ML20238C787
| ML20238C787 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 12/24/1987 |
| From: | Bailey J WOLF CREEK NUCLEAR OPERATING CORP. |
| To: | NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM) |
| References | |
| 87-10, ET-87-0380, ET-87-380, NUDOCS 8712310215 | |
| Download: ML20238C787 (17) | |
Text
.
n W4tLF CREEK NUCLEAR OPERATING CORPORATION John A. Bailey Vice Presiden:
Engmeering and Technmat Services December 24, 1987 ET 87-0380 U. S. Nuclear Regulatory Comissicn ATTN:
Document Control Desk Washington D.C.
20555
Reference:
1)
No. 87-0197 dated 9/11/87, from F. T. Rhodes, WCNOC to NRC
- 2) VM 87-0243, dated 9/28/87, from L. D. Withers, WCNOC to NRC
- 3) Letter dated 11/13/87, from P. W. O'Connor, NRC to B. D. Withers, WCNOC
Subject:
Docket No. 50-482:
Special Report 87-10, Supplement 2-Tendon Surveillance Gentlemen The enclosed Special Report, 87-10 Supplement 2, is submitted to provide the additional information requested in Reference 3 relative to Special Reports 87-10 and 87-10 Supplement 1 ( References 1 and 2 respectively ) on tendon surveillance.
Reference 3 requested that Wolf Creek Nuclear Operating Corporation provide this additional information by December 18, 1987.
During a telephone conference on December 18,1987, an extension of the submittal date until December 24, 1987 was requested by Mr. H. K.
- Chernoff, WCNOC, and approved by Mr. P. W. O'Connor,NRC.
If you have any questions concerning this matter, please contact me or Mr.
O. L. Maynard of my staff.
1 Very truly yours, b-n John A. Bailey
.I Vice-President Engineering and Technical Services JAB /skw Enclosure cci J. E. Cummins (NRC), w/a R. D. Martin (NRC), w/a p
- p. W. O'Connor (NRC), 2 w/a 87123102,j} hh)hh$82 x 411/ Burhngt n, KS 66839 e Phone: (316) 364-8831 g
f'D p AD0 DCD An Eques opportunity Empiover iA F/HCYET S
Enclosure to ET 87-0380 Page 1 of 11 December 24, 1987 WOLF CREEK GENERATING STATION l
SPECIAL REPORT 87-010, SUPPLEMENT 2 The following information is being provided in response to the request for i
additional information related to Wolf Creek Special Report 87-010-01.
This request was received by Wolf Creek Nuclear Operating Corporation on November 19, 1987.
]
Question 1:
j In the report it is stated that due to physical characteristics of the j
sheathing filler material and industry standard installation techniques, i
voids up to approximately 15 percent could be expected after the initial
)
filling operation. Describe the physical characteristics and the installation techniques that may result in voids up to 15 percent.
Response la As stated in letter KMLNRC 85-264, dated 12/06/87, voids in the tendon sheathing may be attributed to a number of additive factors:
i (1) Visconorust 2090P-4 has a coefficient of expansion which yields ag expansion of about one percent per every 20 degrees Fahrenheit
( F).
Init&al filling temperatures of the filler material can average 160 F.o Cold weather conditions can cool the filler material to 40 F, giving a contraction of 6 percent of the net duct volume.
(2)
Calculated voids between the wires which comprise the tendon bundle are approximately 7 percent of the net duct volume.
If i
during the initial fillingo perations the tendon bundle is cold o
(ambient temperature of 65 F) and, as the filler material is i
pumped into the duct void, it solidifies on the surface of the l
tendon bundle, small voids will be left between the wires. As the filler material (grease) gradually heats the tendon bundle during tendon surveillance, it is likely that the voids between the wires allow migration of the filler material into the tendon bundle.
In addition, this type of migration could also occur at other areas such as where tendons are in contact with the sheathing.
(3) Characteristics of the initial filling method may induce air entrapment into the filler material.
Pumping operations can introduce air into filler material and may add up to as much as 2 percent of the net duct volume.
This void value could be higher l
for horizontal tendons due to the lower pumping head used when compared to the vertical tendons.
