L-2013-240, Fourth Ten-Year Interval, Relief Request No. 7, Rev. 0

Fourth Ten-Year Interval, Relief Request No. 7, Rev. 0

ML13220A029
Person / Time
Site:	Saint Lucie
Issue date:	08/05/2013
From:	Katzman E Florida Power & Light Co
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
L-2013-240
Download: ML13220A029 (43)

Text

0 August 5, 2013 FPL.

L-2013-240 10 CFR 50.4 10 CFR 50.55a U. S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555 Re: St. Lucie Unit 1 Docket No. 50-335 Inservice Inspection Plan Fourth Ten-Year Interval Unit 1 Relief Request No. 7, Revision 0 Pursuant to 10 CFR50.55a(a)(3)(ii), Florida Power & Light, is requesting relief from the requirements of ASME Code,Section XI, Subsection IWA-4000 for defect removal prior to repair, since compliance would result in hardship or unusual difficulty without a compensating increase in the level of quality and safety. The details and justification for this request are provided in Attachments I and 2 to this letter.

FPL requests approval of this relief request to support the upcoming SL1-25 Fall 2013 refueling outage.

This relief request is applicable to the St. Lucie Unit I Fourth Inservice Inspection Interval which began February 11, 2008 and ends February 10, 2018.

Please contact Lyle Berry at (772) 467-7680 if there are any questions about this submittal.

Sincerely, Eric S. Katzman Licensing Manager St. Lucie Plant Attachments ESK/LRB Florida Power & Light Company 6501 S. Ocean Drive, Jensen Beach, FL 34957

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 1 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 PSL Relief Request In Accordance with 10CFR50.55a(a)(3)(ii)

-Hardship or Unusual Difficulty without Compensating Increase in Level of Quality or Safety-

1. ASME Code Component(s) Affected Class 3 Intake Cooling Water (ICW) System 30" diameter piping in Unit 1 as follows:

System 21, 1-30"-CW-29 and 1-30"-CW-30 (Discharge piping downstream of Component Cooling Water (CCW) Heat Exchangers only)

2. Applicable Code Edition and Addenda

The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Rules for Inservice Inspection of Nuclear Power Plant Components, Section Xl, 2001 Edition with Addenda through 2003111 as amended by 10CFR50.55a, is the Code of Record for the St. Lucie Unit 1 4 th 10-year interval.

USAS B31.7 Class 3, 1969 Edition [2" is the Construction Code for St. Lucie Unit 1. The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Rules for Construction of Nuclear Power Plant Components, Section I1l, Class 3, 1971 Edition with Addenda through Summer 1973' ], is the Code of Record for St. Lucie Unit 1 based on reconciliation with the Construction Code.

3. Applicable Code Requirement

ASME Code,Section XI, Paragraph IWA-4421 of the 2001 Edition with Addenda through 2003[11 states that "Defects shall be removed or mitigated in accordance with the following requirements:

..." Subparagraph IWA-4422.1 states that "A defect is considered removed when it has been reduced to an acceptable size."

4. Reason for Request

The nuclear safety related ICW System for St. Lucie Unit 1 is comprised of two redundant trains (i.e., 'A' and 'B'). 1-30"-CW-29 and 1-30"-CW-30 are open ended discharge pipes to the ocean discharge canals. Due to the seawater content, the ICW piping constructed from Standard Wall 30" (0.375 inch wall), A-155 KC-65 (equivalent to SA 106 Grade B) Carbon Steel, has an internal liner to preclude the loss of internal pipe wall due to corrosion. The piping being addressed in this relief request is cement or epoxy lined 30 inch nominal diameter buried piping with a nominal liner thickness of 1/8-inch. The outer surface of the piping is coated with Coal-Tar Epoxy. The ICW piping is classified as a Class 3 component, qualified in accordance with ASME Code,Section III, Subsection ND criteria. Burial depths range from 4 feet-3 inch to 16 feet below grade.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 2 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 St. Lucie station performs single train internal pipe inspections each outage, resulting in 100%

inspection every other outage. The inspections are performed in accordance with St. Lucie's commitment to the NRC Generic Letter GL 89-13[41. The objective of this commitment is to perform routine inspection to ensure that corrosion, erosion, protective coating failure, silting, and biofouling does not degrade the performance of the ICW safety-related system. ICW pipe inspections at St. Lucie are performed by a qualified pipe inspector. The inspection methodology consists of draining the pipe and removing a section to allow internal access, cleaning the pipe surface, and performing a visual examination of the cement or epoxy liner. The inspector observes for signs of corrosion deposits, staining, cracks, missing lining, area blisters, peeling/delamination, surface irregularities, or discoloration. UT inspection of degraded pipe metal is performed where there is degradation.

The above described pipe inspections have from time to time identified localized areas of liner loss resulting from corrosion cells in the underlying piping. Should measurements detect a pipe wall loss resulting in a remaining pipe wall thickness less than the prescribed ASME Code required minimum pipe wall thickness or a through-wall leak is identified, a repair in compliance with ASME Code Section Xl, Article IWA-4000 "Repair and Replacement" would be required. Full defect removal of discovered localized thinning per IWA-4000 may result in a through-wall defect. This case and in those instances where a through-wall defect is discovered, would result in the potential for leakage due to damage to the external coating. If the external coating was not damaged during the defect removal, a traditional repair of cutting a hole and installing a welded rolled plate to return the piping to its original design condition is not possible as the pipe is buried and the outside of the pipe is not easily accessible. Welding would destroy the surrounding exterior coating and the location would prevent NDE of the exterior of the pipe. Consequently, Florida Power & Light, pursuant to 10 CFR 50.55a(a)(3)(ii), is requesting relief from the requirements of ASME Code,Section XI, Subsection IWA-4000 for defect removal prior to repair since compliance would result in hardship or unusual difficulty without a compensating increase in the level of quality and safety.

Florida Power and Light has installed several repairs without removing the defects, and is requesting relief to leave the existing repairs in place and to allow installation of additional repairs in the future to repair similarly damaged areas. The earliest existing repairs that are still in service were installed in 2005. The ASME Code, Section Xl requirements before the current 10-year inspection interval regarding removal of defects are equivalent to those listed in Section 2 and Section 3 above.

The existing repairs include six installed plates in 1-30"-CW-29 (Train B) consisting of sizes of 3.5"x3.5", 7.5"x11.5", and 10"xll". The plates in 1-30"-CW-29 were all installed in 2012. An additional nineteen plates consisting of sizes of 3.5"x3.5", 11"xll", 8"x8", and 10"xll" are installed in 1-30"-CW-30 (Train A). One of the plates was installed in 2005, one in 2008 and the remainder in 2012. The total length of pipe in both trains that contains the bolted patch plates is approximately 200 feet. Isometric views showing the relative location of the bolted patch. plate repairs in the ICW piping are provided in Figure 3 through Figure 7.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 3 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0

5. Proposed Alternative and Basis for Use Proposed Alternative Install internal bolted patch plate repairs typical of that illustrated in Figure l and Figure 2 to cover the damaged areas of the inside surface of the pipe. The internal bolted patch plates are designed to meet the criteria of the applicable Code of Record 131, as required by ASME Code, Section XI1",

Paragraph IWA-4221.

Basis A description of the process used to qualify the design, a description of the installation process, and the inspection program to monitor the condition of the repairs is included in this section.

Design Qualification Process:

The design qualification process determines the minimum pipe wall thickness using design formulas of ASME Code,Section III and the criteria presented within FSAR Table 3.9-3 for reviewing interactions of pressure stress and longitudinal bending stresses. The calculations evaluate the required reinforcement versus the actual reinforcement available around the corrosion holes and reviews bolting requirements for the patch plate which is analyzed as a blind flange. Reinforcement interaction is reviewed for the multiple holes to ensure additional reinforcement is not required.

The design qualification process includes the following steps:

1. Develop a minimum pipe wall thickness based on hoop stress and longitudinal bending stress per ASME Code,Section III, ND-3641.1 as required by Subsection ND.

2. Determine required and actual reinforcement areas and zones per ASME Code,Section III, Subsection ND.

3. Determine patch plate thickness requirements per ASME Code,Section III, Subsection ND.

The installed plate nominal thickness is at least equal to the nominal thickness of the undamaged pipe.

4. Determine the gasket loading and bolt requirements per ASME Code,Section III, Appendix E.

5. Review thread engagement using machinery principles.

6. Address interaction or reinforcement zones per ASME Code,Section III, Subsection ND.

7. Perform stress intensification factor review.

Installation Process Summary:

1. Avoiding damage to any external coatings on the pipe outside surface (OD), prepare the surface of corrosion holes by blast cleaning and fill with epoxy material to the profile of the pipe ID.

