ML20094M767

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Electrical Raceway Support Tests Rept,Part 1
ML20094M767
Person / Time
Site: Midland
Issue date: 11/25/1981
From: Nowak A
BECHTEL GROUP, INC.
To:
Shared Package
ML19258A087 List: ... further results
References
CON-BX21-036, CON-BX21-36, FOIA-84-96 NUDOCS 8408150720
Download: ML20094M767 (100)
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{{#Wiki_filter:. f f MIDLAND PLANT UNITS 1 AND 2 BECHTEL JOB 7220 CONSUMERS POWER COMPANY "5056i V MIDLAND, MICHIGAN 1 ELECTRICAL RACEWAY SUPPORT TESTS REPORT PART 1 j m Bechtel Associates Professional Corporation Ann Arbor, Michigan Prepared by: bO ~ A.S. owak [/1 [ 4[ Reviewed by: '(.V. Regup'athy ~ Approved by: 7. 1,. Dh * - - S.L. Sobkowski i 8408150720 840718 PDR FOIA RICE 84-96 PDR n.. ---n, v.,,--,..,,.,.,,.,,

Midland Plant Units 1 and 2 f. 8-Electrics 1 Rrcew;y Supp3rt TOOto R port ELECTRICAL RACEWAY SUPPORT TESTS REPORT 05056i CONTENTS PART 1 Page

SUMMARY

l'

1.0 INTRODUCTION

2 2.0 ITEMS TESTED 2 2.1 POWER STRUT SECTIONS 2 2.2 CABLE TRAY SECTIONS 3 2.3 POWER STRUT FITTINGS 3 3.0 SAMPLING PROCEDURE 4 4.O TEST ARRANGEMENT 4 4.1 POWER STRUT AND CABLE TRAY SPOT WELDS 4 4.2 TENSILE TESTS OF CABLE TRAY AND POWER STRUT 4 MATERIAL 4.3 ULTIMATE CAPACITY OF POWER STRUT FITTINGS 4 5.0 TEST EQUIPMENT 5 6.0 ACCEPTANCE CRITERIA 5 6.1 POWER STRUT BASE METAL 6 6.2 CABLE TRAY BASE METAL 6 6.3 PCWER STRUT SPOT WELDS 7 6.4 CABLE TRAY SPOT WELDS 7 6.5 POWER STRUT FITTINGS 9

7. 0*

TEST DATA 9 8. 0, ACCEPTANCE CRITERIA VERSUS TEST DATA 10 8.1 POWER STRUT BASE METAL 10 8.2 CABLE TRAY BASE METAL 10 8.3 POWER STRUT SPOT WELDS 11 i

Midland Plant Units 1 and 2 "l******21 " " " Y 8"" " 'O * " ' " " 05056i 8.4 CABLE TRAY SPOT WELDS 17 8.5 POWER STRUT FITTINGS 18 9 6 m 9 i e I l i ii l l

Midland Plant Units 1 and 2 05056i sl.ctrieni R:cew:y Supp rt Tcata Rep:rt l f TABLES 1. Summary of Spot Weld Test Results 2. Summary of Base Metal Test Results 3. Summary of Power Strut Fittings Test Results 4. Number of Samples Selected for Tests 5. Power Strut Spot Weld Test Results 6. Husky and Burndy Cable Tray Spot Weld Test Results 7. Power Strut Base Material Tension Test Results 8. Cable Tray Base Material Channel Test Results 9. Cable Tray Base Material Rung Test Results

10. Power Strut Fitting Test Results
11. Section Properties for Power Strut Members I

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Midland Plant Units 1 and 2 e 05056 i ,1 1,1,21 Rcceway Su,, ort Tcata R:,,rt FIGURES 1. Power Strut Section Designations 22. Test Sample Configurations, Items PS-101, PS-151, PS-155, PS-201, -PS-205'

3. --Test Sample Configurations, Items PS-202, PS-204
4. - Test Sample Configurations, Item PS-3151 5.

Test Sample Configurations, Item PS-207 6. Typical Power Strut Test Coupon 7. Typical Cable Tray Sample 4 8. Cable Tray Test Sample Configuration 9. Typical Cable Tray Test. Coupon i i

10. Power Strut Fittings
11. Typical Power Strut Test Arrangement
12. Cable Tray Test Arrangement

~

13. Power Strut Fittings - Test Arrangement for PS-3064 i
14. Power Strut Fittings - Test Arrangement for PS-3375 l

}

15. Power Strut Fittings - Test Arrangement for PS-3127R&L

~

16. Power Strut Base Metal Tension Test Results i

i i

17. Cable Tray Channels Base Metal Tension Test Results
18. Cable Tray Rungs Base Metal Tension Test Results t
19. Spot Weld Test Results - PS-101 "A", PS-151 "B", P-201 "D"
20. Spot Weld Test Results - PS-155 "C"

i j

21. Spot Weld Test Results - PS-201 "D" l
22. Spot Weld Test Results - PS-202 "E" 4

i 23~ Spot Weld Test Results - PS-204 "F"

24. Spot Weld Test Results - PS-20

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25. Spot Weld Test Results - PS-205 "H" l

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Midland Plant Unito 1 and 2 8 E i triC01 REC;W Y support Taato RIport 5056i

26. Spot Weld "_'est Results - PS-152 "I"
27. Spot Weld Test Results - PS-3151 "J"
28. Spot Weld Test Results - Cable Trays
29. Power Strut Fittings Test Results - PS-3064
30. Power Strut Fittings Test Results - PS-3375
31. Power Strut Fittings Test Results - PS-3127L and R
32. Load-deformation Plot for PS-201, Power Strut Base Metal
33. Load-deformation Plot for PS-207, Power Strut Base Metal
34. Load-deformation Plot for PS-3151, Power Strut Base Metal
35. Load-deformation Plot for Cable Tray Base Metal
36. Load-deformation Plot for Cable Tray Base Metal
37. Load-deformation Plot for Cable Tray Base Metal
38. Load-deformation Plot for PS-201, Power Strut Spot Weld
39. Load-deformation Plot for PS-201, Power Strut Spot Weld
40. Load-deformation Plot for PS-201, Power Strut Spot Weld
41. Load-deformation Plot for PS-3375, Power Strut Fitting
42. Load-deformation Plot for PS-3127, Power Strut Fitting
43. Load-deformation Plot for PS-3064, Power Strut Fitting
44. Fusion Zones of Power Strut Welds
45. Cross-Sections of Power Strut Spot Welds APPENDIX Certificates of Verification and Calibration for Testing Machines e

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Midland Plant Unita 1 and 2 Elcctrical RecLwny Support Tacta RIport 05056i REFERENCES A NRC Inspection and Enforcement Information Notice 79-14 B Bechtel Meeting Notes No. 1078, issued November 9, 1979 C Calculation 31-(b) Q D J. Heuschkel, The Expression of Spot-Weld Properties, Welding Journal (October 1952), as commented by Yu, Cold-Formed Steel Structures, McGraw Hill, NYC-1973, page 306 E Calculation 20-46(Q) F Specification 7220-E-55(Q), Rev 5 2 G Drawing 7220-E-42(Q), Rev 51 H Bechtel Interoffice Memorandum; Mettallographic Examination-of Midland Unistrut Spot Welds, Job 7220-001, File Number GRS-061-09, June 11, 1981 I Power Strut Catalog 20-3R, p 45 and 106 J

Larson, H.J.,

Introduction to Probability Theory and Statistical Inference, John Wiley and Sons, New York, 1969 K Specification 7220-C-92(Q), Rev 1 L Specification 7220-C-501(Q), Rev 11 ~ M AISI Specification, Cold-Formed Steel Design Manual, 1968 Edition N Letter, Power Strut (L.N. Mears) to Bechtel (L.H. Curtis), 8/7/61 (Com 038848) f O Letter, Power Strut (D. Gebhardt) to Bechtel (L.H. Curtis), 8/18/81 (Com 039868) P Calculation 31-c(Q) R

  • Calculation 31-d(Q)

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Midicnd Plcnt Unita 1 cnd 2 Elcctrical Racawny Support Tacto R3 port 05056i PART 2 1. Volume I, Power Strut Tests Samples A-E 2 Volume II, Power Strut Tests Samples F-J 3. Volume III, Cable Tray Sections 4. Volume IV, Power Strut Fittings / 9 ,/ e d l ~ vii

Midland Plant Units 1 and 2 Electrical Rtc;way Supp rt Tacto R:; port U5056i

SUMMARY

Tests were made to verify the adequi q of electrical raceway supports, particularly Power Strut hardware and cable trays from Husky Products, Inc., subsidiary of Burndy Corporation. The tests included: Shear strength tests of Power Strut spot welds Shear strength tests of cable tray spot welds Yield stress tests of base metal in Power Strut members Yield stress tests of base metal in cable trays (channels and rungs) Ultimate capacity tests of Power Strut fittings Tests were conducted in accordance with Specification 7220-C-92(Q), Rev 1. The test data are contained in Part 2 of this report. The summary of results is presented in Table 1 for spot weld tests, Table 2 for base metal tests, and Table 3 for Power Strut fittings. Safety factors are calculated for the considered members and spot welds and are compared to the minimum required values. On the basis of the test results, the electrical raceway supports are found to have adequate safety factors. 4 W 1 o -~ ~ e

Midland Plant Unita 1 and 2 ElEctriccl RncEwny Support Tacts Rsport ~ 05056i l.0 INTRODUCTION / ~ procurement)andinstallation The NRC requires that the esl // of Class 1E electrical syst andsbciatWd' support systems be f treated as safety-related and Q-1isted (Reference A). Until the end of 1979, only the Bechtel design and installation of the Class 1E cable support system satisfied 10 CFR 50, Criterion II, Appendix A requirements. The cable support system was' procured as non-Q-listed material. Also, the installed trays and supports were not. traceable to a specific batch or delivery date. It was decided (Reference B) that samples of Husky cable trays and Power Strut hardware would be tested to determine the following capacities: a. Ultimate tensile strength of the Power Strut and cable tray material b. Ultimate shear capacities of the spot welds in Power Strut members and Husky cable trays c. Ultimate capacity of Power Strut fittings Materials and Quality services (1%QS) in San Francisco performed tests on samples selected from the storage area at the Midland jobsite. M&QS prepared and tested the specimens either in the M&QS San Francisco laboratory or at Anamet Laboratories, Inc., in Berkeley, California. The test program followed Specification 7220-C-92(Q), Rev 1 (Reference K). The test data are contained in Appendix C of this specification. 2.0 ITEMS TESTED Three classes of hardware items were tested: Power Strut sections, Husky cable tray sections, and Power Strut fittings. 2.1 POWER STRUT SECTIONS Power Strut sections are light-gage channels manufactured by cold-forming mild strip steel. These channel sections are connected to each other in various configurations, as shown in i Figure 1. Connection is provided at 3-inch intervals, using a process commercially known as spot welding. l For the spot weld tosting program, Power Strut sections were divided into three categories, based on the welding prcce.-c. One category included channel sections welded back-to-back (PS-201, j PS-151, PS-155, PS-205, and PS-101). The second category included channels welded side-to-side (PS-202, PS-152, PS-155, 2 l

Midland Plant Units 1 and i Electrical RncEwny Support Testo Rsport ~ 05056i -i and PS-205). The third category included channel sections welded side-to-back (PS-204, PS-207, and PS-3151). Members PS-155 and PS-205 included both back-to-back and side-to-side configuration of spot welds and, consequently, were evenly divided between categories 1 and 2. A typical sample was 11 inches long and had a minimum of three spot welds. The ends were made as indicated in the appropriate figure prior to performing the tests (see ~ Figures 2 through 5). For ultimate tensile strength testing, Power Strut hardware was lumped into one category regardless of section type. Test coupons were shaped in accordance with the requirements of ASTM A 370 and ASTM E 8. Figure 6 shows a typical test coupon. 2.2 CABLE TRAY SECTIONS Cable tray sections consisted of two thin-gage channel sections connected at 6-inch intervals by tray rungs. Testing of cable tray spot welds involved testing the tray rung-to-channel connection as a unit (two spot weldr). Figure 7 shows a typical cable tray sample. Samples were taken from 12, 18, 24, and 36-inch width trays. A proportionate number of samples was obtained from curved cable trays. Each sample was cut into two pieces, yielding two separate test samples. Each test sample was modified as shown in Figure 8 prior to performing tests. For tensile strength testing, cable tray sections were lumped into one batch regardless of tray width. Both cable tray channels and cable tray rungs were subject to tensile testing. Test coupons were obtained in accordance with the requirements of ASTM A 370 and ASTM E 8. Figure 9 shows a typical test coupon. 2.3 POWER STRUT FITTINGS Five types of Power Strut fittings are used in the raceway support system. These fittings are shown in Figure 10. The fittings that include welding in their manufacturing process were tested because the welding procedure was not qualified. These fittings are made from 1/4-inch thick strip steel conforming to ASTM A 575. Based on their geometry, Power Strut fittings were separated into four categories: 'a. PS-3064 (baseplate - double) _. b. PS-3375 (yoke base bracket) c. PS-3033 (baseplate - single) d. PS-3127R and PS-3127L (angle plate) 4 3

