ML20210A633
| ML20210A633 | |
| Person / Time | |
|---|---|
| Site: | Quad Cities, 05000000 |
| Issue date: | 06/22/1972 |
| From: | Foley W, Lofy R PARAMETER, INC. |
| To: | US ATOMIC ENERGY COMMISSION (AEC) |
| Shared Package | |
| ML20209J032 | List:
|
| References | |
| CON-AT(11-1)-1658, FOIA-87-40 DC-98-DRFT, NUDOCS 8705050133 | |
| Download: ML20210A633 (75) | |
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USE ONLY No. 1, 15 pag n _ Report of Preliminary Inve,stigation FAILURE OF HANGER BOLTS ON SUPPRESSION CHAMBER SUCTION HEADER at Quad Cities Nuclear Station, Unit -2
- Commonwcalth Edison Company
, Icrxa-Illinois Gas and Electric Company
. Rock Island, Illinois Report'No. DC-98 (Draft) June 19, 1972 (Issued) June 22, 1972 Prepared for: U. S. Atomic Energy Conn.
Directorate of Regulatory Operations AEC Contract AT(11-1)-1658
, Task "A" '
PAR: 71-72 A by: b L ~ = ;t .- A 4 8' f,
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Walter J. Foley, P. E. g50gj3870428 PARAMITER , Inc. THOMAS 87-40 PDR Consulting Engineers Elm Grove, Wisconsin FOR OFFIGAL - USE ONLY
Vagu 5 1 l NOTICE This report was prepared as an account of work sponsored by the United States
. Government. Neither the United States nor the United States Atomic Energy Commission, nor any of their employees, nor any of their
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contractors, subcontractors, or their employees, makes any warranty, express or I implied, or assumes any legal liability os responsibility for the accuracy, complete-ness or usefulness of any information, apparatus, product or process disclosed, or represents that its use would not infringe privately-owned rights. I e
_ = - _ . ._- -1 i ,,', Page 3 ) Distribution: Copics: AEC Regulatory Organization Directorate of Regulatory Operations i i Technical Assistance Branch - Washington (6) G. W. Reinmuth L. L. Beratan Region NII, Glen Ellyn, Illinois (3) B. H. Grier AEC Contracts Division Chicago Operations Office (1) H. N. Miller, T. Katisch i^ PARAMETER, Inc. (1) i 1 i 4 4
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Table of Contents: Page: I Introduction 5 II Summary of Findings 7 III Discussion of Inspection 12 IV . References 16 V Attachments 17 Attachment No. 1, " Analysis of Support Bars and Bolts of 24 Inch Diamete: Header for Suppres: lion Chamber", Rev. O , 6/19/72 I e
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Introduction:
At the request of AEC Regulatory Operations, Technical Assistance Br., the writer assisted Mr. L. L. Beratan, Senior Structural Engineer, RO-Hg. and Mr. E. Jordan, Reactor Inspector, RO-III, on June.6 and 7, 1972, in a review of the failed suction header hanger bolts on the Quad Cities suppression chamber. The review consisted of a physical inspection and fact
, finding discussion with operating, construction, and design personnel at the Quad Cities plant; and a follow-up session with AEC personnel at Region -III in Glen Ellyn.
PARAMETER's investigation to date, which must be considered preliminary pending the availability of analysis and test data to be assembled by the licensee, includes a check on the flooded weight of the ring
' header and an estimate of the unit load under which the originally installed support bolts might have been expected to fail. Also included is an assessment of the proposed redesign for static loads.
Failure of four adjacent header support hangers by double shear of the clevis bolts was noted during tests of plant systems. Quad Cities, Unit -2, is a 809 MW(e)BWR being supplied by General Electric to Commonwealth Edison on a turnkey basis. Sargent and Lundy was the Architect-Engineer and United Engineers and Constructors, the general contractor-for the - plant. The plant is in its stx11-up phase. The attendees at the inspectie; and meetings of June 6 and 7 at Quad Cities were: (titles may be approximate or unknown) C+>mmonwealth Edison Company (CECO) l H. Hoyt, Operations l F. Palmer, Plant Superintendent R. W. Thompson B. Stephenson, Assistant Plant Superintendent l .
I Pcg3 6 I
Introduction:
continued General Electric Comapny (GE) R. Leasburg, Project Manager L. Hartley, Site Manager Sargent & Lundy (S&L) E. R. Weaver, Structural Engineer Chicago Bridge & Iron (CB&I) T. J. Ahl, Design Engineer / Analyst AEC Regulatory Operations
- E. Jordan, Reactor Inspector, RO-III L. L. Beratan , Senior Structural Engineer , RO-Hg .
