Design Report for the Enhanced Shield Building · DSER Design Safety Evaluation Report EEDM earthquake energy dissipating mechanism EPRI Electric Power Research Institute FME foreign

Westinghouse Class 3 Nonproprietary

APP-1 200-S3R-003Revision 3

September 2010

Design Report for the API 000Enhanced Shield Building

A Westinghouse

WESTINGHOUSE CLASS 3 NONPROPRIETARY

APP-1200-S3R-003Revision 3

Design Report for the AP1000 Enhanced Shield Building

September 30, 2010

This document contains sensitive unclassified non-safeguards information (SUNSI) related to the physicalprotection of an AP1000 Nuclear Plant. SUNSI information should be withheld from public disclosurepursuant to 10 CFR 2.390(d).

Westinghouse Electric Company LLCP.O. Box 355

Pittsburgh, PA 15230-0355

© 2010 Westinghouse Electric Company LLCAll Rights Reserved

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TABLE OF CONTENTS

AP1000

LIST OF TAB LES ....................................................................................................................................... xi

LIST OF FIG URES .................................................................................................................................... xii

ACRONYM S AND ABBREVIATION S ................................................................................................ xxxii

a,cS IN TRODUCTION ........................................................................................................................ 1-1

2 SH IELD B UILD IN G D ESIGN .................................................................................................... 2-1 a,c

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TABLE OF CONTENTS (cont.)

SHIELD BUILDING CYLINDRICAL WALL DESIGN ............................................................. 3-1 a,c

4 SHIELD BUILDING STEEL CONCRETE COMPOSITE TO REINFORCEDC O N CRE TE CO N N EC TIO N S .................................................................................................... 4-1 a,c

DESIGN OF THE TENSION RING AND AIR INLET STRUCTURE ....................................... 5-1

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6 REINFORCED CONCRETE REGIONS OF THE SHIELD BUILDING ................................... 6-1

7 SHIELD BUILDING TEST PROGRAM ..................................................................................... 7-1

a,c 0

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8 BENCHM ARKING ...................................................................................................................... 8-1 a,c

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9 CONSTRUCTION AND CONSTRUCTION INSPECTION ...................................................... 9-1 a,c

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SHIELD BUILDING DESIGN PROCESS ........................................................... 10-1 a,c

11 SHIELD BUILDING DESIGN MARGIN AND CONSERVATISMS ....................................... 11-1 a,c

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a,c- 12 C O N C L U SIO N ........................................................................................................................... 12-1

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APPENDIX A

APPENDIX B

APPENDIX C

APPENDIX D

APPENDIX E

APPENDIX F

APPENDIX G

APPENDIX H

APPENDIX I

APPENDIX J

APPENDIX K

REVIEW OF INTERNATIONAL TEST DATA RELATED TO AP 1000SHIELD BUILDING SC CONSTRUCTION ......................................................... A-1

LEV EL 2 A N A LY SE S ............................................................................................. B -1

LEV EL 3 A N A LY SES ............................................................................................. C -1

D ESIG N SK ETCH ES ............................................................................................. D -1

ACI 349 REINFORCEMENT DESIGN ..................................................................... E-1

FORCE CONTOURS OF LINEAR ELASTIC ANALYSIS .................................... F-i

EXCEL MACRO TO SIZE REINFORCEMENT ................................................... G- 1

ATTACHMENT TO DCPNRC_002995 ............................................................... H-1

BENCHMARKING ANALYSIS .............................................................................. I-1

SHIELD BUILDING BEHAVIOR AND DESIGN PHILOSOPHY ........................ J-1

SHIELD BUILDING MARKUPS .......................................................................... K-1

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ACRONYMS AND ABBREVIATIONS

AASHTO American Association of State Highway and Transportation OfficialsACI American Concrete Institutea/d shear span ratioAISC American Institute of Steel ConstructionANSI American National Standards InstituteASCE American Society of Civil EngineersASME American Society of Mechanical EngineersASTM American Society of Testing and MaterialsATR adiabatic temperature rise

AWS American Welding SocietyBTU British thermal unitCDFM conservative deterministic failure marginCDP concrete-damaged plasticityCEF concrete elastic fracture

