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{{#Wiki_filter: | {{#Wiki_filter:ACCESSION NBRFACIL:50-31550-'316AUTH.NAMEALEXICH>M.P.RECIP.NAMEMURLEYJT.E.REGULATOINFORMATION DISTRIBUTION STEM(RIDS)8711190120 DOC.DATE:87/11/13NOTARIZED'O DOCKETDonaldC.CookNuclearPowerPlant>Unit1>Indiana505000315DonaldC.CookNuclearPowerPlant>Unit2>Indiana005000316AUTHORAFFILIATION IndianaMichiganPowerCo.(formerly IndianaScMichiganEleRECIPIENT AFFILIATION DocumentControlBranch(Document ControlDesk) | ||
==SUBJECT:== | ==SUBJECT:== | ||
Forwardsexecutive summaryof.investigation> | |||
resultsof-investigation Scconclusions reintegrity ofcontainment operating deckhatches.DISTRIBUTION CODE:*002DCOPIESRECEIVED: | |||
LTRiENCLJ.SIZE:TITLE:ORSubmittal: | |||
GeneralDistribution NOTES:RECIPIENT IDCODE/NAME PD3-3LAWIGGINGTON> | |||
DINTERNAL: | |||
ARM/DAF/LFMB NRR/DEST/CEB NRR/DEBT/RSB S/ILRB01EXTERNAL: | |||
EG8cGBRUSKE>SNRCPDRCOPIESLTTRENCL01101111111RECIPIENTIDCODE/NAME PD3-3PDNRR/DEST/ADS NRR/DEST/MTB NRR/DOE*/TSB OGC/HDS1RES/DE/EIB LPDRNSICCOPIESLTTRENCL551111111011111TOTALNUMBEROFCOPIESREQUIRED: | |||
LTTR21ENCL18 ttgh IndianaMichiganPowerCompanyOneSummitSquareP.O.Box60FortWayne,IN468012194252111AEP:NRC:1043 DonaldC.CookNuclearPlantUnits1and2DocketNos.50-315and50-316LicenseNos.DPR-58andDPR-74INVESTIGATION OFINTEGRITY OFCONTAINMENT OPERATING DECKHATCHESEXECUTIVE SUMMARYU.S.NuclearRegulatory Commission Attn:DocumentControlDeskWashington, D.CD20555Attn:T.E.MurleyNovember13,1987 | |||
==DearDr.Murley:== | ==DearDr.Murley:== | ||
OnAugust24,1987, | OnAugust24,1987,Unit1wasinthelaststagesofarefueling outage,whenaboltsupporting areactorpumphatchcover(512)brokewhilebeingtorqued.Because.ofthis,otherboltsinthathatchwereexamined. | ||
D.C.COOKNUCLEARPLANT- | Someoftheotherboltsappearedtohavebeencutoffandreweldedtothesealchannel.Theboltsintheothercontainment operating deckhatchesinbothUnits1and2werethenexamined. | ||
Iiatchesinbothunitswerefoundt:ohavesuspectbolts.Unit2wasimmediately shutdownandaninvestigation ofthecontairunent hatchcoveranchorages wasinitiated. | |||
Theattachments tothisletterprovideadetailedsummaryofourinvestigation, theresultsoftheinvestigation, andourconclusions concerning theintegrity oftheD.C.CookUnits1and2containment operating, deckhatches.Asdiscussed intheattachedsummary,wehaveconcluded thatboththeUnit1andUnit2containment operating deckhatcheswouldnothavefailedduringanaccidentand/ordesignbasisearthquake. | |||
oTheanalysisoftheCRDMhatchwasmadeassumingthatthefour(4)cutandreweldedboltsdidnotexist. | Inaddition, theas-foundconditions metthedesignbasisasdescribed intheD.C.CookFSAR,Section5.2.2.4.Wehave,however,madeorplantomakecertainenhancement(s) totheanchorage ofsomeofthehatchcoversasdescribed inourreport.8711190120 871113PDRADQCK050003i5PPDR Dr.T~E.Murley-2-AEP:NRC:1043 Thisdocumenthasbeenpreparedfollowing Corporate procedures whichincorporate areasonable setofcontrolstoensureitsaccuracyandcompleteness priortosignature bytheundersigned. | ||
I' Basedonoursearchesandinterviews, | Sincerely, M..AlechVicePresident cmcc:JohnE.DolanW.G.Smith,Jr.-BridgmanR.C.CallenG.Bruchmann G.CharnoffNRCResidentInspector | ||
D.C.COOKNUCLEARPLANT- | -BridgmanD.H.Danielson, NRC-RegionIIIA.B.Davis-RegionIII 4h~~' | ||
II. | D.C.COOKNUCLEARPLANT-UNITglCONTAINMENT INVESTIGATION | ||
III.TestProgram-Hatch523Boltg9inhatch423andasectionoftheseal, | -REACTORCOOLANTPUMP&CRDMHATCHESEXECUTIVE SUMMARYHatchDesignA.LocationThefour(4),UnitglReactorCoolantPump(RCP)hatchesarelocatedontheContainment operating deck,elevation 652'-71/2".Theyareidentified bynumbersll,12,13and14whichdesignate theunitandthequadrantintheunitwherethehatchislocated(i.e.,RCPhatchIllisinquadrantglinUnitgl).Theoperating deckhasone(1)othersimilarhatchontheoperating deckatelevation 652'-71/2".ThisistheCRDMhatchwhichallowsaccesstotheControlRodDriveMechanism (CRDM)exhaustfans.(FigureNo.1)B.RCPandCRDMHatchDesignTheRCPhatchesareapproximately rectangular inshapeandmeasure7feet6inchesbyaboutllfeet.(FiguresNo.2&3)TheCRDMhatchisrectangular inshapeandmeasures3feetby6feet.(FigureNo.23)Eachofthefour(4)RCPhatchesandtheCRDMhatchhasasteeltraywhichholdsleadbricks.Thissteeltrayissituatedbelowbutisindependent ofthehatchcoverwhichisaweldedplateframefilledwithconcrete. | ||
I Thecutoffandreweldedboltswerepulltestedinplace.Alpcutandreweldedboltswerepulltestedtoatleast20exceptboltN9whichhadbeencutoutwithaportionofthesealchannelandbolt418wherenoembeddedboltwasfoundintheconcretebelowthesealchannel.Boltsg8andN10werepulledagainstthesealchannel. | Theleadtrayandthehatchcoverrestonledgesformedintheconcretedeckbyanangleframeembedment. | ||
(FigureNo.4)EachRCPhatchcoverisanchoredtotheoperating deckbyeither18or19-3/4"or7/8"diameterASTMA193,gradeB7highstrengthanchorboltswhichfitintopocketsinthecover.TheCRDMhatchisanchoredtotheoperating deckby12-3/4"diameterASTMA193highstrengthanchorboltswhichfitintopocketsinthehatchcover.(FiguresNo.6&24)Asealrodweldedtothebottomofthehatchcoverfitsintoasealchannelweldedatoptheanglethatformstheupperledgewhichsupportsthehatchcover.Thesealchannelwhichrunsaroundtheperiphery ofthehatchhasacontinuous notchcutintoit,intowhichanelastomeric sealmaterialisfitted.Thesealrodonthebottomofthehatchcoverseatsintotheelastomeric materialinthenotch.inthesealchanneltosealthehatch.(FigureNo.24) | |||
Theoperating deckisareinforced concreteslab,thirty-four andone-halfinches(341/2")thick.Theanchorboltsareembeddedtwenty-one andthreequarterinches(213/4")intotheconcrete. | |||
Eachboltisanchoredbya5inchsquareby1inchthicksteelplateembeddedintheconcrete. | |||
II.AsFoundCondition ofUnitglHatchesA.Background OnAugust24,1987,Unitglwasinthelaststagesofarefueling outageandUnitg2wasoperating. | |||
