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)

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~yl~FinalConstruction Deficienc ResortDamaeResultinFromDerrickFailureDurinHurricane DavidNameofStation:Owner:Architect/Engineer:

DateofDeficiency:InterimReportPiled:Supplement toInterim,ReportFiled:FinalReportPiled:St.LuciePlant-UnitPi2'loridaPower&LightCompanyEbascoServices, Incorporated September 3,1979October4,1979December7,1979February1,1980 TableofContentsISummaryIIDescription IIIAssessedDamageIVCorrective ActionsVSafetyImplications VIConclusion Tables'Table1-Dispositioned ConcreteNonconformance ReportsTable2-Dispositioned Electrical Nonconformance ReportsTable3-ConcreteDesignChangeNotices~FiuresI-ReactorAuxiliary Building-LocationofPulseEchoTesting(Elevation

+43ft)2-ReactorAuxiliary Building-LocationofPulseEchoTesting(Elevation

+62ft)Attachment

,'ketches SK2998'G7'5.01to7'5.06 I-Slk2fARYOnMondaymorning,September 3,1979,atapproximately 10:45a.m.,the.ChicagoBxidge&Ironguyedderrickbuckled,twisted,andcollapsed duringHurricane David.Thelowerportionofthederrick(below'Elevation

+192feet)didnotcollapseandwasleaningataslightanglefromthevertical, remaining bracedtothecontainment shieldwallbyvirtueofthehorizontal strutbraces.Theupperportionofthederrickbecamedismembexed and,fourmajorsectionscametorestinorontheReactorAuxiliary Buiding.Aportionoftheboomremainedsuspended byguywir'esfromthetopofthecontainment shieldwall.Theguywirespexformed,their intendedfunctionanddidnotfail.Pertherequirements of10CPR50.55(e)

>theeventwasdeemedreoortable because'Ithederrickfailurecausedsignificant.

damagetosafety-related structures,

,which,wereittohavexemaineduncorrected, couldadvexsely affectthesafetyofoperations oftheplant,anddidrequixeextensive evaluation andrepaix'.Notification oftheincidentwastelephoned intotheNRCInspection andEnforcement OfficeonSeptember 4,1979(approximately ll:45a.m.)byMrNWeems,FloridaPower&LightCompany's Assistant Manager,QAConstruction.

Vianumerousonsiteinspections bytheArchitect/Engineer andengineering reviewofonsiteconfirmatory destructive andnondestructive testing,alldamagedareaswexeidentified andcoxrective'actions wereissued.IX.DESCRIPTION TheconcreteShieldBuilding.and theReactorAuxiliary Buildingwereatthe.following stagesofconstruction whenthehuxricane passedthejobsite:TheconcreteShieldBuildingcylinderhadbeencompleted toElevation

+191.42feetandtheReactorAuxiliary

Building, beingconstructed inastaggered manner,hadwallsandcolumnscompleted totheunderside offloorslabsatElevations

+43feet,+62feetand+82feet.ActionstakentoIdentifDamaeAstormdamageteamwasassembled todetermine anddocumenttheextentof.damageresulting fxomthederrickfailure.Theteamconsisted oftheEbascoCivilSiteSupportEngineerandtwocivilconstruction officeengineers.

In DESCRIPTION on')conjunction, theArchitect/Engineer visitedthejobsite,bothbeforeandafterderrickremovalandcleanup,toobservethedamageandtoconfirmandtaskforcefindings.

Nonconformance reportswerepreparedforobserveddamagetoconcreteandreinforci ng,andcorrective actionsforremovalandinitialrepairwereissuedwithArchitect/Engineer reviewandapproval.

Architect/Engineer directedconstruction toproceedwithtwo,testing pro-gramstoconfirmtheextentofdamagewithintheReactorAuxiliary BuildingandShieldBuilding.

Thefirstprogramrequiredtestingofreinforcing steelsamplesremovedfromthedamagedfloorbeamsandslabsoftheReactorAuxiliary BuildingatElevation

+62feet.Testresultswould'indicate ifthereinforcingwhichextendsintothesurrounding soundconcretehadbeenoverstressed duringmissileimpact.Thesecondprogramrequirednondestructive testingof:Pa)ReactorAuxiliary Buildingconcretemembers1)adjacenttodamaged'loor slabax'easatElevations

++3feetand+62feet,including allthebeamsatElevation

+43feetwhichwereobservedtohavesurfacecracks,and2)anexteriorwallal'ongthenorthsideofthebuildingwhichhadonlyfivedayconcretestrengthwhenasectionofthederrickhitthetopofthewall.b)ShieldBuildingcylinderwall1)atthreelocations ontopofwallwheredowelswerebentandshearedoff,and~2)atagougedareaonoutside-face ofwallatElevation

+112feet.Thepulseechomethodwasselectedandwasperformed byifuenowandAssociates ofCharlotte, NorthCarolina.

