Text

Testimony of Hn Singh Re Plant Fill Problem at Diesel Generator Bldg.Pp 1-12.Supporting Documentation Encl
	ML20054B168
Person / Time
Site:	Midland
Issue date:	04/12/1982
From:	; Atomic Safety and Licensing Board Panel
To:	;
Shared Package
ML20054B157	List: ML20054B154; ML20054B168;
References
	ISSUANCES-OL, ISSUANCES-OM, TRN-820412, NUDOCS 8204160364
	Download: ML20054B168 (35)
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D U: Il Lis SIAILS Ol' AMEl:1CA Sl'CLI:AR RI A:l:LAIORY CO!!!11SS10N 1;Li'ol:1. Till A'lo' llc SAFl;TY AND LICl:NSING I!OAPD i

in thi Lt ter of

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CONSl"fi I::. POi;I: COMPA..Y

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Docket Nos. 50-329-0M & OL g

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50-330-0M & 01.

(Midland Plant, Unita 1 and 2)

)

Ti.STIMoNY OF llAl:1 N. SINGil CONCE!!NING Tile PLANT FILL pl:0BLl;!! A'I 'lill DIESEL CENERATOR BUILDING Q.l.

Please stati your nani and position.

A.I.

My nane is llari Singh.

I am a Civil Engineer in the Geotechnical Branch Engineering Division, U.S. Army Corps of Engineers, North Central of the Division, Chicago.

you prepared stateraents on your professional qualifications?

Q.2.

llave A.2.

Yes, copies are attached.

of your responsibiliteis with respect to the 0.3.

please state the nature

!!idland plant.

A.3.

1, liari Singh, became involved with the.Hidinnd Plant in !!ay 1980, when l

1 was assigned the responsibility as the Co/ps'. lead reviewer for the l

geotechnical aspa_ts of the plant.

On !!ay' 7,1980, I joined the Corps' the team of engineers and geologists of the Geotechnical Section of Dettoit Dlutrict, who were engaged in reviewing the foundation design f

of the !!!dland Plant.

As the full-time lead reviever, my responsibilities l

to cooordinate uith all Corps reviewers, examine their comments, f

were l

f perforn uy own review. discuss comment

with the Sect.Jon and Branch Chiefs

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and prepare final letter reports for transmittal to the NRC.

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-l-8204160364 820412 PDR ADOCK 05000329 PDR 3.gA(

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.a Q.4.

L' hat is the purpose, of this testimony?

A.4.

This testimony is limited to the Diesel Generator Building (DGB) and describes the plant sett1cuent problems in the area of the DGB up to the present status of review by covering the following topics:

a) Description of the plant fill problem which caused the settlement,

and selected renedial treatment (Surcharging).

b)

The Corps of Engineers' request for borings and laboratory testing and the resulting engineering evaluation of this information.

c)

The Corps of Engineers' evaluation of the laboratory test results, the measured and the predicted settlements of the structure by the Applicant.

.d)

Request. by the Corps to evaluate the stresses in the Diesel Cencrator Building due to the differential settlements that have occurrcd, (1) prior to the surcharge, (2) after the surcharge, and (3) predicted settlements for the life span of the plant.

Q.5.

h"n a t is the problem at the Diesel Generat.or Lullding area?

A.S.

The fill soil placed in the foundation supporting the Diesel Generator Building has settled excessively and unevenly, causing varping of the building fo, tings and cracking of the building walls (Attachment 4, Figure 1 and 2).

The efforts in the Geotechnical Engineering portion of the flidland review have been directed to establishing the magnitude of total and di f f er ent ial set tlements of the foundation soils ubich have already occurred and the settlerents which will likely occur in the future during the remainder of construction and plant operation. This determination of

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l settlement and compressibility characteristics of the foundation soils is l

important input into the structural and ncchanical engineering analysis which evaluate the effect.s of the settlement (cracking, overstressing, l

distortions) on the safe operation of structures and underground piping and conduits.

0.6.

Ubat. has caused the plant fill problems?

A.6.

The settlement nonitoring program, which had been established by the Applicant to provide settlement records during construction and plant operation and as a check on the setticments predicted in design, un-covered set.tlements greiter than anticipated in August 1978 at the DGE.

