ML20010E304

Technical Rept on Underpinning Svc Water Pump Structure. Two Oversize Drawings Encl.Aperture Cards Are Available in PDR

ML20010E304
Person / Time
Site:	Midland
Issue date:	08/25/1981
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML20010E302	List: ML20010E301 ML20010E304
References
NUDOCS 8109030308
Download: ML20010E304 (21)

Text

{{#Wiki_filter:I TECilNICAL REPORT ON UNDERPINNING Ti!E SERVICE WATER PUrlP STRiiCTURE FOR rilDLAND PLANT UNITS 1 AND 2 CONSUr!ERS POWER CO?!PANY DOCKET NUrlBERS 50-329 AND 50-330 AUGUST 25, 1981 i 8109030308 810826 PDR ADOCK 05000329 A PDR

TECIINICAL REPORT ON UNDERPINNING TIIE SER7 ICE WATER PUMP STRUCTURE TABLE OF CONTENTS 4 i Section Title j l 1.0 INTRODUCITON j 2.0 PRESENT CONDITich 3.0 REMEDIAL ACTIO!J 4.0 DESIGN FEATURFS i 5.0 CONSTRUCTION f i 5.1 DEWATL "NG l 5.2 BUIIJING POST-TENSIONING 1 5.3 CJNSTRUCTION PROCEDURES J i I 5.3.1 Initial Construction Activities 'l ) 5.3.2 Final Jacking Stage I 5.3.3 Lgg;1etion of the Underpinning Wall 6.0 MONITORING REQUIREMENTS i 6.1 SETTLEMENTS f 6.2 CRACKS 7.0 ANALYSIS AND DESIGN j 7.1 STRUCTURAL BEllAVIOR 7.2 DESIGN CRITERIA AND APPLICABLE CODES e i 7.3 LOADS AND LOAD COMBINATIONS i j 7.4 STRUCTURAL ACCEPTANCE CRITERIA 8.0 QUALITY ASSLPdNCE REQUIREMENT i 9.0 ADDITIONAL KgC REQUIREMENTS i l miO881-0412a100 I 1 ... - ~. - -. -

1 TAlli.ES. TAI!LE_1, Loail E<piat ions for the Service Water Pump Structure t!oiliiie<1 to i nc luile Preloail. FIGURES FIGURE 1 Service Water Pump Structure Concrete Floor Plans at El. 592'-0" anil EL. 634'-6"(C-94, Rev 8) FIGURE 2 Service Water Pump Structure Section (C-97, Rev 2) FIGURE 3 Service Water Pump Structure Unilerninning Herguirements FIGU'<E 4 Service Water Pump Structure Unilerpinning Plan & Sections FIGURE 5 Service Water Pump Structure unuerpinning Sections anil Details FIGURE 6 Se evice Water Pump Structure Tensian Ties, i miO881-0412a100 ii l l

l MIDLAND PLANT UNITS 1 AtJD 2 TEClif11 CAL REPORT ON UNDERPINtJING Tile SERVICE WATER PUt1P STRUCTURE

1.0 INTRODUCTION

This report describes the design and construction require-ments of the remedial action for the service water pump structure (SWPS) necessitated by the settlement potential of the plant fill underlying the structure. 2.0 PRESEtJT CONDITIOt1 The SUPS is a two level, rectangular, reinforced concrete structure. Below c1 617', it measures 86 feet by 71 feet 11 inches; above el 617' it measures 106 feet by 86 feet. The maximum overall height is 69 feet [See Figures 1 and 2 (FSAR Figures 3.8-56 and 3.8-57)). The structure was designed to be supported by the two foun-dation slabs, one at el 587'-0" and the other at el 617'-0". The lower slab rests on undisturbed natural material and the upper slab rests on fill material placed during construction in 1977. After discovering settlement of the fill under the diesel generator building, an investigation of the plant fill revealed some questionable areas under the upper base slab, el 617'-0", of the SWPS. 3.0 ret 1EDI AL ACTION For the part of the structure resting on plant fill, a con-tinuous underpinning wall, resting on undisturbed natural material, is provided to support the structure adequately under all design load conditions. The underpinning wall provides the necessary vertical and horizontal support to the affected part of the structure. To ensure adequate load ] transfer, the underpinned structure is jacked from the underpinning walls (Refer to Figure 3). 4.0 DESIGN FEATURES The proposed underpinning is a 4-foot thick, reinforced concrete wall that is 30 feet high and is constructed to act as a continuous member under the perimeter of the structure overhang. The entire wall is founded on undisturbed natural material. The base of the north underpinning wall is belled out to a 6-foot thickness to limit bearing pressures to the allowable values, whereas the bases of the east and west side walla are 4 feet wide. The allowable bearing prensures

