ZS-2012-0519, Additional Information Supplementing the Request for Amendment to Approve Methods of Analysis, Use of the Upgraded Fuel Handling Building Crane System as a Single-Failure Proof Crane and Approval of NUREG-0612 Compliant Heavy..
| ML12359A020 | |
| Person / Time | |
|---|---|
| Site: | Zion File:ZionSolutions icon.png |
| Issue date: | 12/20/2012 |
| From: | Daly P ZionSolutions |
| To: | Document Control Desk, NRC/FSME |
| References | |
| NUREG-0612, ZS-2012-0519 036675-23, ZION001-CALC-034 | |
| Download: ML12359A020 (11) | |
Text
ZIONSOLUTIONSLC AnEnergySoludon. Company 10 CFR 50.59 10 CFR 50.90 December 20, 2012 ZS-2012-0519 U.S. Regulatory Commission ATTN: Document Control Desk Washington, DC 20555-0001 Zion Nuclear Power Station, Units l and 2 Facility Operating License Nos. DPR-39 and DPR-48 NRC Docket Nos. 50-295 and 50-304
Subject:
Additional Information Supplementing the Request for Amendment to Approve Methods of Analysis, use of the Upgraded Fuel Handling Building Crane System as a Single-Failure Proof Crane and Approval of a NUREG 0612 Compliant Heavy Loads Handling Program.
Reference:
- 1. ZionSolutions, LLC Letter, Daly to NRC, "Request for Amendment to Approve Methods of Analysis, use of the Upgraded Fuel Handling Building Crane System as a Single-Failure Proof Crane and Approval of a NUREG 0612 Compliant Heavy Loads Handling Program," dated October 25, 2012 ZionSolutions, LLC (ZionSolutions) submitted Reference 1 to request that the NRC amend the ZionSolutions licenses to allow for use of an upgraded Fuel Handling Building Crane as a single failure proof crane in accordance with the applicable criteria listed in NUREG-0554 "Single-Failure-Proof Cranes for Nuclear Power Plants" and to any applicable criteria as listed in NUREG-0612 "Control of Heavy Loads at Nuclear Power Plants: Resolution of Generic Technical Activity A-36" Appendix C."
In that letter ZionSolutions identified that there was an ongoing analysis of the existing rail clips on the Fuel Handling Building crane runway rails. The analyses results indicated that the rail clips would be overstressed during the safe shutdown earthquake (SSE, also referred to as the Design Basis Earthquake or DBE) if the crane is loaded to its maximum critical load. A modification to the runway clip arrangement has been designed and analyzed to demonstrate acceptability of the ZionSolutions crane during a seismic event with full load. The design of the clip and analysis summary are provided in Attachment 1 to this letter. Please consider this information as the supplement to Reference 1 to progress the staff's review.
During additional review of the crane clip analysis, conducted by the Architect Engineer, it was found that the existing runway girder splice connections to the Fuel Handling Building (two places, one on each runway) would be overstressed during SSE if the crane is loaded to its maximum critical load. A modification to these connections will be installed to reduce seismically-induced stresses to within code allowable limits. A summary of the calculation and details of stresses in the modified connection will be provided upon completion of the detailed calculation package.
101 Shiloh Boulevard, Zion IL 60099 (224) 789-4016
- Fax: (224) 789-4008
- www.zionsolutionscompariy.com
ZionSolutions, LLC ZS-2012-0519 Page 2 of 3 During a separate review of calculations by ZionSolutions as preparation for the crane site acceptance test, it was discovered that one calculation performed by the equipment vendor, under contract to ZionSolutions, contained an error. Calculation No. 036675-23, "Main Hoist Reeving Stress" has been corrected. No change in the calculation summary description that was provided in the earlier letter is needed, however the calculated stress values and the allowable stress values for the upper block have changed from the original submittal, but remain within the code acceptable limits. The differences from the original submittal are provided in Attachment 2.
The information on the rail clip modification and revision to the main hoist reeving stress results are being provided in this letter to allow the NRC review to continue, until the remaining information is available. The runway girder splice analysis summary and design of any modifications will be provided when available.
ZionSolutions is reviewing these occurrences, as well as other data from our Corrective Action Program to assess the extent of condition. Approximately 85 per cent of the design activities are complete with respect to the ISFSI Project. Accordingly our efforts will include the following actions.
- An assessment of the actions of each of the contractors involved to determine whether the corrective actions taken to date by each company are sufficient and complete. Based on that assessment:
o Evaluations will be performed to determine if additional compensatory actions should be taken prior to delivery of the remaining design products; and o Determine if additional reviews must be performed of the previously completed design products.
- An assessment of the effectiveness of the ZionSolutions program that reviews design and determination if additional actions are needed for past design products or for new products.
An update of the actions taken during these reviews and the results will be provided when available, but no later than January 18, 2013.
