ML20214V295
| ML20214V295 | |
| Person / Time | |
|---|---|
| Site: | Peach Bottom  |
| Issue date: | 04/28/1987 |
| From: | PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC |
| To: | |
| Shared Package | |
| ML20214V226 | List: |
| References | |
| PROC-870428, NUDOCS 8706120045 | |
| Download: ML20214V295 (18) | |
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2870040960 Docket No. 50-278 DESCRIPTION OF PLM4S FOR RECIRCULATION NO RESIDUAL HEAT REMOVAL SYSTEMS PIPING REPLACEMENT AT PEACH BOTTOM UNIT 3 DOCKET No. 50-278 APRIL 28, 1987 8706120045 870529 PDR ADOCK 05000278 P
PDR i
2870040960 Description of Plans for Peach Bottom Unit 3 Recirculation and Residual Heat Removal Systems Piping Replacement outline Itan Page 1.0 Introduction 1
1.1 Purpose 1
1.2 Scope 1
2.0 Project Description 1
2.1 Scope of Work 2
2.2 Overall Organization 5
2.3 Project Managanent 6
2.4 Engineering 6
2.5 Contractor 6
2.6 Support Services 6
2.6.1 Quality Assurance 6
2.6.2 Health Physics 6
2.6.3 Consultants 6
2.6.4 Licensing 6
2.6.5 Authorized Nuclear inspector 7
3.0 Description of Work 7
3.1 Defueling/ Fueling 7
3.2 Work Sequence 7
3.3 Systen Testing for Startup 8
4.0 Replacement Design 8
4.1 Material Selection 8
4.2 Piping Design improvenent 9
5.0 Health Physics Control 10 6.0 Codes & Standards 10 7.0 Quality Assurance / Quality Control 11 t
2870040960 Itsn (Continued)
Page 8.0 Training 11 8.1 Mockup Training 11 8.2 Welder Qualification 12 8.3 Health Physics 12 9.0 Piping Analyses 12 9.1 Nuclear Class I Component Evaluation 12 Based on ASME Section III 9.2 Piping Stress Analysis 13 9.3 Pipe Support Design 14 10.0 111ustrations 15 10.1 Figure 1 Modified Recirculation Piping
2870040960 1.0 introduction 1.1 Purpose This submittal describes the activities and system design for the replacement of the recirculation system piping on Peach Bottom Unit 3.
1.2 Scope This submittal describes the engineering, design, procurement, removal and Installation of the recirculation system piping and portions of the residual heat removal (RHR) system piping. The configuration of the replacement recirculation and RHR piping Is shown In Figure 1-1.
2.0 Project Description It is planned to chemically decontaminate, renove, and replace the Recirculation and RHR Shutdown Cooling piping inside primary containment. The 10 recirculation system inlet nozzle (N-2) safe-ends, the two-outlet safe-er.ds (N-1), the core spray safe ends and the two Jet puno instrment seals at the (N-8A, N-88) RPV nozzles will be replaced. The replacement material will be 316NG which has Improved resistance to IGSCC.
The Inlet safe-ends have been redesigned to eliminate the creviced regions which are conducive to IGSCC. Large bore piping will be electropolished to reduce the rate of *adioactive buildup on the piping inside surface to reduce future personnel radiation exposure.
The existing mirror Insulation on the piping will be replaced with soft, fiberglass, blanket-type insulation.
In addition, the eight ECCS pmp suction strainers in the torus (4 RHR and 4 Core Spray) will be replaced with larger strainers meeting the reouirements of NRC Regulatory Guide 1.82 as a result of the use of the replacement fiberglass blanket-type Insulation. All snubbers will be removed frcm the drywell during the piping replacement. Scme snubbers and pipe whlp restraints may not be reinstalled due to redesign.
