ML18044A589

Facility Steam Generator Repair Rept, Revision 5

ML18044A589
Person / Time
Site:	Palisades
Issue date:	02/29/1980
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML18044A588	List: ML18044A586 ML18044A589 ML19296D430
References
PROC-800229, NUDOCS 8003040571
Download: ML18044A589 (77)

Text

Remove ii, Rev 1 v, Rev 0 vi, Rev 4 viii, Rev 3 ix, Re.v 0 LOEP-1, Rev LOEP-2, Rev LOEP-3, Rev LOEP-4, Rev LOEP-5, Rev LOEP-6, Rev 4-3, Rev 0 1

1 1

0 1

1 4-lQ; to 4-16, Figure 4.1-3 Figure 4.1-4 PALISADES PLANT SGRR' Rev 0 Cl pages)

Figures 4.1-19 to 4.1-37 (19 pages) 7-5, Rev 0 10-1, Rev 0 D-6-1, Rev 4 Insert*

ii, Rev 5 v, Rev 5 vi, Rev 5 viii, Rev 5 ix, Rev 5 LOEP-1, Rev LOEP-2, Rev LOEP-3, Rev LOEP-4, Rev LOEP-5, Rev LOEP-6, Rev LOEP-7, Rev LOEP-8, *Rev 4-3, Rev 5 5

5 5

5 5

5 5

5 4-J,b~- to 4-16, Rev 5 Figure 4.1-3, Rev 5 Figure 4.1-4, Rev 5 (1 pages)

Figures 4.1-19 to 4.1-37, Rev 5 (one page) 7-5, Rev 5 10-1, Rev 5 D-6-1, Rev 5 Supplement 1 80oso40 5'7 J

\\:.

PALISADES PLANT SGRR 2.2 COMPONENT DESIGN IMPROVEMENTS 2-5 2-.2.1 DESIGN. FEATURES TO IMPROVE PERFORMANCE 2-6

2. 2. 2 DESIGN FEAl'URE;S.. TQ IMPROVE MAINTENANCE 2... 11

., *AND INSPECTlON 2.3 SHOP TESTS AND INSPECTIONS 2~12 2~4 STORAGE CRITERIA FOR NEW STEAM GENERATORS 2-12 I

3.. 0 BALANCE-OF-PLANT SYSTEM MODIFICATIONS 3-1 3.1 SLOWDOWN SYSTEM 3-1 3.2 RECIRCULATION SYSTEM 3.3 SAMPLING SYSTEM 3.4 PRIMARY HEAD DRAINS 3.5 WIDE. RANGE LEVEL INDICATION

.. 3. 6 MAIN STEAM ISOLATION VALVE CLOSURE SIGNAL 4.0 REPLACEMENT PROGRAM AND PROCEDURES 4.1 CONSTRUCTION CONSIDERATIONS 4.1.1 SITE PREPARATION

.4.1.2 RIGGING 4.1.3 RIGGING LOAD SUPPORTS 4.1.4 CONSTRUCTION-RELATED INCIDENTS 4.1.5 CONTAINMENT STRUCTURAL CONSIDERATIONS

. --. 3-1 3-2 3-2 3-3 I I

_3,..3 4,..1 4-11*

4-1 1 1 s 4-5 4-9*

4-9 4.-10 1 s 4.2 EQUIPMENT AND MATERIAL REMOVAL AND REPLACEMENT 4.2.1 MEcHAN!CAL EQUIPMENT 4-16 4-16 4.2.2 INSTRUMENTATION

4. 2 *. 3

• ELECTRICAL EQUIPMENT 4.2.4 PIPING ii 4-16 4-17 4-22 Revision s February 1980

PALISADES PLANT SGRR 7.0 ENVIRONMENTAL ASPECTS OF THE REPAIR PROGRAM 7.lGENERAL 7.2 RESOURCES COMMITTED 7.2.1 NONRECYCLABLE BUILDING MATERIALS 7

• 2 ~ 2.

LAND RESOURCES 7.2.3 WATER RESOURCES 7.3 WASTEWATER 7.3.1 SANITARY FACILITIES 7.3.2 LAUNDERING OPERATIONS 7.4 CONSTRUCTION.

7.4.1 NOISE

7. 4:. 2.

DUST 7.4.3 OPEN BURNING 7.5" RADIOLOGICAL MONITORING 7.6 RETURN TO OPERATION 7.6.1. WATER USE 7.6.2 OPERATIONAL EXPOSURE 7.6.3 RADIOLOGICAL RELEASES a.a EVALUATION OF ALTERNATIVES 8.1. INTRODUCTION 7-1 7-1 7-1 7-1 7-2 7-2 7-3 7-3 7-3 7-3 7-3 7~4 7-4*

7-4*

7-4 7-4*

7-5

-.7-5 8-1 8-1 8.2 CONTINUED TUBE PLUGGING AND PLANT DERATE 0-2 8.3 IN-PLACE TUBE SLEEVING 8.4 IN-PLACE TUBE REPLACEMENT 8.5 REPLACEMENT WITH COMPLETE UNITS v

8-2 8.-3 8-4 Revision 5 February 1980 I 5

PALISADES PLANT SGRR

8. 6 REPLACEMENT OF STEAM GENERATOR

• 8-6 EVAPORATOR SECTIONS

8. 7 MANREM CONSIDERATIONS 8-6

8. 8 CONCLUSIONS 8-7 9.0 COST BENEFIT ANALYSIS FOR THE DECONTAMINATION, 9-1

• .STORAGE, AND DISPOSAL OF THE OLD STEAM GENERATORS CONSIDERING ALARA

9.1 INTRODUCTION

9-1 9.2 STEAM GENERATOR.IN-PLACE DECONTAMINATION 9-1 9.3 STEAM GENERATOR STORAGE AND DISPOSAL 9-2

9. 3.1 LONG~TERM STEAM GENERATOR STORAGE

. 9-2

• ONSITE 9.3.2.

IMMEDIATE. SHIPMENT BY BARGE 9-2 9.3.3 SHORT-TERM STORAGE.WHILE UNITS ARE 9-3 CUT UP FOR SHIPMENT (WITHOUT DECONTAMINATION)

9. 3. 4.

CONCLUSIONS 9~3

10.0 REFERENCES

APPENDIX A - RESPONSE TO NRC QUESTIONS*OF 4/17/79 APPENDIX B - RESPONSE TO NRC QUESTIONS OF 4/19/79 APPENDIX C - RESPONSE TO NRC QUESTIONS OF 5/16/79 APPENDIX D - RESPONSE TO NRC QUESTIONS OF 10/15/79 APPENDIX E -* RESPONSE TO NRC QUESTIONS 2

10-1 js A-l(a)-1 B-l(a)-1 c~1-1 I 3 D-1-1 \\-,-5.

SUPPLEMENT 1 - CONSTRUCTION OPENING REPORT vi E-1-1: I 4 Revision 5 February 1980

FIGURE 2.2-1 2.2-2*

2.2-3.

2.2-4 2.2~5 2.2-6 2.2-7

• 2-.2-s 2.2-9 2.2-10 2.2-11 3.1-1 3.. 1-2 3.. 3-1

3. 3-2.

3.4-1 3.5-1 4:.1~1 4.1-2 4.1-3 4.1-4 4.. 1-5 4.1-6 4.1-7 4.1-8 4.1-9 4.1-10 4.1-11 4.1-12 4.1-13 4.1-14 4.1-15 4.1-16 4.1-17

• *.PALISADES PLANT.SGRR LIST OF FIGURES TITLE

. REPLACEMENT S.TEAM GENERATORS DELETED.

DELETED BOTTOM BLOWDOWN DUCT ASSEMBLY TUBE SUPPORT TYPES EGGCRATE ASSEMBLY BEND REGION TUBE SUPPORT TUBE SUPPORT UPPER ASSEMBLY STEAM GENERATOR -

FLOW RESTRICTOR NOZZLE PRIMARY HEAD.DRAINS EXISTING BLOWDOWN AND RECIRCULATION SYSTEM MODIFIED BLOWDOWN AND RECIRCULATION SYSTEM EXISTING-TURBINE ANALYZER PANEL FOR SAMPLING SYSTEM MODIFIED TURBINE ANALYZER PANEL FOR SAMP.LING SYSTEM PRIMARY HEAD DRAIN SYSTEM WIDE RANGE LEVEL TRANSMITTER S.ITE PLAN BARGE SLIP DELETED DELETED CONTAINMENT LAYDOWN AREAS GENERAL ARRANGEMENT PLAN VIEW, SH 1 GENERAL ARRANGEMENT PLAN VIEW, SH 2 GENERAL ARRANGEMENT SECTION A*A GENERAL ARRANGEMENT SECTION B-B DOWN-ENDING STEAM GENERATOR ONTO SLEDS LOWERING STEAM GENERATOR FROM ELEVATOR PLATFORM ONTO TRANSPORTERS STEAM GENERATOR IN HOISTED POSITION, SECTION VIEW STEAM GENERATOR ON TRANSPORTER BETWEEN STORAGE AND CONTAINMENT STEAM GENERATOR ON TRANSPORTER BARGE TO STORAGE OFF-LOADING STEAM GENERATOR FROM.BARGE, PLAN VIEW OFF-LOADING STEAM GENERATOR FROM BARGE, ELEVATION VIEW I

5 ou.;.._~OPJ)ING STEAM GENERATOR FROM BARGE'

---

SECTION=-=--~iIEW...

viii Revision 5 February 1980

4.1~1a 4.1-19*

. 4.1-20 4.1-21 4.1-22 4.1-23 4.1-2.4 4.*1-2s 4.1-26 4.1-27 4.1-28 4.1-29 4.1-30 4.1-31 4.1-32 4.1-33 4.1-34 4*. l-35 4.1-36 4.1-37 4.2-1 4.. 2-2..

4.2-3 PALISADES PLANT SGRR

• LIST OF FIGURES CONTAINMENT INTERNALS.-.RIGGING-DESIGN LOADS DELETED*

DELETED.

