ML20091N249

Forwards Util Response to Cygna 840330 Telcon Questions Re Allowables & Safety Factors for Richmond Inserts.Certificate of Svc Encl.Related Correspondence

ML20091N249
Person / Time
Site:	Comanche Peak
Issue date:	06/08/1984
From:	Ellis J Citizens Association for Sound Energy
To:	Spence M TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
References
NUDOCS 8406120244
Download: ML20091N249 (23)

Text

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$ 2s.I*

RELATED CORRESPONDENCE e C A S E===

(CITIZENS ASSN. FOR SOUND ENERGY) j

'84 JUN 11 P1 :58 l

June 8, 1984 Lf DOC. ;lia a sg.

BRANCH i

Mr. Michael D. Spence President Texas Utilities Generating Company Skyway Tower 400 North Olive Street, L.B. 81 Dallas, Texas 75201

Subject:

In the Mattee of Texas Utilities Generating Company, et al Comanche Peak Steam Electric Station, Units 1 and 2 Docket Nos. 50-445 and 50-446 Attachment to CASE's 6/7/84 Letter re:

Barriers to Settlement On Design and Design QA Issues We are attaching a copy of TUGCO's response to Cygna's 3/30/84 Telecon questions regarding allowables and safety factors for Richmond Inserts.

This document was referenced on page 5, item 2, of our 6/7/84 letter to you under subject of Barriers to Settlement on Design and Design OA Issues.

It was inadvertently omitted when we mailed our 6/7/84 letter.

Sincerely, CASE (Citizens Association for Sound l

Energy)

I M

Mrs.) Juanita Ellis l

President I

cc: Service List in Dockets 50-445 and 50-446 (With attachments to Board Members, parties, and Docketing and Service only) 0406120244 840608 DR ADOCK 05000445 PDR 1

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TEXAS UTILITIES GENERATING COMPANY P. O. BOX 1002 CLEN ROSE. TEXAS 76043 PEECT fitE Ma y 2, 1984, -.---- -. --

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CYGNA Energy Services I., a.g ~,; g 8/'V/PV 101 California Street Jh W.

Suite 1000 San Francisco, California 94111 El//w#. (4 u

Attention:

Ms. Nancy Williams, Project Manager A 4-l' E?

SUBJECT:

COMANCHE PEAK STEAM ELECTRIC STATION CYGNA REVIEW QUESTIONS

Reference:

Popplewe17 (TUGCO) to Williams (CYGNA) letter dated April 19, 1984

Dear Ms. Williams:

In reference (1) TUGC0 stated that several responses required further review.

In addition, CYGNA has asked several new questions.

Provided in this letter are responses to previous and new CYGNA questions, a status of TUGC0 responses and a correction to a previously supplied TUGC0 response.

Due to the many responses that TUGC0 has committed to provide and the new CYGNA questions asked, TUGC0 is providing, below, the status of our responses that we believe to be correct as of April 27, 1984.

In addition, attached are TUGC0's responses to the following CYGNA questions:

1.

All CYGNA questions of March 30, 1984, telephone conversation between D. Rencher (TUGCO) and J. Minichiello (CYGNA).

2.

CYGNA question 1 of April 23, 1984, telephone conversation between D. Rencher (TUCC0) and J. Minichiello (CYGNA).

3.

CYGNA question 1 (a,b,c,d) of March 19, 1984, of Reference (1) above.

(TUGC0 committed to provide response the week of April 23, 1984)

CYGNA QUESTION /TUGC0 RESPONSE STATUS I

The following are all of TUGCO's outstanding commitment items that have not j

been answered by this letter or the letter of reference (1), all other items are considered complete:

1.

CYGNA question (2) of March 16, 1984 of Reference (1) above, TUGC0 to provide response by May 10, 2.

CYGNA question (5) of March 19, 1984 of Reference (1) above, TUGC0 to provide results of testing regarding U-bolt and pipe diametrical expansion.

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Ms. Nancy Williams May 2,1984 Page 2 3.

CYGNA question 2(b) of March 22, 1984 of Peference (1) above TUGC0 to provide response later.

4.

CYGNA questions 2 and 3 of April 23, 1984, telephone conversation between D. Rencher (TUGCO) and J. Minichiello (CYGNA).

CYGNA should note that a correction is required in TUGCO's previous response reference (1), CYGNA question (4) of March 19, 1984, regarding the local effect of a U-bolt through a tube steel beam.

TUGC0 stated that no local deformation or failure of this member would occur because the member has already resisted its maximum load and no deformations have occurred, and the CYGNA calculations provided did not adequately account for the rounded corners of the tube steel and the area under the nut.