r for the undisturbed natural material are based on safety factors of 2 for dynamic loading and 3 for static loading. A predetermined jacking force is applied to the overhang perimeter to provide adequate load transfer from the struc-ture to the underpinning. TLe connection between the underpinning wall and the exis-ting structure is made by 2-inch diameter rock bolts at the vertical interfaces and 2-3/4-inch diameter anchor bolt assemblies at the horizontal interfaces (Refer to Figures 4 and 5). The connectors are designed to transfer shear and tension forces to the underpinned wall. The connectors are not subject to stresses during the jacking procedures be-cause the rock bolts have not yet been installed and the anchor bolts have not been tightened (Refer to Subsec-tion 5.3.2). After the underpinning wall is connected to the existing structure, the connectors are stressed by loads applied to the underpinned structure. 5.0 COtJSTRUCTIOt3 The construction procedures discussed in this report are recommended for underpinning the SWPS. If subcontractor recommendations result in improved procedures, they will be incorporated. For details of construction and the construc-tion procedures, refer to Figures 4 and 5. 5.1 DEWATERING To construct the underpinning, the SWPS site is dewatered: The groundwater level is lowered to el 587 (approximately) by using temporary dewatering wells. These wells will be sealed after the underpinning wall is completed. The accep-tance criteria for the dewatering system require that the system produces an effluent that has less than 10 parts per million of soil particles larger than 0.05 millimeters. 5.2 BUILDING POST-TEtJSIOtJING [ Construction site dewatering removes the buoyancy force on the overhang portion of the structure, resulting in addi-I tional loading on the overhang. To compensate for this l additional loading of the overhang, temporary post-ten-sioning system applies a compressive force to the upper part of the building along each north-south wall. This post-i tensioning allows the additional force to be transferred from the overhang by beam action to the adjoining walls which rest on undisturbed natural material (Refer to Fig- ) ure 6). The post-tensioning system is removed after the initial jacking loads are applied. l I 2

5.3 CONSTRUCTION PROCEDURES The underpinning is constructed as individual piers tied together by threaded reinforcing bar couplers and shear keys to form a continuous wall. Refer to details and procedures in Figures 4 and 5. 5.3.1 Initial Construction Activities To preserve the structural integrity of the building, the underpinning wall is constructed in small sections (piers) from tunnels which are advanced simultaneously from access shafts located at the northeast and northwest corners of the building. The tunnels initially extend only far enough to construct an approximately 30-foot deep, 5 foot by 4 foot, sheeted pit at each corner of the overhang. The pit is hand 4 dug. The shear strength of the subgrade soil is assessed I with a Corps of Engineers cone penetrometer, model CN-973. Under a maximum force of 150 rou-!s, the cone should not penetrate the surface more than 1/2 inen. After the sub-grade is inspected and approved by a geotechnical engineer, reinforcement, cubgrade settlement monitoring instrumenta-tion, and anchor bolt assemblies to tie the pier to the underside of the slab, are installed. The pier is then cast with concrete punped from the access shaft. After at least 48 hours of curing, an initial jacking load is applied to the overhang from jacks placed on the pier top. To ensure adequate support to the building, the tunnel is not advanced to the next stage until the pier is jacked. Simultaneously with applying the jacking force, the tunnels are advanced to the location of the next pier, which is constructed in a similar manner to the first pier. The piers are tied together with threaded reinforcing bar couplers and shear keys to form a continuous underpinning wall. The threaded reinforcing har couplers (see Detail 1, Figure 5) conform to the requirements of Section III, Divi-sion 2 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, 1980 Edition, 1980 and 1981 Summer Addenda. The tensile strength of the splice system is not less than 125% of the specified minimum yield strength of the spliced bar. A settlement monitoring program for the top and base of each pier begins immediately after pier construction. Instruments accurate to 0.001 inch are installed before the initial jacking is applied. The information from the monitoring program is used to evaluate the time required to dissipate shrinkage and creep of the concrete and creep of the undis-turbed natural material. The rate of settlement decreases with time. At the proper point on the settlement-time curve (as determined by the geotechnical engineer), the final jacking operations (as described below) begins. 3

