MALB RPT

NUCLEAR POWER CORPORATION OF INDIA LIMITED
(A GOVERNMENT OF INDIA ENTERPRISE)
PROJECT: KAPP-3&4
Design Report on the

Embedded Part (EP) For Main Air Lock Barrel (MALB) in
Inner Containment Wall (ICW) of KAPP-3&4
Report Number: KAPP-3&4/DC/21000/40/R0
AUGUST 2010
(A GOVT. OF INDIA ENTERPRISE)
PROJECT: Kakrapara Atomic Power Project-3&4
Revision Number: R0
Date of Issue : August
(Month/Year) 2010
Total Number of Pages:
27
(Including Cover Sheet)
Design Report on the Embedded Part (EP) for Main Air Lock Barrel (MALB) in
NAME SIGNATURE DATE
PREPARED BY: Shrikant Devmani Mishra

Engineer (C)
Rajiv Ranjan
Sr. Executive Engineer (C)
CHECKED BY: Madhumangal Das

Executive Engineer (C)
Indrajit Ray
Dy. Chief Engineer (C)
REVIEWED BY: G Prabhakar

Addl. Chief Engineer (C)
APPROVED BY: Raghupati Roy

Addl. Chief Engineer (C)
FIRST ISSUE: August, 2010

(FOR REVISIONS SEE REVISION CONTROL SHEET)
Revision Control Sheet
DOCUMENT TYPE: DR
Design Report on the

Embedded Part (EP) For Main Air Lock Barrel (MALB) in
REV NO PREPARED CHECKED REVIEWED APPROVED

DESCRIPTION
DATE BY BY BY BY
REV NO.:
DESIGN REPORT ON THE EMBEDDED KAPP-3&4/DC//21000/ R0
PART (EP) FOR MAIN AIR LOCK BARREL 40/R0 AUGUST
(MALB) IN INNER CONTAINMENT WALL 2010
(ICW) OF KAPP-3&4
PAGE: of
Table of Contents
Table of Contents.........................................................................................................................................................4
List of Tables ..............................................................................................................................................................5
List of Figures ..............................................................................................................................................................5
Abbreviations Used......................................................................................................................................................6
CHAPTER:-1 INTRODUCTION..................................................................................................................................7
1.1 GENERAL.....................................................................................................................................................................7
1.2 OBJECTIVE..................................................................................................................................................................7
1.3 SCOPE..........................................................................................................................................................................7
1.4 REPORT LAYOUT.........................................................................................................................................................7
1.5 DOCUMENTS AND APPLICABLE CODES.......................................................................................................................7
CHAPTER:-2 GENERAL DESCRIPTION OF THE EMBEDDED PART FOR MAIN AIR LOCK BARREL........9
2.1 GENERAL.....................................................................................................................................................................9
2.2 DETAILS OF EP AND JOINT BETWEEN I.C. AND MAIN AIRLOCK BARREL..................................................................9
2.2.1. Details of EP......................................................................................................................................................9
2.2.2. Joint between I.C. and Airlock Barrel...............................................................................................................9
2.3 MATERIAL...................................................................................................................................................................9
2.4 LIMIT OF STRESSES.....................................................................................................................................................9
CHAPTER:-3 ANALYSIS METHODOLOGY..........................................................................................................12
3.1 GENERAL...................................................................................................................................................................12
3.2 LOADS.......................................................................................................................................................................12
3.3 ANALYSIS METHOD..................................................................................................................................................12
3.3.1. FE Model.........................................................................................................................................................12
3.3.2. Load Modelling................................................................................................................................................12
3.3.3. FE Model Boundary Condition.......................................................................................................................13
3.4 ANALYSIS OF EP FOR MALB...................................................................................................................................13
3.4.1. Calculation of Strains on Outer Face of IC Structure.....................................................................................13
3.4.2. Calculation of Stress and Strain in EP for MALB...........................................................................................13
3.5 ANALYSIS RESULTS..................................................................................................................................................14
3.5.1. Stresses in the EP for MALB...........................................................................................................................14
CHAPTER:-4 DESIGN, SUMMARY AND CONCLUSION....................................................................................15
4.1 GENERAL...................................................................................................................................................................15
4.2 DESIGN OF EMBEDDED PART (EP)...........................................................................................................................15
4.3 DESIGN OF ANCHOR..................................................................................................................................................15
4.3.1. Design for pull-out...........................................................................................................................................15
4.3.2. Design check for anchor bond.........................................................................................................................16
4.3.3. Design for anchor strength..............................................................................................................................16
4.3.4. Design check for shear....................................................................................................................................16
4.3.5. Design of Bearing Plate at the end of anchor.................................................................................................17
4.4 WELD DESIGN...........................................................................................................................................................17
4.4.1. Between EP plate and stud..............................................................................................................................17
4.5 SUMMARY.................................................................................................................................................................18
4.6 CONCLUSION.............................................................................................................................................................18
REFERENCES ............................................................................................................................................................19
REV NO.:
(ICW) OF KAPP-3&4
PAGE: of
List of Tables
Table-1: Applicable Documents and Codes........................................................................................8

