0 0 0 Ccrbonate-(CO3 ) 0 0 3107 0 0 0 Eiocrbon.ne (HCO3 ) 54 115 67 9312 12 2 6397 Chicridea ppni 1005 32,415 0 3112 840,6 Nitrites dhell #250 0 ppm 13.75 34.60 1.00 9.075 --- Pfun ppm dulphates ppm 0 0 1263 0 0 0 hust ettelmed meterial is iron oxide which had sentact with he VFI rope #fter its forma ion. A water ext.raos or the in 350 M1 or water had a pH or 7 9 ses the rust 10 1. s)es e su er 7.5. These are bot.h on the alkaline side as as soldity, c,,.recte/ p etuateos, Respectfully aut:aitt.ed, CA/ar//c c'* - to t, Sn~P cl 6, [A.,mdo i,#f dtaM .B.c r.
. CNEM-BAC LABORAT Es, INC. aetun//y It'e 4 PP'" p v
,fh)./%Af. Mr. Coc.fran *f C4es.-Bac. . n J. C. Ihabbell 2 -/N #-
supervising Chemist M4/. o - A. I. Feat od JASCO Jervice, Inc. 2 Rector St., New York, New York ;
. INDEPENDENT LABORATORIES
- CHEMISTS + B ACT E RIOLOGISTS + CONSULTANTS T ESTIN G + INSPECTION
- DEVELOPMENT +
QUALITY CONTROL
C -l a -2 C H E M.B A C 44444tova, k l i 2500 WEST BLVD., CHARLOTTE, N. C. 28203 , P. O. BOX 3114 TEL. 392-5388 Febreary 3D, 1968 EF: B-111-3-, Analysts of Cerrosian Predssts S FOR: E34300 Services, Ins. P. O. Dez 2006 Hartsville, s. C. 29550 Atta Mr. M. A. E;Daffie MIDS 8suple 1 Corrosien Produst Sagles reseLied at Chem >Bao Imborateries, Ins. en W EATvava Chlorides (as C1) Regative nitritos (as 302) 43 7 P P sultates(asso 920 pp Calsium(as ) 483 pp Irea oxides Balance Sample is essentially irem ezido or mast. Respeetfally submitted, Cusu-aAC unnaaeoazza, Inc. i
. C. Hubbell l Supervising Chemist f 1
W4 ., .. .. .ea,s., /
-l IN DE P E N D E N T LABOEATORIES
- CHEMISTS
- B ACT E RIO LOGISTS
- CONSULTANTS TESTING
- INSPECTION
- D EV ELOPM EN T
- Q U ALITY CONTROL
h Vert Dividen- New Jersey, Main Office Centrol P.nnsylvanie C.T.L. INC. CitTWit0 ft5flHG LADORATORl(5, INC. ASTR TECH INC. W Helperin Avenue Brena 41, N.Y. 155 U.S. Rede 130, tordensown, H.1 7801 Allensown Blvd. U. 5. 22 Herraburg, Pa. (N.e, Code 212) 824 1414 (Area Code 609) 290 3255 (Ar.e Code 717) 452 1750 ALLENTOWN TESTING LABORATORIES, INC. Division el Certified Testing Labora#ades, Inc. lpection .:. Testing . . Research
- Chemical Analysis . Industrial Rad. ology .. Soils .. X Ray .. Water . / Seeel, 754 East Fairview 5:reet Bethlehem, Pennsylvania Phone 215-865 2674 Certificate of Test and Analysis Dale 1/15/68
- Stressteel Corporation Lab. No. C-786 221 Conynsham Avesse Wilkes-Barre, Penna. h M M48 u mple of Corrosion Products, Water, Rope peived: 1/5/6a see w on ==.m e Breer ener,2/5/6a
%.d. i I mined wish the following results: I Corrosion Corrosion Water Water l Products "C" L Macte "A" can "C"- Can "A" h Nitrite-- - - - - -- 0.0046% 0.00 Bis $ 6.73 ppm 6.29 pga Trace sulfite----- nil nil -- Sulfate-~~- 0.0031% 0.0006% nil all 106 as Flu & ride- -- nil all - Iron i Farrous as Feo-- 1 254% 2.18% - - .! Farric as Fe2 0 3- 26.3% 22 5% -- - Nitrcte- - --- - --- - -- - 141.2 mg l Chloride----- -
- le60 ppm 26.4 pga 132 mg Calcium =-- - -- = 6 91 pga 0.48 pga --
sodium------- - - -- 0.84 pga 1.16 ppa - Hydroxide------- all 3.4 pga - sit--- -- - 6.48 8.70 - 189 5 217 5 - l specific (uahos/ca.) ce=*etance l l mrted 6: above (Mr. W. E. Earsen) Respectfully submitted, ALLENTOWN TESTING LABORATORY, INC. hM p No. A.115 C
.All Reports are the confidential property el clients, and inforenetien cereeined may not be pubbshed or reproduced, pending our wrieten approval.
REP @RT c-i-e-i?> Electrical Testing Laboratories. Inc. 2 EAST END AVENUE NEW YORK, N. Y.10021 Report No. 403566 Order No. 72441-C Date January 25,1%8 l ElialDERED TO EBASCO SERVICES, INCORPOLATED ANALYSIS AND ESTS OF FCUR MATEEAIS l Client's Authorisation: Intter, January 11,1%8 Material Eubmitted: 2 os. of liquid; 5 inch piece of repe; 2 os, of white powder and scrapings from inside of steel pipe. Results of Tests Liquid Identified by client.as, " Methyl Alcohol from Stressteel Cory." The liquid is pure synthetic methyl alcohol as indicated by infrared analysis and its specific gravity of 0.795. Rooe Identified by client as, " Rope from bottom of C'. Petroleum benzine extractable material such as oils and wamse is 3.5 per cent by weight of the sample as reiceived. A bro m powder which sifted from the rope was armained micro-scopically and was found to consist of opaque amorphous particles. This material would not sublimate at temperatures alightly abon mon temperature. White Powder Identified b ammonium nitrate)y ; 10%client as, (diisopropyl "VPI-250; 90% VFI-260 (dicyclohexy VPI-220 asmanium nitrate)". l i Micmscopical eramination reveals that the powder consista of I clear, water white crystals. The crystals sublimate easily at temperatures slightly above room temperature. l l
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C c -2 Report No. 403566 2. Results of Tests (cont'd) Scrapings from pipe Identified by client as, ' Scrapings from inside 6" galvanized steel pipe." Semi-cuantitative Spectingraphic Analysis Zine - - - - - - - - - - - - Major Iron - - - - - - - - - - - - Minor Magnesium - - - - - - - - - Minor Silicon - - - - - - - - - - 0.I-Minor Imad - - - - - - - - - - - - 0.I Chromium - - - - - - - - - - 0.I Aluminum - - - - - - - - - - 0.1 Manganese - - - - - - - - - 0.I Cadmium - - - - - - - - - - 0.I los Tin - - - - - - - - - - - - 0.0I Titanium - - - - - - - - - - 0.0I Note: Major = above 5% estimated. Minor = 1.5% estimated.
.I, .0I, .001, etc. - concentration of the elements estimated to the nearest decimal place - e.g. 01 =
.01.09% estimated.
Report Approved by: , , 3Ck_'LcwSw4 Aw - Q.A*Jer..}br, Chief Chanist Supervisor, Chemical Laboratory Copied by: ek Checked by:p 6 (- 4 i * *
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C c -3 ELECTRICAL TESTING LABORATORIES, INC. 2 EAST END AVENUE. NEW YOnK. N. Y. 9002 9 (2 9 2 8 SUTTEnFlELD S.2s00 l taevano . inerscrious . centerication stectnicat a enysicat . cwsuicat D IRITEt REPGtT NO. 403686 February 7,1968 Order No. 72441-C Ebasco Services, Incorporated Attention: Mr. R. B. Richardson 2 Rector Street New York, New York 10006 Dear Mr. Richardsons As you requested in your letter dated February 2,1968, we have de-ttrained the amount of oil and waxes in two samples of rope submitted by you. Results of Test Oil and waxes, per cent by weight of sample as recevied Rample from Tendon No. 6 14.6 Sample from Tendon No. 74 11.1 Samples were extracted with petroleun benzine. Ve.y truly yours, G2 M V ' R. H. Tamr*i , Supervisor, Chemical Iaboratory at M*fl.in.*?"??*JJ."".".N'.'0"Ist/Nio",'."'. ! 0 Je'7"c*',".'EL"cI'% i,*.'.h"'u"c",'I "."'.NI.".'ll'!J.**!JN."!Jl U',%
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C- 1 -d -1 cah Amos. *wn ILA" NEW YOaK Lab. No. H-30,685 NEW YORK TESTING LABORATORIES, INC. EllVIR0leeftflTAL NIC. le0ft DESTRUCTIVE. MATERIALS AllD CHEMICAL TESTile8 tl Ust AM A78NUS, WIttsutT, t. I.. N.T.11598 . Sie80s.w..d 4 7779 I February 6,1968 l REPORT OF TES'IVB . Lab. No. & Client - H-30,685 - Ebasco Services, Inc. Material - One Sample of White Powder Qient's Order No. - N.Y.179236 Mentification Submitted for - Chloride Content Chloride, per cent - 0.0093 Respectfully submitted, YORK TESTING LABORATORIES, INC.
. voy To: ging Director Ebasco Services, Inc.
2 Bactor Street New York 6, N.Y. Att Mr. R. B. Richardson EA Report on sample by client apphes caly to sample. Report on samples by us applies only to lot sampled. Iarormatica contained herein is not to be used for reproduction except by special permission. Samples retained for thir+y days maximum after date of report unless specMcally requested otherwise by client. ; The liability of the New York Testing Laboratories. Inc. with respect to the services caarsed for herein. shall in no event exceed the amount of the invoice. ream see a.s M
w cahie Add,es 'wmRA" NEW YORK Imb, No. H-30,'ua-a 722 NEW YORK TESTING LABORATORIES, INC. ENVIRONMENTAL. ELECTRONIC MON DESTRUCTIVE. MATERIALS AND CHEMICAL TESTINC 01 Ut4 AM AVENUI WllisutV. t. l., N.Y.11598 . Sl4 EDeew.e4 4 7779 abrum s,1968 REPORT OF TESTS Imb. No. & Client - H-30,722 - Ebasco Services, Inc. Material - Sample of Rope and Sample of idhite Powder Client's Order No. - Letter 2/8/68 l Identification - Submitted for - Tests as indicated below R0PE SAMPLE 011 Content, per cent by weight 0.65 pH (1% water extract) 6.8 Chloride, parts per million 135 MIITE P0dDER Zinc as Zinc 0xide, per cent 93.5 Nitrites, parts per million 215.0 Respectfully submitted, NEW YORK TESTING LABORATORIES, INC.
)
J. Harvey
.anaging Director 1.
Ebasco Services, Inc. 2 Rector Street New York, N. Y. 10006 . Atta Mr. A. W. Peabody l Supervising Corrosion Engineer cwk Report on sample by client applies only to sample. Report on samples by us apphes caly,to lot ===gdad Information contained herein is not to be used for reproduction special perminanan Samples retained for thirty days maximism after date of report unless s y requested otherwise The liability of the New York Testing Laboratories, Inc. with respect to services charged for borese, is no event exceed the amount of the invoice. roase ese oss o.or
6, C a - 1 PITTSBURGH TESTING LABORATORY COPY l January 10, 1968 Stresateel Corporation PG-18813 221 Conyngh=M Avenue Lab. No. 670209 Wilkes Barre, Pennsylvania 18703 Attention: Mr. Walter Larson Rsforence: Ebasco Services Incorporated letter of 1/5/68. Project: Carolina Power & Light Company H B Robinson Steam diectric Plant 1970 - 700 000 KW Extension - Unit No. 2 Testing G entlemen We are enclosing stress strain curves to cover the following: Bar #74 - 5' Lons Bar #6 - 5' Long PITTSBURGH TESTING IABORATORY Earl Gallaghe Manager Physical Test ng Department n .
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C -2 b - 1 STRESSTEMI. CORPOR.A.TIO35Er 221 Conyngham Avenue Wilkes-Borre, Pennsylvanio 18702 i 717 824-3506 January 18, 1968 Mr. Al Wern Ebasco Services, Inc. c/o Central File, Room 200 Two Rector Street New York, New York Re: Our WO 66-213 H. B. Robinson Steam Elec. Plant Robinson, South Carolina
Dear A1:
I am transmitting herewith three copies of Allentown Testing Laboratories' report on the Chemical Analysis which were performed recently. Also for the record I am listing below the Chemical Analysis for tell-tale bars #6,and #74 as received by telephone from PTL. C 2 Mn. Cr.
#6 .70 1.14 .88
#74 .77 1.13 1.17 Very trul' ,
l< Walter E rson Vice-Presi ent WHL/rs Encl.
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C-4 41 - Schupack and Associst 2 1 MEMO TO: Al Wern - Ebasco Services, Inc. FROM: E. Marlowe DATE: January lo, 1968 REF: Robinson Plant (66-441) The following information was gathered in order to evaluate the possibility of the presence of chemicals in manila rope which might cause corrosion of steel:
- 1. Manila rope is obtained from the abaca, a wild banana plant, grown in the Phillipines. Various oils and waxes are applied to the fibers in the manufacture.
- 2. A special waterproofed rope is also manufactured. It is not likely this was used inadvertently since it is specially marked and more expensive.
3 Mr. Schupack spoke to Mr. Rockwood of American Manufacturing Co., Brooklyn, New York, Telephone (212) 389 4000. They are the manu-facturers of the particular manila rope used for the Robinson tendons. < (a) In Military Spec TR 605, Type M stands for Manila, and Class 1 stands for high grade rope. (b) Mineral oils and waxes are added. (c) Rope contains 5% to 10% moisture. (d) Salt water is not used in the manufacture. (e) The fibers come from the Phillipines. They are not soaked at all. (f) The composition of manila hemp, the fiber from which manila rope in made, according to "The Textile Fibers" by J. Merrit Matthews, John.Wiley 1924, is as follows: , l
Menos C 2 ash 1.02% water 11.85 aquius extract 0 97 fat and wax 0.63 cellulose 64.72 encrusting and pectin 21.83 a (g) Durin6 the manufacture, mineral oils and waxes are melted together in a tank and applied hot to the fibers. About 80% ] mineral oil and 20% wax is used. This mixture forms 10% to 15% of the finished product. 1 (h) The mineral oil is a petroleum derivitive consisting of hydrocarbons of the paraffinic or naphthenic type. It is called cordage oil. i' (i) The waxes are paraffin or micro-crystalline waxes as pur-chased from Socony, for example. j (j) There is nothing else added to the rope. No salts are used. ) (k) Mr. Rockwood is not aware of any instances of corrosion due to acids in manila rope. They make sisal and poly-propylene cores for the wire rope industry. A corrosion inhibitar, such as Alkatary T, made by Commercial Solvents Company, may be used when specified by the purchaser. (1) He recommended drying the rope in an oven prior to use in order to get maximum saturation,' and eliminate water source,.