2. Remove a section of the pipe lining centered on the affected area.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 4 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0

3. Clean and smooth interior of pipe to support closure plate fit-up.

4. Layout bolt hole locations on pipe and ultrasonically inspect for thickness. The degraded areas are ultrasonically inspected to determine surrounding wall thickness. All readings outside of the areas of degradation are within the manufacturer's tolerance of nominal wall thickness.

5. Drill and tap Y4" deep bolt holes. Do not allow holes to exceed Y" depth to maintain minimum wall thickness.

6. Install the studs wrench tight without lubrication.

7. Apply epoxy to pipe beneath closure plate area including corrosion holes previously filled and the gasket area.

8. Before epoxy hardens, install gasket, closure plate, washers and nuts (lightly lubricated).

9. Trim studs flush with the tops of the nuts, degrease and surface prep the exposed area, and cover the entire repair area with epoxy coating, Ensure that the coating is blende-dto.

provide smooth transitions to minimize ICW flow turbulence.

Post-installation Inspections:

The piping inspections described in Section 4 are continued after the internal bolted plate repairs are performed. In addition to the visual inspection, a hammer test is generally performed for all patches installed in the pipe. Partial disbondment of a patch will produce a hollow sound when tapped with a chipping hammer. A solid, non-hollow sound indicates that the patch remains in good condition. If a patch is suspect based on visual examination or hammer test results, the patch is removed from the pipe surface for further examination.

Since the bolted patch plate is installed on the inside surface of the piping and it completely covers the damaged area with a gasketed closure, the damaged area is isolated from the corrosive environment. Also, the damaged area is covered with an epoxy coating prior to the repair, including filling the damaged areas for a smooth repair surface, and after the repair, further isolating the damaged area from the corrosion surface. There is therefore minimal potential for the damaged area to expand over time during service such that the repair would no longer be effective. Based on a typical corrosion rate of carbon steel exposed to seawater of 30 mils per year (mpy)Is], the maximum extent of corrosion should the epoxy coating and gasket be breached to allow access to the original defect area would be 0.09-inch, assuming a 3-year inspection interval. The extent of the bolted plate beyond the defect area is always much greater than 0.09 inch so any additional corrosion of the defected area would be identified and corrected during the next inspection. Note that the minimum nominal thickness of the bolted plate is at least as thick as the undamaged piping so the potential corrosion of the plate is no greater than that of the undamaged piping.

Periodic inspections completed to date have not identified any degradation of the existing internal bolted plate repairs.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 5 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 In early 2012 during the SL1-24 outage, the Unit 1 discharge headers were internally refurbished with Plascite coatings from the CCW Building to 45-degree elevation drop near the discharge canal.

This is the area that includes the existing bolted patch plates. The remainder of the two headers and overflow pipes were replaced with new carbon steel piping internally and externally coated with Plascite. This section is normally below the level of the discharge canal and requires divers for inspection.

As discussed above, the bolted patch plate repair is installed on the inside surface of the piping which isolates the damaged area from the corrosive environment. Also, the damaged area is covered with an epoxy coating prior to the repair, including filling the damaged areas for a smooth repair surface, and subsequent to the repair, further isolating the damaged area from the corrosion surface. There is therefore minimal potential for the damaged area to expand over time during service such that the repair would no longer be effective. Limitation on the life of the repair based on the potential degradation to grow to an unacceptable size for the repair or additional subsequent inspections is not required.

The design qualification process, installation process, and the post-installation inspections for the bolted patch plate repairs provide reasonable assurance of the structural integrity of the repair: The location of the defects and the potential additional damage that could occur if the defects were removed prior to the repair as required by the ASME Code, Section Xl support the request for an alternative to the ASME Code,Section XI requirement because complying with the requirement would represent a hardship or unusual difficulty without a compensating increase in the level of quality or safety.

6. Duration of Request This relief request is applicable to the St. Lucie Unit 1 Fourth Inservice Inspection Interval which began February 11, 2008 and ends February 10, 2018.

7. Precedents There are several precedents for installation of a repair without removal of the initiating defect.

These precedents limit the life of the repair because the repair leaves the damaged area exposed to the degradation environment and/or requires subsequent inspection of the damaged area to ensure that it does not grow to an unacceptable size for the repair. Examples of these precedents are listed below:

"Seabrook Station, Unit 1 - Request for Relief to Use an Alternative to the Requirements of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section Xl (TAC No.

ME9187)," SER Dated January 14, 2013, Accession Number ML12185A069.

"Indian Point Nuclear Generating Unit No. 3 - Relief Request (RR) No. RR-3-43 for Temporary Non-Code Repair of Service Water Pipe (TAC No. MD6831)," SER Dated February 22, 2008, Accession No. ML080280073.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 6 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0

8. References

1. ASME Code,Section XI, "Rules For Inservice Inspection of Nuclear Power Plant Components,"2001 Edition with Addenda through 2003.

2. USA Standard Code for Pressure Piping, USAS B31.7-1969, "Nuclear Power Piping."

3. ASME Code,Section III, "Rules for Construction of Nuclear Power Plant Components," 1971 Edition with Addenda through Summer 1973.

4. St. Lucie Letter No. L-2013-005 10 CFR 50.4, dated January 10, 2013 to the USNRC Re: St.

Lucie Units 1 and 2, Docket Nos. 50-335 and 50-389, "Clarification of NRC Commitment Regarding Generic Letter 89-13," Accession No. ML13025A208.

5. "Seabrook Station, Unit 1 - Request for Relief to Use an Alternative to the Requirements of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code,Section XI (TAC No. ME9187)," SER Dated January 14, 2013, Accession Number ML12185A069.......

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 7 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 V

KEY PLAN 1-30"-CW-29 Carbon Steel Pipe STD WT (.375 wall)

A-155 KC65 Concrete Lined 4

Section J-J Plate Location # 8 Figure 1: Typical Bolted Patch Plate Drawing Key Plan and Section J-J View

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 8 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 DRILL FOR TAPPING 1/4' BLIND HOLE a Nominal Section G-G Torque 2 ft. lbs 3.5' (typ) 4 Section F-F Plate Location #2, 6, 7 & 8 Figure 2: Typical Bolted Patch Plate Drawing Sections F-F and G-G Views

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 9 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 9 ~1o 11 12 ' 13 14 r-30-CW-29 BOLTE[ CLOSURE PLATE LOCATrONS BOLTED PLATE REPAIR LOCATION #8 @2:00 EC275443 2D) 2 BOLTED C.OSURE PLATE LOCATIONS

@3:30 EC274859 2012

@5:30 EC235503 (MSP 05192) 2005 *

@11:00-12:00 EC235964 (MSP 08168)2005 Figure 3: Bolted Patch Plate Repair Locations 1-30"-CW-30 (Train A) (Three Locations)

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 10 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 Figure 4: Bolted Patch Plate Repair Locations 1-30"-CW-30 (Train A)

(Sixteen Locations)

See Figure 5 for Location Listing

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 11 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 I-30-CW-29 BOLTED CLOSURE PLATE LOCATIONS 0 12 BOLTED PLATE REPAIR LOCATION # 1 @7:00-10:00 EC275443 2 0 12 BOLTED PLATE REPAIR LOCATION #2 @5:00 EC275443 2 BOLTED PLATE REPAIR LOCATION #5 @3:00-6:00 EC275443 2012 BOLTED PLATE REPAIR LOCATION #6 @5:00 EC2754432012 BOLTED PLATE LOCATIONS 3 &4 D0 NOT EXIST BOLTED PLATE REPAIR LOCATION #7 @3:00 EC275443 2012 I-30-CW-30 BOLTED CLOSURE PLATE LOCATIONS 20 1 2 BOLTED PLATE REPAIR LOCATION #1 @6:30 EC275645 BOLTED PLATE REPAIR LOCATION #2 @7:00 EC275645 2012 BOLTED PLATE REPAIR LOCATION #3 @5:00 EC275645 2012 BOLTED PLATE REPAIR LOCATION #4 @6:00 EC27564512012 BOLTED PLATE REPAIR LOCATION #5 @5:30 EC275645 201.2 BOLTED PLATE REPAIR. LOCATION #6 @12:00 EC275645 2012 BOLTED PLATE REPAIR LOCATION #7 @9:30 EC275645 2012 BOLTED PLATE REPAIR LOCATION #8 @2:30 EC275645 2012 BOLTED PLATE REPAIR LOCATION #9 @10:00 EC2756452012 BOLTED PLATE REPAIR LOCATION #10 @5:30 EC275645 2012 BOLTED PLATE REPAIR LOCATION #11 @2:00 EC275645 2012 BOLTED PLATE REPAIR LOCATION #12 @2:00 EC275645 2012 BOLTED PLATE REIPAIR LOCATION #13 @7:00 EC275645 2012 BOLTED PLATE REPAIR LOCATION #14 @4:00 EC275645 2012 BOLTED PLATE REPAIR LOCATION #15 @8:15 EC275645 2012 BOLTED PLATE REPAIR LOCATION #16 @8:00 EC27564512012 Figure 5: Iolted Patch Plate Repair Location Listing for Figure 4