Midland Plant Units 1 and '2 Electrical Racnwcy Support Tasts Rcport 05056 i Only ultimate capacity tests were performed on Power Strut fittings. 3.0 SAMPLING PROCEDURE The sampling procedure selected representative samples of mat) rial for tests. The number of samples for each tyrie reflected the proportion of the quantity of each item to the total quantity of material in its category. In the lot from which the samples were selected, all the items were numbered. Selection was based on a computer-generated list of random numbers. Table 4 specifies the numbers of items selected in each category. No samples were selected for 9 inch cable tray channels and Power Strut fitting PS-3033. These items were not available in the jobsite warehouse. 4.0 TEST ARRANGEMENT 4.1 POWER STRUT AND CABLE TRAY SPOT WELDS Figure 11 shows an arrangement for Power Strut sections. The test arrangement for cable tray sections is shown in Figure 12. The dial gage was placed on the test specimen, attaching it to the sample as shown in Figures 11 and 12. A tensile load was applied in increments of approximately 400 pounds. At each load increment, the deflection was recorded on the test data sheet. The load was increased until failure occurred. The failure load was recorded, and the load-deflection values were plotted on the test data sheet. 4.2 TENSILE TESTS OF CABLE TRAY AND POWER STRUT MATERIAL The procedure for sizing test coupons and for subsequent tensile testing followed ASTM A 370 and ASTM E 8 guidelines. Test data and results were entered on the test data form. 4.3 ULTIMATE CAPACITI OF POWER STRUT FITTINGS f The following test arrangements were used: 4

=

6 4

Midland Plant Units 1 and 2 e i Elcctrical Rtcaway Support Tasts Rsport 05056i Testing Test Machine Power Arrange-Load Strut ment Application Load Fitting [Fiqure) Direction Increment 400 PS-3064 13 Compressian PS-3375 14 Tension 400 l PS-3033 (Testing not done because these items were J not available in the jobsite warehouse) PS-3127R 15 Compression 400 and L or Tension A dial gage was placed across the opening of the testing machine to measure vertical displacement of the specimen. At each load increment, the deflection was recorded on the test data sheet. The load was increased until failure occurred, and the failure load was recorded. 5.0 TEST EQUIPMENT Two testing machines were used: the Tinius Olsen Universal testing machine of Bechtel M&QS Laboratory, San Francisco, and ~ the Riehle Universal testing machine of Anamet Laboratories, Inc., Berkeley. The certificates of verification and calibration are in the appendir. 6.0 ACCEPTANCE CRITERIA ? n,w] Power Strut sections and cable traysd except fittings and spot welds, were designed on H e basis of an American Iron and Steel Institute (AISI) specification (Reference M). This specification uses the specified yield stength of base metal. To demonstrate 3 the adequacy of material in Power Strut channels and Husky trays, E it is sufficient to show that at least 95% of the members have yield strength equal to or larger than the specified value with a j confidence level of 95%. The fifth percentiles of yield stress were determined from the tests results. A cumulative distribution function was assumed for each item. X2 tests were performed to check the adequacy of this assumption with the confidence level of 95%. For soot welds and fittings, the structural acceptance-criteria are contained in Specification 7220-C-92(Q), Rev 1 (Reference K). Appendix A of this specification provides the minimum required spot weld strength and the minimum required Power Strut fitting strength. It is specified that if any test sample fails to meet 5 ~.

Midland Plant Units 1 and 2 Electrical Rcctway Support Tests Rtport 05056i or exceed these loads during the testing procedure, then further engineering analysis is required. The purpose of this analysis is to demonstrate, with 95% confidence, that at least 95% of the considered items are equal to or exceed the design loads. The fifth percentiles of strength were determined from the test results. A cumulative distribution function was assumed for each item and test was performed to check the adequacy of this assumption, ax with the confidence level of 95%. Safety factors were then calculated as ratios of the strength and design load. The safety factors were compared to the minimum required values. For spot welds AISI recommends a safety factor.of 2.5 i (Reference M). Specification 7220-C-501(Q), Rev 11 (which satisfies FSAR Section 3.8.6) allows a stress increase of 25% for operating basis earthquake (OBE) and 50% for safe shutdown earthquake (SSE). Based on these criteria, the minimum required safety factors for spot welds and fittings are: 2.50 - For the load combinations including dead load and live load 2.00 - For the load combinations including dead load, live load, and OBE (2.50 =2.00\\ (1.25 j 1.67 - For the load combinations including dead load, live load, andSSE[2.50=1.67 g.50 j l The load combination including dead load plus live load plus SSE ~ produces the largest design load. Therefore, if the corresponding safety factor exceeds 2.5, it also verifies the adequacy of the other two load combinations. 6.1 POWER STRUT BASE METAL The power strut channel manufacturer guarantees a minimum yield strength of 33,000 psi (Reference I). This value of yield stress was-used in the design. Therefore, the minimum acceptable 5th percentile of yield strength is 33,000 psi. 4 6. 2_ CABLE TRAY BASE METAL ~ Cable tray channels and rungs have a manufacturer's guaranteed minimum yield strenth of 30,000 psi. This value was used in the design.' Therefore, the minimum acceptable fifth percentile of yield strength is 30,000 psi. 6 i

O (.c;056i nidland Plant unita 1 and 2 w Electricel Raceway Support Ta ts R2 port 1 6.3 POWER STRUT SPOT WELDS The maximum design shear force for the Power Strut sections under SSE loads are given in Specification 7220-C-92(Q), Rev 1. These forces are obtained by adding the maximum static force envelope to the maximum dynamic force envelope at any location for each Power Strut section. This is conservative because the. greatest ~ dyn'amic shear does not necessarily occur at the same point as the greatest static shear. The maximum design load values were conservatively increased by 25%. Additional calculations were made for dead load plus live load, and dead load plus live load plus OBE loads (Reference C). The factors of safety are calculated for the considered load combinations. 6.4 CABLE TRAY SPOT WELDS In Specification 7220-C-92(Q), the acceptance criteria for the spot weld shear strength are based on the minimum recommended strength by the AISI specification (Reference M). In the following, the maximum allowable load or the minimum acceptable shear strength per weld is calculated using the maximum cable tray width, applicable maximum seismic accelerations, and maximum cable tie spacings. Safety factors are based on these calculated strengths. The linear safety criterion to calculate the minimum allowable shear force is: y+t< V T1 where v = shear force per weld due to loading (four welds per rung) V = allowable shear force t = tensile force per weld due to loading (four welds for rung) T = allowable tension As stated in Reference D, the tensile strength was conservatively i ass,umed to be 25% of the shear capacity: It can be seen that for the steel specified in the AISI specification, the tensile strength of spot Qelding can be conservatively taken as 25% of the shear strength. Therefore, the safety criterion becomes: 7 t 1

r50%i Midland Plant Unita 1 and 2 Elcctrical Ricsway Support Tasts Rnport il 4.t Z 25V V or v + 4t i V The weight of the rungs and cables (vertical) and the seismic f loads (vertical and horizontal) comprise the load. For-the four buildings involved, the maximum vertical ~ a, and horizontal accelerations, ah, were accelerations, y calculated (Reference E). The results are shown below. Maximum Vertical Horizontal Acceleration

  • Acceleration Building (q)

(q) Auxiliary building 1.188 0.62 Containment building 1.250 0.88 Diesel generator building 1.233 1.15 Service water pump structure 1.75 1.85

  • Including lg for dead load Pa Pa The shear force (v) and tension force (t) equal I V and I h, respectively (P equals mass of the rung and. attached. cables).

The working load is 70 lb/ft fer the 36-inch wide cable trays (see Reference F). The working load is lower for cable trays narrower than~36 inches. The safety criterion can be written as: Pa + Pah iV y 4 whereas P = 70 x Smax/9 where Smax = spacing between cable ties connecting cables to rungs; P is divided by four to determine the force per weld. (Four spot welds connect each rung, with two welds on each end.) Therefore, thekinimu)mvalueoftheallowableshearforceis: V = 70Smax (0.25ay ah)/9 + 4 The maximum allowable spacings between cable ties are given below (Reference G): 8 i

-{$Q$$l Midland Plant Units 1 and '2 Electrical Rtenwny Support Tosts Rsport AllowalbeLimit Building (ft) Auxiliary building 4.0 Containment building 3.6 Diesel generator building 3.0 Service water pump structure 2.0 The allowable shear forces, V, corresponding to the above-lihted spacings are calculated from the safety criterion: Allowable Shear Force per Weld i Building (lb) Auxiliary Building 257 Reactor Building 300 Diesel Generator 306 Building Service Water Pump 320 Structure f 6.5 POWER STRUT FITTINGS The maximum forces (shear, axial, or moment) for Power Strut fittings are given in Specification 7220-C-92(Q). The safety factors are calculated based on these forces. 7.0 TEST DATA The test data contained in Part 2 of this report include test records with tables of loads and deformations as well as load deformation plots. Typical load deformation plots are shown in 3 Figures 32 to 34 for Power Strut base metal, Figures 35 to 37 for Power Strut cable tray base metal, Figures 38 to 40 for Power Strut spot wells. In most cases, as illustrated by the plots, a ductile failure mode was observed. Thd three weakest spot welds in the Test Group D were subjected to metallographic examination by the Material and Quality Services Department (M&QS) in San Francisco. The results of this examination are summarized in Reference H. The photographs of welds and their cross sections exposing the fusion zone are shown in Figures 44 and 45. Reference H confirmed the reldtionship' between weld size (fusion zone area) and its shear strength. 9

Midland Plant Units 1 and 2 / Elc tri al REcLWEy Support Tata RLport 5056i Typical load deformation plots are shown in Figures 41, 42, and 43 for Power Strut fittings. The following modes of failure were observed in Power Strut fitting tests. Plastic deformation of base metal and rupture of the a. weld for Power Strut fittings PS-3064 and PS-3375 'b. In the case of PS -3127L and R, the prevailing' mode of failure was buckling of plates forming the fittings. The test results are summarized in Table 5 for Power Strut spot welds, Table 6 for Husky cable tray spot welds, Table 7 for Power Strut base metal tests, Table 8 for cable tray base metal channel tests, Table 9 for cable tray base metal rung tests, and Table 10 for Power Strut. fittings. 8.0 ACCEPTANCE CRITERIA VERSUS TEST DATA For each test group, the fifth percentile of resistance was determined. For base metal these values were compared to the minimum acceptable values. For spot welds and fittings, safety factors were calculated and compared to the minimum acceptable values. 8.1 POWER STRUT BASE METAL The Power Strut channel manufacturer guarantees a minimum yield strength of 33,000 psi (Reference I). The distribution function of yield strength for the test samples is shown on normal probability paper in Figure 16. The fifth percentile is 42,800 psi (Reference R) and exceeds 33,000 psi. This justifies l the adequacy of Power Strut base metal. 8.2 CABLE TRAY BASE METAL Cable tray channels and rungs have a manufacturer's guaranteed minimum yield strength of 30,000 psi. The tensile tests of base metal were performed to demonstrate that the fifth percentile of yield strength exceeds this value. 8.2'.1 Channels The distribution function of base metal yield strengtly for the test samples is shown on normal probability paper in F?ugur,g 17. Qs. The fifth percentile is 38,800 psi (Referenc,e'R{ - 30,000 psi. This justifies the adequacy of-Husty w..

