L-2013-261, RAI Response to Fourth Ten-Year Interval Relief Request No. 7, Revision 0

RAI Response to Fourth Ten-Year Interval Relief Request No. 7, Revision 0

ML13283A011
Person / Time
Site:	Saint Lucie
Issue date:	08/30/2013
From:	Katzman E Florida Power & Light Co
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
L-2013-261
Download: ML13283A011 (47)

Text

August 30, 2013 L-2013-261 10 CFR 50.4 10 CFR 50.55a U. S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555 Re:

St. Lucie Unit I Docket No. 50-335 Inservice Inspection Plan RAI Response to Fourth Ten-Year Interval Unit 1 Relief Request No. 7, Revision 0

References:

1. FPL Letter L-2013-240 dated August 5, 2013, "Inservice Inspection Plan Fourth Ten-Year Interval Unit I Relief Request No. 7, Revision 0," (ML Accession No. ML13220A029).

2. NRC e-mail from Siva Lingham to Ken Frehafer dated August 16, 2013," St Lucie Unit 1--

Relief Request 7 Regarding Alternate Repair of Intake Cooling Water Piping (TAC No.

MF2529) - Request for Additional Information (RAI)."

In Reference 1, Florida Power & Light Company (FPL) requested relief from certain requirements of American Society of Mechanical Engineers Boiler and Pressure Vessel Code (ASME Code),Section XI, IWA-4000 regarding the repair of intake cooling water piping at St Lucie Unit 1. FPL proposed an alternative repair for the intake cooling water piping as documented in Relief Request Number 7, Revision 0. In Reference 2, the Nuclear Regulatory Commission (NRC) submitted a request for additional information (RAI) to complete its review.

The three (3) attachments to this letter forward the subject RAI response. There are no new regulatory commitments contained in this letter.

If there are any questions, or if additional information is required, please contact Eric S. Katzman, Licensing Manager, at (772) 467-7734.

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

L-2013-261 Page 2 of 2 Attachments (3)

1. Request for Additional Information Relief Request Number 7 Alternate Repair of Intake Cooling Water Pipe St. Lucie Unit I Florida Power and Light Company Docket Number 50-335.

2. Typical Bolted Patch Plate Sketch (PSL CADD File ENG 08168-001 R1.DWG).

3. FPL Calculation PSL-IFSM-05-031, Rev. 1, "Evaluation of 1-30"-CW-30 Patch Plate Repairs.

ESK/LRB

L-2013-261 Page 1 of 10 REQUEST FOR ADDITIONAL INFORMATION RELIEF REQUEST NUMBER 7 ALTERNATE REPAIR OF INTAKE COOLING WATER PIPE ST LUCIE UNIT 1 FLORIDA POWER & LIGHT COMPANY DOCKET NUMBER 50-335 By letter dated August 5, 2013 (Agencywide Documents and Access Management System Accession No. ML13220A029), Florida Power & Light Company (the licensee) requested relief from certain requirements of American Society of Mechanical Engineers Boiler and Pressure Vessel Code (ASME Code),Section XI, IWA-4000 regarding the repair of intake cooling water piping at St Lucie Unit 1. The licensee proposed an alternative repair for the intake cooling water piping as documented in Relief Request Number 7, Revision 0. To complete its review, the Nuclear Regulatory Commission (NRC) staff requests the following additional information.

1. The proposed repair includes the use of a gasket and epoxy.

(a) Discuss the gasket and epoxy material, how many years are the gasket and epoxy qualified for in the seawater environment, and the industry standards to which the gasket and epoxy are qualified.

Response

The gasket is cut from a sheet of 1/16" red rubber, which is Styrene Butadiene Rubber (SBR). EPRI Report NP-6608, May 1994, "Shelf Life of Elastomer Components" [10]

provides a shelf life of 32 years for SBR.

Based on the design, the gasket is encapsulated between the carbon steel pipe, plate and epoxy material. The gasket is not exposed to the seawater, air, sunlight, high temperatures or the pipe external environment and has a long shelf life.

Based on this, the gasket is not expected to degrade.

The epoxy coatings used on the carbon steel surfaces of the internal piping and repair plate in accordance with SPEC-M-023 are Carboline Splash Zone A-788 and Duromar SAR-UW.

See "Typical Bolted Patch Plate Sketch" for depiction of epoxy coatings.

These are solvent free repair compounds that are formulated for both wet and underwater applications and will cure in either environment. Carboline A-788 and Duromar SAR-UW were used to separate the plate from the salt water environment of the ICW piping and to fill the degraded pipe cavity. The coatings were smoothed by hand to provide an optimized surface for fluid flow resulting in a total coating thickness over the patch plate in excess of 3/8 inch. These barrier coatings have service histories of over 25 years installed as immersion repair compounds protecting steel surfaces from corrosion.

The Epoxy repair compounds that were specified for this repair are subject to the internal seawater environment of the ICW system which is with in normal operating conditions for both epoxies. No elevated temperatures above 140 F [14] or sunlight/UV radiation are present. Both repair compounds cure chemically by crosslinking and are

L-2013-261 Page 2 of 10 inert or non-reactive when maintained in seawater at normal lCW operating conditions.

Epoxy compounds when properly installed degrade locally and do not fail catastrophically. The most likely cause of coating failure for properly installed coatings in this application would be due to scissorization or the breaking of the cross linked bonds which cause embrittlement. This reaction is driven by elevated temperatures and time which are outside the operating conditions for the lCW system and the effects would be detected by visual inspection.

The coating industry has established that the most effective way to detect coating degradation is through visual inspection.

Visual inspection of localized coating defects caused by scissorization will reveal cracking at which time physical examinations for embrittlement can be performed.

This is not considered a credible cause of coating failure in the operating seawater environment of the lOW system.

(b) Section 4 of the relief request states that the inside of the subject pipe is lined with 1/8-inch thick epoxy or cement. Provide the thickness of epoxy covering the bolted plate.

Response

As stated in the response above, in accordance with SPEC-M-023 the epoxy coatings used for the bolted patch plate are Carboline Splash Zone A-788 and Duromar SAR-UW. The Product Data Sheet for Carboline Splash Zone A-788 [12] provides allowable thickness range of 125 mils to 2" (0.125" to 2").

Product Data Sheet for Duromar SAR-UW [13] provides allowable thickness range of 40 mils to 1000 mils (0.040" to 1"). See "Typical Bolted Patch Plate Sketch" for depiction of epoxy coatings. Based on the minimum epoxy thickness and the configuration, the epoxy coating would exceed the 1/8" thickness of the original epoxy or cement.

(c) Confirm that the epoxy applied on the bolted plate will cover the studs, nuts, plate edges and gasket.

Response

The epoxy coating completely covers the bolted plate, studs, nuts, plate edges and gaskets and is blended with surrounding coatings to provide smooth transitions to minimize lCW flow turbulence. See attached "Typical Bolted Patch Plate Sketch" for depiction of epoxy coatings.

2. Discuss the design life of the bolted plate assembly and how the design life is derived. Discuss the criteria or conditions that would require the in-service bolted plate to be removed.

Response

The design life of the bolted plate is the same as the pipe based on inspection. 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 or plate would be performed where there is degradation. The inspection of the pipe and bolted patch plates during internal inspections of the pipe are performed every other refueling outage. The inspection

L-2013-261 Page 3 of 10 frequency is a commitment per L-2013-005, dated January 10, 2013, "Clarification of NRC Commitment Regarding Generic Letter 89-13" [15] and is instituted by Model Work Orders as part of the Preventive Maintenance Program. The inspections determine the condition of the internal coatings on the pipe and patch plate.

3. On page 4 of the relief request, the licensee states that a typical corrosion rate for the carbon steel in the seawater environment is 30 mils per year. The licensee further states that should the epoxy coating and gasket be breached to allow access to the original defect area the maximum extent of corrosion would be 0.09 inches, assuming a 3-year inspection interval. Based on this discussion, it appears that the licensee did not apply any safety factor to the corrosion rate of 30 mils to cover uncertainties in the corrosion rate. ASME Code Cases (e.g., Code Case N-821) require a factor of 2 to 4 applying to the corrosion rate to consider uncertainties.

(a) Discuss whether the corrosion rate of 30 mils is used in the design of the repair. If yes, discuss whether a factor is used on the corrosion rate in the bolted plate repair method. If a safety factor is not used, provide justification.

Response

The 30 mils per year (mpy) was not used in the design of the repair, however, the repair is adequate for this corrosion rate without a safety factor as discussed herein.

A review of the literature has been performed illustrating that the limiting corrosion rate of carbon steel in oxygen saturated flowing seawater is approximately 30 mils per year.

This rate decreases with increasing exposure time in the environment. The supporting data and discussion are presented below.

As demonstrated in Figure 1, the general corrosion rate of carbon steel exposed to flowing oxygen saturated seawater at approximately 7 ft/s is less than 30 mpy [1].

,t ot -low Rate on General Corrosion ot Carbon steel in Fresh Water and Seawater [1]

L-2013-261 Page 4 of 10 Since the general corrosion rate of carbon steel in aqueous solutions follows parabolic kinetics as shown in Figure 1 and as a sketched in Figure 2, i.e., the amount of corrosion is proportional to the square root of time (/t), the use of a linear general corrosion rate such as 30 mpy is conservative and there is no need for an additional "safety factor' for the corrosion rate, Figure 3 (theoretical calculated curve) [2].

EE 15 E

CF

~Corrosion=4 2 10 0

5 0

0 100 200 300 400 Time Figure 2. Theoretical Calculated Example of General Corrosion Carbon Steel 0.6 0.5 E

E 0.4 0

E Corrosion rate E

CD 6 0.3 0

C.)

0 0.2 U

500 600 vs. Arbitrary Time for 100 200 300 Time 400 500 600

L-2013-261 Page 5 of 10 Figure 3. Theoretical Calculated Example of General Corrosion Rate vs. Arbitrary Time for Carbon Steel Actual general corrosion rate data for carbon steel exposed to seawater is presented in Figure 4 [3], confirming the rate information presented in Figure 3. It can be seen that the corrosion rates decrease with exposure time and the long-term corrosion rates in this environment are very low.

