ML20217B173
| ML20217B173 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 04/16/1998 |
| From: | Curham J, Denny B, Shubert J FLORIDA POWER CORP. |
| To: | |
| Shared Package | |
| ML20217B163 | List: |
| References | |
| NUDOCS 9804220436 | |
| Download: ML20217B173 (32) | |
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i FLORIDA POWER CORPORATION CRYSTAL RIVER UNIT 3 TENDON SURVEILLANCE PROGRAM l ENGINEERING EVALUATION ofthe SIXTH TENDON SURVEILLANCE l
Performed By:
Matthew F. Der 63 Reviewed By: -
hn D. Shu ert, Jr.(I Approved By: b ht /P/WL fflohn J. Curham
$88422ggggggggg$o2 p PDR
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l l INDEX Section Page l !
1.0 Introduction I i
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2.0 Tendon Selection 2 I I
3.0 Tendon Physical Inspection 4 }
l 3.1 Anchorage Assembly Inspection 4 3.2 Physical Condition Tests f
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4.0 Tendon Elongation 4 i 5.0 Individual Tendons Lift-Off Force Evaluations 5 ,
5.1 Evaluation of Tendon 5lH26 6 5.2 Evaluation of Tendon 42H32 7 ,
5.3 Summary of Lift-Off Testing 11 6.0 Historical Trends 12 7.0 Tendon Related Concrete Inspection 12 1
8.0 Corrosion Protection System Inspection 13 9.0 Sixth Tendon Surveillance Conclusion 14 10.0 References 16 Figures 17 Appendix A 20 Appendix B 27 i
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FLORIDA POWER CORPORATION CRYSTAL RIVER UNIT 3 l TENDON SURVEILLANCE PROGRAM ENGINEERING REPORT l.0 INTRODUCTION The sixth tendon surveillance for the Crystal River Unit 3 (CR-3) Reactor Building post tensioning system was performed between October 20,1997 and January 16,1998. The surveillance was performed to demonstrate the integrity of the containment prestressing system, including containment tendons, tendon end anchorage hardware, general and adjacent concrete integrity, and corrosion protection system. The tendon surveillance was performed in accordance with the CR-3 Improved Technical Specifications (ITS). This surveillance occurred during the twenty-second year after the CR-3 structural integrity test, which took place in November,1976. The tendon surveillance was completed while the plant was shut down.
l The inspection activities at CR-3 were performed by Precision Surveillance Corporation (PSC). Florida Power Corporation (FPC) controlled and monitored all activities. The PSC Report,20th Year Physical Surveillance At Crystal River Nuclear Plant (Reference 1) ,
presents the results of the inspection activities performed during the surveillance period. l The inspection was performed in accordance with FPC Surveillance Procedure SP-182 l
Revision 13, Reactor Building Structural Integrity Tendon Surveillance Program (Reference 2). Laboratory test results of material samples (tendon wires and bulk filler ;
grease) are included in the PSC Report.
The purpose of this report is to summarize the results of the tendon surveillance, with respect to the requirements of the CR-3 Tendon Surveillance Program. Nonconformances identified during the surveillance are summarized in the PSC Report. Results found to be outside of the acceptance criteria, and not previously accepted, were evaluated and dispositioned by FPC, and are discussed in their respective sections within this report.
All work performed for this surveillance was evaluated based on the acceptance criteria as presented in Regulatory Guide 1.35, Revision 3 (Reference 3), issued July 1990, and incorporated into SP-182. The specific instructions are contained in PSC Inservice Inspection Manual N604 (contained in Section 9.0 of the PSC Report).
The references listed in section 10.0 of this report are available for review upon request.
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2.0 TENDON SELECTION l Sixteen tendons were scheduled for inspection during the sixth surveillance. This population included the eight deferred tendons exempted during the fifth surveillance. The selection process involved the consideration of the following criteria: ;
A. Tendons were selected to be random but representative of the entire tendon l
population. Samples were selected to represent the areas of containment that were not previously surveyed and that were accessible.
B. Representative samples were selected to represent the respective groupings of tendons, including D100 series, D200 series, etc.
- C. Control tendons previously selected.
