ML18043A932
| ML18043A932 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 07/06/1979 |
| From: | Hoffman D CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| NUDOCS 7908090654 | |
| Download: ML18043A932 (25) | |
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- Area Code 517 788-0550 July 6, 1979 Mr James G Keppler Office of Inspection and Enforcement Region III US Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, IL 60137 DOCKET 50-255 - LICENSE DPR PALISADES PLANT - IE BULLETIN 79-02 Ju"'iCHOR BOLTS References (1) IE Bulletin 79-02 dated March 8, 1979.
(2) CP Co Letter tu NRC dated March 29, 1979.
(3) NRC Response to CP Co dated April 26, 1979.
(4) IE Bulletin 79-02 Rev l dated June 21, 1979.
Consumers Power Company responded to IE Bulletin 79-02 by letter on March 29, 1979.
In that letter, we proposed incorporating IE Bulletin 79-02 into SEP Topic III-5.A.
We considered the two subjects to be somewhat compatible and fully expected our proposal to be accepted.
We received your negative response to this proposal on April 30, 1979 which placed us well into the 120 days allowed by IE Bulletin 79-02.
Following receipt of your response, we have worked actively toward resolving the Bulletin in the predefined ti.me frame.
We do not have adequate original installation quality control data to support a complete response at this time.
Therefore, per Item 4 of the Bulletin, we must proceed with an inspection and testing program.
Due to the large number of pipe hangers at Palisades, we have contracted with an architect-engineering firm (Bechtel) to assist us in all phases of the resolution of this Bulletin.
Review of plant design records pertaining to pipe hanger supports have been underway since May, 1979.
As of June 30, we identified 1,016 specific hangers on safety-related piping.
Six hundred forty-one (641) of these have one or more baseplates attached by expansion anchor bolts.
We have completed the initial analysis of bolt loads on 511 of these pipe hangers.
The bolt load analyses have incorporated predefined hanger loads and baseplate flexibility considerations as defined in the attached plan.
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JUL.9 1979
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2 In general, computer based analyses were used for large diameter piping while chart methods were used for small diameter piping in the original plant design.
As a result, we have more definitive individual hanger information for the large diameter piping.
A rough estimate is that approximately 95% of the han-gers evaluated to date have been on ~ 3" diameter piping.
Because of the large number of hangers, we expect the analytical work to con-tinue for several more weeks.
Coupled with this analytical work are site inspections of as-built hanger assemblies to verify that they are as defined in design documents and to correct these documents where necessary.
When as-builts do not match design documents, the actual field information will be used as the source data for bolt load. calculations.
We.have prepared preliminary versions of purchase specifications for potential repair materials such as expansion anchor bolts and baseplate steel.
We have also issued preliminary specifications defining anchor bolt acceptance criteria, inspection procedures, testing procedures and repair procedures.
All of these documents are contained in a draft work package which has been issued for re-view and comment.
A condensation of that package is enclosed.
The field implementation procedures for this project will be a specific part of this work package.
The development of these procedures is now under way.
The final version of these procedures will be based on the above-described specifi-cations.
The pipe support detailed inspection procedure will be finalized within the next few days to support the start of actual piping walk downs for data gathering and design verification on approximately July 11, 1979.
We intend to employ a combination of pull and torque testing.
Testing equipment has been ordered and is expected to arrive in early August.
Testing and repair procedures will be verified at that time.
Field testing and engineering crews will then be established with actual testing to take place during the refueling outage (September, 1979).
We cannot provide evidence of significant testing results at this time.
- However, we can inform you that hanger unit inspections performed for ISI, permanent main-tenance procedures, snubber testing inspections, recent pipe support modifications and informal walk downs of piping systems have not identified any significant de-ficiencies with anchor bolts at Palisades.
David P Hoffman (Signed)
David P Hoffman Assistant Nuclear Licensing Administrator CC Director, Office of Nuclear Reactor Regulation Director, Office of Inspection and Enforcement
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PIPE SUPPORT BASE PLATE AND EXPANSION ANCHOR EVALUATION REPORT FOR PALISADES NUCLEAR PLANT CONSUMERS POWER COMPANY
1.0 INTRODUCTION
This report describes the program to fulfill the requirements of USNRC IE Bulletin 79-02 Rev. 1 dated June 21, 1979 pertaining to pipe supports base plate designs using expansion anchor bolts in seismic Category I systems.
