ML20084B593

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Special Rept 5 Torus Ring Header Support Failure
ML20084B593
Person / Time
Site: Quad Cities, 05000000
Issue date: 10/26/1972
From:
COMMONWEALTH EDISON CO.
To:
Shared Package
ML20084B553 List:
References
NUDOCS 8304060538
Download: ML20084B593 (56)
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Text

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o OUAD CITIES STATION SFECIAL REPORT NO. 5 TORUS RING IIEADER SUPPORT FAlf.URE l

OCTOBER 26, 3C72

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INDEX PAGE

~1-1.0 I?TTROIUCTION

2.0 DESCRIPTION

OF RING IIEADER AND SUPPORT SYSTDI 2.1 Ring llender 2.2 !!eader Support System 2.3 1bthod of Fabrication and Asserbly 2.4 Ileader Support Ibsign

3.0 DESCRIPTION

OF EOLT FAILURE 3.1 Fabrication and Assembly Deficiencies 3.2 Design Deficiencies 3.3 1bthod of Failure and Location 4.0 (X)RRECTIVE ACTION 5.0 EVALUATION ,

5.1 Static loading 5.2 Lynamic Loading 5.3 Calculated Stresses 6.0 CONCLUSI0'4S 7.0 UNIT NO.1 CORRECTIVE ACTION 8.0 APPENDICES 8.1 Unit I llanger Loadings 8.2 Unit 2 Ilanger Loadings 8.3 hTTP Examination Reports 8.4 Torus Mover.cnt Test Procedure 8.5 henty-Four Inch IIcader Drawings l

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1.0 IffrRODUCTION 1 Airing startup testing of relief valves for Quad-Cities Unit 2 on Sunday, May 28, 1972, it was discovered that four pipe hangers for the 24-inch tonis suction header had failed. The reactor was promptly shut down for investigation and repair of the failed hangers.

'Ihe 24-inch suction header encircles tne torus and provides a manifold for the suction of the various ECCS pumps. 'lhe header is connected to the torus by four 20-inch OD pipes spaced 90 degrees apart and is supported by twelve hangers which are connected to the torus shell.

Three of the four failed hangers were located within a 90 degrec segnent between two of the 20-inch connecting pipes resulting in a maximu:n sag in the header pipe of approximately 5-3/4 inches within that segncnt. The pipe hangers consist of double strap horizontal and vertical members connected to gussets which are welded to the torus shell and the 24-inch pipe. Failure consisted of shearing the bolts that were used to connect the vertical straps to the gusset.

Investigation revealed no other damage or evidence of excessive stress at the torus shell, the 24-inch header pipe, the 20-inch connecting ,

pipes, or the welded connections.

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2.0 DESCRIPTION

OF RING IIEADER R1D SUPPORT SYSTB4 2.1 Ring IIcader l

ne Quad-Citics Unit 2 containment vessel consists of a light t t'

bulb shaped drywell and concentric torus shaped suppression l

chanher. The suppression chanber is filled with water to approximately mid-depth and a pittp suction header (ring header) is attached to the outside of the torus. This header is a 24-inch OD pipe and is connected to the torus by short lengths of 20-inch OD pipe. In addition to the four 20-inch header inlet  ;

nozzles, there arc six outlet nozzics which am used to withdraw water from the header for the Residual lleat Removal System, Core Spray System, liigh Pressure Coolant Injection System, and Reactor Core Isolation Cooling System. % c header is shown on Gicago Bridge and Iron Ccmpany (CBI) drawing No. 216, Rev. 5 and No. 217, Rev. 5.

2.2 licador Support System The 24-inch ring header (suction header) is supported by the four 20-inch pipe connections and twelve hanger assenblics.

%c hanger assemblics have horizontal and vertical members attached to gussets on the torus shell and the 24-inch header.

Details of the assenblics are shoan on CBI drawing No. 218, Rev. 1. The gussets consist of 1/2" thick plate welded to 1" thick pad plate which is then welded to the torus shell and a 1/2" thick collar type plate welded to the 24" pipe.

O O The torus diameter is very large resulting in a radius to thick-ness (R/t) ratio that is very large (300). The R/t ratio is a l

measure of the ficxibility of t' .: shell and its ability to with-i stand concentrated loads. The pad plate is used at the tonis shell attachment in order to spread the applici load over suffi-cient area to minimize stresses and defomations. The smaller diameter pipe is stiff enough (R/T ratio of 30) to resist the applied load by transfer through the yoke-type collar.

The horizontal and vertical double hanger straps originally installed were 2 1/2" wide by 1/2" thick with a 13/16" diameter

! hole at each end for attachment to the gussets with 3/4" diameter A307 bolts.

! Table 2-1 defines the ring header supports, inlet nozzles and outlet nozzles along with their approximate orientation.

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I TABLE 2-1 L

QUAD CITIES UNIT NO. 2

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!! ANGER AND NO22LE ORIEVTATION i

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Ileader Support Approx. Ileader Nozzle Nozzle Approx.

Ntaber Orientation. Ntmher ' Descrip. Orientation 4

1 67 30' X-204A Inlet 4: '

2 90* X-204B Inlet 135*

3 112 30' X-204C Inlet 225*

4 157 30' X-204D Inlet 315*

5 180* X-223A lillR 157*30' 6 202*30' X-223B PJIR 202*30' 7 247*30' X-224A Core Spray 22*30' 8 270 X-224B Core Spray 337 30' 9 292*30' X-225 IFCI 337*30' 10 337*30' X-226 RCIC 292*30' 11 0*

12 22*30' I

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1 2.3 bbthod of Fabrication and Assently As discussed in part 2.1 and 2.2 the ring header and hanger assemblics are shown on CBI drawing Nos.216,217,and218 -

i for CBI Contract 9-6771. 'Ihe hanger clip assemblies (218-A l and 218-B) were welded to the toms shell prior to the shell l

being assembled in the basemnt of the reactor building. With  ;

i the torus assembled in the basemnt the shop built header sub- l asserrblics 216-B were attached to the torus penetration at the

. . . -- -- - _ - . - _ ~ . . . . . . - - - . _ _ _

O O field weld joints (see IMg. 216, Section E-E for field weld i

location). With these four subassenblics welded in place, the mmaining segments of the header were welded together utilizing tenorary supports for positioning. 'Ihe cogletion of the entire header welding was followed by the attaciment of the j collar type gussets (pc. 5 on IMg. 218) to the 24" pipe header.

l Because of the allowable fabrication tolcrances on both the major and ninor diameters of the torus as well as the ring header and the positioning of the header, the attachment of the horizontal and vertical hanger straps could not be cogleted with the as-built straps. 'lhe alignment of the horizontal and vertical straps wquired sone adjustments and strap rodifications.

