ML17258A903

Requests That Ofc of Nuclear Reactor Regulation Evaluate Containment Tendon Surveillance Test Results to Determine Need for Addl Licensee Action

ML17258A903
Person / Time
Site:	Ginna
Issue date:	11/30/1979
From:	Jordan E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:	Shao L Office of Nuclear Reactor Regulation
Shared Package
ML17258A902	List: ML17258A901 ML17258A903
References
REF-SSINS-9124 NUDOCS 8103260387
Download: ML17258A903 (53)

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UNlTfD STATES NUCLEAR REGULATORY COMMISSION WASHINGTON,D. C. 20555 NOV S0 1979

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ENCLOSURE 2 SSINS 49124 Docket No. 50-244 MENORAHDUtl FOR:

L. C. Shao, Acting Assistant Director for Engineering

Programs, Division of Operating

Reactor, NRR FROtl:

SUBJECT:

F. L. Jordan, Assistant Director for Technical

Programs, Division of Reactor Operations Inspection, IE CONTAINYIENT TENDON SURVEILLANCE TESTING AT GINNA In October 1979, Rochester Gas and Electric performed containment tendon sur-veillance testing at Ginna Nuclear Power Plant (A/E - Gilbert Associates).

This testing was done in response to questions raised during an IE investigation regarding the adequacy of the concrete in the containment structure and the licensee's concern regarding the marginal acceptability of thq previous tendon tests done in 1977.

The 1977 tests showed an average prestress (14 tendons) of 60.2% of the ultimate strength, whereas by Technical Specifications Section 4.4.2.2.a the minimum average prestress limit is 60%.

The recent October 1979 tendon liftofftest results indicated an average prestress of 59.8% (by the shim method).

The average prestress valve is based on 22 tendons

{expanded sample), with 14 of the 22 tendons having been previously tested.

Tihe licensee's description and evaluation of the test results are enclosed.

The two testing methods to measure tendon liftoffwere by sounding and by removal of a 0.032 inch shim.

The shim method, considered a more con-sistent test, was to verify the data obtained in previous tests which used the sounding method.

The two testing methods seemed to correlate well, with the sounding method giving results about 0.5% to 1% lower than by the shim method.

It appears that the 12% relaxation of the tendons over forty years assumed by Gilbert Associates may not have been accurate.

The cause of the low tendon liftoffvalue has not yet been determined.

Currently, a retensioning program.

is being formulated and as of yet no schedule has been proposed.

We request that NRR evaluate the test results to determine the need for additional licensee action, to evaluate the acceptability of the licensee s retensioning

program, once it has been defined, and to determine the need for any change to the Technical Specifications.

From discussions with B,. D. Liaw, EB, we understand that the test results at Ginna will be factored into the generic study of containment tendon surveillance testing and the associated draft CONTACT:

H. J.

Wong, TP 49-28180

C L. C. Shao Regulatory Guides 1.35, Revision 3 and 1.35.1.

Me recommend that the NRC be involved in the early stages of the licensee's retensioning program to assure that any NRC concerns are adequately addressed.

lP staff is available to discuss the findings to date on tendon relaxation.

Me request a response describing your planned actions to this request in order that we may closely follow any licensee site activities in response to NRR'actions.

Enclosure:

Ltr. Mhite to Gner dated October 18, 1979 ard ordan, Assistant Director for e

nical Programs Division of Reactor Operations Inspection cc; w/encl osure N. C. Hoseley, IE R.

E. Shewnaker, IE E. J. Brunner, RI (AITS F01004794)

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obtained for the John Holfis Bankhead Dam, Warrior River, Alabama, also confirm the conservatism of a bond development length developed on the basis of the average bond stress of l70 psi between grout and rock.

The diameter of the drilled hole for each rock anchor is 6 inches.

The

~assumed breakout angle of 45'o the vertical is most conserv'ative as demonstrated during the reduced scale rock anchor test,, and in Reference 8.

Weight of rock in kips per ft. circumference ~'0.096d 2 Internal Pressure in kips per ft. circumference 0.072 d (2r - d)

The depth d ~ 26.5 ft., was established based on'preliminary design.

No surcharge beyond the internal pressure of the containment vessel was considered to be effective in determining the rock anchors hold-down capability.

