ML20065B882

Part 21 Rept Re 170 Wire Tendon post-tensioning Sys.Problem Lies W/Poor Const Techniques Not Nonconforming Threads. Nonconforming Threads Not Responsible for Failures Exhibited at Job Sites.Qa Procedure Encl

ML20065B882
Person / Time
Site:	Byron, Braidwood, 05000000
Issue date:	01/27/1983
From:	Matykiewicz C, Waitkus D PRECISION SURVEILLANCE CORP. (FORMERLY INRYCO, INC.)
To:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20065B885	List: ML20065B882 ML20065B902
References
REF-PT21-83 QA-830126-1, NUDOCS 8302230542
Download: ML20065B882 (11)

Text

INRYCO, Inc.

- Concret) Systems Division 7200 S. Narragansett Avenue Bedford P rk Chicago, !!Iinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TLX-72-1497 h Inryco January 27, 1983 United States Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, IL 60137 Attention: Director, Regional Of fice

SUBJECT:

Byron /Braidwood Nuclear Plants Compliance with 10CFR Part 21 Concluding Report Re: Inryco Letter QA 830126-1 Gentlemen:

The attached documents have been submitted to those clients of Inryco, Inc. who have been supplied 170 wire tendon post-tensioning systems.

While the nonconforming threads may exist for the projects other than >

Byron /Braidwood, it is our contention that the problem lies not with the nonconforming threads, but more with poor construction technique.

We already know that the anchorage threads if conforming, provide no less than 138% of the guaranteed ultimate strength of the tendon. Yet, 100% strength of the coupled threads can be assured if the stressing adaptor is within tolerance, while the minor, major and pitch diameters can be reduced 0.100" from the minimum dimension.

/ With these facts in mind, we conclude that the nonconforming threads were not responsible for the failures exhibited at the Byron /Braidwood jobsite. As a result of the failures the same controls developed for Byron /Braidwood must be applied to the stressing equipment and constr-uction technique on future surveillance or restressing work on any vessel that used the 170W system.

dg Sincerely, CVea 58 N ER o

1 g D'b onald W. M M.

Waitkus Supervisor, Quality Assurance e:c 88

'( - -

ge

$$ Chester E. Matykiewicz GO 03 Responsible Officer I/8 J7 TE/9

( d)Widtalg Steel company

INRYCO. inc.

ConcrGto Systems Division 7200 S. Narragansett Avonue Bedford Park Chicago, Illinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TDC-72-1497 lnryCO January 27, 1983 Metropolitan Edison Co.

TMI Nuclear Station P.O. Box 480 - Rte. 441 S Middletown, PA 17057 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0170 WIRE ANCHORAGE SYSTEM USED ON: Three Mile Island - Unit 1 POST TENSIONING ENGINEERING BULLETIN I

It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryco undertook an extensive testing program to evaluate the effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related nature.

an inlanct Stael company J

INRYCO. inc.

Anchorage failure is a condition to be avoided by OBSERVING THE FOLLOWING PRECAUTIONS:

1. BE SURE that the stressing adaptor is an acceptable dimensional match-up with the anchorage to be coupled.

2. BE SURE that the stressing ram adaptor is fully engaged with the anchorage before application of any force.

3. DE SURE that while coupling the stressing adaptor to the anchorage, the bushing (170W15) has not disengaged or partially unthreaded from the shop anchorhaad (170WlA).

We are including the following procedure for your use in verifying the above stated conditions. These documents should also be included in any bid package for work that would require detensioning or restressing operations; especially In-Service-Inspections or Surveillance of tendons.

1. Procedure QC 1021 - Anchorage Measurement Control Attachments I thru 6 Any questions you may have can be referred to the Inryco Concrete Systems Division Engineering Department. Please return the acknowledgement of receipt.

Sincerely,

--1 .

J(133 - m ilm -

D Id W. Waitkus

\ Supervisor, Quality Assurance Chester E. Matykiewicz Responsible Officer cc: USNRC Region III an Inland Steel company

IN RYCO, Inc.

Concr:t] Systems Division 7200 S. Narragansett Avenuo Bedford Pcrk Chicago, illinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TD(-72 1497 h inryco January 27, 1983 Metropolitan Edison Co.

IMI Nuclear Station P. O. Box 480 - Rte. 441 S Middletown, PA 17057 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORAGE SYSTEM USED ON: Three Mile Island - Unit 1 POST TENS 10NING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryeo undertook an extensive testing program to evaluate the effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operacions which are normally considered to be of a non-safety related nature, an inland Steel cc,mpan/

IN RYCO, Inc.

Concr: t) Systems Division 7200 S. Narragansett Avenue Bedforc8 Park Chicago, lilinois 60638 312 585 73OO Chicago 312 594 7300 Suburban TD(-72-1497 h inryco January 27, 1983 Alabama Power Co.