D. Except for the control tendons, tendons were selected which were not previously tested.
E. Documentation was researched and inquiries made of FPC personnel to determine if there were any leaking or problem tendons which should be included in the scope of I this surveillance. No specific tendons were identified.
F. Tendon historical data sheets were reviewed and the number of effective wires reviewed and considered. A tendon with the minimal number of efTective wires was not selected for detensioning or as a control tendon.
G. The reduced force dome tendons are not in the selected population since their I prestress forces are significantly less than all other tendons.
H. Accessibility for the surveillance equipment was considered in walkdowns.
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The initial tendons selected for the sixth tendon surveillance were:
DOME HOOP VERTICAL D113 42H18 12VI C D115 42H32 23V2 D212 C 42H44 61V21 D D304 D SlH26 C 61V10 A D311 53H2 D131 A 53H46 62H41 D 62H46 62H22 A C = Control Tendon D = Detensioned Tendon l A = Alternated Tendon i
FPC inspected eleven additional hoop tendons due to the low prestress forces in some of the initial hoop tendons selected. These tendons were:
l 42H29 42H36 42H30 42H37 ,
42H31 5iH25 42H33 51H27 l 42H34 51H28 42H35
- l. The end-caps of two tendons were also removed to investigate deformations. The l removal of the end-caps did not reveal any abnormal conditions. The tendons were then j restored (i.e., gaskets replaced and regreased). These tendons are: !
51H41 (Field End; Buttress 5) 43V4 (Shop End; Top) l l Predicted tendon prestress force curves were prepared for all of the selected tendons, an l alternate tendon from each tendon group, and for adjacent tendons on each side of the selected tendons. The force curves for the additional eleven hoop tendons were generated and included into FPC Calculation Package S95-0082 (Reference 4).
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3.0 TENDON PHYSICAL INSPECTION l
l 3.1 Anchorage Assembly Inspection l Tendon anchorage assembly components, including stressing washers (anchorheads),
l buttonheads, bearing plates, and shims were all inspected during the surveillance. The PSC report summarizes the results of the inspection for corrosion at each of the tendon ends.
l The tendon anchorage assembly components did not exhibit unacceptable levels of corrosion.
3.2 Physical Condition Tests Sample wires were removed from the three tendons, D304, 62H41, and 61V21, selected for detensioning. In addition to these scheduled wire tests, one random wire was removed from tendons 51H26 and 42H35. A broken wire was also removed and tested from tendon 5 lH26. All samples tested were found to be acceptable.
Tendon wires, and specifically ineffective tendon wires, are tabulated in Appendix A, and were evaluated in accordance with the acceptance criteria, as defined in SP-182, Enclosure 9.
The results of the tendon wire inspections provide additional assurance that the tendon wires are performing their intended function and that no local problem areas exist in the tendon post ten sioning system.
4.0 TENDON ELONGATION Information on tendon elongation was taken for all detensioned tendons during the retensioning process. The tendon elongation measured during the surveillance was compared to the measured elongation at originalinstallation. The difference in percentage l ofelongation was compared to the acceptance criteria. A difference exceeding plus or i
minus ten percent was required to be investigated to determine if the difference is related to wire failure or wire slipping at anchorage.
Measured elongation values from this surveillance are presented in the PSC repon for each tendon. One tendon did not meet the acceptance criteria. Tendon 51H26 had a negative 11.6 % variance in elongation when the surveillance results were compared to the original measured elongation. The negative value indicates that less elongation was measured in the current surveillances than at the original stressing. This condition was observed in prior surveillances for other tendons as well. FPC concluded that the condition was not indicative ofwire failure and slippage. The elongation differences 4 of 30
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I obtained in this surveillance are also not considered to be an indication ofwire failure and slippage.
Tendon SlH26 had two wires removed for inspection and testing. Tensile and yield strength tests were performed on the wire samples. These wires were visually inspected and found to be in good condition and the test results demonstrated that all wires met the guaranteed minimum ultimate tensile and yield strengths for the material.
The less than expected tendon elongation is not the result of wire failure or slippage.
Therefore, there was no adverse or detrimental efTect on the integrity of the post tensioning system.