2.0 SCOPE This program consists of identification of systems involved, expansion anchor pipe support evaluations, development of procedures and implementation of field inspection and testing, including documentation.
A final report will be prepared, summarizing the results and conclusions when the program is completed.
1
The pipe supports for lines 2 inches and under have been designed for the Palisades plant, using criteria developed from basic industry standard guidelines and charts.
We shall demonstrate that these methods are highly conservative.
Therefore, per the guidelines of the IE bulletin, an inspection will be performed on the anchor bolts and base plates for 2 inches and under piping.
However, these items are excluded from the form~l analysis and testing portions of the program.
3.0 SYSTEMS INVOLVED 3.1 USNRC IE Bulletin 79-02 requires that investigations be made of pipe supports using expansion anchors in seismic Category I systems, as defined by Regulatory Guide 1.29, "Seismic Design Classification", Rev 1, dated August 1973, or as defined in the appliciable FSAR~
The Palisades plant-FSAR, Appendix A, identifies safety seismic systems.
Appli-cable piping in the systems identified by the FSAR, Appendix A will be evaluated except as follows:
- a.
Radioactive waste treatment piping ev~luation will be confined to the gaseous system with the excep-tion of a portion of the liq~id discharge release line, plus related containment penetrations.
2
- b.
Plant instrument air piping evaluation will be confined to the high-pressure air-operated valve system and containment penetrations.
Appendix A of this report lists,the system drawings which includes the specific lines being evaluated *
. 3.2 USNRC IE Bulletin 79-02also requires evaluation of expansion anchor bolts subjected to high cyclic operating loads.
The original static ~quivalent pipe support design loads have included the effects of cyclic loads in addition*
to other appropriate loading conditions, ~uch as seismic, dead, and thermal loads.
This aspect is discussed in Section B-6.0 of Appendix B.
4.0 TYPES OF EXPANSION ANCHORS Based on the preliminary review of *engineering documents and visual field inspection performed at the Palisades plant, the majority.of expansion-type concrete anchors used for safety seismic systems pipe supports are of the ~hell type *.
There also exists a number of supports using stud (wedge) type expansion anchors.
3
5.0 ENGINEERING EVALUATIONS As a part of the current program, the supports and re-straints using expansion anchors are being analyzed and tabulated.
Calculations are presently in progress, using analytical guidelines outlined in Appendix B for verification of expansion anchor safety factors and the flexibility of base plates.
6.0 INSPECTIONS AND TESTING Inspection and testing will be performed to assure that the expansion anchors and pipe support base plates have been properly installed and that the expansion anchors have the required design factors of safety.
Technical specifications have been developed outlining the procedures for p~rforming the various inspections and testing.
These specifications will be utilized as the basic field working procedures.
Section BlO.O -of Appendix B identifies selected inspection and testing characteristics for this program.
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7.0 ACCEPTANCE AND REPAIR SPECIFICATIONS Technical specifications. have be~n developed for the acceptance
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and repair of shell-type and stud (wedge) type expansion anchors to ensure proper installation of existing and new expansion anchors *
. a.a INSPECTION AND TESTING PROGRAM An inspection and testing program will be conducted to establish the confidence level.of existing expansion anchors.
Inspection and testing will be performed on.a limited. number of.base plates and expansion anchors.
As presently ~lanned, the base _
plates will be selected from a representative sample of supports, which can be made-available for insp~ction and testing to demonstrate a confidence level of 95% that no more than 5% of installed base plates and-expansion. anchors are defective.
The*acceptance criterion is in Section BlO.O of Appendix B..
The program will consist of testing one anchor bolt in-selected base plates distributed over various systems identified in Appendix.A.
9.0 DOCUMENTATION Complete documentation.will be maintained in accordance with the technical specifications developed for this work.
This 5
will provide adequate traceability of inspection ane--tes-ting,---------- - - -- -- ----- --
including design verification performed on expansion anchors and the base plates for safety seismic lines.
10.0 SCHEDULE A schedule as shown in Figure 4 is attached in Appendix C, reflecting the completion of various activities.
-Inspec~ion--------- ----- ------
will begin prior to, and bulk of testing will be performed during the plant's scheduled refueling outage.
Some pre-liminary testing may be done prior to the start of the re-fueling outage.
As presently planned, the outage is scheduled to commence in early September 1979.