DELETED DELETED

. *DELETED DELETED DELETm)

DELETED DELETED DELETED DELETED

. DELETED DELETED DELETED*

DELETED DELETED DELETED DELETED DELETED TEMPORARY ELECTRICAL POWER SUPPLIES -

ALTERNATIVE~l TEMPORARY ELECTRICAL POWER SUPPLIES ALTERNATIVE-2 PLANT SINGLE LINE DIAGRAM*

ix Revision 5 February 1980 5

-** -**-*-- --. -**- ----- - --- *------ *-* ***--**-*. -- -*****-------*: - -*-*--*. - ----~---------- *---**-*-.. -**--*- -***-------------------------*.... *--*- ----*-** ------ *--* *--* --*-**----------- ---. *-....

',°;*

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PALISADES*PLANT STEAM-GENERATOR REPAIR REPORT LIST OF EFFECTIVE PAGES

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.Fig. 4.2-6 Fig. 4.2-7 Fig. 4.2-8 Fig. 4.3-1 Fig. 4.3-2 Fig. 4.3-3 Fig. 4.3-4 Fig. 4.3-5 Fig. 4.3-6 Fig. 4.3-7 5-1 5-2 6-1 6-la 6-lb 6-lc 6-ld 6-le 6-lf 6-lg 6-lh 6-2 6~3' 6-4 6-5 6-6 6-7 6-8 Table 6.2-1 Table 6. 2-2

• Table 6.2-3 Table 6.2-4 Table 6.2-5 7-1 7-2 7-3 7-4 7-5 8-1 8-2 8-3 8-4 8-5 PALISADES PLANT SGRR Latest Amendment LOEP-5 o*

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e PALISADES PLANT SGRR Page Latest Identification Amendment 8-6 0

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e PALISADES PLANT SGRR

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• • Table C-1-3, Sh 7 Table C-1-3, Sh 8 Table C-1-3, Sh 9 Table C-1-3, Sh 10 Table C-1-3, Sh 11 Table C-1-3, Sh. 12 Table C-1-3, Sh 13 Table C-1-3; Sh 14 Table C-1-4, Sh 1 Table C-1-4, Sh 2 Table C-1-4, Sh 3 Table c-1-5, sh 1 Table c-1-s, sh 2 Table C-1-5., Sh 3 c-2-1 C-3-1 C-3-2 c-3-3

• Fig. C-3-1 Fig. C-3-2 Fig. C-3-3 Fig. C-3-4 C-4-1 c-5-1 C-5-2 C-5-3 c.. 6-1 C-6-2 c...,1-1 Table*C-7;..1 c-a-1 C-8-2 C-9-1 c-10-1 D-1-1 D-2-1 D-2-2 D-3-1 D-4-1 D-5-1 D-6-1 D-7-1 Latest Amendment*

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• D-12-1 D-13-1' D-14-1 D-15-1 D-16-1.

E-1*1 E-2-1 E-3-1 E-4.1-1 E-4.2-1 Fig. E-4.2-1 Fig. E-4.2-2 E-4.3-1 E-5.1-1 E-5.2-1 E-5.3-1 E-6-1 E-7-1 E;..8-1 E-9-1 E-10-1 E-11-1 E-12-1 E-13-1 E-14-1

. PALISADES. PLANT SGRR

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\\

PALISADES PLANT.SGRR 4.1. L 2 Steam Generator Storage Facilities The storage* requirements are different for the new. and old steam generators.

4.1.1.2.1 Storage of New Stea~ Generators If storage of the new steam generators is needed, the storage facilities will conform to the criteria set forth in Section 2. 4. **

4.1.1.2.2 Storage of.Old.Steam Gener~tors The requirements and design criteria for a storage building for the old steam generators are described in Section 4.4.2.

If this building is.necessary, adequate biological shielding 5

will be provided in the form of normal weight (150 lb/ft3 )

concrete walls all arourid its p~riph~ry (see Section 4.4.6).

This building is located in a plant area where there are no safety-related structures or equipment.

4.1.1.3 Temporary Construction Facilities Existing plant warehous~ and off ices will be utilized, as far as possible, to support the construction force and store equipment and tools duri~g the steam generator repair effort.

Exact areas and details relating to temporary construction facilities will be developed before the construction phase.

4.1.1.4 Containment Preparation 4.1.1.4.l Defueling of the Reactor All fuel assemblies will be removed from the reactor and stored in. the spent fuel pool before the commencement of the repair activities that could affect plant safety.

4.1.1.4.2 Equipment and Material Modifications Equipment and material will be temporarily relocated to provide rigging clearances as discussed in Section 4.2.

Rigging equipment inside the containment is discussed in Section 4.1.2.

4-3 Revision 5 February 1980

PALISADES PLANT SGRR

b. * * *Dropping old/new steam generators* during transportation

c.

Dropping old/new steam generators during rigging operations at the steam: generator storage area

d.

Dropping old/new*steam generators during rigging operations adjacent to the containment building

e.

Dropping old/new steam generators, rigging, or other equipment during construction activities inside the containment The locations of hypothetical incidents a. through c. are physically far enough.removed so as not to affect any safety-related structures or equipment.. Hypothetical incidents d. and e. could resul~ in damage to the containment structure: however, they would not present a hazard to fuel pool cooling and makeup capability.

None of the fuel cooling and makeup system equipment is located inside the containment nor in areas which could be exposed to any of the postulated incidents.

Since the reactor will.

be defueled, any damage to safety-related equipment inside the containment as a result of the unlikely drop of stea~

generator, rigging, or other equipment during construction activities will not involve any safety cons id era tions relative to the safe shutdown condition of the plant.

Even though the above postulated events are not likely to occur, precautions will be taken to* further minimize any damage to the containment building or safety-related equipment.

In addition to the rigging controls described in Section 4.1.2.5, construction equipment, such as cranes required for erection of rigging equipment outside tbe containment, will be positioned or rigged to preclude any possibility of their having a s.ignif icant impact on Class I structures or safety-related equipment needed for fuel pool cooling.

4.1.5 CONTAINMENT STRUCTURAL CONSIDERATIONS Containment structur~l considerations are addressed* in the Construction Opening Report, Supplement 1 to this report.

4-10 Revision 5 February 1980

PALISADES PLANT SGRR DELETED 4-11 Revision 5 February 1980

PALISADES PLANTSGRR DELETED 4-12 Revision 5 February 1980

PALISADES.PLANT SGRR.

DELETED

)*

4-13 Revision 5 February 1980

• PALISADES PLANT SGRR

• DELETED 4-14

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February 1980

PALISADESPLANT SGRR*

4.2 EQUIPMENT AN)) MATERIAL REMOVAL AND REPLACEMENT 4.2.l MECHANICAL EQUIPMENT As presently being considered; no major mechanical equipment will have to be relocated because it interferes with the replacement of,~he steam generators.

As appropriate, equipment within the containment will be covered to ehsure cleanliness during the. repair.

4.2.2 INSTRUMENTATION The following instrumentation, sensing lines, and associated suppo~ts will be temporarily re~oved and relocated inside the containment:

a.

• Sensing lines on Steam Generator E-SOA for Pressure.

Transmitters PT-0751A through D, Level Transmitters LT-0751A through D, LT-0701 and LT-0702, arid Sampling Point SX-0719

b.

Sensing lines on Steam Generator E-SOB for Pressure Transmitters PT-0752A through D~ Level Transmitters LT-0752A through D, LT-0703 and LT-0704, and Sampling Point SX-0718

c.

The sensing line support structures for the sensing lines described in a. and b.

Disconnection of instrumentation cables to the above transmitters is discussed in Section 4.2.3.

The open ends of lines will be capped to ensure cleanliness during the repair.

As appropriate, the instrumentation and sensing lines will be returned to service using standard procedures followed during routine plant maintenance programs.

4-16 Revision 5 February 1980 I 5

e PALI SADES PLANT SGRR

• FIGURE 4.1-3 DELETED Revis ion 5 February 1980

~

PALISADES PLANT SGRR FIGURE 4.1~4 DELETED Revision 5 February 1980

-PALTSADES. PLANT. SGRR *_

FIGURES 4.1-19 TO 4.1-37 DELETED Revision 5 February 1980

PALISADES PLANT SGRR gallons for heater train, condensate polishers, and hotwell.

This is.the amount necessary to refill the systems if maintenance had been performed that required draining the systems.. Approximately 75,000 gallons would be required for primary system dilutions to return to power.

Depending on various. chemical parameters.,. as much as 50% of this water could be recovered through the plant recoverysystems, such as clean radwaste system, boric acid recycle system, *and steam generator blowdown r~covery system.

Following replacement of the steam generators, it is.*

expected that forced outages associated with steam generator tube plugging and/or. tube sleeving will be essentially eliminated; however, it is not anticipated that the water consumption associated with the current inspection program will be significantly reduced because of the continuing requirement to inspect (eddy current test) the steam generator tubing at regular intervals.

7.6.2 OPERATIONAL EXPOSURES Section 4.3.7 discusses the future reduction in man-rem exposure as a consequence of the repair program.

A potential savings of 250 man-rem/yr may be realized because of the expected elimination of the necessity to plug tubes in the repaired steam-generators and the decrease in the number of inspections required (Regulatory Guide 1.83).

7.6.3 RADIOLOGICAL RELEASES Although the Palisades Plant has experienced only seven I 5 primary-to-secondary leaks from tube failure, the repair of the steam generators should reduce the probability of future secondary releases as a consequence of the same tube failure mechanism.