Even under optimum filling conditions, voids of approximately 15 percent could be expected after the initial filling operations.
l t
' Enclosure to ET 87-0380 Page 2 of 11 December 24, 1987 Question 2:
In the report it is claimed that three additional factors by themselves can contribute to voids of more than 15 percent.
Please' explain why the voids in the hoop tendons are less than those in the vertical ones, and also less than 15 percent.
Response 2:
The three additional factors mentioned in the report are the three additive factors discussed in Response 1 above.
The average of all horizontal surveillance tendons for the first and second surveillance is 5.6 percent while the average of all vertical surveillance tendons for first and second surveillance is 7.7 percent.
An evaluation of the data available from the first and third year tendon surveillance concluded that the voids for the horizontal and vertical tendons are approximately the same.
Question 3:
Describe the quality assurance program used during construction for installing the grease in the tendon sheathing, specifically the quality and quantity of the grease installed.
Response 3:
Quality Program Description The installation of the post-tensioning system at WCGS was conducted by the Inryco Company (Inryco) of Melrose Park, Illinois.
Inryco commenced site construction activities in November, 1981.
The work was controlled by a SNUPPS contract. The Inryco Quality Assurance (QA) Manual and Field Installation Manual were reviewed and approved by Bechtel.
Bechtel specifications included appropriate criteria for the procurement, storage and handling, placement, buttonheading, stressing, and greasing of the post-tensioning system components.
Inryco was required by contract to maintain a quality program in accordance with the requirement of Specification 10466-QA-1 which is a 10CFR50 Appendix B, 18 criteria QA program.
The original tendon installation and greasing operation was performed by Inryco in acc?rdance with their approved Field Installation Manual.
The inspection of the greasing activity was provided by Inryco Quality Control (QC) personnel in accordance with the Field Installation Manual.
The number of Inryco QC Inspectors assigned to Wolf Creek was increased and the scope of required inspection was defined by Kansas Gas and Electric (KG&E) in order to ensure that the Inryco Quality Program could support the post-tensioning construction activities (i.e., assure a quality product).
The Inryco QC Inspectors were certified and met the requirements of ANSI N45.2.6 as referenced by the Inryco QA Manual.
The certifications of personnel were reviewed by both KG&E and USNRC personnel during the installation of the post-tensioning system at WCGS.
l Enclosure to ET 87-0380 l
Page 3 of 11 l
I December 24, 1987 Grease Installation and Inspection Installat&on of grgase was accomplished utilizing a heated storage tank (140 F to 210 F), grease pump, interconnecting lines, valves, and Y-assemblies. The method of installing the grease varied depending on whether the tendon duct to be filled was vertical or horizontal.
For horizontal tendons, the heated grease was pumped from the storage tank into the grease can at one end of the tendon duct. All tendon duct drains were closed prior to pumping, while all tendon duct vents were opened. Vents were closed as soon as grease exited from them.
Pumping continued until clean grease exited from grease cans at the l
opposite end of the tendon duct. The temperature of the grease, exiting the opposite end, was required to be 120 F minimum (See Attachment I).
For vertical tendons, the heated grease was pumped from the storage tank into the grease cans at both ends of the tendon duct.
Pumping was on a staggered basis (one end and than the other) until grease arrived at the dome vent from one end.
Pumping from this end was stopped, and pumping from the opposite end was resumed until grease arrived at the vent from this end also.
Pumping was then initiated from both ends simultaneously, until clean grease egited the dome vent. Minimum temperature of the exiting grease was 120 F.
(See l
Attachment II.)
Installation of grease was documented on the " Tendon l
Greasing Card" (See Attachment II).
These cards were forwarded to the INRYC0 QC Inspector who reviewed them for accuracy and completeness.
The tendons were tensioned in a predetermined sequence consisting of 6 phases with approximately 40 tendons tensioned in each phase.
Inspection of the original greasing operations was required for a l
minimum of 10 percent of the tendons in each phase. As stated in the INRYC0 Field Installation Manual, "The inspection will be distributed as follows:
(1) The first three tendons of each phase; (2) The last three tendons of each phases and, (3) The remaining tendons, to meet the 10 percent control requirement, will be sampled at Inryco's QC personnel discretion with a random distribution between the first three and the last three of each phase.