5.0 INDIVIDUAL TENDONS LIFT-OFF FORCE EVALUATIONS This tendon surveillance is based on the requirements of Regulatory Guide 1.35, Revision 1 3, as described in SP-182. Previous surveillance data incorporated parts of Regulatory Guide 1.35, Revision 3, for information only. Such data is used where appropriate in this evaluation.
The Normalizing Factor used in the surveillance is defined as the effect of the original l
installation sequence of stressing. This value varies from plus to minus, depending on the l tendon's position in the stressing sequence.
A liR-offis performed on each surveillance tendon to monitor the force exerted by the tendon onto the structure. Measured lin-off forces are the average of both ends, except for the vertical tendons where lift-offis measured from the top only. LiR-off forces for all 27 tendons in this surveillance are presented in Table VII of the PSC Report.
Vertical tendon lift-offs were found to be above the Base Value except for 12VI, which was above 95% of the Base Value. All dome lift-off averages were above the Base Value.
Horizontal lift-offs revealed two isolated areas, 42H30 to 42H36, inclusive and 51 H26 and 5 IH27 where average tenden lin-offs were between 90% and 95% of Base Value.
t Two tendons, 5 IH26 and 42H35, were found to be below 90% of base and were detensioned for continuity tests. These continuity tests revealed that all of the wires were continuous, one wire was removed for testing and the tendons restored to base value -0%,
+6%. All other tendons found between 90% and 95% of Base Value were subsequently restored per SP-182 to the Base Value.
All other tendon lift-offs were either above Base Value or 95% of Base Value and therefore, acceptable.
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4 5.1 EVALUATION OF TENDON SlH26 The lift-off force of 1320 Kips fell below the 90% Base Value of 1362 Kips. This was determined to be unacceptable and was reported to the NRC in FPC Special Report 97-
- 07. The tendon was also identified as having one broken wire.
The tendon was detensioned, the broken wite removed and one other wire removed for testing to determine if wire failure contributed to the lower than predicted tendon force.
The tendon was retensioned to 6% above the Base Value of 1513 Kips, with allowance being made for the loss of the two wires.
Tendon 51H26 had liR-off tests performed in the third z.nd fourth surveillances. The results of those tests were, in both cases, about 92.5% of the Base Value at the time of the test. There were no broken wires identified. The results are plotted on the attached Figure 1.
As seen in Figure 1, the predicted value lines are parallel to the historical trend line plotted for the third and fourth tendon surveillance. Extending this historical trend line to the l sixth tendon surveillance yields a value of 1390 Kips. Correcting for the one broken wire yields a predicted value of 1381 Kips. The actual lin-off of 1320 Kips is 4.5% below the j historical predicted value of 1381 Kips.
The Normalizing Factor for SlH26 is -75 Kips. When the actuallift-ofrof 1320 Kips is normalized, the resulting normalized liR-off force is 1245 Kips. This was 7 Kips (0.6%)
below the required minimum tendon force of 1252 Kips.
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5.1 CONCLUSION
FOR TENDON 51H26 The two adjacent tendons,51H25 and 51H27, were subsequently tested for lia-off. The i
results obtained were 97% and 93% of their respective Base Value. ;
Because tendon 51H27 had a lin-off force below 95% of Base Value, a lift-off test was l performed on the adjacent tendon, 51H28. The lin-off force obtained for this adjacent I tendon was 96% of the Base Value.
l The average normalized tendon lin-off force for tendons 51H25,51H26,51H27, and SlH28 is 1378 Kips. This was 126 Kips (10.1%) above the required minimum tendon force of 1252 Kips for hoop tendons. Subsequent to the lin-off testing, the four tendons were retensioned and locked-off at 6% above their respective Base Value.
The lower than predicted lift-off force for tendon SlH26 is acceptable. This is based on past surveillance results for the tendon, small deviation from the historical predicted force, and the fact that the group of tendons comprising 51H26 and adjacent tendons 1 51H25,51H27, and 51H28 have an average normalized tendon lin-off force which exceeds the required minimum tendon force. Further, there is no indication of degradation within the tendon components.
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9 Tendon 51H26 was designated as a Control Tendon. Because the tendon was detensioned and had wires removed, it is no longer available to be a Control Tendon.
