iPCHG-DESG E 4'FqJFjOG Sheet I of 1 Record of Lead Review · John Hollidav .., Pil 08/10/09 Lead Reviewer aJ (printlsign) Discipline Date Item I Deficiency Resolution No. NONE 1

iPCHG-DESG E 4'FqJFjOG

Sheet I of 1Record of Lead Review

0000063016R3

Document: Phase 1 Additional Creep Test Plan Revision 0

The signature below of the Lead Reviewer records that:- the review indicated below has been performed by the Lead Reviewer;- appropriate reviews were performed and errors/deficiencies (for all reviews performed)

have been resolved and these records are included in the design package;- the review was performed in accordance with EGR-NGGC-0003.

-] Design Verification ReviewF-- Design ReviewI Alternate CalculationLI Qualification Testing

LI Engineering Review 2 Owner's Review

L- Special Engineering Review

LI YES LI N/A Other Records are attached.

John Hollidav .. , Pil 08/10/09Lead Reviewer aJ (printlsign) Discipline Date

Item I Deficiency ResolutionNo.

NONE1.

2.

3.

FORM EGR-NGGC-0003-2-10This form is a QA Record when completed and included with a completed design package.Owner's Reviews may be processed as stand alone QA records when Owner's Review iscompleted.

EEGR-NGGC-0003 Rev. 10

ATTACHMENT Z45R3 Page 1 of3

C-PCHG-DESG ENGINEERING CHANGE 0000063016R3

Celebrating 35 YearsNovember 25, 2008 1973 2008

Progress Energy Florida, Inc.15760 W. Powerline Street (SA2C)Crystal River, Florida 34428-6708

Attention: Ms. Debbie Hanna

Reference: Proposal for Additional ServicesCrystal River Nuclear PlantSteam Generator Replacement Restoration of the ContainmentOpeningPhase II-Additional Creep TestingCrystal River, FloridaS&ME Project No. 1439-08-208Contract 373812

Dear Ms. Hanna:

S&ME, Inc. (S&ME) is pleased to submit this proposal for additional services for thereferenced project. This proposal is in response to a verbal request from John Holliday ofProgress Energy during a conference call on November 19, 2008. This proposaldescribes our understanding of the additional scope of services, outlines the projectschedule and presents the associated compensation for our services.

PROJECT INFORMATION AND SCOPE OF SERVICES

Our understanding of the scope of work is based upon our discussion with ProgressEnergy and Sargent and Lundy duringa conference call on November 19, 2008. Theinitial Phase II scope included the testing of two different concrete mixtures for potentialuse to restore the containment opening. The Phase II testing is non-safety related anddoes not include creep testing. Phase III testing is to include the testing of the selectedfinal concrete mix. Phase III testing is safety related and will include creep testing. Inorder to obtain an indication of how the two Phase II mixes will perform during creeptesting and to provide additional information to the project team prior to mix selection,S&ME has been requested to have short term creep tests performed on the two proposedPhase II mixes. In general, the testing will be performed as follows:

Creep tests will be performed in general accordance with ASTM C 512. Initial curilngwill be performed in the autogenous chambers for approximately 4 days, and thenspecimens will be express shipped to CTLGroup for scheduled arrival at an age of. fivedays. Once the specimens arrive, gage points will be installed to measureddeformation (three readings per specimen). Specimens will be tested in the drying stateonly, to measure total creep and shrinkage.

S&ME, INC. /1413 Topside Road / Louisville, TN 3 7 777/p 865.970.0003 f 865.970.2312 / www.smeinc.comATTACHMENT Z45R3 Page 2 of 3

"P 15CýHG-DESG ENGINEERING CHANGE 0000063016R3Proposal for Additional Services S&ME Project No.: 1439-08-208Crystal River Nuclear Plant/Phase II Additional Creep Testing November 25, 2008

Two creep specimens and two shrinkage specimens will be tested for each mix. Inaddition, one specimen will be tested for compressive strength at 5 days and twospecimens will be tested for modulus of elasticity at 5 days.

For the creep test, six readings will be taken on the first day:1) Before loading (out of frame)2) Before loading (in frame)3) Preload (200 psi)4) .Initial load (2000 psi)5) 10 minutes after initial load6) 2-6 hours after initial load

Readings will be taken approximately every day for the first week with subsequentreadings taken on 14, 21, and 28 days after loading, with the exception of weekends andholidays. Data will be reduced and a brief summary report will be prepared.

COMPENSATION

S&ME proposes a cost of $7,350.00 per short-term creep test as defined above, for a totaladditional cost of $14,700.00.

SCHEDULE

The schedule for performing this additional scope of work will be dependent on thetiming of the authorization to proceed. However, it is anticipated that the mixes would beperformed and specimens cast during the first or second week of December.

AUTHORIZATION

It is anticipated that the authorization for this additional work would come through theissuance of an amendment existing Contract 373812 between Progress Energy and S&MEto add this scope and pricing and, if needed, to increase the original Not-to Exceed value ofthe contract.

Should you have any questions after reviewing this proposal or if we may be of additionalservice, please do not hesitate to contact us at your convenience.

Sincerely,

S&ME, INC.

.l B. Pearson Michael R. StomerMaterials Engineer Vice President

ATTACHMENT Z45R3 Page 3 of 3

PCHG-DESG ENGINEERING CHANGE 0000063016R16

0 0®

PLAN VIEW

CONTAINMENT OPENING

CORE BORE LOCATIONS

NOTES:

1. FIELD TO DRILL NINE (9) 4 INCH DIA. CORE BORES IN THECONCRETE CONSTRUCTION OPENING WALLS WITH 2'MINIMUM SPACING.

2. THE LOCATIONS CHOSEN SHALL BE IN GOOD CONCRETEWITH NO VISUAL CRACKING PRESENT.

3. THE CORE SHALL BE LOCATED AT THE APPROXIMATEDISTANCE HALF WAY BETWEEN THE LINER PLATE AND THEVERTICAL TENDONS.

4. IF REBAR OR MISC. STEEL IS ENCOUNTERED, DRILLADDITIONAL CORE AT NEW LOCATION. USE DRILL STOPSFOR CORE BORING.

5. DRILL CORE BORES IN ACCORDANCE WITH ASTM C-42 ANDAI-480.

6. AFTER DRILLING IS COMPLETE WIPE OFF SURFACE WATERFROM CORE SAMPLE AND ALLOW WATER TO EVAPORATE.

7. WHEN SURFACE IS DRY, BUTNO LATER THAN ONE HOUR,WRAP THE CORE SAMPLE IN PLASTIC.

8. PLACE EACH CORE SAMPLE IN SEPARATE PLASTIC BAGSAND SEALTHE BAGS TO PREVENT MOISTURE LOSS.

9. PROTECT THE WRAPPED CORE SAMPLES FROM EXPOSURETO DIRECT SUNLIGHT AND STORE AT ROOMTEMPERATURE.

10. MATCH MARK CORE SAMPLES WITH LOCATIONS SHOWN.

SIDE VIEW

CONTAINMENT OPENING

CORE BORE LOCATIONS

CRONTAINRENT OENING

CONTAINMENT OPENINGCORE BORE LOCATIONS

Z65R1 6 PAGE 1 OF 1

PCHG-DESG " .ENGINEERING CHANGE 10000063016R15

Purpose:The purpose of this Attachment is to evaluate the Liner Plate for the proposed lifting configuration shown inAttachment Z22R9 (Bechtel is responsible for the design of the rigging equipment).

Results:The liner plate is structurally acceptable for the lift configuration shown in Attachment Z22R9.

Methodology:The structural analysis of the liner plate for the lift configuration shown in Attachment Z22R9 is performed in thefollowing three steps:

1. Liner Plate and vertical reinforcement bending stress around horizontal (X) axis2. Liner Plate and horizontal strongback stress around vertical (Y) axis3. Local Liner Plate stress at lift points

Detailed Calculations:Attachment Z22R9 shows the different postions of the liner plate during the lifting process. Position 6 is the worstcase position to determine bending and local stresses.

Section 1: Liner Plate around Vertical (Y) Axis

DWliner.plate:= !5kip

see Attachment Z22R9 Page 2

Aliner:= 23.511-24.751f

Aliner = 581.625.ft2

Liner ileight= 24.75 ft

LinerWidth:= 23.5ft

DWliner_plateWw~idth -Liner Width

DWliner-plate POSITION 5,

wheight Lin= PueightLiner-Height LEG I CUI LOOSL. CR'AIE HAS LOAD

Ibf •Wwidth t638--

w

lbfWhcight = P I

ATTACHMENT Z64 Page 1 of 5

PCHG-DESG ENGINEERING CHANGE F0000063016R151

Bending about Verticial Axis

Iw:= 7ft + 3.75in + 7ft + 5.75in Iw= 14.792-ft

Conservatively consider simple beam

.23.5ft- 1waw'- 2 aW = 4.354. ftz

M- Wwidth' Iw

y: 8M Y= I7.457-kip'ft

Strongback and Liner Plate Section Modulus

Effective plate width considered as part of section modulus

Neutral Axis

A, := 0.375inmb

A2 := 2-1.19in2

b:= 6in

Y2:" 0.275in +3in + 1.5in

0.375.

2

AI.Y1 + A2.Y2

A1 + A2

n = 2.546-in

Y2

C = * ~ = A

xSt ron gback

n

3in

E~Z~b

Moment of InertiaLiner Plate

I1 = ,0.187 .in 42in-(3in) 3 (2 - 0.5)in-(3in - 0.5in) 3

12 1212 = 2.547-in

4 b.0.375in3

12

in:= 1 + A-2-(Y. - n) 2 + 11 + A,. n - 07i

~ ~ 2)in = 27.075-in4

inSh := -

n

Sh

Sh = 10.636-in 3

fb= 19.696.ksi < I 0.6-36ksi = 21.6-ksi OK


I ATTACHMENT Z64

Page 2 of 5 1

I PCHG-DESG ENGINEERING CHANGE 10000063016R15

Bending about Horizontal Axis,

ah:= 6ft + 1.5in ah = 6.125.ft't Ih:= 18ft + 7.5in - ah Ih = 12.5:ft

Conservatively consider simple beam with distributed load on vertical stiffener only

2_ Wheight'lh 1.5ft

M : 8 2335ft.

S:= 0•542in3 Angle L3x2x1/4

MX =0.ý756-kip-ft

fb = 16.728.ksi < O.6.36ksi '=. 21.6;ksi ,OK

Local Plate StressesThe local plate stresses based upon the worst case load condition were determined byperforming a finite element analysis in GT STRUDL. The lift points were modeled assupports and a surface load was applied to the plate.

DWliner_platep := Aliner p = 25.79.psf

The stress profile in the liner plate is shown below:

L N

IUI

I P"


PCHG-DESG ENGINEERING CHANGE 100000630116R15I

The locally stressed regions shown in the stress profile above are listed in detail inthe STRUDL output file, themaximum stresses are listed below:

MAXIMUM AND MINIMUM SUMMARY OF ABOVE RESULTS

RESULT* MAXIMUM SURFACE JOINT * MINIMUM SURFACE JOINT *

* SXX • 0.263025E+05 TOP 1684 , -0.263004E+05 BOTTOM 1684 *

SYY * 0.312231E+05 TOP 1684 *-0.312232E+05 BOTTOM 1684 *

* SXY 0.771544E+04 TOP 697 . -0.771544E+04 TOP 1684 *- - - - - - - -

Although two elements are shown to be overstressed, the stress profile shown above does not indicate-an even stressdistribution around the overstressed elements. The STRUDL output excerpt of the surrounding elements is shown below:

AVERAGE STRESSESJOINT SURFACE NUMBER OF ELEMENTS SXX1683 TOP 4 0.912358E+041683 BOTTOM 4 -0.912138E+04

SYY SXY0.175492E+05 -0.154991 E+04-0.175495E+05 0.1 54709E+04

16841684

TOPBOTTOM

44

0.263025E+05-0.263004E+05

0.312231 E+05-0.312232E+05

-0.771544E+040.771038E+04

1685 TOP 4 0.141190E+05 0.207881E+05 -0.574417E+041685 BOTTOM 4 -0.141198E+05 -0.207880E+05 0.574137E+04

The stresses in the adjacent elements are significantly below allowable weak axis bending stress (0.75*30ksi = 22.5ksi).Therefore, the 6"x6" mesh is not fine enough to adequately reflect the stress distribution in areas of materialdiscontinuities (the high stressed region is in the liner plate elements of 0.375" adjacent to thelstiffened liner plate with0.75" thickness. Taking average of three elements 481,482 and 483 and 1844, 1845, and 1846, theaverage stress willbe(0..... 1.1)! 3 - 1,.5 ,. . " . Note that the vertical load used in the finite element analysisis conservative, since the, sling attached to the lug at the liner plate will be at an angle and will exert. less vertical loadthan used in the analysis.

Therefore, the liner plate is structurally acceptable for the lift configuration shown in Attachment Z22R9.