Table-2: Mechanical Properties of Material of EP for MALB............................................................9
Table-3: Summary of Stress Intensity (Permissible Stresses in EP for MALB ) in MTon/m 2..........10
Table-4: FE Model Details of the EP for MALB..............................................................................12
List of Figures
Figure-1: General Arrangement of EP for MALB.............................................................................20

Figure-2: General Arrangement of EP Anchor for MALB.................................................................21
Figure-3: Plan and Elevation of Joint Between ICW and Bellow......................................................22
Figure-4: Inner Containment Structure (ICS) and Main Air Lock Barrel (MALB)............................23
Figure-5: Forces around MALB Opening due to Bellow Load..........................................................24
Figure-6: Sxx Stress Contour Around MALB Opening due to Bellow Load.......................................25
Figure-7: Syy Stress Contour Around MALB Opening due to Bellow Load.......................................26
Figure-8: Effective Stress Area for Anchorage Pullout......................................................................27
REV NO.:
(ICW) OF KAPP-3&4
PAGE: of
Abbreviations Used
The following abbreviations have been used in this report:

NPCIL Nuclear Power Corporation of India Limited
KAPP Kakrapara Atomic Power Project
NPP Nuclear Power Plant
PHWR Pressurized Heavy Water Reactor
ICS Inner Containment Structure
NB Nuclear Building
RB Reactor Building
ASME American Society of Mechanical Engineers
OBE Operating Basis Earthquake
SSE Safe Shutdown Earthquake
IC Inner Containment
MALB Main Air Lock Barrel
EALB Emergency Air Lock Barrel
SA Sealing Arrangement
IS Indian Standard
DL Dead Load
IP Internal Pressure
TA Temperature Accident
FEM Finite Element Method
MS Mild Steel
EP Embedded Part
DESIGN REPORT ON THE EMBEDDED REV NO.:
PART (EP) FOR MAIN AIR LOCK KAPP-3&4/DC//21000/ R0
BARREL (MALB) IN INNER 40/R0 AUGUST
CONTAINMENT WALL (ICW) OF KAPP- 2010
3&4 PAGE: 7 of 27
CHAPTER:-1 INTRODUCTION
1.1 General
This report covers the analysis and design of the Embedded Part (EP) for Main Air Lock
Barrel (MALB) in the Inner Containment (IC) wall of KAPP-3&4 as per ASME Section-
III, Division-I, Sub-part NE.
1.2 Objective
The present analysis and design work of the EP in the IC wall of KAPP-3&4 has been
carried out for the maximum load coming from the bellow corresponding to maximum
allowable axial and lateral movement of bellow as per design under design load
combination.
1.3 Scope
The scope of the present report is the analysis and design of the embedded part (EP) for
Main Air Lock Barrel (MALB) in the Inner Containment Wall (ICW) of KAPP-3&4 for
loading condition due to bellow type expansion joint.
1.4 Report Layout