7-5 Revision 5 February 1980

r.t PALISADES PLANT SGRR

10.0 REFERENCES

.1. Deleted

2. United.Nuclear Industries, Inc. Study, Decontamination of Palisades Steam Generators, November 1, 1975

3. Electrical Power Research Institute (EPRI 404-2)

Primary System Shutdown. Radiation Levels at Nuclear Power Generating Statioh, p~56,

.. :December 1.975

4. Acceptance Criteria for Emergency Core Cooling.

Systems for Light Water-Cooled Nuclear Power Reactors, 10 CFR 50.46 and Appendix K of 10 CFR SO, Federal Register, Volume 39, Number 3, January 4, 1974

5. LOCA Analysis for Palisades at 2530 MWt Using the ENC WREM-II PWR ECCS Evaluation Model, Exxon Nuclear Co. XN-NF-77-24, July 1977

6. L.L. Beranek, Noise and Vibration Control, McGraw;...Hil1 Book Company, Chapters 7 and 18, 1971 10-1 Revision 5

/

- February 1980

SGRR D-6*

PALISADES PLANT SGRR D-6 Your analysis.of gaseous releases from cutting reactor coolant piping presented in Table 6.2-1 does not appear to be corre6t.

The equation presented does not yield the answer given and the area of cut values of 0.5

RESPONSE

• square inches is too low.

Estimate the releases from cutting the blowdown, feedwater, and main steam piping using similar analyses.

Also, estim~te the releases from cutting the construction opening of the contain-ment.

Estimate the amount of gaseous radioactivity which will be released from routine refueling/~ork outage activities such as fuel movement.

Also, estimate the added releases from steam generator repair activi-ties such as complete defueling, local decontamination and construction activities within containment.

The area of the cut was presented erroneously, but it was used properly to obtain the results.

The area of cut presented in the equation from Table 6.2-1 should be as follows:

(0.5 inch) (rr) (inside diameter of pipe) or

( 0

• 5 ) ( rr )

( 3 0 ) = 47

• 12 sq i n arid (0.5) (rr) (42)

~ 65.97 sq in Total release for Cr-51 was estimated as follows:

Airborne activity<near cut (µCi) =

(47.12 sq in) (0.589) (µCi/sq in). (8 cuts)

+ (65.97 sq in) (0.589 µCi/sq in) (4 cuts) = 378 µCi No significant airborne releases are expected from cu~ting blow-down main steam or feedwater piping.

Prior to cutting the construction opening liner plate, the internal surfaces of the plate will be decontaminated to reduce zhe 'amount of transferable contamination to below 2,200 dpm/100 cm

• Gaseous radioactivity associated with repair outage will be simi-lar and not expected to exceed the amount of gaseous effluents associated with other routine refueling/work outages.

Gaseous effluents for the 1976 refueling/steam generator inspection outage, which included a complete offload of the core, totaled 1.31 Ci.

D-6-1 Revision 5 February 1980

• I I

.. PAI.ISADES* PLA'NT U.S. NUCLEAR REGULATORY COMMISSION

• DOCKET NO. 50-255

• CONS'l'RUCTION.

OPF!NING REPORT SUPPLEMENT NO. 1.

TO STEAM GENERA'IOR REPAIR REPORT

TABLE OF CONTENTS l~O INTRODUCTION l*.1 GENERAL 1. 2

SUMMARY

AND CONCLUSIONS 2.0 MATERIAL 2.1

• GENERAL 2.2 CONCRETE AND GROUT 2.3 REINFORCING SYSTEM 2*. 4 LINER PLATE SYSTEM 2.5 WELDING MATERIAL 2.6 POST-TENSIONING SYSTEM 3.. 0 CODES AND STANDARDS 3.1 GENERAL 4.0 ANALYSIS AND DESIGN 4.1 GENERAL 4.2 LOADS AND LOAD COMBINATIONS 4.3 CRITERIA AND ALLOWABLES 4.4 MATERIAL PROPERTIES 4.5 ANALYSIS 4.6 PRESTRESS IN TENDONS 4.7 EXTREME ENVIRONMENTAL LOADS 4.8 MISCELLANEOUS 5.0 FABRICATION AND CONSTRUCTION 5.* 1 GENERAL 5.2 CONCRETE AND GROUT 5.2.1 5.2.2 5.2.3 REMOVAL PLACING AND CURING INSPECTION AND TESTING 5.3 REINFORCING SYSTEM 5.3.1 5.3.2 5.3.3 REMOVAL INSTALLATION INSPECTION AND TESTING 5.4 POST-TENSIONING SYSTEM DETENSIONING REMOVAL e

Palisades* Plant SGRR

• . Supplement 1 5.4.1 5.4.2 5.4.3 5.4.4 INSTALLATION AND TENSIONING INSPECTION AND TESTING ii

I, 5.5 LINER PLATE SYSTEM 5.5.1 5.5.2 5.5.3 REMOVAL ERECTION INSPECTION AND TESTING 6.0 CONTAINMENT STRUCTURE TESTING 6.1 GENERAL 6.2 INTEGRATED LEAK RATE TEST 7.0.

MISCELLANEOUS CONSIDERATIONS Pa..

ades Plant SGRR *

• . supplement 1 7.1 CLOSURE OF THE CONSTRUCTION OPENING

8.0 REFERENCES

iii

• TABLE S.4-1 S.4-2 LI ST OF *TABLES*

TITLE FORCES AT SELECTED LOCATIONS (REFERENCE.FIGURE S.1-1)

Pa.ades Plant SGRR Supplement 1 MAXIMUM AND MINIMUM STRESSES (psi) FROM DEAD AND PRESTRESS LOADS iv

FIGURE S.l-1 s.1-2 S.4-1 S.4-2 S.4-3 S.4-4 S.4-5 S.4-6 S.4-7 S.4-8 S.4-9 S.4-10 S.4-11 S.4-12 Pa.sades* Plant' SGRR

• *. Supplement 1 LIST OF FIGURES TITLE CONTAINMENT OPENING IN CONTAINMENT VERTICAL STRESS AT THE OPENING LEVEL FROM PRESTRESS (F) AND DEAD (Wa) LOADS EFFECT OF DETENSIONING HOOP TENDONS FINITE ELEMENT MODEL FOR CONTAINMENT SHELL ANALYSIS - SELECTED LOCATIONS CONTAINMENT INTERNALS - RIGGING DESIGN LOADS THREE-DIMENSIONAL PLOT OF CONTAINMENT SHELL (WITHOUT OPENING)

THREE-DIMENSIONAL PLOT OF CONTAINMENT SHELL (WITH OPENING)

MEMBRANE STRESSES VERSUS HEIGHT (WITHOUT OPENING)

MEMBRANE STRESSES VERSUS AZIMUTH (WITHOUT OPENING)

MEMBRANE STRESSES VERSUS HEIGHT (WITH OPENING)

MEMBRANE STRESSES VERSUS AZIMUTH (WITH OPENING)

MEMBRANE STRESSES VERSUS HEIGHT (OPENING CLOSED)

MEMBRANE STRESSES VERSUS AZIMUTH (OPENING CLOSED) v

PALISADES PLANT SUPPLEMENT l STEAM.GENERATOR REPAIR REPORT LIST OF EFFECTIVE PAGES Page Identification i ii iii iv v

LOEP-1 LOEP-2 s-1 s-2 Figure S.1-1 Figure s.1-2 S-3 S-4 s-s S-6 s-7 S-8 S-9 S-10 s-11 s-12 S-13 S-14 S-15 S-16 S-17 S-18 S-19 Table S.4-1 Table S.4-2 Figure S.4-1 LOEP-1 Latest Amendment 0

0 0

0 0

0 0

0 0

0 0

0 0

0

0.

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

LIST OF EFFECTIVE PAGES (Continued)

Page Identification

. Figure S.4-2 Figure S.4-3 Figure S.4-4 Figure S.4-5 Figure S.4-6 Figure S.4-7 Figure S.4-8 Figure S.4-9 Figure S.4-10 Figure.S.4-11 Figure S.4-12 s-22 S-23 S-24 S-25 S-26 S-27 S-28 I

LOEP-2 Latest Amendment 0

0 0

0 0

0 0

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0

,0 0

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1.0 INTRODUCTION

1.1 GENERAL CO-RUCTION OPENING REPORT SUPPLEMENT.1 PALISADES PLANT SGRR This report supplements the Steam Generator Repair Report, Palisades Plant, U.S. NRC Docket 50-255, January 1979.

However, some of the information is repeated to make this report self-contained.

Information is provided* herein to illustrate that the containment will satisfy the.original structural design criteria during and after construction for steam generator replacement.

The containment is shown.in Figure S.1-1.

It is a prestressed six-buttress concrete building.with*a circular flat base slab, a 160-foot-high vertical cylinder, a shallow dome, and a-ring girder.

The inside diameter of the containment.is 116 feet.

The inner surface of the containment is lined with a 1/4-inch steel plate.

The dome is 3 feet thick and is prestressed with 165 tendons.

The cylinder is 3 1 -6 11 thick and is prestressed with 522 hoop tendons and 180 vertical tendons..

Each tendon is made of ninety 1/4-inch-diameter high-strength wires.

An opening of approximately 27 (eet 'wide by 30 feet high will be made inthe cylindrical portion to allow the steam generator*

replacement.

The opening, as shown by solid lines in Figure S.1-2, is centered at the southeas.t corner (Azimuth N 118° 40 '),

approximately 76 feet above the t9P of the base slab.

As shown in Figure S.1-2, 70 vertical tendons and 47 hoop tendons in and around the opening area are planned to be detensioned to maintain the concrete and reinforcing steel stresses within allowable limits during the construction period.

Dome tendons will not be disturbed.

Among the detensioned tendons, 14 vertical tendons and 35 hoop tendons in the opening* area are planned to be removed.

Then the opening will be made by cutting and removing tendon sheaths, concrete, reinforcement, and liner plate.

After the steam generator replacement, the opening will be closed with new materials.

New tendons and detensioned tendons.will be tensioned.

Detailed analyses have been performed using three-dimensional finite element models to predict the behavior of the containment during and after the construction period.

Because the containment will not be required to perform any safety-related function during the construction period, extreme environmental loads such as tornado and earthquake loads need not be considered.

However, the significance of these loads is discussed in this report.

To minimize the effects of differential creep and shrinkage between old and new concrete, studies with preplaced aggregate concrete for new concrete in the opening area are in progress.

The results presented here are based on analyses with normal replacement concrete for the opening area and are considered conservative.