TheattachedPigures1and2showtheconcx'ete memberswhichwereinvestigated.

Areascompletely unaffected bythederrickfailurewerereleasedforcontinued plannedconstruction.

.III.ASSESSEDDAMAGETheinitially observeddamagetothecontainment shieldwallwaslimitedtobentandsheareddowelsproject'ng fromthetopofthecylinderwallandasmallsurfacegougeontheexteriorwallface.Theinitially observeddamagewithintheReactorAuxiliary Buildingwasextensive andconsisted ofpenetraLion offloorslabs,shattered floorbeam,spalledconcrete, andbent.andsheareddowelsforcolumnsandwalls.Thelocationofderrickandboomsectionrestingpositions, anddetailsofobserveddamagetotheReactorAuxiliary Buildingarepresented onSketches, SK-2998-PG 75.01to75.06(Attachment).

Inadditiontothenoteddamageonthesketches, crackswereobservedonthesurf'aceofafewelevation

+43feetfloorbeams.Thesecrackswerech'ppedbacktodetermine depthandwereobservedtobeonlysurfaceshrinkage cracks.Inadditiontotheabovestructural damageintheReactorAuxiliary

Building, thefollowing isalistingofdamagedequipment andsupports:

,1)ConduitonElevation

+43feet2)Cabletrayrestraint onElevations

+43feetand+62feet3)4.16kVSwitchgear 2A3-1,2,3,4,5,6,7,84)StationServiceTransformer 2A2-5)480VSwitchgear 6)Pressurizer heaterbuses-2A3and2B3Thedestructive testingofreinforcing steelandnondestructive testingofconcretemembersproceeded inthefollowing sequencewithresultsasnoted:ReactorAuxiliary BuildinElevation

+62feet(floorslab,beams,girders,andsupporting columnandexteriorwall)..Allshattered andbadlycrackedconcreteofbeam3B3betweenColumnlines2RA1and2RA2andadjacentslabswereremoved.

IASSESSEDW~E(Cont'd)Samplesofexposedbeamandslabreinforcing were*removed andtestedby.Construction QualityControltodetermine ifASKSminimumrequirements weremetorifthereinforcing had'ecome overstressed uponimpact.Testresultsindicated thattheslabreinforcing (No.6and8rebars)metallASTi~frequirement andbeamreinforcing (Ho.9rebars)metallASMrequirement exceptpercentelongation whichindicated valuesaslowas3percentvsaminimumallowable of7percent.-Tocheckthefieldtestresults,samplesofthefieldtestedrebarsandadditional samplesofthebeamreinforcing weresenttotheArchitect/

Engineerforinvestigation andtensiletesting.Hicroscopic inspection ofthefieldtestedrebarsdidnotrevealtheelongated grainwhichtypifymaterialexposedtoplasticstrain.Tensiletestingoftworebarsamplesindicated thatallAS'Bfrequirements weremetexceptforelongation inonesample.Itwasnotedthatbothsamplesfailedatsurfaceindentations whichwerecausedbynicksandgougesduringconcreteremoval.Thetest-ingprogramconcluded:

1)Thereisnoevidenceofrebarstraining-due tothecranecollapse.

2)TheNewYorkOfficetestedrebarsfailedatthegouges(stressrisers}(Copyofthereportiscontained withinJBrodsky(EbascoMaterials Engineer) memotoLMPetrick{ChiefMaterials andWeldingEngineer) dated-12-18-79.

Foradditional information ontheeffectsofloadingofreinforcing steelpast-yield, theArchitect/Engineer requested fieldtensiletestingofreinforcing ofsamesize(No.9rebars)andheatnumberasinstalled inBeam383.Testingproceeded asfollows:1)Measurediameter, 2)Loadtoyieldpointandholdfor5-10sec,3)Slowlyreleaseload, 4)Measureelongation anddiameter, 5)Loadtoultimateand6)Determine elongation, ForallrebarstestedallASTi'!requirements weremet.Nondestructive testingofvisuallysoundconcretemembersadjacenttotheimpactareaindicated thefollowing:

1)Microcracking andlossofconcretebondtoreinforcement inthetopfourinchesofconcretewithinbeams3B2and3B4adjacentt;oimpactedBeam3B3,andinBeam3B3south.ofColumnLine2RA2.2),Microcracking inadjacentslabs.throughouttheonefootdepthandforadistanceof3;5feetpastbeams3B2and3B4.3)Microcracking onexteriorwallatsupportpointofBeam3B2foradepthoflessthanthreeinches.Todocumentvalidityoftestresults,nondestructive testingofconcretemembers-away fromthedamagedareawasalsoperformed andresultsindicated soundconcrete.