-o (m) He also suggected the use of polypropylene or nylon rope.
He judged that this would bold 20% of liquid in the spaces between the fibers. a
C 3 Menos 4. From the McGraw-Hill Encyclopedia of Science and Technology, pg 627,
...... " deterioration from rubbing can be retarded by such lubricants as acid-free paraffin or graphite worked into the strands during laying or twisting to form the rope."
5 A photostat is er.elosed from Thorpe's Dictionary of Applied Chemistry by Jocelyn Field Thorpe and M. A. Whitely, Fourth Edition, Volume V, l 1941, Longmans, Green aid Company, London, New York and Toronto. l Four sentences are marked in the left margin. The latter three Indicate the possibility of some mild acid in the fibers.
- 6. I spoke to a Mr. Coon of Columbian Rope Company, Auburn, New York, Telephone (315) 253-3221. He is a chsmist from their laboratory.
Mr. Coon presented the following: (a) The Ph of manila rope is slightly acid. (b) The rope contains 13 - 15% of an oily mixture of which 75% is light mineral oil and the rest is natural wax. (c) It contains some soaps which are not soluble in water.' (d) There is nothing in manila rope that will cause corrosion. There is nothing present of an ionic nature. (e) The mineral oil used in the manufacture of manila rope is a petroleum derivitive consisting of saturated hydrocarbons, which may be paraffinic or nephthenic. It is a light mineral oil which looks like automobile motor lubricating oil, 10W or lighter. It looks like machine oil. It is commonly used in rubber processing, and goes by the common nemes of " cordage oil" and " rubber processing oil".
C-4-4 Memot 5 1 7 I spoke to Mr. Kirkpatrick of Plymouth Cordage Products, Plymouth, j Mass. Telephone (617) 746-4300. (This is actually a division of I Columbian Rope.) Mr. Kirkpatrick is the Plant Mannger. They do not have a chemist or technical man. ) He stated that there is nothing in rope that can cause corrosion. Any acids would be intolerable since they would attack the fibers of the rope itself, and destroy its usefulness very quickly. i b The rope and lubricants used for wire rope centers are somewhat different from those used for commercial rope, however, neither the lubricants nor the fibers of commercial rope contain acids. I He felt that the manufacturing proceeses used at his plant, and
- by his competitors were standardized so t hat unusual occurrences resulting in the introduction of corrosive agents into a particular batch would not occur.
l SCHUPACK AND ASSOCIATES
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j E. Marlowe S&A:EM:pdg i
f ** 84 FEBRER. TECETABLE. IIIl!FA W N IX e ehedaur nn eupnaure ta manhght. If idesch- JrT NreartTrtron.-A number of plant f a sr@ea.-Tlw knila twmp .4 eummer e l t 4nt 4 a* * *lt.% ate I t. a b r este+t in St . ng is newanary it in efectal either he erwisma partrularly thnac hebegma ta Fa a. bisewe ,n.mpact .4 atramte up to I*. ft. in length arme l tick-na amt the Argemtur stel ran hr groen
"**r"'- f.a.
"" l* I'"8 ny hbmte, or be permanas.nate f.dlount by and Tabere. seht hast riheca neradar to jute s.n ing 6n near fn.ru pale sera. to brou n. tihre ,m aw-t temiata'e se sulphite, or by Imth prareamen neceem. ami espahle .4 hems apun as a mulatstute (w et the I mtal kmeben.
ThJ arramla are .4 eswe or Ira einuhr en- raltn*,.m end Med.aaM.=4 +4 Or Me The ennre imp >riant c6 .ntan arat are neml==ast .4 edtimate niace fram avely Careful centrolis e eery nearepeible neceamary to artack dunng hieneiung. amthewthe 6hre 6hren arelor in a.lanntere Amhan an.1 Wna Jute. aseh it. 2 to If mm. in 1.t jth aiwi l*i-1*,s in m <h ofgn.u a. man ne n ahtannal fn.n* * *ki 3%**""'" h sk reate 6bres of jute re. ige fenen shaat i Simhpatam Jute (Ambari. Mesta or nw m ** mpa- t al'i' a' **' i" pla"'a**- p The uusmate 6hn* are atrassht amt ars#. hase s hu h gnes a neaalera% bdu, 3W and 173 to 4 mm. in length and from in t sup in ; Deccan Memoi. a 6hre chiaely resemhhng true ,eU.tchew I lumens ami su apl=*ra , . l.=fy fanhe nta meet e beagana the . 43r4>== el time enintth. Dett lumenn show amaiderable vana. jute in character. obtainnt frnas the stems esf n,emhic th. e nt tame I fnem ansat leas es, se lesnar ennaaragnL Hoenn h en th Jan in .hanneter arar nwrenganding ductuarmea 4/,4. arse tenne 4 ama, a plant euttivatal in parts ) lamia notama alas.t Ir*. 4 hanen awl 74-weur in the tlucknees off he evil e n!! In ers=a- of Intsa. The hhee in separatal by rettme in a n*, of wUukmc on the amnture-free material; brentmg .4 impmsnt atrama he in Ie.gn=* iretiosi tae mitaniate 6bre e a pJ 3 cm-uanally manner enaratially the name na that emphnnt analytirti figuren vary, kneever. mith the grade (Maanry Cdieve. Nem Zealamit eith 5 or a sidea. An analyam by lehne amt for jute. The prialect in rather enarart than The 14ant emaiata af gre*p= *f leesea arranen
.4 the 6bre. The ash wntent affon!* a nacful in the turm e.f " fana almngmg dicedly fn.en Mepmann (Z. angew.Oem 192.L N.931 given. true jute let can hr uant for practVally su the indacatam of tM grath. of the Gle, the figure rh zonw . Cutting .4 the tras en 6 rat e== urs
*er an everage sample of clesa jute, moenture amene purpunca. 4 ether venetica of Hihe.rua. heu.a a more or nr a pnwremaire sm,came unch At than age the 1142*.'. ash 4k73* neguemas entract 3 IL4*a. e.g. /I. as44arige (ltoselle 6hrel. fl. caral**fas. the inferistity of the grade of the Ehre (Butt u hen the at in bH ycars .41.
~a ta, w:nen, etc. I44% wilulose459113* henm amt II. laaernful.na, also yickt maeful 6 teres gimp. Inat. 1922,20, lot 1 Ica'e4
- sh an. Ic.ad niatis4 tlan ami le 83*4 a.nd farkrandehyde yiebl 18 -39*&. t,ut are of minor importance nemmerciaDr. Battle avatemetse en can b ham l=vn abnw .. nnerni cith a hani eutwir are sheet les ft.
(?. C. LeMiuan amt 31. Il lien (J. Test. Innt. China Jute. A6atdem Aricaaw, the Indian Unila twmp. Inantser amt it.a rm h (llu!L length. The leaf fans are o ut off a few am he. in 1939. N. T73) give 6gures rangma from ole to malk>w. is euttivatal in thina and the Abre ca. a,,,,, gen. **lansen. 1933, 26. N hase in.m the spend. Iraimg & sentral M. A F55*4 for the natural was centent ni jute. A partal onder the name nf M%na jute /* fresh en.p e4 leasea sa not reawly for harvesting rensnini determinatirma e4 wrtain 4 the erwa of samples neprearnting dderent quality Fibre from plants of the NiJe app. mal of the merhankal geopertwo of the Abre. The saria. for am.ther 3 or 4 ) cars. Tlw abarader anil ates anatyard he A. G. Norman (Biorhen i t'rene app. (caperiauy Cerag idarte) in al.a. h.htv of the tenmale attength of the Eles, escu atru.tuw of the h ases maken ethnent acparatum 1934. W. tGI), lerniahnt the follasing resulta espahle of being mant an a jute aulatitute- a beit of the same origin an the pewla etnam, ba. .4 the til re m an ummpaired n.ruhtput difh.stt dry Abre): celluinae ti9 4-734ra lignin the+ he estraction of 6hre from Npartismejsecease 1,nn pointni est hv M. Tinen (phdigme J. to aninnpip h. Stripping mae hmra are em. 13-984, total furfurablebyde so-II 2*&. sylan (Spanish immm. " Genesta ") has rewin nt set 8932. 48. 2431/ hmla hemp in naturally playal, tait th ne at pre. cat asadable are not a veGuinee 149-12 8% T e better grade sitention in recent yeare in Italy. The 6hre ahrhtly arid and the relathm ta t seen the amamlere.t ta le entuely matadadary. ,After pad-mapirotended to have a higher reuukwe rcatent, may te used for tIse manufacture of rapra. m.phis .4 the hine and see tennele attength has aanpping amt vanhan the libre in not the daderence in compnastion of the samples annia.yarna amt enarac fahrica. In the cottonesed Inn imcatigatal hv P. t_ and ll. E. bherman .ba ked." is. pren.1 una in dr3 mg fielda f.* il%hypne J. Nri. I92a. 37, 21L ulus fourut a a.4eral days ta dry an l. ta mune estent, t.. een not very snarked amt was pmbably partly state the nbre may le enpb>3ed in the maru-iecountnl for by diferenrea in the cleanlinema facture of finer fahrk,. Fibre uma entracted de.renae in tenade attength eith an im renae in bleach. Finally, the tihre in wrut.hnt, blnl 4 the Abre, fmm the comman nettir in Germany denng the armht v. The arshtv of Wmla may h ad to arkt gra. Int men eee.4eight Government gradca. Jute 6a a highly ligni6cd 6bre armt uns enn. war of 1914-114: and more rewntly emperiment* meern'al nen-wm m'lwn it in unnt for the 6hre Wibt 1%rmium gitem a thre 3 m-bl ensuuntma to 6teral by Crona and Desen to he nempnaed of have been made with hap 6hre. of unre ropea. Met tuals of estimatme the in-14*a .4 the mecht of the lenwa.
;, " _' - compound cellulone. Subac. a.shty e4 the 6bre are gisen bv J. E. p. ) lay ne. iharner *a.-l%rmium tibre ummista.4 bag . lisant work, particularly Lray investigations, gay yggm Nfeti in Mmes Itenran b li.ia'nt. Pager Na. 97 atrando ehm b may he ela.ut tu ft. in length an.4
_ naa.bowever. mi to the mod:Seatinn of the riesa and 'IMs.l. Nguesfication No. 32*a. 1934, m rathve resembic Masula hesnp in a ppauranse tet sa a ames pioneer wedera, amt their theory of Manila Hemp (Abaca).-Vanilahempia the shsh it in apnsf.e t that the a ishty .4 mmla baseser.=.fter amt weaker. W astrage begth bemical union hetween the cellukne and the pn=luct of .lf ase terfilia, a memher of the hanana hemp Intemini for 6Lre a res ab.ubi le am b .4 tle altamate hbres ia alamt s mm the sumi, ignh in no kmger accepted, l.ignin in nas family leerma innhide frmt. INewlurtem e4 the that not nuere than 24 mL +4 X lu KOH in mum length 2 mm. and the maumana 11 enm. smandernt to le present an an anwerphana, in- She is an alennet enmplete manopoly of the n3mred for the neutrahasti m .4 in g. e4 fil.re (Wa.-The pnnopel use 41%rmmm in for rumams matenal A serica of pagern denhng phihppine falarula. A sman quantity of Emla when teste.t hv the 15.N 8. mettual. J. E. 4 8 the manufa tun. ed tuirwa amt netage It sa with the thermistry of jute ligmn has been sa now twing enported from Numatra and from h ,w (f.rd llna vientihnt the as ide s hirfly partwidarly aseitable E r s=srlaan eternarwlmg a sublished by P. IL Narbar IJ. Indian Chem. Bnti.h North Borneo. ndam=etJe for the nevhty of Lmla a sett w .adter hhre than mal ee mamla. Oairac fahru, 4pe. 1931-35). Narkar han foural jute hgnin Celtirefica sad Esfreetian.-The plant re- amt f..nnie meata, preent in the quant h * +4 may alaa le manufa.turnt from the file. The n warmble lignina from other anarres arpt quires a gooil soil, trapical temperature arut a sen47*. 0.rmic arvi an.1 e& l47*asettw a. ht, for hela agt wati l ma as a aturhng maternal for
' be puta forwant the view that its neatitu. set ehmate. & fibre accura in the hmad leaf IVa.--The m.ain u.e of % nil.a twmp ia fue ' . .r.st we am a imwhng matermt La errtain . : inn in that of a fuHy saturated enenpnund with stalks ubb gmw urapped rnand the atender the nianufa.ture .4 shigi rules arul c=145. an plaatera. %
e saolenstar neight of M3n enntaining in the watral stem in overlapping layera to form a emp.etant tirbt in ub h at tw414 an unrisallnt h uitalshty of I'h.eniium kr marnie molecule 5 methosyl gmura in ether hnkaze. 3 thieu parato stem. up ta en ft. in height when g= =4t um. The fit re in al a want for the mann. nelage La lawn insntig=tnl by tlw Imle-rial hydroxyl groups aral one methy icned ony fully grown. Lture planta canai-t of cluml* 84.ture ..f amah mia. neta.14mler tu nw. etc Institute amt tlw Admiruits litull. Imti. In.d.