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 12 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 BOLTE LT RPI OCATION #2 I@57OD:00 EC275443 )

BOLTED PLATE REPAIR LOCATION #2 @5:0-:00 EC275443 BOLTED PLATE RE*PAIR LOCATION #5 @350-:00 EC275443 BOLTED PLATE LOCATIONS 3 6 4 DO NOT EX15T Figure 6: 1-30"-CW-29 (Train B)

(Five Locations)

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a Attachment 1, Rev. 0 13 of 13 St. Lucie Unit 1 FOURTH INSPECTION INTERVAL RELIEF REQUEST NUMBER 7, Revision 0 Figure 7: 1-30"-CW-29 (Train B)

(One Location)

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 1 of 29 CALCULATION COVER SHEET Calculation No: PSL-1FSM-12-007 Revision No: 2

Title:

Min Wall Thickness and Bolted Plate Repairs-Line 1-30"-CW-29 and CW ICW Discharue to Canal This calculation determines the pipe minimum wall thickness for Internal Corrosion per ASME Section III and the criteria presented within UFSAR Table 3.9-3 for reviewing interactions of pressure stress and longitudinal bending stresses.

Revision 1 addresses application of bolted plate repairs on line I-30"-CW-29, which could also be applicable to I-30"-CW-30.

Revision 2 adds information about the weight of the plates, the shear of the bolting, the seismic properties of the plates and pipe and the Stress Intensity Factor of the bolting LIST OF EFFECTIVE PAGES Page Section Rev Page Section Rev 1 Cover, LOEP, TOC 2 11 Section 5.0 2 2 Section 1.0, 2.0 2 12 Section 5.0 2 3 Section 3.0, 4.0 2 13 Section 5.0 2 4 Section 5.0 2 14 Section 5.0 2 5 Section 5.0 2 15 Section 5.0 2 6 Section 5.0 2 16 Section 5.0 2 7 Section 5.0 2 17 Section 5.0 2 8 Section 5.0 2 18 Section 5.0 2 9 Section 5.0 2 19 Section 6.0 2 10 Section 5.0 2 TABLE OF CONTENTS Section Title Pane

-- Cover Sheet 1

-- List of Effective Pages and Table of Contents 1 1.0 Purpose/Scope 2 2.0 Methodology 2 3.0 References 3 4.0 Assumptions/Data Input 3 5.0 Calculation 4 6.0 Results 19 No. Attachment Title Pages Rev 1 Pipe Stress Input 1 0 2 Stress Intensification Review 1 1 3 PCA Engineering, Inc. UT readings, taken 2-4-12 7 1 4 Patch Plate Addition 1 2 2 Added info about By D. Russer

______ _ 8/1_

seismic and bolt hole Check W. B. Neff  ?, /I -A reinforcement Apr S. Ramani , - -I i.

Added Repair Plate By Carol M. Wallace Signature on File 2/7/2012 Design Check Steve Marshall Siqnature on File 2/7/2012 Apr C. Wallace for S. Ramani Signature on File 2/7/2012 0 Issued For Use By Carol M. Wallace Signature on File 2/2/2012 Check W.B. Neff Signature on File 2/2/2012 Apr Steve Marshall Signature on File 2/2/2012 No. Description Printed Name Signature Date REVISIONS Form 82A (4/11), 82B (6/94), 82C (6/94) Equivalent

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 2 of 29 St. Lucie Unit 1 Min Wall Thickness and Bolted Plate Repairs-Line 1-30"-CW-29 and CW ICW Discharge to Canal 1.0 Purpose I Scope This calculation determines the pipe minimum wall thickness for Internal Corrosion per design formulas of ASME Section III and the criteria presented within UFSAR Table 3.9-3 for reviewing interactions of pressure stress and longitudinal bending stresses.

Revision 1 addresses application of bolted plate repairs on line I-30"-CW-29, which could also be applicable to line I-30"-CW-30. The subject lines have no isolation valves to the discharge canal and operate at near atmospheric pressure. The calculation reviews a repair methodology that blanks off the corrosion holes or deep pitting with bolted plates on the ID of the pipe. Calculation Parts 2-6 are added in Revision 1.

Revision 2 addresses the weight of the plates on the pipe, the shear of the bolting, the seismic properties of the plates and pipe and the Stress Intensity Factor of the bolting.

Calculation evaluates the required reinforcement versus the actual reinforcement available around the corrosion holes and reviews bolting requirements for the bolted plate which is analyzed as a blind flange.

Reinforcement interaction is reviewed for the multiple holes to ensure additional reinforcement is not required.

Calculation developed in support of AR 1730604.

2.0 Methodoloqv Part 1 The methodology used in the analysis is to:

1. Develop a minimum pipe wall thickness based on hoop stress.

2. Develop a minimum pipe wall thickness based on longitudinal stress calculated using the maximum allowed stress for each code equation.

3. The larger calculated minimum wall is used as the minimum wall criteria.

This analysis extrapolates the original pipe stress analysis to determine new longitudinal stress interaction ratios. A new pressure stress is calculated for the assumed wall thickness and the bending stresses within the interaction equations are extrapolated by the ratio of the nominal wall section modulus to the reduced wall section modulus.

Analysis assumes uniform wall reduction from the ID within the area of interest of the pipe run.

Additional local wall thinning may be acceptable with further analysis and information on actual wall thickness of surrounding areas.

2 Determine required and actual reinforcement areas and zones per ASME Section III, Subsection NC.

3 Determine repair plate thickness requirements per ASME Section III, Subsection NC.

4 Determine gasket loading and bolt requirements per ASME Section III Appendix E.

5 Review thread engagement using machinery principles.

6 Address interaction of reinforcement zones per ASME Section III, Subsection NC.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Aft. 2, Rev. 0, Page 3 of 29 3.0 References

1. St. Lucie Unit 1 FSAR Amendment 24

2. St. Lucie NAMS DataBase

3. Navco Piping Catalog, Edition 11, 1984

4.Section III, 1971 Edition, Summer 1973 Addenda, NC-3641.1

5.Section III, 1971 Edition, Summer 1973 Addenda, Appendix I

6.Section III, 1971 Edition, Summer 1973 Addenda, NC-3611.1

7.Section III, 1971 Edition, Summer 1973 Addenda, NB-3652

8. EBASCO Backfit Stress Analysis Design Criteria, Rev 2, 12/7/87--- -.. - --- *-- - -

9. Roark's Formulas for Stress & Strain, 6 Edition, pages 67, 518

10. Not Used

11. Stress Calc 1000, Rev 5 & 1001, Rev 5 (Orig Code of Record ANSI B31.7 Class 3)

12. Stress Iso R-SK-172-11, Rev 5 and R-SK-172-12, Rev 5

13. Piping Isometric 8770-G-125 Sh CW-F-10, Rev 3 14 EPRI Good Bolting Practices Volume 1, NP-5067 15 Machinery's Handbook, 26 Edition, Industrial Press, Inc., Pages 1490, 1491 16 Fastener Standards, 6th Edition, Industrial Fasteners Institute 17 EC 275443 18 ASME Section III, 1971 Edition, Summer 1973 Addenda 19 Specification FLO-8770.099, rev. 4, General Power Piping 4.0 Assumptions/Data Input 1 Plate material will be a low carbon steel, such as SA/A-106 Grade B (Allowable 15,000 psi, lowest allowable of materials allowed by Ref. 19 for Pipe Code CS-1). Equivalent materials are acceptable.

For specific materials used, see EC.

2 Fastener material will be SA-193 Grade B7 and SA-194-2H. Equivalent materials are acceptable.

For specific materials used, see EC.

3 Plate is on ID of Pipe. An arbitrary external pressure of 15 psig will be used to calculate gasket loading assuming zero pressure within the piping.

4 The addition of the stud holes and the required reinforcement area does not have a negative effect on the required reinforcement area of the branch connections as defined in the ASME Code Section NC-3643.3(c). Furthermore, the stud holes were not drilled beyond the minimum wall thickness.