CFR Code of Federal RegulationsCFS concrete-filled steelCJP couple joint penetration weldCO carbon monoxideCSC concrete-smeared crackingCSDRS Certified Seismic Design Response SpectraCV containment vesselDCD Design Control DocumentDSER Design Safety Evaluation ReportEEDM earthquake energy dissipating mechanismEPRI Electric Power Research InstituteFME foreign material exclusionFFT fast Fourier transformFR Federal RegisterGD&T geometric dimensioning and toleranceGDC General Design CriteriaGPR ground penetrating radarGRT gamma radiographyHCLPF high confidence of low probability of failureHRHF Hard Rock High FrequencyHVAC heating, ventilating, and air conditioningIAEA International Atomic Energy AgencyICC International Code CouncilITAAC Inspections, Tests, Analyses, and Acceptance CriteriaIEM impact-echo methodIMI Irving Materials, Inc.IP in planeIR impulse responseIRT infrared thermal imagingJEAG Japanese Electric Association Nuclear Standards Committee

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ACRONYMS AND ABBREVIATIONS (cont.)

kN kilonewtonksi kips per square inchLLL Lawrence Livermore LaboratoryLS-DYNA Livermore Software- Design Analysis

LVDT linear variable differential transformerMN meganewtonMPa megapascal

MSIV main steam isolation valveMTR mill test reportMTS materials testing system

NCHRP National Cooperative Highway Research ProgramNDE nondestructive examination

NDT nondestructive testingNRC U.S. Nuclear Regulatory CommissionNUREG Nuclear Regulatory Commission report

OC on centerOOP out of planePCS passive containment cooling system

PiP partial joint penetrationPSF pounds per square footPSI pounds per square inchQA quality assuranceQC quality controlRAI request for additional informationRC reinforced concreteRLE review level earthquakeRSA response spectrum analysesRT radiography testingSAFT synthetic aperture focusing techniqueSB shield buildingSBCEP Shield Building Construction Execution Plan

SC steel concrete compositeSCC self-consolidating concreteSr stress rangeSRSS square root of the sum of the squaresSSE safe shutdown earthquakeUSW ultrasonic surface waveUT ultrasonic testingVT visual inspectionW/CM water-to-cement ratioWEC Westinghouse Electric Company

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EXECUTIVE SUMMARY

AP1000 Shield Building Function

The AP 1000 Shield Building, a Seismic Category I structure, serves the following primary functions:

0 Provides shielding for the Containment Vessel (CV) and the radioactive systems and componentslocated in the Containment Building

0 Protects the Containment Building from external events during normal operations

* Provides the required shielding for radioactive airborne materials that may be dispersed in thecontainment

a Provides support for the passive containment cooling water storage tank (PCCWST) forcontainment cooling

* Provides for natural air circulation cooling of the containment vessel

Enhanced AP1000 Shield Building Requirements

On June 12, 2009 the U.S. Nuclear Regulatory Commission (NRC) issued a new regulatory requirement(74 FR 28112) to address the beyond design basis aircraft impact events. Westinghouse developed theenhanced Shield Building design for the AP1000 to address these requirements.

The original certified Shield Building was of reinforced concrete (RC) design. In response to the newregulatory requirements, it was necessary to modify the AP1000 Shield Building design for the portion ofthe Shield Building above grade that is not protected from external hazards by the Auxiliary Buildingstructure. The unprotected Shield Building structure was changed from an RC structure to an enhanced(strengthened) steel concrete composite (SC) structure.

In the initial Westinghouse design process for the SC Shield Building, Westinghouse relied on theconservative application of ACI 349 code provisions for RC nuclear structures and conservatively appliedthese provisions to the SC design of the Shield Building. This conservative application design processwas consistent with design methodology that Westinghouse had developed for structural modules. Thismethodology was based on calculations and analyses where finite element (F/E) analyses of the structureare performed and the structural allowable limits are derived from the ACI 349 code. This methodologyis supported by extensive international testing and is the basis for other international building codes forSC structures.

On October 15, 2009, the NRC provided a letter to Westinghouse summarizing their review of theAP1000 Enhanced Shield Building design and the Westinghouse design process. The NRC determinedthat the proposed design of the Shield Building would require modifications in some specific areas toprovide its ability to perform its safety function under design basis loading conditions and to support afinding that it will meet applicable regulations.

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Specifically, the design of the steel and concrete composite structural module (SC module) must

demonstrate the ability to function as a unit during design basis events; the design of the connection of theSC module to the RC wall sections of the Shield Building must demonstrate the ability to function during

design basis events; and the design of the Shield Building tension ring girder, which anchors the ShieldBuilding roof to the wall, must be supported by either a confirmatory test or a validated (or benchmarked)

analysis method.