At this time, the DGB uns only partially completed. A subsurface investi-gation program was completed in the full of 1978 on the conpacted fill materials in the DGB area and revealed these foundation materials to be quite heterogeneous and in some areas to be inadequately conpacted.

The fjl1 soils rangtd from sands with relative densities ranging from loose to very stiff. The inadequately compacted fill soils caused the excessive and uneven settlements.

Q.7.

Uaat settlement of the DGB had occurred prior to surcharging and how did it compare with predicted values?

A.7.

As of.lanuary 1979, before placement of the surcharge fil], the corners of the east vall of the DGB structure had set.tled approxin.ately 50% more than t heir counterparts of t he vest wall, with a maxinum ret tlement of 4.25" being indicated at the southeast cornt r and a minimum settlen.ent of 2.09" at the northwest corner (See Attachment 1, Figure 27-10).

3-

The Consultants retained by the Applicant had concluded based on the results

'. of tiie field and laboratory investigations completed in the f all of 1978, that the plant fill was settling under its own weight and reconmnded surcharging as the renedial treatment to accelerate the set tlement which could be expected to occur unde r the final design load.

Initially In the PSAR the set tienent had been estinated to be on the order of one-half inch or less for structures to be founded on the compacted fill but later was revised with the subulttal of the FSAR in Agust 1977 to estimte an ult inat e se ttlement for the DGB ranging fron 2.8 inches to 3.2 inches.

Q. 8.

What did the surcharge progran accomplish?

A.8.

The surcharge program, is expected, produced additional consolidation in the fill naterials which accelerated the settlements, but it reaised questions:

(1) whether the precompression stress produced by the surcharge would exceed the stresses that would be created by fut ure l oad s, and therefore any future settlenent would be minimal and insignificant to the safety of the structure, (2) whether the rigidity of the structure prevented the surcharge loads fron becoming Inriediately ef fec t ive in producing consolidation in the sof ter, nare conpr." sible founda t ion soil s, but because of future cracking uould event ually allow a redistribution of loads in the future, and (3) whether, the additional se ttlenents crea ted by the surcharge load (See Attachnent 1, Figure 27-11 for settleuents due to surcharge) caused p e rna ue n t damage or in. lured unaccept able strerses in either the part ially completed st ructure or the already in;talled condults and piping underneath the structure.

These questions requi re annue rs not

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only 'or the condition which existed 'ollowing nurcharging but also for the ability of the structures and piping to withstand severe future environmental loads (carthquake, tornado, e tc. ).

The Corps of 1:ngineers questioned the validi ty of the surcharge results, and in its report of 7 July 1980, which was transmitted to the applicant on 7 August 1980 by the NRC, requested the applicant to verify the field observed settlenents by settlements computed on the basis of results of laboratory tests conducted on representative-soil sanples (details of req ue s t for soil explorations and testing given in Question No. 10).

The Corps also requested the applicant in its report of 7 July 1980 and 15 April 1981, and at va rious meetings (structural audit in April 1981 a t Ann Arbor, and in a necting at Bethesda in the first week of June 1981) to compute stresses in the foundation due to settlements.

The above requests would have provided answers to the above three questions, but as of today, the Corp., of l',ngineers has not received the satisfactory response to its request.

No satisfactory answer to stress eval uation due to differential settlement has yet been received, an1 as such, the Corps of 1:ugineers is not in a position to complete its review and testify regarding the adequacy of the Diesel Generator Building.

Q. 9.

What are the effects of the settlenents which the Diesel Generator Building experienced before and during the surcharge progran?

A. 9.

Structures founded on a soll mss net tle depending upon the conpreusihtlity and unifomi ty of the soil r.a ss unde r the fou nda t ion.

Nornally before buIldi ng a st ruct ure, soil explorations and testings are carried out to de te rni ne actual soil characteristics.

This i nf o rma t ion 5-

is used to determine the most suitable location for the structure and to properly proportion the buildings foundation. This exploration and design work is intended to assure that the constructed building will not experience settlenents in excess of tolerable limit s.

