ML17208A315

Final Const Deficiency Rept:On 790903,Chicago Bridge & Iron Guyed Derrick Collapsed During Hurricane David,Damaging Reactor Auxiliary & Concrete Shield Bldgs.Caused by Inadequate Securing.New Derrick Will Be Erected 800107

ML17208A315
Person / Time
Site:	Saint Lucie
Issue date:	02/01/1980
From:	FLORIDA POWER & LIGHT CO.
To:
Shared Package
ML17208A314	List: ML17208A313 ML17208A315
References
NUDOCS 8003190685
Download: ML17208A315 (17)

Text

~yl~FinalConstructionDeficiencResortDamaeResultinFromDerrickFailureDurinHurricaneDavidNameofStation:Owner:Architect/Engineer:DateofDeficiency:InterimReportPiled:SupplementtoInterim,ReportFiled:FinalReportPiled:St.LuciePlant-UnitPi2'loridaPower&LightCompanyEbascoServices,IncorporatedSeptember3,1979October4,1979December7,1979February1,1980 TableofContentsISummaryIIDescriptionIIIAssessedDamageIVCorrectiveActionsVSafetyImplicationsVIConclusionTables'Table1-DispositionedConcreteNonconformanceReportsTable2-DispositionedElectricalNonconformanceReportsTable3-ConcreteDesignChangeNotices~FiuresI-ReactorAuxiliaryBuilding-LocationofPulseEchoTesting(Elevation+43ft)2-ReactorAuxiliaryBuilding-LocationofPulseEchoTesting(Elevation+62ft)Attachment,'ketchesSK2998'G7'5.01to7'5.06 I-Slk2fARYOnMondaymorning,September3,1979,atapproximately10:45a.m.,the.ChicagoBxidge&Ironguyedderrickbuckled,twisted,andcollapsedduringHurricaneDavid.Thelowerportionofthederrick(below'Elevation+192feet)didnotcollapseandwasleaningataslightanglefromthevertical,remainingbracedtothecontainmentshieldwallbyvirtueofthehorizontalstrutbraces.Theupperportionofthederrickbecamedismembexedand,fourmajorsectionscametorestinorontheReactorAuxiliaryBuiding.Aportionoftheboomremainedsuspendedbyguywir'esfromthetopofthecontainmentshieldwall.Theguywirespexformed,theirintendedfunctionanddidnotfail.Pertherequirementsof10CPR50.55(e)>theeventwasdeemedreoortablebecause'Ithederrickfailurecausedsignificant.damagetosafety-relatedstructures,,which,wereittohavexemaineduncorrected,couldadvexselyaffectthesafetyofoperationsoftheplant,anddidrequixeextensiveevaluationandrepaix'.NotificationoftheincidentwastelephonedintotheNRCInspectionandEnforcementOfficeonSeptember4,1979(approximatelyll:45a.m.)byMrNWeems,FloridaPower&LightCompany'sAssistantManager,QAConstruction.VianumerousonsiteinspectionsbytheArchitect/Engineerandengineeringreviewofonsiteconfirmatorydestructiveandnondestructivetesting,alldamagedareaswexeidentifiedandcoxrective'actionswereissued.IX.DESCRIPTIONTheconcreteShieldBuilding.andtheReactorAuxiliaryBuildingwereatthe.followingstagesofconstructionwhenthehuxricanepassedthejobsite:TheconcreteShieldBuildingcylinderhadbeencompletedtoElevation+191.42feetandtheReactorAuxiliaryBuilding,beingconstructedinastaggeredmanner,hadwallsandcolumnscompletedtotheundersideoffloorslabsatElevations+43feet,+62feetand+82feet.ActionstakentoIdentifDamaeAstormdamageteamwasassembledtodetermineanddocumenttheextentof.damageresultingfxomthederrickfailure.TheteamconsistedoftheEbascoCivilSiteSupportEngineerandtwocivilconstructionofficeengineers.In DESCRIPTIONon')conjunction,theArchitect/Engineervisitedthejobsite,bothbeforeandafterderrickremovalandcleanup,toobservethedamageandtoconfirmandtaskforcefindings.Nonconformancereportswerepreparedforobserveddamagetoconcreteandreinforcing,andcorrectiveactionsforremovalandinitialrepairwereissuedwithArchitect/Engineerreviewandapproval.Architect/Engineerdirectedconstructiontoproceedwithtwo,testingpro-gramstoconfirmtheextentofdamagewithintheReactorAuxiliaryBuildingandShieldBuilding.ThefirstprogramrequiredtestingofreinforcingsteelsamplesremovedfromthedamagedfloorbeamsandslabsoftheReactorAuxiliaryBuildingatElevation+62feet.Testresultswould'indicateifthereinforcingwhichextendsintothesurroundingsoundconcretehadbeenoverstressedduringmissileimpact.Thesecondprogramrequirednondestructivetestingof:Pa)ReactorAuxiliaryBuildingconcretemembers1)adjacenttodamaged'loorslabax'easatElevations++3feetand+62feet,includingallthebeamsatElevation+43feetwhichwereobservedtohavesurfacecracks,and2)anexteriorwallal'ongthenorthsideofthebuildingwhichhadonlyfivedayconcretestrengthwhenasectionofthederrickhitthetopofthewall.b)ShieldBuildingcylinderwall1)atthreelocationsontopofwallwheredowelswerebentandshearedoff,and~2)atagougedareaonoutside-faceofwallatElevation+112feet.ThepulseechomethodwasselectedandwasperformedbyifuenowandAssociatesofCharlotte,NorthCarolina.TheattachedPigures1and2showtheconcx'etememberswhichwereinvestigated.Areascompletelyunaffectedbythederrickfailurewerereleasedforcontinuedplannedconstruction.