S-1

Pa.sades Plant SGRR Supplement 1 This report describes the properties of' materials involved, results of the structural.analyses, and fabrication and construction features.

1.2

SUMMARY

AND CONCLUSION

• The cutting and* closure of the construction opening in.the containment structure has been evaluated both analytically and from

• the.standpoint of construction feasibility.

Results of the detailed investigation outlined.in the subsequent sections have shown that the cutting operatic:m and closure of the construction opening will have no detrimental.effect upon plant safety.

The structural integrity of the.containment will be fully restored.

S-2

EL. 782'-

EL. 768 I -1" ------

I LDome EL. 696 I -8" 116' EL. 590 I -0" L. 585 I -0" 8'-6" Ring*

Girder

~ 7'-8"

. ~1 Cylindrical:-----

Shell Polar Crane Bracket 18'

--~ 3'-6" PALISADES PLANT STEAM GENERATOR REPAIR REPORT CONTAINMENT Figure* 5.1...: 1

~1--- Tendon Gallery

EL. 766'-8" s

205° 180°

• I 188°-40' 118°-40' t; opening E

N I

85° 00

- I.

48°-40' EL. 748'-6"

. I I

I

...,....... Ring Girder f

I

• ~-- Buttress.

35 Hoop Tendons Removed

': ----- ~ ----,

-- -*-*--** ------*.:...---* --*--- **----*--*- -*-- -- rr-~

1,._.... -

p 47 Hoop Tendons De tensioned I

I "I I

I I

____ i_ ____ LJ EL. 588'-6" ~~--+-~__,IL---L_:_~~~~L.--1...~~~~~.l.--'-~~~-:---~-'---'---i EL. 58~-~-L~~~~...-~~~~~~~~~~~~~~i--~~~*~

r I,

~1 14 Vertical Base Slab Tendons Removed 70 Vertical Tendons Detensioned OUTSIDE DEVELOPED ELEVATION OF CONTAINMENT PALISADES PLANT STEAM GENERATOR REPAIR REPORT OPENING IN CONTAINMENT Figure S.1-r't.

CONSTRUCTION OPENING REPORT

• PALISADES PLANT SGRR SUPPLEMENT 1 Pal.sades Plant SGRR Supplement 1 -*

2.0 MATERIAL 2.1 _GENERAL The construction opening in*the containment used for the.replacement of the steam generators will be closed and restored to its original level of integrity by using~ wherever possible, material conforming to the same material standards as used in the design and construction of the original containment wall.

In some cases, material changes have been made because of updated code requirements and/or commercial availability.

Where new materials are used, they will be at least equal to and compatible with the-original materials.

The* following is a listing of both the existing materials and the new materials to be used in the containment wall.

2.2 CONCRETE AND GROUT 2.2.1 CONCRETE 2.2.1.1. In this section, the discussion is based upon conventional concrete.

However, preplaced aggregate concrete is also under investigation because of its low creep characteristics.

2.2.i.2 The existing and new concrete ingredi~nts consist of the following:

a.

Portland cement, Type II in conformance with ASTM C 150

b.

Air-entraining agent in conformance with ASTM C 260.

c.

Water-reducing agent in conformance with ASTM C 494, type A or D

d.

Pozzolan in con:forma.nce with ASTM C 618 Class F

e.

A crushed dolomitic limestone aggregate obtained from Drummond Island in Lake Huron.

2.2.1.3 The principal placement properties of the existing and new concrete are as follows:

a.

An air content of 3 to 5%

b.

Placement using steel forms on the exterior face, with a textured architectural surface, and liner plate for the interior face

c.

Horizontal and vertical construction joints adequately prepared by conventional means S-3

2.2.2 GROUT Pa.ades Plant SGRR Supplement 1 Existing and new grout have the same sand-cement ratios as the concrete mix.

• 2.2.3 CONCRETE MIX.DESIGN

2. 2. 3.1 The existing concrete was designed to ACI 6.13. having a required strength of 15% over the 5,000-psi 28-day strength.

2.2.3.2.The new concrete mix proportions will be in accordance with ACI 211.1 and ASTM c 94, Alternative 2 with a required average strength of 15% over the 5,000 psi 28-day strength.

2.3 REINFORCING SYSTEM 2.3.1 EXISTING REINFORCING STEEL 2.3.1.1 The existing reinforcing steel in the containment wall required for plant safety.consists primarily of AST?-1A15, *No. 10 and 11 bars.

Any cut reinforcing steel required for plant safety will be replaced.

Reinforcing steel used for construction purposes will not be replaced.

2.3.1.2 The existing reinforcing steel was placed in accordance with ACI 301 and 318.

2.3.2 NEW REINFORCING STEEL

. 2.3.2.1 The new reinforcing steel placed in the containment wall to close the construction opening will consist of* ASTM A 615, either Grade 40 or 60.

Lapped splices may be used in place of mechanical splices for new No. 10 and 11 bars.

2.3.2.2 The new reinforcing steel will be placed in accordance with ACI 318, Sections 7.5 and 7.6.

2.3.3 MECHANICAL SPLICES Mechanical splicing of new and existing reinforcing steel will be by the CADWELD process using T-series connections.

2.4 LINER PLATE SYSTEM.

2.4.1 EXISTING LINER PLATE The existing 1/4-inch liner plate conformed to ASTM A 442,.Grade 55, flange quality and was fabricated in accordance with ASME Code, Sec;:ti9n VI~I, Division ~' Paragr~phs UW-26 through UW-35.

The existing liner plate stiffeners conform to ASTM A 36.

2.4.2 NEW LINER PLATE The new 1/4-inch liner plate will conform to ASTM A 442 or A 516, both Grade 55.

Liner plate stiffeners will conform to ASTM A 36.

S-4

2.5 WELDING MATERIAL Pa.lsades Plant SGRR

• .. Supplement 1.

2.5.1 *welding material used on the existing liner-plate.conformed toASTM A 223 and A 559-with Type E 6010 electrodes* using the ASME~

Code,Section IX.

2.5.2* Welding material to be used.on the new liner.plate will conform to the ASME Code,Section IX.

2.6 POST..;;TENSIONING SYSTEM 2.6.1 EXISTING AND NEW POST-TENSIONING SYSTEM SIMILARITIES 2.6.1.1 Both the existing and the new post-tensioning systems are the BBRV system.

2.6.1.2 Each tendon consists of ninety 1/4-inch diameter wires, cold-drawn and stress-relieved, having a guaranteed minimum ultimate tensile strength (fRu) of 240,000 psi, and a minimum yield strength not less than 0.80 fpu*

2.6.1.3 Both the existing and the new prestressing steel tendons during shipment and storage are protected in shipping racks from mechanical damage and corrosion.

2.6.2 EXISTING AND NEW POST-TENSIONING SYSTEM DISSIMILARITIES 2.6.2.1 The shipping protection film used for the existing tendons was a film of "Visconorust 1601, Amber." The new tendons will be protected using a thin film of "Visconorust 1702, Amber" or equal, manufactured by Viscosity Oil Company.

2.6.2.2 The tendon filler grease for the existing tendons was 2090p.

The grease for the new tendon. ducts will be Visconorust 2090p-4, manufactured by Viscosity Oil Company~

2.6.2.3 The existing and new anchor heads and shims conform to AISI 1141, Special Quality.

2.6.2.4 The existing tendon ducts conform to ASTM A 366.

The new ducts will be galvanized, spiral-wrapped, semi-rigid, corrugated tubing conforming to ASTM A 527 carbon steel, or equivalent.

2.6.2.5 The existing tendon wires conformed to ASTM A 421, Type BA.

The new tendon wires will conform to ASTM A 421, low relaxation wire criteria with maximum 4% relaxation at 70% of ultimate tensile strength fpu.

s-s

• ~

CONSTRUCTION. OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT l 3.0 CODES AND STANDARDS 3.1 GENERAL The following codes and standards were used in the design and*

construction of the containment wall or will be used for the repair of the containment w~ll as required for the steam generator replacement effort.

Codes and Standards ACI 211.1-77 ACI 301-63 AC! 318-63,77 ACI 613-63 AISI 1141-63, 77 Recommended Practice for Selecting Proportions for Normal and Heavy-weight.Con-crete Specif ica-tions for Structural Concrete for Buildings Building Code Requirements for Rein-forced Con-crete Recommended Practice for Selecting Proportions for Concrete Anchor Heads and Shims Used for Existing Contain-ment Wall x

x x

x S-6 To Be Used for Repair of Contain-ment Wall After SG Change (See Note 1) x x

. x Reason for Original Code or Standard. Not Being Used for New Concrete Current code requirements Not being used in current power plant construction Current code Using.ACI 211.1, which is current practice

Codes and Standards Used for*

.Existing

• Contain-ment Wall ASTM A.15"".'63 ASTM A 36-63, 77a ASTM A 223-63 ASTM A 366-63 ASTM A 421-63, 77 ASTM A 442-63,

78.

ASTM A 516-78 ASTM A 527-71

( 7 5)

Reinforcing Steel Structu.ral

• Steel Alloy Casting for General Application Steel, Carbon, Cold-Rolled Sheet, Commer-cial

Uncoated, Stress-Re-1 ieved Wire for Pre-stressed Con-crete Pressure Ves-sel Plates, Carbon Steel Improved Transition Properties Pressure Vessel Plates, Carbon Steel, for Moder-ate and Lower Temperature Ser-vice Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, Lock-Forming_ Quality S-7 x

x x

x x

x Palisa** Plant SGRR Supple t 1 To Be Used for Repair of Contain-ment Wall After SG Change (See Note 1) x x

x x

x Reason for Original Code or Standard Not Reing Usen for New Concrete Replaced by ASTM A 615 Current code Discontinued Using ASTM A 527 material,* which is current*prac-tice Current co.de Current code Alternative liner plate material Current code

Codes and Standards ASTM A 559-63*

Welding Electrodes ASTM A 615-7&

Deformed and ASTM C 33-63, 78 ASTM C 94-78a ASTM C 260-63, 77 ASTM C 150-63, 78a ASTM C 350-63 ASTM C 494-63, 79 ASTM C 618-78

. Billet-Steel Bars for Con-crete Rein-forcement Concrete Aggregates Ready-Mix Concrete Air-Entrain-ing Admix-tures for Concrete Portland Cement Pozzolan Admixtures Chemical Ad-mixtures for Concrete..