I I

0 0

a: Wrightsville Beach, NC [91 b: Panama Canal Zone [121 c: Wrightsvllle Beach, NC [10]

• Coupon specimen 0 Pilling 0.3 E

C-0.2 0

0.1 ml!

I-I 0

-ee-4 0

00 b'*~

0 0

0 O0 0

0 0

0 0

0 Io0 0

00 10 20 Time of exposure (year) 30 40 Figure 4. Average General Corrosion of Steel Continuously Immersed in Seawater [3]

Figure 4 reveals a long-term exposure general corrosion rate of less than approximately 0.1 mm/y or approximately 4 mpy, which provides significantly more than a safety factor of 4 conservatism in the suggested corrosion rate.

L-2013-261 Page 6 of 10

4. (a) Discuss whether the bolted plate provides structural support to the pipe wall underneath or it simply isolates the defect area from seawater without performing any structural support.

Response

As shown in the calculations no reinforcement of the pipe is required due to the hole, the patch plate acts as a closure plate to isolate the defect area from seawater and provides a pressure boundary for the location. No structural support of the pipe from the patch plate is credited.

(b) On page 4 of the relief request, the licensee stated that the bolt hole drilled into the pipe wall will not exceed 1/4 inch deep to preserve the pipe minimum wall thickness requirement. Discuss the tolerance on the bolt hole depth.

Response

The depth of the bolt holes is controlled in the Engineering Change Package implementation instructions as follows:

Notify Engineering if any excess degradation is observed during cleaning, drilling or pipe thickness at bolt hole locations is <0.350".

Drill and tap 1/44"-20 UNC holes, 1/4" deep on plate bolt pattern.

Do NOT allow holes to exceed 14" depth to maintain minimum wall thickness. (Note due to a field installation problem, 5/16"-18 UNC holes were used at one plate location and shown acceptable in calculation PSL-1FSM-05-031)

These instructions were transferred into the Work Order instructions. The wall thickness readings at the bolt hole locations were documented on inspection reports.

The calculated minimum wall thickness using the design pressure and temperature is 0.090". Using the above limitations provides 0.350"-0.250" = 0.100" which provides a margin of 0.01". However, based on review of the inspection reports, the wall thickness readings at the bolt hole locations range from 0.362" up to maximum of 0.435". Based on this, sufficient margin is provided to ensure that the minimum wall thickness is maintained.

(c) On page 2 of the relief request, the licensee stated that the repair performed in 2012 for intake cooling water pipe 1-30"-CW-29 (Train B) includes three plate sizes--3.5" x 3.5", 7.5" x 11.5" and 10"x 11". The licensee previously installed on intake cooling water pipe 1-30"-CW-30 (Train A) plate sizes of 3.5" x 3.5", 8" x 8", 10" x 11" and 11" x 11".

The licensee presented stress analyses for plate sizes 3.5" x 3.5", 7.5" x 11.5", and 10" x 11", but not 8" x 8" and 11" x 11" as shown in Attachment 2 to the August 5, 2013 submittal. Discuss whether plate sizes, 8"x 8" and 11" x 11" were analyzed. If yes, submit the analysis. If not, provide justification.

Response

The 8"x 8" and 11" x 11" plates were analyzed in an earlier calculation, PSL-1FSM 031 Rev. 1. A copy is attached.

L-2013-261 Page 7 of 10 (d) Discuss the maximum plate size that is qualified to be used in the repair. The NRC staff notes that the plate size should maintain a certain margin with respect to the defect area that it covers. See the following question.

Response

At present, the largest qualified plate by area is the 11" X 11" plate on an approximately 9" corroded area. See discussion in response to question 5, below.

5. Attachment 2 (pages 5 to 8) to the August 5, 2013 submittal provides calculations to demonstrate that reinforcement is not needed if the repair is applied from a minimum assumed hole size of 0.25 inch to a maximum assumed hole size of 30 inches. The NRC staff would have reservations if the repair would apply to a 30-inch hole. The NRC staff notes that the plate size should exceed the hole size by some minimum margin with respect to the hole size to allow for potential corrosion growth.

(a) Discuss the maximum hole size and defect area that is allowed by the relief request.

Response

The reinforcement calculation for holes of 0.25" to 30" inches was performed to provide a bounding calculation so as not to have to re-calculate for each individual hole. It is not the intent to cover a 30" hole with a patch plate. From review of the calculations, if the plate thickness is maintained the same as the pipe wall thickness of.375", then the size of the hole is limited. At present, the largest plate sizes included in the calculations are 7.5" x 11.5" and 11" x 11", with a required plate thickness of 0.360" and 0.341",

respectively. Based on the plate thickness limitation, the maximum dimensions of the plate and hole would be limited to slightly larger than the current calculation allows.

(b) Discuss the minimum margin between the plate size and the defect area and/or holes size that is permitted by the relief request. The minimum margin would be the minimum plate size divided by the maximum allowable defect area or hole size (use the larger of the defect area or the hole size). The NRC staff notes that in general corrosion the defect area is usually larger than the hole size.

Response

Calculations performed for hole size were conservative and not based on the through wall hole dimension (i.e., the 9" hole was actually approximately 5" by 7").

The existing analysis maximum allowable plate versus hole/degradation is based on an 11" X 11" plate (area 121 sq inches) on a 9" diameter hole (63.6 sq inches), 121/63.6 = 1.9 margin. Review of the Engineering Change Packages and Inspection Reports indicates than the margin is typically higher than this value due to the presence of localized pitting instead of wide scale degradation.

6. Section 5 of the relief request appears to state that the bolted plate design will be used to repair a 100 percent through wall defect. Pages 26 and 28 in Attachment 2 to the August 5, 2013 letter identify two holes at two locations on pipe 1-30"-CW-29 and they appear to be part of the repair performed in 2012. After a hole is filled with epoxy and the bolted plate is installed on the inside surface of the pipe, the corrosion could continue to grow laterally from the outside diameter surface if the pipe is in contact with ground water.

L-2013-261 Page 8 of 10 (a) Discuss how the bolted plate repair can eliminate corrosion from the outside diameter surface if the repair is performed on a 100 percent through wall defect.

Response

The bolted patch plate by the use of studs and nuts instead of welding does not impact or destroy the external coatings on the pipe. The corrosion hole is cleaned and filled with epoxy material to the profile of the pipe ID. The application of epoxy to the through wall hole provides protection for the pipe and patch plate. The corrosion cell would need to extend a relative large distance past the gasket seating surface to be visible during internal inspection. Based on UT reading around repair areas, external corrosion has not been observed.

(b) Discuss the defects (e.g., planar cracks) and/or degradation mechanisms (e.g.,

stress corrosion cracking) for which the bolted plate repair will not be applicable.

Response

The bolted plate repair is only applicable to wall loss defects resulting from general corrosion and flow erosion. The bolted plate repair is not applicable for any other types of defects (e.g., planar cracks) or any other local degradation mechanisms (e.g., stress corrosion cracking).

7. Discuss pressure and temperature during normal operation, considering seasonal changes.

Response

Based on the location of this open ended discharge piping downstream of an orifice, during normal operation pressure varies down the pipe from being under a slight vacuum at the orifice [9] to the elevation difference in the piping, which is -12 feet [5 & 6]. There is no instrumentation in this section of piping but an estimation of the pressure range would be slightly less than 0 psig to 5.2 psig. Temperatures in the subject piping during normal operation vary a few degrees above seawater temperatures [7] because there is little heat load on the Component Cooling Water Heat Exchangers during normal operation. DBD-ICW-1 [8] provides the recorded minimum and maximum ocean water temperatures as 520 to 870 F.

8. The relief request stated that the subject pipe is fabricated with A-155 KC-65 (equivalent to SA-106 Grade B carbon steel) and the plate is made of SA-106. The bolt is made of alloy steel, SA-193 Grade B7 and the nut is made of SA-194 Grade 2H.

Confirm that galvanic corrosion is not a concern for the bolted plate assembly and it has not been observed in the repaired locations since 2005.

Response

The most straight forward way to determine whether there is a potential galvanic couple between the SA-106 Grade B carbon steel plate, the SA-193 Grade B7 low alloy steel bolt and the SA-194 Grade 2H carbon steel nut is to evaluate the measured standard electrode potential of the two steel alloys in seawater. Figure 5 presents the galvanic or electromotive series for various metals and alloys exposed to seawater [4].

It is observed that since electrode potentials for carbon steel and low alloy steel in seawater are approximately the same, there would be minimal electrochemical driving force between them to facilitate measurable accelerated corrosion of the carbon steel.

L-2013-261 Attachment I Page 9 of 10 Volts versus saturated calomel reference electrobe (Active)

(Noble)

-1.6

-1.4

-1.2 1.0

-0.8 0.6

- 0.4

-0.2 0

0.2 Graphite Platinum Ni-Cr-Mo alloy C Titanium Ni-Cr-Mo-Cu-Si alloy G 0 Nickel-iron-chromium alloy 825 Alloy 20 stainless steels, cast and wrought II

/

Stainless steel-types 316, 317 Nickel copper alloys 400, K-500 Stainless steel--types 302, 304, 321, 347 Ii J

]

4 silver oj Nickel 200 SlIver-bronze alloys Nickel-chromiumalloy6 6000 0 Nickel-aluminum bronze 70-30 copper nickel Lead Stainless steel-type 430 I

80-20 copper-nickel 90-10 copper-nickel Nickel silver D Stainless steel-types 410, 416 Tin bronzes (G & M)

Silicon bronze [3 Man anese bronze ED Admiralty brass, aluminum brass =3 5OPb-50Sn solder Copper Tin Q Naval brass, yellow brass, red brass Aluminum bronze.

Austenitic" ni'le cs Iroln I

Low-alloy steel L

rbon steel, cast Iron Cadmium U Aluminum alloys Beryllium0 Zinc Magnesium I

Figure 5. Galvanic Series in Seawater [4]

A second and equally important factor for galvanic corrosion is the relative areas of the two materials. In this St. Lucie case, a small area cathode (e.g., low alloy steel bolts) is coupled to a large area anode (e.g., carbon steel bolted plate repair), which is the most favorable condition when galvanic couples cannot be electrically isolated. The reverse combination, i.e., small anode/large cathode is the combination for utmost corrosion concern (e.g., steel nails attaching copper plates to a wooden ship hull or aluminum bolts secured to stainless steel in seawater).

