ML17272A938

Ack Receipt of Re Corrective Action Plan Resolving Quality Problems Identified W/Joining Sacrificial Shield Wall Rings

ML17272A938
Person / Time
Site:	Columbia
Issue date:	04/04/1980
From:	Engelken R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:	Strand N WASHINGTON PUBLIC POWER SUPPLY SYSTEM
References
NUDOCS 8004290118
Download: ML17272A938 (21)

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UNITED S fATES" NUCLEAR REGULATORY COMMISSION REGION V 1990 N. CALIFORNIABOULEVARD SUITE 202, WALNUTCREEK PLAZA WALNUTCREEK, CALIFORNIA94596 S004S90 I l;g

~wig Docket No. 50-397 o<<>no Washington Public Power Supply System P.O.

Box 968 Richland, Washington 99352 Attention:

Nr. N. 0. Strand Managing Director

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Gentlemen:

Subject:

Washington Nuclear Project No.

2 'Sacrificial Shield Mall

References:

(1)

WPPSS letter from D. L. Renberger to R.

H. Engelken of flarch 25, 1980.

Subject:

Sacrificial Shield Wall, Pipe Whip Restraints, and Related Structures (2)

NRC Letter from R.

H. Engelken to N. 0. Strand of February 8, 1980.

Subject:

WNP-2 Pipe Whip Restraints and Sacrificial Shield Wall (3)

WPPSS Letter from D. L. Renberger to R, H. Engelken of February 1, 1980.

Subject:

Sacrificial Shield Wall, Pipe Whip Restraints, and Related Structures (4)

WPPSS Letter from D. L. Renberger to R.

H, Engelken of December 10, 1979.

Subject:

Stop Work, Repairs and Attachments to the Sacrificial Shield Wall, MNP-2 (5)

NRC Letter from R.

H. Engelken to N. 0. Strand of November 21, 1979.

Subject:

Stop Work, Repair and Attachments to the Sacrificial Shield Wall, MNP-2 Thank you for your letter of March 25, 1980 (reference

1) regarding your corrective action plan for resolving the quality problems identified with the joining of sacrificial shield wall rings 3 and 4.

Your corrective action plan and request to commence preparation of the joint for the weld joining SSM rings 3 and 4 has been forwarded to NRC Headquarters for review and evaluation.

You will be advised of the results of our findings when the review has been completed.

Sincerely, R.

H. Engelken Director

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Reference:

NRC Region V Letter, R.

H. Engelken to N. 0. Strand, WNP-2 Pipe Whip Restraints and Sacrificial Shield Wall, dated February 8, 1980

Dear Hr. Engelken:

The corrective action plan for the sacrificial shield wall (SSW) has been finalized. It consists of providing justification for the slot weld replacement by the partial penetration weld, perform-ing a welding defect/structural impact assessment to evaluate the SSW as-built structural capabilities, selection and qualification of the shield material for shim gaps and concrete voids, and a

final report at a later date discussing all items of concern on a

case-by-case basis.

The interim welding defect/structural assessment is being performed in a conservative, bounding manner with the following considerations:

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Welding defects identified by the recent Burns and Roe SSW visual inspection of 1001. of accessible

welds, e

Welding defects identified by magnetic particle examinations performed on the SSW by site contractors,

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Welding defects identified by ultrasonic examinations performed on the SSW by site contractors and Leckenby,

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The SSlt welding defect and repair history experienced by Leckenby during fabrication,

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o Assessment of Leckenby NDE credibility, welding procedures and welder qualifications/capabilities, I

o Lamellar tearing, o

The use of cold forming and heat. straightening processes during SSW fabrication,

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'This technical e'valuation will establis),'the,SSW,acceptability, as,-'is',

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This, evaluation will'be performed,in a typical;...,,

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i".e'".,"'i'ndependent checking'f the'echn'ical" res'ults.

I The replacement of the slot welds by the partial penetration weld at El. 541'-5" is considered to be an equal and alternate method of achieving the horizontal shear design requirements.

We do not view it as a change in design requiring prior NRC approval in that it is not an unreviewed safety question or change in technical specifications.,

Burns and Roe Technical Memorandum No. 1173, provides justification for the use of the partial penetration weld between SSW rings 3 and 4 including SSW as-built dimension considerations.

Attach-ments 2, 3, 4 and 5 provide details for the joint preparation and welding of the partial penetration weld.

The preparation of this joint will provide additional information about the material in this area of the SSW; it does not preclude any investigative work.

Considering the above, and the reference, it is requested that the Supply System at this time be allowed to commence preparation of the joint for the weld joining SSW rings 3 and 4.