(17.5+31.2+20.7)/3 = 23.1 ksi slightly over the allowable, however the verticalload used in the analysis is conservative as mentioned in Revision 14,therefore slight increase less than 3% of the allowable is acceptable.

I I. I I I I I ~ I I I I I I I '. I I I I I I I I I I I I


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PCHGoDESG .,.ENGINEERING CHANGE 10000063016R15

STRUDL INPUT FILE: Liner Plate Lift RA2.txtSTRUDL 'LINER PLATE EVALUATION FOR LIFTING'UNITS FEET POUNDS DEGREESTYPE SPACE FRAMEMATERIAL STEEL ALLJOINT COORDINATEGEN 47 JOINTS CARTESIAN ID 1 1, X 0.0 0.5REPEAT 49 TIMES ID 47 Y 0.5GEN 49 MEM ID 2400 1 F 3 47 T 50 47REPEAT 14 TIMES ID INCR 49, FROM INC 3. TO INC 3STATUS SUPPORT 574 602 1749 1777JOINT RELEASE574 602 MOM X Y Z KFZ 5000 KFX 20001749 1777 MOM X Y Z KFZ 5000 KFX 2000MEM PROPERTIES2400 TO 3134 TABLE 'ULANGLE 'L3X2X1/4'CONSTANTSBETA 113.7 2400 TO 3134TYPE PLATEGEN46ELEMENTSID1 1 FROM1 1TO21TO49 1TO481REPEAT 48 ID 46 FROM INCR 47 TO INCR 47 TO INCR 47 TO INCR 47GEN 49 ELEMENTS ID 2255 1 FROM 46 47 T 47 47 T 94 47 T 93 47ELEMENT PROPERTIES1 TO 468 472 TO 495 499 TO 514 518 TO 541 545 TO 560 564 TO 587 591 TO 606 610 TO 633 637 TO 1618 TYPE 'SBHQ6' THICK 0.3751622 TO 1645 1649 TO 1664 1668 TO 1691 1695 TO1710 1714 TO 1737 1741 TO 1756 1760 TO 1783 1787TO 2303 TYPE 'SBHQ6' THICK0.375STOP LEFT SWIVEL HOIST CONNECTION1619 TO 1621 1665 TO 1667 1711 TO 1713 1757 TO 1759 TYPE'SBHQ6&THICK 1.125"$BOTTOM LEFT SWIVEL HOIST CONNECTION469 TO 471 515 TO 517 561 TO 563 607 TO 609 TYPE 'SB'Q6' THICK 1.125STOP RIGHT SWIVEL HOIST CONNECTION1646 TO 1648 1692 TO 1694 1738 TO 1740 1784 TO 1786 TYPE 'SBHQ6' THICK 1.125SBOTTOM RIGHT SWIVEL HOIST CONNECTION496 TO 498 542 TO 544 588 TO 590 634 TO 636 TYPE 'SBHQ6' THICK 1.125LOADING 1 'ELEMENT LOADS'ELEMENT LOADS1 TO 2303 SURFACE FORCE GLOBAL PZ -25.8STIFFNESS ANALYSISLOAD LIST IOUT BY MEMOUT DEC 2 Revised Maximum stress inPARAMETERSCALCULATE AVERAGE STRESSES AT TOP BOTTOM SURFACES 1 TO 2303 Page 4 under Rev. 15.

Prepared by: C.G..RanganathDate: 10/04/09

Preparer: Checker:

Jackson, Jabari Ranganath, CasabaPrepared By Checked By2009.10.03 03:03:43 -04;0'- 2009.10.03 05:52:48 -04'00'

Jabari Jackson, PE Casaba Ranganath, PE


EC 63016R12 Z63R12 Page 1 of 5Evaluate the use of Hydrochloric Acid

Evaluation of 17% Hydrochloric Acid for Control Room Habitability

1.0 Purpose and Scope

1.1 Purpose

The purpose of this evaluation is to evaluate a potential new hazard at the CrystalRiver 3 Nuclear Plant (CR3). The hazard is from the temporary storage and use of1600 gallons of 17% hydrochloric acid. It is used to control PH levels in water usedfor containment building hydro-demolition activities associated with the station'sRefuel 16 Steam Generator Replacement Project. Of primary concern with theintroduction of any new hazardous material for CR3 is:

a) The explosion hazard from the new chemical; andb) The safety of the Main Control Room (MCR) operators from toxic vapor or

asphyxiation from the new chemical in the area. The toxic vapor could betransported to the MCR through the Control Complex HVAC system.

This evaluation will demonstrate that the use of a 17% solution of hydrochloric acidwill not pose a threat to the MCR operators by either explosion or hazardous levelsof vapor.

1.2 Scope

The evaluation described in Section 1.1 will be performed for the 1600 gallons of17% solution of hydrochloric acid that will be transported on site and temporallystored in a vented tank outside of CR3's protected area.

Acceptance Criteria:a) Toxicity (One of the following conditions must be met)

The concentration of vapor in the MCR caused by hazardous chemicalrelease cannot be more than the Immediately Dangerous to Life andHealth (IDLH) toxicity limit. Also, the concentration of oxygen inside theMCR cannot drop below 19.5%, causing asphyxiation (Ref 2, pg. 4). InReg. Guide 1.78 (Ref 2, pg. 6), it states "the use of IDLH values astoxicity limits is considered appropriate since it provides an adequatemargin of safety as long as control room operators use protectivemeasures within 2 minutes after the detection of hazardous chemicals;they therefore would not be subjected to prolonged exposures at theIDLH concentration levels."

ii. More than two minutes must elapse between the time of detection andthe time when the concentration inside the MCR reaches the IDLH limit(Ref. 2, pg. 6). Note that detection can be by either automatic systems orthrough nasal detection.

Note: CR3 has not adopted Reference 2.2. The use of its acceptance criteria isjudged an acceptable industry practice.


b) Explosions cannot cause an over-pressure of more than 1 psi at CR3 Reference[1] at page 1.

2.0 References2.1 CR3 Calculation No. M07-0005, Revision 0, Evaluation of Proposed New Chemical

Hazards to the Crystal River Site.2.2 USNRC Regulatory Guide 1.78, "Evaluating the Habitability of a Nuclear Power Plant

Control Room During a Postulated Hazardous Chemical Release," Rev 1, December2001.

2.3 NUREG-0570 "Toxic Vapor Concentrations in the Control Room Following aPostulated Accidental Release," James Wing, June 1979.

2.4 MSDS for Hydrochloric Acid, Science Lab.2.5 FSAR, Rev 31.32.6 CR3 Technical Specification thru amendment 235, Section 3.7.12.2.7 CR3 Technical Specification Bases, Rev 80, Section 3.7.12.

3.0 Definitionis)

The IDLH limit is a toxic gas exposure limit. From Reg. Guide 1.78, this the concentration ofa toxic gas that is "likely to cause death or immediate or delayed permanent adverse healtheffects if no protection is afforded within 30 minutes. [This limit] can be tolerated for 2minutes without physical incapacitation of an average human" (Ref. 2.2, pg. 6). Because 2minutes is the required time for a control room operator to don a respirator after detection,the IDLH is considered the maximum acceptable toxic gas concentration for a control roomoperator.

4.0 Input Data

Hazardous Chemical 17% in Solution Hydrochloric Acid (hydrogen chloride)* 1,600 Gallons stored on site Limitation* Storage conditions are 14.7 psia and 100 OF (max) Limitation* Hydrogen chloride has an IDLH limit of 210 mg/m3 or 50 ppm Ref. 2.1* Odor threshold of 0.25 to 10 ppm Ref. 2.4

5.0 Assumptions

The Reference 1 Chemical Hazards Evaluation has the following relevant assumptions:o The gas vapors that maybe released as vapors will obey the ideal gas law. This

assumption is consistent with common engineering practices for gasses atatmospheric pressures and temperatures.

o All chemical vapors are assumed to be at atmospheric temperature soon afterthey are released.

o Atmospheric pressure is assumed to be 14.7 psia.o The storage tank will be under observation by equipment operators or other

watch at least once each hour.

6.0 Evaluation

In regard to protection from toxic gas releases, other major sources of toxic gas have beenremoved from the site. The most significant sources remaining are ammonia at CR Units 4/5


(Ref. 2.1) and the potential to use chlorine and sulfur dioxide for short periods of time at theHelper Cooling Towers. The use of administrative limits for toxic gas at CR3 has resulted innasal detection being adequate for operator protection and eliminated the need for automaticdetection and isolation. The operator donning self-contained breathing apparatus within 2minutes of nasal detection will ensure they are not exposed to debilitating levels of toxic gas.

Regulatory Guide 1.78 states "For chemicals that are gases at 100 OF and normal atmosphericpressure but are liquids with vapor pressure in excess of 10 torr, consideration should be givento the rate of flashing and boiloff to determine the rate of release to the atmosphere and theappropriate time duration of the release. For lighter-than-air gases, the buoyancy effect shouldbe considered in determining the dispersion characteristics". As noted in the attached E-mailfrom Sargent & Lundy it was concluded that 17% concentration hydrochloric acid solution is nota hazard to the Crystal River site.

The worst case scenario is the catastrophic failure of the tank holding the hydrochloric acid. Thestorage tank is an atmospheric tank and Reference [2.4] outlines that the acid solution is non-flammable and non-explosive. The catastrophic failure of the tank would cause the acid to poolin the retaining area built up around the area. And not cause the instantaneous formation of agas cloud that could move with little dissipation towards the control room ventilation intakes.

A tank failure would result in a plume release that would form over time. The plume would resultfrom the evaporation of the chemical over time. Reference [2.1] describes a plume release andhow a liquid puddle evaporates and how the vapor dissipates as it travels with the wind. Areleased liquid quickly spreads by gravity from its initial shape into a pancake on the ground.

The continuous source of the plume, pools with boiling points greater than the ambienttemperature, is the evaporation rate of the liquid. Reference [2.4] establishes that forhydrochloric acid concentrations less than 20%, the boiling point of the fluid is higher thanwater. Reference [2.4] establishes that the vapor density of the acid is 1.267 as compared to airat 1. With this density the evaporating gas plume will tend to initially gather at the surface of thepool and not spread upward. It is of additional note that the storage tank is located more than 40feet below the elevation of the control room ventilation intakes.

The above establishes that, under ambient heat conditions, by observation a reasonable time(over one hour) exists for station personnel to identify a failure of the acid holding tank beforesignificant accumulation of hydrochloric acid vapor. Moreover, vapor accumulation will becontinuously disbursed into the environment limiting the vapor concentration (i.e. the vapors willtend not to gather over long periods and then move as an intense vapor cloud).

The ventilation system for the control room circulates the air inside the MCR with air taken fromthe intake. As a result, the concentration of a toxic chemical in the MCR is different than theconcentration at the inlet Reference [2.1]. Reference [2.4] provides that hydrochloric acid has astrong pungent order with an odor threshold of 0.25 to 10 ppm. The IDLH established forhydrochloric acid is 50 ppm (see reference 2.2) providing ample time for an operator to don self-contained breathing apparatus within 2 minutes of nasal detection thus ensuring that they arenot exposed to debilitating levels of toxic gas.

Reference [2.4] identifies materials that should not come in contact with Hydrochloric Acid. Awalk down of the tank, retaining container, and general area revealed no metal substances or


other substances that would interact with the acid are in the immediate area if the tank were tofail.It should also be noted that CR3 has approved the storage of hydrochloric acid in thewarehouse and subsequent use in the plant.

> Cat ID 1120310 - Hydrochloric Acid Concentrated, Liquid Form, Reagent Grade,> Cat ID 1120312 - Hydrochloric Acid Concentrated, Liquid Form, Reagent Grade, 35

Gallon Drum,> Cat ID 1120321 - Hydrochloric Acid, 20 Baume (32% concentration), Supplied in 55

gallon drums is approved.

7.0 Recommendations:A watch placed over the transportation vehicle established when chemical arrives on site withpositive controls established with the control room.

Establish a periodic surveillance of the acid tank for leaks of other failures.

Bechtel Safety coordinator should sign off on work order tasks ensuring all required MSDSmeasures are in place including but not limited to:

Personnel safety (fumes, contact with liquid)Monitoring ability (confirm <5ppm in air)Protection from rain, direct sunlight / heat (a tarp with wood supports, w/ventilation)Physical protection of the tank (jersey barriers, bollards, traffic control)Spill mitigation (dykes, plastic sheet, isolation from oxidizers and other acids))Fire protection (hydrogen gas produced by reaction with metals)Waste disposal

Barriers between the tank and vehicular traffic should be established.

8.0 Conclusion

This evaluation demonstrates that with the storage and use of a 17% solution of hydrochloricacid does not create a hazard to the MCR operators by either explosion or hazardous levels ofvapor.