.fi'

/~'~~~- - - - - - - - - 10

Midland Plant Units 1 and 2 05056i Elcactrical Rtcsway Support,Tu ts Rsport 8.2.2 Rungs The base metal yield strength distribution function for the test samples is shown on normal probability paper in Figure 18. The fifth percentile is 38,800 psi (Reference R) and it exceeds 30,000 psi. This justifies the adequacy of Husky rungs. 8.3-POWER STRUT SPOT WELDS The test results indicate significant. differences in the strengths of spot welds for various types of sections and welds. Generally, back-to-back spot welds are stronger than side-to-side or side-to-back welds. Spot welds connecting channels deeper than 1-5/8 inch (PS-200) show lower strength. The technological explanation for these strength variations is that longer or curved electrodes are less effective. The shear force in a spot weld (P) is caused by the shear force in the member (V). The following equation determines the relationship between P and V: P = QVd/(In) where ~ Q = static moment of the appropriate area d = spacing between welds; for Power Strut members, the maximum spacing is 3 inches ; d is conservatively assumed to equal'3 inches. I = moment of inertia of the section n = number of spot welds subject to shear in the considered plane Table 11 lists the basic section properties for the tested Power Strut sections. The adequacy of spot welds was checked separately for various sections and welds. j .g 8.3.1 PS-101, Back-to-Back Spot Welds, Test ID.A I X- ~ Two spot welds were tested and withstoodt4,080 and 790 pounds, The maximum design shear tercurin-the-s/ection, respectively. including SSE, is 123 pounds (Reference K). To check.the adiiquacy of spot welds, a design shear force equalling 200 pounds was used instead. The corresponding shear force per spot weld is 126 pounds (200 x 0.63). -(The value 0.63 is from Table 11. ) The joint distribution function for PS-101, PS-151, and PS-201 is 2 plotted in Figure 19. The following x test checks whether the 11

  • w--

w., - _ +, - -,. ,y --_,,e

5056i Midland Plant Unito 1 and 2 Electrical rec;wsy Supp3rt Tasts Rcport distribution is normal. A 95% confidence level was assumed. The test data indicate the maximum likelihood estimates of the mean and standard deviation are 3,'427 and 1,065 pounds, respectively. 2 For the X test, 11 intervals were considered; j denotes -in*arvals: j, i 1,'979 pounds -1,979 pounds < j2 1 2,426 pounds 2,426 pounds < j3 1 2,756 pounds 2,756 pounds < j, 1 3,033 pounds 3,033 pounds < j, 1 3,279 pounds 3,278 pounds < j, 1 3,576 pounds 3,576 pounds < j7 1 3,'821 pounds 3,821 pounds < j, 1 4,098 pounds 4,098 pounds < j, 1 4,428 pounds 4,428 pounds < jia 1 4,875 pounds 4,875 pounds < j3, According to statistical theory (Reference J), the following is a 2 X random variable, with 8 degrees of freedom (11-2-1): 11 E (x4 - nP4 )2 where X = number of spot welds with strength in interval "j " n = 58 (number of spot welds tested) Pj = probability of the strength to be in interval "j" if the distribution of strength was normal 2 Frcm the table of x distribution function (Reference J) acceptable 2 maximum value of X function to satisfy 95% confidence level is 15.5. The final test is: 11 E (X.; 2 (3 - 5.04)2 + ( 6 - 5. 03 )2 (8 - 5.26)2 + nP4 1 = + j=1 'q 5.04 5.03 5.26 (5 - 5.30)2 (9 - 5.14)2 (3 - 6.46)2 + ( 2 - 5.14 )2, + + 5.30 5.14 6.46 5.14 (5 - 5.30)2 + ( 5 - 5. 26 )2 + ( 8 - 5. 03 )2 (4 - 5.04)2 + 5.30 5.26 5.03 5.04 = 11.12 < 15.5 4 Therefore, the strength of back-to-back spot welds can be con _sidered as normally distributed with the mean 3,427-pounds and standard deviation of 1,065 pounds. The confidence level is 95%. The 5th percentile of this distribution, F.05, is calculated as O follows: i l l 12

Midland Plant Units 1 and 2 Elsctrical Racsway Support Tosto Rsport r:5056i 3,427 - 1,065 4-'(0.05) F = O.05 where 41(0.05) = inverse of standard normal distribution for 0.05; from a table of standard normal distribution, 4*'( 0. 05 ) = 1. 645 therefore s E'O.05 = 1,675 pounds The safety factor for A type weld is 13.29 (1,675 divided by 126). This justifies the adequacy of these welds. 8.3.2 PS-151, Back-to-Back Spot Welds, Test ID.B Four spot welds were tested and withstood 3,040; 3,960; 4,160; and 4,760 pounds. The maximum design shear force in the section, including SSE, is 27 pounds (Reference K). To check the adequacy of spot welds, a design shear force equalling 200 pounds was used. The corresponding shear force per spot weld is 168 pounds (200 times 0.84). The fifth percentile of strength, which was taken from the joint distribution for PS-101, PS-151, and PS-201 (see Section 8.3.1), is 1,675 pounds. The safety factor for B type weld is 9.97 i (1,675 divided by 168). This justifies the adequacy of these welds. 8.3.3 PS-155, Back-to-Back Spot Welds, Test ID.C One specimen with two spot welds was tested and withstood 6,860 pounds for two spot welds, or 3,430 pounds per spot weld. The maximum design shear force in the section, including SSE, is' 1,435 pounds (Reference K). The corresponding shear force per spot weld (two spot welds in a section) is 603 pounds (1,435 X 0.42). The fifth percentile of spot weld strength (taken from the joint distribution for PS-101, PS-151, and PS-201, see Section 8.3.1) is 1,675 pounds. The safety factor for C type welds is 2.78 (1,675 divided by 603). This justifies the adequacy of these spot welds. 8.3k4 PS-155, Side-to-Side Spot Welds, Test ID.C Eight specimens with two spot welds each were tested,;resulting in the following shear force per weld: 3,330; 3,840; 4,190; 4,608; 5,100; 5,600; 6,100; and 7,000 pounds. 1 The strength distribution function is plotted on normal probability paper in Figure 20. Because the sample size is small, the fifth percentile of weld strength cannot be determined l l 13 l [ _.p. . _. _ ~.

Midland Plant Units 1 and 2

i. 5 0 5 6 i ricctrical Racsway Support Tasto Raport from the tests of PS-155 members.

Instead the analysis is based on test data for PS-152, which are made of two identical channels welded side to side. In Reference R, it is shown that the cumulative distribution function of shear strength for I tests can be approximated by a normal function with the mean 3,755.5 pounds and standard deviation 1,606 pounds. In a PS-155 section, there are two statistically independent side-t_o-side spo't welds. Therefore, the shear strength per weld in'a PS-155 section is also normally distributed with the mean the same as in 3 and the standard deviation is equal to I tests,J,755.5 pounds, 1,606. = 1,135.5 pounds. The fifth percentile of shear strength per weld of side-to-side welds in PS-155 is F = 3,755.5 - 1,13 5. 54*1 (0. 0 5 ) O.05 where I 4~'(0.05)4-' = 1.645, as defined in Section 8.3.1, and therefore, F0.05 = 1,887 pounds The maximum design shear force due to dead load and live load is 609 pounds (Reference C). The corresponding shear force per spot weld is 329 pounds (609 times 0.54). The safety factor is 5.74 (1,887 divided by 329). The maximum design shear force due to dead load, live load, and SSE is 1,435 pounds (Reference K). The corresponding shear force per spot weld (two spot welds in a section) is 775 pounds (1,435 times 0.54). The safety factor is 2.44 (1,887 divided by 775). These safety factors satisfy the minimum requirements specified in Section 6.0, which justify the adequacy of these spot welds. 8.3.5 PS-201, Back-to-Back Spot Welds, Test ID.D PS-201 is the most common type of section used in electrical raceway supports. The distribution function of strength of back-to-back spot welds, which was obtained from the tests, is shown in Figure 19. Power Strut PS-201 members are welded by four l different electrodes so that each of any four consecutive welds j are, statistically independent (References N and 0). The distribution of strength of back-to-back spot welds for PS-201 can be approximated by a normal distribution function with a confidence level of 95% (see Section 8.3.1). The minimum number of spot welds in electrical raceway supports l is three (Reference G). Any four consecutive welds in PS-201 are statistically independent. Therefore,, the shear capacity of a 14 c- ,-.m.- ,.,w --c. -w.e%, .w---,.-

Midland Plant Units 1 and 2 Electrical Recaway Support Tasta Rtport {.5056i system of three spot welds can be derived from the basic theory of probability (Reference J) as follows. The strength of a single weld in PS-201 is normally distributed, with a mean 3,427 pounds and a standard deviation of 1,065 pounds. The joint strength of three welds is also normally distributed, with the mean equalling the sum of the means for single welds, 3 x 3,427 = 10,281 pounds, and the variance equalling the sum of variances, or standard deviation equalling (3 x 1,0652 )l'2 = 1,845 pounds. The strength per single weld (in a 4 set of three) is also normally distributed with the mean equalling 10,281 3 = 3,427. pounds and the standard deviation equalling 1,845

  • 3 = 615 pounds.

For comparison, Figure 21 shows the normal distributions of weld strength for a single weld and for a weld in a set of three independent welds. ) s calculated as The fifth percentile of D type welds (F0.05 follows: 4 F = 3,427 - 615 4"(0. 05) 0.05 where 4~'(0.05) = 1.645, as defined in Section 8.3.1 therefore: F = 2,415 pounds O.05 The maximum design shear force due to dead load and live load is 703 pounds (Reference C). The corresponding shear force per spot weld is 865 pounds (703 times 1.23). The safety factor is 2.79 (2,415 divided by 865). The maximum design shear force due to dead load, live load, and ~ OBE is 789 pounds (Reference C). The corresponding shear force per spot weld is 970 pounds (789 times 1.23). The safety factor is 2.49 (2.415 divided by 970). The maximum design shear force due to dead load, live load, and j SSE is 1,090 pounds (Reference K). The corresponding shear force per spot weld is 1,340 pounds (1,090 times 1.23). The safety factor is 1.80 (2,415 divided by 1,340). The above safety factors satisfy the minimum requirements specified in Section 6.0, which justifies the adequacy of these i spe7t welds. 8.3.6 PS-202, Side-to-Side Spot Welds, Test ID.E The distribution function of strength is shown on normal i probability paper in Figure 22. The fifth percentile is l 3,800 pounds (Reference R). 15

b bl Midland Plant Unita 1 and Electrical RtcEway Support Tacts Report The maximum design shear force per member, including SSE, is 645 pounds (Reference K). The corresponding shear force per spot weld is 716 pounds (645 times 1.11). The safety factor is 5.31 ) (3,800 divided by 716). This justifies the adequacy of these spot welds. 8.3.7 PS-204, Side-to-Back Spot Welds, Test ID.F The strength distribution function is shown on normal probability paper in Figure 23. The 5th percentile is 1,400 pounds (Reference R). The maximum design shear force per member, including SSE, is 115 pounds (Reference K). To check the adequacy of the spot welds, a design shear force equalling 200 pounds was used. The corresponding shear force per spot weld is 250 pounds (200 times 1.25) The safety factor is 5.6 (1,400 divided by 250). This justifies the adequacy of these spot welds. 8.3.8 PS-207, Side-to-Back Spot Welds, Test ID.G There are three spot weld connections in a PS-207 section. Two spot welds were tested simultaneously. The resulting distribution function is shown on normal probability paper in Figure 24. The number of tested samples of this item does not allow direct determination of the fifth percentile'of the shear strength of spot welds. The side-to-back spot welds in PS-207 ~ are similar to those in PS-204. Therefore, the fifth percentile shear strength per weld of Section PS-204 is taken for PS-207 F.05= 1,400 pounds. This value is (Section 8.3.7);therefore, 0 conservative because in PS-207 sections there are two statistically independent welds. The maximum design shear force per member, including SSE, is 270 pounds (Reference K). The corresponding shear force per spot weld is 149 pounds (270 times 0.55). The safety factor is 9.52 (1,400 divided by 149). This justifies the adequacy-of these i spot welds. 8.3.9 PS-205, Back-to-Back Spot Welds, Test ID.H i One specimen with two spot welds was tested and withstood 2,655 pounds per weld. The maximum design shear force per member, including SSE, is 25 pounds (Reference K). A design shear force of 200 pounds was used to check adequacy of spot welds. The corresponding shear force per spot weld is 124 pounds (200 times 0.62 ). The fifth percentile of spot weld strength, 1,675 pounds, was taken from the joint distribution for PS-101, PS-151, and PS.-201 4 (see Section 8.3.1). The safety factor is 13.51 (1,675 divided by 124). This justifies the adequacy of these spot welds. 16 _ ________,J