In addition the plate and bolting is encapsulated in epoxy. Therefore, galvanic corrosion is not a concern for the St. Lucie bolted plate assembly.

L-2013-261 Page 10 of 10 References

1. R. Moss, "Effect of Flow Rate on Carbon Steel Corrosion," paper presented at the NACE Western Region Meeting, 1966.

2. H. H. Uhlig and R. W. Revie, Corrosion and Corrosion Control, Third Edition, J.

Wiley & Sons, Inc., New York, NY, 1985.

3. I. Matsushima, "Carbon Steel -

Corrosion by Seawater," Chapter 32, UhliQ's Corrosion Handbook, Second Edition, R. W. Revie, Editor, J. Wiley & Sons, Inc.,

New York, NY, 2000, p. 545.

4. H. P. Hack, "Evaluation of Galvanic Corrosion," Metals Handbook Ninth Edition Volume 13 Corrosion, ASM International, Metals Park, OH, 1987, p. 234.

5. Drawing 8770-G-125 Sh. CW-F-3 Rev. 23

6. Drawing 8770-G-125 Sh. CW-F-10 Rev. 5

7. PI - Process Book EWIS - St. Lucie Unit 1 TCW/CCW Temps Trend 8/28/13

8. DBD-ICW-1 Rev. 4, Intake Cooling Water System

9. Calculation 129154-M-0014 Rev. 2, Hydraulic Analysis of Plant St. Lucie ICW System

10. EPRI Report NP-6608 dated May 1994, Shelf Life of Elastomeric Components

11. SPEC-M-023 Rev. 7, St. Lucie Units 1 and 2 ICW & CW System Inspection and Repair

12. Splash Zone A-788 Carboline Product Data dated March 2013

13. Duromar SAR-UW Product Data Sheet Rev. 05/13

14. Letter from Jerry Arnold of Carboline to Garth Dolderer of FPL dated August 28, 2013

15. 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"

16. SIA Report No. 1300894.403.RO, St. Lucie Unit 1 Relief Request No. 7, Alternate Repair of Intake Cooling Water Pipe - SI Responses to Request for Additional Information Nos. 3, 6.(b), and 8 Page 1 of 1 L-2013-261 DRILL FOR TAPPING 1/4' BLIND HOLE Hote/Degrcdation fitted with Duromar SAR-UW or Carboline Y4' (Max.)

Splash Zone A-788 Do Not Drill Thru 1st Application of Damaged Area Duromar SAR-UW I fl Pipe Wall Concrete Lining or Epoxy Pipe ID Pipe OD

.Trim Studs After Assembly Final coating of CarboLine Splash Zone A-788 2nd Application of Duramar SAR-UW TYP BOLTEb PATCH PLATE rETCH BILL OF MATERIALS 1

STUDS 1/4'-20-UNC x 1 1/8' LONG, SA-193 GRB7, QL-1 (QTY=8) 2 NUTS 1/4' x 20, SA-194-2H, QL-1 (QTY=8) 3 FLAT WASHER 1/4' STD, STEEL, ZINC PLATED, QL-3 (QTY=8) 4 CLOSURE PLATE 8'x8'X3/8' THICK, CUT FROM 30' SA-672 GR C65/70 PIPE OR CUT FROM SA-155 GR 65/70 PLATE AND ROLL TO SUIT, QL-1.

5 GASKET, RED RUBBER, 1/16' THICK, QL-3 CADD FILE ENG 08168-001 R1.DWG

L-2013-261 CALCULATION COVER SHEET Page 1 of 34 Calc # PSL-1 FSM-05-031 Pagelof 18, Rev 1 Calculation No:

PSL-1 FSM-05-031

Title:

Evaluation of 1-30"-CW-30 Patch Plate Repairs This calculation addresses application of bolted repair plates on line 1-30"-CW-30. The subject line has no isolation valves to the discharge canal and operates at near atmospheric pressure. The calculation reviews a repair methodology that blanks off the corrosion holes with bolted plates on the ID of the pipe. Bounding hole sizes are assumed for the analysis.

By Check Apr By Check Apr 1

Add plates for By PCM 08168, EC 274859 Check W,&

(.2.

Apr A~

zN-AJq-~ 1L 0-2 0

Issued For Use By Gordon McKenzie On File 10/30/05 Check W.B. Neff On File 10/30/05 1

Apr P.G. Barnes On File 11/03/05 No.

Description By Printed Name Signature Date REVISIONS Equivalent of Form 82A, rev. 1

L-2013-261 Page 2 of 34 Calc # PSL-1FSM-05-031 Page2of 18, Rev 1 Calculation No:

PSL-1 FSM-05-031

Title:

Evaluation of 1-30"-CW-30 Patch Plate Repairs LIST OF EFFECTIVE PAGES Paae Section Rev 1

Cover Sheet 1

2 List of Effective Pages and Table of Contents 1

3 Sec 1.0, 2.0 Purpose / Scope, Methodology 1

4 Section 3.0 Assumptions, References 1

5 Section 4.0 Data Input 1

6 Section 5.0 Part 1 - Minimum Wall Calculation (ASME NC-3641.1) 1 7

Section 5.0 Part 2A - Reinforcement for 5.5" Hole 1

8 Section 5.0 Part 2A - Reinforcement for 5.5" Hole 1

9 Section 5.0 Part 3A - Plate Thickness for 5.5" Hole 1

10 Section 5.0 Part 4A - Bolt/Gasket Loading for 5.5" Hole 1

11 Section 5.0 Part 5A - Bolting for 5.5" Hole 1

12 Section 5.0 Part 2B - Reinforcement for 9" Hole 1

13 Section 5.0 Part 2B - Reinforcement for 9" Hole 1

14 Section 5.0 Part 3B - Plate Thickness for 9" Hole 1

15 Section 5.0 Part 4B - Bolt/Gasket Loading for 9" Hole 1

16 Section 5.0 Part 5B - Bolting for 9" Hole 1

17 Section 5.0 Part 6 - Reinforcement Zone Interaction Review 1

18 Section 6.0 Results 1

TABLE OF CONTENTS Section Title Paae Cover Sheet 1

List of Effective Pages 2

Table of Contents 2

1.0 Purpose/Scope 3

2.0 Methodology 3

3.0 References 4

4.0 Assumptions 4

5.0 Data Input 5

6.0 Calculation 6

7.0 Results 18 ATTACHMENTS No.

Attachment Title Pages Rev 1

Stress Intensification Review for Unreinforced Tee 1

1 2

Drawing Plate 1: ENG-05192-001, Sheets 1-3 3

1 3

Drawing Plate 1: CRN 05192-12929 6

1 4

Drawing Plate 2: ENG-08168-001, Sheets 1-3 3

1 5

Drawing Plate 3: EC274859-M-001, Sheets 1-3 3

1 Equivalent of Form 82B, Rev 6/94, Form 82C, Rev 6/94

L-2013-261 Page 3 of 34 Calc # PSL-1 FSM-05-031 Page3of 18, Rev 1 St. Lucie Unit 1 Evaluation of 1-30"-CW-30 Patch Plate Repairs 1.0 Purpose / Scope Calculation addresses application of bolted repair plates on line 1-30"-CW-30. The subject line has no isolation valves to the discharge canal and operates at near atmospheric pressure. The calculation reviews a repair methodology that blanks off the corrosion holes with bolted plates.

Calculation determines the minimum pipe wall thickness using design formulas of ASME Section III and the criteria presented within FSAR Table 3.9-3 for reviewing interactions of pressure stress and longitudinal bending stresses. Calculation evaluates 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.

Design concept was used on Unit 1 per NCR 1-380, PSL-1-S-M-90-0002 and JPN-PSL-SEMS-90-012.

Design concept was used on Unit 2 per CR 2005-710, MSP 05010, PSL-2FSM-05-001.

Revision 0 was developed to support EC 235503 (MSP 05192). Revision 0 was subsequently used to support EC 235964 (08168).

Revision 1 provides a general update to address multiple openings and formally encompasses EC 235503 (MSP 05192), EC 235964 (08168), EC 206588 (CRN-08168-12929), and EC 274859. Due to the general revision, revision bars are not utilized.

2.0 Methodolocq¥ Part 1

Develop a minimum pipe wall thickness based on hoop stress and longitudinal bending stress.

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

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

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 ND.

L-2013-261 Page 4 of 34 Calc # PSL-1FSM-05-031 Page 4 of 18, Rev 1

3.0 References 1

St. Lucie Unit 1 FSAR Amendment 24 2

St. Lucie NAMS DataBase 3

Navco Piping Catalog, Edition 11, 1984 4

Code of Record (COR): ASME Section III, Class 3, 1971 Edition With Addenda through Summer 1973 5

COR NC-3641.1(a) 6 Roark's Formulas for Stress & Strain, 6 Edition, page 67 7

EBASCO Backfit Stress Analysis Design Criteria, Rev 3, 12/7/87 8

Piping Isometric 8770-G-125 Sh CW-F-3 Rev 22 9

St. Lucie Unit 1 Stress Calculation 1001 Rev 5, DP19 & 181 10 St. Lucie Unit 1 Stress Isometric: CW-172-12 Rev 5 11 Spool Detail 1-30-CW-30-1 12 EPRI Good Bolting Practices Volume 1, NP-5067 13 Machinery's Handbook, 26 Edition, Industrial Press, Inc., Pages 1490, 1491 14 Fastener Standards, 6th Edition, Industrial Fasteners Institute 15 Drawing ENG-05192-001, Sheets 1-3, Rev 0 16 Drawing ENG-08168-001, Sheets 1-3, Rev 0 17 Drawing EC274859-M-001, Sheets 1-3, Rev 0 4.0 Assumptions 1

Plate material will be a low carbon steel, such as SA/A-106 Grade B (Allowable 15,000 psi)

Equivalent materials are acceptable. For specific materials used, see EC.

