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Inservice Inspection and Examination-High Pressure Vessels and Boilers-Handout, Exercises of High Pressure Vessels and Boilers

This handout is related to High Pressure Vessels and Boilers course. It was distributed by Prof. Sajjan Janesh at Avinashilingam University. Its main points are: Responsible, Engineer, Unbonded, Post-tensioning, System, Inservice, Inspection, Multiple, Plants, Concrete

Typology: Exercises

2011/2012

Uploaded on 07/17/2012

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IWL-2310 REQUIREMENTS FOR CLASS CC COMPONENTS IWL-2421
(4) to determine the condition of concrete surfaces
affected by repair/replacement activities, in accordance
with IWL-5250.
(c) Visual examinations shall be performed directly
or remotely, with adequate illumination, by personnel
with visual acuity sufficient to detect evidence of degra-
dation.
(d) The Owner shal define qualification requirements
for personnel performing examinations of concrete and
tendon anchorage hardware, wires, or strands.
(e) The Owner shall define requirements for visual
examination of tendon achorage hardware, wires, or
strands.
IWL-2320 RESPONSIBLE ENGINEER
The Responsible Engineer shall be a Registered
Professional Engineer experienced in evaluating the
condition of structural concrete. The Responsible Engi-
neer shall have knowledge of the design and Construc-
tion Codes and other criteria used in design and con-
struction of concrete containments in nuclear power
plants.
The Responsible Engineer shall be responsible for
the following:
(a) development of plans and procedures for examina-
tion of concrete surfaces;
(b) approval, instruction, and training of concrete
examination personnel;
(c) evaluation of examination results;
(d) preparation or review of Repair/ Replacement
Plans and procedures;
(e) review of procedures for pressure tests following
repair/replacement activities;
(f) submittal of a report to the Owner documenting re-
sults of examinations, repair/replacement activities, and
pressure tests.
IWL-2400 INSERVICE INSPECTION
SCHEDULE
IWL-2410 CONCRETE
(a) Concrete shall be examined in accordance with
IWL-2510 at 1, 3, and 5 years following the completion
of the containment Structural Integrity Test CC-6000
and every 5 years thereafter.
(b) The 1, 3, and 5 year examinations shall commence
not more than 6 months prior to the specified dates
and shall be completed not more than 6 months after
such dates. If plant operating conditions are such that
examination of portions of the concrete cannot be
251
completed within this stated time interval, examination
of those portions may be deferred until the next regularly
scheduled plant outage.
(c) The 10 year and subsequent examinations shall
commence not more than 1 year prior to the specified
dates and shall be completed not more than 1 year
after such dates. If plant operating conditions are such
that examination of portions of the concrete cannot be
completed within this stated time interval, examination
of those portions may be deferred until the next regularly
scheduled plant outage.
IWL-2420 UNBONDED POST-TENSIONING
SYSTEMS
(a) Unbonded post-tensioning systems shall be exam-
ined in accordance with IWL-2520 at 1, 3, and 5 years
following the completion of the containment Structural
Integrity Test and every 5 years thereafter.
(b) The 1, 3, and 5 year examinations shall commence
not more than 6 months prior to the specified dates
and shall be completed not more than 6 months after
such dates. If plant operating conditions are such that
examination of portions of the post-tensioning system
cannot be completed within this stated time interval,
examination of those portions may be deferred until
the next regularly scheduled plant outage.
(c) The 10 year and subsequent examinations shall
commence not more than 1 year prior to the specified
dates and shall be completed not more than 1 year
after such dates.
IWL-2421 Sites With Multiple Plants
(a) For sites with multiple plants, the examination
requirements for the concrete containments may be
modified if the containments utilize the same pre-
stressing system and are essentially identical in design,
if post-tensioning operations for each subsequent con-
tainment constructed at the site were completed not
more than 2 years apart, and if the containments are
similarly exposed to or protected from the outside
environment.
(b) When the conditions of IWL-2421(a) are met,
the inspection dates and examination requirements may
be as follows.
(1) For the containment with the first Structural
Integrity Test, all examinations required by IWL-2500
shall be performed at 1, 3, and 10 years and every
10 years thereafter. Only the examinations required by
IWL-2524 and IWL-2525 need be performed at 5 and
15 years and every 10 years thereafter.
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IWL-2310 REQUIREMENTS FOR CLASS CC COMPONENTS IWL-