Midland Plant Units 1 and 2' O'S056i Electrical Rtcsway Support Tosta Rnport 8.3.10 PS-205, Side-to-Side Spot Welds, Test ID.H Seven specimens with two spot welds were tested and each weld withstood the following: 4,700; 4,800; 5,600; 5,600; 6,000; 7,800; and 8,000 pounds. The distribution function is plotted on normal probability paper in Figure 25. The size of the sample does not allow for direct calculation of the fifth percentile of shear strength of a spot weld with a confidence level cf 95%. Therefore, the test data for PS-202 were used. PS-202 is made of identical channels connected by side-to-side spot welds. From Reference R, the fifth percentile is 3,800 pounds. The maximum design shear force per member, including SSE, is 25 pounds (Reference K). To check the adequacy of spot welds, a design shear force of 200 pounds was used. The corresponding shear force per spot weld is 110 pounds (200 times 0.55). The safety factor equals 34.5 (3,800 divided by 110). This justifies the adequacy of these spot welds. 8.3.11 PS-152, side-to-Side Spot Welds, Test ID.I The strength distribution function is shown on normal probability paper in Figure 26. The fifth percentile is 1,114 pounds (Reference R). The maximum design shear force per member, including SSE, is I 270 pounds (Reference K). The corresponding shear force per spot weld is 289 pounds (270 times 1.07). The resulting safety factor is 3.85 (1,114 divided by 289). This justifies the adequacy of these spot welds. 8.3.12 PS-3151, side-to-Back Spot Welds, Test ID.J The strength distribution function is shown on' normal probability paper in Figure 27. The fifth percentile is 3,471 pounds (Reference R). The maximum design shear force per member, including SSE, is 1,369 pounds (Reference K). The corresponding shear force per spot weld is 1,054 pounds (1,369 times 0.77). The safety factor is 3.24 (3,417 divided by 1,054). This justifies the adequacy of these spot welds. i 8.4', CABLE TRAY SPOT WELDS The' test results are plotted on normal probability paper in

Figure 28.

TW ~~fth percentile of shear strength per spot weld

~

To check the adequacy of the spot .,i's.11, S3 Q~ f"[j' u.teIence R). . gs to the channels, maximum design shear wel'dsic6nnec 4-t forces per weld (Section 6.4) were compared with 1,536 pounds ( fifth percentile of strength). The results are as follows: i l l 17 l

Midland Plant Units 1 and 2

  • i5056i E1ccerical Rtcavay Support To=ts Report 1

Required Strength Including SSE Building (lbs) Safety Factor Auxiliary Building 257 5.97 Reactor Bui3 ding 300 5.11 Diesel Generator 306 5.02 Building Service-Water Pump 320 4.79 Structure Spot welds connei: ting the rungs to the channels in 9 inch cable trays were not tested because these. items were not unavailable in the jobsite warehouse. The spot welds in 9 inch cable trays are identical to the spot welds in wider cable trays. The werking load..for the 9 inch-wide cable tray is 18 lb/ft against 70 lb/ft -for 36 inch-wide cable tray. Thus, the spot welds in 9 inch cable trays satisfy the minimum requirements. This justifies the adequacy of spot welds connecting rungs to channels in cable trays. 8.5 POWER STRUT FITTINGS 8.5.1 Power Strut Fitting PS-3064 The maximum design compression force per fitting, including SSE, is 1,090 pounds (see Reference P). Figure 29 shows the ultimate capacity distribution. The fifth percentile is 31,340 pounds i (Reference R). The resulting safety factor is 28.75 (31,340 divided by 1,090), which justifies the adequacy of these fittings. 8.5.2 Power Strut Fittinc PS-3033 No samples were tested because these items were unavailable in-the jobsite warehouse. The Power Strut fittings PS-3064 and PS-3033 are similar (Figure 10). Hence, the fifth per centile strength for PS-3033 is based on PS-3064. The length of the weld in PS-3033 is 5.90625 inches, and 7.53125 inches in PS-3064 (Page 45, Reference I). Fifth percentile strength for PS-3064 is 31,340 pounds (Reference R). Therefore, fifth percentile strength for PS-3033 is 31,340 x 5.90625 7.53125 =24 578 pounds The maximum design force for PS-3033 is 4,150 pounds (Reference P). The resulting safety factor is 5.92 (24,578 divided by 4,150). This justifies the adequacy of these fittings. 18 y r---,w-y .-c-w,-m -y--r-;-g y ,g- -y .r-- ---e --w ,e--,- --,-a, r w-

Midland Plant Units 1 and 2 Electrical Rtenway Support Tasts Rnport 05056i 8.5.3 Power Strut Fitting PS-3375 The maximum design tensile force per fitting, including SSE, is 4,320 pounds (see Reference P). The accelerations for SSE are tabulated in Section 6.4. The lowest acceleration due to SSE is j the vertical component for the auxiliary building, 0.188 g. Therefore, for PS-3375, it is assumed that the maximum design load due to dead and live load is 4,320 1.188 = 3,636. pounds. Figure 30 shows the distribution of ultimate capacity. The fifth percentile is 9,200 pounds, (Reference R) and the safety factor is 2.53 (9,200 divided by 3,636), for dead and live load i condition and 2.13 (9,200 divided by 4,320) for dead load, live load, and SSE loading condition which justifies the adequacy of these fittings. 8.5.4 Power Strut Fitting PS-3127 L and R The maximum design compression load per fitting is 1,179 pounds (Reference P). According to Specification 7220-C-92(Q), the direction of load application (tension or compression) for PS-3127R&L fittings was to be based on four initial tests: two in tension and two in compression. The remaining fittings were to be tested following the governing mode. However, this procedure was not followed in selection of the test mode. Only two specimens were tested, one in tension and one in compression. The results of these initial tests were: 7,900 pounds in compression and 7,600 pounds in tension. Despite these results, 62 fittings were tested in compression. The tests were arranged so that two fittings (one left and one right) were loaded simultaneously. The resulting capacity is the capacity of two. fittings. The test results are shown on normal probability paper in Figure 31. The fifth percentile of a single fitting capacity was determined in Reference R. The distribution for fittings was approximated by a normal distribution function, with a mean of 9,397 pounds and a standard deviation of 627 pounds. These values represent the parameters for double fittings. For single fittings, the distribution of capacity is also normal, with the mean 4,698 pounds (9,397

  • 2) and a standard deviation equal to 443 pounds (627 *,/2).

The corresponding normal distribution for single fittings is also shown in Figure 31. The fifth percentile of the single fitting capacity is: i I I 19 1 i .. ~...

'O5056i Midland Plant Units 1 and 2 Electrical Racsway Support Tanta Report F.05 = 4,698 - 443 + ' (O. 0 5) 0 where 4~'(0.05) = 1.645, as defined in Section 8.3.1, and v.herefore, ,9 9 Pounds. F = O.05 The resulting safety factor is 3.37 (3,969 divided by'1,179), wh,ich justifies the adequacy of these fittings. m 9 20 ,y _.,r._.--

0505Si $20/8/fN/ S 4 6 5 3 f! LAsonAToRY CERTIFICATE ,r namet J h.60t a t o ri e s ANALYTICAL 1 ' n c.

    • '- ** '.6 3 CA4.

META M.U ans'- =.e.ase - ....6.,c...,.....,,. ' mesa rs= e=Aruna A m ase. samen December 18, 1979 i BLN: 1279-5 M&QS Log #JCG 1279-34 LABORATORY NUMBER: Job #531/-/0002 1279.242 A P.O. 50S1-8-00096 s SAMPLE: Calibration of Dial Calipers MARK: 6" Dial Micrometer S/N 16 Brown & Sharpe No. 579/1 DATE GUBMITTED: December 18, 1979 REPORT TO: Bechtel National, Inc. P.O. Box 3965 San Francisco, California 94119 Attn: Mr. R. T. Dillon R[PQRI True Length, Measured Length 0.0000" 0.1600" 0.000" 0.2500" 0.159(5)" 0.5000" 0.249(7)" 1.0000" 0.499(7)" 2.0000" 1.001(4)" 3.0000" 1.999(5)" 4.0000" 2.999(5)" 5.0000 4.001" 4.999(5)" 4/24/79, traceable to NBSUsed Jo blocks and End standards, calibrated by Ul 232.12/216449 _12/218345, 11 April 1978, NBS 213.12/216449,, 25 May 1977, and NBS 213. n 25 May 1977. Respectfully submitted, ANAMET LABORATORIES, INC. ~ By_ b. Ca. h. =, I. A. Foreman Manager, Quality Control , jm

TABLE 1

SUMMARY

OF SPOT WELD TEST RESULTS c: Ln. CD I Strength (1b)- f cn-I23 (per weld) Design Load Calculated ao Type of Fifth ( pe r we ld ) Loading Safety Item Weld Average Percentile (1b) Condition Factor PS-201 Back-to-back 3,427 2,415 865 D+L 2.79 970 D+L+E 2.49 1,340 D+L+E'. 1.80 PS-101 Back-to-back 3,427 1,675 126 D+L+E' 13.29 PS-151 Back-to-back 3,427 1,675 168 D+L+E' 9.97 PS-205 Back-to-back 3,427 1,675 124 D+L+E' 13.51 PS-155 Back-to-back 3,427 1,675 603 D+L+E' 2.78 PS-152 Side-to-side 3,756 1,114 289 D+L+E' 3.85 i PS-202 Side-to-side 5,063 3,800 716 D+L+E' 5.31 PS-155 Side-to-side 4,808 1,887 329 D+L 5.74 775 D+L+E' 2.44 i PS-205 Side-to-side 5,644 3,800 110 D+L+E' 34.50 PS-204 Side-to-back 3,732 1,400 250 D+L+E' 5.60 PS-207 Side-to-back 3,578 1,400 149 D+L+E' 9.52 g PS-3151 Side-to-back 5,631 3,417 1,054 D+L+E' 3.24 5$ I Cable Rung-to-2,227 1,536 320 D+L+E' 4.79 ea na l Tray Channel "5' o Notes: 1. In the above table, D, L, E, and E' denote: aw ) D - Dead load WD l L - Live load E" E - Operating Basis Earthquake (OBE) E' - Safe Shutdown Earthquake (SSB) Nna 2. Required factor of safetyt m /* D+L 2.5 e p. D+L+E 2.0 g, l oo D+L+E' l.67 na 3. Factor of safety is not computed for D+L and D+L+E loading conditions for N g those items where safety factor for D+L+E' loading condition is nore than 2.5 m mn 4. Factor of safety is not computed for D+L+E loading condition for those items where FS for D+L+E' is more than 2.0 g En 6 s

E Midland Plant Units 1 and 2 05056 E1actrica1 arc 2,2y Support T.t asport i TABLE 2

SUMMARY

OF BASE METAL TEST RESULTS Yield Stress Design (psi) Yield Fifth Strength Item Average percentile (psi) Power Strut 47,268 42,800 33,000 channels Cable tray 43,091 38,800 30,000 channels Cable tray 47,923 38,800 30,000 rungs e W 1 6 W e 9 4 =