2 Fastener material will be SA/A-193 Grade B7 and SAIA-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.

L-2013-261 Page 5 of 34 Calc # PSL-1FSM-05-031 Page5of 18, Rev 1 5.0 Data Input Piping System Inputs:

Pipe Size:

30 Schedule:

0.375 Material:

A-155 KC65 Class 1 t-nominal: tnom 0.375 in Outside Diameter: Do 30 in Corrosion Allowance : (generally 0 for this analysis) 0 in Design P:

90 psig Design T:

125 deg F Stress Analysis Inputs:

ASME Section IlII, Class 3 Piping Isometric 8770-G-125 Sh CW-F-3 Rev 22 Stress Calculation 1001 Rev 5, DP 19 & 181 Stress Isometric: CW-172-12 Rev 5 Code of Record:

ASME Section III, Class 3, 1971 Ed. With Add. through Summer 1973 Piping designed and fabricated per USAS B31.7 Class 3, 1969 Edition Max Stress Long Press. Stress (tnom) (Do NOT include in below Eq's) 1733 psi Eq 8 (P)+(Dead Weight)**

600 psi**

Eq 9 Upset Conditions (P)+(DWt+OBE Inertia)**

846 psi-Eq 9 Emergency (P)+(DWt+DBE Inertia) 1092 psi**

Eq 11 (P)+(DWt +Thermal + Seismic Anchor Moments OBE)-

142 psi*

Stress Allowable Hot: Sh 15000 psi Allowable Stress Range for Expansion Stresses: Sa 22500 psi y coefficient (0.4 if less than 900F) 0.4 Stress Analysis Data Input Vrificion:

Prepared:

I Verified: _._.__

REF 2

2 11 3

3 2

2 REF 8

9 10 9

1,7,8 9

9 9

9 9

9 9

5

• For information only. Data not used by the analysis.

-*Equations Show General Form with Pressure Stress Included The 4 Boxed Max Stress Values Provide the Moment Stress Only (Pressure Stress subtracted out)

L-2013-261 Page 6 of 34 Calc # PSL-1FSM-05-031 Page6of 18, Rev 1

6.0 Calculation Part I - Minimum Wall Calculation (ASME NC-3641.1)

Develop tmin based on Hoop Stress:

tmin based on Hoop Stress (P Do)l(2 (Sh + P y)) + A 0.090 Original Section Modulus:

Z = 3.14/32 (Do^4 - Di^4)/Do 255.167 Nominal WalT tnom 0.375 Mill Tolerance (tnom +/- 12.5%)

0.328 to 0.422 Determine if tmin based on Hoop Stress bounds Longitudinal Stress:

in cu in in in in in cu in psi 61 123x tmin based on Hoop Stress Diameter Inside Di' New Section Modulus Section Modulus Ratio Longitudinal Pressure Stress From above calculation Di'=Do-2tmin Z'= 3.14/32 (DoA4 - Di'A4)/Do SM Ratio = Z I Z' (P Do)/(4 tmin) 0.090 29.820 62.866 4.06 7518 Eq 8 = P + SM Ratio (DWt)

Eq 9 = P + SM Ratio (Dwt + OBE Inertia)

Eq 9 = P + SM Ratio (Dwt + DBE Inertia)

Eq 11 = P + SM Ratio (Th + Dwt + SAM OBE)

May Not Exceed L Stress IIR1.0 Sh 15000 9953 0.66 1.2Sh 18000 10952 0.61 1.8 Sh 27000 11950 0.44 5

6 6

I Sa + Sh 1 37500 16212 0.43 1

a a

a.

Minimum Wall Based On Hoop Stress is Sufficient for Longitudinal Stresses.

The Analysis Table Above Controls. Ignore the Analysis Table Below Determine trmin Based on Longitudinal Stresses:

tmin based on Longitudinal Stress (Guess & Iterate)

Diameter Inside Di' Di'=Do-2tmin New Section Modulus Z' = 3.14/32 (DoA4 - Di'^4)/Do Section Modulus Ratio SM Ratio = Z / Z' Longitudinal Pressure Stress (P Do )/(4 tmin) 0.060 29.881 41.787 6.106 11345 in in cu in psi REF 6

6 1

May Not Exceed L Stress IR<1.0 Eq 8 = P + SM Ratio (DWt)

Eq 9 = P + SM Ratio (Dwt + OBE Inertia)

Eq 9 = P + SM Ratio (Dwt + DBE Inertia)

Eq 11 = P + SM Ratio (Th + Dwt + SAM OBE)

Sh 1.2 Sh 1.8 Sh Sa + Sh 15000 18000 27000 37500 15008 16510 18013 24424 1.00 0,92 0.67 0.65 I

a -

a ~

The Minimum Wall Criteria is 0.090 Inches.

The minimum wall criteria is controlled by the hoop stresses.

L-2013-261 Page 7 of 34 Calc # PSL-1FSM-05-031 Page7of 18, Revl Part 2A - Reinforcement for 5.5" Hole Branch Connection Reinforcement Calculation per ASME Section III, NC-3643.3 q%/MhnI I InitQ nflcrinfinn Dob in outside diameter of branch connection Doh in outside diameter of header dI in inside diameter of branch connection d2 in half width of reinforcing zone, greater of dI orTb+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 lea. =1.41 tc 5.5" Branch Connection (assumed size bounds the two throughwall holes)

Leave 5.5" hole in main line 1-30"-CW-30, std. wall Pipe Code CS-1, Material ASME SA-155, KC65 Class 1 Dob Doh dl d2 L

te Tb (ave)

Tb (min)

Th (ave)

Th (min) tmb tmh P

T S

y A

a a radians 5.5 30 5.5 5.5 0.000 0.000 0.375 0.328 N/A 0.090 90 125 15,000 0.4 90 1.571 dI Tb+Th+(dl/2)

Dob 5.5 3.125 5.5 Tmb=(P*Dob)/ 2 (S+Py) + A Assumed, Bounding Design Assumed, Bounding NC-3643.3 NC-3643.3 NC-3643.3 Assume no reinforcing pad Assume no wall thickness 87.50%

NAMS 87.50%

NC-3641. l(a)

See Part 1 NAMS NAMS See Part 1 See Part 1 See Part 1 Design 360 degrees =2 71 radians NC-3643.3 Not Used Not Used Ref 15, 16 2

15, 16 4

4 4

3 2

3 5

2 2

9 5

5 15, 16 4

1/4" 0

0.7Tb 0

tc w

0 0

L-2013-261 Page 8 of 34 Calc # PSL-1FSM-05-031 Page8of 18, Revl Calculate area required:

Area required = 1.07(tmh)(dl) 0.528 sq. in.

Calculate area available (see ASME Section Ill, ND-3643.3 for clarification):

Area Al = (2*d2-dl)*(Th min-tmh) 1.311 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 1.311 sq. in.

Compare area available to required area:

Avail Required area 1.311 sq. in.

0.528 sq. in.

No additional reinforcement of the assumed 5.5" hole is required.

L-2013-261 Page 9 of 34 Calc # PSL-1FSM-05-031 Page 9 of 18, Rev 1 Part 3A - Plate Thickness for 5.5" Hole Data used in the 5.5" hole plate and bolting analysis is summarized in this section.

Patch Plate Inputs:

Value Units Design Temperature 125 F

Design Pressure 90 psig Base Metal Information Pipe Nominal Wall 0.375 in Material SA/A-155 KC65 CL1 Allowable Stress Table 1-7.1 Assume SA/A-106 Gr. B 15000 psi Patch Information Height 8

in Width 8

in Material SAIA-106 Gr B Allowable Stress Table 1-7.1 SA/A-106 Gr. B or equiv 15000 psi Opening Dimensions Gasket Width 0.75 in Height 8" - 2(1/8" + 3/4")

6.25 in Width 8" - 2(1/8" + 3/4")

6.25 in Bolting Information Diameter 0.25 in Material SA1A193 Gr. B7 Allowable Stress Table 1-7.3 25000 psi Yield Stress Table 1-1.3 105000 psi Number of Bolts 8

Area of Bolt 0.0318 in^2 k for Thread Lubricant N-5000 0.15 Minimum Required Patch Plate Thickness (ASME Section III, NB-3647.2) tm minimum thickness = t + A calculated thickness = d6*(3*P/16*S)h.5 d6 Gasket ID Assume 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% *6.25*((3"90)/(16"15000))^0.5+0 =

0.231 in Required plate thickness is 0.375 in REF 2

2 2

11 4,9 15, 16 15, 16 15, 16 4

15, 16 15, 16 15, 16 15, 16 15, 16 4

4 15, 16 14 12

L-2013-261 Page 10 of 34 Calc # PSL-1 FSM-05-031 Pagel 0 of 18, Revl Part 4A - Bolt/Gasket Loading for 5.5" Hole See Att. 3 for evaluation of alternate bolting.

FLANGE JOINT LOADING/GASKET SEATING CALCULATIONS ASME Section III Appendix E methodology, modified for square patch plate GASKETAREA Value Units W

Pressure Width Gasket Centerline 7

in H

Pressure Height Gasket Centerline 7

in Land Gasket Width 0.75 in b

1/2 Gasket Width Land/2 0.375 in A

Short Dimension Cover 8-2 (0.125) 7.75 in B

Long Dimension Cover B-2 (0.125) 7.75 in C

Short Dimension Gasket ID 8 - 2 (0.125 +.75) 6.25 in D

LongDimension Gasket ID 8 - 2 (0.125 +.75) 6.25 in d

Bolt Diameter 0.25 in N

Number of Bolts 8

PRESSURE AREA P Area W*H 49 in^2 REQUIRED SEATING LOAD (Wm2) y 200 lb/inA2 G Area (A*B)-(C*D)(N'3.14159/4*(d+0.125)A2) 20.1 inA2 Wm2 y* G Area 4023 lb OPERATING SEATING LOAD (Wml)

P ext Patch is on ID, Assume 15 psi external 15 psig P Area W*H 49 in^2 m

Gasket Factor 1

Wml (P ext*P Area)+(G Area*m*P ext) 1037 lb REQUIRED BOLT STRESS/TORQUE Load Greater of Wml or Wm2 4023 lb Bolt Diameter 0.25 in Load/Bolt Load / N 503 lb Bolt Stress Load/Bolt/(3.14/4*Bolt DiaA2) 10245 psi Bolt Torque K*d* (Load/Bolt)/12 1.57 1 ft-lb I~

2ft-lbs specified Part 5A - Bolting for 5.5" Hole See Att. 3 for evaluation of alternate bolting.