In no case will less than nine tendons be inspected in any phase."
Inspections were documented on the " Post Tensioning Operations Inspection Checklist" (See Attachment IV).
The inspector was required to verify that the greasing activity was performed in accordance with the Field Installation Manual.
Pronram Monitoring KG&E conducted audits and surveillance of Inryco construction operations.
One audit (TE:
57720-K001, 01/23/82) conducted by KG&E observed the greasing of tendon V-13.
The tendon preparation, grease hock-up, greasing opeiation, and disconnect of equipment was observed and was in accordance with the Inryco program and procedures.
The Inryco QC involvement /ft:nction while tendon V-13 was greased was noted l
during this audit.
It was noted that the temperature of the storage l
tank, check of craft training, observation of the greasing operation, completion of the Tendon Greasing Card, and completion of the l
l
~
Enclosure to'ET 87-0380 Page 4 of 11 December 24, 1987 inspection checklist was conducted by the Inryco QC Inspector in accordance with the Inryco Field Installation Manual. Five KG&E surveillance were conducted from 11/81 to 7/82 observing / monitoring
.various Inryco work activities at Wolf Creek Generating Station (WCGS). A USNRC Post-Tensioning System program review of the Inryco procedures and Bechtel specifications; review of quality records for Maintenance and Test Equipment (MT&E) quality personnel certifications and receipt of purchased material; KG&E surveillance / Audit' Reports; and observations of work / inspection activities was conducted during March 1982, STN 50-482/82-04, dated 7/13/82, by a USNRC inspector.
There were no items of noncompliance identified in the program areas.
Quantity of Grease During the initial greasing operation, WCGS was committed to Regulatory Guide 1.35 Revision 2.
For the inspection of filler grease the NRC Regulatory Guide 1.35 Revision 2 required that 'The method used for checking the presence of sheathing filler grease should account for (1) the minimum grease coverage needed for different parts of the anchorage system including, for example, buttonheads; (2) the influence of temperature variations, especially the lowest temperature likely to occur between two successive inspections; (3) the procedure used to uncover possible voids in grease in the trumpet; and (4) requirements imposed by grease specifications, qualification tests, and acceptability tolerances". Records of exact amount of fill grease used were not required by Revision 2 of Regulatory Guide 1.35.
WCGS is currently committed to proposed Revision 3 to Regulatory Guide 1.35.
The proposed Revision 3 to the Regulatory Guide 1.35 requires, in addition to the requirements in Revisjon 2, that "the exterior surface of the containment should be visually examined with a view to detecting areas of widespread cracking spalling and grease leakage
" and that the "... presence of significant volds within the grease filler material,.... be considered reportable." Under the discussion part of Regulatory Guide 1.35 Revision 3, the following is required *... The volume of the filler grease injected after the completion of the lift-off testing should also be recorded.
If the volume of the newly injected filler grease is excessive compared to tl.e removed grease, it could be indicative of leakage in the tendon duct system.
If the required additional amount is small (say, up to 5 percent of the net duct volume), it may not be a cause of concern, since temperature effects during and after installation could have formed voids in the filler grease that were filled up during reinjection." These requirements are currently being met at WCGS. At the time of initial tendon duct grease filling, these requirements were not in effect.
Quality of Grease The grease purchased was required to meet the properties in Table 1.
l Enclosure to ET 87-0380 Page-5 of 11 December 24, 1987 Question 4:
Discuss the procedure you used in performing the tendon surveillance, specifically how the grease in the vertical and horizontal sheathings was taken out and reinstalled and quality assurance exercised. What are the sign-off requirements? Do you use a check list?
Response 4:
Program Description 1
The third year post tension surveillance (second surveillance) was performed by the VSL Corporation of Campbell, California.
The work was done in accordance with VSL procedure number SP-170W, which incorporated all essential requirements of Bechtel Specification 16577-C-158(Q) Revision 3.
Quality Inspector (s) qualifications were submitted to WCNOC prior to their coming on site and were reviewed and approved by QA personnel.
