ML20137M033

Inryco Post-Tensioning Div Jm Farley Nuclear Plant Anchor Head Investigation Operating Metallurgical Div Investigation 20617

ML20137M033
Person / Time
Site:	Farley
Issue date:	08/19/1985
From:	Henger G INLAND STEEL CO.
To:
Shared Package
ML20137M015	List: 05000348/LER-1985-005, Forwards Results of Testing/Insp of 11 Tendon Anchor Heads, Based on Commitment in 850812 LER 85-005-01 to Conduct Addl Tests & Insps on Tendon Anchor Heads Which Failed Due to Hydrogen Stress Cracking.Anchor Heads Acceptable ML20137M033 ML20137M042
References
NUDOCS 8601280171
Download: ML20137M033 (34)

Text

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O O INTER-COseRJNICATION 188.Afe STEEL aprANY Im!ANA HAme0R WORKS DATE AustST 19, 1945 t

/f R.C.SCINE r TO TITLE etANAGER PROM -

• f DEPT. OPERATING TEO*s0 LOGY G.W.04NSER '/

(

TITLE SECTION MAN 5GER DEPT. OPERATING TEOosDLOGY FILE RtP. OIe PILS NO. 30817 l

CDP!ts TO J.NEllt M.MONA00 H.HENDRICKSON-4 P . P . Det SthJECT l INRYCD POST TENSION!N8 O!v!SION JOStPH M. Pantry leJCLEAR PLANT ANCHDR HEAD INVESTIGATIOp*

i OND INVESTIGATION NO. 50017 IN MAY CP 1985 MAGNETIC PARTICLE INSPECTIONS REVtALED INDI*

CATIONS WHICH APPEAmt0 TO 94 ORACKS IN TWO PIELO ANoen MEADS INSTALLED ON THE CONTA!IcetNT SUILO!Nel 0F THE JOSEPH N. PAftLEY IAJCLEAR PLANT LOLAfte AT 00TNAN. ALASAfeA. PURTMA EAAsetstATIDI CBN*

CLUDED THAT ONLY ONE AtemeDR HEAO, PN 039. WAS CRAGttO. THE ANDem HEADS WRt SUPPLIED AND INSTALLIO SY 18stVQ3 POST TENSIONING DIVISION. THE PLANT. WHICH HAS SEEN IN SERVICE POR APPROR!uAftLY t!aMT YtAAS, IS OPERAft0 BY THE ALABAf44 POWtR ODir ANT . THE ATTACHED REPORT BY est. 0.7. KRATING COVERS .TNE ApeALYttl Age letTALLURGICAL EVALUAT1088 0F THESE TWO ANCMDR HEADS, PN OSS AND Pt OSS. IN ALDITION. THE REPORT COVERS THE IEETALLURGICAL RVALUATION OF t!GHT OTHtR ANCMOR HEADS, WHICH wtat Atle0VfD PRoel THE CONTA!Na IstNT SUILO!NGS BUT SHowtD NO INDICATIONS OF CRACKS, IN A00! TION,

• ONE ANOGR HEAD, TFD 24, WH!cM WAS PRost THE LOT Ult 0 POR REPLAct* ,

NtMTS, WAS ALSO TfSTED. Ist KEATING'S CONCLUSIONS Allt AS POLLOWS 0601200171 060117 POR ADOCK 0D000340 t

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1. CRACKING OF ANCM04 HEAD FN 02S WAS DUt TO IN St#VICE PAATI AL EMBAITLEMENT AS INDICATto BY THE PetSENCE OF SteNIFICANT ANDUNTS OF l INTRAGRAMJLAR SEPAAATION (1951 ON THE PetCAACKt0 PRACTunt Facts.

IT WAS CONCLUDE 0 THAT THE EMBA!TTLEMENT ASSULTIO PAON IITHER j MYOROSEN STRESS CAACKING IMSC). STatSS COSAOSION CAACKINS (SCC) l OR A COMBINATION OF BOTH.

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! 2. TMt CAACKS OF ANCM04 MEAD FN 028 ORIGIN 4ft0 AT THE SMIN PACE AND PA0PASATED NORMAL TO TMAT FACE IN A STRA!0NT AND PARALLtL j OSIENYATION TO THE AOLLING DIRECTION.

l 3. TMt ANCHORAGES CAM!s!TED VARYINS 0E048E8 0F C0880SION PITTING AT THC

] SMIN AND SUTTONMEAD Fact $ IMOICATING THAT ACTIVE COAA0SION WAS n OCCUSAING 04 MAD OCCUA880. FN Ott SMOWE0 ME AVT COAAOSION PITTINS i AT SONE CAACKS ON THE SMIN FACE. IN A00! TION. ALL PetCAACMEO

FRACTURE Facts 0F PN 02S SHOWE0 VARYING 0808E85 0F C0820SION.

j A. OTHER POS5teLt SoueCES OF ISS MAVE BREN ELIMINAf t0 SY THE CONeINA-I TION OF SCANNING ELECT 20N MICROSCOPY (SIMI AND NECMANICAL TESTING OF THE ANCHORA4il. NOM 0F TMt LABORATORY.CARAf t0 PRACTuttS (TENSILE  ;

SPECIMENS AND INPACT SPECINENSI SMOWE0 ANY ISS. '

{ S. ANCH04 MEAD FE OSS DIO NOT CONTAIN A CAACK CONTRARY TO AN INDICATION F0ume OY ALAGANA POWEA COMPANY 1APCol. McWtVta, A SteutNCE OF NANY l

