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@ ConsumersPowerJames W Cook

0 00f Vice President - Projects, Engineeringand Construction

General offices: 1945 West Pernall Road, Jackson, MI 49201 (517) 788-0453

May 6, 1983 80-04 #9

Mr J G Keppler, Regional AdministratorUS Nuclear Regulatory CommissionRegion III799 Roosevelt RoadGlen Ellyn, IL 60137

MIDLAND ENERGY CENTER PROJECTDOCKET NOS 50-329 AND 50-330HELBA RESTRAINT DESIGNFILE: 0.4.9.41 SERIAL: 22184

References: J W Cook letters to J G Keppler, Same Subject:

(1) Serial 8830, dated September 19, 1980(2) Serial 10070, dated December 1, 1980(3) Serial 11525, dated April 3, 1981(4) Serial 13663, dated September 4, 1981(5) Serial 14634, dated December 14, 1981(6) Serial 16147, dated March 31, 1982(7) Serial 19039, dated September 15, 1982(8) Serial 20686, dated January 30, 1983

This letter, as were the referenced letters, is an interim 50.55(e) reportconcerning HELBA restraint design. Enclosure I provides a current status ofthe actions being taken with regard to this matter.

Another report, either interim or final, will be sent on or beforeFebruary 20, 1984.

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JWC/WRB/cd

Enclosure 1: MCAR-40, Interim Report 9, "High-Ener8y Line Break Analysis(HELBA) Pipe Whip Restraint Designs," dated April 18, 1983

CC: Document Control Desk, NRCWashington, DC

RJCook, NRC Resident InspectorMidland Nuclear Plant

MAY 91983OC0483-0036A-MP018305170283 830506PDR ADOCK 05000329 1pel/S PDR \ a

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Serial 2218480-04 #9

CC: CBechhoefer, ASLB PanelRSDecker, ASLB PanelFPCowan, ASLB PanelAS&L Appeal PanelMMCherry, EsqMSinclairBStamirisCRStephens, USNRCWDPaton, Esq, USNRCFJKelley, Esq, Attorney GeneralSHFreeman, Esq, Asst Attorney GeneralWHMarshallGJMerritt, Esq, TNK&JINPO Records Center

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OC0483-0036A-MP01

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Bechtel Associates Professional Corporation

i i 2218 Ii.2.562Management Corrective Action Report (MCAR)

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SUBJECT: MCAR 40 (issued 8/26/80)

High-Energy Line Break Analysis (BELBA)Pipe Whip Restraint Designs

INTERIM REPORT: 9

DATE: April 18, 1983 j'PROJECT: Consumers Power Company

Midland Plant Units 1 and 2Bechtel Job 7220

Introduction

This report provides the current status of MCAR 40 and actions performedsince Interim Report 8. I

Description of Deficiency

FSAR Section 3.6.2.2 states that the analysis of the thrust forces whichresult in the event of a pipe rupture is described in BN-TOP-2. Contraryto the intent of BN-TOP-2, the steady-state thrust forces rather than thetransient peak thrust forces were used in the energy balance techniquesfor the design of HELBA pipe whip restraints.

Summcry of Investigation

All of the blowdown thrust force time histories have been determinedusing the computer program PRTHRUST and comparable hand calculations.The restraint designs have been evaluated with the PIPERUP computerprogram as discussed in Corrective Action below.

Analysis of Safety Implication

The safety-related function of a pipe whip restraint is to limit pipemovement following a high-energy line break to prevent unacceptabledamage to essential systems or components. Designing the restraint usingthe steady-state thrust force instead of the higher transient thrustforce could compromise this safety function. The size of the restraintsmay be inadequate for the increased loads, and/or their location may beinadequate as a higher thrust force may cause the plastic hinge length todecrease outside the range of the restraint. This deficiency, were it tohave remained uncorrected, may have adversely affected the safety ofoperations at the Midland plant if certain types of accidents were tooccur.

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Bechtel Associates Professional Corporation12 2 I B

MCA dInterim Report 9Page 2

Probable Cause

The probable cause of this discrepancy has been identified as amisinterpretation of the requirements of BN-TOP-2.

Corrective Action

Status of Restraint Reanalysis:

The attached table shows the current status of restraints potentiallyaffected by the concern of this MCAR.

The initial population of restraints affected originally was 325.Deletions due to pipe rerotting, shifts in break locations, changes inanalysis assumptions, etc., have reduced the number of affectedrestraints to 116.

