ML20129F596

Forwards Final Rept on Investigation of Failed Field Anchor Heads HV016 & HV038 from Jm Farley Nuclear Power Plant Unit 2 Containment & Anchor Head Investigation Final Rept. Rept Corrections Also Encl

ML20129F596
Person / Time
Site:	Farley
Issue date:	07/10/1985
From:	Mcdonald R ALABAMA POWER CO.
To:	Varga S Office of Nuclear Reactor Regulation
Shared Package
ML20129F600	List: ML20129F596 ML20129F611 ML20129F633
References
NUDOCS 8507170400
Download: ML20129F596 (24)

Text

C:lling Address Alabama Power Company 600 Nortn 18th Street Post Office Dox 2641 Birmingham Alabama 35291 Telephone 205 783-6090 R. P. Mcdonald Senior Vice President Flintridge Buildin Mabanla POW'M July 10, 1985 ,

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Docket Nos. 50-348 50-364 Director, Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission Washington, D.C. 20555 Attention: Mr. S. A. Varga Joseph M. Farley Nuclear Plant - Units 1 and 2 Containment Tendon Anchorhead Failure Reports - Unit 2 Gentlemen:

During meetings held on February 7 and March 1,1985 to discuss tendon anchorhead failures at the Joseph M. Farley Nuclear Plant - Unit 2, Alabama Power Company provided the NRC with its preliminary findings and with a commitment to update these findings after Inryco investigation reports were available. Attachment 1 provides the results of the Inryco investigation which concludes that the tendon anchorheads failed as a result of hydrogen stress cracking caused by moisture in the environment of the tendon anchorheads. Enclosed with Attachment 1 is the Inland Steel Metallurgical Laboratory Report, the Battelle Report and a summary of the load tests and magnetic particle test results as well as the results of the Suburban Laboratories grease sample analyses. Attachment 2 provides a list of minor corrections to the two reports enclosed as part of Attachment 1.

The tendon anchorage inspection and replacement programs have been completed for Units 1 and 2. Laboratory analysis of additional anchors is in progress. Details of the inspection and replacement program and results of additional anchorage analyses will be provided in a supplemental LER.

If there are any questions, please advise.

Yours truly, S

0 850710 K 05000348 gl,). lbrM 5 PDR

'fy '

R. P. Mcdonald /

p' (M h(

RPM / JAR:bdy-D28 Attachments '72 U cc: Mr. L. B. Long Dr. J. N. Grace f/g Mr. E. A. Reeves /

Mr. W. H. Bradford J

INRYCO, Inc.

. C.:ncr't2 Systtms Di*tision 7200 S. N rraginsett Avinus Bedford Park L Chic:go,Illin:is 60638-6087 312 585 7300 Chicago 312 594 7300 Suburban /

TLX 721497 BDPK e ggi l[jj FAX: Ext. 202 InryCO 4 . / ,'

June 3, 1985 y/

V WGHY N M

. JEG "

I DEM Mot JWM wec HDT Alabama Power Co.

P.O. Box 2641 00C. N Bitiningham, AL 35291 Attention: Mr. W. G. Hairston III

SUBJECT:

Joseph M. Farley Nuclear Plant - Unit 2 Failure Investination

Dear Mr. Hairston:

The reports of the anchorhead failures contain minor errors.

They are hereby corrected with the enclosed addenda.

Very truly yours, a H e inager, Contract Management JWH:lgw Enc.

I an inland Steel company

INRYCO, Inc.

l W. G. Hairston Alabama Power Co.

June 3, 1985 ADDENDUM 1 TO METALLURGICAL LABORATORY. INVESTIGATION NO. 19975 - FINAL REPORT INRYCO POST TENSIONING DIVISION JOSEPH M. FARLEY NUCLEAR PLANT, UNIT 2 -

ANCHORHEAD INVESTIGATION Page 1 Line 3 - Correct "Dolton" to read "Dothan".

Page 2. Item 2, line 3 - Correct "nacent" to read " nascent".

Page 1. Introduction, line 1 - Correct "Dolton" to read "Dothan".

Page 1. Investigation No. 19975, line 11 - Correct "three anchorages" to read 4 "two anchorages".

