ML20071J867

Final Response to NRC IE Bulletin 79-02,Revision 2

ML20071J867
Person / Time
Site:	Columbia
Issue date:	03/31/1982
From:	WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:
Shared Package
ML20071J834	List: GO2-82-380, Forwards Final Response to NRC IE Bulletin 79-02,Revision 2 ML20071J867
References
REF-SSINS-6820 IEB-79-02, IEB-79-2, NUDOCS 8204270394
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{{#Wiki_filter:, FIflAL RESPONSE TO NRC IE BULLETIN 79-02, REV. 2 FOR WASHINGTON NUCLEAR PLANT (WNP-2) HANFORD WASHIflGTON BY WASHINGTON PUBLIC POWER SUPPLY SYSTEM RICHLAND, WASHINGTON i flarch 31, 1982 %o %q 0.9 S a B

TABLE OF CONTENTS ITEM Page INTRODUCTION.........,............... 1 NRC ACTION ITEM N0. 1.................... 2 1.0 - RESPONSE TO ACTION ITEM NO. 1.............. 2 1.1 I NTRODUCT I ON...................... 2 1.2 ORIGINAL BASE PLATE DESIGN 3 1.2.1 WNP-2 Original Design Method 1.2.2 _ Increases in. Stress Allowable 1.2.3 Preload of Bolt 1.3 FINAL BASE PLATE DESIGN AND QUALIFICATION........ 5 1.3.1 Flexible Base Plate Analysis 1.3.2 Description of Analytical Model 1.3.3 Shear and Tension Interaction 1.3.4 Typical Base Plate 1.4 COMPARISON OF RIGID AND FLEXIBLE ANALYSIS........ 8 1.4.1 Conventional Rigid Plate Theory 1.4.2 Examples 1.4.3 Comparison 1.4.4 Summa ry - 1.5 TESTING......................... 12 1.5.1 Description-1.5.2 Comparison of Test and Analytical Results 1.6 DISCUSSION OF CYCLIC LOADING,............. 14 1.7 MAJOR CONSERVATISMS................... 14 1.7.1 Interaction of Shear and Tension 1.7.2 Seismic Load 1.7.3 Expansion Bolt Testing 1.7.4 Anchor Bolt Stiffness CONCL'SIONS....................... 16 1.8 U NRC ACTION ITEM NO. 2.................... 18 2.0 RESPONSE TO ACTION ~ ITEM N0. 2.............. 18

2.1 INTRODUCTION

18 2.2 TEST PROGRAM,..................... 19 2.3 TEST RESULTS...................... 19 2.4 ALLOWABLE LOADS 20 2.4.1 WNP-2 Original Design Allowables Used By Contractors i

TABLE OF CONTENTS CONTINUED ITEM pg 2.4.2 Anchor Allowables~ Used for Final Plate Qualification 2.5 FACTORS OF SAFETY 20 NRC ACTION ITEM NO. 3.................... 21 3.0 RESPONSE TO ACTION ITEM N0. 3.............. 21 NRC ACTION ITEM N0. 4.................... 22 4.0 RESPONSE TO ACTION ITEll NO. 4.............. 23

4.1 INTRODUCTION

23 4.2 ANCHOR BOLT PRELOADING 24 4.2.1 Torque / Tension Testing 4.2.2 Anchor Retorquing Program 4.3 L EV E L I NG NUT S...................... 25 4.4 VERIFICATION OF INSTALLATIONS.............. 25 4.4.1 Contract 213A - Primary Containment - 4.4.2 Contract 215 - Mechanical Equipment Installation-and Piping 4.4.3 Contract 216 - HVAC and Plumbing Installation 4.4.4 Contract 217 - Fire Protection System 4.4.5 Contract 220 - Instrument Installation 4.4.6 Contract 233 - Piping Supports NRC ACTION ITEM NO. 5.................... 30 5.0 RESPONSE TO ACTION ITEM N0. 5.............. 30 NRC ACTION ITEM N0. 6.................... 31 6.0 RESPONSE TO ACTION ITEM N0. 6.............. 31 NRC ACTION ITEM N0. 7 and No. 8 Not applicable NRC ACTION ITEM NO. 9.................... 32 9.0 RESPONSE TO ACTION ITEM NO. 9.............. 32

9.1 INTRODUCTION

32 9.2 BASE PLATE ANALYSIS................... 32 9.3 GENERIC ANCHOR INSPECTION CRITERIA........... 32 ii

TABLE OF CONTENTS CONTINUED ITEM Page

10.0 REFERENCES

33 LIST OF TABLES Table 1.5 Comparison of Test and Analytical Results........ 13 Table 4.1 Contract 215 Retroinspection Program for Anchors Installed Prior to February 1978............ 27 Table I Allowable Expansion Anchor Loads Provided to Contractor. 34 Table II Final Design and Qualification Expansion Bolt Allowables....................... 36 Table III WNP-2 Expansion Anchor Installation Torques and Preloads........................ 38 LIST OF FIGURES Figure 1.4.1 Comparison of Analytical Methods on Eight Bolt Base Plate 11 Figure 1.7.1 Comparison of Test Results to Analytical Method....................... 17 Figure I Field Test..................... 39 Figure II Bolt Load Comparison for Test 1........... 40 Figure III Bolt Load Comparison for Test 2........... 41 Figure IV Bolt Load Comparison for Test 3........... 42 Figure V Bolt Load Comparison for Test 4........... 43 Figure VI Shear-Tension Interaction Diagram......... 44 Figure VII Structural Responses................ 45 Figure VIII Structural Responses................ 46 LIST OF EXHIBITS Sheets Exhibit A 3/4 Inch HDI Torque Values............ I thru 8 Exhibit C Leveling Nuts................... 1 thru 11 Exhibit C NRC Bulletin 79-02 Inspection Requirements.... I thru 3 Exhibit D NRC Bulletin 79-02 Inspection Requirements for C215....................... 1 thru 4 Exhibit E C215 Retroinspection Requirements (Revision 0).. I thru 23 Exhibit E C215 Retroinspection Requirements (Revision 6).. I thru 24 Exhibit F NRC Statistical Sampling Method and C215 Sample Retroinspection Program I thru 4 Exhibit G C215 Sample Parabolt Retroinspection Program (C233 Installations)............... I thru 10 iii

INTROD'JCTION The Nuclear Regulatory Commission IE Bulletin No. 79-02, dated March 8, 1979, directed holders of Nuclear Power Plant Construction permits to respond to the concerns of the NRC regarding the reliability of pipe support base plates that use concrete expansion anchor bolts in Seismic Category I Piping Systems as defined by Regulatory Guide 1.29, " Seismic Design Classification", Revision 1, dated August 1973, or as defined in the applicable FSAR. Revision 1 of the Bulletin, providing clarifications, was issued June 21, 1979. Revision 2 of the Bulletin, providing additional clarification and new items of concern, was issued November 8, 1979. This final response supercedes the previously sub mitted response and addresses the Bulletin " Action Items" as given in Revision 2 of the Bulletin. Action Item No. 7 is not applicable to WNP-2 and Action Item No. 8 does not require a response. In this reply, the NRC " Action Item" is first stated followed by the Washington Public Power Supply System response. o i !~ t I i i PEC ACTION ITEM NO. 1 Verify that pipe support base plate flexibility was accounted for in the calculation of anchor bolt loads. In lieu of sup-parting analysis justifyinc the assumption of rigidity, the base plates should be considerec flexible if the unstirrened distance between the member welded to the plate and the edQe of the base plate is creater than twice the thickness of the plate. It is recognizec that this criterion is conservative. Less conserva-tive acceptance criterion must be justified and the justifica-tion submitted as part of the response to the &Jlletin. If the base plate is determined to be flexible, then recalculate the bolt loads using an appropriate analysis. If possible, this is to be done prior to testing of anchor bolts. These calculated bolt loads are referred to hereafter as the bolt desian loads. A description of the analytical model used to verify that pipe support base plate flexibility is accounted for in the calcula-9 tion of anchor bolt loads is to be submitted with your response to the Bulletin. It has been noted that the schedule for analytical work on base plate flexibility for some facilities extends beyond the Bulle-tin reporting time frame of July 6,1979. For those facilities for which an anchor bolt testing program is required (i.e., sur-ficient QC documentation does not exist), the anchor bolt test-Ina program should not be delayed. 1.0 RESPONSE TO ACTION ITEM NO. 1

1.1 INTRODUCTION

l The WNP-2 Contractors affected by the Bulletin requirements are Primary Containment (C213A), Mechanical Equipment Installation and Piping (C215), HVAC and Plumbing Installation (C216), Fire Protection Systems (C217), Instrument Installation (C220), and Spray Pond Piping (C233). Pipe Supports and their base plates have mainly been designed by these contractors and their subcontractors. The supports installed by C213A and C233 were designed by the Engineer. The total number of Seismic Category I supports is approximately 16,000; one third support large diameter piping (above 2 inches) and the remain-3 der support small diameter piping (2 inches and smaller). These Seismic Category I pipe supports are supported from structural steel, embedded plates, cast-in-place inserts or by expansion bolts. Only the expansion bolt installations are the subject of this response. Approximately 3,000 supports use expansion bolts of which nearly 2,000 were installed by Contract 215 and by C213A. 1 :

1.2 ORIGINAL BASE PLATE DESIGN From an examination of the contractor's pipe support calculations, it is clear that.they used a rigid plate design throughout. Preload was neg-lected in the design approach although the installation specifications required expansion bolts to be preloaded in excess of the bolt design load. Additionally, no concrete compression was assumed, and bending and torsion were resisted by the respective moments of inertia of the bolt group. 1.2.1 WNP-2 Original Design Method In the Original Design Method at WNP-2, the highest loaded (criti-cal) bolt is assumed to fail causing the remaining bolts to carry the loading. First, the plate is analyzed as rigid and the loads are resisted by the moment of inertia of the bolt pattern. The bolts are assumed to carry all the shear, tension, and compression. No loading occurs between the plate and the concrete. Next, the critical bolt is removed from the bolt pattern and the new center of gravity (CG) of the bolt pattern is located. The applied loads are transferred from the attachment to the new CG, Finally, the plate is analyzed with the critical bolt missing for the new configuration and the remaining bolts are checked for adequacy. EXAMPLE: FOUR COLT PLATE (M >M ) x y Y u Critical BoltyMy l [ fails u I O-d .N C l C.G. P x O O j l di c l l l BOLT LOAD = SP_ + Mx + My_ 12 d 2d 1 i.

Shear is assumed to be distributed equally among the bnlts. This assumption receives support in the discussion for steel bolted con-nections of Reference 5. This text deals in its entirety with bolt-ed and riveted joints. For these steel bolted connections, shear is distributed relatively equally when the number of bolts on line is limited. For example, from Reference 5, consider four fasteners in line. The plate material is A36 and the fasteners are 7/8" A325 bolts. The shear stress is approximately 42 ksi for the two inside bolts and approximately 46 ksi for the two outside. The difference for four in line is slight. We conclude that the difference for three or less fasteners on line will be negligible. Our most fre-quent case is to have three or less on line. The bolt loads (tension and shear) determined froin this method were then combined in a linear interaction formula to account for com-bined effects of shear and tension on the bolts. The interaction formula was formulated as follows: I I t (actual tension) s (actual shear) O, ) t (allowable tension) + Fs (allowable shear) I 1 F 1.2.2 Increases in Stress Allowable The International Conference of Building Officials (ICBO) report (Reference 2) permits anchor allowable loads to be increased one-third for short time loading such as wind or seismic forces. The Engineer and WNP-2 Contractors used the same design criterion. Additional justification for this action is provided by the ASME Code for Subsection NF components such as base plates. This Code allows an increase of nearly 100 percent in the allowable loads for NF component under faulted (seismic) loading conditions. 1.2.3 Preload of Bolts The advantages of anchor bolt preload were rieglected for design pur-poses. However, they were preloaded during installation to over 100 percent of their allowable tension load. Preload is fully discussed in the response to Action Item No. 4. l I f 1 i L

1.3 FINAL BASE PLATE DESIGN AND QJALIFICATION In response to the Bulletin, all flexible Seismic Category I pipe support base plates are being qualified by flexible plate analysis. Factors of safety higher than those originally used are now being utilized. For maximum support load (typically faulted condition) a 33 percent increase in allowable anchor load is no longer permitted. The following is a dis-cussion of the current analytical method used for both design and final quellflation at WNP-2. 1.3.1 Flexible Base Plate Analysis Base plates are considered flexible when the unstiffened distances between member welded to the plate and the edge of the base plate is greater than twice the thickness of the plate. Most base plates without stiffeners are categorized as flexible. Analysis of flex-Ible base plates is being performed with a finite element computer program, ANSYS (Reference 4). If a computer evaluation is not per-formed, a comparision is made to a typical base plate with greater flexibility. Since these typical base plates were evaluated by ANSYS for flexibility, all subject base plates have flexibility in-cluded in the evaluation of anchor loading. 1.3.2 Description of Analytical Model In the manner of assessment. presented in Reference 8, flexible base plates are evaluated with a finite element computer program, ANSYS (Reference 4). Consideration is given to plate and concrete stiffness, expansion bolt stiffness and proper dimensions of the attachment. The unique computer program capabilities are used to perform a static, elastic, non-linear finite element solution. Additionally, a preprocessor program is used to simplify the input. The steel plate is represented by quadrilateral and/or triangular plate shell elements. This element, STIF 63, has six degrees of freedom at each node and permits both bending and membrane loading. Located below each plate node is an element which simulates the concrete. The concrete is represented by a STIF 40 element type which has a spring constant and a gap. A STIF 40 combination element is used to resist the compressive forces in the vertical direction between the plate element and the concrete. Since this element has gap capabil-ity, only compressive forces will occur. A non-linear iterative solution is therefore required to assure a converged and accurate solution. The concreto spring constcnts, K, are calcul:ted using eltstic half space theory as follows: K = 4G Ro 4@ = 4506 C 1-v = fiF(1-v) Where: G the shear modulus of concrete = the effective radius of the concrete area in contact Ro = with the plate is the Poisson's Ratio of concrete v = is the effective contact area = rRo2 A = Attachments welded to the base plate transmit the pipe support load to the base plate. These attachments provide a stiffening effect (reduces out-of-plane bending) which is modeled as a rigid region on the common plate nodes. Since the applied loads occur at the at-tachment center of gravity, the plate model provides a collocated node for applying loads. The anchor bolt element is also simulated as a spring gap element, STIF 40. However, this element is modeled to support tension only. As a two node element, one node is common to the plate mesh at bolt locations and the other node is fixed to ground. I The anchor bolt stiffness used is an important factor in determining the base plate load distribution and the final anchor bolt loading. The primary factors which determine this anchor loading are the plate flexibility and anchor bolt stiffnesses. The anchor bolt stiffness is provided to the finite element computer program as a spring rate. Pull tests performed on Site were used to determine realistic spring rates. At Hanford WNP-2, the shell type anchors (WI's) are the most common expansion anchor type. Since test re-sults show this anchor type normally exhibits a constant stiffness (elastic characteristic) to ultimate load capacity, a bilinear spring rate simulation is not required. For Hilti Super Kwik (HSK) type anchors, a ductile behavior-is ex-hibited and the bolt stiffness is conservatively taken as the ini-tial slope of the load deflection curves from Reference 3. Table II provides the elastic spring rates conservatively used for each type of anchor. l 1.3.3 Shear and Tension Interaction The basic tension interaction in conjunction with basic allowable shear interaction is combined with the following elliptical equation: l l l 4/3 4/3 4/3 ITotal

• ITension + IShear Where:

I Total interaction 11.0 = Total Calculated tensile bolt load Or see section y Tension Allowable tenslon bolt load 1.3.4 for typical base plates Calculated shear bolt load I Shear Allowable shear bolt load It is to be noted that.n this interaction formula, the flexibility of the plate affects r.ily the tension portion of the formula not the shear portion. 1.3.4 Typical Base Plates Typical base plate configurations were analyzed on the finite ele-ment computer program. The maximum support loads found by solving individual load cases on four, six, eight, and ten bolt base plates with and without stiffeners. The results were used to formulate an - empirical equation to permit load combinations. An example of a four bolt base plate is shown below: Pullout Mx + My ITension " Allowable Pullout Allowable Moment Where: I Tension interaction = Tension Pullout Applied tensile pullout = Mx and My Applied moments in the x and y = directions Pullout Allowable Allowable base plate pullout based = on finite element evaluation Moment Allowable Allowable base plate moment based on = finite element evaluation i l For base plates with larger attachments or thicker plates, less plate flexibility will occur and the interaction equation can be conservatively utilized. l l l !

1.4 COMPARISON OF RIGID APO FLEXIBLE ANALYSIS 1.4.1 Conventional Rigid Plate Theory The simplest method and perhaps the most common method for perform-ing base plate evaluations is to assume the plate rotates rigidly about one edge. Using all the bolts as active members, the maximum bolt load can be solved by static equilibrium. Although this method for performing base plate evaluations was not used for design pur-poses on WNP-2, the method is used only for comparative purposes with the original design concept and the final qualification meth-od. This method is commonly used in industry. 1.4.2 Examples Flexible Plate Analysis Bulletin requirement (Cur-rent Evaluation) WNP-2 Original Design Method One bolt redundant was ori-ginally used. Conventional Rigid Plate Analysis Common design by industry before Bulletin 79-02 To provide a fair means of comparison of analytical methods in the following examples, the tension expansion anchor allowable is con-stant at 4.53 KIPS for 3/4" WI and shear loading is neglected. Typical Four Bolt Base plate O O Dimensions: 12X12X3/4 X Bolt Spacing: 9" center to center -D

Attachment:

TS 3X3 O O I Allowable l Allowable Type of Analysis l Plate Pullout (KIPS) Plate Moment (IN. KIPS) I Flexible Plate Analysis l 14.0 l 66.9 I I WNP-2 Original Design l I 10.5 l l l 40.8 l Method l l l l Conventional R10 d i 18.1 l 97.1 i Plate Analysis l l l l Conclusion WNP-2 Original Design Method is conservative for this four bolt plate and most four bolt plates previously installed. i

Yi O O Typical Six Bolt Base plate y =, Dimensions: 21X12XI 0 O => =, Bolt Spacing: 9" center to center

Attachment:

TS SX5 0 O l Allowable. l Allowable Type of Analysis l Plate Pullout (KIPS) l Plate Moment-X (IN. KIPS) l l Flexible Plate Analysis l l 12.3 l l 133. I l WNP-2 Original Design i 17.9 l l 95.1 1 Method l l 1 l Conventional Rigid l 27.2 l 299. Plate Analysis l l l 1 Conclusion WNP-2 Original Design Method has mixed results. Yt O O O Typical Eight Bolt Base plate X

=

O O Dimensions: 21X21XI = 3 Bolt Spacing: 9" center tu center U

Attachment:

TS SX5 or W6X25 l Allowable l Allewable Type of Analysis l Plate Pullout (KIPS) l Plate Moment (IN. KIPS) l I Flexible Plate Analysis l l 20.1 l l l 112.6 l 1 WNP-2 Original Design l 25.0 l 173.6 Method One Bolt l l Redundant l l l 1 Conventional Rigid l 36.2 l 318. Plate Analysis l l l l Conclusion WNP-2 Original Design Method produced non-conservative loading capability compared to flexible plate analysis. I 1.4.3 Comparison The purpose of this section is to show conclusively that the design criteria used during final qualification of WNP-2 base plates satis-fies the bulletin's analytical concerns. I Figure 1.4 shows the bolt tensile load on a typical' support with an eight bolt base plate. These curves provide an overview of analy-tical methods. 1) Curve A represents conventional rigid plate theory, which was i the most common methods used by others prior to issuance of the Bulletin. 2) Curve 8 represents the WNP-2 Original Design Method used. 3) Curve C represents flexible plate theory without preload. This curve is used to determine the allowable support load for a flexible plate since the only applied loading is pipe support loading. 4) Curve 0 represents a preloaded anchor bolt with flexible plate theory. Verified by test results (Section 5), this curve simu-lates the actual bolt load. 5) Curve E represents the theoretical behavior of a preloaded rigid plate. 1.4.4 Summary The comparison study shows that for small plate up to 12X12, with four bolts and a minimum thickness of 3/4", the WNP-2 Original De-sign Method provided satisfactory results. However, as the plate gets larger and more bolts are included, the flexible plate ap-proach provides a more accurate method for determining bolt loads. In addition, as shown in Curve D, the actual bolt load increased only 1.0 KIP over preload when the design support load is applied. Thus, the cyclic stresses due to alternating support loading is minimized and the Bulletin concern for alternating stresses due to dynamic loading is satisfied. 4 } [ l ii j ;

14 - C 12 - 10 - l 5 i 9 5 .g gf g R 3 g$' I I 6 E n aJ l \\ b l c# o 8 F.S.=4.0 l w d 4 I co I Ei el z i M Si l 2 ~ ~ al El I n. i i i i i I l 0 2 4 6 8 10 12 APPLIED SUPPORT LOAD - KIPS p FIGURE 1.4 COMPARISON OF ANALYTICAL METHODS ON EIGHT BOLT BASE PLATE e m e e---

1.5, TESTING 1.5.1 Description A series of tests have been performed at the WNP-2 Site under actual field conditions to verify the analytical results for six bolt and eight bolt patterns. A typical hanger (see Figure I) was loaded in a manner simulating actual field conditions. The hanger was instru-mented to measure strain and deflections. Load sensing bolts were used to measure strain in Bolts B1, B2, 83, and 84. The 3/4 inch Dia Hilti Drop-In expansion bolts were torqued to pre-load of greater than the allowable design load. Then, tension load increments were applied by means of a hydraulic ram at a 36 inch eccentricity from the centerline of the plate. The applied loads k k k were 1.33k, 2.76, 3,ok, 5,33, and 10.67, 1.5.2 Comparison of Test and Analytical Results A comparison of the results of the loads in the expansion bolts from the analytical analysis and the test for o range below and above design load is presented in Table 1.5. The analytical results typically agree with the test results to within 10% even when the applied support load is two times the support design load. A plot' comparing the analytical results with the test results for this test and three additional tests is summarized below. Approximate Test No. Figure No. Maximum Loading Type of Plate 1 II .4x Design Eight Bolt 2 III 9x Design Zight Bolt 3 IV 3x Design Eight Bolt 4 V 2x Design Six Bolt l During Test 2, the suppolo load was increased to ultimate. The ultimate load was defined to be the point where the hanger would no longer resist l l the applied load due to excessive deflection in the support wide flanges. This ultimate load (26.0 KIPS) was approximately nine times the design load established for final qualification of WNP-2 base plates. l since the critical anchor (Bolt No. 3) apparently initiated slip at a support load of 17.5 KIP, a load redistribution occured and considerable L difference between test and ANSYS predicted results occured. (ANSYS pre-dicted much higher loads.) l} Test 3 and Test 4 results show similar correlation, i?

i l7 il

Table 1.5 Bolt Load Comparison Applied Load (KIPS) Bolt No. Test Analytical % Difference Preload Only B1 5.54 5.54* O B2 5.09 5.04* O B3 5.55 5.55* O B4 6.29 6.29* O 1.33 B1 5.54 5.59 1.0 B2 5.29 5.07 4.3 B3 6.34 5.75 10.3 B4 6.35 6.31 0.6 2.67 B1 5.60 5.72 2.1 B2 5.54 5.18 6.9 83 7.01 6.61 6.0 B4 6.44 6.91 0.5 3.0 B1 5.66 5.94 4.9 B2 5.80 5.80 9.4 B3 7.76 7.71 0.6 84 6.49 6.52 0.5 5.33 81 5.86 6.48 10.6 B2 6.21 5.78 8.4 B3 8.92 9.03 1.2 84 6.60 6.81 3.2 10.67 B1 7.28 8.75 20.2 B2 8.08 7.71' 4.8 83 14.90 16.25 5.5 B4 6.99 8.70 24.

• Analytical preloads were made equal to test preload values by using un-equal preload displacements on the ground nodes.

