Text

Affidavit Re Contention I-A on Substandard Reinforced Concrete Const.All Welds Reinspected.Random Testing Revealed No Defects
	ML20011A465
Person / Time
Site:	Callaway
Issue date:	10/07/1981
From:	Gallagher E; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:	;
Shared Package
ML20011A456	List: IR 05000483/1977006; IR 05000483/1977011; IR 05000483/1978001; IR 05000483/1978003; ML20011A455; ML20011A458; ML20011A459; ML20011A460; ML20011A462; ML20011A464; ML20011A465; ML20011A468; ML20011A470; ML20011A473; ML20011A474; ML20011A482; ML20011A486; ML20011A487; ML20011A489; ML20011A491; ML20011A494; ML20011A503; ML20011A506; ML20011A513; ML20011A519; ML20011A520; ML20011A528; ML20011A530; ML20011A531; ML20011A534; ML20011A535; ML20011A537; ML20011A543; ML20011A546; ML20011A550; ML20011A554;
References
	ISSUANCES-OL, NUDOCS 8110130444
	Download: ML20011A465 (5)
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UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In t' c Watter of UdION ELECTRIC COMPANY

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Docket Nos. 50-483 OL (Callaway Plant, Unit 1)

AFFIDAVIT OF EUGENE J. GALLAGHER IN SUPPORT OF NRC STAFF MOTION FOR

SUMMARY

DISPOSITION ON THE ISSUE OF JOINT INTERVEN0RS'S CONTENTION 1-A I, Eugt.1e J. Gallagher, being duly sworn, depose and state:

1.

I am a civil es gineer with the U.S. Nuclear Regulatory Comission.

Since February 1981, I have been assigned to the Reactor Engineering Branch, Division of Resident and Regional Reactor Inspection, Office of Inspection and Enforcement.

Prior to February 1981, I was a reactor inspector assigned to the Region III, Reactor Construction and Engineering Support Branch: Office of Inspection and Enforcement.

I was assigned to the teilt.way Plant (among others) during the period of L%cember 1977 through September 1980. A state-ment of my professional qualifications is appended hereto.

2.

As a civil engineer inspector for the Region III office of Inspection and Enforcement I conducted five inspections with respect to the Callaway Plant, Unit 1, in n Jer to:

(1) ascertain whether adequate quality assurance plans, instructions and procedures had been cytablished for tne construction of concrete structures; (2) provide an independent evaluation of the perf0teance, work in pra ress and completed work to k,k0k$ocf0S000 0

ascertain whether activities relative to concrete constructhm were ac-complished in accordance with HRC requirements, and (3) review the quality related records to ascertain whether these records reflected work accom-plished consistent with NRC requirements and license commitments. The results nf these inspections are contained in the following NRC inspection reports:

50-483/77-11, conducted December 13, 1977 through January 8,.978.

50-483/78-01, conducted January 10, 1978 througt February 8,1978.

l 50-483/78-03, conducted March 29, April 18-19,1978.

50-483/80-14, conducted April 10, 1980 through (Attachment 1)

August 14, 1980.

50-483/80-16, conducted June 10-12, 1980.

3.

The purpose of this affidavit is to address Joint intervcnors' Contention I-A as identified in the Special Prehearing Conference Order, dated April 21, 1981.

4.

Embedded plates are steel plates set in concrete to serve as supports for piping, electical conduits 4.nd caole trays, HVAC coupunents, dnd structural steel framing. The plates are constructed by welding studs to one side of the plate. A plate is then positioned before concrete for the walls is poured. The concrete hardens around the studs, thereby affixing the plate to the wall.

5.

Stuc are welded to the plates by one of two methods. They can either be manually welded to the plate material by use of thE shield metdl are process in accordance with American Welding Society (AWS) code, or the studs can be welded to the plates by use of automatically-

timed machine in accordance with AWS code.

Both manual and machine-welded plates na used e the Callaway Plant. All the ;itates for the facility were welded by the C:ves Steel Company at their plant in Gouverneur, l

liew York.

6.

On June 9, 1977, during a routine f1RC inspection (documented in Report tio. 50-483/77-05), an t4RC inspector identified embedded plates with mact. ne-welded studs which did not contain full 360 degree weld (flash) material and had not been bend tested as required by AWS D1.1-75 (Part F) welding code. The bend test requires studs without 360 degree weld to be bent fif teen degrees in the directlon opposite to the gap in the weld.

If a crack in the weld appears (or if the stud breaks off from the plate), repairs must be made. Otherwise, the weld and the stud ey be used as is.

7.

As a result of '.ae liRC inspection, Union Electric issued two "stop work" orders pending a complete investigation of the problem. One stop verk order prevented further placement of concrete with embedded plates; the other prohibited Cive; frim transportinc any additional plates from its factory to the Callaway site.

Prior to June 9, 1977, l

480 safety-related plates had been embedded in concrete.

255 of these 1

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plates used machine-we'ded studs; 225 used manually-welded studs.

8.

As a first step in resolving the problem, a 100% reinspection program of all welds was initiated t,y Applicant, its architect-engineer

{3echtel), and Daniel Construction, of all the plates at the Cives plant and at the Callaway site. This inspection included manually-welded as well as macr.ine-welded studs.

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9.

Machine-Keld-j studs that upon visual inspection did not reveal a complete 360 degree weld were subjected to the required AWS bend test. Of 81,643 machine-welded atuds, only 66 studs failed the AWS bend test. This defect rate of 0.08% is exceedingly low and demonstrates t.5at adequate quality controls were in effect daring fabrication of the embedded plates. The studs that failed were subsequently repaired.

10. The inspection also revealed that certain of the manually-welded studs curtained visual weld defects. These visual defects were all corrected before the affected plates were used at the site.

11.

In addition to the 100% reinspection program, the NRC requested that Applicant have some tests performed on embedded plates to give assurance tnat tts 480 installed plates would not constitute a safety problem. Twelve manually-welded studs with visual weld defects were tested at Lehign Universitj.

Six studs were bend tested to 30 degree 1; six studs were subject to tensile tests.

None of the stud welds failed the tests. This provides adequate assurance that even if manually-welded stud, with visually defective welds had been embedded, they would behave acceptably over the life of the plant.

12. Six sf the installed plates with machine-welded studs were randomly selected and tension-tested to design load conditions. All e,rformed acce iably. This testing, coupled with the extremely low stud r

failure rate, provide adequate assurance that the machine-welded studs will not adversely affect the safe operation of the plant.

13. The Staff reviewed and evaluated tne inspection and testing program related to the embedded plates. The results of our review are set forth in HRC Report 50-483/80-14 (Attachment 1).

As there documented,

we find adequate assurance that the 480 installed plates will not threaten the safe operation of the plant and that none of the uninstalled plates contain any studs with defective welds.

14. Joint Intervenors complain that Applicant was improperly granted exceptions to the AWS code. Yne granted exceptions, which are listed in FSAR Section 3.8.3.6.4.3, pertain only to manually-welded studs. Briefly stated, the exceptions state:

(1) a vertical leg of the wald may be up to 1/16 of an inch smaller than specified in the design drawing; (2) the vertical legs need not be equal in length; (3) weld profile and convex lty requiremer.ts need not be imposed; and (4) an undercut of up to 1/16 of an inch for 10% Gf the weld length may be permitted. These exceptions are minor in nature and do not uf?ect the basic weld design or the capacity of the connection.

EugeMe J(/Gallaghe0 Subscribe {and sworn to before me this '}t day of October,1981.

hAuS*A. W riotary Public g

My Commission expires:bb

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EUGENE J. GALLAGHER OFFICE OF INSPECTION AND ENFORCEMENT U.S. NUCLEAR REGULATORY COMt11SSION PROFESSIONAL OVALIFICATIONS I am a Civ.11 Engineer in the Division of Resident and Regional Reactor Inspection, Reactor Engineering Branch, Office of Inspection and Enforcement.

I received a Bachelor of Engineering Degrec in Civil Engineering from Villanova University in 1973 and a Master of Science Degree in Civil / Structural Engineering from Polytecnnical Institute of New York in 1974 I am a registered Professional Engineer in the States of Illinois (f37828), Florida (#29114) cnd Louisiana (#16376).

I an a member of the American Society of Civil Engineers, American Concrete Institute and Tau Ccta Pi National Engineering Honor Society.

In my present work at the NRC I provide technical assistance in the area of civil engineering to Regional effices and resident inspectors with particular enphasis on the design and construction of reinforced and prestressed concrete structures, foundations, structural steel buildings

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and in structural testing and surveillance.

In addition, I provide techpical input for the development and interpretation of industry codes, standards and regulatory requirements, relating to inspection activities.

From 1973 to 1981 I was a nember of the NRC Region 3 inspection staff responsible for the inspections of civil engineering aspects of plants under construction'and in operation. This included the Inspection of laboratory and field testing of concrete, steel and soils naterials, earth embankments and dams, naterial sources, piping systens and reinforced and prestressed concrete structures.

In addition, a review of I

management controls and qual'ty assurance programs were parformed at plants under construction.

I participated in approximately 90 inspections of reactor Milities.

Prior to joining the NRC Staff I was employed by EBASCO Services Inc. in New York City from 1973 to 1978.

I performed designs of reinforces concrete and steel structures, design of hydraulic and water supply systems and preparation of specifications for construction.

From 1976 to 1978, I was the civil resident engineer at the Waterford 3 Nuclear Plant f

site responsible for providing technical assistance to construction.

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During 1972 and 1973 I was enployed by Valley Forge Laboratory in Devon, PA performing inspection and testing on concrete, steel and soil natarials.

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ADDITIONAL. NRC TRAINING Fundamentals of Inspection, NRC, February 1973 (40 hours4.62963e-4 days 0.0111 hours 6.613757e-5 weeks 1.522e-5 months )

BWR Fundamentals Course,.4RC, March 1973 (40 hours4.62963e-4 days 0.0111 hours 6.613757e-5 weeks 1.522e-5 months )

Cencrete Technology and Codes, Portland Cement Assoc., May 1978 (80 hours9.259259e-4 days 0.0222 hours 1.322751e-4 weeks 3.044e-5 months )

Quality Assurance Course 3 NRC, August 1978 (40 hours4.62963e-4 days 0.0111 hours 6.613757e-5 weeks 1.522e-5 months )

Nondestructive Examination and Codes. Rockwell Int'1., August 1978 (*220 hours)

PWR Fundamentals Course, NRC, November 1973 (40 hours4.62963e-4 days 0.0111 hours 6.613757e-5 weeks 1.522e-5 months )

Welding Metallurgy, Ohio State University September 1980 (80 hours9.259259e-4 days 0.0222 hours 1.322751e-4 weeks 3.044e-5 months )

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.s ATTACHMENT 1 l

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UNITED STATES i' V. s.