11.0 QUALITY ASSURANCE REQUIREMENTS Quality Assurance will be in accordance with the Consumers Power Company QA program and Bechtel QA Program for Palisades Plant Operations.
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Drawing M-201 M-202 M-203 M-204 M-205 M-207 M-208 M-209 M-210 M-211 M-212 M-213 M-214 M-215 M-218 M-219 M-220 M-221 APPENDIX A SYSTEM DRAWINGS AND DESCRIPTION
System Description
Primary Coolant System Chemical Volume Control Safety Injection, Containment Spray Shutdown Cooling Safety Injection, Containment Spray Shutdown Cooling Main Steam and Auxiliary Turbine System Feedwater and Condensate System Service Water System Component Cooling Water System Radwaste Treatment System -
Clean Radwaste Treatment System -
Dirty and Gaseous Service and Instrument Air Circulating Water, Screen Structure Chlorination, and Fire System Lube Oil, Fuel Oil, and Diesel Generator Plant Heating System HVAC System Sampling System Makeup Water, Domestic Water, and Chemical Injection Spent Fuel Pool Coolant and Shield Cooling System A -
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APPENDIX A (Continued)
Drawing M-222 M-224 M-225 M-226 M-650 M-651
System Description
Miscellaneous Gas Supply System Gas Analyzing System High-Pressure Air-Operated Valves Steam Generator Blowdown Modification Radwaste Evaporator System Clean Wastes Radwaste* Evaporator System - Miscellaneous Wastes A -
2
APPENDIX B ENGINEERING GUIDELINES GUIDELINES FOR IMPLEMENTATION OF TESTS, INSPECTIONS, AND DESIGN CALCULATIONS IN FULFILLING REQUIREMENTS OF NRC IE BULLETIN 79-02, REV. 1 DATED JUNE 21, 1979 B-1.0 SCOPE This document gives guidelines for implementation of tests, inspections, and design calculations in fulfilling the require-ments of the USNRC IE Bulletin 79-02, Rev. 1 dated June 21, 1979.
B-2.0 TYPES OF *CONCRETE EXPANSION ANCHORS Expansion anchors used for supporting piping systems at the Palisades plant include the following:
- a.
Stud-type anchors (wedge or sleeve), see Figure 1, and
- b.
Shell-type anchor (self drilling or predrilled),
see Figure 2.
B -
l
B-3.0 FLEXIBILITY OF THE BASE PLATE B-3.l UNIAXIAL TENSION The effect of prying action in base plate-to-concrete connection using expansion anchor bolts is considerably less than the same phenomenon in steel-to-steel connections,-
mainly due to the expansion anchor having a much lower stiffness.
If the bending stresses in the base plate are within _the AISC allowables, *the plate is then thick enough for the prying action to_be negligible.
Flexibility of the plate, however, shall be considered in distributing the load among the bolts.
B-3.2 BENDING The moment arm "C" to determine the tension in the expansion
- Moment ancihor bolt "T" =
C
~ will be taken to be equal to c1 as shown_ in Figure 3.
This is a conservative approach.
In reality the moment arm is greater than c1 and will approach c2 as the plate becomes inf init~ly rigid. _
An analytical approach, which is based on finite element analysis, has been formulated, taking into account the base plate flexibility and the bolt stiffness.
This approach J
will be used, where required, when the conservative approach fails to meet the safety requirements.
B -
2
B-4.0 SAFETY FACTOR A minimum factor of safety between the bolt design load and the bolt ultimate capacity, determined from manufacturer's published data or static load tests simulating the actual conditions of installation, shall be equal to four for stud-
.type anchor bolts and five for the shell type_ in accordance with Paragraph 2.0 of IE Bulletin 79-02.
B-5.0 SHEAR-TENSION INTERACTION If the bolt is *subject to tension and shear, it must be checked for the combined effect using following interaction formula:
(
v )2 Vall
+
(
T *)
2
< 1 Tall where T and V are the applied tension and shear, and Tall and Vall are the allowable tension and shear, respectively.
B-6.0 DESIGN REQUIREMENTS FOR CYCLIC/SEISMIC LOADS The original design of the piping systems considered deadweight, thermal stresses, cyclic vibration, seismic loads, and dynamic loads (including water. hammer in the B -
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feedwater and main steam sy'stems) in the generation of the static equivalent pipe support design loads.
