ML19296D430

Const Opening Rept, Supp 1 to Steam Generator Repair Rept

ML19296D430
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
NUDOCS 8003040576
Download: ML19296D430 (49)

Text

PATJSADES PLANT U.S. NUCLEAR REGULATORY COMMISSION DOCKET NO. 50-255 CONSTRUCTION OPE 1\\IVG REPORT SUPPLEMENT NO.1 10 STEAM GEXERATOR REPAIR REPORT

@ Compan Consumers Power soo3040 h

Palisades Plant SGRR Supplement 1 TABLE OF CONTENTS

1.0 INTRODUCTION

1.1 GENERAL 1.2

SUMMARY

AND CONCLUSIONS 2.0 MATERIAL 2.1 GENERAL 2.2 CONCRETE AND GROUT 2.3 REINFORCING SYSTEII 2.4 LINER PLATE SYSTEM 2.5 WELDING MATERIAL 2.6 POST-TENSIONING SYSTEM 3.O 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 REMOVAL 5.2.2 PLACING AND CURING 5.2.3 INSPECTION AND TESTING 5.3 REINFORCING SYSTEM 5.3.1 REMOVAL 5.3.2 INSTALLATION 5.3.3 INSPECTION AND TESTING 5.4 POST-TENSIONING SYSTEM 5.4.1 DETENSIONING 5.4.2 REMOVAL 5.4.3 INSTALLATION AND TENSIONING 5.4.4 INSPECTION AND TESTING ii

Palisades Plant SGRR Supplement 1 5.5 LINER PLATE SYSTEM 5.5.1 REMOVAL 5.5.2 ERECTION 5.5.3 INSPECTION AND TESTING 6.0 CONTAINMENT STRUCTURE TESTING 6.1 GENERAL 6.2 INTEGRATED LEAK RATE TEST 7.0 MISCELLANEOUS CONSIDERATIONS 7.1 CLOSURE OF THE CONSTRUCTION OPENING

8.0 REFERENCES

iii

Palisades Plant SGRR Supplement 1 LIST OF TABLES TABLE TITLE S.4-1 FORCES AT SELECTED LOCATIONS (REFERENCE FIGURE S.1-1)

S.4-2 MAXIMUM AND MINIMUM STRESSES (psi) FROM DEAD AND PRESTRESS LOADS iv

Palisades Plant SGRR Supplement 1 LIST OF FIGURES FIGURE TITLE S.1-1 CONTAINMENT S.1-2 OPENING IN CONTAINMENT S.4-1 VERTICAL STRESS AT THE OPENING LEVEL FROM PRESTRESS (F) AND DEAD (W ) LOADS d

S.4-2 EFFECT OF DETENSIONING HOOP TENDONS S.4-3 FINITE ELEMENT MODEL FOR CONTAINMENT SHELL ANALYSIS - SELECTED LOCATIONS S.4-4 CONTAINMENT INTERNALS - RIGGING DESIGN LOADS S.4-5 THREE-DIMENSIONAL PLOT OF CONTAINMENT SHELL (WITHOUT OPENING)

S.4-6 THREE-DIMENSIONAL PLOT OF CONTAINMENT SHELL (WITH OPENING)

S.4-7 MEMBRANE STRESSES VERSUS HEIGHT (WITHOUT OPENING)

S.4-8 MEMBRANE STRESSES VERSUS AZIMUTH (WITHOUT OPENING)

S.4-9 MEMBRANE STRESSES VERSUS HEIGHT (WITH OPENING)

S.4-10 MEMBRANE STRESSES VERSUS AZIMUTH (WITH OPENING)

S.4-11 MEMBRANE STRESSE3 VERSUS HEIGHT (OPENING CLOSED)

S.4-12 MEMBRANE STRESSES VERSUS AZIMUTH (OPENING CLOSED) v

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CONSTRUCTION OPENING REPORT SUPPLEMENT 1 PALISADES PLANT SGRR

1.0 INTRODUCTION

1.1 GENERAL 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'-6" 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 feet wide by 30 feet high will be made in the cylindrical portion to allow the steam generator replacement.