Grease Removal and Installation During the first and second surveillance, in accordance with approved i
procedures, the plugs in the grease cans were removed and any flow collected in a container which allowed volumetric measurement. The grease cans were then removed and the shims and buttonheads cleaned with the grease being removed during the cleaning process placed in the same measurable container. The quantity of grease removed was measured and recorded on the Sheathing Filler Removal and Replacement Data Form with separate forms for each end of the tendon (two forms per tendon), (See Attachment V).
Other required testing and inspections were performed at this point and satisfactory results gained prior to reinstallation of grease.
In regreasing, the grease cans were reinstalled with new gaskets.
It should be noted that any grease which remained in the grease cans when they were removed was protected from contamination and remained in the can when they were reinstalled for regreasing. A valve was placed in the drain / fill hole of the can and a positive dispiccement type pump connected to the opened valve. New grease was pumped from a 55 gallon drum into the tendon void with the pressure at injection being monitored continually. Pressures of 60 psig in the horizontal tendons and 140 psig in the verticals were maintained within limits.
Theo grease temperature was also required to be maintained between 140 F and 210 F and this was maintained and documented. The pressure was limited to assure containment structural integrity.
No evidence has been found to date that suggests that the additional grease pumped during the surveillance has gone cnywhere other than the tendon duct.
The causes of the voids were previously stated in Letters KMLNRC 85-264 and KMLNRC 86-038 and in Response 1 of this report.
1
Enclosure to ET 87-0380 Page 6 of 11 December 24, 1987 The surveillance program requires the measurement of voids that exist in the tendon sheath by requiring that a small quantity of grease exit the opposite end of the tendon for horizontal tendons, and from the top vent the vertical tendon. The pressure of Brease pumped was limited to 140 pounds per square inch (psi) for vertical tendons and 60 psi for horizontal tendons, and if no grease was pumped from the tendon the precsure was held for a time limit of one hour, and if no grease exited the tendon grease can, discontinue the pumping.
The quantities of grease pumped were recorded, again on the Sheathing Filler Removal and Replacement Data Form, for each end of each tendon.
I Both ends were then summed and the total amount of grease removed and i
added was determined. This net grease amount was compared to the I
calculated void volume and recorded.
If the ratio of the net quantity used during replacement to the calculated volume exceeded 5 percent, the Owner, Wolf Creek Nuclear Operation Corporation (WCNOC), was requi ed to be notified for further action.
The sign-offs and the required checklist are shown on Attachment V, Sheathing Filler Removal and Replacement Data Form.
Question 5 This is the second time that your surveillance program has identified tendons with grease voids that exceeded the technical specification limit.
It is important that the root cause of voids be determined.
If the root cause is the preexisting voids during the time of construction it is very important that one of the tendons that was refilled during the 1985 surveillance (presumably with the largest void ratio) be reexamined.
Response 5:
"he surveillance program at Wolf Creek requires that certain surveillance tendons (one hoop and one vertical) be common during most of the surveillance years to develop the tendon history.
The program requires a wire to be removed and evaluated from a horizontal and a vertical tendon bundle, Currently, these removals are selected prior to commencement of the surveillance.Due to the physical properties of i
l the grease the filling of the space between the wires which make up the l
tendon bundle will occur over a period of time.
The time will depend l
on the temperature of the wire bundle and the grease. Voids in the filler grease are expected as the grease migrates into the tendon bundles.
Enclosure to ET 87-0380 Page 7 of 21 December 24, 1987 The root cause of the void percent being above the Technical Specification (T/S) limit is believed to be preexisting voids created during the time of construction. This can not be verified because records of the actual amount of gresse initially installed are not available for evaluation.
Such records were required by Regulatory Guide 1.35 Revision 2, which WCGS was not committed to during initial filling.
Three contributing factors for up to 15 percent of the voids are discussed in Response 1 of this report.
A wire was extracted from the tendon bundle on the one tendon that had voids in excess of 15 percent. The wire showed no signs of tendon degradation. Therefore, even though the percent voids may be above the T/S limit, there is adequate grease to prevent tendon degradation and ensure that the post-tensioning system is capable of fulfilling its intended function.
Two tendons which were examined during the first surveillance l
were reexamined during the second surveillance. These tendons were 45BA and V65.