At sonc locations it was necessary to decrease the 3cngth of the vertical straps by 2" to 2 1/2". Some horizontal strap lengths were changed by amounts in excess of 2". 'Ihe modifications required to coglete the alignment and assenbly of the pipe hanger straps consisted of some torch cutting of bolt holes in the collar gussets and hanger straps as well as torch cutting the straps length to suit cach installation. 'Ihe original holes were punched. .

'she hanger straps were connected to the gussets with 3/4",

100NC cap screws (bolts threaded full length). Due to the torch cutting of some of the holes in the vertical straps, there was sone nisalignment of the bolts and uneven distribution of the load. This was evident from the installed bolts not being per-pendicular to the straps.

2.4 lleader Suoport Ibsien

  • lhe haager support asserblics were originally designed for the static dead load of the 24" header plus horizontal and vertical seismic loads. The operating bases carthquake horizontal ground acceleration is .12g. Tne containment tonis analysis in the FSAR (12.2.2.5) used a resulting horizontal coefficient of .40g ,

O combined with the vertical acceleration of .08g acting simult-ancously. The original de' sign was based on a computed maximum hanger load of approximately 8,000 lbs with the load being approximately equal for all hangers.

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G 3.0 DESCllIlfflON OF BOLT FAILU1Ui 3.1 Fabrication and/or Assenhly Ibficiencies It can be seen from Section 2.3 that the methods used to correct the misalignnent problems encountered during assembly were less than desirabM. Buming holes for bolts, regardless of the craftsman, results in a nonuni.orm bearing surface for the bolts.

In addition, the hales that were punched appeared to have some slight coning which is con:r.on for ptmching operations. This slight coning effect causes the bolt to be st.essed at one edge sooner than at the adjacent edges.

Although the contract drawings did not call for bolts with a clean shank, the original stress analysis was based on an unthreaded shank, 3/4" diameter bolt. 'lhe effective cross-sectional area or an unthreaded 3/4" bolt shank is .4418 square inches versus .302 square inches for the threaded shank. This would have increased the calculated failure load in doubic shear from 27,180 lbs. to 39,760 lbs. for the bolted connections.

'lhe use of 3/4" diameter bolts with an unthmaJed shank would therefore have been desirable.

Since the original hanger system did not have provisions for adjustments, the exact distribution of loads on the support system were different from the theoretically calculated loading.

To assist in detennining the reason for the bolt failure and its location, the loading on each vertical hanger in the  ;

original installatien was determined. The measurements were made by recennecting the original straps and then applying a >

force with a hydraulic jack to each hanger point until the bolt in the connection was loose indicating that the jack was I carrying all of the load. The weight in pounds was detennined  !

from the pressure of the hydraulic fluid in the jack. The measured loads are shown in Tabic 3-1.

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TABLE 3-1 4

QUAD CITIES UNIT NO. 2 ORIGINAL SUPPORT SYSTD1!! ANGER LOADS

  • SUPPORT NO. IDAD SUPPORT NO. IDAD N N 1
  • 5.4 7 3.6 k k 2 } 13.2 8 7.6 k 9 12.0 k 3 59.4 k 10 22.3 I

4 13.0 k k 5 0.7 11 0.7 k N 7 11.6 12 113.2

  • Loads are as ncasured aftcr replacement bolts had been installed but before any strap lengths were changed. See Appendices, Section 8.2.

It is obvious that the distribution of load is not unifom in l that support No.10 is carrf ng i a load of 22,300 lbs. , whereas support Nos. 5 and 11 were only carrying 700 lb. 'Ihis inequity in load distribution indicates that some more precise method of hanging the ring header should have been used. It also 1

indicates that a static load of at least 22,300 lb. could be accomodated without fai. lure on a 3/4" 10UNC bolt threaded its full length.

3.2 Design Deficiencies Computing an average of the loads shown in Tabic 3-1 results in a wlue of approximately 9,400 lbs. per hanger. 'Ihe original maximum computed load to which the hangers were designed is i

approximately 8,000 lbs. The inequities in the load distribution-shown in Table 3-1 and the average load per hanger indicate that 1 l l

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l the mthod used in designing the har.ger asserblics was inadequate from a purely static condition approach. The wide range of load distribution indicates that the hanger design perhaps should have called for some method of adjustment to make up for the differences in the dimensions that result from allowances for fabrication of the torus and the 24" pipe header.

'lhe average load per hanger of 9,400 lbs. (average of masured loads) vs the 8,000 lb. used for the original design, indicates that not all loads were accounted for in the original analysis.

'lhe measured static load at hanger No.10 was significantly greater than that reasured at any of the other hangers. This would indicate that sonc dynamic effect from the testing that had been performd, contributed the force necessary to shear the bolts in failed hangers 1, 2, 3, and 12, but did not add enough to shear the bolts in hanger No.10. *lhis dynamic effect was not identified and thus not included in the loading used for the original hanger design.

3.3 Method of Failure and Location _

'lhe testing of relief valves (Startup Test No,' 26) was being performd when the first indication of failure was noted.

llelief valves A then B had been tested when a 3/4" bolt was found beneath hanger No.12 which is at the point in the toms where A discharges. A temporary replacement bolt was installed and testing proceeded with relief valves C,D, and II. After the

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testing was completed, failed bolts were found beneath hangers i

No. 1, 2, and 3. In each case, it was a bolt in the vertical hanger straps that was sheared. The relative positions of the hangers, the ring header connt .tions, and the discharge points '

I of the miief valves in the torus are tabulated in Table 3-2.

Also shown on the table is the approximate as-built static loading on each hanger from Table 3-1.