To the extent static equivalent pipe support design loads include cyclic considerations, these effects were included in the design of the hangers, base plates and anchorages.
The safety factors used for concrete expansion anchors, installed on supports for safety related piping systems, were not increased for loads which are cyclic in nature.
The use of the same safety factor for cyclic and static loads is based on the FFTF Tests. (Drilled -
In Expansion Bolts Under Static and Alternating Loads, Report No. BR-5853-C-4 by Bechtel Power Corp., January, 1975).
The test results indicate:
- a.
The expansion anchors succes~fully withstood two million cycles of long term fatigue load-ing at a maximum intensity of 0.20 of the static ultimate capacity.
When the maximum load inten-sity was steadily increased beyond the afore-mentioned value and cycled for 2,000 times at each load step, the observed failure load was about the same as the static ultimate capacity.
B -
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- b.
The dynamic load capacity of the expansion anchors, under simulated seismic loading, was about the same as their corresponding static ultimate capacities.
B-7.0 INSTALLATION OF EXPANSION ANCHORS.
B-7.1 INITIAL INSTALLATION TORQUE FOR STUD-TYPE ANCHORS Th~ initial in~tall~tion torque shall be as specified by the bolt manufacturer (if data is availabl~). If manufacturer's data is not available, then torque values shall be as specified in Table 2.
The installation torque has a significant impact on the stiffness characteristics of the anchorage, however, it has no effect on its ultimate capacity.
The bolt preload shall not be considered in design.
Preload relaxation amounts to 50-60% of the initial value.
B-7.2 INITIAL INSTALLATION OF SHELL-TYPE ANCHORS The initial installation of shell-type anchors shall be as specified by the anchor manufacturer.
The setting depth of the shell shall be such that the shoulder of the shell does not extend beyond the surface of the concrete so that it will not touch the back face of the base plate.
The shell B -
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shoulder-to-cone length shall be as specified.
Bolt-to-shell minimum thread engagement shall not be less than one bolt diameter.
B-8.0 SPACING BETWEEN ANCHOR BOLTS The minimum bolt center-to-center spacing and edge distance (between centerline of bolt and. edge of concrete member) shall be according to the manufacturer recommendations.
However, minimum spacing may be reduced provided the ultimate capacity of the bolt is not less than 90.% of its ultimate shear cone capacity.
B-9.0 TESTING EXPANSIONS ANCHORS FOR PULLOUT CAPACITY Expansion anchors shall be tested with a tensioner. Test load values equal to or greater than 100% of the allowable design tension load shall be used. If the nut on the bolt has been untightened during testing, the-bolt shall be retorqued after testing to the minimum installation torque value.
In lieu of tension testing, installed expansion anchors can be tested using a calibrated ~anually operated torque wrench.
Minimum torque values as given in Table 3 shall be obtained during testing.
B -
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-'ii. t B-10.0 PROCEDURE FOR INSPECTING EXPANSION ANCHORS AND BASE PLATES B-10.1 STUD TYPE The inspe_ction of stud-tyI>~ expansion anchors-shall be _____________________ _
performed as follows:
- a.
Check stud length.
- b.
Verify stud diameter.
- c.
Determine stud projection from concrete surface.
- d.
Verify that the nut is not bottomed out on the stud.
- e.
Verify that the spacing of the studs meets the manufacturer's requirements and/or the requirements
. of Section ~~a.o*of this appendix.
- f.
Verify full nut engagement.
- g.
Check the stud capacity by testing, as specified in Section B-9.0 of this appendix.
- h.
Check the concrete surrounding the plate for signs of failure.
B -
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B-10.2 SHELL TYPE The inspection of shell-type expansion anchors shall be performed.as follows:
- a.
Check that the shell is not in contact with the support plate, and that the shell does not protrude beyond the concrete surface.
- b.
Check that the--thread engagement of the bolt meets
_ the r_equirements of Section B-7. 2 of this appendix.
- c.
Verify bolt diameter.
- d.
Verify that the spacing of t.he bolts meets the manufacturer's requirements and/or the requirements of Section B~a.o of this appendix.
- e.
Verify shoulder-to-cone length.
- f.
Check the bolt capacity by testing, as specified in Section B-9.0 of this appendix.
- g.
Check the concrete surrounding the plate for signs of failure.
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B-10.3 BASE PLATES The following are significant items to be checked in the base plate inspection:
- a.