5.3.2 Final Jacking Stage After Piers 10 (Figure 4) are constructed, the underpinning wall has progressed to within 6 feet of the vertical inter-faces with the existing structure, and the final jacking load is applied. Settlements caused by this load are monitored. When the geotechnical engineer judges that the settlement rate has decreased to a proper value, the load is transferred from the jacks to wedges positioned between the top of the piers and the underside af the overhang, and the jacks are removed. Piers 11 are poured, encasing rock anchors that were previously drilled into the vertical face of the existing structure and thereby connecting the under-pinning wall to the vertical face of the existing stuct.re (Refer to Detail 5, Figure 5). The space between the top of the underpinning wall and the underside of the base slab is filled with nonshrink grout, and previously placed anchor bolt assemblies (which tie the top of the piers to the foundation slab) are tightened (Refer to Detail 7, Figure 4). The underpinning wall is connected to the structure at both the vertical and horizontal interfaces. 5.3.3 Completion of the Underpinning Wall The tunnel is backfilled with lean concrete beginning at the vertical interface and at the north wall. The completion of the tunner backfilling terminates at the locations of Piers 12. These piers are then constructed, completing the un<lerpinning wall. 6.0 f tONITORING REOUIRPMENTS During construction, the underpinning of the existing struc-ture is monitored for settlement and crack propogation. The long-term surveillance program of the building after the construction of the underpinning is being evaluated. 6.1 SETTLEMENTS The elevations of settlement markers attached to the structure are measured in accordance with a schedule based on construction procedures. Expected building movements during underpinning i operations are small. These movements are recorded, and those exceeding 1/4 inch will be evaluated and reported to the NRC. 6.2 CRACKS Monitoring of existing or new cracks appearing during the underpinning construction is scheduled. Because of the 4

sequencing of construction procedures, it is not anticipated that existing cracks will significantly widen or new cracks will appear. However, any new structural cracks or changes in existing structural crack widths exceeding 0.010 inch will be evaluated and reported to the NRC. 7.0 ANALYSIS AND DESIGN The SWPS was originally designed in accordance with FSAR requirements for Seismic Category I structures. A prelim-inary analysis of the underpinned structure was made which complied with these FSAR requirements, and added a jacking load to the load combinations. The seismic loads used in this analysis were extrapolated from the seismic loading from a previous underpinning design based on piles. When the final seismic loads become available, they will be incorporated in the final design. In the final design, seismically induced forces and instructure response spectra of the structure are generated in accor-dance with FSAR Section 3.7. The revised model portrays the structural behavior including the effects of the underpinning and associated foundation modification. The mathematical seismic model and a description of the soil-structure interaction coefficients to be used in the seismic analysis will be submitted to the NRC in Septem-ber 1981. The static structural analysis uses an analytical model capable of representing the structure behavior. The interface between the existing structure and the underpinning wall is modeled to transfer direct loads without providing rota-tional restraint. The soil media are represented by springs of appropriate stiffness at the base of the structure. The detailed analysis will be performed by conventional methods such as beam theory and/or plate theory or by using the computer program Bechtel Structural Analysis Program (BSAP). For details of the BSAP computer program see FSAR Subsec-tion 3.8.3.4. 7.1 STRUCTURE BEHAVIOR The vertical loads of the structure are transmitted to the foundation medium through the existing base slab at el 587'-0" and the underpinning wall bearing area. The lateral forces due to seismic and tornado loads are resisted by the shear walls in the structure. These lateral loads are transferred to the foundation medium by the combined action of the base slab at el 587'-0" and the underpinning wall bearing area. To ensure this action, the underpinning walls are connected to the existing structure by rock anchors and anchor bolts capable of transferring all direct loads. This connection is a pinned connection that is consistent with the analysis method. 5