5 The Stress Intensity Factor (SIF) was reviewed for the studs of each plate and was found to have a negligable effect on the result of Attachment 2. No additional evaluation was required however the conditions of Attachment 2 still apply.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 4 of 29 Piping System Inputs: 130" 0.375 (STD) A-155 KC-65 (2) t-nominal: tnom 0.375 in Outside Diameter : Do 30 in (3)

Inside Diameter: Di 29.25 in (3)

Corrosion Allowance : A (generally0 for this analysis) 0 in (4)

(2)

Design P: 90 psig IDesign T: 125 deg F*

Stress Analysis Inputs: PSL 1 Section III REF Prepared: See AUt. 1 Verified: See Att. 1 (11)

Code of Record: ASME B&PV Code Section III, 1971 Edition through Summer 1973 Addenda (11)

Stress Calc 1000, Rev 5 & 1001, Rev 5 (Orig Code of Record ANSI B31.7 Class 3)

Stress Iso R-SK-172-11, Rev 5 and R-SK-172-12, Rev 5 (12)

Piping Isometric 8770-G-125 Sh CW-F-10, Rev 3 (13)

Max Stress I Long Press. Stress (tnom) (Do NOT include in below Eq's) 2633 psi (11)

Eq 8 (P)+(Dead Weight)** 502 psi** (11)

Eq 9 Upset (P)+(DWt+OBE Inertia)** 1134] psi** (11)

Eq 9 Emergency (P)+(DWt+DBE Inertia)** 176 psi** (11)

Eq 10 Thermal** 453 psi** (11)

Stress Allowable Hot: Sh 15000 psi (11)

Allowable Stress Range for Expansion Stresses: Sa 22500 psi (11) y coefficient (0. 4 if less than 900F) 0.4 -

• For information only. Data not used by the analysis. **Equations Show General Form with P Included The 4 Boxed Max Stress Values Provide the Moment Stress Only (Pressure Stress subtracted out) 5.0 Calculation Part 1 - Minimum Wall Calculation Develop tmin basedon Hoop Stress: REF tmin based on Hoop Stress (P Do)/(2 (Sh + P y)) + A 0.090 in (4)

Original Section Modulus: Z = 3.14/32 (Do4 - Di4 )/Do 255.167 cu in (9)

Mill Tolerance (tnom +/- 12.5%): 0.328 to 0.422 in tnom 0.375 in (3)

Develop tmin Based on LongitudinalStresses:

I tmin based on Longitudinal Stress (Guess & Iterate) 0.074 in Diameter Inside Di' Di'=Do-2tmin 29.853 in New Section Modulus Z' = (3.14/32) (Do4 - Di' 4)/Do 51.630 cu in (8)

Section Modulus Ratio SM Ratio = Z / Z' 4.942 Longitudinal Pressure Stress (P Do )/(4 tmin) 9169 psi (9)

Code Equations & Acceptance Criteria: May Not Exceed LStress IR<1.0 Eq 8 = P + SM Ratio (DWt) Sh 15000 11650 0.78 (11)

Eq 9 = P + SM Ratio (Dwt + OBE Inertia) 1.2 Sh 18000 14773 0.82 (11)

Eq 9 = P + SM Ratio (Dwt + DBE Inertia) 1.8 Sh 27000 17892 0.66 (11)

Sa 22500 22502 1.00 (ii)

Eq 10 = SM Ratio (Th)

Calculation assumes general wall reduction due to Internal Corrosion The Minimum Wall Criteria is 0.090 inches.

Calculation assumes general wall reduction due to Internal Corrosion Additional local wall thinning may be acceptable with further analysis, provided the wall thickness of the surrounding area is greater than the above minimum wall criteria.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Aft. 2, Rev. 0, Page 5 of 29 Part 2 (Case 1) - Reinforcement for Minimum Assumed Hole Size (0.25")

Branch Connection Reinforcement Calculation per ASME Section III, NC-3643.3 Pipe Code CS-1 Symbol Units Descrintion Symbol Units Descrintion Dob in outside diameter of branch connection Doh in outside diameter of header dl in inside diameter of branch connection d2 in half width of reinforcing zone, greater of dl or (Tb+Th+(dl/2)) but not > Dob L in height of reinforcement zone outside of run or reinforcement = 2.5Tb te in thickness of attached reinforcing pad Tb in thickness of the branch, use minimum Th in thickness of the run, use minimum tmb in required minimum wall thickness branch tmh in required minimum wall thickness header / run P psi internal Design Pressure T deg F internal Design Temperature S psi maximum allowable stress for the material at design temperature y coefficient A in additional thickness a deg angle between axes of branch and run tc in weld throat, smaller of 1/4" or 0.7Tb(ave) Fig NB-3352.4-2 w in weld leg, =1.41 tc Ref Dob 0.25 Assumed, Bounding Doh 30 Design 2 dl 0.25 Assumed, Bounding dl Tb+Th+(dl/2) Dob NC-3643.3 18 d2 0.25 0.25 0.45 0.25 NC-3643.3 18 L 0.000 NC-3643.3 18 te 0 Assume no reinforcing pad Tb (ave) 0 Assume no wall thickness Tb (min) 0.000 87.50% 3 Th (ave) 0.375 NAMS 2 Th (min) 0.328 87.50% 3 tmb N/A tmb=(P*Dob)/ 2 (S+Py) + A NC-3641.1 (a) 18 tmh 0.090 See Part 1 P 90 NAMS 2 T 125 NAMS 2 S 15,000 See Part 1 11 y 0.4 See Part 1 18 A 0 See Part 1 18 a 90 Design 17 a radians 1.571 360 degrees = 2 p radians 1/4" 0.7Tb Lesserof Fig NB-3352.4-2 18 tc 0 0 0 Not Used w 0 Not Used

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 6 of 29 Calculate area required:

Area required = 1.07(tmh)(dl) 0.024 sq. in.

Calculate area available (see ASME Section III, NC-3643.3 for clarification):

Area Al = (2*d2-dl)*(Th min-tmh) 0.060 sq. in.

Area A2 = 2L*(Tb min-tmb)/sina 0 sq. in.

Area A3= area provided by deposited weld metal beyond OD of run & branch 2 (0.5

• w*w) 0 sq. in.

Area A4= area provided by a reinforcing ring, pad or integral reinforcement 0 sq. in.

Area A5= area provided by a saddle on right angle connections 0 sq. in.

Aavail= Al +A2+A3+A4+A5 0.060 sq. in.

Compare area available to required area:

Avail Required area 0.060 sq. in. > 0.024 sq. in.

No additional reinforcement of the assumed hole is required.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Alt. 2, Rev. 0, Page 7 of 29 Part 2 (Case 2) - Reinforcement for Maximum Assumed Hole Size (30")

Branch Connection Reinforcement Calculation per ASME Section III, NC-3643.3 Pipe Code CS-1 Symbol Units D~scrintion

':;vmhol Units Descrintion Dob in outside diameter of branch connection -

Doh in outside diameter of header dl in inside diameter of branch connection d2 in half width of reinforcing zone, greater of dl or (Tb+Th+(dl/2)) but not > Dob L in height of reinforcement zone outside of run or reinforcement = 2.5Tb te in thickness of attached reinforcing pad Tb in thickness of the branch, use minimum Th in thickness of the run, use minimum tmb in required minimum wall thickness branch tmh in required minimum wall thickness header / run P psi internal Design Pressure T deg F internal Design Temperature S psi maximum allowable stress for the material at design temperature y coefficient A in additional thickness a deg angle between axes of branch and run tc in weld throat, smaller of 1/4" or 0.7Tb(ave) Fig NB-3352.4-2 w in weld leg, =1.41 tc Ref Dob 30 Assumed, Bounding Doh 30 Design 2 dl 30 Assumed, Bounding dl Tb+Th+(d 1/2) Dob NC-3643.3 18 d2 30 30 15.33 30 NC-3643.3 18 L 0.000 NC-3643.3 18 te 0 Assume no reinforcing pad Tb (ave) 0 Assume no wall thickness Tb (min) 0.000 87.50% 3 Th (ave) 0.375 NAMS 2 Th (min) 0.328 87.50% 3 tmb N/A tmb=(P*Dob)/ 2 (S+Py) + A NC-3641.1 (a) 18 tmh 0.090 See Part 1 P 90 NAMS 2 T 125 NAMS 2 S 15,000 See Part 1 11 y 0.4 See Part 1 18 A 0 See Part 1 18 a 90 Design 17 a radians 1.571 360 degrees = 2 p radians 1/4" 0.7Tb Fig NB-3352.4-2 18 tc 0 0 0 Not Used w 0 Not Used

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 8 of 29 Calculate area required:

Area required = 1.07(tmh)(dl) 2.882 sq. in.

