ML19256D534

Reactor Containment Bldg:First Tendon Surveillance Test One Yr After Structural Integrity Test. Prepared for Met Ed

ML19256D534
Person / Time
Site:	Three Mile Island
Issue date:	09/29/1975
From:	Herr J GILBERT/COMMONWEALTH, INC. (FORMERLY GILBERT ASSOCIAT
To:
Shared Package
ML19256D535	List: ML19256D534 ML19256D536
References
GAI-1880, NUDOCS 7910180844
Download: ML19256D534 (26)

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's gal Report No.1880 THREE MILE ISLAND NUCLEAR STATION UNIT 1 REACTOR CONTAINMENT BUILDING FIRST TENDON SURVEILLANCE TEST ONE YEAR AFTER S.I.T.

METROPOLITAN EDISON COMPANY SUBSIDI ARY OF GENERAL PUBLIC UTI.'..lTI ES COR POR ATION 1451 168

,fgl Gilbert Associates, Inc.

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4 September 29, 1975 GAI REPORT NO. 1880 THREE MILE ISLAND NUCLEAR STATION UNIT 1 REACTOR CONTAINMENT SUILDING FIRST TENDON SURVEILLANCE TEST CNE YEAR AFTER S.I.T.

METROPOLITAN EDISON COMPANY Subsidiary of General Public Utilities, Corp.

Prepared By: - N

[J.C. Herr,P.E.

Gil rt Associates, Inc.

Approved 3y: N' a4ue j n'

.S.FgiRgaman/~Oeneration

.Ianago, in ering Eng/2 Met" i.;11rfin Edison Co.

Gilbert Assocf.2t 4.a . * .

525 Lancasts .m: , .

Reading, Pe:r;3ylvania 1451 169 Gil,BERT 4550CI ATE 5. I.SC.

• 1

L TABLE OF CONTENTS Section Title Page 1.0 SYNOPSIS 1

2.0 INTRODUCTION

2 3.0 ACCEPTANCE CRITERIA AST CONCLUSIONS 3 3.1 ACCEPTANCE CRITERIA 3 3.1.1 Tendon Prestress Force :enfirmation Test 3 3.1.2 Tendon Physical Conditien Test 3 3.1.3 Tendon Anchorage Assembiv Insoection 4 3.1.4 Insoection of Corrosion Protection Svstem 4

3.2 CONCLUSION

S 4 4.0 TEST PROCEDURE 6 4.1 DEVIATIONS 6 4.2 EQUIPMENT CALIBRATION 7 5.0 DISCUSSION OF RESULTS 7 5.1 RESULTS OF TENDON PRESTRESS FORCE CONFIRMATION TEST 7 5.2 RESULTS OF TENDON PNYSICAL CONDITION TEST 8 5.3 RESULTS OF TENDON ANCHORAGE ASSEMBLY INSPECTION 9 5.4 RESULTS OF INSPECTION OF CORROSION PROTECTION SYSTEM 10 6.O SCHEDULE VARIATION 11

7.0 REFERENCES

11 APPENDIX I POST TENSION SYSIEM-FIRST TEEDON SURVEILLANCE PROGRAM (INRYCO) 1451 170 git.BERT 4530Cl4TES. INC.

A LIST OF TABLES TABLE 1 CRITERIA AND CATEGORIES FOR RATING DEGREES OF CORROSION ON TENDON ANCHORAGE ASSEMBLIES AND SELECTED WIRES TABLE 2 CRITERIA FOR MISSING, BROKEN, AND/0R DAMAGED WIRES LIST OF FIGURES FIGURE 1 REACTOR BUILDING - MTON LAYOUT FIGURE 2 HOOP TENDONS LOCATION DIAGRAM - INSPECTION PERIOD 1 FIGURE 3 DOME TENDONS LOCATION PLAN - INSPECTION PERICD 1 FIGURE 4 VERTICAL TENDONS LCCATION PLAN - INSPECTION PERICD 1 LIST OF EXHIBITS EXHIBIT A VISCOR QUALITY CONTROL SPECIFICATION SHEET - CASING FILLER E.GIIBIT B HYDRAULIC JACK CALIBRATION RECORD (MET ED)