N0mmetTALLIC INCLUSIONS A0JActNT TO TMt BUTTOMMEAD Fact OF THE ANCHOR MCAO IN A LINsAA PATTERN SETWEEN TWO TENDON MOLES WAS NOTED WHICM C0AntSPON080 TO TMt LOCATION OF TMt SUPPOSE 0 CAACK AS SITIO SY APCO. k e

)

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6. ANCMDR HEAD HV 038 EXHIS!TED A M AN CROSS-StCTIONAL ACTUAL HRC l HARONESS A40VE THE SPtCIF!ID HARONE$$ RANSE, AND ANCMORAOCS MU 010, i

PL 040, FC OSS, PN 007. PK 010. PN 008 AND TPD 24 MAD MEAN CROSS-3 SECTIONAL HARONESSES SELOW THE RANGE. ALL OTHER ANCMORAM S

! EXH!t!TED MAN CROSS SECTIONAL HARONESSt$ WITHIN THE SPECIFIED i RANGC. IT SHOULD Bt NDTED THAT LOWER HARONESS WOULO St SENEFICIAL IN REDUCING THE SUSCEPT!s!LITY 70WARO HSC OR SCC. THE STatNGTHS --

AND DUCTILITIES APPEARED NORMAL POR THE STEEL ALLOY GRAOC ANO CON 0! TION AND WERE CONSISTENT WITH THE MARONESSES.

/

l T. ALL ANCMORAets MT THE CHEMICAL RieUIREMENTS OF THE ASTN AND INRYC0 SPECIFICATIONS. ALL RES!OUAL ELEM NTS WERE AT ACCEPTA4LE LEVELS.

\ 8. THE MICR0 STRUCTURES AND N!CROCLEAMLINES$t1 0F THE SAMPLt1 M Rt AS j EXPECTto FOR THE STEEL GRADE AND CON 0! TION.

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M

o o INRYC0 POST TENSIONING O! VISION . INVESTIGATIDN NO. 20017 PAGE !

LIST OF TAalt$

TASLE 1 W TALLUAGICAL TEST DATA DN ANCMOR HEAD HV OSS TABLE 2 NCTALLueGICAL TEST DATA ON ANCMOR HEAD HP 014 TASLE 3 NETALLURGICAL TEST DATA ON AMCMDR HEAD 64J Ott -

l TASLE 4 MTALLUSGICAL TEST DATA ON AMCMDR HEAD FE 024 TAaLE S M TALLURGICAL TEST DATA ON ANCMDR HEAD PL 048 r

l TA8LE 8 NETALLURGICAL TEST DATA ON ANCMDR MtAD FN 035 i

TASLt 7 NCTALLueGICAL TEST DATA ON ANCMDR HEAD FE Ott a

TA8LE 8 NETALLURGICAL TEST DATA ON ANCHOR HEAD FN Ott i TABLE O MTALLumetCAL TEST DATA ON ANCHOR HEAD FK Ott i

TAalt to MTALLURGICAL TEST DATA ON ANCMOR Hf AD FN 028 TA8Lt 11 NCTALLueGICAL TEST DATA ON AMcMOR HEAD TFD 24 l

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INRYC0 POST TENSIONING O! VISION INVEST!aATION NO. 20817 PAst !!

LIST OF FIGURES FIQunt 1 SKETCH OF TENDON LOWER END COMPONENTS P!Gunt 2A POSITION OF TESTING ON ANCHORAGES

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FIGURE 28 POSITION OF TESTING ON ANCHORAetS t FIGutt 2A PHOTOGRAPH OF CORROS!ON PITTING OF FN 028 FIGURE 28 PHOTOGRAPH OF Con #05!0N PITTING OF FN 028 FIGUAE 4 FRACTOGAAPH OF FN 028

.IGURE S FRACTOGRAPH OF FN 025 WITH OVERLAY

.'!GUAE 8 PRACTOGRAPH OF FN 025 WITH DVERLAY FIQURE 7 FRACTOGAAPH OF FN 025 WITH OVERLAY FIGL'RE 8 FRACTOGRAPH OF FN 025 FIGuat 8 SEN FRACTOGRAPH OF ISS AT PetCAACK ON FN Ott F1004E 10 SEN FRACTOGRAPH OF ISS AT PARCRACK ON FN 02S I

FIGURE 11 SEN FRACTOGAAPH OF 105 AT PRECRACK ON FN 025 FIGunt 12 SEN FRACTOGRAPH OF 105 AT P#tCAACK ON FN 035 FIGutt 12 SEN FRACT0eAAPH OF P#tCRACK TIP ON FN 025 Fleunt 14 SEN FRACT00AAPH OF CLEAVA4C AT POST CRACK ON FN 025 1

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l TABLE t. INL AM) STEEL METALLURGICAL LABORATORV WETALLURGICAL TEST DATA ON WSEPH M. FARLET POWER PtANT ANCHOR HEAD Dfv036 CHEMICAL ANALYSIS:

C seN P 5 SI CU NI M0 CR AS CR V TI AL N 8 02 SN 58 Shk 5$bh Ib5h $bh7 Ihh $ih $hk h5 k$lh $ BIS $bth $bb Ubbh $bbbh $bh7 $bbh b8 Ibi bi PPM MICROANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A4H, 82H, C3-4H CARSIDE MO2PHOLOGY TEMPERED MARTENSITE HARCNESS (PROFILE):

HRC CONVERTED SHN CONV.