1.6 DISCUSSION OF CYCLIC LOADING - The main reason that WNP-2 expansion bolts are preloaded to a value above the bolt allowable load is to reduce stress reversals in the bolts sub-jected to cyclic loads. This preload procedure also ensures that each bolt is properly installed and achieves a minimun. load carrying capacity equaling the preload value. The preload is greater than the bolt allow-able load. A similar approach is used in standard high strength steel bolted connec-tions. For high strength A325 and A490 bolts, (Reference 6), a preload to 70 percent of the ultimate tensile strength of the bolt.is recommend-ed, but the allowable load of the bolt is only 60 percent of the yield point. The resulting ratio between the preload and allowable load is approximately two. Generally, under applied design load the actual expansion bolt load be-comes sightly greater than preload. Since each expansion bolt is instal-led with a prescribed preload, it is assured that it can carry this load after installation. In the analysis of the typical eight bolt pattern, it was found that uti-11 zing the flexible plate approach in the determination of bolt load, the bolt load increased only one KIP over that obtained by (preloaded) rigid plate analysis. However, this increase occurs on one bolt of the group only, while the stress in the remaining bolts equal or slightly exceed the preload stress. Thus, while it is apparent that this one bolt is subject to a stress increase when flexible plate approach is considered, the remaining bolts in the bolt group are not. Our results are similar to those presented in Reference 5 for tension T-connections. In the' T type, the bolt load increase above the preload bolt force due to applied loads is kept small. Thus, our results confirm results from standard steel practice. 1.7 ' MAJOR CONSERVATISMS We have presented results thus far for the effect of flexibility upon bolt design and how the consideration of flexibility provides a more ac-curate means of bolt determination in achieving a suitable factor of safety. However, there are additional major factors which contribute to insuring safety. These include conservatisms in accounting for shear and tension interaction, conservative seismic loads used in design, and high quality expansion bolt testing program. These conservations are discus-sed in more detail in the following sections.

1.7.1 Interaction of Shear and Tension The shear and tension interaction of an expansion bolt is conserva-tive in three respects. First, the interaction formula (Equation 1) conbines the effects of shear and tension conservatively. Figure VI compares Et,uation 2 with the actual interaction (Reference 10) of shear and tension. Second, shear is distributed equally to all holts whereas for a flexible plate, each of the tension loads is not uniform. And while the use of the interaction formula will produce a result for the bolt with the highest tensile strength it should be pointed out that the strength of a pipe support is dictated by the capability of all of the bolts in the support and over emphasis should not be placed on the capability of one bolt where if any overstress occurs, there will be a redistribution of load to the remaining bolts which are not as highly stressed. Third, the clamp-ing caused by the preload gives frictional resistance which in-creases the capacity of the plate to carry applied shear. 1.7.2 Seismic' Load -The seismic loads used in the hanger design are based on the follow-ing conservative seismic analysis of all Seismic Category I structures. A lumped mass model representing a Seismic Category I building was used in computing the floor response spectra. In this model, the soil-structure interaction effects were accounted for by lumped springs and lumped viscous dampers. The damping coefficients of these dampers, conservatively calculated from the solution.of a rig-id footing on an elastic half space, are given in the following table. Also shown in the table are the actual damping values used in the seismic analysis. SOIL DANPING RATIO Elastic Half Space Actual Values Seismic Category I Theory Used in Analysis ~ Building Horiz. Rocking Vert. Horiz. Rocking Vert. Reactor Building 32 8 66 10 5 10 Radwaste Building 39 65 98 10 5 10 Diesel Generator 38 22 63 10 5 10 Building The Building responses from lumped mass modeling are very conserva-tive because soil material and geometric dampings are purposely kept low. A more realistic finite element modeling of the soil structural in-teraction effect has been subsequently used to recalculate the building responses of the Seismic Category I buildings. The compu-ter program, FLUSH, Reference 9, is used for this purpose. The geo-metric damping effect due to infinite boundaries and nonlinear soil properties for both shear moduli and material damping are properly accounted for in the analysis. The structural responses from the finite element analysis are sub-stantially lower than those which have been used as input to the hanger design. Figures VII and VIII demonstrate the reductions in typical floor response spectra as discussed above. Although this conservation is applicable to the majority of the con-cerned pipe supports at the WNP-2 Project, there is one exception to this, namely the pipe supports in the wetwell. For these pipe sup-ports, this conservatism is not available. 1.7.3 Expansion Bolt Testing Field testing of expansion bolts has been conducted at WNP-2 over a period of two years to provide a custom made criteria applicable to the actual project site. The testing program as discussed in our response to Action Item No. 2 has provided data as to capacities of the WNP-2 expansion bolts,'and other characteristics, such as load deflection behavior and failure mechanisms. 1.7.4 Anchor Bolt Stiffness The essentially bilinear nature of the ductile behavior exhibited by the expansion anchor bolts used at WNP-2 has not been used in the analytical model of the flexible base plate. Typically, expansion anchor bolts exhibit some ability to slip but yet maintain their capability to carry load. This unique ability provides a load-limit feature for the critical anchor and permits a load redistribution for the base plate. Evidence 'of this redistribution was seen during the pipe support test performed on site (see Section 1.5). When the support load reached approximately six times design load, apparent anchor slippage occurred permitting the support to reach approxi-mately nine times design load without anchor failure. Figure 1.7 shows this comparison. Therefore, the factor of safety for. a pipe support can more accurately be represented by the capacity of all the bolts rather than that one critical bolt. As a result, the flexible plate analysis performed at WNP-2 induces considerable conservatism relative to the Bulletin strength requirements.

1.8 CONCLUSION

S In response to the Bulletin's concerns, all flexible Seismic Category I pipe support base plates are being designed and qualified by flexible plate analysis. At WNP-2, the effects of flexibility on small (four bolt) plates is minimal compared to the Original Method of Analysis. Where it is found to be significant on larger plates with a greater num-ber of bolts, additional stiffening of plates is being added to ensure that excessive bolt load does not occur. k 25 - E 1 l i b 20 - l / l l / l I / 15 - 8 l' g ,sf l $I 9 1 5 1 / l 10 - E"'I / l l / 9gt 5 ? /[ W al / 'p / hl j 'i 1 1 I I I I O 5 10 15 20 25 APPLIED SUPPORT LOAD - KIPS FIGL'RE 1,7 CCPPARISON OF TEST RESULTS TO MRLYTICAL IETHOD _ _....

W C ACTION ITEM NO. 2 Verify that the concrete expansion anchor bolts have the following minimum factor of safety between the bolt design load and the bolt ultimate capacity determined from static load tests (e.g., anchor bolt manufacturer's) which simulate the actual conditions of installation (i.e., type of concrete and its strength properties): a. Four - For wedge and sleeve type anchor bolts, b. - Five - For shell type anchor bolts. The bolt ultimate capacity should account for the effects of shear ten-- sion interaction, minimum edge distance and proper bolt spacing. If the minimum factor of safety of four for wedge type anchor bolts and five for shell type anchors cannot be shown then justification must be provided. The Bulletin factors of safety were intended for the maximum support load including the SSE. The EC has not yet been provided ade-quate justification that lower factors of safety are acceptable on a long term basis. Lower factors of safety are allowed on an interim basis by the provisions of Supplement No.1 to IE Bulletin No. 79-02. The use of reduced factors of safety in the fsctored load approach of ACI 349-76 has not yet been accepted by the EC. 2.0 RESPONSE TO ACTION ITEM NO. 2 l

2.1 INTRODUCTION

At WNP-2 a factor of safety of four is used in final plate qualification-for both the wedge type and the shell type anchors. Apparently, by re-quiring a factor of safety of five, the shell type anchor is being penal-ized for its typically brittle mode of failure while no reduction 1s re-quired to account for yield load (load at which the load-deflection curve departs from a straight line) of wedge type anchors. For the wedge type anchor to reach ultimate, the anchor typically will exhibit considerable deflection (slip). This characteristic of 1/2" to 1-1/2" slip makes the-ultimate capacity unusable for most anchorage systems which typically can only tolerate anchor movements in the range of 1/8" or less. However, the shell type anchor undergoes deflections of less than.1/8" to the ul-timate load which means that this load capacity is truly available to the anchorage system. Thus, the advantages and disadvantages of each type anchor appear to cancel each other out. In addition to the above reason a factor of safety of four for the shell type anchor is justified because of the extensive load test program per-formed on site. (See References 3,13, and 15.) l l ! l

2.2 TEST PROGRAM The WNP-2 load test program was initiated to establish realistic design tensile allowables to ensure a minimum factor of safety of four in. anchor installations existing at the time the Bulletin was issued and in all future anchor installations. All testing was performed by an independent testing agency using WNP-2 standard production concrete (4000 psi mix design) as the test medium. Testing was conducted to determine the effects of different embedments, epoxies or amounts of expansion on shell type anchors and the effect of different embedment on wedge type anchors. This testing was required so that the ahchor allowables could be adjusted for these irregular condi-tions if found in installations existing prior to issuance of the bulletin. In addition, anchors were installed in strict compliance with manufac-turer's recommendations using standard construction techniques and tested to establish design tensile allowable for all anchors. These allowables were used for design of anchorage systems after the issuance of the Bulletin. Five anchors of each configuration (i.e., different embedment or differ-ent amount of expansion) were tested. Each anchor was loaded increment-ally until failure occurred. After each loading increment was added, the total slip with respect to the concrete for that load was recorded. The 4 anchor was considered failed when one of the following occured:

1) The concrete failed, 2) The anchor body failed, or 3) The anchor slipped 1/8" i

with respect to the concrete. The following is a listing of the different type of drilled in concrete [ anchors tested: Anchors No. Tested Phillips Red Head 290 Hilti Drop-In 170 Hilti Kwik Bolt 60 Hilti Super Kwik Bolt 10 Parabolts 30 2.3 TEST RESULTS l The results of the tests are documented in References 3,12, and 13. Typical failure modes were slip for Hilti Kwik Bolts, Hilti Super-Kwik Bolts, and Parabolts, slip or anchor body failure for Phillips Red Heads and concrete failure for Hilti Drop-Ins. These test results confirm the typical brittle failure for shell type anchors (Red Heads and Drop-Ins) and considerable slip typical of wedge type anchors (Kwik Bolts, Super Kwik Bolts, and Parabolts) as previously discussed in Section 2.1. L

Th;se test data este used for establishing the ultimate and allorable tensile load values (Table II) used for the final qualification of flex-ible Seismic Category I pipe supports to satisfy the concerns of the Bulletin. The results of these tests were used further to statistically establish that with a 95 percent confidence level less than 5 percent of the expan-sion bolts of the types tested will have an actual capacity smaller than their design load. This confidence level is as conservitive as the con-fidence level established by the NRC in Appendix A to the Bulletin, Revi-sion 2, entitled, " Sampling Methods". I 2.4 ALLOWABLE LOADS 2.4.1 WNP-2 Original Design Allowables Used by Contractors The allowable design loads for expansion anchors used by contractors has changed during the course of the job. Initially, the contrac-tors were directed to use a minimum factor of safety of four based on manufacturer's ultimate strength, but, this was subsequently changed and they were directed to use International Conference of Building Officials (I.C.B.O.) values (References #1 and #2) early in the job before any major work was accomplished. Values for ultimate tensile loads for WNP-2 were developed through the extensive field testing program discussed in Section 2.2. A comparison of these ~' ultimate values and the I.C.B.O. values are shown in Table I. In general, the use of the I.C.B.O. values by the contractors was con-servative. 2.4.2 Anchor Allowables Used For Final Plate Qualification The allowable design loads for expansion anchors used for final plate qualification are based on the ultimate loads of the field testing program and a factor of safety of four and are shown in Table II. S 2.5 FACTORS OF SAFETY One of the major reasons for choosing high factors of safety is the un-certain installation practices and incomplete documentation of many faci-lities. At WNP-2, there have been rigorously specified installation pro-cedures and documentation that check the requirements necessary to ac-hieve proper installation. Also, programs were initiated in 1978 to ver-ify the adequacy of all existing expansion anchors (see response to Action Item No. 4). Therefore, based on the extensive field testing of expansion anchors and the strict installation and inspection procedures for expansion anchors a factor of safety of four for both-shell type and wedge type anchors is justified. In addition, the major conservatisms discussed in Section 1.7 serve to increase the factor of safety beyond a minimum of four. ( l i -m-t

NRC ACTION ITEM NO. 3 i Describe the desig1 requirements if ap111 cable for anchor bolts to withstand cyclic loads (e.g., seismic loads and ligh cycle operating loads. 3.0 RESPONSE TO ACTION ITEM NO. 3 Preloading of bolts is required in the installation procedures for the installation of expansion bolts to assure that compression between the base plate and the concrete remains when subjected to cyclic loading, such as seismic loading and high cycle operating loading, so as to avoid fatigue failures or loosening of the expansion bolt assembly due to cyc-lic loading variations. All expansion bolts are required to be torqued so as to provide a preload greater than the allowable tensile load, or as noted in. Table III. This preload requirement assures that the bolt will be subjected only to small stress differences due to changes in load. In the presented example of Action Item No.1, for the eight bolt pat-tern, the maximum stress differences amount to only 6 percent of the ul-timate strength of the bolt. In the case of the four bolt patterns, the maximum stress differences amount to only 2 percent of the ultimate strength of the bolt. In conclusion, the prescribed preload is the design requirement that al-lows the expansion bolt assemblies to carry cyclic loads, without fatigue failure. i S C ACTION ITEN NO. 4 Verify from existing QC documentation that desim requirements have been met for each anchor bolt in the following areas: (a) Cyclic loads have been considered (e.a., anchor bolt preload is equal to or areater than bolt desian load). In the case of the shell type, assure that it is not in contact with the back of the support plate prior to preload testira. (b) Specified design size and type is correctly installed (e.a., proper embedment depth). If sufficient documentation does not exist, then initiate a-testina pro-gram that will assure that minimum design requirements have been met with respect to subitems (a) and (b), above. A sampling technique is accept-able. One acceptable technique is to randomly select and test one anchor bolt in each base plate (i.e., some supports may have more than one base plate). The test should provide verification of subitems (a) and (b), above. If the test fails, all other bolts, on that base plate should be similarly tested. In any event, the test program should assure that each Seismic Category I system will perform its intended function. The preferred test method to demonstrate that bolt preload has been ac-complished is using a direct pull (tensile test) equal to or areater than desim load. Recomizing this method may be difficult due to accessibi-lity in some areas an alternative test method such as torque testina may be sped. If torque testina is used, it must be shown and substantiated IEat a correlation between torcue and tension exists. If manufacturer's data for the specific bolt usec is not available, or is not used, then site specific data must be developed by qualification tests. Polt test values of one-fourth (wedge type) or one-fifth (shell type) of bolt ultimate capacity may be used in lieu of individually calculated bolt desian loads where the test value can be shown to be conservative. The purpose of Bulletin No. 02 and this revision is to assure the operability of each Seismic Category I piping system. In all cases an evaluation to confirm system operability must be performed. If a base plate or anchor bolt failure rate is identified at one unit of a multi-unit site which threatens operability of safety-related plaina systems of that unit, continued operation of the remaining units at tlat site must be immediately evaluated and reported to the NRC. The evaluation must consider the generic applicability of the identified failures. Appendix A describes two sampling methods for testing that can be used. Other sampling methods may be used but must be justified. Those options may be selected on a system by system basis. Justification for omitting certain bolts from sample testing which are in high radiation areas during an outage must be based on other testing or analysis which substantiates operability of the affected system. -n-

Bolts which are found during the testing program not to be preloaded to a load equal to or greater than bolt design load must be properly preloaded or it must be shown that the lack of preloading is not detrimental to cyclic loading capability. Those licensees that have not verified anchor bolt preload are not required to go back and establish preload. However, additional information should be submitted whfch demonstrates the effects of preload on the anchor bo]t ultimate capacity under dynamic loading. If it can be established that a tension load on any of the bolts does not exist for all loading cases then no preload or testing of the bolts is required. If anchor bolt testing is done prior to completion of the analytical work on baseplate flexibility, the bolt testing must be performed to at least the original calculated bolt load. For testing purposes, factors may be used to conservatively estimate the potential increase in the calculated bolt load due to baseplate flexibility. After completion of the analyti-cal work on the baseplates the conservatism of these factors must be verified. For baseplate supports using expansion anchors, but raised from the sup-parting surface with grout ] laced under the baseplate, for testing pur-poses it must be verified tlat leveling nuts were not used. If leveling nuts were used, then they must be backed off such that they are not in contact with the baseplate before applying tension or torque testing. Bulletin No. 79-02 required verification by inspection that bolts are properly installed and are of the specified size and type. Parameters which should be included are embedment depth, thread engagement, plate bolt hole size, bolt spacing, edge distance to the side of a concrete member and full expansion of the shell for shell type anchor bolts. If piping systems 2 1/2 inches in diameter or less were computer-analyzed then they must be treated the same as the larger piping. If a chart an-alysis method was used and this mothod can be shown to be highly conser-vative, then the proper installation of the baseplate and anchor bolts should be verified by a sampling inspection. The parameters inspected should include those described in the preceding paragraph. If small dia-meter piping is not inspected, then justification of system operability must be provided. 4.0 RESPONSE TO ACTION ITEM NO. 4

4.1 INTRODUCTION

Seismic Category I piping system supports have been installed with drilled-in concrete anchors at WNP-2 since about 1976. Our response to this action item addresses our program to assure compliance with the re-quirements of the Bulletin for those anchors installed prior to July 1979 when definitive inspection requirements were first issued in Revision 1 of the Bulletin. Those anchors installed after the issuance of the Bul-i l letin are discussed in our response to Action Item No. 9. It is noted here that the evaluation of the design adequacy and the installation i verification of all small diameter pipe supports are addressed in the same manner as large diameter pipe supports. The specific requirements of the Action Item ara presented as follo:s: 3 Anchor bolt preloading is addressed first and is followed by a discussion of leveling nuts and a discussion of verification of existing installa-tions according to contract. l 4.2 ANCHOR BOLT PRELOADING J A specific requirement of the Bulletin is "... anchor bolt preload is equal to or greater than bolt design load." All WNP-2 contractors were directed by their original specifications to preload anchors to a value greater than design load.. However, documentation for this preloading was not complete. To demonstrate that the anchors fnstalled prior to issu-ance of the Bulletin were properly preloaded the method of torque testing recomnended by the Action Item was selected. 4.2.1 Torque / Tension Testing The Bulletin requires that site specific data must be developed by qualification tests which substantiate that a correlation between torque and tension exists. In response to the Bulletin requirement this testing was conducted at WNP-2 for Phillips Red Head, Hilti a Drop-In, Hilti Kwik Bolt, and Hilti Super-Kwik Bolt anchors. These tests established the torque versus tension relationship for each anchor type and size. (Reference 12). Torque values for Molly Parabolt are those recommended by the manufacturer. They agree well with the test results for Hilti Kwik Bolts, a similar type anchor. Molly Parabolts had very limited usage on the project. The tor,que values, given in Table III, were utilized by all WNP-2 Contractors to preload anchors. The testing confirmed the installation torques being used gave pre-loads ranging between 100 and 300 percent of the anchor allowable tension load, for all anchors except the 3/4 inch diameter Hilti Drop-In. The torque value for this anchor was increased to provide the required preload. Installations using these anchors which were installed prior to issuance of the Bulletin were retorqued. (See Exhibit A.) n 4.2.2 Anchor Retorquing Program As a result of document deficiencies concerning C215 torque wrench calibration and to further insure the integrity of their anchor in-stallations all C215 Seismic Category I anchors are being retor-qued. (Reference 14) The anchors of the other contractors that installed Seismic Category I pipe supports (C213, C216, C217, and l C220) have been excluded from this program because most were in-stalled and all have been torqued after the implementation of the Bulletin requirements. See Section 4.4.6, for a discussion of the Parabolts installed by C233. -

i i 4.3 LEVELING NUTS 4 A specific requiremnt of the Bulletin is-". .. it must be verified that leveling nuts were not used. If leveling nuts were used, then they must j be backed off..." At WNP-2, two contractors installed leveling nuts under some Seismic Cat-t egory I floor mounted pipe supports installed prior to August 1979. They were C215 and C216. After August 1979, their usage was prohibited for all new base plate installations, regardless of Seismic Category. (See Exhibit B.) All of the Seismic Category 1 installations performed by 1 C216 have been reworked to remove or back off the leveling nuts. This rework included torqueing the anchor bolts to their full preload (see Table III) and inspecting for anchor pull-up, before regrouting the pla tes. Anchors which did pull-up were replaced. Leveling nuts installed by C215 are being reworked in a similar manner. However, one exception is being permitted. Base plates which are already grouted and the anchor tension loads do not exceed 10 percent of their allowable tension load require no rework. An anchor tension load equal to 10 percent of its allowable load is only 2.5 percent of the anchors ultimate load. Engineering judgment dictates this staall cyclic load will not be detrimental to the anchor performance. 4.4 VERIFICATION OF INSTALLATIONS In addition to the anchor preload and leveling nut requirements just dis-cussed, the Bulletin listed other specific items for the inspection of ... verification by inspection that bolts are properly in-anchors: stalled and are of the specified size and type. Parameters which should be included are embedment depth, thread engagement, plate bolt hole size, bolt spacing, edge distance to the side of a concrete menber and full expansion of the shell for shell type anchor bolts."; "In the case of the shell type, assure that it is not in contact with the back of the support pla te... ". Documentation of satisfactory compliance with these inspection items was not complete. As a result, a program of installp. tion verificaton was established for each contractor to insure base rglate installation was adequate and satisfied the concerns of the Bulledn. The inspection re-quirements were implemented for all Contractors, except C215, by the di-rective of Exhibit C. The directives issued to C215 are given in Exhibits D and E. These directives covered both those anchors installed i prior to July 1979, when these inspection requirements were issued in Revision 1 of the Bulletin and those anchors installed after July 1979. l The former anchors are discussed in this response and the latter anchors l are discussed in the response to Action Item No. 9. Following is a contract by cuntract presentation of the specific status of each verification program. l I l l l L

4.4.1 Contract 213A - Primary Containment Contract 213A was responsible for the installation of Seismic Cate-gory I piping systems within Containment. Their supports were in-stalled exclusively with Hilti Super Kwik Bolts. Anchor installa-tions were begun in early 1978. All anchor installations have been or are being inspected, verified, and documented to show compli-ance with the requirements of the Bulletin in accordance with Exhi-bit C. 4.4.2 Contract 215 - Mechanical Equipment Installation and Piping The C215 Anchor Inspection program developed to satisfy compliance with the Bulletin requirements consisted of three phases: a) re-inspection of all anchors installed prior to February 1978; b) re-inspection of a sample of the anchors installed between February 1978 and July 1979; and c) inspection of all anchors during instal-lation, after July 1979. The first two of these are discussed here because they pertain to anchors installed prior to issuance of the Bulletin. The third is addressed in our response to Action Item No. 9 of the Bulletin. In addition, a second program was initiated which prohibited the use of leveling nuts after August 1979 and required their removal from most existing Seismic Category I base plates. This was discussed in Section 4.3. The first phase was devoted to a reinspection of all of the anchors installed prior to February 1978. (See Exhibit E.) During this period, the contractor installed Phillips Red Head Self-Drilling shell-type anchors and Hilti Kwik Bolt stud-type anchors. While this reinspection was initiated approximately one year before defin-itive inspection requirements were established by the Bulletin, it included all of the Bulletin inspection items, except three. (See the Table 4.1.) These items were plate bolt hole size, edge dis-tance to the side of a concrete member and shell type anchor in con-tact with the back of the plate. When Revision 1 of the Bulletin was issued in July 1979 giving specific inspection requirements, the retroinspection program was revised to include all of them. Prior to implementation of this revision approximately seventy supports which utilized anchors were inspected; approximately sixty of these were installed with Red Head anchors and the remainder with Kwik Bolts. While these three items were not specifically required as retro-inspection items the contractor had installation criteria for them. Plate Bolt Hole Size was controlled by the American Institute of Steel Constructors and/or American Society of Mechanical Engineers codes as required by the Specification. These codes provided for the maximum plate bolt hole size as a function of bolt diameter and plate thickness. Further, the contractor specified hole size on the base plate drawing and inspected for it as part of the as-built hanger inspections. Contract 215 Anchor Retrospection Program For Anchors Installed Prior to February 1978 I I I I I I Initial Direction l Revised Direction i i i Issued June 1978 l Issued July 1979 l l l 1 i i l l Bulletin 79 Inspection Item l PRH l WB l PRH l WB l i I I I I I I Torque l X l X l X l X l l 1 I I I I I Leveling Nuts I l l @ l l l 1 I I I I I Specified Size I X l X l. X l X l 1 l I I I I I Specified Type l X l X l X l X l l 1 I I I I l Embedment Depth l l X l l X l 1 1 I I I I I Thread Engagement l X l X l X l X l l l l l l l I l X l X l l Plate Bolt Hole Size I l l l l l l l Bolt Spacing I X 1 X l X l X l l 1 I I I I I Edge Distance (Concrete) 1 I l X l X i I X@ I i l I I I Full Expansion of Shell l X@ l l N/A N/A I I I I I I I l N/A i X l N/A I l Pulled Against Plate I I I I I I I Phillips Red Head Self-Drilling shell type anchor PRH = Hilti Kwik Bolt wedge type anchor WB = Anchor was inspected for compliance with this Bulletin item X = See Section 4.3 of the response to Action Item No. 4 = 3 Required to be flush or below the concrete = Required to be 1/16 to 3/8 inch belo'w the concrete = Inspected to expansion requirements established by the Engineer = TABLE 4.1..