NUCLEAR REGULATORY CCSMMISSION 1 p, k h @ [j$

REGION Ill f

799 RoosEvtLT ROAD ctsu etos. n.usois som g,

w go.g SE? I 6 GE Docket No. 50-433 Unio' Electric Company n

ATTN:

Mr. John K. Bryan Vice President - Nuclear Post Office Sox 149 St. Louis, MO 63166 Gentlemen:

This refers to the meeting conducted in your office in St. Louis, MO on April 10, 1980, by Messrs. E. J. Gallagher and R. Landsman of this office and a subsequent meeting held in our office in Glen Ellyn, IL by Mr. G. Fforelli and members of his staff on May 28, 1980, for the purpose of discussing the resolution of the embedded plate matter at the Callaway Unit 1 plant. This also refers to an inspection of available embedded plates and review of quality records that was per-formed by Mess :.. E. J. Gallagher and H. W:,cott on June 10-12, 1980 at the Callaway site and the observation of physical testing of pistas at Leigh University on August 6, 1980 and at the Callaway site on j

August 14, 1980.

The enclosed copy of the report documents the finel review and evalua-tion of the embedded plate matter and details of items discussed during the =eeting.

Based on these reviews and evaluations, load test results, discussions with cognizant personnel of your staff and the 3echtel Power Company and direct hAC inspections, we concur in the findings that the subject embedded plates using both manually and automatic machine welded anchor studs meet requirements. Ve hr r no further questions at this time in te!.ard to this matter-No items of noncon itance with NRC requirements were identified during the course of this inspection.

In accordance with Section 2./90 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, a copy of this letter and the enclosed inspection report will be placed in the NRC's Public Document Room, except as fC.ows.

If this report contains trformation that you

.or your contractors believe to be proprietarf, you mm apply in writtrg to this office, within twenty itys of your receipt of this letter, to withhol! Auch information from public disclosure. The application must include a full statement of the reasons for which the information is con-sidered proprietary, and should be prepared so that proprietary informa-tion identified in the application is contained in an enclenre to the application.

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2-SEP 1 8 'Pi Union Electric Company

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Ve will gladly discuss any questions you have concerning this inspection.

1 Sincerely,

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James G. Keppa.er Director i

Enclosure:

IE Inspection Repo rt No. 50-/.83/8(.- M cc w/ encl:

Mr. V. H. Veber, Manager Nuclear Construction Central Files Reproduction Unit NRC 20b PDR Local PDR NSIC TIC

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Regions I & IV

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Ms. K. Drey Mr. Ronald 51uegge, Utility Division. Missouri Public Service ;ommission 4

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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT RIGION III Report No. 50-483/80-14 Docket No. 50-483 License No. CPPR-139 Licensee: Union Electric Company P. O. Box 149 St. Louis, MO 63166 Facility Name:

Callaway, Unit 1 Meetings / Inspection At: Union Electric Office, St. Louis, MO Callaway Site, Callaway County, MO NRC Region III Office, Glen Ellyn, IL Meetings / Inspection Conducted: April 10, 1980 May 29,1980 June 10-12, 1980 August 6 and 14, 1980 Inspector:

E. J. Gallagher I-2*90

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Reviewed By:

. W. Hayes, hi f Enginen -ing Support Section 1 8

Approved By:

G. Fiorelli, Chief

-3 Reactor Construction and Engineering Support 3 ranch Meetings /I"spection Summary Meetings / Inspection on April 10. May 29, June 10-12, and August 6 and 14 1980 (Report No. 50-433/80-14)

Items Discussed:

Callaway Unit I submittal of March 10, 1978 entitled i

"Acceptabill:y of Embedded Plstes Installed at Callaway Plant, Unit 1".

The review, evaluation and inspection involved 160 inspector-hours by two

.NRC inspectors.

Reso:ts: Resolation of embedded plate item at Callaway Unit 1.

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DETAILS

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1.

Meeting Attendees at Union Electrie Ofijee, April 10, 1980 NRC Region III E. J. Gallagher, Civil Engineer Inspector R. 3. Landsmen, Civil Engineer Inspector 4

Union Electric Personnel f

D. F. Schnell, Manager, Nuclear Engineering D. W. Capene, Assistant Manager F. Field, Quality Assurance Manager R. L. Powers, Quality Assurance Supervisor D. 3. Stecho, Nuclear Engir.eering K. W. Kuechenmeister, Construction Engineering Meeting Attendees at NRC Region III Office, May 29. 1980 NRCRegionIM G. Fiorelli, Chitf, RC&ES Branch E. J. Gallagher, Civil Engineer Inspector R. S. Landsman, Civil Engine?r Inspector H. Verm tt, Project Inspector Union Electrie company s,

D. F. Schnell, Manager, Nuclear Engineering W. Ivanut, Supervisor, Nuclear Engineering R. L. Powers, Quality Assurance Site Superintendent

.{. W. Kuechenmeister, Construction Engineer Bechtel Power Company i

B. L. Meyers, Project Manager E. V. Thomas, Supervising Civil Engineer P. H. Divjak, Project Engineer A. Pagano, Assistant Supervising Civil Engineer K. G. Parikh, En;iseering Specialist Inspection Exit Meeting Attendees at Callaway Site June 10-12. 1980 NRC Region I!I i

E. G. Gallagher, Civil Engineer Inspector H. M. Wescott, Project ia:pector i

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l Union Electrie Uompany D. F. Schnell, Manager, Nuclear Engineciing V. H. Veber, Manager, Nuclear Construction F. D. Fields, Manager, Qua*.ity Assurance R. L. Powers, Superintendeu. 3ite Quality Assurance M. Doyne, General Superintendent K. V. Kuechenmeister, Construction Engineer Daniels Construction i

H. J. Starr, Project Manager 1

2.

Aeferences 1

The following references were used for the review and evaluation of the embelded plates installed at the Callaway Plant Unit 1:

a.

NRC Recorts (1)

Instretion " port 483/77-05 dated July 8, 1977 (2)

Invwicigation Report 483/77-10 dated December 27, 1977 (3) NRC Region II7. Action Item A/I F30360H1 to Headquarters dated April 6, 1978 (4) Transfer of Lead Responsibility to Region III for evaluation of Callaway report on embedded plates dated April 14, 1980

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Union Electric Reports (1) Letter ULNRC-197 dated August 4, 1977, respcase to inspection report 483/77-05 (2) Letter ULNFC-221 dated January 27, 1978, response to investigation report 483/77-10 (3) Letter ULNRC-238 dated March 10, 1978 entitled, "Acceptab.lity of Embedded Plates Installed at Callaway Pirnt, Uni 1" including enclosures 1 through 9 (4) Letter ULNRC-349 dated April 24, 1980, NRC questions on i nion Electric enbedded plate report (5) Letter ULNRC-354 dated May 23, 1980, responses to NRC questions on Union Electric embedded plate report with attachments A thred gh D i

l (6) Letter 'JLNRC-361 dated June 19, 1980, additional responses to NRC Questions

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Other References (1) SNUPPS letter SLU 6-14 dated November 1, 1976 (2) SNUPPS letter SL3M 6-514 dated November 5, 1976 (3) CIVES letter SL:124 dated June 30, 1977 (4) CIVES letter SL:126 dated July 12, 1977 (5) SNUPPS letter SLBM 7-302 dated July 27, 1977 (6) BECP.TEL letter 3LSM-5959 dated August 8, 1977 (7) CIVES letter SL:134 dated August 18, 1977 (8) SNUPPS letter SLM 7-108 dated August 13, 1977 (9) DANIEL memo PQWP-152 dated October 26, 1977 (10) 3ECHTEL letter 3LSE-5195 dated November 21, 1977 (11) BECHTEL letter 3LSE-5227 dated Nove=ber 29, 1977 (12) CIVES Telecopy dated May 22, 1980

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Background===

Embedded plates supplied prior to June 9,1977 to the Uniou Electric Company Callaway Plant Unit I were accepted and installed based on the fabricator's, Cives Steel Corporatioc, and Bechtel's vendor inspectica program. A total of 480 safety-related embedded plates, were installad in concrete prior to June 9,1977, of which 255 plates utilise headed stud anchors attached by auto atl.cally timed stud welding equipment, and 225 plates with threaced rod a'nchors attached using manually welded fillet welds by the shielded metal are process.

An NRC inspection conducted June 7-9, 1977 (Report No. 483/77-05)

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identified machine selded studs to embedded plates which did not contain full 360 degree weld material (flash) and was not bend tested g -

as required by AWS D.1.1-75 velding code, Part F (stud welding).

As a result of the VRC inspection, Union Electric Company issued "stop work order" 19 on June 9,1977 suspending the use of safety-related embedments until a reinspection program was initiated at the Cives fabrication plant and on uninstalled plates at the Callaway site. This reinspf tion included both machine welded and manually welded anchors and is discussed later in this report.

An NRC investigation was also conducted between October 14 and November 22, 1977 (Report No. 483/77-10) which included the question of the adequacy of the concrete embeds used in construction prior to June 9, 1977. The investigation report indicated that the embedded plate matter would be reviewed by the NRC Headquarters staff.

Union Electric Company's analysis of the acceptability of the embedded plates dated March 10, 1978 (Letter ULNRC-238) concluded that "all embeds installed at Callaway are sound and meet design load requiremtets".

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Upon receipt of Union Electric's analysis, the NRC Region III office

.,,. issued Action I*.em A/I F30360H1 dated April 6, 1978 for NRC Headquarters review. The following review and evaluation was conducted by Region III staff in order to address this unresolved matter.

4 Meeting Details Meetings between NRC, Union Electric Company, and Bechtel were held on April 10, 1980 in St. Louis, Missouri and on May 29, 1980 in Glen Ellyn, Illinois. During these meetings a series of questions.from the NRC were presented and responses provided by Union Electric and Bechtel. The questions and responses are documented in letters ULNRC-349 dated April 24, 1980, ULNRC-354 dated May 23, 1980, and ULNRC-361 datsd June 19, 1980. These are included as attachments A, 3, and C to this report.