The critical areas of stress of mating screw threads are:

1. Effective cross sectional area, or tensile stress area, of the external thread (the bolt)

2. External thread shear area which depends principally on minor diameter of tapped hole

3. Internal thread shear area which depends principally on major diameter of external thread In general, the design goal is for the bolt to break before either internal or external threads strip.

ICW Pipe - SA/A-155 KC65 Class 1 (Lower properties of SA/A-106 Grade B Used)

Bolts: SA/A-193 Grade B7, 1/4"-20 UNC-2A D

Bolt Basic Major Diameter (nominal diameter) 0.250 in n

Threads per inch 20 Thread Class (External) 2A Le' Actual Thread Engagement 0.250 in Esmin External Thread Minimum pitch diameter 0.2127 in Dsmin External Thread Minimum major diameter 0.2408 in Yieldbolt External Thread Yield Strength 105,000 psi UTSbolt External Thread Thread Ultimate Tensile Strength 125,000 psi Enmax Internal Thread Maximum pitch diameter 0.2223 in Knmax Internal Thread Maximum minor diameter 0.207 in Yieldhole Internal Thread Yield Strength 35,000 psi UTShole Internal Thread Ultimate Tensile Strength 60,000 psi REF 15, 16 15, 16 15, 16 15, 16 15, 16 15, 16 15, 16 15,16 15, 16 4

4 4

Ass. 3 4

4 4

15, 16 12 REF 15 15 15 15 14 14 4

4 14 14 4

4

L-2013-261 Aftachment 3 Page 11 of 34 Calc # PSL-1FSM-05-031 Page 11 of 18, Rev1

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 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)]

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

As As = 3.1416 n Le Knmax (1/(2n) +.57735(Esmin - Knmax))

0.061 sq in An An = 3.1416 n Le Dsmin (1/(2n) +.57735 (Dsmin - Enmax))

0.089 sq in J

J factor = (As UTSbolt) / (An UTShole) 1.42 Required Length of Internal Threads Q = J

• Le to Develop Full Bolt Load 0.234 in

3. Load Required to Break Bolt/Screw Pbolt Pbolt = At

• UTSbolt 3789 lbs Governing Bolt/Thread Failure Load Threaded Joint Component Failure Review based on minimum load for bolt Failure Load breakage, external thread strippage or internal thread strippage 3789 lbs 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 13 13 13 13 13 13 w3 2 ft-lbs max torque specified.

Developed Percent of Bolt Yield Strength = M 20%

Nut Factor (Fel-Pro N-5000) 0.15 Bolt Torque = M D Yieldbolt At K / 12 2.00 j ft-lbs :

[71 Specified Field torque is 2 ft-lbs

%Yield

%Ultimate Bolt Stress compared to bolt material strength External Thread Stress compared to bolt material strength Internal Thread Stress compared to hole material strenath 20%

17%

13%

11%

F 27%

16%

L-2013-261 Page 12 of 34 Calc # PSL-IFSM-05-031 Page 12 of 18, Rcv 1 Part 2B - Reinforcement for 9" Hole Branch Connection Reinforcement Calculation per ASME Section III, NC-3643.3 F......

t-.....

Dobhn Uins ou itsidedaeen fbrnhcneto Dob Doh d1l d2 L

te Tb Th tmb tmh P

T S

y A

a tc w

in in in in in in in in in in psi deg F psi outside diameter of branch connection outside diameter of header inside diameter of branch connection half width of reinforcing zone, greater of dl orTb+Th+(dl/2) but not > Dob height of reinforcement zone outside of run or reinforcement = 2.5Tb thickness of attached reinforcing pad thickness of the branch, use minimum thickness of the run, use minimum required minimum wall thickness branch required minimum wall thickness header / run internal Design Pressure internal Design Temperature maximum allowable stress for the material at design temperature coefficient additional thickness angle between axes of branch and run weld throat, smaller of 1/4" or 0.7Tb(ave)

Fig NB-3352.4-2 weld leg, =1.41 tc in deg in in 9" Branch Connection (assumed size bounds the throughwall hole)

Leave 9" hole in main line 1-30"-CW-30, std. wall Pipe Code CS-1, Material ASME SA-155, KC65 Class 1 Dob Doh dl d2 L

te Tb (ave)

Tb (min)

Th (ave)

Th (min) tmb tmh P

T S

y A

a a radians tc w

9 30 9

9 0.000 0

0 0.000 0.375 0.328 N/A 0.090 90 125 15,000 0.4 0

90 1.571 0

0 dl 9

Tb+Th+(dl/2)

Dob 4.875 9

tmb=(P*Dob)/ 2 (S+Py) + A 1/4" 0.7Tb 0

0 Assumed, Bounding Design Assumed, Bounding NC-3643.3 NC-3643.3 NC-3643.3 Assume no reinforcing pad Assume no wall thickness 87.50%

NAMS 87.50%

NC-3641.1(a)

See Part 1 NAMS NAMS See Part 1 See Part 1 See Part 1 Design 360 degrees = 2 7t radians NC-3643.3 Not Used Not Used Ref 17 2,17 17 4

4 4

3 2

3 5

2 2

9 5

5 17 4

L-2013-261 Page 13 of 34 Calc # PSL-IFSM-05-031 Page 13 of 18, Rev I Calculate area required:

Area required = 1.07(tmh)(dl) 0.865 sq. in.

Calculate area available (see ASME Section Il1, ND-3643.3 for clarification):

Area Al = (2*d2-dl)*(Th min-tmh) 2.145 sq. in.

Area A2 = 2L*(Tb min-tmb)/sina 0.000 sq. in.

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

• w'w) 0.000 sq. in.

Area A4= area provided by a reinforcing ring, pad or integral reinforcement 0.000 sq. in.

Area A5=

area provided by a saddle on right angle connections 0.000 sq. in.

Aavail=

Al + A2 + A3 + A4 + A5 2.145 sq. in.

Compare area available to required area:

Avail Required area 2.145 sq. in.

0.865 sq. in.

No additional reinforcement of the assumed 9" hole is required.

L-2013-261 Page 14 of 34 Calc # PSL-1FSM-05-031 Page 14 of 18, Revl Part 3B - Plate Thickness for 9" Hole Data used in the 9" hole plate and bolting analysis is summarized in this section.

Patch Plate Inputs:

Value Units Design Temperature 125 F

Design Pressure 90 psig Base Metal Information Pipe Nominal Wall 0.375 in Material SA/A-155 KC65 CL1 Allowable Stress Table 1-7.1 Assume SA/A-106 Gr. B 15000 psi Patch Information Height 11 in Width 11 in Material SA/A-106 Gr B Allowable Stress Table 1-7.1 SAIA-106 Gr. B or equiv 15000 psi Opening Dimensions Gasket Width 0.75 in Height 11" -2(1/8" + 3/4")

9.25 in Width 11 -2(1/8" + 3/4")

9.25 in Bolting Information Diameter 0.25 in Material SA/A193 Gr. B7 Allowable Stress Table 1-7.3 25000 psi Yield Stress Table 1-1.3 105000 psi Number of Bolts 8

Area of Bolt 0.0318 inA2 k for Thread Lubricant N-5000 0.15 Minimum Required Patch Plate Thickness (ASME Section III, NB-3647.2) tm minimum thickness = t + A calculated thickness = d6*(3*P/16*S)A.5 d6 Gasket ID Assume 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%

• 9.25"((3"90)/(16"15000))A0.5+0

=

0.341 in Required plate thickness is 0.375 In REF 2

2 2,17 11 4,9 17 17 17 4

17 17 17 17 17 4

4 17 14 12

L-2013-261 Page 15 of 34 Calc # PSL-1 FSM-05-031 Page 15of 18, RevI Part 4B - Bolt/Gasket Loading for 9" Hole FLANGE JOINT LOADING/GASKET SEATING CALCULATIONS ASME Section III Appendix E methodology, modified for square patch plate GASKET AREA Value Units W

Pressure Width Gasket Centerline 10 in H

Pressure Height Gasket Centerline 10 in Land Gasket Width 0.75 in b

1/2 Gasket Width Land/2 0.375 in A

Short Dimension Cover 11 - 2 (0.125) 10.75 in B

Long Dimension Cover 11 - 2 (0.125) 10.75 in C

Short Dimension Gasket ID 11 - 2 (0.125 +.75) 9.25 in D

LongDimension Gasket ID 11 - 2 (0.125 +.75) 9.25 in d

Bolt Diameter 0.25 in N

Number of Bolts 8

PRESSURE AREA P Area W*H 100 inA2 REQUIRED SEATING LOAD (Wm2) y 200 Ib/inA2 G Area (A*B)-(C*)-(N*3.14159/4"(d+0.1 25)A2) 29.1 in^2 Wm2 y* G Area.

5823 lb OPERATING SEATING LOAD (Wml)

P ext Patch is on ID, Assume 15 psi external 15 psig P Area W*H 100 inA2 m

Gasket Factor 1

Wml (P ext*P Area)+(G Area*m*P ext) 1937 lb REQUIRED BOLT STRESS/TORQUE Load Greater of Wmn1 or Wm2 5823 Ib Bolt Diameter 0.25 in Load/Bolt Load / N 728 lb Bolt Stress Load/BoltI(3.14/4*Bolt Dia"2) 14829 psi Bolt Torque K*d*(Load/Bolt)/12 2.27 1ft-ibs Prft-lbs specified

• Part 513 - Boltina for 9" Hole REF 17 17 17 17 17 17 17 17 17 4

4 4

Ass. 3 4

4 4

17 12 The critical areas of stress of mating screw threads are:

1. Effective cross sectional area, or tensile stress area, of the external thread (the bolt)

2. External thread shear area which depends principally on minor diameter of tapped hole

3. Internal thread shear area which depends principally on major diameter of external thread In general, the design goal is for the bolt to break before either internal or external.threads strip.