Calculate area available (see ASME Section III, NC-3643.3 for clarification):

Area Al = (2*d2-dl)*(Th min-tmh) 7.150 sq. in. -

Area A2 = 2L*(Tb min-tmb)/sina 0 sq. in.

Area A3= area provided by deposited weld metal beyond OD of run & branch 2 (0.5

• w*w) 0 sq. in.

Area A4= area provided by a reinforcing ring, pad or integral reinforcement 0 sq. in.

Area A5= area provided by a saddle on right angle connections 0 sq. in.

Aavail= Al +A2+A3-A4+A5 7.150 sq. in.

Compare area available to required area:

Avail Required area 7.150 sq. in. > 2.882 sq. in.

No additional reinforcement of the assumed hole is required.

The above cases show that hole sizes up to 30" diameter do not require additional reinforcement, provided the wall thickness in the surrounding areas is >0.328".

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 9 of 29 Part 3A - Plate Thickness for 3.5" x 3.5" Plate Data used in the 3.5" x 3.5" plate and bolting analysis is summarized in this section.

Patch Plate Inputs: Value Units REF Design Temperature 125 F 2 Design Pressure 90 psig 2 Base Metal Information Pipe Nominal Wall 0.375 in 2 Material SA-106 Gr B Assumption 1 Allowable Stress Assume SA-106 Gr. B or equiv., Table 1-7.1 15000 psi 5, Aft. 1 Patch Information Width Assume Width is the smaller plate dimension. 3.5 in 17 Height Assume Height is the larger plate dimension. 3.5 in 17 Material SA-106 Gr B Assumption 1 Allowable Stress Assume SA-106 Gr. B or equiv., Table 1-7.1 15000 psi 5, Aft. 1 Opening Dimensions Gasket Width 0.75 in 17 Plate overlap 0.125 in Width =Patch Width - 2 (Overlap + Gasket Width) 1.75 in 17 Height =Patch Height - 2 (Overlap + Gasket Width) 1.75 in 17 Bolting Information Diameter 0.25 in 17 Material SA-193 Gr. B7 17 Allowable Stress Table 1-7.3 25000 psi 5 Yield Stress Table 1-1.3 .105000 psi 5 Number of Bolts 4 17 Area of Bolt 0.0318 inA2 16 k for Thread Lubricant N-5000 0.15 - 14 Minimum Required Patch Plate Thickness (ASME Section Ill, NB-3647.2) tm minimum thickness = t + A t calculated thickness = d6*(3*P/16*S)A.5 d6 Gasket ID Assume max height/width, increase by 10%, conservative.

P Design Pressure Use of design pressure is extremely conservative.

S Stress Allowable A Mechanical Allowances (NB-3613) = 0 tm = (110% *(Height/Width, max)*((3*90)/(16*15000))AO.5+0 0.065 in Meets plate thickness of 0.375 in 1O

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, AUt.2, Rev. 0, Page 10 of 29 Part 4A - Bolt/Gasket Loadinq for 3.5" x 3.5" Plate FLANGE JOINT LOADINGIGASKET SEATING CALCULATIONS ASME Section III Appendix E methodology, modified for square patch plate GASKET AREA Value Units REF W Pressure Width = Gasket Width + Opening Width 2.5 in 17 H Pressure Height = Gasket Width + Opening Height 2.5 in 17 Land Gasket Width 0.75 in 17 b 1/2 Gasket Width =Land/2 0.375 in A Short Dimension Cover =Patch Width - 2 (Overlap) 3.25 in 17 B Long Dimension Cover =Patch Height - 2 (Overlap) 3.25 in 17 C Short Dimension Gasket ID =Patch Width - 2 (Overlap + Gasket Width) 1.75 in 17 D LongDimension Gasket ID =Patch Height - 2 (Overlap + Gasket Width) 1.75 in 17 d Bolt Diameter 0.25 in 17 N Number of Bolts 4 17 PRESSURE AREA P Area W*H 6.25 inA2 REQUIRED SEATING LOAD (Wm2) y 200 lb/inA2 18 G Area =(A*B)-(C*D)-((N*Pl*(d+0.125)A2)/4) 7.06 inA2 18 Wm2 =y* G Area 1412 lb 18 OPERATING SEATING LOAD (Wml)

P ext Patch is on ID, Assume 15 psi external 15 psig Ass. 3 P Area =W*H 6.25 inA2 m Gasket Factor 1 . 18 Wml =(P ext*P Area)+(G Area*m*P ext), modified for rectangle 200 lb 18 REQUIRED BOLT STRESS/TORQUE Load Greater of Wml or Wm2 1412 lb 18 Bolt Diameter 0.25 in 17 Load/Bolt =Load / N 353 lb Bolt Stress =Load/BoltI((3.14*Bolt DiaA2)/4) 7189 psi Bolt Torque =K*d* Load/(N*12) 1.10 ft-lbs 14 I 2 ft-lbs specified Rounded up to next whole number Part 5A - Bolting for 3.5" x 3.5" Plate ICW Pipe -Pipe Code CS-1 (SA-106 Grade B Used, Assumption 1)

Bolts: SA-193 Grade B7, 1/4"-20 UNC-2A REF D Bolt Basic Major Diameter (nominal diameter) 0.250 in 17 n Threads per inch 20 - 17 Thread Class (External) 2A - 17 Le' Actual Thread Engagement 0.250 in 17 Esmin External Thread Minimum pitch diameter 0.2127 in 16 Dsmin External Thread Minimum major diameter 0.2408 in 16 Yieldbolt External Thread Yield Strength 105,000 psi 5 UTSbolt External Thread Thread Ultimate Tensile Strength 125,000 psi 5 Enmax Internal Thread Maximum pitch diameter 0.2224 in 16 Knmax Internal Thread Maximum minor diameter 0.207 in 16 Yieldhole Internal Thread Yield Strength 35,000 psi 5 UTShole Internal Thread Ultimate Tensile Strength 60,000 psi 5

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 11 of 29

1. Review for Potential Stripping of External Threads (Before Bolt Breaks)

Tensile Area of Screw Thread At UTSbolt < 100 ksi: At = .7854 (D- .9743/n)^2 0.030 sq in UTSbolt > 100 ksi: At = 3.1416 (Esmin/2 -. 16238/n)A2 15 Required Length of Engagement for External Threads Le to Develop Full Bolt Load 0.165 in Le = (2*At)

[3.14 Knmax (.5 + .57735 n (Esmin- Knmax)] 15

2. Review for Potential Stripping of Internal Threads (Before Bolt Breaks)

As = 3.1416 n Le Knmax (1/(2n) + .57735(Esmin - Knmax)) 0.061 sq in 15 An = 3.1416 n Le Dsmin (1/(2n) + .57735 (Dsmin - Enmax)) 0.089 sq in 15 J = (As UTSbolt) / (An UTShole) 1.42 15 Q Required Length of Internal Threads = J

• Le 0.234 in 15

3. Load Required to Break Bolt/Screw Pbolt Pbolt = At* UTSbolt 3789 lbs I 15 I Governing Bolt/Thread Failure Load Component Failure Review based on minimum load for Threaded Joint bolt breakage, external thread strippage or internal thread 3789 lbs Failure Load strippage Failure Load = Minimum (1 , Le'/Le, Le'/Q) x (Pbolt)

Torque which will yield undamaged joint with actual Bolt Torque engagement 10 ft-lbs Bolt Torque = (Failure Load/Pbolt) D*Yield bolt*At*K/12 M=Developed Percent of Bolt Yield Strength K=Nut Factor (Fel-Pro N-5000)

Bolt Torque = M D Yieldbolt At K / 12 20%/

0.15 2.00 ft-lbs 71414

%Yield Bolt Stress compared to bolt material strength 20%

External Thread Stress compared to bolt material strength 13%

Internal Thread Stress compared to hole material strength 27%

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 12 of 29 Part 3B - Plate Thickness for 10" x 11" Plate Data used in the 10" x 11" plate and bolting analysis is summarized in this section.