Eked ACTUAL FROM 8m HRC ACTUAL ACTUAL (HRC)

OUTER MIDOLE IpesER DUTER MIDDLE INNER DUTER MIDDLE IPedE R SURFACE TOP 444 429 468 47.9 45.7 48.4 45.2 45.8 45.0 415 (44.5)

MIDOLE 444 415 444 47.1 44.2 47.1 44.2 42.0 43.5 415 (44.5) 80710M 444 444 444 47.1 47.9 47.1 43.5 44.6 44.6 429 (45.7)

TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION CAUGE (KSI) (K5I) (% IN 2*) (%) v5/T5 TRANSVERSE 1 .500* 988.5 204.3 5.0 14.2 0.92 TRAN5 VERSE 2 .505* 189.8 204.8 10.0 15.5 0.93

• O.2% OFF-5ET VIELO STRE F.TH.

IMPACT PROPERTIES:

ROOM TEMPERATURE ItsPACT PROPERTY TRAN5 VERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY A85CRPTION, FT.-L85. 5 5 5 BRITitE FRACTURE, % 95-100 95-100 95-100 LATERAL EXPANSION, IN.

.0010 .0025 .0010 REFER TO FIGURES 24-28 FOR THE TEST POSITIONS AND CRIENTATIONS.

TABLE 2. INL AM) STEEL METALLURGICAL LABORATORY METALLURGICAL TEST OATA DN WSEPH M. FARLEY POWER PLANT ANCHOR HEAD HPOI4 CHEMICAL ANALYSIS:

C MN P 5 SI CU NI WO CR AS C8 V TI 8 AL N 02 $N $8

• 44 .9du .009 .020 .27 .12 .13 .15 1.05 .087 <.008 .00 <.002 < 0005 .036 .008 35 .01 <.01 PPM MICROANAL) SIS:

CLEAMLINESS (J-K RATING ON APPEARANCE) A3H. 82H CAR 8tDE MORPHOLOGY T E MP E R E", .?9fENSITE HARONE55 (PROFILE):

HRC CONVERTED BHN CONV.

Sted ACTUAL FROM BHN HRC ACTUAL ACTUAL (tWC )

OUTER MIDDLE INNER OUTER MIDOLE IPedER OUTER MIDOLE INNER SURFACE TOP 415 388 415 44.5 48.8 44.5 43.0 37.5 43.0 388 (41.8)

MIDOLE 388 352 398 41.8 37.9 49.8 39.0 33.8 38.0 388 (41.8)

BOTTOM 435 388 415 44.5 49.8 44.5 44.2 41.2 41.9 415 (44.5)

TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL REDUCf!ON ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO OIRECTION GAUGE (KSI) (K5I) (% IN 2*) (%) v5/T5 TRAN5 VERSE 1 .502* 149.5 166.8 10.0 15.3 0.85 TRANSVERSE 2 .505* 147.4 172.6 10.0 25.1 0.85

• O.2% OFF-5ET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEtepE R ATURE IMPACT PROPERTY TRAN5 VERSE 1 TRAN5 VERSE 2 TRAP 45 VERSE 3 ENERGY A8 SORPTION. FT.-L85. 8 ft 10 BRITTLE FRACTURE, % 95-100 95-100 95-100 .

LATERAL EXPANSION. IN. .0010 .0045 .0015 '

REFER TO FIGURES 2A-28 FOR THE TEST POSITIONS AND ORIENTATIONS.

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TABLE 3. INtAND STEEL METALLURGICAL LABORATORY METALLURGICAL TEST 04TA ON JOSEPit M. FARLEV POWER PLANT ANCHOR HEAD HUOt9 CHEMICAL ANALYSIS:

C MN P S SI CU NI MO CR AS CS V TI B AL N 02 SN $8 44 9.020 .009 .027 .27 54 .It .t6 1,07 .045 <.008 .00 <.002 <.0005 .021 .009 37 .02 <.01 PPM .

MICROANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A3-4H. 84H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARDNESS (PROFILE ):

HRC CONVERTED 8tN COtN .

BFN ACTUAL FROM 8tN HRC AL.w t ACTUAL (HRC)

OUTER MIDOLE INNER OUTER MIDDLE INNER OUTER .4IDOLE I NP.E R SURFACE TOP 4t5 388 388 44.5 41.8 41.8 49.7 39.9 40.2 444 (47.1)

MIDOLE 388 363 363 41.8 39.1 39.1 40.8 40.4 37.3 415 (44.5)

BOTTON 401 375 363 43.1 40.4 39.1 42.2 39.0 35.0 444 (47.1)

TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH EtDNGATION IN AREA RATIO DIRECTION GAUGE (MSI) (MSI) (% IN 2*) (%) YS/TS TRANSVERSE 1 .499* 172.5 189.7 9.0 29.9 0.91 TRANSVERSE 2 .505" 142.9 172.3 9.0 23.0 0.83

• O.2% OFF-SET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY ABSO2PTION, FT.-LBS. 8 8 8 BRITTLE FRACTURE. % 95-100 95-f00 95-100 .

LATERAL EXPANSION. IN. .0025 .0020 .0025 '

REFER TO FIGURES 2A-28 FOR THE TEST POSITIONS APO ORIENT ATIONS.

TABLE 4. INLAND STEEL METALLURGICAL LABCRATORY METALLURGICAL TESI DATA DN .MSEPH M. FARLEY POWER PLANT ANCHOR HEAD FEO26 CHEMICAL ANALYSIS:

C MN P S St CU NI MO CR AS CB V TI O AL N 02 SN $8

.4% .940 .016 .004 .29 .it .11 .20 .910 .017 <.008 .00 <.002 <.0005 <.008 .Ott 49 .01 <.01 PPM MICROANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A2H. B2H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARONESS (PROFILE):

HRC CONVERTED BHN CONV.