(4) to determine the condition of concrete surfaces affected by repair/replacement activities, in accordance with IWL-5250. (c) Visual examinations shall be performed directly or remotely, with adequate illumination, by personnel with visual acuity sufficient to detect evidence of degra- dation. (d) The Owner shal define qualification requirements for personnel performing examinations of concrete and tendon anchorage hardware, wires, or strands. (e) The Owner shall define requirements for visual examination of tendon achorage hardware, wires, or strands.

IWL-2320 RESPONSIBLE ENGINEER

The Responsible Engineer shall be a Registered Professional Engineer experienced in evaluating the condition of structural concrete. The Responsible Engi- neer shall have knowledge of the design and Construc- tion Codes and other criteria used in design and con- struction of concrete containments in nuclear power plants. The Responsible Engineer shall be responsible for the following: (a) development of plans and procedures for examina- tion of concrete surfaces; (b) approval, instruction, and training of concrete examination personnel; (c) evaluation of examination results; (d) preparation or review of Repair /Replacement Plans and procedures; (e) review of procedures for pressure tests following repair/replacement activities; (f) submittal of a report to the Owner documenting re- sults of examinations, repair /replacement activities, and pressure tests.

IWL-2400 INSERVICE INSPECTION

SCHEDULE

IWL-2410 CONCRETE

(a) Concrete shall be examined in accordance with IWL-2510 at 1, 3, and 5 years following the completion of the containment Structural Integrity Test CC- and every 5 years thereafter. (b) The 1, 3, and 5 year examinations shall commence not more than 6 months prior to the specified dates and shall be completed not more than 6 months after such dates. If plant operating conditions are such that examination of portions of the concrete cannot be

251

completed within this stated time interval, examination of those portions may be deferred until the next regularly scheduled plant outage. (c) The 10 year and subsequent examinations shall commence not more than 1 year prior to the specified dates and shall be completed not more than 1 year after such dates. If plant operating conditions are such that examination of portions of the concrete cannot be completed within this stated time interval, examination of those portions may be deferred until the next regularly scheduled plant outage.

IWL-2420 UNBONDED POST-TENSIONING

SYSTEMS

(a) Unbonded post-tensioning systems shall be exam- ined in accordance with IWL-2520 at 1, 3, and 5 years following the completion of the containment Structural Integrity Test and every 5 years thereafter. (b) The 1, 3, and 5 year examinations shall commence not more than 6 months prior to the specified dates and shall be completed not more than 6 months after such dates. If plant operating conditions are such that examination of portions of the post-tensioning system cannot be completed within this stated time interval, examination of those portions may be deferred until the next regularly scheduled plant outage. (c) The 10 year and subsequent examinations shall commence not more than 1 year prior to the specified dates and shall be completed not more than 1 year after such dates.

IWL-2421 Sites With Multiple Plants (a) For sites with multiple plants, the examination requirements for the concrete containments may be modified if the containments utilize the same pre- stressing system and are essentially identical in design, if post-tensioning operations for each subsequent con- tainment constructed at the site were completed not more than 2 years apart, and if the containments are similarly exposed to or protected from the outside environment. (b) When the conditions of IWL-2421(a) are met, the inspection dates and examination requirements may be as follows. (1) For the containment with the first Structural Integrity Test, all examinations required by IWL- shall be performed at 1, 3, and 10 years and every 10 years thereafter. Only the examinations required by IWL-2524 and IWL-2525 need be performed at 5 and 15 years and every 10 years thereafter.