For presentation purpose, the report has been divided into a four chapters as given below:
Chapter-1: Introduction
This chapter consists of the objective, scope, report layout and the reference documents
and applicable codes.
Chapter-2: General Description of the Embedded Part (EP) for MALB
This chapter consists of the description of the embedded part (EP) for main air lock barrel
(MALB) in the ICW of KAPP-3&4. The material specifications for the EP have been
covered. The design allowable for the EP in terms of permissible stresses as per ASME
Section III Division 1, Sub-part NE has also been covered in this chapter.
Chapter-3: Analysis Methodology
This chapter consists of the description of the loads, finite element model and boundary
conditions for the embedded part (EP). The analysis methodology and the analytical results
have also been covered in this chapter.
Chapter-4: Design, Summary and Conclusion
This chapter consists of the design of the EP and its anchor. This chapter also consists of
the summary and conclusion for the present work. The references used are also mentioned.
1.5 Documents and Applicable Codes

The various documents and the applicable codes used for the present work are given in
Table-1. The latest revision has been used in the analysis and design.
3&4 PAGE: 8 of 27
Table-1:Applicable Documents and Codes

Sr.
Document Title Applicability
No.
SECTION II: Rules for Allowable stress intensity

ASME Boiler and
Construction of Nuclear Power in the MALB EP
1 Pressure Vessel
Plant Components. Part D Sub-
Code
part 1: Properties
SECTION III: Rules for Design of embedded part

Construction of Nuclear Power (EP) for MALB
ASME Boiler and
Plant Components. DIVISION
2 Pressure Vessel
1:Sub-NE The rules for allowable
Code
stress values and allowable stress
intensity
Code of Practice: Hot rolled low, For Material properties of

4 IS 2062 medium and high tensile structural EP
steel
Code of practice for use of metal For weld design

5 IS:816 arc welding for general
construction in mild steel
Code Requirements for Nuclear

6 ACI 349
Safety Related Concrete Structures For steel anchor design
Plain and Reinforced Concrete:

7 IS 456 Development length of
Code of Practice
anchors
3&4 PAGE: 9 of 27
CHAPTER:-2 GENERAL DESCRIPTION OF THE EMBEDDED PART FOR

MAIN AIR LOCK BARREL
2.1 General
The Inner Containment Structure is a prestressed concrete structure consisting of Main Air
Lock Barrel (MALB) and Auxiliary Air Lock Barrel (AALB). The MALB is located on
Grid-3 towards west side of reactor building. The Main Air Lock has rectangular opening
with clear inside dimension of 4.5m wide and 5.54m high. The embedded part (EP) for
Main Air Lock Barrel is made of 10 mm thick steel plate.
2.2 Details of EP and Joint between IC and Main Airlock Barrel
2.2.1. Details of EP
The EP is circular in shape and is made up of 10 mm thick Mild Steel (MS) Plate. The EP
has clear inside dimension of 4.5 m wide and 5.5 m high. The detail of the EP is given in
Figure-1 and Figure-2. The general construction of MAL EP is similar to the EP provided
to TAPP-3&4 projects and design methodology is also similar for the EP of TAPP-3&4.
2.2.2. Joint between I.C. and Airlock Barrel