  • e T-2

~i~T'~T

Midkand Plant Units 1 and 2

05056, Eiccerical Rtcavay Support Taata Rsport i

TABLE 3

SUMMARY

OF POWER STRUT FITTINGS TEST RESULTS Strength (lb) Design . Calculated (2) Fifth Load Loadin# Safety Item Average Percentile (lb) Condition Factor PS-3064 34,209 31,340 1,090 D+L+E' 28.75 PS-3033"U 24,578 - 4,150 D+L+E' 5.92 PS-3375 13,211 9,200 3,636 D+L 2.53 4,320 D+L+E' 2.13 PS-3127 L&R 4,698 3,969 1,179 D+L+E' 3.37 Notes: 1. In the above table, D, L, E, and E' denote: D - Dead' load L - Live load E - Operating Basis Earthquake (OBE) E' - Safe Shutdown Earthquake (SSE) 2. Required factor of safety: D+L 2.5 D+L+E 2.0 D+L+E' 1.67 3. Factor of safety is not computed for D + L and. D + L + E loading conditions were safety factor for D + L + E' loading condition is more than 2.50. 4. Factor of safety is not computed for D + L + E load-ing condition where safety factor for D + L + E' loading condition is more than 2.0. l S. For strength evaluation of PS-3033, see Section 8.5.2. l 9,,y 2 . e, T-3

Midland Plant Unita 1 and 2

05056, Eiccericci acc;way Support Tacta a2 port i

- l TABLE 4 NUMBER OF SAMPLES SELECTED FOR TESTS Total Job Quantity Number (at Time of Sample of Category Item Sampling) I.D. Samples Remarks ) Power Strut PS-201 147,000 ft D 52 spot welds, PS-151 12,500 ft B 4 back-to-back PS-101 5,250 ft A 2 PS-155 3,350 ft C 1 Double weld PS-205 2,700 ft H 1 Double weld Power Strut PS-202 10,100 ft E 25 spot welds PS-152 8,100 ft I 20 side-to-side PS-155 3,350 ft C 8 Double weld PS-205 2,700 ft H 7 Double weld Power Strut PS-204 11,440 ft F 16 spot welds, PS-207 8,000 ft G 12 Double weld side-to-back PS-3151 22,200 ft J 32 Cable tray 9-inch

  • 1,008 ft spot welds 12-inch 2,796 ft 12S 3

Double weld 18-inch 7,104 ft 18S 8 Double weld 24-inch 30,876 ft 24S 37 Double weld 36-inch 3,600 ft 36S 4 Double weld Power Strut PS-201 147,900 ft D 37 base metal PS-151 12,500 ft B 3 tension PS-101 5,250 ft A 1 tests PS-155 3,350 ft C 2 PS-205 2,700 ft H 1 PS-202 10,100 ft E 3 PS-204 11,440 ft F 3 PS-207 8,000 ft G 2 PS-152 8,100 ft I 2 PS-3151 22,200 ft J 6 Cable tray 9-inch

  • 1,008 ft
channels, 12-inch 2,796 ft 12S 2

bas'e metal 18-inch 7,104 ft 18S 5 tension 24-inch 30,876 ft 24S 21 tests 36-inch 3,600 ft 365 3 i ~ i Cable tray 9-inch

  • 1,008 ft j
rings, 12-inch 2,796 ft 12S 2

base metal 18-inch 7,104 ft 18S 5 tension 24-inch 30,876 ft 24S 21 tests 36-inch 3,600 ft 36S 3 l T-4 l l

Midland Plant Unita 1 and 2

05056r, s1,ctrion1 acctyay support root, a; port,

Table 4 (continued) Total Job Quantity Number (at Time cf Sample of Category Item Sampling) I.D. Samples Remarks Power strut PS-3064 950 39 fittings PS-3375 2,200 40 PS-3127 3,531 62 Two fittings L&R at a time PS-3033* 700

  • No samples were selected because the items were unavailable in the jobsite warehouse.

For strength evaluation of 9-inch cable trays and PS-3033 fittings, see Sections 8.4 and 8.5.2. e 4 T-5 v. .wrw v gy,- g w.y

Midland Plant Unita 1 and '2 Electrical Rrc;way Support Teata RLport TABLE 5 POWER STRUT SPOT WELD TEST RESULTS Actual Shear Strength Sample per Weld No. of Welds Type of weld Item ID No. (1b) per Test Back-to-back PS-101 A-1 4,080 One A-2 790 Back-to-back PS-151 B-1 3,040 One B-2 3,960 B-3 4,160 B-4 4,760 Back-to-back PS-155 C-1 3,430 Two Back-to-back PS-201 D-1 4,410 One D-2 4,780 D-3 4,720 D-4 2,920 D-5 4,020 D-6 3,220 D-7 3,240 D-8 2,570 D-9 2,170 D-10 2,610 D-11 3,080 D-12 3,650 D-13 5,220 D-14 3,180 D-15 1,120 D-16 4,540 D-17 3,210 D-18 3,200 D-19 2,740 D-20 4,780 D-21 2,780 D-22 3,370 D-23 4,310 D-24 3,590 D-25 6,030 D-26 3,250 ~ ~ D-27 2,350 D-28 2,120 D-29 4,770 l D-30 2,680 l D-31 3,470 D-32 3,270 T-6

Midland Plant Unita 1 and 2 e5056l Elcctrical Rccewny Support Toets Rrport Table 5 (continued) Actual Shear Strength Sample per Weld No. of Welds Type of weld Item ID No. (lb) per Test D-33 2,630 D-34 4,420 D-35 5,180 D-36 2,600 D-37 4,780 D-38 3,900 D-39 2,630 D-40 2,150 D-41 1,960 D-42 4,130 D-43 2,080 D-44 3,850 D-45 2,830 D-46 2,900 j D-47 2,980 D-48 2,000 D-49 1,630 t D-50 3,320 l D-51 4,730 D-52 4,910 Back-to-back PS-205 H-1 2,655 Two Side-to-side PS-152 I-1 2,820 One l I-2 1,600 I-3 1,100 I-4 3,150 I-5 2,400 I-6 4,680 I-7 6,230 I-8 3,200 I-9 4,000 I-10 3,680 I-11 6,080 I-12 4,820 I-13 4,950 I-14 3,900 ( I-15 1,350 I-16 4,840 J.~ 1-17 4,130 I-18 1,000 I-19 5,460 1-20 5,720 T-7

05056i nid1.ne Plant units 1 and 2 Elsctrical Rtceway Support Tests R; port Table 5 (continued) Actual Shear Strength Sample per Weld No. of Welds Type of weld Item ID No. (lb) per Test __ Side-to-side PS-155 C-2 5,600 Two C-3 3,840 C-4 7,000 C-5 4,190 C-6 6,100 C-7 3,330 C-8 5,100 C-9 4,680 Side-to-side PS-202 E-1 4,002 One E-2 5,320 E-3 5,400 E-4 7,620 E-5 5,550 E-6 4,560 E-7 3,980 E-8 5,400 E-9 4,240 E-10 4,140 E-11 6,800 E-12 3,800 E-13 5,000 E-14 6,030 E-15 6,740 E-16 4,180 E-17 4,740 E-18 5,380 E-19 4,770 E-20 4,660 E-21 5,280 E-22 5,720 E-23 4,030 E-24 4,480 E-25 4,760 Side-to-side PS-205 H-2 4,800 Two H-3 5,600 H-4 6,000 H-5 8,000 J.- E-6 7,800 H-7, 4,700 H-8 5,600 1 1 T-8 .m.

05056i midland Plant unita 1 and 2 Elcctrical REceway Support Tacts R; port Table 5 (continued) Actual Shear Strength Sample per Weld No. of Welds Type of weld Item ID No. (lb) per Test Side-to-back PS-204 F-1 1,600 One F-2 3,120 F-3 3,200 F-4 3,880 F-5 4,440 F-6 4,220 F-7 4,460 F-8 4,580 F-9 3,900 F-10 3,500 F-11 3,570 F-12 6,270 F-13 3,970 F-14 '2,170 F-15 3,580 F-16 3,250 Side-to-back PS-207 G-1 2,010 Two ~ G-2 4,440 G-3 3,620 G-4 4,400 G-5 2,550 G-6 4,220 G-7 3,310 G-8 3,600 G-9 2,910 d G-10 3,490 G-11 4,600 G-12 3,780 Side-to-back PS-3151 J-l 7,120 One J-2 5,400 J-3 4,400 J-4 4,700 l J-5 9,280 l J-6 5,720 J-7 5,820 J-8 8,000 J-9 5,460 J.- J-10 5,430 J-11 5,130 J-12 3,670 T-9 a v... _- ~..,, _ -.. _,

05056i Midland Plant Units 1 and 5 Electrical Rtceway Support Tcats R; port 1 Table 5 (continued) 1 Actual Shear Strength Sample per Weld No. of Welds Type of weld Item ID No. (lb) per Test J-13 5,040 J-14 6,640 J-15 7,680 J-16 6,520 J-17 5,710 J-18 6,170 J-19 5,550 J-20 5,260 J-21 5,460 J-22 3,030 J-23 5,520 J-24 6,000 J-25 6,650 J-26 6,170 J-27 6,350 J-28 5,380 J-29 2,800 J-30 3,920 J-31 4,760 J 5,460 4

  • w_

) T-10 i I

Midland Plant Units 1 and 2 ' Electrical Rrc;wny Support TCata R; port 05 ~^: TABLE 6 HUSKY AND BURNDY CABLE TRAY SPOT WELD TEST RESULTS Actual Shear 4 Strength _Cd31e Tray Width sample per Weld (in.) ID No. (lb) 12 125-71 2,350 12S-89 2,310 12S-94 2,200 18 18S-6 2,350 185-8 2,375 185-18 1,825 18S-22 2,415 18S-27 2,500 185-29 2,400 18S-32 2,100 18S-36 2,125 24 24S-1 2,800 245-12 2,370 245-18 2,400 24S-28 2,730 245-35 1,,?00 245-44 2,860 24S-51 2,860 245-52 2,900 245-63 2,060 24S-74 2,720 24S-80 2,440 24S-82 2,290 24S-87 2,500 245-116 2,340 24S-118 1,100 245-132 2,150 24S-156 2,550 245-161 2,390 24S-181 1,100 24S-186 1,650 24S-195 1,750 24S-205 2,520 24S-214 2,300 245-223 2,060 24S-237 ~- 2,125 245-244 2,130 245-258 2,310 245-263 2,350 24S-264 2,270 24S-267 2,220 T-11

0cci nidiand plant units 1 ane 2 r su u Elcctrical Rcccway Support Tcata Rsport TABLE 6 (continued) Actual Shear Cable Tray Strength Width Sample per Weld (in.) ID No (lb) 245-291 1,200 245-309 2,170 24S-321 2,520 24S-324 2,330 24S-342 2,080 245-374 2,160 24S-394 . 1,440 36 365-30 2,370 365-37 2,175 36S-39 2,285 36S-44 2,700 O d

  • e_

i l T-12

b b5 Midland Plant Units 1 and 2 Elcctriccl Rtcewny Support Tacts R port t TABLE 7 POWER STRUT BASE MATERIAL TENSION TEST RESULTS Actual Yield Sample Strength Item ID No. (psi) PS-101 A-1 45,565 PS-151 B-1 46,332 B-2 57,340 B-3 46,332 PS-155 C-6 52,885 C-7 47,297 PS-201 D-1 45,059 D-2 45,585 D-3 46,000 D-4 45,110 D-5 44,715 D-6 45,142 D-7 46,337 D-8 45,214 D-9 46,906 D-12 44,508 D-13 45,040 D-15 45,309 D-16 46,414 D-17 45,635 D-19 47,177 D-20 49,899 D-21 47,337 D-22 41,284 D-23 44,355 D-26 49,495 D-27 46,365 D-29 43,515 D-30 44,578 D-31 46,625 D-33 45,996 D-34 45,491 D-36 44,862 D-37 46,573 ~ D-38 45,749 D-39 45,566 D-41 43,788 D-42 49,903 D-43 50,100 D-44 49,513 D-46 48,000 1-13 t

UDU301 Midland Plant Units 1 and 2 Elcctrical Rcceway Suppcrt Tests R; port TABLE 7 (continued) Actual Yield Sample Strength Item Id. No. (psi) D-51 51,935 D-52 46,392 PS-202 E-26 50,625 E-27 50,891 E-28 54,082 PS-204 F-9 49,808 F-11 49,705 F-12 50,803 PS-207 G-7 43,595 G-8 42,214 PS-205 H-9 51,650 PS-152 I-19 42,945 I-20 44,311 PS-3151 J-33 52,713 J-34 48,466 J-35 55,970 J-36 44,074 J-37 52,998 J-38 S4,016 I I e