. granp. of 20 ce more e4 the*e upnght trunks in ddierent kit a in b.ains gnend in thrae marketa in famer lect. 29. t : Ita2. 30. I19: ItG3. 31. .'is89
(%3dhurv and Saha liO4. lfon,7.347L have stagea nt development. The trunks are e.at sa 4 abat h vow hnda a limited appheatom in The dura Nhty e4 t he tile to rmeme nrpi tu en-
*samiinal IInc hemkellubme fmm jute. They they mature, an area teing cut over at inters al= mph.4aterv. Waate filee ami eat relea are can unsre gmant mated.edigy. hut alw initentatrength andated their material hv estra <-ting.uith 174*. of alwnst 4 rnonths. De trat 6hre is obtaineet phnng s'.r the saanufacture ed a beg fibrist e41% mmm sarna awl rop = una hable t.* la-untium hpiroside salution, jute uhkb had juat before flauering when the trunk ia 2 c.r 3 palkr pulp fnna w hb b in madr the esnw.lingtv t... los to n'img4v sith t3osetanwnt ale afi.
previoualy hren extracted uith chloroform to yeare nld. ner Lmla paler umst for senwns ancka. entkm . Further 'mork Iy the Adnuralty .ca remon resina, delignaned with CIO. amt aunea. Formerly. the ernp uan entirely in the barkla envelogen, etc. tarent l%emium enlea mamifnetansi anschug eively extracted with henmene, alevient and had. of amau-hablera and the cultisass.n af the plant &4myrepAy. ? Tn hema gie der Testil. ta=4t hive agn slicati.ma gn.e gewusaing n-ulta. mg sater. The 3i cbl anwmntest ta ne. af una cerrard on smiler tru.htinaal and un=esentifir 8m h nela*. ulu,i rnade In.m a amtable rende ef i material shich sage en-la.nf furfural en lashns linea. An increasing anwant of nhre is, iv.u~ fa.ernJ' ,\ . is,Iterhn.1927: lt. to. II rsogL llanf uml tiartfa,ern (nhtnl by11. T. Elecrda 1.twernuum. ucie ncesion*t ta le =* aatiafa. tors sik I2=; hcl. When jute.hemicellui.iae maa n. ming from mientitien!!y.run plantatiana an the ated .4 33. We,v, Alm,a Immla llemph e a asmaar umlage snade inme Itahan twmp, bydn.ly=*l with 2 3*. H,80,. galad.a.r. Ilmeno regi e. The 61ee b f..r tiw nuat Pa* Farmera* Bull. Nei. 12. Enda. 191.* : E. Insei.tigathm of alw i=la t-m=Lnic l'"latti" hvuhae. a rakma.c. s3 b a.c. arul asenme menia atin nheauwel1.v ardurma herpt.= taping meth<ml* G.ekhng. " Cot ton a r=1 Ot her Vegetal 4e of t%rnuum lit. IL Shau. It 18. ftw kmg a*l mere irbititet mm. mat the hydn4y=ia gealm ta. nr by nwana of aimgde enachince. Det .m a fen Fd m i'tesulon,1939 31. J. a e'Irarv. Itur. 5tamt. J. Itea. 1101,6.4386 ffM yrep&y- E. N.mnenma. her. " u sw Jutel' large catasca, de.orteenting machine auch a* a'" Phormiurn Tenax (New Zealand ah..m a t hat nie ta ta r% .4 a esa l et**al*f.s l 1.".l ' *,an Iterlan. leon M. G. Itirker. J. Itay. Nee. Arts, uant for an=al are teing emg46 cel. The ywbt "f a Hemp."-l%rmian te au. Neu Zeakml le .J taim I (nmi tIw hbre. Alkaline n Ling l'ON M. 4?.7. and J. Test. In t. ITPI 30,273; fibre an.ounts en ll.*j*. e4 the weight e4 the ~ hempf Neu z,al g an; is a nwnder..f .4 s tw b a s ca rise a 3 ri 11 al im!p an".unt.
,it. N. Fmb.u. 444. ItG9,30,3.3; H. I., l'araons, fresh atalks. The Enal pro.hu t is graded ancrd--~~ ihe IA ,,e. indiger ua u. New 7saknd. m hk h ing to alamt i4*. 4 tlw me-u:ht a4 8Iw terah ()
4.V tm N. 381. -is tlw unh immortant unalucine omntry, h leases shk h netsin apgm.simately Tua ,, .4
~~
Ing to_pflicial starmlante , eda e Ut
C-Si 507 331'- ) l
~
SHELL OIL COMPANY l 700 WHITE PLAINS ROAD SCAR $ DALE. NEW YORK 10583 February 5, 1968 l l Mr. E. V. Crinnion l Stressteel Corporation 221 Conyngham Avenue Wilkes-Barre, Pennsylvania 18702
Dear Mr. Crinnion:
Our Sevaren Iaboratory has completed tests on the sample of VPI 250 which you forwarded and on the sample of VPI 250 treated rope which you gave me during my January 9th visit. Thecrystalshadachlorinecontentof0.01%vwhichiswell within our specification limits of 0.05% v max. The rope was tested by hanging it 2 inches away from a fres'hly polished steel panel in a closed container maintained at 100% humidity and 100*F. A duplicate control test was run *tthout the rope and this panel was rusted within 48 hours. The panel with the VPI 250 treated rope was free from rust after 3 weeks exposure. I hope this infonnation vill be of assistance in your work. Very truly yours, C. L. Seelbach Products Application Department Eastern Region cc - A. W. Peabody Ebasco Services Inc. 2 Rector Street New York, New York 10006
C6al y i l l i l 5 t Cross-Section of Telltale From Tendon 6 Showing Depth of Pitting Magnification Approximately 13x
C 1 APPENDIX C-7 SUBLIMATION TESTS OF "VPI" 250 Several time dependent experiments were implemented in this investigation. In the first experiment two dishes were weighed. To the first dish (IA) was added an amount of VPI crystals and then the entire unit was weighed and the amount of VPI calculated. To the second dish (IB) VPI crystals and oil were added and the unit weighed. The amount of VPI and the amount of oil was calculated. The excess oil was drained off and the unit reweighed. These dishes were open to the atmosphere. After 15 days the dish containing only VPI lost .003 gram more than the dish containing oil. The total weight loss in the dish containing only VPI was .0292 gram. . Weight measurements were made every two days and the respective weight losses calculated. Two other dishes (IC and ID) were prepared in the same manner as the original two, and weight measurements were taken. One dish contained - VPI crystals and methyl alcohol and the other contained VPI crystals, methyl alcohol and Coray 40 oil (cordage oil). These were also weighed every two days and weight losses calculated. The weight loss in the dish containing 4 VPI and alcohol was essentially the same as for the dish containing VPI, alcohol and oil. A further experiment conducted consisted of three dishes. Two con-tained VPI, the third rnethyl alcohol. In each case the entire units were . _ weighed and the weight of the respective contents of each dish was calculated. One dish (2H) containing VPI and the dish (2J) containing methyl alcohd were - both put under the same bell jar. The third dish (2G) containing VPI was placed under a separate bell jar. Weights of each dish were taken every . two days, and their re'spective weight losses calculated. The dish containing VPI in an alcohol r.tmosphere lost. 0170 gram which was '.004 gram more than the amount of VPI that evaporated from the other dish. r
l C-7-2 l 7 LABORATORY DATA SUBLIMATION TEST OF "VPI" 250
\
i l
C 3 O d h 6 S .3'? 9'. A 9 f5.5 Y /D/t7)9 Sce1
- cm.~s ~,.m
/WM 5 }6-t$ T hNYS LOU 6ttr Dt$ E h ?. hlD-Absw 3/. + pa. ?-///41 1 M)
Disd+- VPE 32./623 p - 2/1/li% s '.- l!Pr C.76is y . 2lI/ft? 3 L . \ C 73cy.c o-/f/69 0.alloya - n . is22.m ip/'s o.o ic oy-3 2,14 86p. 1/1[63 0,0l?7p 3 2. ,I flo p L/11/61 0. o 17 % 3 1 .t 3 9/ , _ 2ht/6e e 02.9 2y.. 3L, I31 l p 1//f/68 0, o 29Lp D5H .9 i . [p - -llj'd8 .2 (s) Dis #fUfZ~ 34 G1%% ;2)//61-
, * , Yl'Z 3 %C'l29w. J{}f68 Disd H'fZtc ot 3g, ttssp. 1lt/gg
.'. o i t.- t,2 86f p 2l//68 DisHt!fz tCIL hk 0 E. I173p 0 f lllb$
- l. 0,1. Dzsiwb o.808'o y . 2lllff SC /u'tp 1/r/si o.oot9 y 3s il 2 Iy . 2/7/t1 0. 6tr2+~
35 / G oeW. 2/7/G5 O. 4 73; p 3rIK42- p 2/'ttl& t 0, d 2J/p 3 5. 1 5 *2 0 y 2)ff(,6 D.OEs3 p 3Ctryly 3//S/gf d. 62 4 2-p i , i
C 4
? ACE 2_
W'S# e (fRom cPic.14nQ
/ TE*/r/ SOTC LUEIG t4T DiPP. EXf 80-hS}{ bb a blE'f*N- fSf6$ hc.)
usa u.r s.so9 ,~. yr/a
** = b' *D Os ( 7 83 y,a. k[lf$
6i f // t-Fl7 t ALCCffvt 37.O33t p 3[f[// ts A LC o ffc L- 8, flo 'f 3 p %f.Qd 3 C , n 37 p tl,/tr 6. /19 7cyuv.
]&. 927f9 >-w 'z.j'?l61 0.2Ab&.a 34, s' stocy. 2. t// 2_/fg C.109fys
.%, C2 3ep zjjf,lgg 0,'2.t0 a J g. & 2.2 '? W .
~2_9.I3 2[//4(
f d, 2. / 0fopq ,
- u. =ges)%
znu .- qsta im
- m. m u,,.,,
h/SWt l'/'I T ' '!1p, 3/ 5f6 *l
. '. wr ! +1 M n vi,,a pdwe uan r n. isrw us/n
.'. moua e. 2.m n ys/a w a vanwnoa 3c. o s+rw >/@s
;. c , u t.17tt sic /ss 2'/, 12.7 G p %[7[63 /,//4 y y 2 1 ft z e <j a > {'ll(o3 6,2.225 p 2't . SW7/<} a >/12/(4 0, L2a f g 1.'t,f03oe g >//t/(,5 4, 2_ 3 < r 73.y 2.7 , f o 3 o y 2/If/s6 4, 2.3/fp
C.7 5 l Pneers
. . y au.ww) ,/TEnf /JG'cor Do.rc aciki-z>n Ex'/', Wo ,
Z>/NH C4. 571sp 2h/6t 2 (+) DNHfL'/'Z- 57,93st w 2/9/tt wn
, ' , VPz /, /2 3FW 2/t/59 "l?b?'
- 79. + 3com 2ln/G% d.66T! p .
s7, + 174p 6I O,o012 p 3 7. +2 x 2- W 2//flhE 2/Jf 0,o)S4p 25.cs/ 57, id+7p 2/?/69 2. (H) D'sH +p'f7 38.2,. 2) p 7ltl67 anose
/,//21% seu.Jwe
, ' , rPr 2/t/gg w,'ra ('2. r3 57,172 e m 7//2-/43 p, tor / y 3E.2.420 m 2//f/0 6. 6/t/ p .
5P.2 doom 1//'5f61 G,b/76 y p).sg. S7, 5s csp 2/7/67 2. g) 7>ic#w a.oa 77 39rt 3m )/9j'4,g- Q[&
,',ntconci }/7,7f2 W 2/1/61 "O(-$
6 / , f3' % m 2/11/l8 tr 8%p [7 53grp 2//f/Ct /q,7 fifp S? C3Vyu.o z//r/68 /7,7Rf p , l t n
l C-82-1 Peas sad psy e.s? EsASCO SERVICES INCORPORATE 3 FIELD TEST DATA SNEET
, H B Robinson S R P No. 2, Carolina Power & Light Company D.S. NO. I Accellerated Corrosion Tests Associated with Prestressing DATE Jan - Feb, 1968 susJECT
- Tendon Corrosion Investigation, Reactor Containment Bldg. , A W P. R B R Laboratory Set-ups Used for Accellerated corrosion Tests 1 Blocks to permit water circulation under the ed e of container Top sealed 6" galvanized Tin can. 5" dia. with plastic- s teel pipe 8" long. by 6-1/2" high. Open bottom in water. Closed top. Open bottom in sater. Test specimens sus- . ner l , Shallow water pans. e i
'd LJ Water 10' F above ambient temperature.
(____- _ __ __
,_-__g -
x=__. _--__.- = , Light bulb as source [ of gentle heat
//////////////. /// / / /// // / / 7, Pipe cap ,
1 SPecimen 1-1/2" i plastic g I J. q [ NOTE: Specimens inside the test containers are pro-window % lpl s l 3 6" galv pipe tected by various means of U gj I # 8" long VPI application as described in the following data sheets c vering test series 1 to 24. Oxegenated
' water in Pipe ,
[ lower pipe cap % _( ,g ,g7_ __ f_ ;l cap to pro-vide 1007. humidity Light bulb
'/ / / / //// //// //.
i cens saa esv s.e, asAsco st;victs INCORPORATro C 2 l l FIELD TEST DATA SHEET l ran N' A $odieson .4A~PAlo,2 dam 6a 1/2 0 6 a.s. no. 2 suostci kaddlA faked s y nr A n n N d / .4 orig l annet bfABA/Bl=d Wil$ bdslfatCC/W0 &sz/n' or er $8k Der esan boisannn AsA/ lam + Sui /als n 4 i _ Ns/ h/o.v.L
-BeiyH dhe / cou, son
- 7hrived sfee/ container per D$.No. .t
-No VPZprofechap,wded (f%/ rad
-Date Gtor/ed.' fin 23,1948 Alotes:
~I)afe Ods eva /iere aed A/s Ar,s
$WSried .2.*d S" S //. Af f.* d5 /N dy'/diedC Dy dansk.f54di I
/-2 3 sn o ie tu rc / n cars,. 3 s,n est ,$,g f s,os py , pp s .p,p,pp.'
74'S f S'Pofs 3,0,oeered /prf dr.
,, OCfdlCf? /rif a j Bricf e/ bfDRJ/) /Sb er* re Sf Color a// o /d/~
3r03f spots are ca/srfed's.s e/ 9:co,1./f. /ft .r.yM/go ros/ 40ots seeec /sr9 e/: No d'ss ee, n < 4 /e c4gg sMJos it
//t 9:eo AN j4/> eeo/ rus./iny nas oo/edafoi<treo ys,.1,
/ ~~'2 5 //r &30 AM. tysfis9 sec.sied so/rie.w,kr/ /e rs_mg_-
[)(psiided 4 0 u, port 2/ 9?oo A.M. //S//Mf Aed /ne M u d
/ s24 eorisider24/u ov'ernif h!Paeha v/ary /rr t/se top ps'un
, fy/n on side //I'/4*,4,M. dan ess/s/ sting +/r iS doe,cos b/fon
/)f 9 30 gas 4' /)p/;?d' /dl?N/!/f d eoff"A l.Y# W'""
especo/4 neer tac fof of bart w/M 9fre"ks 'w/h"J '"'" lU co,idon?s/isn rannino dr.cn Me doo de/op.d . &"'s/x =m s
.coirs c. eso s M.; in o'co'n ear .Me . . . _
EX3xi/nc~d'sl' 9 'GO A.N Sonhildes /z' _fv10 'INA'$f
/ fa __ _
l-3/ bsa//seds/ 6oM cospser9.'co& ored M. iH,4noror Nssr'f'drosdinf dew co<ifixics on
., [ci;dijiest ,cecisied eiwd.stp:/ * /#'0' '#' N 2 -r _ _ Ah .9'.20 4.M .7, mise,ec/ rciy Aewi/y rest < d. ..
g
F*ans $34 CEV 3 87 ESASCO SERVICES INCOAPGAATED DMD FIELD TEST DATA SilEET UR b Y3 1/110 r1 $fblb> $. fm n2 N ) $n D.s. no & sassJEci b /'n / M b* d b erw < ,a n < /< kffnA12N DAgg m wiM /%An-< </no Tindsn &--niisn /s/<<A,sism '
,, 2 sR.