=eetings contained discussion of the background of the e bedded pi

.e matter, results of reinspection by Cives and 3echtel, analysis of the data, AWS Welding Code requirements, specification requirements, and Daniels nonconformance reports.

5.

NRC Insp-etion of Embedded Plates at Callaway Site During the NRC inspection en June 10-12, 1980, a visual inspection of embedded plates installed in concrete prior to June 9, 1977 was pe rfo rmed. The manually embedded plates used to support the structural steel framing was substantially loaded by the floor slab dead leads with no sign of distress or indication of overstress. The machine

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welded embedded plates, some of which were loaded with support attach-ments and others not yet loaded, were. observed to be fully intact with no sign of distress.

6.

Evaluation of Embedded Plates at Callaway Unit 1 The evaluation as to the acceptability of the embedded plates installed at the Callaway plant is separated into two categories:

(a) machine welded studs installed prior to June 9, 1977 and (b) manually welded threaded rod anchors installed prior to June ', l'77.

a.

Machine Welded Anchers (Headed) Studs Embedded plates in concrete with automatically tined machine weldet headed studs to plates are used to provide support for attachments of p..:nr and components to the concrete structure.

In an effort to identify the condition of the 255 embedded plates installed in concrete prior to June 9, 1977, the, licensee initiated a 100% reinspection of plates not installed as of that date and available on-site in storage or located at the supplier's fabrica-tion shop.

The reinspection was performed by both 3echtel and Cives Steel Corporation.

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The results of the reinspec' ion were reported as follows:

Number of Number of Number of I

Places Studs Indications 7543 31,643 457 Number o(

% of Studs

% of Studs Failures' w/ Indications Failed 66 0.56%

0.08%

NOTE:

1. Indications were studs on which a full 360 weld flash was not obtained wnen machine welded and were required to be bead tested.

2. Failures were identified by striking the studs with a ha=mer and bendin3.he studs to an angle of 15 degrees according to AWS D.'.1-75, Section 4.30.1.

It was also indicatad in Union Electric Company response (Item S) of ULNRC-354, attachment "C" that the 56 studs that failed when bend tested were contained on 43 plate.: out of the total 7543 plates. Of these plates, 10 had multiple stud failures with 4 of the 10 plates having adjacent stud failures. Therefore, the percentage of plates having 1 or more stud failures relative to the total number of plates reinspected was 43/7543 or 0.57%.

I The above information regarding machine welded studs was con-s_

sidered not co=pletely sufficient in itself to base a final decision on the acceptability of embedded plates. The NRC re-quested the licensee to test actual embedded plates installed in concrete prior to June 9,1977. The licensee developed test procedures we.tch were revtewed by the NRC prior to being imple-mented. The test program was entitled " Test program to Evaluate Welds of Anchor Rods and Studs to Embedded plates" dated August 5, 1980 and is included in Attachmont D.

The tests were performed at the Callaway site under the supervision of Drs. R. Slotter and J. Fisher of Leigh University. The results of these tests were as follows:

Six plates were loaded to allowable design load without plate failure or plate deflection more than 1/4 inch. The plates

.ested exhibited acceptable behavior under the applied load.

Details of the test and results are contained in Union Electric submitz.s1 ULNRC-3SO dated August 25,1980 (Attactment E).

l The automatically machine welded embedded plates installed prior to June 9, 1977 are considered to provide adequate structural support for piping and component supports based on the following:

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I (1) The 100% reinspection of 754: plates which contained 81,643 machine welded head studs, of which 66 studs (0.08%) were s-identified as not meeting AWS bend test requirements.

(2) Actual load testa to rated capacity performed on embedded plates in concrete prior to June 9, 1977.

b.

Manually Welded Anchors (Threaded Rods)

Embedded plates fabricated by manually welded t'hreaded rods to plates are used for structural steel framing supports at the Callaway Site.

The original licensee commi unt in the PSAR, Section 3.8.1.

6.6.2 (Steel Construction stated that, "AWS D1 1-72 and DI.1 Revision 73, Structural Welding Code, is utsd w.thout exception for velding structural steel".

This comm..an_L has been revised in the current FSAR submittal for Callaway.

FSAR Section 3.8.3.

6.4.3 now states that, embedded ite=s are erected in accordance with AWS D 1.1 Structural Welding Code, except that the qualifi-cation of welders and welding operators may, alternatively, be in accordance with ASME Section IX.

The following exceptiens are permitted for welding between anchor rods and plates embedded in concrete:

(1) Vertical leg of weld may be up to 1/16 inch smaller than that specified on drawings.

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(2) Unequal legs are permitted.

(3) Weld profile and convexity requirements for these welds need not be imposed.

(4) An undercut of up to 1/16 inch for 10% of weld length may be permitted.

In addition to these exceptions it was also deter =ined that welds were less than the minimum AWS requirement of 5/16 inch.

The licensee demonstrated that the the welds less than 5/16 inch are permissible based on an analysis that the smaller weld developes the strength required.

The above exceptions were incorporated ia Rev. zion 9, dated e

July 21, 1977 of Specification C-131, Miscellan2cus Metal, Sec*. ion S.4 and 8.6.

During the months of July and August 1977 Cives Steel Corporation reinspected over 400 manually velded plates of which 80 did not meet the specification requirements of C-131, Revision 9.

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However, the licensee indicated in Letter ULNRC-354 dated."ay 23, 1980 (Item 9) that the welds inspected had an undersize not exceeding 1/3 inch.

to Union Electric letter ULNRC-238 entitled "Investi-gation of Welded Studs" provides an analysis which calculates the reduced load capacity of the anchor due to a 1/8 inch under-size (assumed full 360 around) and a 1/16 inch undercut defect.

The results of the analysis indicate that the reduced load capactties as shown below are not significantly effected by the 1/S.nch undersize. The analysis for the 1/16 inch undercut does not effect the load capacity of the anchor since the reduced dia~eter due to the threads on the anchor rods control the rated capacity of the anchor.

The reduced capacity of the plates due to 1/3 inch undersi:e are as follows:

Lead Capacity (1bs)*

Reduced Capacity (1bs)

Plate Type per Dwe C-0012 Sht. 9 Due to 1/8 Inch Undersize EP 211 200,000 187,000 EP 312 175,000 168,000 EP 412, EP 511 75,000 60,000 EP 611 50,000 47,000 NOTE:

Load capacity shown on Drawing C-0012 are for vertical loads f rom structural steel framing re actions.

(s Sample calculations used to determine the reduced lead capacities were reviewed. The reduced capacities provide adequate stength for the design load.

A number of Daniel inspection reports generated after June 9, 1977 indicated more than allowable undersize on many studs; however, the extent of undersize was generally not recorded.

These reports are contained in NCR-2-0831.

In order to illustrate that the Daniel inspectors overstated the weld deficiencies in their reports, 47 available nanually welded plates typical and fabricated in the same manner as those installed prior to June 9, 1977 were reinspected by a team of Union Electric, Bechtel and Danici inspectors. All 47 plates were originally rejected by Daniel site inspection and recorded in NCR-2-0831.

The reinspection was performed in order to characterize and quanti:y the cause of the rejection since this was not fully recorded on the original Daniel inspection.

The results of the reinspection indicated that 39 of 47 plates did not meet the requirements of Specification C-131, Revision 9 or AWS including 1

8-

I the four exceptions described previously.

The reinspection did indicate that none of the anchors on the plates exceeded the 1/8 inch undersize or 1/16 inch und cut assumed in the analysis of determining reduced capacities the reinspection finding indicated undersized welds of 1/8 inch for a portion of the weld circumference.

These 47 plates have been retained on hold at the site. During an NRC inspection on June 10-12, 1980 the NRC inspectors vis ally inspected the subject plates. The results of this inspection determined that the Union Electric, 3echtel, and Daniel team inspection was valid. The visual appearance of the welds did indicate poor workmanship characteristics.

To demonstrate that the welds provide adequate structural integrity the NRC inspectors requested the licensee to perform Icad tests en selected welds which appeared to have poor workmanship.

In addition, selected anchors were bend tested. These structural tests were performed in accordance with procedure entitled " Test Prograc to Evaluate Velds of Anchor Reds and Studs to Embedded Plates" dated August 5,1980. The tests were performed at Leigh University on August 6, 1980.

The results of the load and bend tests are as follows:

(1) Six anchor rods were bend tested to approximately 30 degrees.

All of the welds successfully withstood the bend test with no sign of failure.

l (2) Six anchor rods were tension tested to ultimate load. All 1

of the welds and rods exceeded the minimum allowable load acceptance criteria established prior to the test and included in Appendix A of the test procedure attached to this report.

l Detailed discussion of the test and results are contained in Union l

Electric submittal ULNRC-380 dated August 28, 1980 (Attachment E).

The manually welded embedded plates installed prior to June 9, 1977 are considered to provided adequate structural integrity for the intended leads based on~ the following:

(1) The reinspection of manually welded plates available in storage ihich indicated that is no case was the welds undersi:ed by more than 1/3 inch.

(2) The analysis that the reduced load capacit_ies are not significantly effected by as 1/3 inch undersised weld or l

1/16 inch undercut due to capacity being controlled in the threads of the anchor rods.

i

.g.

l

t 4

(3) NRC inspection of 47 plates retained on hold at the Callaway

(

site which appear to have poor welding workmanship; however, adequate structural strength.

(4) Load te t performed on undersized welds aod welds of poor workmat;i.ip quality which demonstrate adequate structural strength.

(5) NRC inspection of manually welded embedded plates substantially loaded by structural steel framing and floor slah dead load without sign of distress.

7.

Closure of Embedded Plate R port at Callaway Unit 1 Based on the foregoing review and evaluation of the referenced documents,.

results of reinspections of embedded plates, the analysis of reduced load capacities due to weld deficiencies, direct NRC inspection and actual load test performed, it is considered that the embedded plates using both manually welded and automatic machine welded anchor studs are capable of providing the intended support for structural steel framing, piping, and component support.

ATTACEMENTS:

A.

Union Electric Submittal ULNRC-349 dated April 24, 1980 3.

Unica ilectric Submit al ULNRC-354 dated May 23, 1980 C.