Therefore, for varying internal pressures the rock hold>>

down capacity uniform around the circumference of the. vessel, is as'ollows:

Internal Pressure

( si )

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. 75 90 Rock Hold-down Capacity (kips per ft.

circumference) 67.4 240.4 266.4 283.7 327'0

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For the combination nf operating plus incident loads (i.e.

Load Combination (a) in S~ ctinn 5.1.2.3),

th>> uplift per Coot circumference is constant at 259.0 kips per ft., less than the <<ssumed rock anchor capacity of 327.0 kips pot Et.

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For the combination of operating plus incident plus design earthquake

'oads (i.e.

Load Combination (b)), the maximum uplift per foot circumference, is 274.1 kips per ft. and thd minimum is 150.5 kips per ft.

This considers horizontal and,vertical components of ground

-motion occurring simultaneously and their effects added algebraically.

Due to the group action of anchors, the overcapacity of the rock against lateral loads can be represented by the factor of safety against overturning.

This factor, using the rock hold-down capacity based on the pressure load of 75 psig, is 2'.38.

0 For the combination of operating plus incident plus maximum potential earthquake loads (i.e.

Load Combination (c)), the maximum uplift per foot circumference is 289.2 kips per ft. and the minimum is 25.4 kips per ft.

The factor of safety agaLnst overturning again using the same consideration is 1.96.

Consideration was also given for seismic loading without internal pressure.

For the O.lg ground motion (vertical and horizontal components considered to occur simultaneously and the effects added algebraically) there is no uplift.

Hinimum dowhward component is 0.9 kips per ft.

~ The factor of safety against overturning is 4.62.

For the 0.2g ground motion (vertical an/, horizontal components considered to occur simultaneously and the effects added algebraically) the maximum uplift is 69.2 kps per ft.

The factor of safety against overturning is 2.31.

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"Grab"'amples are taken periodically at the batch plant, upon delivery of cement.

Each sample is tested by the Testing Laboratory for conformance to ASTH C 150, and the results are also compared with"%he certificate supply with each delivery of cement.

Elastometer Bearin Pads Tests are performed on elastomer specimens to ensure compliance with 1I requirements for (1) original physical properties including tear resistance,

hardness, tensile strength and ultimate elongation, (2) change in physical

~l properties due to overaging, (3) extreme temperature characteristics, (4) ozone cracking resistance, (5) oil swell and (6) shear modulus.

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addition, two full size pads are tested, one for creep and one for ultimate load.

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1 is initially placed under essentially Q constant compressive load of 1000 psi (the design pressure) for four days to measure creep.

This pad is then loaded up to 2000 kips (5.3 times. design load) when the test was terminated without failure.

Specimen No.

2 was similarly loaded up to 2000 kips without failure.

The rebound of the pads after tha 2000 hip load was removed is essentially complete.

A summary of the test results is shown in Figures 5.6.1 3 and.'5.6. 1>>4.

Rock Anchor Tests a

Three scaled down test rock anchors were installed to demonstrate f first tbe hold-down capacity of the rock and second the capacity of the bond between, rock and grout.

C 5.6. 1>>4 4/69

Two tests were made on rock anchor "A" which was installed at the center of the proposed containment vessel.

The first test, called test A-1 was to determine rock hold-down capacity.

The set-up for test A-1 is illustrated in Figure 5.6.1-5.

The beam support piers were located beyond the assumed influence circle of rock h'aving a diameter of 23 feet 6 inches.

An independent frame wad erected to obtain defi.ection measurements on the concrete pier at the.anchor.

This placed all supports for lifting as well as measuring devices outside the influence circle of rock.

Dial gauges were used to measure the movement of the concrete pier and the anchor head.

The test load was'pplied with a 150 ton pack mounted on the beams spanning the'.

test anchor.

Measurements of the packing force were made with a dynamometer, calibrated immediately before the test.

The second test on rock anchor "A" (Test A-2) and the tests on rock anchors "B" and "C", also installed near the center of the proposed containment vessel, were made to demonstrate bond capacity.

The set-up for test A-2 and for rock anchors "B" and I

"C" was an arrangement whereby the pack was supported directly by the concrete pier adjacent to th'e test anchor.

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5.6.1-4a 4/69

Rock <<nchor 1

a length of

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~,rnncad for 4 feet. 5-1/2 inches in a 3-1"/2 inch diameter hole.