2-vsne A,wl nin-t A, /s,- o Nofes: l Date dasenO4on s and A/ofes 2-7 Appearssee su s/ ados / +4e same .
=
2-8 li///e sass 9e sf /ed._ _ _ . _ _ _ _
.2 -9 / Y o o f A 3 r e " l C A 3 " ] % . _... . . . . - . .-
2 -/K . . AdakduesZreem!rs'sh.es... . ----. . . . .. - . . - - - 2 */ L -_ r h s c h a <n d .
/
E ~lY . < &nt 8/q S Jhoy/ fb sywg,, _ _ _ _ _ _ S ~/5 I llde Aonf e. - . . . _ _ . _ . _ 2 -/4 /Vo' cnscers/._d/s. ..cA.w/e g 79 /sm e i n ereas e m ers /my
.2 .2o ; (/s e Assj e a' 2-2/ l Gesces/incresse /x res%ny _-
?$1f' /Vo, .2 B n y A + J / c e / 6 ,,o s s 77nnet d'/ec/ Ai,%,/<< pee 3.S, No. /
'/'.e as/es'an/A safor.de f ss/sbos 1//'/ s"cl m e r/y / s /es h o /
- Os/e ffstfed bx .zs, /He
/Vo 7%::
52l=: 0b-:er /:?.J ioe s / //o /es
/ _L*,
6hrere / sf A'.'off?N' Ex3xas.13f 3.'36 AM. andihn./ enico:c o/ms < c nee /s esn bs/ so sy,i .o/ y.s+,,ny, _ _ j _y 3 , fm s'//Jrd.y of ,p:/ o a ssd *dstc' -/ an/je .wAten .:s epest.'.: n oa m.e ec o /: s./.9 fi y r p r m t, _ _ _
,, y" so.ws ex/ siesa a:.7-ssare.d 4.u mera:eds//y./sl,,
A/o sti -/tise o/ r-ni n i sores /siac
. .o .o . . ., u nco = vicis in.co m = = c -s. -4 FIELD TEST DATA SilEET m JA E E,Ln <na A'L*P AL 1 A,mbs AVA 6. o . . . ,,o. 4 m., e, Amk<nA-s A-ssoa frisib Anisw an m wi4 An</>,aaina %2na 6rswas Lw/asAw '
a AAA J % sjer / % Aailim m / L_/ din,a No fez .-
$8he dbser3 /2/i94..: l>VsAex /-24 dlneAs<? wd . . . _ . . ~
ye',y //W/e addibons/rost ap}__ earu19 eri Hee onessAW
/-29 edye. ,4,go roximofe/y y w/q%
Je w .z of'fhe asAsteAvse diss,9eesennW6,i9*er4 Asft/e ehsirye eseep o / f48/ shod 2/3 or'soo//xf
/ -30 issui seeirs< /s Asrc di ceAcco,rW __
/ 4,
/Y,qpest.f adsef /he 3.psse Sept tAsfadsef 3/4 of co3r'urf seens /a has e dissppeared. _ __
2 -/ l (,/ssAsajee/ i 2-g ; $sii1e fexces/s,opestssce. A-5 ash /c rec /ie1, sisd/9 se<e/s/spo/s or adfo.s.
. v , . . . _ -
2 -4 : Ja'na rueAny ofedses ssddjairehos of coa /cdsadoss-saw
! saahass l
2_7 ; $omc y+Ae p,eonet, noses cd f esenerf l 79f /Htf de/d/opss) ___ y .g ( V,, eA s,19e.] . femo ved dar < <ry a Akenoon. Te.s + N o. 3
- BriyA + Cfee/ Coupon l
- 77s?77ed ffec/ G;..irantee pee D. C No. / '
- !/b 6 stedanHi VPZ'-3/soAo /sndcws&ye oi/. wax,oa,,/;,,
- Date Afsrfed.' Jais z 3, i%S No+es Dvfe .
Da sers :.%-> n s s,1d /Vofes Ofprtejs/ K'Go~P.M' fx 2 min ed 37'3:36 /? N'3"/ l 7%vncf eVidai/Jr. c7'dondertse/Atoistyre /tr e es/ but no eu.s fisj o 1 c'oyoir. - 7 7) g ,'C' fu O S 2 i ?N lUS$U ~ 4 5 t/' dA/'N'/l Ab
/-2Y l, side op, s<eaty _/ fini a al esp ariva.wr ey/x"s,J/ -t o n i r.
l l r:nu saa try s.n E ASCO SERVICES INCORPORATED C-8a-5 FIELD TEST DATA SHEET Y 0, $Nniors AfPAL 2 l's/nAns A2 A, ru a.S. u0. .c l sua>Ecr >$eevlmkJ dersnon $ s h >$ den N n k / oriE m wi th fla/w<<m a LA> Sinisos A>&s vs doss av Ad B A' A % A,,/L.,+>,v,, A A,/dm v
/vs' fes :
DMe 66serahsn 6 (' Ns,+es
/ ,26*
$prn6 r/$f/rr 8/o,1 ea/' e o/ nsit -dsafe'ds/od' Tjek ~
are 7'wo rr spo on ose s/c/e ofits4-coy /cc/,, ide. ker/sa$lf ob S<?rr'eci rSuo /eqe a'r.o,ps ofass/cr af f//is
/s eo/<on. 71/.c was 3,op.xr.e,. ,/y syatos/icc/ss /r'sx 7'/>e wofer /n f//e,psr/ w/!<aA ddM YMS Senid F#Sf froni 7'6e 4e/tont6 o/ /nec3</s. ,, ,2 g Os'eslu,yed'. . . . . . . . . _ . - . . . .
771cre appesm/ h be sonic sa'cfit,ons/ resfi,if .2/- Hie fprevioss/y referk./y.r /s ss ws// s s/s,ip rM yeesyys.; ea'9e . . . - . - . -. .- . . . _ . . . . . _ . . . . . _ . . _ _
/-3p /////e cAaaj c .e.<ccf faAout ,2/3 o/co.//saf is fo /C. ,< y /n creas e in ros hi nl a /os 's e<f inen tio nea'.
f eA Nc5 ?dho/= h #57 p ., Aus /iny co n // sue s. I 2 ,2. A/o c4sy.. e noted. . - . . - . - . j _3- LiW/e fese,3/ ,cicw g, se ye,r.y/ spc /.x, s/4 ,/ ,,,,pg cos//"9 has di.cassewi u Son /C rp S //r. ? por Sefy c4 3 n a y c /i e r ; / r u fi s y e st ossc. E '4 '
.s'/de n ear fdp> . ..
p_g Geacrl/ ry.s fi,if o n one 6,.3e pi-sy,,,gis, . Re<>ic./c.t from oireu i t in er frcenco,/ 7e~s / No. 4
- Br.yA/ f/ee / aup si/
- 77no e6 &ec, ' 6o7.v.wev/> ee .D G iva. i l#
---ffh3 'i:<' / /3 l7'Jett/J f4,u:.,; $27*f3lC~Y J N/f" S# I VPf. mis's/co/tr/. it'cre ww.: sue /[/7sf drip,' n;)"'Ne's 4//f.v : b t
- J' YO cow,uon D:/c shered: Ja~s ref /% e
rene saa new s.e, asAsc0 scavicts INCORPORATED C-83-6 FIELD TEST DATA SHEET 10n N. E. 2ohn s an $EP No.1 dermAss N 1 6. o.s. n0. d suurcr Asu/un42 /#oren un E& Acconm A d one m wsM, 8t</ransAnta %dm &mm AnmhaAg,or ' AAA. A u .ter / L +2 m $>an + A m /do a No+es: Du}& / M u /2/iox.s W s % fes d'forr%/ G/ 2+ 9.'oO A.M: /Vo C4anyc'E55W~~ l ~N spparenf 1'Arva9A 7'A e d'sy. _ _
, YO Sf f B r e#1l r V 6 f d of d d 4J ,0 e sst. / yo /Vo cocrosiorr s,pparen h Remo/eay' front cair.
6f Yea $
- Beq 4+ ffee/ 6 p ois
- 7innedStee/CoxArmorpar3.4 No. I
- A Hoche. fo Mai// /s ope. sortiso.fea's.'if4
- so/s/iosi
*b E 8"W Glde bOl
- kgfg estars,4//ow g/ yc sifty i
/ jgy{g,y BNacArk Costf%pg
~
ON Nsdr/dW.' O rr AQ /$ d'$ _ A/oAs: Dak Observahoss 4' Alofe.s
$far/*c/ & # ofsoitfr4,//. No eduyes wen .ppl-l..;r . / -2/ throyA the day. __
_/-Af / Y o rt/J / / n 9 J y f # f C H f l*$0 N'o eoer5s/41 s,oparenf. #%,,,e, ad'/+o,e aa/7 sxawe.v.J 4efA Ces,soos/ orc,7,///t'.er/pf of~gpay 7'//p/pyj/rfy,' g4gwfg& FC,De /// 63r/ and' does fir /:/dd' 7'c6/*
,-g, No sf n of r" s/ /7s s quosered. i 2 -7 fu e/l orig e d' A*A Yo C b 3stf e., _ . _ - . . -
1 \
,:- ... .n ..., n.4.c. . m ica. me . ..r c.s. 7; ;
FIELD TEST DATA SNEET I
- v. A/. 8. Lodinson sA*P A/s. 2 /%An /sk a .... . y sumancs Am/unhd Orrosion 7Aasinc $ds'x / e>erins Awsc/rarAnw ,, L SA?o
&xhv- 0snh.9/nrn&>/ Stji/d'sx o a
hlofeS
- DJld 0b18/~Y'8 h/0 r?s l /\/'e s's .S .
9-7 AY sea // ra.s t eps t //s.s Jer.:/o,mi near r'op of cogss oppoS/fe to rop &. 2-8 A9doaf /Ae 32"'f . . . . . - - . 2-9 d// red ca 9 e e'
,, /%Mee sm.ii/ rs.s/ sp.?r / ras s'en/.sp ./ os sia'e.
A -/.2 epp ossie to rope . _ 2-/3 Adoj? f4e isisse-E -/J ND C b 'J a f C. __
- 2. -/6 /Vo cde<ij c 2 -/f,
(/nc 6sn 7ed' g -,9 No mere Sms// ros/ spots //ste 3,pp.:ar.1J on anfc s4""#d- i to rope 7K> N : ,;:,,..p c. -- - L'-2 / p f b e v .' / // c a s u e . 2 -;3 iM. .:i. asy c.:/ ks/ Ns' . 4 8tiy/// $/eo/&ys,;
~
Tsisaea' s/ee/eesA7/xer,oer D. 9. A/o. .L
- ,t>4.x,;e.i /s /6si/s As/>< da/orsled w/A// JoIs //ok o/ .2o 3/d.)k o /.paas o/ od-wsx s,is z o e.c. os rpr-asin/ ~
,--_ ]) t e d i a e / c :/. San d's / /%8 N.~ ,:
DM Gb se/ /o//ci. s f' /Voi'es . - -
$far/cc/ te:4 af 9.'30 i4. M. / -Es
- e. = ... u ,..., m eco m vices incow e rso c-82-8 FIELD TEST DATA 8 MEET ro:. N A Adisns GEPNs.2 /% Ann AV2 an. '
o... ... x su.ne, A%dmr%ddorruun %/enewsM om l , antA Pe'n+,mais 6 don as>=ma /smsiar/g ,, ' AAA 8xAr 6x/2/x$m/ AnAAxo<
/Voks.'
Dak Observa/'isxs s' A/sks
,._,, forrie yexers/ rsshnf h as s,spside fo wJneA rope is a/tssAe r'. No restAas .ppesar' en side adiasex # -fa rope- . ,_, l 4?stoan t 6,I' ro 5 finf is //ised.7s* mf se see s/de sn/y 2-2 3's<x e 9e,1ere / sppesesses 9 .g- dese,s/ rashsf of esa,s ?,1 se side oppside fa nr' e. No roshnf so .fsde .sd sesst / to espac.
2 -4 2u's//,ig so s,o,s.x//9 sde /rsin espe is he.rrier 2-7 \ # Ass / /A'e spirie . p .g l Some meres.ce in ruci ey b s,i cic/e oppost te /c rs,oe j -9
$bfA/ /neresse in ras //arp sn s/a'e ofsoo.r'fc /c
- rope. Sh// no ras,hnf .o.s rs,os . Side .
,2-/f Y//dkyr'f f /
pg iddss/ rn e .s'amN __ . . . . . . . - 2-N /Vo CA""9 d- . . - . - . - . - . . - - . - . -
.g-y l /7'sjeseen/y VeA esp'.i _
_,, : Rsen y s. : y.u s,,y>uA "pe A o'?'Os "' '^"' i sfe i$s;'ir'..-3s//0);'C s/WC-
} _ j 'J $f/d f a l N $ / // Cri <5s $ d' #
s mere w e.,r. A/o rlust rjsidie s roQ si Nu fSf na'e.d' k& S _ r
/A $ $// ' L' 2 ,2 / Anos / Jh e . core . m it no eus/ s,, ,s}c ,,se.
2-23 A4 4 % g e.
i POEM 944 987 8887 ESASCO SERVICES INCORPORATED C-8a.9 FIELD TEST DATA SilEET
- 10. HAlohnu-> scpw' 2 <% Ann A/1 n. a . S . ,,0. -r Suoner ba/mM &nexisN 7Aske Anm2 fed onE m wi+A A<nuou <7J-tu Mina InasAnA8ir < J
., oa A1> db l* AF kWM asaa + B /dino
/
iGs/ No. 7
- Briyht- stee / dos,oon B-isie4 / eof /A o//-iseAassiriekeykswres,sipe deeos4,a
- No I/PZ~ero/ee hoir p?,o vided' (c's-r ira b
- Dpfe d'fstfed5 k d /, / 9 4 8
/Vo/es 03/6 0kferra7 A/pr74 lNo/es A-/ $1%rfe d desf af ados / nooir.
j_y desers/ res/ 3,pfest;/sy ovc' [5All o &uh o f 25 Jitt/ exces/ rus hnf - quite a n Avier o/ /srp sus.e
.2 -4 Yus//pf 4on//nues - mos//y m s,osf.s ~
f.7 , desists / Ausbof -nwsr esst.<9 i: /ua,y .900T
$=8 l $$r/ llri V/My '7lC rp 4 7'~
.2 -9 Aus/ws ce,i//w:/r donic .reriera /ree^<q /n addi /<w fo 'P= """' 'f'"'-
2 -j3 //4?./r fAc ssac. _.. . . . . - . . . . . _ . . . . - . - - . - .