Edge Distance to the Side of a Concrete Membsr was controlled for all anchors by the requirements cf the International Conference of Building Officials (ICBO) as required by the Specification. ICB0 provided for the anchor edge distance as a function of the anchor diameter. It also gave a method for reducing the anchor allowable load should the edge distance be less than required. Shell Type Anchor in Contact With the Back of the Plate was partial-ly controlled by the requirements of ICBD as given by the Specifica-tion and by the retroinspection program requirements. It was re-quired that the Phillips Red Head Self Drilling anchors be flush or below the concrete surface. Further, both the Specification and the retroinspection program required the anchors to be preloaded by tor-quing. Thus, the anchors were first installed flush with the con-crete surface, in accordance with ICBO, and torqued, in accordance with the Specification requirement. Then in accordance with the retroinspection program, the bolts were untorqued and removed. The anchors were inspected for proper expansion, proper embedment (i.e., flush or below the concrete surface), proper torque and the other items listed in Table 4.1. It is extremely unlikely that an anchor which was loose enough in the hole to pull against the plate, coul_d also meet the expansion and torque requirements of the retroinspec'- tion program. This is borne out by the fact that severly underex-panded anchors tended to turn freely when being torqued or un-torqued. Further, the results of the retroinspection program carried out on supports after the inspection for pull-up was in-cluded showed far fewer violations than allowed by the accepted PC statistical sampling method. (See Exhibit F.) The conclusion is that even though these three inspection items were not included for the first seventy supports of the retroinspection program, the inspections performed did insure the anchor installa-tions are adequate. The second phase of the C215 Anchor Inspection Program is devoted to a retroinspection of a sample of the Seismic Category I anchors in-stalled between February 1978 and July 1979. (See Exhibit F.) This includes the anchors installed after the time period covered by the 100 percent retroinspection program, described above, but before the i issuance of the Bulletin inspection requirements. During this per-iod, the contractors anchor inspection requirements evolved to in-clude all of those specified in the Bulletin. The initial sample size for this retr,oinspection program was select-ed to be in conformance with the accepted NRC statistical sampling i method. The program consists of a review of the selected anchor inspection records. In this review, the actual anchor inspection items _will be compared with those required by the Bulletin. A field inspection will then be performed on one anchor per base plate, for the Bulletin items not previously checked. l l - a

Based upon th:s3 inspection results thm simple size till b] adjusted in accordance with the NRC statistical sampling method, if neces-sary, in order to show all Seismic Category I anchors installed dur-ing the specified period meet the Bulletin requirements. Those not in compliance will be reworked and reinspected. The final phase of the C215 Anchor Inspection Program involves new installations performed after July 1979. At this time, the contrac-tor was directed to inspect 100 percent of his Seismic Category I installations to all of the requirements of the Bulletin. (See Ex-hibit C.) 'This program is fully discussed in our response to Ac-tion Item No. 9. 4.4.3 Contract 216 - HVAC and Plumbing Installation Contract 216 was primarily responsible for Heating, Ventilation, and Air Conditioning installation. However, two of the subcontractors installed Seismic Category I piping. The piping supports were in-stalled with Hilti Drop-In and Hilti Kwik Bolt anchors. All inspec-tions were performed after July 1979 and are documented to show com-pliance with the requirements of the Bulletin. (See Exhibit C.) 4.4.4 Contract 217 - Fire Protection Systems Contract 217 was responsible for the installation of Seismic Cate-gory I fire protection system piping..The piping supports were in-stalled exclusively with Hilti Drop-In anchors. All installations were performed after May 1980. The anchor inspections are document-ed to show compliance with the requirements of the Bulletin. (See Exhibit C.) 4.4.5 Contract 220 - Instrument Installation Contract 220 was responsible for the installation of Seismic Cate-gory I instrumentation control piping. The piping supports were installed exclusively with Hilti Drop-In anchors. Anchor installa-tions weIa begun in early 1978. All anchor installations have been or are being inspected, reverified, and documented to show compli. ance with the requirements of the Bulletin. (See Exhibit C.) 4.4.6 Contract 233 - Spray Pond Piping Contract 233 was responsible for the installation of Seismic Cate-gory I piping supports in the spray ponds. They installed approxi-mately sixty base plates with Parabolts prior to implementation of the Bulletin requirements. Some of the base plates were cast in concrete rendering the anchors inaccessible for retroinspection. However, one bolt per base plate on the remaining accessible base plates is being retroinspected by C215 to show compliance with the Bulletin. (See Exhibit G.) Anchors which do not meet the retro-inspection requirements are required to be reworked. 4 J NRC ACTION ITEM NO. 5 Determine the extent that expansion anchor bolts were used in concrete block (masonry) walls to attach piping supports in Seismic Category I systems (or safety related systems in Seismic Category I systems (or safety related sys-tems as defined by Revision 1 of IE Bulletin No. 79-02). If expansion anchor bolts were used in concrete block walls: Provide a list of the systems involved, with the number of supports, type a. or anchor bolt, line size, and whether these supports are accessible dur-ing normal plant operation. b. Describe in detail any design consideration used to account for this type of installation. c. Provide a detailed evaluation of the capability of the supports, includ-ing the anchor bolts, and block wall to meet the design loads. The eval-uation must describe how the allowable loads on anchor bolts in concrete block walls were determined and also what analytical methud was used to determine the integrity of the block walls under the imposed loads. Also describe the acceptance criteria, including the numerical values, used to perform this evaluation. Review the deficiencies identified in the In-formation Notice on the pipe supports and walls at Trojan to determine if a similar situation exists at your facility with regard to supports using anchor bolts in concrete block walls. d. Describe the results of testing of anchor bolts in concrete block walls and your plans and schedule for any further action. 5.0 RESPONSE TO ACTION ITEM NO. 5 By specification, no Seismic Class I piping system is to be attached to concrete block walls using expansion bolts. To provide further assurance that this specification requirement has been adhered to, all contractors installing piping were directed to review their installations and verify that expansion bolts have not been so used. This verification has been accomplished. l _ 30 _

NRC ACTION ITEM NO. 6 Determine the extent that pipe supports with expansion anchor bolts used structural steel shapes instead of baseplates. The systems and lines reviewed must be consistent with the criteria of IE Builletin No. 79-02, Revision 1. If expansion anchor bolts were used as described above, verify that the anchor bolt and structural steel shapes in these supports were included in the ac-tions performed for the Bulletin. If these supports cannot be verified to have been included in the Bulletin actions: a. Provide a list of the systems involved, with the number of supports, type of anchor bolt, line size, and whether the supports are accessible during normal plant operation, b. Provide a detailed evaluation of the adequacy of the anchor bolt design and installation. The evaluation should address the assumed distribution of loads on the anchor bolts. The evaluation can be based on the results of previous anchor bolt testing and/or analysis which substantiates oper-ability of the affected system. c. Describe your plans and schedule for any further action necessary to as-sure the affected systems meet Technical Specifications operability re-quirements in the event of an SSE. 6.0 RESPONSE TO ACTION ITEM NO. 6 Attachments of structural steel shapes directly to concrete with expan-sion bolts is mainly confined to supports for small diameter piping. Their use is very uncommon for large diameter piping. However, wherever they are used, their effects are being assessed in the same manner as all other flexible base plates (see Action Item No.1). NOTE: NRC Action Item No. 7 is not applicable to WNP-2 and NRC Action Item No. 8 requires no response. i EC ACTION ITEM NO. 9 ' All holders of construction permits for power reactor facilities are requested l to complete Items 5 and 6 for installed pipe supports within 60 days of date of issuance of Revision No. 2. For pipe supports which have not yet been in-stalled, document your action to assure that Items 1 through 6 will be satis-Tied. Maintain documentation of these actions on site available for NRC in-spection. Report in writing within 60 days of date of issuance of Revision No. 2, to the Director of the appropriate MC Regional Office, completion of your review and describe any instances not previously reported, in which you did not meet the revised (R2) sections of Items 2 and 4 and, if necessary, your plans and schedule for resolution. A copy of your report should be sent to the United States Nuclear Regulatory Commission, Office of Inspection and Enforcement, Division of Reactor Construction Inspection, Washington DC 20555. 9.0 RESPONSE TO ACTION ITEM NO. 9 3 9.1 Introduction The response to previous Action Items discussed in detall each affected contractors program for showing compliance with the Bulletin evaluation / inspection requirements for installations made prior to its issuance. Installations performed after its issuance are discussed here. 9.2 Base Plate Analysis All Seismic Category I large and small diameter pipe support base plates, for all affected contractors, are being evaluated and qualified in accor-dance with the requirements of the Bulletin, by the Engineer. Our re-sponse to Action Item No.1 presents a detailed discussion of the analy-tical methodology being employed. 9.3 Generic Anchor Inspection Criteria After Revision 1 of the Bulletin was issued in June 1979, generic inspec-tion criteria was issued to all the contractors installing Seismic Cate-gory I large and small diameter piping supports. (See Exhibits C and D.) These criteria included all of the inspection requirements for an-chor installations deliniated in the Bulletin. Anchor installations performed after this date have been and are being documented to show com-pliance with the Bulletin. Also, the usage of leveling nuts under base plates was prohibited by generic criteria issued in August 1979. (See Exhibit B.) 10.0 Referencas 1. International Conference of Building Officials (I.C.B.O.), Report No. ~ 2895, November 1976. 2. International Conference of Built'ing Officials (I.C.B.0.), Report No. 1372, March 1973. 3. Noble, L. D., and Mead, W. M., Drilled-In Concrete Anchor Tests Performed at the Washington Public Power Supply System, Nuclear Project 2 Site, March 1979. 4. ANSYS - Engineering Analysis System, UP190, Rev. 2, CYB 7600, by Swanson-Analysis Systems, Inc., Elizabeth, PA. 5. Fisher, J. W., and Struik, J. H. A., Guide to Design Criteria for Bolted and Rivited Joints, John Wiley & Sons, New York, 1974. 6. AISC, Specification for Structural Joints Using ASTM A-325 or A-490 Bolts, American Institute of Steel Construction, New York, NY, July 1976. 7. Hanks, Abbot A., " Combined Shear and Tension Testing - Kwik Bolt", Report No. 9059, April 15, 1974. 8. Diluna, L. J., and Flaherty, J. A., "An Assessment of the Effect of Plate Flexibility on the Design of Moment-Resistant Base Plates", ASME, August 1979. 9. Lysmer, et al., " FLUSH-A Computer Program for Approximate 3-D Analysis of Soil-Structure Interaction Problems", Report No. EERC 75-30, November 1975. 10. R. D. Clatto and R. R. Boentgen, " Strength of Concrete Expansion Anchors for Pipe Supports, Teledyne Engineering Services.

11. Chenault, D. M., " Rigid Plate Test Data Transmittal Report", June 1979, In-House Bur.3 arid Roe Report.

12. Chenault, D. M., " Torque-Load Tests in Drilled-In Concrete Anchors", Aug-ust 1979, In-House Burns and Roe Report.

13. Hyde, L.L., Drilled-In Concrete Anchor Test Performed at the Washington Public Power Supply System, Nuclear Project 2 Site, Supplemental Report No.1, August 1979.

14. Bechtel Power Corporation, Task Force Study and Recommendations: Hanger I.

and Anchor Bolt Report, Letter BECMCL-82-0032, January 18, 1982. j

15. Chenault, D.M., Drilled-In Concrete Anchor Tests Performed at the Washington Public Power Supply System, Nuclear Project 2 Site, j

Supplemental Report No. 2, September 1979. 4 7 i i l : l l 1

f TEE I ALLOWABLE EXPANSION ANCHOR LOADS Provided to Contractor-l ) I I l PHILLIPS RED HEAD SELF DRILLING - 51 ELL TYPE ANCHOR l I I I I l l 1 -l l l WPPSS l Allowed l Factor l Manu. l Allowed l Factor l l Size l Ult. Tension l Tension l Safety i Ult. Shear l Shear l Safety i I In. I KIPS l KIPS I 1 KIPS l KIPS l 1 I I I I I I I I i 1/4 l 2.56 I 0.54 1 4.74 l 1.35 l 0.49 l 2.71 l l 3/8 l 4.91 l 1.14 l 4.31 l 3.57 l 1.10 l 3.06 l l 1/2 l 8.0 l 1.72 1 4.65 l 6.72 l 1.75 1 3.84 l l 2/5 l 11.11 l 2.25 l 4.98 l 11.90 l 2.02 1 5.89 l l 3/4 l 10.67 l 2.57 l 4.15 l 16.20 l 2.57 1 6.84 l l 7/8 l 12.44 l 2.90 l 4.29 l 18.45 1 2.80 l 6.59 l l I l HILTI KWIK BOLT - WEDGE TYPE ANCHOR l l I I I I I l l l l WPPSS l Allowed l Factor l Manu. 1 Allowed l Factor I l Size l Ult. Tension l Tension l Safety i Ult. Shear l Shear i Safety 1 I In. I KIPS l KIPS l I KIPS l KIPS l l l l l 1 1 I I l-l 1/4X1-1/2 l 2.89 1 0.54 1 5.55 1 2.61 1 0.49 l 5.55 l l 3/8X2 l 5.15 l 1.14 1 4.52 l 5.11 l 1.10 1 4.64 l l 1/2X2-1/2 l 7.30 l 1.72 1 4.24 l 8.32 l 1.75 1 4.75 l l 5/8X3-1/2 1 9.53 l 2.23 l 4.27 l 11.56 l 2.02 1 5.72 l l 3/4X4 1 15.10 l 2.57 l 5.88 l 17.13 l 2.57 1 7.22 l [ I i l HILTI DROP IN - SHELL TYPE ANCHOR l l l l l 1 I I I l l WPPSS l Allowed l Factor l Manu. I Allowed l Factor l l Size l Ult. Tension l Tension l Safety i Ult. Shear i Shear l Safety l I In. I KIPS l KIPS l I KIPS l KIPS l i l I l I I I I I i 1/4 l 3.90 1 0.64 l 6.09 l 1.78 l 0.49 l 3.63 l l 3/8 1 5.55 l 1.33 l 4.40 l 4.25 l 1.10 1 3.85 l l 1/2 1 9.78 l 2.11 1 4.63 l 6.22 l 1.96 l 3.17 l L l 5/8 l 14.22 l 2.51 'l 5.66 l 12.21 l 3.07 l 3.98 i U, l 3/4 l 20.44 1 4.06 1 5.03 l 17.61 1 4.42 1 3.98 l i l L e,

TABLE I (CONTD) ALLOWABLE EXPANSION ANCHOR LOADS Provided to Contractor I I l HILTI SUPER KWIK BOLT - WEDGE TYPE ANCHOR l l l l l l l l l l WPPSS l Allowed l Factor l Manu. l Allowed l Factor l Size l Ult. Tension l Tension l Safety l Ult. Shear l Shear l Safety I l In. I KIPS l KIPS l l KIPS l KIPS l --- l 1 I I I I l l l 1/2 X 3-1/4 l 9.99 l 2.50 l 4.00 l 11.44 l 2.86 1 4.0 l 1/2 X 4-1/4 1 14.78 l 3.70 1 4.00 l 11.44 l 2.86 l 4.0 l 1/2 X 5-1/4 l 14.57 l 3.64 1 4.00 l 11.44 l 2.86 1 4.0 l 1/2 X 6-1/4 l 15.15 1 3.79 l 4.00 l 11.44 l 2.86 1 4.0 l l l 1 l l 1 l l l 1 X 6-1/2 l 34.97 l 8.74 l 4.00 l 27.54 l 6.89 l 4.0 l l 1 X 8-1/2 1 49.81 l 12.45 l 4.00 l 27.54 l 6.89 l 4.0 l l 1 X 10-1/4 l 49.76 l 12.44 1 4.00 l 27.54 l 6.89 1 4.0 l l 1 1 I I I l l l 1-1/4X8-1/8 l 42.70 l 10.67 l 4.00 l 41.45 l 10.37 1 4.0 l l 1-1/4X10-5/81 55.65 l 15.42 1 4.00 l 41.45 l 10.37 1 4.0 I l l l l l 1 I l I I l MOLLY PARABOLT - WEDGE TYPE ANCHOR l l 1 I I i l i l l I WPPSS l Allowed l Factor l Manu. l Allowed l Factor l l Size i Ult. Tension l Tension l Safety ll Ult. Shear l Shear l Safety l l-In. I KIPS l KIPS l KIPS l KIPS l l I I I I I I I I i 1/2X2-1/4 l 4.61 l 1.15 l 4.0 l 7.35 l 1.15 l 6.4 l l 5/8X2-3/4 l 7.76 l 1.94 1 4.0 l 13.50 l 1.49 l 9.1 l l 3/4X3-1/4 l 12.90 l 3.23 l 4.0 1 21.75 l 2.10 l 10.4 l l 7/8X4 l 18.75 l 4.50 l 4.0 l 30.00 1 2.75 l 10.9 l 1 X4-1/2 l 23.00 l 5.75 1 4.0 1 39.30 1 3.30 1 11.8 l l-1/4X5-1/2 l 35.00 l 8.75 l 4.0 1 63.50 l 4.66 l 13.6 l.

TABLE II ALLOUABLE EXPANSION ANCHOR LOADS USED FOR FINAL BASE PLATE QUALIFICATION PHILLIPS RED HEADS INSTALLED AFTER FEB. 1978 Ultimate Allowable Ultimate Allowable Tensile Shear Size Tension Tension Shear Shear Stiffness Stiffness In. kips kips kips kips k/in, k/in. 1/2 8.667 2.167 6.270 1.680 700 106 5/8 10.801 2.700 11.900 2.975 695 250 3/4 11.467 2.867 16.200 4.050 1460 302 7/8 14.134 3.533 18.450 4.612 1600 300 PHILLIPS RED HEADS INSTALLED BEFORE FEB. 1978 Ultimate Allowable Ul tima te Allowable Tensile Shear Size Tension Tension Shear Shear Stiffness Stiffness In. kips kips kips kips k/in. k/in. 1/2 4.267 1.067 6.720 1.680 700 106 5/8 7.970 1.992 11.900 2.975 695 250 3/4 6.534 1.633 16.200 4.050 1460 302 7/8 11.601 2.900 18.450 4.612 1600 300 FILTI DROP IN Ultimate Allowable Ultimate Allowable Tensile Shear Size Tension Tension Shear Shear Stiffness Stiffness In. kips kips kips kips k/in. k/in. 3/8 5.633 1.408 4.225 1.056 410 205 1/2 8.44 2.11 7.84 1.96 480 106 5/8 10.333 2.583 12.205 3.051 840 250 3/4 18.133 4.533 17.609 4.402 980 302 l l i -.

i TABLE II (C0flTD.) g ~ HILTI KilIK BOLT Ul timate Allowable Ultimate Allowable Tensile Shear Size

• Tension Tension Shear Sh. ear Stiffness Stiffness In.

_ kips kips k i_p s__ _ kips k/in, k/in. 1/2 x 2 1/2 5.52 1.38 8.32 2.08 220 106 1/2 x 4 9.10 2.27 8.32 2.08 412 106 5/8 x 3 1/2 9.08 2.27 11.56 2.89 900 250 3/4 x 4 10.12 2.53 17.08 4.27 900 250 HILTI SUPER KifIK Ultimate Allowable Ultimate Allowable Tensile Shear Size

• Tension Tension Shear Shear Stiffness Stiffness In.

kips kips k_ips kips k/in._ _ k/i n_._ 1/2 x 3 1/4 9.9 2.475 11.44 2.86 300 180 1/2 x 4 1/4 14.78 3.695 11.44 2.86 285 180 1/2 x 5 1/4 14.57 3.642 11.44 2.86 271 180 (') 1/2 x 6 1/4 15.15 3.788 11.44 2.86 259 180 1 x 6 1/2 34.97 8.742 27.536 6.884 1165 500 1 x 8 1/2 49.81 12.452 27.536 6.884 1057 500 1 x 10 1/2 49.758 12.439 27.536 6.884 967 500 12 x 8 1/2 42.7 10.675 41.479 10.370 2083 1000 l' x 10 5/8 53.68 13.42 41.479 10.370 1817 1000 l'. x 13 1/8_ ___64.992 ___ 16.23 41.479 10.370 1611 1000 i j MOLLY PARAB0LT l Ul timate Allowable Ultimate Allowable Tensile Shear I Size

• Tension Tension Shear Shear Stiffness Stiffness In.

kips kips kips kios k/in. k/in. l 1/2 x 2 3/4 7.439 1.859 7.35 1.837 1040 106 l 3/4 x 3 1/4 12.90 3.225 21.75 5.437 1063 302 3/4 x 4 1/2 15.26 3.185 21.75 5.437 963 302 7/8 x 4 1/2 18.75 4.687 30.0 7.5 2556 300 7/8 x 4 7/8 21.667 5.417 30.0 7.5 1878 500 1 x 5 1/2 26.555 6.638 39.3 9.825 1766 500

• Size = Bolt diameter x embedment depth O-

- 3 7,-

TABLE III WNP-2 EXPANSION ANCHOR INSTALLATION TORQUES AND PRELOAOS I I I I I I I l Anchor i Phillip Red Head l Hilti l l Hilti Super l Molly l Type l Self Drilling i Kwik Bolt l Hilti Drop In l Kwik Bolt l Parabolt I I I I l l l Torque l Torque l Torque l Torque .l Torque l h l Size I ft/lbs I -ft/lbs I ft/lbs I ft/lbs I ft/lbs l I I I I I I I l 1/4 l 4-6 l 4 -'6 l 4-6 l N/A I N/A l 7 l 3/8 l 15 - 20 l 25 35 l 15 - 20 l N/A l N/A l l 1/2 l 30 - 35 1 45 - 55 1 30 - 35 l 80 - 85 1 45 - 65 l l 5/8 l 55 - 60 l 80 - 90 l 55 - 60 l N/A l 80 - 90 l l 3/4 l 75 - 80 l 125 - 175 l 130 - 140 1 N/A l 125 - 175 l l 7/8 l 95 - 100 l N/A l N/A l N/A i 165 - 210 l l1 l N/A l N/A l N/A l 345 - 380 l 250 - 300 l l 1 1/4 l N/A l N/A l N/A l 720 - 790 1 400 - 500 1 l i I I I I l l l Average Average l Average l Average l Average i Size l Preload i Preload l Preload l Preload l Preload l l KIPS l KIPS I KIPS I KIPS l KIPS l l l l 1 I I l l 1/4 l 0.63 l 1.23 1 0.63 l N/A l N/A l l 3/8 l 1.51 1 3.79 l 1.51 1 N/A l N/A l l 1/2 l 2.25 l 2.80 l 2.4 l 2.45 1 2.77 l l 5/8 l 3.2 1 4.45 1 3.24 l N/A l 4.66 l t l 3/4.I 3.2 1 8.47 l 5.80 1 N/A l 7.74 l l 7/8 l 4.8 l N/A l N/A l N/A l 11.3 l l l1 1 N/A l N/A l N/A l 15.3 l 13.8 l i 1-1/4 l N/A l N/A l N/A l 20.8 l 21.0 l i l I i I

EIGHT BOLT TEST PLATE SIX BOLT TEST PLATE Test L2,3 TEST 4 i B1 s -t- -+- 't - 7 B1 + D+D -+ 4 i + B4 B3 B2 _il-_ 4- + + PLAE 1" X 12" x l'9" B4 B3 B2 W4x13ATTACmENT PLATE 1" x 21" x l'9" W 6 x 25 ATTACHMENT N i x N - s s N ~ s i 's ~ ~ i l I I I i l ',- 4 LOADAPPLICATION I l 1 I // // // // // // // l B4 B3 B2 FIGUPE I FIED TEST. -

16 /B3 / / / B3 / 14 - / / / 12 - / / / / 10 - / p / 8 / / 22 / -6 7 / TEST DATA j

1. lSYS PESutTS b

Elmr POLT PLATE '. da 4 e S 2 !3a l I I I l 1 0 2 4 6 8 10 12 APPLIED SUPPORT LOAD - KIPS FIGURE II - PoLT LDAD COMPARISON FOR IEST 1 _40 j t

W-j / / %/ / 35 - / / 1 'l / '? ,/ ^ / / / / / B- / / / / 20 - / / / / x 15 - / / 3 Q / b S / e 10 - / TESTDATA zw / ANSYS RESULTS 5 EIGHT IbLT PteTE a / 5 1 I i 0 5 10 35 20 3 APPLIED Support [ DAD - KIPS - IblT LOAD AMPARISON FOR TEST 2 I FIGijE III -. - _ _.