Analysis has been performed on all 116 restraints. However, because someof the calculations containing the analyses have not yet been finalized,the restraint evaluation cannot yet be considered complete.

The analyses show that 33 of the 116 affected restraints meet designrequirements and 83 require modifications. The reanalysis has beenintegrated into the normal HELBA production work and, as such, does notpermit easy differentiation of the effects of the use of the revisedthrust forces from the effects of other modifications. Therefore, therestraints which require modifications do not necessarily do so becauseof the MCAR 40 problem. Based on a review of the blowdown timehistories, it is estimated that no more than half of the 83 restraintswhich require modifications require them because of the MCAR 40 problem.This is about 8% of the total pipe whip restraints in the plant. Thedesign drawings associated with these 83 restraints are being revised.

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MIDLAND UNITS 1 AND 2 .

STATUS OF PIPE WHIP RESTRAINTS AFFECTED BY MCAR 40(1) ,'--*

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Restr Mod. Mod.'

System Pipe (2) Install Constr Size OK Loc OK Size OK Loc OK Needed Needed --*

ID Restraint Bldo (%) Hold Phase I Phase I Phase II Phase II Size Loc C3?

i InsideContainment

DH return line PR-610-2-6 Reactor 50 No No No No No Yes YesDH return line PR-610-2-8 Reactor 50 No No No Yes Yes No No s,3DH return line PR-610-2-10 Reactor 50 No No No No No Yes Yes ,"DH return line PR-610-2-12 Reactor 50 No No No No No Yes Yes -

:DDH return line PR-611-2-3 Reactor 100 No No No No No Yes Yes NaDH return line PR-611-2-5 Reactor 100 No No No No No Yes Yes,

DH return line FR-611-2-9 Reactor 100 No No No Yes Yes No No! DH return line PR-611-2-12 Reactor 0 No No No No No Yes Yes

DH return line PR-611-2-13 Reactor O No No No No No Yes Yes'

DH return line PR-611-2-21 Reactor 100 No No No No Yes Yes No

MFW PR-638-13-5 Reactor 0 No No No Yes Yes No No' MFW PR-638-13-6 Reactor 0 No No Yes No - Yes No

| NFW PR-638-13-7 Reactor 0 No No Yes No - Yes No- MFW PR-638-13-8 Reactor 0 No No No No Yes Yes No

g MFW PR-638-13-9 Reactor 0 No No Yes No - Yes No} MFW PR-638-13-14 Reactor 0 No No Yes No - Yes Noi MFW PR-638-13-15 Reactor 0 No No Yes No - Yes No( MFW PR-638-13-16 Reactor 0 No No Yes No - Yes Nof MFW PR-638-13-17 Reactor O No No Yes No Yes No-

MFW PR-638-13-18 Seactor O No No No No Yes Yes No 0,

- NFW PR-638-13-19 Reactor 0 No No Yes No - Yes No{ MFW PR-638-13-20 Reactor 0 No No Yes No - Yes No

MFW PR-638-13-21 Reactor NA No No No No No Yes Yes

| MFW PR-639-13-2 Reactor 100 No No No No Yes Yes NoMFW PR-639-13-16 Reactor 50 No No Yes No - Yes NoMFW PR-639-13-17 Reactor 50 No No No No Yes Yes NoMFW PR-639-13-18 Reactor 30 No No No No Yes Yes NoMFW PR-639-13-29 Reactor 50 No No Yes No - Yes NoMFW PR-639-13-35 Reactor 100 No Yes Yes - - No No

lj HPI. Normal MU PR-604-1-15 Reactor 0 No Yes No - No No Yesj HPI. Normal MU PR-604-2-41 Reactor NA No Yes No - No No Yes}

| Letdown PR-603-3-2 Reactor 0 No No No No No Yes Yesj Letdown PR-603-3-4 Reactor 0 No No No No Yes Yes No

Letdown PR-603-3-6 Reactor 100 No No No No Yes Yes NoLetdown PR-603-3-8 Reactor 100 No - No No Yes Yes No

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Bechtel Associates Professional Corporation112218 Ii2562

MCAR 40Interim Report 9Page 3

Reportability

This condition was reported by Consumers Power Company to the NRC as apotential 10 CFR 50.55(e) reportable condition on August 21, 1980.