1:nion Elect-ic Submii.t:1 ULNRC-361 dated June 19, 1980 D.

Detailed Procedure for Test Program to Evaluata Welds on Anchor Rods and Studs to Embedded Plates, Revision 2, dated August 5, 1980 E.

Union Electric Submittal ULNRC-3SO daced August 28, 1980 final report on test of embedded plates s

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==.41 2,*, 19Q0 nr..

P.4:. e Cwo 5.

Did Cives Coro.. ins ect the same mechanicallv-welded embeds reported in Daniel Data Packcge under cover D2UC-2399 (Enclosure 7 to ULNRC-238)?

6.

Why was section 9.6 added Oc 3echtel Specification Cl31?

Prior to this revision (9) did-fe Cives bend test machine-welded studs with less than 3600 weldflash?

Wasn't Cives folicwing Dl.1 4. 30.1 prior to June 8, 1977?

If Cives was bend testing questionable studs prier to this *.ime, nc

.".cw c. wh a. w e. e *..'. e.v.'..s e u-....,- r..' c.-.. s...i - e.. '.

r r-

..". a. v. *. - =. ~ e..' o..~ 4.. ~ - a...d.

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s ~.u.e.e a.;.~

d m c "_..e n. a. 4 ~ ~..

4 r

3 Note:

Several Cives & 3echtel letters in NRC files 4..di a.e

..".a.

x e...

.es.s wa.e

.o. "e.7-d o.e 3

prior to Rev. 9 (e.g.:

Cives letters to Bechtel, SL:126, July 12, 1977, and SL:13,4 dated July 14, 1977 and 3echtel letters SLSM-2c3o, -a.a.d. a'u3 8,

lo.oi

.=..d.

d

- x

..'.C.:,

d =. =. '

r :

Nov. 21, l?77).

Was there any-Bechtel follow-u,-.o.w.se 1...e s3 r

7.

Reference Cives letter to Bechtel SL:134, dated Aug. 13, 1977.

l

.w.:.w-4s -

=...a.d a"c"w-s eva r al * ".i.., s

.4.. - k. i s. e.. a.. -- R e.' e - =-.. e s

~

".a. w " 4.s a-de.n

~~.'.e.i..

s. a. e. a.... a " o u

"..o o. k. a..-

~~

a r-secticns of AWS a i.v to our work" and "tclerance for welds hav ng less than 3600 flash".

Also, was reques in this 1e::er to use '77 version of AWS acted upon by Bechtel?

a.'so 7cr. 2.77 '= =' Na.v.

.' o.,.i c. i 7 wh..i -". ~...=";

e s e ^... "

-2 a. =.

2---

C...=.

4.,.

Sr_,,

ac.

.r

.1,, g.......7

.o gr.

.-m o.-.

(ac.a w. e.l ***"ab.'.74.V.

s "-' V, ) *.

r r.--

.M e = a. a. G a.' l =

.k.e.

m-t a.7 d s...a.. c.' ". R F a.e... a.xf.-..i..

c"a'...."

a 7

e g

m..a.i n s.43 -d w.471

.o. og S..a'lv s "

r c.*..=.. a..=.i v. s.# - c# * "..' s s

y a

. v. e. o d a..' a..d.

a c - a.

. = ".d.'.4. v. o.'

...a.- '..i. a. - w e.' ' a. d a... " e d.

r

-a "s.,C

.ce...ed

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d=-.= a..-..i v a s "-' a-e.- a "ed a..d m' ewe'

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e

=

.1a..

s a =

b. a.-a.a c#

.' = ~. e.

"a'C w=s s"sr.'.'*"s

.. - -. e e

~

of this analysis.

NRC would like to see ccr.plete dialogue

^-

- - - " a ' d.'.'. v.- =. o...

r.--

y t

ao wa..'. a ". a.

=.".4.' a..c =. c.*,."..'..io.l a.

d '

e _ a_. s.c a..- e...we d '.

u. w

=any plates were involved in. the 66 s.2d defects?

Bechtel s.

c.

v.da. a.'.is.

.' r.' a. e s '..k..i - 5 c o...a.i..

..w. a,.* ~i d a.' e c..' ". ^.

s.".' =-

(.4.7c.'"-di ng o' o".' =.4.' e d. s--'s) a..d

' = ~ a..-...'.. e 5. c w ~_ =. "

e.e-.".se -

e

., s. e s.w.a a.o e

.w-..an. 3 a

..4

. a 4.,.a s...a.

e 9.

Sechtel states in Enclosure 1 (pg. 1 in Bechtel Report) that v e,e a w,

e -,.. -, - - -< ---

--w

- +

n,mv

,,,-e-,-,

--e a-

-,--e e

,--,,e v.e

-w.

t F.r.

I.

Gallagher

.s p 4.,

2,,

32.

,3

3. a - e

..w.

a..

y

.s-t h e "ma,, o r i ev. " of manually-welded plates did not meet dimensional /.crofile rec.uirements of scecification.

How manv. clates are in this "mai. o ritv " ?

-How manv.clates were censidered acceptable (meetinc. sc. ec) after relaxations (items a, b, c& d) listed in Bechtel Rey In a general statement the NRC uestiened whether AWS 01.1 was fully implemented prier to June 5, 1977.

Sechtel is to verify that AWS was fully utilized as criteria before specification Cl31 was relaxed and determine how effectively 4....as

.4-cse-.

A

-e 10.

D C memo POW?-152, dated Oc:cher 26, 1977 has results of

=

4..s r..-..i o n s c '. a c."..'..a. -w a. ' d e d.

a.m. "., e d s w"..i c ". c'.'.' # a..-

..a.'.<.a. d.' v.

a

. '. -......"... ". e. s... =.... o s ". e '..

".o w.' s m '.'.' a..- =..~..- a.

e x.'.=..'. e d. '.

d c

e Was different critarial used in inspection?

e,,

.s.....,, ser

..c.4x 2,

.awle...

r Whv. were different allowable stress levels used (27ksi

/~

vs. 36ksi) :c calculate embed "1 cad capacity" and " reduced

(

Joad capacity" because of assumed undersire?

Using Nelson "cookbcok" rules for determinine. lead cac.acity, 4.

.-.s.=

s acac.t."; o' re-2'7'.e s "., - " ' d v.=.- v.--. ". a.

d..# #. =..- a....

. -re c...'.'

a..i... s A.."..-".

.?.

( N. RC c. a " ' d... v e..d.' v =..":

e...a' m

. a a.i..i a. s

.#. - =..v.. c...' '. w- "y. =....

.#. '.' ' s. )

d.o w

d..i d

a..'.. =..'

,..a.

, a 4 4. s

.a c n.. c a, +.4., a. s "+ a.-";

.'.. 4 4 # # e.- a....

2 n...

..-r..

-r r

c...'.' -".. =..' ^... s o ' e

.: '.' ' s '.

We.- '.d a ' s o l.' k. e.o. a. '.a a'.".' a..d r

. a to determine how " reduced icad capacity" for all tv.c.es of cla es was arrived at.

,l' 12.

Inclosure 1, Appendix 3, Table 3:

Rationille followed by Bechtel in Table 3b cn allowing

,. /., o ~ -a. e-.

. 4 u

e

.w a.aae.

-ased n.ac..u.a.

a.-=.a o.c a

e l

stud is less than area with 1/16" undercut.

NRC & UI confirmed that scme unthreaded studs are =anually-welded.

I It appears that lead capacities for manuallv-welded Nelsen (c.- 5=.ad ed ) s. u c' a-w.'.n'

.' / l o' "

"...da-."..

=.- a.

c. ad'.-a..ae

.i.

e 3en..w..e.,

, o.

.r Are load capacities in table nes. 1 and 3 based on tension, s h e,

c. a

...u.4.,. a ~. 4. n,.

l s e...c..s.... e h o u a.1c,,.1 a. 4.. c..s a.

..a.4. e. o e.w.-..

.w..

.a4n.s.a e

.c.4 9 1 e. y

,A 9 eg s e.4. y a.

a.c.z. c.

A -. e.. a.c c. e c.

.M c g a co.a a

. o

-e.

w.s

.sa.O.

\\

e l

l' I

Il l

Mr.

E.

Gallagher April 24, 1930 Pace Four s

I l

A co=y of 3LUE-675, dated April 9, 1980 was handed cut which provides a listing of manually-welded embeds with loads calculated assuming 1/8" undersize welds.

After a short discussion, NRC recuested to see calculations of how the reduced lead capacities were determined.

.s.. a d.i.n -

r. e ". *.. a. '

e r.

m...e.n.a

.i c.. s.i -

r... - ' o s "..- a. 6-d On plates deemed acceptable with an average t;nde: size of 1/3", if undersize is concentrated in one area cf plate and lead is applied at this -o.nt, does theerv. that plate e

is acceptable remain valid?

(localized undersize)

Furthermore, if the average weld undersize of 1/8" resulted in a weld profile of less than 5/16", are the 3echtel conclusions on lead capacity still valid an light of AWS limit on weld size of 5/16" minimum?

The NRC's concer'n is that AWS indicates welds less than 5/16" do net contribute s " ' #.4

.d a.... s.. e..:.*.. ~.~ b e. e _' _4 a b.i a..

14.

Cives letter SL:124 dated June 30, 1977:

Table 1:

Attempts := show 1/16" undcrsize is acceptable bu: in making this peint, allowable stress of 43ksi ir ". sed instead of 36.

What is rationalle?

15.

Bechtel letter to Cives dated.7une 24, 1977, from Div!t

.=.,=s.

". c ~ d o.'.. e.".." a.. s c.u -. a. d. 4..

..'..' s ' e.. =..- (.c.

e' r

s... A. s

.t sre e.. e A.,

e.. ) c.a....:.w

.he

....u..-. e.s

.s

~....

.w.....

r

,"a.i.'.4.v. s.".A) '.

w 16.

Seiken letters to Schnell, SLU:5-41, dated Nov.

1, 1976 &

SL3M-6:51:, dated Nov.

5, 1976:

Letters indicate Cives was not in control of production cuality based on Sechtel/SNUp?S inspection findings.

What measures were taken?

Did D C/UE perform the recommended inspections at the site?

NRC believes

..a v e.. 4. w, 4. w. e....s.., e...s w, e.: c e e..._w._ e s

.wa s..., t. 3 2 w

w a

w-r.

were installed.