Containment penetrations for the RHR and RWCU systems are planned to be replaced to eliminate uninspectable welds; however, consiceration for utilizing a corrosion resistant overlay on the Inside surface for these welds is being Investigated versus complete replacement of the penetrations. The existing piping will be removed, packaged and shipped off site for further decontamination and volume reduction prior to ultimate disposal. Selected samples of pipe welds reported to have Indication = will be retained for examination, l
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2870040960
. 2.1 Scope of Work 2.1.1 Recirculation System (loops "A" and "B"):
a)
The 28 inch suction and discharge lines and 12 inch Jet puno inlet riser lines will be replaced. The existing 22 inch nelnifolds wl11 be replaced with redesigned nenifolds which will eliminate the existing equalizer line and valves (M0-65A, M0-65B and M0-66A, MO-66B) between the "A" and "B" loop manifolds, the sweepolet fittings, and end caps.
In addition, seaniess 12 inch double and single bend Jet punp Inlet riser piping will be utilized. The existing Recirculation suction and discharge valves and punps will be reused.
b)
Two new Jet pump instrunent seals and extension piece forgings will be Installed since IGSCC Indications had been previously detected during nondestructive exanination of the existing jet pum Instrunent seals (located at RPV nozzles N-8A and N-8B).
Inconel 182 butter is being eliminated.
c)
A decision to replace all 10 Jet pump Inlet piping safe-ends was nede since IGSCC had been previously detected in the creviced region of the thernal sleeve to safe-end attachnent welds during nondestructive examination. The new design renoves the connecting wold of the thernel sleeve to the safe-end fran the pressure boundary, eliminates the creviced region, provides for improved UT Inspectability and provides an IGSCC resistant barrier between the coolant and the Alloy 182 butter.
An alternate design which replaces the Inconel 182 butter with a noterial that is more resistant to IGSCC is a contingency in the event significant butter cracking is observed upon safe end renoval. The new safe-end noterial Is 316NG which has improved resistance to IGSCC.
d)
Both recirculation outlet safe ends wi be repl aced. The new design provides for improved U.T. Inspectability, provides an IGSCC resistant barrier between the coolant and the Alloy 182 butter and employs of nore IGSCC resistant noterial (316 NG). An alternate design which replaces the inconel 182 butter with a notorial that is more resistant to IGSCC is a contingency in the event of significant butter cracking.
2870040960 5-In addition, the two core spray safe ends will be replaced.
2.1.2 RHR Shutdown Cooling System; a)
The 20 inch Suction line will be replaced from the Recirculation tee up to contairvnent penetration N-12.
b)
The 24 inch Return 1ines (loops "A" and "B")
will be replaced frcm the recirculation tee to containment penetrations N-13A and N-13B.
c)
A set of replacement containment penetrations (1-20 inch and 2-24 inch) for the RHR shutdown cooling suction and return lines are planned to be Installed to eliminate uninspectable welds; however, consideration for utilizing a corrosion resistant overlay on the Inside surface for there welds is being investigated versus a complete replacement of the penetrations.
d)
The containment flued head fitting anchor locations on the RHR Shutdown Cooling lines will be modified (stiffened) to canpensate for the higher design loads on the piping.
1.2.3 insulation
The replacement piping insulation will be a glass fiber type insulation. This insulation is comprised of a flexible, low density, fibrous glass pad insulation, encapsulated in a woven glass cloth forming a canposite blanket. The Insulation will have separately applied stainless steel Jacketing and a mechanism for locating and identifying each weld under the insulation. Renovable insulation sections will be provided at all welds to facilitate inservice Inspection. This insulation has already been reviewed and approved per NRC Regulatory Guide 1.82, Rev. 1, and has been used on PB-2 piping replacement effort.
2.1.4 ECCS Punp Strainers:
The existing 8 ECCS strainers in the torus (4 core spray and 4 RHR) will be replaced with larger strainers meeting the requirements of NRC Regulatory Guide 1.82, Rev. I lssued Novenber 1985 to preclude blockage and head loss to the ECCS Punps in the event of Insulation becoming lodged against the inlet strainers.