A subsequent letter to NRC Region V will specifically address the proposed shield material and request your concurrence to proceed with shim gap shielding repair and welding of rings 3 and 4.

Very truly yours, D. L. Renberger Assistant Director, Technology

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Attachments:

(1) Burns and Roe Technical Memorandum No. 1173, dated

)1arch 19, 1980 4."A.4" ~ l ~

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VQ'. E. Snaith FR'.OM M. N. Fialkow Deva 3/19/80 COP'DIES VO JJVerderber w/1 CJSatir w/1 ACygelman w/1 DCBaker w/1 JO'Donnell w/1 MFialkow w/1 EFerrari w/1 SUPQECY

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REFERENCES:

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2808 EJWagner w/1-Washington Publi'c Power Supply System.

GHarper w/1 WPPSS Nuclear Project No.

2

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HTuthill w/1 Sacrificial Shield Wall Assessment Program SF-2 w/2 Connection of Upper and Lower Wall Segments.

pf w/1 TECHNICAL. MEMORANDUM NO.

1173

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NRC Letter.from R.

H'; Enge1ken to'N'.

O.'trand'date'd,2f8/80 Subject':

Why'hirigkon Nuclear Project No: '2~,'Pipe, Whi'p'h6straj.n s

and'.'acrificial Shield Wall.

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WPPSS Letter WPBR-80-96 from R.

M. Foley to J. J. Verderber,. dated 3/6/80,

Subject:

WPPSS Nuclear Project No. 2, Sacrificial Shield, Wall (SSW)

Assessment Program.

3.

Calculation No. 6.19.37, Book No.

SV 489 Pages 45 61

Title:

WPPSS-Hanford No.

2 Reactor Bldg.

Sacrificial Shield Wall,

Subject:

Correction Measures at Interface El. 541'-5".

4.

Washington Public Power Supply System Nuclear Project No.

2 Report No. WPPSS-74-2-R2-B, "Sacrificial Shield Wall Design Supplemental Information".

5.

ASCE Manual No. 41, "Plastic Design in Steel"I

~ '2nd Edition, 1971, Chapter 10:

Multistory

Frames, pp. 246-247:

P h. Effec ts.

INTRODUCTION:

It has been determined that the horizontal rings in the Sacrificial Shield Wall (SSW), located above and below the interface at Elevation 541'-5", are not welded together as shown on the contract drawings.

Correction measures to transmit the design horizontal shear between the channel ring above the inter ace and the box ring below the inter-face are recgxired.

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Description of correction weld

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Design considerations c.

"Analysis. based on the design,'SSW,configuration

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Analysis for, as-built SSW dzmensi:on'4."

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DESCRYPTION "OP CPR~CTION WELD~'~.~'yA: (,.y,~ i<>..g........,;.7,'"'0

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The correction weld is a partial penetration gro'ove weld with fillet weld reinforcement to be, its'tailed along. the,'xterior circumference between the rings above and below the interface at

. Elevation 541'-5".

The location and extent of the weld are shown in Figure 1; weld details are show'n in Figure 2.

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3'eCHNZCAL t1ENOHANDU>M NO.

1173 The contract reauires that at each of 24 loca ions around the SSW, four slot welds are to be provided in he web of the upper channel ring connecting to the lower box ring.

In lieu of this unfulfilled reauirement, it is proposed to install a partial penetration groove weld along the exterior, circUmference between the two ings.

Structural analysis in justification of the proposed correction has been accomplished (Reference

3).

This memorandum furnishes pe tinent information relative to this analysis< in compliance with letters from USNRC and WPPSS (References 1,

2).

The following is included:

As shown in the figures, the correction weld is to be installed in each of the 24 panels around the SSW for the width available between 'the column splice plates.

Preparation for the groove weld.

requires removal of material from the channel ring.

The specific configuration of the weld in each panel, including the groove depth and the size of the fillet weld reinforcement, depends on the width of ledge at the interface.

From the design viewpoint, a minimum overall weld depth of 2 inches, corresponding to an effective weld throat of 1 7/8 inches, is maintained in all configurations.

DESIGN CONSIDERATIONS FOR CORRECTION WELD 1.

Basic Data The analysis and design of the proposed correction weld utilizes the values of the stress resultants in the members and skin plates obtained in the analysis of the'verall sacrificial shield wall.

A description of the analysis and design of the SSW including loads, load combinations, and acceptance c iteria was submitted to NRC by Report No. WPPSS-74-2-R2-B (Reference 4) and approved by NRC by letter dated October 15, 1975.

Page 3

~ TECHNICAL NEMORANDU'O.