Flyash*and Raw or Cal-cined Natural Pozzolan for Use as a Mineral Ad-mixture in Portland Cement Con-crete Used for Existing Contain-.

. ment Wall x

x x

x x

x x

S-8 P~lisa9 Plant* SGRR Supplement 1

• To Be Used for Repair of Contain-ment Wall*

After SG Change (See Note 1) x x

x x

x x

• Reason for Original Code or.Standard Not Being us*ed for New Concrete Discontinued

.Current code Current code Note 1 Current code Current cod.e Using ASTM C 618, which is current practice Current code Current code

Codes and Standards AISC Nov 1, 1963: 1978 Specification for the De-sign, Fabri-cation, and Erection of Structural Steel for*

Buildings ASME 1977 and Boiler and Addenda, Summer Pressure Ves-1979 sel Code;Section VIII, Division 1, Pressure Ves-sels ASME 1977 and Boiler and Addenda, Summer Pressure Ves-1979 sel Code,Section IX, Welding and Brazing Qual_.

if ication Palisa9 Plant SGRR Sul)plement 1

• TO Be Used for Repair of Contain-Used for ment Wall Existing After SG Contain-. Change ment Wall (See Note 1) x x

x x

Reason for Original-Code or Standard Not Being Used for New Concrete Current code Current*code Current code Note -1:

Materials shall meet or exceed the technical require-ments as originally specified when applicable.

S-9

CONSTRQCTION OPENING REPORT SUPPLEMENT 1 PALISADES PLANT SGRR 4.0 ANALYSIS AND DESIGN 4.1 GENERAL Pa~adesPlant SGRR Supplement 1

. The gross behavior of the containment during the construction period is shown in Figures S.4-1 and S.4~2. It can be seen from the figure that the number of tendons proposed to be detensioned are sufficient to achieve negligible concrete stress due to post-tensioning in the opening area.

A set of detailed linear static finite element analyses has also been performed to predict the behavior of containment during and after construction using the BSAP computer program.

The results of the analyses show that the stresses in the containment will be below the allowable limits.

Prestress levels in retensioned and new tendons are proportioned so that the containment will have sufficient prestress during the remainder of its service life.

The major loads considered during the construction period are de.ad and prestress loads.

Consideration is given to the effect of creep and shrinkage in concrete after the repair.

In the finite element model, an opening of 37 feet wide by 38 feet high is considered as shown by dotted lines in Figure S.1-2.

The original conceptual rigging scheme for the steam generator replacement required an opening this size.

The rigging scheme currently under consideration allows a nominal opening of 27 feet wide by 30 feet high as shown by solid lines in Figure S.1-2.

Results of the finite e'lement analyses based on the larger opening will not be altered significantly by the smaller opening.

Therefore, the results are.applied to both schemes.

4.2 LOADS AND LOAD COMBINATIONS 4.2.1 -DEAD LOAD The dead load is mainly from the self-weight of containment.

4.2.2 PRESTRESS LOAD The cylindrical part of containment has been proportioned to have the following effective prestress, as a minimum, at the end of 40 years:

Hoop Vertical

= 665 k/ft

= 290 k/ft S-10

Pa'8ades Plant SGRR Supplement 1 The.containrnent*was initially prestressed approximately 10-years ago.

The prestress level has been-measured during the past three surveillances.

Using the surveill.ance data as guidance, the current level of prestress is estimated to be approximately 5% above the minimum effective level.

For the purpose of analysis, the minimum effective prestress was used.

However, as described later, the results are factored to predicted levels of prestress at various design stages.

4.2.3 THERMAL LOADS Thermal loads cause self-limiting secondary effects which seldom govern design.

A thermal gradient of lOOF is considered during the normal plant operating condition.

It corresponds to lOSF and SF inside and' outside the containment, respectively.

During the construction period, a thermal gradient of 60F, which corresponds to an inside temperature of 65F and an outside temperature of SF, is considered.

4.2.4 RIGGING LOADS The expected rigging loads are shown in Figure S.4-4.

Maximum concentrated loads of 275 kips at two polar crane support brackets directly above the opening was investigated.

The rigging loads cause relatively small local stresses in the containment.

~.2.5 CREEP AND SHRINKAGE Creep and shrinkage in concrete are time-dependent phenomena.

The rate of creep and shrillkage and their final magnitudes are small in large structures such as the containment compared to-those in concrete test specimens (Reference 1).

The following values are used for the new concrete in the opening:

Shrinkage Creep

= 70 micro strain

= 0.22 micro strain per psi compressive stress In the analysis for the effects of differential creep and shrinkage between old and new concrete, the existingconcrete is conservatively assumed to be stabilized with negligible shrinkage and creep.

However, as described later, the prestress in the detensioned tendons will be adjusted to account for possible creep recovery and subsequent creep in the existing concrete.

4.2.6 LOAD COMBINATIONS The following conditions are considered with the corresponding load combinations:

a.

Existing

b.

Detensioned (without opening)

D + F + T0 D + F + T0 S-11

Palisades* Plant SGRR Supplement 1

c.

Detensioned (with opening)

D + F + C + 'i'0

d. *Operational D + F + T0 Where D

= Dead load F

=

=

c

=

Prestress load, varying for different conditions Operating thermal load during either normal operation or construction, as appropriate Rigging load during steam generator replacement 4.3 CRITERIA AND ALLOWABLES The containment is checked to satisfy the original criteria given in Appendix B of the FSAR.

The applicable allowable stresses are summarized below for the load combinations specified earlier:

Material Nature of Stress Concrete Membrane compression Membrane tension Flexural compression Flexural tension Reinforcement Tension Liner Plate Tension Allowable Stress 0.3 f' c fib.

. 0. 6 f' c 3JT[

0.5 f y 0.5 f y Note (1)

(2)

Notes:

(1) Local compressive stress can be as high as 0.75 f~

( 2) When the flexural tensile stress exceeds 3,/fl;

, the section will be treated as a cracked concrete section with bonded reinforcement.

The above stresses are applicable under primary loads only.

There is no limit specified on the stresses when secondary loads from shrinkage, creep, and/or thermal effects are combined with the primary loads.

However, the integrity of containment is ensured under all loading conditions by limiting the strains in the concrete and the liner plate to 0.003 and 0.0025, respectively.

4.4 MATERIAL PROPERTIES Material properties used in the analysis are given below:

S-12

a.

Old Concrete Instantaneous Young's modulus Sustained Young's modulus

b.

New Concrete Instantaneous Young's modulus

. Sustained Young's modulus

c.

Old and New Concrete Poisson's ratio Density Design strength Coefficient of thermal expansion

d.

Old and New Steel Palisades Plant SGRR Supplement 1 Ee = 5.5 x 10 psi Ecs. = 2.7 x 10 psi Ee

= 5.5 x 10 psi Ecs = 2.7 x 10 psi y

0.17 f

= 150 lb/ft f'

= 5,000 psi c

a

= 6 x 10. -6/°F (Reinforcement, liner.plate, pos-C-tensioning tendons Young's modulus Es

30 x 106 psi Poisson's ratio y

= 0.3 Yield strength of reinforcement f y

= 40 ksi Yield strength of liner plate f y

= 30 ksi Ultimate strength of tendons fpu = 240 ksi The finite element analysis assumes the containment to be made of homogeneous, isotropic, linear elastic materials.

Therefore, the stress distribution under primary loads depends only on the ratio between Young's moduli of the materials.

A Young's modulus of Ecs= 2.7 x 106 psi is used in the finite element analyses when the old concrete alone is invo1ved.

When both old and new concretes are involved, an appropriate ratio between their Young's moduli is maintained in the model.

4.5 ANALYSIS 4.5.1 MODEL*

The containment structure is modeled with 1,401 discrete nodal points and 1,508 finite elements.

As shown in Figures S.4-5 and S.4-6, there are two models: one with an opening and another without an opening.

Quadrilateral and triangular thin shell elements are used to model the cylinder and dome.

Beam elements are used to S-13

'~*.

\\

Pa,sades Plant SGRR Supplement l represent.the ring girder. *The boundary condition at the base which is approximately 76 feet below the center of the *opening has* a negligible effect on the behavior of *the containment shell in and around the opening area.

Therefore, the base slab is not modeled, and *the structure is assumed to be fixed at the base under all loading conditions.

The six buttresses are included in the model.

Penetrations are not m9deled because they are at a sufficient distance away from the proposed opening to preclude structural interaction.

The BSAP computer program is used tq perform linear static analyses of this model under various loading conditions.

Verification of the BSAP program is documented in Reference 2, Article 8.0.

The verification is done essentially by solving a series of test problems using BSAP and comparing the results with benchmark solutions which are considered to be correct~ The benchmark solutions were obtained from hand calculations, technical literature, and other proven computer programs such as NASTRAN, STRUDL, ANSYS, STARDYNE, etc.

4.5.2 REPRESENTATION OF LOADS 4.5.2.1 Dead and Prestress Loads Dead load is represented as a body force in the model by specifying the density of concrete.

The prestress loads are represented as external pressure loads on the shell elements and as nodal point loads at the anchorage points.

An average uniform external pressure load is a good representation of the hoop tendons with staggered spacing along the height of the cylinder.

Because there is only a* small variation of vertical prestress along the height of cylinder due to wobble friction, the vertical prestress is adequately represented by nodal loads at the

• ring girder.

4.5.2.2 Rigging Loads To analyze the containment for the rigging load, concentrated eccentic vertical loads of 275 kips are applied at two polar bracket locations directly above the opening.

4.5.2.3 Shrinkage After the opening is closed, the drying of the new concrete causes shrinkage strain.

For the containment with the iJ:'liler liner plate, the external surface is the drying surface.