!. TABLE 3-2 QUAD CITIES UNIT NO.2 IIANGER, N0ZZLE AND RELIEF DISCilARGE ORII2 RATION I!cader Relief Header Dead Load Appmx. Support on ' Support (1b).

Orientatien Connection Discharge 11 700' 0 ,

Core Spray A 12 13,200 22*30' 45* Inlet '

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  • E 1 5,400 67*30' 2 13,200 90 .

C 3 9,400 112 30' 135* Inlet RHR 4 13,000 157*30' 5 700 180*

EllR 6 11,600 202*30' 225* Inlet l

D 7 :3,600 247*30' 8 7,600 270" RCIC E' 9 - 12,000 292*30' l

315* Inlet Core Spray 10 22,300 i 337 30' i 6IPCI 5

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O From Tabic 3-2 it can be seen that hangers 1, 2, and 3 are located within a 90* segment bc$ ween two 20" inlet pipes which connect the ring header to the torus. With these hangers failed, the span between the inlet pipes was unsupported and dr:pped 5-3/4" at the lowest point. Non-destmetivo tests were performed on four critical welds on the toms shell and the ring header to check for damage. No evidence of irregularities (discon-tinuitics) were shown in these dye penetrant non-destructive tests. See Appendix 8.3 for examination report. A stress analysis of the header and torus shell penetrations was per-fomed based on the deficction of 5-3/4" in the header and no stresses were calculated to be in excess of the minimun yield strength of the materials.

As previously stated, the estimated load required for double '

shear failure of the original bolts is 27,180 lbs. This is based on failure at 3/4 of the ultimate strength of A307 steel and an effective cross-sectional area of .302 square inches for the bolt. This is not to say that the bolts in the hangers all failed in doubic shear. As discussed in Section 3.1, there were some hangers in which bolt holes were burned and which had pairs of straps with different effective lengths. As a result of these fabrication deficiencies, the load at which the bolts could have failed can not be detemined. It is estimated, however, that at least a load of 18,120 lbs. and up to a maxir.um of 27,180 lbs. would be required. .

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I The dynamic effect of the relief valve discharging into the .

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torus adjacent to a pipe hanger adds significant loads to the hanger. It is postulated that the effect is due to a pressure wave inposed on the torus shell by the expansion of the free air

' in the relief discharge line upon initiation of relief valve operation. In order to verify the dynamic effect and to detemine the adequacy of proposed repairs /nodifications, a test was conducted in which measurements were taken (during relief valve, operation), of relative motion of the tonis shell and the ring header in the area of a header support. These Two

' measurements were used to determino maximmt hanger loads.

approaches were used in analyzing the loading. The'first approach (Header Analysis) was subjecting a nodel of the header system to the observed vibrations at instrumented points on i

the header.

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'Ihe second approach (Torus Analysis) uses the measured dis-l 1

placements in the torus shell, and a calculated stiffness term to determine hanger load. The maximum vertical hanger load was calculated to occur during the operation of the singic relief that discharges in the area of the hanger, Tedt E .yThe maximum horizontal hanger load was calculated to occur during the The maximum simultaneous operation of all relief valves, Test R.

values for the loads which were calculated from the measured displacements observed during the testing am tabulated in Tabic 3-3.

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TABLE 3-3_

QUAD CITIES INIT NO. 2 MulhEl DYNAMIC HANTR LOADS IXJE TO RELIEF LINE DISQIARG s

Test E1 Test R Toms IIcader Torus licader Analysis Analysis Analysis Analysis 17,700 12,300 13,900 Vertical 11,600 Load 13,600 0 ,

3,600 0 Horizontal j Load he addition of from 11,600 to 17,700 lb. to the dead weight load of 13,200 lb. on the No.12 hanger was sufficient to exceed the '

18,120 - 27,180 lb. failure load for the bolt. The failure load for a clean shank bolt of the same material is 26,500 - 39,760 lb. ,

It is therefore theoretically possible that hanger failure would have occurred even if a clean shank bolt had been used.

During the testing of relief B or C, there was enough effect on henger No. 2 that it failed resulting in its load being distributed between hanger Nos. I and 3. % is additional load resulted in failure of these hangers. The hangers adjacent to the discharge of valves D and E did not fail and the reason for this can be attributed to the possibility that the fabrication technique was better on these hangers and that the dynamic load on the hanger used for analysis is computed conservatively.

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O O 4.0 CORRECTIVE ACTION The following corrective action was taken to correct the header support deficiencies:

1. The bolt holes were drilled out to 1 1/16" '.iameter for 1" bolts
2. All horizontal and vertical hanger straps were replaced with 1/2" thick by 3" wide, 36,000 psi yield material with 1 1/16" diameter bolt holes. The approximate failure load for these straps (in pairs) is 54,375 lbs.
3. New 1" diameter A325 high strength bolts with 1 1/2" un-threaded length were installed with positive. locking tech-niques included. The approximate double shear failure load _

for these 1" bolts is 70,686 lbs. ,

4. The lengths of the replaccment straps were adjusted to provide si a unifonn distribution of loads between the hangers.

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o 5.0 INALUATION 5.1 Static Loading As part of the bolt and hanger strap replacement, a hydraulic jack with dial pressure gauge was used to :acasure the actual loads at each support point. The jack was raised enough to After the loads were pick up the header load at each point.

reviewed, some modification in tric strap lengths effected a change in the load distribution pattern of the entire system.

The modifying of strap lengths resulted in the static dead load distribution shoval in Tabic 5-1.

TABLE 5-1*

l QUAD CITiliS UNIT NO. 2 FINAL SUPPORT SYSTI?4 IIANGF.R IDADS Load Support No. Load Support No.

7,800 7 6,700 1

10,300 8 7,600 2

9,400 9 7,800 3

7,400 10 7,200 4

8,300 11 8,500 5

7,200 12 8,900 6

  • See Appendix, Section 8.2.

In order to analyze for the dead load and reaction load system, a beam finite element computer program was utilized. This program calculates the loads at each hanter and each nozz1c when st6jected to the header dead load plus header outlet reaction loads. 'Ihese calculated loads for the hangers are shown in Tabic 5-2.