.III.ASSESSEDDAMAGETheinitiallyobserveddamagetothecontainmentshieldwallwaslimitedtobentandsheareddowelsproject'ngfromthetopofthecylinderwallandasmallsurfacegougeontheexteriorwallface.TheinitiallyobserveddamagewithintheReactorAuxiliaryBuildingwasextensiveandconsistedofpenetraLionoffloorslabs,shatteredfloorbeam,spalledconcrete,andbent.andsheareddowelsforcolumnsandwalls.Thelocationofderrickandboomsectionrestingpositions,anddetailsofobserveddamagetotheReactorAuxiliaryBuildingarepresentedonSketches,SK-2998-PG75.01to75.06(Attachment).Inadditiontothenoteddamageonthesketches,crackswereobservedonthesurf'aceofafewelevation+43feetfloorbeams.Thesecrackswerech'ppedbacktodeterminedepthandwereobservedtobeonlysurfaceshrinkagecracks.InadditiontotheabovestructuraldamageintheReactorAuxiliaryBuilding,thefollowingisalistingofdamagedequipmentandsupports:,1)ConduitonElevation+43feet2)CabletrayrestraintonElevations+43feetand+62feet3)4.16kVSwitchgear2A3-1,2,3,4,5,6,7,84)StationServiceTransformer2A2-5)480VSwitchgear6)Pressurizerheaterbuses-2A3and2B3Thedestructivetestingofreinforcingsteelandnondestructivetestingofconcretemembersproceededinthefollowingsequencewithresultsasnoted:ReactorAuxiliaryBuildinElevation+62feet(floorslab,beams,girders,andsupportingcolumnandexteriorwall)..Allshatteredandbadlycrackedconcreteofbeam3B3betweenColumnlines2RA1and2RA2andadjacentslabswereremoved.