Prepared by: Anthony CarrReviewed by: Bob Reynolds


From: [email protected]: Carr, AnthonyCc: Jopling, Daniel L.; Reynolds, Robert B.; [email protected]; Caraballo, Daniel;MATTHEW.M. [email protected]; [email protected]: Hydrochloric AcidDate: Monday, September 28, 2009 4:41:19 PM

Tony,Regulatory Guide 1.78 states that chemicals with vapor pressures less than 10 torr at 100 OFare not a threat to a site and do not need to be analyzed further. From Perry's ChemicalEngineers Handbook, the vapor pressure of 17% concentration hydrochloric acid solution inwater is less than 1 torr at 100 OF. Therefore 17% concentration hydrochloric acid solution is nota hazard to the Crystal River site. The maximum concentration where the yapor pressure ofhydrochloric acid is less than 10 torr at 100 OF is 26%.

Chris SwardProject ManagerSargent & Lundy312-269-7426


ATTACHMENT Z62

Pages 2-4 contain the calculated volume of grease required for each tendon conduit after thetendon has been installed. Per IWL-3221.4 the absolute difference between the amount of greaseremoved and the amount replaced shall not exceed 10% of the tendon net duct volume.

The tendon lengths used in these calculations are based on those contained in Attachment X61.

Calculation By: John Holliday q

Checked By: R. Kopicki R/actaq


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ATTACHMENT Z61

Pages 2 thru 13 contain the calculated lengths of the vertical and hoop tendons affected by theSGR. These lengths have been used in Attachment Z62 to calculate the volume of greaserequired for each tendon. These calculations are based on the original Prescon drawings:

5EX7-003-P 10-A, P3, P16, P40 and P41

Note 1: The slight curvatures that the vertical tendons have at elevation 235' have been ignoredsince their impact on the tendons overall length is negligible (Ref. Drawings P40 and P41)

Note 2: Pages 3, 5, 7, 9, 11 and 14 contain information on how each tendon length was reducedto 1 '-0" segments that were equivalent to either the straight portion of the tendon or the curvedsection and were used in preliminary calculations to evaluate projected tendon elongationsduring retensioning and are for information only.

Calculation By: John Hollida

Checked By: R. Kopicki

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EC 63016

The following 6 pages are for reference only. Their purpose is to provide QC with a suggested format for

recording examination results based on the requirements of IWL-5250 for the replacement concrete in

the access opening and a 2' wide strip around the perimeter of the opening.

John Holliday 9/3/09


PC HG-DESG ENGINEERING CHANGE 000006301i

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From:Sent:To:Subject:Attachments:

Brian Giometti [[email protected]]Tuesday, June 30, 2009 3:41 PMHolliday, JohnRail EQ ReactionsRISA-3D Graphic.pdf; Rail Support - No Roller.pdf

John-

Here are the reactions on the rail during the design earthquake. The values increased a bit from when we last spoke,however this really the best we can do. I've also attached a sketch of the actual lateral support which will be used toprevent tangential movement during the earthquake. Let me know if you have any more questions.

Brian GiomettiProject Engineer

Precision Surveillance Corporation3468 Watling Street I East Chicago I IN 1 46312P: (219) 397-5826 1 F: (219) 397-5867http://www.psctendon.com

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CONTAINMENT IWL REPAIR PLAN

FOR THE CRYSTAL RIVER UNIT 3

STEAM GENERATOR REPLACEMENT MODIFICATION

Progress Energy Florida

Rev. 2

Prepared By: ---4<- CCasaba Ranganath

Reviewed By: ) -J_ nHolliday

Approved By:Dan Jopling

Da-OtDate

Date-OqDate

Date




CONTAINMENT IWL REPAIR PLAN FOR THE CRYSTAL RIVER UNIT 3


TABLE OF CONTENTS

Page

1.0 PU R PO S E ....................................................................................................................... I

2.0 BAC KG RO UND .............................................................................................................. 1

3.0 ACTIVITIES TO BE PERFORMED 2................................................................................. 2

4.0 APPLICABLE CODE EDITION, ADDENDA, AND CODE CASES ............... 3

5.0 M A TER IA L ...................................................................................................................... 3

6.0 QUALITY CONTROL REQUIREMENTS ................................................................... 7

7.0 REBAR SPLICE QUALITY CONTROL REQUIREMENTS ........................................ 9

8.0 PRESTRESSING SYSTEM QUALITY CONTROL ................................................... 10

9.0 DETENSIONING, REMOVAL, REPLACEMENT AND RETENSIONING OF

PRESTRESSING TENDONS ........ 6 .......................................................................... 10

10.0 EXAMINATION OF PRESTRESSING SYSTEM ..................................................... 12

11.0 EXAMINATION AND TESTING ................................................................................ 14

12.0 ACCEPTANCE CRITERIA ....................................................................................... 15

13.0 CUTTING, REMOVAL AND REINSTALLATION OF STEEL REINFORCEMENT ........ 16

14.0 DEMOLITION AND PLACEMENT OF CONCRETE ................................................ 16

15.0 PRESSURE TESTING AND PRESERVICE EXAMINATION ................................... 18

16.0 INTERFACE REQUIREMENTS ............................................................................. 19

17.0 HANDLING, STORING AND SHIPPING REQUIREMENTS ..................................... 19

18.0 RECORDS AND REPORTS .................. .......................................... 19

19.0 REFERENCES .............................................................................................................. 21

20.0 BIBLIOGRAPHY ..................................................................................................... 23


IPCHG-DESG ENGINEERING CHANGE 0000063016R5




REVISION SUMMARY

REVISION NUMBER DESCRIPTION

0 INITIAL ISSUE

1 SECTION 3.1 ADDITIONAL ACTIVITIES.

SECTION 5.1: ADDED DIV. 2 AFTER SECTION III.

SECTION 5.11: ADDED A LINE REGARDING SHEATHING JOINT.

SECTION 9.2: REVISED TENDON CUTTING SEQUENCE.

SECTION 10.1: CLARIFIED THE TENDONS THAT REQUIRE

EXAMINATION OF THEIR END ANCHORAGE COMPONENTS

AND SURROUNDING CONCRETE.

REWORDED BULLET 4 FIRST ITEM.

SECTION 11.3: DELETED THE SECOND BULLET.

SECTION 14.3: DELETED THE LAST BULLET.

SECTION 15.3: REWORDED EXAMINATION REQUIREMENTS

FOR CONCRETE SURROUNDING BEARING PLATES.

SECTION 18.4: ADDED ADDITIONAL RECORDS REQUIRED TO

BE MAINTAINED.

MADE EDIOTRIAL CORRECTIONS IN SECTION 19.0 AND OTHER

SECTIONS.

2 REVISED SECTION 9.2 BULLET 1 AND 2 TO CHANGE VERTICAL

ADJACENT TENDONS FROM 34V8, 34V9, AND 34V10 TO 34V12

AND 34V1 3 REVISED THE PROCESS USED TO REMOVE THESE

TENDONS.





1.0 PURPOSE

1.1 The purpose of this IWL Repair plan is to identify essential requirements

pertaining to the provision of a temporary access opening in the Crystal

River 3 concrete containment structure in support of the Steam Generator

Replacement (SGR) Project. Major activities include hydro-demolition of

concrete, cutting, removal and reinstallation of steel reinforcement,

removal and reinstallation of tendons, sheathing, and corrosion protection

medium, and placement of concrete. The repair/replacement plan

implements the requirements of ASME B&PV Code, Section Xl,

Subsection IWL (Reference 19.2), 10CFR50.55a (Reference 19.3) and

the Crystal River Unit 3 Section Xl Repair and Replacement Program

(Reference 19.17). This document does not include requirements for any

activities associated with removal or reinstallation of the containment liner

plate.

2.0 BACKGROUND

2.1 Steam Generator Replacement (SGR) at Crystal River 3 (CR3) will

require creation of an access opening through the containment shell to

facilitate removal of the existing steam generators and installation of new

ones. Creation and restoration of the access opening will require the

removal and reinstallation of the concrete, rebar, tendons, tendon

sheathing and liner plate within the boundaries of the opening and de-

tensioning and re-tensioning of selected vertical and horizontal tendons

adjacent to the opening. Additionally, a new reinforcing cage comprised

of 2 layers of #11 rebar at 11" center to center spacing, in both the hoop

and vertical directions is to be installed in the opening. The new #11 rebar

are not spliced; these are supported as shown on Drawing 421-350

(Reference 19.31). Related activities may include installing temporary

anchorages to the outer surface of the concrete containment.

2.2 The post-tensioning system used on Crystal River Unit 3 was tested and

supplied by the Prescon Corporation of Corpus Christi, Texas. Each

tendon consisted of 163 7-mm diameter low relaxation wires and

Page 1 of 24





developed a minimum ultimate tendon force of 2,333.5 kips. The low

relaxation tendon wire conforms to the applicable portions of ASTM

A 421-65 (Reference 19.7), type BA with a minimum ultimate tensile

strength of 240,000 psi. The end anchorage of each wire was a "BBRV"

buttonhead type. The details of the tendon system are shown in FSAR

Figure 5-24 and Figure 5-25 (Reference 19.15).

2.3 The creation of the temporary construction opening will affect the

containment wall, vertical and horizontal tendons and sheaths within the

boundaries of the opening. The following tendons within the opening will

be removed and replaced with new tendons:

o 34V8 thru 34V17 (10 verticals)

o 53H27 thru 53H35 and 42H27 thru 42H34 (17 hoops).

2.4 The following vertical and horizontal tendons immediately adjacent to the

opening will be de-tensioned and then re-tensioned:

o 45V22 thru 45V24, 34V1 thru 34V, 34V18 thru 34V24 and 23V1 thru

23V3 (20 verticals).

o 42H22 thru 42H26, 53H23 thru 53H26, 42H35 thru 42H39, and 53H36

thru 53H39 (18 hoops)

3.0 ACTIVITIES TO BE PERFORMED

3.1 The following activities are addressed in this repair plan:

* Degreasing, de-tensioning and removal of tendons.

* Hydro-demolition of concrete.

o Cutting, removal and reinstallation of steel reinforcement.

* Installation of new additional reinforcing bars.

* Cutting, removal and installation of tendon sheathing.

* Installation and subsequent removal of temporary attachments to the

concrete.

" Concrete material tests.

" Placement of concrete.

Page 2 of 24





o Surface preparation required prior to installation of new components

of the tendon system.

* Surface preparation required prior to placement of new concrete and

curing of concrete.

* Installation, tensioning, de-tensioning and re-tensioning of additional

tendons around opening, and re-greasing of tendons.

o Performance of examinations and system pressure test.

4.0 APPLICABLE CODE EDITION, ADDENDA, AND CODE CASES

4.1 The 2001 Edition with addenda up to and including the 2003 Addenda of

ASME Section XI will be used for repair/replacement activities applicable

to Subsection IWL.

4.2 For those repair/replacement activities performed in accordance with the

requirements of ASME Section III, Division 2, the applicable code edition

will be the 2001 Edition with addenda up to and including the 2003

Addenda.

4.3 Design of the concrete containment structure (concrete, tendons and

steel reinforcement) was performed in accordance with "Building Code

Requirements for Reinforced Concrete," ACI 318-63 (Reference 19.5).

Design of the new No. 11 reinforcing will also be in accordance with ACI

318-63.

4.4 The original structural concrete work was performed in accordance with

"Specifications for Structural Concrete for Buildings," ACI 301-66

(Reference 19.4). Structural concrete repair activities will also be in

accordance with ACI 301-66.

5.0 MATERIAL

5.1 Material will conform to the requirements of the original design

specification or ASME Section III Division 2 (Reference 19.1), with the

following exception: Portland cement that is used to restore concrete to

the access opening will be Type I cement, conforming to ASTM C 150

Page 3 of 24





(Reference 19.13). This is a change from the original design, which used

ASTM C150 Type II Portland cement, modified for moderate heat of

hydration. Reconciliation of the differences between Type I and Type II

cement is addressed in Section B.6.10 of EC 63016 (Reference 19.28).

5.2 Replacement concrete that is to be used to restore the containment

access opening will be chemically, mechanically and physically

compatible with the existing concrete. The replacement concrete will be

supplied, placed, inspected and tested in accordance with Specification

CR3-C-0003 (Reference 19.19). The specification requirements assure

that the replacement concrete will have the physical properties required

by calculation S06-0006 (Reference 19.26).

It is noted that the original concrete design for the containment wall

specified ASTM C150 Type II Portland cement and a minimum concrete

compressive strength of 5,000 psi.

5.3 Requirements relating to concrete materials, including cement,

pozzolans, coarse aggregate, fine aggregate, admixtures and mixing

water, are identified in Specification CR3-C-0003 (Reference 19.19).

These will conform. to the applicable ASTM standards as listed in that

specification.

5.4 The original No. 8 deformed reinforcing bars conform to the requirements

of ASTM A 615-68 (Reference 19.11) Grade 40. Damaged or misplaced

reinforcement will be replaced by Grade 60 bars conforming to the

requirements of the latest revision of ASTM A615 as specified in

EC 63016 (Reference 19.28). New No. 11 reinforcing bars also will meet

the requirements of the latest revision of ASTM A615 as specified in

EC 63016 (Reference 19.28). The yield strength and tensile strength of

the new and replacement bars will meet or exceed the minimums

specified for original (Grade 40) bars in ASTM A615-68. Material

property requirements reconciliation is documented in the EC 63016.

o New reinforcing steel intended to be spliced by welding will meet the

requirements of Paragraph CC-2333.1 of ASME Section III, Division 2

(Reference 19:1) as specified in the EC 63016.

