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~ .pc, a [ 4 UNITED STATES 7 h g,,*, ATOMIC ENERGY COMMISSION D WASH 4NGTON. O.C. 20545 N+/ OCT 131972 J. 1i. Hendrie, Deputy Director for Technical Review Directorate of Licensing TECHNICAL ASSISTANCE REQUEST NO. ORB-2-42 Plant Na=e: Quad-Cities Units 1 and 2 Docket Nou: 50-254 and 50-265 Project Leader: J. I. Riesland, Operating Reactors Branch #2 (phone 7403) Technical Review Branch: Hechanical Engineering Branch Target Date for Completion: October 31, 1972 Description of Request: Four nanger bolts for the torus suction header on Quad-Cities Unit 2 failed during startup tests on 1iay 29, 1972. Regulatory Operations investigated the problem with the assistance of consultan ts. This occurrence is of significant safety concern for all BWR plants with tnis design because a failure of the torus suction header is an unrevitwed safety question and could result in loss of tne corus water for emergency core cooling. Based on the information contained in the enclosed draf t report, " Torus Ring Header Report', dated October 6, 1972, and our discussions with CECO in an October 6, 1972 meeting, the corrective measures are not considered to be adequate to prevent header f ailure. It is believed that the design for Quad-Cities Units was used for other BWA facilities. Please review the enclosed documents and prepare questions for our submittal to the licensee. It is also requested that your review of the enclosures consider this as a generic problem for BURS and that appropriate questions be prepared for our submittal to other l licensees to determine if inadequacies exist in their torus suction header supports, t
- Je propose to have the designer, Chicago Bridge & Iron Company, prepare a presentation of their torus auction header designs for other plants relative to that for tae Quad-Cities Units as well as justify their desi n for Quad-Citics. This meeting is expected to take place the 8
weelt of October 16, 1972, and your participation is requested. i 8705050002 870428 PDR FOIA Donald J,/Skovholt THOMAS 87-40 PDR Assistant Director for Operating Reactors j Directorate of Licensing Enclosures and cc: See next page s 4 1 - ~ _, -,, _ _, _ _,, _ _ _ _ _. -. _. _ _,. _,
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Enclosures:
1. " Torus Ring Header Report", Quad-Cities Units 1 & 2 2. Ceco ler dtd 6/7/72 3. R0 ltr to CECO dtd 6/22/72 4. Report by R. A. Lofy dtd 6/22/72 5. R0 itr to Keppler dtd 7/3/72 6. RO ltr to CECO dtd 7/5/72 7. Ltr, Engelken to Skovholt, dtd 7/27/72 8. Note to Skovholt fm Riesland dtd 8/29/72 cc: D. Lange, L (w/ encl) W. Mcdonald, L (w/o enc 1) D. J. Skovholt, L (w/o enc 1) T. J. Carter, L (w/o encl) D. L. Ziemann, L (w/o encl) (g[. I. Riesland, L (w/ encl) R. M. Diggs, L (w/o encl) I i i
e, Y RWT TCOEN. b Ih72 j e. INDEX QwAo htTse 5 LIN6TS.5 NE'*# To% Scan i-lirAoiFi2. PAE ~l-1.0 Il PODUCTION
2.0 DESCRIPTION
OF RING IIEADER AND SUPPORT SYSTDI 2.1 Ring IIcader 2.2 llender Support System 2.3 Method of Fabrication and Asserchly 2.4 licader Support Design '0'
3.0 DESCRIPTION
OF EOLT FAILUPR 3.1 Fabrication and Asserchly Deficiencies 3.2 Design Deficiencies 3.3 ibtitud of Failure and Location 4.0 CORRECiIVE ACTION 5.0 EVALUATION 5.1 Static Loading 5.2 Dyn stic Loading 5.3 Calculated Stresses
6.0 CONCLUSION
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1.0 INTRODUCTION