EXHIBIT C HYDRAULIC JACK CALIBRATION RECORD (INRYCO)

EXHIBIT D CLARIFICATION OF APPENDIX I 1451 171 CILBERT 4550CI ATES. INC.

s

( l 1.0 SYNOPSIS The Three Mile Island Nuclear Station Unit 1 (TMI-1) prestressing system tendons of the concrete reactor containment building were subjected to a surveillance inspection during the period from May 21, 1975 to July 2, 1975. The purpose of this inspection was to demonstrate continued confidence in structural integrity of the prestressing system, in accordance with TMI-l Technical Specification 4.4.2.1, one year after the initial containment Structural Integrity Test (S.I.T.).

The tendon prestress force confirmation test verifies that the lift-off force on the twenty-one selected tendons is within the predicted value.

Three wires from selected tendons were inspected for physical condition. The extracted wires are in excellent condition and show no corrosion or other signs of deleterious changes. During tensile tests, all samples demonstrated strengths cbove the guaranteed ulti= ate strength.

The inspected tendon anchorage assemblies and associated hardware show no excessive corrosion and are structurally sound. The concrete around the inspected tendon anchorage areas is in exceAlent condition with no cracks visible.

The corrosion protection system is functioning properly, as evidenced by the coating of filler grease on the anchorage compcnents and extracted wires. Laboratory analysis of f tller grease samples revealed impurities to be within acceptable limits.

1451 172 GILBERT 4550C14TE5.13C.

s s 2 These observations indicate that the prestressing system tendons and components are in good condition and are fulfilling the design criteria one year af;er the S.I.T.

Collection of data and construction management was perfor=ed by INRYCO, Inc. (formerly Inland-Ryerson), Melrose Park, Illinois; they were also the contractor for prestressing system installation at IMI-1. Quality control and technical assistance was by Gilbert Asscciates, Inc.

2.0 INTRODUCTION

The objective of this tendon surveillance test was to inspect and obtain data from twenty-one selected tendons (six dome tendons, five vertical tendons, and ten hoop tendons) randomly but repre-sentatively distributed. An evaluation was then made of the following:

a. tendon prestress force

b. tendon physical condition

c. tendon anchorage assembly

d. tendon corrosion protection system.

The surveillance therefore verifies the adequacy of the reactor containment prestressing system. The test was performed as the first inspection, one year after the S.I.T.

Testing was performed in accordance with procedural requirements as set forth in Reference 1.

1451 173 I

G1LBERT 4550CIATES. INC.

3 This surveillance test conforms with the U.S. Nuclear Regulatory Cozsission Regulatory Guide 1.35, Revisien 1, " Inservice Inspection of Ungrouted Tendons in Prestressed Concrete Containment Structures",

and complies with the requirements of TMI-l Technical Specification 4.4.2.1, Amend =ent 6.

3.0 ACCEPTANCE CRITERIA AND CONCLUSIONS 3.1 ACCEPTANCE CRITERIA The following sections comprised the acceptance criteria established prior to the test as specified by TMI-l Technical Specification 4.4.2.1 and TMI-1 Surveillance Test (Reference 1).

3.1.1 Tendon Prestress Force Confirmation Test

a. The average value of the forces required to achieve lif t-off at both ends of the tenden shall fall between upper and lower bounds of the predicted tendon force as calculated in Reference 1. One end lift-off force is used for vertical tendons.

b. The allowable limit shall be one defective tendon out of the twenty-one selected tendons, providing adjacent tendons are acceptable.

3.1.2 Tendon Physical Condition Test

a. Wire tensile tests of specified samples shall not fail below the guaranteed ultimate strength of 240,000 psi.

b. Specified sample wires shall be visually inspected for corrosion, pitting, and other signs of deleterious changes.

Any sample wire not =eeting the acceptance criteria of Table 1, and subsequently rejected by Unit Superintendent, shall be reported to the NRC. ~

1451 174 GIL3ERT 45$uCI ATES. DC.