Consideration has been given to the selection of 46H21 as a new Control Tendon. It has been tested in the first and fifth tendon surveillances.
5.2 EVALUATION OF TENDON 42H32 Tendon 42H32 had a lift-off force of 1356 Kips,93% of Base Value, which falls below the 95% Base Value. Therefore, the two adjacent tendons had lift-off tests performed.
The lift-off force for each of these two tendons fell below the 95% Base Value. This was determined to be unacceptable and was reported to the NRC in FPC Special Repon 97-07.
i To investigate the cause of this anomaly, further lift-off testing was performed on additional adjacent tendons. The lift-off testing continued with additional adjacent tendons until the lift-off force of the tendon was greater than the 95% Base Value.
Tendon Lift-off as % of Base Value Nonnalized Lift-off (KIPS) 42H29 100 1441 42H30 95 1357 42H31 92 1317 42H32 93 1341 42H33 92 1326 42H34 95 1364 42H35 89 1280 42H36 94 1343 42H37 97 1387 Subsequent to the lift-off testing, the nine tendons were retensioned and locked-off at 6%
above their respective Base Value. Allowance was made for the one removed wire in 42H35, discussed below The lift-off force of tendon 42H35, at 89% of Base Value, fell below the 90% Base Value.
l To determine if wire failure was the cause, the tendon was detensioned and one wire was removed for testing.
5.2.1 Possible Causes of Low Hoop Tendon Forces Dome and Vertical Tendon Trend of Tendon Forces During the past five surveillances, the dome and vertical tendon forces as measured by lift-off testing have been in good agreement with the Base Value. This would suggest that the cause of the lower than predicted hoop tendon forces is unique to the hoop tendons.
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O Elevated Temperature Localized hot spots and temperature variations along the length of a tendon can cause variations in the force along the length of the tendon. The stress relaxation properties of prestressing steel and the basic concrete creep vary with temperature variations.
l Elevated temperature considerations up to 104 degrees Fahrenheit (F) for the tendon wire were taken into account for CR-3. This would indicate that the resulting stress relaxation would not be as severe as those designs using 68 degree F wire. The center of the hoop tendons was approximately nine inches from the outside face of the concrete and approximately two to three inches from the inside i
face of the containment liner, making the potential effects of higher interior
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temperatures less significant (Reference CR-3 FSAR, Figure 5-11, " Reactor ,
Building Iso-Thermal Curves for Winter Operating Temperature Condition"). l The CR-3 tendon wire is a stabilized, low relaxation wire (Reference CR-3 Enhanced Design Basis Document, Containment System, pages 6 & 7, and Specification SP-5583). The stabilized wires were cold-worked to yield in order i to limit the overall relaxation.
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The effects of elevated temperature are not perceived as a major cause of the CR-3 l lower hoop prestress condition.
Wire Relaxation In addition to the above noted discussion on the type of wire, it is noted that a true wire relaxation problem would likely have an equal effect on all three tendon groups. Since this is not occurring, the effects ofincreased wire relaxation is not
- seen as the sole contributor of the lower hoop prestress condition.
Concrete Creep ,
One of the most significant and variable factors in the computation of time-dependent losses in prestressed concrete containment structures is the influence of concrete creep, (Reference Regulatory Guide 1.35.1, Section 2.2.2 for further l discussion).
The predicted concrete creep losses for the hoop tendons may be effected by the l
softer coarse aggregate, (Gilbert Commonwealth (G/C) Report, " Reactor Building Dome Delamination, Final Report," December 10, 1976). The stresses in the hoop direction are higher than the stresses in the vertical direction (1732 psi vs 967 psi).
This may explain some of the difTerences seen between the dome, vertical, and hoop lift-off force results as compared to their Base Values.
Further studies would be required to determine if the softer coarse aggregate used in the CR-3 concrete may have contributed to the lower hoop prestress condition.
These studies will not be performed at this time due to the trend showing adequate prestress for the 40 year plant life.
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Equipment and Data Accuracy The calibration of the measuring equipment was checked daily with no abnormal conditions noted. The major equipment was calibrated prior to the surveillance and aRer the surveillance. Equipment and data accuracy is not considered as a contributing cause to the low lin-off force values.