As a result of the NRC review and findings of the enhanced Shield Building, Westinghouse is providing

an integrated approach in the revisions to the design, analysis, and testing to demonstrate that the Shield

Building structural components are integrated as a complete structure and act as a single unit to performthe intended safety function under design basis loads. In response to the NRC letter, Westinghouse has

completed the following:

" Design changes were made to the Shield Building that improve its strength and ductility. Withthe inclusion of tie bars connecting the surface plates, it is demonstrated that the structure will act

as a unit in response to design basis events.

" Design changes to the air inlets and tension ring region were made that improve its strength and

ductility. The tension ring is designed as a steel structure in accordance with American NationalStandards Institute/American Institute of Steel Construction (ANSI/AISC) N690 and meetsdesign basis loadings.

* Design changes to the RC/SC connections to use mechanical connectors that directly transfer the

forces from the steel SC structure to the RC structure such that the connection will exhibit

strength and ductility during seismic events.

* A series of confirmatory tests were performed that demonstrate that the Westinghouse design

process that confirms that the ACI 349 code is conservatively applicable to the SC ShieldBuilding structure.

* The design of the Shield Building confirms that the standard design process used for the design

benchmarked nonlinear analyses demonstrate the overall strength and ductility of the AP 1000Shield Building. Specifically these analyses demonstrate that the AP1000 Shield Building is

designed with adequate margin to withstand both the Safe Shutdown Earthquake (SSE) as well as

the review-level earthquake in accordance with NRC regulations.

" Performance of additional analyses that demonstrate ductility beyond that of the review-levelearthquake such that the SC Shield Building structure can be judged to be a safe and robust

design.

* Westinghouse and The Shaw Group have performed constructability reviews of the ShieldBuilding structure and have concluded that the design can be constructed such that the inherent

performance requirements of the SC Shield Building as described in this report will be met. The

design team has also identified inspection technologies that can be applied to SC.

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This Executive Summary and the detail information within the Design Report depict a revised designprocess, revised design features, analysis, testing, construction, and inspection methodology that haveresulted from the Westinghouse response to the NRC's findings, as outlined in their October 15, 2009letter.

The acceptability of the Shield Building design relative to its role of protection against a malevolent

aircraft crash is not addressed as part of this Design Report.

Process for Review and/or Revising the Design

Based on the NRC findings, Westinghouse supplemented its design team with additional outside industryexperts that included members from The Shaw Group, Inc., Purdue University, URS Corporation,Obayashi Corporation, Ansaldo STS, NuStart and their consultants, Twining Laboratories, and RutgersUniversity Research. The expanded team led by Westinghouse has developed an overall integrated designprocess (see Figure ES-1) that includes consideration for civil/structural design, thermal/hydraulics andanalysis, seismic margin, aircraft crash, durability, testing, construction, and inspection of the ShieldBuilding. This integrated design process has resulted in Westinghouse incorporating design changes,

performing additional tests at Purdue University, and performing extensive analysis that demonstrates theadequacy and safety of the AP1000 Enhanced Shield Building. The design, testing, and analysis arepresented in this enclosed report.

Thermal/Hydraulics

CivillStructuralI

I Cnspp on

Co~sructio\

AircraftCrash

SeismicMargin

Dura~bility

iTesting

Figure ES-1 Shield Building Design Process

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1. PCS Tank

6. Compression Ring I5. Knuckle Region

Ig4. SB Roof

3. Air Inlet and Tension Ring

2. SC Cylindrical Wall

1. RC/SC Connections

Figure ES-2 Shield Building Structure Key Areas

Modified Design Features

The integrated engineering team evaluated the seven key areas comprising the Shield Building structureas noted in Figure ES-2. The design modifications were identified for three key areas. These includeArea 1, the RC/SC vertical and horizontal connections; Area 2, the SC cylindrical wall; and Area 3, the airinlets/tension ring. The purpose of the design modifications was threefold: to allow these portions of thestructure to act as a unit; to provide more ductility; and to add more conservatism to the SC design. Adecision was made to limit the use of self-consolidating concrete (SCC) to selected regions, including the

knuckle region of the roof, the air inlets, and the tension ring. The remainder of the Shield Building willbe constructed using standard concrete with a strength of 6000 psi in the SC and 4000 psi in the RC areas.Key areas 4, 5, 6, and 7 are designed as a RC structure in accordance with the ACI and ANSI/AISC codes.