86N ACTUAL FROM 8tN HRC ACTUAL ACTUAL (HRC)

OUTER MIDDLE INNER OUTER MIDDLE INNER OUTER MIDDLE INNER SURFACE TOP 429 401 4t5 45.7 43.1 44.5 41.2 41. 49.0 388 (41.8)

MIDOLE 375 375 388 40.4 40.4 49.8 37.5 37.2 39.2 388 (41.8)

BOTTOM 429 388 388 45.7 41.8 41.8 43.0 43.1 44.0 388 (41.8)

TENSILE PROPERTIES:

SAMPLE VIELD* TENSILF TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE (KSI) (KSI) (% IN 2*) (%) VS/TS TRANSVERSE t .502* 164.7 185.7 12.0 34.3 0.89 TRANSVERSE 2 .503* 159.0 183.7 7.0 tt.6 0.87

• O.2% OFF-SET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSF 3 ENERGY ABSORPTION, FT.-L85. 12 14 14 BRITTLE FRACTURE, % 95-100 95-100 95-100  ;

LATERAL ERPANSION. IN. .0020 .0030 .0025 REFER TO FIGURES 2A-28 FOR THE TEST POSITIONS AND ORIENTATIONS.

148tE 5. INLAND STEEL METALLURGICAL LABORATORY METALLURGICAL TEST DATA DN JOSEPH M. FARLEY POVER PLANT ANCHOR HEAD FLO49 CHEMICAL ANALYSIS:

C MN P S SI CU NI MO CR AS CB V TI B AL N 02 $N $8

.41 .890 .010 .024 .30 17 .16 .14 .930 .019 .012 .00 <.002 <.0005 .017 .010 29 .02 <.01 PPM MICR0 ANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A3H. B3H CARBIDE MORPHOLOGY TFMPERED MARTENSITE HARDNESS (PROFILE):

HRC CONVERTED BHN CONV.

BHN ACTUAL FROM BHN HRC ACTUA' ACTUAL (HRC)

DUTER MIDDLE INNER OUTER MIDDLE INNER DUTER MIDDLE INNER SURFACE TOP' 352 341 321 37.9 36.6 34.3 34.9 35.0 33.0 415 (44.5)

MIDOLE 321 348 302 34.3 36.6 32.1 33.0 34.2 29.9 375 (40.4)

BOTTOM 363 352 34t 39.1 37.9 36.6 40.1 35.5 35.0 415 (44.5)

TENSILE PROPERTIES:

SAMPLE VIELD+ TENSILE TOY REDUCTION ELASTIC TEST STRENGTH STRENGTH ELO irJ,'N IN AREA RATIO DIRECTION

........s...

GAUGE (KSI)

(KSI)

(%,*

'*) .

(%)

YS/TS TRANSVERSE 1 .503' 123.3 149.7 11.0 27.3 0.82 -

TRANSVERSE 2 .502* 129.3 147.0 11.0 24.3 0.83

• O.2% OFF-SET YlELO STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3

... s..................... ............ ............ ............

Ian.0) 'A8539PTION. FT.-LBS. 14 12 13 PRITILE FRACTURE % 95-100 95-100 95-100 i LATERAL EXPANSION. IN. .0040 .0045 .0045 REFER TO FIGURES 2A-2B FOR THE TEST POSITIONS AND ORIENTATIONS, a

TABLE 6. INLAND STEEL METALEURGICAL LARORATORY METALLURGICAL TEST OATA ON JOSEPH M. FARLEY POWER PLANT ANCHOR llEAD FN025 CHEMICAL ANALYSIS:

C MN P S SI CU NI MO CR AS CB V TI B AL N 02 SN' $8

.42 .990 .011 .018 .32 .06 .10 .19 1.06 .016 <.008 .00 <.002 <.0005 .026 .009 39 .01 <.01 PPM MICROANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A2-3H, 83H CAR 8 TOE MORPHOLOGY TEMPERED MARTENSITE HARONESS (PROFILE):

HRC CONVERTED BHN CONV.

BHN ACTUAL FROM BHN HRC ACTUAL ACTUAL (HRC)

DUTER MIOOLE INNER OUTER MIOOLE INNER OUTER MIDOLE INNER SURFACE TOP 444 415 415 47.1 44.5 44.5 45.0 42.0 42.0 415 (44.5)

MIDDLE 415 375 375 44.5 40.4 40.4 40.0 37.5 38.4 415 (44.5)

BOTTON 444 388 415 47.1 41.8 44.5 41.2 41.2 43.0 415 (44.5)

TENSILE PROPERTIES:

SAMPLE VIELO+ TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN taf4 RATIO DIRECTION GAUGE (KSI) (MSI) (% IN 2") .%, VS/TS TRANSVERSE 1 .505" 158.6 182.3 9.0 18.4 0.84 TRANSVERSE 2 .500* 146.5 175.2 8.0 19.1 0.04

• O.2% OFF-SET VIELO STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PRO ERTY

..............."............ TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY ABSORPTION, FT.-L85. 7 7 8 BRITTLE FRACTURE. % 95-100 95-100 95-100 i LATERAL EAPANSION, IN. .0025 .0025 .0005 REFER TO FIGURES 2A-28 FOR THE TEST POSITIONS AND ORIENTATIONS.

TABLE 7. INLAND STEEL METALLURGICAL LABORATORY METALLURGICAL TEST DATA ON JOSEPH M. FARLEY POWER PLANT ANCHOR HEAD FEO59 CHEMICAL ANALYSIS:

C MN P S SI CU Ni MO CR AS CB V TI B AL N 02 SN SB

.40 .91 .015 .004 .28 .11 .92 .21 .89 .012 <.006 <.002

.00 <.0005 < 008 .090 39 .Ot <.01 PPM MICROANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A2H, 85H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARONESS (PROFILE):

HRC CONVERTED BHN CONV.