IWL-2421 1998 SECTION XI — DIVISION 1 IWL-

(2) For each subsequent containment constructed at the site, all examinations required by IWL- shall be performed at 1, 5, and 15 years and every 10 years thereafter. Only the examinations required by IWL-2524 and IWL-2525 need be performed at 3 and 10 years and every 10 years thereafter.

IWL-2500 EXAMINATION

REQUIREMENTS

Examination shall be performed in accordance with the requirements of Table IWL-2500-1.

IWL-2510 SURFACE EXAMINATION

(a) Concrete surface areas, including coated areas, except those exempted by IWL-1220(b), shall be visu- ally examined in accordance with IWL-2310(a) for evidence of conditions indicative of damage or degra- dation, such as defined in ACI 201.1. Selected areas, such as those that indicate suspect conditions, shall be visually examined in accordance with IWL-2310(b). (b) Tendon anchorage areas, including coated areas, except those exempted by IWL-1220(a), shall be visually examined in accordance with IWL-2310(b) for evidence of conditions indicating damage or degradation. Selected areas, such as those that indicate suspect conditions, shall be subject to additional examinations, if specified by the Responsible Engineer. (c) For containments with unbonded post-tensioning systems, the concrete surfaces and tendon end anchorage areas shall be examined for corrosion protection medium leakage, and the tendon end caps shall be examined for deformation. (d) The examination shall be performed by, or under the direction of, the Responsible Engineer. (e) Visual examinations may be performed from floors, roofs, platforms, walkways, ladders, ground sur- face, or other permanent vantage points, unless tempo- rary close-in access is required by the inspection plan.

IWL-2520 EXAMINATION OF UNBONDED

POST-TENSIONING SYSTEMS

IWL-2521 Tendon Selection

(a) Tendons to be examined during an inspection shall be selected on a random basis except as noted in IWL-2521(b) and (c). The population from which the random sample is drawn shall consist of all tendons of a particular type (as defined in Table IWC-2521-1)

252

not examined during earlier inspections. The number of tendons to be examined during an inspection shall be as specified in Table IWL-2521-1. (b) One tendon of each type (as defined in Table IWL-2521-1) shall be selected from the first year inspec- tion sample and designated as a common tendon. Each common tendon shall be examined during each inspec- tion. A common tendon shall not be detensioned unless required by IWL-3300. If a common tendon is deten- sioned, another common tendon of the same type shall be selected from the first year inspection sample. (c) If a containment with a stranded post-tensioning system is constructed with a predesignated number of detensionable tendons, one tendon of each type shall be selected from among those that are detensionable. The remaining tendons shall be selected from among those that cannot be detensioned.

IWL-2521.1 Exemptions. The following require- ments shall apply to tendon anchorages that are not accessible for examination because of safety or radiolog- ical hazards or because of structural obstructions. (a) After the process of randomly selecting tendons to be examined, any inaccessible tendons shall be designated as exempt and removed from the sample. (b) Substitute tendons shall be selected for all tendons designated as exempt. Each substitute tendon shall be selected so that it is located as close as possible to the exempted tendon, and shall be examined in accord- ance with IWL-2520. (c) Each exempted tendon shall be examined in accordance with IWL-2524 and IWL-2525 to the extent that the end anchorages of the exempt tendon are accessible either during operation or at an outage.

IWL-2522 Tendon Force and Elongation Measurements (a) The prestressing force in all inspection sample tendons shall be measured by lift-off or an equiva- lent test. (b) Equipment used to measure tendon force shall be calibrated in accordance with a calibration procedure prior to the first tendon force measurement and following the final tendon force measurement of the inspection period. Accuracy of the calibration shall be within 1.5% of the specified minimum ultimate strength of the tendon. If the post-test calibration differs from the pretest calibration by more than the specified accuracy tolerance, the results of the examination shall be eval- uated. (c) During retensioning of a tendon, the tendon elon- gation shall be measured.