TABLE 5-2 Qt AD CITIES UNIT NO. 2 O CALCLIIATED STATIC IDADS AT EACil llANGER FOR DEAD LOADS PLUS Ollf1ET N0ZZIE REACTION la\DS CALCULATED LOAD SUPPORT NO. CAlfU1ATED la\D SUPPORT 10.

6,900 7 7,000 1

7,100 8 7,200 2

7,200 9 7,400 3 1 10 10,400 4 10,400 )

i 9,700 11 3,700 5

11,300 12 13,000 6

7,200 X-204C 6,100 X-204A 6,400 X-204D 7,400 X-204B This table shows that the calculated loads for a balanced system would not necessarily result in unifonaly loaded hanger i

straps.

5.2 Dynamic Loading i

i In order to analyze the header support system for the maximtun l

postulated load on the vertical hanger, it is necessary to combine the static dead load with the seismic load as well as the maxiratzn relief line discharge load. Utilizing .0Sg vertical and .40g horizontal accelerations due to the operating basis carthquake (FSAR Section 12.2.2.5) and average dead load on the f

hangers, the equivalent maximt:n vertical load is about 6001h and For the the equivalent maximtsa horizontal load is about 3000 lb.

loading due to relief valve discharge, the maximtzn vertical hanger load is chosen to be that detemined using the Torus Analysis method, Test E, and for additional conservatism is rounded up to 18,000 lbs.

-3). 'Ihc maximimt horizontal hanger loading from (seeTable l

l relief valvTdischar'ge is'taken frcn the Ile r Analysis I

i method with a value of 13,600 lbs.

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h' hen the horizontal loads are combined, it can be seen that l' t

they are small compared to the vertical hanger loads due to the J

', contribution of the static dead load in the vertical directiont  ;.

i Thus, the analysis at the hanger components to detemine adequacy j; is performed using the largest vertical load as determined from I i See Table 5-3 for a tabulation of i

the se.mation of all loads. .

,z the total vertical loads. The maximum horizontal load would l

be 16,600 lb. and the maxiiaum vertical load is 31,600 lb. The failure load is approximately 54,375 lbs. with the failure point i

being at the strap bolt holes.

l TABIE 5-3 QUAD CITIES UNIT NO. 2 1

1 K\XIMN VERTICAL llANGER LOADS a

OBE SElhMIC + STATIC + RELIEF LINE DISC!!ARGE h'

Loao caseu on Load Based on

> Calc. Static Measured Static  ;

d SUPPORT NO. Loads Loads 1 25,500 26,400 2 25,700 28,900 l 3 25,800 27,000 l 4 29,000 26,'000 5 28,300 26,900 6 29,900 25,900 7 25,600 25,300  ;

I 8 25,800 26,200 i

9 26,000 26,400 10 29,000 25,900 11 22,300 27,100 12 31,600 27,500

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The ndximttn calculated Icad is located at hanger no.12 and is 31,600 lb. This load is an upper bound load and it is very unlikely that it could occur.

5.3 Calculated Stresses _

The stresses in the bolts and ha .gers from the maximum vertical  :

I Also shown in the and horizontal loads is shown in Table 5-4. i table are allowable stress IcVels adjacent to the applicabic i

- tabulated value.

TABLE 5-4 STRESSES IN IOLTS N'D llANGERS-FINAL HANGER SYSTB1 Vertical Support Horizontal Simport AISC Approx.

1 2 Test E Test R Allow. Failure DL 40BE+ . DL + 0BE+ Stress Stress Test E Test E + OBE + OBE 28.9 31.6 6.6 16.6 --

Load (k)

Bolt Stress 1" /> A325 10.5 22 90 A = .7854 18.35 20.0 4.2 (ksi)

Strap Stress -

at pinhole 8.6 21.5 4.. 58 3 x 1/2 (ksi) 14.9 16.0 3.4 Strap Stress Bearing 68.2 3 --

28.9 31.6 6.6 16.6 1-1/16 6 hole (ksi)

Gusset Stress ~

Ucaring 3 57.8 62.3 13.2 33.2 68.2 --

1-1/16 4 hole

6, , (ksi) 1 Measured dead load (see Tabic 5-1) 2 Calculated dead load (see Tabic 5-2) 3 Based on AISC allowable bearing stress of 1.35 F, multiplied by 1.33 as allowed in AISC paragraph 1.5.6, and using minin2tn allowabic yield of 38,000 psi.

Based on AISC allcwabic stress in tension of .45 F y multiplied by 1.33 as allotted in AISC paragraph 1.5.6 and using a minimtn allowable yic]d of 36,000 psi.

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O O Although the tests showed that the maximtra horizontal and maximum 8

vertical hanger loads did not occur under the same ccnditions, for conservatism the maximtm horizontal and vertical hanger loads were I asstmed to occur simultaneously and the stresses in the toms i

shell were computed at the point where the hanger support is attached. Figure 5-1 defines the points in question and Tabic 5-5 ,

lists the stresses at these points.

t TABIE 5-5 QUAD CITIES UNIT !!O. 2 i STRESSES IN TORUS AT HANGER CONNECTIONS i I

Stmss, psi Point Stress, psi  ;

Point ,

8,600 P 5,800 K

8,600 R 5,800 L -

t 7,900 S 8,300 7 11 f

9,900 T 5,200 N

The stress at the midpoint between the hanger pads (point V of Figure 5-1) is 8,600 psi. These stresses are all well below the allowabic membrane stress for the torus material (SA-515, Gr. 70) of 17,500 psi. Minimum yield stress is 38,000 psi.

Using the displacement measurements taken at the header to torus nozzle during relief testing, the static dead load, and seismic loads, stresses were computed at points around the nozzle to torus junction. The static dead load could not be measured, therefore the These computed loading on the nozzles from Tabic 5-2 are used.

stresses are tabulated in Table 5-6. Figure 5-1 defines the points at which stresses were calculated.

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O O TABLE 5-6 QUAD CITIES UNIT NO 2 STRESSES IN TORUS N0ZZLE CONNECTION Point Stress, psi Point Stress, psi A 6,400 Ay 7,700 B 5,200 By 8,700 C 2,300 C 4,500 1

D 2,700 Dy 6,900 Stress was calculated in the nozzle at point F figure 5-1, and the result is 700 psi. These stresses are also less than the 17,500 psi allowable membrane stress for the material (A516 Gr. 70).