P 14 l / / / i 2 / / / / / [ 10

• /

%/ / / / 9 / 8 / s' / ,/ /- x 6 - y ' [rsg,/ B* 8 1 c .3 TEST DATA be4 NSYS RESULTS Eicar PoLT PLATE a 8 _i Z 2 2 0* 1 l 1 I I I i 0 2 4 6 8 E E AoFLIEDSUPPORTLOAD-KIPS FIGUE IV - BOLT LCAD CrJ1PARISON FOR IEST 3,

i 34 - B3 f 32 - ,/ / / / B3 / 10 - / / / / / 8- / 6 B2 i

3

( 8 l 4 TEST.IhTA a 8 ANSYS RESULTS a Six BOLT PLATE 5 2 Yu' Q l l I I I O 1 2 3 4 5 FIGUPE T APPLIED SUPPORT LOAD - KIPS BOLT LOAD C0ffARISON FOR IEST 4 l l t

1.20 El El 0 1.00 I' 47 o 4 %g# x\\ /7 \\ 0.80 P e a s

1. 1 0.60 -

%o%%'e 4 a 0.40 e-0.20 i I .O - i-- -i-i i 0 0.20 0.40 0.60 0.80 1.00 1.20 V/VMAX I FIGURE E SHEAR - TENSION IIREPACTI0tl DItePM1 i I l

8 1-e 8*~ F-STRUCTU.RAL RESPONSE 2 FOR INPUT TO PIPE o 8,, HANGER DESIGN n E0 0 8 E 8 9-P R \\ E! 5 8 a s,_ M D" $$g 7 h u e SE4-STRUCTURAL RESPONSE FOR FINITE ELEtENT ANALYSIS. 8* _ 8* .o-h- \\ ~ 8 oo.ooo 0.1200 o'400 c'. 60 0 0.'800 1!aco 1.500 1.3400 1'.600 1'.800 2.'000 2.500 2.'400 ~ NATURAL PERIOD - SECONDS WPPSS HANFORD NO. 2 REACTOR BUILDING, MODEL 10. 2 REV. 1 SSE (DBE) FLOOR SPECTRUM - COMBINED VERTICAL MASS NO. 10, EL. 414' -3.0". DAf1 PING = 0.005 t

8*- r-e 8e 1 STRUCTURAL RESPONSE e FOR INPUT TO PIPE HANGER DESIGN 8 EO o. \\ E D v e A x o 5 8 l g-i a = 5i U G 8 ~ 8"_ ,gm ff 28 h)- STRUCTURAL RESPONSE FOR FINITE ELEMENT ANALYSIS. o 8.~ h h d' X ~ ~ 8 0 2.'00 0.000 d.200 0'.400 0.'600 0'.800 1.'000 1'.200 1.'400 1'.600 1.'800 2'.000 2.'200 4 NATURAL PERIOD-SECONDS WPPSS HANFORD NO. 2 REACTOR BUILDING, MODEL NO. 2 REV. 1 SSE (DBE) FLOOR SPECTRU?! - HORIZONTAL MASS NO. 10, EL. 414'-3.0". DA!1 PING = 0.005

I mw/ EXHIBIT 'A 3/4 INCH HDI TORQUE VALUES This exhibit is referenced in paragraph 4.2.2 of.the response to the Bulletin. The vehicle that.is used at WNP-2 to provide engineering _ instructions to Contractors is a Project Engineering Directive (PED). Even though generic instructions are issued which affect several contractors each contractor receives a PED with a unique number. This exhibit consists of the PED issued to Contract 215. However, the instructions are generic and were issued to all affected contractors by the following PEDS: Contract 213A Not applicable Contract-215 215-CS-1214 Contract 216 216-CS-0345 Contract 217-217-CS-0043 Contract 220 220-CS-0260 i l V

nu e.n uyu yc. *~ PROJECT

Qi l j$i Hhi 2

1 1 i ' Nuctet[a PNOncr ENGINEERING i si.! y q_, e p ip m m.pii - 1 DIRECTIVE oATE i/j ;g'1/j/ !s'Vi76l PRIORITY No 2 l' XJ u p rDquluD@in t J> RE ASON F CR P.E.D.: OR ATlON a :; SMET1 OF torevise'therequiredtorquevaluesforthe ~ ~ " ~ ~~- = = " ~ ~ ~ ~ HEFERENCES 3/4" diameter Hilti Drop-In (HDI) concrete Sus]ECT}hl llhENd i anchor. LOCATICN Thj LAvG-l L E N G. SYSTE M Recent torque vs. tension tests performed on S/U 5YSTET.1 the HDI anchors in response to I.E. Bulletin ouAUTY CLASS f4~dh 79-02 has shown that the required torque gg,gigg73gg ~ l is too low. DOCUMENTS Q tj t Q D C'] $.D ~,3 $ * ' 1 i:I i REFERENCE DRAl*ilNGS - R EV.f . OR A.:.:al'NG NO. - SHE ET NO. - SU F F IX -} l-ll l-l l l l l-l) ! DESCRIPTION OF WORK: Contractor is to revise his installation - g -l -l l l, k procedures to incorporate the new torque requirec for the 3/4" diameter Hilti Drop-In. The new g -l l l l l-l l ['l j-l l [gy j -l l-l,,( l l l-l l value is given below. 'g - Q /-lllll-l Torque (ft-lbs.) ll b-l N l -l l l l !- ! l 3/4" Hilti l WN l hi l l l l-l l OM, New Drop-In anchor 75-80 130-140 lll' [m l '-iN ! ]-l l All 3/4" diameter HDIs installed from Sept.1, E 1979 on shall be torqued to the new value. All previously installed 3/4" diameter HDIs ~ I Xup2py spspju c n u n o.jiins nirng e must be retorqued unless it can be shown that 1 RE FEREt-s8 j. PARAGRAPHS l l they meet the criteria beloW. ~y . {R EV,l PARAGRAP) 2 PAGE l The following 3/4" HDI anchors need not be Q -i I ,M retorqued to the new values. [N M/j l l

1) 3/4" HDIs directly substituted for 3/4" f

i j Q{QJ l 1 l & smaller Phillips Red Head Self Drilling anchors g] ._l or 3/4" or smaller Hilti Kwik (SblhMf3 q. q. q. 3..l.3.q.,..p..e p q s:3 3ls.ps,s.;. THis PE D RE /ISES DIRECTION APPR OV A Ls; IM i l1 PR E VIOUSt y FROVIDED 8Y W /%IsC, mAh '# ENGINEER 8 THE FOLLOWING PEDish @DATE ln g ; ; rsis ria ncRK SHOULO UE y Lt J E.6G W E E R DATE l CCO R DIN ATE O WITH K NOe'vN d/k N24 u 8/21I9 E' cv.t a cONTascTen non / 7 I eNec n THe rotLOwsNG Peo s ,cor / . AC7XNG R-D TE 2 :,,5 PE C OEPE NDS ON THE f b M'C 4 NST ALLATION OF [! / b $ ' ' ', / " ' /7 T-: n. u c ci.,c Pt o S l __, f.; a,_ E :.u, Exhibit A t a... i l

....7-.. ej - l 3 l If a contractor elects not to retorque any of these HDIs, he must 7 compile a list of the supports on which no retorquing'will be done. This list shall be furnished to B & R Engineering by Jan'. 4,1980. On supports installed prior to Sept. 1, 1980, this PED applies ~! only to HDI anchors which are Quality Class I (and Quality Class II & G 3

1 which are Seismic Class I).

d;; j The retorquing is to be verified and documented by QC.

l -

~ .i 4 c 633J7 REF DOC PCN RFI WPPSS NUCLEAR PROJECT NO. 2 REF SPEC sECTION ' ~ BURNS AND ROE, INC. PAGE-PARA PEF DWG ~ ~ ' DWG. ZONE-PED pp.pj-/g g q SHT ] OF Q SCALE j"A^N g cart 3d.G{nEvtEWED fr oATE p//7 TITLE: gg Q1GQ ^ * * 'C ' ET pA oa:54Glp aravo A b cat f[lf/ M FOR. AD L s Exhibit A ~ 7o y ~

EXHIBIT B LEVELING NUTS This exhibit is referenced in paragraphs 4.3 and 9.3 of the response to the Bulletin. The vehicle that is used at WNP-2 to provide engineering instructions to Contractors is a Project Engineering Directive (PED). Even though generic instructions are issued which affect several contractors each contractor receives a PED with a unique number. This exhibit consists of the PED issued to Contract 215. _ However, the instructions are generic and were issued to all affected contractors i by the following PEDS: August 1979 D_ecember 1979. Contract 213A NA 213A-CS-0198 s,_- Contract 215 215-CS-1194 215-CS-2075 f' Contract 216 216-CS-0355 216-CS-0381 Contract 217 217-CS-0050 217-CS-0084 Contract 220 220-CS-0265 220-CS-0320 e i

i C00' ~P"Ol 'f0G8*"8'di 0"" 'I'V' J] I !-lC [ - ["[ 3,,d,5 HURHs AND ROE INC 2 1 ~;fq.. t,;,7,, [ t%PPSS ENGINEERING g NUCLE AR PROJECT DIRECTIVE nAft ggg engon ry ,h l' LXL' "$ '; :.' - ?. _.. NO. 7 RE ASON FOR P E.D.: f INF ORM AT ION CONTRACTOHS 'SHft1 1 Of 1 ' _ = _... = REFERENCES To inform contractor that the use of 7 leveling nuts on floor mounted base plates SUBJECT LEVEuns nury/for__fitir utilizing drilled in concrete anchors will LOCA DON fN p_l,.Afg_ ENO. SYSTEM no longer be permitted. S/U SYSTEM QUALITY class 2 y_/ $ l s _a F0 $g fUMENTS Z. E. 611L L E'r! N 71 l ? ORIGIN ATING REFERENCE DR AWINGs 5 E OR AWING NO. - SHEET NO. - SU F Flx - R EV. DESCRIPTION OF WOHK: \\_ -fp_// s j This PED applies to all floor mounted l/ supports that have not yet been grouted. -/r / i l ~ I ~ [/~ The contractor should revise the appropriate procedures to reflect this modification. ~ / \\ l /- -x l-Z - \\ / i A." N s N , ',3 '/ u N . N) i,, fj

L i

/ - \\ .s l &ll 'Wl' 2 'L " L". " " " " " "]h m ,,, m REFERENCE SPEC. PAR AGR APHS ") q in i 5 T' i ; O'# lR EV. PA R AGR APH PAGE J ' - '* ,a' ls.E.3 a: m .y [' j f '_ [ }; t1 4 3 15 1 7 A 31 c 63326 l \\ 40 47 43 44 4 *. 46 47 48 69 50 g, 42 5, g4 3* sagg A pyIOV A LS - ,2r d. -)

1. THIS PED REVISES DIRECTION g

h / [f PREVIOUSLY PROVIDED BY Disf IN NGINEffi ? DATE l THE FOL LOWING PEDisi N 11 s En 2 THIS PE D WORK SHOULO 11E LW W NW E ~ f N COORDIN A T E O WITH k NOWN ]\\/ //4 [ d l h OTHE R CONTR ACTOR 'AOR A _ NGR. D'I UNDL R T HE F OL L OWING PE O S. f-d 3 THIS PED OEPE NOS ON THE PHIOR INST ALL ATION OF M[ SII' b_ _ _ ' D IU R' E i THE F OL LOWl'.G PE D S ,/4S1 ENT PROJ. ENGR. Exhibit B f l l

cOcE moucT cac.rmir.a o.secTive i BURNS D OE, INC. PROJECT C 2 i1 H I F l $ Fi SHalol7[SJ nut. LEAR PROJECT '!'!I ' I ' ! * ' ' '"I ' ' " ' " ' " 'I " ! DIRECTIVE DATEl 1!g/t j lZ/17 f 0 i PRIORITY j NO. 2 (. ^><G i"txj"in XuoP. l I i NN SHFFT 1 OF.h ONTn CTon'; To provide instructions and procedure REFERENCES to contractor regarding modification of floor mounted base plates which utilized leveling l nuts. And to provide a procedure for installa-SUBJECT Floor Mounted Base Plates tion of base plates mounted directly on the LOCATION In Plant floor. ENO. SYSTEM Varies l Also included is the basic guidelines S/U SYSTEM Varies j for obtaining adequate bearing contact for OUALITY class I, II. & G j other than floor supports (i.e. wall and ORIGiNAT NG IE EuH<hn 79-o 2 ceiling). i g ge g g g p g,, - ,e,_.;,. g DOCUMENTS .: ~q. ; r. N REFERENCE DRAWINGS M II A %^"2G NO. - SHE ET NO. - SUU lX - R EV. DESCRIPTION'OINbRF E RITEM I IU N MWI l l-lIl l-If i The attached procedure provides the Uasi f-El} _ll l -.l requireTients for the work described below. i l. l l l l-I, [, I l-j Contractor shall submit a procedure for approval l l l N l l1 l_g l l l_ l using the attached procedure as a guide. I l l ! l- \\l l[l l l l !-l ! l The following subjects are addressed in l l l l l_ j K l_l lll_ill the attached procedure. 1. General flotes lll l-Y l h l l l l-I ! ll 2. Correcting previously installed (and grout-l/ -l N l-ed) base plates utilizing leveling nuts. l 3. Correcting previously installed (and dll l-k ungrouted) base plates utilizing leveling nuts. g u.nb.;nn,p pg,,pobin,p,:,.h,psiniunq j N RE FERENCE SPEC. PARAGRAPHS l 4. Installing floor mounted basc plates j, j,,yi ,,,,c,,,g ,,gg directly on the floor. (flo grout pad). 1 _c l {. 5. Shimming Base Plates. N ~ ~ 6. Grouting Base Plates c 08s)(J N/ ll ~ fx %l i-7. Replacing failed anchors. j,[ lN 8. Grouting criteria for wall and ceiling 4. q.,j.. ,q,j,,,. l,, js.;,, supports. AWWAW M I 1. TH!S PE D REVISES DIRECTION PREVICJSLY PROVICEO BY glsCI E NGINEER DATE THE FCLLOWING PEOts! u:

TwtS PEo work SHOULD BE hI N tN COORO!N AT E D WITH k NO/.N OTHE R CONTRACTOR WORK b

UNDE A T H E FOL LOWING PE D'S C W R TE 3 THIS PED OEPENDS ON THE M f y j / Exhibit B PRtOt !NST ALL ATION OF l T H E F O L L Ct.1N G P E C'S. I .( I a s. N _, u

Other Requirements This PED is applicable to all Quality Classes of hangers. N ever, no retrofit is reauired unless specifically stated in the PED such as paragraph #2 & #3 (which is for Seismic Class I only). The rework required by paragraph #2 & #3 shall be completed by February 1, 1980. Contractor shall supply a list of hangers reworked per paragraph #2 upon completion of work. Contractor is reminded that leveling nuts may no longer be used, shims must be used instead per the attached procedure. The proc 5 dure in this PED is intended to supplement the coiitractor's present procedures, and not to replace them. Therefore, various items may be subject to another installation and inspection procedure e.g. see paragraph 4.2. ./ I c 68830 )J [A WPPSS NUCLEAR PROJECT NO. 2 AEF DOC PCN hl ff\\ RFI HEF. SPEC. sECTION: l\\) /4 PAGE. PARA. BURNS AND ROE, INC. REF. DWG : N[A DWG. ZONE. g PED 21 S -CS-2o75 l ssT. 2 oF{\\ p** ] p M OATE Ubth p f DATE lhis/ MLE f }ggy. pot, SCALE: aEviEWED g Vh $'D V hst }\\cM lamogyg cATp/ */94 c4TE

L PROCEDURE FOR PLACIflG FLOOR MOUNTED SUPPORTS 1. General flotes i 1.1 The base plate for floor mounted supports may be placed directly on the floor regardless of whether the drawing or detail shows a grout pad. However, the requirements of Section 4.0 shall be met. 1.2 Quelity Class II hangers which are Seismic Class II and Quality C1' ass G hangers which must be inspected, need not be ' ~ inspected by QC, instead Engineering may evaluate them. Ali other hangers shall be inspected by QC. (See Evaluation Checklist, Figure #2). 2. Previously installed (& grouted) base plates and/or equipment pads utilizing leveling nuts (Applies to Seismic Class I) 2.1 Chip out all grout. 2.2 Back off leveling nut prior to removing threaded rod and nuts. 3 2.3 Install shims and level plate per Section 5.0 of this procedure. 2.4 Install new threaded rod, nut and lock washer. 2.5 Torque each anchor'to the value shown in Table I. ~ 2.6 Observe the location of the top of the anchor before and after torquing. 2.7 If anchor slips and moves to surface of concrete or above during torquing, anchor is deemed to have failed. QC shall make this check. 2.8 A failed anchor shall be replaced in accordance with Section 7. 2.9 If anchor does not move and sustains the torque it is acceptable. 2.10 Af ter all anchors have been accepted, support shall be re-grouted in accordance with Contractor's approved grouting procedure. g g,'J{ Page 1 PED 15 -CS-zo75 Sheet 3 of 11 Exhibit B

L i 3.0 Previously installed, ungrouted, base plates and/or eauipment pads utilizing leveling nuts (Applies to Seismic Class I hangers only) 3.1 Place shims as required to maintain plate level (Se'e Section 4 5.0) 3.2 Back the leveling nut down untill there is at least a gap between the nut and the bottom of the plate. 3,3 Torque each anchor to the value shown in Table I. 3.4 Observe the location of the top of the anchor before and after torquing, make certain that a gap between leveling nut and plate is maintained during torquing. 3.5 If anchor slips and moves to surface of concrete or above during torquing, anchor is deemed to have failed. QC shall make this check. 3.6 A failed anchor shall be replaced in accordance with Section 7. 3.7 If anchor does not move and sustains the torque it is acceptable. ~ 3.8 After all anchors have been accepted, suppcrt shall be grouted in accordance with contractor's approved grouting procedure. i 4.0 Floor mounted base plates placed directly on the floor (No grout pad) 4.1 When desired floor mounted base plates may be placed directly i on the floor in lieu of a grout pad provided the following procedure is followed. l 4.2 Concrete expansion anchors installed for i.his case shall be i@ inspected per contractor normal installation / inspection procedure. I 4.3 Prior to mounting plate directly on floor make certian that the pipe or equipment will be properly supported, i.e. make certain that everything will fit now that the baseplate is approximately 1 inch lower than it was before. 4.4 Place plate on floor and check for proper bearing per Paragraph

4. 7.

Grout if required per Section 6. Concrete anchors must be inspected or evaluated and accepted prior to grouting. 4.5 In order to obtain adequate bearing area, it is acceptable to remove any concrete surface irregularities by grinding. However, no grinding shall be permitted to exceed 1/4" maximum depth below the surface. PED ZW -CS-7015 Page 2 Sheet 4 of 11 (' hj Q Exhibit B

4. 6 Clearly mark the As-Built indicating that the base plate is, mounted directly on the floor.

4. 7 Grouting is required if the plate has insufficient' bearing as defined below:

1. Any gap that is equal to or exceeds 3/32" for a distance of more than 1/2 of any side of the plate (the gap does not necessarily have to be continuous). The 3/32" is to be measured 1" under the plate. 2. Any gap that is equal to or exceeds 3/32" at two adjacent sides (corner) which when added together is greater than 1/2 the plate icngth (minimum length). 5.0 Shimming Base Plates 5.1 Shims shall be placed adjacent to (within 3/16") each anchor bolt. For anchor bolts adjacent to the edge of the plate the shims may not be placed between the anchor and the edge of the plate. See Figure #3 for clarification. 5.2 Shim size shall be limited to a maximum area of 1" x 1" at required thickness. 5.3 Shim. stock may be of non-traceable steel. 5.4 One shim is require,d for each anchor bolt. 6.0 Grouting of Hanger Base Plates 6.1 This section applies only to floor mounted base plates per Section 4.5 of this procedure. 6.2 Concrete surfaces to receive grout shall be free of dirt, oil, grease, loose material, and laitance. 6.2.1 A boundary or " dam" shall be formed around the base plate using Ebeco 636 grout and/or Sikadur Hi Mod Gel 390 mixed and placed strictly in accordance with the manufacturer's recommenda tions. 6.2.2 At least one (1) air hole shall be placed on each side to allow trapped air to escape. 6.2.3 The boundary or " dam" material shall remain in place for a minimum of twenty four (24) hours after gre t has been placed. Page 3 PED a ts -CS-207s Sheet 5 of 11 Exhibit B C 6,ii3'd

~ 6.2.4 Placing grout shall be "Masterflow 814 C' ble Grout". a 6.2.5 Storage and handling of the grout shall be per manufacturer's instructions. 6.3 Mixing 6.3.1 The grout shall be mixed thoroughly.with an electric mixer per manufacturer's recommendations. 6.3.2 Only enough material shall be mixed to grout plates in an immediate area - in no case shall more than five (5) pounds of dry grout be mixed at a time. 6.3.3 Special. precautions shall be taken when the temperature falls below 40' F or goes above 90* F. If below 400 F at the time of mixing and placing the temperature of the grout 0 after placing shall be maintained at 40 F or above for 48 8 hours. If above 90 F at time of mixing and placing water or iced water shall be added to bring grout temperature down to 50* F to 55 FI 6.3.4 Mixing and placing of grout shall be in one continuous operation once the mixing has started, the grout shall be properly mixed and placed as soon as possible. 6.3.5 When the mixed grout cannot be placed within 45 minutes, all such grout shall be removed from the work area immediately a.nd disposed of. 6.4 Placement of Grout 6.4.1 Grout shall be placed in accordance with manufacturer's recommendations and as stated below. 6.4.2 Area to receive grout shall be kept moist prior to grout placement for the period recommended by the manufacturer. 6.4.3 Grout shall be placed by caulking gun or hydraulically from one side only. 6.4.4 Thin metal or plastic strips shall be inserted in the gro'uting area repeatedly to eliminate trapped air. 6.4.5 The exposed grout shall be kept moist by covering it with clean, wet rags for a minimum of twenty four (24) hours. Page 4 PED tis -CS-Zo~ C 68834 Sheet 6 of 11 Exhibit 8

7,0 Remnving and Replacing Failed Anchors 7.1 If an anchor fails per the criteria of paragraph 2.8 or 3.6 it shall be removed by the following methods. 7.1.1 Remove plate and determine what type anchor it is. 7.1.2 Phillips Red Head Self Drilling anchor - remove it by inserting a threaded rod (the same size as the anchor) which will bear on the plug and pull on the shell. The threaded rod must either be machined on.the end so that it can be inserted past the threaded portion of the anchor shell or steel plugs of appropriate length shall be inserted between rod and plug. By using a portion of pipe larger than the anchor diaqeter and a washer plate the anchor can be removed by turning the threaded rod and a nut attached to the rod, thus holding the plug in place and pulling the shell out. See Figure 1. 7.1.3 HDI's - Remove it by drilling out the plug with a drill bit slightly smaller than the anchor size. After the plug has been drilled out the shell may be removed as in paragraph 7.1.2 above or using a hydraulic jack. 7.1.4 Under no circumstance shall an anchor with the plug intact be removed by hydraulic jack.

7. 2 A failed anchor thall be replaced by one of t'he fol7owing methods.