Page 4 of 24





5.5 All mechanical splices will be BarGrip XL - Nuclear / Type 2 Series cold-

swaged steel coupling sleeves for #8 size rebar, as manufactured by

BarSplice Products, Inc, Dayton OH. Couplings will be manufactured

from seamless steel tubing that conforms to ASTM A 519

(Reference 19.10) Grade 1018. Mechanical splices are classified as

"Safety Related" (Q). Detailed requirements applicable to the mechanical

splices are provided in EC 63016 (Reference 19.28).

5.6 The original low relaxation tendon wire conforms to the applicable

portions of ASTM A 421-65 (Reference 19.7), type BA and was supplied

with a minimum ultimate tensile strength of 240,000 psi. Relaxation test

data are shown in Table 5-1 and Figure 5-26 of the CR3 FSAR

(Reference 19.15). When extrapolated to 40 years, the data in FSAR

Figure 5-26 indicates that the maximum relaxation is less than 2%. The

design is based on a relaxation of 4%.

5.7 The replacement tendons are 163 7mm diameter low relaxation wires that

conform to the requirements of ASTM A421-98a, Type BA and will be

supplied with a minimum ultimate tensile strength of 240,000 psi1. The

wire meets the requirements of Supplement I for Low-Relaxation Wire.

Material property requirements reconciliation is documented in EC 63016

(Reference 19.28).

5.8 Tendon Anchor Heads (163 wire stressing washer) material will meet the

requirements of ASTM A 514 (Reference 19.9) Grade Q per Precision

Surveillance Corporation (PSC) Drawing CR-N1009-502, "163 Wire

Stressing Washer," which replaces Drawing 5EX7-003 Sheet A8

(Reference 19.35) for the new anchor heads for the replacement tendons

34V8 thru 34V17 and 42H27 thru 42H34 and 53H27 thru 53H35. This

'ASTM A421-65 does not specify a minimum tensile strength for 7 mm Type BA wire (anote to the applicable table states that BA wire is not normally supplied with a diameter of0.276 in, which is equal to 7 mm). ASTM A421-98a specifies a minimum tensile strength of235 ksi for 7 mm Type BA wire. However, the CR3 tendon purchase specification requires

that the 7 mm wire have a minimum tensile strength of 240 ksi.

Page 5 of 24





material has been evaluated and found to be suitable for replacing the

original material identified as Armco SSS-100, ASTM A514 Grade E

material. Material property requirements reconciliation is documented in

EC 63016 (Reference 19.28).

5.9 Tendon grease cap gaskets, studs, nuts and washers will be furnished

per original Prescon Drawing 5EX7-003, Sheet A-9D (Reference 19.37)

(for hoop and upper vertical ends) and Drawing 5EX7-003, Sheet A-9C

(Reference 19.36) (for the lower vertical ends).

5.10 Tendon grease cans will be fabricated from HR-LC steel per original

Prescon Drawing 5EX7-003, Sheet A-9D (Reference 19.37).

5.11 Replacement tendon sheathing will be fabricated from ASTM A513

(Reference 19.8), Type 5 resistance welded tubing with a 5" internal

diameter and 5%" outside diameter as specified in EC 63016

(Reference 19.28). Use of this material (which is essentially identical to

the sheathing in the dome and basemat) in lieu of the original 22 gage

galvanized duct provides the semi-rigid, watertight conduit needed to

accommodate installation of the new tendons prior to concrete placement.

Tendon sheathing is not Safety Related. Existing and new tendon

sheathing will be joined by couplings as shown on Drawing 421-350

(Reference 19.31).

5.12 Sheathing couplings will be sealed with Belzona 1211 E-Metal as

specified in EC 63016 (Reference 19.28) and where shown on Drawing

421-350 (Reference 19.31).

5.13 Existing shims (load bearing plates inserted between tendon anchor

heads and bearing plates) will be cleaned, examined and reused unless

found to be damaged or severely corroded. New shims needed during

reactor building restoration will be drawn from the CR3 warehouse

inventory that is stocked for use during periodic tendon in-service

inspection activities. The stocked shims are fabricated from Armor Plate

HY-80 Type 1 (MIL-S-16216). The substitution of this material for the

original Modified Armco VNT (proposed ASTM A633-E) was previously

evaluated in PEERE 987 (Reference 19.38).

Page 6 of 24


PCHG-DESG ENGINEERING CHANGE 0000063016R5CONTAINMENT IWL REPAIR PLAN FOR THE CRYSTAL RIVER UNIT 3


5.14 Corrosion protection medium, which is injected into the tendon sheathing

after stressing, will be Visconorust 2090-P4 or latest compatible

formulation by Viscosity Oil Company. The corrosion protection medium

will be certified to conform to the specifications given in ASME Section III,

Division 2, Table CC-2442-1. This material is fully compatible with the

original corrosion protection medium, a Visconorust 2090-P formulation,

per the evaluation documented in EC 63016 (Reference 19.28).

5.15 Replacement tendons will be protected from corrosion after fabrication at

PSC's manufacturing facility by coating them with Visconorust 1601

Amber by Viscosity Oil Company. This material is fully compatible with

Visconorust 2090-P4 per the evaluation documented in Section B.6.8.b of

EC 63016 (Reference 19.28).

5.16 Welding filler material is classified as "Safety Related"(Q) and will be

controlled accordingly. Welding filler material, which will conform to the

applicable requirements of the Corporate Welding Manual

(Reference 19.18), will be traceable to purchase orders.

5.17 Use of materials of a specification, grade, type, class, or alloy, and heat-

treated condition other than that originally specified will be evaluated for

suitability for the specified design and operating conditions in accordance

with ASME Section Xl, IWA-4311 and documented in EC 63016

(Reference 19.28). Any changes to the original material examination and

testing requirements will be reconciled to the requirements of the original

construction specifications (See References 19.20, 19.21 & 19.22).

6.0 QUALITY CONTROL REQUIREMENTS

6.1 Concrete material qualification testing and control requirements will be in

accordance with Specification CR3-C-0003 (Reference 19.19).

6.2 The new concrete mix will be designed for high early strength and a low

creep coefficient. In addition, the reinforced concrete patch will be

designed to ensure stiffness compatibility with the original concrete. The

proportions for the replacement concrete mix design will be as

Page 7 of 24





determined by the test program specified in EC 63016 Attachment Z13RO

(Reference 19.29).

6.3 A batch plant will be setup 'and qualified on site to furnish concrete in

accordance with ASTM C 94 (Reference 19.12). During concrete

operations, an independent testing laboratory will provide inspectors at

the batch plant to certify the mix proportions of each batch produced at

the plant and sample and test the concrete ingredients per Specification

CR3-C-0003 (Reference 19.19). The inspectors will verify that delivery

tickets conforming to the requirements of CR3-C0003 are prepared for

each load of concrete.

6.4 Concrete delivery trucks will comply with the requirements of ASTM C 94

(Reference 19.12).

6.5 Inspectors at the construction site will inspect reinforcing steel and form

placement, perform slump tests, prepare test cylinders, check air content,

and record weather conditions in accordance with the requirements of

Specification CR3-C-0003 (Reference 19.19). Test cylinders will be

cured, capped and. tested in accordance with CR3-C-0003. Evaluation

and acceptance of test results will be in accordance with ACI 318

(Reference 19.5) 'and Article CC-5232 of ASME Section III, Division 2

(Reference 19.1).

6.6 Placing, consolidating and curing of fresh concrete will conform to

applicable requirements of ACI 301 (Reference 19.4) as detailed in

Specification CR3-C-0003 (Reference 19.19).

6.7 Special requirements will be implemented for cold and hot weather

concreting. These include requirements for insulation, form cooling and

additional test cylinders as detailed in CR3-C-0003 (Reference 19.19).

6.8 Certified mill test reports will be provided for each heat of reinforcing steel

covering chemical composition and ASTM specification requirements for

mechanical properties. Bars will provide identification as to manufacturer,

size, type, and grade or yield strength.

Page 8 of 24





6.9 Reinforcing steel will be procured as safety-related material from a

manufacturer/supplier with a qualified QA Program as specified in

EC 63016 (Reference 19.28). The manufacturer/supplier will be

responsible for performing material tests in accordance with the purchase

order and the requirements of ASTM A615 (Reference 19.11).

7.0 REBAR SPLICE QUALITY CONTROL REQUIREMENTS

7.1 The No. 8 reinforcing removed from the opening area will be spliced to

stub bars by swaged sleeves where possible and otherwise by welding.

To eliminate buckling that can result if a bar is connected by swaged

sleeves at both ends (swaging causes a small increase in bar length),

separate bars willbe spliced to each stub and spliced together by lapping

as shown on Drawing 421-351 (Reference 19.32).

7.2 Swaged sleeve splices will be tested and installed in accordance with

manufacturer's instructions and the requirements of ASME Section III

(Reference 19.1), Division 2, CC-4333 as specified in EC 63016

(Reference 19.28) and shown on Drawings 421-350 and 421-351

(References 19.31 & 19.32). The manufacturer of the swaging system

will provide training on the use of its equipment. The quality control (QC)

requirements in Sections CC-2300, CC-4330 and CC-5320 of ASME

Section III, Div. 2 (Reference 19.1) will apply with the following exception

as specified in EC 63016 (Reference 19.28). Since the swaged couplings

will be quite close to the face of the concrete in the opening, it will not be

possible to cut out production splices and have a sufficient length of stub

reinforcing remaining to remake these. Therefore, all testing will be on

sister splices. The mix of sister splice reinforcing grade combinations

(Grade 40 to Grade 40 and Grade 40 to Grade 60) will be consistent with

that of the production splices.

7.3 Welding of reinforcing bars, welder qualification and examination of welds

will be in accordance with Corporate Welding Manual (Reference 19.18)

procedures incorporating the applicable requirements of AWS D1.4

(Reference 19.14).

Page 9 of 24





7.4 Lap splices will conform to applicable ACI 318 (Reference 19.5)

requirements as specified in EC 63016 (Reference 19.28) and detailed on

Drawings 421-350 and 421-351 (References 19.31 & 19.32).

8.0 PRESTRESSING SYSTEM QUALITY CONTROL

8.1 Tendons and other Quality Related pre-stressing system materials

procured for this repair activity will be handled, stored and shipped per

the requirements of MCP-NGGC-0402 "Material Management (Storage,

Issue and Maintenance)" (Reference 19.24) and ANSI N45.2.2 - 1972

"Packaging, Shipping, Receiving, Storage and Handling of Items for

Nuclear Power Stations" (Reference 19.6).

8.2 Anchorheads, wire and completed tendons will be inspected during

manufacture. In addition, Section B.6.25 of EC 63016 (Reference 19.28)

specifies that replacement tendons and associated hardware shall be

inspected at the plant receiving area prior to receipt and acceptance.

9.0 DETENSIONING, REMOVAL, REPLACEMENT AND RETENSIONING OF

PRESTRESSING TENDONS

9.1 Degreasing, de-tensioning, removal of existing tendons, surface

preparation required prior to installation of new items, installation of new

tendons, tensioning and regreasing of tendons will follow the standard

practice specified in procedures in the PSC Field and Quality Control

Procedure Manual (Reference 19.34) that is incorporated into EC 63016

(Reference 19.28).

9.2 Tendons will be de'-tensioned in the following sequence as developed in

Calculation S06-0005 (Reference 19.25).

During the period after reaching cold shutdown (Mode 5) and prior to

the start of hydrodemolition of the concrete, vertical tendons 34V12

and 34V1 3, which are within the opening area, will be ram de-

tensioned and removed. These tendons will be detensioned with a

hydraulic ram, the buttonheads removed with a hand grinder, coiled

Page 10 of 24





and then saved as a contingency to ensure that replacement vertical

tendons of sufficient length are available in the event that a new

replacement tendon is identified as being too short. Additional

tendons that will be removed from within the access opening will be

accomplished by sequential cutting of button heads at one end using

a plasma arc or similar approved process. Tendon locations are

shown on Drawing 421-347 (Reference 19.30).

o During the period after reaching cold shutdown (Mode 5) and prior to

the start of hydrodemolition of the concrete, after removal of the two

vertical tendons 34V12 and 34V13 stated in the first bullet, the 17

hoop and remaining 8 vertical tendons WITHIN the boundaries of the

containment wall access opening will be removed.

* The following additional tendons outside the boundaries of the

containment wall access opening will be de-tensioned (but not

removed): (I) After the new SGs have been rigged into their

respective cubicles inside the D-Rings thereby ensuring that adequate

prestress will be maintained when loads are imposed on the wall

during generator movements and (11) Prior to placement of new

concrete in the opening area:

A. Nine (9) hoop tendons above and nine (9) below the boundaries of

the containment wall access opening (Total 18), and

B. Ten (10) vertical tendons on each side of the containment wall

access opening (Total 20).