The opening, as shown by solid lines in Figure S.1-2, is centered at the southeast corner (Azimuth N 118' 40'),

approximately 76 feet above the top 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

Palisades 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 CONCL ',0N 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 operation 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'-0" 3'

! 7 ' - 8 ",

A

/

• j a

EL. 768'-1"

+

3 l

\\-

(_ Dome Ring 9

\\

Girder

/

Cylindrical b

Shell i

EL. 696'-8" Polar Crane f

Bracket

.- 3'-6" l

i i

4 116' y

i

.+-

i t

. PALISADES PLANT STEAM GENERATOR REPAIR REPORT CONTAIhM'T Figure 6.1-1 i

i l

EL. 590'-0"

_t

,EL. 585'-0" 5'

f8'-6" p/T s-

/

8' 3

g Tendon l

Gallery

E N

S 205 180 145 85 25 0

l 118 -40'

[ opening 188,-40' 48 -40' EL. 766'-8" Ring i

s EL. 748'-6" Girder

~~

j l

_ Buttress l

t 35 Hoop l

I Tendons Removed i

i c"I EL. 6 79!1" i

d l

/I l

l i

i EL. 6 5013" i

I I

i i

47 Hoop Tendons i

i Detensioned l,

i i

i i

EL. 588'-6" l

t EL. 58 N 1

7 Base Slab 14 Vertical Tendons Removed 70 Vertical Tendons Detensioned OUTSIDE DEVELOPED ELEVATION OF CONTAINMENT PAllSADES PLANT STEAM GENERATOR REPAIR REPORT OPC;IEC IN CD:;TAISMC;T Figure S.1-2.

Palisades Plant SGRR Supplement 1 CONSTRUCTION OPENING REPORT PALISADES 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.

2.2.1.2 The existing and new concrete ingredients 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.

Poz::olan in conformance with ASTM C 618 Class /

A crushed dolomitic limestone aggregate obtained from e.

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

Palisades Plant SGRR Supplement 1 2.2.2 GROUT 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 613 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 ASTM A 15, No. 10 and 11 bars.

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

Reinforcing steel used for construction purposes will nat 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 constructio". 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,Section VIII, Division 1, Paragraphs 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

Palisades Plant SGRR Supplement 1 2.5 WELDING MATERIAL 2.5.1 Welding material used on the existing liner plate conformed to ASTM 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-relieve 1, having a guaranteed minimum ultimate tensile strength ( f u ) 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 stee)

'r equivalent.

2.6.2.5 The existing tendon wires conformed

.sSTM 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-5

CONSTRUCTION OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1 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 wall as required for the steam generator replacenent effort.

To Be Used fo* Repair of Contain-Reason for Used for ment Wall Original Code Existing After SG or Standard Not Contain-Change Being Used for Codes and Standards ment Wall (See Note 1) New Concrete ACI 211.1-77 Recommended X

Current code Practice for requirements Selecting Procortions for Normal and Heavy-weight Con-crete ACI 301-63 Specifica-X Not being used tions for in current power Structural clant construction Concrete for Buildings ACI 318-63,77 Building Code X

X Current code Requirements for Rein-forced Con-crete ACI 613-63 Recommended X

Using ACI 211.1, Practice for which is current Selecting practice Proportions for Concrete AISI 1141-63, Anchor Heads X

X 77 and Shins S-6

Palisades Plant SGRR Sucolement 1 To Be Used for Reoair of Contain-Reason for Used for ment Wall Original Code Existing After SG or Standard Not Contain-Change Reing Used for Codes and Standards ment Wall (See Note 1) New Concrete ASTM A 15-63 Reinforcing X

Replaced by Steel ASTM A 615 ASTM A 36-63, Structural X

X Current code 77a Steel ASTM A 223-63 Alloy Casting X

Discontinued for General Application ASTM A 366-63 Steel, Carbon, X

Using ASTM A 527 Cold-Rolled material, which Sheet, Commer-is current prac-cial tice ASTM A 421-63,

Uncoated, X

X Current code 77 Stress-Re-lieved Wire for Pre-stressed Con-crete ASTM A 442-63, Pressure Ves-X X

Current code 78 sel Plates, Carbon Steel Improved Transition Properties ASTM A 516-78 Pressure Vessel X

Alternative liner Plates, Carbon plate material Steel, for Moder-ate and Lower Temperature Ser-vice ASTM A 527-71 Steel Sheet, X

Current code (75)

Zinc-Coated (Galvanized) by the Hot-Dip Process, Lock-Forming Quality S-7

Palisades Plant SGRR Supplement 1 To Be Used for Repair of Contain-Reason for Used for ment Wall Oriainal Code Existing After SG or Standard Not Contain-Change Being Used for Codes and Standards ment Wall (See Note 1) New Concrete ASTM A 559-63 Welding X

Discontinued Electrodes ASTM A 615-78 Deformed and X

Current code Billet-Steel Bars for Con-crete Rein-forcement ASTM C 33-63, Concrete X

X Current code 78 Aggregates ASTM C 94-78a Ready-Mix X

Note 1 Concrete ASTM C 260-63, Air-Entrain-X X

Current code 77 ing Admix-tures for Concrete ASTM C 150-63, Portland X

X Current code 78a Cement ASTM C 350-63 Pozzolan X

Using ASTM C 618, Admixtures which is current practice ASTM C 494-63, Chenical Ad-X X