Replacement anchors shall be installed and inspected per normal iethllation procedures. 7.2.1 Phillips Red Head Zelf Drilling. Anchor - Thu hole must be reamed to the next larger size for an HDI. For example, a 5/8" Red Head hole should be reamed to 1" diameter to allow insertion of a 3/4" HDI. For 3/4" & 7/8" Red Head anchors the only replacement allowed is.1" & 1 1/4". diameter Hilti Super Kwik Bolts. 7.2.2 HDIs - An HDI anchor of the same size or larger shall replace the removed anchor. t Page 5 PED as -CS-7o7s Sheet 7 of 11 l C 665.'j5 Exhibit B l

I 8.0 WALL AfiD CEILIfiG MOUNTED SUPPORTS l 8.1 Check bearing area in accordance with paragraph 4.7. i 8.2 If adequate bearing area cannot be obtained by grinding (see paragraph 4.5) then support is to be grouted in accordance with Paragraph 6.0. 1 TABLE I TORQUE TEST VALUES l Phillips Red Head HDI Size Test Torque (ft-lbs) Size Test Torque (ft-lbs) 1 't 1/4" 8 'l 3/8" 25 1/2" 40 1/2" 40 5/8" 60 5/8" 65 3/4" 90 3/4" 140 7/8" 100 Note: The above torque values are different than the normal values used 1 I and are for use on this PED only. j c GSS3G .J/A l WPPSS NUCLEAR PROJECT NO. 2 ffQ d RFI REF COC PCN DURNS AND ROE, INC. REF. SPEC SECTION-d[h PAGE: PARA. NT ^*- oWG, ZONE A PED gjg _C3. goIg REF DWG M/A E f1/gj(nRE Floor Mounted g, Exhibit B {l^*1[y jl p oATE I*/ih REviEWE SCALE: d.,k j;"O ' l Amve/P6 caro,[/(/g caTE

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i 0 ~ _Ey&U)AT10'4 CHELLLLSI. j 1 1 HAf;GER MARK # BUILDItiG & ELEVATION 1. Baseplate is leveled & shimmed properly 2. Anchor did not move during test torquing I l t 3. Torque wrench is properly calibrated ) I 4. Proper torque has been applied [ 5. A gap exists between leveling nut and plate i 6. Baseplate has been properly grouted l 7. Baseplate has proper bearing Remarks I i l Engineer Date QC Date l FIGURE #2 [' Clj(-{[v,Q Page 8 REF DOC. PCN A/[4 RFI //3 WPPSS NUCLEAR PROJECT NO. 2 SURNS AND ROE, INC. REF SPEC. SECTION p/A PAGE. PARA PEo Zsc -CS-2075 S"' REF DWG.: d/g OWG. IONE. g bOOy- % Exhibit B ATE Ih/ TITLE. M/4[yf SC At.E. {S**g fQ AEviEwE oArg I l nmc.)y), ofill?{ a yo k\\r, ~L U (3 l] '= ' ns h

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7 m).. i i. e n DRILLED IN CONCRETE -\\ SHIMS (TYP OF 4), t-ASTENER (TYP OF 4) p%..- .,. e ' ~ I M sjef; l \\ t I ) j,_, M) HOLES = e' ' d..r\\ Note: Shim shall be kept inside the bolt line except no more than 1./2 of the shim may extend over the bolt line. f FIGURE #3 ~ C bbb3b Page 9 RFI U/A l Y!PPSS NUCLEAR PROJECT NO. 2 REF COC PCN yg REF. SPEC SECTION: y[g PAGE. PARA: l BURNS AND ROE, INC. REF OwG. q/A OWG. ZONE: . PED 2gg,cg-to7 T 'b 4/h,4jaev.mQ$$rs fy//7f RE {COc Exhibit B SCALE-gy ^*tjgf7jf, a cars p'lh c =* =>rs l<m/n v ca,q!!;If suq V c __ _

= E 1 y. i L EXHIBIT C j i NRC BULLETIN 79-02' INSPECTION REQUIREMENTS i l-This exhibit is referenced in paragraphs 4.4, 4.4.1, 4.4.3, 4.4.4, 4.4.5, and 9.3 of the response to the Bulletin. The vehicle that is used at WNP-2 to provide engineering instructions to Contractors is a Project Engineering Directive (PED). Even though generic instructions are-issued which affect several contractors each contractor receives a PED with a unique number. This exhibit consists of the PED issued to Contract 220. However, the instructions are generic and were issued to all affected contractors i by the following PEDS: Contract 213A 213A-CS-0087 . x.,- Contract 215 See Exhibit D Contract 216 216-CS-0322 Contract 217 217-CS-0033 Contract 220 220-CS-0247 i i V i b,

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• BURNS AND ROE,INC.

PROJECT T T1 2 zio I- !O s!-H 4!d/j7 ENGINEERING TM WPPSs . i o * ' i' i ol"In i o . NUCLE AR PROJECT DATE gy / 7/l DIRECTIVE M ' ?$ '. '.' W "LQ P R IO R I T Y L" L [.N ^' RE AsON FOR P E.Da O T ACT S HffT l Of To clarify and upgrade in-process inspection HEFERENCES requirements for installation of concrete expansion anchors as required by NRC Bulletin SUBJE CT]gr}c_ggn of: ct,,cggt 9, gg pacaro~ ~ i ORMAT1ON C0P, ENO SYSTEM S/U SYSTEh l QUAllTY class _1 _E, G j ORIGINATING l DOCUMENTS 1 y REFERENCE DRAWINGS j OH AWING NO. - SHE E T NO - SU F F I X - R Ey. l l DESCRIPTION OF WORK: \\ y w on sheet 3 of 3 as noted below. ~x l, Revise the specification requirements as shown I \\ ] j[ Paragraph 3.17.2.9 Page 15E-34a. Revise k ,h inspection requirements per page 3 of 3 \\ fj_ and delete pull test requirement. X Note: 1. This PED applies to all Seismic ~ s Class I work and only to future work for / ~ Seismic Class II & G. Contractor shall ,Z _ \\ revise and resubmit installation and / .\\ ~ inspection nrocedures to Engineer. / N 2. Contractor shall report in -b writing to Engineer the results of checking / one bolt per plate per the specification gg "Pi" " " " "L' * " " ". "1" " " "a requirements for the first 100 plates E REFERENCE SPEC. PAR AGR APHS l checked. The report shall include the 3 PARAGRAPH I PAGE lRE V) number of anchors found to be unacceptable -y" J i 3I70A09 I'5' M 4 I and the date the procedure was implemented. 3. Contractor shall provide in writing to the Engineer a list by Mark No. l i of all Seismic I hangers utilizing shell I type anchors which have been installed prior to implementation of this procedure. X"""""""""""":""""'Yj

l. THIS PED REVISES DIRECTION APPROVALS; j

f A O - C' S - O l %, 7 ?> i q' 7//7/77 PREVIOUSLY PROVIDED BY THE FOLLOWING PEDhl M d C ) " ( ' 5 - O h ', %sCtJf i E JGINEER f DATE M 2 THIS PE D WORK SHOULD DE /J DATE COOnDIN ATED WITH ANOWN 71 //.2 ~ 1 /7 7'f '7 OTHL R CONTR ACTOR WORK (-- 'i T CpENGR. DATp UNDE R THE FOL LOWING PE D'S COC O E - II M 1 THIS PE D DEPENDS ON THE PHt0R sNST ALL ATION OF f l /f.}- S Ll+ N ENGR fT'E{ THE FOLLOWING PE D'S 1 s EN PROJ. ENGR. Exhibit C d

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. ? -. = 2 6. * *.' 'E I This list shall also identify which hangers have been inspected in the retrofit program. For the purposes of developing this list (of installed Seismic Pipe i Supports), a pipe support which has not yet been inspected.to the retrofit i requirements shall not be considered " installed". 4. The 20% inspection requirements for Quality Class II & G (non-siesmic I) are minimum and shall be increased if the rejection rate is unacceptable. t Contractor's QA shall decide which 20% of the anchors shall be inspected and the acceptable rejection rate. An acceptable method of sampling and acceptable 1 rejection rates are given below. l Note: Lot size shall be 100 anchors. ( Lot means unit sample size) Step: t I I

1) Randomly select. 20 anchors from a lot for inspection.

i 2)' If the number of failed anchors is equal to or greater than 6, go to step 4. j i 3) If less than 6, continue on to the next lot and return to step 1. j

4) Randomly select an additional 32 anchors from the same lot.

l 5) If the number of failed anchors is equal to or greater than 6, go to step 7.:' I 6) If less than 6, continue on to the next lot and return to step 1. l 7) Inspect all remaining anchors. 8) Inspect 1G0% of the next two lots (200 anchors). If in the second lot, the number of failures is equal to or less than 9, inspection may be reduced. Otherwise, continue 100% inspection untill this condition is reached. 9) Inspect 33% of the next lot of anchors if failure rate is equal to or less than 5, inspection may be reduced.

10) Return to step 1.

I i . - - - Exhibit C i

v 4 .8 If contractor elects to use a stud type insert (e.g. Hilti Kwik Bolt) as an approved equal it must have a length code stamped on the end in order to readily determine,t,he__Amaunt of cabedment.JLf ter installation. h t [9 In process inspNtion requirements for Class I and Class,II installations: 2 a E k a) Quality Class I (and Quality Class II & G which are SC-I) All Quality Class I (and Quality Class II & G which are SC-I) ? installations shall have the installation of drilled-in concrete 3 anchors verified and documented by QC. Such verification shall include as a minimum, a check of embedment, torque, proper size, and proper type for stud type anchors (e.g. Hilti.rswik Bolt) and the L relative dimension, distance below top of concrete, torque, proper j size and proper type for the shell type anchors (e.g.Hilti Drop-In). Contractor shall remove a minimum of one (1) bolt per plate on all shell type anchors that have been successfully installed (and torqued). QC shall verify that the anchor has not pulled out against the plate. All anchors that are found to be pulled out against the plate shall be rejected and the remaining bolts for that plate shall be removed and similarly checked. In a similar manner, one bolt per plate, whether stud type or shell type shall also be checked for proper thread engagement, plate bolt hole size, bolt spacing and edge distance (concrete edge). If an anchor fails to meet the E acceptance criteria for any of these items it shall be corrected and all other anchors on the plate shall be checked. If inspected anchor is acceptable the bolt or nut shall be reinstalled and torqued. l b) Quality Class II & G r All Quality Class II & G drilled-in concrete anchors which i are Seismic Class I shall have their installation verified and documented in accordance with the preceding paragraph. In addition, 20% of the remaining Quality Class II & G drilled-in concrete anchors shall have their installation verified and documented by QC. Such verification shall include as a minimum, a check of embedment, torque, proper size, and proper type for stud anchors (e.g. Hilti Kwik Bolt) and the relative dimension, distance below top of concrete, torque, proper size and proper type for the shell type anchors (e.g. Hilti Drop-In). / ~ i 15E-34a AEF OOC. PCN RFI WPPSS NUCLEAR PROJECT NO. 2 PAGE / G- % PARA 3,g J J ') BURNS AND ROE, INC. AEF SPEC SECitON REF DWG ~ oWG. ZONE h% PEDQQ g d g q/ SHT-3 OF] SCALE {A^ e ( oarg ?[ 7/c DATE 7[/7f77 TITLE nIPEC.tIo n AEviEWED NN @o gd. oarE.gf 7 geev o jMuoarE-)W C or W m ,cy ~t Exhibit'C / g 't

v EXHIBIT D NRC BULLETIN 79-02 INSPECTION REQUIREMENTS FOR C215 This exhibit is referenced in paragraphs 4.4, and 4.4.2 of the response to the Bulletin. V v J

PROJECT hi '{yD M o 'NUCLI' H 'No., 'J N C T l DIRECTIVE oATE g g g PHIORITY ~ % _' 'b' T h 'T ' _ 1 _ _.. h INS ORM A T ION coNin4 Cions _ _ __isneEi l os i I E ASON FOH v E D.- REFERENCES To clarify and upgrade in-process inspection requirements for installation of concrete expansion anchors as required by NRC Bulletin H"5f '0" C" LOCA MON AMhor$ 79-02. i ENO. SYSTEM s/U SYSTEM i QUALITY CL ass

• C, "II d 6

! i .n INFORMATION COP 1 f ORIGINATING l DOCUMENTS i RE FE RENCE DR AWINGs 3 - REV.h OH AWING NO. - SHE E T NO - SU F F l x l- -!l lM DESCRIPTION Oi3OR A: K l t Revise the specification requirements as shewn on l . l. ,-j ] Sheets 3 of 4 and 4 of 4 and as noted below. 1. Paragraph 3.20.3.8 Page 15Q - 30a. Revise "y-t b' M. j a .I !b l[i inspection requirements per page 3 of 4 and l delete pull test requirement. l,% l ll-Q l-ll i 2. Page 15Q-49a Delete tabh 5-B. l Note: 1. Ihis PED applies only to future work. l ll l4-+j._ _ y l_l l: Contractor shall revise and resubmit installation- / and inspection procedures to Engineer. It also kt b MII applies to all small bore pipe as well as larae /l' l {l I ~onre.)ipe.s i.5robi g Contractor shall report in wrii.ing to Engineel f l gl g -,,]L,, ,,,,y,,,,,, ,,, q,,,,,,, ,,,i. 2. l _j L the results of checking for anchors pulled against D L, ^ plates for the first 100 shell type anchors REFERENCE SPEC. PAR AGR APHs f l which are inspected and documented by QC. The

lREV, p A R AG R APH PAGE l

report shall include the number of anchors fou.id [g / 5 M, -3 o!al I l to be unacceptable and the date the procedure 3 2 0 3' was implemented. 8 i, 3. Contractor shall provide in writing to the E I l l l l Engineer a list by Mark. No. of all Seismic I l - I hangers utilizing shell type anchors which j T-- have been installed prior to implementation of ,_ L this procedure. Ihis list shall also identify X b up s" " ","j" " 5" " ui"% 'd wh i c h ha ngers _ha ve__beert_inspectod in tho rotrOfit.___ _ __. v APPROVALS. 1 THG Pt O REVISES OIRE CTtON program. Cont. Page 2 y PHE VIOU$l Y PROVIDED BY INEER ' DATE rHc f *R LOWING PEOld _1ly - (5 - o d7 % J ' DipCIPLIN @fsif$tur, <t,o7 = 1 3-79 f2 THIS P-O WO A % SHOLJLD BE EER DATE e-t COCHOiN A TE D WITH A NOWN f. OTHt F CONT R ACTOR WOAK l t!Not it THt F OL LOWING PE D S. - - i f L__-. PHt0H INST 4L ATION OF._. l 1 TH sb Pt O Of PE NOS ON T Ht. _ _, - - ' fSON E ATE i /; f t L F A L OWiNG Pt O'S t R SIDE N T PROJ. E NGR. Exhibit D

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P WNI Bul4NS 'fe 800. INC.

PAGE 2 Of- + u ? ' a M'Ma'r~ , - _...... _ _ _ _.. ~. i t k REFEHENcE DH AWINGs M REFERENCE SPEC PAR AGRAPHS PAHAGHAPH PAGE HEV. l2 onAwinG no..(sHour no. .sorrix - aEv. w 7 s l -e 4 -_ \\

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..L. _ l.7 p p !i- - 7 i, ,t . I. 1, l. _,,_ / n H 44-f I/7ll-L --l -- t-l ..; 2 i i I I I I I [ -t -- s-. c i_ln.L-lt..._LJ..,f.- I l lu '/i/I y !-] i . l! 17.h_h lf-, 4 v i ! j f._ _I -^ V i i 5 -y s-i .. t._ _L -X i =- k.9' -l \\ a-i 2l ~. L'. l.. } L{-/-td-[--+I f \\1 "[--" I. I !_l l N-(I \\ / ' ;i N _J - .,_g_ s z l _t_. r. c \\ l i 'I m ,=.]Ei !'.'$ 5?J HE1*2HPS 2 t " tA'$5@ l2.5h3'R:$- t For the purposes of developing this list (of installed Seismic Pipe Supports), j 3 a pipe support which has not yet been inspected to the retrofit requirements shall not be considered " installed". ( i j 4. The 20% inspection requirements for Quality Class II and G (non-seismic I) are minimum and shall be increased if the rejection rate is unacceptable. l Contractor's QA shall decide which 20% of the anchors shall be inspected and i the acceptable rejection rate. An acceptable method of sampling and acceptable j rejection rates are given below. 4 1 Note: Lot size shall be 100 Anchors. (Lot means unit sample size) l l Step: l l

1) Randomly select 20 anchors from a lot for inspection.

l l 2) If the number of failed anchors is equal to or greater than 6, j i go to step 4. 3) If less than 6, continue on to the next tot and return to step 1.

4) Randomly select an additional 32 anchors from the same lot.

t l b) If the number of failed anchors is equal to or greater than 6, i go to step 7. i l 14less t%.s c

6) " Continue on to the ilext lot and return to step 1.

l b, f hh,h 7) Inspect all remaining anchors. 8) Inspect 100% of the next two lots (200 anchors). If in the second lot, the number of failures is equal to or less than 9, inspection may be l I l reduced. Otherwise, continue 100% inspection untill this condition is i reached. l 9) inspect 33% of the next lot of anchors if failure rate is equal to or less [ than 5, inspection may be reduced.

10) Return to Step 1.

- Exhibit D i 1 L

.o m. we ....,m... Quality Class I (and Quality Class II & G which are SC-I) a) All Quality Class I (and Quality. Class II & F which are SC-1) installations shall have the installation of drilled-in concrete anchors verified and documented by QC. Such verification shall include as s minimum, a check of the embedment, torque, proper size, and proper type for stud type anchors (e.g. Hilti Kwik Bolt) and the relative dimension, distance below top of concrete, torque, proper size and proper type for the shell type anchors (e.g. Hilti Drop-In). Contractor shall remove a minimum of one (1) bolt per plate on'all shell type anchors that have been successfully installed (and torqued). QC shall verify that the anchor has not pulled out against the plate. All anchors that are found to be pulled out against the plate shall be rejected and the remaining bolts for that plate shall be removed and similarly checked. The anchor shall also be checked for bolt hole size, bolt spacing and edge distance (proper thread engagement, plat concrete edge). If an anchor fails to meet the acceptance criteria for any of these items it shall be corrected and all other anchors on the plate shall be checked. If inspected anchor is acceptable then the bolt shall be reinstalled and torqued. b) Quality Class II & G All Quality Class II & G drilled in concrete anchors which are Seismic Class I shall have their installation verified and documented in accordance with the preceding paragraph. In addition, 20% of the remaining Quality Class II & G drilled-in concrete anchors shall have their installation verified and documented by QC in accordance with the paragraph above. 3.20.4 zmbedded Plates 3.f.3.4.1 Cast-in-Place Embedded Plates : .1_ The structural information drawings of Section 1C of the Specification show the location.of embedded plates in some areas of the reactor building which are intended for the use of installation centrectors for-hangers and seismic restraints. The drawings shcw design locations for embedded plares and rhe instal.b-tion tolerance for these plates is +3". Prior to i f abrication, and after approval, Co. tractor shall ascertain the exact location of all embedded plates to be used by him. Contractor shall s1bmit calculations for each installation verifying that the worst condition of leading, specified hereafter, has been checked and designed for. The calculation shall list the loads on each embedded plate. 15Q-30a REF doc PCN RFI WPPSS NUCLEAR PROJECT NO. 2 AEF SPEC SECTioN ff Q PAGE M -3 A PARA:3, go,3, g4 BURNS AND ROE, INC. PEF DWG DWG ZONE PED Jg_ gg / g SHT.3 oF q SCALE DATE REVIEWED OATE TITLE mum y Md> TEM # E?he t[ DATE 7[yhg DATEf[f; AM/ APPVD Exhibit D y

4 m m m S S ~- a w a m S l o O o O O o =4 Cg i2 o w 6 2 4[ C. y ? Tant.S F [ b ). -i A Insert Installation & Testing Information & Requirements M $ 0 Df e TAnLE 5-A A y ,e 2 Insert Size Masonry Bit Diameter 2 o for Predrilling I! ole Depth of Insert and Top of Set Plug Relative Dimension Detween Top O S o L 3/G" b .572" .577" l-3/4" O.000" 0.925" 9 2 y + m + - 1/2 " ~ .702" -.712" 2'-1/4 " - 1.125" 1.250" g Q n s/a" .osa" .873" 2-3/4" 1.37s" 1.562" o g 3/4" 1.020" -1.030" 3-1/2" 2.000".- 2.187" M 2 53 7/8" 1.14S" -1.155" 3-15/1s" 2.312" 2.500" 'A 4 A ~ w F 8 1. T ". Q ? y 9 n m C ~ i

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EXHIBIT E C215 RETROINSPECTION REQUIREMENTS This. exhibit is referenced in paragraphs 4.4. and 4.4.2 of the response to the Bulletin. This exhibit consists of the original Contract 215 anchor retroinspection procedure dated April 1978 and Revision 6 of this procedure which included all of the Bulletin 79-02 inspection requirements, dated July 1979. This procedure was used for the retroinspection of all anchors installed by the Contractor prior to February 1978. Revision 1.through 5 of the procedure did not change the inspection items given in Revision 0. Similiarly, Revision 7 through 9 of the procedure did not change the inspection items given in Revision 6.

5s'*45 AND ROE. INC' PROJECT 2 1 <2. 3,_jS 'c 4 'i' oisdo WPPSS NUCLE AR PitOJECT DIRECTIVE DATE Q "l / g 3/Lg g PRIORITY NO. 2 D< ' ' E'." "b"$l'1 l' _.1 IN F ORM A T ION RE ASON FOR P.E D.-~ - - -: ~ CON 1 f t AC10H'i Mtt t T 1 Of D__ T., <=.euio. Tue b cziLLes-tu c..oceeTe g eneuci;s - A M e s oie E v 4 Lo - Tio u ei?ocesoe e T= SUBJECT /ygmq,,, baru.es-loAow.co tuc.Long AhhtTioMAL. iMSPECT'lDO EeG0'M M'EMT5 LOCATION M/A F'o r. i o sTALLA rieu e r h e.86Le h -lo A ucH es s ENG. SYST EM g/4 AG eEavieEb 159 THE h.1 RC. S/U SYSTEM a/ja M 7] f Q8 % y 3.J QUALITY CLASS yQ h .1 j s/ f,A'h 3 f 3 a4 ;f /

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~ n)Caace. voc en,%e ucr4cc2. (ses secTiou c,.t.4, p%e 1) \\ A-buccW. ~ ~ 1 Fog S A5E TCATe now T-HoLG b l A MG Te R. / ~ \\. 66cTious (a.2.l.1o,, PA4E 8\\ / ~ EG (e. '2. 2. l ho, PA46 lO AuD / 1 ) / \\ / [h "Mi #'. 25 zr as as so is iz 22 24 n[is n iri% g,q, p%g n. REFERENCE SPEC. PAR AGRAPHS o b lRE"1

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_ p_INEl[g j) , ] DATE PREVIOUSLY PROVIOCD BY ENG ISCI ' THE F OL LOWING PE0ts) If M /NM A l2 THIS Pf D WORK SHOULD GE ~ ~ 'DATE M s l a'E liR COORDIN A TED WITH KNOWN h l OTHE R CONTR ACTOR WORK 4 c,- l UNDE R THE FOLLOWING PE 0'S _ _ _. _ _ CO CO" R, ENGR. / AT M i THIS Pt D DEPE NOS ON THE S/U 'Lly'

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TE PHIOR INST ALL ATION OF __ A7[/( THE FOL L OWING PE O S [ ) SluENT PROJ. ENGH. Exhibit E

fbo 215-cs-Joso > \\,'. DRILLED - IN CONCRETE ANCHOR EVALUATION PROCEDURE WPPSS NUCLEAR PR') JECT NUMBER 2 RICHLAND WASHINGTON REVISION 6 Prepared By wm ill1 h7 Submitted By ed, All ht b 9lIP;/7 Resident Project Engineer M 7[30[79 Quality Assurance Manager [l... q $'M vry c G3739 \\ Exhibit E -t i

Parb 219-c.s c o-DRILLED - IN CONCRETE ANCHOREVALUATIO" PROCEDURF = TABLE OF CONTENTS 1.0 PURPOSE........................................... Page.1 2.0 SCOPE............................................. Page 1 3.0 DEFINITIONS AND ABBREVIATIONS....................... Page 2 4.0-RESPONSIBILITIES FOR EVALUATION..................... Page 3 5.0 EVALUATION REP 0RTS.................................. Page 5 6.0' EVALUATION.......................................... Page 6 7.0 FINAL EVALUATION.................................... Page 13 8.0 REW0RK...............................................Page 14 ATTACHMENT I - ANCHOR EVALUATION CHECKLIST .................Page 15 ATTACHMENT I I - TEST GAUGE................................. Page 16 ATTACHMENT III - GENERIC FIXES............................. Page 17 i ATTACHMENT IV - FLOW CHART................................. Page 23 i f t l l i s i 9 i c 63'7 @ t ' \\ R\\ Exhibit E

f%a 11h-c.s-Iesro ' 1.0 PURPOSE The purpose of the evaluation is to check the adequacy of Installation of Drilled-In Concrete Anchors used in conjunction with pipe supports. A preliminary evaluation of pipe supports indicates a significant percentage of Drilled-In Anchors were not installed properly (improper epoxy used, anchor not fully expanded, etc.). The purpose of this procedure is to provide specific instructions for evaluation acceptance, and any rework required of Drilled-In Concrete Anchors installed on pipe supports prior to February 1, 1978. 2.0 SCOPE All Drilled-In Concrete Anchors on pipe supports installed prior to February 1,1978 shall be. evaluated. 1 The evaluation governed by this document shall be limited to a check for adequate concrete anchor installation and will not include a general inspection of the pipe support. i 1 c G3711 Page 1 Exhibit E

Pe o 2is-ts-)*1 I 3.0 DEFINITIONS AND ABBREVIATIONS The Engineer - Burns and Roe Engineering. Quality Control - The Contractor's Quality Control Department. Quality Assurance - Burns and Roe Quality Assurance. PRH - Phillips Red Head Self-Drilling (Snap-Off) Anchor. HKB - Hilti Kwik Bolt Relative Dimension - For Phillips Red Heads - Dimension from top of set plug to top of test gauge. Note that the relative dimension described here is different from that specified for new installations. . Depth of Embedment - for Hilti Kwik Bolt - Indicates the length of anchor below concrete. 1 i c G3712 Page 2 ( Exhibit E