ICW Pipe - SA/A-1 55 KC65 Class 1 (Lower properties of SANA-1 06 Grade B Used)

Bolts: SA/A-193 Grade B7, 1/4"-20 UNC-2A D

Bolt Basic Major Diameter (nominal diameter) 0.250 in n

Threads perinch 20 Thread Class (External) 2A Le' Actual Thread Engagement 0.250 in Esmin External Thread Minimum pitch diameter 0.2127 in Dsmin External Thread Minimum major diameter 0.2408 in Yieldbolt External Thread Yield Strength 105,000 psi UTSbolt External Thread Thread Ultimate Tensile Strength 125,000 psi Enmax Internal Thread Maximum pitch diameter 0.2223 in Knmax Internal Thread Maximum minor diameter 0.207 in Yieldhole Internal Thread Yield Strength 35,000 psi UTShole Internal Thread Ultimate Tensile Strength 60,000 psi Ref 17 17 17 17 14 14 4

4 14 14 4

4

L-2013-261 Page 16 of 34 Calc # PSL-1 FSM-05-031 Page 16 of 18, Revl

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 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)]

2. Review for Potential Stripping of Internal Threads (Before Bolt Breaks) 13 13 As As = 3.1416 n Le Knmax (1/(2n) +.57735 (Esmin - Knmax))

An An = 3.1416 n Le Dsmin (1/(2n) +.57735 (Dsmin - Enmax))

J J factor = (As UTSbolt) / (An UTShole)

Required Length of Internal Threads Q = J

• Le to Develop Full Bolt Load 0.061 0.089 1.42 0.234 sqin 13 sq in 13 13 in 13

3. Load Required to Break Bolt/Screw I Pbolt Pbolt = At

• UTSbolt IPbolt Pbolt = At* UTSbolt 3789 lbs 13 Governing Bolt/Thread Failure Load Threaded Joint Component Failure Review based on minimum load for bolt Failure Load breakage, external thread strippage or internal thread strippage 3789 lbs 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 3 ft-lbs max torque specified.

Developed Percent of Bolt Yield Strength =M Nut Factor (Fel-Pro N-5000)

Bolt Torque = M D Yieldbolt At K / 12 3.00 f-lbs 1

Specified Field torque is 3 ft-lbs

%Yield

%Ultimate Bolt Stress compared to bolt material strength External Thread Stress compared to bolt material strength Internal Thread Stress compared to hole material strength 130%

25%

120%

17%

41%

24%

L-2013-261 Part 6 - Reinforcement Zone Interaction Review Page 17 of 34 Calc # PSI.- I FSM-05-031 Page l7of 18, RevI Based on the size of the individual openings, determine whether additional reinforcement is required per ASME Section NC-3643.3(f) criteria. Additional reinforcement is required if the individual reinforcement zones overlap.

Individual openings are as follows:

EC CR/AR Location Orientation d2 Plate 1 EC 235503 CR 2005-29217 36" east of flange 5:30 5.5 in Plate 2 EC 235964 CR 2008-33008 42" east of flange 11, 12:00 5.5 in Plate 3 EC 274859 AR 1712438 41" east of flange*

3:30 9

in Per picture 38" to edge + 3" to CL Plate 1 Orientation per CR 2005-29217 Section ND-3643.3(e).

Reinforcement Zones extend from centerline (CL) of opening d2 = reinforcement zone length, extends from centerline (CL) of opening.

Internal Diameter 30" Pipe 29.25iin Circumference 30" Pipe 91.89 in Two closest plates are Plate I and Plate 3.

Minimum distance between CL of openings for EC 274859 and EC 235503 (PCM 05192) without imposing Multiple Opening Reinforcement critera:

Minimum CL distance Plate d2 + Plate 3 d2 4.5 in Actual distance between CLs of Plate 1 and Plate 3 in Angle between CLs of Plate 1 and Plate 3 degrees

==

Conclusion:==

The openings for closest holes are spaced sufficiently apart that additional reinforcement criteria per ASME Ill, Section ND-3643.3(f) is not required.

L-2013-261 Page 18 of 34 Calc # PSL-1FSM-05-031 Page 18 of 18, Rev1 7.0 Results Pipe The Minimum Wall Criteria is The minimum wall criteria is controlled by the hoop stresses.

0.090 Inches 5.5" Diameter Opening No additional reinforcement of a 5.5" hole is required.

Required closure plate thickness Is 0.375 Inches Minimum Bolt Torque (114" -20UNC) is 1.57 Ft-lbs Note that the thread engagement in the lCW 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.

Alternate Bolting (Attachment 3)

Minimum Bolt Torque (5116"-18UNC ) is 2.02 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.

9" Diameter Openina No additional reinforcement of an 9" hole is required.

Required closure plate thickness is 0.375 Inches Minimum Bolt Torque (1/4" -20UNC) is 2.27 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 The openings for closest holes are spaced sufficiently apart that:

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

L-2013-261 Page 19 of 34 Calc# PSL-1FSM-05-031, Attachment 1, Rev 1 Page 1 of 1 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:

Verified By:

Approved By:

Date:

/ Z* -/5" / /

,1 Date:

/_________

Date:

I,

.\\

L-2013-261 Page 20 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 2, Page 1 of 3 KEY PL&

Section A-NOTE; For Implem'enting In~struLctions And Bill Of Materioas See Sht. 3 Mechanicol Engineering rLORIOA POWER & LIGHT COMPANY ST. LUCIE PLANT ENG-05192-001 a DIV: Mech DR: P APPROVAL UNIT 1I DATEICH:"0-w"*

..<q Bolted Plate Repair SHEET DATE:

l1PI1of 3/~k

-0 A

ENG 05192-00LDW

L-2013-261 Page 21 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 2, Page 2 of 3 Y4' (Max.)

Do Not Dritt Thru NOTE: For Implementation Instructions And Bilt Of Materials See Sht. 3 I ENG-05192-001 SHEET 2 of 3

L-2013-261 Page 22 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 2, Page 3 of 3 Implementation Instructions

1.

Perform all epoxy and coating applications in accordance with SPEC-C-004 and the instructions of the Coating Specialist.

2.

Fabricate closure plate in accordance with drawing and apply pro-tect-lve Louuting.

3.

Fabricate gasket in accordance with drawing, Cut out of gasket center is required.

4.

Avoiding damage to any coatings or Ethafoam on the pipe OD, prep surface of corrosion holes and Fill with epoxy material to the profile of the pipe ID. Underfill is acceptable, do NOT overfill.

5.

Remuve an 0' x 0' section of the pipe Lining centered nn the aFfected area,

6.

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

7.

Layout bolt hole locations on pipe wall and UT for thickness

8.

Notify Engineering if any excess degradation is observed during cleaning, drilling or pipe thickness at bolt hole locations is <0.350'

9.

DrilL and tap X'-20-UNC hotes, Wc deep on plate bolt pattern.

Do NOT allow holes to exceed X' depth to maintain minimum wall thickness.

10.

Install the studs wrench tight without lubrication.

11. Trial fit plate and enlarge bolt holes as requireo for fit-up.

Grind off any cavity overfill that would prevent gasket crush.

12.

Apply epoxy to pipe beneath closure plate area including gasket area. Caution: Excessive epoxy may prevent proper gasket crush or push out on tightening.

13.

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

14.

Before epoxy hardens, torque nuts 'to 2 Ft-lbs (24 lnch-lbý) irn a crisscross pattern. Retighten if epoxy creep relaxes fastener torque.

15.

Trim studs flush with the tops of the nuts using suitable means.

Avoid excessive heating.

16.

Degrease and surface prep the exposed area.

17.

Cover entire repair area with epoxy coating. Ensure coating is blended to provide smooth transitions to minimize ICW flow turbulence.

BILL OF MATERIALS I

STUDS I/4'-20-UNC x 1 1/8' LONG, SA-193 GRB7, PC-l (OTY=8) 2 NUTS 1/4' x 20. SA-194-2H, PC-l (QTY=8) 3 FLAT VASHER 1/4' STD, STEEL, ZINC PLATED, PC-3 (QTY=8) 4 CLOSURE PLATE 8"xB'X3/8' THICK, CUT FROM 30' SA-672 OR C65/70 PIPE OR CUT FROM SA-155 OR 65/70 PLATE AND ROLL TO SUIT, PC-I.

5 rASKET, RED RUBBER, 1/16' THICK, PC-3

L-2013-261 Page 23 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 3, Page 1 of 6 REVISION NO.

PROCEDURE TITLE:

14A DESIGN CONTROL PROCEDURE NO.

01-3-PSL-1 ST. LUCIE PLANT APPENDIX E CHANGE REQUEST NOTICE (CRN)

(Page 1 of 1) zw 000 U,

=

-'9 CAI cnj wj PC/M or MSP NO.

SUPPLEMENT UNIT CRN No.

12929 Page 1

of.2,_.

,/fk//0 05192 0

1 SR

[3OR Ol NNS Reason for Change: Wrong sied drill bit used to drill for %'-20 tap. Dril bit used was 1/4" THIS CRN SUPERCEDES CRN45192.12926 rf IF Provide Change Description / Before and After (as required):

Drill out existing holes with an 'F sized drill bit and top all the holes (8)for 5/16 -18 bolting. Change Bill Of Materials to reflect 5/16-18 studs 1-118' long A354 GR BD, 5/14' 2H nuts, 5/16' flat washer. 3/8' diameter holes in item 4 may be enlarged to 7/16 if required.

0 01 Affected Documents:

ENG-05192-001 SH 3 Rev.

0

• /*/.-*

Rev.

.Rev. ____

Rev.

.Rev. __

Rev.

Source of Change:

E] Doc. Update Only (Prelim. Eng. Disp. Not Required) 0i Material Substitution 0

Implementor Convenience 0i Existing Condition 0 Implementor Error EO Other This CRN Affects Work Order(s):

WO(s): 35026597-02 Steps(s):

WO(s):..

Steps(s):

Prepared By: BOB GIBBENS Date:

11/7/06 Department PROJECTS Tel. No.: 3443 WO(s) y*euled completion dale SL1-20 IMPL NTN AR'IIENT SUPV. APPROVAL.