7.2 DESIG?l CRITERIA AtJD APPLICABLE CODES The underpinned structure is designed as a Seismic Category I structure. The design complies with the requirements of ACI 318-71 and the 1969 edition of the AISC. 7.3 LOADS Af1D LOAD COMBINATIOtJS The underpinning structura rests entirely on undisturbed natural material. The preliminary analysis of the underpinned structure utilizes the same load combinations used in the original design. Ilowever, each load combination is modified by adding the jacking load (Pn). For each loading combination, the jacking load was evaluated with two load factors: a value of 1.0, and the load factor associated with the dead load for that load combination. For the design of the underpinning and the connections to the existing structure, the safe shutdown earthquake (SSE) forces were increased oy 50% to provide for a possible future increase in this loading. The 50% increase was applied to the seismic response of the structure correspond-ing to the analytical model with the mean soil properties. The existing structure was checked for a 0.12g SSE. The long-term settlement of the underpinning wall after it is connected to the existing structure will be calculated. The calculation is based on properties of the supporting soil. The long-term settlement effects will be considered in the final analysis of the structure. To provide for these effects, the final ana.'ysis is governed by four addi-tional load combinations. These load combinations are discussed in the response to Question 15 of the tJRC Requests Regarding Plant Pill (September 1979) and were used in the diesel generator building reanalysis. The load combinations are modified by the addition of the jacking load. Table 1 lists 26 load combinations, modified for jacking loads. For the preliminary analysis of the underpinned SWPS, the following load combination was most critical: U = 1.0D + 1. 0L + 1. 0 E ' + 1.0T + 1. 2 5fi + 1.0R + P o o L where D = dead loads L= live loads E' = safe shutdown earthquake 6

T = thermal effects during normal operating conditions g force on structure due to thermal expansion of pipes = under operating conditions R = local force or pressure on structure or penetration caused by rupture ot any one pipe P = load on structure due to jacking preload g In addition to this load combination, the underpinned struc-ture was checked for stability using the load combinations specified in FSAR Subsection 3,8.6.3.4. A complete analysis of the underpinned structure, using all applicable load combinations, will be made when the final se i onu c loads become available. 7.4 STRUCTURAL ACCEPTANCE CRITERIA The acceptance criterion for analyzing the underpinned structure is in accordance with PSAR Subsection 3.8.6.5. 8.0 OUALITY ASSURAt1CE REOUIREf1Et1T This project work is a combination of Q-and non-O-listed work. The construction of the permanent structures such as the under-pinning wall and the connectors are 0-listed, as well as any other activity or structure necessary to protect the SWPS. Con-struction of temporary structures such as the access shafts and tunnels is non-O-listed. A detailed quality plan shall be pre-pared by the subcontractor to identify those specific activities which are required to have a safety "O" quality program applied along with the major quality program elements for these activi-ties. This quality plan shall be approved by Bechtel and Con-sumers Power Company prior to the start of any 0-listed work. 9.0 ADDITIOt1AL f1RC REOUIREt1ENTS 1 For information purposes, an analysis of the critical sections of the underpinned struc ture will be made conforming to the provisions of ACI 349-76 as supplemented by t1RC Regulatory Guide 1.142. 7

TABLE 1 LOAD EQUATIONS FOR THE SERVICE WATER PUf!P STRUCTURE ?10DIFIED TO INCLUDE PRELOAD Responses to NRC Requests Regarding Plant Fill, Ouestion 15 a. Normal Operating Condition 1.05D + 1.28L + 1.05T + P (1) U = g 1.4D + 1.4T + P (2) U = b. Severe Environmental Condition 1.0D + 1.0L + 1.0W + 1.0T + P (3) U = 1.0D + 1.0L + 1.0E + 1.0T + P (4) U = g Loading Under Normal Conditions a. Concrete U = 1. 4 D + 1.7L + P (5) U = 1.25 (D + L + H +C) + 1.0T + P (6) g 1.25 (D + L +H + W) + 1. 0T + P (7) U = g 0.9D ^ 1.25 (H + C) + 1. 0T + P (8) U = g g U = 0.9D + 1.25 (H + W) + 1. 0T + P (9) g g For ductile moment resisting concrete frames and for shear walls U = 1. 4 (D + L + E) + 1.0T + 1.25H + P (10) o o L 0.9D + 1.25E + 1.0T + 1.25H +P (11) U = o o L Structural Elements Carrying Mainly Earthquake Forces, Such as Equipment Supports U= 1. 0D + 1. 0L + 1.8E + 1.0T + 1.25H +P (12) o o L b. Structural Steel fg) (13) D+ L+P (stress limit = g D+L+T +H +E +P (stress limit = 1.25fs) (14) g g g l 8 il.