Minimtrn yield stress is 38,000 psi. -

According the operator's log book, the maximun deficction occurred in the ring header at hanger utenber 2 (with the hangers failed) and was estimated and recorded as 5-3/4 inches. Using this deficction the stresses in the 20" dianeter Torus to IIcader pipes adjacent to the unsupported section of ring header were computed. Stresses were also computed at locations in the unsupported header. These stresses are tabulated in Tabic 5-7. All stresses were less than the minimum yield strength of 38,000 psi for the material.

O O TABIE 5-7 QUAD CITIES UNIT NO. 2 STRESSES IN LEADER, TORUS AND N0ZZLES IN TIIE FAILED CONDITION Stress Stenary - llangers 1, 2, 3 and 12 disconnected Maximum observed deficction from operator's log book = 5 3/4" .

i Mmbrane Stress Point bbmbrane Stress Location Point psi psi Al 24,100 Nozzle X-204B A 21.200 32,900 B1 35,200 Nozzle X-204B B ,

4,800 C1 3,300 Nozzle X-204B C 10,300 D1 13,800 Nozzle X-204B D Nozzle Neck X-204B F 23,800 IIcader at X-204B G 29,200 4

licader at l centerline 11 16,100 .

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9 6.0 CECllJSIONS

%e test program verifies that the relief line discharge sequence intmduces substantial loads into the torus and header systems. 'Ihe h,

conbination of the relief line load, the tordi cut holes and the i

poor initial installation load distribution msulted in the failure L of hangers 1, 2, 3, and 12. %c calculations performed using~

I the results obtained from the test program indicated that stmsses I wem inposed which could have resulted in bolt failure even with l i

drilled holcs, although failure probably would not have resulted i l

in all four stpports.

t It has been shown that there was no evidence of excessive stressing l of the torus shell or the ring header as a result of the hanger failures by non-destructive testing. Stresses computed with the system in the failed condition were below allowable limits.

The revised support system has been shown to be adequate for maximum postulated hanger loads of 31,600 lbs. The approximate failure load has been determined to be 54,375 lbs. with the These failure point being the pin holes in the hanger straps.

postulated loads are based on maximum relative displacement data taken during relief valve testing as well as design scimsic and static loading. The postulated loads were taken conservatively high for the purpose of evaluating the revised support system. The ring header to torus nozzics were also evaluated using a method similar to that used for the (v ', (v :

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  • l hangers. Stresses co:nputed for each area all were below allowabic limits. All stresses were calculated using methods acceptabic to and defined in Section III, Subsection B of the ASME Code, l l

1965 Edition. This is the applicabic edition of the ASME l l

Code defined by the original contract.

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7.0 LNIT NO.1 CORRECTIVE ACTION hhen the deficiencies were uncovered due to the har.ger failures at Unit No. 2, the hangers were checked at Unit No. 1. Similar condi-tions that were discovered at Unit No. 2 were also present at same Unit 1. The original hanger loadings were checked wing the method described for Unit No. 2 and are tabulated in Zabic 7-1.

~5 TABLE 7-1 '

e QUAD CITIES LNIT NO.1 e

j

.[' j ORIGINAL SUPPORT SYS'IB1 ll/GER LOADS g Load k Support No.

Support No. Load 4,000 7 15,?OU ,

1 ',

2,700 8 4,700 ,

2 s. , .

0,000 9 8,800 is 3

10 10,800 s' s 4 14,500 ,

,. 4 6,300 11 9,700. ,

5

( '

t 7,900 12 16,800 s ,

6 l' 3 i

Because of the conditions found at Unit Ntaber'1, the same corrective

<t The hanjer loadings actions were taken as stated in Section 4.0. ,i' were then remeasured and the results are tabul.ated ih Table 3 ' 37-2. i ,

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TABIE 7-2 QUAD CITIES UNIT N0. 1 FINAL SUPPORT SYSTDI IIANGER 1A\DS Support No. Load Support No. Load 1 2,600 7 8,000 2 7,600 8 5,100 l

1 3 7,100 9 7,600 l 4 7,600 10 7,600 5 5,800 11 6,300 6 6,700 12 7,400 l l'

A ccaparison of the loadings on Unit Nurber 1 was made with those of Unit Ntrber 2. On the average, the hanger loadings (dead load) are .

< lower for Unit 1, therefore the stresses associated with the support members and attachment points would be lower than those computed for Unit 2. 'lhe dead load on the four connecting nozzles is higher on Unit 1; however, the increase in the calculated stresses in the

'- nozzle fmm this dead load is sntall and the total is still safely heltu the allowabic limits.

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i 8.0 APPENDICES I

8.1 Unit No. 1 Hanger Loads f i

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General Electric Company

  • Sarr,cnt & Lundy 175 Curtner Avenue 140 South

Dearborn San Jose,

California Chicago, Illinois Attention G. Hoveke Attention D. K. Willett Concral Electric Company Chical,o Bridge & Iron Co. Quad-City Nuclear Power Station  ;

1619 John F. Kennedy Blvd. '

Cordova, Illinois Philadelphia, Pa. ,

~

' Attention R. Leasburg Attention T. Ahl  !,

ON 6/7/72 THE UNIT 1 24" TORUS SUCTION llEADER IIANGER LOAD TilIS WAS ACCOMPL'ISliED BY USE OF A ilYDRAULIC JACK WITil KNO CROSS SECTIONAL AREA MULTIPLIED BY CALIBRATED PRESSURE GAUG SUFFICIENT JACKING FORCE WAS APPLIED TO PElullT TURNING Tile DY llAND. AT TiiE TIME OF MEASUREMENTS THE ORIGINAL 3/4" PI AMETER D t STILL IN PLACE EXCEPT AT POINTS 1 AND 2 WilICll llAD BEEN CilANGED T IIANGER NUMDER 10 WAS ASSIGNED PLANT NORTil, WITil NUMBERS DECitEASING IN A CLOCRWISE DIi1F.CTION. Tile FOLLOWING IIANGER LOALS WERC ODSERVED AS COMPAR WITu 6000 POUNDS INDICATED BY CB&I DESIGN. .