17. (to UE submittal) centains a Bechtel attempt to analyze NCR 0331.

At randc=, NRC picked entry 444 cf A :achmen: *;, pg. 3 and asked why the correspending D:C inspection report was eliminated as a data point.

NRC F:.c.ested (but did not insist on) a reanalysis of each manual and machine-welded embed installed pric to June 9, 1977.

About 225 manually-welded er. reds and 255 l

1 l

e

.v... =. G a '.' a. ". e.-

April 24, 1930 P..a g e

.r i v e

=achine welded embeds are in this group.

A program to evaluate each might consist of:

Identification of each plate location.

a.

b.

Determine where load is a.:.Clied on Pla:e.

c.

Calculate actual lead (vs. plate capacity).

2

..~ s.

.k.a. = v.4 ' v _' a a ' e d s.".w n o s "w.. a.

a 4 '

a.. s a..d

e. =....4.. e w

what happens.

.... 3 4 a..i..a.

..="2 s.k.m w

.k.a. -

s.

.3 w

a.

Some plates may not have been used.

Some may have all icad a:c. lied new.

w S c _..e _..a.. wwe sw 34

.w..,y 3 a e

..a..e,e.....

2 y...,2. 2 a e 3

.w

-.w..

(even with failing stud).

C.

S-...

4.,,-,...

S a...... e., a.. a. a.. 1 C....,. s.

w.

...w...

..y d.

. a.#.' u'." a a..a.',v s.# s 7. a" s k.ew

b = ~.

.# a.i.' ".* a.

r

- C e s.". ^w *...'.. e a. =..*.

a.*. V s V s *. *..~.. c." s..-". *."..~ a.

.#."

7.

a s a # e *.v, "y C.4.. *.

C.

v.' a. w.

w

..w. a. a"w v a.

a.". =.' V s.d

...C s *. C.#

k e e....'. a_ d..e s

..a "; " a....a. v a.

w " a.'...# ^ 7 w

.g.

z.. -.k. a. " C "..".C e.*.*..

..i s." e C C - "..#. e d,

k.*. w e ". e ", * ".. =.

w

- 's A

3 a - -. a.*.

..a v, "w e. c. =.'. "

.4... y. = -. 4. =.'.

gr -

".w '.s w" -"'d

.'.' '< e

.o ".av e a..s'a e. s

~.^w." w.- a. ;... g c,

a. s.. a..a. s *...'..d..

aw--

.' v' da3 s.

.V.*.

G a.'.1 a c..h a.-.is a.. a. - e..d.a.,

.o ~ ^....,c _' e. r.

'.. ' s =...=.' " s.' s of the Callawa.y embed report b.v the end of June (1950).

?.escense must have UI/DIC incut.

Please call me if you have any cuestions or if something 4..r w. =.. - a. 'as c...4

..-d

~.5e ".-=.

14s..

.w w

Verv t r u l.v.v c u r s,

/

d<

Conald F.

Schnell Manager - Nv. clear Engineering r e / s.,,

a.

1 s

c.

+-

)

i

\\

j.-

1 e

l UNION ELCCTRIC CO M PANY 19 0s C m ATact 5 f M C CT. S?. Lov e s May 23, 1920

-..u c..o.cs.

..o....

se se....e.....

Mr.

E.

Gallagher U. S.

Nuclear Regulatory Cc:. mission Region

,AAA 799 Roosevelt Road ULNRC-35 4 Glen Illyn, L.linois 60137

Dear Mr. Gallagher:

n:.S3O..

.S

.O..- QL..S.r h.5 ud

.c

..w

.v m

U.f'.

w. r. 3 1 o C :.. - - C.' '.*.n ".. n' v. c. ' A ". *&

"O.

,. t My letter to you dated April 24, 1930 (ULNRC-349) listed 17 questions generated during our meeting of April 10, 1930 cancerning the subject report.

The following su=marizes our responses to these questionc:

1.

AWS Dl.1-75 is applicable for the manual aciding of thre:dM refs and as such, is invcP.ed for welding in Sptcffication 104C5-C131, with technicall'2 acceptable excections as nri.ed for r

undarsi:e, profile, uneven legs and undercut.

2.

-The welding of threaded rods or anchere is in accordance

(

with Dl.1 M5 with the folicwing exceptions:

A.

The leg of the weld adjacent to the anchor may be up to 1/16 inch smaller than specified on the desien drawings.

3.

Unequal le uelds are permitted.

3 C.

Weld profile and convexity requitcments for these welds

.aad- - ~~ '-

e -... e a e

( bu c..". ". 4 ' y'

- k

- A

' 4.1.4 '. - a c": ' "; ).

a D.

An undercut cf up to 1/16 inch for 10; of the wcld lenc.th may be rermitted.

These deviations are supported as follows:

A.

The undersize leg is satisf.ed by oversiring the welds on the design drawings such that even with the undersine deviation the welds will satisfy design requi.enents.

S/2.

The variation in weld profile including unequal legs and convexity does not result in an effective throat thickness less than -=7 ed to satisfy the design strength.

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. is h LvtNG PRCSLE'.4S TWMOUGM lNVENT*0N & INNOV ATION g 00

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E. Gallacher xay 23, 193r, Page Two

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1 D.

Undercut is limited such that the reduction in cross-sectional area is less than that which occurs as a result of the threads.

The installation (fabrication) of weldcd studs is in accordance with AWS Dl.1-75, Section 4.0 Part F as it app. lies to "other than shear connec, tors. " In Rev. 9 of Specification 10466-C-131 the inspection requirements of Section 4.30.1 (applicable to shear connectors) were imposed in lieu of the requirements of Section 4.30.2 (applicable to other than shaar connectors).

Dear Mr. Reppler:

NRC QUESTIONS CN UE IM3ED REPORT A.ODITICNAL INFOciATICN Cn' '

n' 'a"n.V 'n.'~.

uu In response to requests by NRC Region III representatives at a neering at your offices on May 29, 1930 for additional input en the subject report we are suh=itting herewith cne copy of the

";.' lowing information.

1.

3LUI-700, dated June 12, 1980, including all a::a c;_- e n ts.

2.

Caniel International Corp. Telecen Record Sheet,

[

dated Mav. 29, 1980, Acceptance Criteria Used for

(

Inspectica of Undercut Welds, including attachments.

3.

Caniel International Corp. Quality Control Precedure CCP-507, Rev.

5, Inspectica of Strue' ural and Misc.

Safety Related Welding.

In' reference to our investigation to determine the exact number of embeds involved in the subject report, we are in the process of determining this count and expect Oc be cc=pleted in the first par: of July.

Very truly yours, t

I w 'k.

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.s Ach I.-

Ccnald F.

Schnell

.ianager - Nuclear Engineering DBS/sla cc:

E.

Gallagher w/a e}

9 JUN 2 3 reso t

et @?#

SCLviNG ARCSLEMS T*206 OP' 'NVENT!CN & ;NNCVA?tCN

Bechtel Power Corporation Engineers-Censtrue: cts I

f 15740 Shady Grove Road Gaithersburg. Maryland 20760 301-258 3000

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P.. C. F. Schnell

& nager - W elcar Engineering Union Elec:ric Cc=pany Pes: Office 3cx 149

JUN i 2 $80 S:. Lcuis, P.isscuri 63166 3LUE-7 0 0 File: 0499.4/C-131 3ech:e1 Jcb Nu=ber 10884-C01 SNUPPS Prcject Investication of Welded S tuds -

Additional Infer atien Ref: 1. UI.NRC 238 da:ed 3/10/73

2. ULNRC 349 da:ed 4/24/30

3. ULNRC 354 da:ed 5/23/SO

4. AIF Progra= Reper: en Reac:ct Licensing and Safe:y, Vcl. 2, Nc. 1, P.ay, 1975 Encl: A. Cives 5: eel Cc=pany I4::er SL:367 da:ed June 10, 1980

/-

3. 3echtel Surveillance Inspec:icn Reperts fer Assign =en: 1C466-C-131

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Reper t Nes. 2, 3, 7, and 45 C. Sa=ple Calcula:1cn fer. Manually Welded Pla:e Asse=blies (I? 312)

D. Sa=ple Calcula:icn for P.achine Welded Pla:e Asse=bl'as 'I? $12) -

Reduced Capac., Oue te a ?cstula:ed Inef fec:ive S tud E. DIC y.e=c -

Subject:

UI Inquiries -

t S:ud Weldi.Tg l

Dear P.r. Schnell:

his le::er prevides addi:icnal inpu: reques:ed by NRC Region !!I represen:a:ives a: a reeting in their effice en F.ay 29, 1930.

Specifically, i

this inferr.a:ica includes:

1.

Dcea:nen:a:ica of :he fabrica:ce's s:ud welding prae: ices for i

sachi:.c welded enbed pla:es pric: :c June 9, 1977.-

RECEIVED JUN 1 a. s...c I

D. F. SC.HNELL

~ _

Bechtel Power Corporation j'.r. D. T. Schnell 2

2 A sa=ple calculatica, including discussion of approach, for estabhshing :he reduced capac1:y of =achine velded pla:es due to a pos:ula:ed loss of one veld s:ud.

E= bed Plate,I? 512A is

~

used ss a basis fo: :his -discussion.

3.

A sa=ple calcula:1cn, heludhg discussion of approach, to dece==ine the reduced capaci:v of =anually velded e= bed plates (specifically e= bed pla:e I? 312) resul:ing from a pos:ula:ed 1/16 and 1/8 inch undersize veld, as well as the analy:ical basis for accep:ing a 1/16 inch undercut on the shank of :he ancho rod.

~he foll: wing addi:ional infor=ation is also offered as an aid to the KRC personnel in : heir evalca ica of :he velded s:uds:

4 The effec: of a axi.=c 1/32 inch under: : on the shank of

=anually velded =achine veld studs.

5.

A discussion of the logic e: p? cyed in the probability analysis for =achine velded s:uds.

I e= I In' response to I:e= 1 above, the practica e=picyed by the =achine velded e bed pla:e supplier fe; installation sad inspec ion of =achiae velded s:uds prior to June 9,1977 is su==arized in Incicsure A.

Inclosure 3 s

provides exa=ples of 3ech:el inspec:icn :eports which indicate :he review of welded studs (and stud bending) by the 3ech:ci hspec:or du bg thc pe-icd in question.