Current code 79 mixtures for Concrete ASTM C 618-78 Flyash and X

Current code Raw or Cal-cined Natural Pozzolan for Use as a Mineral Ad-mixture in Portland Cement Con-crete S-8

Palisades Plant SGRR Supplement 1 To Be Used for Repair of Contain-Reason for Used for ment Wall Original Code Existing After SG or Standard Not Contain-Change Beinq Used for Codes and Standards ment Wall (See Note 1) New Concrete AISC Nov 1, Specification X

X Current code 1963; 1978 for the De-sign, Fabri-cation, and Erection of Structural Steel for Buildings ASME 1977 and Boiler and X

Current code Addenda, Summer Pressure Ves-1979 sel Code,Section VIII, Division 1, Pressure Ves-sels ASME 1977 and Boiler and X

Current code Addenda, Summer Pressure Ves-1979 sel Code,Section IX, Welding and Brazing Qual-ification Note 1:

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

S-9

Palisades Plant SGRR Supplement 1 CONSTRUCTION OPENING REPORT SUPPLEMENT 1 PALISADES PLANT SGRR 4.0 ANALYSIS AND DESIGN 4.1 GENERAL The gross behavior of the containment during the construction period is shown in Figures S.4-1 and S.1-2.

It can be seen from the figure that the namber 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 dead and prestress loads.

Consideration is given to the effect of creep and shrinxage 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 soli' lines in Figure S.1-2.

Results of the finite element analyse-based on the larger opening will not be altered significantly by he smaller opening.

There fore, 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

= 665 k/ft Vertical

= 290 k/ft S-10

Palisades Plant SGRR Supplement 1 The containment was initially prestressed approximately 10 years ago.

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

Using the surveillance 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 100F is considered during the normal plant operating condition.

It corresponds to 105F 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.

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

The rate of creep and shrinkage 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

= 70 micro strain Creep

= 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 existing concrete 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 D+F+T o

b.

Detensioned D+F+T o

(without opening)

S-ll

Palisades Plant SGRR Supplement 1 c.

Detensioned D+F+C+T o

(with opening) d.

Operational D+F+T o

Where D

= Dead load Prestress load, varying for different conditions F

=

Operating thermal load during either normal T

=

o operation or construction, as appropriate Rigging load during steam generator replacement C

=

4.3 CRITERIA AND ALLOWABLES The containment is checked to satisfy the original criceria given in Appendix B of the FSAR.

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

Allowable Material Nature of Stress Stress Note Concrete Membrane compression 0.3 f6 Membrane tension 3/ f[

Flexural compression 0.6 ff (1)

Flexural tension 3/f[

(2)

Reinforcement Tension 0.5 fy Liner Plate Tension 0.5 fy Notes:

(1) Local compressive stress can be as high as 0.75 ff (2) When the flexural tensile stress exceeds 3dff 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

Palisades Plant SGRR Supplement 1 a.

Old Concrete Instantaneous Young's modulus E

= 5.5 x 10 psi c

Sustained Young's modulus E

= 2.7 x 10 psi cs b.

New Concrete Instantaneous Young's modulus E

= 5.5 x 10 psi c

Sustained Young's modulus Ecs = 2.7 x 10 psi c.

Old and New Concrete Poisson's ratio Y

= 0.17 Density

/

= 150 lb/ft Design strength ff

= 5,000 psi coefficient of thermal

= 6 x 10 -9/ F expansion a

d.

Old and New Steel (Reinforcement, liner plate, post-tensioning tendons 8

Young's modulus E

= 30 x 10 psi s

Poisson's ratio 7

= 0.3 Yield strength of reinforcement f

= 40 ksi y

Yield strength of liner plate f

= 30 ksi y

Ultimate strength of tendons f

= 240 ksi pu 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 8

Ecs= 2.7 x 10 psi is used in the finite element analyses when the old concrete alone is involved.

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 3-13

Palisades Plant SGRR Supplement 1 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 modeled because they are at a sufficient distance away from the proposed opening to preclude structural interaction.

The BSAP computer program is used to 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 inner 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

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 and 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 partially 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 4

subjected to a uniform thermal strain of -70 x 10 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 0.2 ff and 0.6 ff, 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 defermation 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 and reach an equilibrium condition with a small 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

Palisades Plant SGRR Supplement 1 conditions under primary loads.

Using the results as guidance, this section illustrates that the containment meets the design criteria and allowables.

The implicit 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 estimated 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:

h= -1,307 psi along hoop direction c = -663 psi along vertical direction v

These stresses are below the allowable stress of 0.3 f' = 1,500 psi.

Addition of the thermal gradient of 100F results in the following flexural stresses:

a.

Vertical

-1,491 psi Concrete

=

Reinforcement

-0.263 ksi

=

b.

Hoop

-2,203 psi Concrete

=

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

Palisades 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 s/fs

= 71 psi.