During startup testing of relief valves for Quad-Cit,ics Unit 2 on Sunday, May 2S,1972, it was discovered that 'four pipe hangers for s N the 24-inch torus suction header had failed. The reactor was promptly shut down for investigation and repair of the failed hangers. The 24-inch suction header encircles,the torus and provides a manifold for the suction of the various ECCS ptrps. The header is connected to the torus by four 20-inch CD pipes spaced 90 degrees apart and is supported by twelve hangers which are connected to the torus shell. Three of the four failed hangers were located within a 90 degree segment betvcen two of the 20-inch connecting pipes resulting in a maximum sag in the header pipe of approximately 5 3/4 inches within The pipe hangers consist of double stra'p hori:: ental that segment. and vertical members connected to gussets which are wclded to the torus shc11 and the 24-inch pipe. Failure consisted of shearing the bolts that were used to connect the vertical straps to the gusset. Investigation revealed no other damage or evidence of excessive stress at the torus shell, the 24-inch header pipe, the 20-inch connecting pipes, or the wclded connections. e i l i 1 I
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2.0 DESCRIPTION
OF RING IEADl!R AND SUPPORT SYSTDI 2.1 Ring Ilcader D e Quad-Citics Unit 2 containment vessel consists of a light bulb shaped drywell and concentric toms shaped suppression chanbor. Ec. suppression chanber is filled with water to approximately mid-depth and a pump suction header (ring header) is attached to the outside of the to ms. This header is a 24-inch OD pipe and is connected to the torus by short lengths of 20-inch OD pipe. In addition to the four 20-inch header inlet nozzles, there are. six outlet no::les which are used to withdraw water from the header for the Residual ifcat Removal System, Core Spray System, High Pressure Coolant Injection System, and Reactor Core Isolation Ccoling System. Re header is shown on Chicago Bridge and Iron Company (CBI) drawing No. 216, Rev. 5 i and No. 217, Rev. 5. I i 2.2 IIcader Support System he 24-inch ring header (suction header) is supported by M twelve hanger assemblics. De hanger assenblics have horizontal and vertical members attached to gussets on the torus shell and the 24-inch header. Details of the assemblics are shom on CBI drawing No. 218, I i Rev. 1. Ec gussets consist of 1/2" thick plate wclded to I 1" thick pad plate which is then welded to the torus shell i I and a 1/2" thick collar type plate welded to the 24" pipe. The horizontal and vertical doubic hanger straps originally e installed wem 21/2" wide by 1/2" thick with a 13/16" diancter 2-
hole at cach cnd for attachment to the gussets with 3/4" diameter A307 bolts. Tabic 2-1 defines the ring header supports, inict nozzics and outict nozzles along with their approximate orientation. TABLE 2-1 HANGER AND N0ZZLE ORIEhTATION Header Support Approx. Header Nozzle Nozzle Approx. Number ~ ' Orientation Number ' Descrip. Orientation 1 67*30' X-204A, Inlet 45* 2 90* X-204B Inlet 135' 3 112*30' X-204C Inlet 225* 4 157*30' X-204D Inlet 315* 5 180* X-223A RER 157*30' 6 202*30' X-223B RHR 202*30' 7 247*30' X-224A Core Spray 22*30' 8 270* X-224B Core Spray 337*30' 9 292*30' X-225 HPCI 337*30' 10 337*30' X-226 RCIC 292*30' 11 0* 12 22*30' Method of Fabrication and Assembly 2.3 As discussed in part 2.1 and 2.2 the ring header and hanger Nos.216,217,and218 assemblics are shown on CBI drawing for CBI Contract 9-6771. The, hanger clip assemblics (218-A and 218-B) were wclded to the torus shell prior to the shc11 With being assembled in the basement of the reactor building. the torus asscrbled in the basement the shop built header sub-a assemblics 216-B were attached to the torus penetration at the a . E.