Tendon 45BA Void during first surveillance = 6.7 percent Date:
02/86 Void during second surveillance = 3.6 percent Date 09/87 Tendon V65 Void during first surveillance = 1.7 percent Date 02/86 Void during second surveillance - 4.5 percent Date 09/87 Discovery of additional voids during the second surveillance for the above common tendons may be attributed to the following reasons:
Due to a combination of low temperature and the upper limits placed on pumping pressure during the surveillance, the " pump-through" of the grease was accomplished only for the V65 tendon during the second surveillance.
" Pump-though" of the grease for the V65 tendon during the second surveillance allowed us to discover voids over the entire tendon duct length.
However, it is noted that mere " pump-through" of the grease does not ensure discovery of all the voids in the entire tendon duct system.
During each surveillance, the inspection process may identify additional voids in the tendon duct. Formation of voids since the first surveillance is due to additional migration of grease into void space between the wires and temperature shrinkage effects (since hot grease was pumped into the duct during the first surveillance.)
i-Enclosure to ET 87-0380 Page 8 of 11.
December 24, 1987 Question 6:
Provide actual records of how much grease was filled in the ducts with greater than 5 percent rates.
Response 6:
A record of how much grease was filled in the ducts with greater than 5 j
percent, voids is provided in Table 2.
Data sheets are available at WCGS for review.
==
Conclusion:==
Based on inspection and test results of additional aspects of the post tensioning system, such as grease coverage of tendon wires, absences of cracks, corrosion, and damage from tendon wires, and changes in the physical appearance of the filler grease, for the inspected tendons it was confirmed that the presence of voids in excess of 5 percent of net duct volume did not. degrade the structural integrity of the Containment.
The amount of grease found was more than adequate as all inspected tendon wires and anchorage components had extensive grease coverage. There were no signs of water or evidence of significant corrosion within the tendon ducts or grease can assemblies.
Additionally there was no evidence of concrete cracking adjacent to the tendon anchorages.
Prevention of corrosion of the tendons is assured by adequately coating the tendon wires and anchorage components, The material used in the WCGS post-tensioning system, Visconorust 2090P-4, accomplishes its corrosion protection function by the filler material's affinity to adhere to steel structures, its ability to emulsify any moisture in the system nullifying its rusting ability, and by its resistance to moisture, mild acids and alkalis. As long as sufficient grease has been introduced into the system to coat the wires and anchorages completely, corrosion protection is assured.
Protection is also afforded by each tendon wire being individually precoated with Amber 1601 prior to installation. The degree of filling the interstitial spaces, which comprise the net duct volume, is not directly related to the degree of coating which occurs and, consequently, is not of significant importance as an indicator of operability of the sheathing filler material.
In summary from the results of the first and third year tendon surveillance at WCGS confirmed that the containment post-tensioning is adequately performing its design function and that no abnormal degradation had occurred since the initial containment structural integrity test.
4 Enclosure to ET 87-0380 Page 9 of 11 December 24, 1987 i
TABLE 1 Physical Properties Method Required gounds Pgr Gallon at 60 N/A 7.3-7.8 F (15.5 C)
Specific Gravity at 60 ASTM D-287 0.88-0.94 o
F (15.5 C)
Gong 6 sling Point ASTM D-938 135-145 F( C)
(57-63) o o
Flash Point F( C)
ASTM D-92 420 (215) minutes Vis60sity Sgspension at ASTM D-88 150-225 210 F (98.9 C) seconds ASTM Consistency gone ASTM D-937 190-220 Penetration at 77 F millimeters (25 C)
Thermal Coefficient of N/A Approximately expansion SZ for 50-150 F Thermal N/A Approximately Conductivity 0.10 BTU-FT/HR -
SQ FT Specific Heat N/A Approximately o 0.51 BTU /LB - F Heat of Fusion N/A Approximately 63.2 BTU /LB.