Patch Plate Inputs: Value Units REF Design Temperature 125 F 2 Design Pressure 90 psig 2 Base Metal Information Pipe Nominal Wall 0.375 in 2 Material SA-106 Gr B Assumption 1 Allowable Stress Assume SA-106 Gr. B or equiv., Table 1-7.1 15000 psi 5, Att. 1 Patch Information Width Assume Width is the smaller plate dimension. 10 in 17 Height Assume Height is the larger plate dimension. 11 in 17 Material SA-106 Gr B Assumption 1 Allowable Stress Assume SA-106 Gr. B or equiv., Table 1-7.1 15000 psi 5, Att. 1 Opening Dimensions Gasket Width 0.75 in 17 Plate overlap 0.125 in Width =Patch Width - 2 (Overlap + Gasket Width) 8.25 in 17 Height =Patch Height - 2 (Overlap + Gasket Width) 9.25 in 17 Bolting Information Diameter 0.25 in 17 Material SA-193 Gr. B7 17 Allowable Stress Table 1-7.3 25000 psi 5 Yield Stress Table 1-1.3 105000 psi 5 Number of Bolts 8 17 Area of Bolt 0.0318 inA2 16 k for Thread Lubricant N-5000 0.15 14 Minimum Required Patch Plate Thickness (ASME Section III, NB-3647.2) tm minimum thickness = t + A t calculated thickness = d6*(3*PI1 6*S)^.5 d6 Gasket ID Assume max height/width, increase by 10%, conservative.

P Design Pressure Use of design pressure is extremely conservative.

S Stress Allowable A Mechanical Allowances (NB-3613) = 0 tm (110% *(Height/Width, max)*((3*90)/(16*1 5000))^0.5+0 0.341 in Meets plate thickness of 0.375 in 1OK

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 13 of 29 Part 4B- BoltlGasket Loading for 10" x11" Plate FLANGE JOINT LOADINGIGASKET SEATING CALCULATIONS ASME Section III Appendix E methodology, modified for square patch plate GASKET AREA Value Units REF W Pressure Width = Gasket Width + Opening Width 9 in 17 H Pressure Height = Gasket Width + Opening Height 10 in 17 Land Gasket Width 0.75 in 17 b 1/2 Gasket Width =Land/2 0.375 in A Short Dimension Cover =Patch Width - 2 (Overlap) 9.75 in 17 B Long Dimension Cover =Patch Height - 2 (Overlap) 10.75 in 17 C Short Dimension Gasket ID =Patch Width - 2 (Overlap + Gasket Width) 8.25 in 17 D LongDimension Gasket ID =Patch Height - 2 (Overlap + Gasket Width) 9.25 in 17 d Bolt Diameter 0.25 in 17 N Number of Bolts 8 17 PRESSURE AREA P Area W*H 90 inA2 REQUIRED SEATING LOAD (Wm2) y 200 lb/inA2 18 G Area =(A*B)-(C*D)-((N*Pl*(d+0.125)A2)/4) 27.6 inA2 18 Wm2 =y* G Area 5523 lb 18 OPERATING SEATING LOAD (Wml)

P ext Patch is on ID, Assume 15 psi external 15 psig Ass. 3 P Area =W*H 90 inA2 m Gasket Factor 1 18 Wml =(P ext*P Area)+(G Area*m*P ext), modified for rectangle 1764 lb 18 REQUIRED BOLT STRESSITORQUE Load Greater of Wml or Wm2 5523 lb 18 Bolt Diameter 0.25 in 17 Load/Bolt =Load / N 690 lb Bolt Stress =Load/Bolt/((3.14*Bolt Dia^2)/4) 14065 psi Bolt Torque =K*d* Load/(N* 12) 2.16 ft-lbs 14 3 tlsspecified Rounded up to next whole number Part 5B - Bolting for 10" x 11" Plate lOW Pipe -Pipe Code CS-1 (SA-106 Grade B Used, Assumption 1)

Bolts: SA-193 Grade B7, 1/4"-20 UNC-2A REF D Bolt Basic Major Diameter (nominal diameter) 0.250 in 17 n Threads per inch 20 17 Thread Class (External) 2A 17 Le' Actual Thread Engagement 0.250 in 17 Esmin External Thread Minimum pitch diameter 0.2127 in 16 Dsmin External Thread Minimum major diameter 0.2408 in 16 Yieldbolt External Thread Yield Strength 105,000 psi 5 UTSbolt External Thread Thread Ultimate Tensile Strength 125,000 psi 5 Enmax Internal Thread Maximum pitch diameter 0.2224 in 16 Knmax Internal Thread Maximum minor diameter 0.207 in 16 Yieldhole Internal Thread Yield Strength 35,000 psi 5 UTShole Internal Thread Ultimate Tensile Strength 60,000 psi 5

L-2013-240, 10 CFR 50.4, .0 CFR 50.55a, Att. 2, Rev. 0, Page 14 of 29

1. Review for Potential Stripping of External Threads (Before Bolt Breaks)

Tensile Area of Screw Thread At UTSbolt < 100 ksi: At = .7854 (D- .9743/n)^2 0.030 sq in UTSbolt > 100 ksi: At = 3.1416 (Esmin/2 -. 16238/n)^2 15 Required Length of Engagement for External Threads to Develop Full Bolt Load Le Le = (2*At) 0.165 in

[3.14 Knmax (.5 + .57735 n (Esmin- Knmax)] 15

2. Review for Potential Stripping of Internal Threads (Before Bolt Breaks)

As = 3.1416 n Le Knmax (1/(2n) + .57735(Esmin - Knmax)) 0.061 sq in 15 An = 3.1416 n Le Dsmin (1/(2n) + .57735 (Dsmin - Enmax)) 0.089 sq in 15 J = (As UTSbolt) / (An UTShole) 1.42 15 Q Required Length of Internal Threads = J

• Le 0.234 in 15

3. Load Required to Break Bolt/Screw Pbolt Pbolt = At* UTSbolt 3789 Ibs I 15 I Governing Bolt/Thread Failure Load Component Failure Review based on minimum load for Threaded Joint bolt breakage, external thread strippage or internal thread 3789 lbs Failure Load strippage Failure Load = Minimum (1 , Le'/Le, Le'/Q) x (Pbolt)

Torque which will yield undamaged joint with actual Bolt Torque engagement 10 ft-lbs Bolt Torque = (Failure Load/Pbolt) D*Yield bolt*At*K/1 2 M=Developed Percent of Bolt Yield Strength K=Nut Factor (Fel-Pro N-5000)

Bolt Torque = M D Yieldbolt At K / 12 30%

0.15 3.00 1 ft-lbs 147 14

%Yield Bolt Stress compared to bolt material strength 30%

External Thread Stress compared to bolt material strength Internal Thread Stress compared to hole material strength 41%

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 15 of 29 Part 3C - Plate Thickness for 7.5" x 11.5" Plate Data used in the 7.5" xl1.5" plate and bolting analysis is summarized in this section.

Patch Plate Inputs: Value Units REF Design Temperature 125 F 2 Design Pressure 90 psig 2 Base Metal Information Pipe Nominal Wall 0.375 in 2 Material SA-106 Gr B Assumption 1 Allowable Stress Assume SA-106 Gr. B or equiv., Table 1-7.1 15000 psi 5, Att. 1 Patch Information Width Assume Width is the smaller plate dimension. 7.5 in 17 Height Assume Height is the larger plate dimension. 11.5 in 17 Material SA-106 Gr B Assumption 1 Allowable Stress Assume SA-106 Gr. B or equiv., Table 1-7.1 15000 psi 5, Att. 1 Opening Dimensions Gasket Width 0.75 in 17 Plate overlap 0.125 in Width =Patch Width - 2 (Overlap + Gasket Width) 5.75 in 17 Height =Patch Height - 2 (Overlap + Gasket Width) 9.75 in 17 Bolting Information Diameter 0.25 in 17 Material SA-193 Gr. B7 17 Allowable Stress Table 1-7.3 25000 psi 5 Yield Stress Table 1-1.3 105000 psi 5 Number of Bolts 8 17 Area of Bolt 0.0318 inA2 16 k for Thread Lubricant N-5000 0.15 14 Minimum Required Patch Plate Thickness (ASME Section III, NB-3647.2) tm minimum thickness = t + A t calculated thickness = d6*(3*P/116*S )A .5 d6 Gasket ID Assume max height/width, increase by 10%, conservative.

P Design Pressure Use of design pressure is extremely conservative.