Whilereinstalling thecoveronRCPhatchf12inUnitgl,bolt510brokewhilebeingtorqued.Becauseofthis,theotherboltsinthathatchwereexaminedandseveralwerefoundwiththeappearance ofhavingbeencutoffandreweldedtothesealchannel.Theremaining boltsinthenine(9)otherRCPandCRDMhatchesinbothunitswerethenexaminedbyplantQCpersonnel andhatchesinbothunitswerefoundtohavesuspectbolts.Unitg2wasimmediately shutdown.Thisandsubsequent NDEandvisualinspections identified eight(8)boltswhichhaddiscontinuities atthelevelofthesealchannelandthree(3)boltswhichweremissinginUnit51.AsummaryoftheresultsoftheNDEandvisualexaminations follows.B.Description ofAsFoundUnitglConfiguration HatchIllAllboltswerefoundtobesound.Hatch4124boltscutoffandrewelded-bolt410,Ill,gl2,and513.Notethatbolt410brokeintheweldwhilebeingtorqued.Hatch4132boltsmissing-boltsg9and415.Thishadbeendocumented andanalyzedpreviously. | |||
Hatch5141boltmissing-bolt47.Thishadbeendocumented andanalyzedpreviously. | |||
CRDMHatch4boltscutoffandrewelded-boltsgl,g6,g7and412. | |||
Theboltlayoutandthelocations ofthesuspectboltsareshowninFigureNo.25.III.Analysis-UnitglRCPandCRDMHatchesAllofthehatcheswereanalyzedfor:oTheoperation ofUnitglintheas-foundcondition. | |||
oTheoperation ofUnitglaftermodification oftheanchorage. | |||
oTheoriginalanchorage design.Intheanalyses, anequivalent pressureloadof18psiwasappliedtoeachhatchcoveranditsanchorages. | |||
Theequivalent pressureloadincludedtheeffectsofdeadload,earthquake andaccidentinaccordance withtheloadfactorequations oftheD.C.CookPlantupdatedFSAR.TheStructural DesignSectionofAEPSCanalyzedallofthehatchesinbothunits.Thehatchcoversandtheiranchorage wereevaluated usingthecomputerprogramGTSTRUDLandmanualcomputations. | |||
RCPHatchesgl2,f13and$14andtheCRDMhatchwereanalyzedassumingthatthecutandreweldedboltsandthemissingboltsdidnotexist,althoughasnotedintheUnitg2HatchInvestigatxon Executive Summary,thein-situ,plantpulltestsmadeontheRCPhatch423boltsinUnitg2established thatthecutoffandreweldedboltswerecapableofcarryingaconsiderable amountofload.TheanalysisofRCPhatch512wasmadeassumingthatboltsgl0,gll,512andgl3didnotexist.Withoutthesebolts,thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake. | |||
TheanalysisofRCPhatch513wasmadeassumingthatthetwomissingboltsg9and515didnotexist.Thiswasaknowncondition thathadbeenanalyzedpreviously. | |||
Thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake. | |||
TheanalysisofRCPhatchgl4wasmadeassumingthatthemissingbolt,57didnotexist.Thiscasewasenveloped bytheRCPhatch513analysis. | |||
Thiswasaknowncondition thathadbeenanalyzedpreviously. | |||
Thehatchwasfoundtobestructurally adequateandwouldnot'haveunseatedinanaccidentand/orearthquake. | |||
oTheanalysisoftheCRDMhatchwasmadeassumingthatthefour(4)cutandreweldedboltsdidnotexist.Thehatchwasfoundtobestructurally adequateandwouldnothaveunseatedinanaccidentand/orearthquake. | |||
TheanalysisoftheUnitglRCPandCRDMhatchesiscontained inCalc./Anal. | |||
No.DC-D-3195-165-SC. | |||
AcopyoftheanalysisofRCPhatch412wasgiventotheNRCRegionIIIpersonnel whoattendedtheSeptember 10,1987presentation ontheUnitglhatchesatD'.C.CookPlant.IV.Restoration ofUnitglRCPandCRDMHatchesV.Basedontheresultsoftheanalysesoftheas-foundcondition oftheUnitgloperating deckhatchesandbecausetheboltswhichwerecutoffandreweldedtothesealchannelarerequiredtocarrysmalltensileloads,itwasdecidedtoenhancetheanchorage ofonlyRCPHatch512atpresent.kToenhancetheanchorage alongthecranewallsideofRCPhatch512,threeholddownplatesweredesignedandboltedtoexistingembeddedplatesinthecranewallabovethehatchopening.Theremaining cutandreweldedboltscanbeusedtotightendownonthehatchcover.Theholddownplatessitatopthehatchcoverandholdthehatchcoversealrodinplacealongthecranewallduringanaccidentand/orearthquake. | |||
Theseholddownplatesaidinholdingdownthehatchcover,buttheyarenotrequiredtomaintaintheintegrity ofthehatchbecausetheremaining effective anchorboltsarecapableofdoingthatwithouthelp.(FiguresNo.26&27).Basedontheexperience gainedinrestoring theboltscutoffandreweldedinUnit52,AEPhasdecidedtorestorealltheUnitglboltsthatwerecutoffandreweldedormissinginawaysimilartothatwhichwasdoneonUnitg2.Thisworkisplannedforthenextscheduled Unitgloutagein1989.(FiguresNo.12through15,17,19and21showthetypeofrestoration plannedfortheUnitglbolts.)Documentation ofAs'-found HatchBoltConfigurations Aspartoftheinvestigation, wemadeextensive searchesandconducted pertinent personnel interviews inattempting tolocaterecordsthatwouldaddresstheas-foundboltconfigurations. | |||
Bothconstruction andoperation recordswerereviewedandpursued.Personnel involvedwiththeconstruction historyandpersonnel involvedwiththeoperations historyoftheD.C.CookPlantwereinterviewed. | |||
I' Basedonoursearchesandinterviews, webelievethattheapplicable boltswereprobablycutandreweldedpriortotheunitgoingoperational. | |||
Certainconstruction meetingminutesindicatethatworkactivities, relatedtothealignment ofthehatches,continued foranextensive periodoftime.Thoughnotconclusive, thepossibility existsthattheapplicable boltswerecutandreweldedduringtheextensive hatchalignment period.Nootherrecordswerefoundwhichaddresstheboltswhichwerecutandrewelded. | |||
VI.Conclusions Webelieve,basedontheanalysesthathavebeenperformed ontheUnit:NlRCPandCRDMhatches,thatthehatchcoverswouldnothavefailedduringanaccidentand/orearthquake andthatintheasfoundcondition, thesehatchesmetthedesignbasisinsection5.2.2.4oftheFSAR.Theplantwasoperatedwithasecuredividerbarrierbetweentheupperandlowercontainments. | |||
Themodifications madetotheanchorage ofRCPhatch412enhancethestructural integrity ofthehatch. | |||