, 4 3.1.3 Tendon Anchorage Asse=bly Inspection

a. Selected tendon anchorage assemblies and associated hardware shall be visually inspected for corrosion, off-size or cracked buttonheads, cracks, missing wires, and broken wires. Any component not meeting the acceptance criteria of Table 1 or Table 2, and subsequently rejected by Unit Superintendent, shall be reported to the NRC.

b. Crack widths in concrete around the selected tendon anchorages greater than 0.010 inch wide shall be recorded and reported for evaluation and resolution. Any crack vidth greater than 0.050 inch wide shall be cause for investigation to determine the amount of structural impairment upon the reactor building and its continued structural integrity.

3. 4 Inspection of Corrosion Protection System T!.e corrosion protection systes shall be inspected by visual observations and laboratory analysis of the filler grease.

The acceptance criteria limits the amount of chloride, sulphide, and nitrate to 10 ppm; the ratio of water / dry weight shall not exceed 5 percent.

3.2 CONCLUSION

S Data collected during the present surveillance inspection sub-stantiates that the concrete reactor containment prestressing system for TMI-l is fulfilling its design function with no evidence of adverse deterioration. The results of this data are as follows:

1451 175 GILBERT tisOCI ATEs. INC.

5

a. The measured tendon prestress force on all selected tendons falls between the predicted upper and lower bounds, and is acceptable. In fact, the force is greater than the predicted expected lift-off force for all selected tendons.

b. The ultimate strength of the tested wires was above the guaranteed value of 240,000 psi, showing no significant change in the ultimate strength of the wire, and is acceptable.

The three extracted wires were free of corrosion, pitting, or other signs of deleterious changes, and are acceptable.

c. The selected tendon anchorage assemblies and associated hardware have been visually inspected for corrosion, off-size or cracked buttonheads, cracks, and missing or broken wires. These components have =et the acceptance criteria and are acceptable.

No concrete cracks are visible around the selected tendon anchorages,

d. The filler grease on the surveillance end anchorage components is acceptable as to color, consistency, and coating of components. There was no evidence of water within the end caps.

Laboratory analysis of filler grease is within acceptable limits. No detectable amounts of chloride, sulphide, nitrate, or water have aeen found.

1451 176 GIL8ERT 4$50Cl 4TE5. l.NC.

4 6

4.0 TEST PROCEDURE The subject tendon surveillance test was conducted in accorCance with the detailed procedure of Reference 1.

The general tendon layout for the Reactor Building is shown on Figure 1, and the location of the selected surveillance tendons is shown on Figures 2, 3, and L.

4.1 DEVIATIONS Deviations, which were approved by cognizant engineers and will be incorporated in future revisions, have been made from Reference 1 as follows:

a. In addition to the stressing jack furnished by Met-Ed, INRYC0 used a larger stressing jack. The two jacks were used on opposite tendon ends for most hoop tendons, with the Met-Ed Jack on the ends with limited access. The prestress force test on dome and vertical tendons was done with the INRYC0 jack,

b. Bulk filler grease used in refilling was Visconorust 2090P-4 Casing Filler, Nuclear Grade (see attached Quality Centrol Specification Sheet, Exhibit A) . This product is the current generation of Visconorust 2090P used in original installation and the products are compatible.

c. Selected tendons given in Reference 1 were requested to be changed by Met-Ed letters GQL1063, dated May 14, 1975 and GQLil31, dated June 9, 1975, to U.S. NRC. TMI-l Technical Specification 4.4.2.1, Amendment 6, dated July 1,1973 reflects this change, and this surveillance test complies therewith.

1451 177 GILBERT d50CIATES. I.NC.

• 7 4.2 EQUIPMENT CALIBRATION The two stressing jacks were calibrated prior to starting the surveillance test. The equipment used in calibrating is trace-able to the National Bureau of Standards. Calibration records are shown in attached Exhibits 3 and C.

5.0 DISCUSSION OF RESULTS 5.1 RESULTS OF TENDON PRESTRESS FORCE CONFIRMATION TEST The expected lift-off force given in Appendix I, Data Sheets 6, 7, and 8 is based on the mini =um tendon force at installation.

The actual tendon force at installation varied from -0 percent to

+5 percent. Based on the actual tendon force at installation, percentage of actual loss of prestress force is tabulated as:

Tendens Excected Loss (") Actual Average Loss (*)

Dome 10.3 11.8 Vertical 8.2 9.1 Hoop 10.3 10.8 The actual loss deviated from the expected by 0.5 percent to 1,5 percent and is understandable considering possible errors and accuracies of jack pressure readings, determination of lif t-off, estimation of losses for concrete creep and shrinkage, wire stress relaxation, and time averaging.