IASSESSEDW~E(Cont'd)Samplesofexposedbeamandslabreinforcingwere*removedandtestedby.ConstructionQualityControltodetermineifASKSminimumrequirementsweremetorifthereinforcinghad'ecomeoverstresseduponimpact.Testresultsindicatedthattheslabreinforcing(No.6and8rebars)metallASTi~frequirementandbeamreinforcing(Ho.9rebars)metallASMrequirementexceptpercentelongationwhichindicatedvaluesaslowas3percentvsaminimumallowableof7percent.-Tocheckthefieldtestresults,samplesofthefieldtestedrebarsandadditionalsamplesofthebeamreinforcingweresenttotheArchitect/Engineerforinvestigationandtensiletesting.Hicroscopicinspectionofthefieldtestedrebarsdidnotrevealtheelongatedgrainwhichtypifymaterialexposedtoplasticstrain.TensiletestingoftworebarsamplesindicatedthatallAS'Bfrequirementsweremetexceptforelongationinonesample.Itwasnotedthatbothsamplesfailedatsurfaceindentationswhichwerecausedbynicksandgougesduringconcreteremoval.Thetest-ingprogramconcluded:1)Thereisnoevidenceofrebarstraining-duetothecranecollapse.2)TheNewYorkOfficetestedrebarsfailedatthegouges(stressrisers}(CopyofthereportiscontainedwithinJBrodsky(EbascoMaterialsEngineer)memotoLMPetrick{ChiefMaterialsandWeldingEngineer)dated-12-18-79.Foradditionalinformationontheeffectsofloadingofreinforcingsteelpast-yield,theArchitect/Engineerrequestedfieldtensiletestingofreinforcingofsamesize(No.9rebars)andheatnumberasinstalledinBeam383.Testingproceededasfollows:1)Measurediameter,2)Loadtoyieldpointandholdfor5-10sec,3)Slowlyreleaseload, 4)Measureelongationanddiameter,5)Loadtoultimateand6)Determineelongation,ForallrebarstestedallASTi'!requirementsweremet.Nondestructivetestingofvisuallysoundconcretemembersadjacenttotheimpactareaindicatedthefollowing:1)Microcrackingandlossofconcretebondtoreinforcementinthetopfourinchesofconcretewithinbeams3B2and3B4adjacentt;oimpactedBeam3B3,andinBeam3B3south.ofColumnLine2RA2.2),Microcrackinginadjacentslabs.throughouttheonefootdepthandforadistanceof3;5feetpastbeams3B2and3B4.3)MicrocrackingonexteriorwallatsupportpointofBeam3B2foradepthoflessthanthreeinches.Todocumentvalidityoftestresults,nondestructivetestingofconcretemembers-awayfromthedamagedareawasalsoperformedandresultsindicatedsoundconcrete.ReactorAuxiliaBuildin~Elevation+43feet(beams,girdersandsupportingcolumns)ShatteredandbadlycrackedconcreteofslabeastofcolumnlineRAGandbetweencolumnlines2RA2and2RA3wasremoved.Samplesofexposedslabreinforcing,wereremovedandtested,andwerefoundtomeetASTi'lminimumxequirements.Nondestructivetestingwasperformedonallbeamsonwhichaportionofthederrickhadcometorestandgirdersandsupportcolumnsadjacenttothedamagedconcreteslab(beams2B4-2B13betweencolumnslines2RA2and2RA3).Nomicrocracksweredetec'tedandanyvisuallyobservedsurfacecrackswerefoundnottoextendbeyondtwotothreeinchesindepth.