D.C.COOKNUCLEARPLANT-UNIT52CONTAINMENT INVESTIGATION REACTORCOOLANTPUMPHATCHESEXECUTIVE SUMMARYHatchDesignA.LocationB.Thefour(4),Unit52ReactorCoolantPump(RCP)hatchesarelocatedontheContainment operating deck,elevation 652'-71/2".Theyareidentified bynumbers21,22,23and24whichdesignate theunitandthequadrantintheunitwherethehatchislocated(i.e.,RCPhatch521'isinquadrantglinUnit42).Theoperating deckhasone(1)othersimilarhatchontheoperating deckatelevation 652'-71/2".ThisistheCRDMhatchwhichallowsaccesstotheControlRodDriveMechanism (CRDM)exhaustfans.(FigureNo.1)RCPHatchDesignTheRCPhatchesareapproximately rectangular inshapeandmeasure7feet6inchesbyaboutllfeet.(FiguresNo.2&3)Eachofthefour(4)RCPhatcheshasasteeltraywhichholdsleadbricks.Thissteeltrayissituatedbelowbutisindependent ofthehatchcoverwhichisaweldedplateframefilledwithconcrete. | |||
Theleadtrayandthehatchcoverrestonledgesformedintheconcretedeckbyanangleframeembedment. | |||
(FigureNo.4)EachRCPhatchcoverisanchoredtotheoperating deckbyeither18or19-3/4"or7/8"diameterASTMA193ggradeB7highstrengthanchorboltswhichfitintopocketsinthecover.(FiguresNo.5&6)Asealbarweldedtothebottomofthehatchcoverfitsintoasealchannelweldedatoptheanglethatformstheupperledgewhichsupportsthehatchcover.Thesealchannelwhichrunsaroundtheperiphery ofthehatchhasacontinuous notchcutintoit,intowhichanelastomeric sealmaterialisfitted.Thesealbaronthebottomofthehatchcoverseatsintotheelastomeric materialinthenotchinthesealchanneltosealthehatch.(FigureNo.5)Theoperating deckisareinforced concreteslab,thirty-four andone-halfinches(341/2")thick.Theanchorboltsareembeddedtwenty-one andthreequarterinches(213/4")intotheconcrete. | |||
Eachboltisanchoredbya5inchsquareby1inchthicksteelplateembeddedintheconcrete. | |||
II.AsFoundCondition ofUnitg2HatchesA.Background OnAugust24,1987,Unitglwasinthelaststagesofarefueling outageandUnit52wasoperating. | |||
Whilereinstalling thecoveronRCPhatch412inUnitgl,bolt410brokewhilebeingtorqued.Becauseofthis,theotherboltsinthathatchwereexaminedandseveralwerefoundwiththeappearance ofhavingbeencutoffandreweldedtothesealchannel.Theremaining boltsinthenine(9)otherRCPandCRDMhatchesinbothunitswerethenexaminedbyplantQCpersonnel andhatchesinbothunitswerefoundtohavesuspectbolts.Unit52wasimmediately shutdown.Thisandsubsequent NDEinspections identified twenty(20)boltsinUnit52whichhaddiscontinuities atthelevelofthesealchannel.AsummaryoftheresultsoftheNDEexaminations follows.B.Description ofAsFoundUnitg2Configuration Hatch$213boltscutoffandrewelded-boltsg3,g4&g5.1studwithnoembeddedanchorboltinconcretebelow-bolt417.Hatch5221boltcutoffandrewelded-boltgl.1studwithnoembeddedanchorboltinconcretebelow-boltg3.Hatch42312boltscutoffandrewelded-boltsgl,52,g8thrugl6,andgl9.1studwithnoembeddedanchorboltinconcretebelow418.Hatch5241boltcutoffandrewelded-boltgl.'CRDMHatchAllboltswerefoundtobesound.Theboltlayoutandthelocations ofthesuspectboltsareshowninFigureNo.7. | |||
III.TestProgram-Hatch523Boltg9inhatch423andasectionoftheseal,channelitwasattachedtowerecutoutandalengthwise slicewasmadethroughthespecimentoexaminetheweld.Thisboltwasselectedbecausefrompreviousanalysesweknewthatbolt59wasoneofthelesserloadedboltsinthehatch.Cuttingoutthisboltposedlessriskintherestoration ofthehatch.TheslicewassenttoWestinghouse ElectricCorporation's GeneralTechnology SystemsDivision(metallurgical laboratory) fortestingtoestablish ananalytical baseline. | |||
Theresultsofthemetallurgical analysisshowedthat:TheStudwasa0.254carbonsteel.~(Specimen TensileStrength=85ksi)TheembedboltwasAISI4140steel*(Specimen TensileStrength=150ksi).ThesealchannelwasacarbonsteelsimilartoASTMA36steel*(Specimen TensileStrength=70ksi).TheweldwasalowcarbonsteelprobablymadebyanE7018electrode. | |||
*(Specimen TensileStrength=95ksi).*Approximate specimentensilestrengths wereobtainedfromhardnesstestconversions. | |||
Theweldsweremapped.WeldSizes,locationanddescriptions wereindicated onas-foundsketches. | |||
Boltstampsidentifying boltmaterialwerenotedwherefound.Thisinformation wasdocumented byplantQCandsitedesignpersonnel. | |||
TheAs-foundboltlocations weredocumented. | |||
Allboltswerephotographed andvideotaped. | |||
Aseriesofsamples/mockups werefabricated andtestedtoapproximate theas-foundconditions andtoestablish ananalytical baseline. | |||
Thesetestswereproposedandimplemented byStevenson andAssociates ofCleveland. | |||
AEPSCreviewedandapprovedthetestprogram.Mostofthemockupswerefabricated atD.C.CookNuclearPlant.Thesingleexception wastheembeddedangle/seal channelmockups.ThetestsweremadeatHeronLabsandCaseWesternReserveUniversity inCleveland underthedirection ofStevenson andAssociates personnel. | |||
I Thecutoffandreweldedboltswerepulltestedinplace.Alpcutandreweldedboltswerepulltestedtoatleast20exceptboltN9whichhadbeencutoutwithaportionofthesealchannelandbolt418wherenoembeddedboltwasfoundintheconcretebelowthesealchannel.Boltsg8andN10werepulledagainstthesealchannel.Allotherboltswerepulledagainstbeamswhichrestedontheopegating decklevel.Allboltsreachedatensionof20withoutbregkingexceptboltgl0whichbrokeatatensionof16.5.Thisboltbrokeintheweld.BoltsNS,N13,414,gl5andgl6wereretested. | |||
Bolt48waspulledygainstthesealchannel.Theboltwastensioned to30withoutapparentdistressanddidnotbreak.BoltN13brokeat41.25,1/2"abovethesealchannelintheheateffectedzoneoftheshankofthejolt.Boltgl4brokeinthreadsatakloadof24.2.Bolt415brokeataloadof24.45inthethreadsandattheweldsimu(taneously. | |||
BoltN16waspulledtoatensionof35.43,whenthetestwasstopped.Manyofthesepulltestswerevideotaped'nd photographed. | |||
Thepulltestswereconducted byWiss,JanneyandElsnerAssociates, Chicago,whousedtheirownequipment. | |||
Thepulltestswerewitnessed bypersonnel fromthePlantQCdepartment, AEPSCCivilEngineering | |||
: Division, Stevenson andAssociates, andWissJanneyandElsner.IV.Analysis-RCPHatchesN21,f22,f23and424Allofthehatcheswereanalyzedfor:oTheoperation ofUnitN2intheas-foundcondition. | |||