The tendon force after retensioning in all cases is equal to or greater than the lift-off tendon force.

'4hile detensioning various tendons, the end rotated, indicating relaxation of the twist, thus decreasing the force. During recensioning it was necessary to add shi=s greater than the GILBERT 4550CI ATES. INC.

1451 178

, 8 previous thickness, in order to lock-off the tendon at the required force.

During this test THE-1 experienced an outage, thus the Reactor Building temperatures shown in Appendix I, Data Sheets 6, 7, and 8, reflect correspondingly lower interior temperatures.

The actual percent of tendon force loss has not been affected by this temperature difference, as demonstrated by the folicwing:

Tendon Int. Temo. ( F) Loss (%)

Avg. Hoops 116.6 10.85 H13-046 84 10.32 H13-034 84 10.38 H35-028 128 12.08 H13-028 126 11.10 H51-012 127 9.36 GAI has evaluated the steel relaxation loss of the tendons adjacent to the Inter =ediate Building where the high Sc=peratures have been observed. The effect of a localised high ambient te=perature on vertical tendons is negligible. The hoop tendens would experience approximately a 3.4 percent greater loss of prestress force, which would not jeopardize the structural integrity of the Reactor Building. The opportunity to verify the prestress losses will be afforded by future surveillance tests.

5.2 RESULTS OF TENDCN PHYSICAI. CONDITION TEST The results of this test have confirmed that there are no appreciable changes in the ultimate strength or physical condition of the tendon wires. This further indicates the corrosion protection system is functioning properly.

1451 179 CILBERr 4550C14TES. ISC.

9 5.3 RESULTS OF TENDON ANCHORAGE ASSEMBLY INSPECTION The inspection revealed no missing or defective buttonheads.

Millscale and acceptable corrosion on anchorage hardware existed at the time of installation. Other than the bearing plate surface outside the grease can, no deccrioration has occurred. Reco gnizing that the coating on the bearing plates is deterierating, TMI-1 has implemented Work Regaest No. 9707, " Coating Procedure, Reactor Building, Tendon Anchorage System". Upon completion, the coating will provide long-ters protection to those anchorage components exposed to the weather, in particular the outer portion of the bearing plates.

Vertical tendon V27 was cbserved to have ona brokan wire, which was renoved as two pieces approximately 90 feet long, however all buttonheads are acceptable. Table 2 allows three missing wires.

The tendon is therefore acceptable. The result of an inspection of the broken wire is given in Appendix I, Section 2.1.

Hoop tendon H13-046 has one broken / missing wire at buttress No. 3.

Field inspection of the anchorage at buttress No. 1 could not identify which wire was broken. Tendon installation cards do not inideate this condition occurred during installation. The condition is acceptable for the same reasons given previously in this section l for tenden V27.

1451 180 l

CIL8ERT 4550014TE$.13C.

' 10 The absence of any cracks in the concrete for the selected ;endon anchorages indicates excellent condition of the concrete.

5.4 RESULTS OF INSPECTION OF CORROSION PROTECTION SYSTIM The laboratory tests and observations have indicated no degradation of the bulk filler grease. Examination of components has demon-strated continued confidence in the performance of the corrosion protection system.

The removed grease was less viscous than expected, e.g., the grease drained from some vertical tendons approximated the viscosity of r_c or oil. For infor=ation, the temperatures of the drained grease were recorded as follows:

Tendon End Tem 7 ' F)

V16 Bottom 105 V158 Bottom 85 H13-028 Butt. #1 140 H13-028 Butt. '13 96 H62-016 Butt. #2 87 H62-016 Butt. #6 86 Viscosity 011 Company, supplier of the filler grease, has stated that similar installations have experienced the less viscous condition; there has been no detrimental effect on the corrosion protection capability of the bulk filler grease.

1451 181 GILBERT 4550Cl4 TE$.1.%C.

, 11 6.0 SCHEDtJLE VARIATICG As stated in Met-Ed letter GQL1152 to NRC, dated June 13, 1975 the completion date for this surveillance test was to be June 10, 1975.