9.3 After the tendons that are not to be removed have been de-tensioned, the

degreased tendons will be protected from the elements as specified in

procedures in the PSC Field and Quality Control Procedure Manual

(Reference 19.34) that is incorporated into EC 63016 (Reference 19.28).

9.4 Prior to installation of new tendons, waffle assemblies will be pulled

through the sheathing to clean out residual corrosion protection medium

as well as accumulations of water and debris that may have entered

following tendon removal and during hydro-demolition of the concrete.

Page 11 of 24





9.5

9.6

9.7

Tendons will be installed and tensioned/re-tensioned in accordance with

procedures in the Field and Quality Control Procedure Manual

(Reference 19.34) that is incorporated into EC 63016 (Reference 19.28)

and following the sequence shown on Drawing 421-352 (Reference

19.33). To offset friction loss and provide adequate force at the center of

each tendon, end force is initially raised to 80% of guaranteed ultimate

tensile strength (GUTS). It is then reduced to 70% (± a tolerance) for

lock-off.

Tendon elongation will be measured during stressing and will be

compared to predicted values provided by Engineering. Deviations from

the predicted values will be evaluated against the acceptance limits

specified in ASME Section III, Division 2 (Reference 19.1).

Tendon regreasing will be completed within 30 days of Mode 2 Entry.

Corrosion protection medium will be replaced following procedures in the

PSC Field and Quality Control Procedure Manual (Reference 19.34) that

is incorporated into EC 63016 (Reference 19.28).

10.0 EXAMINATION OF PRESTRESSING SYSTEM

10.1 The pre-stressing system will be examined in accordance with PSC Field

and Quality Control Procedure Manual (Reference 19.34) procedures,

EC 63016 (Reference 19.28), and work order instructions. Required

examinations and associated tests are summarized below.

* Prior to Detensioning

o End anchorage components, including bearing plates,

anchorheads, shims and buttonheads will be examined for

signs damage and corrosion (Detensioned / Retensioned

Tendons only).

o Concrete adjacent to bearing plates will be examined for

cracking and other indications of damage or degradation

(Detensioned/Retensioned and removed / replaced tendons).

o After De-Tensioning

Page 12 of 24





o End anchorages will be examined for indications of broken

wires which, if found, will be extracted, examined and / or

tested in accordance with ASME Section Xl, Paragraph IWL-

2523.2 to determine the cause of failure.

o Wires that protrude from the anchor head as well as visible

areas of the wire bundle between the anchor head and the

bearing plate will be examined for corrosion or pitting which, if

found will be evaluated by the IWL Responsible Engineer.

o Prior to Tendon Installation

o Tendon wires, button heads, anchor heads and bearing plates

will be examined for signs of damage, pitting and corrosion.

* Prior to Concrete Placement

o Sheath and couplings will be examined for alignment, and

signs of damage including kinks, dents, oval areas, and holes.

Verify the attachments are secure.

o Sheath and coupling sealant will be examined for holes and

tears as well as to verify complete joint coverage.

o Following Re-Tensioning

o End anchorage components including bearing plates,

anchorheads, shims and buttonheads will be examined for

signs of damage and corrosion.

o Concrete adjacent to bearing plates will be examined for

cracking and other indications of damage or degradation

Acceptance standards for the above examinations and tests will be as

listed in the PSC Field and Quality Control Procedure Manual (Reference

19.34) procedures, EC 63016 (Reference 19.28), and work order

instructions as specified in ASME Section Xl, Article IWL-3000 and as

established by the IWL Responsible Engineer.

10.2 Examination and test results that do not meet acceptance standards are

evaluated and dispositioned by the IWL Responsible Engineer in

accordance with the requirements of ASME Section Xl, Article IWL-3000.

Page 13 of 24





11.0 EXAMINATION AND TESTING

11.1 Personnel performing the examinations and tests required under this plan

will be trained, qualified and certified in accordance with the CR3 Quality

Assurance Program (Reference 19.16) or under approved vendor quality

assurance programs. In addition, personnel performing reactor building

.concrete examinations will be approved by the IWL Responsible Engineer

in accordance with the requirements of ASME Section Xl, IWL-2320(a).

Personnel training and certification programs will incorporate applicable

requirements of the following documents.

* ASME Section Xl (Reference 19.2), Sub-Sections IWA and IWL

0 Specification CR3-C-0003 (Reference 19.19)

o AWS D1.4 (Reference 19.14).

11.2 Concrete materials, including mixing water, and production concrete will

be sampled and tested to ensure conformance to the requirements of

Specification CR3-C-0003 (Reference 19.19) and the ASTM standards

cited therein. Additional tests will be performed to verify that the selected

design mix meets the unit weight, air content, bleeding, slump, strength

and creep coefficient requirements specified in CR3-C-0003.

11.3 Construction examinations and tests will be performed as required by

EC 63016 (Reference 19.28).' These examinations, except those

associated with the pre-stressing system that are covered in Section 10.0,

are summarized below. Instructions specific to each of these

examinations are as delineated directly or by reference in EC 63016.

* Detailed visual examination of reinforcing stubs (after the No. 8 bars

are cut and concrete has been removed from the opening) as

required by ASME Section Xl, IWL-4220(c) and, if determined

necessary by the IWL Responsible Engineer, repair in accordance

with IWL-4230.

Page 14 of 24





" Visual examination of welded and swaged sleeve reinforcing

splices.

" Load testing of welded and swaged sleeve reinforcing

demonstration splices.

o Load testing of swaged sleeve sister splices.

" Other NDE of welded reinforcing splices as specified by the IWL

Responsible Engineer.

* Visual examination of the concrete surfaces at the bottom, top and

sides of the opening prior to concrete placement (Sections A5.2.10,

D.2.2.4-2 and D.2.2.5-1 of EC 63016 - Reference 19.28).

o Visual examination of reinforcing curtain alignment, lap splices, ties

and supports prior to concrete placement (Sections A5.2.10,

D.2.2.4-2 and D.2.2.5-1 of EC 63016 - Reference 19.28).

0 Batch plant certification examinations and tests per ASTM C94

(Reference 19.12) requirements.

11.4 The new concrete will be visually examined before, during and after the

pressure test as required by ASME Section Xl, Article IWL-5250

(Reference 19.2). These examinations will follow the applicable

requirements of Procedure EGR-NGGC-0015 (Reference 19.23) and

will satisfy the ASME Section Xl, Article IWL-2230 requirement for post-

repair pre-service examination.

12.OACCEPTANCE CRITERIA

12.1 The results of the tests and examinations identified in this plan will be

evaluated against the acceptance standards included (directly or by

reference) in EC 63016 (Reference 19.28), and Specification CR3-C-

0003 (Reference 19.19) as well as in the codes, standards and

procedures cited in Sections 10.0 and above.

Page 15 of 24





13.0CUTTING, REMOVAL AND REINSTALLATION OF STEEL REINFORCEMENT

13.1 The No. 8 steel reinforcement will be cut and removed from the opening

area as specified in EC 63016 (Reference 19.28). Steel will be cut in a

manner that ensures adequate stub length for later reattachment using

swaged sleeve or welded splices as applicable to the stub location. Steel

removed from the opening area will be cleaned, examined and stored for

reuse if determined by the IWL Responsible Engineer to be in acceptable

condition.

13.2 The original layer of No. 8 reinforcing bars will be restored following

installation of tendon sheathing. Restoration work will be done in

accordance with the instructions in EC 63016 (Reference 19.28). The

restored layer will include new Grade 60 bars conforming to the

requirements of ASTM A615 (Reference 19.11) and may include Grade

40 bars that were removed and stored for reuse. The new and reused

bars will be spliced to the stub reinforcing protruding from the periphery of

the opening as described in Section 7.0 of this plan.

13.3 Two layers of new reinforcing (No. 11 bars @ 11" each way) will be

installed in the opening area as shown on Drawings 421-350 and

421-351 (References 19.31 & 19.32). The new reinforcing will be

procured to the requirements of ASTM A615 (Reference 19.11), for

Grade 60 deformed carbon steel bars. This new reinforcing, which is

safety related (Q) is provided to increase the stiffness of the concrete in

the opening area as discussed in Calculation S06-0006 (Reference

19.26).

14.0 DEMOLITION AND PLACEMENT OF CONCRETE

14.1 Concrete will be removed from the opening by high pressure water jets

(hydrodemolition) as described in EC 63016 (Reference 19.28).

Demolition will begin after tendons passing through the opening area

have been removed and will be generally continuous except for

interruptions to allow removal of the No. 8 reinforcing steel curtain and

Page 16 of 24





tendon sheathing. Water jet pressure will be reduced during removal of

the final 6 in of concrete to minimize the potential for liner damage.

14.2 New concrete will be placed following the installation of the new No. 11

reinforcing curtains, new tendon sheathing #8 reinforcing curtain and

formwork (Per Section D.2.2.1-4i of EC 63016, Reference 19.28, new

tendons can be pulled through the sheathing either prior to concrete

placement or after concrete strength has reached 3,000 psi). Concrete

will be batched, mixed, conveyed, placed and consolidated in accordance

with the requirements of Specification CR3-C-0003 (Reference 19.19)

and the ASTM and ACI standards referenced therein.

14.3 The opening area will be prepared for concrete placement as specified in

EC 63016 (Reference 19.28) and Specification CR3-C-0003 (Reference

19.19). Preparation activities will include the following.

* Roughening, cleaning and soaking the top, bottom and sides of the

opening to improve bond between new and existing concrete.

o Cleaning debris, oil, grease and deleterious material from the liner,

tendon sheathing and the reinforcing steel.

o Examining the concrete surfaces, liner, reinforcing steel, tendon

sheathing and formwork to ensure readiness for concrete

placement.

14.4 The outer formwork will be installed after splicing of the No. 8 reinforcing

curtain and cleaning and inspection of the opening area are complete.

The formwork will be supported by form ties welded to liner stiffening

angles and spaced, as specified in Calculation S06-0007 (Reference

19.27), to ensure proper support of both the formwork and the liner during

concrete placement. Ties will consist of standard threaded rod and

helical insert elements as shown on Drawing No. 421-351 (Reference

19.32).

14.5 Concrete will be placed and consolidated in continuous horizontal layers

as specified in Specification CR3-C-0003 (Reference 19.19). Overall

placement rate will be limited as specified in CR3-C0003 to ensure that

Page 17 of 24





form pressure does not exceed design limits for the liner (as derived in

calculation S06-0007 - Reference 19.27) or the formwork. Delays in

concrete placement due to consolidation activities will be minimized to

ensure that there are no cold joints.

15.OPRESSURE TESTING AND PRESERVICE EXAMINATION

15.1 A reactor building pressure test will be performed after de-tensioned and

replaced tendons have been re-tensioned. The test will be conducted as

specified in EC 63016 (Reference 19.28), which incorporates the

applicable requirements of ASME Section Xl, Article IWL-5000

(Reference 19.2). The IWL Responsible Engineer will authorize

performance of the test.

15.2 The pressure test Will be conducted at the design basis accident

pressure, P, = 54.2 psig (calculated peak containment DBA pressure), as

specified in Reference 19.2, prior to returning reactor building to service.

15.3 The surface of all containment concrete placed during repair/replacement

activities will be visually examined in accordance with the requirements

developed in EC 63016 (Reference 19.28), which incorporates the

requirements of ASME Section Xl, Article IWL-5250 (Reference 19.2).

The examinations will be done (1) prior to the start of pressurization, (2)

at test pressure, and (3) following completion of depressurization. In

addition, concrete surrounding the bearing plates of all new and de-

tensioned / re-tensioned tendons will be examined per ASME Section XI,

Subsection IWL Section 2524.1 (Reference 19.2) following the completion

of depressurization. The preservice examination required by IWL-2230

will be conducted in accordance with procedure EGR-NGGC-0015

(Reference 19.23).following completion of depressurization 2. If the results

of the post-test and preservice examinations do not meet the acceptance

standards developed by the IWL Responsible Engineer in accordance

2 A single examination can satisfy the requirements of both IWL-5250 and IWL-

2230.

Page 18 of 24





with IWL-31 10, corrective action will be taken as required by IWL-3113

and IWL-5260.

16.0 INTERFACE REQUIREMENTS

16.1 The ANII will be notified prior to starting the repair/replacement activity

and will be kept informed of progress so that necessary inspections may

be performed.

17.0 HANDLING, STORING AND SHIPPING REQUIREMENTS

17.1 Materials procured for this repair activity will be handled, stored and

shipped per the requirements of MCP-NGGC-0402 "Material

Management (Storage, Issue and Maintenance)" (Reference 19.24) and

ANSI N45.2.2 - 1972 "Packaging, Shipping, Receiving, Storage and

Handling of Items for Nuclear Power Stations" (Reference 19.6).

17.2 Constituent concrete materials will be handled and stored in accordance

with the requirements in Specification CR3-C-0003 (Reference 19.19).