PCD 21V4s-ISTC 4.0 RESPONSIBILITIES FOR EVALUATION (See Attachment IV) 4.1 EVALUATION TEAM The Evaluation Team shall be made up of the following personnel; one representative of the Contractor's Engineering Department, one representative of the Contractor's Quality Control Department, and any Craftsmen necessary to provide labor. Representatives of the Engineer and the Burns and Roe Quality. Assurance. Department will be present on a part-time basis to monitor the evaluation process. 4.1.1 CONTRACTOR'S ENGINEERING REPRESENTATIVE The Contractor's Engineering Representative shall direct the overall evaluation of the pipe support in accordance with this Evaluation procedure. The evaluating engineer will utilize whatever tools necessary to perform engineering evaluation and will insure that the Checklist is properly filled out. At. the conclusion of the evaluation he shall. sign and date the Evaluation Report. 4.1.2 CONTRACTORS QUALITY CONTROL REPRESENTATIVE The Contractor's Quality Control Representitive stiall be notified when an anchor.has been determined to be acea.ptable. He shallitake the final' inspection mea M ements ard record them on the Evaluation Checklist before any' rework is done on the, Hanger utilizing that anchor. At the conclusinn of the inspection he shall sign and date the Checklist. 4.2 CONTRACTOR'S ENGINEERIllG DEPARTMENT The Contractor's Engineering Department shall be responsible for coordinating the overall evaluation effort to ensure that it is carried out in an orderly and timely fashion. As :Evalua-tion Reports prepared by the Engineer are received, the Contract-or's Engineering Department shall assign the. pipe support to an Evaluation team, ensure that the pipe support is ready for Evaluation (scaffolding for access in place, etc.), and ensure that the necessary craftsmen to provide labor for the actual Evaluation are available. After evaluation is complete, the Contractor's Engineering Department shall review the Evaluation Report for correctness. The Contractor's Engineering Department shall be responsible for providing As-Built drawings and initiating RFI's as required by this procedure prior to return-ing EvaluatinnReports to the Engineer. All Eva,luation Reports completed in a returned via letter to the Engineer by noo. given week shall be n Tuesda.y of the follow-ing week. 4.3 THE ENGINEER { {]'] For oipe supports requiring evaluation the Engineer shall prepare Evaluation Reports (see section 5.0, Evaluation Reports; for details) and transmit them to the Contractor by letter. Page 3 Exhibit E

P&O 215 CS-Iss The Engineer shall be responsible for providing the Contract-or with Generic Fixes (see section 7.2.1 and Attachment III for details) to be used when anchor installation is found to be inadequate and rework is required. If a generic fix is not applicable (see section 7.2.2), the Contractor's Engindering Representative shall perform any necessary redesign. 4.4 QUALIFICATION OF EVA_LUATION TEAM all personnel (excluding crafts) responsible for any part of this evaluation shall attend training sessions conducted by the Engineer to assure each member of the Evaluation Team is fully cognizant of his duties and responsibilities. Only evaluation Team personnel whose names appear on a list approved by the Engineer shall be allowed to perform evaluation work. e a c 63711 Page 4 Exhibit E

C 2tr-45 fogo 5.0 EVALUATION REPORTS Each evaluation report will consist of a copy of the pipe support detail and an Evaluation Checklist (see Attachment I) for the Drilled-In Concrete Anchors in each plate. Items 1 through 8 on the checklist will have been filled out by the Engineer. These include the hanger number, building and elevation, hanger plate number, applicable generic fix numbers, anchor numbers, size of anchor, center to center spacing for the anchors and a sketch of the anchor configu-ration on the plate. The anchors will be numbered consecutively, starting in the upper left hand corner and numbered clockwise around the plate. For plates on the ceiling or floor, North will be considered as up. I Page 5 (3 k)b [1 Exhibit E

P6D 2/5-45-/00f f 6.0 EVALUATION 6.1 GENERAL HANGER EVALUATION f-6.1.1 Compare hanger configuration to detail attached to Evalua-tion. R.eport. Check critical dimensions ciirdled on hanger detail. If the actubY dimensions fall outside the tolerance listed on the detail, then hanger configuration does not confom to the detal. The tolerance fog center to center spacing of Drilled-In Anchors shall be -1/2" for all hangers. Circle the appropriate part of Item 9 on the Checklist. If the hanger. configuration does not conform to the detail, then refer to Section 6.1.2. If the Hanger configuratien does conform to the detail, then proceed to Section 6.1.3. 6.1.2 If the hanger configuration does not conform to the hanger detail per the criteria specified above, calculations-perfomed by tfe Engineer are no longer valid and a final evaluation of Drilled-In Anchor installation cannot be made (see Section 7.3). Evaluation of the pipe support may continue following the criteria in the procedure with the following exceptions: In Section 6.2.1.1g, the relative dimension shall be measured and recorded but not compared to the maximum acceptable relative dimension listed under Item 15a. The comparison in Section 6.2.2.3 shall not be performed. At the conclusion of the evaluation, Item 19d on the check-2 ' list shall be marked, and an as-built drawing of the pipe su.ppy.t attached to the Evaluation Report before it is-returned to the Engineer. Note, that no rework is to be performed on the pipe support until final evaluation of the Evaluation Report and as-built drawing by the Engineer. j 6.1.3 Check anchor spacing from nearby embedded items to ensure that the following criteria for minimum allowable distance ~ for a Drilled-In Anchor from an embedded item am met: Embedded Plates: 3"+h of the center to center bolt spacing. This spacing is to be from the edge of the embedded plate to the center of the Drilled-In Anchor. Ik" Richmond Inserts: 6"+h of the center to center bolt spacing. This spacing is to be from the center of the Richmond insert to the center of, the Drilled-In Anchor. Page 6 c G3"i46 Exhibit E L j

ciuveuueu un i s i. u i.. og v e us i.ne cem.er cu teni.er m m - c.. bolt spacing. This spacing is to be from the center of the emb:dded unistrut to the center of the Drilled-In Anchor. NOTE: Bolt spacing referred to is the spacing l listed under Item 7 on the checklist. If the criteria are violated, note this on Item 10 with an "S". If another hanger is attached to the embedded l item, note the type of hanger (pipe, cable tray, duct, etc.) and hanger number if possible and mark up Item 8 showing the location of the embedded item relative to the anchors. If the embedded item is a unistrut or strip plate, only report hangers attached within 12 inches of the anchor being inspected. If the criteria are not violated, simply check Item 10. NN w A 6.1.4 Check that the anchor meets the following criteria for minimum allewable distance for a Drilled-In Anchor from i free edge of concrete: l NOMINAL DIAMETER EDGE DISTANCE (in.) L 1/2" 3 3/8 2 5/8" 4 l 3/4" 4 3/4 7/8" 5 3/8 i j .If the criteria are violated, note this on Item 10 with an l "S and mark up Item 8 showing the location of the free edge of concrete relative to the anchors. If the criteria are not violated, simply check Item 10. v m_ 6.2 EVALUATIrN OF DRILLED-IN CONCRETE ANCHORS I' 1 Using an acceptable type of marker:, number the bolts on the plate exactly as they are numbered on the checklist, i.e. starting with No. 1 in the upper left hand corner and number clockwise l around the plate (for plates in ceiling ~or floor, use North as l "up"). y 6.2.1 EVALUATION OF PHILLIPS RED HEAD ANCHORS p.; + 6.2.1.1 Visual Evaluation of Anchor l 6.2.1.la This operation should be done one bolt at a time, unless it can be established that removal of more than one bolt will not cause hanger to move. If at any time during anchor evaluation the hanger assembly moves, so note under remarks. 1 c 63'T.17 Sharpie 3000 Felt Tip Marker as manufactured by Sanford, or approved equal.

1. 98 Exhibit E u

• *# N 'h If any or all bolts to be tested cannot be removed b::cause of interferences, so note under r: marks.

Torque each bolt per Table I. Remove bolt from each anchor to be inspected. Fill in Item 11.using "PRH" for Phillips Red Head Anchor. Check that the anc has not pulled out against plate. If the anchor, hor has pulled out against the plate, mark Item ~12 with an "X" and note in remarks. Check the nominal bolt diameter. If the diameter is different from that listed in Item 6, circle the diameter listed in Item 6 and record the actual bolt diameter next to the circled diameter (Check the base plate bolt hole diameter. The bolt hole diameter may be a maximum of one-eighth inch (1/8") larger than the installed bolt if an approved welded washer plate is not used. If the bolt hole diameter does not meet this criteria, note in remarks. J 6.2.1.lb Check location of top of anchor with respect to concrete surface. If the top of the anchor is approximately 1/16" to 3/8" below the surface of concrete, simply check Item 12. If the top' of the anchor is above or flush with the surface of the concrete, mark Item 12 with an "X". 6.2.1.1c After each bolt has been removed, visually' examine anchor to see if it has been modified (i.e. cut short a.t top), if it is loose in the hole, stripped threads are apparent, etc. If any obvious irreg-ularities exist, mark Item 13 with an "X" and report details in remarks. If no irregularities exist, simply check Item 13. Note: If a star anchor has been used (as evident by the silver plug) it must be removed in accordance with Section 8.3. 6.2.1.1d Check the angle of the anchor with respect to the face of the plate by threading an 8" long (minimum) threaded steel rod of proper diameter into insert and measuring the smallest acute angle between the rod and the surface of the plate. If this angle is greater than 85* simply check Item 14 on the checklist. If this angle is between 80* and 85*, a beveled washer must be used when reinstalling the bolt and Item 14 shall be marked with a "W". If this angle is less than 80*, mark Item 14 with an "X". 6.2.1.le Check bolt removed for length and thread damage. Bolt must be long enough for a four (4) full thread engagement. If threads are damaged or bolt is short, replace with a new bolt. Page 8 Exhibit E a

b.z.1.it Examine sn3 1 interior to sen it epoxy is present " *" d ' * -' S -i $< over top of th2 plug. If it is, it must bm ground off or oth:rwise removed (so the metallic top of set plug is visible) to enable the relative dimension to be taken. s 6.2.1.1g Check relative dimension from top of set plug to snap off line of anchor with test gauge-(see Attachment II). Insert test gauge into anchor and obtain a four (4) full thread engagement. Insert a machinist's rule or other suitable measuring device into the central hole of the test gauge until it hits the top of the plug. Take the measurement to.the top of the test gauge and record it under Item 15b on the checklist. Compare the actual relative dimension (15b) to the maximum acceptable relative dimension (15a). If the actual relative dimension exceeds the maximum acceptable, circle the actual dimension. 6.2.1.2 TORQUING OF ANCHOR After visual evaluation is complete, replace bolt in anchor and apply torque per Table I. ~ TABLE I Torque Requirements for Phillips Red Heads Nominal Diameter Torque 1/2" 30-35 ft-lbs. 5/8" 55-60 ft-lbs. 3/4" 75-80 ft-lbs. 7/8" 95-100 ft-lbs. If these torques cannot be obtained within one turn after bolt is seated on the plate, mark Item 17 with an "X". If the torque is reached, simply l check Item 17. 6.2.2 EVALUATION OF HILTI KWIK BOLTS 6.2.2.1 Visual Evaluation of Anchor 6.2.2.la This operatian should be done one stud at a time unless it can be established that removal of more than one nut will not cause the hanger to move. If at any time during anchor evaluation the hanger I assembly moves, so note under remarks. If any studs cannot be inspected because of inter-ferences, so note under remarks. 6.2.2.lb Fill in Item 11 using "HKB" for Hilti Kwik Bolt. Check nominal anchor bolt diameter. If the diameter l is different from that listed in Item 6, circle the diameter listed in Item 6 and record the actual bolt diameter next to the circled diameter. b 63740 Page 9 Exhibit E (

Check In oase piate ooi c noie uionecer. ine voit 3 j' ~ hole diameter may be a maximum of one-eighth (1/8") 1-larger than the installed bolt if an approved welded washer plate is not used. If the bolt hole diameter does not meet this criteria, note in remarks. 9 6.2.2.lc Visually examine anchor stud to see if it has been modified, if it is loose in the hole, stripped threads are apparent, etc. Check stud length to insure i it penetrates base plate far enough for one full nut engagement and that nut is not. bottomed on threads (i.e. unthreaded section of stud must not be above surface of plate.) If these irregularities exist, mark 13 with an "X". If no obvious irregularities exist, simply check Item 13. 6.2.2.1d Check angle of anchor with respect to face of plate by threading a standard coupling onto the stud and measuring the smallest acute angle between the coupling and the surface of the plate. If this .i angle is greater than 85*, simply check Item 14 on the checklist. If this angle is between 808 and 850, a beveled washer must be installed between the plate and nut and Item 14 should be marked with a "W". If this angle is less than 80*, mark Item 14 with an "X". 6.2.2.2 ULTRASONIC EXAMINATION FOR LENGTH 6.2.2.2a Equipment The ultrasonic equipment used shall have a digital readout and a range from 0 to 12 inches. The Contractor shall submit manufacturer's literature and specifications (on the proposed equipment) to the Engineer for approval prior to performing ultrasonic testing. 6.2.2.2b nCalibration The U. T. equipment shall be calibrated to a standard-length Hilti Kwik Bolt specimen prior to inspection i of each hanger and more often if required. i 6.2.2.2c Procedure Each Hilti Kwik Bolt on the hanger shall be U.T.'d for length unless it has a standard length code stamped on the end. Prior to applying the trans-ducer to the end of the bolt, ascertain that the bolt end is relatively smooth and perpendicular to the axis of the bolt. If needed, touch up with a file. Subtract the exposed length from the total length to get the embedded length and record the actual embedment under Item 16 of the Checklist. Page 10 S m. Exhibit E PEO 2 J

6.2.2.3 MINIMUM ACCEPTABLE EMBEDMENT

• *" * / #

R2fer to Item 16 on the Evaluation Ch:cklist. Compare the actual depth of embedment to the minimum acceptable embedment (Table II). If the actual embedment is less than the minimum accepfable - embedment, then circle the actual embedment (Item 16). TABLE II Minimum Acceptable Embedment for Hilti Kwik Bolts Nominal Diameter Minimum Embedment 1/2" 2 1/2" 5/8" 3 1/2" 3/4" 4" In certain cases, the Engineer has determined that a Kwik Bolt should not be used for a particular-Anchor. An Asterisk will appear under Item 16a if use of a Kwik Bolt is not acceptable. If in-spection shows that a Kwik Bolt has been used, circle the appropriate part of Item 16a. 6.2.2.4 TORQUING After inspection is complete, apply a torque to the stud per Table III. TABLE III Torque Requirements for Hilti Kwik Bolts Nominal Diameter Torque 1/ 2 45-55 ft-lbs. 5/8" 80-90 ft-lbs. 3/4" 125-175 ft-lbs. If these torques cannot be obtained, try sto reset the anchor by redriving it into the hole. If the torque values still cannto be obtained, mark Item. 17 with an "X". If the torque value is reached, simply check Item 17. Note: Only try to redrive the anchor cnce. 6.3 LOAD TESTING 6.3.1 Procedure g The evaluation checklist when initially issued to the Contractor will indicate under Item 18 if a pull' test is required and the applicable load. The concrete anchor shall be pull tested to this value and the amount of slip at that loading shall be recorded. If it exceeds 1/16", Exhibit E Page 11

used on Phillips Red-Head Anchors if Item 15b is un-acceptable and torque requirements are met. If Pull Tcst is found to be acceptable and all other items on Evaluation Checklist are acceptable, then Item 19A of the Evaluation Status should be checked. The load shall be as indicated in Pull Test Procedure. 6.3.2 Equipment The Owner will supply the initial test device. Contractor may also provide this equipment but it must meet the Engineer's approval. The pull test device will basically consist of a hydraulic ram with holder and pump gauge for determining hydraulic pressure and dial gauge indicator for determining the amount of slip. 6.3.3 Calibration All gauges and hydraulic system r..ust be calibrated every six months, or when repairs are necessary, or there is any reason to doubt the accuracy of the gauges. 1 .,.. rt. ) [, 10 i O,4s Page 12 Exhibit E d

7.0 FINAL EVALUATION N NS IC 7.1 Acceptable If none of the items or dimensions in Item 15 (relative dimension) and Item 16 (HKB use and embedment depth) are circled, the hanger configuration conforms to the attached detail for the criteria specified in Section 6.1.1, and no X's appear under Items 12,13,14,17, or 18, the anchor is acceptable and Item 19a of the evaluation status should be. checked. If any of the dimensions in Item 15 are circled, acceptance of the anchor will be based on the results of a Pull Test. See section 6.3.1. 7.2 Not Acceptable If any of the dimensions in Items 15 and 16 are circled or any X's appear under Items 12, 13, 14, 17, or 18b or the bolt hole diameter does not meet the criteria specified in Section 6.2.1.la or 6.2.2.lb, then the hanger requires rework (unacceptable anchors must be replaced). 7.2.1 Generic Fix If possible, a G'eneric Fix should be used to reviork the hanger plate (see Item 4 on the Checklist and Attachment III for applicable Generic Fixes). The Generic Fixes are designed to be relatively simple modifications to the hanger plate that may be used during the ' evaluation and without having to obtain the Engineer's concurrence. If a Generic Fix is to be used, mark Item 19b on the Checklist and record the Generic Fix Number in the space provided. 7.2.2 Redesign I l If a Generic Fix is not to be used (none listed in Item 4 interferences, etc.), the support plate must be redesigned and Item 19c on the checklist marked. 'At some time after L the Evaluation Report is returned to the Engineer (with 19c marked), an as-built of the redesigned hanger shall be furnished to the Engineer. 7.3 FINAL EVALUATION PENDING i If the hanger configuration does not conform to the detail (per criteria outlined in Section 6.1.1), then a final evaluation cannot be made pending a review of the as-built drawing by the Engineer. In this case, Item 19d on the Checklist should be marked. l c 65753 i l l Page 13 Exhibit E

l Peu M.cs,- M 8.0 REWORK 8.1 Conformance to Procedures and Specifications All rework, whether replacement of an anchor, Generic Fix, or rework due to redesign shall be performed in accordance with the Contractor's approved procedures for field modification of j hangers. All specification requirements shall be met unless the Engineer specifically waives these requirements by an RFI. i l 8.2 insoection I Upon completion of rework, newly installed anchors shall be i inspected as follows: Replacement: If an anchor is replaced the new anchor shall be inspected to the latest approved revision of Work Procedure 65 & 85. Generic Fix: If a Generic Fix is applied to a hanger, only newly installed anchors shall be inspected. These new anchors shall be inspected to the latest approved revision i of Work Procedure 65& 85. Anchors previously inspected, and j found acceptable per this procedure, shall not be reinspected. 8.3 Replacement of Anchors 8.3.1 Red Head Self-Drilling Anchors A Red Head anchor or star anchor may be removed by use of a pulling device which holds the plug in place and pulls the shell out. The hole must then be reamed out to the next larger size before it can be replaced with a Hilti Drop In or Hilti Super Kwik Bolt. 8.3.2 Hilti Kwik Bolts A Hilti Kwik Bolt may be removed by chucking the end of the stud in an electric drill and spinning it until the wedges wear sufficiently on the stud to allow it to be easily removed. The hole must then be reamed out to the next larger size before it can be replaced with a Hilti Drop In or Hilti Super Kwik Bolt. c 63754 Page 14 Exhibit E 2

1) Hanger flumber Rev.

8) Anchor Configuration

2) Building / Elevation

3) Hanger Plate ilumber

4) Applicable Generic Fixes

5) Anchor tiumber 6)AnchorSize (diameter)

7) Center to Center Spacing 9). Hanger Configuration Does/Does NOT conform to Hanner Detail

~ 10) Spacing from ~ Embedded Item

11) Type of Anchor

12) Depth Below Concrete

13) Anchor tiodified

14) Angular tiisalignment 15)' Relative Dimension (PRH) a) flaximum Accep. table b) Actual

16) Embedment Depth (HKB) a) HKB use acceptable

17) Torque Applied 18)' Pull Test Required / Load l

a) Amount of Slip b) Reject

19) EvaTuation Status

~ a) O Anchor Installation Acceptable b) O Anchor Installation NOT Acceptable - Generic Fix # c).O Anchor Installation fl0T Acceptable - Redesign d) O Final Evaluation Pending

20) Remarks Engineer -

Date Quality Control C bbIbb Date Page 15 Attachment I Exhibit E 1 g

Headquarters Of f ace-Oradell, NJ. . W.'O. N r. NOO Data /2 / / /'76 Book No. Page N o. Draw ng o. Calc. N 2. Sheet I Cont. en Sheet ~ YYeN Checked Approved .. =. By Q5 Titled WPPSS - MSM4'2D ^1 o. '2 'T*s s ;~ 6v A u s t 52 2EL.frTIVE f!MEM StoM ~ 'e 1 TEST GAUGE FOR DRILLED-IN CONCRETE ANCHORS _ _ _ _.. M a c ain e d.. S o m c s a n _ __ A___ O ___~ i ... q._ p._ 1 I = _. 1 1 . _.__ g _.. p _ ___ _.. l _. l. _ __ ..g._.___.___ ._ q.. _ ' l I l l _._.J _. l __ _ _ _ M Ac w Eb _ G o u,-- .Q I I. l. .._._ % Au4 'biamareg,., a. _. i...._ .fseE_I4st.E. "aEww). ______ _ ....I l. _. ~ I I ... _. g.,.. __. 4 _Fou _.Ou mooim es.....__ _l l .Twens .. g ! 3 I L-r- -3 . _,y . _~_..___....__-.----. r s l- - o. 2 s " H o t. E. -BOLT SIZE THREADS /IN-MACHINED-BOLT .. _. SHANK DIA. . _ _... _. 1/2" - ~~---- ~ - - - - --------13---- --0.438"- 0.500" 5/8" 11 3/4" 10 0.625" 7/8" 9 0.750" = W 54.19 or 2e ' ' ' ~ - ~~~ Page 16 PEb 216 i Form BR 8002 2 (5/78) Exhibit E .J

W.O. No. D00O Date //

• 27' 78 Book No. 5H Pag 2 No.

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M Pag; No. W.O. No. 3808 Date E /~2. 4 /7 A Book No. Drawing No MA Calc 5$o. h4 E. D7-Nh-

• 8

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2. CHEcx THAT ExtsT. INSi>z73 Oo Nor Secon=

OVE,qi 0,90ED c 63761 Page 21 Exhibit E 1%c \\

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{ l,! l~ I T f*[2 O i l o 4 Burns l l i 3 PREPARED 215 Coordinate Final Evaluation ! l %9 m 1 8 and j 2 Contract t i. EvalDation o Roe j { Evaluation PKGS. Engineering Evaluation Team Engineering y E i i. 1' i i i l t I l l f No !I Rework i Req'd? j I i i / i o o a. } -l 7 i l i Yes g t i i l I i l i i i a i I i [ Q i U j i F fu I j i i i ? Contrac't i I Contract l I I { IE I yes i i 21 5 i i2 i 215 i general: i l 3 Q.C. 2 QC @c! ro ' fiX7 ' l I i Inspection i I I i Inspection i 4 i g 3 t i e 4 i I I I 2 No ! g' [ fi !.l' l-

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5. 055UED gy Waddnyton Public Power Sopply Systern 3000 Ceorpo Washington r/sy WNP-2 Project Management Group P.o. so 9ca Richiand. Yta shington 99352

8. 61EFE RENCE DOCUMENTS

7. CONT R ACTOR N ara E AND ADD RESS 15"ai. '"r-WSH/Boecon/GERI a a i r. * ' -

A Joint Venture and ZIP Code) P. O. Box 1040 Richland, Washinpton 99352 3 A. CONTH ACT PRICE AOJuSTMENT T HIS CH Ar*GE ONLY 58 CON T R ACT %CHCDULE ADJUSTfAENT THis CH ANGE ONLY . If.C ft[ ASE ADD DECREASE I - O t' L E T E DAYS. CODE (a) This unilateral Contract Ptodification le issued pursuant to The muClfications set forth in bloctr 18 ase anade to the s',ove asumbered contract. (D) The above numbered contract is modifies to reflect the administrative chariges set f orth eri t,tock it. (c) h This citateral Contsact Modification (Supplemental Agreenientils enteret'lato oursuant to autharaty at _$pffiAn Ik OrtiflO "I_O IhAgggg_in thg,_hQph modiflet the above numbered contract at set forth In bloca II. ~ 3s. DESCRIPfluN OF MODIFIC ATIOr4 1. The Contractor is to provide the following work in accordance with the terms and conditions of the Contract: Incorporate the attached " Drilled-in Concrete Anchor Inspection Procedure" into the the procedures required under Contract 215 Specification 15Q, Article 3.21.2. FOR EMATION 0:\\LY E,: e pt s. v.

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Exhibit E m., R, wo r t,

i ~ DRILLED - IN CONCRETE ANCHOR INSPECTION PROCEDURE WPPSS NUCLEAR PROJECT NUMBEP. 2 RICHLAND WASHINGTON i R." VISION 0 I l-Prepared By W1-. A %J 4ltd9s Submitted By kr 'M' 4. 2/1V 4[u.3 Resident Project Engineer af Quality Assurance Manager O h. b //7F l I Exhibit E t.