oTheoperation ofUnitg2aftermodification oftheanchorage. | |||
oTheoriginalanchorage design.Intheanalyses, anequivalent pressureloadof18psiwasappliedtoeachhatchcoveranditsanchorages. | |||
Theequivalent pressureloadincludedtheeffectsofdeadload,earthquake andaccidentinaccordance withtheloadfactorequations oftheD.C.CookPlantupdatedFSAR.TheStructural DesignSectionofAEPSCanalyzedallofthehatchesinbothunits.Thehatchcoversandtheiranchorage wereevaluated usingthecomputerprogramGTSTRUDL. | |||
~~ | ~~ | ||
Hatchesf21,522and424wereanalyzedassumingthatthecutand' | Hatchesf21,522and424wereanalyzedassumingthatthecutand'rewelded boltsdidnotexist,althoughasnotedabove,thein-situ,plantpulltestsmadeonthehatch523boltsestablished thatthecutoffandreweldedboltswerecapableofcarryingaconsiderable amountofload.oTheanalysisofhatch521wasmadeassumingthat.boltsg3,g4,55andf17didnotexist.Withoutthesebolts,thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake. | ||
VI. | oTheanalysisofhatch422wasmadeassumingthattwoboltsgland53didnotexist.Thiscasewasenveloped byhatch521.Thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake. | ||
VIII. | oTheanalysisofhatchf24wasmadeassumingthatonebolt,gldidnotexist.Thiscasewasenveloped byhatches521and522.Thehatchwasfoundtobestructurally adequateandwouldnothaveunseatedinanaccidentand/orearthquake. | ||
IlItIILATSI\HearHHVklJkt~TOhuLRV~~ | TheanalysisoftheUnitg2RCPhatchesiscontained inCalc./Anal. | ||
No.DC-D-3195-167-SC. | |||
AcopyoftheanalysiswasgiventotheNRCRegionIIIpersonnel whoattendedtheSeptember 30,1987presentation ontheUnit52hatchesatD.C.CookPlant.AnalysisofHatch523-PastOperations intheAs-FoundCondition. | |||
Hatch423wasanalyzedindependently bytheStructural DesignSectionofAEPSCandbyStevenson andAssociates, whoactedasconsultants toAEPSCinthematteroftheas-foundcondition oftheRCPHatches.Thetestresults(discussed above)wereusedtoestablish theultimatetensilestrengths ofthecutoffandreweldedbolts.Hatch423wasanalyzedfortheequivalent pressureloaddescribed inpartIVonpage4.TheanalysismadebytheStructural DesignSectionofAEPSCfoundthatHatch523wasstructurally adequateandwouldnothavebecomeunseatedduringanaccidentorearthquake. | |||
ThedraftreportontheanalysesmadebyStevenson andAssociates datedOctober20,1987onHatch423concludes asfollows:"Hatch23inits"as-found" condition iscapableofsustaining adifferential pressureof'atleast20.6psiwithoutfailureofanyboltsandwithdeformations wellwithinthecapacityofthesealingmechanism". | |||
VI.Restoration ofUnit¹2RCPHatchesAEPmodifiedtheas-foundconfiguration ofeverysuspectUnit¹2anchorbolttoaconfiguration asclosetotheoriginaldesignaswaspossible. | |||
Withtheexception ofbolt¹17onHatch¹21,bolt¹3onHatch¹22andbolt¹18onHatch¹23,alloftheUnit¹2RCPhatchanchorboltsthatwerecutandreweldedhavebeenmodifiedinaccordance withFiguresNo.8thru22.Thereweldedstudsh'avebeenremoved.Theembeddedanchorboltshavebeenfreedofanyconnection tothesealchannel.Thetopoftheembeddedanchorboltshavebeenthreadedandextension nutshavebeeninstalled onthosethreads.ASTMA193studshavebeeninstalled intheotherendoftheextension nutstofitintothehatchcoverboltpockets.Theseboltpocketsweremodifiedtoacceptthelocationofthemodifiedanchorbolts.Atbolt¹17onhatch¹21,bolt¹3onhatch¹22andbolt¹18onhatch¹23,noembeddedboltwasfoundtoexist.Alloftheseboltsaresituatedinacornerofthehatchadjacenttothecranewall.TheanalysesmadebybothAEPSCandStevenson andAssociates showthatthesecornerboltscarryverylittletensileloadduringanaccidentand/orearthquake becauseofthewaythehatchcoverframingwasdesigned. | |||
Therefore, holesweredrilledandtappedinthesealchannelandASTMA36studswereinstalled inthosecornerstoensureatightseal.VII.Documentation ofAs-foundHatchBoltConfigurations Aspartoftheinvestigation, wemadeextensive searchesandconducted pertinent personnel interviews inattempting tolocaterecordsthatwouldaddresstheas-foundboltconfigurations. | |||
Bothconstruction andoperation recordswerereviewedandpursued.Personnel involvedwiththeconstruction historyandpersonnel involvedwiththeoperations historyoftheD.C.CookPlantwereinterviewed. | |||
Basedonoursearchesandinterviews, webelievethattheapplicable boltswereprobablycutandreweldedpriortotheunitgoingoperational. | |||
Certainconstruction meetingminutesindicatethatworkactivities, relatedtothealignment ofthehatches,continued foranextensive periodoftime.Thoughnotconclusive, thepossibility existsthattheapplicable boltswerecutandreweldedduringtheextensive hatchalignment period.Nootherrecordswerefoundwhichaddresstheboltswhichwerecutandrewelded. | |||
VIII.Conclusions Webelieve,basedonthetestingprogramthatwasdoneandontheanalysesthathavebeenperformed bybothAEPSCandbyStevenson andAssociates ontheUnitN2RCPHatches,thatthehatchcoverswouldnothavefailedduringanaccidentand/orearthquake andthatintheasfoundcondition, thesehatchesmetthedesignbasisinsection5.2.2.4oftheFSAR.Theplantwasoperatedwithasecuredividerbarrierbetweentheupperandlowercontainments. | |||
Themodifications madetotheanchorage ofthehatchesandtothehatchcoverboltpocketsenhancethestructural integrity ofthehatches. | |||
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k~HATCHCOVER~~AA~~~.lb~0LEADTRAYt,'oi0ulpdA-Amy~~~~tc~W~auHAZcQ.QsnL< | k~HATCHCOVER~~AA~~~.lb~0LEADTRAYt,'oi0ulpdA-Amy~~~~tc~W~auHAZcQ.QsnL<gcxnnel r)c+saba(Q+)FIGURENO.4 1Illl~smrag!resF~rl t | ||