I:ees 2 and 3 Sa=ple calcula:icas for :he e= bed plates discussed in I:e=s 2 and 3 above are included in Inclosures 3 and C respectively.

Ite: I.

Althcugh :he vas: =ajori:y of =achine velded s:uds are ins alled au::-

=4:ically vi:h special " guns" under car.: rolled condiciens, there are a li=1:ed nu=ber of occasions where the s: ds =ay have ei:her been ins:alled or repaired by =anual fille: welding.

As indica:ed by field personnel in Inclosure I, such field welding was on a very li=ited basis.

UI has indica:ed tha: the field practice in inspecting these li=1:ed nu ber of s:uds f : undercu: vas :o use 4 1/32 inch accep:ance cri:erien on the shani of :he s:ud in lieu of the = ore res::ic:ive require =en:s of.01 inches as specified in A'JS Dl.1-75 Para. 3.6.4 Zhe resul: is :ha: se=e redue:ica in :he safety =argins could occur on these isola:ed s:uds. Ecvever, in :he unlikely case l

~

_ ~ - -. -

Bechtel Power Corporation Mr. D. F. Schnell 3

~

. tha: a =axi=== 1/32 inch undercu: is pos:ula:ed to extend around :he en: ire pert =e:er of a stud, the revised stud capacity, as cor.puted using :he =ini=u= specified yield streng:h, s:111 would exceLc the design require =en:s.

Design drawings have been revised o clarily the design inten:.

I:em 5 The probabili:y saslysis for pistas with =achine velded studs presented in Reference i van prepared to evalua:e the po:encial for failure of pla:es installed in cencrete prio: to the reinspec: ion effer:.

In crier to es:ablish this probabill:p :he analysis accounts for several f ac: ors; :he probabili:y of a s:ud being inef fec:ive (?l), the pr:bacili:y of a pla:e (which is assu=ad :o have an ineffective scud) suppo::ing a saie:y related a tar'-an:

(? ), the probabili:y of a load 2

on a place being of sufficien: =agnitude and a: a location rela:1ve to an assu=ed failed s:ud :o exceed the failure capacity of :he pla:e

(? ) and the probabili:y of the plate :o ever experience the a::ach=en:

3 design lead (P;). None of these factors in itself is represen:a:ive of pla:e failure.

Rather the resul:an: probabili:y agains: a single pla:e failure is the produe: of :hese factors, or:

? = [(? g + ?;

P ' 23 + ? " 3 - P ' " 3 P4)

The facco: (?;) is established f::= the reincoec: ion da':a of 81,673 s:uds which were ins:alled and shop inspected in the sa=e manner as chcse studs on the places in question. One could express the results of this reinspection in ter=s of a " Confidence Level" in a f ashion

-I si=ila: to that e= ployed by the NRC in II Sulle:in 79-02.

This bulle:in

\\s requires licensees to reviev concrece expansion anchors which serve essen:ially the sa=e fune: ion as :he e= bed pla:es in ques: ion.

Ihe accep ance cri:erien es:ablished in this bulle:in was :o have a 957.

confidence level tha: less than 5% defec:s exist. Us ing the f o r=u-la ions included in the bulle:in (which are based on a 95'. confidence level) and :he reinspection resul:s, less ch;n 0.17. defec:s are iden:i'ied. Many of the plates suppor: a::sch=en:s which are not safe:y rela:ed. A1: hough these plates share an equal probabili:y of having ineffec:ive s:uds :here is no safe y consequence.

Pla:es re::ieved f::= :he laydown area prio: to June 9, 1977 would have been :aken fro =

the sa=e stadt whe:her used for a safe:y rela:ed or non-safe:y related l

I fune:1cn. The fac:o

(?2) accounts fo: chose pla:es which have safety related a::ach=en:s.

The factor (? ) addresses the effec: the a::acb=ent load and i:s 3

loca: ion have on 7 given plate, assu=ing the. p' a:e has an ineffective scud en or adjacan: to che a::ach=ent loca: ion. Ac:ual loads resulting f ro= the at:ach=en: for each plate were de:er=ined.

In order to ine.ude the possibilt:y cha: the a::ach=en: =ay be a: any loca: ion on the plate, the load was applied in ecch of 9 zones shown in Ske:ch la of the repor: (Reference 1). It is assu=ed :he load has an equal possibili:y of being in any one of nine zones, hence ?"3 = 1/9. This is a conserva-tive assu=p:ica in cha: the load will nor= ally be appif _ f the cen:e:

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Bechtel Power Corporation

}ir. D. T. Schnell 4

cf the plate.

In f ac: a drawing revision since the report was preparad requires d-a: the cent:cid of the a::ach4=g weld be within the =iddle third of the pla:e. These applied leads were co= pared to the f ailure load in each :ene of each pla:e as.sc=ing*:he stud in :ene I to be inef f e c:ive.

If the actual 1 cad exceeded the failure load a pos:u-laced failure was iden:ifir.d. The f ailure load is identsfied for each of these :enes if any of :he s:: esses reach the

-'a'- = specified yield s::ess. For cc=puta:Lonal purposes the ineffec:ive s:ud was assu=ad :o occur in :ene I.

A finite nu=her of oos tulated f ailures were iden:ified fo: :enes I, II, III and VI as shovu. in the repor: (?'3).

Since :he ineff ec:ive stud has an equal chance of occurring in any one

)

of the four scuds within a cluster the chance of 1: being in :ene I is one in four. Conversely, :enes I7, VII and IX have as equal chance as :ene I of having the load applied over a postulanad ineffec:ive l

stad.

C--b'-3-g :he rand = possibili:y of an inef fec:ive stud at a given corner with the possibility tha: one of four cc ner zones could have a load over a pos:ulated ineffec:ive s:ud yields a factor of 1/4 X 4/1 = 1 (?'"3). A si=ila argu=e n holds for leads applied in o ther :=nes.

Since a one in nine chance was assu=ed for the lead to be applied in a given :ene, it is necessary :o sum =he resul: for all nine :enes.

In fact, since no po:encial f ailures were.iden:ified for

enes IV, V, VII, VIII and IX (?"33 = 0) :he ac:ual se=na:ica includes only :enes I, II, III and VI.

Note tha: ?3 indicates oniv che proba-bility of a plate f ailure for a postulated ineffective stud adjacent :o the load poin: whichis a saf ety rela:ed attach =ent with the ce=pu:ed

(.

a::ach=an: icad applied.

in itself is =caningless fe i: is ec=puted en the The fact: ?3 pre =ise hat every a::ach=en: is on or adjacen to an ineffective s:ud.

Further= ore, it is based on applying each a::ach=e== icad in each ci the nine :enes Oc delibera:ely seek pos:ula:ed f ail =res.

Reali:ing tha: plates vi:h saf e:y rela:ed a::ach=ents have a c==hined total of approxi=a:ely 2,f00 s:uds, :he reinspectica resul:s would suggest tha:

only approxt=a:ely rao s:uds cculd be pos ulated to f ail. Of course thesc rue s:uds =ay be loca:ed in areas of the plana not affected by the attach =ent icads. The poin: is that one emu;ca isola:e one factor independen; of others in the pr:babili:y analysis.

Rather, the probability of a pla:e failure =us: consider all f ac:::s in concert.

l i

An equally L=portan: considera:icn is the possibility of the plate ever experiencing :he design load.

As one exa=ple, a significant contribu:1:n to che loads i= posed en the pla:e is d=e to :he seis=ic event.

Dr. New= ark, in Reference 4 suggests :ha: L= ce=bining the safe:y =argins used :o iden:Lfy :he seis=ic even: a=d =he =gitipli-

[

catica of =argins of safe:y resul:ing fre= :he critaria and analytical methods i= posed, a probabill:y tha: the s: ue:ure will ever experience the design leads =ay be in the order of 10-8 A probability of 10-4 t

l was conserva:ively assu:ad in the report for this acnsideration.

t - - - -,.

Bechtel Power Corporatiori 1

Mr. D. F. Schnell 5

.-. In su==ary the probability of a plate f ailure is the product o'f the probabili:y of having an ineffec:ive scud, the probabili:y of :he place wi:h an assu=ed ineffective stud supporting a safe:y related lead, the probabili:y of tha: load exceeding :he plate capaci:y due to an assu=ad adjacen ineff ective stud, and the probability of' the attach = ant load ac:aally occurring.

As p:cvided in Acfcrence 1, a total of 10 plates had =ul:1ple scud 1

failures. Mal:1ple s:ud failures on a given plate have no addi:ional effe:: on the probabili:y analysis unless they occur on adjacen scuds.

,l Fon: occurrences of adjacent s:ud f ailures can be iden:ified f := the data. No case exis:s where = ore than tuo studs failed w1;hin a s:nd clus:e (the basis for design being a four stud cluster).

t An analysis has not been 9: ducted to evaluate the p cbabili:y ef f ect if a two adjacen: stud fa:Aure weru considered. Based on so=a st=ple ce=parisons we believe 1: is evident tha: this censidera:ica vill no:

substan:ially aff ee: :he resul:s. The probabili:y ce=putation for a two s:ud f ailure is sLnila: to tha: given above for a single scud failure, excep: tha: ra:her than censidering :he probabili:y of a f ailed scud :o the :o:al nu=ber of scuds inspected (P1) one =us:

ce= pare 1: :o the to al av=her of stud clusters availab'74. 34 sed on a to:al of S1,673 studs, a: leas: 31,673/4 a 20,418 stud clusters exis:.

Actually :here are sc=ewhat =cre :han this nu=ber of s::d clus:ers i

I available since pla:es vi:h =cre :han 4 scuds have studs that ca;, ie in =cre than one s:ud cluster. However, a si=ilar equal increase in

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the nu=ber of clus:c: possibilities f or the pair of ineffec:Lve s:uds also exists so tha: :he effect is essencially self-cancelling. The 1

or less than 1/4 the value result is tha: ?1 becc=es 4

=

20,418 5,104 fe: the single stud failure.

An increase in the probabi21:7 of ?3 vill occur. Although the calcu-la:1cns have no: been genera:ed :o es:ablish =4gni:ude of this increase fir =ly we believe 1: to be in the neighborhood of a f ae:c of 2 to 4 All c:her f ac: ors re=ain essentially the sa=a as for a one stud f ailure.

