ML18051A616
| ML18051A616 | |
| Person / Time | |
|---|---|
| Site: | Palisades |
| Issue date: | 09/23/1983 |
| From: | Toner K CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | Crutchfield D Office of Nuclear Reactor Regulation |
| References | |
| TASK-03-07.B, TASK-3-7.B, TASK-RR NUDOCS 8309280187 | |
| Download: ML18051A616 (22) | |
Text
{{#Wiki_filter:consumers Power company General Offices: 1945 West Parnall Road, Jackson, Ml 49201 * (517) 788-0550 September 23, 1983 Dennis M Crutchfield, Chief Operating Reactor Branch No 5 Nuclear Reactor Regulation US Nuclear Regulatory Commission Washington, DC 20555 DOCKET 50-255 - LICENSE DPR PALISADES PLANT - SEP TOPIC III-7.B "DESIGN CODES, DESIGN CRITERIA AND LOAD COMBINATIONS" - EVALUATION OF STEEL EMBEDMENT In a letter dated February 28, 1983, Consumers Power Company committed to resolving the remaining open item in SEP Topic III-7.B by submitting an evaluation of the ability of steel embedments to meet the requirements of the American Concrete Institute Standard ACI-349-80, Appendix B. This letter responds to the commitment by providing the attached report in which it is concluded that the original embedment design is acceptable. ~lt:l~uAJ Kerry A Toner Senior Licensing Engineer CC Administrator, Region III, USNRC NRC Resident Inspector - Palisades Attachments ,r -S3092So"1S7 ___ S30923 _____ -- ' PDR ADOCK 05000255 P PDR OC0983-0014A-NL02
r----- ------ ATTACHMENT Consumers Power Company Palisades Plant Docket 50-255 SEP TOPIC III-7.B "DESIGN CODES, DESIGN CRITERIA AND LOAD COMBINATIONS" EVALUATION OF STEEL EMBEDMENTS September 23, 1983 6 Pages OC0983-0014B-NL02
- e.
I. INTRODUCTION SEP III-7.B CODE CHANGE EVALUATION AC! 349-80, Appendix B The following report addresses the last remaining open item on SEP Topic III-7.B on "Design Codes, Design Criteria and Load Combinations*." This last item concerns a new code addition in an American Concrete 1 .Institute Standard,.ACI 349-80, Appendix B,*entitled "Steel Embedments." This new addition to AC! 349-80 provides general (philosophical) and specific (dimensional and detailing) requirements for the design of steel embedments. These embedments include headed bolts, shapes and plates, and expansion anchors, among others. Although this is the first time the AC! addresses this issue, this does not necessarily imply that the old design methods were inadequate; merely that the criteria are now better defined and require less interpretation by the d~signer.
- II.
EVALUATION METHODOLOGY ACI 349-80, Appendix B and its commentary provides the philosophical requirements of embedment design in terms of preferred failure modes and specific requirements in terms of spacing, edge distance and factors of safety. Its scope is necessarily detailed and comprehensive. An item-by-item comparison, as suggested in our earlier action plan, is considered unnecessary because the integrated approach used in this re-port is more effective. In this integrated approach, the code is re-viewed synoptically and the key elements are highlighted. These are compared with the related design code or industrial guides available at the time of the construction of the plant. The result of this compar-ison should allow one to focus on the areas of concern. With these areas of concern in mind, the structural drawings of the Class I structure are reviewed and any structural element built and loaded accordingly is identified. These are analyzed per the new code with the actual loading or a conservative upper-bound estimate. The
- results are then summarized and reported.