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'ONALDC.COOKNUCLEARPLANT-BRlDGEMAN MLDI.MRlNLPOR.DATKAItVOCDlkKNB.APfVDDKS.SECT.ilBN.~g0FigureNo.26SSK-nuesT..<2-.ECH~WTCHCOVERaoci>Powwipc.ArJ.(CmiouMjS-Z-SRFC-OC-i-Peg' gg~yNl.trefACvlStONPROCEDURE FORTHEINSTALLATION OFHOLDDOWNPLATESOPTION2FORUNIT$1R.C.P.HATCH$121.WorkthisProcedure withORr+~H+SSK-HC4A Sht1of2.2.One1"x4"x6"longho'lddownplateshallbeinstalled oneachMK3926-P71plateembeddedinthecranewallifthe2~minimumdimension ofitem$3canbemet.3.TheOption2holddownplatesmaybeusedwheretheexistingMK3926-P71embeddedplatesextendaminimumof2inchesabovethetopofthehatchcover.The2"measurement maytakeplacewiththehatchcoverfullyseatedagainstthesealchannel.4.Grindsmooththoseareasoftheexistingembeddedplates,theconcretewallandthetopofthehatchcoverthatwillreceivetheholddownplates.5.Fullyseatthehatchcoverbytightening eachofthehatchcoverholddownboltsinaccordance withplantprocedures. | |||
6.Withthehatchcoverinthefullyseatedposition, usetheholddownplates,positioned asshownonoRAWHQHC4A,astemplates todrillandtaptheholesintheexistingembedplates.Theactualdrillingandtappingmaybeperformed withthehatchcoverofforinplace;7.Atthebackofthedrilledandtappedholesintheembeddedplatespocketsshallbedrilledintheconcretetoadepthof1/2"toaccommodate boltprojection. | |||
Thepocketsshallbecleanedofloosematerial. | |||
Noreinforcing steelshallbecutorexposedduringthisoperation. | |||
ContacttheColumbusStructural DesignOfficeifreinforcing isencountered. | |||
8.Withthehatchcoversfullyseated,installtheholddownplatesandtightenthe5/8inchdiameterA307boltstoatorqueof35FT-LBS.Eachtimethehatchcoverisreinstalled theboltsmustbetorquedto35FT-LBS.9.Shimsmaybeusedbetweentheholddownplateandthetopofthehatchcovertoinsure.thattheholddownplatesbearuniformly onthehatchcover.DESIAA'4'lSlg&". | |||
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~/8ucZOOOvvWF'M7ZOct~ONpRFC-DC-rF-89~5SSK-Hc'4AFigureNo.27 0qQ~3,i-7~5*~I}} | |||
Revision as of 08:25, 29 June 2018
| ML17325A450 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 11/13/1987 |
| From: | ALEXICH M P INDIANA MICHIGAN POWER CO. (FORMERLY INDIANA & MICHIG |
| To: | MURLEY T E NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM) |
| References | |
| AEP:NRC:1043, NUDOCS 8711190120 | |
| Download: ML17325A450 (53) | |
Text
ACCESSION NBRFACIL:50-31550-'316AUTH.NAMEALEXICH>M.P.RECIP.NAMEMURLEYJT.E.REGULATOINFORMATION DISTRIBUTION STEM(RIDS)8711190120 DOC.DATE:87/11/13NOTARIZED'O DOCKETDonaldC.CookNuclearPowerPlant>Unit1>Indiana505000315DonaldC.CookNuclearPowerPlant>Unit2>Indiana005000316AUTHORAFFILIATION IndianaMichiganPowerCo.(formerly IndianaScMichiganEleRECIPIENT AFFILIATION DocumentControlBranch(Document ControlDesk)
SUBJECT:
Forwardsexecutive summaryof.investigation>
resultsof-investigation Scconclusions reintegrity ofcontainment operating deckhatches.DISTRIBUTION CODE:*002DCOPIESRECEIVED:
LTRiENCLJ.SIZE:TITLE:ORSubmittal:
GeneralDistribution NOTES:RECIPIENT IDCODE/NAME PD3-3LAWIGGINGTON>
DINTERNAL:
ARM/DAF/LFMB NRR/DEST/CEB NRR/DEBT/RSB S/ILRB01EXTERNAL:
EG8cGBRUSKE>SNRCPDRCOPIESLTTRENCL01101111111RECIPIENTIDCODE/NAME PD3-3PDNRR/DEST/ADS NRR/DEST/MTB NRR/DOE*/TSB OGC/HDS1RES/DE/EIB LPDRNSICCOPIESLTTRENCL551111111011111TOTALNUMBEROFCOPIESREQUIRED:
LTTR21ENCL18 ttgh IndianaMichiganPowerCompanyOneSummitSquareP.O.Box60FortWayne,IN468012194252111AEP:NRC:1043 DonaldC.CookNuclearPlantUnits1and2DocketNos.50-315and50-316LicenseNos.DPR-58andDPR-74INVESTIGATION OFINTEGRITY OFCONTAINMENT OPERATING DECKHATCHESEXECUTIVE SUMMARYU.S.NuclearRegulatory Commission Attn:DocumentControlDeskWashington, D.CD20555Attn:T.E.MurleyNovember13,1987
DearDr.Murley:
OnAugust24,1987,Unit1wasinthelaststagesofarefueling outage,whenaboltsupporting areactorpumphatchcover(512)brokewhilebeingtorqued.Because.ofthis,otherboltsinthathatchwereexamined.
Someoftheotherboltsappearedtohavebeencutoffandreweldedtothesealchannel.Theboltsintheothercontainment operating deckhatchesinbothUnits1and2werethenexamined.
Iiatchesinbothunitswerefoundt:ohavesuspectbolts.Unit2wasimmediately shutdownandaninvestigation ofthecontairunent hatchcoveranchorages wasinitiated.
Theattachments tothisletterprovideadetailedsummaryofourinvestigation, theresultsoftheinvestigation, andourconclusions concerning theintegrity oftheD.C.CookUnits1and2containment operating, deckhatches.Asdiscussed intheattachedsummary,wehaveconcluded thatboththeUnit1andUnit2containment operating deckhatcheswouldnothavefailedduringanaccidentand/ordesignbasisearthquake.
Inaddition, theas-foundconditions metthedesignbasisasdescribed intheD.C.CookFSAR,Section5.2.2.4.Wehave,however,madeorplantomakecertainenhancement(s) totheanchorage ofsomeofthehatchcoversasdescribed inourreport.8711190120 871113PDRADQCK050003i5PPDR Dr.T~E.Murley-2-AEP:NRC:1043 Thisdocumenthasbeenpreparedfollowing Corporate procedures whichincorporate areasonable setofcontrolstoensureitsaccuracyandcompleteness priortosignature bytheundersigned.
Sincerely, M..AlechVicePresident cmcc:JohnE.DolanW.G.Smith,Jr.-BridgmanR.C.CallenG.Bruchmann G.CharnoffNRCResidentInspector
-BridgmanD.H.Danielson, NRC-RegionIIIA.B.Davis-RegionIII 4h~~'
D.C.COOKNUCLEARPLANT-UNITglCONTAINMENT INVESTIGATION
-REACTORCOOLANTPUMP&CRDMHATCHESEXECUTIVE SUMMARYHatchDesignA.LocationThefour(4),UnitglReactorCoolantPump(RCP)hatchesarelocatedontheContainment operating deck,elevation 652'-71/2".Theyareidentified bynumbersll,12,13and14whichdesignate theunitandthequadrantintheunitwherethehatchislocated(i.e.,RCPhatchIllisinquadrantglinUnitgl).Theoperating deckhasone(1)othersimilarhatchontheoperating deckatelevation 652'-71/2".ThisistheCRDMhatchwhichallowsaccesstotheControlRodDriveMechanism (CRDM)exhaustfans.(FigureNo.1)B.RCPandCRDMHatchDesignTheRCPhatchesareapproximately rectangular inshapeandmeasure7feet6inchesbyaboutllfeet.(FiguresNo.2&3)TheCRDMhatchisrectangular inshapeandmeasures3feetby6feet.(FigureNo.23)Eachofthefour(4)RCPhatchesandtheCRDMhatchhasasteeltraywhichholdsleadbricks.Thissteeltrayissituatedbelowbutisindependent ofthehatchcoverwhichisaweldedplateframefilledwithconcrete.
Theleadtrayandthehatchcoverrestonledgesformedintheconcretedeckbyanangleframeembedment.