ReactorAuxiliaBuildin~Elevation

+43feet(beams,girdersandsupporting columns)Shattered andbadlycrackedconcreteofslabeastofcolumnlineRAGandbetweencolumnlines2RA2and2RA3wasremoved.Samplesofexposedslabreinforcing, wereremovedandtested,andwerefoundtomeetASTi'lminimumxequirements.

Nondestructive testingwasperformed onallbeamsonwhichaportionofthederrickhadcometorestandgirdersandsupportcolumnsadjacenttothedamagedconcreteslab(beams2B4-2B13betweencolumnslines2RA2and2RA3).Nomicrocracks weredetec'ted andanyvisuallyobservedsurfacecrackswerefoundnottoextendbeyondtwotothreeinchesindepth.

III.ASSESSEDDAHACE(Cont'd)ReactorAuxiliaBuildinWallsbetweenElevation

+19.5feetto+43.0feetNondestructive testingofnorthexteriorwallbetweencolumnlinesRABandRAEindicated microcracking inthetoptwotothreefeetforaportionofthewall.Nondestructive testingofinteriorwalloncolumnlineRAEbetweencolumnlines2RA2and2RA3,aroundanareawhichhadbeendamagedandunsoundconcreteremoved,indicated nomicrocracking.

ReactorBuildinzShieldWallNondestructive testing,performed atAzimuths70,130and160degreesbetweenElevations

+191.42and+186feet,indicated microcracking uptosixinchesbelowtopofwallforthecompletethickness.

Nondestructive testingaroundagougelocatedatAzimuth160degrees-.atElevation

+112feetindicated surfacemicrocracking forafoursquarefootareaontheoutsidefaceoftheshieldwall.Forcompletedescription ofnondestructive testingprogram,including technique andtestresultsforallareasinvestigated, seeifuenowandAssociates "FinalReportOntheNDEEvaluation ofConcreteDamageatStLucieUnitNo.2"whichisfiledatthesite;IV.CORRECTIVE ACTIONSActions-TakenFloridaPower&LightCompanyretainedCadcom,adivisionon<<fanTechofNewJerseyCorporation, toinvestigate thecauseofthederrickfailureandtomakerecommendations concerning theerectionofa.replacement derrick.TheCadcomReportconcludes thattheguyedderrickshouldhavewithstood thehurricane forcewindshaddifferent securingprecautions beentaken.In CORRECTIVE ACTIONS(Cont'd)addition, thereportrecommends minormodifications thatcouldbemadetofurtherenhance.thehurricane withstand capability ofthecrane.TheCadcomReportwassubsequently reviewedbyChicagoBridgeandIron(CBI),whodesigned, manufactured andsuppliedthecrane.CBI,concurred thattheCadcomReportprovidesareasonable accountofthederrickcollapse, andthattherecommendations forsecuringthederrickwhenhurricane windsareexpectedaretechnically sound."Following theirowndesignreview,andconsideration oftheCadcomReport'BI hasconcluded thatthefollowing actionsshouldbetakentosecurethereplace-mentderrickwhenhurricane windsareexpected:

l)Raisetheboomashighaspossibleandallowtheboomandmastto"weathervane."

2)Removethespreaderbeamfromtheboom.3)Fixthemast-tower swiveljointtothetowerwithboltsorweldedlugs.Aduplicate replacement derrickwillbeerectedatthesite,withinstallation commencing January7,1980..FloridaPower5LightCompany's equalityControlDepartment hadtheresponsibility topreparenonconformance reports(NCRs)wheredamageoccurredtocompleted con-struct>on activities (i.e.,afterconcreteplacement) orequipment.

TableIcontainsdispositioned NCR'ssummarizing categories ofstructural members,typesofdamageandcorrective actiontobetaken.Table2containsdispositioned NCR'ssummarizing theequipment damageandcor-rectiveactionbetaken.

IV.,CORRECTlVE ACTIONSTable3containsdesignchangenotifications'DCN's) whichwereissuedbytheArchitect/Engineer torepairdamagedconcreteandreinforcing asdeter-minedfromvisualobservations andfromtheresul'tsofthedestructive andnondestructive testingprograms.