R. A. Lofy, Consulting Engineer, YARAMETER, Inc.
- During the afternoon briefing session on June 7, the inspection team also met with the following RO-III personnel at Glen Ellyn:
B. H. Grier, Director, RO-III G. Fiore11i, Senior Reactor Inspector, Operations D. Hunnicutt, Senior Reactor Inspector, Start-up Note: Detailed notes and calculations assembled in connection with preparation of this report are maintained on file for the AEC by PARAMETER, Inc. under Assignment No. DC-98.
II Sum:.ary of Findinos:
. 1. The design of the bolted pipe hanger connection meets the stated gravity plus vertical seismic load require-ment with a minimum margin based on its AISC rating.
Stated (CBI) design weight load: 8000 lbs. Weight plus .089 seismic load: 8640 lbs. - AISC Rating of Bolt: 8840 lbs. (Ref.-4) (A-307, 3/4" Dia.) (Sect.4-4) The use of fully threaded bolts added no conservatism to the design.
- 2. Calculations by PARAMETER, Inc. (Attachment -1) veri-fied the suction header flooded weight which resulted in the stated 8000 lb. load per hanger used in the-design. The load of the 3600, 26" Dia header and contained water was assumed to be uniformly supported by each of the four (4) nozzles connected to the torus plus twelve (12) hangers. The 8000 lb. load per support point (16 points) does not reflect any forces due to built-in distortion (preload) of the header or imposition of loads from piping connected to the header. The assumption of proportionate sharing of the total weight load between hangers and nozzles and the non-symmetry of th,3 supports show the basic design (gravity) load alone to be non-conservative. (See Attachment -1)
- 3. Calculations by PARAMETER, Inc. (Attachment -1),
based on root area double shear as was actually experienced, indicate that the hanger connection should have had an ultimate load catrying capability of approximately 24,000 lbs. (Attachment -1, p. 10). This value is based on a shear stress of 2/3 the minimum ultimate tensile strength of the material. The failure load of the material could have been lowered somewhat by the tapered (punched) holes in the structural members and poor fit-up. l l In the absence of material defects, the wide dispari-ty between predicted failure load for an individual hanger, and the dead weight design load is great , enough to point to the possibility of other imposed 4 loads contributing to the failures. They could be one or a combination of the~following: l l D I I e
Page 8 - II Summary of Findinos: continued
- a. Dynamic loads due to valve opening /
closing or pump starting / stopping on systems connected to the header,
- b. Dynamic loads due to observed movement of'the torus wall during steam relief valve blowdown into the suppression chamber.
- c. Uneven loading of hangers due to initial installation and/or residual distortion
. of the header. These loads, particularly if the nozzles do not carry their share of the gravity load, could preload some hangers well beyond their nominal
" balanced" design load.
- d. Gravity loads from connected pipe not accounted for in the weight balance or not compensated for by hangers in the attached systems.
- 4. Measurements of actual static loads carried by individual hangers will establish conclusively whether the conditions described in 3c and 2d above exist. (The individual hanger loads could conven-iently be checked when temporary bolts are replaced.)
The total load carried by the twelve (12) hangers can also be used to verify the proportion of load shared by the nozzles. -
- 5. A test program is being formulated by GE to measure movement of the torus and header during operation of the steam relief and safety injection systems and to monitor vibration. The results of these tests, in conjunction with the static load measurements described in Item -4 above should be useful in determining if there are strong dynamic loads on the header which could have been a major contributor to the failures.
Paga 9
. II Summary of Findings: continued
- 6. A possible explanation of the timing of the failures, occurring during systems tests, in the presence of a grossly overloaded condition, is the breaking loose of the bolting friction, and loss of part of the load carrying capability of the hanger bolts from the vibrations reported to be associated with the tests.
- 7. The revised . design will utilize a 1" Dia. A-325 steel bolt with the threads excluded from the shear plane. The AISC rating for this bolt in a tight structural connection is 34,000 lbs. A pair of revised hanger bars (3 " :: 1/2"), evaluated as an AISC clevis will have a safe working load of 15000 lbs. (Attachment -1, p. 13). Thus, the hanger bars become the weaker link in the revised design. Whether they are adequate will depend upon the individual hanger loads determined to exist from the possible dynamic or static effects described in Item -3 above.