TUGC0 stated that washer plates would be added, this however, is incorrect.

TUGC0 believes that due to the reasons cited above adding additional washer plates is un-necessary.

If there are any further questions, comments, or discrepancies, please contact me or Mr. George Grace at the CPSES site (Ext. 500).

Very truly yours, TEXAS UTILITIES GENERATING COMPANY ENGINEERING DIVISION

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20 L. M. Popplewell Project Engineering Manager LMP/lp Attachments cc:

D. Wade J. Finneran File l

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March 30, 1984 Telecon C)GNA QUESTION:

1.

CYGNA requested response to the following four comments:

A.

In reviewing the allowables for Richmond inserts ( Appendix 3 to Spec. 2323-SS-30), CYGNA has noted allowables which do not match those suggested by Richmond.

In response to an Action Item, TUSI provided CYGNA with test reports.

CYGNA is aware that the Rich-mond data is based on 3000 psi concrete, while the TUSI data is for 4000 psi concrete.

CYGNA, however, still has the following questions:

1.

How were the Tables in SS-30, Appendix 3, developed, since only a shear test was done?

ii.

How were the spacings determined?

iii. How do the safety factors in SS-30 compare to those suggested by Richmond (3:1) for tension?

h TUGC0 RESPONSE:

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Ai, iii.

Recommended allowable loads by the P,ichmond Screw Anchor Co.

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are based on tension tests conducted at the Polytewhnic Insti-5g tute of Brooklyn in 1957.

Two tension tests each were performed

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on 1" 9 and Ih" 9 inserts in concrete test blocks with moderate

<g reinforcement with the following results:

muy 1" 9 1h" 9 g

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Avg. Conc. Strength 2850 psi 2950 psi Avg. Ultimate Load 25050#

65000#*

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• 5 Failure Mode Conc.

Bolt pullout threads

• Ultimate strength of 1 " 9 insert mechanism or of concrete failure cone not determined.

Richmond's recommended' allowable loads are based on their average ultimate test loads and a factor of safety which has ' varied over the years, i.e.,

Richmond Recommended Allowable Tension Load (Factor of Safety)_

Bulletin 1" 6 IS"O k

k

1. 6, 1961 11.0 (2.3) 25 (2.6) k k

1. 6, 1971 10.0 (2.5) 25 (2.6)

1. 6, 1975 8.2/ (3.0)

'21.67 (3.0)

Design Approach - It was recognized that the CPSES 4000 psi design concrete strength, being significantly greater than the nominal 3000 psi concrete used in the Richmond tests, would result in higher ultimate capacities for the inserts than the Richmond test values.

It'was also evident very early in construction that the concrete strengths actually being acaieved were between 4500 and 5000 psi, whic. would further increase the ultimate capacity of the inserts.

In addition,-the heavier surface reinforcement used in the actual :

i I

Page 2 construction at CPSES as compared to that used in the test blocks for the Richmond tests would tend to result in yet higher concrete pullout cone tensile strengths. The design approach used was to calculate the ultimate insert capacity based on 4000 psi using the ultimate concrete tension value 4p M over the projected area of the postulated cone pullout, where p =

0.65 as recommended in ACI 349, Appendix B and, checking for an equivalency to the actual test results. Because of the conservatism inherent in dis-counting the high concrete strength test values being achieved and the effects of heavier surface rebar described above, a factor of 2 was applied to these values to establish allowable loads.

On this basis there is good agreement between the Richmond test values and the calculated ultimate load:

A. Allowable Tensile, 0 = 0.65 f'c = 4000, Safety Factor = 2 Richmond Allowable Size Test load Calculated Ultimate Load Load k

k k

1"O 25.05 23.1 11.5 k

k 1 "O 65 62.6 31.3 for 3

A325(A490 5w 28.1 for z"

A307/A36 Sb EW However, the tabulated values in A above, do not consider that the Richmond W8 test results would indicate an actual 9 = 0.~84 and that f'c at CPSES was QlC significantly higher.

A more accurate safety factor considering these higher values is shown in B:

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B. Estimated Ultimate Tensile Loads & Safety Factors Il Allowable Est. Ult. Loads & (Safety Factors)

E Size D

Load 4000 psi 4500 psi 5000 psi k

1"9 84 11.5 29.8 (2.6) 31.6 (2.7) 33.4 2.9) k k

k k

1h"0

.84*

31.3 80.9(2.6) 85.8 (2.7) 90.4 (2.9)

(w/A325,A490 Bolt) k

.84*

28.1 80.9 (2.9) 85.8 (3.0) 90.4 (3.2)

(w/A307,A36 Bolt)

• Used 1"9 value as calculated 9 of 0.79 for lh"0 based on bolt thread failure not concrete pullout.