• v' 1-, esi as pp!Iab /I ENGINI RING PRELIMINARY DISPOSITImON."

El HOLD 0 PROCEED AT RISK This CRN has been discussed (0 by phone [J In person) with:

Gordon Mckenzie Dept. ENG_ Datel 1/7/06 (N/A if prepared by Engineering or for Doc. Update Only) 4 E]Design Evolution

[]Design / Drafting Error DPIanned rPhysical Field Discrepancy L0 ther Scope of Workc Di Increase Li Decrease [3 Unchanged IMPACT OF CHANGE

1. Design Basis / Analysis Affected

2. 60.68 Applic / Scrn / Eval Affected'

3. PODs Functionally Affected

4. PMT, OPS or Maint Reqmls Affected

5. Document Update Required

6. TEDB Affected

• If Yes Do Not Use CRN YES NO 1:10 0 15 El 0 11IS El 0 El N (9

z Zaw U.1 FINAL DISPOSmON:

D"Approved C3 Not Approved I

r f,*', "it" Cognizant Design Organization (COO)

Date:

f l,5O Date:

Date:

Additional Affected Documents: K Listed Below Lj Listed on Page:

E*(- OS/ 3-Qo/lt ev.

Rev.

-Rev.

Rev.

Rev.

Rev.

Revy.

Re..Re.

Remarks/Basis for Disposition:

END OF APPENDIX E

L-2013-261 Page 24 of 34 PSL-1FSM-05-031, Rev. 1, Att. 3, Page 2 of 6 CRN 05192-12929, Page I. of._L BASIS FOR DISPOSITION CRN 05192-12929 concerns substitution of 5/16" bolting material due to a field drilling error. Per discussion with Planning, some of the subject holes were drilled with a 1/4/" drill bit which is oversize for tapping the design WA"

-20 stud hole. Engineering's direction was to substitute 5/16" fasteners in lieu of the design fasteners at all holes.

Substitute materials for WO 35020597 are addressed below.

Material Design CRN Substitution Stud 1/4"-20UNC-2A, SA-193 Gr B7 5/16"-18UNC-2A. A-354, Gr BD SC 237879-1 Nut 1/4"-20UNC-2B, SA-194 Gr 2H 5/16"-18UNC-2B, Heavy Hex, SA-194 Gr 2H SC 27945-1 Washer 1/4", Std Steel, zinc plated 5/16", Std Steel, zinc plated, SC 27698-3 Fastener materials remain in accordance with SPEC-M-004. Material strength remains in accordance with design assumptions and material type is standard pressure boundary material in ASME Section III design. The use of ASTM stud material in place of ASME stud material (due to availability) is acceptable for use within Unit 1.

The 5/16" size and number of fasteners is adequate to develop the required gasket seating load and the X" depth of stud engagement of the studs is adequate to achieve the required fastener load. Fastener Torque remains unchanged at 2 ft/lbs per attached calculation reviewing fastener substitution.

The slightly coarser thread for the 5/16' bolt will provide marginally fewer number of engaged threads. This reduction is acceptable given the low loads, conservative design (pressure stress provides additional clamping force) and the offsetting increase in stud diameter..

Based on the above, this CRN change is acceptable for use.

L-2013-261 Page 25 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 3, Page 3 of 6 Review of Fastener SubStitution

Reference:

Calc PSL-l FSM-05-031 Rev 0 CRN 05192-12929, Page j3 o'._ý Part 4, Bolt/Gasket Loading Review Note that although the patch plate is on the inside of the piping, the bolted connection is designed as if it were on the OD.

WMter pressure actually decreases bolt load requirements.

FLANGE JOINT LOADING/GASKET SEATING CALCULATIONS Per ASME Section III Appendix E, modified for square patch plate 1/4" stud 5/16" stud Value Value Units GASKET AREA H

W Bolt Centerline Bolt Centerline Land b

I/2 Gasket Width Land/2 A

Short Dimension Cover B

Long Dimension Cover C

Short Dimension Hole D

Long Dimension Hole d

Bolt Diameter N

Number of Bolts Gasket Area (A*B)-(C*D)-(N*3. 14159/4"(d+0.125)^2)

PRESSURE AREA AREA' (of Opening)

WIH REQUIRED SEATING LOAD (Wm2) y Gasket Area (A*B)-(C*D)-(N*3.14159/4*(d4.0.i25)^2)

Wm2 y* Gasket Area OPERATING SEATING LOAD (Wml)

PRESS Use of operating is conservative as patch is on ID AREA' WIH m

gasket factor Wm I (PRESS*AREA')+(AREA*m*PRESS)

REQUIRED BOLT STRESS/TOROUE LOAD Greater of Wnl or Wm2 BOLT DIA LOAD/BOLT Fp= LOAD/N BOUl St1KE*i LUAD/HOLi7(3.141 59i-gOLI UIA"21/4)

BOLT TORQUE K*d*FDt12 7

7 in 7

7 in 0.75 0.75 in 0.375 0.375 in 7.75 7.75 in 7.75 7.75 in 6.25 6.25 in 6.25 6,25 in 0.25 0.3125 in 8

8 20.1164278 19.79736 in^2 49 49 in^2 200 200 lb/in^2 20.12 19.80 ins2 4023.29 3959.47 lb REF (14)

(14)

(14)

(14)

(14)

(14)

(14)

(14)

(14)

(8)

(14)

(15) 60 49 1

4146.99 4146.99 0.25 518.37 I1060.22 1.62 60 psig 49 ln'2 1

4127.84 lb 4127.84 Ib 0.3125 in 515.98 lb 6727.34 psi 2.02 fl-lbs

L-2013-261 Page 26 of 34 PSL-1FSM-05-031, Rev. 1, Att. 3, Page 4 of 6 CRN 05192-i2929, I'agejLOf (I Part 5: Bolt Strength and Thread Engagement Review The critical areas of stress of matiny scitw thieads Ie.

1. Effective cross sectional area, or tensile stress area, of the external thread (the bolt)

2. External thread shear area which depends principally on minor diameter of tapped hole

3. Internal thread shear area which depends principally on major diameter of external thread In general, the design goal is for the bolt to break before either internal or external threads strip.

ICW Pipe - A-1 55 KC65 Bolts: SA-193 Gr B7. 1/4"-20 UNC vs.. A-354 Gr BD. 5/16"-18-2A UNC 1/4" stud 5/16" stud Value Value D Bolt Basic Major Diameter (nominal diameter) 0.250 0.3125 in n Threads perinch 20 18

1. Win Thread Class (External) 2A 2A Le' Actual Thread Engagement 0.250 0.250 In Esmin External Thread Minimum pitch diameter 0.2127 0.2712 in Dsmin External Thread Minimum major diameter 0.2408 0.3026 in Yieldbolt External Thread Yield Strength 105,000 130,000 psi UTSbolt External Thread Thread Ultimate Tensile Strength 125,000 150,000 psi Enmax Internal Thread Maximum pitch diameter 0.2224 0.2817 in Knmax Internal Thread Maximum minor diameter 0.207 0.265 in Yieldhole Internal Thread Yield Strength 30,000 30,000 psi UTShole Internal Thread Ultimate Tensile Strength 55,000 55,000 psi Calc 4 PSL-I FSM-05-031 Page lOofl0 Revo

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

Tensile Area of Screw Thread At UTSbolt < 180 ksi: At =,7854 (D-.9743/n)A2 0.032 0.052 sq in UTSbolt _ 180 Ksl: At = 3.1416 (Esmln/2 -.15238/n)^Z Required Length of Engagement for External Threads Le to Develop Full Bolt Load 0.173 0-223 in Le L

(2*At)

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

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

REF (14)

()4)

(14)

(14)

(17)

(17)

(8)

(8)

(17)

(17)

(81 (8) tl7,18)

As An J

Q As = 3.1416 n Le Knmax (1/(2n) +.57735(Esmin - Knmax))

An = 3.1416 n Le Dsmin (1/(2n) +.57735 (Dsmin - Enmax))

J factor = (As UTSbolt) / (An UTShole)

Required Length of Internal Threads Q = J

• Le to Develop Full Bolt Load 0.064 0.105 0.093 0.152 1.55 1.88 0.268 0.420 sq in (18) sq in in CAUTION: Full thread engagement is not provided by internal threads

3. Load Required to Break Bolt/Screw (Pbolt Pbolt = At* UTSbolt 3978 7865 lbs Governing Bolt/Thread Failure Load Threaded Joint Component Failure Review based on minimum load for Thread bolt breakage, extemal thread strippage or internal 3704 4685 lbs thread strippage Bolt Torque Torque which will fail undamaged joint with actual 10 16 ft-lbs engagement (D*Yield bolt*At*K/121 The Minimum Bolt Torque is 1.62 2.02 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, the torque is limited to 2 ft-lbs which will prevent stripping of the hole.

L-2013-261 Page 27 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 3, Page 5 of 6 DRILL FOR TAPPING 5/16' BLIND HOLE CRN ICRN 05192-12929 PAGE~ -5 0 CADD FILE: CRN 05192-12929 DWO 4

8A

+~

F Dam~aged Area I

w=t1I13

-B=,

NOTE1 For Ir*mpernentation InstruLctions And BiLL Of Materials See Sht. 3 FLORIDA POWER & LIGHT COMPANY ST. LUCIE PLANT ENG-05192-001 UNIT I Bolted Plate Repair Secilons / Oetafls S

oEET 2 of53

L-2013-261 Page 28 of 34 PSL-1FSM-05-031, Rev. 1, Att. 3, Page 6 of 6 CRN 05192-12929 PAGE_ -(

F Imptementotion Instructions CADD FILE: CRN 05192-12929.DWG I.

Perform all epoxy and coating applications in accordance with SPEC-C-004 and the instructions of the Coating Specialist.

2.

Fabricate closure plate in accordance with drawing and apply protective coating.

3.

Fabricate gasket in accordance with drawing. Cut out of gasket center Is required.

4.

Avoiding damage to any coatings or Ethafoam on the pipe OD, prep surface of corrosion holes and fill with epoxy material to the profile of the pipe ID. Underfil is acceptable, do NOT overfill.

5.