Voids / Delamination in Concrete The possibility of voids and/or delamination of the concrete cylinder were investigated.
At the time of the dome delamination in 1976, the question was raised and investigated regarding delamination of the concrete cylinder. The conclusion, based on field investigations and engineering studies, was that there was no delamination of the concrete cylinder.
A loss of tendon force of 150 Kips could be caused by a change of tendon . length of about 0.5 inches. Delamination and resulting movement of the containment liner would result in bulges, ripples, possibly flaked containment coating, and other visible defects. The radial movement would be about 0.5 to 1.0 inches ifit occurred between two buttresses. On December 9,1997, observations of the containment liner in the area of these nine tendons were conducted. There were no visible defects noted during this tour.
A delaiaination in the concrete could become a receptacle for grease from the tendon ducts. Past surveillances have had vertical tendons with upward of 40 gallons ofgrease added over that which was removed (Reference past surveillance reports, including G/C " Engineering Evaluation Report for the Fifth Tendon Surveillance Inspection Period," June 20,1994). There were no instances of excessive grease replacement for any tendons during this surveillance.
There is no evidence to suggest that voids and/or delamination of the concrete cylinder exist or have contributed to the lower than predicted hoop lift-off forces.
Calculated Prestress Levels Possible conservatism in the design basis calculations for the determination of the three prestress forces (i.e., Dome = 1215 Kips, Vertical = 1149 Kips, and Hoop =
1252 Kips) has been previously investigated. FPC concluded there was no excess conservatism included in those calculations. Thus, it is not likely the minimum design prestress requirement of 1252 Kips for the hoop tendons would be lowered.
Required Minimum Tendon Force Lin-off testing was performed on 19 horizontal tendons during the sixth !
surveillance.
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The average normalized tendon lift-off force for the horizontal tendons is 1399 Kips. This is 147 Kips (11.7%) above the required minimum tendon force of 1252 Kips for hoop tendons.
1' Figure 2 shows the plot of the regression line representiag the trend oflosses for the tested hoop tendons. The data point for this tendon surveillance,1399 Kips, has pad correlation with the first through fifth trend line. Projecting the first through fifth trend line to the sixth tendon surveillance would predict an average force of about 1395, indicating less than 1% difference in the predicted and actual.
j Further, the projected trend line at the end of the 40 year plant life is above the I required prestress level of 1252 Kips.
Tendon 42H32 and the two adjacent tendons,42H31 and 42H33, had an average normalized lift-off force of 1328 Kips. This normalized lift-off force exceeds the i required minimum tendon force of 1252 Kips by 76. Kips (6.0%).
In this group of nine tendons, the tendon with the lowest lift-off force was 42H35.
j Tendon 42H35 and the two adjacent tendons,42H34 and 42H36, have an verage 6 normalized lift-off force of 1329 Kips. This normalized lift-off force exceeds the I required minimum tendon force of 1252 Kips by 77 Kips (6.0%). I The normalized lift-off force for tendons 42H31 through 42H36 was calculated in groups of three (i.e.,42H31 to 42H33 and 42H34 to 42H36). The results vcere average normalized lift-off forces of 1328 Kips and 1329 Kips respectively. These ,
results were plotted on Figure 2 Considering the close correlation of the data !
point for the 19 tested hoop tendons, a parallel trend line has been constructed on Figure 2 from the normalized lid-off forces of 132S Kips and 1329 Kips. The projected trend line at the end of the 40 year plant life is above the required ;
prestress level of 1252 Kips. j Variance in Tenden End Lift-off Values i The lift-off forces of tendons 42H29 through 42H37 were calculated by averaging the lift-off force of the two ends, shop end at Buttress 4 and the field end at !
Buttress 2. In all cases, the field end lift-off force was lower than the shop end. A The difference varied from 62 Kips to 276 Kips. A review of the original stressing records show that in general the field end was locked-off at a lower level than the shop end. The maximum difference was about 50 Kips. However, three of the i tendons had the shop end locked-off at a lower level the the field et d. Tendon {
42H35 with lift-offless than 90% of Base Value was detensioned ano a " push- i pull" test was performed. The results of this test did not ofrer any in-(ght into the !
difference in end lift-off force values. Further actions included the rnnoval of a !
wire for testing, which had no abnormalities found.