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RC/SC Horizontal and Vertical Connections (Key Area #1)

The RC/SC connection has been redesigned. The steel plate modules are anchored to the RC basemat andwalls of the Shield Building by mechanical rebar connections. The connectors provide for the directtransfer of forces from the RC reinforcing steel to the SC liner plates.

At the horizontal connection at the interface with the RC structure that occurs on the bottom of the lowestSC wall module, each vertical reinforcing bar in the RC basemat wall is connected to a mechanicalcoupler. A similar vertical connection occurs on the vertical edges of SC wall modules that interface withthe RC portion of the Shield Building wall. In the vertical connection, each hoop reinforcing bar in the

RC wall is connected to a mechanical coupler, and forces are transferred directly from the hoop bars tothe SC liner plate. The mechanical connection is designed to the allowable working stress limits ofANSI/AISC N690 for loads in the reinforcing bars equivalent to 125 percent of the yield strength of thereinforcing bars and are proven components used in existing structures. This connection improves theoverall ductility of the RC/SC connection.

SB Cylindrical Wall (Key Area #2)

The cylindrical wall has been redesigned. The Shield Building surrounds the CV and shares a commonbasemat with the CV and the Auxiliary Building. The cylindrical shield wall has an outside radius of72.5 feet and a thickness of 36 inches. The cylindrical wall section that is below the Auxiliary Buildingroof line is a reinforced concrete structure. The section that is not protected by the Auxiliary Building is asteel concrete composite structure, where two 0.75-inch plates act compositely with 34.5 inches ofconcrete via tie bars and shear studs. The steel plate modules are connected to the reinforced concretebasemat and walls by mechanical connectors as described above.

A typical configuration of the SC wall is shown in Figure ES-3. The overall thickness of 36 inches is thesame as the RC wall below. The concrete for the SC portion is standard concrete with compressivestrength of 6000 psi. The SC portion is constructed with American Society for Testing and Materials(ASTM) A572 Grade 50 steel surface plates which act as concrete reinforcement. The nominal thicknessof the steel faceplates is 0.75 inches. In each module, 0.75-inch tie bars are welded to the outside faces ofthe steel faceplates to develop composite behavior of the steel faceplates and concrete. The 0.75-inchshear studs are at nominal 8.375-inch circumferential spacing and nominal 8.5-inch vertical spacing, andare welded to the inside surface of the steel plate. The tie bar reinforcing bars are at 6-inch centers in thehigher stress regions. The reinforcement detailing incorporates both American Concrete Institute (ACI)349 R1.4 and ACI 318-08 requirements.

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The use of tie bars and mechanical connections at the RC/SC interfaces addresses the issues raised in theNRC letter (dated October 15, 2009) that the AP 1000 Shield Building must act as a unit. Westinghousehas performed testing and analysis that demonstrates this behavior. Use of 0.75 inch steel plate alsoaddresses issues raised in the NRC letter with respect to ductility and the effects of creep. Figure ES-3illustrates this design.

Figure ES-3 Enhanced Shield Building Wall Panel Layout

Air Inlets and Tension Ring (Key Area #3)

The air inlets and tension ring region have been redesigned. The configuration and plate size of the airinlets have been changed to enhance its structural performance. The air inlets structure (as shown onFigure ES-4) is located at the top of the cylindrical wall portion of the Shield Building, beginning at

approximately Elevation 251 feet and rising to approximately Elevation 266 feet. The air inlets serve asthe intake for air as part of the passive containment cooling system (PCS).

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W36x393 Roof Girder _ -Z

Beam Seat

Shear Stud -

Tie Bar

-Tension Ring

Air Inlet Pipe Opening

Figure ES-4 Elevation View of Tension Ring and Air Inlets

Above the air inlets, at approximately Elevation 266 feet, is the connection designated as the tension ringthat connects and supports the conical roof. The tension ring also contains 32 radial beam seatconnections where the W36 x 393 radial beams for the conical roof are connected.

The air inlets region is 4.5-feet thick with 1-inch plates on each face as the primary reinforcement, whichare connected using 0.75-inch tie bars. The number, size, and spacing of the air inlet openings has beenmodified to enhance structural performance. The 236 air inlet openings are formed using 18-inchdiameter, Schedule 40 pipe at a downward inclination of 38 degrees from the vertical. The pipe spacing isapproximately 2.81 degrees circumferentially with shear studs welded to the outside surface of the pipes.The 18-inch diameter air inlet pipes are welded to the faceplates and tie the faceplates together.

