ZS-2013-0353, Additional Information Regarding Performance of the Zs Fhb Crane Bridge Deflection Test

Additional Information Regarding Performance of the Zs Fhb Crane Bridge Deflection Test

ML13316A263
Person / Time
Site:	Zion  File:ZionSolutions icon.png
Issue date:	11/04/2013
From:	Daly P ZionSolutions
To:	Document Control Desk, NRC/FSME
References
ZS-2013-0353
Download: ML13316A263 (4)

Text

ZIONSOLUTIONS An EnergySo/utins Coralpany November 4, 2013 ZS-2013-0353 U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, DC 20555-0001 Zion Nuclear Power Station, Units 1 and 2 Facility Operating License Nos. DPR-39 and DPR-48 NRC Docket Nos. 50-295 and 50-304

Subject:

Additional Information Regarding Performance of the ZS FHB Crane Bridge Deflection Test

References:

1.) ZionSolutions, LLC Letter to NRC, "Notification to the NRC that the Single-Failure Proof Modifications to the Fuel Handling Building Overhead Crane are Complete,"

ZS-2013-0320, dated October 4, 2013 2.) KNES Procedure 36675-27: "Site 125% Load Test Procedure R3",

dated December 12, 2012 3.) P & H Drawing # 54238670: "Iso-Test Weight, Main Hoist, 125% & 100%"

4.) Work Order 0144057-10: "FB Crane Girder Deflection Test," dated October 5, 2013 5.) P &H Calculation No. 36675-05: "ZION Bridge Structural Calculations",

dated April 17, 2012 BACKGROUND:

In Reference 1, Item 4, ZionSolutions, LLC (ZS) describes the plan to perform a deflection test of the newly installed Fuel Handling Building (FHB) Single-Failure-Proof (SFP) crane using the NAC MAGNASTOR Transfer Cask (MTC) loaded with a Transportable Storage Canister for a mass greater than 60% of rated load. The following discussion describes the basis and results of this test and the technical and regulatory conclusions resulting from our review of the test results.

DISCUSSION:

As described in Reference 1, a 125% load test was performed by the vendor that manufactured the new trolley for the Fuel Handling Building Crane. This test served also as a "cold proof test" for setting a lower allowable temperature limit for safe crane operation. Documentation of the successful test and the subsequent acceptable inspections of all critical welds are found in Reference 2. As documented in Reference 3, the actual test weights used were equal to or greater than the 1.25 x 125T (312,500 pound) load required. Following the 125% cold proof test, a series of 100% rated load tests were performed to verify the operability of the FHB crane design features. This testing included full performance testing of the crane handling system at 100% load for all speeds and motions for which the system is designed. Functionality of the main hoist emergency lowering system and individual holding brakes were also tested at 100%

of rated load. Visual observation of the crane component performance was conducted during these tests and no abnormalities were observed.

101 Shiloh Boulevard, Zion

• IL60099 (224) 789-4016 - Fax: (224) 789-4008

• www.zionsolutionscompany.com

ZionSolutions, LLC ZS-2013-0353 Page 2 of 3 Although the NOG-1 Compliance Matrix, submitted with the License Amendment Request (LAR) contained a commitment to perform a full load deflection test, the measurement was inadvertently omitted from the final test procedure. ZS attempted to perform a deflection measurement during the lift sequence, however either due to method or instrument error, the result was not considered realistic (a measurement of 0.0 inches or no deflection was obtained).

The anomalous nature of the result was not identified until the test weights were disassembled and since the deflection measurment was not part of the test procedure, it was not re-performed.

Additionally, the measurement was not considered to be required to satisfy code since it was to determine deflection of the bridge, which was not replaced as part of the NOG- 1 upgrade.