field wcld joint (sce Deg. 216, Section E-E for field wcld hfith these four subassemblics welded in place, the i location). remaining segments of the header were welded together utilizing The conpletion of the temporary supports for positioning. entire header welding was followed by the attachment of the collar type gussets (pc. 5 on Deg. 218) to the 24" pipe header. Because of the allowabic fabrication tolerances on both \\ major and minor diamators of the torus as well as the ring header and the positioning of the header, the attachment of the horizontal and vertical hanger straps could not be conpleted E c alignment of the horizontal.and with % e as-built straps. vertical straps required sone adjustments and strap modifications At some locations it was necessary to decrease the length of the Some horizontal strap vertical straps by 2" to 2 1/2". He modifications lengths wre changed by amounts in excess of 2". required to complete the alignment and assembly of the pipe hanger straps consisted of some torch cutting of bolt hoics in the collar gussets and hanger straps as well as. torch cutting L e original holes the straps length to suit cach installation. were punched. The hanger straps were connected to the gussets with 3/4", Due to the torch 10UNC cap screws (bolts threaded full length). cutting of some of the holes in the vertical straps, there was some misalignment of the bolts and uneven distribution of the This was evident from the installed bolts not being per-load. pendicular to the straps. !!cador Support Design _ 2.4 Re hanger support assemblics were originally designed for th static dead load of the 24" header plus horizontal and vertica The operating bases carthquake horizontal ground seismic loads. no containment torus analysis in the FSAll acccTeration is.12g. (12.2.2.5) used a resulting horizontal coefficient of.40g .i. 9
i 0 combined with the vertical acceleration of.08g acting simult-The original design was based on a computed maximum ancously. hanger load of approximately 8,000 lbs. with the load being approximately equal for all hangers. 9 es 4 4 S O I I \\ NN \\ e a G i t i O 5-
~ ] 3.0 DESCRITTION OF BOLT FAILURE 3.1 Fabridation and/or Asserbly Deficiencies It can be scen from Section 2.3 that the methods used to correct the misalignment prob 1 cms encountered during assembly were 1 css than desirabic. Burning holcs for bolts, regardless of the craftsman, results in a nonunifom bearing surface for the bolts. In. addition, the holes that were punched appeared to have some This slight coning which is common for punching operations. slight coning effect causes the bolt to be stressed at one edge sooner than at the adjacent edges. Although the contract drawings did not call for bolts with a cican shank, the original stress analysis was based on an unthreaded shank, 3/4" diameter bolt. The effective cross-sectional arca of an unthreaded 3/4" bolt shank is.4418 square inches versus.302 square inches for the threaded shank. This would have increased the calculated failure load in doubic shear from 27,180 lbs. to 39,760 lbs, for the bolted connections. ne use of 3/4" diameter bolts with an unthreaded shank would therefore have been desirable. Since the original hanger system did not have provisions for adjustments, the exact distribution of loads on the support system were different from the theoretically calculated loading. To assist in determining the reason for the bolt failure and its location, the loadiag on each vertical hanger in the original installation was detemined. The measurements werc made by reconnecting the original straps and then applying a force with a hydraulic jack to cach hanger point until the bolt in the connection was loose indicating that the jack was carrying all of the load. Ec weight in pounds was detomined The from the pressure of the hydraulic fluid in the jack. neasgired loads are shown in Tabic 3-1. / 6-
.~ w k TABLE 3-1 ORIGINAL SUPPORT SYSTBI !!ANER LOADS u ri J 2 QUAo cme 6 l I$AD SUPPORT NO. l k SUPPORT NO. IDAD 3.6 k 7 5.4 k 1 7.6 g k 8 13.2 g-R.O 2 k~ 9 9.4 k 3 22.3 13.0 k j k 10 4 0.7 0.7 k ] k 11 13.2 5 k 12 11.6 7 d but
- Loads are as measured after replacement bolts had been g/
before any strap lengths were changed. g It is obvious that the distribution of' load is n 0 lbs., whereas that support No.10 is carrying a load of 22,30 This inequity support Nos. 5 and 11 were only carrying 700 lb. in load distribution indicates that some more precise It also hanging the ring header should have been used. indicates that a static load of at Icast 22,300 lb. could d d its accomodated without failure on a 3/4" 10UNC full length. 3.2 Design Deficiencies _ gs + #4s*# Computing an average of the loads shown in Tabic J/ dab 'Y ' The original hanger. 4A#8 in a value of approximately 9,400 lbs. per maximum computed load to which the hangers wer p, y- .r h,ta e car io:.,*d re d w hThe inequitie Cu e *4da? apprqximately 8,000 lb_s. ht shown in Tablo 3-1 and the average load per hange j L4thT l d 3. 04,5GlM AL-- Fest 4ces Appennices, p,23 H ANG,U A. LcADS. 7
~ the method used in designing the hanger assemblies was inadequate r The wide range of from a purely static condition approach. load distribution indicates that the hanger design perhaps ~ should have called for some method of adjustment to make f up,for the differences in the dimensions that result from k allowances for fabrication of the torus and the 24" pipe header. he average load per hanger of 9,400 lbs. (average of measured loads) vs the 8,000 lb. used for the original design, indicates jsu / M that not all loads were accounted for in the original analysis. eos f p hJic. lo+ k The measured static load at hanger No.10 was significantly This greater than that measured at any of the other hangers. would indicate that soma dynamic effect from the testing that had been performed, contributed the force necessary to shear the I bolts in failed hangers 1, 2, 3, and 12, but did not add enough to shear the bolts in hanger No.10. Bis dynamic effect was not identified and thus not included in the loading used for the original hanger design. N Method of Failurc 'and' Location 3.3 The testing of relief valves (Startup Test No. 26) was being performed when the first indication of failure was noted. Relief valves A then B had been tested when a 3/4" bolt w found beneath hanger No.12 which is at the point in the torus A temporary replacement bolt was installed where A discharges. After the and testing proceeded with relief valves C,D, and II. l .g.