Air flow calculations were completed as a result of changing the air inlet numbers and sizing of the ShieldBuilding. The path for the air circulation continues to meet the safety requirements for the PCS for theShield Building. The assessment of the impact on the containment cooling was submitted to the NRC in aletter report and is not included in this Shield Building Design Report.

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The tension ring has been redesigned as a structural steel box structure with concrete infill and shearstuds. Also the connection of the RC conical roof to the tension ring has been redesigned to a mechanicalconnection. The air inlets and tension ring design methodology is supported by linear analysis andbenchmarked nonlinear analysis as presented in this report. The tension ring is designed to ANSI/AISCN690 and is a concrete-filled box girder, with two continuous 1.5-inch thick steel plates top and bottomthat connect the inner liner plate to the outer liner plate, as shown in Figure ES-5.

Shield BuildingReinforcing Bar Roof ReinforcementMechanicalConnection

Tension RingBox Girder OuterFlange

W36x393 Roof Girder

Tension Ring BoxGirder Inner Flange

Beam Seat

Tension Ring Box GirderContinuous Web

ES-5 Shield Building Tension Ring

SB Roof, Compression Ring, Knuckle Region, and PCS Tank (Key Areas #4, #5, #6, and #7)

The other areas of the Shield Building have been designed to existing industry code requirements, andinclude the conical roof, the PCS tank, the compression ring, the knuckle region, and their relatedattachments. Linear analysis was previously performed on these areas and no additional designmodifications, analysis, benchmarking, or testing is required. These areas are designed as RC structuresin accordance with ACI 349. The steel frame for the roof is designed for the applicable building codeANSI/AISC N690. The concrete roof is designed to ACI 349 requirements without credit for the steelplate on the bottom of the concrete.

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Structural Analysis

Benchmarked structural analyses using detailed finite element model are used to demonstrate structural

adequacy for the critical areas of the Shield Building. For the Shield Building cylindrical wall and therelated connection regions to the roof, the Auxiliary Building, and the basemat, a combination of testingand benchmarked analysis is used to confirm the structural adequacy of the design.

Load combinations for seismic Category I concrete and steel structures were used for the design of theShield Building. Loads for the design of each structural element were based on the conditions to whichthe particular structural element is potentially subjected and on the applicable U.S. Nuclear RegulatoryCommission Standard Review Plan NUREG 0800. The governing loads and evaluations for variouslocations were considered. Linear elastic analyses and nonlinear analyses, and load distribution usinganalysis tools such as SASSI, ANSYS, and LS-DYNA and ABAQUS were performed to confirm thatcracking is not significant for load distribution; to confirm that regions of the Shield Building act as aunit; and to show margin for beyond design basis review-level earthquakes.

The Shield Building design has reserve strength that provides seismic margin above the review-levelearthquake. The analyses show that the seismic high confidence of low probability of failure (HCLPF)value is above the review-level earthquake value of 0.5g. The standard seismic margin calculations arebased on conservative design loads. The linear elastic analyses calculation that shows margin betweenthe capacity of the structure and the design basis loading.

Benchmarked nonlinear analyses were performed on the Shield Building anchorage, cylindrical wall,tension ring, and roof anchorage connections. The benchmarked nonlinear analyses demonstratesignificant margin over and above that demonstrated in the linear elastic analyses. Benchmarked Level 2and Level 3 analyses were performed to demonstrate the system strength and ductility, both at the globallevel (Level 2) and at the component level (Level 3). In all cases the analyses demonstrate large marginto regulatory safety limits and demonstrate sufficient ductility in the AP 1000 Shield Building.

The design life of the Shield Building is 60 years. Nonlinear analyses were performed to assess thatbuckling, creep, and shrinkage were not significant factors in the design. Concrete material andplacement testing was conducted as part of the overall comprehensive test program. Thermal analysiswas performed to quantify the effect of daily and seasonal thermal cycles on the cylindrical wall and theeffect of cracking due to thermal gradients.

Confirmatory Testing

A confirmatory test program was developed and conducted as part of the Shield Building design processto demonstrate the adequacy of the design modifications and to address NRC comments. The testingprogram, in conjunction with Purdue University and under the direction of Dr. Amit Varma, includedanchorage, out-of-plane shear (with and without tension), and in-plane shear tests. The goal of the testingwas to demonstrate the behavior and adequacy of the Shield Building based on the AP 1000 designprocess assumption that the ACI 349 code provisions for RC nuclear structures are conservativelyapplicable to the SC design of the Shield Building.