& Y0 A Y en ss.o a/ ends ~
-f y _,,g l"ovpos arouns dorto /wamNedo noe rosf rac/ -os feisdon est e,id mers.psistf nIAl y ~lb Coupoo cus fm.o,,, & rs ss' feria'sn rosfwp so</c.n.9-da s' e<>d ef,zcc.$: Lp sh's d Sonta ruf/ _.
9,, g L ie iseie n in couros. ro.sfmf f-pi deee/s/'isere.wse /n ers//sj ses 4sM eospss ssr/ W2/
$dh / ndrc.yg saf .:///s (tf fe,yc/sn - few GoM A SS ~1b//d 7 //
Y~
.7 WAife rons our / 3bp// os hcc.,/ sit e $ro/A .s in.a v t f /?/ s s t e , Mr side oncf
eeen see new son, asasco sanvicts inconeonatso C-83-10 FIELD TEST DATA SHEET , N A AAinm ffPA/n. 2 /%L A/L A. o . . . ,,o . m sueJaci YelmN8"nx1Ax he A<<nLi2 M oArt man-wirA ALxJnwns 7Ldn AL-us/nes/issAm " '
,, AAA Bse Jo,- ALn A$inmm + As JAn a Nst No. 8
- BrigA / # Ass./de,spon
?-/sie4 /eofAd o/4'-M'Aofswwfvrf'If"d,P'f' Ar confs/nen
/,/g' goafm' asi/4 P'PZ- o/ssdo l
- Da/e starfed. fed 6 9'8
/Vofe.S: 38/e 04seretehon 6 4'Nohe.s - 2 -t 6'/s, fed fes/ shou / nosa, _._ 2-2 9evera / ros f spofs - rnaf b e l'"f P"'? M - / 400 f '" ed9e o/ coa Pyn 9 6*tres4 A - 6~ go,,,a ,asy spp asema w ares.c ++apwere anyion/rj~ piHeg eg,rgy,afa/ 9e of coahng /spsfusdersdap
/6usf spots increasing - /s,os/in ares o/ cos//xj.
9_y severs / gos>f.s on ns"-soafed side 2-8 /f b_s u / # A e s a n s e... . _ .. . _ A?Asu / f4e esne. it%msred the soupsn, s//ssedi/ + v<y 2_9 arro' phs /sfra,phedif. NSt /Vs. 9
-frigAfffee / Qupon mese/en f4 mer c/ 6-as4 disme/srys/<mzedpipe ne
- {/2 gsa wi/4' 1 'P[ /
slesAs,/ si/sadwa;<
- Ds/e fforr'ed': 54 5 /966 /Ysles ,
Dste Obseryalion s 4' A/ ole r . - 2 -/ 9/srfed tes/ aAouf noon.
roam ses nav s.or taasco senwicas inconeonarao C -8a -I l FIELD TEST DATA SilEET von Y b. b //fon $b 0,f $ bna $l b. e.s. no. // susarci M oe/es/ed d erM/oe h <dr A o m 4 d o4rg m wA ALAaisu %dn sanna ZaJi. win~' '
,, AAf Aa A,e /L,ALn- J Asn/ dis a v
IVsles: b re 0dserr:zdzosts d'/%.tje,s
.2 -2 sea <s/ eos+ spots sppeansf -may se /]nfespemis 2-f Sonie siderosoa / sp/.y.,oeanny io /de s/es e/sovAny on sor--
9_g dc/cryI /3rf e 6,osth el /~ psf 43rc des /s/poed or one side y-y /c b G f C d'/J S i spo < sc<e/nmg hofb/l' Sceni3 sese top,Dedaft#A . Ndaff 701/*
$~6 [us/ f,Oo/s sed /7/ $ b/MJ more des ///y 2-9 do9" wJc rc#sr<sj a//ued & d,y, asd/Jephsy,, pia 2u's. hap appeared -4 6e meressay raps /y.
N.s / Alo. /o 1
,8ng4f S' fee / daupo<i i,ich /ea9/4 of 4-meho'as<4,9s/m2Wp90< 4e c:sn/s/ ser-
~
/Y//ad//Cd /c kffsf**l8 b 6 f s37$/f9fdW.<//ll1 $c/p//cr/c/
v'PZa<ida/soho/, ses,oe was wefw/resi s/tode.,/ to esuosn Ds.4,fferkd.' 54 /, /.94e
/bs:
D3h Odserve//ox< c' A/, pes 2-/ 7Es / e / seres a / aAou+ n,.,, 3p // //H/e roc / nesf do,o o/ es.'pos .opps.< /5rste, p-g /1// H/e yeser:/ rasi%; seside o/ coy >ss spss. rite
- roEe f -f // boy f /ke fd7t?tG ,
?
rom sea may e.sv c:Asco senwicts inconronAtto C"-Sah2 FIELD TEST DATA SilEET ro,1/ 8. Aokosoir 9 EPA 4J An6 AVLA o . , . ,,o . >1 su.ste,s%Aers/&d,,/wos %+n Assuida om _ wia L+rewss Ls, &ressiss /n>wMils' ' ., AAA A%hi- d,n hi>>n>rs + Addsx;
/ Votes:
Date 0bsersanus3/>dA/sA.-; 97 9 sore byAt eu a.y s,i ein o,s,sseik rooe i 2-8 d i H /e c A.sv;f e
;-9 dome rus +/sf sn sia'e e,p,ossh rs,pe neaH37 .2 -/ 3 ife/s///e/y bH/e C4asif 2.
2 -/9' Asm.e ye se<v/<vs/mf o,i sWe opps.riN re.se 2-/f iVo c4ssf e. ~~~ 2 -/4 AVbesif ff?e 6@nf&
.2 -/9 (/ns /isay ed 2-20 /VboJ / !stC .42nte g _y , Ys Y/$/ble abessf 8. $fi// sio ryS//stf pd f/de
.a a)' d ce s / -fo esp e..
2-23 f/n eA eisp e d
~~
/ es/ Alo. //
f?,,9H ffee/dou,pss 8 mea / eof /4 s/ /-mea a'w**/erf'on'#"'*<dP 4*'- Ai- een +am er k1llac' bed'N lfdM//d b,dd d8' 7$/r/W/s/7Y.5"d/$///on of ViO[arids/so4o/, As,oe was sr'y wdo e//ssAed
& esu
~ D3 fe A,osirfs.r/es/ 54 /, /94 8
reen ese es ,e.e, seasco saevices inconronatto C -8a -13 FIELD TEST DATA SNEET ron ll A. Ahn <nn AEP AL 2 An Ann /N & o.s. no. xe sueanciknen/s.r2>b d A m eson Ye/c $11ans&d onse m wi+A ba/>w<nno 75xAs Assurisx LuthosAM,
- or AAA Alar (2x 4 ,- - /- Boi/d>n; Alotes:
33/e Observ's/ ions adNohes
.? / t f/ ark d fe.s/ udos/ noon.
2 -2 No tos / ris/4.L- . . . . . , 2-5 /Vo appses/tv.:rhn9 _ 2-4 No e4sxpe _ 2-7 On' edaged' J-B No ro s f ~ 2-9 A/o n s +in g . 2 -/2 N'o eusf n sib /e
.2 -/3 6 ln a 4 o y e d J'N ^l* 9d?ny e 2-M CM <10 ros f _ _
2 -/6 NoessAwf-.. 1 2-Jo Alo ns.S/ . . . _ _ . . .. Nh e- .e,eyey myg,g,, , , , _, , l l 2*23 /Yo ryS/M49 _. - _ . - . . _ . . . . , . . . _ . _ . _ _ , . - _ l i
poem ese est e.e, seasco ssRvices incoRPoRAft0 C 14 FIELD TEST DATA SilEET poa H.A, AAinion JfP A/s.1 ArwA>,n Al d. a.s. no. J4 ausaacT $^'* WA/ A sd b_ m shen &Am M oATE _ mi+A A+-amo 7En,dni Arnoa /nmasa,, ., 1AA L.s e /L.+->nn,u + L/ Jins v I i l ht No. / 2. I
~~~ Bright $/ee/ dou,pon \
/ss4 /esf f4 & 4-med d'ionsfer ps/rwzedpipe- l Sea /ed' os doFA ends' w. -A 4 ' "o/hp wofer on As /km.
P/exif /e ci coveredwinc/o.u edou/ /'d"diosvefer-C"f inflpe ~4e o 4.rerya// sis l
- i4ffee4ed /o mani/s to,oe cofo' e&/rd'Wi/4 MQZ- \
sles Ao/ co/sfran . 4%pe was we # aiheer er/r'ssArd' l \ +o aouppn.
- De/e sfaefed. Fed /, /948 g,
D2/e 0Aserys' f/oris and' /Vofed 2 -, 7~es/ sferfedaf sboa f V. oo /?g 2 .2 6A ser(2fioss diMcuN. dos /d' see iso tos / _ _ _
- 9. g- Ato ruc/ on rope side,. some res / on opposi/c side.
Sese jes,reto/ toe +inf eor s/de' oppor/Ar evpe J%ie. 2-6 MoicrWre o re ise4. rpn oaf of offer #4 reeds.' 7g~ 4Arxedee,o Jy hmiy e 2-7 Meshrestiy of osos side eme opposiferof,o,se4se eide os c .ao +oppear fa be. , b /001f/MJ on cid'c 0,ppocift? refe -Mo fdIf on ref e sise' .,, , 7b/S taf.S 4 exces& fAoY,dhfoW3f/cl80 on the side wes sfo/V 7?}cwhee A/sese ojooreoc/.waspasperi
/> </ reg hwn o/ Ko a side s who/* wet ses psions of si,1 o//e, deyisj.
fnUser o/p//e waIfb*+ofref4elfrise r'o.scrapin9, 7 e~ s i+ N o' . / 3
- Brif h t sfee / dospon 7.~oned Cfee/ 6xfeixe e per 29.S A/o' t
- fope rGom 7e*1 don #4
---Dsrb s/sr/edl sGA 4*/948
3 rem see es, e.e7 seasco sanvicts incoeronarso C-8a-15 FIELD TEST DATA SilEET ran N* $. b b /s/ to n $ $ N 2 $ a A s s k l } /$s. o.s. no. /$ suntcr A"afuchedbrration &h< A osinfo) osrg oi,a ALami-n rAn L.m K;mAuk, ' ,, AAA Ass /%Aoif w Ao,/dia - y 1 s fCC
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2-8 #doaf Me ame
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AAA 0+->efae fLi/eTsm os/ BoJ4n; f Nefex: Da fe 0Acw&97'ssir.c and' A /o/>v _
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-33/e $h.se/c /.' 81 64
ream ses osv e.e, taasco staveces incoaronarso C -8a - 17 FIELD TEST DATA SilEET ren l/> b. babinson $ #5i N A 2 $ lm n N $ /s e.s. no. 1 7 sueatci Am le n/sd A>vuxins dr $1samin/wd - ossg , .amar wi/A $th's<rsnaNudos fm1-Zsas}sfs12ag, or $AW , B-A,/ AL. A,-n,-s A o/ dis; Nota: Da/& 0b$ery'3b/dAS BMW/Yolt5 _ _ . . . .._ _ ... _ .
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poem see me ,e.e, tsasco sanvicas incoarons.tse C-83-18 l FIELD TEST DATA SNEET , M A ALAw ffPA/1/%,An AtL & .... . si sueJEgg MAlunMbsmrin Yd f N k s*1 DNd oAst m w1Jd ba gsbwsrinm &du lAmsAd /d/Ar/'sa ' av fA A l B-Joe /LAalauf AsiNin,o Notes! Dafe 04eerr'sfiooe a,14' N,,/,es_
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- B rip h / s ta e / & sp o ,,
- krica' dfee/ &<r Ariser per D. $ No. /
- AW3eAest to drosdod do1'7'oo es,se sai'zir.yfedwif4 VPZ-o/eshe/so/stics. Jo,oe was oNabeddry
-Defe sfarted. FeA 9, /96 8 No/eq
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ream esa es, e.e, seasco samvicas inconronarso C -h - 19 I FIELD TEST DATA SNEET FOR Yo - D JA SDA M Neo Al > M A' & D. s. Fe0. / SUeJECT fYt'A#ll/*GW /$/12F/1^29 Y YMAA/AF Y/dlJY oATa .,,,n, Pen +rmixo &dox Ar//wss he/><aAos ' ' s, fA/ s0endos Wmwnnesaf A>> A/nao v
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..p r:nm se4 es,e.er reasCo SERVICES INCOWORATre C 20 FIELD TEST DATA SNEET von }l, 8 b Ass) o n $CP A/s. 2 i% Ann 9d1 & o.s. no. 2 o suenCr A =c AvnA" / bsrbAssA <fs Affs 1 oheda>>Ali oArt _
m et 8ndreisin3 7Enloss /%swnalo' m />ashon er AAA 8nJns WL Aoixmaa f Sw /di,,s ' ' v
/ Voted .' $47/8 hbfdrV2 b/d/td aric/ /\loh?s 2-9 7h/ f/stjed ~
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03ld $l27A!/.fA /A, /948__ _ IVo' fex:
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$8f/f/ f ll1 C .s'A/s)/g,,a !
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1 roam see as> s.or asAsco sanvicts inconeoeATro C-82-22 f I FIELD TEST DATA $NEET ron }/A, Ahnun MP No. 2. /%a An s //2. /2. . o.s. no. 27 sueasci h'l&2hd__{,$,ms > TdAhs Acessaks'a'i/l' oATe
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~~ Ds/t$/Nrt'ec/.',$5d /2, /96s Nofec ).?lC 0b.Se:r4?t'/01/1 cvrud' //jfkg f _ _ _ . .
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. . . ,&}iJ!E. . ; al a:Q_ y Q, g@gQh-Te st No. 5. Front and back of sample protected with manila rope saturated with VPI-alcohol solution. Alcohol dried completely before using rope. Excellent protection
, during 26 day exposure at 100% humidity, e
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contained 11.1% oil and wax. Sample exposed 16 days in 100% humidity j environment. Note absence of corrosion using rope with lower oil content. I i l
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.
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. J I L P. SUDRABIN P.E.