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I h hangers iled bolts were found beneat rtical testing was completed, fain cach case, it was a b 1 No.1, 2, and 3. The relative positions of the I hanger straps that was sheared. and the discharge points hangers, the ring header connections,s are tabulate 1 of,the relief valves in the toruihate as-built static I Also shown on the tabic is the approx r 1 1 loading on each hanger from Table 3 TABLE 3-2 ORIENTATION l{ ANGER, N0ZZLE AND RELIEF DISOIARGE U4 N '4 J d ass :::= G, c. #,0 Dead Load Relief ' Support'pnSupport(1_M Header Header Discharge Approx. Connection 700 ' Orientation hocsf 11
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13,200 . A.L \\' 12 r s 0 f ore Spray 6,* C
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' 22*30' i 5,400 !* M' S '7" Inlet [ s,$7[ 45' B 13,200 2 ,. d e. j'-t ) 67*30' ,.l 3 9,400 g 90* f,,.:' F X 112*30' 13,000 }l~ Inlet 4 135' [,** 700 MIR [,- 5 157'30' s . ; ' \\s y* 11,600 6 180* @MIR-f 202*30' 3,600 ? Inlet ^7 .! ( 225' h 7,600 ~ 8 6 p r[ 247*30' l 12,000 9 RCIC.r.[f Cg 270' y[E,\\ 292*30' ~ ~ cu 22,300 i! rn Inlet D 10 315' . G Core Spray m !a h ; S 337'30' f HPCI J R N e- ' g.
From Tabic 3-2 it can be seen that hangers 1, 2, and 3 are located within a 90* segment between two 20" inlet pipes which connect With these hangers failed, the the ring header to the torus. span between the inlet pipes was unsupported and dropped b #M'h 5-3/4" at the. lowest point. Non-destructive tests were perfomed on four critical welds on the torus shell and the ring header s.: 'f, nd I co.g,*/,,' s ,'7c,,,g No evidence of ex'cessive s es were to check for damage. [* A_ stress du"* af y"** ' shown in majgetic partical and _ dye penetrant tests. d analysis of the header and torus shell penetrations was per- ' /#ad. formed based on the deficction of 5-3/4" in the header and no stresses were calculated to be in excess of the minimum yield strength of the materials. As previously stated, the estimated load required for doubic This is shear failure of the original bolts is 27,180 lbs. based on failure at 3/4 of the ultimate strength of A307 steel and an effective cross-sectional area of.302 square inches for the This is not to say that the bolts in the hangers all bolt. failed in doubic shear. As discussed in Section 3.1, there were some hangers in which bolt holes were burned and which had As a result of pairs of straps with different effective icngths. these fabrication deficiencies, the load at which the bolts could have failed can not be determined. It is estimated, however, that at least a load of 18,120 lbs. and up to a maxinum af 27,180 lbs. would be required. e \\ \\ l 10-
r ne dynamic effect of the relief valve discharging into the torus adjacent to a pipe hanger adds significant loads to the ~ hanger. It is postulated that the effect is due to a pressure wave imposed on the torus shell by the expansion of the free air in the relief discharge line upon initiation of relief valve ope' ration. In order to verify the dynamic effect and to determine the adequacy of proposed repairs / modifications, a test was conducted in which measurements were taken (during relief valve operation), of relative motion of the torus shell enl/ d in the area of a header support. These u *ht t:ime. W"gf and thn ring hea er M 4 /44./ ca ~ f measurements were used to determine maximum hancer loads. Two The first E'3" ' ' approaches were used in analyzing the loading. approach (Header Analysis) was subjecting a model of the header oN& b / ? system to the observed vibrations at instrumented noints on
- 4 the header.
%c second approach (Torus Analysis) uses the measured dis-l N placements in the torus shell, and a calculated stiffness tem \\ to detemine hanger load. The maximum vertical hanger load was calculated to occur during the operation of the singic relief / that discharges in the arca of the hanger, Test E. E c maximm y O horizontal hanger load was calculated to occur during the Le maximum simultaneous operation of all relief valves, Test R. values for the load:, yhteh "am "lenw~i-frnm the measured displacements observed durine the testinn are tabulated in Tabic 3-3. 6 b.