BHN ACTUAL FROM BHN HRC ACTUAL ACTUAL (HRC)

OUTER MIDDLE INNER OUTER MIDDLE INNER OUTER MIDDLE INNER SURFACE TOP 429 415 363 45.7 MIDDLE 375 363 363 44.2 39.1 38.2 40.9 35.5 415 (44.5)

BOTTOM 388 388 363 40.4 39.1 39.1 38.8 35.0 32.5 401 (43.1) 41.8 41.8 39.1 42.2 39.0 37.2 415 (44.5)

TENSILE PROPERTIES:

SAMPLE VIELO+ TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE (KSI) (KSI) (% IN 2*) (%) YS/TS TRANSVERSE 1 .506* 148.8 164.7 10.0 26.4 0.90 TRANSVERSE 2 .504* 143.4 171.4 12.0 23.0 0.84

• O.2% OFF-SET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY A8 SORPTION. FT.-LBS. 14 18 15 BRITTLE FRACTURE % 95-100 95-100 95-100  ;

LATERAL EXPANSION. IN. .0030 .0050 .0020 REFER TO FIGURES 2A-28 FOR THE TEST POSITIONS AND ORIENTATIONS.

TABLE 8. INLAND STEEL METALLURGICAL LABORATORY METALLURGICAL TEST DATA DN JOSEPH M. FARLEY POWER PLANT ANCHOR HE AD F DJO97 CHEMICAL ANALYSIS:

C MN P S SI CU NI NO CR AS CB V TI B AL N 02 SN SB

.39 .99 .012 .016 .32 .06 .19 .20 1.07 .089 < 008 .00 <.002 <.0005 .025 .009 47 .01 <.01 PPM MICROANALYSIS:

CLE ANLINESS (J-K RATING ON APPE ARANCE ) A3H. 82-3H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARONESS (PROFILE):

HRC CONVERTED BHN CONV.

BHN ACTUAL FROM BHN HRC ACTUAL ACTUAL (HRC)

DUTER MIDDLE INNER DUTER MIDDLE INNER DUTER MIDOLE INNER SURFACE TOP 444 401 409 47.1 43.1 43.1 41.2 39.4 42.8 444 (47.1)

MIDDLE 388 363 363 41.8 39.1 39.1 37.5 35.1 36.3 415 (44.5)

BOTTDM 429 388 388 45.7 41.8 41.8 44.1 42.2 40.8 415 (44.5)

TENSILE PROPERTIES:

SAMPLE VIELD* TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION CAUCE (KSI) (KSI) (% IN 2*) (%) VS/TS TRANSVERSE 1 .500* 143.1 171.2 9.0 17.2 0.84 TRANSVERSE 2 .502* 147.5 174.3 10.0 17.5 0.85

• O.2% OFF-SET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PPOPERTY TRANSVERSE 1 TRANSVERSF 2 TRANSVERSE 3 ENERGY ABSORPTION. FT.-LBS. 11 11 9 BRITTLE FRACTURE. % 95-100 95-800 95-800  ;

LATERAL EXPANSION. IN. .0045 .0020 .0015 REFER TO FIGURES 24-28 FOR THE TEST POSITIONS AND ORIENTATIONS.

O

TABLE 9. INLAND STEEL METALLURGICAL LABORATORY METALLURGICAL TEST DATA CN JOSEPH M. FARLEY POWER PLANT ANCHOR HEAD FMOt6 CHEMICAL ANALYSIS:

e C MN P- 5 St CU NI WO CR AS CB V TI 8 AL N 02 SN SB

.42 .87 .010 .025 .31 .07 .14 .54 f.02 .018 <.008 .00 <.002 <.0005 .039 .009 25 .01 <.09 PPM MICROANALYSIS:

CLEANLINESS (J-M RATING ON APPEARANCE) A3H. 82-3H

• CARSIDE MORPHOLOGY TEMPERED MARTENSITE HARDNESS (PROFILE):

HRC CONVERTED BIN CONV.

BHN ACTUAL FROM BHN HRC ACTUAL ACTUAL (HRC)

DUTER ullDOLE IDMER DUTER MIDDLE INNER OUTER MIDOLE INNEP SURFACE TOP 388 375 388 41.8 40.4 41.8 39.1 39.0 40.0 415 (44.5)

MIDDLE 331 352 363 35.5 37.9 39.1 32.8 36.1 36.5 444 (47.1) 80TTDM 388 375 401 41.8 40.4 43.1 30.8 37.8 39.2 415 (44.5)

TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATIDN IN AREA RATIO DIRECTIOf3 GAUGE (MSI) (MSI) (% IN 2") (%) VS/TS TRANSVERSE t .504* 133,3 161.7 12.0 29.3 0.82 TRANSVERSE 2 .504* 129.8 164.2 11.0 19.2 0.79

• O.2% OFF-SET YIELD STRENGTH.

. t IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY ABSDRPTION. FT.-LBS. 8 8 9

[RITTLE FRACTURE, % 95-100 95-100 95-ivo (

LATERAL EXPANSIDN. IN. .0015 .0015 .0040

, REFER TO FIGURES 2A-28 FOR THE TEST POSITIONS AND ORIENTATIDNS.

a

TABLE 10. INLAND STEEL METALLURGICAL LABORATORY METALLURGICAL TEST DATA DN JOSEPH M. FARLEY POWER PLANT ANCHOR HEAD FMO28 CHEMICAL ANALYSIS:

C MN P S SI CU N1 MO CR AS CB V TI B AL N 02 SN SB

.40 .90 .010 .024 .30 .18 .it .14 .870 .003 .015 .00 <.002 <.0005 .003 .010 37 .02 <.01 PPM MICR0 ANALYSIS:

CLEANLINESS (J-K RATING ON APPEARANCE) A3-4H. B2-3H. C3-4H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARDNESS (PROFILE):

HRC CONVERTED BHN CONV.

