ML031050404

Containment Structural Integrity Surveillance Program 30-Year Tendon Surveillance

ML031050404
Person / Time
Site:	Palisades
Issue date:	04/07/2003
From:	Cooper D Nuclear Management Co
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML031050404 (18)

Text

NI Committed to Nuclear Excellence Palisades Nuclear Plant Operated by Nuclear Management Company, LLC April 7, 2003 U S Nuclear Regulatory Commission 10 CFR 50.55a ATTN: Document Control Desk Washington, DC 20555-0001 PALISADES NUCLEAR PLANT DOCKET 50-255 LICENSE No. DPR-20 CONTAINMENT STRUCTURAL INTEGRITY SURVEILLANCE PROGRAM 30-YEAR TENDON SURVEILLANCE Nuclear Management Company, LLC (NMC) has recently completed the subject surveillance for the Palisades Plant. The inservice inspection summary report for the 30-year tendon surveillance is attached. The summary report is prepared in accordance with ASME Section Xl, 1992 Edition, IWA-6200 and 10 CFR 50.55a (b)(2)(viii). The summary report is being submitted in accordance with Palisades Technical Specification Administrative Controls section 5.6.7, which requires submittal of the report within 90 days after completion of the tests. Surveillance testing activities were completed on January 13, 2003.

SUMMARY

OF COMMITMENTS NMC makes the following new commitment as a result of free water and chemically combined water discovered during inspection of containment dome tendon Dl-38:

NMC will inspect containment dome tendon Dl-38 and adjacent tendons Dl-36 and D1-40 for free water and chemically combined water during the 35-year tendon surveillance.

I o ugls E. Cooper Site V e-President, Palisades 27780 Blue Star Memorial Highway

• Covert, Ml 49043 Telephone: 616.764.2000 1~q-

CC Regional Administrator, USNRC, Region IlI Project Manager, USNRC, NRR NRC Resident Inspector - Palisades Attachment

ATTACHMENT 1 NUCLEAR MANAGEMENT COMPANY PALISADES NUCLEAR PLANT DOCKET 50-255 CONTAINMENT STRUCTURAL INTEGRITY SURVEILLANCE PROGRAM 30-YEAR TENDON SURVEILLANCE 15 Pages Follow

Palisades Nuclear Plant ASME Section XI, IWE and IWL 30-Year Tendon Surveillance Summary Report 2003 CONTAINMENT STRUCTURAL INTEGRITY SURVEILLANCE PROGRAM, ISI

SUMMARY

Submitted in accordance with ASME Boiler and Pressure Vessel Code,Section XI, Article IWA-6000, 1992 Edition, 92 Addenda

1. Date: August 2002 through January 2003

2. Company Headquarters: Consumers Energy Company, LLC 2112West Michigan Avenue

-Jacckson, Michigan 49201

3. Plant: Nu,clear Management Company, LLC Pal isades Nuclear Plant 27 780 Blue Star Memorial Highway Cotvert, Michigan 49043

4. Unit No: On e

5. Commercial Service Date: De,cember 31, 1971

6. Major Component Inspected:

Component Manufacturer Equipment Number Post-tensioning System Bechtel N-54A

7. Completion Date of Examination: Jar wary 13, 2003

8. Code Inspector: KLIBlake

9. Authorized Inspection Agency: Ha rtford Steam Boiler of CT.

Ha rtford, CT.

10. Abstract: Sei a attached report

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report 1.0 PURPOSE This report provides a summary of examinations, inspections and corrective actions related to the 30-Year Containment Tendon Surveillance. All activities were performed in accordance with ASME Section Xl, Subsection IWL, 1992 Edition, 1992 Addenda as modified by 10CFR50.55a(b)(2)(viii).