The License Amendment Request provided in Reference 1 will be updated through page changes, with the information contained in Attachments 1 and 2 as well as the design arrangement and analytical information for the modification associated with the runway girder splice, once the girder splice information is available and our evaluation of these design errors is fully evaluated.
ZionSolutions is notifying the State of Illinois of this request for change to the operating license by transmitting a copy of this letter and its attachments to the designated State Official.
Patrick Daly Senior Vice President ZionSolutions, LLC
ZionSolutions, LLC ZS-2012-0519 Page 3 of 3 cc: John Hickman, USNRC Senior Project Manager Service List Attachments: Affidavit Attachment 1: Crane Rail Clip Modification Description and Analysis Summary Attachment 2: Main Hoist Reeving Stress Modification of Upper Block Stress Results
Zion Nuclear Power Station, Unit 1 and 2 License Transfer Service List cc:
Patrick T. Daly Thomas Magette Senior VP and General Manager Senior VP Nuclear Regulatory Strategy ZionSolutions, LLC EnergySolutions 101 Shiloh Boulevard 6350 Stevens Forest Road, Ste. 2000 Zion, IL 60099 Columbia, MD 21046 Patrick Thurman, Esq. Russ Workman VP Regulatory Affairs, Licensing & General Counsel Document Control EnergySolutions ZionSolutions, LLC 423 West 300 South, Ste. 200 101 Shiloh Boulevard Salt Lake City, UT 84101 Zion, IL 60099 Illinois Department of Nuclear Safety Gary Bouchard Office of Nuclear Facility Safety VP Engineering, Ops & Nuclear Security and 1035 Outer Park Drive Decommissioning Plant Manager Springfield, IL 62704 ZionSolutions, LLC 101 Shiloh Boulevard Kent McKenzie Zion, IL 60099 Emergency Management Coordinator Lake County Emergency Management Agency Alan Parker 1303 N. Milwaukee Avenue President Projects Group Libertyville, IL 60048-1308 EnergySolutions 1009 Commerce Park Drive, Ste. 100 Regional Administrator Oak Ridge, TN 37830 U.S. NRC, Region III 2443 Warrenville Road John Christian Lisle, IL 60532-4352 President of Logistics, Processing and Disposal (LP& D) Group John E. Matthews EnergySolutions Morgan, Lewis & Bockius LLP 1750 Tysons Boulevard, Suite 1500 1111 Pennsylvania Avenue, NW Mclean, VA 22102 Washington, DC 20004
STATE OF ILLINOIS )
)SS COUNTY OF LAKE )
Patrick T. Daly, being duly sworn according to law deposes and says:
I am Senior Vice President and General Manager of ZionSolutions, LLC, and as such, I am familiar with the contents of this correspondence and the attachments thereto, concerning the Zion Nuclear Power Station, Units 1 and 2, and the matters set forth therein are true and correct to the best of my knowledge, information, and belief.
Subscribed and Sworn to before me this ,* _da 2012 Notary Public of Illinois LINDA CHOU OFFICIAL SEAL Notary Public, State of Illinois My Commission Expires December 07. 2015 Crane Rail Clip Modification Description and Analysis Summary Crane Rail Clip Modification Description and Analysis Summary Calculation, ZIONOO 1-CALC-034 Fuel Handling Building (FHB) 125 Ton Crane Rail Clip Modification and Rail Evaluation In the Seismic Analysis Summary section of the License Amendment Request a new section "h."
will be added. This section will provide the calculation summary that describes the analysis of the bridge runway rail and rail clips following addition of the modified rail clips. This modification will be completed prior to use of the crane as a single failure proof crane. Drawings associated with the rail clip design and the placement of the rail clips on the runway girder are included as part of this attachment.
The addition to the License Amendment request is provided below:
- h. Calculation ZIONOO1-CALC-034, Fuel Handling Building (FHB) 125 Ton Crane Rail Clip Modification and Rail Evaluation Summary: Calculations performed in calculation ZIONOO 1-002, Appendix B, demonstrated that the original runway rail and rail clip design is not adequate for the new design basis load case for a seismic event with a load on the hook. This new calculation evaluates the proposed rail clip modification and the runway rail with the proposed modification installed.
Model/Methodology
Description:
Simplified hand calculations are used to design a new crane rail clip assembly using MathCad 15. Governing crane wheel forces at the top of the crane rail for all crane and trolley positions for each of the load combinations from Attachment 56 of Ref. 3.7 are considered in. the calculation for the new rail clip design.
As-built survey data of the crane runway rail determined the maximum existing clip center to center spacing to be 2ft.-7in. The majority of the existing clips are 2 ft.-0 in.
center to center spacing. The new rail clips will be installed between two existing rail clips providing generally the same center to center spacing (2 ft. -0 in.) as the existing design. Conservatively, the new clips are designed for full wheel forces applied to a single rail clip without relying on the distribution of forces to the adjacent existing clips providing unanalyzed margin.