• f 1

Page 2 Investigation No. 19975, lines 13 and 14 - Correct "... January 25, {

1985. During a 30 day refueling shutdown...." to read "... January 27, 1985.

During a refueling shutdown...".

Page 16 Investigation No. 19975, line 26 and 27 - Revise to read "In addition a water sample obtained from the cover on V-21 was sent to Suburban Laboratory for analysis. The test result was subsequently sent in an Inryco transmittal dated 4-16-85."

Page 17. Investigation No. 19975, line 19 - Correct "nacent" to read " nascent".

l I

t an inland Steel company f

INRYCO, Inc.

$ W. G. Hairston Alabama Power Co.

June 3, 1985 ADDENDUM 1 TO BATTELLE FINAL REPORT DATED APRIL 9, 1985 CW l

INVESTIGATION OF FAILED FIELD ANCHOR HEADS MV016 AND HV038 FROM THE J. M. FARLEY.

NUCLEAR POWER PLANT, UNIT 2 CONTAInumrT l

Page 21, last line, last word - Delete "tt".

Page 27 second to'last line - Correct " failed" to read " failure".

Page 32, line 19 - Correct "A3222" to read "A322".

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an inland Steel company

I INRYCO, Inc.

Concr:te Syst:ms Dreisi:n 7200 S. N:rrtgensett Avenu3

, Bedf rd Park Chic go,lihnois 60638 6087

• Y 312 585 7300 Chicago 312 594 7300 Suburban TLX 721497 BDPK FAX: Ext. 202 W i i

April 16, 1985

~

\

Alabama Power Company P.O. Box 2641 Birmingham, Alabama 35219 Attention: Mr. W. C. Hairston III SUBJgCT: Joseph M. Farley Nuclear Power Plant Containment Building 2 Failure Investigation of Post Tensioned Field Anchorheads HV016 and HV038

Dear Mr. Hairston:

We are enclosing reports entitled " Joseph M. Farley Nuclear Plant, Unit No. 2, Anchorhead Investigation: Metallurgical Laboratory Investigation No. 19975 - Final Report" dated March 27, 1985, from l

Inland Stool Co. and Final Report dated April 9, 1985 from Battelle Columbus Laboratories. Inryeo generated ti.ese reports as part of the subject failure investigation at your request: Your P.O. #40578 Dated 1/29/85, as Amended.

These investigations concluded that the anchorheads failed as a result of hydrogen stress cracking caused by the moisture in the l environment of the anchorhead. Intergranular separation (ICS) was l found on the fracture faces supporting the embrittlement l conclusion. The labs also found evidence of water, both in the I grease can that surrounds the anchorage, as well as grease on the l anchorhead of HV038. '

As stated in meetings with the NRC, the source of water might be from rain, water present during installation or from ground water.

The environment of the anchorhead must be free of water to preclude further anchorhead problems.

an inland Steel company

_ _~_ _ __. - .. - - - - - - . .. - - - - - --

INRYCO, Inc.

s Mr. W. G. Hsirstes III Alabama Power Co.

Page Two April 16, 1985

.The presence of water in contact with high strength steel (the anchorhead), stressed to a high value, and also in contact with Zinc constituted a galvanic corrosion cell. The corrosipn reaction

released nascent hydrogen at the steel surface and oxidized the zinc. The hydrogen thus released entered the atomic lattice of the

~

steel and caused cracking of the highly stressed steel. The cracks continued to grow as long as the galvanic action continued to produce nascent hydrogen, until it reached critical dimensions, at which point complete failure of the remainder of the anchorhead occurred. These final crack paths were transgranular (cleavage) and even ductile.

The origin of the cracks was typically in the perforated region, on the shim surface; in the conter of the anchorhead. Once they were initiated the cracks propagated radially from ligament to ligament, as well as upward in the direction of the anchorhead depth. Final failure occurred when the crack entered the unperforated portion of the anchorhead and propagated radially outward and upward through the last piece of resistance.

There are several other failure mechanisms that result in intergranular cracking. They were ruled out on the basis of our testing as outlined in the reports. Temper-Embrittlement was an early candidate that we subsequently eliminated based on the fact that the unfractured portions of the steel had high strength and ductility characteristics. This was also coupled with the fact that temper-embrittlement is not time - dependent. Certain anchors were re-tempered and showed no significant differences in properties from the other anchorheads. In general, the anchorhead steel unaffected by Hydrogen had good to excellent tenslie properties, and would not have failed in a neutral environment.