CoNGULTING ENGINEEfl ) 78 estmonc avsnwa enons ] sanastav ><sonte. M.J. etLLEvaLLE. M. J. l anca cops aos PLyssouTM 9 800o i PMoss 464 8720 *Y Ltd January 31, 1968 FE02 1988 RECEIVED Stresstccl Corporation Walter H. Larson, Vice-President ' Wilkes-Barre, Pennsylvania
Subject:
Corrosien Control "'.ar and Strand Tendons P. E. #1801 s Ocar Mr. Larson: This letter will suanarize my observations of the corrosion situation n bar tendous in a Nuclear Power Plant construct-on in nort Carolina and on strand tendons to be used in the construction at Albany Plaza. A conference was held on Thurs-- day, January 25, 1968 in the conference room of Stressteel Cor-poration, Wilkes-Barre, Pennsylvania with the following present: Mr. Ed Schechter, Stres~ steel Corporation Mr. Walter Larson, " " Mr. Mario Suarez, " " Mr. Edward Crinnion, " " Mr. L. P. Sudrabin, Consulting Engineer Nuclear Power Plant . , , , .L It was reported that the examination in early January,1963, of "tcll tale" bars removed from four (4) galvanized pipe sleeves at the Nuclear Power Plant under construction in North Carolina, showed signs of corrosion attack. All of the pipe sleeves con-tained V.P.I. (Vapor Phase Inhibitor) in the form of hemp rope, extending the length of the pipe sleeve, impregnated with a 2 lb. V.P.I./5 gal. Methanol slurry. The most severe carosion was noted near the midsection of each bar and was greatest on the bar with - signs of maximum moisture condensation. The "tell tale" bar sealed the grout pipe entry at the base of the pipe sleeve. Several of the grout pipes were found containing water ranging in pH from 6.6 to 12.2. Continued /... . r 6
(2) C E The latter pH is probably related .co inicakacc of concrete unter at the time of pour. The lower pH water may represcnt condensation from " breathed in" air or by entry of rain watcL. These possibilitics can be confirmed by water analysis. The rope and the corrosion products in #6 pipe slecyc contain-ing the "tell tale" bar with the greatest corrosion attack ucre analyzed. The rope reportedly contained 9.07. Uitrite and ' the corrosion product 1.07. Nitrite. There was visual evidence of "uhite" V.P.I. on the rope and on the bar when removed and examined. It must be concludad that V.P.I. was present through-
- out the bar exposure period.
In order to evaluate the performance of V.P.I., Stressteel Cor-poration prepared three (3) assemblics of bar tendons in galvan-ized pipe. Assembly A. Control B Assembly B. Bars treated with V.P.I. slurry Assembly C. V.P.I. saturated rope in assembly g These assem$lics were exposed outdoors in Wilkes-Barre in Feb-ruary, 1967 and first examined in June, 1967. Assemblics B and C appeared unattacked at that time. They were disassembled in Jan-uary, 1968. Assembly A. Found with water in assembly. Tendon bars found cor-roded at weak points in oxide film. Cold rolled rod showed con-siderable pitting attack. Internal ~ pipe galvanized surface covered with white product. Assembly B. The assembly was dry. There was only slight attack on the tendon bars and on the cold rolled rod. There,vas consid-crabic white product on the lower internal, surfaces of the galvan-ized pipe. . Assembly C. Water was found in the lower end of pipe with only a trace of Nitrites. High Nitrate content and virtually no Nitrites were found in the rope. The tendon bars were corroded, most severe-ly on the surfaces facing the galvanized pipe, but less severely attacked than Assembly A. The behavior of V.P.I. on polished metal surfaces are described in the papar "Dicyclohexylammonium Nitrite, A Volatile Inhibitor for Corrosion Preventitive Packaging" by A. Wachter, T. Skar and N. Stillman, CORROSION, 7,~ 284-294,1951 (Sept.) Copies of this paper were made in your office. . Continued / . . . 4 e g s e
O (3) O c-9-3 L*poa revicuing this paper, it is my opinion that the failure to obtain corrosion control on the tendon bars treated with l".P.I. in the presence of moisture is attributible to corros- , ion cells established with anodic areas initiated at weak points in the oxide film on the bars. It must be assumed that ade ;uate mounts of V.P.I. were unable to reach the anodic arcas to passivate the active metal surfaces. Continuing carosion, in the presence of water condensation, builds up corrosion product e further impeding the V.P.I. reaching the critical surface. U.R. . Evans, " Metallic Corrosion Passivity and Protection," pg.159 (1960) Edward Arnols, points out if Nitrites are not available . in sufficient amounts pitting will occur. "If any corrosion pro-ducts (containing ferrous compounds) should arise, they will in-teract and destroy the inhibitor". i ncferring to the Wachter paper it will be noted that the V.P.I. increased the corrosion attack on zinc. The V.P.I. may be con-sumed by reaction with zinc and with the corrosion product. formed on the bar. Virtually no effect by oil upon the effectiveness of V.P.I. was reported. s It is my opinion that adequate co control on the tendc.n bars at the Nuclear Power Plant in ort Carolina can be achieved by the removal of free water, purg e a stem with dry air and the use of silica gel _dessicant to absorb n'a moisture that may enter the pipe. A relative humidicy not exceeding 50% at 40*F should prevent further corrosion. Albany Plaza '
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4 e .__ . Very truly yours, S[drabin, wl4dk - Consulting Engineer LPS/pn i . 6
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.m....... P6.v ovva e.aoos Pesoms 444 5720 February 14, 1968 -
G 7) t'" N U La dD('s D jl rah*,k - F E :. I ", m a Stressteel Corporation Walter H. Larson, Vice-President 19r*C, c pIVED Wilkes-Barre, Pennsylvania ,
Subject:
Corrosion Control - Bar and Strand Tendons , P. E. #1801 5 Your WO 66-213
Dear Mr. Larson:
This letter will summarize my observations on tests related to the use of V.P.I. to control corrosion on Stressteel bars during a meeting at Ebasco Services, Inc., 2 Rector Street, . New York cn Monday afternoon February 12, 1968. The following were present: Mr. A. W. Peabody, Ebasco Services, Inc. Mr. R. Richardson, " " " Mr. A. Wern, " " " ' Mr. L.P. Sudrabin, Consultant ' Polished steel specimens exposed for periods up to 17 days to high humidity and to V.P.I. treatment inciuding variables of alcohol, rope oil and wax and galvanized vessels were dis-played. All panels sh0wed corrosion' control effects by V.P.I. l treatment when compared to the control panel. The offectiveness
- of corrosion control by V.P.I. appeared to be somcwhat lessened by the variables mentioned, particularly by the combination of ,
the galvanized containment vessel and rope oil and wax in the V.F.I. ? These tests have in part been presented in the Ebasco Interim ! Report dated February 1968. , It is my understanding that in some preliminary tests on V.P.I. . sublimation, the rate does not appear to be affected by the pres-ance of alcohol or by the ropa oil and wax. Continued /...
- t 4
C-10-2 (2) Stresstecl Corporation Uilkes-Barre, Pennsylvania February 14, 1968 . I feel that a most meaningful test was conducted on a Stress-tec1 bar about 4" long split longitudinally. Each of the two specimens formed had a flat bright metal surface and one half . of the circucierence with the orignal oxido scale surface. The specimens were exposed Friday, February 9,1968. . The' control specimen exposed to a humid atmosphere showed act-ive spots of corrosion on the bright area and characteristic . attack on the oxide scale surface. The other specimen exposed to the humid atmosphere with a V.P.I. impregnated cotton rope from whbh the alcohol had evaporated - before exposure, showed no attack on the bright surface. The oxide scale surface showed corrosion ' attack only slightly less than found on the control specimen. There was concern about the effect s of mild acidity, pH reported to be about 6.5, found in the cotton rope. I suggested that additional tests be conducted with V.P.I. treat-ment on oxide scale covered surfcces of Stressteel Bar surfaces.
- 1. A test in a humid atmosphere in which everything be done to assure the efficacy of V.P.I. by climinating the variables of rope, rope oil and vaxes, galvanizing, '
etc. Such a test would demonstrate whccher this inhibi-tor treatment is equally effective on an oxide scale , covered surface as on a polished stest surface. l
- 2. A test conducted on a previoutly corroded oxide scale '
surface, ideally treated with V.P.I., to determine whether corrosion once initiated can be controlled. Such control may be evaluated by carefully coordinated photography to establish any increase in the volume of the corrosipa product and/or areas of attack, subsequent to the ideal V.P.I. treatment. Very rul rs
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Consu Engineer LPS/pn k
4 APPENDIX D Report on Quality Control for the Manufacture of Prestressing Steel Tendons at H. B Robinson Steam Electric Plant 1970 - 700 000 Kw Extension - Unit No. 2 of Carclina Power & Light Company
7 , SYNOPSIS One of the nonstructural corrosion monitoring bars for the prestressing steel tendons at the H B Robinson Steam Electric Plant, Unit No. 2 proved, [ i on teat, to have a yield strength 7.7 percent below and an ultimate strength l 1 percent below that specified for structural bars. Since this bar should ! l have been made of the same material as the structural bars, an investiga-tion of all of the steel used in the prestressing tendons and corrosion moni-toring bars was made. Based on this investigation it is concluded that the substandard bar was unique and that all other bars are made of the proper mate rial. A logical explanation for the occurrence of below specification mate-rial in the substandard bar has been deduced and is described herein along with supporting information. Information is also included to demonstrate that the quality of the other bars is as specified. The quality control pro-cedures in effect during tendon fabrication when the substitution of the substandard bar occurred have been reevaluated. While they were good procedures, they can be improved and guidelines are set forth herein for such improvement. f I i 1 I i J
.- - - ._ . . - - -. __- - _ . - .~ .
l ': l l I C O N'T E N T S Page SYNOPSIS . . . . . . . . . . . . . . . . . . . i l TABLE OF CONTENTS . . . . . . . . . . . . . . 11 I - INTRODUCTION . . . . . . . . . . . . . . . D-1 II - LOWER TENDON ASSEMBLY BARS Investigation of Quality Control in Manufacture i A - Tendon Bars . . . . . . . . . . . . . D-2 B - Telltale Bars . . . . . . . . . . . . . D -4 Physical Investigation of Telltales A - Laboratory Investigation . . . . . . . . . D-6 1 B - Analyses of Mechanical Testing . . . . . . . D-ll , C - Analyses of Chemical Testing . . . . . . . D-ll III - CONCLUSIONS . . . . . . . . . . . . . . . D-13 , IV - REVISED PROCEDURES . . . . . . . . . . . . D - 14 EXHIBITS Exhibit 1 - Bethlehem Steel Shipping List (6/3/67) Exhibit 2 - Stressteel Bar Receiving Report (6/6/67) Exhibit 3 - Bethlehem Steel Shipping List (6/23/67) Exhibit 4 - Stressteel Bar Receiving Report Exhibit 5 - Stressteel Bar Stretching Record (6/15/67-6/23/67) i Exhibit 6 - Stressteel Heat Treating Record (6/7/67) Exhibit 7 - Stressteel Bar Stretching Record (5/22/67-8/24/67) ! Exhibit 8 - Stressteel Heat Treating Records Exhibit 0 - Stressteel Furnace Temperature Charts Exhibit 10 - Stressteel Inspection Report of H B Robinson's Lower Tendon Assemblies Exhibit 11 - Ebasco Inspector's Inspection Reports Exhibit 12 - Affidavits Exhibit 13 - Stressteel List of Incoming Bar Mill Heats Exhibit 14 - Stressteel Quality Control Procedure Exhibit'15 - Lucius Pitkin Lab. and Bethlehem Steel Chemical Reports Exhibit 16 - Telltale 6 Stress Strain Curve Exhibit 17 - Bethlehem Steel Chemical Report (3/14/68)' i i'
l l D-1 1 - INTRODUCTION The 139 foot high walls of the containment vessel in Hartville, South Carolina e.re being constructed in two stages. In the first stage, approxi-mately 30 festt high, the eteel bars which are to be incorporated in future concrete, have been placed. Of these bars, there are two types: normal reinforcing bars and special grade, high strength, post-tensioning bars. Stressteel Corporation of Wilkes-Barre, Pennsylvania, a company exclusively devoted to the fabrication of post-tensioning bars and strands, are supplying the post-tensioning bars for the H B Robinson project. The bars are grouped in tendons of which 119 have been delivered and installed. Each tendon consists of six bars 1-3/8 inch diameter enclosed in a 6-inch diameter pipe which prevents the bars from being bonded to the concrete until a cement grout is injected into the pipe. The pipes are temporarily not filled to allow the surrounding concrete to harden prior to post-tension-ing and grouting. Post-tensioning consists of pulling the bars with hydraulic jacks and anchoring them, thereby exerting a compressive force on the hardened concrete. Four of the tendons presently in place incorporate an extra remov-able bar known as a telltale bar. The telltales are not to be post-tensioned but are only for monitoring corrosion. Three of them (Nos. 6, 40 and 74) have been visually inspected and contain some rust on portions of their surfa ce s. The fourth one is being held in reserve for future observation. The three examined bars were tested to determine the effect of this rust on the mechanical properties of the bars. No discernible effects were noted due to the presence of rust. However the test of telltale 6 re-l vealed that its yield strength was 7.7 percent and the ultimate strength I was 1.1 percent below the requirements of the applicable specification. Subsequently an investigation into the quality of all the lower tendon assembues was initiated.
D-2 II - LOWER TENDON ASSEMBLY BARS The hot-rolled bars used for this project were purchased in accordance with ASTM A-20 and ASTM A-322 by the Stressteel Corporation. Stressteel Corporation used a bar whose chemistry was modified as permitted by Sec-tion 3 of ASTM A-322-64. Processing the bars consists of cold working, furnace heating, thread-ing and assembling. Cold working, the first step, involves pulling a bar to a predetermined minimum force of 208 000 lb, at the same time approxi-mately checking the resulting elongation. Heating the bars at 700 F for 4 hours is the subsequent process which improves the yield strength and ductility. After furnace heating, the bars are cut to length, threaded and assembled into tendons. The bars are identified at each stage of the process. Investigation of Quality Control in Manufacture A - TENDON BARS On June 6,1967 a shipment of 1-3/8 inch diameter hot-rolled bars from Bethlehem Steel Corporation was received at the Stressteel Plant in Wilke s -Ba r re . This shipment included 12 bundles containing 202 bars 63 feet 6 inches long and 12 bundles containing 200 bars 65 feet 6 inches long for a total of 402 bars as shown on the shipping list of Bethlehem Steel Corporation (Exhibit 1). Stressteel Corporation Bar Receiving Report (Exhibit 2) shows a c.ount of 401 bars. The apparent discrepancy is of no significance inasmuch as the count at the time the bars are received is only made for an approximate check of quantity and weight. In effect, subsequent reports confirm Bethlehem's count (Exhibits 5, 6, 7 and 8). All bars included in the above-mentioned ship-ping list were from the same heat number 524T0110 (hereinafter referred to as heat i10). Exhibits 3 and 4 are the shipping lists and the Bar Receiving Reports corresponding to another shipment which arrived in Wilkes-Barre 3 weeks late r. This shipment included bars from heat 110, whose lengths were 65 feet 0 inches, 78 feet 0 inches and 83 feet 0 inches. Only the 78-foot and 83-foot bars were of the same diameter as the bars received on June 6.