BHN ACTUAL FROM BHN HRC ACTUAL ACTUAL (HRC)

DUTER MIDDLE INNER OUTER MIDDLE INNER OUTER MIDDLE INNER SURFACE TOP 363 321 321 39.1 34.3 34.3 36.5 37.7 35.0 401 (43.1)

MIDDLE 321 311 331 34.3 33.1 35.5 30.0 29.8 30.5 375 (40.4)

BOTTOM 363 321 331 39.1 34.3 35.5 36.0 31.8 34.4 388 (41.8)

TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE (KSI) (KSI) (% IN 2") (%) YS/TS TRANSVERSE 1 .504* 117.8 145.9 13.0 20.3 0.81 )

TRANSVERSE 2 .504* 119.0 145.6 13.0 19.9 0.82

• O.2% OFF-SET YIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY ABSORPTION, FT.-LBS. 9 9 11 BRITTLE FRACTURE. % 85-95 85-95 85-95 ,

LATERAL EXPANSION. IN. .0030 .0045 .0060 '

REFER TO FIGURES 2A-2B FOR THE TEST POSITIONS AND ORIENTATIONS.

~

O l

l i

e **

e es O.

e V 2 e ==

~ ma O e e

N e OE Qe ti CL e &

e ==

2e ==

• O e

.=e eamm a == ue e=@@

J e w g e a . . . ,,

e=

4 eO Ie wamee o a uw e u e ti n ti 2 e 4 ewww 4 e6

.J em .J e 2 4 e 4 a 3e to a 2 3 e e e n N ==

E e Z e- e eemv u e w e . Eue e ti n n me O e e =w 3 e v 4 e e t-==> e Q w e4 >= N e e. e.

2

> cL e N

>=

• • 44me OO JE>e Q> e O e e ae w e

=w == e 2 e ti *

(a > a O. w e e w2e e e. m. O.

22 e y e- e 2e

• O CR e e e o4 m ae == s f4 N N saa e

.eee 2 C6 4 2 eO o X

4 e Q4 e e 3 e CD > ==

4 eQ 3e sad e me W e gQ e we @ e Q e-

& . > e Q e= eae >= M

• e . . e >e

• Efl Q *(

IT e - O u4Me e s'5 e ee e J

4%C N Nw ue 4 e oe oe e. e. e. 3 -e ti ti e 2e

. m.

2 ED a e == a = 0 *= c2 e e4 e w

.U w L ,w= e e w ue I e n n C1 w a= e eae ==

Oe CD e O Ue II

• CL gae 2e Cg e eee a 2Cc o. Nw

. we O e a we ae 3"34 e v 4 >= e e= s O. m. O. .

3e Ne O w

.J

1. 2% e 3e fi O v

• O e ti n n 2ae C*

=

• e e 2 to eo a 4 e we 4

> a en e

• a= N e o aeee c0 w4 4e

.J >

442e e O. O.

2 wI ae ee e 3 > .g. O. e ae w ga we me O 2 4o e

>= a= scw a ae > e*OO O Jc2 O e**

• weee e = ===

w e nas2e a t1. *. n. >= Me ao >a2e >

4 eO e2e wNv .J - e e 4 e w> ga @ Q e e= a I >= IA Oe p w2e n ti (1 - nas e O e ae e mW e . .a e>e Q l

a e- I e saa e w e CL i

nas a e e .J e == me t

O u w e O e *= = == wZ e > e == e >=

ZJ Oe e 2 3eoe . . . .,

e 1e .'

e e 44 == 4 Qe == e 19 ti fi e 4O>a= = ee== . O. >= e wa w 1

.J u e E ge Ie ti n (1 e2eo*g has aM e OO >

I 2* 4 Uh a ZwMe9w W e EE e $>

l == 0 Las e2e saa CE w e * == "

l EE *= a m u e a saa e N e O Las CL e >> e 6 2 t

l 3

.J 2e O.

e CL 4

g ans e m. *. ti.

e >'e e3e ONT en a w e

> e gg m eee r= O. >

.J

. Q e 2e e Q e n (4 ti e4 e Cr 4 2 M

>= 3e e O e er e O w uo Z e N.

e >= e w O. ewa e I e O eae o o me e v. ei. O e 2 e w e

• N ** .J 2 m e v = e e ce

== a 2e NON eaaw g e

• N e

= a == >= == gr w e = = =

e en e me 4 e 2 e ci ti n

.J e e= >>=

ea 4 e n. CE > 4 e e

W a

a e .J e

N M8 3 e taJ e

>= e .J e***

e e. . to e e e >= 2. w Oe O e .J u e C e * * ** > e 6 == CE

• ) O ..

4 ee Q ans e e e g

== e, ti ti (1 >= a eQ a 3

• O e .

wI e t.S e N .. gg e . . O CL laJ eEa las 3e O to nas e 2 og ==

M CE .J e e-o 4 e @ w & e Q nas c h W WO *=. e CK e e- Oe . .