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As previously noted, there is no evidence to suggest that voids and/or delamination of the concrete cylinder exist or have contributed to the differena in the shop / field end lift-ofTforces.
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There is no apparent reason for the difference in the lift-off forces of the shop and j field end. As previously noted, the force in a hoop tendon is based on the average !
of the two ends. The averages used for this aurveillance were not adjusted due to the variance in force found for the shop and field ends.
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2.2 CONCLUSION
FOR TENDON 42H32 The lower than predicted lift-off force for tendon 42H30 through 42H36 is acceptable based on:
l l _ Tendon 42H32 and the two adjacent tendons having an average normalized lifboff
! force exceeding the required minimum tendon force of 1252 Kips.
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_ Tendon 42H35 and the two adjacent tendons having an average normalized lifboff !
force exceeding the required minimum tendon force of 1252 Kips. i l
_ 42H32 and 42H35 and their adjacent tendons have a projected trend line at the end i of the 40 year plant life above the required prestress level of 1252 Kips.
_ There is no indication of degradation within the tendon components.
5.3
SUMMARY
OF LIFT-OFF TESTING i !
The results of the surveillance with regard to the hoop tendon prestress has demonstrated ,
i that the CR-3 containment has been maintained at a level sufYicient to maintam '
containment integrity throughout the plant's life. ;
, The lower than predicted lift-off force for tendon 51H26 is acceptable. This is based on past surveillance results for the tendon, small deviation from the historical predicted force, no indications of distress, and the fact that the group of tendons comprising 51H26 and '
adjacent tendons 51H25, S lH27, and 51H28 have an average normalized tendon lift-off force which exceeds the required minimum average tendon force.
Tendon SlH26 is no longer available to be a Control Tendon. Consideration has been given to the selection of 46H21 as a Control Tendon.
l Tendon 42H32 and the adjacent tendons are acceptable. This is based on no indications of distress, and the acceptable normalized prestress forces.
There is no indication of failure of tendon elements from corrosion or material deficiency.
The present tendon system appears to have suflicient prestress for the 40 year plant life.
l Plant life extension would require a review of the tendon system, possibly retensioning of tendons, and adequate planning.
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6.0 IllSTORICAL TRENDS l A comparison of the lift-off forces from this surveillance to the original installation lock- )
off forces was made in an effort to detect any evidence of system degradation. The lock- l off forces were compared in order to detect any abnormal force loss which would possibly indicate an underestimation of the creep, shrinkage and/or elastic shonening effects in the l Reactor Building.
Three tendons were excluded from the results due to inconsistencies. Tendons 23V2 and 53H2 both reported higher lift-offs during the sixth containment tendon surveillance than at installation. Both of the original reported lift-offs appear to be lower than the group average at installation, the horizontal by almost 5%, which could indicate an error in recording the original result. Tendon D304 lost only 12 Kips from the original recorded lift-off. In no case were any conditions found that would indicate problems with the wire j conditions or forces found. These results are not considered detrimental to the structure. l Due to these results being inconsistent with the rest of the results, they have been omitted from the group averages. The group averages have been plotted with previous surveillance results and are included in Appendix B.
7.0 TENDON RELATED CONCRETE INSPECTION As part of the surveillance, visual inspections were performed to evaluate the condition of the concrete immediately adjacent to each tendon area. In addition, a general inspection was performed to evaluate the concrete conditica " .e exterior of the Reactor Building.
These inspections were performed as required by a 82. Results are documented in the PSC Report in Section 4 on data sheets SQ8.3 and W8.4.
SP-182 requires that concrete cracks greater than 0.010 inches in width be evaluated.
l Cracks in excess of 0.050 ir.ches shall be investigated for cause and effect on the structural l l
integrity of the Reactor Building. During this surveillance, two tendons had concrete gaps greater than the 0.050 inch acceptance criteria. These tendons areas are D311 and 51H26.
l Cracks were evaluated and accepted as shrinkage or surface cracks and were found to l have no impact on the ability of the structure to perform its design function. The gap l found around tendon 51H26 was determined to be due to the spalling of cosmetic concrete. The cosmetic concrete was removed by design change, Modification Approval Record (MAR) 95-09-02-01 (Reference 10) The gaps (small cracks with pieces missing) found on tendon D311 were evaluated as having no detrimental effect on the Reactor Building. The evaluaticn and determination of corrective actions is continuing per Precursor Card (PC) 97-8303.