The ne: result is tha: the probability for pla:e failure due to a pos:ula:ed =al:iple stud f ailure is of :he sa=e =agni:ude (exponen: vise) as for a one stud f ailure i.e., the increase in 23 is app cxi=ately offse: by the decrease in P.

t Since the probability for a one scud f ailure and a two seud f ailure A-e add!:ive, the overall probabili:7 =ay a: wors double. However the order of =agnitude (exponen: vise) re=ains essen:ially the sa=4 as presen:ed in Reference 1.

l Ve--

uly yours,

/

Q J. h. a a IWT:bg

? oject

.ginee._n3 Manage:

ec:

N. A. ?strick l

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8 cNv4C4 STREET.ecVeEANEUA.NEW rCM 13642 (315) 257 2200 TW1 f, c.257 4951 I

Mw w'N Qfs O

C.0,dt(O noloto qt t uv{AY tbThern Dvisco June 10, 1990 SL: 367 Sech:e1 Power Cort: ration P.C. 3:x 507 GL.thersburg, MD 20750 A::ention: Mr. Paul Divj ak

Reference:

SNUPPS Proj ect 10466-C-131 Miscellaneous Metals Gentlemen:

In regard to Purchase Order Item No. 2 embedded plates with concre:c anchors, we hereby verify that Cives inten: since the I

beginning of the production of these plates has been to obtain

't a 360' fille: on the machine welded studs.

If the applied stud did no: have 360*, the stud was either a) bend ::5:ed per AWS 4.30.1, or b) repaired per AWS 4. 29. 3, or c) replaced.

Very truly yours, CIVES STEEL COMPANY Nor: hem nut.ision I

L hk -

Ted Tctten Proj ect Manager TT:sw CC: Dean N.

Parshley e

1

.s-i l

1 DETAILED PROCEDUP.E FOR TEST PRCCP.AM TO EVA1UATI l

k'E'. S OF ANCHOR RCDS AND ST.'US TO Ev.3EDDED PLAES s

i 3ECHTEL ?Ob?.R CORPORATICN t

l CAISIERSBURG, MARYLAND t

a Prepared by:

K. Parikh July 2, 1980 i

Revised July 11, 1980 Revised Aug. 5, 1980 b

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.s-TABLE OF CONTINTS Pih t 1.

Purpose of the Tes: P rog rt:s 1

l 2.

Description of " e Tes: 7:ogram 1

I 3.

Organi:a: ion for the fest Progras 2

l 4.

Detailed Procedures 3

5.

Results and Report 6

Figure 1 f

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Set Up of Testing Rig aad Typical Section Through 3en: Anchor Rod.

Dug. C-U009 Rev. 0 d\\

AP?E!OIX A:

Acceptance Criteria ForJelds of Anchor Rods and Studs To Embed Pla:es.

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1.0 Purpose of :he Tes: Progra=

'#,This progra: Is au:hori:ed by Ur. ion Electric Co=pany to evaluate the per-for=ance of weld =ents which sceure anchor reds and studs onto e= bedded pla t e s. These tests vill supple =en: Union Electric's report of the Accept-ability of E= bedded Pla:es dated March 10, 1978 (ULNRC-238) and its findings.

1 Although the referenced report established that the velds on both the =an-ually veldad anchor rods and the =achine velded studs installed in. concrete prior to June 9, 1977 vere a "co=ple:ely acceptable" product, physical

ests on a rando: sa=ple of those embeds =anuf actured during that period vere requested by the NRC.

The test progra= is directed only at the eval-uation of :he velds be:veen :he s:uds and anchor rods to :he plates.

The bend tests as identified herein are be 45 conducted for infor=ation only. Tests of this nature are not required my the governing codes or specifications, ner does such testing reflec: loads i= posed on :he veldee asse=bly by design intent. Therefore, failure of a seld during the bend tes: canno: of itself cons:itu:e a deter =ina: ion that the veld was not suitable for the purpose intended by the design.

2.0 Description of the Test Progra=

The folleving tests vill be conducted:

2.1 Manually velded e= beds Fro = the 45 pla:es segregated and stored at the Callaway jobsite twelve plates have been selected for testing. Six rods on six sep-

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arate plates have been selected for bend tetts. The specific rods

(

have been designated and their direction of cend specified by the NRC.

Six additional rods on six other plates were selected by Union

~

Elec:ric for tension testing. The selec: ions included ds having velds with =est apparent visual deviations. These sele.. ions vill be available for NRC review before the test.

Eend and tensien tes:-

ing vill be done a: Lehigh University.

2.2 Machine velded plates Six plates, e= bedded in concrete prior to June 9, 1977 shall be identified at the jobsi:e and tested in place to a load not exceed-ing the design lead conditions (plus load tolerances). The pla:e selections will be reviewed by the NRC prior to testing.

2.3 Resul:s and Reports The testing vill be witnessed at the jobsite and/or the laboratory by :he persons specified below or their authorized representatives.

A report, based on the tes:s, vill be issued sher:1y thereaf ter.

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30 Drganizat t.: for the Tes: Progr:c

..s-The following lites various entities and their afff**ated personnel involved La the test progra: including their pri=ary respon/'illities, where applicable.

Union Electric C =pany D. Schnell - Overall responsibility and coordina:ica with NRC

. Ivanut - UI coordina:or and witness for testing K. Kuechen=eis:er - Tield coordinator with DIC R. Powers - QA and witness for 4 sting Nuclear Regulatory Cc==1ssion E. Callagher - Witness and observer 2 '; test progra=;

Reviev :est progra= for acceptability to NRC 3echtel ?over Corporation P. Divjak - coordir.ator hetveen UE/NRC.

E. The=as/A. Pagano - Tecnnical direction, responsible for the tes set-up.

(

'K. Parikh - Overall coordinater for test progra and report.

Wi: ness for the tes: progra=.

Daniel in:erna:ional, Inc.

,- Assistance in the field test progra=.

Turnishirg labor, =aterials and :: anspor:ation as required for the :es progra=.

Dr. Fisher and Dr. Slutter - Consul: ants; advise tes: se -up and tes: pro-cedures and for conducting testing at Lehigh Universi:y and at :he jobsite as well as secord-ing and reporting all test resul:s at both the labora:ory and jobsite.

=

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. 4.0 De: ailed Proceduits

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4.1 Manually velded rods Frem the 45 plates 'sola:ed and held in storage at the jobsi:e, twelve places designated herein shall be shipped to Dr. Roger Slu::er, Lehigh Um.iversi:y, Depart =ent of Civil Enginear'.ng, Frit: Engineering Lab-oratory #13, 3ethlehem, PA 18015. The following plates and anchor rods are to be used for :he designated tes:ing method.

Tension Tests Bend Tests I?412 A16-19 Lef:. Red #5 E?611 A31-2 Rod #2 EP711 A7-155 Rod #5 I?511 A32-2 Red #5 E?$11 A11-1 Rod #5 E?511 A11-46 Rod #9 I?ill A16-18 ?cu., Rod #12 I?$11 A11-42 Red #10 E?412 A16-18 Top, Red #10 E?611 D24-1 Red #5 I?711 A7-223 Rod #6 EP611 A24-2 Rod #1 Upon arrival at the tes: labora:ory, the pla:es shall be properly s:ored in a secure place.

The anchor rods which are to be tested shall be visually exa:ined for any da: age during the shipnent. If the anchoY :od or the 3" x 3" place at the end of the rod is found to be da= aged, the overall co-ordinator shall deter =ine 1:s suitabili y for the test progra=.

f' The velds that are tested shall then be photographed from at least

(

two angles.

/

The 3" x 3" plates for :he qualified bolts shall be painted red for

/

he tension :est and green for the bend test. At least one additional ancho: red c:her : hat tnese identified previously in each category shall be selec:ed for use in refining the loading procedures. Thus, seven bol:s in each category are required for the :est progra=. The selec:1on process described above shall be perfor=ed in :he prssence of a consultan: and the overall coordina:or. In the event :he selection of an anchor red for the test progran has changed, the overall coor-dirator shall notify Union Electric, before :esting proceeds.

The selec:ed anchor rods shall be isola:ed by cutting a necinal A2 4" x 4" square plate arount each bolt.

The initial " rough" cu::ing of the pla:e =ay be done by gas torch; however, the final cut:ing shall be done by saving the plate under -he supervisien of :he con-sultant. ? ecautions shall be :aken :o assure tha: the veld at the juncture of anchor rod and the pla:e is no: affec:ed by :he cutting processes.

l

!$e individual assemblies obtained shall be sequentially numbered with a va:erproof =arker such tha: :he marks or tags vill be vis-ible during :esting. A record referencing the assembly nu: bars to the original plate nu=bers shall be =aintained by :he conr21: ant.

~-

~ _ _, _ _-, __

The testing shall take place in the presence of designated personnel.

The tension tests and the bend tes:s shall be done in the 300,00C#

capacity Baldwin machine. Certified calibration records indicating dates of calibration of the Baldwin =achine, strain gagee, and assoc-iated instrumentation shall be given to the overall coordinator prior to testing. Photograr's of each test and a video cassette of test progress shall b recursed and referenced in accordance with the rod numbers.

4.1.1 TINSION TEST - RODS _

Tension :ests shall be condue:ed by gradually increasing the lead in 10 kip increpan:s until failure of the rod shank or the failure of the veld sseurs. The change in the leng:h of the rod shall be recorded for each load incre=ent. Addi-

icnal inter =ediate readings =ay be taken to obtain suffic-ient data :o develop an elastic curve with a well defined yield point.

All test data shall be record (d by the consul-tants and the originals of the recorded da:a shall'be signed by at least one person fro = each entity represen:ed.

4.1.2 3END EST - ROD 5 A bend test shall first be performed on a selected anchor roc ether :har those listed above to establish de: ailed lead-ing procedure'. During this first test the relationship of

he applied load to deflection angle, the grip at base :o hold the asse bly, recovery of deflection when the load is

(

released and approxi= ate bend line above the plate shall be noted.

I 1

l yer bend tes:s on the designated anchor rods a strain gage shall be attached to the shank of the rod where =ax1:u: strain is expected, based on results of the initial test.

The load shall be applied in 100 lb. incre:ents or less as required l

o develop data for a load-strain curve. The applied leads and the corresponding strains fres the strain gage shall be j

recorded. The anchor rod shall be bent up to a 30 degree angle wi:h :clerances of ;,2 degrees. The welds sF,11 be observed for any sign of cracking during the applica: ion of the load.