All test rock anchors were oversized so that the test load of 100 kips would develop only about 30/ of the u]ttmate capacity of tendon wires whil>> dvvelnpi,ng a bond stress of 170 psi which is the design stress for the. containment rock anchors.

This permitted testing bond

-tresses well in excess of design (170 psi) without exceeding ultimate wire stresses.

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zr'he test procedure for test A-1 was as follows:

I Tbe anchor was loaded in 20,000 pound increments to 100,000 pounds.

The 'load was maintained.at each increment for 15 minutes prior to taking measurements for elongation of the tendon and clevations of the concrete pedestal and

'djacent rock surface.

Because the anchor heyd appeared from visual observation

'o not have lifted off at the 100,000 pound'load, the load was increased to 110,000 pounds at which point liftoff was apparent.

Subsequent review of measurements on the movement of the anchor he'ad indicate that actual lift off

~

occurred between 80,000 pounds and 100,000 pounds as would be expected.

In test A-2, "B"'and "C"; tendon was jacked from.the concrete pier immediately

.adjacent to the tendon.

Table 5.6.1-1 lists measurements taken during test A-1.

figures 5.6.1>>6, 5.6.1-7 and 5.6.1-8 show plots of load's.

elongation deflection for all tests.

. The application of' test load of 110 kips to rock anchor "A" (as. indicated by the results of test A-1 shown on Figure 5.6.1-6) is equivalent to 137.5X'f the calculated hold-down capacity assumption used in the"design is valid.

The plot of load vs. elongation deflection for rock anchor "A" tests A-2

'see Figure 5.6.1-6) and "B" and "C" (see Figures 5.6.1-7 and 5.6.1-8) indicate a factor of safety against slippage by the grout and rock of at least 2.0 (200 kip load vs.

100 kip design load) for r'ock anchor "B".

Xf slippage occurred within the grout the factor of safety against failure is even greater.

'The plot of load vs. elongation for rock anchor "A" shows an apparent dis-continuity which is indicated by a dashed line on Figure 5.6.1-6.

This represents settlement of the concrete pier adjacent to the rock anchor when the load was transferred from the lifting frame used in test A-1 to the lock'ut which bears

'on the concrete pier.

~

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5.6.1-5

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TEST A I Irl MOVEMENT OF PIE IIIIMOVEMENT OF TENDON NFAP

~ ~

z 120 100 80 AO 20 II I

o o"

o" ROCK ANCHOR "AM TEHDOtl:

20-1/4" y HIRES ULTIt1ATE TEHDOH LOAD = ?40 (1.372)

~ 330 HAX. OVERSTRESS LOAD = 0.8 (330)

= 264 TOTAL TEHOOt< LEHGTH = 12'- 8-3/4" EFFECTIVE DEPTH OF 'GROUT ~ 4' 5-1/2" 0

0 II liA INCNES ~ DEFOIIMATION I5 IS

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~I 280 260 80 IM = 26'4 2iO 220 200 SEE NOTE I80 160 o lao 0

120 100 80 ROCK AHCHOR "8" TEHDOH:

28-1/4" y WIRES ULTIfQTE TEHOOH LOAD ~ 330 HAX. OVERSTRESS

~ '0.8 (330)

~ 264 TOTAL TEHOOH LEHGTH ~ 13' 2-1/2" EFFECTIVE DEPTH OF GROUT ~ 5'-5" n

Rl Q O~

Xnm m ~

-I m I

60 40 20 NOTE:

JACKING FORCE INCREASED TO 208 WHEN SLIPPING OCCURRED-AND STOPPED WITH A TOTAL EI.ONGATION OF 2 II/ I6" AND A JACKING FORCE OF. I9S o JACKING WAS HALTED TO AVOID POSSIBLE DAMAGE TO JACK.

~A 1

I 'A INCHES <<DEFORMATION h

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240 240

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IN IHCHES DEFDRMA'flDH III 1%

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28-1/4" y WIRES ULTINATE'EHDOH LOAD ~ 33P"

'X.