600 North 18th St.

Birmingham, AL 35291 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORAGE SYSTEM USED ON: Farley - Units 1 & 2 POST TENSIONING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorege, when insufficiently coupled to the stressing ram adaptor, Inryco undertook an extensive testing program to evaluate the effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum "itimate tensile strength of the corresponding prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related nature, an inland Steel company

INRYCO, Inc. l Concrr.tm Systems Division l

, 7200 S. Narragansett Avenue '

Bedford Park Chicago, Illinois 60638 1

312 585 7300 Chicago  ;

312 594 7300 Suburban TD(-72 1497 i h Inryco January 27, 1983 Union Electric P.O. Box 149 St. Louis, MO 63166 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORAGE SYSTEM USED ON: Callaway - Unit 1 POST TENSIONING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-7 8.

As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryco undertook an extensive testing program to evaluate the effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV&C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding prestressing steel element af elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements , it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related nature, an inland Steel cornsany __ _ _ _ _.

INRYCO, inc.

Concr;te Systems Division 7200 S. Narragansett Avenus Bedford Park Chicago, Illinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TU(-72-1497 lIWyCO January 27, 1983 South Carolina Electric & Gas P.O. Box 764 Columbia, SC 29202 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0170 WIRE ANCHORAGE SYSTEM USED ON: V. C. Summer POST TENSIONING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryco undertook an extensive testing program to evaluate the ef tectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding j prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has i

shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related

( nature.

{

i an Inland Steel comsann

INRYCO, Inc.

Concret] Systems Division

,, 7200 S. N rragansett Avenus Bedford Park Chicago, Illinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TUC-72 1497 h inryco January 27, 1983 Tannessee Valley Authority 400 Commerce Ave.

Knoxville, TN 37902 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORAGE SYSTEM USED ON: Bellefonte - Units 1&2 POST TENSIONING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-78.

( As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryc o undertook an extensive testing program to evaluate the effectiveness of vdrious thread combinations. Of the l unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding l prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related i nature.

1 l

l l

an IMand Steel company

INRYCO, Inc.

Conecta Systems Division s , 72CX) S. N:rragansett Avenue i Bedford Park i Chicago, Illinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TDC-72-1497 h Inryco January 27, 1983 Commonwealth Edison Co.

Station Nuclear Engrg. Dept.

One First National Bank Bldg.

P.O. Box 767 Ch ic ago , IL 60690 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORACE SYSTEM USED ON: Byron - Units 1&2 Braidwood - Units 1 & 2 POST TENSIONING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions i

for the 170 wire system may not conform to the requirements I of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorage, when insuf ficiently coupled to the stressing ram adaptor, Inryco l undertook an extensive testing program to evaluate the

! effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding prestressing steel element of elements being anchored or j coupled (CC2451).

While those anchorages that have been stressed in any l containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related na ture.

l

INRYCO, Inc.

Concrit) Systems Division

• s , 7200 S. Narragansett Avenue Bedford Park Chicago, Illinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TDC-72-1497 h Inryco January 27, 1983 Kansas Gas & Electric P.O. Box 309 Burlington, KS 66839 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORAGE SYSTEM USED ON: Wolf Creek POST TENSIONING ENGINEERING BULLETIN It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryco undertook an extensive testing program to evaluate the effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV6C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist as the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related nature.

an inland Steel comlp.vy

INRYCO, Inc.

C ncr:ta Systems Division

.. 7200 S. Narragansett Avenue Bedford P rk Chicago, lilinois 60638 312 585 7300 Chicago 312 594 7300 Suburban TLX-72-1497 h Inryco January 27, 1983 Consumers Power Co.

212 W. Michigan Ave.

Jackson, MI 49201 Attention: Director of Quality Assurance Director of Power Generation

SUBJECT:

INRYC0 170 WIRE ANCHORACE SYSTEM USED ON: Midland - Units 162 POST TENSIONING ENGINEERING BULLETIN l

l l

It has been determined that the anchorage thread dimensions for the 170 wire system may not conform to the requirements i of Federal Standard H28 Appendix 13 dated 8-31-78.

As a result of a failure of a 170 wire anchorage, when insufficiently coupled to the stressing ram adaptor, Inryco undertook an extensive testing program to evaluate the effectiveness of various thread combinations. Of the unstressed anchorages sampled, it was determined that the worst as-threaded condition would still meet ASME Section III Division 2 CRV&C Code requirements of 110% of the specified minimum ultimate tensile strength of the corresponding l prestressing steel element of elements being anchored or coupled (CC2451).

While those anchorages that have been stressed in any containment have met the specification requirements, it should be noted that the Inryco investigative program has shown that potential deficiencies could exist ar the result of a lack of control over material, equipment or operations which are normally considered to be of a non-safety related nature.

an Inland Steel conmoyz