A suitable stainless steel bellow type expansion joint is provided between I.C. Wall and
barrel to allow the relative movement between these two structures under the action of
internal pressures, earthquake, temperature variation etc. The elevation of IC@MAL is
given in Figure-3. The internal diameter of bellows weld ends and common connector is
7605 mm. The overall length of expansion joint is 980 mm. The bellow wall thickness is
10 mm. The maximum axial stiffness is 750 Kg/mm and the maximum lateral stiffness is
85000 Kg/mm. The allowable axial movement is 16 mm, allowable lateral movement
along vertical direction is 4 mm and the allowable lateral movement along horizontal
direction is 11 mm.
2.3 Material
The material used for design of EP for MALB is weldable type structural steel as per IS:
2062 Grade C (Designation is Fe410WC).The mechanical property of the material as used
in the design is given in Table-2 below:
Table-1:Mechanical Properties of Material of EP for MALB

Sr.
Parameter Value Unit
No.
1 Minimum Tensile Strength 410 MPa
2 Minimum Yield Strength 250 MPa
3&4 PAGE: 10 of 27
2.4 Limit of Stresses
The design allowable for the design of EP for MALB has been specified in terms of
stresses, forces and displacement, as applicable. The rules for allowable stress intensities
and allowable stresses are given in NE-3200, where the allowable stress intensity Smc is 1.1
times the S value given in ASME Section II, Part D, Sub-Para 1, Tables 1A, except Smc
shall not exceed 90% of the material yield strength.
The value of S is taken for that grade of steel, which has yield strength and tensile strength
values closer to the values of the IS 2062 Grade C steel. The value of S is 17.1 ksi. Hence,
the value of Smc = 1.1 * 17.1 = 18.8 ksi, i.e. 13220 T/m2.
As per the basis for establishing allowable stress values, for Class I components given in
Appendix III of ASME Section III Division 1, Clause III 2110, Sm,1 for class 1 component
is lowest of the following:
a) One third of the specified minimum tensile strength: i.e. 0.333 x 410 = 136.67 MPa
b) Two thirds of the specified yield Strength: i.e. 0.667 x 250 = 166.67 MPa
Hence, Sm,1 = 136.67 MPa i.e. 13667 t/m2
As per Table NE 3221-1 or Figure- NE 3221-1 to 3, allowable limits of stress intensity for
various stress categories are summarized in Table-3.
Table-2:Summary of Stress Intensity (Permissible Stresses in EP for MALB ) in MTon/m 2

LOADING CONDITIONS
STRESS
LEVEL A & B LEVEL C
Primary Pm 1.0 Smc = 13220 1.2 Smc or 1.0 Sy* = 15864
1.5 Smc = 19830 1.8 Smc or 1.5 Sy* = 23796

PL
If, PL < = 0.67 Sy*
1.8 Smc or 1.5 Sy* = 23796
PL +Pb 1.5 Smc = 19830 If, PL > = 0.67 Sy*

[2.5-1.5(PL/Sy)] 1.2 Smc
= 15864
Or
[2.5-1.5(PL/Sy)] Sy
3&4 PAGE: 11 of 27
Secondary PL + Pb + Q 3.0 Sm,1 = 41000 N. A.

Notes:
1. For IS: 2062, Grade C, Smc = 13220 T/m2. Sy = 25000 T/m2
2. Pm is general primary membrane stress.
3. PL is local primary membrane stress.
4. Pb is primary bending stress.
5. Q is the secondary stress due to general thermal stress and bending stress at gross
structural discontinuity.
In the design of EP for MALB, loads from the bellow has been calculated based on the
axial and lateral stiffness of bellow and corresponding allowable axial and lateral
deformation. The deformation corresponds to the maximum deformation of the IC around
the MALB opening under design load combination. As such for MALB EP design check,
the stress level cannot be categorized in to level A, B, or C. However, the minimum stress
level corresponding to primary membrane stress has been used as a limiting value of stress
for MALB EP design, which is 132.2 MPa or 13220 T/m2.
The allowable stress for anchor has been calculated as per ACI: 349, Cl.B.4.2. The
allowable stress limits has been calculated and is given in section 4.3.
3&4 PAGE: 12 of 27
CHAPTER:-3 ANALYSIS METHODOLOGY
3.1 General
The EP for MALB in the IC wall of KAPP-3&4 has been analyzed using analytical
approach using FEM for structural response for a loading condition due to bellow type
expansion joint. The EP for MALB is designed according to rules of ASME-NE-3100 &
NE-3200, while the studs (anchors) are checked using ACI: 349 rules.
3.2 Loads
The EP for MALB is subjected to loads due to bellow type expansion joint. The allowable
axial spring rate is 750 Kg/mm and the allowable lateral spring rate is 85000 Kg/mm. The
allowable movements of bellow are specified in Chapter-2. Hence, for their movement the
maximum axial load is 12 MTon in the axial direction and the maximum horizontal load is
935 MTon in the horizontal direction and the maximum vertical load is 340 MTon in the
vertical direction.
3.3 Analysis Method