If cracking occurs, the corresponding strain in the red shall be recorded.

Upca :o pletion of :he tests all assemblies shall be packed and shipped to Daniel International Corporation, State Eigh-way CC - 3 =iles nor:h of Highway 04 Portlan?, Mo 65057, A::ention:

K. Kuechen=eister.

G

. 4.2 Machine welded studs

~~

The ovarall coordinator, vi:5 the assistance of field personnel, shall select six plates which were embedded in concrrte prior to June 9, 1977. The field coordinator shall obtain co'ies of =ater-ial certificates for the plates and concrete cylindre test results for the applicable pours and forward the= to ti2 ovetall coordinator.

The selection shall be based upon accessibility to e,e places and feasibility of =ouni.ng a test rig for the plates. The 3 elected d

plates shall be sequentially nu=bered and a record of the assigned nu=be. to the designated place nu=ber shall be maintained by the field coordinator.

Ths tes:ing rig, a 30-ton jack and accessories, and two dial gages to =easure deflection shall be supplied by :he consul: ants. Cer-tified calibration records indicating the date of calibra: ion fot

he jack and associa:ed ins: tu=en:ation shall be given to the over-all coordina:or prior to '.41:ing.

A 1-1/2 inch dia=eter threaded rod of at least ASTM A-36 quality as shown in Figure 1 shall Le velded :o each pla:e near the cen:er of a four s:ud cluster as defined by the overall coordina:or. The veld shall be exa=ined by the =agnetic particle =ethod prior to testing.

The attach =ent shall be welded 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months prior :u :he actual testing and care shall be exercised to ascertain that the airecb.=en: is not leaded by the cons:ruction personnel prior to testing. For holding the testing rig in place 4 expansion anchors 1/2 inch dia=e:ar and 4" long shall be installed as shown on Figure 1 (See Specification C-103A).

The testing rig shall be =ounted on the expansien anchors and fir =1y secured in place. The jack shall be installed on the threaded attach-

=ent to the plate and the hydraulic pu=p shall be set on a table nex: to the vall. Dial gages shall be mounted by the consul: ants on the plate at desirable loca: ions. Load shall be increased grad-ually on the plate and the deflection readings corresponding to the applied load shall be recorded. The =axi=us applied load shall be a: leas: the design load but shall not exceed the design lead plus

- hen the =axi=u= load is reached, :he final reading for the 15%.

deflec:icn shall be taken two =inutes later and the load shall be released. The test rig shall be =oved to the next plate and the sa=e procedure shall be continued.

The originals of the field results shall be signed by :he overall coordinator and the consultan:. Photog-achs and a video cassette shall record :he test progress.

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l Note: Minor concre:e spalling =ay occur during pla:e :esting and 2

should not be considered an unusual occurreace.

.s-50 Results and Repor:

he recorded ru ults shall be represen:ed in a tabular s.nd a graphic for=at in a report. The report shall be prepared by Bech:e1 with assistance frc:

he consultants. The report shall include conclusions of the test.

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A??ENDIX A Acceptance Cri:eria for Welds of Anchor Rods and Studs to E= bed Plates 1.

Tension Tes on Anchor Rods (Laboratory)

All rods sele:ted for testing ere 1 inch in diameter. The design load (allowable load) based or. a factor of safety of 1.6 (lead factor) on :hese rods is 13.65 kips raxf-"- for an EP511 plate.

The design lead of 13.65 kips is rela:ed :o the ra:ed pla:e capacity of 75 kip's (f ac:ual use the =axt=u= lead on an EP511 pla:e e= bedded in concrete prior to June 9, 1977 did not exceed 60 kips). The velds between the anchor r;ds and plates shall be dee=ed acceptable if the connection carries a lead of 13.65 kips vi:hout any sign of distress.

In any event the :esting shall be carried out :p f ailure as specified in the de: ailed procedure.

2.

Pull Test on Machine Welded Plates (Tield)

The salected plates are I?512 and I?912 in one or more four-s:ud clusters.

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For EPS12 pla:es the acceptance cri:eria shall be a 14.5 kip load applied within a four-stud cluster without plate f ailure or plate deflection

= ore than 1/4 inch.

St=ilarly, EP912 plates shall be dee=ad acceptable a 29.2 kip load saf ely applied within a four-stud cluster.

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.s-i 11.'!ERIM CST PIPORT

'aTLOS OF A::CHOR :1005 A::D Sr.,~):

TO EMBEOL~~J PIATIS G

(-.

l BECH~IL PCLTR CORPO?a!!0N Gai:hersburg, Marylar.d I

Augus: 27, 1980 Prepared by:

h K. Parikh S.

e&*

TA3LE CF CONTENTS 1.

S ta:e=en: of Proble:

Page 1 2.

Descrip:ica of Tes:ing Paga 1 3.

Tes: Resul:s Pa ge 1 4

C:nclusions Page 2 f.ppet. dix A - Tes: Rasult Da:a Sheets t

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1.

Statement of Preble=

.s The testing progra: described herein was authori:ed by Union Electric Co=pany folleving a request by the NRC. The tests furnished physical evidence regarding the adequacy of welds at the junction of ancho rods and s:uds to plates which were :o be embedded in concrete. The testing progra= supplemen:s a previous study and report sub=1::ed to the NRC on March 10,1978 (see ULNRC-238).

2.

Descriptien of Testing All tests were performed in accordance with the "De: ailed Procedures for the Tes: Progra= te r.valua:e Welds of Anchor Rods and Studs :o E= bedded Pla:es" which was sub=1: ed :o the NRC (see ULNRC-365 dated July 17, 1960).

Six anchor rods selec:ed by Unica Elec:ric for :ension testing vare tes:ed a: Lehigh Universi:y on August 6, 1930. Six additional ancher rods were bend tested to a 30 angle a: Lehigh Universi:y on the same day.

The rods chosen and diraction of band were specified by the NBC.

With NRC concurrence six readily accessible e: bedded plates with machine velded s:uds were selected at the Callaway jobsite by Unica Electric (D. Stecko and K. Kuechensais er) and Ecchtel (K. Parikh) for tension tastins.. The plates were prepared for testing Sy Daniel Interra:ional Corp. in accordance with tne prograu tes: procedures f

(

and verc tas:ad on August 14, 1980.

All test results were observed and recorded by Dr. R. Slu::er of Lehigh University.

Dr. Slu::e also assisted vi:h :he develop = ant ei test precedures and i=plementation of the test progra=. An NRC representartve vi:nessed all tests.

3.

Tes: Resui:s Field data sheets of the test results and a grapnical representation of the da:a obtained for the tension and bend tests are includsd in Appendix A.

Tension tes:s on the six designated rods showed the capacities of the velds to be fairly close to the ulti=a:e s::eng:h of :he red material, and significantly higher :han :he 13.65 kips designated in the cri:eria fer accep a-bility of the velds.

The ul:i=ste loads on the sin rods were found to be berveen 46.2 and 51.5 kips.

The six bend tes:s were successfully ce=pleted :c an angle of 3G+ degrees withou: any sign of visual dis::ess or o:her detrimen:a1 effect on the ve lds.

Jol-;ite censica tests en four Z?512 e= bedded plates tes:ed to a load of 15 x1ps and ran I?912 embedded pla:es tested :c a load of 30 kips indicated tha: :he e= beds sa:isfcc:orily suppor: :he t=pesed Icad (no:e -

design icads were 14.5 kips and 29.5 kips respectively).

Racorded deflec:Lons were less than ene tenth of :he acceptance criteria..

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Conclusions Sa=ples were selected for :esting either rande=1y (e= beds a: :he Ca11 sway tobsite) or specifically ( eds with the u.os: undesirable, visual weld

.Uhsracteris:ics). All test results met or exceeded the design require:.ents and acceptance criceria and further de=enstrate che accep: ability of the subject c= beds.

ne testing supper:s :he conclusions presen:ed in :he repor: forwarded by U12G.C-238 da:ed P2 ch 10,1978 that the e= beds a: :he Ct11away jobsite are an accep:able product.

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i-r ATTACHMENT c

P dites,T;/7 fe m # M A SNUPPS All_other welds are examined in accordance with AWS Dl.l.

C..".

"I High strength bolted joints are examined in accordance with 5

the requirements of the AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts.

Examination of embedded anchor bolt materials used for RCS component support embeds meets the requirements of Section NF-2580 of the ASME Code for Class 1 component supports.

3.8.3.6.4.3 Erection "estraints and embedded items are erected in accordance with the following:

%==

a.

AWS Dl.1 Structural Welding Code is used, except

~

that the qualification of welders and welding op-erators may, alternatively, be in accordance with ASME Section IX.

In addition, weld procedures for joining structural steel and sleeves used for mechanical splicing of reinforcing steel may be qualified in accordance with ASME Section IX.

The following exceptions are allowed for welding between anchor studs and plates embedded in concrete:

1.

Vertical leg of weld may be up to 1/16 inch smaller than that specified on drawings.

MM

=2) 2.

Unequal legs are permitted.

~

3.

Weld profile and convexity requirements for these welds need not be imposed.

4.

An undercut of up to 1/16 inch for 10 percent 1

of weld length may be permitted.

I b.

AISC Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings sections l

1.23 and 1.25 are used without exception.

AISC Specificacion for Structural Joints Using ASTM c.

A325 or A490 Solts is used without exception.

d.

Erection tolerances for pipe whip restraints, pipe whip restraint embeds, and RCS component support o

embeds are in accordance with the following:

1.

AISC Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings, for rolled plates and shapes 2.

AWS D1.1 Structural Welding Code for welded assemblies 1

RE:

EE_

3.8-56 Rev. 1 9/80 1

--

ML20011A465

Contents

Text

SUMMARY

Enclosure:

Dear Mr. Gallagher:

Dear Mr. Reppler:

Subject:

Dear P.r. Schnell:

Reference:

=wwv' vsy-y-w wyw-y p*w-Sw-,

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ML20011A465

Text

SUMMARY

Enclosure:

Dear Mr. Gallagher:

Dear Mr. Reppler:

Subject:

Dear P.r. Schnell:

Reference:

=wwv' vsy-y-w wyw-y p*w-Sw-,

Navigation menu

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