(FigureNo.4)EachRCPhatchcoverisanchoredtotheoperating deckbyeither18or19-3/4"or7/8"diameterASTMA193,gradeB7highstrengthanchorboltswhichfitintopocketsinthecover.TheCRDMhatchisanchoredtotheoperating deckby12-3/4"diameterASTMA193highstrengthanchorboltswhichfitintopocketsinthehatchcover.(FiguresNo.6&24)Asealrodweldedtothebottomofthehatchcoverfitsintoasealchannelweldedatoptheanglethatformstheupperledgewhichsupportsthehatchcover.Thesealchannelwhichrunsaroundtheperiphery ofthehatchhasacontinuous notchcutintoit,intowhichanelastomeric sealmaterialisfitted.Thesealrodonthebottomofthehatchcoverseatsintotheelastomeric materialinthenotch.inthesealchanneltosealthehatch.(FigureNo.24)
Theoperating deckisareinforced concreteslab,thirty-four andone-halfinches(341/2")thick.Theanchorboltsareembeddedtwenty-one andthreequarterinches(213/4")intotheconcrete.
Eachboltisanchoredbya5inchsquareby1inchthicksteelplateembeddedintheconcrete.
II.AsFoundCondition ofUnitglHatchesA.Background OnAugust24,1987,Unitglwasinthelaststagesofarefueling outageandUnitg2wasoperating.
Whilereinstalling thecoveronRCPhatchf12inUnitgl,bolt510brokewhilebeingtorqued.Becauseofthis,theotherboltsinthathatchwereexaminedandseveralwerefoundwiththeappearance ofhavingbeencutoffandreweldedtothesealchannel.Theremaining boltsinthenine(9)otherRCPandCRDMhatchesinbothunitswerethenexaminedbyplantQCpersonnel andhatchesinbothunitswerefoundtohavesuspectbolts.Unitg2wasimmediately shutdown.Thisandsubsequent NDEandvisualinspections identified eight(8)boltswhichhaddiscontinuities atthelevelofthesealchannelandthree(3)boltswhichweremissinginUnit51.AsummaryoftheresultsoftheNDEandvisualexaminations follows.B.Description ofAsFoundUnitglConfiguration HatchIllAllboltswerefoundtobesound.Hatch4124boltscutoffandrewelded-bolt410,Ill,gl2,and513.Notethatbolt410brokeintheweldwhilebeingtorqued.Hatch4132boltsmissing-boltsg9and415.Thishadbeendocumented andanalyzedpreviously.
Hatch5141boltmissing-bolt47.Thishadbeendocumented andanalyzedpreviously.
CRDMHatch4boltscutoffandrewelded-boltsgl,g6,g7and412.
Theboltlayoutandthelocations ofthesuspectboltsareshowninFigureNo.25.III.Analysis-UnitglRCPandCRDMHatchesAllofthehatcheswereanalyzedfor:oTheoperation ofUnitglintheas-foundcondition.
oTheoperation ofUnitglaftermodification oftheanchorage.
oTheoriginalanchorage design.Intheanalyses, anequivalent pressureloadof18psiwasappliedtoeachhatchcoveranditsanchorages.
Theequivalent pressureloadincludedtheeffectsofdeadload,earthquake andaccidentinaccordance withtheloadfactorequations oftheD.C.CookPlantupdatedFSAR.TheStructural DesignSectionofAEPSCanalyzedallofthehatchesinbothunits.Thehatchcoversandtheiranchorage wereevaluated usingthecomputerprogramGTSTRUDLandmanualcomputations.
RCPHatchesgl2,f13and$14andtheCRDMhatchwereanalyzedassumingthatthecutandreweldedboltsandthemissingboltsdidnotexist,althoughasnotedintheUnitg2HatchInvestigatxon Executive Summary,thein-situ,plantpulltestsmadeontheRCPhatch423boltsinUnitg2established thatthecutoffandreweldedboltswerecapableofcarryingaconsiderable amountofload.TheanalysisofRCPhatch512wasmadeassumingthatboltsgl0,gll,512andgl3didnotexist.Withoutthesebolts,thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake.
TheanalysisofRCPhatch513wasmadeassumingthatthetwomissingboltsg9and515didnotexist.Thiswasaknowncondition thathadbeenanalyzedpreviously.
Thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake.
TheanalysisofRCPhatchgl4wasmadeassumingthatthemissingbolt,57didnotexist.Thiscasewasenveloped bytheRCPhatch513analysis.
Thiswasaknowncondition thathadbeenanalyzedpreviously.
Thehatchwasfoundtobestructurally adequateandwouldnot'haveunseatedinanaccidentand/orearthquake.
oTheanalysisoftheCRDMhatchwasmadeassumingthatthefour(4)cutandreweldedboltsdidnotexist.Thehatchwasfoundtobestructurally adequateandwouldnothaveunseatedinanaccidentand/orearthquake.
TheanalysisoftheUnitglRCPandCRDMhatchesiscontained inCalc./Anal.
No.DC-D-3195-165-SC.
AcopyoftheanalysisofRCPhatch412wasgiventotheNRCRegionIIIpersonnel whoattendedtheSeptember 10,1987presentation ontheUnitglhatchesatD'.C.CookPlant.IV.Restoration ofUnitglRCPandCRDMHatchesV.Basedontheresultsoftheanalysesoftheas-foundcondition oftheUnitgloperating deckhatchesandbecausetheboltswhichwerecutoffandreweldedtothesealchannelarerequiredtocarrysmalltensileloads,itwasdecidedtoenhancetheanchorage ofonlyRCPHatch512atpresent.kToenhancetheanchorage alongthecranewallsideofRCPhatch512,threeholddownplatesweredesignedandboltedtoexistingembeddedplatesinthecranewallabovethehatchopening.Theremaining cutandreweldedboltscanbeusedtotightendownonthehatchcover.Theholddownplatessitatopthehatchcoverandholdthehatchcoversealrodinplacealongthecranewallduringanaccidentand/orearthquake.
Theseholddownplatesaidinholdingdownthehatchcover,buttheyarenotrequiredtomaintaintheintegrity ofthehatchbecausetheremaining effective anchorboltsarecapableofdoingthatwithouthelp.(FiguresNo.26&27).Basedontheexperience gainedinrestoring theboltscutoffandreweldedinUnit52,AEPhasdecidedtorestorealltheUnitglboltsthatwerecutoffandreweldedormissinginawaysimilartothatwhichwasdoneonUnitg2.Thisworkisplannedforthenextscheduled Unitgloutagein1989.(FiguresNo.12through15,17,19and21showthetypeofrestoration plannedfortheUnitglbolts.)Documentation ofAs'-found HatchBoltConfigurations Aspartoftheinvestigation, wemadeextensive searchesandconducted pertinent personnel interviews inattempting tolocaterecordsthatwouldaddresstheas-foundboltconfigurations.
Bothconstruction andoperation recordswerereviewedandpursued.Personnel involvedwiththeconstruction historyandpersonnel involvedwiththeoperations historyoftheD.C.CookPlantwereinterviewed.
I' Basedonoursearchesandinterviews, webelievethattheapplicable boltswereprobablycutandreweldedpriortotheunitgoingoperational.
Certainconstruction meetingminutesindicatethatworkactivities, relatedtothealignment ofthehatches,continued foranextensive periodoftime.Thoughnotconclusive, thepossibility existsthattheapplicable boltswerecutandreweldedduringtheextensive hatchalignment period.Nootherrecordswerefoundwhichaddresstheboltswhichwerecutandrewelded.