1173 1

Date Typed:

3/19/80 The analysis and design of the correction weld is in con-formance with NRC Standard Revi'ew Plan (SRP) 3;8.3.

In particula=,

reauirements relative to loads, load combina" ions, and acceptance criteria are complied with.

The basis of design is the elastic working stress method, Part 1 of the 1969 AISC design specification.

2.

Sianif cant Loads The following signi icant loads, considered in the analysis and design of the sacri'ficial shield wall, are applicable to the correction measures:

p>pe Dead and live loads Seismic. loads:

OBE and SSE

'ressurization of the annulus between RPV-'and SSW Reactions, due to pipe. br'eak; I

I Annulus 'pressurizations include those due, to postulated breaks in the following lines:

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Recirculation outlet lines Recirculation inlet lines Feedwater lines RHR/LPCI lines Pipe break reactions include those due to the preceding breaks and due to other severe postulated breaks occurring in the drywell proper.

Ten controlling breaks in the drywell are included.

.3.

Controllin Loadin and Load Combination The significant loads are considered in the load combinations of SRP 3.8.3 with regard to horizontal loads at the interface.

The controlling loading with associated acceptance criteria with regard to horizontal loading per panel is noted below:

SRP Combination 5:

1.6S D + L + Pa

+ Yr + E D, L:

dead, live load Pa:

annulus pressure due to break in feedwater line at azimuth 90 Yr..pipe reaction due to the feedwater line break E:

combined effect (by SRSS) due to OBE seismic events in the easterly, northerly, and vertical directions.

TECHNICAL

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3/ AV/ 0 V ANALYSIS BASED ON DESIGN SSW CONFIGURATION Desi n Concept.

2.

The correction weld carries the horizontal shear loads which are transmitted between the ring channel above the interface and the ring box member below the interface.

The horizontal loads from the channel are due to horizontal reactions from the skin plates and columns which connect to the channel from above.

Re'actions from the analysis of the SSW in its design configuration ar'e used.

The shear loads from the skin plates are tangential (circumferential) in direction.

'Shear loads from'he,'columns'ave tangential and radial components.

.-Th'e connection design is based on tQe largest comb'ined shear load>'ip,'an',.on'e jahel due,to the associated skin plates<" and,~cbgtiqiis"., 'h', 'jame,correction, is 'applique to', ill panels.',.',y,.. ,> ",.",,',',

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The largest combination of shear loads per panel in the controlling load combination 5 'has magnitudes as listed below:

Skin plates:

. Tangential shear

= 318.1 kips Column:

Tangential shear

=

8.9 kips Radial shear

=

27.4 kips The total panel tangential

shear, 327.0 kips, is taken to act with half applied along each flange of the ring channel.

The total panel radial shear, 27.4 kips, is taken to act along the line of the column web.

3.

Weld Desi n Criteria Welding procedures will be qualified in accordance with the requirements of the Structural Welding Code AWSDl.l.

Weld design is based on allowable stresses associated with partial penetration groove welds.

4 Correction Weld Stress Anal sis The panel design loads result in tangential and radial shear resisting forces in the panel correction weld.

The total panel tangential load causes a uniform tangential force in the'weld of 9.9 kips per inch.

A radial weld force which varies linearly between extreme values at the ends of the weld esists the moment on the weld due

44+ I TECHNICAL MEMORANDUM KO.

1173 ua ~a

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~y ~i( v v to the eccentricity of the applied tangential load along the interior. face; the maximum value of this radial force 's 21.6 kips per inch.

An additional radial weld force with constant magnitude equal to 2.7 kips per inch acts over a limited portion of the weld near its end to resist the applied radial load along the column web line.

The maximum value of the resultant weld force occurs at the end of the weld and is equal to 26.3 kips per inch.

5.

Controlling Desi n Mar in The design margin, which is the ratio of the permissible stress to'he ac ual stress, equ'als 2.3 for the above maximum value, of the weld for'ce.'

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1 ANALYSIS FOR'S-. BUILT SSR DIMENSIONS 1.,

Concept. foi'nal sis As-built deviations of the SSN which affect the proposed correction weld at interface Elevation 541'-5" are illustrated in Figure 3.

As shown in the figure, the deviations from verticality of the columns above the interface and the deviations from the design circularity of the ring channel members above" the interface are involved.

The lateral'isplacement of one end of a member,'5, relative to the other end in conjunction with the primary axial load in the member, P, results in additional (secon-dary) shears and moments in the member (reference

5).

This Pb, effect with the associated end bending moments and shears is shown below:

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PD

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,TECHNICAL MEMORANDUM YO.