The results of the general exterior inspection found concrete spal!ing 31 feet from the top of the dome. The previous patching was found breaking apart. This condition was addressed per PC 97-7986 and found to be cosmetic. Repair plans were developed and an implementation plan is being formulated.
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Exterior walls were all found to be in good condition. There was evidence ofleaking ;
grease plugs on tendons 62H43,62H33,62H23 and a slight gasket leak on tendon 53H40. '
The slight grease leaks have been determined to be minor leaks and will be corrected during the next surveillance.
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Based on the results of the tendon adjacent area concrete inspections and the general !
exterior Reactor Building inspection, no significant problems were found which would affect the integrity of the post tensioning system of the Reactor Building.
8.0 CORROSION PROTECTION SYSTEM INSPECTION I Visual examinations of the grease were performed with results of each tendon presented in
- the PSC Report, Appendix B and summarized in Table 2. There were no adverse findings.
l It was noted that the P-4 grease is lighter in color and thicker than the older P-2 grease. !
This difference was taken into account in the acceptance criteria for visual grease inspection.
1 Samples of bulk filler grease were removed from each end of the tendons and sent for laboratory testing. Tests were performed for the following conditions:
L Acceptance Criteria Chlorides 10 ppm maximum l
l Nitrates 10 ppm maximum l Sulfides 10 ppm maximum Moisture content 10% Maximum Reserve Alkalinity Greatei than 50% of the installed (Base, Neutralization No.) value, or greater than 0 when the installed value was less than 5.
All samples met the acceptance criteria, as stated above, with the exception of tendon 51H25 field end which had a water content result of 14.9%. This condition was reponed to the NRC in FPC Special Report 98-01. Since there was a limited amour.t of grease available for testing in the grease cans, due to the large shim volume, there was not sufficient grease available for additional samples. This result was not necessarily indicative of the tendon grease condition throughout the tendon. Inspection of the tendon end anchorage, shims, and buttonheads showed no abnormal corrosion which would indicate a moisture problem. The gasket was replaced and the anchorage refilled with new grease.
Grease replacement quantities for individual tendons were monitored, as required by SP-182. The specified acceptance criteria was that the absolute difference between the amount of grease removed and the amount of grease replaced on a given tendon shall not exceed 5% of the net duct volume. The replaced grease data has been tabulated in Table XII of the PSC Report. Five tendons (D212, D304, D311,42H30, and 42H34) exceeded the acceptance criteria. This candition was reported to the NRC in FPC Special Report 13 of 30
l 97-09. A review of prior surveillance reports indicates that CR-3 has not been able to '
meet this acceptance criteria in the past. This exceedance has typically been in the range of 10 to 23 gallons (-9% to ~20 %) over that removed. FPC has previously evaluated this condition for past surveillances and the evaluation is still applicable at this time. This 1 evaluation can be found in the G/C report, dated June 20,1994, Attachment D.
Inspections performed this outage of the Reactor Building have not identified any tendon grease leakage problems. The inspection of bottom end caps of all vertical tendons, as required by the current revision of the regulatory guide, was performed with no leaks found. In addition, an observation of the interior surface of the Reactor Building was conducted with no abnormal conditions (bulging, bowing, etc. ) found. The overall condition of the tendon wires remains good, and successful wire tests performed for all six j surveillances support the conclusion that the corrosion protection system is performing well and maintaining the integrity of the tendons.
9.0 SIXTH TENDON SURVEILLANCE CONCLUSION 1
l The results of the surveillance have demonstrated that the structural integrity of the CR-3 Reactor Building has been adequately maintained to ensua its operability through the lite j of the plant.
i Conclusions based upon the various inspections and tests performed during this surveillance are summarized below.