4-2870040960 2.1.5 Pipe Whip Restraint Deslan:
Where the piping configuration has not been changed and existing pipe whlp restraints can be reused, the criteria for break location will be in accordance with the original design basis.
The original design basis was the General Electric Docunent,
" Design Report Recirculation System Pipe Whip Restraint for the BWR 4, 218 and 251 Mark I and Mark II Product Line Plant". Where the piping configuration has been changed, as with the header, and new pipe whip restraint design and/or analysis is needed, it will be done to the latest criteria; NRC Regulatory Guide 1.46, Standard Review Plan 3.6.2 and Branch Technical Position MEB 3-1 requirements.
2.1.6 ALARA
The principal objective of the Al. ARA program is to maintain collective radiation exposure "as low as reasonably achievable". This objective is attained by reducing:
a)
The radiation levels in the work area.
b)
The nurber of personnel In the radiation area.
c)
The amount of time In the radiation fleid.
An ALARA plan is being Invlemented for the pipe replacement project. The major elements of the plan are:
a)
Calculation of dose estimate for the project, b)
Identification and use of of dose mitigating measures.
c)
Contamination control.
d)
Access control.
e)
Organization and Administration.
f)
Proper work planning including work packages and radiation work permit adninistration, g)
Training.
h)
Perfonmnce of surveys and measurements.
1)
Dose tracking and reporting.
2.1.7 Engineered Support and Restoration:
The piping removal, disposal, and replacement piping procurement, fabrication, polishing, and Installation at Peach Bottcm 3 will be performed in accordance with specifications, procedures, and drawings prepared by PECo or PEco vendors and will be reviewed and approved before being utilized.
2870040960
-s-The procedures, specifications and drawings will address the design, analyses, and procurement of the recirculation system piping and safe ends, Jet punp Instrunent safe ends, core spray safe ends, RHR and RWCU systems, bottan head drain piping, electropolishing of the replacement piping, and the preoperational and startup testing of the replacement piping installation. The Installer will prepare procedures required for renoving the existing piping and installing replacement piping; they will also furnish procedures for the disconnection, removal, and reinsta11ation of any mechanical equipment, piping, or structural steel Interferences.
A IIst will be developed Identifying all Interferences that need to be removed. These items will be checked to assure that proper docunentation exists to restore the Interference. This evaluation involves a review of the documentation requirements to reinstall the items, a review of regulatory changes which may affect the reinsta11ation, and a cost / benefit analysis of the effort required to remove and reinstall the item as conpared to the performance of work in an alternative manner that would eliminate the need to remove the Interference.
All design, docunentation and drawings will be prepared to facilitate the reinstallation.
Material movement paths, laydown storage areas and procedures and techniques for protecting items for reuse will be Identlfled.
A material control and tracking system will be designed that is capable of tracking all items as they are removed, stored, reworked, and reinstalled.
2.2 Overall Organization The project is organized with Philadelphia Electric Conpany (PEco) providing the overall direction to the engineers and contractors involved. PECo will also review and approve the specifications and procedures to be used.
Each engineer or contractor will perfonn his work under the controls provided by his or PEco's Quality Assurance Plan and Implementing procedures. An overall project interface docunent has been prepared to provide control of the Interfaces between the Individual organizations' procedures.
. 2870040960 2.3 Pro. lect Management PECo is responsible for overall project management. The services of the engineers and contractor are used to prepare major docunents and schedules at PECo's request.
l 2.4' EngineerIno i
Engineering and major material procurement will be provided in ceneral by the organizations which did so for the original plant Installation. General Electric Company (GECo) will design and provide material for the Reactor j
Recirculation System. Bechtel Power Corporation (Bechtel) will design and provide material for the portions of the RHR 4
System which are being replaced.
1.
2.5 Contractor
)
Chicago Bridge and Iron Conpany (CBI) will be the prime contractor for the pipe replacement work.
