ML19343B813

Second Interim Deficiency Rept,Originally Reported on 801106,re Site Qualification Testing of Hilti-Kwik Bolts Which May Not Meet Spec Requirements for 1.5 Times Working Load & Ultimate Capacity (Max Pullout Load)

ML19343B813
Person / Time
Site:	Perry
Issue date:	12/19/1980
From:	Davidson D CLEVELAND ELECTRIC ILLUMINATING CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR-050.55E, 10CFR-50.55E, NUDOCS 8012300599
Download: ML19343B813 (3)

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wCC FRESiOENT M Nu ENG. NEE AtNG AND CON 5tmuCT oN December 19,-1980 Mr. James G. Keppler Director of Region III Of fice of Inspection and Enforcement - -

U. S. Nuclear Regulatory Commission 799 Roosevelt Road-Glen Ellyn, Illinois 60137 ,

RE: Perry Nuclear Power Plant Docket Nos. 50-440; 50-441 Interim Report on Qualification Testing of Hilti-Kwik Bolts

Dear Mr. Keppler:

This letter serves as a second Interim Report in accordance with 10CFR50.55(e) concerning results of site qualification testing of Hilti-Kwik Bolts. The first Interim Report was submitted on November 6,1980. The November 6 report indicated that the Final Report would be submitted to the NRC by December 19, 1980. Mr. J.

Hughes, Resident NRC Inspector, was informed on December 17, 1980, by Mr. G. Leidich of The Cleveland Electric Illuminating Company, that a second Interim Report would be submitted in lieu of the Final Report which will be submitted at a later date.

This report includes a revised description of the condition, testing evaluation and corrective actions, and the planned date for the Final Report. <-

Problem Description Test results for various sizes of safety-related Hilti-Kwik Bolts, manufactured by Hilti Fastening Systems, Inc., Tulsa, Oklahoma, may not meet specification require-ments for "1.5 times the working load" and ultimate capacity (maximum pull-out load).

Qualification testing conducted in accordance with Specification SP-208-4549-00, dated June 28, 1978, does not provide assurance that Hilti-Kwik Bolts, as currently

-L- installed, meet the specification requirements. ,

Testing Evaluation and Corrective Actions Additional qualification testing of Hilti-Kwik Bolts was performed during November ~

1980. The following conclusions and corrective actions were cade as a result of the evaluation of the available test data:

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, M,r. James G. Keppler December 19, 1930 A. Conclusions of the Evaluation

1. The installation torque of 480 ft.-lbs, for installing 1-1/4 inch diamet'er Kwik-Bolts provides a minimum preload at time of installation of 1.1 times maximum working load used for design. This is in excess of the 1.0 times maximum working load required by USNRC I.E. Bulletin 79-02, but less than the 1.5 times working load required by the Perry installation specification. The maximum working load as defined by the specification is based on the manuf acturer's published ultimate pull-out load with a minumum safety factor of 4'.0,

2. The 1-inch diameter Hilti-Kwik Bolt has not reasonably demon-strated its ability to develop an average ultimate capacity of.

22,550 lbs. in 3,000 psi concrete as . required by the installa-tion specification. It has, however, demonstrated its ability

! to achieve the revised ultimate capacity indicated by the manufacturer in their October 27, 1980 letter, which notified Perry Project Organization that a report has been filed by Hilti in accordance with 10CFR21. The revised average ultimate capacity is 20,820 lbs, for 3,000 psi concrete.

3. The 1/2-inch diameter Hilti-Kwik Bolt has not demonstrated its ability to achieve manuf acturer's ultimate capacity in the in situ Category I concrete at Perry.

4 The ability of the 1/4-inch diameter Hilti-Kwik Bolt to achieve manuf acturer's capacity in 3,000 psi concrete is borderline, The September 1980 tests show an average 15% below the manu--

facturer's data for the actual concrete strength, B, Corrective Actions to be Taken

1. The installation of 1/2" diameter Hilti-Kwik Bolt was s, topped on November 8,1980, by the issuance of the following Engineering Change Notices: 5544-49-189; 5545-90-88; 5546-33-1004; 5543 453; 5548-39-59; 5549-38-92; 5550-20-740; 5551-91-194; and 5555-68-22. The deletion of the 1/2-inch diameter Hilti-Kwik Bolts will remain in ef fect indefinitely. The practice of substituting 5/8-inch bolts for designs requiring 1/241nch , bolts will continue. Designers will be notified that 1/2-inch bolts are not to be specified.

. 2. The installation specification will be revised to require an installation torque of 560 f t.-lbs. for all future 1-1/4 inch diameter Hilti-Kwik Bolt installations. One and one-quarter inch diameter Hilti-Kwik bolts installed to date are acceptable since they meet minimum USNRC requirements as stated in I. E.

Bulletin 79-02. .

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• Mr. James G. Keppler Dacember 19, 1980

3. The ultimate capacity for future designs using 1-inch diameter Hilti-Kwik Bolts is 20,820 lbs. Designers will be informed of this reduced value. The specification will be revised to reflect this reduced value.

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4 A statistical evaluation of all existing concrete cylinder breaks for Category I concrete used at Perry to date is being initiated to establish a minimum anticipated concrete compressive strength for use in evaluating prior designs utilizing 1/4-inch,1/2-inch and 1-inch diameter Kwik Bolts.

Planned Date for Final Report The Final Report will be submitted to the NRC by May 15, 1981. This time will permit engineering evaluation and identification of any action to be taken for installed safety-related Hilti-Kwik Bolts.

Very truly yours D. R. Davidson Vice President System Engineering and Construction ksz cc: "r. Jack Hughes Resident NRC Inspector i

Mr. Victor Stello, Director Office of Inspection and Enforcement

• U. S. Nuclear Regulatory Commission Washington, D. C. 20555 .

U. S. Nuclear Regulatory Commisison -

c/o Document Management Branch Washington, D. C. 20555 i

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