VI.Conclusions Webelieve,basedontheanalysesthathavebeenperformed ontheUnit:NlRCPandCRDMhatches,thatthehatchcoverswouldnothavefailedduringanaccidentand/orearthquake andthatintheasfoundcondition, thesehatchesmetthedesignbasisinsection5.2.2.4oftheFSAR.Theplantwasoperatedwithasecuredividerbarrierbetweentheupperandlowercontainments.
Themodifications madetotheanchorage ofRCPhatch412enhancethestructural integrity ofthehatch.
D.C.COOKNUCLEARPLANT-UNIT52CONTAINMENT INVESTIGATION REACTORCOOLANTPUMPHATCHESEXECUTIVE SUMMARYHatchDesignA.LocationB.Thefour(4),Unit52ReactorCoolantPump(RCP)hatchesarelocatedontheContainment operating deck,elevation 652'-71/2".Theyareidentified bynumbers21,22,23and24whichdesignate theunitandthequadrantintheunitwherethehatchislocated(i.e.,RCPhatch521'isinquadrantglinUnit42).Theoperating deckhasone(1)othersimilarhatchontheoperating deckatelevation 652'-71/2".ThisistheCRDMhatchwhichallowsaccesstotheControlRodDriveMechanism (CRDM)exhaustfans.(FigureNo.1)RCPHatchDesignTheRCPhatchesareapproximately rectangular inshapeandmeasure7feet6inchesbyaboutllfeet.(FiguresNo.2&3)Eachofthefour(4)RCPhatcheshasasteeltraywhichholdsleadbricks.Thissteeltrayissituatedbelowbutisindependent ofthehatchcoverwhichisaweldedplateframefilledwithconcrete.
Theleadtrayandthehatchcoverrestonledgesformedintheconcretedeckbyanangleframeembedment.
(FigureNo.4)EachRCPhatchcoverisanchoredtotheoperating deckbyeither18or19-3/4"or7/8"diameterASTMA193ggradeB7highstrengthanchorboltswhichfitintopocketsinthecover.(FiguresNo.5&6)Asealbarweldedtothebottomofthehatchcoverfitsintoasealchannelweldedatoptheanglethatformstheupperledgewhichsupportsthehatchcover.Thesealchannelwhichrunsaroundtheperiphery ofthehatchhasacontinuous notchcutintoit,intowhichanelastomeric sealmaterialisfitted.Thesealbaronthebottomofthehatchcoverseatsintotheelastomeric materialinthenotchinthesealchanneltosealthehatch.(FigureNo.5)Theoperating deckisareinforced concreteslab,thirty-four andone-halfinches(341/2")thick.Theanchorboltsareembeddedtwenty-one andthreequarterinches(213/4")intotheconcrete.
Eachboltisanchoredbya5inchsquareby1inchthicksteelplateembeddedintheconcrete.
II.AsFoundCondition ofUnitg2HatchesA.Background OnAugust24,1987,Unitglwasinthelaststagesofarefueling outageandUnit52wasoperating.
Whilereinstalling thecoveronRCPhatch412inUnitgl,bolt410brokewhilebeingtorqued.Becauseofthis,theotherboltsinthathatchwereexaminedandseveralwerefoundwiththeappearance ofhavingbeencutoffandreweldedtothesealchannel.Theremaining boltsinthenine(9)otherRCPandCRDMhatchesinbothunitswerethenexaminedbyplantQCpersonnel andhatchesinbothunitswerefoundtohavesuspectbolts.Unit52wasimmediately shutdown.Thisandsubsequent NDEinspections identified twenty(20)boltsinUnit52whichhaddiscontinuities atthelevelofthesealchannel.AsummaryoftheresultsoftheNDEexaminations follows.B.Description ofAsFoundUnitg2Configuration Hatch$213boltscutoffandrewelded-boltsg3,g4&g5.1studwithnoembeddedanchorboltinconcretebelow-bolt417.Hatch5221boltcutoffandrewelded-boltgl.1studwithnoembeddedanchorboltinconcretebelow-boltg3.Hatch42312boltscutoffandrewelded-boltsgl,52,g8thrugl6,andgl9.1studwithnoembeddedanchorboltinconcretebelow418.Hatch5241boltcutoffandrewelded-boltgl.'CRDMHatchAllboltswerefoundtobesound.Theboltlayoutandthelocations ofthesuspectboltsareshowninFigureNo.7.
III.TestProgram-Hatch523Boltg9inhatch423andasectionoftheseal,channelitwasattachedtowerecutoutandalengthwise slicewasmadethroughthespecimentoexaminetheweld.Thisboltwasselectedbecausefrompreviousanalysesweknewthatbolt59wasoneofthelesserloadedboltsinthehatch.Cuttingoutthisboltposedlessriskintherestoration ofthehatch.TheslicewassenttoWestinghouse ElectricCorporation's GeneralTechnology SystemsDivision(metallurgical laboratory) fortestingtoestablish ananalytical baseline.
Theresultsofthemetallurgical analysisshowedthat:TheStudwasa0.254carbonsteel.~(Specimen TensileStrength=85ksi)TheembedboltwasAISI4140steel*(Specimen TensileStrength=150ksi).ThesealchannelwasacarbonsteelsimilartoASTMA36steel*(Specimen TensileStrength=70ksi).TheweldwasalowcarbonsteelprobablymadebyanE7018electrode.
- (Specimen TensileStrength=95ksi).*Approximate specimentensilestrengths wereobtainedfromhardnesstestconversions.
Theweldsweremapped.WeldSizes,locationanddescriptions wereindicated onas-foundsketches.
Boltstampsidentifying boltmaterialwerenotedwherefound.Thisinformation wasdocumented byplantQCandsitedesignpersonnel.
TheAs-foundboltlocations weredocumented.
Allboltswerephotographed andvideotaped.
Aseriesofsamples/mockups werefabricated andtestedtoapproximate theas-foundconditions andtoestablish ananalytical baseline.
Thesetestswereproposedandimplemented byStevenson andAssociates ofCleveland.
AEPSCreviewedandapprovedthetestprogram.Mostofthemockupswerefabricated atD.C.CookNuclearPlant.Thesingleexception wastheembeddedangle/seal channelmockups.ThetestsweremadeatHeronLabsandCaseWesternReserveUniversity inCleveland underthedirection ofStevenson andAssociates personnel.
I Thecutoffandreweldedboltswerepulltestedinplace.Alpcutandreweldedboltswerepulltestedtoatleast20exceptboltN9whichhadbeencutoutwithaportionofthesealchannelandbolt418wherenoembeddedboltwasfoundintheconcretebelowthesealchannel.Boltsg8andN10werepulledagainstthesealchannel.Allotherboltswerepulledagainstbeamswhichrestedontheopegating decklevel.Allboltsreachedatensionof20withoutbregkingexceptboltgl0whichbrokeatatensionof16.5.Thisboltbrokeintheweld.BoltsNS,N13,414,gl5andgl6wereretested.
Bolt48waspulledygainstthesealchannel.Theboltwastensioned to30withoutapparentdistressanddidnotbreak.BoltN13brokeat41.25,1/2"abovethesealchannelintheheateffectedzoneoftheshankofthejolt.Boltgl4brokeinthreadsatakloadof24.2.Bolt415brokeataloadof24.45inthethreadsandattheweldsimu(taneously.
BoltN16waspulledtoatensionof35.43,whenthetestwasstopped.Manyofthesepulltestswerevideotaped'nd photographed.