\\ Table 1 (Continued) D+ L+T + 11 +W+ P (stress limit = 1.33fs) (15) o o L In addition, for structural elements carrying mainly earthquake forces, such as struts and bracing: D+L+T +H +E+P (stress limit =fs) (16) o e L Loading Under Accident Conditions a. Conc re te U = 1. 05D + 1.05L + 1.25E + 1.0T + 1.0H (17) + 1. 0 R + Pg U= 0.95D + 1.25E + 1.0T + 1. 0ll + 1.0R + P (18) A A g U = 1.0D + 1.0L + 1.0E' + 1.0T + 1.25H (19) O O + 1.0R + Pg U = 1. 0D + 1.0L + 1.0E' + 1.0T + 1. 0lI + 1.0R (20) A A + Pg U = 1. 0 D + 1.0L + 1.0B + 1.0T + 1.2511 +P (21) o o L U = 1. 0D + 1. 0L + 1. 0T + 1. 2 511 + 1.0W' +P (22) o o L b. Structural Steel D+L+R +T + !! + E' t P (23) O 1.3fs) (stress limit = (24) D+L+R+T + !I t E' +P (stress limit = A A g 1.5f ) s D+ L+B +T + !! +P (stress limit = 1.5fs) (25) o o L 1.5fs) (26) D+ L+T + !! + W' + P (stress limit = o o L where U = required strength to resist design loads or their related internal moments and forces For the ultimate load capacity of a concrete section, U is calculated in accordance with ACI 318-71. F = specified minimum yield strength for structural steel f = allowable stress for structural steel; f is calcula-s ted in accordance with the AISC Code, 1963 Edition for design calculations initiated prior to February 1, 1973. f is calculated in accordance with the AISC Code, 1969 Edition, with Supplements, 1, 2, and 3 for design calculations initiated after February 1, 1973. i 9

Table 1 (Cont g ed) D = dead loads L = live loads load on structure due to jacking preload P = R = local force or pressure on structure or penetration caused by rupture of any one pipe T = thermal effects during normal operating conditons g force on structure due to thermal expansion of pipes H = O under operating conditions T = total thermal effects which may occur during a design A accident other than HA H = force on structure due to thermal expansion of pipes 3 under accident condition E = operating basis earthquake (OBE) E' = safe shutdown earthquake load (SSE) B = hydrostatic forces due to the postulated maximum flood (PMF) elevation of 635.5 feet W = design wind load W' = tornado wind loads, including missile effects and dit'ferential pressure p = capacity reduction factor The capacity reduction factor (9) provides for the possibility that small adverse variations in material strengths, workmanship, dimensions, control, and degree of supervision, although individually within required tolerances and the limits of good practice, occasionally may combine to result in undercapacity. NOTES: 1. In the load equations, the following factors are used: 9 = 0.90 for reinforced concrete in flexure p = 0.75 for spirally reinforced concrete compression members 9 = 0.70 for tied compression members 9 = 0.90 for fabricated structural steel ( 10 l L

1 Table 1 (Continued) 9 = 0.90 for reinforced steel in direct tension p = 0.90 for welded or mechanical splices of reinforcing steel 2. Unity load factor is shown for P An alternative load 7 factor to be considered in all load combinations is the load factor associated with dead load (D) in that loading combination. For load combinations 23-26: Maximum allowable stress in bending and tension is 0.9 F Maximum allowable stress in shear is 0.5 P Y Y For these load combinations, the maximum allowable stress except for local areas that do not affect overall stability is limited to 0.9 F for bending, bearing, and tension and 0.5 F for shear. Yhe time phasing between loadings is used Y where applicable to satisfy the above ecuations. Structural components subjected to postulated impulse loads and/or impact effects are designed in accordance with BC-TOP-9-A, Rev 2, using ductility ratios not exceeding 10. Structural members subjected to missile and pipe break loads are decigned in accordance with Bechtel's BC-TOP-9-A, Rev 2, and Bechtel's BN-TOP-2, Rev 2. I i a 11

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