18.0 RECORDS AND REPORTS

18.1 The preparation, submittal, and retention of records and reports of

examinations, tests, and repair/replacement activities will be in

accordance with the CR3 Quality Assurance Program (Reference 19.16)

and the requirements of ASME Section XI, Article IWA-6000

(Reference 19.2).

18.2 Records and reports indicated in this section will be filed and maintained

for the service lifetime of the containment in accordance with the CR3

Quality Assurance Program (Reference 19.16) and in a manner that will

allow access by the Regulator and the Authorized Inspector.

18.3 A report for repair/replacement activities will be prepared on ASME

Section Xl Form NIS-2 upon completion of all required activities

associated with this repair/replacement plan. Upon completion, Form

NIS-2 will be submitted to the Inspector for signature.

Page 19 of 24





18.4 The following records will be maintained in accordance with the CR3

Quality Assurance Program (Reference 19.16)

* Record index,

,, Records and reports of repair/replacement activities,

* Rebar welding procedures and weld qualification records,

o Inspection/examination reports,

* Deficiency evaluations, if any, as required by ASME Section Xl,

Paragraphs IWA-4160 and IWL-331 0.

o Changes made to material, design, or configuration, if any, as

required by ASME Section XI, Paragraph IWA-431 1.

o Repair/Replacement Program and Repair/Replacement Plan,

o Reconciliation documentation,

o Owner's Report for Repair/Replacement Activities, Form NIS-2,

* Nondestructive examination (NDE) procedures and records,

including NDE personnel qualifications/certifications,

* Pressure test procedures and test records,

0 Concrete test reports.

Page 20 of 24





19.0 REFERENCES

19.1 ASME B&PV Code, Section III, Division 2 "Rules for Construction of

Nuclear Power Plant Components." 2001 Edition with 2002 and 2003

Addenda

19.2 ASME B&PV Code, Section Xl, "Rules for Inservice Inspection of Nuclear

Power Plant Components," 2001 Edition with addenda up to and including

the 2003 Addenda.

19.3 1OCFR 50.55a, "Codes and Standards"

19.4 ACI 301-66, "Specifications for Structural Concrete"

19.5 ACI 318-63, "Building Code Requirements for Structural Concrete"

19.6 ANSI N45.2.2 - 1972 "Packaging, Shipping, Receiving, Storage and

Handling of Items for Nuclear Power Plants"

19.7 ASTM A 421, "Standard Specification for Uncoated Stress Relieved Steel

Wire for Prestressed Concrete," 1965 and 1998.

19.8 ASTM A 513-69, "Standard Specification for Electric Resistance Welded

Carbon and Alloy Steel Tubing"

19.9 ASTM A 514-05, "Standard Specification for High-Yield-Strength,

Quenched and Tempered Alloy Steel Plate, Suitable for Welding

19.10 ASTM A 519-06, "Standard Specification for Seamless Carbon and Alioy

Steel Mechanical Tubing"

19.11 ASTM A 615-68, "Standard Specification for Deformed and Plain Billet -

Steel Bars for Concrete Reinforcement."

19.12 ASTM C 94-07, "Standard Specification for Ready-Mixed Concrete"

19.13 ASTM C 150, "StandardSpecification for Portland Cement," 1967 & 2007

19.14 AWS D1.4 2005, "Structural Welding Code - Reinforcing Steel," 6th

Edition.

19.15 Crystal River 3 Final Safety Analysis Report, Revision 31.2, Chapter 5.

19.16 NGGM-PM-0007, CR3 Quality Assurance Program.

19.17 CR3 ASME Section Xl Inservice Inspection Program / Interval 4 / Repair

& Replacement Program, Revision 13.

Page 21 of 24


PCHG-DESG ENGINEERING CHANGE 0000063016R5.



19.18 NGGM-PM-0003, Corporate Welding Manual.

19.19 Specification CR3-C-0003, "Concrete Work for Restoration of the SGR

Opening in the Containment Wall"

19.20 Specification SP-5569, "Furnishing and Delivering of Structural Concrete",

23 June 71.

19.21 Specification SP-5583, "Tendons and Associated Conduit - Reactor

Building", 18 Sep 68.

19.22 Specification SP-5618, "Placement of Structural Concrete", 14 Apr 72.

19.23 Procedure EGR-NGGC-0015, "Containment Inspection Program"

19.24 Procedure MCP-NGGC-0402 "Material Management (Storage, Issue and

Maintenance)"

19.25 Calculation S06-0005, Rev. 0, "Containment Shell Analysis for Steam

Generator Replacement - Shell Evaluation During Replacement

Activities"

19.26 Calculation S06-0006, Rev. 1, "Containment Shell Analysis for Steam

Generator Replacement - Evaluation of Restored Shell."

19.27 Calculation S06-0007, Rev. 2, "Containment Liner Evaluation for SGR"

19.28 Engineering Change Package 0000063016, Rev. 3 "Containment

Opening."

19.29 Laboratory Testing Requirements for Concrete Proportioning (See

Attachment Z13RO of EC 63016R3)

19.30 Drawing 421-347, Sheet 1, "Reactor Building Temporary Access Opening

for SGR - Vertical & Horizontal Tendon Positions"

19.31 Drawing 421-350, "Reactor Building Temporary Access Opening for SGR

Restoration," Sheet 1 of 3.





Page 22 of 24





19.34 Precision Surveillance Corporation, "Post Tensioning System Field and

Quality Control Procedure Manual for Progress Energy Florida Inc.,

Crystal River Nuclear Unit 3, Steam Generator Replacement Project,

Containment Building Tendon Installation", Revision 0, 29 Aug 08.

19.35 Drawing 5EX7-003-A-08, Revision 3, (Dwg key #S-001529)

19.36 Drawing 5EX7-003-A-09C, Revision A, (Dwg key #S-001532)

19.37 Drawing 5EX7-003-A-09D, Revision 1, (Dwg key #S-001533)

19.38 PEERE 987, Rev. 0, "Plant Equipment Equivalency Replacement

Evaluation."

20.0 BIBLIOGRAPHY

20.1 ASME QAI-1 - 2005, "Qualifications for Authorized Inspection"

20.2 ACI 309R, "Guide for Consolidation of Concrete"

20.3 ASTM C 29-07, "Standard Test Method for Bulk Density ("Unit Weight")

and Voids in Aggregate"

20.4 ASTM C 31 - 08, t"Standard Practice for Making and Curing Concrete

Test Specimens in the Field"

20.5 ASTM C 33, "Standard Specification for Concrete Aggregates," 1967 &

2003.

20.6 ASTM C 39-05, "Standard Test Method for Compressive Strength of

Cylindrical Concrete Specimens"

20.7 ASTM C 40-04, "Standard Test Method for Organic Impurities in Fine

Aggregates for Concrete".

20.8 ASTM C 127-07, "Standard Test Method for Density, Relative Density

(Specific Gravity), and Absorption of Coarse Aggregate".

20.9 ASTM C 128-07a, "Standard Test Method for Density, Relative Density

(Specific Gravity), and Absorption of Fine Aggregate".

20.10 ASTM C 136-06, "Standard Test Method for Sieve Analysis of Fine and

Coarse Aggregates".

Page 23 of 24





20.11 ASTM C 143 - 08, "Standard Test Method for Slump of Hydraulic-Cement

Concrete"

20.12 ASTM C 231 - 08, "Standard Test Method for Air Content of Freshly

Mixed Concrete by the Pressure Method"

20.13 ASTM C 1064 - 08, "Standard Test Method for Temperature of Freshly

Mixed Hydraulic-Cement Concrete"

20.14 Procedure NEP-229, Rev. 4, "Guidance for Implementation and Use of

ASME Section Xl Repair/Replacement Program Documents"

20.15 Procedure SP-182, Rev. 16, "Reactor Building Structural Integrity Tendon

Surveillance Program"

20.16 Drawing 5EX7-003-A-09, Revision 5, (Dwg key #S-001 530)

20.17 Drawing 5EX7-003-A-09A, Revision 5, (Dwg key #S-001 531)

20.18 Title 10, CFR Part 50, Appendix J, "Primary Reactor Containment

Leakage Testing for Water-Cooled Power Reactors'

20.19 NRC Regulatory Guide 1.163, Performance-Based Containment Leak-

Test

20.20 NEI 94-01, Revision Ij, Industry Guideline for Implementing Performance-

Based Option of 10 CFR Part 50, Appendix J

20.21 ANSI/ANS 56.8-1994, Containment System Leakage Testing

Requirements

Page 24 of 24



CONTAINMENT LINER IWE REPAIR PLAN

FOR THE CRYSTAL RIVER UNIT 3

STEAM GENERATOR REPLACEMENT

MODIFICATION


Rev. 18/5/09

Prepared By:

Reviewed By:

Casaba Ranganath

John Hlia

Date:

Date:

Date:Approved By:

Dan Jopling




CONTAINMENT LINER IWE REPAIR PLAN FOR THE CRYSTAL RIVER UNIT 3


TABLE OF CONTENTS

Page

1.0 PU RPO SE ....................................................................................................................................... 1

2.0 BACK GR OUND ............................................................................................................................ 1

3.0 APPLICABLE CODE EDITION, ADDENDA AND CODE CASES ...................................... 1

4.0 M ATERIAL ................................................................................................................................... 2

5.0 REMOVAL AND INSTALLATION/REPAIR OF THE LINER PLATE .......................... 3

6.0 EXAMINATION AND TESTING ......................................................................................... 4

7.0 PRESSURE TESTING ........................................................................................................... 7

8.0 PROTECTIVE COATING SYSTEM ..................................................................................... 8

9.0 SUPPORT OF LINER DURING CONCRETE PLACEMENT ........................................... 8

10.0 HANDLING, STORAGE AND SHIPPING REQUIREMENTS ...................... ........................ 8

11.0 RECORDS AND REPORTS ................................................................................................... 8

12.0 INTERFACE REQUIREMENTS ................................................................................................ 9

13.0 REFERENCES ............................................................................................................................ 10

14.0 BIBLIO GRAPHY ........................................................................................................................ 11

TC-I






REVISION SUMMARY

REVISION DESCRIPTION

0 INITIAL ISSUE

ADDED EXCEPTION IN SECTION 3.1.

ADDED REFERENCE TO IWA-4200 IN SECTION 3.2.

CHANGED REFERENCE 13.1 TO 13.15 IN SECTION 7.1

DELETED REFERENCE TO NRC IN SECTION 11.3.

ADDED REFERENCE 13.28.

TC-2





1.0 PURPOSE

1.1 The purpose of this IWE Repair/Replacement plan is to identify essential

requirements pertaining to the cutting, removal, handling and reinstallation of the

containment liner plate and the installation and subsequent removal of temporary

attachments to the liner or stiffener angles in support of the Steam Generator

Replacement (SGR) Project at Crystal River 3 (CR3). The repair/replacement

plan implements the requirements of ASME B&PV Code, Section Xl, Subsection

IWE and the Crystal River Unit 3 Repair and Replacement Program.

1.2 This repair plan covers the following SGR project activities: Initial coating

inspection, welding of temporary attachments, liner cutting, welding to restore

liner plate and stiffeners, attachment of form ties, nondestructive weld

examination, removal of temporary attachments, coating repairs, and system

pressure test.

2.0 BACKGROUND

2.1 Steam Generator Replacement (SGR) at Crystal River 3 (CR3) will require

creation of an access opening through the containment shell to facilitate removal

of the existing generators and installation of new ones. Creation of this Reactor

Building access opening requires the removal of the Reactor Building wall

concrete and the pressure boundary steel liner. Creation of the access opening

will commence in Mode 5 with the hydrodemolition of the concrete within the

boundaries of the opening. After the Unit is defueled (No Mode) the exposed

liner plate will be cut and removed, thus creating the access opening. Related

activities may include installing temporary anchorages to the concrete

containment liner.

3.0 APPLICABLE CODE EDITION, ADDENDA, AND CODE CASES

3.1 The 2001 Edition with addenda up to and including the 2003 Addenda of ASME

Section Xl will be used for repair/replacement activities applicable to Subsection

IWE, except as noted in Section 3.2.

Page 1 of I I





3.2 Except as noted hereinafter, items to be used for liner repair/replacement activities

will meet the following original construction codes as applicable. In accordance

with ASME Section XI, Article IWA-4200. The materials, details of fabrication,

welding and workmanship will conform to the requirements of the 1965 Edition

of the ASME B&PV Code, Section II1, Subsection B, "Nuclear Vessels Code for

Class B Vessels" (Reference 13.2) and American Standard ASA N 6.2.-1965,

"Safety Standard for Design, Fabrication and Maintenance of Steel Containment

Structures for Stationary Nuclear Power Reactors" (Reference 13.6).

4.0 MATERIAL

4.1 The 3/8" thick steel liner plate conforms to ASTM A 283, Grade C with a

minimum of 0.2% Cu (Reference 13.27), which has a P1 material grouping per

ASME Section IX (Reference 13.4). Replacement material, if required to repair

liner damage, will conform to the current edition of the same standard. EC 63016

(Reference 13.23) provides the reconciliation, as required by ASME Section XI

(Reference 13.5), Paragraph IWA-4224. 1, for use of the later edition of the

standard.