1 an inland Steel company

INRYCO, Inc.

d .

Mr. W. G. Hairston III Alabama Power Co.

Page Three April 15, 1985 Inland Steel Co., Operating Technology Department and Battelle Columbus Laboratories performed all metallurgical evaluation.

Inland Steel also performed the grease analyses. Additional grease analyses were done at suburban Laboratories, Hinsdale, Illinois.

The structural laboratory at the University of Illinois, Chanpaign-Urbana, performed the load test. Magnetic Particle tests were conducted at our own facilities. Copies of these have been previously submitted and are submitted for completeness.

Very truly yours,

/t k H se

% nager, Contract Management JH:1gw Enclosures .

cc: Mr. D. Mansfield, Alabama Power Co.

Mr. R. Lawler Mr. H. Hendrickson Mr. D. Waitkus Mr. H. Presswalla l

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l an inland Steel company

-... . . . .r - . . . ~

FARLEY NUCLEAR POWER PLANT - 417-2400 "

ANCHORHEAD TESTING

SUMMARY

FORM FNP-ATP-8 ANCHOR Mo. OF CRACKS (MPT) man TEST COMPOSITION MEAD TOP MECHANICAL TESTING (transverse) METarrm;tAPNY FRACTOGRAFNY BOT PULT MODE 4140/42 ? TS (ksi) YS 'ksi) RA (%)

I.D. PRE POST PRE Posf % GUTS GRAIN INCLUSION (REMARES) l L= Minh Loet Minh Lott Minh SIZE RATING NV0161 -- -- -- --.

A3-4M flex YES 199 201 164 168 13.9 18.6 8 or 32N ICS and i

failure finer temo M cleavane MV0381 -- -- - - - flex YES 193 202 161 161 11.1 13.4 A3-4N failure temo M MV039 0 0 3 12 137 A3-4M ICS on flex YEs 200 207 170 184 15.9 15.9

' 32N' pro cracks crack tems M ' only MV028 0 0 0 0 140 some A3-4M YES 192 203 159 173 ' 10.7 14.5 33M No ICs teso M MV0272 0 0 0 13 115 A3-4M flex YEs 183 191 157 168 5.5 14.1 crack 32M No ICs temo M MV049I O O 0 11 120 flex A3-4H YES 188 196 156 175 9.3 17.4 32N No ICs

_ crack temo M i

NOTE: 1) Fiele Failure of Aachorbead

2) Rotempered 0 830*F. for 4 hrs. before load test *

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STRUCTURAL TESTING ANCHORNEADS PROCEDURE QC TESTING DOCUMENTATION FOAM FNP-LT BF anIniend Steelcompany sold 30185 FA!!AFRK Lead LOAD IN & 9F REMARES LOAD IN EIPS 1178 MMM 4- TENDON SFTS Eleutes Target Asteal Asteel Describe treature TIIB Target Astual or other evoets.

. 1.0 S00 500

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1.0 1000 I***

1.0 1500 JJoa f

1.0 1s00 JF00 203^ 8 1%$ -l ,

1.0 2000 2,888 W~

2 9m0-I'1 (Y

• c = i 1.0 2200 22.* 4 2 fee - I l!#*

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1.0 2400 2y00 1.0 26002Ge

• Fracters Lead or 2.0 2800 2.90o Fra hPT_CfEKS

• Fest WT Aacherhead Nest Code N Y#3 I Bataland Distorties at 2800 EiFs MFA7[ Bushing Beat Code M!A visible cracks YU [(WT(# w tt -

e Acca YEI Reject M*Lvsmskrost$t Back ties setse is emitted during testing, that valse in Elps will be desumsated.

Data Recorded by:

p y, sissed b .M .'

Title 7M 9W c v '

A. , ~C" ( h .'

nat. '2.-It-95 Witaama:

81.med AR 1 A m ne mein a,L. n y Agency b A Y1) bgLg 1A I

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a E:"" 2-18-85 ZZ,A

• 1 og 3

• • d*5**iA N flP$(-8*Se f RFf D f or

2-J

'Y STRUCTURAL TRSTING ANCMORMEADS PROCROURE QC TESTING DOCUMENTATION FORM FNP-LT SP an intend Steelcorneeny Nold 30185 PAILUBE l Lead LOAD IN % OF RENARES 1AAD IN EIPS EIPS MODE 8( TENDON SUTS i

Niestes farset Actual Asteal Tm Desaribe feastere l Target Astual or other events. I

. 1.0 ' S00 500 1.0

• 1000 Jo*8 1.0 1500 #Fe*

i 1.0 1800 l800 1

1.0 2000 1 8'8

, s..