In accordance with ASME Section Xl, IWA-6240(b), "The inservice inspection summary report shall be submitted within 90 calendar days of the completion of each refueling outage." In accordance with Technical Specification Administrative Controls Section (ADMIN) 5.6.7, reports shall be submitted to the NRC covering prestressing and anchorage tests 90 days after completion of the tests. The 30-Year Tendon Surveillance activities were completed January 13, 2003.

2.0 EXAMINATION AND INSPECTION SCOPE The examination and inspection scope for the 30-Year Tendon Surveillance is summarized in the following table:

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report 2.1 Examination Cateaorv L-B. Unbonded Post-Tensionina System Examination Item Parts Examined Examination Examination Acceptance Data Sheet Comments Category Number ____________ Requirement Standard Number Dome Tendons D2-43 (Common) Al193 through Stsatr L-B , 1l.L2.1 0 lDl-38 Tendon Force IWL2522 IWk3220 A200tStsatr 2.O 0-18 D- Measurements IL22 W~2O A0 Vertical Tendons V-334 (Common) Tendon Force A201 through L-B L2.10 V-30 Measurements IWL-2522 IWL-3220 A206 Satisfactory V-I 16 Stsatr Horizontal Tendons H-84DF (Common)

H-78CE L-B L2.10 H-22AE Tendon Force IWL-2522 IWL-3220 A207 through Satisfactory H-23BD (Adjacent) Measurements A221 H-24BD H-25BD (Adjacent)

_ _ __ __ __ _ _ _ _ _ _ _ H-6 2B F _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Wire A222 hog L-B L2.20 3 D3-1 W or Strand IWL-2523 IWL-3220 A2 to Satisfactory Satisfactory with Corrective L-B L2.30 Surveilled Tendons Anchorage Hardware IWL-2524 IWL-3220 A83 through A122 Action CAP031384 &

CAP032845 IWL-2524 IWL-3220 A23truh Satisfactory L-B L2.30 Surveilled Tendons Surrounding Concrete A192 DAccessible Grease Gisual 10CFR50.55a(b) A287 through 1.-B N/A Caccssil rae Grease Caps Viul(2)(viii)(A) A316 Satisfactory

_ s_ _ _ _ _ _ _ _ _ __ __ __ __ _ _ ca

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _I_ _ _ _ _ _ _I

Palisades Nuclear Plant ASME Section XI, IWE and IWL 30-Year Tendon Surveillance Summary Report 2.1 Examination Category L-B. Unbonded Post-Tensioning System Examination Item Parts Examined EaitonExamination Acceptance Data Sheet Comments Category Number Examination Requirement Standard Number L-B N/A Surveilled Tendons Tendon Force Trend IWL-2522 (2)(viiR)(B) TSSP FT-2 Satisfactory D3-20 10CFR50o55a'b) A240 through L-B N/A V-30i6 Tendon Elongation IWL-2522 (2)(viii)(C) A247 Satisfactory V-1 16 H-62BF Satisfactory IWk3220 and lwith Corrective Corrosion Protection IWL-2525 IOCFR50.55a(b) BI through B18 Action L-B L2.40 Surveilled Tendons Medium (2)(viii)(D) CAP031258 Satisfactory Corrosion Protection IWL-2526 IoCFR50.55a(b) A248 through with Corrective L-B L2.40 Surveilled Tendons Medium (Grease , (2)(viii)(D) A316 Action Replacement) CAP032838 Satisfactory IW-22 lCZFR50.55a(b) A42 through A82 with Corrective L-B L2.50 Surveilled Tendons Free Water IWL-2524 (2)(viii)(D) Action CAP031258

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report 3.0 ADDITIONAL CORRECTIVE ACTIONS In addition to the regularly scheduled surveillance, the following tests and examinations were conducted to address corrective action requirements from previous examinations associated with the post-tensioning system.

Examination Item Parts Deficiency Corrective Action Comments Category Number Examined Document Grease leakage at dome tendon D2-40 No action taken. Joint does L-A L1.10 Concrete is a result of a poorly consolidated CPAL9701328 not affect containment construction joint. structural integrity.