? TABLE 3-3_ t MAXIMJM DYNAMIC IIANGER LOADS IXJE TO RELIEF LINE DISQlARGE l' Test R Test E1 Header Torus lieader Torus Analysis. Analysis Analysis Analysis Vertical 11,600 17,700 '12,300 13,900 ~ Load Horizontal 3,600 0 13,600 0 ,., e Load l he addition of from 11,600 to 17,700 lb. to the dead weight load of 13,200 lb. on the No.12 hanger was sufficient to exceed the 7- /,S % c failure load 18,120 - 27,180 lb. failure load for the bolt. / 3 :.'.' -}l 26,500 - 39,760 lb. for a clean shank bolt of the sr.e material is J, t; '/. -reccae rice. It is thereforc possibfo~that hanger failure would have occurred > y .iT.d 4 even if a cican shank bolt had been used. J '. c 4 I: s During the testing of relief B or C, there was enough effect on hanger No. 2 that it failed resulting in its load being distri This additional load resulted in between hanger Nos.1 and 3. no hangers adjacent to the discharge failure of these hangers, of valves D and E did not fail and the reason for this 4?%/m" attributed to the possibility that the fabrication techniquo was better on these hangers and that the dynamic load on the
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//,r*/,rfgf,,f hanger used for analysis is conputed conservatively. .. d * / r,',/ 5,8 / ep, / 1 12
^ o, 4.0 CORRECTIVE ACTION /, NGN od C.O d'^fS Ik ' Re following corrective action was taken to correct the header support deficiencies: 1. %c bolt holes were drilled out to 1'1/16" diameter for s 1" bolts 2. All horizontal and vertical hanger straps were replaced with 1/2" thick by 3" wide, 36,000 psi yield material with 11/16" diamator bolt holes. 3. New 1" diameter A325 high strength bolts with 1 1/2" un-threaded length were installed with positive locking techniques included.
- 4., The lengths of the replacement straps were adjusted to provide M
a uniform distribution of loads between the hangers. 456. @ g.
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5.0 EVALUATION 5.1 Static Loading As part of the bolt and hanger strap replacement, a hydraulic jack with dial pressure' gauge was use'd to measure the actual loads at each support point. The jack was raised enough to pick.up the header Ibad at each point. After the loads were reviewed, some modification,in the strap lengths effected a change in the load distribution pattern of the entire system. The modifying of strap 1cngths resulted in the static dead load distribution shown in Tabic 5-1 4 TABLE 5-l' FINAL SUPPORT SYS1Et !! ANGER LOADS Gw;o c. Tit:s u di r 2, Support No. Load Support No. Load 1 7,800 7 6,700 2 10,300 8 7,600 3
- 9,400 9
7,800 4 7,400 10 7,200 5 8,300 ll 8,500 6 7,200 12 8,900 l N In order to analy:e for the dead load and reaction load system, a beam finite cicment computer program was utili:cd. This program calculates the loads at cach hanger and cach no::1c when subjected to the header dead load plus header outlet reaction loads. These calculated loads for the hangers are shown 'in Tabic 5 2. g "M I dee AgkMCOT., f 29 reA FwA L u no,ac,3 ou u n a s i 4 3.. 14
TABLE 5-2 i CALCULATED STATIC LDADS AT EAGI IL\\NGER FOR DEAD LOADS PLUS OUrLET N0ZZLE REACTION LOADS a . SUPPORT NO. CALCULATED LOAD SUPPORT No. CAlfULATED LOAD 1 6,900 7 7,000 2 7,100* 8 7,200 l 3 7,200 9 7,400 4 10,400 10 10,400 5 9,700 11 3,700 6 11,300 12 13,000 This table shows that the calculated loads for a balanced system would not necessarily result in unifomly loaded hanger straps.