> e ti .. WX E *N*

e ie O e ** a e-w e las e IE p= dg e e- 3 e O

.J CL e a en 2 O e e= e fi O N w a gh a & e- 2 e-J 4 e Q es me saa 2 e 3 e (1 (i (1 & e *= N tas e$u4 to 4

2 4

e . m

.J o 2*

ch w

e oe o e c6 > e o 4 ct er

> e J 4m ct 3eww O u e eh et se: w

=J Eee 4 las & W (L o se e m a 4e gww w I 4 -E e e Z -J 4 en tea me e EE & ge4 W saa 3 taJ .J e= p= 0 W nas ae w .J E l u e 4 uu w .J O .4 4eoe>> >= == e > .J 4 i O & O >= *= Ewweee u 6 O > Eg E

LaJ e PJ 2

k Cop

>===0 e e>me22 4 e m >= ena 2 Oe g .u 2 en == e 4 4 CL e nas == e-

= 4 3g w o e gg a 3 e 2 gg 4 u e 3  % > e e- p- == e nas a .J

O

~

O Tendon Tendon Wires (170)

Tensile Loading Conduit h < ,

concrete l

Concrete a

\

,v .

NN 1 I

r I i .

Bearing Plate

>[8_ . .._

r

~

Shim Stack Protective Grease in spaces Field Anchor Head 4 Grease Cover 5

e Figure 1. Sketch showing the approximate orientation and layout of the components at the lower end of the vertical tendons.

The sketch is not to scale.

,,, ,e-- e - -- -- -

f Surface Hardnesses - m e (Brinell) / T -

/ 09090 O2'O 0 O X,O'd '- OO h C' 3 C * "'U Y'O O '\

e d chemical

@ O E J- O li O,c bkO,-j0 gt, '-f r.O h

^"*I Y

i Mo'f0fOY6c,O,-y, TOY  !

if J  !!

G _, MicrosectJons

, Offg' -go cgo' do ,// (longitudinal)

• Slice for cross- t, OO Q 0 0'0

/

sectional hardness profiles (Brinell

( \,

O 0O0 E ' V~

O O" C' j/

~

and HRc). @ denotes '

/

the nine positions tested.

\ -

f

/

~ . . _ .

Buttonhead Face eee -

t

. s l

J Chemical 4@@@ '

Analyses h

ggg l I  ; I Microsections I l (longitudinal)

Shim Face Figure 2A. Test locations for the hardnesses, microsections and chemical analyses. Figure not drawn to scale.

i

,--v -

o O, -

/ N'

[ ,

/ g

/ O ' O

' h v oj'f gG

\

g 09, O l Sf 8 f' c S h fi

'\  !!'5 O :,0 8'

O

! f I --

Duplicate threaded i ' u "..OQ 0 ' '

.505" diameter Ob '

transverse tensile -  ; O, 'O ,/ Triplicate transverse specimens with 2" s / full size impact gtuge lengths.

Position 1 taken

\s , specimens. Notched

/ parallel to the rolling cdjacent to the 'N / direction and taken shim face. \ /

~

' adjacent to the shim

' ~ , , _ _ - face only.

Buttonhead Face k I s 5 i

i 4

i l Shim Face l

l Figure 2B. Test locations for the tensile specimens i

and Charpy V-Notch impact specimens.

Figure not drawn to scale.

l

--m.

O O l ,

li M . .' , 4 s.,

w -g i

\. 't p - 1 -

4

$*\.'N,\'l

(* h\ ' t .' '

't-I}

l

, jjhjg,4;;' .

l l

+- ?.;; -

'$f , ,

. S.; fv; -

N 52 : '--

I'

\

.}N['-~g R v .;c ~

, .,  : -~ ,

> '._.-  ; y_ ' _; ;, .,

~ Q.'-$f,$.Wl .+ *- . n 't; ' n T&;,;A'.L* 'i';,') ' ' n ~

' 'h

'#1a+ LE C iL E A',52 O . Q 8. m- - ** '- E. 'T;6 ' /[:~ . .. l .

f.

I I

Figure 3A-B. Shim face cf Anchor Head FN 025 showing significant corrosion pitting at some of the cracks indicating that active corrosion had occurred.

Approx. 75X l

l l

r _

s

O O

l

- Shim Face l

0 l

.s ,(

Cut Sections f

i I i jf .

g i'i ,, i ,,...g',

;

'i 'i'l a ,

h' - I 1

u- c c-- "};'  : av tg a i Figure 4. Light fractograph of FN 025 showing the precracked fracture faces (dark areas) and post-cracked laboratory-created i

fractures (light areas) through the honeycomb web of the anchor head. The ,

shim face is shown at the top of the fractograph. i Approx. 0.80X i

_-- --- ,o-_a ---_-- .-.a sa,_ - - -- -_m- ,_u,. m - - --a --_- - ...w- -- -u--_-s4 --.- - -_am a- a ar.

a m --a sam __--m--am l

j

\

N  %

w N N N N

N N N \ N N N N N N,

s* N N N N

N '

N '

b N

s O

M -

1. 9 1

J l

l

.. -,_m., - _.. . - . , , _ _ _ _ . , - ,,. - , , _ __._,,,__________ _ , , ,,_m.___,_,._,.

1 O o

~

1 l

1 i

I i Shim Face

, l l

)

1 i

1 l

l Cut Section j i l llll!'I!ll l;\:lll! '

c.,

i j

7 I ,

(.' : cl v

l l

6 Figure 5. Light fractograph showing a section of the precracked fracture face of FN 025. Note ,

the woody and corroded appearance of the i fractures. The shim face is shown at the j top of the fractograph.  ;

l Approx. 1.38X t

e i

• =s-  %._

-- -- - -----,,-----------------2_ a - - - - - - . _ ,- - - - - - __- ,.- - -

i b

a O

4 l 4

- xs

I s i

\ l D '

1 i

l i

l l

l l

l l 1

l I.