III.ASSESSEDDAHACE(Cont'd)ReactorAuxiliaBuildinWallsbetweenElevation+19.5feetto+43.0feetNondestructivetestingofnorthexteriorwallbetweencolumnlinesRABandRAEindicatedmicrocrackinginthetoptwotothreefeetforaportionofthewall.NondestructivetestingofinteriorwalloncolumnlineRAEbetweencolumnlines2RA2and2RA3,aroundanareawhichhadbeendamagedandunsoundconcreteremoved,indicatednomicrocracking.ReactorBuildinzShieldWallNondestructivetesting,performedatAzimuths70,130and160degreesbetweenElevations+191.42and+186feet,indicatedmicrocrackinguptosixinchesbelowtopofwallforthecompletethickness.NondestructivetestingaroundagougelocatedatAzimuth160degrees-.atElevation+112feetindicatedsurfacemicrocrackingforafoursquarefootareaontheoutsidefaceoftheshieldwall.Forcompletedescriptionofnondestructivetestingprogram,includingtechniqueandtestresultsforallareasinvestigated,seeifuenowandAssociates"FinalReportOntheNDEEvaluationofConcreteDamageatStLucieUnitNo.2"whichisfiledatthesite;IV.CORRECTIVEACTIONSActions-TakenFloridaPower&LightCompanyretainedCadcom,adivisionon<<fanTechofNewJerseyCorporation,toinvestigatethecauseofthederrickfailureandtomakerecommendationsconcerningtheerectionofa.replacementderrick.TheCadcomReportconcludesthattheguyedderrickshouldhavewithstoodthehurricaneforcewindshaddifferentsecuringprecautionsbeentaken.In CORRECTIVEACTIONS(Cont'd)addition,thereportrecommendsminormodificationsthatcouldbemadetofurtherenhance.thehurricanewithstandcapabilityofthecrane.TheCadcomReportwassubsequentlyreviewedbyChicagoBridgeandIron(CBI),whodesigned,manufacturedandsuppliedthecrane.CBI,concurredthattheCadcomReportprovidesareasonableaccountofthederrickcollapse,andthattherecommendationsforsecuringthederrickwhenhurricanewindsareexpectedaretechnicallysound."Followingtheirowndesignreview,andconsiderationoftheCadcomReport'BIhasconcludedthatthefollowingactionsshouldbetakentosecurethereplace-mentderrickwhenhurricanewindsareexpected:l)Raisetheboomashighaspossibleandallowtheboomandmastto"weathervane."2)Removethespreaderbeamfromtheboom.3)Fixthemast-towerswiveljointtothetowerwithboltsorweldedlugs.Aduplicatereplacementderrickwillbeerectedatthesite,withinstallationcommencingJanuary7,1980..FloridaPower5LightCompany'sequalityControlDepartmenthadtheresponsibilitytopreparenonconformancereports(NCRs)wheredamageoccurredtocompletedcon-struct>onactivities(i.e.,afterconcreteplacement)orequipment.TableIcontainsdispositionedNCR'ssummarizingcategoriesofstructuralmembers,typesofdamageandcorrectiveactiontobetaken.Table2containsdispositionedNCR'ssummarizingtheequipmentdamageandcor-rectiveactionbetaken.

IV.,CORRECTlVEACTIONSTable3containsdesignchangenotifications'DCN's)whichwereissuedbytheArchitect/Engineertorepairdamagedconcreteandreinforcingasdeter-minedfromvisualobservationsandfromtheresul'tsofthedestructiveandnondestructivetestingprograms.CInvolvementTheprocedures'util'izedtoidentifydamage,evaluateanddispositioncorrectiveactionarethefollowing:1)SiteQualityProcedureSQP-21"CorrectiveActions"forthehandlingofNCR's.TheFloridaPower&LightCompany'sQualityControlDepartmenthasindependentlyreviewedthedamagedareasandissuedNCR'stoidentifydamagedareasandequip-ment.Theyfollow-upthecorr'ectiveactiondispositionedbyEngineeringandapplythenormaltestingandinspection-requirementsforfinalapproval.Inaddition'totheabovenormalQCinspectionandapprovalprocessanddocumenta-tion>thestormdamageteamhasphotographedandmappedthedamagedareastopermitadditionaldocumentationontheextentofdamage.V.SAFETYGPLXCATIONSTheChicagoBridge&IronderrickfailurecausedsignificantdamagetotheReactorAuxiliaryBuildingstructurewhichrequiredextensiveevaluationandrepairtoestablishtheadequacyofthe,structuretoperformitsintendedsafetyfunctionandmeetthecriteriaandbasesstatedinthePreliminarySafetyAnalysisReport.Ifitweretohaveremaineduncorrected,thestruc-turaldamagecouldhavepossiblyaffectedthesafetyofoperationsoftheplant.VI.CONCLUSIONTheChicagoBridge&IronderrickfailurewasdeterminedtobeapotentiallyreportableaccidentonSeptember4,*1579"andsuchnotificationwasmadetothe