When a horizontal seismic load from the crane wheel is applied to the head of the crane rail, the force is decoupled into a bearing force on one edge of the crane rail base (bottom flange) along with the corresponding shear force and an uplift force on the opposite edge of the crane rail base (bottom flange). There are rail clips on each edge of the base (bottom flange) of the crane rail. Therefore each clip will either see force from shear with corresponding bearing or force from uplift. No credit is taken for friction between the bottom flange of the rail and the girder. On the bearing side, clips and bolts are designed for the applied shear force. On the uplift side rail clips and bolts are designed for the bending moment due to the rail bearing on the rail clip support.
The crane rail is checked for the applied forces for web shear, web bending and local rail base (bottom flange) bending.
The rail clip is connected to the top flange of the bridge runway girder. A local stress check of the crane runway girder flange for the applied rail clip forces is also performed.
Crane girder global analysis for the applied new rail clip forces is not within the scope of
Attachment I Crane Rail Clip Modification Description and Analysis Summary this calculation. Calculation ZIONOO1-CALC-002 (Ref. 3.7) describes the crane runway girder analysis.
Assumptions: Assume existing 175 lb crane rail is 50ksi material. Per documentation attached to the calculation, minimum yield stress for rail head, rail web and rail base (bottom flange) for controlled cooled crane rail range from 65ksi to 90 ksi. Therefore, this is a conservative assumption and does not need to be verified.
Results: The highest loads and stress values along with allowable values are listed below. Note there are two clip styles; Clip 1 is the standard clip, Clip 2 is located at column tie-backs. The values below are for the limiting clip style for each load type.
Component/Load Description Load/Stress Allowable Bending in clip due to uplift (Clip 2) 34.516 ksi 37.5 ksi Shear in clip due to uplift at reduced 7.055 ksi 20 ksi section (Clip 1)
Bearing in clip at bolt location (Clip 1) 23.383 ksi 45 ksi Block shear in clip (Clip 2) 72.34 kip 85.55 kip Bolt Tension (Clip 1) 17.515 kip 53.7 kip Bolt Shear (Clip 1) 36.17 kip 39.8 kip Girder flange local bending due to 5.015 ksi 27 ksi tension in clip Girder flange local bending due to 25.973 ksi 27 ksi compression Girder flange local bearing 14.289 ksi 32.4 ksi Girder flange local block shear 72.34 kip 299.334 kip Crane rail local web shear 9.114 ksi 20 ksi Crane rail local web bending 32.427 ksi 37.5 ksi Crane rail minor axis bending 31.325 ksi 37.5 ksi Crane rail bottom flange local bending 20.094 ksi 37.5 ksi Main Hoist Reeving Stress Modification of Upper Block Stress Results Main Hoist Reeving Stress Modification of Upper Block Stress Results Calculation No. 036675-23 Main Hoist Reeving Stress In the Seismic Analysis Summary section 4. g. titled "Calculation No. 036675-23 Main Hoist Reeving Stress" in the License Amendment Request (Calculation Summary located on page 28 and the Table located on page 29), the analysis description is unchanged. However, upon correction of the calculation related to the upper block, the limiting load case has become the broken rope load case with limiting stresses located at Equalizer Frame plate 2. As a result the acceptance criteria and results have changed but remain within code allowable limits. The table listing the results for the Upper Block is provided in both strike-out form as well as smooth form as it will be inserted into the Licensing Amendment Request revision.
The first table below provides the strikeout version showing differences between the Table submitted on October 25, 2012 and the updated calculation. Insertions are shown in red and shaded, deletions are shown in strikeout. The second Table shows the Table with revisions incorporated.
Strikeout Table from Calculation No. 036675-23, Main Hoist Reeving Stress Upper Allowable stresses are per NOG- 1 Table 4311-1 or NUREG-Block: 0612/0554. The ihmitlng values listed below are from the erational broken rope load case, which was moree limiting that the broken rope evaluiation due te the festriefivc allow~able stresscs Calculated Stress Allowable Stress Max. Bending or Normal Stress ksi j4.-.2 - 7 ksi (Equalizer Frame Plate4-2)
Max. Shear Stress (Tearout at 6-2-7Fl4 94 ksi 9-62=265 ksi Equalizer Frame Plate 4-2 Hole)
Max. Weld Stress (Equalizer 8-2-5 ksi 49i2Yi3 ksi Frame Plate 4-2)
Main Hoist Reeving Stress Modification of Upper Block Stress Results Smooth table from Calculation No. 036675-23, Main Hoist Reeving Stress Upper Allowable stresses are per NOG-1 Table 4311-1 or NUREG-Block: 0612/0554. The limiting values listed below are from the broken rope load case.
Calculated Stress Allowable Stress Max. Bending or Normal Stress 34.25 ksi 37.50 ksi (Equalizer Frame Plate 2)
Max. Shear Stress (Tearout at Equalizer Frame Plate 2 Hole)
Max. Weld Stress (Equalizer 15.27 ksi 28.35 ksi Frame Plate 2)