  1. 6 0

T-14 ~

.y$0$$i Midland Plant Units 1 and 2 Electriccl Rtcewsy Support Tsots Rsport TABLE 8 CABLE TRAY BASE. MATERIAL CHANNEL TEST RESULTS Cable Tray Actual Yield i Width-Sample Stre.ngth (in.) ID No. (psi) 12 125-96C 47,672 125-106C 48,768 18 185-3C 41,962 18S-4C 44,101 185-15C 42,520 185-25C 41,667 185-34C 42,105 24 245-33C 44,032 245-58C 47,170 24S-62C 38,120 24S-77C 41,444 41,417 24S-88C l 245-102C 39,889 24S-131C .38,251 245-150C 42,541 245-153C 40,437 245-167C 43,646 245-173C 42,781 245-234C 45,902 245-247C 39,617 245-270C 40,000 24S-295C 41,322 24S-338C 42,703 245-343C 43,407 245-351C 45,179 245-362C 43,597 24S-370C 44,205 245-393C 44,444 36 365-7C 44,687. 365-10C 46,900 365-40C 45,355 t T-15

c505Si Midland Plant Units 1 and 2 ' Electrical Rrceway Support Tsats R; port TABLE 10 POWER STRUT FITTING TEST RESULTS Sample Ultimate Strength Item ID. No. (lb) PS-3064 1 34,600 2 34,150 22 33,800 35 32,275 53 35,900 68 36,050 84 34,300 99 32,350 102 32,950 122 31,050 144 31,400 156 38,150 159 35,150 170 35,350 226 36,850 258 36,300 314 36,.050 354 32,150 363 34,200 381 37,100 400 32,100 419 33,800 455 34,050 462 32,800 477 35,950 504 32,725 513 32,900 515 33,025 523 34,400 570 34,250 605 35,900 628 35,800 633 33,900 668 34,400 732 30,650 769 36,250 65 33,125 230 33,050 304 34,9.50 PS-3375 1 13,700 35 13,700 55 14,700 8 3' 15,000 102 10,800 T-17 w M T -v g-^ --' =- 8 e ---w---y 9 -- ---- -= --e

05056i Midland Plant Units 1 and 2 ' Elcctricc1 RCcew2y Supp0rt TOcts R3 port TABLE 10 (continued) Sample Ultimate Strength Item ID. No. (lb) 107 13,600 133 12,600 156 15,000 161 12,800 193 11,000 228 13,000 247 15,700 253 15,700 270 15,400 358 13,500 364 13,300 409 14,700 483 12,400 497 15,000 498 13,700 534 14,100 562 15,000 575 12,600 604 14,000 634 12,'700 664 14,450 690 14,000 733 15,000 757 13,560 799 12,800 814 7,670 817 13,000 829 10,000 904 9,500 959 10,700 996 15,440 1005 11,600 1060 12,500 1161 12,000 1221 12,500 PS-3127 L&R 2L/1331R 9,000 56L/1552R 9,900 137L/479R 9,099 175L/632R 9,020 219L/1500R 9,140 257L/980R 8,800 265L/1507R 9,300 l 294L/330R 10,040 315L/111R 8,580 318L/1092R 9,650 376L/645R 8,630 l l l T-18 l

U Midland Plant Units 1 and 2 - Electrical Rtcewny Support TCots R;9ert TABLE 10 (continued) Sample Ultimate Strength Item ID. No. (lb) 393L/1630R 9,800 407L/2R 8,95.0 444L/621R 9,900 591L/215R 9,440 601L/209R 10,180 -780L/968R 9,340 796L/142R 9,880 820L/1421R 9,340 854L/136R 9,880 880L/1R 9,820 995L/317R 9,040 996L/1456R 9,140 1045L/887R 9,400 1095L/751R 9,140 1194L/847R 9,300 1209L/1221R 10,570 1260L/423R 9,950 1317L/1417R 10,440 1347L/239R 10,420 1367L/305R 9,600 1382L/541R-9,300 1582L/178R 10,000 1642L/1343R 9,540 1657L/1535R 9,140 1730L/547R 9,440 1748L/487R 9,180 1797L/1068R 8,480 ~ 1851L/714R 10,000 1916L/1088R 8,860 2011L/1022R 8,550 2014L/666R 8,780 1138L/46R 8,950 416L/73R 9,640 926L/232R 8,060 1L/255R 8,680 766L/258R 9,390 1507L/337R 9,300 167L/360R 9,790 90L/363R 8,330 1342L/665R 9,050 1754L/692R 8,370 1249L/768R 9, LQO ~ 674L/807R 10,410 391L/922R 10,780 948L/1108R 9,640 821L/1120R 9,780 447L/1208R 10,140 T-19

'O505Si nialand Plant unit. 1.na 2 Electrical Rcceway Suppsrt Tact 3 Raport TABLE 10 (continued) Sample Ultimate Strength Item ID. No. (lb) 1490L/1282R 9,997, 1894L/1402R 7,670 667L/1632R 9,990 521L/1012R 9,400 e W 4 i f 1 } e T-20

05056i 3WER S-L-~ S EC'~ O \\' J ES G \\W O \\'S i 853e u a r1 r L 1 r' r 7 r PS 201 PS 202 PS 204 r, e r 7 L l I J F J LJ L PS 205 PS 207 PS 3151 r, r r, r L J F J LJ L PS IST PS 152 PS 155 u: \\ .a p PS 101 rG AE

0'5 c'S ". - ~~ ES-~ SA V? __ E CO \\ G aA-.0 \\ S i , 0 : a :. ITEM PS 2OI l TYPICAL FOR PS101., PS 151 / 4h" TYPICAL w x y .___-__---1_. x s r. x .x l' 3" TYPICAL Sh" TYPICAL SPOT WELD BEING TESTED ITEM PS 205 TYPICAL FOR PS 155 4)( TYPICAL / j i g r n X,,X N X X A s e, / /3" TYPICAL j') %" TYPICAL SPOT WELD BEING TESTED rGURE 2 l B

6sas'si ~~ES SAV3 _E CO\\c GAK O\\S 4650.0 ~~ E V 35 202 ~ ~~Y? CA TO R ~~ E.V DS'52 ' 4k TYPICAL / 2 w x ~. x h / / $ TYPICAL .N-p TYPICAL SPOT WELD BEING TESTED ~~ E.V 35 204 ' 4/y II2 TYPICAL M,, [ f A [ x k ['3" TYPICAL d' TYPICAL / 2 SPOT WELD BEING TESTED e b =GUlE 3

05058i - ES-~ SAP _.E CO\\r GJRK O\\S . 4650-l TEM PS 3151 ~ / 4/' TYPICA L 2 r X i E! 'l '[ M x + ..--m SPOT WELD BEING TESTED 66 -6 - 64 W mew W -- mem-mme S... / + x n n n o / 3' TYPICAL TYPICAL / W GJRM 4 ~

5055' e - ES-SAV? E CO\\ r GaA-~ O\\S I6538 ITEM PS207 18 / 4k TYPICAL / 2 b s 6 / /3 TYPICAL U k[ TYPICAL SPOT WELD SEING TESTED f l l j J., GURE 5 6 l.

.n303s; 0W? :CA_ 30WE 7 S aU-~ ~~ ES-~ COU30 N [ FOR DIMENSION OF 4 TEST COUPON, SEE ASTM A-370. TEST COUPON b 1 4 4 1 4 6 l 4-4 i l 2GE 6 i t ^

0'50561 TYP CA_ CA3_E - PAY SAV 3 _E 46538 CHANNEL WIDTH VARIES FROM 9 TO 36 INCHES [,.... 6 RUNG l., 9

  • ~A

.s. SPOT WELDS n';: *(' TO BE TESTED y- 'pa '[' d i = P L rGLRE 7 .~.,--n...-,_-.e

050561 l ~~ES-~ SAV]_E CO\\ r GURK O\\ ':46538 4"X4"X k PLATE g CABLE TRAY RUNG SPOT WELDS i TO BE TESTED -k / h i n s $ lk i j f/ ( .. A,, li"X 4 X i" PLATE ,k* i 2" / 2"Ds,- T i. 'T PLATE BOTTOM LEG OF CABLE TRAY CHANNEL. REMAINDER OF CHANNEL HAS BEEN REMOVED AND DISCARDED. GU7E8

0$0561 ~~Y 3 CA3_E TRAY ~~ ES- ~COU 3O N 146538 / l I i FOR DIMENSIONS OF ( TEST COUPON SEE ASTM-A-370 l TEST COUPON ~ l f F GL 7E 9,,