1173 L)ace

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3 J. / 0 v Conservatively, the additional end moment M~ and the additional end shear Q~

are each evaluated as hough the other is non-existent.

This is done in the following equations.

M~.5 p~

The controlling axial loads in the columns and ring channels are due to the same applied loads taken in SRP Com-bination 5 which control for the transmission of shear across the interface.

The axial force in the ring channel is taken equal to the design pane3: tangential shear of 327.0 kips.

The axial force in the column is taken as. the total panel vertical load due to both column and skin plate reactions..-

Conservatively, the maximum vertical loads in..the. column jand skin plates are used even though these are not located in the same panel, as the panel which controls for shear.,

The design vertical axial load is 316.5 kips.

n 3.

Effect on Annulus Pressurization With respect to the effect of as-built SSW dimensions on annulus pressurization calculations, the following is noted:

a.

The measurements of 'concern apply to the annulus space between the sacrificial shield. wall and the reflective insulation.

These measurements are very difficult to obtain and are not available.

However, it is noted that the insulation support system is mounted on the SSW so that the dimension between insulation and wall would tend to be unaffected by the as-built deviations.

b.

For the design of the wall, NRC required that calcula'ted annulus pressurization loads be increased by 40 percent.

One of the reasons for this requirement was to account for as-built conditions being different from the conditions assumed in the analysis.

4.

Ma n'tude of As-Built Deviations The as-bu'lt deviations used in the analysis are based on the most conservative interpretation of the revised erection tolerances which were adopted for the erection of the SSW together with a supplementary field check of the deviations.'

~ TECHNICAL ~IENORANDUH No -

1173 JJCLI 4 J Jgl M ~

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P/ 'UV Prior to erection of the wall, the contractor requested and was granted relaxation of the original contract reauirements on erection tolerances.

The maximum permissible deviation from circularity was changed to

+ 0.90 inches in lieu of the original

+ 0.12S inches.

The maximum horizontal'deviation at the top of the wall from the vertical line through the corresponding point in the base of the wall was revised to + 0.90 inches in lieu of the original + 0.2S incnes.

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The most conservative interpretation of the adopted tolerances results in the deviation values noted'elow.

These values are used in the analysis.

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.Circularity;,The maximum tolerance. is taken to, occur

.at one column 'relative,to. the, adjacent columns on either, side.

Referiing to 'Fj.gure

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I Verticality The maximum tolerance is taken to occur at a column between Elevation 541'-5" and Elevation 549 '-5>4".

Using the terminology of Figure 3 f L= O,AO -(0,9O)

=

l.80 inch<<.

~ Field measurements pertinent to the. vertical and circular deviations have recently been made.

The 'magnitudes of /4 as defined in Figure 3 were determined around the shield wall.

However, precise determination of the circular deviation is not practical due to interference of existing construction.

As a measure of the.circular deviation, the radial deviation between the ring box member below the interface and the ring channel above the interface is used.

Comparison o

the deviations from field measurements with those based on the tolerances makes apparent the conservative basis of the analysis.

Thus the analysis uses L> = 1.8 inches compared to a maximum measured value of 0.625 inches.

Also, the analysis uses Lg,'R i+< =

1. 8 inches compared to a corresponding value of

0. 875 inches based on field data.

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Correction Weld Stress Anal sis As noted in the Concept for Analysis, the design axial loads acting with the adopted design deviations result in additional end,moments and shears in the columns and ring channels located above the interface.

The additional end moments in the column and ring channel are 285.0 inch kips and 294.3 inch kips respectively.

The associated increases in flexural stress in the members are less than 0.7 kips per square inch.

This increase in stress is relatively small and is within the capacity of the wall members.

~ The additional column radial'hear'is 5.9.kips.

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The additional radi'al shear in each. of the thor'ring members..at

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column is 13..4 kips.

~ Tgus, a tr'qta3; pf,P2.'7; kj;ps of additional, radial shear results dueto the: Pesign deviations.

Conservativelv, this additional radial'shear is taken" td /occut in the contiolling panel used for the design of the correction. weld.

The.total panel radial shear is increased to 60.1 kips'nd the resulting local'adial weld force increases to 6.0 kips per inch from the previous

'alue of 2.7 kips per inch in the Analysis Based on Design SSW Configuration.

6.

Desicrn Mar in With the above increase in panel radial shear, the design margin is 2.1 as compared to the previous value of 2.3.

CONCLUSION

'ased on the preceeding

analysis, the proposed correction weld at interface Elevation 541'-5", has sufficient capacity to sustain the required loads.

The correction provides a design margin in excess of 2.1.

Prepared by:

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P. O'Donnell

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