S Stress Allowable A Mechanical Allowances (NB-3613) = 0 tm= (110% *(Height]Width, max)*((3*90)/(16*1 5000))AO.5+0 0.360 in Meets plate thickness of 0.375 in O

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 16 of 29 Part 4C - BoltiGasket Loading for 7.5" x 11.5" Plate FLANGE JOINT LOADING/GASKET SEATING CALCULATIONS ASME Section III Appendix E methodology, modified for square patch plate GASKET AREA Value Units REF W Pressure Width = Gasket Width + Opening Width 6.5 in 17 H Pressure Height = Gasket Width +: Opening Height 10.5 in 17 Land Gasket Width 0.75 in 17 b 1/2 Gasket Width =Land/2 0.375 in A Short Dimension Cover =Patch Width - 2 (Overlap) 7.25 in 17 B Long Dimension Cover =Patch Height - 2 (Overlap) 11.25 in 17 C Short Dimension Gasket ID =Patch Width - 2 (Overlap + Gasket Width) 5.75 in 17 D LongDimension Gasket ID =Patch Height - 2 (Overlap + Gasket Width) 9.75 in 17 d Bolt Diameter 0.25 in 17 N Number of Bolts 8 17 PRESSURE AREA P Area W*H 68.25 inA2 REQUIRED SEATING LOAD (Wm2) y 200 lb/inA2 18 G Area =(A*B)-(C*D)-((N*Pl*(d+0.125)A2)/4) 24.6 inA2 18 Wm2 =y* G Area 4923 lb 18 OPERATING SEATING LOAD (Wml)

P ext Patch is on ID, Assume 15 psi external 15 psig Ass. 3 P Area =W*H 68.25 inA2 m Gasket Factor 1 18 Wml =(P ext*P Area)+(G Area*m*P ext), modified for rectangle 1393 lb 18 REQUIRED BOLT STRESS/TORQUE Load Greater of Wml or Wm2 4923 lb 18 Bolt Diameter 0.25 in 17 Load/Bolt =Load / N 615 lb Bolt Stress =Load/Bolt/((3.14*Bolt DiaA2)/4) 12537 psi Bolt Torque =K*d* Load/(N*12) 1.92 ft-lbs 14 2 ft-lbsspcfe Rounded up to next whole number Part 5C - Bolting for 7.5" x 11.5" Plate ICW Pipe -Pipe Code CS-1 (SA-106 Grade B Used, Assumption 1)

Bolts: SA-193 Grade B7, 1/4"-20 UNC-2A REF D Bolt Basic Major Diameter (nominal diameter) 0.250 in 17 n Threads per inch 20 - 17 Thread Class (External) 2A - 17 Le' Actual Thread Engagement 0.250 in 17 Esmin External Thread Minimum pitch diameter 0.2127 in 16 Dsmin External Thread Minimum major diameter 0.2408 in 16 Yieldbolt External Thread Yield Strength 105,000 psi 5 UTSbolt External Thread Thread Ultimate Tensile Strength 125,000 psi 5 Enmax Internal Thread Maximum pitch diameter 0.2224 in 16 Knmax Internal Thread Maximum minor diameter 0.207 in 16 Yieldhole Internal Thread Yield Strength 35,000 psi 5 UTShole Internal Thread Ultimate Tensile Strength 60,000 psi 5

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 17 of 29

1. Review for Potential Stripping of External Threads (Before Bolt Breaks)

Tensile Area of Screw Thread At UTSbolt < 100 ksi: At = .7854 (D- .9743/n)^2 0.030 sq in UTSbolt > 100 ksi: At = 3.1416 (Esmin/2 - .16238/n)A2 15 Required Length of Engagement for External Threads Le to Develop Full Bolt Load 0.165 in Le = (2*At)

[3.14 Knmax (.5 + .57735 n (Esmin- Knmax)] 15

2. Review for Potential Stripping of Internal Threads (Before Bolt Breaks)

As = 3.1416 n Le Knmax (1/(2n) + .57735(Esmin - Knmax)) 0.061 sq in 15 An = 3.1416 n Le Dsmin (1/(2n) + .57735 (Dsmin - Enmax)) 0.089 sq in 15 J = (As UTSbolt) / (An UTShole) 1.42 - 15 Q Required Length of Internal Threads = J

• Le 0.234 in 15

3. Load Required to Break Bolt/Screw Pbolt Pbolt = At* UTSbolt 3789 Ibs I 15 I Governing Bolt/Thread Failure Load Component Failure Review based on minimum load for Threaded Joint bolt breakage, external thread strippage or internal thread 3789 lbs Failure Load strippage Failure Load = Minimum (1 , Le'/Le, Le'/Q) x (Pbolt)

Torque which will yield undamaged joint with actual Bolt Torque engagement 10 ft-lbs Bolt Torque = (Failure Load/Pbolt) D*Yield bolt*At*K/12 M=Developed Percent of Bolt Yield Strength K=Nut Factor (Fel-Pro N-5000)

Bolt Torque = M D Yieldbolt At K /12 20%

0.15 2.00 ft-lbs 14--

14~

%Yield Bolt Stress compared to bolt material strength [0%

External Thread Stress compared to bolt material strength 13%

Internal Thread Stress compared to hole material strength 27%

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 18 of 29 Part 6- Interaction Between Multiple Openinqs ASME III, Section NC-3643.3(e) defines reinforcement requirements for multiple openings:

When any two or more adjacent openings are so closely spaced that their reinforcement zones overlap, the two or more openings shall be reinforced in accordance with NC-3643.3(c) and (d), with a combined reinforcement that has strength equal to the combined strength of the reinforcement which would be required for the separate openings. No portion of the cross-section shall be considered as applying to more than one opening or be evaluated more than once in a combined area.

ASME III, Section NC-3643.3(f) defines reinforcement zone:

The reinforcement zone is a parallelogram the length of which shall extend a distance d2, on each side of the centerline of the branch pipe and the width of which shall start at the inside surface of the run pipe and extend to a distance, L, from the outside surface of the run pipe, when measured in the plane of the branch connection.

From Part 2, Cases 1 and 2, d 2 is the hole size for the location.

Based on review of PCA Engineering, Inc. UT readings (Att. 3):

The openings for closest holes are spaced sufficiently apart that the reinforcement zones do not overlap.

Therefore, additional reinforcement criteria per ASME Ill, Section NC-3643.3(f) is not required.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 19 of 29 6.0 Results Pipe The Minimum Wall Criteria is 0.090 Inches The minimum wall criteria is controlled by the hoop stresses.

Calculation assumes general wall reduction due to Internal Corrosion Additional local wall thinning may be acceptable with further analysis, provided the wall thickness of the surrounding area is greater than the above minimum wall criteria.

Reinforcement Part 2, shows that hole sizes up to 30" diameter do not require additional reinforcement, provided the wall thickness in the surrounding areas is >0.328".

Plate Thickness To consolidate stock, the required plate thickness is compared to design plate thickness of 0.375".

3.5" x 3.5" Plate Required closure plate thickness is 0.065 Inches Minimum Bolt Torque (1/4" -20UNC) is 2.00 Ft-lbs Note that the thread engagement in the ICW piping does not meet standard design to assure the bolt breaks before stripping the threads. However, field torque limitations will prevent stripping of the hole.

10"x 11" Plate Required closure plate thickness is 0.341 Inches Minimum Bolt Torque (1/4" -20UNC) is 3.00 Ft-lbs Note that the thread engagement in the ICW piping does not meet standard design to assure the bolt breaks before stripping the threads. However, field torque limitations will prevent stripping of the hole.

7.5" x 11.5" Plate Required closure plate thickness is 0.360 Inches Minimum Bolt Torque (1/4" -20UNC) is 2.00 Ft-lbs Note that the thread engagement in the ICW piping does not meet standard design to assure the bolt breaks before stripping the threads. However, field torque limitations will prevent stripping of the hole.

Interaction Between Multiple Openings Based on review of PCA Engineering, Inc. UT readings (Aft. 3):

The openings for closest holes are spaced sufficiently apart that the reinforcement zones do not overlap.

Therefore, additional reinforcement criteria per ASME III, Section NC-3643.3(f) is not required.

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 20 of 29 Pipe Stress Input Location Unit 1 CR / CSI Loc No. NA Line Number 1-30"-CW-29, -30 Description CCW HX to Discharge Canal 30" Diameter Schedule 0.375" Design Pressure 90 psi Temperature 125OF Piping Isometric and Revison 8770-G-125, CW-F-10 &CW-F-3 Original Design Spec and Edition USAS B31.7, Class 3 Civil Pipe Stress Input Units Stress Code and Edition - ASME Section III 1971-S73 / Class 3 Stress Iso and Revison - R-SK-172-11 & 12, R5 Nodes 17 Stress Calc and Revison - 1000 R5 & 1001 R5 Long Pressure Stress psi 2633 EQ 8 Deadweight (P)+(Dead Weight) psi  !-o 5021.