- 8. In Reference -2, CB&I reports the approximate membrane stresses calculated in the header and torus wall in the failed ondition. Significant stresses are reported in the torus insert plate at the nozzle neck (25,200 psi. ) and in the torus shell adjacent to the insert plate (26,700 psi.), both in a circumferential direction with respect to the torus. The reported calculated ,
stresses result from the static load of the header between two nozzles with the intermediate three hangers missing. The theoretical deflec-tion of the header associated with the reported stresses is 4". (The deflection of the header in its at-rest position af ter the bolt failure as measured was 5-3/4") l' The stresses reported by CB&I nay not be as high
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. *: Pags 10 . II Summary of Findinos: continued as actually realized for a number of reasons:
- a. The dynamic effect of the header dropping and coming to rest in its displaced posi-tion was apparently not considered.
- b. The fourth failed hanger on the opposite side of the nozzle bounding the quadrant of three failed hangers was presumably not in the analytical model.
c... Dynamic and/or static loads imposed on the system which are still unknown were obviously not considered. Because a 5-3/4" deflection was observed at the l header mid-point af ter the hanger bolts failed, the 4" theoretical deflection and associated stresses would not appear to reflect an entirely conservative analysis. Other factors accounting for the difference between calculated and measured values of deflection, either positively or nega-tively, might include:
- a. An initial upward deflection of this section of the header (preload) might have' existed when installed.
- b. Some restraint or additional load could have been received from connecting piping.
- c. The fact that torsional deflection of the nozzles was not considered in the analysis (and thus did not contribute to the total calculated deflection).
- d. The header could have taken some permanent set as a result of the stresses occurring at time of failure. Calculation of such stresses would require a dynamic analysis.
l l l .
Paga 11 II Summary of Findinas: continued Combined with negligible radial pressure stress, the circumferential membrane stress of 26,700 psi, reported by CB&I in Reference -2 results in a stress intensity of 26,700 psi. which exceeds slightly the 1.5S design limit (Ref. -6) of 26,250 psi.' for local membrane stress intensity.
, Because bending stresses are not reported by CB&I for nozzle areas, evaluation of their results cannot be made at the present time.
- 9. CB&I r.eported (Ref. -2) as a result of their visual inspection, that there was no apparent yielding of the suppression chamber (torus) shell.- In the writer's inspection, made after the header was returned to its original position, no permanent deformation was observed. Lack of any gross yielding, appropriate nondestructive testing, and evaluation of stresses as reported J
in Item -8 above v:ould, in the author's opinion , support the position that the components are suitable for their normal service life.
- 10. During the discussion with Quad Cities operating personnel, the bolt failure was described by Mr. Palmer as having the appearance of the wearing through or experiencing a " hacksaw" effect due to motion. It is the author's opinion that '
"hacksawing", wear or fatigue were not significant factors in causing the failure. The total double shear of the bolt into three pieces indicates a gross overload with a follow-up capability.
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.. o Page 12 , III Discussion of Inspection:
The design of the 24" Dia. Header which supplies water to various safety injection and cooling systems from the suppression chamber torus section and its method of support was described by CB&I drawings, (Ref. -1,
- a. b. c.). The header is a continuous 3600 mitered pipe assembly supported by twelve pipe hangers and four nozzles connecting to the torus at approximately equal spacing. Failure of three (3) vertical hangers in one quadrant between nozzles and one (1) adjacent hanger on the opposite side of the nozzle occurred by complete double shear and parting of the bolts at the clevis type connection. Remaining bolts which did not fail, showed varying degrees of thread deformation and offset. (See sketches of Attachment No. 1, p. 6).
The design of the ring header , as part of the suppres-sion chamber system was completed by CB&I to S&L specifications. Mr. Ahl of CB&I stated that the nomi-nal dead load for design of the hangars was 8000 lbs. to which static seismic factors of 0.089 vertical and 0.39 horizontal were applied. Dynamic effects of seismic activity or operating loads were not specified as such or considered by CB&I in their design. Thermal considerations are not a factor in hanging the header as it contains water at the same temperature as the torus. It was determined in discussion that a dynamic analysis of the torus and header was performed by Blume and , Associates for GE. It was not established whether the results of that analysis were directly inputed to the f specifications to which CB&I was working. It was indicated that seismic snubbers were not required on f this system on the basis of Blume's dynamic analysis. l l (The Dresden plant has snubbers which were specified on the basis of static analyses.) The CB&I design was reported to be based on applied-forces, moments, shear loads, and static seismic factors specified by S&L and CB&I's orm determination of gravity loads. The methods of Welding Research Council Bulletin No. 107 (Bijlaard methods) were used to evaluate stresces l l I .
Page 13 III Discussion of Inspection: continued
'in the torus at both hanger and nozzle attachment points.