L-AoncretConcrt Iout' tpwere disvered in No action taken. Pop-outs L-A L1.10 Concrete concrete14pdo-notsawerecdiscoveredai the access tunnel near several tendons. onoteaffetysrutua iA07 Grease stains cannot be fully L-A L1.10 Concrete Grease stains APAL980121 removed.

Loose grout was removed L-A L1.10 Concrete Loose grout WO 24012793 and replaced.

Vertical All tests and examinations LB L- L2.IO 210V-14 Tendons Grease leakage Safeguards roominto East Engineered APALS8O121 APL811satisfactory for V14 and V16 were except grease V-16 loss for V16 was 14 4%.

Gaskets were replaced for all locations in the test and Oil discovered on containment buttress. corrective action scope.

L-B L2.10 Grease cans Grease leakage discovered in access CAP007614 Locations were inspected for tunnel near V1176 and V306. water and grease coating was verified at 100%

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report Examination Item Parts Deficiency Corrective Action Comments Category Number Examined Document Gaskets were replaced for all Anchor rod neoprene gaskets, which are locations in the test and part of dome, containment grease cans corrective actioninspected scope. for L-B N/A Grease cans on the are dry-rotted and located CPAL9701328 Locations were cracking. water and grease coating was verified at 100%.

Several grease cans on the containment WO 24210212 Grease cans were cleaned L-BN/A Grease cans dome exhibit surface rusting. and painted.

Palisades Nuclear Plant ASME Section Xi, IWE and IWL 30-Year Tendon Surveillance Summary Report 4.0 EXAMINATION AND INSPECTION RESULTS AND CORRECTIVE ACTIONS 4.1 The following items are being reported as required by 10 CFR 50.55a(b)(2)(viii)(D), which states, "The absolute difference between the amount of grease removed and the amount replaced exceeds 10 percent of the tendon net duct volume."

As documented in corrective action document CAP032838, the following tendons exceeded the acceptance criteria for grease replacement:

Dome Tendon D1-38, 18.3 gallons or 32 percent Vertical Tendon V-16, 11.3 gallons or 14.4 percent Vertical Tendon V-30, 9.9 gallons or 12.6 percent Vertical Tendon V-116, 8.8 gallons or 11.2 percent Vertical Tendon V-330, 8.2 gallons or 10.5 percent Each tendon met criteria for tendon force measurement, anchorage hardware and surrounding concrete. Tendon wire surfaces were fully covered with a protective grease coating. Therefore, tendons remained fully operable. All locations were refilled by injecting new grease.

As required by 10 CFR 50.55a(b)(2)(viii)(E), Nuclear Management Company, LLC (NMC) has considered the possibility that this condition may exist in inaccessible areas. Based on the results of inspections, it is concluded that the level of leakage in inaccessible areas and the results of leakage are the same as accessible areas. Additionally, it is concluded that the tendons would meet force measurement, wire surface and greasing coating acceptance criteria in a similar manner to that documented for accessible areas.

4.2 The following items are being reported as required by 10 CFR 50.55a(b)(2)(viii)(D), which states, "Grease leakage is detected during general visual examination of the containment surface."

As documented in corrective action document CAP031171, grease leakage was discovered at the main gaskets for vertical tendons V-98, V-1 32, V-1 34, V-1 50, V-154, V 178, V-218, V-166, and V-186. All leaks were from the top or "shop" end on the containment dome. It is considered that filling of the grease cans during the steam generator replacement project, which occurred during a cold weather period in 1991, and subsequent heating by the sun and containment internal heating, expanded the grease and pushed it by the main gasket. Main gaskets were replaced and grease leakage from the subject grease cans

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report stopped as part of the tendon surveillance project. The quantity of grease replacement is sufficient to cover tendon end anchorage hardware, but an air pocket is being left in the upper portion of the can to allow for grease expansion and contraction. Grease forms a protective layer for tendons and this layer has not been compromised by the small amount of leakage noted.