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Dynamic Loading _ (G cc G.C. FS Ai1 becwu 5.2 In order to analyze the header support system for the maximum postulated load on the vertical hanger, it is necessary to combine the static dead load with the scismic load as well as the maximum relief line discharge load. Utilizing.08g vertical
- f. 2 Aw and.40g horizontal accelerations due to thc/g~narid: basis 4
(tems carthquake,and an average dead load.on the hangers, the equiva-lent maximum vertical *aad is about 600.Ib y d M quivalent maximum horiz.ontal load is about 3000 lb. 6 N !. Tid 3 5. MjMCJid@NETMg For the loading due to relief valve discharge, the maximum vertical hanger load is choser to be that detennined using the Torus Analysis method, Test E, and for additional conservatism is rounded up to 18,000 lbs .ic x Def
D l The maximum horizontal hanger loading from (sco Tabic 3-3). relief valve discharge is taken from the !!cador Analysis method irith a value of 13,600 lbs. i ~ 4%sDOS When the horizontal loads are combined, it can be seen that ~ d due to the they are small compared to the vertical hanger loa s cont,ribution of the static dead load in the vertical dire Thus, the analysis at the hanger componchts to detemine \\ 4./.'s.1 J e f,Aer.. M. is performed using the largest vertical load as determined from p,,,,, j e., See Table 5-3 for a tabulation of v es w sa-the summation of all loads. The maximum horizontal load would Wha / /Mh the total vertical loads, 7 om con.r'ohet*/ be 16,600 lb. and the maximum vertical load is 31,6 ? .3 q c c< - G.6, n D
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( ras ac lctwi thin.nt? TABLE 5-3_ MAXIEM VEP.TICA1. HANGER LOADS 'Dt3f G)Le- }@m C::5 SEISMIC + STATIC + REl.IEF I,INE DISOIARGE gg gy g Load Based on Load Based on Measured Static f;cqd M [/ M Calc. Static Cgads Loads 2 SUPPORT NO. / 26,400 25,500 1 .g 28,900 g 25,700 2 gl j hl) 27,000 25,800 ls t
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26,000 29,000 ge 26,900 l 4 l 28,300 5
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25,900 29,000 6 25,300 25,600 I 7 26,200 25,800 8, 26,400 26,000 9 i 25,900 29,000 10 27,100 22,300 l 11 27,500 ~ N-
~ m ~. [. I 12 and The maximten calculated load is located at hanger no. i This load is an upper bound loact and it is very ! is 31,600 lb. g,,t. j yf f.ff,y, / Wiy unlikel'y that it could occur. y, y wre--me endo r '[ +-r:W d-Calculated Stresses imum vertical [ 5.3 The stresses in the bolts and hangers from the max i Also shown in the and horizontal loads is shown in Table 5-4. f to the applicable tabic are allowabic stress Icycis adjacent I i tabulated value. TABLE 5-4 I BI STRESSES IN BOLTS AND HANGERS-FIN I Horizontal Steport AISC Approx. Vertical Suenort Failurc g 7,r5 DL+0i3E+ Test E Test R Allow. 2DE Stress _ o + OCE. Stress. yf)- DL+C2+ Test Rf * + 05t Test E_ ~ 22ni. /c ~ J t,. - 16.6 31.6 Ardir 28.9 i.oad (k) G.G 90 S 22 ,( Bolt Stress Me '$55 1" 4 A325 18.35 20.0 .f 12. /0 4 (t A =;.7354 0 (ksi) \\ 58 16 Strap Stress A g {g at pinhole 14.9 3.4 N8 6 16.4 3 x 1/2 (ksi) ~~ Strap Stress p M 68.4 31.6 \\ Bearing 28.9 66 /6>, lo 1-1/16 4 holo (ksi) 68.4 Gusset Stress $M 62.3 Bearing 57.8 j$,2 $5.2 1-1/16 4 hole (ksi) 42Y fl Ca CS <!O b 4J.C. $%Le$ GU b~ OGk M fCL [ Cat.ltt.h k. O k 5 n
~. Using the maximun horizontal and vertical hmiger loads and assuming that they could occur simultaneously, the stresses in the torus shell were coq 1uted at the point where the hanger su'pport is Figure 5-1 defines the points in question and Tabic 5-5 attadted. lists the stress'es at these points. TA13111 5-S STRESSES IN TOPJJS Kr llMER CMCTIQ'iS Point Stress, psi Point Stmss, psi P 5,800 K 8,600 R ,5,800 L 8,600 S 8,300 M 7,900 T 5,200 N 9,900 between the hanger pads (point V of The stmss at the midpoint These stresses are all well below the Figure 5-1) is 8,600 psi. minimum yield stmss for the torus material (SA-515, Gr.70) of 38,000 psi. Using the displacement measumments taken at the header to torus nozzle during relief testing, the static dead load, and scismic loads, stresses were computed at points arotnd the nozzic to ton 2s These stresses are tabulated in Tabic 5-6. Figurc 5-1 junction. defines the~ points at which stresses wem calculated. O i / e t. TABLli 5-6 STIUISSliS IN T0ltUS N0ZZIE CO'Gl!CTIC4 Point Stress, psi Point Stress, psi A 2,700 A 6,900 ~ 1 \\ B 2,300 B 4,500 y C 5,200 C 8,700 y D 6,500 D 7,800 y Stress was calculated in the nozzle at point F figure 5-1, and the result is 18,200 psi. 'lhese stresses are also less than the 38,000 psi minimtn yield stress for the material. o 6 1
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4'l. l O'/ .s-rocus ,Q ) . !. ' f. '\\ \\ h /u c \\ 1 1 7 f / N i / rr FIGului 5-1' ( ~'.