~~I~~VICONCLUSTON(Cont'd)NRCinspectionandEnforcementOfficethesameday.Priortoanyrepairworkornewconstructionintheaffectedareas,eachareawasspecificallyevaluatedforstructuralsoundnessandrepairmeasuresapproved.Adequatedocumentationonthestructuralevaluationandrepairworkismaintainedatthesite.Asaresultofthedispositionedcorrectiveactiondescribedabove,thedamagedportionsoftheReactorAuxiliaryBuildingandReactorBuildingshieldwallhavebeenrestoredtooriginalstructuralsoundness.

Table1nedConcreteNCRsIssuedNCRs830C831C,841C,845C,846C,848C,850CCateoxiesCoveredbNCRInteriorwall.andprojectingreinfoxcingColumns,wallsandprojectingreinforcingTeofDamaeBentrebarsSpalledconcreteandbentrebarsinwalls-andcolumnsCorrectiveActionRebendrebaxstooriginalpositionsChipconcreteback1'-6,cutoffdamagedrebarsandmechanicallysplicerebaxs835C832CColumnsandprojectingrein-forcingBentxebaxsWallandprojectingreinforcingCrackedconcreteandben"rebaxsChipback1ftintosoundconcreteandmechanicallysplice'ebarsChipconcretebacktospecifiedelevationforfullrebaxlapspliceandinstallnewxebars.836CforcingReactorShieldBuildingandpxojectingreinforcing834CSlab,beamsandgirderatElevation+62feet(RAB)851C,BeamsatElevation+43feet860C(RAB)870CExteriorWall(RAB)842CSlabandgixdersatElevation+43feet(RAB)833CColumnsandp'rojectingrein-Crackednear'loorlevelMicrocrackingattopofwall,andbentrebarsConcretemicro-crackinganddamagedxebarsSuperficialsur-facecracks.Superficialsur-facecracks..CxackedconcreteandbentxebarsChipconcretecolumandreplacedamgedreinforcingChipback1ftintosoundconcreteandmechanicallysplicerebars.SeeDCN550.203and513.609NoneNoneChipconcreteandlapspliceslabrebarsan;.mchanicallysplicegirderrebars.

tTable2DisositionedElectricalNCRsIssuedNCRsEuiomentCoveredbNCRDisosition839E84QEConduitsonElevation+62feetRemovedamagedconduitandreplacewithnew838EElectricalEquipmentScrapandreplace837ECabletrayrestraintsonElevations+43feetand+62feetTworestraintsaretoberepairedbyConstructiontowithinAISCtolerances.Balancetobescrapped.

Table3ConcreteDCNsIssuedDCNs550.203513.609CatepriesCoveredbDCNSlab,beamsandgirderatElevation+62feet(RAB)eofDamaeConcretemicrocrackinganddamagedrebarsCorrectiveActionRemoveconcreteandrebars,andlapspliceandmechanicallyspliceasspecified.550-208Wall(RAB)ConcretemicrocrackingChipbackintosoundconcreteasspecified550-207SlabElevation+43feet(RAB)'rackedconcreteanddamagedrebarsRemoveconcreteandrebars,andspliceasspecified.