OVERSTRESS

~ 0.8 (33O)

= 264k TOTAL.TEHDOH LEHGTH ~ 14' 8-3/4" EFFECTIVE OEPTH OF GROUT ~ 4' 5-1/2"

Gilbort Associates, fcc.

r RaadIng,PannaTIvanIa ANALYSIS/CALCULATION SUBJECT WOmE S~~ ~~78 REVe 0

MICROFII MED ORIGINATOR g~

DATE i/Qig//

CISIO PAGF OF PAGES

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STATUS OF TENDON LOSS EVALUATION POSSIBLE CAUSES - ELIHINATED Tendon Thermal Expansion due to Ambient or Local Temperatures (penetrations) eliminated by calcu-lations.

2.

Out-of-Calibration of Stressing Ram and Pressure Gauge.

3.

Rock Failure 4.

Rock Creep 5.

Rock Anchor Failure 6.

Procedure for Determining Lift-Off POSSIBLE CONTRIBUTORS STILL UNDER CONSIDERATION l.

Elastomeric Pad Creep 6% Overstress Effect.

3.

Tendon Hire Stress Relaxation Properties 4.

Effect of Hydraulic System on Ram and,Gauge Calibration Values.

5.

Summer Versus Hinter Lift-OffTests.

SUBJECT CIS ID PAGE Gilbert Associates, inc.

ReadIng, Dennaylva nla ANALYSIS/CALCULATlON RKV MICROFII MKO ORIGINATOR OATK 0

OF PAGES

~ 6' 7aitJZO~J ZoSS WV'Aau<r~OW I

Couc~uSioeS nW MCa rOuZ Pace Re'CAn85 I

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II 4

ROCK AND ROCK ANCHORS Investigation into the reason for the tendon losses has included the rock anchors and whether they have experienced a loss of function.

Based on the results summarized below, it is concluded that the rock anchors are functioning properly.

Rock 1.

Under all the loading conditions on the rock and rock anchors to date, there has always been a downward force on the rock, in close proximity to the rock anchor.

This force is equal to or greater than the upward force on the rock exerted by the rock anchor.

Therefore, the resultant force at the base of a hypothetical break-out wedge of rock is compressive.

Consequently, no upward forces would have existed to precipitate break-out of the wedge.

2.

During stressing of the rock anchors, survey instruments were used to measure any changes in e1evation of the rock top surface which might occur.

No changes in elevation were observed.

Consequently, no rock movement occurred.

Bond 3

Tests on small scale (28 wire) versions of the rock anchors are reported in the FSAR, Section 5.6.1.

These tests demonstrate that the average bond stress of 170 psi between the grout and rock used in the design is conservatively low.

This value established the first stage grout depth of 22 ft, and an average bond stress of 170 psi is calculated to exist during the tensioning of the rock anchors t'o 0.80 GUTS.

However, from the test results reported in the FSAR, an average bond stress of 340 psi was developed without any significant slippage, and a bond stress of 4SO psi was developed and sustained the maximum applied test force.

June 1980 Tests on Rock Anchors

-In the June 1980 retensioning, 133 of the 160 tendons were stressed to 0.735 GUTS.

This force had to be resisted by the rock anchors.

Consequently, the tendon re-I tensioning also constitutes a test on the rock anchor.

The el,qpgations of the wall tendon, measured at its upper anchor head, are a combination of (1) the wall tendon strains times the tendon length plus (2) the movement, if any, of the upper anchor head of the rock anchor.

The measured elongations agreed closely with those predicted based solely on the wall tendon strains.

These results indicate that the rock anchors developed a force of 0.735 GUTS with no perceptible slippage or move-ment of their upper anchor head.

l t

~

~

TABLE 1 GINNA FORCES AND ELONGATIONS FOR RETENSIONED TENDONS Sheet 1 of 4 TENDON I.D.

NO+

LIFT-OFF FORCE Ki s)

FINAL LOCK-OFF FORCE (KX s)

(in)

CALCULATED MEASURED ELONGATION 1

2 3

4 5

6 (b) 78(b) 9 10 11 12 13 14 15 16 17(b) 18 (b) 19 20 21 22 23 24 25 26 27 28 29 30(b) 31 32(a) 35(a) 36(a) 37 (a) 38(a) 39(a) 40( )(b) 41 42 43 44 45(b) 618 626 633 618 614 618 626 603 603 633

.610 629 580 584 626 633 611 580 603 611 626 603 588 565 618 603 603 603 580

'609 596

. 648 603 596 596 569 633 773 758 769 765 765 769 758 769 758 758 761 758'61 758 769 758 776 773 761 773 765 754 750 761 761 769 769 765 769 761 754 765 769 758 76a