Commercially available NISA software is used for analysis of the EP for MALB in the IC
wall of KAPP-3&4. The software has been validated for the earlier projects.
3.3.1. FE Model
A detailed 3-D finite element model of IC has been developed to analyze the exact
behaviour of the EP for MALB in the IC wall of KAPP-3&4.The EP for MALB is
modeled using general shell element (NKTP-20) of NISA software. The large opening due
to main air lock barrel is modeled in F.E. model. The FE model developed for the EP for
MALB is shown in Figure-4. The FE model details are given in Table-4 below.
Table-2: FE Model Details

Sr. Number of Nodes Number of Shell Element
No.
1 17408 11552
3.3.2. Load Modelling

The maximum axial load applied is 12 MTon in the axial direction. The maximum
horizontal load applied is 935 MTon in the horizontal direction and the maximum vertical
load applied is 340 MTon in the vertical direction. These loads are applied at the 52 nodes
of the FE model at the nodes near the periphery of bellow welding circle. The bellow load
applied is shown in the Figure-5.
3.3.3. FE Model Boundary Condition

Fixed boundary condition is considered for IC structure at the NB raft-IC wall junction.
3&4 PAGE: 13 of 27
3.4 Analysis of EP for MALB
3.4.1. Calculation of Strains on Outer Face of IC Structure

The principal strains and the maximum shear strain of concrete on outer face of IC
structure are calculated as:
ε 1,2=(ε x + ε y )/2± √[ (ε x
2
/ 2−ε y /2 ) +(γ xy /2 ) ]
2
εx
= Strain on outer face of concrete element in the local X-direction
εy
= Strain on outer face of concrete element in the local Y-direction
γ xy
= In plane shear strain on the outer face of concrete element
γ max =( ε −ε
1 2)
ε 1 ε 2
Where, and are major & minor principal strain on the outer face of concrete element,
γ max
is maximum in plane shear strain.
3.4.2. Calculation of Stress and Strain in EP for MALB

The EP for MALB is integrated with outer face of IC structure, the strains on the EP for
MALB is same as that of outer face of IC structure where it is connected to concrete
through the anchors. The strain in the EP plate is worked out by combining the strains
σ xx σ yy
obtained from the IC analysis. The stress contour ( and ) induced in the concrete
portion on the outer face of IC structure around the MALB opening is shown in the Figure-
6 and Figure-7. The stress induced in the EP plate can be calculated using Hook’s law if
the strain in the EP plate is in the linear range of stress-strain curve of EP plate. The
principal stresses in the EP for MALB is calculated as follows:
2
σ = E s /(1−ν )∗[ ε + ν ε ]
1 1 2
2
σ = E s /(1−ν )∗[ ε +ν ε ]
2 2 1
τ = γ ×G
1,2 max s
3&4 PAGE: 14 of 27
Es = Elastic modulus of elasticity of steel plate
Gs = Shear modulus of elasticity of steel plate
σ σ
1 2 τ 1,2
, are major and minor principal stresses in the EP plate and is the principal shear
stress in the EP plate.
3.5 Analysis Results
3.5.1. Stresses in the EP for MALB