1.0 2200 22 oo .

1.0 2400 1400 1.0 2600 1600 Fractura Load or t.0 2800 2. W*

• Pro MPT Op2[9/85 Post MPT Aashorhead Neat Code M VO 2.8 Retataed Distortion at 2800 Eips M#MI Dushiss Neat Code M/A ,

)

Visible Cracks N a#6 Accept YES tejoet Each time noise is emitted during testing, that value is Elps will be desamented.

j Data Recorded by:

M%h 179E sissed b T7/=d- r' WD # ^^ h l sit 1. -fA w -

us.., L '

Date . i,1 - /9- IES,Mf

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STRUCTURAL TESTING ANCMORMIADS TESTING DOCUMENTATION F0ml FWF-LT OF PROCEDURE QC 4 kwyce aninland Steelcomparv E

Mold NOISE FAILURE 14&D IN 5 QF f Emed Le&D IN EXPS EIPS REua323 NDOS E TWID05 SffS

Ninetes , Target Asteal Amtsel TDE Target Describe feastsee Astsel er other events.

. 1.0 ,

500 5*o .

1.0 1000 I888 h 1.0 1500 1500 1.0 1800 lSOO 1.0 2000 2.o a o g' A #5 l 1.0 2200 2200 1.0 2400 2. Y a o 1.0 2600 2.680 9%:,

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Batained Distorties at 2000 ElFs Aieuf mushias meat code M/A

! Yksible Cracks NONI Assept _ YES Reject Beek time satse is emitted during testias, that valse la Rips will he desumented.

Data Recorded by:

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r STRUCTURAL TESTING ANCMORNEADS PROCBDURE QC sust y w w TESTING DOCUMENTATION FORM FNF-LT DF en intend Steelesmeeny sold 301st FAttygg. EAAD IN E OF Lo.4 IAAD 1m EIPs REMAREs EXPs 2 0s &- Tsuen W Ts Minetes Target Asteal Actual Describe feastare TIIE ., Target Actual er other events.

W

. 1.0 500 500 1"" ' # g* f~* "4 '

1.0 1000 1888 1 G ** * - 1 1.0 1500 I5*o 3*19*-I ,-

Igee -/ W ' -

1.0 1800 l700 1 88* - 8 ~3 1 11eo - 1 I:e4/

1.0 2000 2eso 2Fle-/ '

19es-l 1.0 2200 1188 .

1.0 2400 2.488 1.0 2600 '3480 Fracture Lead er 2.0 2000 190* ,

), o 290o z 9o5 -

Fra urf D K 'I/lI M es F t u r f Aseherhead Neat code M V0W Batained Distortion at 2800 Kips M

• A/E s shins seat code M/A

)/fS espTif 16LES Visible Cracks 3#iai SvMAcf Accept YEI Rajinct Back time sense is emitted duries testing, that value la Eips will be desmosated.

Data nesorded bys

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. _ , r- aia wmo SUBURBAN LABORATORIES, Inc.

4140 UTT ORIVE HILLS 40E, ILUNOIS 80142 1183 EMILL floSEMBEAG HJL THoedAS,Jelt Preemens owector February 21, 1985 Concrete Systems Division

~

7200 South Narragansett Avenue Bedford Park .

Oticago, Illinois 60638 Re: P. O. #4172400-8 Attention:,

W. Harry Hendrickson Neutralization No Samles Received: 2/14/85 Chlorides Nitrates Sulfides 1 dater Content Total Base No.