As required by 10 CFR 50.55a(b)(2)(viii)(E), NMC has considered the possibility that this condition may exist in inaccessible areas. Based on the results of inspections, it is concluded that the level of leakage in inaccessible areas could be the same as accessible areas. However, even if this condition exists in inaccessible areas, it is expected that, tendons would meet performance requirements in a similar manner to that documented for accessible areas.

4.3 In accordance with ASME Section Xl, 1992 Edition, 1992 Addenda, Subsection IWL, the following items are being reported as conditions failing to meet acceptance criteria IWL-3221.3(c)

As documented in corrective action document CAP031384, surveillance activities discovered three missing button heads on vertical tendon V-30, field end. One of the missing button heads was previously recorded during plant construction.

The cause of two additional failed button heads appears to be fabrication flaws inserted during the button heading process, as evidenced by the lack of button heads in the removed grease. The lack of button heads indicates failure occurred prior to the previous installation of the grease can, which for V-30 was during plant construction. There was no visible sign of deterioration at the end of the individual tendon wires. Tendon V-30 met all other applicable test and inspection acceptance criteria.

As documented in corrective action document CAP032845, surveillance activities discovered a single protruding wire at dome tendon D3-22, shop end. A protruding wire may be an indication of tendon wire corrosion or breakage resulting in increased wire length. lin the case of D3-22, the protrusion is due to a break somewhere along the length of the wire as evidenced by all buttonheads being in place at the field end. Efforts to remove the wire were unsuccessful making it impossible to determine the cause for failure. There was no visible sign of deterioration at the ends of the wires. Tendon force measurement testing was not performed for D3-22 due to obstructions; however all other test and inspection acceptance criteria were met for grease coating, sampling and loss, inspection for water, anchorage corrosion and concrete inspection, As required by 10 CFR 50.55a(b)(2)(viii)(E), NMC has considered the possibility that these conditions may exist in inaccessible areas. Based on the results of

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report inspections, it is concluded that the degree of button head or wire failures in inaccessible areas and the results of failures are the same as accessible areas.

It is concluded that, even with the same level of failure, inaccessible tendons would meet performance requirements in a similar manner to that documented for accessible areas.

4.4 The following items are being reported as required by 10 CFR 50.55a(b)(2)(viii)(D), which states, "The sampled sheathing filler grease contains chemically combined water exceeding 10 percent by weight or the presence of free water."

Water infiltration has been documented during previous tendon surveillances at Palisades. The cause of water infiltration has been traced to degraded grease can gaskets and migration through-concrete cold joints and tendon sheathing.

The concern is that water in contact with anchorage components may cause stress corrosion of the anchor head or tendon wire, or hydrogen embrittlement of the anchorage. -However, tendon force measurements and visual inspections have been satisfactory for tendons affected by water infiltration.

As documented in corrective action document CAP031258, inspection of tendon Dl-38 shop end, discovered 20 ounces of free water. Additionally, the grease sample testing for this tendon indicated chemically combined water at 11 percent at the shop end, only. To fully determine tendon condition, tendon force measure tests and visual exams were performed. Force measurement tests were satisfactory and inspections did not discover any degradation of anchorage components. On the basis of this information, it is concluded that the presence of free water or chemically combined water in the grease is insufficient to cause corrosion or cracking of the anchorage components. Tendon Dl-38 was refilled by injecting new grease.

As required by 10 CFR 50.55a(b)(2)(viii)(E), NMC has considered the possibility that this condition may exist in inaccessible areas. Based on the results of inspections and tests, it is concluded that this condition is isolated to tendon Dl-38 due to its location and the existence of a horizontal cold joint near this tendon end anchorage. The cold joint and tendon grease sheathing are not water tight, and can allow water infiltration when sufficient void space exists.