1 DRILLED - IN CONCRETE ANCHOR INSPECTION PROCEDURE \\ 2< TABLE OF CONTENTS 1.0

PURPOSE

........................................... Page 1 2.0 SCOPE ............................................. Page 1 3.0 DEFINITIONS AND ABBREVIATIONS....................... Page 2 4.0 RESPONSIBILITIES FOR INSPECTION..................... Page 3 5.0 INSPECTION REP 0RTS.................................. Page 5 6.0 INSPECTION.......................................... Page 6 7.0 FINAL EVALUATION.................................... Page 13 8.0 REW0RK...............................................Page 14 { ATTACHMENT I - ANCHOR INSPECTION CHECKLIST.................Page 15 ATTACHMENT I I - TEST GAUGE................................. Page 16 1 ATTACHME"T I I I - GE"ERI C FI XES............................. Pa ge 17 D ATTACHMENT IV - FLOW CHART..-............................... Page 23 i i i t I i i p^ Exhibit E

1.0 _ PURPOSE C The purpose of'the inspection is to check the adequacy of Installation of Drilled-In Concrete Anchors used in conjunction with pipe supports. A preliminary inspection of pipe supports indicates a significant percentage of Drilled-In Anchors were not installed properly (improper epoxy used, anchor not fully expanded, etc.). The purpose of this procedure is to provide spc;ific instructions for inspection, acceptance, and any rework required of Drilled-In Concrete Anchors installed on pipe supports prior to February 1, 1978. 4 2.0 SCOPE All Drilled-In Concrete Anchors on pipe supports with concrete anchor design loads exceeding 50% of allowables shall be inspected. The inspection governed by thic document shall be limited to a check for adequate concrete anchor nstallation and will not include a general inspection of the pipe support. f l d i i l I IThe Engineer shall determine which pipe supports meet this criteria. \\s_,1 Page 1 I l m Exhibit E L-

h 3.0 DEFINITIONS AND ABBREVIATIONS The Engineer - Burns and Roe Engineering. \\' ' l Quality Control 'The Contractor's Quality Control Department. L Q, uality Assurance - Burns and Roe Quality Assurance. PRH - Phillips Red Head Self-Drilling (Snap-Off) Anchor. HKB - Hilti Kwik Bolt Relative Dimension - For Phillips Red Heads - Dimension from top of set plug to top of test gauge. Note that the relative dimension described here is different from that specified for new installations. Depth of Embedment - for Hilti Kwik Bolt - Indicates the length of anchor below concrete. V I J. r L l l V Page 2 Exhibit E

4.0 ~ RESPONSIBILITIES F0R INSPECTION (S a Attachm:nt IV) 4.1 INSPECTION TEAM y The Inspection Team shall be made up of the following personnel; one' representative of the Contractor's Engineering Department, one representative of the Contractor's Quality Control Department, and any Craftsmen necessary to provide labor. Representatives of the Engineer and the Burns and Roe Quality Assurance. Department will be present on a part-time basis to monitor the inspection. 4.1.1 CONTRACTOR'S ENGINEERING REPRESENTATIVE The Contractor's Engineering Representative shall direct the overall inspection of the pipe support in accordance with this Inspection Procedure. Hs shall. monitor 'ths inspection of the pipe suppoht'and ensure the Inspection Checklist is properly filled out. At the con-clusion of the inspec. tion he shall sign and date the Inspection Report. r 4.1.2 CONTRACTORS QUALITY CONTR01. REPRESENTATIVE The Contractor's Quality Control Representative shall take all. recuired inspection measurements and fill out the Inspection Checklist. At the conclusion' of the inspection he shall sign and date the Inspection Repnrt. V 4.2 CONTRACTOR'S ENGINEERING DEPARTMENT The Contractor's Engineering Department shall be responsible for coordinating the overall inspection effort to ensure that it is carried out in an orderly and timely fashion. As Inspec-tion Reports prepared by the Engineer are received, the Contract-or's Engineering Department shall assign the pipe support to an inspection team, ensure that the pipe support is ready for inspection (scaffolding for access in place, etc.), and ensure that the necessary craftsmen to provide labor for the actual inspection are available. After inspection is-complete, the Contractor's Engineering Department shall review the Inspection Report for correctness. The Contractor's Engineering Department shall be responsible for providing As-Built drawings and initiating RFI's as required by this procedure prior to return-i t ing Inspection Reports to the Engineer. All Inspection Reports completed in a given week shall be returned via letter to the Engineer by noon Tuesday of the follon-ing week, 4.3 THE ENGINEER v The Engineer shall be responsible for determini.ng by calcu-lation which pi.pe supports require inspection for pipe supports s requiring inspecti.on th.e Engineer shall prepare Iytspecti,on R,epor Page 3 Exhibit E i

(see section 5.0, Inspection Reports, for details) and transmit them to the Contractor by letter on a system by system basis. \\' .The Engineer shall be responsible for providing the Contract-or with Generic Fixes (see section 7.2.1 and Attachment III for details) to be used when anchor installation is found to be inadequate and rework is required. If a generic fix is not applicable (see section 7.2.2), the Engineer shall perform any necessary redesign. 4.4 QUALIFICATION OF INSPECTION TEAM All personnel (excluding crafts) responsible for any part } of this inspection shall attend training sessions conducted by the Engineer to assure each member of the Inspection Team is fully cognizant of his duties and responsibilities. Only Inspection Team personnel whose names appear on a list approved by the Engineer shall be allowed to perform inspection work. I i I i l f-l l ( l l 9 V Page 4 ( l Exhibit E

~ 5.0 INSPECTIO!1 REPORTS Each inspection report will consist of a copy of the pipe support detail and an Inspection Checklist (see Attachment I) for the Drilled-In Concrete Anchors in each plate. Items 1 through 8 on the checklist will have been-filled out by the Engineer. These include the hanger number, building and elevation, hanger plate number, applicable generic fix numbers, anchor numbers, size of anchor, center to center spacing for the anchors and a sketch df the anchor configu-ration on the plate. The anchors will be numbered consecutively, starting in the upper left hand corner and numbered clockwise around the plate. For plates on the ceiling or floor, North will be considered as up. i 4 t L. l \\s_- l x. l l i L t l r i C Page 5 j Exhibit E

6.0 INSPECTION b 6.1 GENERAL. HANGER INSPECTION ~ i 6.1.1 Compare hanger configuration to detail attached to Inspect-ion Report. Check critical dimensions cdrdled on hanger detail. If the actual dimensions fall outside the tolerance listed on the detail, then hanger configuration does not conform to the detal. The tolerance for center to center spacing of Drilled-In Anchors shall be !1/2" for all hangers. Circle the appropriate part of Item 9 on the Checklist. If the hanger configuration does not conform to the deicil, then refer to Section 6.1.2. If the Hanger configuration does conform to the detail, then proceed to Section 6.1.3. 6.1.2 If the hanger configuration does not conform to the hanger detail per the criteria specified above, calculations performed by the Engineer are no longer valid and a final evaluation of Drilled-In Anchor installation cannot be made (see Section 7.3). ,1nspection of the pipe support may continue following the criteria in the procedure with the following exceptions: g,, In Section 6.2.1.19, the relative dimension shall be measured and recorded but not compared to the maximum acceptable relative dimension listed under Item 15a. The comparison in Section 6.2.2.3 shall not be performed. At the conclusion of the inspection, item 19d on the check-list shall be marked, and an as-built drawing of the pipe support attached to the Inspection Report before it is-returned to the Engineer. Note, that no rework is to be performed on the pipe support until final evaluation of the Inspection Report and as-built drawing by the Engineer. I 6.1.3 Check anchor spacing from nearby embedded items to ensure that the following criteria for minimum allowable distance for a Drilled-In Anchor from an embedded item are met: Embedded Plates: 3"+ of the center to center bolt spacing. This spacing is to be from the edge of the embedded plate to the center of the Drilled-In Anchor. Ik" Richmond Inserts: 6"+ of the center to center bolt spacing. This spacing is to be from the center of the Richmond insert to the center of L the Drilled-In Anchor. i Page 6 Exhibit E 7

Embedded Unistrut; 31".+ h of the center to center 3 bolt spacing. This :; pacing is to be from the center of the embedded'unistrut to,the center of the Drilled,In. Anchor. e s s_, x 5 NOTE: Bolt spacing referred to is the spacing listed under Item 7 on the hhecklist. s 4 g 'N If the criteria' art violated, note this on Item 10 with an "S". If another' hanger isattached to the embedded item,+ note the type of hangeE hipe,- cible tray, duct, etc.) and' hanger number if-possible and mark up Item 8 show-ing the location of ths embedded item relative to the anchors. If the embedded item is a unistrut or. strip ~, ~ plate, only report hange.rs' attached within 12 inches of-the anchor'being inspected. q - ~_ ~ If the criteria'are not violated, sirdp(ly check Item 10. n y p 6.2l INSPECTION OF DRIlll0-IN C0NCRETE ANC_ HOR $';\\y,( 1% s g Usinganaccept5bletypesqffmarke' ser'the' bolts on the plate exactly as they~are numbered.. ch;e' checklist, i.e. starting with No.,1 in the, upper left-hland ~corne'r and number - clockwise. around the plate (for' plates l in geiling' or floor, use nortn as "up"). .V A r - n 6.2.1 INSPECTION OF PHILLIPS RED HEAD' ANCHORS H g ~ s... 6.2.1.1 Visual Inspection of Anchor ~ 6.2.1.la This, operation should be' done' one bolt at a time, unless it can be established that removal of more ,~ thanoneboltwillnotcauseQangertomove. If s. [s at any time during anchor inspection the hanger assembly moves, so note under remarks. K If any or'all bolts to be l tested cannot be removed because of inteffeEences, so note under remarks._ Remove bolt'fhom each anchor to be inspected. Fill in Item 11 using "PRH" for Phi-1 lips Red Head Anchors Check the nominal bolt diameter. If the diameter 7~~ is different: from that' listedt in Item 6, circle the dicmeter listed in Item 16 and record the actual bolt diameter next.ito the circled t diameter. '" t 7, s.s x. 1, 1 Sharpie 3000 Felt Tip91arker as manufactured by Sanford, ~ t ~ 71.or,approvedequal. 1.' w% Page'7 ExLibit E m g

6.2.1.lb Check location of top of anchor with respect to concrete surface. If the top of the anc. hor is flush or below surface of concrete, simply check Item 12. If the top of the anchor is 9 above the surface of the concrete, mark Item 12 with an "X". 6.2.1.lc After each bolt has been removed, visually exa[nine anchor to see if it has been modified (i.e. cut short at top), if it is loose in the hole, stripped threads are apparent, etc. If any obvious irreg-ularities exist, mark Item 13 with an "X" and report details in remarks. If no irreg-ularities exist, simply check Item 13. 6,2.1.1d Check the angle of the anchor with respect to the face of the plate by threading an 8" long. (minimum) threaded steel rod of proper diameter into insert and measuring the small6st acute angle between the rod and the surface of the plate. If this. angle is greater than 850, simply check Item 14 on the checklist. If this angle 0 is between 80 and 85, a L'eveled washer must be used when reinstalling the bolt and Item 14 shall be marked with a "W". If this angle is 0 less than R0, verk Item li with an "X". V 6.2.1.le Check bolt removed for length and thread damage. Bolt must be long enough.for a four (4) full thread engagement. If threads are damaged or bolt is short, replace with a new bolt. o

6. 2. i. l f Examine shell interior to see if epoxy is present over top of the plug.

If it is, it must be ground off or otherwise removed (so the metallic top of set plug is visible) to enable the relative dimension to be taken. 6.2.1.19 Check relative dimension from top of set plug to snap off line of anchor with test gauge (see Attachment II). Insert test gauge into anchor and obtain a four (4) full thread engagement. Insert a machinist's rule or other suitable measuring device into*. % e central hole of the test gauge until it hits the top of the plug. Take the measurement to the top of the test gauge and record it under Item 15b on the checklist. Compare the actual relative dimension (15b) to the maximum acceptable relative dimension (15a). If the actual rel-ative dimension excceds the maximum acceptable, V circle the actual dimension. Page 8 Exhibit E i

6.2.1.2 TORQUING OF' ANCHOR ~ After visual inspection is complete, ( replace bolt in anchor and apply torque per Table I. TABLE I Torque Requirements for Phillips Red Heads i Nominal Diameter Torque 1/2" 30-35 ft-lbs 5/8" 55-60 ft-lbs 3/4" 75-80 ft-lbs 7/8" 95-100 ft-lbs If. these torques cannot be obtained within one turn after bolt is seated on the plate, mark Item 17 with an "X". If the torque is reached, simply check Item 17. 6.2.2 INSPECTION OF HILTI KWIK BOLTS 6.2.2.1 Visual Inspection of Anchor 6.2.2.la This operation should be done one sted at a time unless it can be established that re- \\/ moval of more than one nut will not cause the hanger to move. If at any time during anchor inspection the hanger assembly moves, so note under remarks. If any studs cannot be inspected because of interferences, so note under remarks. 6.2.2.lb Fill in Item 11 using "HKB" for Hilti Kwik Bolt. Check nominal anchor bolt diameter. If the diameter is different from that listed in Item 6, circle the diameter listed in Item 6 and record the actual bolt diameter next j to the circled diameter. 6.2.2.lc Visually examine anchor stud to see if it has been modified, if it is loose in the hole, stripped threads are apparent, etc. Check stud length to insure it penetrates base plate far enough for one full nut engagement and that nut is not bottomed out on threads (i.e. unthreaded section of stud must not be above surface of plate.) If these irregularities exist, mark 13 with an "X". If no obvious \\s_s irregularities exist, simply check Item 13. 6.2.2.1d Check angle of anchor with respect to face of plate by threading a standard ' coupling onto the stud and measuring the smallest acut Exhibit E Page 9 j

angle between the coupling and the surface of-the plate. If this angle is greater than 850, simply check Item 14 on the checklist. If this-angle is between 800 and 850, a beveled y washer must be installed between the. plate and nut and Item 14'should bemar.ked with a "W". -If this angle is less than 80, 0 mark Item 14 with an "X". 6.2.2.2 ULTRASONIC EXAMINATION FOR LENGTH 6.2.2.2a Equipment The ultrasonic equipment used shall have a digital readout and a range from 0 to 12 inches. The Contractor shall submit manufactur-er's literature and specifications (on the pro-posed equipment) to the Engineer for approval prior to performing ultrasonic testing. 6.2.2.2b Calibration The U.T.' equipment shall be calibrated to a standard length Hilti Kwik Bolt specimen prior to inspection of each hanger and more often if required. 6.2.2.2c Procedure ,v Each Hilti Kwik Bolt on the hanger shall be i U.T.'d for length unless it has a standard length code stamped on the end. Prior to applying the transducer to the end of the bolt, ascertain that the belt end is relatively i smooth and perpendicular to the axis of the. i bolt. If needed, touch up with a file. Sub-tract the exposed length from the total len~gth to get the embedded length and record the actual embedment.under Item 16 of the Check-list. 6.2.2.3 MINIM' M ACCEPTABLE EMBEDMENT J Refer to Item 16 on the Inspection Checklist. i l Compare the actual depth _of embedment to the miriimum acceptable embedment (Table II). If the actual embedment is less'than the minimum accept-able embedment, then circle the actual embedment (Item 16M. I Page 10 Exhibit E

TABLE II Minimum Acceptable Embedment for Hilti Kwik Bolts y tiominal Diameter . Minimum Embedment 1/2" 3" 5/8" 3-h" i 3/4" 4" In certain cases, the Engineer has determined that a Kwik Bolt should not be used for a particular Anchor. An Asterisk will appear under Item 16a if use of a Kwik Bolt is not acceptable. If inspection shows that a Kwik Bolt has been used, circle the appropriate part of Item 16a. 6.2.2.4 TOROUItiG After inspection is complete, apply a torque to the stud per Table III. TABLE III . y . Torque Requirements for Hilti Kwik Bolts flomirial Diameter Torque 1/2" 45-55 ft-lbs 5/8"- 80-90 ft-lbs 3/4" 125-175 ft-lbs If these torques cannot be obtained, try to reset tne anchor by redriving it into the hole. If the torque values still cannot be obtained, mark Item 17 with an "X". If the torque value is reached, simply check Item 17. I fiOTE: Only try to redrive the anchor once. 6.3 LOAD TESTItiG 6.3.1 Procedure The inspection checklist when initially issued to the Contractor will indicate under Item 18 if a pull test is required and the applicable load. The concrete Anchor C shall be pull tested to this value and the amount of slip at that loading shall be recorded. If it exceeds 1/16", mark Item 18 " reject" with an "X". tio anchor be pull tested unless it has been otherwise found Exhibit E Page 11

acceptable. 6.3.2 Equipment The Owner will supply the initial test device. Contract-or may'also provide this equipment but it must meet the Engineer's approval. The pull test device will basically consist of a hydraulic ram with holder and pump gauge for determining hydraulic pressure and dial gauge indicator for determining the amount of slip. 6.3.3 Calibration All gauges and hydraulic system must be calibrated every six months, or when repairs are necessary, or there is any reason to doubt the accuracy of the gauges. J V i ( l 1 i ,V Page 12 Exhibit E )

7.0 FINAL EVALUATION 7.1 Acceptable V If none of the items or dimensions in Item 15 (relative dimension) and Item 16 (HKB use and embedment depth) are circled, the hanger configuration conforms to the attached detail for the criteria specified in Section 6.1.1, and no X's appear under Items 12,13,14,17, or 18, the anchor is acceptable and Item 19a of the inspection status should be checked. 7.2 Not Acceptable If any of the dimensions in Items 15 and 16 are circled or if any X's appear under Items 12, 13, 14, 17, or 18, then the hanger requires rework (unacceptable anchors must be replaced). i i 7.2.1 Generic Fix If possible, a Generic Fix should be used to rework'the hanger plate (see Item 4 on the Checklist and Attachment I~I for applicable Generic Fixes). The Generic Fixes are designed to be relatively simple modifications to the hanger plate that may be used during the inspection and without having to obtain the Engineer's concurrence. If. a Generic Fix is used, mark Item 19b on the Checklist and record the Generic Fix Number used in the space y provided. i 7.2.2 Redesian If a Generic Fix is not used (none listed in Item 4, interferences etc.), the support plate must be redesigned and Item 19c on the checklist marked. At the same time the Inspection Report is returned to the Engineer (with 19c marked), an RFI shall be initiated by the Contractor reauesting a redesign for the hanger plate in question. In order to coordinate the redesign, the RFI number shall i appear on the Inspection Report and the Inspection Report number on the RFI. a The Engineer shall perform the redesign and return it to j the Contractor via the RFI. The Contractor shall then re-j work the hanger as required to conform to the redesign. 7.3 FINAL EVALUATION PENDING 11 the hanger configuration -does not conform to the detail (per criteria outlined in SEction 6.1.1), then a final evaluation cannot be made pending a review of the as-built drawing by the { Engineer. In this case, Item 19d on'the Checklist should be marked i y Page 13 Exhibit E 1

8.0 REWORK \\L - 8.1 Conformance to Procedures and Specifications All rework, whether replacement 'of an anchor, Generic Fix, or rework due to redesign shall be performed in accordance with the Contractor's approved procedures for field modification of hangers. All specification requirements shall be met unless - the Engineer specifically waives these requirements by an RFI. 8.2 Reinspection Upon completion of rework, newly installed anchors shall be inspected as-follows: Replacement: If an anchor is replaced the new anchor shall be inspected to the latest approved revision of Work Procedure 65. Generic Fix: If a Generic Fix is applied to a hanger, only newly installed anchors shall be inspected. These new anchors shall be inspected to the latest approved revision of Work Procedure 65. Anchors previously inspected, and found accep, table per this procedure, shall not be reinspected. B ' Redesign: A new inspection report will accompany pipe support s,_- redesigns when they are returned to the Contractor via RFI. All anchors on pipe supports that are redesigned shall be inspected as per this procedure. l i ( l I I l l ! V l Page 14 i Exhibit E

1) Hanger Humber Rev.

8) Anchor Configuration

2) Building / Elevation

3) Hanger Plate f! umber y

4) Applicable Generic Fixes'

5) Anchor Number

6) Anchor Size (diameter)

7) Center to Center Spacinq

9) Hanger Configuration Does/Does t'OT conform to Hanqer Detail

10) Spacing from Embedded Item

11) Type of Anchor

12) Depth Below Concrete

13) Anchor fiodified

14) Anoular tiisalignment

15) Relative Dimension (PRH) a) flaximum Acceptable g,.

b) Actual

16) Embedment Depth (HKB) a) HKB use acceptable

17) Torque Applied

18) Pull Test Required / Load a) Amount of Slip b) Reject

19) Final Evaluation

~~ ~~ a) Anchor Installation Acceptable b) [:] Anchor Installation fl0T Acceptable - Generic Fix # c) [:) Anchor Installation !!0T Acceptable - Redesign - RFI f d) [:] Final Evaluation Pending

20) Remarks Enaineer Date Quality Control Date ATTACHf1EtiT Exhibit E Pace 15

~ ....,...w. New brwy + New Yerk

• Connecticut
• Cali ornia f

W.O. No. 3 6G8 -lb Date - A Ptit 17 - l3')B _ Bo k No. Page No. Drawing Ns. Cafe. No. Sheet I of I By W M-A^t 60 -_ Checked Approved' Tith UPPW Wun Paarter

• 2 h GAuu Fort Etuv.;I B. -M w j

U KSi' GAUGE FOR DRILLED - IN CONCRETE AMCHORS I. J( l i I i 1 i g l1 mR l - I y w m w s s s s w l I m a co m = = = = w i R I I + + + + m i l 3 1 3 I II I l l ~ I I ,V I,{ l l I I ~ i l i x m l M Y ] s I w w a ( 4, 1 e -o ~. u w r l D } 2 s s n ( 4 I y N il , g .O U. -o-r Em b Page 16 Exhibit E f Form BR 8002-2 -J

""* *

• D t$UMNb ANU HOE, INC.

New Jersey

• New York
• Connecticut
• California i

W.O. No. 9Boe Date .3/ L7 h s _ soou no.J R - page no. Drawing No._ A/A Caf e. No. 6.'2, f, o 2 dT JSeet / o' By f&dN Checked _ W 3l50l?S Approved _ 'Ud b %7Y

Tits, VJPPS.S - HAufoAp ^/a. u '-

PIPE SvPNkrs v V GENEK/c f/K FoR SUPPORT $ W.//h:tPROPERLY /NJTALLED OR ll L. ED - IN /M.5ER Y, F/XNO./ f$ ADDiTiowAL INJSAI(ITR) A l, 3" I l__ 3"_ ^ Mc.5x9 l l-3 '2."x 3" nu.12 (77P) 4<' \\ \\ I 1 l l i l 8 Y Q' S (, 1 Q d Botp>fMc5 I i l ~S Exis7/gc ./. e swPogr it s W w. SV' e, 0-i { E)v.sTiHG IN.TERU(7)'JT) l f ADDI TIONAL INSER T MC3 ? (TYP 14 J rrm h \\\\ % W #t#. #1 g ,[ EIL L k S/rME THICKNESS AS Suff0R7~ k '^ 7"Y/? P & A. M osriou.e / N J L K 7" (q. A f~0g No72~C SEE SH7~, 2 Page p

BURNS AND ROE, INC. 3""' '*D New Jes*y W.O. N2. 380A 3 /2 7 h. Nsw Yctk

• Conn:cticut
• Caldoen.s Dat:

8 Book No. J U

• P:ge No.

Drawing No. A/A Cele. No.. b. ~l. C D 2 &N Sheet 2 of By h.d M, Checked IF 3I30 /7A Approved ND 5'iY Title WPPSS $ NAWORO Wo.'z. ~ Pirs 6 sA n r 4 GENERIC. Fix foR suffoA7-4 w/istPkop.cety in.crAt.t to OR/ t L.F.J)- /H /N:ER T No i E s * /. USE A.s SHOWW fc/Q REPt. Ac.Str1ENT OF 2. BoGT1 oM A stoE.

2. UCE foR ANY S/pa of ANy.S/sE k PAoyi.OEO Alo & fore TArgW 2 BOLTS NEED To 82 REPLAcEb ON THAT..S/OE. PAoV/DE hot..C /N MC 3x9 foe.

80! 7/NG IO /NSERTS NOT BEING R9*LAcso ort PLATES NAVING MoRE THAiv' d BOLT.s.

3. (hE SAME St&E ADD!DoHAL IN:ERT.: A.s Ext: 7 I G IN sER TS.

l

4. MA y SE usED foR REPL AC/NG-alt 4

B oL7.c on A 4 B ot.r g i Page 10 Exhibit E J

BURNS AND ROE,INC. SHEET. 3 0F 6 New Jerstyf Nrvw York + Connecticut

• Cahfornia W.O. Ns.