The structural response of the EP has been studied in terms of stresses in the EP portion.
The stresses have been studied in terms of principal stresses σ 1 and σ2, principal shear
stresses and the stress intensity. As per ASME Section III, Division 1, Sub-part NE, the
stress intensity is the difference between the algebraically largest principal stress and the
algebraically smallest principal stress at a given point (Clause NE3213-1 & NE 3215). The
maximum stress intensity in the EP plate is 19.6 MPa which is much less then the
allowable stress intensity of 132.2 MPa as specified in Table-3 and the minimum stress
intensity is 0.284 MPa.
3&4 PAGE: 15 of 27
CHAPTER:-4 DESIGN, SUMMARY AND CONCLUSION
4.1 General
The embedded part (EP) for main air lock barrel is designed according to rules of ASME
Section III: Division-1: Sub NE-3100 & NE-3200, while the studs (anchors) are checked
using ACI: 349 rules.
4.2 Design of Embedded Part (EP)

The maximum calculated stress intensities for the loading conditions due to bellow loads
are less than allowable stress intensities given in Table-3 hence the design is safe.
4.3 Design of Anchor

The maximum axial spring rate of bellow type expansion joint is 750 Kg/mm and the
maximum axial movement is 16 mm so, the maximum axial force subjected to anchor is 12
MTon. The maximum resultant lateral spring rate is 85000 Kg/mm and the maximum
resultant lateral movement is 11.70 mm so, the maximum lateral shear force on anchor is
995 MTon.
4.3.1. Design for pull-out

It is conservatively assumed that this 12 MTon axial force along the longitudinal direction
of bellow is resisted by the 372 anchor of the EP plate that is welded to the bellow.
The total no of anchor having center to center spacing equal to 600 mm = 222
The total no of anchor having center to center spacing equal to 400 mm = 150
Assuming each stud resists pullout using its own effective concrete area, the area of
concrete available to resist pullout when spacing between anchors is 600 mm:
0.555*0.2 = 0.111 sq.m.
The area of concrete available to resist pullout when spacing between anchors is 400 mm:
0.2*0.2 = 0.04 sq.m.
The detail of the effective stress area for anchorage pullout is given in Figure-8.
Design pullout strength of concrete according to ACI: 349, CI.B.4.2:
4∗φ∗√ f c '
4*0.85*0.083(45*0.8)0.5= 1.69 MPa =172.67 T/m2
Maximum Permissible pullout force when spacing between anchors is 600 mm:
3&4 PAGE: 16 of 27
= 172.67 * 0.111
= 19.16 MTon
Maximum Permissible pullout force when spacing between anchors is 400 mm:
= 172.67 * 0.04
= 6.9 MTon
The total maximum permissible pullout force when spacing between anchors is 600 mm:
= 222 * 19.16
= 4253.52 MTon
The total maximum permissible pullout force when spacing between anchors is 400 mm:
= 150 * 6.9
= 1035 MTon
The total maximum permissible pullout force for combined case:
= 4253.52 + 1035
= 5288.52 > 12 MTon <safe>
4.3.2. Design check for anchor bond

τ bd
The design bond stress for M45 strength concrete = 1.9 MPa [Cl. 26.2.1.1, IS: 456]
The calculated tension force = 1.9 * π * 16 * 300 = 2.86MTon
The total no of anchor on the bellow plate = 372
The calculated total tension force = 372 * 2.86
= 1065 MTon > 12 <safe>
4.3.3. Design for anchor strength
Maximum tension in the stud: 0.24 T (from FEM analysis)
Stress in the stud = 0.24 / (π * 0.016 * 0.016/4)

= 1194.26 T/sq.m < 22500 T/sq.m [Clause B.6.2.1, ACI 349]
4.3.4. Design check for shear

τv
The design shear stress = 100 MPa [Sections B.5.1.2, ACI 349]
The total no of anchor subjected to shear on the bellow plate = 372