CInvolvement Theprocedures'util'ized toidentifydamage,evaluateanddisposition corrective actionarethefollowing:

1)SiteQualityProcedure SQP-21"Corrective Actions"forthehandlingofNCR's.TheFloridaPower&LightCompany's QualityControlDepartment hasindependently reviewedthedamagedareasandissuedNCR'stoidentifydamagedareasandequip-ment.Theyfollow-up thecorr'ective actiondispositioned byEngineering andapplythenormaltestingandinspection-requirements forfinalapproval.

Inaddition'totheabovenormalQCinspection andapprovalprocessanddocumenta-tion>thestormdamageteamhasphotographed andmappedthedamagedareastopermitadditional documentation ontheextentofdamage.V.SAFETYGPLXCATIONS TheChicagoBridge&Ironderrickfailurecausedsignificant damagetotheReactorAuxiliary Buildingstructure whichrequiredextensive evaluation andrepairtoestablish theadequacyofthe,structure toperformitsintendedsafetyfunctionandmeetthecriteriaandbasesstatedinthePreliminary SafetyAnalysisReport.Ifitweretohaveremaineduncorrected, thestruc-turaldamagecouldhavepossiblyaffectedthesafetyofoperations oftheplant.VI.CONCLUSION TheChicagoBridge&Ironderrickfailurewasdetermined tobeapotentially reportable accidentonSeptember 4,*1579"andsuchnotification wasmadetothe

~~I~~VICONCLUSTON (Cont'd)NRCinspection andEnforcement Officethesameday.Priortoanyrepairworkornewconstruction intheaffectedareas,eachareawasspecifically evaluated forstructural soundness andrepairmeasuresapproved.

Adequatedocumentation onthestructural evaluation andrepairworkismaintained atthesite.Asaresultofthedispositioned corrective actiondescribed above,thedamagedportionsoftheReactorAuxiliary BuildingandReactorBuildingshieldwallhavebeenrestoredtooriginalstructural soundness.

Table1nedConcreteNCRsIssuedNCRs830C831C,841C,845C,846C,848C,850CCateoxiesCoveredbNCRInteriorwall.andprojectingreinfoxcing Columns,wallsandprojecting reinforcing TeofDamaeBentrebarsSpalledconcreteandbentrebarsinwalls-andcolumnsCorrective ActionRebendrebaxstooriginalpositions Chipconcreteback1'-6,cutoffdamagedrebarsandmechanically splicerebaxs835C832CColumnsandprojecting rein-forcingBentxebaxsWallandprojecting reinforcing Crackedconcreteandben"rebaxsChipback1ftintosoundconcreteandmechanically splice'ebars Chipconcretebacktospecified elevation forfullrebaxlapspliceandinstallnewxebars.836CforcingReactorShieldBuildingandpxojecting reinforcing 834CSlab,beamsandgirderatElevation

+62feet(RAB)851C,BeamsatElevation

+43feet860C(RAB)870CExteriorWall(RAB)842CSlabandgixdersatElevation

+43feet(RAB)833CColumnsandp'rojecting rein-Crackednear'loor levelMicrocracking attopofwall,andbentrebarsConcretemicro-crackinganddamagedxebarsSuperficial sur-facecracks.Superficial sur-facecracks..CxackedconcreteandbentxebarsChipconcretecolumandreplacedamgedreinforcing Chipback1ftintosoundconcreteandmechanically splicerebars.SeeDCN550.203and513.609NoneNoneChipconcreteandlapspliceslabrebarsan;.mchanically splicegirderrebars.

tTable2Disositioned Electrical NCRsIssuedNCRsEuiomentCoveredbNCRDisosition839E84QEConduitsonElevation

+62feetRemovedamagedconduitandreplacewithnew838EElectrical Equipment Scrapandreplace837ECabletrayrestraints onElevations

+43feetand+62feetTworestraints aretoberepairedbyConstruction towithinAISCtolerances.

Balancetobescrapped.

Table3ConcreteDCNsIssuedDCNs550.203513.609CatepriesCoveredbDCNSlab,beamsandgirderatElevation

+62feet(RAB)eofDamaeConcretemicrocracking anddamagedrebarsCorrective ActionRemoveconcreteandrebars,andlapspliceandmechanically spliceasspecified.

550-208Wall(RAB)Concretemicrocracking Chipbackintosoundconcreteasspecified 550-207SlabElevation

+43feet(RAB)'rackedconcreteanddamagedrebarsRemoveconcreteandrebars,andspliceasspecified.

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