III. GENERIC COMPARISON A. AC! 349, APPENDIX B For code comparison, the latest AC! 349-80 code was used in conjunc-tion with a recently approved revision to that code (reference AC! Journal March-April 1983 and September-October 1983). As a synopsis, the key requirements that may be relevant to Palisades are: rp0983-0189a-63-42
2 General The preferred failure mode is ductile failure of the steel embedment rather than brittle tensile cracking of the concrete. Tension In tension, ductile failure means that the force required to pull out the potential failure cone is greater than the ultimate strength of the embedment. The former is measured approximately by 4~ acting on the projected tensile stress area of the failure cone. The effect of overlapping of potential failure planes and reduction of effective stress area due to edge effect must be considered. The load factors are per Section 9.2 of ACI 349-80 and the strength reduction factor ¢ is 0.85 except for embedment located in cracked sections in which ¢ is 0.65. The design steel strength is 0.9f or 0.8f t; whichever is less. y u Shear The strength of anchors subjected to shear is not significantly af-fected by concrete strength unless the anchors are located near an edge or the anchors exhibit nonlinear load deflection behavior. For embedments subjected to shear loading toward a free edge, the code requires a minimum edge distance such that the shear strength of the anchor steel can be fully developed. Again, overlapping of effec-tive stress area has to be considered. For the design of bolts and bars, the shear friction mechanism can be assumed. The design steel strength is based on 0.85fut" Bearing Bearing requirement may be satisfied automatically with an accept-able anchor head configuration. Combined Tension and Shear For design of bolts, the area of steel required for tension and shear is additive. Expansion Anchors Design of expansion anchor bolts is similar to the above except that the strength reduction factor is reduced to 90% of those for headed bolts. Bolt strength is based on average tensile or minimum speci-fied tensile strength (if such is defined). The codes consider satisfying this criteria as ensuring a ductile failure. Alter-nately, for expansion anchors that do not meet the above ductility requirement, the allowable design strength of the anchor should be 1/3 of the average tension and shear test failure load. rp0983-0189a-63-42
I 3 Inserts and Grouted Anchors Similar guidelines are given for inserts and grouted anchors. B. DESIGN PHILOSOPHY CIRCA 1967 Because of an apparent lack of design documentation pertaining specifically to embedment at the Palisades Plant, the approach taken here is to survey codes, standards and industry design guides contemporary with Palisades design and construction activities (ca 1967).
- 1.
ACI 318-63 ACI 318-63 recognizes the 45° failure cone for diagonal tension failure. The shear stress allowable for this cone failure is also 4/f': The strength reduction factor is the same as ACI 349-BO except that the 1963 code does not explicitly address a factor for embedment in cracked concrete. It can be concluded that embedments made out of prefabricated shapes and plates meet current requirements except when embedded in cracked concrete (eg, tension side of beams and slabs loaded at or beyond cracking moment). This loading situation is un-likely to be found in seismic Class I structures.
- 2.
Uniform Building Code (1967 Edition) For bolts embedded in concrete, the UBC specifies a limiting shear load which results in an average shear stress of 4.0 to 4.5 ksi (Enclosure No 2). Tensile load is not addressed in the 1967 edition of UBC. Furthermore, no material is specified. For comparison, the lowest grade of bolt used at Palisades was A307 with an ultimate tensile stress of about 55 ksi. For HS bolts A325, the ultimate stress is approximately 115 to 120 ksi. In other words, the allowable stress implied by UBC is roughly 10% to 5% of fut for A307 and A325 bolts, respectively. There-fore, it can be inferred that UBC design implies a brittle failure mode. Furthermore, the 1967 UBC does not specify minimum bolt spacing and minimum edge distance requirements. Overall, however, the high factor of safety should preclude brittle failure due to occasional overload.
- 3.
Concrete Stud Anchors Nelson studs were used extensively at Palisades. *Since 1961, Nelson had published a design guide entitled "Engineering Design Data - Nelson Concrete Anchors." This guide provides guidelines for the design of tension and shear load and their combination. There were no specific guidelines for stud spacing and edge distance. A comparison of the Nelson guidelines with ACI 349 (Enclosure No 1) shows that Nelson's guidelines for design of rp0983-0189a-63-42
4 stud is at least 1.4 and 1.7 times more conservative than ACI requirements for tensile and shear load, respectively, for a single bolt. Nelson design is also based on ductile failure. Bearing requirement is automatically satisfied by their head-to-shank dimensions. Shear and tension combination requirements are identical to the ACI approach.
- 4.
Expansion Anchor Bolts In response to IE Bulletins 79-02 and 79-14, it is found that the majority of the expansion anchor bolts are "Red Head" Phillips anchors. A 1972 catalog indicates design loads that were based on tests which results in brittle~concrete failure for tensile load and bolt shear failure for shearing loads. The factor of safety recommended was four (4.0). Compared to AC! 349 on a per bolt basis, this is 33% more conservative. However, there is no guideline for bolt spacing and edge distances nor are there any specific guidelines for design of tension and shear combinations. C. OTHER RELATED REANALYSIS/MODIFICATION Since the initial design of the plant, various reanalysis/modifi-cation has been performed. Some of these that are of interest to the present discussion are as follows:
- 1.
Block Wall Modification (NRC IE Bulletin 80-11) Among other issues, the block wall anchorage was modified to withstand seismic load.
- 2.
Safety-Related Electric Equipment (per NRC IE Information Notice, Dated January 1, 1980) Safety-related electrical equipment support was reanalyzed and modified as required.