BI2I4.ISl7~IBRL)CRal<<la'atoCIICRA]ZN'PhJQAfQttRhO't1(o.)',3PCS~>,Q0l~¹sasg,'tCS'CSg'(O0a'<QlttatleRy~~'I.DCQh4<a<~O'OI'll0IRASaIO<DCaaaV0saaiMS+4S)Qas-0;a~~~a')RA30r'lRl4-I0rraI'%RA,(o+A,0gr~Irrr)uutl\\arrl<C0Sostcc~scuaitalLSSCr-H~>~s.~--.~.-.-LJ-raltSt<I~.I<a~I',='(aQa)~atalt~~~ri4a~I<I~~i'b)C<<a4\'ItsIII(t.5LR()'s.~/I~~~~lIss~41Ja(IIS/..z'.~QC/Xl'a/~aX5<as-~I~5tabisI~II('<045aJ5<lbsIali<a<a.JL.l."'B~~I~/(a(,/~sIIIsIIs(Is(~~~~llI~a('.J/r.I~.Jrr~~~~UE~I(itslI<IsaI~s~<Il~I'II~III~s~~~I~II~(~(..<~(a'I)1(~IISalI~Il~I'IIIts'llI~a~aaI~~o.sCgL~,'ZRGg1~~raII'"'I'~~~rs~~sII'Ia~aI<'1Issls'J)IIr\aIU...3its~csC~~5yqO~'QI~~'a7.-~I:5<5,'sa'4aII(asr"I~~~rsa~aa~<rrarrFROME'Ll9ToQL45,o,'Ito%.HCbst((Llb.C0I-ItO.COgCl-1ISgC.ggCaaLTa>~~,<crtCDatt~0C(<>.II~II!05(IC(f<CI(<CR0'CI)IS-)(It)I'&(tIC(rt.~<(SII5I;lCos(PI.CSSC<(ltS~IttI(CISISSI(Sr(tll<CIIIO<fLO~4W><CSttr'S'0'0o4'0<0<0soloIC0ICS'lr-re(-RJ~4'aSDS/JsbLIVELVA0:ZOOfs5C,IsO.SOOOlbCOMCCa<T<<AT50LoaoPLLLj-'EL43.+0UIJtFSSLjOTEDICOSttRtt<R.)ua<tt'0S<SO<CO<tpIIIIraaa'TC(sQfStabCll'2/rlus<L(Sst)otlb.ltttr(r)<S<t($.C~<S~tt((<<<(saCC~)aa<(5<asI(I~<OI<lsorI(scl(cc~tI;(a.M$()<4attALLCaRC<RSC'aaC~<tCotuMas5ll'.<r()Ca(<)<lOala~S<lls~<NDICLT(\tI4a4.ataa.SDI<tiars(>Cr4514'lalararatf4~aOS<Iota<<t.CD'I~4a,tOaaraICltaal.~a(I4rw,5,lar~~DaDIV.DR.DATECH.-S)CALEAPPROVEDEBASCOSERVICESINCORPORATFDFly.lPZACTORAUXILlh.RYKUO.DlLLQlOCexlagor-PuL.SC.L-CHOVE.+TlQQasaMRwsrwluaaaaaaaasar<sar~~

'I~~TR)It}aD.st}'4I.)t~'SlCI~~lII(4I'r-'rrsIISl)Is+()0I'+'(0t}IQsslLc(RI*100~leeeptt~eel'Its+)st'l"sss24FIt'4~DAO'RhCI-l,$00~9CISMtlreO'0=lr'5~Ias)s((IIE'l~sI-I)(),)'Eg~r~~I(II(I((I');II,'(stI~Ie~se'RX10l((lt)I)III(I=IIII~II~Il~(j(sIII[I.IIII'I-(I(III(()Io()IIIII.I.I,J.LII39.!'T7)ss.)TIIIII()stXg(dI(d)MII()IIIIIIgIII)(.('.II,II'r))r'(II,~+a~OyyIi.,Isq.owe(.oetoIIosso00IIoZZ4+~StePl~e'tIl~II'I~I~'N'.A$~:Crll)IJIP~~r\hqI,IX~rIf'SL4%l~~)Ie.'ItAAAPPsb'CCatrpIS)usa~:bors'vubp~DTCO)~I.Db(}Ca,ibCCSVC%SITR<TCO(.Cl(SPLhIJ-KLG2.OOI:0Strst(1TP)IsesttSSssO(P0DIV.DR.DATECH.SCALEAPPROVEDeesses~ssssessessalesspteelesssseeesE8ASCOSERVICESINCORPORATEOFLCIiRCACTORA,uslLlh-QYM)LDlNQLOCb.TlOklCFPULK&ECHO7ESxl4Creeerreeltoeve!L'e5eselrrreeeeeeeseereeeeleeseeeeemoeeeeet1 Ve<e