6.0 CGiCLUSIONS Tic test ' program wrifies that the relief line discharge sequence Tic introduces substantial loads into the toms and header systems. conbination of the relief line load, the torch cut holcs and the poor initial ihsta11ation load distribution msulted in the failure of han'gers 1, 2, 3, and 12. Mic calculati,ons performed using the results obtained from the test program indicated that stresses f, were inposed which could have resulted in bolt failure even with drilled holcs, although failure probably would not have resulted in all four supports. (J It has been shown that there was no excessive stmssing of i the torus shell or the ring header as a result of the hanger failurcs by conputation of stresses at critical points en the header and torus and by non-destructive testing. [3 g,;- co.- 53, cco i b 6) The revised support system has been shown to be adequate for 3 (3/s 6cc loSh maximum postulated hanger loads 4 These loads are based on mlative displacenent data taken during mlief valve testing as well as scismic and static loading. Die postulated loads were taken conservatively high for the purpose of evaluating the mvised support system. Tic ring header to torus no::les were also evaluated using a method sinilar to that used for the l Stresses conputed for cach area all were below allowabic hangers. All stresses were calculated using nethods acceptabic limits.
- l to and defined in Section III, Subsection B of the AS'E Code, ___
e 1965 Edition. This is the applicabic edition of the ASSE Code ~ defined by the original contract. J e 0 e a 9 4.
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/ "i b} ,./ C;*ICAGO DPIDG.? AND I'RON CO. ATriR. TION T., mil 901 I?. 22nd S t. wit Oakbrook, Illir.ois 60521 M. ON 6-12-72 ?17 UNIT NUN 3ER ONE SUCTION liEADER IIANGER LOADII:CS lifP.E f MEASURED /JTER ADJUSTING REVISED ;; ANGER SYSTEM TO IMPROVE LOAD DIS-I TP.IBUTION IN ACCORDANCE 1 I'l!! GENERAL INSTRUCTIONS GIVEN BY T. AliL, CliICACO \\ BRIDGE AND IRON CO. IIANGER NUN 3ER 10 UAS ASSIGNED PLANT NORTli WITil NUM3ERS DECR7./. SING IN A CLOCXUISE DIRECTION. TiiE FOLLO'.iING HA5GER LC/.DS 1.TRE 03SER'/ED. .\\ s.
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2,600 7. 8,000 2. 7,600 8. 5,100 nn ,,,.n 7,,.v v 9. <,%v c(c'r/,1..- q o/, 8 p' ' ' 3, r s. 4. 7,600 10. 7,600 5. 5,600 11, 6,300 6. 6,700 12. 7,400 I (Y) ~ f9 / / cc: Ser;;cnt & Lundy, G. Ho /cke /b G' E. Grny { Gencrc.1 Elec tric Co., D. K. '.?'llctt Project Su;erintc.de:.t R. Leasburg United Engineers & Constra L. A. liartleY o s UE&C, J. R. D.:.y tryk d-v
.Sargent & Lundy General Electric Company 175 Curtner Avenue 140 South Dearborn Chietico, Illinois San Jose, California Attention C. liovcke Attention D. K. Willett Chicago Bridge & Iron Co. General Electric Company Quad-City Nuclear Power Station 1819 John F. Kennedy Blvd. 'Cordova, Illinois Philadciphia, Pa. Attention T. Ahl ' ' Attention R. Locaburg ON 6/7/72 THZ UNIT 124" TORUS SUCTION IIEADER IIANGER LOADINGS WERE ::EASURED. THIS UAS ACCOMPLISHED BY USE OF A liYDRAULIC JACK UITil RN0*:.*N ZFFECTIVE PLU :GT.R CROSS SECTIONAL AREA MULTI? LIED BY CALIBRATED PRESSURE CAUCZ READINGS. SUFFICIENT JAC::,ING FORCE UAS APPLIED TO PERMIT TURNING Tiin LOUER HA::GER BOLT LY I:AND. AT 7;;; TIMZ 07 MEASL7.Z:: NTS 7;;E CRICINAL 3/4" DIA:: t:R 30LTS L P. STILL IN PLAC2 ENCEPT AT POINTS 1 AND 2 WiiICH HAD BEEN C!!ANGZD 701" BOLTS. }! ANGER NL}GER 10 UAS ASSIGNED PLANT NORTil, WITil NU'iBERS DECREASII:G I3 A CLOC:GlISE DIRECTION. THE FOLLO'.lING HANGER LOADS WERE OBSERVED AS CONPARED WITii E000 POUNDS I;OIC/.TED LY C31I DESIGN. 1. 4,000 7. 15,200 2. 2,700 8. 4,700 s 3. 0,000 9. '8,800' Y " " N 1 2.0 0
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10,000 5. 6,300 11. 9,700 6. 7,900 12. 16,800 / G. E. Gray Project Superintendent United Engineers & Constructors Inc.