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Each of the test program elements also included variations of specimen plots to determine their

fundamental behavior. A summary of the key test program elements is as follows:

1. Out-of-plane (OOP) shear without tension to demonstrate that the OOP shear strength of theAP 1000 SC design can be estimated using ACI code provisions for the shear strength of RCbeams

2. OOP shear with tension to demonstrate that axial tension will not significantly affect the ACI

strength prediction

3. OOP shear cyclic to demonstrate ductility

4. Pushout to demonstrate the general behavior of SC structures

5. Weld fatigue to determine if the fatigue specimens can support a minimum of 73000 cycles

6. Cyclic in-plane shear to demonstrate that shear strength of SC can be conservatively estimatedusing ACI code provisions for RC walls as well as ductility

7. Anchorage to demonstrate the strength of the RC/SC connection in tension

8. The in-plane shear strength is greater than that calculated using ACI 349 code

All tests demonstrate the robust behavior of the AP 1000 SC structural components. The test program

confirms the Westinghouse design approach that the ACI 349 code can conservatively be used to designthe SC AP 1000 Shield Building. These tests are also used to by Westinghouse in the benchmarking of thenonlinear analyses presented in this report.

Construction and Inspection

Good construction practice starts early by integrating constructability and inspection reviews into thedesign process.

For the AP 1000 design, including the Shield Building, parallel integrated construction and inspection

reviews have been proactive and have been included in the design process for the purposes of identifying

and accessing engineering information to enhance the design certification process and the development ofthe overall constructability plan.

These reviews are based on using current available construction and inspection technologies, practices,

and procedures.

The objectives of the review are to:

" Validate constructability processes and techniques

" Develop construction interfaces, tolerances, and complete construction sequencing

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* Incorporate logic ties for material take-offs, module identification, fabrication, manpower estimates,installation sequences, and inspection

" Detail the structural and architectural critical areas of construction for required mockups andprocedures such as concrete placement, welding, and quality assurance

* Analyze the material requirements and establish the required procedures -for concrete placement, mixrequirements, welding procedures, and inspection techniques according to industry codes andqualification requirements

When critical areas are analyzed and established such as the RC/SC basemat connection and air inletsregions of the Shield Building, they are identified as challenging areas of construction which are thenincluded in the construction mockup plan. The mockups will be fabricated and constructed as a physicalrepresentation of the structure for craft, Quality Control inspectors, and construction supervisors.

Post-mockup activities include visual inspections of the mockup surfaces by disassembling the mockupand examining surfaces for verification of strength and/or defects. When defects are found, theprocedures will be revised and the mockups repeated until the required results are obtained.

Constructability reviews performed on the Shield Building have yielded improvements and designchanges that offer the assurance that the end product of the engineering design will result in awell-constructed plant.

In addition to these constructability practices, additional insights on nondestructive examination (NDE)programs are applied regarding NDE technology in the inspection of post-placement concrete.

Summary

The foregoing claims revised the design process, and the revised design features, analyses, testing,construction, and inspection have resulted in an AP1000 Shield Building revised design that is safe andconservative. This is substantiated by the details of conformance as shown in a detailed compliancematrix. The compliance matrix was developed from the October 15, 2009, NRC letter concerning theoriginal enhanced Shield Building Design Report and is provided as the Executive Summary andChapter 12 to the report.

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Table ES-i Compliance Matrix

NRC Identified Key Issue Westinghouse Actions

10 CFR 50.55a Westinghouse design approach on how it demonstratesthat the Shield Building SC design is safe andconservative and meets NRC regulations has beenoutlined in Section 2 of the report.

The Shield Building is a hybrid structure. There areareas of the Shield Building that fall within establishedcodes. For those structures safety is demonstrated byshowing margin against code allowable. There areother areas that are considered special structures inaccordance with ACI 349, Section 1.4. For thosespecial structures, in addition to meeting Coderequirements, safety and margin are demonstrated bytesting or benchmarked analyses.

+

10 CFR 50, Appendix A

General Design Criterion (GDC) 1

Quality Standards and Records: insufficientinformation regarding detail, design analysis,construction, inspection, and testing.