Submitted by:J.A." ClementsNuclear Systems Group Supervisor

Approved by: M7 h ME.M. HughesProject Engineer

Concurrence by. /AA d &,

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K L. LoosChief Nuclear Engineer

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Concurrence by: .ME.H. Smi';h

Engineering Manager

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Concurr nce by:

f [ M.A. Dietrichf Project Quality Assurance

Engineer

JAC/DDK/lb(N)| 121604s/J

Attachment: Status of Pipe Whip Restraints Af fected by MCAR 40,dated 4/15/83

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diae Mq}a uos22eluas VJJe32eP qA M3VH DO )sou3}unep( 3

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Hes22 mop * NOP* 3NC,

sAs2em dideyg( lus2eII 3ous23 STEe 03 100 03 S13# 03 1oD 03 NeePeP NeePeP( ,__

IO Hes22etua sIPD )t( HolP dqese I dutse I dqese II dqese II 813e 103;)IE "'

gotponu dH-90E-E-6 Hee 0202 100 NO - NO Nc Aes Aes go I *la2ponu dH-90E-E-IO Hee 0202 O NO - NO NO Aes Aes NO | 1

+ .--

legponu dE-90D-E-L Hee 0202 O NO NO NO NO NO Aes Aes - - -.

[ 102ponu dH-909-E-6 Hee 0202 100 NO NO NO NO NO Aes Aes3%01e2ponu dE-90D-E-IO Hee 3202 NV NO - NO NO NO Aes Aesi

la2ponu dH-9OD-E-D3 Hee 0202 0 dC NO NO NO NO Aes Aes )fot I

3LE ;

[ onas}po ;swcaouge}umeug,

2

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VJM dH-9EE-D-D vnI O NO NO NO NO les Aes Not

i VJM dE-9EE-S-I Ynu O NO NO NO No Aes Aes NO[ VJM dH-9EE-5-ZV yna 0 Aes NO No NO NO Aes Aes; VJM dH-9EC-S-E Wnu O NO NO NO Aes Aes NO MO

VJM dH-9EE-5-S Vnu 0 Aes NO NO NO Aes Aes NOVJM dH-9EE-5-9V ynI 100 NO NO No NO NO Aes Aes,

VJM dE-9CE-S-93 ynu 100 NO NO NO NO No Aes iesVJM dE-9EE-S-L Wna O NO NO NO NO NO Aes ies ,

VJM dH-9EE-5-6 VRX O NO NO NO NO No Aes Aes[ VJM dH-9EE-S-IZ vnI O NO NO NO NO NO les Aes! VJM dE-9EE-5-IS VnI O NO NO NO NO No los AesI

; VJM dU-9ED-5-I Ynz O NO NO NO NO NO Aes Aes;

VJM JH-9ED-S-Z vnI O NO NO NO NO NO Aes ies g

VJM dE-9ED-S-E VnI O NO NO NO No Aes Aes NO, VJM dH-9CD-5-DE VnI O NO NO NO No Aes Aes MO ('

,

VJM dH-9ED-5-10 vnu 100 NO NO NO NO NO Aes Aes'

WJM dH-9CD-9-ZV Vnu 100 NO NO NO NO NO Aes Aes ,

VJM dE-9ED-9-C Vnu O NO NO NO les Aes NO NOVJM dH-9ED-9-D Vnu 100 NO NO NO NO NO Aes Aes ;

I, VJM dH-9CD-9-A Vnu 100 NO NO NO NO MO Aes 103 ,

VJM dE-9CD-9-0 Vnu 100 NO NO NO NO NO Aes Aes .f; ,

Ne}u s2esu dE-9CI-Z-I Wnu NV - - Aes Aes NO MO1

} Ne}u sgaru dH-9EI-Z-Z Vnu MV - - Aes Aes NO NO ;

p Netu steem dH-9EI-Z-E vnI NV - - Aes ies NO NO ;

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XeTU steem dE-9EI-E-D An2q}uo DO Mo - - NO Aes Aes go

we}u steem dE-9EI-Z-9 An2qluo DO NO - - NO Aes Aes NO .'|wetu steem dE-9EI-Z-S 1n2qiuo DO NO - - NO Aes Aes NO'

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| welu steem dE-9EI-t-I YnI 6S NO - - Aes Aes NO NO |Netu steem dE-9EI-E-Z Wnu 65 NO - - Aes Aes NO NO *

wetu steem dE-9EI-E-E Wnu 65 NO - - Aes ies NO NONelu s2esu dE-9EI-E-D 1n2qluo O NO - - NO Aes' 188 NO

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deSe Z00EZn 0D/IS/SE

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Pipe Whio Restraints Affected by MCAR 40 (continued) I'3 iN