While this measure of deflection at full load was committed in the LAR by ZS, it is otherwise not required for a bridge that was not replaced and not constructed to NOG-1 standards. The bridge was analyzed to the requirements of the NOG-l standard, but the bridge design remains in accordance with EOCI-61. The bridge was qualified by successfully performing a cold proof load test as required by NUREG-0554 Section 8.2, Static and Dynamic Load Tests. Therefore the decision was made not to restack the test weights just to measure girder deflection. ZS performed a 50.59 to re-evaluate the commitment for the deflection measurement and concluded that a deflection measurement at 60% or greater of rated load would provide an adequate reference for future comparison, since the measurement scales linearly. In this case, the reduced load deflection measurement satisfies the intent to compare the actual deflection to calculated values because that comparison can be made with a linear calculation. In fact, the same calculation to account for additional weight needs to be performed even when the measurement is made with 100% load. This is because the calculated deflection includes trolley weight, which needs to be adjusted with the trolley installed. The only difference in the ZS case is the field measurement is adjusted for the trolley dead load and a portion of the rated live load versus adjusting for the trolley dead load only.

Consistent with the conclusion of the 50.59, ZS performed a separate deflection measurement with the maximum available on-site loads. The load consisted of the NAC MAGNASTOR Transfer Cask and a Transportable Storage Canister (with lid) filled with water. The weight of the load was measured by the crane load cell as being 88 tons, which is approximately 70% of the crane rated capacity. As expected, the deflection determined from the test, when adjusted for trolley dead load, was less than the calculated value due to the inherent conservatisms in the analysis. These include minimum yield strengths and Young's Modulus properties, conservative modeling and the slight end fixity provided by the welded/bolted end truck supports compared to the pinned condition assumed in the model. The measured deflection also serves to verify the modeling performned in Reference 5 since it is slightly lower than calculated, as expected. The calculated and measured deflections also are below the allowable ASME NOG-1 -2004 Section 4341 deflection, noted as an additional consideration to NOG-1.

The ZS Quality Assurance organization has responsibility to assure that code requirements, as specified by engineering, are implemented. In this instance, the performance of the test is below the threshold at which the Quality Assurance Program Plan or the Quality Assurance organization would stipulate testing, other than to review the engineering approach. ZS Engineering has concluded that a deflection test at 60% or greater load is acceptable and the Quality Assurance organization has acknowledged that determination via its review of the test.

ZionSolutions, LLC ZS-2013-0353 Page 3 of 3 ZS considers that, consistent with the conclusions of the 50.59, the NOG-1 2004 deflection criteria has been satisfied in an appropriate manner. ZS also concluded that the test was not required and the LAR contained an unnecessary commitment.

Patrick Daly Senior Vice President &

ZionSolutions, LLC cc: John Hickman, U.S. NRC Senior Project Manager Service List

Zion Nuclear Power Station, Unit 1 and 2 License Transfer Service List cc:

Patrick T. Daly Russ Workman Senior VP and General Manager General Counsel ZionSolutions, LLC EnergySolutions 101 Shiloh Boulevard 423 West 300 South, Ste. 200 Zion, IL 60099 Salt Lake City, UT 84101 Patrick Thurman, Esq. Illinois Department of Nuclear Safety VP Regulatory Affairs, Licensing & Document Office of Nuclear Facility Safety Control 1035 Outer Park Drive ZionSolutions, LLC Springfield, IL 62704 101 Shiloh Boulevard Zion, IL 60099 Kent McKenzie Emergency Management Coordinator Gary Bouchard Lake County Emergency Management Agency VP Engineering, Ops & Nuclear Security and 1303 N. Milwaukee Avenue Decommissioning Plant Manager Libertyville, IL 60048-1308 ZionSolutions, LLC 101 Shiloh Boulevard Regional Administrator Zion, IL 60099 U.S. NRC, Region III 2443 Warrenville Road Alan Parker Lisle, IL 60532-4352 President Projects Group EnergySolutions John E. Matthews 1009 Commerce Park Drive, Ste. 100 Morgan, Lewis & Bockius LLP Oak Ridge, TN 37830 1111 Pennsylvania Avenue, NW Washington, DC 20004 Dan Shrum Senior VP Regulatory Affairs EnergySolutions 423 West 300 South, Ste. 200 Salt Lake City, UT 84101