Chemical Properties Method Reauired Water Soluble Chlorides ASTM D-512 2 PPM maximum Water Soluble Nitrates ASTM D-992 4 PPM maximum Water Soluble Sulfides Standard 2 PPM maximum Methods (14th Edition) Number 428 or Hach Chemical
4 Enclosure to ET 87-0380 Page 10 of 11 December 24, 1987 TABLE 1 (continued)
Chemical Properties Method Reauired Major Constituents N/A Fully saturated petroleum hydro-carbons Neutralization Number ASTM D-974 15 milligrams (Total Base Number)
Modified NOTE: Abbreviation Table
]
o C
Degrees Centigrade o
F Degrees Fahrenheit I
Percent ASTM American Society of Testing and Materials BTU British Thermal Unit FT Foot HR Hour LB Pound PPM Parts Per Million SQ FT Square Foot i
4
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1
Enclosure to ET 87-0380 j
Page 11 of 11 December 24, 1987 1
I l
TABLE 2 J
l Grease Grease Net Grease 4
Date Removed Added Added Percent Tendon Discovered (Gallons)
(Gallons)
(Gallons Void 1
V18 09/08/87 39.4 76.9 37.5 12.8 V47 09/08/87 68.9 87.6 18.7 6.8 V1 09/08/87 37.1 113.4 76.3 28.9 47BA 09/11/87 9.6 23.6 14.0 7.5 1
35BA 09/11/87 10.7 27.6 16.9 9.0 l
14BA 09/14/87 8.1 19.9 11.8 6.2 5AC 09/14/87 11.4 22.1 10.7 5.6 1CB 02/21/86 13.25 26.7 13.45 7.3 51BA 02/25/86 12.0 25.9 13.9 8.1
)
45BA 02/26/86 13.0 25.2 12.2 6.7 9AC 02/26/86 10.75 20.9 10.15 5.5 9CB 02/26/86 9.75 22.0 12.25 6.6 1
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Page 1 of 1 ATDOf02E IV i
December 24, 1987 JMrrCD Pmm 'n'NS1(NnG OPfmATICr6 INS:PICTI(N OEDITST su u a a - ch.pt r 9 POST TENSIONING OPERATIONS i N SPECT10N CHECK L1ST O Du_
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PROCEDURES IN ACCORD NCE VITH F. I,M ANU AL I ]
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-si httiv,;hment. V' to. Special Report 87-10, Supp. 2
-Page 1 of 1 ATTACHMENT V December 24,.1987 I
WOLP CI EEK GEra: RAT!rtC STATIO ;
YEAR TEriDON SURVEILLAf1CP SilEAT!!IriG PILLER RE." OVAL A!1D REPLACEMENT DATA FOP.*i TEt:Dotl 1:0.
At Gi10H lu:AD.I. D.
1:0,-
Teridon End A
' Tendon End D I.
Sheathing Piller Removal:
1.
Exterior Concrete Temperature Near Tendon Anchorage
- F Thermometer No.
2.
Verify Grease Sample Taken (A/B)
'/
l 3.
Color of Grease (A/B)
/
4.
Total Volume Grease Removed Gal.
5.
Visual Examination of Grease Removed Recorded By: (A/B)
/
VSL QC Inspector Date: _
II.
Grease Can Installation:
1.
New Gasket Installed (A/B)
/
2.
Anchorage Buttered (A/B)
/
3.
Grease can Reinstalled (A/B)
/
Witnessed By: (A/B)
/
VSL C/C Inspector Date:
III. Sheathing Filler Replacement:
1.
Ext.erior Concrete Temperature Near l
Tendon Anchorage
- F
-Thermometer No.
2.
Grease Temperature at Inlet
- F Thermometer No.
3.
Grease Ternperature at Outlet
._ F Thermometer No.
4.
Total volume Grease Installed Gal.
j 5.
Installation Pressure Psi 9 Pressure Gauge No.
6.
Grease Ejected from Opposite End of Tendon? (horizontals)
High Point Vent? (Verticals)
Yes/No IV.
Percentage Void Volume Calculation:
~
1.
(Total Volu:nc Grease Added (A+D) - (Total Volume gal.
Grease Removed (A+D)
=
2.
As Found. Volume Replaced / Net Duct Volume =
(Supplied by Owner)
Note:
If Greater Than or Equal to 5%, Notify the Owner Immediately
- Dy: VSL OC Inspector Date:
REVIEWI:D ILY:
vendor O.C.
Inspector DATE n r.
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