Thus, the moisture must move to the outer surface.

This drying process has been represented by the diffusivity phenomenon (References 3 and 4, Article 8.0).

As shown in Reference 4, the drying of mass concrete is very slow, and there will be variation in shrinkage strain across the thickness of wall.

The external drying surface will have a large shrinkage strain, and the inner surface will have almost zero shrinkage strain.

When this free shrinkage strain is restrained, stresses will develop resulting in micro cracks at the external surface.

To S-14

e Palisades Plant SGRR Supplement 1

• control*this*shrinkage cracking, the containment has a minimum of 0.15% reinforcement* near the external surface along each direction.

Shrinkage* strain apd shrinkage cracks are not unusual in any

~concrete structure.

A. temporary construction. opening of approximately 40' x*40' is usual

• for a concrete containment.

This is. larger than the opening size under consideration for steam generator replacement.

When a

• temporary construction opening is closed, the shrinkage of new concrete is restrained part~ally at the boundary by the old hardened concrete leading to some internal stresses.

To consider this shrinkage effect, the shell elements in the opening area are subjected to a uni~orm thermal strain of -70 x 10-6 4.5.2.4 Creep Concrete under stress undergoes a gradual increase of strain with time because of the creeping phenomenon in concrete.

Between a stress range of O. 2 f~ and O. 6 f~, creep deformations are almost proportional to the stress level (Reference 5, Article 8.0).

Generally, creep has little effect on the strength of a containment, but it causes a redistribution of stress and a loss in prestress under service conditions.

Creep deformations are beneficial in reducing a discontinuity effect due to relatively stiffer and softer portions in the containment.

When the tendons in and around the proposed opening are detensioned, the reduction in stress may cause some creep' recovery resulting in slight stress redistribution.

When the opening is closed with new concrete and the tendons are retensioned, the new concrete will undergo a relatively larger amount of creep deformation leading to a reduction of stress in the opening area and an increase of stress in the surrounding area.

This increased stress in the surrounding area will cause creep deformations in the old concrete, which will* result in an increase of stress in the opening area and a reduction of stress in the surrounding area.

The creep deformations will continue gradually arid reach an equilibrium condition with a smal!

stress difference between old and new concrete.

The creep effect has been considered on a worst-case basis by analyzing the containment with a lower Young's modulus for the new concrete after.the closure of the opening.

4.5.3 RESULTS The results of the analysis for differential creep and shrinkage between old and new concrete presented in Tables S.4-1 and S.4-2 are based on an analysis of poured concrete in the opening.

However, the possibility of minimizing these effects by use of preplaced aggregate concrete is being studied.

Results of the finite element analysis are shown in Figures S.4-7, S.4-8, S.4-9, S.4-10, S.4-11, and S.4.,..12.

Table S.4-1 contains the membrane forces at a few selected locations shown in Figure S.4-3.

Table S.4-2 shows the maximum concrete stresses during various S-15

Pal,ades Plant SGRR Supplement 1 conditiqns under primary loads.

Using the-results. as. guidance, this section illustrates. that the* containment m*eets the design criteria and allowables.

The i,mplicit conservatism.involved in the containment analysis and design should be noted.

Existing 10-year-old concrete has a strength of at least* 8, 760 psi as demonstrated by the test results.

reported in Appendix F-of the FSAR.

However, only the *28-day strength of 5,000 psi is used while checking the containment to meet the design.criteria and allowables.

4.5.3.1 Existing Conditions As already explained, the current prestress level is estima~ed to be 5% more than the minimum effective level.

Membrane stresses under

. dead and prestress loads at the center of the opening are calculated as the following:

ah= -1,307 psi along hoop direction crv= -663 psi along vertical direction.

These stresses are below the* allowable stress of O. 3 f' = 1, 500 psi.

Addition of the thermal gradient of lOOF results in the following flexural stresses:

a.

Vertical Concrete

=

-1,491 psi Reinforcement

=

-o.263 ksi

b.

Hoop Concrete

=

-2,203 psi Reinforcement

=

-10.3 ksi These stresses satisfy the acceptance criteria given in Section 4.3.

4.5.3.2 Detensioned Condition Before Opening From Figures S.4-7 and S.4-8, it can be seen that the stresses in and around the opening area are reduced by detensioning.

Table S.4-1 shows that the vertical compressive force at the center of the opening decreases from -346 k/ft to -98 k/ft which includes a dead load of. -74 k/ft.

Similarly, the hoop force at the center of the opening changes from -702 k/ft to 18 k/ft.

There is an increase in vertical compressive force from -340 k/ft

(-633 psi) to -366 k/ft (-682 psi) at the location (12) diametrically opposite to the proposed opening.

A minimum vertical compressive force of -16 k/ft occurs at the location {1) near the ring girder directly above the opening.

S-16

Pa~ades Plant SGRR

.Supplement 1.

There is no noticeable increase in hoop compressive stress.

The maximum*hoop tensile stress of 62*psi occurs at the location (9).by the side of the proposed opening~-.. Allowable tensile stress is

,ff[

= 71 psi.

The thermal gradient of 60F, in conjunction with the other loads, results in the following flexural stresses:

a.

Vertical Concrete Reinforcement

=

-805 psi 6.5 ksi At (6), center opening

b.

Hoop Liner plate

=

1.12 ksi Reinforcement

=

23.35 ksi At (9), side of the opening_

These stresses satisfy the acceptance criteria given in Section 4.3.

4.5.3.3 Detensioned Condition with Opening The number of tendons proposed to be detensioned are sufficient to reduce the stresses in the opening area to small values.

Therefore, there is not much stress redistribution as shown in Table S.4-1 because of the opening.

For example, the vertical compressive force increases to -389 k/ft (-724 psi) at location (12) diametricaJly opposite to the opening.

There is no noticeable increase in hoop stress.

The maximum forces and* corresponding stresses from the concentrated.

rigging load of 275 kips on a polar crane bracket in the vicinity of the bracket are determined to be the following:

Meridional moment

=

51.4 k-ft/ft; +175 psi Hoop moment

=

58.0 k-ft/ft; +197 psi Membrane shear

=

23.7 k/ft; 47 psi Vertical force

=

34.9 k/ft; 69 psi Hoop force

=

25.3 k/ft; 50 psi The above maximum concrete stresses occur in the vicinity of the bracket and are small.

Also, the containment has extra reinforcement near the polar crane bracket areas.

4.5.3.4 Closed Condition Prior to Retensioning Shrinkage of new concrete causes some local stresses in and around the opening area as shown in Figures S.4-11 and S.4-12.

The S-17

Pal.ades Plant SGRR Supplement 1 fc;>llowing peak stresses occur. near the boundary betwe.en new and old

• co~crete:

Vertical:

Hoop:

crv= 71 psi and -64 psi crh= +58 psi These shrinkage stresses are small and secondary in nature.

4.5.3.5 Operational Condition Stresses during the operational condition, including.the effects of differential creep between new and old concrete, are obtained by analyzing the containment under sustained dead and prestress loads with a lower Young's modulus for the new concrete.

The results are shown in Tables S.4-1 and S.4-2.

It can be seen that the creep effects are localized, leading to a stress reduction in the new concrete and an increase of stress in.the old concrete adjacent to the new concrete.

As explained in Section 4.5.2.4, the act1.1al creep effects will be small.er than those obtained from the analysis because the creep deformation will continue, leading to a small stress difference between old and new concrete.

Also, creep has a minimal effect on the strength of the containment.

4.6 PRESTRESS IN TENDONS For convenience, the tendons in the containment are divided into the following three groups.

Group I - This consists of tendons far away from the opening area.

These tendons will not be detensioned for the steam generator replacement.

Group II - Fifty.:.six vertical and 12 hoop tendons are planned to be as included in this group.

These tendons are around the opening and will be detensioned but not removed during the steam generator replacement.

These tendons have had most of their relaxation losses occur during the last 10 years in the stressed condition.

These tendons will be retensioned to a stress level account for the prestress losses from the elastic and creep deformations in the old concrete around the tendons.

Group III - Fourteen vertical and 35 hoop tendons 'are planned to be included in this group.

These tendons are in the opening area.

They will be detensioned and removed during the steam generator replacement.

These tendons will be replaced by new tendons.

They will be tensioned to a stress level to account for the prestress losses from steel relaxation and from the elastic, creep, and shrinkage. deformations in the concrete.

S-18

4.7 EXTREME*ENVIRONMENTAL LOADS Pal.ades Plant SGRR Supplement 1 As explained earlier, extreme environmental loads need not be considered during* the construction period.

However,. the.containment has been analyzed for tornado windeffects and the operating basis earthquake (OBE) as. described in the FSAR.

The tornado has a maximum rotational velocity of 300 mph and a maximum translational velocity of 60 mph.

The free field OBE level is 0.10 g.

The results of the analyses are shown in Table S.4-1.

It can be seen

• that the OBE is more severe than the tornado condition.

The OBE contributes mostly to the stress condition along the hoop direction by the side of the proposed opening when the tendons are detensioned.. Forces for this cas~ are the following:

Hoop Force Bending Load Dead + prestress OBE Total Membrane 33 k/ft 34 k/ft 67 k/ft These forces cause a stress of 9.3 ksi in stress of 30.7 ksi in the reinforcement.

containment is expected, even from an OBE period.

4.8 MISCELLANEOUS CONSIDERATION 9.4 k-ft/ft 0

9.4 k-ft/ft the liner plate and a Thus, no damage to the during the construction Major structural elements other than the containment shell which are affected by the steam generator replacement were also investigated for their structural integrity.

During the steam generator replacement operation, the existing polar crane rail will be used for supporting the rigging equipment.

The crane rail girder and its supporting brackets were checked for structural adequacy.

The internal structures of the containment were checked for structural.adequacy. It was found that the resulting stresses are within allowables specified in the FSAR.

The expected rigging equipment loads inside the containment structure are shown in Figure S.4~4.