Base plate dimensions
- b.
Bolt hole size and orientation
- c.
Degree of flatness, gaps between attachment plate and face of concrete.
B-11.0 TEST SAMPLE SIZE AND ACCEPTANCE CRITERION.
A representative sample will b.e selected and tested.
In order to demonstrate with a confidence level of 95% that no more than 5% defective anchors have been installed, the sampling'program shown in Table 4 shall be applied.
Representative samples of stud and shell-type anchors shall be identified separately and sample. tested as two different lots.
B -
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TABLE 1 ULTIMATE CAPACITY OF EXPANSION ANCHORS IN TENSION OR SHEAR (kips)
STUD-TYPE SHELL-TYPE Anchor Diameter Minimum (in~)
Capacity Embedment (in.)
1/4 1.2 1-1/8 1.5 3/8 2.0 1-5/8 2.5 1/2 4.8 2-1/4 6.0 5/8 6.4 2-3/4 a.a 3/4 9.6 3-1/4 12.0 7/8 12.0 4
15.0 1
14.4 4-1/2 18.0 NOTES:
- 1.
The values.given are for 3,000 psi concrete.
For 4,000 psi concrete or better, factor of 1.15 may be used.
- 2.
The values given are minimum values.
Higher capacities, if required, will be determined based on. test results or higher strength concrete.
- 3.
The minimum spacing.or edge distance, as specified in Section B-a*.o of this appendix, must be maintained in order to use the ultimate values given.
- 4.
This table is applicable for expansion anchors manu-factured by Phillips Drill Co. (Red Head wedge or sleeve-type and shell-type)~ and by Hilti Fastening system, Inc. (kwik bblts stud anchor).
TABLE 2 INSTALLATION TORQUE VALUES (Anchor threads shall not be lubricated)
Anchor Diameter 1/4 3/8 1/2 5/8 3/4 7/8 (in.)
Installation Torque 5-10 25-35 45-65 80-90 125-175 200-250 (ft-lb)
(See Note 4 under Table 1)
B -
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250-300
"ii. t TABLE 3 MINIMUM TESTING TORQUE VALUES Anchor Diameter 1/4 3/8 1/2 5/8 3/4 7/8 1
( in.; r--- -
Testing Torque 4
10 25 55 75 105 150 (ft-lb)
(See Note 4 under Tablelj-- - -
TABLE 4 SEQUENTIAL SAMPLING PROGRAM Acceptable Number of Defective*
Sample Sfze in the Sample 58 0
92 1
123 2
152 3
180 4
207 '
5 233 6
259 7
285 8
310 9
335 10 360 11 385 12 409 13 433 14 457 15 481 16 505 17 i
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Sleev~Type Expansion Anchor Wedge'.""'.Type Expansion Anchor.
F'IGU RE I.
SUOUI.. DER-TO-CONE S~lf-Dril.led Type Expansion Anchor Predrilled-Type Expansion Anchor *,
FIGURE 2.
B.:..- 1:2
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TENSION COMPRESSIO FIGURE 3.
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ORIGINAL ISSUE REPORT STAllTREFUEL1NGOUTAGE OF ~~,ij~ffr;E~8TAGE ISSUE FINAL lSSUEFINAL a:
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TABULATION OF LARGE PIPE SUPPORTS WITH TABULA ION OF LA lr.E PlPISUPPORTS EXPANSION ANCHOR BOLTS
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2 REVIEW DESIGN LOADS & SAFETY FACTORS R VlEWDESI GNLOADS& !ft.FETYFAi: ans.
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LEGEND
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INSPECTION & TESTING PROCEDURES
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ACCEPTANCE CRITERIA PRE RE-CIR FC-
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THE CONSTRUCTION SCHEDULE IS BASED ON TWO 14 SHIFTS OF TO HOURS PER DAY I ii I
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36 37 38 39 40 41 42 43 44 45 46 BECHTEL ANN ARBOR, MICHIGAN 47 PALISADES - CONSUMERS POWER COMPANY 48 I
Pl PE SUPPORT EXPANSION ANCHOR BOLT DESIGN & LOAD VERIFICATION 49 i
I TARGET PROJECT SCHEDULE 50 MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG ti I JOB N~i DRAWING NO. I REV I UPDATE 1979 1911) 12447-033 FIGURE 4
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