ML19329E788
| ML19329E788 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 06/17/1977 |
| From: | Dhar B BECHTEL GROUP, INC. |
| To: | |
| Shared Package | |
| ML19329E780 | List: |
| References | |
| NUDOCS 8006170942 | |
| Download: ML19329E788 (30) | |
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V. . , SUBJECT
'MISPLiCED TENDON SHEATHINGS MIDLAND PROJECT BECHTEL JOB NO. 7220 FINAL REr0RT I
e Subsitted by: ~ /C l B. IDhar l O. .t' - ' :-^ I
-i Approved by: @ 4Y FA M s; G ot# l IR. L. Castleberry -
Report Date: 6-'/3-7 7 , Revised: 8 " / 7--7 7- l l 8006170 t .
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9 INTRODUCTION This report summarizes Project Engineering's evaluation of. four mis-placed tendon sh'eachings, and completes Project Engineering's action required to resolve the problem. DEFICIENCY On April.19, 1977, a nonconformance to the project design documents was found, involving four misplaced tendon sheathings to be installed at approximate elevation 700'-704' in the Midland Unit 1 containment build-ing. As shown on the vendor drauings, these four tendons were to be . deflected downward to clear the two main steam penetrations at center *
'line elevation 707'0". Contrary to this, two tendon sheathings (H32-036 and H13-035) were installed level, 'and two tendon sheathings (H32-037 and H13-037) were not installed in the local area directly below the penetrations. Concrete had been placed to a construction joint at elevation 703'-7" approximately one week before this nonconformance was found. This nonconformance was found by the survey team during pre- '
parations for the next wall lift. The original design and "as-built" alignment of these tendons are shown in Figure 1. CURRECTIVE ACTION Project Engineering has reviewed the "as-built" condition and has studied various relocations for the affected *endons. Based on this review, it was concluded that the original design criteria could be met by rerouting one sheathing originally planned ,for below the penetration to a new-alignment above the penetration. Sheathing H13-037 can be installed below the penetration. There is a 14 inch clearance between the construction joint and the ' bottom of the penetration. This will allow a 6 inch clearance between the realigned sheathing (H13-037) and the edge of the penetration, and a 6-1/2 inch center-to-center spacing to the adjacent horizontal sheathing (H32-036). The 6 inch clearance to the penetration'is consistent with the recommendations of BC-TOP-5A, Rev. 3 (Ref erence 1), and the 6-1/2 inch center-to-center spacing between sheathings is consistent with the original design. The tendon sheathing-(H32-037).is rerouted above the penetration, necessitating minor adjustments of one adjacent tendon (H13-038). Both relocated tendon sheathings still allcw a minimum 25'-0" bending radius about the penetrations. The two level tendon sheathings (H32-036 and H13-036) do not require modifications.
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- The new alignment for the tendon sheathings is shown in Figure 2. The differential friction. losses between the reviced alignment and the original alignment have been evaluated by INRYCO, the vendor for the post tensioning system design. The results are summarized in Table 1. A typical force diagram for a dc51ected hoop tendon is presented in Figure 9. It is evident from the tabulated results that the friction losses in the ' subject tendons have been reduced due to this revised alignment. Lower f riction losses improve the capability of the con-tainment structure to resist forces like internal pressure. Hovever, the variations are small in relation to the applied force, and are considered insignificant.
The main steam penetration openings are 4'-6" in diameter, which is less e than two and one-half times the 3'-6" vall thickness. Therefore, the main steam penetrations are classified as small penetration openings, according to the provisions in BC-TOP-5A. In the original design, no special analysis was performed to determine the stresses in concrete around a small penetration due to prestressing forces. The stresses at the center of a small opening, deter =ined from the axisymmetric analysis for prestressing forces, were distributed around the opening taking into consideration the reduction in wall area due to the opening. This i analytical approach is consistant with the provisions of EC-TOP-5A. Dua to the the realign =ent of the tendons, none of the design parameters Y 1a ...
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calculations for concrete were required. Also, the new alignment satisfies all the BC-TOP-5A requirements adopted by the original layout, thereby eliminating the possibility of overstressing the concrete in local areas.
- The revised alignment requires cutting several penetration gusset plates (Figure 3) . The cuts in the gusset plates reduce the torsional strength
' and the vertical bending strength o2 the penetration assembly (sleeve, flange plates and gusset plates). To replace the torsional strength lost due to the cuts in the gusset plates, eight additional bearing plates were added as'shown in Figure 6. The additional bearing plates vera designed to fully replace the torsional resistance provided by the portion of'the original gusset plates shown as a shaded region in Figure
- 7. To replace the lost bending strength, the penetration sleeve will be extendec, a new flange plate will be added, and external gusset plates will be positioned between the new and original flange plates, as shown -
in figure 6. The new external gusset plates will restore the stiffness that was lost when the' original gussets were cut. e m
t . 4 - The embedment hooks on the following rebars adjacent to the relocated-tendon H13-037 were cut to facilitate its installation:
- 1) One vertical #18 on each side of penetration at 77 (Figure 4)
- 2) Two . vertical #11 on one side and three vertical s
#11 on the other side of penetration at 1030 (Figure 5)
- 3) One hogi: ental #11 on one side of penetration at 103 (Figure 5)
To restore the strength of the wall to its original level, the anchorage , lost due to cutting of these hooks will be replaced. By examining documents on chemical composition of these bars, it has been determined that the subject bars can be welded. For one #11 vertical bar, a standard hook will be velded to the cut rebar. Due to space limitation , the other cut vertical rebars will use plug welded anchor plates to develop equivalent embedments of standard hooks. These details are presented in Figure 8. The hook on the one hcricontal rebar which was cut will be restored by a bar equivalent to the original design. The anchor plates will be grouted to ensure proper bear d-~ *nrfaces. The following design documents have been revised ..orpo-
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- 1) INRYC0 drawings no. PS-lL2, Rev. 7 and PS-143, Rev. 6, Unic #1 tiall tendon locations
- 2) Bechtel drawing C-419, R ev. 2 - Liner plate
. requirement - Penetration details' sheet 5.
SAFETY IMPLICATION The relocated tendon sheathings provide a design equivalent to the
. original' design. Routing one of the tendon sheathings over the main steam penetrations, instead of under the penetrations as originally planned, has no effect on the strength of the contain=ent wall. Also, the_ strength losses due to cuts in the penetration gusset platss and the cutoffs of reba'rs, both necessitated by the rerouting of the tendon sheathings, have.been fully replaced by the modifications discussed -
above. Therefore, there is no adverse safety implications. REFERENCE
- 1) Bechtel Topical Report BC-TOP-5A, REv. 3
" Prestressed Concretc Nuclear Reactor Containment Structures" - Accepted by NRC.
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TABLE 1 MI!!DHDI TE iDO:1 FORCES USED IN DESIGN *
' Original Design Revised Design Tendon. Refersace Minimum Distance Minimum Distance
- No . Buttress- Effective from Ref. Effective fro: Ref.
- Tendon Buttress Tendon Buttress 2 Force (f t) Force (ft)
(kips) (kips) H13-036 1 1044 124.03 1097 133.37 H32-036 3 1050 146.61 1097 133.37 H13-037 1 1035 125.59 1045 124.78 H32-037 3 1029 156.37 1032 154.33 i nia-vao 1 Tess T.'.,7v3 .,0 - CC
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