CilICAGO LRIDSE AND ID0N CO. l.*
- ATTDTION T. /J1L 901 W. 22nd Strcct Oakbrook, Illinois 60521 NERTWOTORUSSUCTIONHEADERHANGERLOADINGSWERE ON 6/17/72 THE UNIT NU::
ME/5JRED AFTER ADJUSTING REVISED HANGER SYSTE:1 T t IN }! ANGER ADJUSTNENT WAS ACC0Y.?LISirIED BY REF/J3RICATION ACCORD /.'<CE WITH DISCUSSION AND INSTRUCTIONS CIVEN BY T. AliL, CH AND IRON CO.' 1: ANGER NIT.:33R 2 UAS ASSIGNED PL/J;T NORTil MITil NG;DERS AFTER 03TAINING READINGS, THEY INOREASING IN A CLOC;G;ISE DIRECTION. I UERE DISCUSSED WITH NR. AHL 3Y TELEP;;0NE ON 6/17 AND IIE FEELS LOAD D THE FOLLOWING HANGER LOADS UERE ODSERVED. TRIL' ZION IS CURRE'.;TLY /,CCE?TA3LE. 1. 7,800 7. 6,700 2. 10,350 / 8. 7,600 3. 9,400 9. 7,600 4.. 7,400 10. 7,200 ', 5. 8,300 11. 6,500-6. 7,200 12. 8,900 ] /( ,%v r G.E. Gray / Project Superintendent United Engineers & Constructors Inc. Sargent & Lundy, G. Hoveke cc: Cencral Elo.ctric Co.: D. K. Willett R. A. Leasburg L. A. Harticy. UE&C INC.: 'J. R. D.r.ytryk
CllICAGO DRIDSE_A!;D IRON CO. AWENTION T. A!;L 901 W. 2'ind Street Oakbrock, Illinois 60521 ON 6-11-72 THE UNIT TWO 24" TORUS SUCTION liE Ti!IS WAS ACCOMPLIS; ED BY USE OF HYDRAULIC JACK WI MEASURED. EFFECTIVE PLUNGER CROSS SECTION AREA MU ~ SUFFICIEUT JAC::!NG FonCO WAS APPLIED TO GUACC READINGS. THE REVISED 11 ANGER SYSTEM COI;SISTII:G OF THE LO'.1ER iiANCI;R LOLT LY IIAND. M-1020 MQ 7;;REE INCH WIDE STRAPS WITH A325 IIIGli STR PLACE WITi; 1: ANGERS INSTALLED TO RU-SUPPORT Tile H 7;;IS IS ??.E FIRST SET 07 LOAD READINGS TA:GN FOR UN POSI'IION, HANGER NUM3ER 2 UAS. ASSIGNED PLAST l'OR THE FOLLO'!ING UANGER LOADS WERE OliSERVE CLOC;C.'ISE DIRECTION. i 1. 5,400 L 7. 3,600 2. 13,200 " 8. 7,600 ~ 3. 9,400 9. 12,000 100 k Iln^i T0 3'- 4. 13,000 10. 22,300 5. 700 11. 700 b 6, 11,600 12. 13,200 * / /,X..,. x, Sargent & Lundy, C. Hoveke ~ s. E.' Gray / cc: General Electric Co., D. K. Villett Project Superin tenu.$. 1 -. R. Leasburg United Engineers & Con,tr L. A. Ilarticy J. R. Dmytryk UE&C Inc. 2 g _.
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