'50 765 1 13/16 1

9/16 1

5/8 1

3/4 1

7/8 1 13/16 1

5/8 2

1/16 2

1 11/16 1

5/8 1

5/8 2

1/8 2

1/8 1

1/2 1

5/8 13/16 1 as/16 1 15/16 1 13/16

'1 ll/16 1

7/8 3/8 2

5/16 I 13/16 2

3/16 2

1/8 2

2 a/4 2

2 1

9/16 2

1/16 2

1/8 2

1/8.

1/4 1 ll/16 1 11/16 1

5/8 1

9/16 1 11/16 1

3/4 1 11/16 1

5/8 1

7/8 1

7/8 1

9/16 1 13/16 1'/16 2

a/16 2

1/16 1

5/8 1

9/16 1

.3/4 2

1/16 1

7/8 1

3/4 1

5/8 1

7/8 2

2 1/4 1 11/16 1

7/8 1

7/8' 7/8 2

1/16 1 13/16 1 15/16 1

3/8 1

7/8 1 15/16 1 15/16 2

3/16

• 1 9/16

TABLE 1 (Continued)

TENDON I.D.

NO.

LIFT-OFF FORCE Ki s FINAL LOCK-OFF FORCE Ki s in MEASURED CALCULATED ELONGATION(d) 46 47 48(b)

'49 50(b) 51(b) 52 53(b)

S4 55 56( )

57 58(b) 59 60(b) 61 62 63 (b) 64

'5 66

. 67(b) 68 69 70 71 72 73 (e) 74 75(b) 76(b) 77 78 79 80 81 82 83 (b) 84(")

85 86 87 88 89 90 91 92 603 626 558 569 603 588 584 596 565 603 607 573 580 596 645'96 573 573 606 595 618 877 596 618 599 580

~ 475

'65 565 596 580 595 595 599 591 603 576 625 603.

614 595 618 603 603 606 769 758 746 754 765 765 758 761 761 754 769

'54 761 761 769 773 769 761 768

.761 753 761 761 761 768 765 (c)

746, 761 754 761 753 746 768 768 753 753(c) 753 761(c) 746 (c) 768 757( )

'72 757 750(c) 772 1 11/16 1

7/16 1 iS/ae 1 11/16 1

7/8 z

1/4 2

5/16 2

1/8 2

5/16 1 al/16

. 1 9/16 1

3/4 3/16 2

1 7/16 2

2 3/8.

2 5/16 1 13/16 1 13/16 1 ll/16 Z

3/16 2

1/16 1 ll/16 2

a 7/8 a/4 1 13/16 z

7/16 2

1/8 2

1/8 a/8 2

1/16 2

1/8 2

5/16 1 ll/16 1 15/16 1 15/16 z

1/8 1

5/8 1 15/16 2

1/8 1 15/16 7/8 1

5/8 2

5/16 2

3/16 1

7/8 2

2 1/16 1 15/16 2

1/4 1

7/8' 13/16 2

3/16 2

1/16 1 15/16 1

7/16 1 15/16 2

3/16 2

3/16 1 13/16 1 15/16 1 11/16 2

1/8 1 15/16 1 ll/16 7/8 2

1/16 3

3/16 2

1/4 2

1/4 1 15/16 2

1/16 1 15/16 1 15/16 1

7/8 2

1 7/8, 2

1/8 1'/8 1 7/8 1

3/4 1 15/16 1 11/16 1

7/8 1

7/8 1 13/16

TABLE 1 (Continued)

Sheet 3 of 4 TENDON I.D.

NO.

LIFT-OFF FORCE Ki s FINAL LOCK-OFF FORCE Ki s (in)

CALCULATED MEASURED ELONGATION( )

93 94 95(b) 96(b) 97 98 99 100(b) 101 102 103 104 105 106(b) 107.

108 109 110(b) 111(<)

aa2(e) 113 (e) aa5(

)

aa6(e) 117(')

11S(e) aa9(e).