4.2 Stiffener angles conform to ASTM A 36 (Reference 13.12) or ASME

(Reference 13.1) SA 36, "Specification for Structural Steel". Replacement

material, if required to repair damaged angles, and plate used to reconnect angles

(per Drawing 421-351, Reference 13.25) will conform to the current edition of the

same standards. EC 63016 (Reference 13.23) provides the reconciliation, as

required by ASME Section XI (Reference 13.5), Paragraph IWA-4224.1, for use

of the later edition of the standards.

4.3 Certificates of compliance or typical certificates of analyses for the weld rod or

weld filler metal for the main liner welds are acceptable and will be maintained in

accordance with Section 1I of this plan.

4.4 Welding filler material for stiffener welds, liner seam welds, repair welds and

temporary attachment welds will be made using E7018 material. This material

will be procured and controlled in accordance with the applicable CR3 procedures

and will be traceable to purchase orders.

Page 2 of I 1





5.0 REMOVAL AND INSTALLATION/REPAIR OF THE LINER PLATE

5.1 The steel liner plate cutting process will not be initiated prior to completion of

Reactor Vessel fuel off-load and plant entry into No Mode.

5.2 Welding and weld repair activities will be performed in accordance with the

Progress Energy Corporate Welding Manual (Reference 13.18) and ASME

Section III (Reference 13.2).

* The qualification of welding procedures and welders will be in

accordance with the Progress Energy Corporate Welding Manual

(Reference 13.18).

* Weld examination requirements are reconciled in ECED 70586

(Reference 13.24) as required by ASME Section XI (Reference 13.5)

Paragraphs IWA-422 1(c) and IWA-4411 (a).

5.3 Weld details for welded attachment to the liner for rigging requirements and

alignment are provided in CBI Drawing ER-4 (Reference 13.26).

5.4 When the liner section is reinstalled, the edges of the plates to be welded together

will be aligned to ensure that the offset of the butt joint does not exceed 25% of

the plate thickness.

5.5 Metal removal will be performed by thermal methods following contractor

procedures that will have been reviewed by Progress Energy for conformance to

the Corporate Welding manual (Reference 13.18).

" When thermal removal processes are used on P-No. I materials, surface

oxides will be removed by mechanical processing prior to welding on cut

surfaces. However, mechanical processing is not required when the thermal

metal removal process is qualified/evaluated in accordance with the

requirements of ASME Section XI (Reference 13.5) Article IWA-4461.4.1.

* Metal cutting and removal processes include oxyacetylene cutting, carbon arc

gouging, plasma cutting, metal disintegration machining (MDM), and

Electrical Discharge Machining (EDM).

5.6 Defect removal, if required, will be accomplished in accordance with the

requirements of ASME Section XI (Reference 13.5) Article IWA-4420.

Page 3 of 11





5.7 The liner plate will be re-installed to its original configuration using full

penetration butt-welds that utilize low hydrogen electrodes and welding from two

sides, in accordance with the original construction Specification SP-5566

(Reference 14.2). Alternatively, the full penetration weld can be made from one

side with backing on the outside of the liner shell. Liner weld details are shown

on Drawing No. 421-351 (Reference 13.25). Liner stiffeners will be welded using

details shown on Drawing 68-3871-17 (Reference 13.27).

5.8 Welding procedures and qualifications will incorporate instructions designed to

control porosity. These instructions will cover allowable welding currents,

removal of slag and flux and welding techniques to control porosity.

5.9 Uphill welding of vertical welds will be required, except that downhill cover

passes or backgouged root does not need to be qualified, but should be noted in

the Welding Procedure Specification as a nonessential variable. Downhill cover

passes or backgouged root can be welded by downhill welding.

5.10 Note that Reactor Vessel refueling operations cannot begin until after the liner

plate repair welds are completed and examined in accordance with Paragraph 6.3

below.

6.0 EXAMINATION AND TESTING

A. Weld Examination

6.1 Liner welds made as part of repair/replacement activities will be examined in

accordance with the applicable requirements of ASME Section XI

(Reference 13.5), Subsection IWE and Article IWA-4000 as well as ASME

Section VIII (Reference 13.3).

6.2 The requirements of ASME Section XI (Reference 13.5) Article IWA-4500 will

be used for examination and testing of welds. Personnel performing

nondestructive examinations (NDE) will be qualified and certified using a written

practice prepared in accordance with ASME Section XI (Reference 13.5) Article

IWA-2311 and ANSI/ASNT CP-189 (Reference 13.9). As stipulated in ASME

Section XI (Reference 13.5) Article IWA-23 10(a), certifications based on ASNT

SNT-TC-IA (Reference 13.10) are valid until recertification is required.

Page 4 of I I





6.3 After the liner plate has been welded back to its original configuration the

following Non-Destructive Examinations (NDE) will be performed, in accordance

with the applicable sections of ASME Section VIII (Reference 13.3) and ASME

Section XI (Reference 13.5) Subsections IWA and IWE, on the liner plate butt

welds around the perimeter of the Opening:

o 100% visual examination

o 100% vacuum box leak testing

o 100% magnetic particle testing (Double sided welds will receive magnetic

particle examinations of the final layer on both sides of the liner shell. Welds

with backing will receive Magnetic Particle Examinations after the first and

final layers).

6.4 Magnetic particle examination methods and acceptance criteria will be in

accordance with Appendix 6 of ASME, Section VIII (Reference 13.3).: The basis

for using magnetic particle in lieu of spot RT is addressed in ECED 70586

(Reference 13.24).

6.5 Results of magnetic particle examination, leak testing by vacuum box methods,

and visual inspection will be recorded as part of construction records.

6.6 Temporary fit-up devices that have been welded to the liner plate or liner

stiffeners to aid in aligning and supporting the reinstallation of the liner plate will

be either:

a. Removed (by grinding) and all removal areas inspected and tested per the

requirements of ASME Section XI (Reference 13.5), Division I, Subsection

IWA and IWE. This alternative will apply to all temporary fit-up devices

welded to the inside face of the liner.

b. Cut off approximately 'A" from the liner plate or stiffener. This alternative

method will eliminate grinding of the liner plate or stiffener plate and

additional NDE examinations. This alternative may be selected for the

concrete side of the liner provided that the welds have been made as safety-

related welds and all applicable NDE examinations for safety-related welds

to the IWE liner as per SP-0215 have been completed.

Page 5 of I 1





6.7 All containment pressure boundary repair full penetration liner welds will be

tested using a soap film and vacuum box. The testing will be performed utilizing

a pressure differential of not less than 4 psig. The rate of inspection will not

exceed two feet of weld per minute. The box will overlap a minimum of six

inches over the previously tested section. All detectable leaks will be corrected.

6.8 Results of nondestructive examinations will be evaluated in accordance with

Section 9.2.6 of Procedure EGR-NGGC-00 15 (Reference 13.19).

B. Pre-Service and Related Examination

6.9 Personnel performing visual examinations as required by'ASME Section XI

(Reference 13.5), Subsection IWE will be qualified and certified in accordance

with a written practice approved by the Responsible Engineer as specified in

Subsection 9.1.13 of EGR-NGGC-0015 (Reference 13.19). The written practice

will conform to the applicable requirements of ASME Section XI (Reference

13.5), Article IWA-2300 as amended by IOCFR50.55a (Reference 13.7).

6.10 Prior to removal of the liner coating, the affected liner surface will be visually

examined in accordance with ASME Section XI, (Reference 13.5) Table

IWE-2500-1. Examination results will be evaluated for acceptability by the

Responsible Engineer.

6.11 Both surfaces of the liner and the L3x2x ¼" stiffeners on the back side will be

visually examined for dents, warping, deformation, punctures or other damage

that may affect their ability to serve their safety-related function as components of

the containment pressure boundary. The Responsible Engineer will evaluate

examination results for acceptability and specify repairs as deemed necessary.

Any damage to the 3/8" thick liner plate that occurs during hydrodemolition

and/or just prior to cutting the plate is acceptable if the reduced thickness of the

plate is > 3/16". If the original liner plate is to be reinstalled, damaged areas will

be evaluated for potential repair and/or replacement actions prior to concrete

placement. Repairs to the removed liner section will be made in accordance with

the requirements of ASME Section XI (Reference 13.5), Article IWA-4000 and

this repair plan. Prior to returning the liner to service, the suitability of the

repaired item will be evaluated in accordance with ASME Section XI (Reference

Page 6 of I 1


PCHG-DESG ENGINEERING .CHANGE 0000063016R3



13.5), Article IWA-4160. If the liner repair is determined to be deficient,

appropriate corrective provisions will be implemented and included in the repair

documentation.

6.12 Preservice examination of the liner will be performed in accordance with ASME

Section XI (Reference 13.5), IWE-2200, after re-coating is complete but prior to

returning the liner to service. CR3 requirements for preservice examination are

specified in Section 6.5 of the CR3 ASME Section XI Repair & Replacement

Program (Reference 13.14). The Responsible Engineer will evaluate pre-service

examination results for acceptability as specified in ASME Section XI (Reference

13.5), Article IWE-31 10.

7.0 PRESSURE TESTING

7.1 After liner repairs are completed and prior to returning the Reactor Building to

service, the restored containment structure will be subjected to an integrated

leakage rate test (ILRT) that satisfies the Type A Test requirements of 1 OCFR50,

Appendix J (Reference 13.8). The ILRT, which will be performed in accordance

with the Technical Specification Containment Leakage Rate Testing Program

(Reference 13.15) and the requirements of SP-178 "Containment Leakage Test-

Type A Including Liner Plate" (Reference 13.17) will satisfy the ASME Section

XI (Reference 13.5), Article IWE-5221 requirement for a post-repair leakage test.

The measured leakage from this test will be included in the summary report

required by I OCFR50 Appendix J (Reference 13.8), Section V.B. The acceptance

criteria of IOCFR50 Appendix J, Section III.A.5(b) will be met. Details of the test

procedure and acceptance criteria are given in test procedure SP- 178 (Reference

13.17).

7.2 Surface areas that were repaired or replaced will be visually examined (VT-I)

prior to the start of reactor building pressurization for the Type A Test and

following the completion of de-pressurization. This examination will satisfy the

requirements of ASME Section XI (Reference 13.5), Article IWE-5240.

Page 7 of I 1





7.3 Documentation will be provided for all tests. This documentation will be

included in the modification records for permanent retention (See Section 11 of

this Plan).

8.0 PROTECTIVE COATING SYSTEM

8.1 After repair of the liner plate is completed, all exposed surfaces of the liner will

undergo surface preparation and reapplication of coating in accordance with the

requirements of Specification CPL-XXXX-W-005 (Reference 13.22) and

Procedure MNT-NGGC-0009 (Reference 13.20).

9.0 SUPPORT OF LINER DURING CONCRETE PLACEMENT

9.1 The liner will serve as the inner form during placement of concrete in the opening.

It will be attached to the outer form by ties welded to the vertical stiffener angles

as shown on Drawing 421-351 (Reference -13.25). Form ties are sized and spaced

to minimize deformations of both the liner and the outer form as specified in

Calculation S06-0007 (Reference 14.1).

10.0 HANDLING, STORING AND SHIPPING REQUIREMENTS

10.1 Materials procured for this repair activity will be handled, stored and shipped per

the requirements of MCP-NGGC-0402 "Material Management (Storage, Issue

and Maintenance)" (Reference 13.21) and ANSI N45.2.2 - 1972 "Packaging,

Shipping, Receiving, Storage and Handling of Items for Nuclear Power Stations"

(Reference 13.11).

11.0 RECORDS AND REPORTS

11.1 The preparation, submittal,-and retention of records and reports of examinations,

tests, and repair/replacement activities will meet the requirements of ASME

Section XI (Reference 13.5), Article IWA-6000 as incorporated into the CR3

Quality Assurance Program (Reference 13.13) and NEP 229 (Reference 13.15).

11.2 Records and reports indicated in this section will be filed and maintained for the

service lifetime of the Reactor Building in accordance with the CR3 Quality

Page 8 of 11





Assurance Program (Reference 13.13) and ASME Section XI (Reference 13.5),

Article IWA-63 10.

11.3 Following the completion of liner repair and replacement activities, reports

required by the CR3 ASME Section XI Repair & Replacement Program

(Reference 13.14) and NEP-229 (Reference 13.16) will be prepared and submitted

to the ANII for review and approval as specified in those documents.

12.0 INTERFACE REQUIREMENTS:

12.1 As specified in NEP-229 (Reference 13.16), which incorporates the requirements

of ASME Section XI (Reference 13.5), Article IWA-4170, the ANII will be

notified prior to starting the repair/replacement activity and will be kept informed

of progress so that necessary inspections may be performed.

Page 9 of I 1





13.0 REFERENCES

13.1 ASME B&PV Code, Section I1, "Materials, Part A - Ferrous Material

Specifications", Current Edition.