Even if this condition exists in inaccessible areas, it is expected that, tendons would meet performance requirements in a similar manner to that documented for accessible areas.

In order to monitor this condition, dome tendon Dl-38 will be added to the inspection scope for the 35-Year tendon surveillance. Additionally, adjacent

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report tendons D1-36 and Dl-40 will be inspected for water intrusion during the 35-Year surveillance activities.

5.0

SUMMARY

The Technical Specification ADMIN 5.5.5, Containment Structural Integrity Surveillance Program, demonstrates continued containment operability by providing assurance that the containment is capable of fulfilling designed operating and accident functions. -Based on an evaluation of the 30-Year Tendon Surveillance results, and after reviewing the acceptable disposition of non-conforming items, NMC concludes that the containment structure has not experienced abnormal degradation related to the post-tensioning system and continues to be operable.

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report 6.0 ATTACHMENTS Attachment 1 , NIS-1 Form, "Owners Data Report for Inservice Inspection" Attachment 2, NIS-2 Form, 'Owners Report for Repairs and Replacements" None

Palisades Nuclear Plant ASME Section XI, IWE and IWL 30-Year Tendon Surveillance Summary Report , NIS-1 Form, "Owners Data Report for Inservice Inspection" - To be added at final copy.

FORM NIS-1 OWNER'S REPORT FOR INSERVICE INSPECTIONS As required by the Provisions of the ASME Code Rules

1. Owner &X>SL S &Y<' LURE 91 -r^ 4 Ave. S34Cr4h')rnz: J4 (Name and Address of Owner)

2. Plant L\AS fIATV 43t1s-81&5JS5 W A77l *, e'YrS3

&vu%,

(Name and Address of Plant)

3. Plant Unit 1 4. Owner Certificate of Authorization (if required) NA

5. Commercial Service Date th/3 6. National Board Number for Unit N r 3

7. Components Inspected Note: Supplemental sheets in form of lists, sketches, or drawings may be used, provided (1) size is 8% in. x 11 in.,

(2) information in items 1 through 6 on this report is included on each sheet, and (3) each sheet is numbered and the number of sheets is recorded at the top of this form.

(1 2/82) This Form (E00029) may be obtained from the Order Dept., ASME, 345 E. 47th St., New York, N.Y. 10017

FORM NIS-1 (Back)

8. Examination Dates 8 -to 9. Inspection Interval from 5

0/ct5 to ________

10. Abstract of Examinations. Include a list of examinations and a statement concerning status of work required .

for current interval. "30-Ye 14v.wvtL-ee- ar

11. Abstract of Conditions Noted See, Abo°'i

12. Abstract of Corrective Measures Recommended and Taken -

- See-6ALovJf.

We certify that the statements made in this report are correct and the examinations and corrective mea-sures taken conform to the rules of the ASME Code,Section XI.

Certificate of Authorization No. (if applicable) N./A Expiration Date A Date 4'4/7 I

a__WSigned co 6tBy

~owner '

y'NMC*

CERTIFICATE -OF INSERVICE INSPECTION I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and the State or Province of - r'Yl%.cA nand - employed by H of ec~t; .- have inspected the components described in this Owner's Report during the period

- -to I ZAL(! 2 , and state that to the best of my knowledge and belief, the Owner has performed examinations and taken corrective measures described in this Owner's Report in accordance with the requirements of the ASME Code,Section XI.

By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the examinations and corrective measures described in this Owner's Report. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from o connected with this inspection.

______Co mmissions mAa: o 76 NEI, NS Inspector's Signature National Board, State, Province, and Endorsements Date y 7/ A r 70a3 (12/82)

Palisades Nuclear Plant ASME Section Xl, IWE and IWL 30-Year Tendon Surveillance Summary Report , NIS-2 Form, "Owners Report for Repairs and Replacements" - There were no repairs or replacements performed during this inspection. Therefore, no NIS-2 forms were generated