A metallurgical test of the failed bolts has been obtained ,(Ref. -3). -It confirmed that they were A307 material (3/4"-IONC) as specified (Ref. -la.). The CBLI representative referenced the AISC Manual (Ref. -4) (Section 4) in indicating that'the allowable load for 3/4" Dia. A307 bolts in double shear is 8840 lbs. (This load rating would just about equal the stated static load per hanger including the vertical seismic factor). Author's Note: The AISC rating for a bolted structural connection is based on a nominal (3/4") diameter. For A307 bolts, the Manual does not differen-tiate in its rating between the load
, carrying capability for shear through the body diameter versus shear through the threads. For the condition, threads in the shear plane, as was experienced at Quad Cities, there would be considerably less conservatism in the application than for the case of full shank diameter. ,
In spite of the use of low strength (A307) fully threaded bolts, considering the factor of safety implicit in the rating of bolted connections by AISC, one would expect the bolt in question to be able to sustain loads greater than the 8000 lb. design static load by a factor of 2 to 3. When questioned as to his theory of failure, Mr. Ahl speculated that failure occurred due to poor initial fit-up and uneven loading of the hanger links. After failure of one bolt, the load transference to adjacent _ ,, ,y- .,_.,_.r,. ., _.__.__._-y,_.__ . , , - , _ _ _ _ _ _ _ _ _ _ _ . _ , _ . , _ _ . . _ _ _ ,
_. . - ___ .= _ . . i 4 Page 14 Y j III Discussion of Inspection: continued hangers would promote their failure in sequence.
\
., The proposed bolt fix was discussed. A325 bolts, , 1" Dia. have been installed ~with holes in the hanger l bars and clip assembly drilled and reamed to size. New bars (3" x.1/2") replace original bars (2-1/2" x 1/2"). l Although no damage to horizontal restraints was noted, the 3/4" bolts will also be replaced with the 1" size. . The 1" bolts presently in place, have some of the threads in the shear plane. These will be further i substituted with A325 bolts to provide for full } shank diameter in both shear planes. A rating of j approximately 23,000 lbs. was said to be achieved j with the present installation (1" partially threaded bolts). (This would assume that the hanger bars do not become limiting as clevis connections.) i
; Questions regarding field installation of the header
! assembly established that the pads supporting the l header were field welded to the torus. It was j indicated that the pad location was not necessarily j matched to the header, but rather the fit-up of the J header'made by adjusting the hole distance in the
! links. This was evident in subsequent physical inspection of the link bars for the ft.iled bolt l connections which showed a variation in hole distance and overall length of about 3 inches.
Inspection of the 1/2" thick hanger bars revealed that i most holes had been punched (versus being drilled), I thus having a tapered inside diameter and were some-what over the 13/16" specified diameter. The tapered l hole would not present as uniform a bearing surface to the bolt as a constant diameter and could account [ for some degradation of the load carry capability of
! the bolts in shear. Some of the holes in the hanger j bars were just rough burned, which could similarly
! lower the bolt strength. Two of the pairs of bars j of the'four on which bolts failed had such torch cut i holes. i . (
- i .
, Paga 15 III Discussion of Inspection: continued CB&I has performed an analysis of stresses which were imposed on the header and its points of attachment to the torus as a result of the hanger bolt failures.
These were reported in Ref. -2. A three dimensional finite element' analysis was used to obtain moments and forces in the header and at the nozzles connecting to the torus. The Bijlaard method was used to calculate nozzle and shell stresses. Stresses quoted are for the calculated deflection based on gravity loading. - It was noted by the team, that the calculated deficc-tion of 4" of the header under gravity load did not agree with the measured deficction of 5-3/4" before the header was replaced in its original position. The final analysis report is to address itself more specifically to the stress levels or other factors that might .have been associated with the measured deflection. . Further analysis of the header is also to consider the effects of dynamic loads due to operation of plant systems which are to be. identified and quanti-fled in instrumented tests planned by GE. The analysis will also specify the seismic basis for the design. Stresses in the torus wall and pad connec-tions will also be reported in the analysis to make a complete disposition of the effects of the hanger failure and substantiate the design for normal plant operation. It was decided by the team not to request CB&I's preliminary analysis report for review at this time as it did not include the above considerations. A visual inspection of the torus by the writer revealed i no observable deformation in the torus wall at the areas of reported local high stress. 1 l l 4
o o. Page 16
- IV
References:
- 1. Reduced size prints of Chicago Bridge and Iron Company drawings (Ref. Contract No. 9-6771):
- a. No. 213, Rev. 1, Support Assembly for l 24" Dia. Header.
i b. No. 216, Rev. 6, Shop Details, 24" Dia. Header for Suppression Chamber.