13.2 ASME B&PV Code, Section III, Subsection B, "Nuclear Vessels Code for

Class B Vessels," 1965.

13.3 ASME B&PV Code, Section VIII, "Unfired Pressure Vessels", 19651 Edition.

13.4 ASME B&PV Code, Section IX, "Welding and Brazing Qualifications", Current

Edition.

13.5 ASME B&PV Code, Section XI, 2001 Edition with addenda up to and including

the 2003 Addenda.

13.6 ASA N6.2-1965, "Safety Standard for Design, Fabrication and Maintenance of

Steel Containment Structures for Stationary Nuclear Power Reactors".

13.7 Code of Federal Regulations; Title 10, "Energy"; Part 50, "Domestic Licensing of

Production and Utilization Facilities"; Section 50.55a, "Codes and Standards".

13.8 Code of Federal Regulations; Title 10, "Energy"; Part 50, "Domestic Licensing of

Production and Utilization Facilities"; Appendix J, "Primary Reactor

Containment Leakage Testing for Water-Cooled Power Reactors".

13.9 ANSI/ASNT CP- 189, "Standard for Qualification and Certification of

Nondestructive Testing Personnel".

13.10 ASNT SNT-TC- 1 A-2006, (Recommended Practice No. SNT-TC- 1 A), "Non-

Destructive Testing," 2006 Edition.

.13.11 ANSI N45.2.2 - 1972 "Packaging, Shipping, Receiving, Storage and Handling of

Items for Nuclear Power Stations".

13.12 ASTM A36-05, Standard Specification for Carbon Structural Steel.

13.13 CR3 Quality Assurance Program.

Reactor Building Liner Specification SP-5566 (Reference 14.9) cites ASME Section VIII for certain weld

related items but does not identify a Code year. This specification was first completed in Jul 68 (and issued

in Oct 69). At the time that the specification was under development, the 1965 Edition of the ASME Boiler

and Pressure Vessel Code was current. Since SP-5566 is silent as to Code year, it is presumed that the 1965

Edition of Section VIII is the appropriate reference.

Page 10 of I1





13.14 CR3 ASME Section XI Inservice Inspection Program / Interval 4 / Repair &

Replacement Program, Revision 13, 14,Aug 08.

13.15 Crystal River Unit 3 Operating License (Through License Amendment No. 229),

Specification 5.6.2.20, Containment Leakage Rate Testing Program.

13.16 Procedure NEP 229, "Guidance for Implementation and Use of ASME Section XI

Rcpair/Replacement Program Documents", Revision 4, 14 Aug 08.

13.17 Procedure SP- 178 "Containment Leakage Test-Type A Including Liner Plate"

13.18 NGGM-PM-0003, "Corporate Welding Manual"

13.19 Procedure EGR-NGGC-0015, "Containment Inspection Program"

13.20 Procedure MNT-NGGC-0009, "Application of Protective Coatings," Rev. 5.

13.21 Procedure MCP-NGGC-0402 "Material Management (Storage, Issue and

Maintenance)"

13.22 Specification CPL-XXXX-W-005, "Nuclear Power Plant Protective Coatings."

13.23 Engineering Change 63016, Containment Opening.

13.24 ECED 70586, "Containment Opening Liner Plate Owner Reconciliation"

13.25 Drawing No. 421-351, "Reactor Building Temporary Access Opening for SGR

Restoration, Sheet 2 of 3"

13.26 CBI Drawing ER-4, "Lift Frame on Door Sheet"

13.27 Drawing No. 68-3871-17, CB&I, Shell Stretchout & Plate Details, Rev. 3.

13.28 SP-0125 "ASME Section XI Non-destructive Examination"

14.0 BIBLIOGRAPHY

14.1 Calculation S06-0007, Rev. 0, "Containment Liner Evaluation for SGR.

14.2 CR3 Specification SP-5566, "Reactor Building Liner and Penetrations and

Personnel Access Locks", Addendum C, Oct. 1969.

Page II of 11



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ATTACHMENT Z56R3L PageA8 of 9

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PCHG-OESG ENGINEERING CHANGE 000063016R003

PC HG-OR SG ENGINEERING CHANGE 000063016 R003

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RATTACHMENT Z56R3 Page 9 of 9

PCHG DESG ENGINEERING CHANGE 000063016R003

SS&IE

S&ME, INC. KNOXVILLE BRANCH

PHASE III ADDITIONAL TESTINGCuring Comparison

FORCRYSTAL RIVER UNIT 3 STEAM GENERATOR REPLACEMENT PROJECT

S&ME PROJECT NUMBER 1439-08-208Contract 373812, Amendment 4

Prepared for:Mr. John Holliday

PROGRESS ENERGY FLORIDA, INC.

15760 West Powerline StreetCrystal River, Florida 34428-6708

July 6, 2009

PREPARED BY:

REVIEWED BY:

QA BY:

APPROVED BY:

All work contained in this report was conducted in accordance with the requirements of the referenced procurementdocuments and the S&ME, Inc., Knoxville Branch Quality Assurance Manual, Volume I, Revision 4, dated December 5,2003.

ATTACHMENT Z55R3

S&ME, INC. / 1413 Topside Road / Louisville, TN 37777 /p 865.970.0003 f 865.970.2312 / %ww.smeinc.com

Page 1 of 5

PCHG DESG ENGINEERING CHANGE 000063016R003PHASE Ill ADDITIONAL TESTING - Curing Comparison July 6, 2009S&ME Project 1439-08-208

BACKGROUND

S&ME, Inc. (S&ME) has completed the Phase III Curing Comparison Testing for theCrystal River Unit 3 Steam Generator Replacement Project. The testing was performed asoutlined in Contract 373812, Amendment 4. To date, the concrete mixture testing for thisproject has included compression testing of cylinders at ages of 5 days and 28 days. Asrequired by the project specification the cylinders have been cured in autogenous curingcontainers for the first 5 days in an attempt to better represent the curing conditions of theconcrete that will be placed for the containment opening restoration. Autogenous curingcontainers are not planned to be used to cure the production cylinders cast during thecontainment opening restoration concrete placement. For this reason, Progress requestedthat a concrete mix be batched and cylinders cast for compressive strength testing usingboth forms of curing (autogenous containers and the curing method proposed forproduction) so that a comparison of the obtained compressive strengths could bedocumented.

TESTING

One batch of concrete was mixed using the materials and proportions used in the initialPhase III testing, adjusting admixture dosages to achieve the desired fresh properties.Twenty 6" x 12" cylinders were cast from the batch. Two cylinders were tested incompression at ages of 1, 2, 3, 5 and 28 days for the two different curing conditions. Thefirst curing condition involved placing the cylinders in autogenous curing containers untilthe time of test, for up to five days. For this curing condition, the cylinders that were tobe tested at 28 days were removed from the autogenous containers at an age of 5 days andplaced in a curing environment maintained at 73 ± 3°F, but without access to additionalcuring moisture until the time of test. The remaining ten cylinders were cured the entiretime in the 73 ± 3'F environment without access to additional curing moisture.

NOTICE OF ANOMALY/CORRECTIVE ACTION

During the comparison study, one Corrective Action Report (CAR) was issued (CAR-09-04). The CAR was issued to address exceeding the calibration interval on the sulfurcapping compound. The capping material was re-verified after this was discovered and wasfound to be within tolerance, therefore there was no impact to the test results. A copy of theCAR is attached.

RESULTS

A summary of the results of the Phase Ill Curing Comparison Testing is attached.

ATTACHMENT Z55R3 2 Page 2 of 5

PCHG *&ME Te~bnqRSumma ry 000063016R003

Client: Progress Energy Material: Concrete Mix IAProject: Crystal River Source: Laboratory MixS&ME Project No.: 1439-08-208 Quantity: 4.75 cubic footContract/P.O. No.: 373812 Date / Time Mixed: May 27, 2009, 9:45 am (Eastern)

S&ME Log No.: 09-044-001

Mixture Proportions (calculations based on one cubic yard)

Constituent Materials S&ME Log No. Weight (Ibs) Volume (ift)Type 1/1i Portland Cement (Holly Hill) 08-040-001 560 2.86

Class F Fly Ash (Proash) 08-034-001 140 0.93

No. 67 Stone (Maryville) 08-037-001 1613 9.23Natural Sand (Lilesville) 08-032-001 1515 9.23

Water N/A 262.5 4.21Target Air (2%) N/A --- 0,54

Totals 4,090 27.0

Actual Admixture Dosages (Admixtures dosed to achieve desired fresh properties.)

Constituent Materials S&ME Log No. Dosage Rate (oz/cwt)ADVA CAST 575 09-012-001 7.3

Recover 09-004-001 2

Target water/cementitious ratio 0.375

Theoretical Unit Weight (pcf) 151.5

Measured Plastic Properties

Property ASTM Designation Result

Slump (in) ASTM C 143-05a 7.75

Air content (%) ASTM C 231-04 2.3

Measured Unit Weight (pcf) ASTM C 138-01 151.1

Concrete Temperature (OF) ASTM C 1064-05 79Air Temperature (OF) N/A 75

Notes Concrete batching performed in accordance with ASTM C 192-06, except that final mixing time was extended by 2 minutes.

Compressive Strength, psi (ASTM C 39-0561) (Average of 2 cylinders per test age)

Age ,day(s) Autogenous Containers Alternative Proposed Curing

1 5,620 4,760

2 6,450 5,930

3 6,590 6,320

5 6,860 6,830

28 8,050 8,480

Notes Autogenous cured cylinders remained in the autogenous containers until time of test up to and including 5 days age.The 28-day autogenous cylinders were removed from the autogenous containers at 5 days and remained seated intheir plastic mold at 73+1-30 F.Production curing cylinders remained sealed in their molds at 73+1-3'F up to test age.


1413 Topside Road Louilsvifle, Tennessee 37777 Phone: 865-970-0003 Fax., 865-970-2312

PCHG DESG , QUALITY ASn'U~XW 0MORANDOM 000063016R003

TO:

FROM:

CAR Files

John W. Coffey, Sr., Quality Assurance Manager Nuclear

DATE:

SUBJECT:

Projects

June 12, 2009

Closure of CAR-09-04

This memo is to close CAR-09-04

The calibration/verification of the capping compound was completed satisfactorly.

The concrete personnel were instructed to re-read ASTM C 617.

This CAR is now closed.

•o• W.Coffey, Sr.Quality Assurance ManagerNuclear Projects


PCHG DESG ENGINEERING CHANGE 000063016R003

CORRECTIVE ACTION REPORT CAR NUMBER:CAR-09-04

PREPARED BY: John W. Coffey, Sr. DATE: 06-12-09REQUIRED ACTION DATE: June 12, 2009

ACTION ASSIGNED TO: Jason B. Burgess SIGNIFICANT CONDITIONORGANIZATION/PROJECT: 1439-08-208 ADVDERSE TO QUALITY

D3 YES I ENO

PART A - DESCRIPTION OF NONCONFORMANCE/PROBLEM: ASTM C 617, paragraph 5.1.4States in part that the calibration interval is not to exceed three months or upon receipt of each newshipment. Contrary to this the last calibration perform was on 01-09-09 with calibration due on 04-09-09however the next calibration was conducted on 06-12-09.

SINGATURES/DATEQUALITY XXý7ýNCEORI&7A'TOR

PART B -. ACTION AGENCY

I 1. ROOT CAUSE OF NONCONFORMANCE/PROBLEM: Due to an over sight by the concretelaboratory personnel the required due calibration date of 04-09-09 was passed and the re-calibrationwas performed on 06-12-09. A equipment use log was not assigned as a hold point prior to executionof the work task.

2. CORRECTIVE- ACTION-TO PRECLUDE-RECURRENCE:- The concrete-laboratory-personnel was--instructed to be more diligent on the calibration interval of three months of calibration/verification onthe capping compound. The concrete personnel were required to re-read the ASTM C 617 "StandardPractice for Capping Cylindrical Concrete Specimens",. QA will consider this QA Hold Point onupcoming tasks..

3. DATE CORRECTIVE ACTION TO BE COMPLETED: June 12,2009

4. SIGNATURES/DATE: 06-12-09DATEQA SUFMWSORI

PART C - QUALITY ASSURANCE

1. QA REVIEW/COMMENTS: Comparison was made between the calibration/verification record ofthe 0 1-09-09 and the 06-12-09 calibration/verification records. The average compressive strength ofthe verification on 01-09-09 was 5930 PSI and the average compressive strength of the 06-12-09verification is 5400 PSI. The required average compressive strength should be 5000 PSI. Thecapping compound is within the required strength.

2.3.4.S.6.

DATE CORRECTIVE ACTION VERIFIED:CORRECTIVE ACTION ACCEPTABLE:REPORTABLE PER 10 CFR 21:DATE CAR CLOSED: June 12, 2(SIGNATURE/DATE

June 12, 2009El YESC3 YES

E3 NO[] NO

.. T.L-TY ASSURANCE

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