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

a.

Vertical Concrete

=

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

=

b.

Hoop Liner plate 1.12 ksi

=

23.35 ksi At (9), side of the Reinforcement

=

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) diametrically opposite to the opening.

There is no noticeable inc2Dase 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; 1175 psi

=

58.0 k-ft/ft; 1197 psi Hoop moment

=

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

Palisades Plant SGRR Sepplement 1 following peak stresses occur near the boundary between new and old concrete:

Vertical:

c = 71 psi and -64 psi y

Hoop:

ch: 158 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 actual creep effects will be smaller than those obtained from the analysis because the creep deformation will continue, leading to a small stress difference between old and new concre e.

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

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

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

However, the containment has been analyzed for tornado wind effects 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 case are the following:

Hoop Force Load Membrane Bending Dead + prestress 33 k/ft 9.4 k-ft/ft OBE 34 k/ft 0

Total 67 k/ft 9.4 k-ft/ft These forces cause a stress of 9.3 ksi in the liner plate and a stress of 30.7 ksi in the reinforcement.

Thus, no damage.to the containment is expected, even from an OBE during the construction period.

4.8 MISCELLANEOUS CONSIDERATION 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 k/ft at Location Condition 1

2 3

4 5

6 7

8 9

10 11 12 13 14 Existing (DtF)

-315 -313 -697

-322

-675

-346 -702

-356

-699

-414 -397 -340 -695 -316 Detensioned

-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 (DtF)

Long-te rm 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

0 (23)

(29)

(36) 7 OBE - without 131 145 132 163 135 173 135 170 134 1118 Ill8 I73 I35 I31 opening OBE - with opening 131 145 132 0

0 NA NA 177 0

1118 Ill8 Il00 I68 I31 Tornado - without il 13 15 16 17 18 18 17 18 120 I20 I8 I8 Il opening

= creep effects based on a Young's modulus for the new concrete which is half of that NOTES:

for the old concrete

()

forces in the adjacent new concrete

=

D

= dead load F

= prestress load OBE = operating basis carthquake S-20

Palisades Plant SGRR Sunplement 1 TABLE S.4-2 MAXIM 11 AND MINIMUM STRESSES (psi) FROM DEAD AND PRESTRESS LOADS Vertical Direction Iloop Direction Condition Stress Location Stress Location Current

-46i (11), base

-1,257 (5), top of opening

-663 (8), center of opening

-1,307 (7), center of opening Detensioned

-30 (1), ring girder 62 (9), side of opening before

-682 (12), opposite to opening

-1,322 (3), above opening opening Detensioned 4

(4), top of opening 2

(9), side of opening with

-724 (12), opposite to opening

-1,322 (3), above opening opening Long-term

-439 (11), base

-950 (Sa), inside opening with peak creep

-745 (8), side of opening

-1,546*

(5), top of opening effects NOTES:

1.

Refer to Figure S.4-3 for locations.

2.

Allowable primary compression = -1,500 psi 3.

Allowable primary tension = 71 psi 4.

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

S-21

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STEAM GENERATOR REPAIR REPORT MEMBRNE SIRESSES VERSUS W.el's H T (OPENDG CIDSED)

Figure S.4-l2

Palisades Plant SGRR Supplement 1 CONSTRUCTION OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1 5.0 FABRICATION AND CONSTRUCTION 5.1 GENERAL 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.

Closure 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.

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Palisades 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 piece (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.

5.2.3 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 left 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.

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Palisades Plant SGRR Supplement 1 5.4 POST-TENSIONING SYSTEM 5.4.1 DETENSIONING 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 detensioned 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.

The 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 Lae post-tensioning system.

Inspection, S-24

Palisades 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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Palisades Plant SGRR Supplement 1 CONSTRUCTION OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1 6.O CONTAINMENT STRUCTURE TESTING 6.1 GENERAL 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 leaktightness of the containment, an integrated leak rate test will be performed in accordance with t.ke 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 50.

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

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

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Palisades Plant SGRR Supplement 1 CONSTRUCTION OPENING REPORT PALISADES PLANT SGRR SUPPLEMENT 1

8.0 REFERENCES

1.

Hansen, T.C.

and Mattock, A.H.,

"Influe ce of Size and Shape of Member on the Shrinkage and Creep c Concrete," Journal of the American Concrete Institute (February 1966),

pp 267-290 2.

BSAP - Verification Report (June 1978), Bechtel Power Corporation 3.

Pickett, G.,

" Shrinkage Stresses in Concrete," Journal of the American Concrete Institute (January 1946), pp 165-204; (February 1946), pp 361-398 4.

1resler, 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.,

" Creep and Drying Shrinkage of Lightweight and Normal-Weight Concretes," National Bureau of Standards Monographs 74 (March 1964)

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