S-19

Palisades Plant SGRR Supplement 1 TABLE S.4-1 FORCES AT SELECTED LOCATIONS (SEE FIGURE S.4-3)

Loading Membrane Forces in k7ft at Location Condition 1

2 3

4 5

6 7

8 9

10 11 12 13 14 Existing (D+F)

-315

-313 -697

-322

-675

-346 -702

-356

-699

-414

-397

-340

-695

-316 De tensioned

-16

-26

-710

-68

-307

-98 18

-78 33

-117

-454

-366

-697

....,324 without opening (D+F)

Detensioned with

-30

-27

-710 2

-295 NA NA

-109 1

-227

-466

-389

-696 -348 opening (D+F)

Long-term with

-300 -296

-658

-262

-830

-261

-620

-400

-634

-395

-378

-336

-663

-301 creep* (D+F)

(-253)

(-510)

(-251)

(-625)

Shrinkage 2

5 0

19

-29 25 9

-32 4

6 2

1 0

• o

( 23)

(29)

(36) 7 OBE - without

+31

+45

+32

+63

+35

+73

+35

+70

+34

+118 +us

+73

+35

+31 opening OBE - with opening _:t31

+45

+32 0

0

.NA NA

+77 0

+118 +us +100

+68

+31 Tornado - without

+l

+3

+5

+6

+7

+8

+8

+7

+8

+20

+20

+8

+8

+1 e

opening NOTES:

creep effects based on a Young's modulus for t;he new concrete which is half of that for the old concrete

()

forces in the adjacent new concrete D

dead load F

p.restress lOad OBE operating basis earthquake S-20

.Condition Current De tensioned before opening De tensioned with opening Long-term with peak creep effects NOTES:

P~lisades Plant SGRR Supplement 1 TABLE S.4-2 MAXIMUM AND MINIMUM STRESSES (psi) FROM DEAD AND PRESTRESS LOADS Vertical Direction Hoop Direction Stress

-461

-663

-30

-682 4

-724

-439

-745 Location

( 11), base (8), center of opening (1), ring girder (12), opposite to opening (4), top of opening (12), opposite to opening (11), base (8), side of opening

1.

Refer to Figure S. 4-3 for locations.

2.

Allowable primary compression = -1,500 psi

3.

Allowable primary tension = 71 psi Stress

-1,257

-1,307 62

-1,322 2

-1,322

-950

-1,546*

4.

Stress shown with asterisk (*) includes secondary effects and satisfies Section 4.3.

S-21

• Location (5), top of opening (7) t center of opening (9), side of opening (3) t above opening.

(9), side of opening (3) t above opening (Sa), inside opening (5), top of opening

i.

I

. After detensfoning ar9efore

. cutting ihe opening.

/(_::;:*;:*;:.~:_:. *--."-,

Detensioned I,/'

/

'-,~,,_

• :Vertical Tendons f

I*,

I

• \\

1..'

I I (

220°.:

1 Plan at the II*,'*

I

\\

li center ne

!~*

(\\

T

-~------

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Kern

\\

/

1

~oint

\\

// / /

.* //

"-~

//

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~----~y~

ELEVATION

~~

J. ___

,.,_.* _. ---1--1 i

Centroid of Prestress Kern Point Location a = 0.49R e = 0.50R B?'-

7 STRESS FROM PRESTRESS F = 69860 K LOAD

-149 psi Wd = 28145 K STRESS FROM DEAD LOAD

-132 psi Afte-tensioning.and*after cutting the opening I I

• -1----"

.1 w =

d I I

~i

...;L.

• 1- **- ---.

a =

e =

a' =

0.4R o.41R.

0.089R

= 69860 K 27395 K I

...j..

-193 psi Edge of Opening PALISADES PLANT STEAM GENERATOR REPAIR REPORT VERTICAL STRESS AT TRE OPENING LEVEL FROM PRESTRESS(F)

AND DEAD (Wd) LOADS Figure.5 ~ 4*~ l

.~J T

42' cl::, Containment Force from hoop tendons

-1 341 52 6

I

• R=59.75 cE, Proposed opening*

'63

____ :10

-1,341 Hoop Stress (psi) 52 Meridional Moment (k-ft/ft).

PALISADES PLANT

-6 Radial Shear (k/ft)

STEAM GENERATOR REPAIR REPORT f!..FF~cf-OF. PETe~~*10..:i"1""16---

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SHELL ANALYSIS

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PALISADES PLANT STEAM GENERATOR REPAIR REPORT CXJNrA.nHm Im'ERNALS-RIOOING DESirn UlADS Figure S. 4

• 4

. ~

e PALISADES PLANT STEAM GENERATOR REPAIR REPORT THREE DIMENSICNAL PI.Or OF CXN!'AINMENI' SHELL (WI'm0t11' OPENING)

Figure S. 4-5.

PALISADES PLANT STEAM GENERATOR REPAIR REPORT

'lHREE DIMENSIONAL PIJ:Jr OF CCNI'AINMENr ( wr:m OPENING)

Figure S.4-6

CJ CJ III n.J CJ CJ CJ CJ III n.J I

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)(

CJ U1 C!

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?::::=

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VERTICAL avss SECI'ICN '.I'HmJ CTlll'ER CF OPENIN:;

~

DE'TENSicmD, WALL WI'IHOUI' OPENING MERIDIAN AND HOOP STRES.5ES n~ PSI' HEIGHT rn FEET lHJ.DlJ 6lJ.lJD i

I i

L OPNG.

DETENSIONED 18[).lJlJ

\\*

I

\\

I

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HOOP TENDONS

\\

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160.DD i8D.OD HEIGHT I +-MERIJJ.

X-HC?.l~P I J OP[N1NG Nne* AC 0

TYPICAL HORIZONTAL CROSS-SECTIOI\\

ELEVATION PALISADES PLANT STEAM GENERATOR REPAIR REPORT MEMBRANE STRF$ES, ~.

HEIGffl' (W.I'Im1r CPEmN:i)

Figure 5,4.7

Cl Cl CJ

!.D Cl MEMBRANE STRESSES DUE 'ID D:rnD PllJS PRESTRESS 1.0AOO HORIZCNrAI:, CKSS SECT.ION THRU CENI'ER OF OPENil-Ki TENDrnS DEI'EN.5IONED I WAIL WI'lliCXJI' ~

MERIDIAN AND HCX>P STRESSES IN PSI, AZIMUIH IN DEX;ru:J:s o.+--~~~~~_._~~~---~1--~~-+.-~~1--~-T"~~-+-~---..~~~~--.-~~~--,~~~~---,r-~~~--,

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~

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OPNG.

DETENSIONED 160.DD I

VERTICAL TENDONS J 2DIJ.IJO 2YD.DO 280.DD 320.DD 360.0u RZIMUTH

/

N

/*rt>

TYPICAL HORIZONTAL CROSS-SECTION OPENING

.i--~--+-..-.---1' -- *6Q'

-1..0'

-120 oP£N1NG eo~*

ELEVATION PALISADES PLANT STEAM GENERATOR REPAIR REPORT MEMBRANE S1'RESSES ~

AZnuIB (WI'lBX1l' CffNlK;)

Figure S. 4-* &

f r

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TENIXNS Dm'ENSICNED, WALL WI'lli QPENill; MERIDIAN AND HOOP STRESSES IN PSI, HEIGlfl' IN F'Err

l.

OPNG.

160.0!J 180.00 HEIGHT I

+-MERill.

X...-H~~p

./

N

/*r:t>

TYPICAL HORIZONTAL CROSS-SECTION wo'

-120 OPEN*""°'

eo~*

-20' ELEVATION PALISADES PLANT STEAM GENERATOR REPAIR REPORT MEMBRANE ~

VERStE BEIGEfl' {WITH CPEmNG)

Figure S. 4* q

(.

__.r,:

Cl Cl Cl LO Cl CJ CJ m

0 CJ CJ ru CJ CJ 0

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STRESSE.5 'AT WALL SURFACES Il-l PSI, AZIM11'H IN ~

16D.OD 2IJO.IJO 2YD.O:J 280.IJIJ 320.00 36IJ.IJO AZIMUTH N

/10-1

/

TYPICAL HORIZONTAL CROSS-SECTION 0P£NJNG 16Q.

-wo*

--120 OPENING eo~*

ELEVATION PALISADES PLANT STEAM GENERATOR REPAIR REPORT Figure S.4* lO

-../,*

Ln w Ln Ln w Lr

~

Ln w

z rr Lr i:{J

r: w

r:

0 0

0

<.[)

0 N

0 tO 0

0 MEMBRANE STRESSES OOE 'ID.s HR.I~.KA.~~

~r:-r=-ec; HORIZCNrAL CRa>S SH:TICN 'IHRJ CfNI'ER OF OPENING

'I'ENIXH> TENSICNED, WALL wrrna.rr OP~

MERIDIAN AND HCXlP. STRESSES IN PSI, AZ1Ml1I'H IN DEXiREES i

t OPNG.

I

+-MERIJl.

1

• _ X-H~~p 320_[)[)

35[)_[)0 AZIMUTH I

./

./

N

/*~l TYPICAL HORIZONTAL CROSS-SECTION OPENING eo~*.

ELEVATION PALISADES PLANT STEAM GENERATOR REPAIR REPORT MEMBRANE STRES3ES VERSUS A'?. I ivw n; (OPENING CioSFD)

Figure s. 4* ll

Lf1 l..J lJl lI1 w a:.:._.

lI1 w

z

((

a:.:

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0 c

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0 C'J

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0 MEMBRANE STRESSES 00E 'IO SH R. ! 1-.J K A.Ei!::

E. F F ~ c T VERTICAL cross SOCTICN THRlJ CENI'ER CF OPEN.Ill; TENIXNS TENSICNID, WALL WI'IHXJT OPENJN; MERIDIAN AND HCOP STRESSES n~ PSI' HEIGlfl' rn FEm' 59 :B 11.nB i

t.

OPNG, 91 22 ISS.56 115.0[1 HEIGHT TYPICAL HORIZONTAL CROSS-SECTION EL.~**o*

OPENl"'IG 141().