The set tlerents of the foundation soils unde r the Diesel Cencra'.o r buildi ng have exceeded the expected limits of settlenents.

Because of the structure's anticipated high rigidity, snaller and svare uniform nettlement s were expected under the building, but the nettlenents observed prior to the surcharge indicated larger and uneven settleuents creating dif ferent ial.ettlements and resulting in curvatures of the s t ruc t u re footing and walls (Attaciumnt 2, Figure 1).

Consequently, additional flexural and shear stresses have been induced in the structure.

Subsequent to the surcharge, the magnitude of the nettl ement a further increased and the curvatures of the footingc in come area increaned causing further increase in bending and shear stresses.

At. t a ch ne u t 2, Figure 4 chown a qualitative assessnent of increase in curva t ure of the footings under the east uall of the Diesel Generator lio i l di ng.

The ualI supported by this footing has shown considerable l

increane in nunber of cracks, since the surcharge load was applied f

(number of cracks prior to surcharge 10, as per response to Question 14, i

10 CFI' 50. i4(f), Figure 14 2, mnber of cracks since surcharge 16).

The additionat curva ture created by the nurcharge appearn to be a mjor f act or a u creating these cracks.

Figures 1, 2 and 3 of Attachment 2 l,

show change-in curvature of the nouth wall of the Diesel Generator l

nulldlug caused by the di f ferent ial net tlenents a t 1, t a ge n ; (1) prior to nurcharge; (2) a f t er nurcha rge; and (3) at the end of the Itfe span of l

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the plant.

The settlements in (1) and (2) were obtained by actual neasurements and arc shown in Figures 1 and 2 of the Attachnent 2 and those in (3) are predicted on the lusts of the secondary consolidation paranaters of the soils under the foundation of the structure and are shown in Figure 3 of Attachment 2.

Curvatures in the foundations of other walls of the Diesel Generator 15uilding created by the dif ferential set.tlenents could be denonstrated by the procedure similar to that used to draw Figurer, 1, 2 and 3 of Attachment 2.

Fron the above observations, it is clear that the Diesel Generator Building's foundations and the walls have undergone change in curvatures due to the differential settlements resulting in hending nonents and shear forces additional to those cuased by loads.

The applicant should evaluat e the stresses due to such dif ferential settlements considering the appropriate rigidity of the structure at the various stages as outlined in At tachment 2, and de te rnine the adequacy of the "tructure by incorporating stresses due to dif ferential settlenents in appropriate loading conbinations.

Q.10. ITnat was the purpose of the borings and laboratory testing which were requested by the Corps of Engineers for DGB aren?

A.10. The infornation concerning record naapling of the fill naterial furnished in the PSAR was not adequate to evaluate the stability and set tienent of the Diesel Generator linilding.

The soil data furnished in the FSAR did not provided actual soil data of the ruterial at the Diesel Gene ra t o r fin ildi ng.

The data requested was essential to de t e rmi ne further settlenent of the hallding anzi it's stability.

The load test Co ~

results, present ed by t he Applicant, wa s in our opinion, inelusive in predict ing f uture settienent.

7

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llave.the requested borings and laboratory testing been completc.d?

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0. } t The laboratory testing and six borings requested along the peri-A.ll.

Yes.

phery of the DGB were completed during the period of liarch through July 1981 by Woodward-Clyde Consultants G.'CC) who had been retained by CPC The results of these to complete the boring and lab testing programs.

programs for the DGli were provided to the NRC in two reports which were enclosures to the July 31, 1981 letter of trannnittal from James U. Cook, CPC, to 11arold R. Denton, NRC.

The first report dated July 8,1981 doc u-ment ed the boring and sampling program and the coupleted laborator';

test-ing which included soil index properties, gradation, shear strength and consolidation tests. The second report dated July 22, 1981 presented consolidation pressure of cohesive fill materials estimates of maximum past The maximum past prior to and after completion of the surcharge program.

consolidation pressures had been independently estimated by three geo-technical engineers on UCC staff in an effort to assess the uncertainty in the technique used to establish the maximum past conso]idation inherent pressure. The second report also contained a graphical comparison of the esticited manimum past consolidation pressures with estimated in situ ef fect ive overburden pressures at varying depths below the ground sur f ace.