Restr Mod. Mod. cyySystem Pipe (2) Install Constr Size OK Loc OK Size OK Loc OK Needed Needed

| ID _ Restraint Blde (%) Hold Phase I Phase I Phase II Phase II Size Loc:

! Main steam PR-631-3-5 Turbine O No - - No Yes Yes NoMain steam PR-631-3-6 Turbine O No - - No Yes Yes No

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Main steam PR-632-2-1 Aux 95 No - - Yes Yes No No p3I Main steam PR-632-2-2 Aux 95 No - - Yes Yes No No! Main steam PR-632-2-3 Aux 95 No - - Yes Yes No No CJ''

Main steam PR-632-2-4 Turbine 40 No - - Yes Yes No No C7)! Main steam PR-632-2-5 Turbine 40 No - - Yes Yes No No es)! Main steam PR-632-2-6 Turbine 40 No - - Yes Yes No No

Main steam PR-632-2-7 Turbine 40 No - - Yes Yes No No1 Main steam PR-632-2-8 Turbine O No - - Yes Yes No No

Main steam PR-632-2-9 Turbine O No - - Yes Yes No Noi

Main steam PR-632-3-1 Aux 95 No Yes Yes No No- -'

Main steam PR-632-3-2 Aux 95 No - - Yes Yes No NoMain steam PR-632-3-3 Aux 95 No - - Yes Yes No NoMain steam PR-632-3-4 Turbine O No - - Yes Yes No NoMain steam PR-632-3-5 Turbine O No - - Yes Yes No No

| Main steam PR-632-3-6 Turbine O No - - Yes Yes No NoMain steam PR-632-3-7 Turbine O No - - Yes Yes No NoMain steam PR-632-3-8 Turbine O No - - Yes Yes No NoMain steam PR-632-3-9 Turbine O No - - Yes Yes No NoMain steam PR-632-3-10 Aux 90 No Yes Yes - - No No

Main steam PR-660-1-1 Aux 90 No No Yes No - Yes NoMain steam PR-660-1-2 Aux 90 No No Yes No - Yes NoMain steam PR-660-1-3 Aux 90 No - - Yes Yes No NoMain steam PR-660-1-4 Aux 90 No - - Yes Yes No NoMain steam PR-660-1-5 Tunnels 0 No No No No No Yes YesMain steam PR-660-1-6 Tunnels 0 No No Yes No - Yes NoMain steaa PR-660-1-7 Tunnels 0 No No Yes No - Yes NoMain steam PR-660-1-8 Tunnels O No No No No No Yes YesMain steam PR-660-1-9 Tunnels O No No Yes No - Yes NoMain steam PR-660-1-10 Tunnels 0 No No No No No Yes YesMain steam PR-660-1-11 Tunnels O No No No No No Yes YesMain steam PR-660-1-12 Tunnels O No No Yes No - Yes NoMain steam PR-660-1-13 Aux 95 No No Yes No - Yes NoMain steam PR-660-1-14 Tunnels 0 No No No No No Yes YesMain steam PR-660-1-15 Tunnels 0 No No No No No Yes Yes-

Letdown PR-603-15-1 Aux 0 No No No - - Yes Yes,

Letdown PR-603-15-4 Aux 0 No No No - - Yes Yes*

* Letdown PR-603-15-5 Aux 0 No No No - - Yes Yes

Letdown PR-604-15-1 Aux 0 No No No - - Yes Yes[ Letdown PR-604-15-2 Aur 0 No No No - - Yes Yes$

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Ploe Nhio Restraints Affected by MCAR 40 (continued) I

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Restr Mod. Mod.System Pipe (2) Install Constr Size OK Loc OK Size OK Loc OK Needed Needed -

ID Restraint Bldo (%) Hold Phase I Phase I Phase II Phase II Size Loc --.

NLetdown PR-604-15-3 Aux 0 No No No - - Yes YesLetdown PR-604-15-5 Aux 0 No No No - - Yes Yes

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Letdown PR-604-15-7 Aux 0 No No No - - Yes YesCO

(1) Phase I is an energy balance analysis: Phase II is a time-history (dynamic) analysis _

(2) Total potentially affected pipe whip restraints = 116,,

NLEGEND:t 11

DH: Decay heatMFN: Main feedwater NAFN: Auxiliary feedwa'erHPI: High-pressure injectionNU: WakeupAUK: AuxiliaryNA: Not availableLoc: LocationMod: Modification

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