1. 4,000 7. 15,200

'. 8. 4,700

2. 2,700
3. 0,000
9. 8,000
4. 14,500 10. 10,800
5. 6,300 11. 9,700
6. 7,900 12. 16,500

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G. E. Gray Project Superintendent United Engineers & Cons truc tors Ing

. . F

. o CHICAGO BRIDGE AND IRON CO.

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ATTENTION T. AllL 901 W. 22nd Street '

Oakbrook, Illinois 60521 '

N. .

ON 6-12-72 Til,E_ UNIT NUMBER ONE SUCTION llEADER IIANGER LOADINGS W

/ =

MEASURED AFTER ADJUSTING REVISED F'NGER SYSTEM TO IMPROVE

{

TRIBUTION IN ACCORDANCE I WITH GENERAL INSTRUCTIONS GIVEN B

. . BRIDGE.AND IRON CO. HANGER NUMBER 10 WAS ASSIGNED PLANT NORTil WITil !. .

NUM3ERS DECREASING IN A CLOCRWISE DIRECTION. THE FOLLOWING -

. l LOADS kT.RE 03 SERVED. .

i

-* 1. 2,600 7. 8,000 ,

T

2. 7,600 8. 5,100  ;
3. 7,100 9. 7,600 ,

4, 7,600

10. 7,600 s f
5. 5,800 11. 6,300 ,'

7,400  :

6. 6,700 12.

cc Sargent & Lundy, G. Hovoke .

- G. E.' Gray ,

Concral Electric Co., D. K. Willett Project Superintendent R. Leasburg , United Engineers & Construc

  • L. A. Harticy UE&C, J. R. Dmytryk e

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8.2 thlit No. 2 llanger Loads 4

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Cl!ICAGO BRIDGE AND IRON CO.

  • ATTENTION T. AHL '

901 W. 22nd Street Oakbrook, Illinois 60521 .

, e ON 6-11-72 THE UNIT 'IWO 24" TORUS SUCTION HEADER HANGER LOADINGS WERE HEASURED. THIS WAS ACCOMPLISHED BY USE OF HYDRAULIC JACK WITl! KNOWN EFFECTIVE PLUNGER CROSS SECTION AREA MULTIPLIED BY CALIBRATED PRESSURE CUAGE READINGS. SUFFICIENT JACKINO FORCE WAS APPLIED TO PEIUi1T TURNING Tile LOWER HANGER BOLT BY HAND. Ti!E REVISED HANGER SYSTEM CONSISTING OF M-1020 MQ THREE INCH WIDE STRAPS WITH A325 IIIGH STRENGTH BOLTS WAS IN PLACE WITH llANGERS INSTALLED TO RE-SUPPORT THE IIEADER IN Tile ORIGINAL POSITION. THIS IS THE FIRST SET OF LOAD READINGS TAKEN FOR UNIT #2.

IIANGER NUMBER 2 UAS., ASSIGNED PLANT NORTil WITH NUMBERS INCREASING IN A CLOCKWISE DIRECTION. THE FOLLOWING HANGER LOADS WERE OBSERVED.

"4, ,

. 1. 5,400 v 7. 3,600 13,200 ' 7,600

2. 8. .
3. 9,400 "- 9. '12,000

. 4. 13,000 10. ,22,300

- . 5. 700 11. 700

~

6. 11,600 12. 13,200 "

cca Sargent & Lundy, G. Hovcke , / q

M. E.' Gray /

General Electric Co., D. K. Willett Project Superintendent R. Leasburg .

United Engineers & Cons tr

~ L. A. Ilarticy

.i UE&C Inc. J. R. Dmytryk l l

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CllICAGO BRIDGE AND IRON CO.

ATTESTION T. AllL .

901.W. 22nd Strce r. -*

Oakbrook, Illinois 60521 .

ON 6/17/72 Tl!E UNIT NUMBER TWO TORUS SUCTION HEADER HAN MEASURE,D AFTER ADJUSTING REVISED HANGER SYSTEM TO IMPR

!! ANGER ADJUSTMENT WAS ACCCMPLISHED BY RITABRICATION O '

ACCORDANCE WITH DISCUSSION AND INSTRUCTIONS CJVEN BY T. Alit, CilICAG

'I AND IRON CO.\ }{ASCER NUP.BER 2 WAS ASSIGNED PLAST NORTil WI t' AFTER OBTAINING READINGS, T11EY INCREASING IN A CLOCKWISE DIRECTION. i-WERE DISCUSSED WITil MR. AHL EY TELEP110NE ON 6/17 AND HE F THE FOLLOWING HANGER LOADS WERE OBSERVED TRIBUTION IS CURRENTLY ACCEPTABLE. .

. 1. 7,800 7. 6,700 ,

7,600 ,.

'2. 10,30'O 8. ,

- 3. 9,400 9. 7,800 ,

I 4. . 7,400 10. 7,200 - t

- '5. 8,300 11. 8,500-S

' . 6. 7,200 12.

8,900 w

G.E. Gray J Project Superintendent United Engineers & Constructors Inc.

cc: Sargent & Lundy, G. Hovoke

  • Concral Electric Co.: D. X. Willett

- R. A. Lessburg -

L. A. Ha)tley ,

UE&C INC.: J. R. D:aytryk , .

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8.3 N17F Examination Report i

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Oa June 2,1972 a licuid penetrant excnination of Unit #2 suppression charaber to 24" diac.cter suction header at pene-tration X204A and B was .aade. The liquid penetrant examination covered th outside surface of the ucld joirting the neck (2G' pipe $1ozzle) to insert plate and. insert plate to torus shc11; with results oficxamination acceptable.