IWL-2523 1998 SECTION XI — DIVISION 1 IWL-

TABLE IWL-2521- NUMBER OF TENDONS FOR EXAMINATION

Required Maximum Percentage1,2^ Minimum^1 Required Inspection of all Tendons Number of Number of Period of Each Type^3 Each Type Each Type 1st year 4 4 10 3rd year 4 4 10 5th year 4 4 10

10th year 4 2 3 5

NOTES: (1) Fractional tendon numbers shall be rounded to the next higher integer. Actual number examined shall not be less than the mini- mum required number and need not be more than the maximum required number. (2) The reduced sample size listed for the 10th year and subsequent inspections is applicable only if the acceptable criteria of IWL- 3221.1 have been met for the last three inspections. (3) A tendon type is defined by its geometry and position in the containment: e.g., hoop, vertical, dome, helical, and inverted U. (4) The number and percentage of tendons to be examined every 5th year thereafter shall remain the same.

IWL-2523 Tendon Wire and Strand Sample Examination and Testing IWL-2523.1 Tendon Detensioning and Sample Re- moval. One sample tendon of each type shall be completely detensioned. A single wire or strand shall be removed from each detensioned tendon.

IWL-2523.2 Sample Examination and Testing (a) Each removed wire or strand shall be examined over its entire length for corrosion and mechanical damage. The examination shall determine the location of most severe corrosion, if any. Strand wires shall be examined for wedge slippage marks. (b) Tension tests shall be performed on each removed wire or strand: one at each end, one at midlength, and one in the location of the most corroded area, if any. The following information shall be obtained from each test: (1) yield strength (2) ultimate tensile strength (3) elongation

IWL-2523.3 Retensioning. Tendons that have been detensioned shall be retensioned to at least the force predicted for the tendon at the time of the test. However, the retensioning force shall not exceed 70% of the specified minimum ultimate tensile strength of the tendon based on the number of effective wires or strands in the tendon at the time of retensioning.

254

IWL-2524 Examination of Tendon Anchorage Areas IWL-2524.1 Visual Examination. A detailed visual examination in accordance with IWL-2310(b) shall be performed on the tendon anchorage hardware, including bearing plates, anchorheads, wedges, buttonheads, shims, and the concrete extending outward a distance of 2 ft from the edge of the bearing plate. The following shall be documented: (a) concrete cracks having widths greater than 0.01 in.; (b) corrosion, broken or protruding wires, missing buttonheads, broken strands, and cracks in tendon an- chorage hardware; (c) broken wires or strands, protruding wires and detached buttonheads following retensioning of tendons which have been detensioned.

IWL-2524.2 Free Water Documentation. The quan- tity of free water contained in the anchorage end cap as well as any which drains from the tendon during the examination process shall be documented.

IWL-2525 Examination of Corrosion Protection Medium and Free Water IWL-2525.1 Samples (a) Samples of the corrosion protection medium shall be taken from each end of each tendon examined. Free water shall not be included in the samples. (b) Samples of free water shall be taken where water is present in quantities sufficient for laboratory analysis.

IWL-2525.2 Sample Analysis (a) Each corrosion protection medium sample shall be thoroughly mixed and analyzed for reserve alkalinity, water content, and concentrations of water soluble chlorides, nitrates, and sulfides. Analyses shall be per- formed in accordance with the procedures specified in Table IWL-2525-1. (b) Free water samples shall be analyzed to deter- mine pH.

IWL-2526 Removal and Replacement of Corrosion Protection Medium (a) The amount of corrosion protection medium re- moved at each anchorage shall be measured and the total amount removed from each tendon (two anchor- ages) shall be recorded. The total amount replaced in each tendon shall be recorded and differences between amount removed and amount replaced shall be docu- mented.