050561 ,a s g - e. RJWE7 S-~ 7U- ='-~~~ N GS ? w .w ,c is <w n <w ',L N e

< o?.. r w Q s j r. 0 0 1_e e e 4- - I. w PS 3064 PS 3033 2. PS 3375 '4
.g,s.+.
GURE O = g- ,-,.,y- .,------,-,._----,-.,.w --i.---,-----..-,----_ _,m____ ~ ~4653E 050561 - Y 7 30W E R S~~ RU'- ~~ ES" A R RA \\ G EV EN-- L CLAMPING MECHANISM OF TENSILE TESTING g., MACHINE. t.! M ~ O-ATTACH DIAL GAGE AS SHOWN ,7 USING MAGNETIC ~ STANDS. /,- TYPICAL / N(MAX) TEST s.- SAMPLE v<>/e / N' v 6: g-F i. s i } rGE .t. 5 0 5 S i " 8 3 3dA 3 E ~~7AY ~~ ES-A 7 7A \\ G EV EN-~ CLAMPlNGNIECHANISM OFTENSILE TESTING \\\\ -f MACHINE. s ,4 3" MAX. N !' y
  • s b
R N ~ N N TEST \\ SAMPLE \\ \\ ATTACH DIAL \\ GAGE AS SHOWN g' g USING MAGNETIC STAN DS. s N* N, N 'h ,i 2GE 2 ,--.----...,.,.-.,-.---.-..-...,---.,..,.,-n.- , ~. -, ~ - - ~ .i' POWE7 STRUT =IT~~ \\G I g ~~EST AR7ANGEV ENT u_ C'3 cn CD APPLY LOAD WITH MOVING 12'X 4'X 8' STEEL BAR \\ \\ CROSSHEAD ~ ~ ~ ' i+ x g ( ; _4_3 _4: . g'.3 h-4: 7 X 9 PLATE (.TYP) l 2' ' 1' 8 TOP VIEW s 4 4 g = l5 I 2 4 t:q:u_u 44
h...X l X 5 BAR _(TYP)
__ + I N 1,. s f (<% } -2' 2' f %PS 3033 OR I5 + w sk/ PS 3064 's ---k DIAL o II X 12 X $ PLATE E.t7.!!h GAGE 4 '8 14' d
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~' / l 5g, O +. & :h + u4 O O FRONT VIEW I \\ / I ( ) [" ! S'TATIONARY \\ \\ / TYR TYR \\ /k CROSSHEAD ' MV ^'u 7 ALL PLATES AND STIFFENERS ARE f MATERIAL a 12 n n SIDE VIEW l FIGURE 13 4 e e
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.._ y l, i I Ar, =.._ ..O:Q: - =::..L.:.. : :.:... _.......... .e ~ _ -. .,s t .-.._.. f.... h._-... }. 8 .._s = _. s 4 .l.... i. 4 - -g e 4. ..) .i_. l.._.... ..+. ..g.. ......,.... p... ........-t.-__..... 4.. .1 1. - i --- '. ~ ~. r --.- -- 8 ......I,... ...l_......& l k. l.... .._ __4 e. _ =... e. .p-TEST RESutihoR Two 6TTiNaSH }., = . ___ 1 l ..._i MODELLED DISTRIBUTION FOR SINGLE PITTINGS s t t Figure 31 - Power strut fittings j - test results - PS-3127 Land R t 6 F 3 "4 5 6 7 8 9 10 11 12
  • Cepecity (kips) 5th PERCENTILE (Desermined analytically, Reference R)
l e POWER STRUT - TENSION TEST COUPON SAMPLE D3, PS 201, NO. 23 l t cn W 3.5 r 6 3.0 U l
s
<= ~ tf c'. 2.5 O o 2.0 0 I ~-~--' ---~ ~ 1.5 0 g 1.0 i p O.5 0 ~ ~ ~ ~~ ~']~ ~ ~ ~ ~ ~ ~~ 7 2 4 6 8 10 12 14 16 18 20 DellectioninInches X 10-3 G 1842-01 4 l Figure 32 - load-deformation plot for PS-201, Power Strut base metal. I e q POWER STRUT - TENSION TEST COUPON e.- SAMPLE Ga, PS 207, NO.138 m 1 r m c.o 3.5 __ w i s- ~ ~T 11 ~'- ~ M ^ ~ a ~ (.m j 3.0 m p-i i l 2.5 3 "o [- [ 2.0 ~ I ~ ~ ~~ n. .E 1.5 ~ n. l l 1.0 O ~ l ..O i 0.5 -i l' .i9_- __cl 2 4 6 8 10 12 14 16 18 20 i DeflectioninInches X 10-8 o-1 s42-02 ~ Figure 33 - load-deformation plot for PS-207, Power Strut base metal. _ w c r.an# 2, 0 3 % m m r. 2 0 2 4 ~ 8 o ~ 8 I 1 ~ l a t e m e 6 s 1 a b tu I r t S 4 r 1 N e f w O P 0 o P U 9 O 4 L C _S 2 1 O 3 5 1 T 1 S N e 0 3-E 1 T1 X S 5 N s P 1 e OI 3 h r 0 c o S 1 n S i f NE P in t y n o T s l 3 io 7 p tc T J l n e U le o ~ RE 8 D t i TL a SP m RM r o EA f WS e O d 6 P d ao L 0 L 4 I 4 3 e J r u g ~ i _. i F l 2 G I 7 ~ i ~ g 0 O ~ ~ 5 0 5 0 5 0 5 3 3 2 2 1 1 0 I ,Oe .j G. !i
t
( li i , 3. vaug_. e , m. m o a. s 0 4 2 0 ~ 2 4 8 1 -0 ~ 8 t 1 ' ~ 6 1 la I tem e ~ 4 s a 1 b N t y O a P r U T O 2 3 e C l 1 b 0 T a S R 1 C E 3 X TS s r e o N8 h f c O1 0 n t g o I I SE g 1 NL in lp n EP io n t TM c o e i A l f t Y e a AS 8 D ~ m R r T o ~ E fe I L B d A d C 6 ao l l 4 53e .r 4 r .i u 5 g iF 2 ) ,i ~ 5 0 5 0 5 0 5 3 3 2 2 1 1 0 "o " X aE lI
,Ill l[l
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1 I
j! -{.l;I %I; i. 1ili j! i i .r. Q (A ") CABLE TRAY - TENSION TEST COUPON SAMPLE 24S-33R ' I I 3.5 e.n c3 3.0 m m L 2.5 o e-2.0 4 .E 1.5 4 ; 1.0 0.5 y u j m ^ 2 4 6 8 10 12 14 18 18 20 l' Dellectionininches X 10-a G-t a42-c5 Figure 36 - load-deformation plot for Cable Tray base metal. f a j = n CABLE TRAY TENSION TEST COUPON SAMPLE 24S-234C m 3 I I j c.3 3.5 l 3.0 cm 1 i i i 2.5 i, X 2.0 l a. - I i E l 1.5 ] l 1.0 y j 1 [ = l 0.5 . G g,__ i 2 4 6 8 10 12 14 16 18 20 i I l Dellectionininches X 10'8 a 1e42-oe i Figure 37 - Load-deformation plot for Cable Tray base metal. 1 0505Si POWER STRU r (SPOT WELDS) SAMPLE D3, PS 201, NO. 23 046538 10 ~ 8 l f l 9 i i I I ! I 3 G C t i t t 7 t I I I i 1 i 6 O 1 i i O C. X en 5 0: 0-1 5 i i t i g O J 4 0 I Ae 3 0' i I 3 i 2 l0: - i . a l 4 i t I I i 1. 4 0 1 2 3 4 5 6 7 Deflection in inchee X 10-2 Figure 38 - Load-deformation plot for PS-201, Power Strut spot weld. G-1842-07 I lL--- - ---- x _ l 0505Si POWER STRUT (SPOT WELDS) SAMPLE D13, PS 201, NO. 92 6538 10 i 1 1 i i 9 i 8 i 7 j l 5 I 6 1. ' i 6 g o 1, e i A X 5 4 O! 8 O 1 '+ .E 1 i, E 4 0 o =J J G l i 3 i W i G. l 4 i 2 0 \\ 1 i t ' j O - 1 i, 1 I t l j O 1 2 3 4 5 6 7 1 Deflection in inches X 10-2 ) Figure 39 - 1.oad-deformation plot for PS-201, Power Strut spot weld. G 1842-08 05056i POWER STRUT (SPOT WELDS) SAMPLE D2, PS 207, NO. 24 166536 T I L ] 9 W I 1, i 1 I I ) I 3 i I i e 1 i 8 , i 1 e j1 t t t ' t i 1 i 1, I I i ! I r i I t i i t i I f Y 7 i 1 1 1 1 9 W 1 1 I t I t i i + i t i t 6 ) I t ! I l t i i l t t i 3 i i 1 1 i o 6 i ,i c3 i, l i, J X e V g 5 c. 5 o a I ! t I t 4 0 e-3 1 i l i 4 6 i e I I I 2 t t i, I D t I i t i t.e i i ! i t t i t t ! I t i . I i 1 _ 4, 4 4 I t t W < 3 I M. l i f 4 t l O 1 2 3 4 5 6 7 Deflection in inches X 10-2 i Figure 40 - Load-deformation plot for PS-207, Power Strut spot weld. G-184249 e 056i POWER STRUT FITTING PS 3375 TENSILE TEST SAMPLE 102 046538 %e 16 1 6 1 3 + i i ; 14 I I 12 COo J 10 x j a-8 Oa 6 t ( 1 4 6 1 i, i ie i -2 t 0 0.2 0.4 0.6 0.8 1.0 Deflection ininches Figure 41 - Load-deformation plot for PS-3375, Power Strut fitting. G-184210 e i I Q v* POWER STRUT FITTING PS 3127 COMPRESSION TEST u) SAMPLE 31SL/111R O w [ I a . w I (J) 4 ~ 12 l j s f 10 l 9 8 I O 8 X -I I .G 6 i-tp : ~ . I' I 4! 4 0 I . l p I l 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 l Deflection in inches 0-i842.s t Figure 42 - load-deformation plot for PS-3127, Power Strut fitting. J 056i 066538 ar.. p -3 : - gei'7 COMPARISON OF SPOT WELDS (1X) '"ifLN - /-
g'E.. if,,,.
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SPC,T WELD 3 ' gg*~ -r 7 s FIGURE 45 - X-sections of Power Strut spot welds. c,.. -.w,-... 050561 f,,g,r,ps a Appgg;y ~ ~uaae [ PACIFIC CALIBRATION SERVICES 133 Uncoln Drive / Sausalito. CA 94965 /C (415) 332 9180 CERTIFICATE OF VERIFICATION / O/V*7 ) (No. / YI N t O s b t t E.f( OMtUFKIAL-Testing This is to certify that the ma ns - t v e. Tf f.M TE L taJ c R Machine, $erial Number /OV WS Located at ....,.e NNRem O L ., M AT-L A&. has been calibrated by AN e....... 17 ") O - TO and verified to be accurate Pacific Calibration Services personnel on
o., a.', a over the following ranges:
\\ MACNINE R ANCE LOADING RANGE ' MACHINE RANGE LOADING RANGE O Otro $ S O M
  • T C OCD tooD-to een "
lo.c & Method of verification and listed data'are in accordance with ASTM Designation E 4 other applicable specifications.or manufacturers recommended procedures. For verifica- ' tion details, refer to the Testing Machine Calibration Data and Report. PACIFIC CAllBRATION SERVLCES M, e, d. sy I O "5056i f,,,,,, - g g 4 b b [. L f l PACIFIC CALIBRATION SERVICES f 133 Lincoln Drive / Sausalito. CA 94965 (415) 332-9160 CERTIFICATE OF VERIFICATION ( No. O/1O ) This is to certify tnet the t EM LEE N t(J s8rf" f A L Testing ....v.. Machine, Serial Number 4 b 7 3 S Located at k N AM P 7 El k 0 -. 4 . c ou-su, ~ sus DN I"f-EN bLf F. , FI A T* I A r"f . has been calibrated by cir, a svava os er. Pacific Calsorarson Services personnel on /0
  • h
  • h o and verified to be accurate cave ever the following ranges:
MACHINE RANCE LOAQiNCRANCE MACHINE R ANCE LOADING RANCE 12c. arm 12 coo-12a m ' Q m.5,,,, f -do.nem den - sa d 6 30.m Cere-Ja ooo }2. con /2.ev-H rev' Method of verification and listed data are in accordanca with ASTM Designation E 4 other applicable specifications.or manufacturers recommended procedures. For verifica - ' tion details, refer to the Testing Machine Calibration Data and Report. PACIFIC CALIBRATION SERVICIS pucal duh. ce&uJ /O-/2-PO ar e E. CA.d- //[/k77 dCt~'- -M G 9 Pcd. &P har %. v b U b_o t.mair7.f2.__._.Jm. \\1 % 0 4 e-n4 q O Sok7% u,,,,,l. r e -a - e - no, n -.,~ 00 m.o. O on a i D. GJ (2b a,s nta7 ~ Sri 4r7 s, oIt 79 os u." ". ?e*"C* R os * - O soO -D l M C= d 8 aCC N k c'*ca oad odi o enfgr s noecs E a.ooir w/o Cohbrae n O Y i 'a 3 0/m.t3AAh*9 Ja Mi a I-t N2.2. D {_. ACo *"re.?p 4 l
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/-1 .TC5i:'M0 In oTY part Numate seiEF DE5CRIPTioN QTY PaRt NUM8Ee seiEF DE5ceiptioN ~ $/ e e _w 3 N 51ANDAa0 USED apoD. s SER. s CEff. DATE ACC. boreM94 $*mst.ent /* *1 -13 C. f */ A-N sco3 - AJY to-ISTf 2 ** ~ f.fr, %m . certify that the above o C iTE 7- //- # I = ork was performed one that cobbrosion.was in accoroonce with Nut.C.45662A, and against stondoras L oceable to the National Bureou of Standards. Santa Cloro, Calif. 95050 382 Mortin Ave. e. SIMCO electronics I ~. r, (Q = p; m ] W5 L - I E.M L,_1 F' 2 s ;g cri.4 PURCHASE ORDER O REQUIRED [Ttus savasifutsas Avion imo ionic w LE es~esneonuso mTwour O NOT REQUIRED lmmeonizAnoen user or AuTwonizAnow cooes.. g ;'.. DD NCA'Isa'Tio" aumonizeo assi.v. < -J T-' y.wons aut=onizao not to smesso aos or vaLus on smenumewv. NO. 7 A MIMitsWM MANDL!NG CHARGE
  • 3 g.aovies rimes rimao Pasca PoA LAton oesLYtespont emocasciano.
..=ge m wo cincumeTaan. '** es aTso sm a ow ou i l AUTHORIZED (WHETMER A PURCHASE 'n.womit auteeomizso esor To sacaso ooL'Lan Liesstations in coot CREER 88 ISBUED OR NOT. d coLuaseL,,7.--a.a. '-kg- )TE' .I 7..-A : 7 yQ*..... *. $ 'OIIE 'A b' I'T
  • CUZRENT RATE SCHEDULE SUPPUED oN REoutsr.
NOT RESPONSISLE FOR EQUIPMENT UN. ~ / j CLAIMED OVER 30 DAYS AFTER NOTICE f
7. / 7/A l
CP wo* K COMPLETION. MMANUALfPROBE(NOTE:UN LESS MARKED INDICATED ITEMS ARE NOTWITH INSTRUM .TH:LCETACHABLE LINE CORD: I have received the instruments ~~ ** DAM AGE Note Belour- ,, listed above, and certify that they SPECIAL NOTES: have no bvi e de scept as l I /I Te ~ ffl l l LAsonATeN CERTIFICATE ,c e, 046538 ANALYT: CAL kn aweet5 3 L ab o r a t o rie s, Inc. = =.,.. =;,,7,;'y;,- December 18, 1979 BLN: 1279 - MSQS Log fJCG 1279-34 Job #631/-/0002 LABORATORY NUMBER: 1279.195 P.O. #0S1-8-00096 Calibration of Dial Indicator Gage SAMPLE: MAP.K: Dial Hand' Gage (1 Inch) S/N 3 Mitutoyo No. 241,6 DATI SUBMITTED: December 18, 1979 RIPORT TO: Bechtel National, Inc. P.O. Box 3965 San Francisco, California 94119 Attn: Mr. R. T. Dillon REPQRI True Length Measured Length 050000" 0.0000" 0.1600" 0.1600" 0.2500" 0.2496" 0.5000" 0.4995" 0.7500" 0.7500" 1.0000" 0.9996" Used Jo blocks and End standards, calibrated by Ultralab on 4/24/79, traceable to NBS 232.12/216449, 25 May 1977, and NBS 213. 12/218345, 11 April 1978, NBS 213.12/216449, 25 May 1977. Respectfully submitted, ANAMET LABORATORIIS, INC. By h. Ca. I. A. Foreman Manager, Quality Control 3c i jm ? e I l a
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O' /. /- / / / .. _... Figure 30 - Power strut fittings a test results - PS-3375 i_ e ,*7 8 9' 10 11 12 13 14 '5 16 i - ~ 5th PERCENTILE 1 - .a.u......i........ l e