In another let ter f rom James U. Cook to !!arold R. Denton dated August 17, 1981 two additional enclosures were t.ransmitted to the NgC. Ubich pro-vided a comparison of too maximun past consolidation pressures with presnures estinated to exist f rom loading during surcharging, and an evaluation of the boring anct lab test.

Corps of 1:nginecru satisfied with the boring and soil campling q,}?.

Is the program which was completed in the DGB area?

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A.12.

Yes.

NRC approved the Corps request to continuously observe the drill-ing and sampling operations in the field and to make one visit to the soil testing laboratory of WCC.

Based on these field and lab observations completed by the Corps of Engineers, we conclude the soil exploration pro-gram uns properly carried out in accordance with the state-of-the-art method and we find t.his information to be acceptable.

0.13.

lias the Corps of Engineers completed their review and technical evaluation of the three reports provided by the Applicant?

A.13.

Yes.

The Corp.s of Engineers has reviewed these reports and submit the following comments:

a) The drained shear strength parameters ( ii, c) determined by the consolidated undrained tests with pore pressure measurement ( CIU, CAU )

and presented in Tables D-1, U-2 are better than those used by the appli-in its couputation of the bearing capacity analysis, which was sub-cant i

mitted by the appliennt in response to Question 40(2), 10CfR50.54(f).

Ilowever, in it s responde to Question 40(2), the applicant has not demon-st. rated that e: hear strength paraneters, ii = 29. 2 and C = 114 lbs per l

1:q ua re foot, used in it.s analysis were the representative parameters for the soil underncath the Diesel Generator Building.

I b) The resul ts of the consolidation t. cst:. indicate that all the tests were carried out toamaxiu(consolidationstressof64tonspersquare foot (t sf). The maxinum past consolidation pressures (precont;olidation pret.sure) have reportedly been computed by three engineers independently on the basis of t.he tests carried to 64 tsf consolidation pressures as well a on the basis as if the tests stopped at 16 tsf consolidation pressures.

_6-C

The computed preconsolidation pressures are tabulated in Table-3 of

., part two.

The results indicate that preconsolidation pressure computed' on'the basis of the consolidation tests carried to 64 tsf stress are not consistent with the settlements that have occurred under the foundations of the Diesel Cencrator' Building prior to surcharging.

For exampic, the computed preconsolidation pressures for eight samples i

taken from COE-13A and COE-13B varies from 1.48 tsf to 5.20 tsf with an average of 3.41 tsf. Excluding the effects of 1.1 tsf of surcharge and approxinately 1.05 tst of overburden (overburden pressure at mid-j 1

i depth of the clay colonn at COE-13A, with average soil density of 140 lbs/u'), the net average precompression prior to surcharge turned out l

to be 1.2 tsf. With this preconsolidation pressure in the clay soil at COE-13 and its close vicinity, the south-east corner of the Diesel Generator Building, any settlement caused by a foundation: pressure of 1.2 tsf and less would have been negligible, being the results of precompression. IIowever, field neasurements has indicated that the south east corner of the building had settled 4.25" (See Attachment 1) under a foundation pressure of 0.7 tsf (See Attachment 5, Figure 4-1A, 10 CFR 50.54(f) ).

Thus the observed settletient of 4.25" under a pressure 0.7 tsf at the southeast corner is inconsistent with the preconsolidation pressure computed on the basis of consolidation test carried to 64 tsf consolidation pressure.

In the opinion of the Corps of Engineers the raaximum past consolidation pressures based on test 4

carried to 16 tsf are appropriate for computing settlements to verify l

the observed settlements.

l c) After the completion of the review, the l'RC, the Corps of Engineers llc I

l and the appliennt held a meeting in September, 1931, at,linC office in I

lieth'c'da to resolve the disagreements regarding preconsolidation pressures l

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between the staf f (NRC, Corps) and the applicant's consultants.