Due to factors mentiened in subject letter, the test was actually completed on July 2, 1975. Appropriate measures have been ;aken to prevent this from reocurring during future inspections.

7.0 REFERENCES

1. Metropolitan Edison Co., " Reactor Building Structural Integrity Tendon Surveillance Program", TMI Surveillance Test No. 1301-9.1, Revision 0, December 4, 1974 1451 182 GILBERT 4550Cl4TE5. INC.

TABLE 1*

CRITERIA AND CATEGORIES FOR RATING DEGREES OF CORROSION ON TENDON ANCHORAGE ASSEMBLIES .*ND, SELECTED WIRES Degrees of Corrosion

1. Bulk filler material intact, bright metal, no visible oxidation.

2. Change of color in bulk filler material, metal reddish brown color, no pitting.

3. Change of color in bulk filler sacerial, metal having patches of red oxide, removable but ready to starr pitting.

4. Change of color in bulk filler =aterial, metal having patches of red oxide, not removable and/or leaving noticeable pits.

5. Change of color in bulk filler material, metal having heavy rusting, dark red, and about to form an extremely hard crust which when re=oved leaves very noticeable pitting.

6. Conditions more severe than category 5.

Acceotance Criteria -

Anchorage assembly components in category 1, 2, or 3 are acceptable.

Wire in category 1 or 2 is acceptable.

Anchorage assembly components in category 4, 5, or 6 and wire in category 3, 4, 5, or 6 are subject to rejection and should be further evaluated by the Unit Superintendent.

1451 183

• The criteria in this table are identical to Table 4 of Reference !.

GILBERT 4850CitTES. ISC.

TABLE 2*

CRITERIA FOR MISSING, BROKEN, AND/OR DAMAGED WIRES

1. Any tendon with more than three missing, broken, and/or damaged wires is subject to rejection.

2. Any tendon with one missing, broken, and/or damaged wire is subj ect to rejection, if at the same time four additional buttonheads do not meet acceptance criteria for buttonheads.

3. Any tendon with two missing, broken, and/or damaged wires is subj ect to rej ection, if at the same time three additional buttonheads do not =eet acceptance criteria for buttonheads.

4. Any tendon with three missing, broken, and/or damaged wires is subj ect to rejection, if at the same time two additional buttonheads do not meet accept :ce criteria for buttonheads.

NOTES:

a. Missing, broken, and/or da= aged wire criteria is based on original quantity of 169 wires per tendon.

b. Any tendon not meeting above criteria, and therefore being subj ect to rejection, shall be further evaluated by the Unit Superintendent.

c. See Inland-Ryerson's Field Quality Assurance Program, Chapter 5, Appendix 2, Button Head Criteria 1610A, for acceptance criteria for buttonheads.

1451 184

• The criteria in this table are identical to Table 5 of Reference 1.

GILBERT 4550Cl 4TES. INC.

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EXHIBIT B HYDRAULIC JACK CALIBRATION RECORD re ifu/%

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T W TICAL RAM AREA: / 4. 6 ivi MAX. PRESSURE: hb /7C P.S.I.

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TARGET PSI l P.S.I. GAUGE READ 0UT CnMPUTED FORCE RAM AREA 1003 I/M/0 / /, , /

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de9/,% p W #1451 191

4 EXHIBIT D CLARIFICATION OF APPENDIX I

1. The accuracy of all data sheets has been verified and signed off, i.e. approved, by GAI personnel.

2. Data Sheets 1, 2, 3, and *: Tables 4 and/or 5, as referred to under " Notes," are tables from Reference 1, and are presented as Tables 1 and 2, respectively, of this report.

3. Data Sheets 4, 5, 6, 7, and 8: Sections or Figures as referred hereto are from Reference 1.

4 Data Sheet 7: Column 9, although left blank, has the identical values as column 10. <

5. The following minor editorial refinements have been made:

(a) Renumbered Data Sheets pages to be in sequence with the text of Appendix I.

(b) Deleted Data Sheet identification with regard to SP 1301-9.1.

(c) Added reference to Data Sheets and page numbers, and Appendix I-A to the Table of Contents.

145i 192