120( )

121 (')

122 (e>>

123 1.4(b) 125 126(e) 127

'128 129 130(b) 131 133 (b) 134 135 136 137 13S(b) 139 140(b) 603 618 648 625 625 603 610 610

'14 618 599 610 621 633 625 618 603 633 580 588 629 603 625 573 629 621

~ 610 580 595 569 580 595 603 640 584 761 761 772 761 753 746 746 753 (e) 746(c) 768 757 753 746 (e) 746 761 753 750 753 757 753 768 761 753 753 768 768 757 753 753 757 753 753 761 765 7/S 3/4 1

a/p 3/4 1 ll/16 1

7/8 1 13/16 1

7/8 1 15/16 3/4 2

1/16 1

5/8 1 11/16 1

5/8 3/4 1

5/8 1 15/16 7/16 7/S

,1 7/8 1

1/8 1

7/16 1

1/16 2

3/16 9/a6 1 13/16 1

7/8 2

1/16 2

2 3/16 2

3/16 2

1 7/8 3/8 2

3/16 2

2 1/16 9/16 1

7/8 1

5/8 2

3/16 1

9/16 1 11/16 1

3/4 2

1/16 1 15/16 2

3/16 2

1/16 1 15/16 1

7/8 1

7/16 2

1/16 1

7/8 1 11/16 1

3/8 1

5/8 1

5/8 1

7/8 3/4 3/4 1

3/4 1 11/16 1

7/8 3/4 1

5/8 1

9/16 1

5/8 1 ll/16 1

7/8 1

9/16

I t

i TABLE 1 (Continued)

Sheet 4 of 4 TENDON I.D.

NO ~

LIFT-OFF FORCE Ki s FINAL LOCK-OFF FORCE Ki s ELONGATION (in)

MEASURED CALCULATED 141 142(b) 143 144 145 146 147 148 149 150 (b) 151

~

152 153 154(b) 155 156 157 158 159(b) 160(b) 610 606 618 633 640 625 648 606 618 641 580 614 603 o25 641 596 614 625 645 603 753 746(c) 753 761 768

. 753 746(c) 757 768 761 761 758 761 761 754.

761

'58 768 761 761 1

3/4 1 15/16 1

5./P 1

9/16 1

3/8' 5/8 1

7/16 1

3/4 1 13/16 1

7/16 2

5/16 1

7/8 1 15/16 1

5/8 1

3/8 2

1/16 1 13/16 1

9/16 1

7/16 7/8 1

.3/4 1 13/16 1 11/16 1

9/16 1 '/16 1

5/8 1

3/8 1 13/16 1 11/16 1

7/16 2

1/16 1

3/4 1

7/8 1

5/8 1

7/16 1 15/16 1

3/4 5/8 1

7/16 1

3/4 AVE.

607 760 7/8 1 13/16 FOOTNOTES:

(a)

These tendons were retensioned at 1000. hrs. after original stressing, and they were not included in, the 10 yr. retensioning.

(b)

These tendons have been included in past surveillances; consequently, a

tendon force history has been'established.

(c)

(d)

These'orces reflect remeasured values due to tendon twist in the 6X overstressing process.

These are the tendon elongations from lift-off (column 2) to 6Z overstress (73;5% GUTS):

~ a e

SUBJECT C IS ID PACK Gilbert Associates, Inc.

Reading,Fennsytvania ANALYSIS/CALCULATIOH REV MICROFILMED ORIGINATOR DATE OF PAGKS

Stress Relaxation Curve Wire No.

Test Condition 876-A 876-B 876-C 851-A 851-B 8 51-C 851-D 8150-A 8'150-B 8150-C1 8150<<C2 8150-D 86 88 87 81 83 84 85 811 815AB-10 812 815AB 0.75 + 104 P

0.70 + 104 P

0 70 ~ 68oP

~ (f 0.75 + 104oF 0 70+ 104oF 0.70 +'68oP 0 70 ~ 78oF/

104oP 0 75 + 104oF 0 70 + 104oF 0.70 + 68oF 0 70 y 68oP 0.70 + 78oF/ 104oP TABLE 1.

STRESS RELAXATION TEST CONDITIONS

IS l7 16 76 A I5 Ih I5 Io X

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SUMMARY

DISTRIBUTION QOocket Files NRC PDR Local POR TERA NSIC N. Hughes O. Crutchfield R. Snaider H. Smith OELO OI8E (3)

ACRS (16)

K. Llichman A. Hafiz J.T.

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