Remove an 8' x 8' section of the pipe lining centered on the affected area.

6.

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

7.

Layout bolt hole locations on pipe watl and UT for thickness

8.

Notify Engineering if any excess degradation is observed during cleaning, dr Itl p-....oDoiet.ickness at bolt hole locations is (0.350'

9.

Drill and tap 5/16'-_B-UNC _,oles, 9" deep on plate bolt pattern.

Do NOT allow 6

eed X'" depth to maintain minimum walt thickness.

I.- CRN

10.

Install the studs wrench Night without lubrication,

11.

Trial fit plate and enlarge bolt holes as required for fit-up.

Grind off any cavity overfill that would prevent gasket crush,

12.

Apply epoxy to pipe beneath closure plate area including gasket area. Caution: Excessive epoxy may prevent proper gasket crush or push out on tightening.

13.

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

14.

Before epoxy hardens, torque nuts to 2 ft-tbs (24 inch-ibs) in a crisscrogs pattern. Retighten if epnwy creep relnwie_

fnstener torque

15.

Trim studs flush with the tops of the nuts using suitable means, Avoid excessive heating.

16.

Degrease and surface prep the exposed area.

17.

Cover entire repair area with upuxy Luutir*y. Ernbure LOUting Is blended to provide smooth transitions to minimize ICW flaw turbulence.

BILL OF MATERIALS CRN I STUD:S5/16'-18-UNC x 1 1/8' LONG, A-354 GRBD, PC-I (QTY=8) 2l NUTS 5/16" x 18, SA-194-2H, PC-i (QTY=8)

FLAT XJASHFR 5/16 ISTD.

STFEI.,

ZINC PLATED, PI-3 (OTY=*

4 CLOSURE PLATE 8'x8'X3/8, THICK, CUT FROM 30' SA-672 OR C65/70 PIPE OR CUT FROM SA-156 OR 65/70 PLATE AND ROLL TO SUIT, PC-I.

5 GASKET, RED RUBBER, 1/16' THICK, PC-3

L-2013-261 Page 29 of 34 PSL-1FSM-05-031, Rev. 1, Att. 4, Page 1 of 3 KEY PLAN 2' ETHAFOAM 220 I-30'-C'S-30 Carbon Steel Pipe STD WST (375 waVt)

A-155 KC65 Cement Lined Section A-A NOTE, For Imptementing Instructions And BILL Of Materios See Sht, 3 FLORIDA POWER & LIGHT COMPANY ST. LUCIE PLANT UNIT 1 ENG-081 68-001 Bolted Plate Repair SHEET 1 of 3 ENG 08168-O0DWG

L-2013-261 Page 30 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 4, Page 2 of 3 Section C-C 48' I

4' NOTE' For Implementatlor Instructions And BILL OF MaterlaLs See Sht. 3 FLORIDA POWER & LIGHT COMPANY ST. LUCIE PLANT UNfT 1 ENG-081 68-001 2of3 0

Bolted Plate Repair Sections /

Details ENG 08168-OOIOWG

L-2013-261 Page 31 of 34 y

PSL-1FSM-05-031, Rev. 1, Att. 4, Page 3 of 3 Implementation Instructions

1.

Perform all epoxy and coating applications In accordance with SPEC-C-0D4 and the Instructions of the Coating Specialist.

2.

Fabricate closure plate In accordance with drawing and apply protective coating.

3.

Fabricate gasket In accordance with drawing. Cut out of gasket center is required.

4.

Avoiding damage to any coatings or Ethafoam on the pipe OD, prep surface of corrosion holes and fill with epoxy material to the profile of the pipe ID. Underfltt is acceptable, do NOT overfILL.

5.

Remove an 8' x 8' section of the pipe lining centered on the affected area,

6.

Clean and smooth Interior of pipe to support closure plate fit-up,

7.

Layout bolt hole locations on pipe wall and UT for thickness

8.

Notify Engineering if any excess degradation Is observed during cleaning, drilling or pipe thickness at bolt hole locations is <0.350'

9.

Drill and tap,'-20-UNC holes, M' deep on plate bolt pattern.

Do NOT allow holes to exceed X%' depth to maintain minimum wall thickness.

10, Instatl the studs wrench tight without lubrication.

11, Trial fit plate and enlarge bolt holes as required for fit-up, Grind off any cavity overfill that would prevent gasket crush,

12.

Apply epoxy to pipe beneath closure plate area including gasket area. Caution' Excessive epoxy may prevent proper gasket crush or push out on tightening.

13.

Before epoxy hardens, Install gasket, closure plate, washers and nuts (lightly Lubricated).

14.

Before epoxy hardens, torque nuts to 2 ft-lbs (24 Inch-lbs) In a crisscross pattern. Retighten If epoxy creep relaxes fastener torque,

15.

Trim studs flush with the tops of the nuts using suitable means, Avoid excessive heating, 16, Degrease and surface prep the exposed area.

17.

Cover entire repair area with epoxy coating. Ensure coating Is blended to provide smooth transitions to minimize ICW flow turbulence.

BILL OF MATERIALS 1

STUDS 1/4'-20-UNC x 1 1/8' LONG, SA-193 GRB7, PC-I (QTY=8) 2 NUTS 1/4' x 20, SA-194-2H, PC-I (QTY=8) 3 FLAT WASHER 1/4' STD, STEEL, ZINC PLATED, PC-3 (QTY=8) 4 CLOSURE PLATE 8'x8'X3/8' THICK, CUT FROM 30' SA-672 GR C65/70 PIPE OR CUT FROM SA-155 GR 65/70 PLATE AND ROLL TO SUIT, PC-1.

5 GASKET, RED RUBBER, 1/16' THICK, PC-3 Mechanicol Engineering FLORIDA POWER & LIGHT COMPANY

-ST.

LUCIE PLANT ENG-08188-OO1 DIV:

Mech DR" PDB APPROVAL uNI 1 OH:

Baited Plate Repair SHEET DATE' I Wite--ot, Bill Of Materials And Notes 3 of 3 A

04008160O~tOW A

ENO 08168-O00LWO-

L-2013-261 Page 32 of 34 PSL-1 FSM-05-031, Rev. 1, Att. 5, Page 1 of 3 KEY PLAN

'/- a l-30 "-CW 4-30 Carbon Steel Pipe STD WST (.375 watL)

A-155 KC65 CLASS I

\\

Cement Lined Section A-A NOTE, For Implementing Instructlons And Bitt Of Materlals See Sht, 3 FLORIDA POWER & LIGHT COMPANY ST. LUCIE PLANT UNrT I Bolted Plate Repair IE0274859-M-OO1

L-2013-261 Aftachment 3 Page 33 of 34 y PSL-1FSM-05-031, Rev. 1, Att. 5, Page 2 of 3 4

Section B-B NOTE, For Implementatlon Instructions And BiLt Of Materials See Sht, 3 Mechani cl Enineering FLORIDA POWER &L UGHT COMPANY ST. LUCIE PLANT EC274859-M-001 DIV: Mech DR: PD0 APPROVAL uNrr CH:

TIJ Bolted Plate Repair SHEET DATE:

[

t Sections / Details 2 of 3 FO A

EC274859-M-O0 tMDV

L-2013-261 Page 34 of 34 PSL-1FSM-05-031, Rev. 1, Att. 5, Page 3 of 3 ImpIemenfation Instructions

1.

Perform oil epoxy and coating applications In accordance with SPEC-C-004 and the instructions of the Coating Specialist,

2.

Fabricate closure plate In accordance with drawing and apply protective coating.

3, Fabricate gasket In accordance with drawing. Cut out of gasket center Is required.

4.

Avoiding damage to any coatings or Ethafoam on the pipe OD, prep surface of corrosion holes and fill with epoxy material to the profile of the pipe ID. Underfll Is acceptable, do NOT overfill.

5.

Remove a 12' x 12' section of the pipe lining centered on the affected area,

6.

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

7.

Layout bolt hole locations on pipe wall and UT for thickness

8.

Notify Engineering If any excess degradation Is observed during cleaning, drilling or pipe thickness at bolt hole locations Is <0.350"

9.

Drill and tap )('-20-UNC holes, X' deep on plate bolt pattern.

Do NOT allow holes to exceed 9' depth.

10.

Install the studs wrench tight without lubrication,

11.

Trial fit plate and enlarge bolt holes as required for fit-up.

Grind off any cavity overfill that would prevent gasket crush, 12, Apply epoxy to pipe beneath closure plate area including gasket area, Caution, Excessive epoxy may prevent proper gasket crush or push out on tightening.

13.

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

14.

Before epoxy hardens, torque nuts to 3 Ft-tbs (36 Inch-Ibs) In a crisscross pattern. Retlghten If epoxy creep relaxes fastener torque.

15.

Trim studs flush with the tops of the nuts using suitable means.

Avoid excessive heating,

16.

Degrease and surface prep the exposed area.

17.

Cover entire repair area with epoxy coating. Ensure coating Is blended to provide smooth transitions to minimize ICS flow turbulence.

BILLL OF MATERIALS 1 STUDS l/4'-20-UNC-2A x 1 1/8' LONG, SA-193 GRB7, QL-1 (QTY=8) 2 NUTS 1/4' x 20-UNC-2B, SA-194-2H, IL-I (QTY=8) 3 FLAT VASHER 1/4' STD, STEEL, ZINC PLATED, QL-4 (QTY=8) 4 CLOSURE PLATE 11' x 11' x 3/8' THICK, CUT FROM 30' SA-672 GR C65/70 CLASS 22 OR 42 PIPE OR CUT FROM SA-155 GR 65/70 PLATE AND ROLL TO SUIT, DL-1.

5 GASKET, RED RUBBER, 1/16' THICK, QL-3 Mechanic Engineering FLORIDA POWER & LIGHT COMPANY DIV:

APROA 9EiST.

LUCIE PLANT EC274859-M-O01 D

D:Mc R:

B APPROVAL UNrr 1 CH:

I f -.,_.

a:,,

Boiled Plate Repair SHEET DATE:

i-I

/ /PL'qjJ*j/

Bill Of Materials And Notes 3 of 3 0'O A

EC274059-M-OOtOWG a

EC274859-M--O0tNW