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the raceting the applicant was requested to draw pressure distribution diagrans below the foundation elevation at each boring location, considering the influence of structure (dead load and live load) and the dewatering, and then superinpose the preconsolidation pressures deternined by the UCC with 16 tsf consolidation tests to determine whether or not the soll layers supporting th)(e structure have been preconsolidated to stresses which are nore than the actual pressures caused by the overburden, dewatering and the structure loads.

In cases of the soil layers where the preconsolidation pressure f alls below the actual pressure, the layer would unde rgo virgin compression, and the applicant was requested to evaluate settlenents due to such virgin compression and add to the observed primary settlements.

The applicant f urnished its response to the above request on 21 October 1981. shaus the details of the response subnitted by the applicant. The additional settler:ents as shown on page 2 of the Attachment appear to be negligible; the re f o re, the Corps of Engineers considers the observed settlenents of the Diesel Generator Building (Attachment 1, Figure 27-11) very close to the 100% prinary settlement, and these settlementr, should be used to evaluate settlenents stresses in the structure at the stage of nurcharge reno va l.

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f Q.14. Uhat are the Corps of Engineers conclusions with regards to the adequacy of the infornation provided by CPC to demonstrate the effectiveness of the completed surcharge progran?

A.14. 'lhe Corps of Engineera concludes the following on the adequacy of the submitted information:

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(a) Shear strength parameters determined for the foundation soils under the Diesel Generator Building are better than those previous arbitrarily assumed parameters used in bearing capacity analysis and furnished in response to Question 40 (10 CFR 50.54(f) ).

Therefore, the bearing capacity of the foundation soils is adequate.

(b) A comparison of the preconsolidation pressures deternined by the con-i solidation test results with pressure distributions below the foundation indicate that approximately 100% of the primary con-solidation has been completed by the surcharge load. Additional average primary settlement computed by the applicant on the basis of the test results is 0.2" which is less than 3.4% of the total avetage settlement; and in my opinion is of no consequence, therefore, for all practical purposes,100% primary consolidation'is considered-completed.

indicatc5 (c) The applicant has not yet furnished any information that that it has determined the stresses in the strecture incorporating f

the effects of differential ettlements at various stages of loadings llc as outlined in the last paragraph of,ansuer to Question 9 (the I

settlement s that has a3 ready occurred due to the dead load and I

surcharge load, and the future secondary settlements).

l (d) The settlement stresses are permanent in nature and as such are equivalent to the stresses produced by dead loads. Therefore, in checking structure stresses in various load co:abinations it must be considered as dead load stress.

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1. On 3 28 78 the completed portion of the building consisted of the concrete pedestals and building wa!!s to elevation 6s4'.

2. The settlements were measured while the building was being constructed.

On 1 19 79 the completed portion of the building consisted of the concrete pedestas and building walls to mezzanine floor elevation 664'.

3. On 3-22 79 the building was completed.

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CONSUMERS POWER COMPANY MIDLAND PLANT UNITS I & 2 Measured Settlement S i Inches During Surcharge s

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O BUILDING / PEDEST AL SETTLEMENT MARKER 1.20 SETTLEMENT IN INCHES NOTES:

1. See Figste 27 9 f of f urther definition of S,

3

2. See Figure 27 2 fee apprcrimate average loading histories during surcharge prograrn.

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O d rn er) Ne-3 POST *;LACD SETILEEiT CALCL7.ATIO2S 3ASED ON RESULTS OF

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SOIL 30 RINGS AS REQUES SD BY IiRC In discussions and meetings with the IiRC and their consultants, they requested a ec=putation of the settlement of the diesel generator buildirg according to the =ethod desevibed below.

Several borings, COE 9, 9A,10A,11A,12A,13A, and 133, had been drilled at the request of the staff. These bcrings and the results of tests on the soil sa=ples obtained by Woodward-Clyde consultants (WCC) were used in this analysis. The in-situ effective overburden pressure vs elevation was calculated for each boring using the soil density obtained frem soil sa=ples in their respective borings. The structural dead plu's live load pressures vs elevatien vere then ad: led to the overburden pre {sures at the location of the borings.