Thepulltestswereconducted byWiss,JanneyandElsnerAssociates, Chicago,whousedtheirownequipment.
Thepulltestswerewitnessed bypersonnel fromthePlantQCdepartment, AEPSCCivilEngineering
- Division, Stevenson andAssociates, andWissJanneyandElsner.IV.Analysis-RCPHatchesN21,f22,f23and424Allofthehatcheswereanalyzedfor:oTheoperation ofUnitN2intheas-foundcondition.
oTheoperation ofUnitg2aftermodification oftheanchorage.
oTheoriginalanchorage design.Intheanalyses, anequivalent pressureloadof18psiwasappliedtoeachhatchcoveranditsanchorages.
Theequivalent pressureloadincludedtheeffectsofdeadload,earthquake andaccidentinaccordance withtheloadfactorequations oftheD.C.CookPlantupdatedFSAR.TheStructural DesignSectionofAEPSCanalyzedallofthehatchesinbothunits.Thehatchcoversandtheiranchorage wereevaluated usingthecomputerprogramGTSTRUDL.
~~
Hatchesf21,522and424wereanalyzedassumingthatthecutand'rewelded boltsdidnotexist,althoughasnotedabove,thein-situ,plantpulltestsmadeonthehatch523boltsestablished thatthecutoffandreweldedboltswerecapableofcarryingaconsiderable amountofload.oTheanalysisofhatch521wasmadeassumingthat.boltsg3,g4,55andf17didnotexist.Withoutthesebolts,thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake.
oTheanalysisofhatch422wasmadeassumingthattwoboltsgland53didnotexist.Thiscasewasenveloped byhatch521.Thehatchwasfoundtobestructurally adequateunderthedesignloadsandwouldnothaveunseatedinanaccidentand/orearthquake.
oTheanalysisofhatchf24wasmadeassumingthatonebolt,gldidnotexist.Thiscasewasenveloped byhatches521and522.Thehatchwasfoundtobestructurally adequateandwouldnothaveunseatedinanaccidentand/orearthquake.
TheanalysisoftheUnitg2RCPhatchesiscontained inCalc./Anal.
No.DC-D-3195-167-SC.
AcopyoftheanalysiswasgiventotheNRCRegionIIIpersonnel whoattendedtheSeptember 30,1987presentation ontheUnit52hatchesatD.C.CookPlant.AnalysisofHatch523-PastOperations intheAs-FoundCondition.
Hatch423wasanalyzedindependently bytheStructural DesignSectionofAEPSCandbyStevenson andAssociates, whoactedasconsultants toAEPSCinthematteroftheas-foundcondition oftheRCPHatches.Thetestresults(discussed above)wereusedtoestablish theultimatetensilestrengths ofthecutoffandreweldedbolts.Hatch423wasanalyzedfortheequivalent pressureloaddescribed inpartIVonpage4.TheanalysismadebytheStructural DesignSectionofAEPSCfoundthatHatch523wasstructurally adequateandwouldnothavebecomeunseatedduringanaccidentorearthquake.
ThedraftreportontheanalysesmadebyStevenson andAssociates datedOctober20,1987onHatch423concludes asfollows:"Hatch23inits"as-found" condition iscapableofsustaining adifferential pressureof'atleast20.6psiwithoutfailureofanyboltsandwithdeformations wellwithinthecapacityofthesealingmechanism".
VI.Restoration ofUnit¹2RCPHatchesAEPmodifiedtheas-foundconfiguration ofeverysuspectUnit¹2anchorbolttoaconfiguration asclosetotheoriginaldesignaswaspossible.
Withtheexception ofbolt¹17onHatch¹21,bolt¹3onHatch¹22andbolt¹18onHatch¹23,alloftheUnit¹2RCPhatchanchorboltsthatwerecutandreweldedhavebeenmodifiedinaccordance withFiguresNo.8thru22.Thereweldedstudsh'avebeenremoved.Theembeddedanchorboltshavebeenfreedofanyconnection tothesealchannel.Thetopoftheembeddedanchorboltshavebeenthreadedandextension nutshavebeeninstalled onthosethreads.ASTMA193studshavebeeninstalled intheotherendoftheextension nutstofitintothehatchcoverboltpockets.Theseboltpocketsweremodifiedtoacceptthelocationofthemodifiedanchorbolts.Atbolt¹17onhatch¹21,bolt¹3onhatch¹22andbolt¹18onhatch¹23,noembeddedboltwasfoundtoexist.Alloftheseboltsaresituatedinacornerofthehatchadjacenttothecranewall.TheanalysesmadebybothAEPSCandStevenson andAssociates showthatthesecornerboltscarryverylittletensileloadduringanaccidentand/orearthquake becauseofthewaythehatchcoverframingwasdesigned.
Therefore, holesweredrilledandtappedinthesealchannelandASTMA36studswereinstalled inthosecornerstoensureatightseal.VII.Documentation ofAs-foundHatchBoltConfigurations Aspartoftheinvestigation, wemadeextensive searchesandconducted pertinent personnel interviews inattempting tolocaterecordsthatwouldaddresstheas-foundboltconfigurations.
Bothconstruction andoperation recordswerereviewedandpursued.Personnel involvedwiththeconstruction historyandpersonnel involvedwiththeoperations historyoftheD.C.CookPlantwereinterviewed.
Basedonoursearchesandinterviews, webelievethattheapplicable boltswereprobablycutandreweldedpriortotheunitgoingoperational.
Certainconstruction meetingminutesindicatethatworkactivities, relatedtothealignment ofthehatches,continued foranextensive periodoftime.Thoughnotconclusive, thepossibility existsthattheapplicable boltswerecutandreweldedduringtheextensive hatchalignment period.Nootherrecordswerefoundwhichaddresstheboltswhichwerecutandrewelded.
VIII.Conclusions Webelieve,basedonthetestingprogramthatwasdoneandontheanalysesthathavebeenperformed bybothAEPSCandbyStevenson andAssociates ontheUnitN2RCPHatches,thatthehatchcoverswouldnothavefailedduringanaccidentand/orearthquake andthatintheasfoundcondition, thesehatchesmetthedesignbasisinsection5.2.2.4oftheFSAR.Theplantwasoperatedwithasecuredividerbarrierbetweentheupperandlowercontainments.
Themodifications madetotheanchorage ofthehatchesandtothehatchcoverboltpocketsenhancethestructural integrity ofthehatches.
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6.Withthehatchcoverinthefullyseatedposition, usetheholddownplates,positioned asshownonoRAWHQHC4A,astemplates todrillandtaptheholesintheexistingembedplates.Theactualdrillingandtappingmaybeperformed withthehatchcoverofforinplace;7.Atthebackofthedrilledandtappedholesintheembeddedplatespocketsshallbedrilledintheconcretetoadepthof1/2"toaccommodate boltprojection.
Thepocketsshallbecleanedofloosematerial.
Noreinforcing steelshallbecutorexposedduringthisoperation.
ContacttheColumbusStructural DesignOfficeifreinforcing isencountered.
8.Withthehatchcoversfullyseated,installtheholddownplatesandtightenthe5/8inchdiameterA307boltstoatorqueof35FT-LBS.Eachtimethehatchcoverisreinstalled theboltsmustbetorquedto35FT-LBS.9.Shimsmaybeusedbetweentheholddownplateandthetopofthehatchcovertoinsure.thattheholddownplatesbearuniformly onthehatchcover.DESIAA'4'lSlg&".
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