. ~ +..,... 05056i TWO WEl.DS AT A TIME I l b o l l .f _4 j ,i I ..... _ g. _.... _. r ....... I... w .t....,.. '. . _ _ __.J s P, - {j. e ,......v._ _ ~. _... . - - :! ! * ? '.. "

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.~ ,3 3 4 .g 9 = - l y --_..._e _.. 8 . _ _. _ g Figure 28 - Spot weld test = l results - Cable trays l .f __._ _ =_* 1,000 2,000 3,000 4,000 5,000 Sheer Strength (Pounds) l 5th PERCENTILE l .~ .i.m. -,., w. p u.4. (Detsemined '1f n"y, Reference R)

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=- e e e e-M e . _.. _e.. _... .__s-- .o e e._ . e ..__..__.e_ _.. _ i e e- .. _ ~ + e e a M, -+ e =. _. _ _ l ~ Fi ure 29 - Power strut fittin s. test results - PS-3064 t l 32 33 34 35 36 37 38 39 "

  • 30 31 Camcity (kips) 5th PERCENTILE (Determined analytically, Reforwee R)

, a.66:6, %.e.. 4

uscssi EXTENSION POW E R S--RU-- FITS INTO nq pe CLAMPING ~ r --~~ N G 7 ES~~ MECHANISM ARRANGEV E \\ ~~ OE TENSILE TESTING MACHI N E /["T i 0 1/2 O A325X BOLT I PS 3375 \\ TAP HOLE IN BLOCK FOR N 1/2 0 A325X BOLT (TYP) 1 0// 4 X344 X 2k2 \\/ STEEL BLOCK N-I- G E '4 4 l

h., POWE a ST 7U~, TTl NG TEST AllANGEV E\\T i TORQUE BOLT TO SO FT LBS.(TYR) DRILL /f HOLES FOR k" BOLTS (TYR) 9 I 2 m j l/l k MOVING es $ A-325 BOLT O F CROSSHEAD oi 12 M A X. (TYP) X 2" A-325 X O O 2 BOLT (TYPICAL) [oaoo f PS 3I27R AND PS3127L W-90' e Y Y \\ m Y = 2-4 X 5 X h E 8 \\ / TYP. (TYPICAL) l 7167 y BOLT 8'X8'X h, l E TO TESTING o ![' 'f TYR g 0, j STATIONARY TYR AT 4 \\ LOCATIONS / 3 V NM@ 75 a FIGURE 15

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, O. s ~ y [ e 6 8 e.,., y 9 .... g. 0 .G .e-...-------- e ._ O. Figure 36 - Power strut base l l l metal tension test results 1 e., s i 40 42 44 48 48 50 52 54 56 I Yield Stress (ksi) 5th PERCENTILE i c,.c6m n n v,-n n,...- 4

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t, 3 e h h.... ...._i l ..I.. j i ...._ q r D . _._,s t_ ...6 O a .f.. ._... q + 6 .F ~- .{. ....e. e e ~ a S .g. g O O e e 4 e 0 .3 0 e ~g .. ~. e ~ 0 = T e e e 9 r ..O e. O 5 ._ _ _. __. Figure 17 - Cable tray channels ! base metal tension test results I t, 1, P T e E32 34 36 38 40 42 44 48 48 50

  • 5th PERCENTILE (Determined analytically, Reference R) r i.oiei.
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~... O i d 'D3 a i 1 -....-_e l ...4 ... -. =, .._e s'.,._. I i ._I,_..' .l g.. t ,;. Q &..G.5 Q... . L...... _.. d .. u... J -. 7.... ... _~ g,._.....

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=. -., .............. = - _--.. _,_.. ._._i .~. _ + ~,i. [. T Y. ..t....._._.. ..__....e.. .t.... ..i....... _.....................-.k. ..a..... 3.. .6 ..... -.......,.i__ .~ ..4... .4._._.._._..;_.....n._...;__.... ..s.. _......_... .+ i ......l....____. s o. 4 . l 4.-.... - .i + ...........s...... . i.. 4 .I._ g. ,g s .} t --... _. Figure 18 - Cable tray rungs i base metal tension test results l g ' 36 40 44 48 52 56 60 64 68 72

  • a.

Yield Stress (ksi) ~ 5th PERCENTILE (Deestmined analytically, Referenos R) 4

.5..".. = 0 6,i - a2 0 3 1 C l I I i l _.. _... I. _ _1... _. q. _ __ __.._ [. n .i-- 6 U U

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._=5=_3..g-~_.-_.....__._._.__._ . - _. -J _...1:- 3 : :... gg.; _ _ _. g.: 3 .t. _.. ' a. a-i 6 .i... ..-...--._-_i.......... .l. ... e. =t- ....._3...._...._. a__._._.- .. _1 * ._...___.w. .i..._.___.3.,..__.......A_.__.__ ......1 .p .o i i .._...t._...._..'. .u..... _......i ...r. .._. n_ ~ .1. ..._ = y ~ = .= . e t ~ ... s ~. _.... Figure 19 - Spot weld test results - = i l PS-101 "A", PS-151 "B", PS-201 "D" [,000 5,000 3,000 4,000 5,000 6,000 7,000 8,000 5th PERCENTILE (M niaa 8 enalvticsify, Reference R) 4 .,.s.a.ue..n u. .es w r.

r Y...... l . A. 3 O i i i i . _ _.t.. G4 .__.i__.... .i...._.._..__..i.. .. i.. . I... . L,,.... ._._.....l- _........ _...... _.. b............... - _. ......_b i ._...... _._.. _...... ~_..._ _ -t, . __._._. _1._ _.-*. ..,6 4 -. . 4..... }. {_-.. ._,._..d ...._ j... _ a [ ..i, .......L,.____..._..... .___.s .9 e, ,4 ~. . e.. t e = ..... _.... ~ e. .._s . _.. s b _....1. Figure 20 - Spot weld test i results - PS-155 "C" s 3,000 4,000 5,000 6,000 7,000 8,000 4 1,000 Sheer Strength (Pounds) 5th PERCENTILE .i... %.i,

p. 4.

(Determined _.G "y, see Section 8.3.4) 4

.".5.l....F ..c., 05056i MODEU_ED DISTRIBUTION FUNCTIONS E II- .l.!illl!!l!!!IIIlllllI llllllll ll!l ll!!' ll!! ll!! !!!!!I!! ! !! !i!' i ..o ou om,o,, ,i ii ( in .io no ,in>ii .io.o. ,,, T - 1,. .i.... ii . i, .i..,: .i, e - 1 1 a 2 titil'iil i'illiti' ii iil'. E .titl'i: istii 'i.it;ill i i s. s .s i .i. .iis t;il liti

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.i- /6 4 : li.. .I t-1 4 i ,f i : .I a.., n ./ I i i _ l: i!!!li!!! !!!!$ll l llll lll! llll [Il! lll[llI llII lll! !!lilllll Ie!!' !i!l '{i t 1 i 12-ti!' till itti Itll/l l ' s fiflutti! llll ll111! 18 f. i : l l, - C.ORRELATED WELDS .ii, i.,, iiii i-:,i esi/..J' 4/-+- ii e* iii. .3, i. _ ...i / .!ii

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5 ,8 ,d - . I ! j f. g . =. .e,, ... _ 4.__ _ _ _ ; >g y i i 3 ~ _,; j .T ! R 2 ~ . ~,y'l ~, j__/err UNCORRELATED WELDS s ~E--j]. l _.....1 I 3 l l 2 Is .y i r --i,i f i! 4.i.e !..i. eiae t.. .i.i ' i.s i- . t'.. i.6: /.a i. 5 e iiriei-viiiii.e. if .,./ .!st si.i! i st! itii titi ii: t i.ii iii. i ; i ~ il/i !Ii!I lill lill lill illi illi illi liti 1.!! it!!ist'; lill 1: ./ t l~ /l::!! l/!! !II'. ll!! 'llil Ill! llil illi i.!: l!!! l!!! ,l'Ill. iet' ~ a: >>.ii.. 1-6 r r' ' i i e ...m m, ivi io. ,o. ...o. .i. i..,e .,,i o i,. o o.co un n o. lu nu iin on int inc ionoo i. = i... ,.: o.. ull.ll{fl k,jl.*.ll! h!. i.llti lllI Iil? hiI6 i!hI h = _.,i im- ! l'il-I g Figure 21 - Spot weld test . m. mi oli results - PS-201 "D" m . !!n !!il tillllll Ill l Illi Illi 8 1,000 '2,000 " 3,000 4,000 5,000 6,000 7,000 8,000 Sth PERCENTILE (Determined analytically, see Section 8.3.5)

r. w ;mi, se..,e in,s.6.

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mW ..."M.... 05056i m.~ s f C'* C. i i i. i- .....,i._ --m A f l n..:. _. :..._'.. _.4 _...... 3._. . g g.... a y s i i _ i..

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p___. ...{.. 3_. _. -..a..- _.-....,_.-...-._. _..... _ _. _.. _ _........ _ _., J. -l. . s. ...f'._.....,. _.. '.. -. - -. _ -.. .6.. ,6 .l. ._.,....._..,..____.y__. e.. e .s,.. _._.. - .z._..._.._ e .i i, i c I, - 4 I t .._._4 .e / .g. . :....}.... / g ..... _. -... s. ..._.n. .2 ... +.. ,..g t.. .a. .,,,/_._....... s. e s / A .i g t ^. = gs ...__ ^ e ,I g _.i .t Igure po we es I results - PS-202 "E' l = 4,000 5,000 6,000 1,000 2,000 3,000 e Sheer Strength (Pounds) 5th PERCENTILE r, i.9..n.,.i, *., m. 4.

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  • 6

_.. p =. .f i .l...-__ ..L L . j... e ..._4 J j e j 1 __.p - 4 I .t. Figure 26 - Spo,t weld test 1 res ults - PS-152 "__I"... T 1,000 " 2,000 3.000 4,000 5,000 6,000 7,000

  • 5th PERCENT 4LE

... wi..iii.... i,.. 96 6. (Determined anstytically, Reference R)

.as.+ 05056e 2 C83 i IL: t I l ..__t .___...._..__-_.___.u____'.____i. l 1 _._________.___.,i_._,:.___.,....__..__,!.._.____._. m. .._.i ,3 .... v, b.... ...y - -- _ _ : 1, ; -_..t:_,- ... n :... g. - ;__ :_ a. a + i i. . _1_ _. 3 __._ ! _ __4 w =: .i .g ...._..i. ._..._t..._. ..___ c ,;..._.._._.u......_..._._._-4._...__;_. ..._.....a. ....-.g..._......i..._,_. i ,..___.e.._. ~ r ..._l. ... :. __ ____.._ I _ .9 6..._..'__._.4.. ...= .......t.. s . _. _.....e 7 -- e __ ~ e e 4 Figure 27 - Spot weld test results - PS-3151 "J" e E 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 l 5th PERCENTILE (Determined analytically, Reference R) r ur.n., ,.o s. m,6. ~ e L}}

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