The precensolidatien pressure was then calculated by WCC from consolidation tests in these borings. The preconsolidation pressures were esti=ated frc=

the results of te,sts having saxi=u= pressure of 16 TSF.

l l

The cc=pression ratio, C

was determined by WCC using that portion 1+eo of the compressien curve for the maxi =u= consolidation pressure of 16 TSF.

I 1

The !i3C (See Figures 1 thru 5) chose layers of clay fill corresponding to elevations for which the calculated precenselidation load, Fe, was less.than l

the effective overburden pressure plus the pressure due to the structural icade,.?.

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2 The settle =ent was calculated using the folicving femula:

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I 6 = H( Cr

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6 = settle =ent in feet i

E

= layer thickness in feet C.

= co=pression ratio 1+e o

? = effective in-situ overburden plus 4

structure load pressure in ESF P

= prec nsolidad on load in E c

The settle =ent values calculated ranged between 0 inches for COE 10A to 0.h inches for COE 11 A and are listed below:

30EING SE LD'E'C 18 c.Q COE 9, 9A 0.2 in e.c N

COE 10A 0

in d

COE llA 0.L in 3 Ct &

COE 12A C.3 in i

COE 13A, 133

0. 3 in n

ct e.5 e.g i

It is the opinien of the !'RC that these settlement values represent the a=ount of pri=ary censolidation re=aining following the re=cval of the diesel generater building surcharge load.

1 We helieve that the pri=a y censelidatic: vas ce=plete prior to eurcharge 4

re= oval.

This was de=enstrated by the dissipation of excess pore pressures and the shape Of the settlement-leg time cu-res for the building sett'e=ent

}

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markers prior to surcharge removal. Tnis has been discussed en several occasic:is with the staff and in ansvers to 50.5k(f) questions.

'n'e do not agree with the method of calculating preconsolidation pressure from coil sc=ples taken after ce=pacticn and surcharging. This has also been previously discussed with the staff and these precenselidation pressure values leave =uch roc: for interpretation.

e

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DlESEL GENERAT03 BUILDING

+

TOTAL SETTLEMENT OF WALLS. FROM 7-14-78 TO 6-29-79 IN INCHES (20 FEET OF SURCHARGB c

Dj) - /.

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EAST WALL EAST SIDE LOOKING WEST B

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r TABLE 4-IA SFTTLEMENT

SUMMARY

OF DIESEL GF.NERATON BtilLDING A. Settlement History (butiding Loads Only)

Construction Stage i

11 Ill tv v

vg time Period Beginning of con-3/28/78 to I/19/7.9 1/26/19 to 8/15/19 8/15/19 to I/16/80 1/16/80 to 12/31/88 12/31/81 to struction to 3/28/78 12/31/2025 Estimated Average O t o 0.8 0.8 to 1.4

1. 4 t o 4.4 2.2 2.2 t o 3.0 3.0 Pressure (ks!)

No Surcharge Surcharge Remarks No Surcharge The completed por-The completed por-The hullding was Latest reading in-Date of final Plant life tion of the tasild-t ion of the Imild-completed on cluded in this re-piping connections is estimated to ing consisted of ing consisted of 3/22/19 (2.2 kat).

the concrete pedes-concrete pedestals Surcharge commenced 1/16/80.

12/31/81.

12/31/2025.

S sponse was taken on is estimated to be extend t o tais and building and building walls on 1/26/19 walls to el 654' on to mezzanine floor Surcharge 3/28/78.

el 664' on 1/19/19.

was in place on 4/6/19 (2.2 kst).

Between H/15/19 and 8/30/79, sur-clearge was removed.

Range of Settlement (Inches) 8 8

0 0

8 8

1 2

8 8

2 3

Heasured Predicted Measured Predicted Heasured Predicted Measured Predicted Hessured Predicted Measured, Predicted Building Not 2.3 to

1. 5 t o O to 0.15 t o 0.5 to

0. 7 t o recorded 4.3 3.4 0.04 0.31 0.9 1.5 Pedestals Not 1.1 t o 2.0 t o O to 0.17 t o 0.5 to 0.8 to recorded 4.5 3.4 0.10 o,31 0.9 1.5 4-6 Revision 5 2/80 e

R

ML20054B168

Text

3.4 LEGEND

SUMMARY

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