[h/?'Iffs Jir.1 Eagle

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Grinnell Co:apany e

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i 8.4 Tonts hbvement Test Procedure 9

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, . . ._.._...._s,___...... QUAD CITIE'; '

DulPMENT DEPARTMCHT

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..- f.TCMIC PO .,ce.. 22A2189 STARTUP TEST Iris CTIONS' '""* 98.0 -

Plant: nupn ci its Test

Title:

Torus riovement 98 Test Mo:

Revision !!o: 1 Date: June 5, 1972 ,_

1 i

( PREPARED BY: Startup Test Design and Analysis Unit Startup and Training Subsection -

Atomic Power Equi lwent Department ~

San Jose, California

< 4, APPROVED BY:

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005 b ATcuit PoWE({ }JtPL8cHT DErARTuENT

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'a as 98.1 ca~'""'"**' .2 STARTUP TEST INSTRUCTIONS .

. i

1. PURPOSE l

i The purpose of this test is to measure the movement of the torus surface relative to the ring header during actuation of relief valves, l

.llPCI, RCIC, RHR & surveillance testing of the core spray system.

l

2. DESCRlpTI0il  :

The position of the torus surface relative to the reactor building will be monitored at preselected locatinns. The position of the ,

ring header relative to the reac-tor building alse will be monitored

, These relative positions will be at the same or similar locations.

recorded during actuation of ene or more relief valves and each of the other systems. The movement of the torusDepending relative to the ring header -

upon the results of the can be inferred from these measurements.

measurements with individcal syst, ems, rieasurements during the actuation of more than one system may be made when the simultaneous operation of these systens is consistent with the design of the Quad Cities station.

3. CRITERIA 3.1 Level 1

(

3.1.1 Do not exceed the bulk torus air or water temperature limit specified in Figure 26.1 of the Quad Cities Test Instructions.

3.1.2 Stop all testing and return the reactor to a cold shutdown condition if the following displacements are exceeded:

(values to be provided before the test) 3.2 Level 2 3.2.1 Do not exceed a local torus air or water temperature of 2000F.

3.2.2 . Do not exceed a torus overpressure of 1.3' psi.

l 3.2.3 Do not exceed the follewir.g displacements:

~

(values to be provided before the test)

4. IllSTAl.LATIOl1 IllSTRUCT10tlS 4.1 Install instruments and readout equipment as specified in the attached sheets.

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1 STARTUP TEST ItiSTRUCTIONS 4.2 Set up telephone ccamunications frari the control room to ihe loca of the readout equipent.

4.3 It is desired, but not required that khe readou

5. INITIAL C0tlDIT10NS NOTE: Defore ycu perfona this tes t .M sure to review STI 26 and STI 15 Review 4he for special instrut'.iuns or precautions to be taken.

operating procedeces for. the HPCI , RCIC, RRR and core zrc' r.y

.1c cer:r"; ecca.

5.1 Station a man at the local panel, in cantact with 5.2 The system of interest is ready to operate.

canter lir.e.

5.3 Torus water level is no more than 1 foot below the w"::

preferably 5.4 The torus water temperature should be as uniform as pess. sic near 700F. ~

5.5 The reactor must be operating at a power level icst. sufficien{ so 4 reactor depressurization will not occur during the.

1 G. PROCEDURE I'm s:-quence NOTE:

Steps 6.1 thru 6.6 should be done in the sequence listc). For in which the different systa.s are tested is not it p tr.t.

example, if desired the HPCI, step 6.8, n'ay be t<:. red cefere the relief valves , steps 6.1 thru 6.6, or af ter the RCic, itar. 3.'3.

6.1 Relief Valve B 6.1.1 Start the recording egoipment and record all data foe it least Those data which are recorded periodically N nuid have 1 minute.

at least 3 sets of data taken. - 3 6.9.2 Make sure that the printer is set to the shcrtest .uail die cyc ,

~

time.

6.1.3 Make sure that the linear recorders are set to eparata at grea than 5 inches per second and that the timing makers are p synchronized between the several recorders.

6.1.4 Operate relief valve B.

6.1.5 Record all torus and ring header movements and torus tence l -

da.ta .

G Ell E R A.,%) E LE CT R IC ATcuic ro::CR PHENT DEPH U ENT QUAD CITIES

.-c c. r.2 2 A2 i t') ** c v a 1 1 l m ao- 98.3 co~ro~i cc- .4 i* l .

STARTUP TEST I'!STRU'CT10'!S 6.1.6 Record the reactor pressure vessel pressure and the torus pressure.

6.1.7 Af ter the moveuents of Itthe torus and ring header have dined, close relief valveDo B. not i rieexpected is that this will tal:e une the relief valve open for more minute or less.

than 5 minutes.

6.1.8 Reepen relief valve within 5 seconds of the tir..e it was closed in step 6.1.7 and allcw it to rmain oran for 10 seconds before reclosing. 7.11 recor6.r; s! auld % nue: 0 ting during thi: !tep.

6.1. 9 Continue data recording until near steady-sta'.c conditions are J reached. J 6.2 Hepeat step 6.1 excluding step 6.1.8 for each relief valve in tta.

Each valve should be open about 30 seconds.

6 .'3 Repeat steo 6.1 excludinq step 6.1.8 for a simul.taneous 30 seconc!s actuation of relief Valvci A & B.

6.4 Depeat step 6.l' excluding step 6.1.8 for a simultaneous 30 seccne actuation of relief valvcs A, B, & C.

-6.5 Repeat step 6.1 excluding step 6.1.8 for a simultaneous 30 seccnds actuation of relief valv(s A B, C, & D. ~

6.6 Repeat step 6.1 excluding step 6.1.8 for a simultaneous 30 seconds actuation of all 5 relief

  • valves.

6.7 RilR 6.7.1 Start the recording equipment and record all data for at least 1 minute. Those data which are recorded periodically should have at least 3 sets of data taken.

6.7.2 Make sure that the printer is set to the shortest available cycle time.

6.7.3 Make sure that the linear recorders are set to operate at greater -

' than 5 inches per second and that the timing eakers are properly synchronized between the several recorders.

6.7.4 Start the fdlR system in one of the modes of operation which circulates water or steam to or from the torus.

6.7.5 Record all torus and ring header movements and torus temperature data.

' 6.7.6 Reccrd the reacter pressure vessel pressure and the torus pressur!