This revision of Shield Building Design Report hasbeen structured to outline the design criteria utilized;the justification as to why the design criteria isadequate; and how the Westinghouse enhanced ShieldBuilding design is meeting the criteria. Specificallythe Shield Building design attributes are addressed inthe following sections:

- Detail Design Sections 1.2, 3.1, 3.4, 4.1, and 6.1- Design Analysis Section 2- Construction Section 9- Inspection Sections 9.7 and 9.8- Testing Section 7

In addressing general design criteria as defined,Westinghouse has modified and revised its design,analysis, testing, construction, and inspection aspreviously identified in the report submittal.

General Design Criterion (GDC) 2

Design Bases for protection against naturalphenomena; requires safety-related structures towithstand the most severe natural phenomena such aswinds, tornadoes, floods, earthquakes, and theappropriate combination of loads.

Westinghouse has revised the design of the cylindricalwall steel concrete composite (SC) and connectiondesigns, where the reinforced concrete (RC) structuresand SC structures interact, to function as an integratedunit. Three criteria were utilized to demonstratecompliance:

1) Adequate strength margins to industry andregulatory codes and standards

2) Adequate ductility margin3) Adequate building durability

Specifically these criteria are demonstrated in thefollowing report Sections:

- Strength and Ductility Sections 4.2, 3.2, 5.2,6.2 and Section 10

- Durability Section 3

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Table ES-1 Compliance Matrix(cont.)


Detailing, Design, and Analysis

1. Westinghouse(WEC) has not demonstrated that it Sections 3, 4, 5, 6, and 10, provide the design featureadequately designed and detailed the steel concrete descriptions, methodology, and demonstration ofcomposite (SC) module to function as a fully margin for compliance for the revised Shield Buildingcomposite unit as assumed in the WEC design/analysis. design.In addition, WEC has not demonstrated that the SCmodule has sufficient ductility to survive severe The modified cylindrical wall and connection designs,earthquakes or tornado winds, specifically address the adequacy of the structure to actas an integrated unit, providing adequate ductility and

durability in severe earthquakes or other naturaldisasters.

With respect to comments made regarding thediscontinuity of the six-inch studs, as described in thegeneral description of the Shield Building, Section 1.2,the new tie bars included in the Westinghouse designnow employ tie bars spaced on six-inch centers in thehigher stressed regions. There are six-inch studs alsospaced between the tie bars at 17-inch centers in thelower stressed regions. This creates a maximumspacing between stud and/or tie bar of 8.5 inches.

2. The SC module wall to reinforced concrete (RC) The design and detailing for the RC portion of thewall connection lacks design and detailing for the RC connection has been added to the Shield Buildingportion of the connection. Thus, it cannot be design report. Inclusion of the RC support structuresdetermined whether the connection will carry the SB provides a thorough demonstration of the interactiondesign loads, between the two types of structures. The finite element

models utilized to analyze these details provide anoverall analysis of the interaction, demonstrating theintegration of the building structures.

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Table ES-i Compliance Matrix(cont.)


3. The design and analysis of the shield buildingtension ring (i.e., ring girder) and the air inlet region isnot supported by a validated design/analysis method(i.e., benchmarked to experimental data), or byconfirmatory model tests.

The tension ring and air inlet has been designed to takefull advantage of the steel structure (i.e., the exteriorand interior steel plates, the steel air tubes, and therebar in the structure). The tension ring has beendesigned in accordance to AISC/ANSI N690. Verydetailed finite element models of the air inlets andtension ring were used to demonstrate the adequacy ofthis design. Consistent with the analysis approachoutlined in the report, a Level 3 analysis of the tensionring and air inlets was performed. This analysis modeltakes into account the details of the design, which usesthe loads/deformations from the Level 2 analyses. BothLevel 2 and Level 3 analyses have been benchmarkedto experimental data. The design is discussed inSection 5.

4. The use of a simple shell element to represent the36-inch-thick SC wall module and the use of coarsemeshes near the areas of discontinuities may beadequate for performing preliminary evaluations ofoverall building responses, but are insufficient forperforming the subsequent detailed design/analysis(i.e., assessing stress/strain magnitudes) forstress/strain distributions within the elements and atstructural discontinuities (e.g., SC-RC and the auxiliarybuilding roof connection areas).