3 OOfS Date __3/ 'L7/78 sook no. SE-e.g. no. _ ~ Orawing!#4 M" Calc. No. 3_i_2.fJ_1 /D eet ___d. of No. NA By Checked @ 3/Dl7S Approved N bM7 Titte WEAbb "NAhlf0AO NO - 2 ~ f/PE SuPPb A7s G GENf.R/C S/K fpA.5uPPoR7 /$ w/imPRoP5Rt.y /NT74l!_ED ORIL.LsD ~ /d /h!3EM. F/ X NO. 2

h. ADDITIONAL INSER7" A

14 { EX/$T./MSEKTS V S" PIC h99 e ; 4 I / Y l l N C' G O $ bot.n, 4 Mc 3 I i l i l] \\ 3 '2 k 3 N'L h N n e 5 y v %SuPP CRT~ k A w n v AloTE.5 : /. USE ZAME SI5-E AcosrioNM. iA/.trar AC Exis7./xs&f

2. CHEcx THAT Exist. /NSEATI DO NOT SECoME O VERI.oADED 1

-3, IF 2xisr. INSERTS 8EcoME o Vf_Rt. 0A OSD USE FIX ^/o. / N. Page 19 Exhibit E

BURNS AND ROE,INC. Nea hesty. Ne.v York

• Connuticut
• Cehfornia W.O. No.

3808 Dat?._1I2. A /7 A Book fJo. kII Page No. Drawing No. MA Caf e. fJo. _._ (o_,_"2. C. 0 2- / Sheet d o f.___ >s By M 4l-Checked l.8 3[M/76 Approved /tM) 5 Yk Tive WPPSS ~ H A&AD ^/O, ?. - $Pa SoPA-Ac73 GE//ERIC flX EdR SUPPORT $ W//M oPEJ21 y /^/STA/ LED DR/Lt ED-IN INSSRTS F/X /v'O. 3 REMOVE EXts7; 8x7 (7y/?) Q SuPPOAT Fb 3" = (T'/?)jfje 3" W l (TYR) a ( ~ m I ch S 0l .I C

4. Accirionst /x: Ris

--1" ~ D k I A,. kk l s WN6 d W'} 6V (TYP.) -i- 't l SvPPoa7 & 3 j."v d37,pp 4 - / I$e \\ i s-s w r. E < 4 T to\\ c xtST w ~ M SuPPoR7/b -. -Q ---..-- - Q f Esis7/NG insais(7yP) l bloTES : I. t, = SuPFox T $ TH/CKNESS = WNG 8. 7H/cKMESS

2. USE As SNo wn' Fo/L REPL ACEMENT OF 2 SotrJ ON /NY SIDE, G

3. USE ioA FovA So:.T h's. DETAn. /M y SE v.cE D OH 150rg .stDEs of k To REPL6CE Au. fovA 60.;75 /f REQb 4 UsE SAM E S/ sa ADDIT /okAL INSERIS A S & pano on J

BURNS AND ROE, INC. m5&6 th 3!"w J1rsey

• Mew Ycrk
• Connecticut a Cahfornis W.O. No.

bbo 6 L7 /78 Book No. __S YT Page No. Dat: Drawing No. NA Cale. No. ____[p.1 C. O 7 OO 1 / Sheet J of By U 4 //- Title WPP S.S - HA>>f o RD blo /3cl2B-- _ Checked. LI-3 Aporoved 0-D W

• 2 ~ P i p s Sup pagzJ G E N E K !c f}x F o A SuPPoer,$ tv//nPRoPSely /N.57ALLED O*R/U ED~

/N MSSA T. F/X NO. 4 '2 ST/FAk f SvPPoa.T k IIW) A c o 1 7 1 o w A t. /MSE.RT (TYP. ) L $X.5 X glm / \\ (TYP) h O _f\\ f ADOITIorYAL /HJERTS a % q v/ N v v / / 1 l \\ k V T1P i,A y l // SV f~ Y llx 2. ST/ff /b (TYA) 2. g TYP / gff, v s_ +- ~ f SUPPORT k 4 ~ ~ '~ f SUPPcRT k. Exis T O-O ( 2X/S7"/NG /NSLRTS fI/A) f(ST/M.f'S No rEs : I. USS SAME Si 2 E A DDI T/ou A L IN.SE.R T A S & X/S TIN G JNSEA T

2. CHECK IMAT E XI.S T. INS 5KTS Do Nor SecomE OVEgt CADED L

Page 21 Exhibit E

BURNS AND ROE, INC. SHEET 6 0F 6 { New)rrsry. Naw York

• Connecticut
• California W.O. No.

3803 Dat: __31_1o / 7B Book No. 5 E-Page No. Drawing No. NA Calc. No. Io 101 7\\ - % I S eet __b_ of - By AM4M-- - - Checked b3.2.2Q./2A Accroved N bE

nn, WPPS S ~< 14 AA/F0/2.D ND.'2 ~ P/PE_

f.5v_QQog')~.T GEN ERI c. F1x fo R* SuPP o RT lb WllMPRo PEA L Y /N STA L LEJ3 DRit t so - tu insEp 7 3 4 Exist.SuPP.$ FIXNO.5 4 "'" 't i i gw. i e I l DW l R t v i Dn -: A { ADDITIONAi-- n 0 v v /NSERTS C Q p,) E \\ u H a i fi REMov'E Bour l O 0-f ExtCT GRtH 11 I /NSiRTS (a swOt\\ i ~'r- -7 45 ~6 8 /34Q d 11 i

• (r>P.!)

l ,.__ f. -ll._ y f-f EXIS T., ') ~ 't w Exis r. 6 _.'__ __j s,y iI(n* SuPP. 2 SuPPoAT ~2 --* \\ Qj - ii O f Ex/4 7, 1l l l /NSERTS / i /x /%"eaa s e ss

• / T,5d Fog t 7 3[

f NorE : 1. +.:. = TitickwaS3 of EXI. STING supPoer /$ $ Wmd /b

2. Rx MM BE u.SEO FoR 2 CENTER BoL TS ON G oR 8 Euot 7 /$.

3. CHEcl< THA T Ex/.T T. /NSER T.T Do N07~ BEcoME OvaA L o A.oE D.

Page 22 Exhibit E

i w 4J O -.o Burns & Roe Contract Engineering

Prepared, 215

_C.cordinat L Inspection Final Evaluation 'k a insp. Pkgs. 3 Engineering Inspection A Team _h Rework ~ Require .io Signed Inspection-Package., _ DRILLED-IN CONCRETE ANCHOR jYes 3 3 INSPECTION PROGRAM -1 5 l i t.i h y E FLOW CHART j Rework ,j g gjg { Group yes Generic Fix? / C5 OY / M_ Red,eggn_, / g a- <g ~ -g g i t re d Ho g 3[ 2j Reinspection _1_,_ __ 4.d ? z xo Contract 215 .j Engineering u y y 1 Burns & Roe Contract 215 Inspection A Completed Engineering

iigned Insp.

Team Engineering Yackage Redesign Insp. Package fF,i g Burns & Roe 2 jg Enginecring 3; 6 il s i d6AE 3 L .h I (- ( L.. + --,w,- .._,-m -,_._,--._-o. ^ ~ -

v EXHIBIT F fiRC STATISTICAL SAMPLIf1G liETH00 AfiD C215 SAMPLE RETROIf1SPECTI0fl PROGRAM This exhibit is referenced in paragraph 4.4.2 of the response to the

Bulletin, v

V a

.NRC STATISTICAL SAMPLE MET 110D Table 1 - Initial Sample Size to Assure at.95% Confidence' Level 5% Defective Pooulation size Sample Size (with no failures)' i 40 31 60 38 80 42 i i 100 4'S l 200 51 300 54 400 55 500 55' l 600 56 700-1200 57-i 1300-3000 58-Greater than 3000 60 Table II Defectives Allowed Samole Size Allowable No. of'Oefectives 100 2 200 6 300 9 500 18 700 26 1000 40 3000 131 Exhibit F

~~ CODE: l PROJECT ENGINEEDING DIRECTIVE 2! 1 21 1 5 , -l C 1 5 l-{ 213 - 4 5 BURNS AND ROE,INC. PRWECT t 2 3 4}s' e 7' :l9I to l i s l 12 l1s ' 14 ' is WPPSS ENGINEERING NUCLEAR PROJECT DIRECTIVE DATE o Ll/ olt:/lO 2 x,. l,,i w.i,. %, 'N ^I* " REASON FOR P. E. D.: NA CCPIES To provide the necessary direction to the Contractor to perform a sample inspection of drilled-in concrete anchors which were installed between February 1978 and July 1979. REFERENCES SUBJECT Concrote Anchor Incmartinn LOCATION Various ENG. SYSTEM Various S/U SYSTEM 7 [d O .OUALITY CLASS I & Seismic Cat. I INFORMATION C0F==r i DESCRIPTION OF WO RK: PED 215-CS-2401 provided retro-inspection requirements for anchors installed prior to February 1978. PED 215-CS-1019 provided inspection requirements for new installations performed af ter July 1979. It is the intent of this PED to initiate a sample inspection program of the anchors installed between these dates. Attached is a list of 69 hangers which are distributed through the plant. The Contractor shall select 60 hangers from the list for this sample inspection N program. The selected hangers shall be Quality Class I, Seismic Category I and utilize drilled-in concrete anchors which wpre installed between February :978 and July 1979. Also atta'ched is a form entitled, " Supplement to Hanger Inspection l Checklist f4F-237". The Q.C. Inspector shall first review the 11 anger Inspection Checklist, form f1F-237, in each selected hanger package. The inspector shall fill in the required l informatia on the " Supplemental" form and check-off those items which were pre-viously verified on form flF-237. The inspector shall then, if necessary, field inspect, in accordance with Contractors current approved procedures, one of the drilled-in concrete anchors on each of the baseplates of the selected hangers for those items on the attached " Supplemental" form which were ng previously verified l on fann fiF-237. Use a separate form for each anchor. All items which do not conform l to the requirements of the procedure shall be indicated on this form by the inspector. 1. THIS PED REVLSES DIRECTON R EVISE. PREVCUSLY PROVIDED BY NA THE FOLLCWING PEDW: SPECIFICATION 2. THIS PED VCIDS DtRECTION PED 215-CS-2405 PREVOUSLY PROVIDED BY THE FOLLCWING PEDM: PHI 216-L3_3prg APPROVALS: g OA m.-6M / ' 7'02 3. THIS PED wCRK SHOULD BE pen 21s_rc_lolo 2 DJNA DW KNOw PED 215_r$_2401 0 G EER V A 'gT UNDER THE FOLLOWING PE.D s: R F 4 THIS PED DEPENDS ON THE NA ~ ' ENGINpR ///$fg,c S/M A QAT PR OR INSTALLATON OF f g, THE FOLLOWING ?ED'S: $SIDENT PROJECT ENGIN EE R 'DATE REV 2 BR 803-2 NO tML INPUT REOUtRED JM llN OME

Prior to loosening the bolt / nut, of an anchor to be field inspected, nicasure and record the breakaway torque required to just initiate additional tightening of it. It is recommended this be perfomed with a torque wrench which has a dial indicator read-out. When this torque is less than specified in the proce-dure, tighten the bolt / nut to the specified value' prinr to perfoming this

nspection.

All items on the Supplemental Checklist must be filled in. When the required information is not available, place a ilA in space provided. When an item does not apply to the installation, cross that item out. The complete " Supplemental" fom shall become a part of the hanger package. Contractor shall transmit a copy of the complete fom, a copy of the anchor original liF-237 inspection fom, and any other pertinent information found during this sample inspection program to L. floble, Burns and Roe Engineering, for evaluation. AEF OOC. PCN 2ts -742.8) l WPPSS NUCLEAR PROJECT NO. 2 ppg AFF SPEC. SECTICN PAGE. - PARA. l BURNS AND ROE. INC. REF owr *- oWG ZCNE. PEo 215-CS-2345 sur 2 c5 4 S M E. gla*= g' j/ n,yp yfj Tm E. ~ Concrete Anchor Insp E N W eAM'!7/g2;AN CAM Ifhffr g REV 1 d V Exhibit F s

9 LIST OF HANGERS Hanger No. Hanger No. Hanger No. AS-ll4 MS-333 RHR-399 AS-132 MS-334 RHR-412 AS-153 MS-335 RHR-910N AS-166 MS-336 RHR-919N 1 AS-182 MS-337 RHR-949N DE-6 RCC-324 RHR-973N DE-15 RCIC-6 RRC-2 DE-24 RCIC-79 RRC-6 DE-44 RCIC-920N RUCU-92 DE-58 RFW-63 RWCU-136 FPC-61 RFW-65 RUCU-137 FPC-64 RFW-66 RtlCU-138 HPCS-43 RFU-67 RUCU-159 LPCS-28 RFW-69 RWCU-160 LPCS-90lN RFW-73 RWCU-164 LPCS-902H RHR-6 Rl!CU-165 MS-28 RHR-ll RWCU-166 MS-29 RHR-37 Rl!CU-167 MS-31 RHR-179 RUCU-229 MS-33 RHR-209 RWCU-235 MS-36 RHR-245 RWCU-262 MS-275 RHR-328 RUCV-272 MS-319 RHR-371 VR-8 ) nE8 coc PCN ari 215-7429 WPPSS NUCLEAR PROJECT NO. 2 l E.F F SPEC SECTICN PAGE PARA BURNS AND ROE, INC. I OES owG OWG ZONE PED 215-CS-2345 sHT 3 Cr 4 SCALE gla**g,j/ oavg /,j L TITLE t eMk5 3w 0^'t '[7/.G2 l ^vOde= D* 4 thW-f

c. y,

I i

-. -...... g.. a . -, q n.; g e..;;- 7 .r r+ce:a M :_. 3. Q -c M ) a Panje. :etail *;o. 4. Oaality Class Sis-ic Cis:: HaaCee oef ginally inspected to Fevision of hF-237 Date ancnors installed e Aaeces cricinally tornued with *.rench I.D. e yeasure the tcrque required to just start tig*ltening bolt / nut: Torque (i ren less than proper torque, apnly prerer torque) Wrench 1.D. e Insrect only those ite"Is g previously verified on NF-237 INSFECTION ITEM VERIFICATION ON

• 0.C.

'J. m lthh fnm Sign-Off v"a

1) Verify proper anchor type per hanger detail (Check one)**

PRH HDI P v,B

2) terify proper anchor size per hanger detail 3a) Verify preper relative dimensicn (PP 4 nniv)

30) Verify setting tool snouldered on anchor (HDI only) 3c) Verify e:-ced+ent depth in concrete (HVS oniv)

4) Verify anchor not pulled against plate (P?H % CI cniv)

5) Verify proper thread engagement

6) Verify preper plate bolt hole size

7) Verify pecper free concrete edge spacing

8) Verify proper anchor spacing from embedded items

9) Verify anchor achieves proper torque af ter above inspection. Torque Wrench I.D.

• Check the correct column
  • PRd = Fhillips Ped-Fead Anchor, bDI = Hilti Crop-In Anchor HKC = Hilti Kwik Bolt Anchor The drilled-in concrete anchor inspection required by this checklist shall Le performed in accordance with Contractor's current procedure.

Procedure used Revision Co-ren ts : 1 1 l Q.C. Inspecter_ Date (Send a copy of this corplete fom and a copy of the fom f;F-237 in the hanger package to L. Noble, B & R Engineering. Attach original of this form to fom NF-237 in hanger package) } 5tTTCH F W:Grr r:SFr!ne: (Show locationofanchorbeinginspected) \\ 1 i i l Attachrent to PED 215-05-2245 sheet : of : Exhibit F l

v' EXHIBIT G C215 SAMPLE PARAB0LT RETR 0!flSPECTION PROGRAM (C233 INSTALLATIONS) This exhibit in referenced in. paragraph 4.4.6 of the response to the Bulletin. 1 l l l f v r

g {NotG E L n% e.w N6 BURf.S AND ROE, INC. EU !1.L l_M.1_5 c lC S -' 1 ' 9' T 4 wepss ''''''!l""!""'"'! NusLEAR PROJECT DlH ECTIVE ca n i 1. l >< Zi 6f'7 : 9 Pyoa Tv I. S Q, 3 p..,,,Upga.; NO. 2 l OF ]h.\\ IN70 AV A T ION l RE ASON FOR P E D.: CCNI H AC1010. '.H f f T ~ ~. - '- ~ ~ HerEneNcas To sample, inspect and test parabolt concrete inserts for integrity per flRC ll I.E. Bulletin 79-02. sua;Ec7 Pat.abol1_ Inserts i.oc ATioN Spr_ay Ponds I A & IB l' I ENG.sysT2M All i sio ;vsisi All l lj CUALITV CLASS _y ORIGINATING _ tlRC I.E. Bulletin il l I cocumsNis _ 77.02 y. RE FERENCE DAAWINGs { N - SU F F IX - R EV. l $ jOR AWING. O SHE a T tJ0. 3533' H Iil H IIl 'd2 ' DESCRIPTION OF WORK. l l i l d*ssy H I I I H I I i ; Ids 7 - t See attached sheets. .g] ;_j j j j j_j l j l gi dby l H l 11 l-! I l l Hda' l i ! I -i l l l H I l i l-l I ! i I l l ' H ! l i l-i l i f H ! ! l _f - l I i l l l H l l 1 H i I i H l li f f _2,3.[ ispip.49tsc2 g py 3jgispf U. RE FERENCE SPEC. PAR AGR APHS I Pt. A AGR APH PACL jTtfV,j

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- l,l! J,' i l i' l i lillit. ll'iti Illi !!llil'il r, ' l ill! c t; M il l !'.;: 1 III H li,'ll gy... y. g.,...p y..p.n o,,r, n y.i,,.y ~) APPROVAL {- l 1 THIS PE D HEVISE S DIHEC TION d,A N PR E'. f CUSL Y PROVIOE D B V , dis '!PL ;E ::N}iNEEr4 ,) v DATE TH E F OL ( Obd.NG t'EDisi b 2 THIS PE D WORK SHOULD OE N U (( M 8 CO O H OiN A T E D WIT H M N O.'.N ( y $l of sE n coNTR ACTOR iNO A A i Eo7W nayT ee,ca. oue ~ eNorn na,ou O.soPm s -__ ___ M' f2 ~ ~~ dMM rnis no oiPsNoscN T E ar.- i

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/ Exhibit a _ g.,"d.. " " moe,NsT Au AT,0. o. o, v e u c,.,N m s _. j v., c.._., e----n---------m------ v - - -n~~----,, -n

_ - _ _ _ - _ _ _ _ _ _ = - _ _ _ - De,cription of Work 1.0 Contractor will inspect and test concrete inserts from the walls and slab of Spray Ponds IA & 18 that were installed by Contract #233, a) From the attached drawings S533-5536, sheets 7,8,9,'& 10 of this PED, Contractor sill select one bolt from each plate denoted by ~ mark number. (i.e. Plate 13, Plate 14, etc.) b) The selected bolt will be numbered (i.e.1,2,3, or 4, etc.). Bolt number I will be considered from the north upper left corner of the plate. Numbers will increase consecutively moving clockwise around the plate. c) Refer to item' 2.0, this PED, for inspection and testing. d) Submit results of inspection and testing to Engineer by letter on Exhibit "A" (Sheet 6 ): 2.0 Inspection and testing of the installed expansion bolts shall consist of the following: 2.1 Results to be entered on Exhibit "A" (Sheet 6 ) 2.2 The contractor will inspect the following items: a. Proper size anchor b. Proper type anchor c. Embedment depth d. Thread engagement e. Plate bolt hole size f. Bolt spacing g. Edge distance j h. Torque 2.3 Torque Testing: A calibrated torque wrench shall be used [ fcr this test. i a. This test shall consist of applying torque in' the tightening direction to the embedded anchor. Torque shall be applied until additional tightening of the nut is observed, or until the specified maximum torqua value is reached, whichever occurs first. If tightening is observed before reaching the specified maximum, this breakaway torque value shall be recorded and checked to assure that it is greeter than the'specified minimum torque, as shown on sheet ". HEF OOC PC f. nFa WPPSS NUCLEAR PROJECT NO. 2 REF SPEC sECTION -. PAGc - PARA BURNS AND ROE, INC. REF oWG oWG ZONE PECg g.gg3q sHT Q Oy Q SCALE y g TITLE pqAh CT-T RE vtE *ED DATE }*"[o (fk o*rt "/u/g apav oMi oat /2.f 77 rnsEEG Exhibit G g

Torque (Ft-lbs.) Size Minimum 1/2" 45 3/4" 125 7/8" 165 1" 250 2.3 (continued) b. Any turning, lateral and/or vertical motion of the embedded anchor, looseness of the anchor system, or other fJrms of unsteadiness of the embedded anchor observed during the torque test shall be' cause for rejection. The torque test shall be perfonned without any special lubricant on the threads. 2.4 Edge distance: taken from the centerline of the bolt to the edge of the concrete. (Refer to Table III on sheet 5 ). 2.5 Bolt spacing: refer to Table III for minimum. 2.6 Plate bolt hole size: maximum 1/8" larger than the anchor size. 2.7 Thread engagement: full thread engagement. 2.8 Embedment depth: 4 a) Refer to Table III for minimum. b) The ultrasonic equipment used shall be a NORTEC 131 CRT or approved equal. c) The U.T. equipment shall be calibrated to a standard length Parabolt specimen prior to inspection of each mark number and more often if required. d) Each Parablot shall be U.T.'d for length. Prior to i applying the transducer to the end of the bolt, ascertain that the bolt end is relatively smooth and perpendicular to the axis of the bolt. If needed touch up with a file. Subtract the exposed length from the total length to get the embedded length and record the actual embedment on Exhibit "A". 2.9 Proper type anchor: Molly Parabolt concrete anchors. 2.10 Proper size anchor: refer to reference drawings b bdNJ 5533, S534, S535, S536. RFI WPPSS NUCLEAR PROJECT NO. 2 REF DOC PCN REF SPEC. SECTIOW PAGE ' PARA: BURNS AND ROE, INC. PEC p y g. g { sHT Q OF g h REF DWG DWG ZONE TITLE]g 7 SCALE 0,A,T E 9 AEviEWED DATE DATE 'fMfp APPv0% 0 ATS7,[/{ 1Q{p DJD h 8 a

t c 2.11 If any inspected item fails,to meet its acceptance, criteria, the anchor will be considered to have failed inspection. 2.12 If any anchor on a plate fails, all other anchors on the plate shall be inspected. 3.0 Rejected Ekpansion Bolts: / Rejected bolts will be noted as such on Exhibit "A" and submitted to the Engineer ( P.& R ). 4.0

References:

Installation Procedure - Field Procedure FP-EB-1 Rev. 3, Paragraphs 2.4 and 2.5.(B & R File 233-00-0046) i c 68161 REF OOC PCN RFI WPPSS NUCLEAR PROJECT NO. 2 ~ AEF SPEC SECTION PAGE " PARA BURNS AND ROE. INC. REF DwG DWG ZONE PEDai 5-C5-19 3d"' '" ^ SCALE j," g Dat!g 7y Rt vit *E D DATE 6RA60f T Exhibit G f =,p tpy oa n sfu,(1, suvo mf o*N. i h .Tn5F GD

m ^ j'-" ,y N. * --g N-4 ~ ~ n. 1 n s a 't i )j* ,3_ {\\ r 1 + - y ~; s,. N TABLE III"' \\ THREAD H0LE MINIMUM MIlllMUM

• MIMffdM SIZE LENGTH DIAMETER EMBEDMEflT SPACE-BETWEEft EDGE \\0ISTANCE-BOLTS l-1/4" 3/4" 1/4" 1 1/8" 3"

I 1 1/2" 3/8" 1 1/8" 3/8" 1 1/2" 4 1/2" ' 2 1/4" 1/2" 1 1/4" 1/2" 2 1/4" 6" 3" ^ 5/8" 1 1/2" 5/8" 2 3/4" 7 1/2" 3 1/4" 3/4" 1 1/2" 3/4" 3 1/4" 9 4 1/2" s s 7/8" 2 1/4" 7/8" 4" 10 1/2" 5 1/4" 1" 2 1/4" 1" 4 1/2" 12" 6'? NN '~ / Minimum space between bolts shall be as specified above or as noted on B & R contract drawings (S533, S534, S535, S536). s rg N t h t j j u i / l r l c 68465 l i l REF DOC PCN ~ RFI WPPSS NUCLEAR PROJECT NO. 2 PEF SPEC SECTION PAGE - PARA-BURNS AND ROE, INC. AEF DWG DWG ZONE-PEDgg 05-M3i sst g oe fg SCALE TITLE ygggT" 047 7 REviEwtD. DATE k"$/phb DATE '//k / A APV D Mtd OATE/[bIh bbb 7 t

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