-120 OPE"'NG 80.!>

0 ELEVATION PALISADES PLANT STEAM GENERATOR REPAIR REPORT MEMBRANE~~.

µ, e.1 ~ wr (OPENING crnc;m)

Figure S.4* 12.

CONSTRUCTION OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1 5.0 FABRICATION-AND CONSTRUCTION 5.1 GENERAL Pa,sades Plant Supplement 1 SGRR Methods and procedures for cutting the construction opening were evaluated to ensure that there will be no detrimental effect on the containment structure and on the safety of the plant.

The sequence of cutting will be as.follows:

a.

Plant shutdown, cooldown, and starting of defueling

b.

Marking the construction opening boundaries with a surface cut in the concrete

c.

Completion of detensioning tendons

d.

Chipping concrete from outside of the containment

e.

Completion of defueling

f.

Cutting the liner plate

g.

Removing cutoff concrete and making the opening The details of cutting operations _are outlined in the subsequent sections.

Closµre of the construction opening was also investigated to ensure that the structural integrity can be restored.

The prestressing requirement for the retensioned tendons will account for the differential creep between new and old concrete (see Article 4.0).

All work will meet the requirements of the quality assurance program.

(See Section 4.7, SGRR.)

5.2 CONCRETE.AND GROUT 5.2.1 REMOVAL Concrete removal from the construction opening will be accomplished by utilizing conventional, mechanical means.

This-will consist of multiple crews working on the outside of the containment building from scaffolding using jackhammers and/or other concrete chipping equipment.

A saw cut will be made on the outside wall approximately 2 to 3 inches deep using a standard concrete saw to create a border for the closure placement.

Diamond blade saws may also be used on the inside of the containment wall in conjunction with the chipping operation.

S-22

Pa.Mades Plant SGRR Supplement 1 The liner plate and reinforcing steel will be cut as explained* in Sections 5 ~ 3.1 and 5. 5.1..

The concrete and liner plate will be removed together in one or more* pieces.

The p.l.ece(s) will be rigged with slings* and lifted, out with a crane, possibly with the assistance of a jacking operation.

5.2.2 PLACING The construction joints.will be.prepared and wetted in accordance with specification requirements.

The concrete will be pumped to tremies at the top of each lift and will be batched, deposited, and vibrated in accordance.with specification*requirements.

The resulting construction joint will be prepared and moist cured.

The wall surface will be sprayed with*curing compound when the forms are removed.

At the top of the final lift of concrete, a topping of nonshrink grout will be deposited.

.S.2.3 INSPECTION AND TESTING To ensure the quality of concrete, it is required that the batch plant be inspected and that sample testing be performed~ Concrete placing activities which affect quality shall also be inspected.

Detailed requirements for inspection and testing will be included in the technical specifications for supplying concrete and for forming, placing, finishing, and curing concrete.

These specifications satisfy the requirements of codes and standards..

5.3 REINFORCING SYSTEM 5.3.1 REMOVAL After the concrete has been chipped out, the rebar will be cut with a torch to enable the construction opening piece(s) to be removed.

Sufficient length of rebar will be left protruding from the remaining in-place end to allow for cadwelding the replacement bars, and a sufficient number of bars will be le!t uncut for supporting the piece(s) until the rigging has been completed and the crane is ready to accept the load.

It is not planned to bend the protruding rebar.

5.3.2 INSTALLATION

• The rebar will be replaced using cadwelds at the cut ends and standard splice lengths wherever feasible between the cadwelds.

The bars to be mechanically spliced will be cadwelded in accordance with specification requirements and the manufacturer's recommendations.

5.3.3 INSPECTION AND TESTING The reinforcing system will be fabricated and placed in accordance with the technical specifications for purchase of reinforcing steel and for placing of reinforcing steel.

These specifications satisfy the requirements of codes and standards.

S-23

f) 5.4 POST-TENSIONING SYSTEM

. 5. 4.. 1

• DETENS I ON ING Pa.ades Plant SGRR Supplement 1*

Hoop tendons which were double-end stressed will be detensioned utilizing two jacks.

Because of*interferences, some of the hoop tendons may need.to be detensioried from one end.

The vertical tendons were single-end stressed from the top and will be detensioned utilizing one jack.

The detensioning will.be performed in accordance with the applicable engineering specifications and procedures.

It will generally consist of removing the grease*caps, attaching the jacks, restressing the tendons to remove the shims, and then removing the jacks.

For the

.tendons to be retensioned rather than replaced, records will be kept of the amount of grease removed, the lift-off, and elongation readings.

5.4.2 REMOVAL Vertical tendons will be removed from the top.

The grease cans will be removed, and provisions will be made to collect the filler material in the tendon gallery.

The buttonheads in the tendon gallery will be cut off and the. anchor heads removed, then the tendons will be removed from the sheathing.

Hoop tendons will be removed in a similar manner.

5.4.3 INSTALLATION AND TENSIONING New tendons replacing the ones which were removed will be tensioned after the construction opening concrete has reached the required design strength in a balanced sequence.

The vertical tendons will be single-end stressed with jacks placed on the ring girder.

The tendons will be stressed, the shims placed, and the maximum gage readings, lift-off readings, and elongations will be recorded.

The grease cans and new gaskets will then be installed.

For the tendons which only need to be retensioned, grease will be installed by pumping, pouring, or packing methods.*

As a minimum, the amount of grease which was removed will be replaced.

Th.e hoop tendons will be double-end stressed except where access is restricted by existing interferences.

The jacks will be operated in conjunction with each other so that the tendon is stressed from both ends at virtually the same time and with similar elongation measurements.

The remainder of the operation for the hoop tendons is then identical to that described above for the vertical tendons.

5.4.4 INSPECTION AND TESTING The post-tensioning system shall be fabricated, installed, and.

prestressed in accordance with the requirements included in the technical specifications for purchase of the post-tensioning system and for installation of the post-tensioning system.

Inspection, S-24

. Pa,lsades *Plant SGRR

• Supplement 1 sampling,. and testing of the post-tensioning system shall be made in accordance with quality assurance requirements.

5.5 LINER PLATE.SYSTEM 5.5.1 REMOVAL The liner plate will be cut with either a saw or by a torch/air arc gouge operation.

It will be removed as an integral part of the concrete piece(s).

5.5.2 ERECTION The liner plate will have stiffeners welded on the,plate prior.to being installed.

The liner plate will be fitted,*tack welded, and checked for the specification erection tolerances prior* to the start of production welding.

All seam welds will be full penetration, multipass* welds, and it is expected that virtually all seam welds will use a backup bar.

The backup bar will* be removed, if required, for inspection of the seam welds.

The stiffeners on the back side of the liner plate will be spliced to the existing stiffeners..

Additional stiffeners may be added to the vertical angles for accommodation of the concrete/form placement.

5.5.3 INSPECTION AND TESTING The containment liner plate system will be fabricated and erected in accordance with the criteria set forth in the technical specifications for furnishing, fabrication, and delivery of the containment* structure liner plate and for erecting the containment structure liner plate.

Inspection, testing, and examination will be made on all materials and welds of the containment liner plate system to ensure the quality as stated in the above specifications.

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CONSTRUCTION. OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1 6.0 CONTAINMENT STRUCTURE TESTING 6.1 GENERAL Pa.sades Plant SGRR Supplement 1 After the steam generator replacement is completed, the construction opening will be closed with new concrete.. New tendons will be installed over the construction opening area and tensioned.

Detensioned tendons beyond the construction opening area will be retensioned.

The new concrete provided will be at least equal in strength to the existing concrete and placed with controlled curing to minimize differential creep between new and existing concrete and dry shrinkage in the new concrete (see Sections 2.2.3.2 and 5.2.2).

The new tendons provided will be at least equal in strength to existing tendons (see Section 2.6.1).

Both new tendons and detensioned tendons. will be tensioned to a stress level that accounts for prestress losses from steel relaxation and from the elastic, creep, and shrinkage deformations in the concrete (see Section 4.6).

The containment will be restored to its original structural integrity.

The construction activity is limited to a relatively small, localized area.

Therefore, a structural integrity test, which is required for initial structural acceptance, is not applicable to this repair activity.

To ensure leaktigbtness of the containment, an integrated leak rate test will be performed in accordance with the guidelines established in the FSAR for the Palisades nuclear plant.

6.2 INTEGRATED LEAK RATE TEST After the steam generator replacement operation, the containment structure will be subjected to an acceptance test to verify that the leaktight integrity is compatible with FSAR acceptance criteria.

The-leak rates measured.will not-exceed those permitted* in Appendix J of 10 CFR SO.

Details of the test procedure and instrumentation plan will be in accordance with the integrated leak rate test procedure in effect prior to the +epair.

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. CONSTRUCTION. OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1 7.0. MISCELLANEOUS* CONSIDERATION 7.1 CLOSURE OF THE CONSTRUCTION OPENING P~IJsades Plant SGRR Supplement 1 A temporary closure of the construction.opening will be provided* for weather protection and access control purposes.

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8.0 REFERENCES

CONSTRUCTION- *OPENING REPORT PALISADES PLANT.. SGRR

, SUPP.LEMENT 1 P.ades Plant SGRR

. s;upplement. 1

1.

Hansen, T. c. and Mattock, A.H.,

11 Influence of 'size and Shape of Member on the Shrinkage and Creep of Co'ncrete, 11 Journal of the American Concrete Institute (February 1966),

pp 267-290

2.

BSAP -.Verification Report (June 1978), Bechtel Power Corporation

3.

Pickett, G.,

11Shrinkage.StreSses in Concrete, 11 Journal of the American Concrete Institute (January 1946), pp 165-204; (February 1946), pp 361-398

4.

Bresler, B. and Iding, R.H., "Effects of Normal and Extreme Environment on Reinforced Concrete Structures," SP 55-11, Special Publication, American Concrete Institute

5.

Reichard, T.W.,

11Creep and Drying Shrinkage of Lightweight and Normci.l-Weight Concretes, 11 National Bureau of Standards Monographs 74 (March 1964}

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