Thus the actual minimum safety factors range from 2.6 to 2.9 for 4000 psi concrete to 2.9 to 3.2 for 5000 psi concrete.

An evaluation of the concrete strength tests indicates that the actual minimum design strength of concrete produced at CPSES is approximately 4500 psi.

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shear values for the 1"9 and 1%"# Ricnmond insert.s.

Shear tests conducted by Richmond in 1965 on 1"9 inserts an average load at failure of 27 kips.

Failure mode was by shearing of the bolts.

Allowable shear values were established based on AISC bolt values for the materials used, but were not permitted to exceed the allowable tension loads in A, above. As shear tests did not involve concrete failure, the concrete shear capacity of the insert coul'd only be esHn=+=rt usingf'c = 4000 psi and assuming 9 = 0.84 as for tensile loads discussed above.

Finally, shear tests conducted in 1983 on 1%" 9 inserts indicated that ultimate capacities were governed by bolt material, and varied between 88.1 and 95.4 kips.

Ultisate capacity of the insert and 'of concrete in shear were not reached.

1 C. Allowable and Ult 4mmte Shear Capacities and (Safety Factors Est. Ult. Cbnc.

Nhaar SL =yua

' Inst Ult.

Size Material

, Allowable Loads 4000 psi /9-0.84 Ioad Richmond CPSES 1"9 A-307 8.O 7.8[

29.N(3.8) k k

k 11.5 29.7 (2.6) 1"9 A-325 k

k ik"9 A-307 18.0 17.6Y 80.5 (4.6) 88.1-95.4 (5.0 -

5.4) i 26.51 80..Y (3.0) 88.1-95.4 (3.3 -

k 1\\"9 A-325 3.6) 4 l

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- To put the factors of safety utilized fo2 the

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R$camond adchors at CPSI5S in perspective, it

useful -

to look at the f actors of safety required by tac FSMt

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(and NRC Standard Review Plan) for steel and concrete structures.

(See FSAR paragraphs 3.8.3.3.2, 3.8.3.3.3, 3.8.3.5.2 and 3.8.3.5.4).

These safety factors can be as low as 1.56 for concrete and 2.0 for steel under normal and upset load conditions when compared to the ultimate strength of the mata Mals.

To further evaluate the significance of'the factors t

of safety for the-CPSES Richmond inserts, their reliability should be considered.

The manufacturing process for the inserts furnished for CPSES use is controlled by QA/QC procedu'res to assure that the anchor material and fab $-ication conforms to or exceeds l

requirements necessary to assure material capability to meet capacity requirements.

Construction procedures and tolerance requirements are controlled by site QA/QC regulations.

Failures to meet these procedures and requirements are visually identified upon removal of concrete forms.

When out-of-tolerance placement or improperly consolidated concrete around the insert is l

observed, corrective action o'r abandonment of the insert is required.

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See Attached sheets numbered 11, 12, and 13 for typical calculations.

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CYGNA QUESTION:

18.

In reviewing supports inside and outside containment, CYGNA has noted

-use of through bolts for certain cases (MS-1-002-001-S72R, for example).

In each case, the bolts are checked against appropriate Code allowables.

i.

Who is responsible for checking the spacing between bolts, concrete edge distance and minimum thickness of concrete allowed?

11.

Who is responsible for checking the concrete element (possible local failure, shear, bearing)?

iii.

Please provide documentation showing the above checks have been done by the responsible party.

TUGC0 RESPONSE:

The use of through bolts is employed on a case-by-case basis as required by the detail being designed.

As such, Gibbs & Hill, the;A/C,did not provide generic design criteria for their use.

Gibbs & Hill has designed, reviewed, and approved their own use of through bolts in accordance with (i) and (ii) a bove.

For details concerning through bolts designed by other organizations (i.e.,

PSI, ITT, NPSI, etc.), Gibbs & Hill has or will be provided with loads and details to establish acceptability of the building structure.

All through bolt designs will be reviewed specifically or generically to determine their acceptability prior to fuel loading.

This was anticipated as part of the design course.

Since (1) and (ii) above are a continuing action representative documentation of these design checks may be seen in attached calculation book SRB-15BC Set 1, Sheets 22, 23, 24, 25 and 33 through 38.

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