(ppe) (ppe) (ppe) , 5 (as ros/g)

S/L #1537 - Sample A, hcontrolled Button Head Surface Field End, HV038V21 w/ tape 4.30 0.113 0.002 3 21' 46.97 S/L #1538 - Sample B, ancontro11ed around Threads Field Ehd HV038 Y21 0.70 0.113 0.007 1.02 47.86 S/L #1539 - Sample #1, Y64 hoontrolled 1.40 0.113 0.007 0.18 51 35 S/L #1540 - Grease Can, Y102 Top 0.40 0.075 0.012 0.19 49.48 S/L #1541 - Beated Pumped Out Y21, Top 0 70 0.075 0.007 0.17 50.57 S/L #1542 - #840069 Tendon Y-17 Top #1 1.40 0 325 0.007 0.27 50.88 S/L #1543 - #840070 Tendon Y-17 Top #2 2 90 0.150 0.002 0.18 48.50 S/L #1544 - #840071 Y-17, Botton Grease 2.00 0.180 0.012 1.52 48.18 from Lowest Point #3

• S/L #1545 - #840072 Tendon Y-17, Botton 1st from Can #4 1.40 0 300 0.012 en 50.02 S/L #1546 - #840073 Y-17, Bottos Upper Portion #5 1.40 0.230 0.012 1 34 45.84 (Continued)

- - __- _ ~ - .. .. . ..

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1 .

Inryco, Inc.

February 21, 1985 Fage #2 Neutralization No:

Samples Received: 2/14/85 Chlorides uitrates Sulfides Water content Total Base No.

• (ppe) (ppe) (ppe) 5 (as ros/s)

Field Anchor Cap / Y-21 S/L #1547 - Grease wrapped in Plastic 1.40 0.250 0.012 1.11 48.36 S/L #1548 - Layer #1," Top Edge 0.40 0.280 0.016 0.54 46 33 l S/L #1549 - Iayer f1, Top Center 0 70 0.280 0.002 0 77 44 37 S/L #1550 - 14yer #3, Edge 0 70 0.280 0.0 16 0.27

' 46.95 3/L #1551 - tayer #3, Centor 0 70 0.300 0.020 0.44 45.46 S/L #1552 - Layer #4, Edge 2.00 0.300 0.012 0 38 45 74 j 3/L #1553 - Layer #4, Center 0 70 0.300 0.012 . 0.54 47.67 l S/L #1554 - Layer #6, Botton Edge 0.70 0.325 0.016 0 70 45 37 S/L #1555 - !ayer #6, Botton Center 2.00 0 325 0.012 1.42 46.55 Interior Anchor Head S/L #1556 - Field Ehd / V-17 0.70 0.280 0.012 es se j Dates Tested: 2/19/85 & 2/20/85 2/20/85 2/20/85 2/19/85 i

ANALYSIS CERTIFIED BY:

'/

< , Director (ERT:ih)

Chlorides (Sect. 5.11) Method: ASTM D-512 Nitrates -* Method: ASTM D-992 4

Sultides

• Method: AF8A 427-C

~

Mater content (Sect. 5.2) ,

Method: ASTM 4-95 seutralisation Ember (Sect. 5 3) Method: ASTM D-97,4 (Modified)

• Black color appears in the water layer ~

Insufficient sample teameers of Arnerican Chemical Secteer . American Society for Micsoedotog Weemr Featutaen Contpel Federatten . Institute of Food Technoingy 1

Cert.f cat cas. U S O A e1783

• E Dept.of % Heesth ai7136 . Amer.SeceTrade Asan. . F 0A 8tes #1419878 118. EPA 8100191 ga

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Teeephone (312) 644-3200 SUBURBAN LABORATORIES, Inc.

4140 LITT DRIVE HILLSIDE. ILLINOIS 00182 1183 mg,noogasseng .,' H.R. THOMAS JR.

possement Detector February 25, 1985 i

Inryoo, Inc.

Concrete Systems Division 7200 South Narragansett Avenue Bedford Park Chioago, Illinois 60638 Attention: W. H. Hendrickson Saanle Received: 2/22/85 Source: S/L #1880 - Mater from Y-21 Field Cap Chloride (ppa) 180.80 I

ANALYSIS CERTIFIED BY: , Director (HRT:ih) f Momtiere of American Chemical Sectety e American Society for M4crotnoto0V Water Postutaan Contaos FeeeratNm

• Institute of Food Technoso0F Certif6catione. U S D A.e1783 +

118 Dept.of PutW6c Health 817136

• Amer. Sp6ce Trees Aeon. . F.D A Aeg 81419876

• Ist EPAs100101

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