3&4 PAGE: 17 of 27
The total no of anchor subjected to shear on the EP plate welded to bellow = 220
So, the total no of anchor subjected to shear = 592
The total no of anchor subjected to pullout on the EP plate welded to bellow = 132
τv
Shear strength of anchor = 592 * * (π * 16 * 16/4)
= 1189.68 MTon
τ bd
Pullout strength of anchor = 132 * * π * 16 * 300
= 378 MTon
Total shear strength = 1189.68 + 378
= 1567.68 > 995 MTon <safe>
4.3.5. Design of Bearing Plate (0.05×0.05 Square) at the end of anchor
Area of concrete available for bearing = 0.3*0.3/4 = 0.0225 sq.m
Bearing stress on concrete = 7.53/0.0225 = 326.67 T/sq.m
Permissible bearing stress in concrete of grade M45, as per AISC manual

= 1.6* 0.28fck =1.6 * 0.28 * 4500
= 2016 T/sq.m > 326.67 T/sq.m <safe>
4.4 Weld Design
4.4.1. Between EP plate and stud

The permissible stress in fillet weld based on its throat area = 110 MPa [Cl. 7.1.2, IS: 816]
Assuming size of weld, s = 8 mm
Effective throat thickness, t = 0.7 * s = 5.65 mm
The diameter of anchor, D = 16 mm
Length of weld = π * D = 50.26 mm
Weld shear strength = (π * D * t * 110)
= 3.12 MTon
3&4 PAGE: 18 of 27
The total no of anchor subjected to shear = 592
Combined shear strength of all weld = 592 * 3.12
= 1847 > 995 MTon <safe>
4.5 Summary
The present analysis and design work of the EP for MALB of the IC of the Nuclear
Building (NB) of Kakrapara Atomic Power Project-3&4 has been carried out to check the
adequacy of the MALB EP plate for load conditions due to bellow type expansion joint.
The EP for MALB has been analyzed using both analytical and numerical approach for
global response of the system. The structural response of the EP for MALB has been
studied in terms of stresses in the embedded part (EP).
4.6 Conclusion
Based on the above study it has been found that the design of EP for MALB is safe and
meets the design requirements.
3&4 PAGE: 19 of 27
REFERENCES
1 Document No.: KAPP-3&4/PSAR/01000/01/R2 July-2008 ‘Preliminary Safety Analysis Report
Section-3: Plant Layout, Buildings and Structures Part-2, Nuclear Power Corporation of India
Limited (A Government of India Enterprise), Mumbai, India.
2 Report No.: KAPP-3&4/DC/21000/15/R0 April, 2009. ‘Design report of Inner Containment
Structure (ICS) of KAPP-3&4’, Nuclear Power Corporation (A Government of India Enterprise),
Mumbai, India.
3 “ROARK’S Formula for Stress & Strain” by Warren C Young, 6 th edition, McGraw-Hill
International Editions.
4 Subramanian N. Design of Steel Structures. Oxford University Press, 2008.
5 Report No.4005/E/DN-32 (R0) Jan 1999. Design Report on Sealing Arrangement for SG
Opening in IC Dome of TAPP-3&4. STUP Consultant Limited, Navi Mumbai.
6 Drawing No.: KAPP-3&4/21032/2000/DD, Details of EP for Main Air Lock Barrel in the IC
Wall of KAPP-3&4.
3&4 PAGE: 20 of 27
Figure-1: General Arrangement of EP for MALB

3&4 PAGE: 21 of 27
E EL 106950
Figure-2: General Arrangement of EP Anchor for MALB

3&4 PAGE: 22 of 27
Bellow
Horizontal & Vertical

Stiffness
= 85000 Kg/mm
Axial
Stiffness
= 750Kg/mm
ICW
Allowable axial movements = 16 mm

Allowable vertical movements = 4 mm
Allowable horizontal movements = 11 mm
Figure-3: Plan and Elevation of Joint Between ICW and Bellow