O

~

O l

l i

l l

l l l

l l

, i Shim Face l

~

l l

'l Cut-Section -

unpuum u s ueuumummmme  !

l ll{ ll

7. .

llll8 9, Figure 6. Light fractograph showing a section of the precracked fracture face of FN 025. The shim face of the anchor head is at the top of the fractograph. Note the woody and l corroded appearance of the fractures. The ,

arrow points to areas shown in Figures 9 and 10.  !

l Approx. 1.66X  :

6 l

I i

l t

_4 _ _ ,,,a,,_,,, , ,. _- --- . .,&m_..% _ _ - _ - , - - - . - - - - - - - , - - - - _ - - - - - - -

i 4,

O 2

a -

N N,

N N

x N

N N

x N

N N

N aI N N N N. N N N. N N i N N N

D .

o -

l l

l 1

I Cut Section i

f i

j 1

e

.4 1

7 i 1

k I i

I i

', .w

. ;,- --" Cut Seetion INB' lN MIMiEl

• fj

. 1. ~

iJ .) f4 T. . ....- ..

..> ..s..~

l g  ? (Qf, sh 1M f .Y

,ymmmm.

1 p , p

+

a-- t .; . . .

l 1 I I

j Figure 7. Light fraccograph showing a section of the j precracked (dark areas) and post-cracked ,

laboratory-created fractures (light areas) l

.l' of FN 025. The right arrow points to areas l shown in Figures 11 and 12. The left arrow points to areas shown in Figures 13 and 14.

i Approx. 1.67X i ,

l r l

I i

I l

I i

. l l'

t

.I o o -

i i

l l l l

j Cut Section i

i l

J '

I l 4 j '

~

i i

U '.k. y

• #' 4 l Cut Section i

l '(

\ 7. .

8. .

. ?. R Figure 8. Light fractograph showing the crack tips of FN 025. The precracked fractures (dark) I are corroded and exhibit a woody appear-ance, while the post-cracked laboratory-created fractures (light) exhibit a smocth, crystalline appearance.

Approx. 1.62X l

l l

l

O .-

O l l

l l

l i

i l

Y Y

' A1

^n t

,1 r

.g,'h-75 y '

.u .

. - f. /,

1 l

k(w %

- f.'* f.. '

.,f*

l

'A'

.. * ,, a

• i 9 ,

f'(

& ,' \

1 ' *

, - Yg , z ,

1-

. ~ , ,, ,

l

.i ,

-o, s ,

, '; '! .. j 9

7 ": - . , , i -

i l

.l Figure 9. SEM fractograph of FN 025 of area denoted l l

by the arrow in Figure 6, clearly showing l intergranular separation. ,

! l 1,000X l

l l

1 i

i 0

........-----....m_ _ _ _ _ - -_ _ - _ - - - - - - _ .__ wa _ mm wn,-

O O l

i

l. .

b N .

.h

' ~

- q') y, '

fk

j~lf ?

'4 , >

l, i Q

~

l b

,jg

-f' ~

. */

2~ >

,. s ,,, ., ,

' i A'  % ,. j\ ,f '

t

• 4 f

,j N..i, Q ri',3..-

'. 't

, .s ,, .

l

, a J d) 4

',  ?,

• p

>l

.'s : ',.*,r- A ,..g%. ~ ~ s, , ) n

263X 1,030X Figure 10. SEM fractographs of FN 025 of area denoted by arrow in Figure 6, showing heavy intergranular separation. Note the inclusion troughs at the lower magnification.

l l

l l

l l

O O l

1 I

/ I I ,, _ . _ _ . m- l

'e ,

' hEa -

.A: ;r..

l P '4 l

7

, Y '

.- l l

\ \

~

c A t Figure-11. SEM fraccograph of FN 025 of area denoted  !

by the right arrow in Figure 7, clearly j showing intergranular separation.  !

l 1,000X l

l I

l l ,

l

~

l O O i i

l i

l ' ~7 ~g Q L ~ Kf '

h'..

.p '

1 I

. .2 s .

1 -

3 A I I

',, p '4 s

. I

c. .h  : -

• 1 Figure 12. SEM fraccograph of the precracked web area of FN 025 denoted by the right  ;

arrow in Figure 7, showing heavy inter- i granular separation.

1,000X t

r i

O O l

IGS < l > Cleavage ICS < l > Cleavage I

1

' l i

20'.4.56 ,. q A

ig? t -

((

i >-

I I" A ,

l

.'. h

!.'sMAT , ,.

ith -

h ', g ,i 1 ,. - ,,,h,+

s ,

,. s

' ' N-E

1. 5? Oh u  ; n .

l

'" I

,g .

p i Usmsam ,,,,  :. 1 255X 1,000X l

Figure 13. SEM fractograph of the crack tip in the web area of FN 025 denoted by the left arrow of Figure 7. The fractographs clearly show a transition from the precracked IGS fracture mode to a predominantly brittle (cleavage) fracture mode of the post-crack. Note the inclusions at the low magnification.

4 0

i O O l

l l

e

., L a

i

!

• 2 ' . .',

'.. '- 4:. .

r N4Y f'!>wY2

~

x Figure 14. SEM fractograph taken of the post-crack laboratory-created fracture just below l the crack tip shown in Figure 13. Note j

the fracture mode is predominantly brittle (cleavage). Also note the inclusion

, troughs, some still containing inclusions.

1,000X I i

i l

_ _ . - - _ _ - . . _ -