EQ 9 Upset (P)+(DWt+OBE Inertia) psi 1"134 EQ 9 Emergency (P)+(DWt+DBE Inertia) psi 1765 EQ 10 Thermal (Thermal)** psi -.4553 EQ SAM (P)+(DWt +Thermal + Seismic Anc. Moments OBE) psi :N/A Stress Allowable Hot: Sh psi 15000 Allowable Stress Range for Exp. Stresses: Sa psi 22500

'*Boxed Values are Moment Stress Only (Pressure.Stre- s.ms Has Been Subtracted Out) -

Civil Input: Values are worst case of 1000 and 1001 Prepared By: z2-1' 2012 Verified By:

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 21 of 29 Stress Intensifiction Factor Review The bolted patch plate repair methodology provides a branch connection but does not impose any moment inducing loads from branch piping. ASME Section III Edition 1971 through Summer 1973 Addenda provides stress intensification factors (SIFs) for various configurations which impose moment loading of piping components but does not address a branch hole with or without a bolted covering.

Stress indices and stress intensification factors (SIFs) are used in the design of piping systems that must meet Code requirements. SIFs are fatigue correlation factors that compare the fatigue life of piping components (for example, tees and branch connections) to that of girth butt welds in straight pipe subjected to bending moments.

As the subject opening with a bolted cover is not subjected to increased bending moments or externally applied loads, a SIF does not need to be applied to the configuration. Code criteria regarding reinforcement zones for a branch penetration apply.

Similarly, a SIF is not required for multiple openings. Code criteria regarding overlap of reinforcement zones for adjacent penetrations apply.

Prepared By: Date: / z. is'~' If Verified By: Date: /2-/~~ ~i/

Approved By: Date: 12... iS. ~

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 22 of 29 PCA Engineering, Inc. UT readings, taken 2-4-12 Wallace, Carol From: Smit, Marty Sent: Saturday, February 04, 2012 1:23 PM To: Russer, David Cc: Atkinson, Paul; Wallace, Carol; Marshall, Steve; Ramani, Sharam; Harmon, John; Wolaver, Mark; Hollowell, Ed; Rodriguez, Omar (PSL); Jenkins, Jeffery; Oscarson, Kevin; Ensmenger, Paul

Subject:

UT data of CW-29 buried pipe results from 020312 pipe ID survey Attachments: Layout CW-29 Cells 1-6.pdf Attached find the current file from PCA showing the location of the pipe ID corrosion defects on the CW-29 underground ICW piping downstream of the CCW pit perimeter wall. The pipe run inspected is located on northbound run of CW-29 about 20 - 30 feet downstream of the elbow near the outbound ICW penetration in the east side of Unit 1 CCW pit. A few defects are thru wall.

The sketch of the ICW pipe ID surface, is laid out lengthwise from south to north. The "elevation" view is of the pipe split length- wise down the top centerline when viewed from the right (south) end at the elbow. The diagram shows a "plan" view of the pipe unrolled to a flat panel, with the 3 o'clock half on the top and th4e 6 o'clock half on the bottom. -

The pipe downstream of this location has had a limited inspection through a soiled surface. Additional surface cleaning may reveal additional defects. Therefore, discovery on CW-29 may not yet be complete.

There are a few relatively small diameter defects with a "conical" profile that shows corrosion initialing from the ID off the pipe.

Cold patch plates are suggested by PCA to prevent heat affected damage on the OD coating that results from weld repairs. The size of the proposed patch plates is shown on the detail sketches of the wall defects. Pictures of the defects are also included.

Information in Text Boxes was added by Carol Wallace based on Discussion with Richard Montgomery of PCA.

P-0.185"RxO.75"D means Pit (versus a hole) with 0.185" remaining wall thickness and pit diameter of 0.75" at the pipe ID.

HOLE 0.25" x 2" diameter means Hole with diameter 0.25" at OD and 2" at ID.

I

Location dimensions are referenced from elbow at weld CW-29/FW-4 on Isometric Drawing 8770-G-1 25, Sheet CW-F-10 TOP OF PI1 3 O'CLK ElV OW I INVERT 9 O'CLK TOP OF PII BOTTOM OF RISER PLAN VIEW

-EL 8'-3' DEFECTS El I..-.'

1=1 BOTTOM OF RISER 101 L2i 30-CW-29 EL 14-9' IBTRAIN PCA ENGINEERING, INC. 30-CCW-29 DISCHARGE DRAWN: R.H.M.

57 CANNONBALL RD POMPTON LAKES, NJ COATING REPAIRS DATE: 01/10/2012 DWG.NO. A301251 7/6/10 Pier #8.di

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Att. 2, Rev. 0, Page 24 of 29 SEAM ID 1.

_______________________________ 1 -- (3' 0.372' 0.396' P-0.185" x 0.75" HaLE 0.25' X 2" D F-I 0.376 -4 7-( 00.386 0*-0 P-O.1BSR X .75D j0404 P-O.185R X .75D 0.389' 0.3 83'

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375" NOM 3" DIA GOOD STEEL

-- -- 0.375" 0.383"

L-2013-240, 10 CFR 50.4, 10 CFR 50.55a, Aft. 2, Rev. 0, Page 29 of 29 Patch Plate Addition:

The purpose of this evaluation is to determine the impact on the affected pipe stresses and pipe support loads resulting from adding internal patch plates to the 1-30"-CW-29 and CW-30 piping lines (ICW Piping).

The subject piping is evaluated within calculation CW-2930-U1, Rev. 0. Per NAMS, the piping is classified as Quality Group C, Seismic Category I, or Class 3 Code piping.

The patch plates are 3/8" thick held in place with 1/4"-20 studs (SA-193 Gr. B7), and vary in overall size, and total number of studs. Review of patch plate drawings within EC-275443 and EC-275645 reveals that the largest patch plate is 11"x11". Conservatively considering a 12"x12" plate results in an added weight of 20 lb (12"x12"x0.375"xO.284 lb/in 3xl.2 (bolting) = 18.4 Ib). The ICW Piping is 30" OD having a wall thickness 0.375" (3/8"), and a weight of 118.7 lb/ft. The piping is shown on isometric drawing 8770-G-125, Sheet CW-F-10, Rev. 5. In accordance with the calculation of record CW-2930-U1, Page-10, the worst case OBE factor is 0.68, thus SSE is 1.36 (SSE = 2xOBE). Therefore, to account for seismic excitation the evaluated weight will be 30 lb (20 lb x 1.36g = 27.2 Ib).

In accordance with Specification SPEC-M-004, the SA-193 Gr. B7, 1/4-20 studs have Tensile Stress of 125 ksi, and a Yield Stress 105 ksi, and As is 0.0318 in2 . Thus the shear stress on a 1/4-20 stud resulting from the seismic loading of the patch plate is 943.4 psi < 21,000 psi (Shear Allowable per AISC 9t Edition) with the entire load on one bolt (flow force is negligible). The effect on the pipe stresses due to added patch plate (weight increase) will be evaluated using the results of the analysis of record as shown below:

Weight ratio factor = (added patch plate weight)/(analysis of record piping weight) = (30 lb +119 Ib) / 119 lbs = 1.25.

Since the percent increase in the pipe stresses is directly proportional to the weight increase, conservatively the deadweight and seismic stresses (maximum stress), including the unaffected pressure stresses, will be adjusted by the weight ratio factor (Note: CW-30 is worst case).

In addition, to account for the effect of any frequency change due to the increased weight, the above maximum seismic stresses will also conservatively be increased by a dynamic factor of 1.5.

Analysis of record EQ. 8 stress = 9,467 psi New EQ. 8 stress = 9,467 x (1.25) = 11,834 psi < 1.0 SH = 15,000 psi; thus o.k.

Analysis of record EQ. 9 stress (Seismic SSE) = 7,461 psi New EQ. 9 faulted stress = 7,461 x (1.25) x (1.5) = 13,989 psi < 1.8 SH = 27,000 psi; thus o.k.

Multiple plates: per drawing 8770-G-125, Sheet CW-F-3, Rev. 23, at CW-30 three (3) plates have been installed in close proximity to one another. There are two (2) 8"x8" plates and one 11 "x11" plate. The combined weight of these plates is 26.5 lb x 1.2 (bolting) = 31.8 lb. The conservatisms used in the above evaluation for the weight ratio for 30 lb is considered to be envelope the three plate scenario.

Based on the above, the affecte iping section meets the stress requirements of the design criteria for each individual patch plate I ca Prepared By: Date: / /1"3 Verified By: 2<Date: /[

Approved By: Approved By: Date~

Date: -a ~ I k I I -s