Group Tendon Forces The average prestress condition for each of the three groups of tendons is currently projected to exceed the required minimum levels at the end of the expected 40 year plant life. The projected trend of prestress forces for each of the three tendon groups shows adequate margin available at the projected end of the 40 year plant life.
Anchr, rage and Assembly Hardware Tendon anchorage hardware was inspected and found to be in good condition. There l were instances of corrosion that were found, such as on bearing plates outside of the 0-Ring end-cap seal. These corrosion instances are typical of that expected for a plant in service almost twenty years and did not exceed the acceptance criteria contained in SP-182.
l Wires '
Tendon wires were found to be in good condition. No corrosion was found on the tendon wires removed from the detensioned tendons. Material tests on the tendon wires showed that all wires met the minimum guaranteed ultimate tensile strength.
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Corrosion Protection System Based on the visualinspections performed during the surveillance and the results of sample testing of the bulk filler material,it can be concluded that the corrosion protection system is performing its protective function with no abnormal degradation. I I
j Concrete J j
i '
A few minor cracks and spalls found during the inspection were typical for a facility of this age. No concrete problems were observed that impacted the design function or integrity -
of the Reactor Building.
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10.0 REFERENCES
(1) Precision Surveillance Corporation Repon,20th Year Phys: cal Surveillance of the Crystal River Nuclear Plant Containment Post Tensioning System, Revision 0,4/1/98. (Volumes I, IA and II).
(2) Surveillance Procedure, SP-182 Revision 13, FPC CR-3, Reactor Building Structural Integrity Tendon Surveillance Program.
(3) U.S. Regulatory Guide 1.35, Revision 3, July 1990, Inservice Inspection of Ungrouted Tendons in Prestressed Concrete Con;ainments.
(4) FPC Calculation Package, S95-0082, Preparation of Tendon Force Curves for 6th Tendon Surveillance.
(5) CR-3 Enhanced Design Basis Document (EDBD), Containment System.
(6) G/C Specification SP-5583.
(7) U.S. Regulatory Guide 1.35.1, Revision 0, July 1990, Determining Prestressing Forces for Inservice Inspection of Prestressed Concrete Containments.
(8) G/C Report, Reactor Building Dome Delamination, Final Report, 12-10-76.
(9) G/C Repon, Engineering Evaluation Report for the Fifth Tendon Surveillance Inspection Period,6-20-94.
(10) Modification Package, MAR 95-09-02-01, Revision 0, Repair R.B.
Concrete Buttresses.
(11) CR-3 FSAR, Revision 24.01.
I (12) FPC Special Reports 97-07,97-09, and 98-01.
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APPENDIXA TENDON WIRE SUMMARIES DOME,IIGOP AND VERTICAL GROUPS I
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INEFFECTIVE WIRE
SUMMARY
UPDATED TO SLXTH SURVEILLANCE Acceptance Criteria
- 1. Maximum of 8 ineffective wires per tendon.
- 2. Maximum of 3% ineffective wires per 10 consecutive tendons.
- 3. Maximum of 2% ineffective wires per group.
The vertical tendons group consists of one stressing sequence quadrant of 36 tendons.
The dome tendons group consists of one series layer of 41 tendons (i.e., D100, D200 and D300 groups). The hoop tendons group consists of one side of a buttress or 47 tendons.
The results of all tabulated data are summarized as follows: l Tendon Group Max / Tendon Max /10 Tendons Max / Group Domes Actual 7 (Note 1) 30 67
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! Allowable 8 49 134 l
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j Verticals Actual 6 21 38 Allowable 8 49 117 Hoops Actual 6 18 49 Allowable 8 49 153 Notes
- 1. Dome tendons D-217 and D-233 wit'i 16 and 12 ineffective wires respectively exceed the 8 wire maximum per tendon, but were previously accepted for that condition.
These two tendons are reduced force dome tendons and it was determined that the high number ofineffective wires was due to unseating as a result of the reduced !
tensioning force in the tendons. I
- 2. The calculation for the ten consecutive tendons for the last nine tendons was l'erformed by using the data from first tendons at the top of the listing. ]
- 3. Maximum wires per group are noted on the tendon group sheets.
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1 APPENDIXB TENDON TREND OF LOSSES 1
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