Westinghouse has outlined an analysis approach in thereport which utilizes a combination of analysistechniques categorized as Level 2 and Level 3analyses. Each analysis chapter of this report has botha Level 2 and 3 sections. Both Level 2 and Level 3analyses use solid elements to represent the 36-inch-thick SC wall module. The Level 3 section providesthe very detailed finite element models which are beingused to assess stress-strain magnitudes within criticalregions, demonstrating the adequacy of that criticalregion design.

5. WEC has not considered the self-consolidatingconcrete (SCC) material properties and their effect(e.g., higher shrinkage and creep strains, less shearresistance and ductility compared to that of normalconcrete) on the behavior of the shield building, anddid not include those effects in its design/analysisprocess.

An examination of self-consolidating concrete (SCC)behavior has been documented in industry performancetests. In addition, Westinghouse has providedconstruction field tests performed as part of theAP 1000 plant construction in China that demonstrateacceptable strength and shrinkage properties of SCC.

SCC has been minimized in the revised design of theAP1000 Shield Building by the constructabilityreviews performed on the design. SCC will be used inthe air inlets and knuckle regions of the roof, andRC/SC connection. The remainder of the ShieldBuilding will be constructed using standard concrete.

The use of SCC for the tension ring and knuckle regionof the roof is judged acceptable for these sectionsbased on the design analysis performed.

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6. WEC has not considered the daily and seasonal The issue of thermal cycling has been addressed inthermal cycling effect on the fatigue of welded joints Section 3.3 of the report.between the SC module steel faceplate and studs, thestress and strain reversal in concrete and studs, and the In effect, finite element heat transfer and nonlineardegradation of bond strength between the concrete and analyses were performed to address these issues. Instuds. addition, the design modifications to the SC wall,which incorporated shear ties that tie the plates

together, make the SC wall design less susceptible tofatigue due to thermal cycling.

7. The thickness of steel faceplates in the SC module Westinghouse modified the cylindrical wall by(1/2 inch) appears to be less than required, because the increasing the plate thickness from 0.5-inch ASTMactual maximum principal stress appears to be higher A572 Grade 65 steel plate to 0.75-inch ASTM A572than the allowable principal stress. Grade 50 steel plate connected together with 0.75-inch

reinforcing tie bars.

These changes provide additional design (stress)margin as well as contributing to overall strengthmargin of the Shield Building.

8. WEC has not provided sufficient information to Section 3.3.2 of the report addresses creep effects ondemonstrate that the effect of local buckling of the SC the design. The analysis has demonstrated that creep ismodule faceplates are precluded, not an issue.

Even with conservative assumptions on shrinkage andcreep, the surface stresses in the steel plate are wellbelow the strength of the steel plate. Additionally theincreased plate thickness and decreased stud spacinghas reduced the potential for local plate buckling. This

is described in Section 3.3.1.

Construction and Inspection

WEC has not provided construction and inspection Section 9 of the revised Shield Building Report is fullymethods required to ensure the safety of the shield dedicated to construction and inspection practices,building design. Inspection of voids, cracking, including critical construction mockups. In addition,delamination, and substandard construction of concrete Section 9.8 of this report describes the NDEare needed to ensure integrity of the structure, technologies available for post-placement concrete

inspection and the results of NDE testingdemonstrations performed by Westinghouse.

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Table ES-I Compliance Matrix

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Testing

1. The proposed test specimens are not fully The cylindrical wall design has changed and the testsrepresentative of the SC module (e.g., substituting performed were fully representative of the SC modulestuds for L-shaped angle stiffeners and ignoring welded configuration.joints of the faceplates). Section 7 of the report describes at length the design of

the test specimens and why they are representative ofthe design and design loading of the Shield Building.

2. The proposed WEC test setup for demonstrating the The in-plane test has been significantly changed toadequacy of the SC wall module under combined address the comments provided. Specifically, the setupin-plane shear and tension loading [Test #4] has of the test has been changed that the boundaryboundary conditions that will constrain the test conditions will not cause an overestimation of actualspecimen and thus lead to an over-estimation of actual strength. Section 7 of the report is dedicated to the in-strength. Further, the proposed test loads are plane test.monotonic and thus do not represent the reversedmonooni andthu do ot epreentthe evesed Two specimens are being tested for in-plane cycliccyclic dynamic loads on the shield building generated Two specimgnby earthquakes. shear capacity.

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Documents

Design Report for the Enhanced Shield Building · DSER Design Safety Evaluation Report EEDM earthquake energy dissipating mechanism EPRI Electric Power Research Institute FME foreign