- 3.
Safety-Related Piping (per NRC IE Bulletins 79-02 and 79-14) Essentially, all safety-related, large bore piping supports were tested and reanalyzed. Such test criteria include checking for bolt center-to-center spacing and edge distance. Reanalysis includes shear and tension interaction. Safety-related pipiµg supports evaluated have been found acceptable after the neces-sary modification.
- 4.
NUREG/CR-1833 (UCRL-53015), "Seismic Review of the Palisades Nuclear Power Plant Unit 1 as Part of the Systematic Evaluation Program" (December 1980) In this report, many items of mechanical equipment and tanks were evaluated with regard to their structural integrity under rp0983-0189a-63-42
5 seismic load. One of the criteria is bolt pullout failure. In most cases, the bolt stresses are at a low stress level. In one instance, the bolt is predicted to fail by yielding.
- However, this tank (T-81) was classified as a Class III structure in the original design.
D.
SUMMARY
OF POTENTIAL CODE CONCERNS
- 1.
Structural Groups Excluded As a result of work performed in III.C above, certain groups of structures are excluded in this evaluation. Furthermore, light structures such as platforms, walkways and catwalks are ~gnored since their primary design loads are small and static in nature. The summary of structural groups excluded is:
- a.
Prefabricated shapes and plates (III.B.1).
- b.
Expansion anchor bolts (since they are primarily used for pipe supports and light structures such as platforms and walkways).
- c.
Block walls.
- d.
Safety-related electrical equipment.
- e.
Tank supports.
- 2.
Structural Elements Included for Drawing Survey With Respect to Potential Code Concern
- Headed bolts and stud anchors:
- Center-to-center spacing and edge distance for bolts subjected to tensile load. - Edge distance for shear load and overlapping failure planes. IV. RESULTS OF EVALUATION AND CONCLUSION From a survey of structural drawings involved, there are only limited cases which fall into the categories in III.D.2. Two of these are evaluated (Enclosures No 3 and No 4). Based on these evaluations and inferences made from an understanding of the state of the art of anchor design circa 1967, it can be concluded that the original design uses a very low allowable stress on the anchor (ie, a high factor.of safety against rupture). This design philosophy will result in a brittle failure mode; ie, the concrete cone will pull out prior to anchor failure. Furthermore, there is a lack of specific control on bolt spacing and edge clearance which may cause brittle cone failure. However, with the large factors of safety against rupture and rp0983-0189a-63-42
6 with practical limits regarding bolt spacing and edge clearance, brittle failure is unlikely. Therefore, evidence indicates that, though there is a lack of clearly defined guidelines, the original design is acceptable because there is considerable margin against a brittle concrete failure in case of an occasional overload. rp0983-0189a-63-42
ENCLOSURE 1 Consumers Power Company Palisades Plant Docket 50-255 SEP TOPIC III-7.B "DESIGN CODES, DESIGN CRITERIA AND LOAD COMBINATIONS" EVALUATION OF STEEL EMBEDMENT Calculation /fl "Comparison of ACI 349 Appendix B with Industry Guidelines for Studded Anchor Bolts" September 1983 4 Pages OC0983-0014B-NL02
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'\\';'.'.~ '*. : *'.. ENCLOSURE 2 Consumers Power Company Palisades Plant Docket 50-255 SEP TOPIC III-7.B "DESIGN CODES, DESIGN CRITERIA AND LOAD COMBINATIONS" EVALUATION OF STEEL EMBEDMENT Calculation 112 "UBC 1967 Requirements for Anchor Bolt Design" September 1983 One Page OC0983-0014B-NL02
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ENCLOSURE 3 Consumers Power Company Palisades Plant Docket 50-255 SEP TOPIC III-7.B "DESIGN CODES, DESIGN CRITERIA AND LOAD COMBINATIONS" EVALUATION OF STEEL EMBEDl1ENT OC0983-0014B-NL02 Calculation 113 "Sampling of Shear Capacity of Embedment with '!felson Stud Anchors" September 1983 3 Pages
consumers Power company OPERATING SERVICES DEPARTMENT
Subject:
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consumers Power company*-- OPERATING SERVICES DEPARTMENT
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ENCLOSURE 4 Consumers Power Company Palisades Plant Docket 50-255 SEP TOPIC III-7.B "DESIGN CODES, DESIGN CRITERIA AND LOAD COMBINATIONS" EVALUATION OF STEEL EMBEDMENT Calculation 114 "Sampling of Tension Capacity of Headed Bolt Group" September 1983 2 Pages OC0983-0014B-NL02
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