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hELECTRIC l'PMiiT DEPkRT;4F.HT

[ ATCatiCPoWER QllAD C

.ec.~o.2fkIf[$2h.'; . c y. .] } ,i '

STARTUP TEST ItiSTRUCTIO'lS

. . 98.4 c m o~ e

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6.7.7 When steady conditions are reached relati'>c to torus and ring header movements stop t.he RHR.  ;

6.7.8 Continue data recording until r. ear steady-state conditior.s i

are reached. ,

6.7.9 Repeat steps 6.7.4 thru 6.7.8 for each of the poesicle mcdes of RilR operation with the follcuing restrictions. ,

6.7.9.1 to water tiill be injected into the reat.to. system.

6.7.9.2 Any mode of operation which does not effect the t:aus ~

will not be tested. '

6.8 IIPCI

6. 8.1 Start the recording equipmr.nt and record all data for at lent 1 minute. Those data which are recorded periodically should have at least 3 sets of data taken, ,

6.8.2 flake sure that the printer is set to the shortect available cycle time.

6.8.3 Make sure that the linear rec'orders are set to operate at areater than 5 inches per second and that the timing makers are 1 properly synchronized between the ~several re. corders.

i 6.8.4 Initiate a quick start of the HPCI without injecting water into the RPV.

6.8.5 Record all torus and ring header movertents and torus temperature data. ,

6.8.6 Record the reactor pre'ssure vessel pressure and torus pressure.

6.8.7 Uhen steady conditions are reached relative to torus and ring header movements stop the llPCI .

6.Q,8 Continue data recording until near steady-state conditions are .

reached.

6.9 RCIC 6.9.1 Start the recording equipment and record all data for at least 1 minute. Those data which are recorded periodically should have

.. at least 3 sets of data taken.

6.9.2 Make sure that the printer is set td the shortest available cycle time. .

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. . GEN EH Adl El.E CTRIC 011/6 CITIES  !

ATome PohER La PHENT VCPARYMENT sese. -o. 2A2189 aov.ao.1

=a a > 98.5 coa' aa 5-r c ' Fj STARTUP TEST IftST.iUCTI0f15 set to operate at greater 6'.9.3 11ake sure that the linear recor@rs are than 5 inches per second and that the timing makers are properly -

synchronized between the several recorders.

6.9.4' Initiate a quick start of tht RCIC without injecting uatar into the RPV.

6.9.5. Escord all torus and ring header movements and torus teaperature data.

6.9.6 Record the reactor pressure vessel pressure and the tores presst.re.

6.9.7 When steady conditions are reached relative to torus and ring header movements stop the RCIC.

6.9.8 Continue data recording until near steady-state conditions are ,

reached.

6.10 Core Spray 6.10.1 Start the recording equipment and record all . data for at least I rainute. Those data which are recorded periodically should have

(

at least 3 sets of data taken.

6.10.2 Make sure that the printer is set to the shortest available cycle time.

6.10.3  !!ake sure that the linear recorders are set to operate at greater than 5 inches per second and that the timing aakers are properly synchronized between the several recorders.

6.10.4 Start the core spray system in the mode which draws water from or injects water into the torus.

6.10.5 Record all torus and ring header movements andt' orus temperatura data. '

6.10.6 Uhen steady conditions are reached rela ~tive to torus and ' ring s

header movements stop the core spray system.

6.10.7 Continue data recording until near steady-state conditions are reached.

7. DATA #lALYSIS 7.1 All data will be returned to San Jose for detailed analysis, g

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N./ 'v' QUAD CITIES UNIT fl0. 2 .

TORUS MOVEMEllT TEST Measurement #_ Azimuth Location 1 67 30' (atheadersupport) vert. between top of torus and roof of ring room on center line of torus 2 67 30' hor. at center line of torus _ atueen torus inner (Rx) wall of ring room 3 67 30' vert. at center line of torus between bottom of torus and floor of ring room ,

4 U

67 30' hor, at center line of torus between torus and outer wall of ring room 5 67 30' vert. at center line of ring header between ring header and floor of ring room 6 67 30' hor, at center line of ring header between ring header and outer wall of ring room 7

0 67 30' on radius of torus through center line of ring header between torus surface and r.h. surface 8 67 30' vert. between upper connection point of part 6 drawing 218 and upper surface of r.h.

9 67 30' radially from center line of torus between upper connection point of part 6 drawing 218 and outer wall of ring room 10 45 (at center line of penetration 216 x 204A on CB&I dwg. 217, rev. 5, vert, between top of torus and roof of ring room on center line of torus 11 45 hor, at center line of torus between torus and inner wall of ring room 12 45 vert. at center line of torus betucen bottom of torus and floor of ring room 0

13 45 hor. at center line of torus between torus and outer wall of ring room

- 14 45 U vert. at center line of ring header and center line of penetration 216 x 204A between r.h. and floor

)n O O i

Measurement # Azimuth _ -Location 45 0

hor. at center line of r.h. and center line of )

15 penetration 216 x 204A between r.h. and outer wall of ring room 16 45 vert. at center line of penetration 216 x 204A between the in.ersection of penetration 216 x 204A and the torus and the floor of the ring -l i

room il 17 45 hor at center line of penetr' tion 216 x 204A L between the intersection of penetration 216 x  ;

1 204A and the torus and the outer wall of the ring f 18 90 hor. at center line of torus between torus and outer wall of ring room  ;

19 135 hor, at center line of torus between torus and '

7.

outer wall of ring room 20 180 hor. at center line of torus between torus and ,

outer wall of ring room  ;

U 21 225 hor. at center line of torus b'etween torus and outcr wall of ring room 22 67 30' Radially from center line of torus between torus-and ring room floor as shown on sketch 23 67 30' Radially from center line of torus between torus and outer wall of ring room as shown on sketch

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Notes:

A. No clamps, attachments, or other sources of potential interaction are to be pennitted between the measurement devices and their supports and pipes or brackets, etc., which may move during the test. This specifically includes tha corus supports.

B. Measurement devices 16 and 17 are to be installed in such a way that there will be no interference with the ring header during the test.

Assume the r.h. may move as much as 2" vert. or hor. relative to the torus for the purpose of instrument installation.

C. All horizontal measurements are to made on a radius from the RPV center line.

D. Azimuth identification is from S&L drawing B-400.

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