D-3 The second shipment also contained 186 bars from heat 531S0006 The bundles were received at the Stressteel Plant with metal straps and tags designating producing mill, the heat number, the bar size (diameter), and length. Of the 402 bars received on June 6 four bars were randomly selected from four different bundles to be processed and mechanically tested at Pittsburgh Testing Laboratory. The fabrication process the four bars underwent, was identical to the process to be given to the bars destined for the H B Robinson site. The selection of these bars is described in the Ebasco Factory inspector's report dated June 7,1967 (Exhibit 11). These bars were identified as PTL 388 A, B, C, and D. They were cold stretched and heated in a furnace as shown on Stressteel Corporation records (Exhibits 5 and 6). The remaining 398 bars of 63 foot 6 inch and 65 foot 6 inch lengths were cold stretched from June 15, 1967 through June 23,1967 as shown on the Stressteel Corporation bar stretching record (Exhibit 5). Bar stretching record sheets covering the period from May 22 through August 24, 1967 are also attached (Exhibit 7). These records ahow the different heats of steel that were being processed through the plant in Wilkes-Barre up to the approximate time of the last shipment of the lower a s se mblic s. The column entitled " percent stretch" in Exhibit 5 and Ex-hibit 6 should read force applied (psig). All stretching included clongation checks through the use of an indication light installed on the stretching machine. After ccid stretching, the 397 bars (one bar was rejected at the time l of cold stretching because of surface defects) were heated in the furnace l as shown on Stressteel Corporation furnace heat records numbered 1547 through 1552 (Exhibit 8) and corresponding charts (Exhibit 9). Each bundle was taken by a crane to the cold stretching machine as a unit. The metal straps were cut so that the bars could be cold stretched individually. After cold stretching, all the bars in a given bundle were rebundled. New metal straps with bright yellow fasteners were used to tie the bundles together and the original metal tag was attached to the re-assembled bundle. All the bars in a specific bundle are stretched before any other bundle is brought to the cold stretching area. The etretched bundle is then taken by a crane to an area in the shop adjacent to the fu rna ce.
4 D-4 s Groups of bundles were then heated in the furnace .u;d then stockpiled still as a unU in the same originn1 bundle. It should be noted that the fastener is discolored when the btmdla is removed from the furnace. Each tagged hundle is kept in the storage area until neced for the following stage of cutting to the lengths required and then threaded. .- Upon cuttag dich of the original bars, two bars of the required lengths re sult. The cutting and thrcading of both ends was done in unitss of a full bundle . When the total number of bars in each bundle were cut to their proper lengths and threaded, they were again stockpiled in a liase condi-tion but at a special location in the plant. At this stage of fabrication, not only were the bars stored in a specific location, but their length and special thread made tbeni unique and unmistakably idea:.'ified them as correspond-ing to the H B Robinson job. The last operation was putting together each of the lower sendon assemhtit s for shipmen: to the jobsite.
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s The bar and pipe assemblics were put together using a fixture. The base plate, containing six threadea n71 cs, was st-t in the fixture and six bars (alternating short and long bais) were Installed in the plate by coating the threaded area with a Colma Dur LV thread seal. Each ba r's threaded area was driven its entire lengtb into the plate using an impact wrench. The Stre ssteel inspection reports of the lower tendon assemblies (Ex-hibit 10) ahow the dates'they were put together and also indicate a check on the bars as to heat number, length and adequacy of the thread size. The se records also show whesithe four telltale bar assemblies were put together, namely, assembly No. 40 on June 30, as sembly No. 74 on July 14, assembly No. I10 on August 9 and. assembly No. 6 on August 24. During the fabric-tion of the lower tendon assemblies an Ebasco in-spector visited th 7 Stressteel plant periodically. The inspector's reports
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can be found in Exli1 bit 11 B - TELLTALE BA{tS-The procedure for cutting and threading iby telltale bars was different from the normal abop pr'os,ess of cutting anC, threading the standard H B Robinson bars. ThElength of the.!elitale bars is 32 feet b inches as compared ..Jh 31 feet 8-1/4 inches and 32 feet 8-1/4 inches for the tendon
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D-5 bars. The telltale bars were threaded only on the bottom end. The thread was a special size because the 1-3/3 inch bar had to be threaded with a 1-1/4 inch thread. This required that a hollow milling setup be made on one head of the threading machine. This special operation has only been performed by one threading machine operator in the last two years. The fabricator reports that prior to June 30, 1967 when the first tell-tale assembly (40) was put together, four bars from heat 110 were pre-pared and set aside for use as te11 tales. The bars were chosen one at a j time and wiped clean of a residue which is induced in the furnace, and incorporated into tendons as required by the delivery schedules. The first bar was incorporated in tendon No. 40 and was included in the first shipment to the jobsite. Thereupon followed No. 74, and No.110. During the course of assembling, one of the four originally fabricated tellt 'e bars was rejected because of a minor surface defect and another telltale bar for ! l installation in tendon No. 6 had to be fabricated. It is reported through a notarized affidavit (Exhibit 12) that a 78-foot piece was selected for the 32 foot 6 inch long telltale bar. Such a selection would result in a longer and more desirable salvage 1cngth. Howeve r, 78 - foot bars were available in at 1 cast two heats of steel at that time, includ-ing heat 110 That is, the records show that heat 110 included delivery of 78-foot bars in addition to the 63 foot 6 inch and 65 foot 6 inch lengths destined for the Robinson project. These longer lengths were not str 'ed with the Robinson bars but were in general inventory. The 78-foot Icg bar could have been chosen frona a heat other than heat 110 It could have been from a heat which Stressteel designates as regular grade as opposed to the special grade required for this project. It is the contention of Stressteel Corporation that only at this point could a bar from another heat of steel been introduced. The nature of the assembly line processes were such that this could happen. Exhibit 13 is a list of incoming bar mill heats supplied by Bethlehem Steel and U. S. Steel. Prior to Stressteel's using any bar shipment, two bars from the same mill heat are processed through the Stressteel shop
, to determine whether the material as fabricated will meet either Stressteel's f
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D-6 i regular or special grade. Stressteel supplies two types of bar grades one of which is designated regular grade. The regular grade has a mini-
- mum yield strength of 130 000 psi and a minimum ultimate strength of 145 000 psi. As noted earlier the special grade bar (minimum 140 000 psi
! yield strength and 160 000 psi ultimate strength) was ordered for the H B ! Robinson job. (Note: strengths are based on nominal areas of bars.) In analyzing the lists and other Stressteel reports it was concluded that the only probable heats telltale 6 could have come from were Bethlehem Steel heat 538P0841 or United States Steel heat 47A294. The chemical composition, ultimate strength and reduction in area of these heats correspond to the data obtained from chemically and mechanically analyzing telltale 6. However, the yield strength of telltale 6 was lower. One possible explanation of this, is that the bar was not stretched to the same extent as were the bars for the H B Robinscn job. For the H B Robinson job, a light indicator was attached to the stretching machine to indicate that a specific bar elongation has occurred. It was reported by Stressteel personnel that the indicator light was not used on their other 2 jobs. Physical Investigation of Telltale Bars A - LABORATORY INVESTIGATION It was considered necessary to determine whether or not any other installed bar had the same strength properties as telltale 6 consequently a test or series of tests was needed to determine the differences in the bars. It was imperative that the test or tests to be chosen would be able to establish a difference in a specific material property between the bar that met the specification minimum strength requirements and the one that did not. The following is a list of tests analyzed for their effective-ness in distinguishing amongst the subject telltale bars.
- 1) Hardness testing
- 2) Macroexamination of bar surface with an etchant
- 3) Sulfur test
- 4) Ultrasonic testing
- 5) Chemical analyses r ,y w- *, -ug....- -
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l D -7 , i 1 - Hardness Testing I' It is possible sometimes to substitute a nondestructive test for a tensile test to determine the plastic deformation behavior of a metal. A hardness test can be designated as such a test. Hardness is a measure of a metal's resistance to permanent or plastic deformation. It is usually measured by the size of an indentation produced when an indentor of a specific shape is pressed into the metal surface by a known force. The number obtained as the hardness of the metal can be related to the yield strength or tensile strength of the given metal as determined from a tension test. The ex-istence of such a relationship is based on the knowledge that when an in-dentation is made on the metal surface some plastic and elastic deformation will take place. The force required to produce the indentation will there-fore depend upon the yield stress and the rate of work hardening after the yield stress has been exceeded. Because of the correlation between hardness and tensile tests it was decided to remove a cross section from each of the three tensile tested te11 tales (Nos. 6, 40 and 74) and perform hardness teste using a Rockwell Hardness tester. The test was performed using a diamond indentor and a weight of 150 lb. Hardness readings were obtained in nine similar lo-cations for each of three sections. The results are as follows: . Hardness (Rockwell C) Telltale Ave rage Range 6 33.4 32.6-34.8 40 34.1 32.9-35.9 74 33.9 33.1-34.8 The difference in hardness between the telltale sections is not sig-nificant. Consequently the use of the hardness test is precluded to dif-ferentiate between the bars. 2 - Macroexamination The nature of inhomogeneities in a metal, that is the location and ex-tent of segregation, nonuniformity of structure, distribution and variation in size of nonmetallic inclusions and the presence of fabricating defects, can be determined by macroetching a representative section and_ subse . 'l 1 quently visually examining the subject' surface. The inhomogeneities in a ; metal are revealed by macroetching because they react at different rates. I
D-8 It was hoped that by macroetching transverse sections from telltales 6, 40 and 74 respectively inhomogeneous characteristics associated only with telltale 6 could be observed. The following is a list of etchants used: A- 5% Nitric Acid 95% Ethyl Alcohol B - 10% Nitric Acid 90% Ethyl Alcohol 2% Sulfuric Acid 98% Water D - 38% Hydrochloric Acid 12% Sulfuric Acid 50% Wate r No discernible difference in structure was observed amongst the etched bar sections. It was concluded from the results of the etching tests that macroetching the bar surface could not be used to distinguish between bars. 3 - Sulfur Test Sulfur may exist in a chromium steel either as manganese sulfide or as iron sulfide. To determine and permanently record the distribution of sulfur in steel, a sulfur print is made. Transverse sections were removed from Bar No. 6 and Bar Ne Both sections were polished using fine grit paper so that their sur. ( 16 were reasonably smooth and free from foreign matter such as dirt 76 grease. The sections were placed on bromide printing paper that had been soaked in a 2 percent aqueous solution of sulfuric acid. This re . sults in the reaction of the sulfuric acid with the sulfide regions of the steel producing hydrogen sulfide gas. The hydrogen sulfide gas reacts with the silver bromide in the paper emulsion. Each piece of printing paper was then placed in a photographic fixing solution subsequent to being washed thoroughly. A visual examination of a sulfur print will reveal the precise location of sulfur inclusions because of the presence of dark areas of silver sulfide. The agglomeration of such silver sulfide areas indicates the presence of sulfur segregation, while a dispersion of such areas denotes a more uniform
D -9 distribution of the sulfur inclusion. The sulfur prints for Bars No. 6 and No. 74 were carefully examined and no difference in sulfur distribution or content were observed. 4 - Ultrasonic Testing Bar No. 6 and Bar No. 71 were examined by ultrasonic testing to de-termine if a difference in attenuation could be detected between the two specimens. Attenuation is a gradual loss of energy which occurs as the ultrasonic vibrations travel through the material under test and return to the searching unit. Ultrasonic energy is reflected or scattered from the discontinuities at the grain boundaries. The amount of energy scat-tered is dependent upon the magnitude of the wave length and the average diameter or structure of the material, it was hoped that the subject bar grain structure or degree of segregation differed to the extent that the amount of energy loss would differ between the two specimens. A Branson Sonoray Model 301A with a 2.25 me transducer was used in the ultrasonic examination of the samples. The test was performed in the radial and longitudinal directions using glycerine as the couplant. Sound transmission into the specimen was confirmed by observing the first back reflection and then adjusting the instrument to show multiple back reflections. No discernible difference in energy loss was observed between the two specimens examined. 5 - Chemical Analyses The Stressteel quality control procedure (Exhibit 14) specified that the steel chemistry shall fall within the following limits: Carbon - 0.55-0.73 Mangane se 0.90-1.25 Chromium 0.80-1.15 Silicon 0.20-0.35 Phosphorus 0.035 max Sulfur 0.040 max - Specimens from three of the te11 tales examined (Nos. 6, 40, 74) were analyzed using quantitative techniques by Pittsburgh Testing Laboratories. Within experimental accuracy the content of each element was within the specified limits. However, the chromium content of telltale No. 6 was 0.88 percent by weight while the chromium content of telltales 40 and 74 was 1.18 and 1.11 percent by weight respectively.
D - 10 The ladle analyses performed by Bethlehem Steel on heat 110 de-termined the chromium content to be 1.10 percent by weight. Based on these results it was decided to chemically analyze for chromium only in three sections from telltale 6 and in three sections from telltale 74 to determine the consistency of the previous evaluation. The results re-ported by Lucius Pitkin Laboratories (Exhibit 15) were as follows: Chromium Content Telltale (Percent by Weight) 6 .90,.88,.87 74 1.11, 1.15, 1.12 Sections from telltales 6, 40, 74 and 110, were sent to the Bethlehem Steel Corporation for analyses using the same equipment employed for performing the ladle analysis on heat 110 (Exhibit 15). The results re-ported are: Chromium Content Telltale (Percent by Weight) Ladle Analysis Heat 110 1.10 Telltale 6 .88 Telltale 40 1.10 Telltale 74 1.10 Telltale 110 1.12 Based on the above chemical tests it was concluded that the bar designated telltale 6 came from a heat other than 110 Therefore by chemically analyzing any of the installed bars for chromium, a determi-nation can be made to establish the heat from which a bar came. In a desire for an even simpler chemical test a sample from telltale 6 and telltale 74 was also analyzed semiquantitatively for trace element using spectrographic techniques. Elements found to be present in both samples we re: iron, chromium, silicon, manganese, aluminum, nickel, copper, molybdenum and vanadium. Elements checked out and not found in either samples are: zinc, cadmium -
- indium, bismuth, antimony, arsenic, lead, tin, cobalt, tungsten, titanium Magnesium, zirconium.
No distinguishable difference in chemistry with respect to elements present or the presence of any significant amount' of a trace element was noted between the two telltale specimens using the semiquantitative method.