- c. No. 217, Rev. 5, Field Details for 24" Dia. Header for Suppression Chamber.
1
- 2. Telex No. 2531B6, T. J. Ahl, CB&I to E. Weaver,
! Sargent & Lundy, dated June 2, 1972 (Report of
- Stresses).
l { 3. Test Results, Ring Header Support Bolts - Letter June 2, 1972, G. C. Kuhlman, Sargent & Lundy, to 4 R. Leasburg, General Electric, with enclosures. 4 Manual of Steel Construction, Seventh Edition, l American Institute of Steel Construction, Inc., o 101 Park Avenue, New Y'rk. i 5. The American Society of Mechanical Engineers, Materials Specifications. Part A - Ferrous, j ASME Boiler and Pressure Vessel Code, Section II, 1971 Edition. I 6. The American Society of Mechanical Engineers, Rules for Construction of Nuclear Power Plant l' Components , ASME Boiler and Pressure Vessel Code, Section'III, 1971 Edition. i I t i i l i l -
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i SCHEDULE REPORT O il TORUS BEHAVIOR DURING RELIEF VALVE DISCHARGE COMPLETE DATA REDUCTION 10-72 TABULATION - - - - 8 24-72 R E V I E lf A N D COMPARE DATA-ANALYTICAL APPROACH AND 8-72 DETAILED OUTLINE PROVIDE COPIES OF DETAIL 15-72
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REFINE & VERIFY AN ALYTIC AL
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ACCEPTABILITY CRITERIA OBJECTIVE: A safe and adequate containment for the life of the plant. G
ACCEPTARILITY CRITERIA It is recognized that one measure of acceptability and adequacy is the A5ME Code, Section III,. Subsection NE, for MC Components.
ACCEPTABILITY CRITERIA ASME Code
- 1. General primary membrane stress intensity -
Allowable - Sm 2 Local membrane stress intensity - Local membrane plus primary bending stress . I intensity - Allowable - 1 5 Sm
- 3. Local membrane plus primary bending stress intensity plus s scend4g b*nd!"$
l Allowable range - 3 Sm l
- 4. Cycli (fatigue) for life of plant -
Allowable - Fig. I-9-1 l l 1
BROWNS FERRY TORUS Plate Material: SA-516, Grade 70 Sm = 19,3 ksi l l 1.5 Sm = 28.9 ksi 3 Se = 57.9 ksi
l l BROWMS FERRY TORUS Cosparison with Criteria: 1 Sm Loadings to be considered are those which produce general membrane stresses: For any torus location:
, Dead Loads Internal pressure (from small break)
Earthquake Locations to be considered: (a) In the vicinity of the header nozzle (b) Other, e.g. on the bottom of the torus midway between stiffeners l l l {
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BROWNS CERR' TORUS Comparison with Criteria. 2 1.5 Sm Loadings to be considered are thos'e*which produce membrane and primary bending stresses. For any torus location. Water and pressure in torus Water and metal weight of header Vertical earthquake on header Horizontal earthquake on header End cap load from header Locations to be considered- . (a) In the vicinity of the header nozzle (b) Other, e o_ at cradle bottom or midbay torus bottom
J BROWMS FERRY TORUS Comparison with Criteria: 3 3 Sm Range Loadings to be considered are those already discussed. In this case the total range of stress encountered in normal operation must be considered. The stresses include secondary bending due to mechanical leadings, l i i l l ' - . . - . . . . - - - - - _ . ._
BROWNS FERRf TORUS, Comparison with Criteria: 4 Cyclic Analysis (Fatigue) For this discussion assume: 20 valve lifts per year - 8 significant stress cycles per lift - 40 years - 6400 cycles total in plant life From ASME Code, Fig. I-9-1 Sa = 43,000 psi. Range = 2 Sa = 86,000 psi for cyclic analysis l Assuming that the cumulative usage factor available for this condition is -0.9 (seismic, testing, and accidents do not have high usage factors), the following is the case: l Adequate margin is still.available after the , application of a reasonable stress concentration factor.
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ACCEPTABILITY CRITERIA ASME Code
- 1. General primary membrane stress intensity -
Allowable - Sm
- 2. Local membrane stress intensity -
Local membrane plus primary bending stress intensity - Allowable - 1.5 Sm
- 3. Local membrane plus primary bending stress intensity -
Allowable range - 3 Sm 4 Cyclic (fatigue) for life of plant - Allowable - Fig. I-9-1 l
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