3&4 PAGE: 23 of 27
Figure-4: Inner Containment Structure (ICS) and Main Air Lock Barrel (MALB)
3&4 PAGE: 24 of 27
Figure-5: Forces around MALB Opening due to Bellow Load

3&4 PAGE: 25 of 27
Figure-6: Sxx Stress Contour Around MALB Opening due to Bellow Load
3&4 PAGE: 26 of 27
Figure-7: Syy Stress Contour Around MALB Opening due to Bellow Load
3&4 PAGE: 27 of 27
Figure-8: Effective Stress Area for Anchorage Pullout

MALB RPT

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NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A GOVERNMENT OF INDIA ENTERPRISE)

Design Report on the

Report Number: KAPP-3&4/DC/21000/40/R0

PROJECT: Kakrapara Atomic Power Project-3&4

Report Number: KAPP-3&4/DC/21000/40/R0

NAME SIGNATURE DATE

PREPARED BY: Shrikant Devmani Mishra

CHECKED BY: Madhumangal Das

REVIEWED BY: G Prabhakar

APPROVED BY: Raghupati Roy

FIRST ISSUE: August, 2010

Report Number: KAPP-3&4/DC/21000/40/R0

Design Report on the

REV NO PREPARED CHECKED REVIEWED APPROVED

Table-1: Applicable Documents and Codes........................................................................................8

Figure-1: General Arrangement of EP for MALB.............................................................................20

The following abbreviations have been used in this report:

KAPP Kakrapara Atomic Power Project

NPP Nuclear Power Plant

PHWR Pressurized Heavy Water Reactor

ICS Inner Containment Structure

ASME American Society of Mechanical Engineers

OBE Operating Basis Earthquake

SSE Safe Shutdown Earthquake

MALB Main Air Lock Barrel

EALB Emergency Air Lock Barrel

1.4 Report Layout

1.5 Documents and Applicable Codes

Table-1:Applicable Documents and Codes

SECTION II: Rules for Allowable stress intensity

SECTION III: Rules for Design of embedded part

Code of Practice: Hot rolled low, For Material properties of

Code of practice for use of metal For weld design

Code Requirements for Nuclear

Plain and Reinforced Concrete:

CHAPTER:-2 GENERAL DESCRIPTION OF THE EMBEDDED PART FOR

2.2 Details of EP and Joint between IC and Main Airlock Barrel

2.2.2. Joint between I.C. and Airlock Barrel

Table-1:Mechanical Properties of Material of EP for MALB

2.4 Limit of Stresses

Hence, Sm,1 = 136.67 MPa i.e. 13667 t/m2

Table-2:Summary of Stress Intensity (Permissible Stresses in EP for MALB ) in MTon/m 2

Primary Pm 1.0 Smc = 13220 1.2 Smc or 1.0 Sy* = 15864

1.5 Smc = 19830 1.8 Smc or 1.5 Sy* = 23796

If, PL < = 0.67 Sy*

1.8 Smc or 1.5 Sy* = 23796

PL +Pb 1.5 Smc = 19830 If, PL > = 0.67 Sy*

Secondary PL + Pb + Q 3.0 Sm,1 = 41000 N. A.

CHAPTER:-3 ANALYSIS METHODOLOGY

3.3 Analysis Method

Table-2: FE Model Details

3.3.2. Load Modelling

3.3.3. FE Model Boundary Condition

3.4 Analysis of EP for MALB

3.4.1. Calculation of Strains on Outer Face of IC Structure

is maximum in plane shear strain.

3.4.2. Calculation of Stress and Strain in EP for MALB

Es = Elastic modulus of elasticity of steel plate

Gs = Shear modulus of elasticity of steel plate

3.5 Analysis Results

3.5.1. Stresses in the EP for MALB

40.850.083(45*0.8)0.5= 1.69 MPa =172.67 T/m2