V' D-ll Therefore, using this technique to chemically analyze the bars was con-sidered to be inadequate. B - ANALYSES OF MECHANICAL TESTING The telltale bars were not supplied for the purposes of strength, how-ever, it was assumed they were of the same quality as all of the bars in the structure. This did not prove to be the case. In one bar a difference in the mechanical properties for the telltale bar from tendon No. 6 can be seen in the graphical representation of the test loads and resulting bar stretch, which are plotted as stress strain curves in Exhibit 16. This difference is most notable at the lower levels of strain while at the higher levels this difference is less pronounced. For purposes of comparison, Exhibit 16 also includes the results of control tests conducted during fabrication of the tendons. When making comparisons an appreciation of the raw data used to construct the graphs
- should be kept in mind. The data includes test and material variations I which must be taken into consideration. Test variations begin with the difficulty of ascertaining when a bar deforms inelastically. Neither load nor strain are easily measured, and coordinating load and strain at the
! zero point further adds to this problem. These and other difficulties render tensile test results to an accuracy of approximately 2 percent. This understanding does not vitiate the belief that telltale 6 was from a different heat of cteel. It is introduced to maintain a sense of propor-6 ion and an appreciation of the situation which has been disclosed. C - ANALYSES OF CHEMICAL TESTING 4 By chemically analyzing the four telltales it was noted that the chromium content of telltale 6 was less than the other three; however, the chromium was well within the limitation of the applicable specification. Bethlehem Steel, United States Steel and Ebasco metallurgists were contacted to as-certainwhetheritwould be possible to determine the difference in mill heats
'of high strength chromium steel using chromium composition as the indi-cator. It was agreed that chromium is less prone to segregate than carbon and manganese within a melt of steel; consequently, this ~ fact would permit
, a determination as to whether a.section of steel containing chromium could have come from a particular mill heat. A chemical analysie in the general I sense cannot determine positively from which heat a bar came. Howeve r, ,
D - 12 a conclusion can be formulated within experimental accuracy as to whether it is possible for a material to have come from either one of two known heats. To substantiate the above findings, five grams of metal were removed by drilling from the tops of 10 bars in the field using a drill guide designed by Stressteel. A quantitative analysis was then performed on each sample to determine its chromium content. The 10 bars tested were selected from different assemblies. The selection of the bars was based on Stressteel's assembly and shipping records to enhance the statistical analyses. The analyses were performed by Bethlehem Steel to keep within the same experimental accuracy as the mill test reports on ana-lyzing each sample. The results reported by Bethlehem Steel are (Ex-l'ibit 17); Chromium Content Tendon (Percent by Weight) 16 1.13 18 1.09 35 1.11 36 1.11 67 1.12 69 1.08 99 1.10 101 1.10 132 1.12 133 1.10
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l D-13 l III - CONCLUSIONS It has been shown that sufficient quantity, proper size and an ac-ceptable grade of steel was purchased and processed into tendons by Stresateel Corporation for the first phase wall construction at the Robinson project. This is corroborated by the Ebasco inspection re-ports issued during fabrication. Additional information shows that shipment and delivery schedules correlate with each other. The docu-mentation is consistent with minor explainable exceptions. Plant in-spections showed that the type of documentation is maintained routinely by the Stressteel Corporation. The fabricator's facilities consist of a well run plant staffed by technically competent personnel. It is concluded that the subject tendons at the H B Robinson site contain only bars from heat 110 which meet the strength requirement of the applicable specification. This is based on the following evidence:
- 1) The proper number of bars were observed to be physically in the fabricating plant.
- 2) The qual'ty control records indicate that only one steel heat was used in the fabrica-tion of the H B Robinson tendons except for one of the telltale bars.
- 3) Stressteel's fabrication technique minimizes the possibility of intermixing bars from different mill heats.
- 4) The chemical analyses of the telltale bars and selected tendon bars indicate that the bar substituted for the original telltale bar 6 was not from mill heat 110.
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l D - 14 i IV - REVISED PROCEDURES Upon entering the second stage of fabrication, a reevaluation of the quality control procedures is appropriate in light of experience gained during the first stage. This experien a exposes both strengths and weaknesses in the present procedure. ctrangthe are seen in the weighty accumulation of evidence which could be reconstructed upon demand. The quality control requirements will be revised. Sample bars will be extracted from bundles prior to assembling of the tendons. This will give a random sample of the output. Current procedure is a random sample of the input with controlled processing. Predetermined areas within' the shop will be devoted exclusively to the storing of bars for the H B Robinson project.
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l EXHIBIT 6 STRESSTEEL Corporation FURNACE HEAT No, /8 Yb _ Da te : b~7 19
- 1. LOAD HEAT No. 1' Weight - Pounds 1 Pcs, i Lenoth ' Siza locatinn L8 #
/./6 C. L / / f o 2. O / f~ 76. /7 LM / d 8 '/3 ? a '7 4 6
/'/ 9Y 'l LT f c g y 3 ry tj 9y3 fl 77 / pg
. RB //6c2,/7 / o 4. O /[ 7d _ RT 77'l. 379 /) C. - 37 Y . loN l[ Rd i e 1. - - '
'7 TOTAL 7
,2 Steel Pyrometer in Bundle /r at # O port. 3 Gas Meter Reading: At end of cycle OOO6CO At Start of cycle /7705# 4 Light Up Time: TI 40 A$ Gas Consumed i40 ' S. TEMPERATURE Time Control ? Steel "1 Time ' Control Steel cjlo o / 5^o /Jf u lo'.o o -500 130
//eo 6 ao ' < Web?2 I Z '<10 47i"' g.ll l'oD 10 0 $75 2.'90 '700 700 3'50 70 0 700 fOO ')O O 900 _
6 Remarks: TIME : 7 Pyrometer Air Temperature Readings: TIME: 1 2 3 : 4 gef t Top .. Eeft Bottom B.icht Too - Right Bottom
, , ,, - + ,,---s . , , ~ - --...
l' EXHIBIT 7 1 of 7 l n l l l su '
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EXHIBIT 7 3 of 7 5 0 m O ey s 's. s N $ ' N 9t 7 n gnya s c C O
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1 EXHIBIT 7 q 5 of 7 N
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- EXHIBI.T. 7 7 op );- -
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STRESSTEEL Corporation EXHIBIT E 1 of 6 FURNACE HEAT No. / < U '7 _ Date: 4-/d 19.1 1 1 LOAD Locationj HEAT No. Weicht - Pounds 1 Pcs. 1 Lenoth ' M - 6~9 !! 1' 6 .*/ n $~ vs / )9 6 3' ?" }?.? Ta 016 J/ o 4>x9 _s2 A?'d" /f! . Ta ns */~ 0 // n af Ps a /c 6 T' F " / ?S ,
~~ n V fo // n <- ts . <.~/ )9 4 3 ' e' " /k' R" n sin is e r 9 o .o ir
- r. ' A l / lA I
Rt ( _ q TOTAL 2 Steel Pyrometer in Bundle Ar _ at # 3 port. 3 Gas Meter Reading: At end of cycle 4o1 <~7 o At Start of cycle c a o O' 8 4 Light Up Time: P.'oo Gas Consumed / M '> o 5 TEMPERATURE Time Control 1 Steel '1 Time ! Control J Steel
.> sac :o co i is von una I
!! S ?S K 90 f i.o ao ns
/ 6 9 /> 9A D 6
AGo - 9A />
.3- 40.6 bfs y b10 76 0 _
6 Remarks: TINE :
= _
7 Pyrometer Air Temperature Readings: TIME: 1 2 3 4 i EeYt Top ' ' ' P Eef t Bottom Bioht Too i Right Bottcm j
EXHIBIT 8 STRESSTEEL Corporation 2 of 6
?URNACE HEAT No, MW Date: 4 - /p 19M 'l. LOAD HEAT No, P Weicht - Pounds 1 Pcs. 1 Lenoth '
Si zet Location j 0 <- p u 7f // ,
~
O do o }6 d s V' / ?_,2 L .1 i, o r F7n6 19 A C ' ' Jh/ T ,, i,,
< 5_, a a ,( , p i,3 i, ,-.pp RB i ,. /r ga( ,4 _ p, gs z s. ,y
,h .L ,,j I y or l j3/9 RM /, s,i gyn, -
Rt 1 q q 1, TOTAL 2 Steel Pyrometer in Bundle 1 -r at # / port. A 6 .2 f /4 3 Gas tieter Reading: At end of cycle At Start of cycle a a / a-'7 6 4 Light Up Time #f y rs' Gas Consumed 99o 5 TEMPERATURE Time Control [ Steel 1 Time j Control } Steel > Jo odd USo
// dn n 6'9S~
l
!N l> 9 6 (. _T6 l i &9e .n n l D ! n ,< Onp l 9 49o ooo
'l -
/
6 Remarks: Tire : 7 Pyrometer Air Temperature Readings: TIME: ___ _ y . 2 n 3 ! 4 TeYt Too feft Bottom
~ .
Bicht Too Right Bottom
, ~n- e ,
EXHIBIT 8 3 of 6 STRESSTEEL Corporation FURNACE HEAT No, _ /sy 7 Date: if .- es a 19 O
- 1. LOAD '
Weicht - Pounds 1 Pcs, 1 Lenoth h Location HEAT No. } LB , y , go ,, g 4 33,, ,,
, , , , Q, L IA /! /! ffao j9 /, f '- t " }}p LT ,
si er gon jg /, c '. d' ) f? RB /t !! gga g ,9 p,3 .f 4 /fy l h !!. l // I' fran jo LCQlJSP
' ~
Rt [ - -- 1 1 . TOTAL 2 Steel Pyrometer in Bundle Ar at # o port. 3 Gas 14eter Reading: At end of cycle _
> d 2> J '7 O At Start of cycle S a a d' / 6 4 Light Up Time: P! vs Gas Consumed O4e =
4 5 TE!!PERATURE Time Control F Steel Time Control i Steel-l} l
/0 8 90 ryp I
// 6 l'O 9eh
/3 / . t> n '? b d
/ l6 ?? 08 0
_ 4 A9A Ob6 S t
- s 6 Remarks:
TItG :
- 7 Pyrometer Air Temperature Readings: TIhE :
1 2 3 ? 4 _feYt Too t
-h Eef t Bottom Richt Too Right Bottom l
l I
- 1 EXHIBIT 8 l l STRESSTEEL, Corporation 4 of 6 FURNACE REAT No. /rfo Date
- / J/ 19 6 1 LOAD Location ( HEAT No, P Weloht - Poundn_ i Pcs. 1 Lenoth ' Siza LB g a yfs/je S/ 31 /& /: 3 ' ' /Z LM y // Cy gj )9 6 3' d }})
LT l /, u 4 y f, j7 f, y ' z 'r jh RB f // k pp o ,,, f, Q g n jfp RM // /r grag J7 l/:f't^l}$'_ Rt y i TOTAL 2 Steel Pyrometer in Bundle c-r at # 3 port. 3 Gas Meter Reading: At end of cycle 5 6 t/ /> '~ ^ At Start of cycle 4 a N 3 '7 o 4 Light Up Times Cao Gas Consumed 72o _ 5 TEMPERATURE Time Control Jj Time ' Control Steel _ { Steel l 9 </ o o J e- r lo 46n .e w
~
l
// ( 76 7s6 f JQ 690 '70 0 . I ?9e '96 6 2 L9s pso 0 696 9so 1
L 6 Remarks: TIh3: 7 Pyrometer Air Temperature Readings: TIME: 1 2 3 t 4 _i'eJt Too
' < b ref t Bottom Richt Too l
Right Bottom l __- _ _ _ ne -
EXHIBIT 8 j STRESSTEEL Corporation 5 of 6
- EURNACE HEAT No, / 5 s*/ Date
- / M> 19 < 0 l 1 LOAD Location i HEAT No, t Weicht - Pounds Pcs, i Lenoth '
.912e.
l Is t a h i ? 6606 JT 9$ /?/h } _L U ta r. .. ,, , a i: .< .'> n .
/V % /h i .?/ -
}_LT ,,( ( _, , , ,. p a ,, u 4, RB , , , , ,,o j g ;g ,,, , pf _ n g , Y] RM a ,, y 3 ,,, , , p, , ,g jp I. 4 ,- ,- l /.I's az t .: c. , , a ca i o i ., u ' i&? TOTAL n' 2 Steel Pyrometer in Bundle f e at # / port. i 3 Gas Meter Reading: At end of cycle o o f b 44 At Start of cycle n e i, ~^ l 4 Light Up Time: Phe' Gas Consumed 9#B 5 TEMPERATURE 1 Time Control 4 Steel "j Time J Control J Steel
/^ D to Yw i l' d/o do)$~
- /. ."9 Q t' 0
/ b '/ 6 96 5 o 9 90 OsA l 1
i ) 6 Remarks: } TIFE: 7 Pyrometer Air Temperature Readings: TIME: 1 ; 2 3 : 4
%e_Yt Top " '
b Eef t Bottom
~
Bicht Too l Right Bottom
. _ , , , ..,...,.._, ., ,, , -.- ,-. ._-- . , . . _ _ . . - . , , , _ ---r~-,.,p,~,.. .,_..,_,_,,yy _, .w., , , ,. , . , , , . , , ,,y
EKHIBIT 8 STRESSTEEL Corporation 6 of 6 FURNACE HEAT No, /#Sa - Dato: 4 -f/4 19 /'9 1 LOAD HEAT No, Weight - Pounds 1 Pcs, I Lt'noth ' SizJ, Location 1, P l LB ,g. ,, , ( ,,A ,, p, ,ffpe
, , ,, ,c ,_ , u L*
6 9 2 42 F' E/ p .s // '72 /h-s o tiTo its s es .es 19 d3 ' d " } VV C O 41*s !! O Sc/ m l ') , C .R ' d
- J N' R U' c !T*o 116 C/ 3 s /4 4 .? ' t h)?/
7, </ , Rt j q TOTAL
- 2. Steel Pyrometer in Bundle Ar at # 9 port.
3 Gas Peter Reading: At'end of cycle o4580 0 At Start of cycle aofooo 4 Light Up Time: P.'o o Gas Consumed a 7 5 TEMPERATURE Time Control 1 Steel fi Time ' Control " Steel 9 4 70 Voo sA d r~a Cetr r/ A 96 90 O 19 S9D 9s D l l l96 %e
=
2 490 90n 3 43 6 Osb 6 Remarks: TIf4E : 7 Pyrometer Air Temperature Readings: TIME: 1 2 3 : 4 Zeft Too h- - Eeft Bottom Bicht Too Right Bottom-y y w , -- y ,
10 A n II A*E gaW "* ""n" 0%gy-n =ff=l
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