2.6 support services 2.6.1 Quality Assurance i
Each engineering organization and contractor provides the required quality control services for items within their scope of work.
In addition Philadelphia Electric Company performs periodic audits of the project participants to verify conpliance with contractor's QA/QC plan and
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procedures.
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2.6.2 Health Physics j
i The required health physics controls are provided l
as part of'a Radiation Protection Management
)'
program being conducted by General Electric under the direction of PECo. General Electric personnel I
will be assisted by CB&I and by subcontractors, Including some contractors working directly for CBI.
i 2.6.3 Consultants Consultants have been retained as needed to provide specific expertise or supplement the activltles of 1
PEco personnel.
2.6.4 Licensino i
Licensing will be directed by PECo with specific i
assistance being provided for submittals by the engineers and contractor.
1 1
2870040960
_7-2.6.5 Authorized Nuclear Inspector The authorized nuclear inspector will be Hartford Steam Boller Inspection and Insurance Ccmpany.
3.0 Description of Work 3.1 Defue1Ino/Fuelino Prior to initiation of the piping replacement, the entire core will be off-loaded and stored in the fuel pool.
Following core off-loading it is anticipated that due to ALARA considerations, some peripheral control rods will be removed as well.
Following ccmpletion of the pipe replacement and other maintenance tasks associated with the refueling outage, the core will be reloaded to cormlete the refueling portion of the outage.
3.2 Work sequence The construction plan is divided into four phases:
Phase One - Interference Ranoval and Piping Decontamination Phase Two - Sever / Remove Existing Piping Phase Three - Machine / install New Piping Phase Four - Interference Restoration / Testing a)
Phase One - Interference Removal and Piping Decontamination.
During this phase final planning will be done, drywell systems which will Interfere with the piping changeout will be checked, and, where appropriate, termorarily removed. The drywell RHR and recirculation systems piping will be prepared for removal. Both systems will be decontaminated to the extent practical to minimize exposure to those personnel involved in the modifications.
b)
Phase Two - Sever / Remove Existing Piping.
Following system decontamination and the removal of Interferences In the drywell, equipnent will be set up to cut and remove the recirculation and RHR piping. To accelerate this renoval, the existing system will be cut into manageable pieces for removal from the drywell.
System severing will be done with the use of plasma cutting or machining. Mockups will be made and a system for containing alrborno contamination for certain cutting and welding operations will be tested prior to use Inside the drywell.
8-2870040960 c)
Phase Three - Machine / Install New Piping.
This phase covers the preparation of'In-place weld joints and Installation of the new recirculation and kHR piping loops. Retrote automatic welding and machining processes will be utilized as much as possible for ALARA considerations.
d)
Phase Four - Interference Restoration / Testing.
Inventory control Inplemented when systems or structures are removed will assure proper restoration of replaced, modified, and temporarily modified components and systems within the drywell prior to restarting the unit.
3.3 system Testino for startup Non-destructive examination (NDE) techniques Involving radiographics, ultrasonics,11guld penetrant testing, and/or magnetic particle testing will be employed as required by the appilcable codes during fabrication and installation.
Testing will be performed in accordance with PECo-approved procedures.
Upon completion of Installation work, a baseline examination will be made of all new piping welds in accordance with Section XI of the ASME Code and the PECo In-Service Inspection (ISI) program.
A pre-operational test program will be developed and implemented for replaced, modified, and systems temporarily 1
modified for Interference removal.
In addition surveillance testing will be perfonned prior to startup in accordance with the Technical Specification.
4.0 Replacement Deslan 4.1 Material Selection The existing piping made from Type 304 material will be replaced with Type 316 Nuclear Grade (NG) material in accordance with NUREG-0313 Rev. 1.
Type 316 NG is an austenttic stainless steel with a high resistance to IGSCC in the BWR environmental due to its low carbon content and the addition of molybdenun. This material has a carbon content not exceeding.02 weight percent.
In addition, the nitrogen content to this alloy is controlled to counter-balance the loss in strength due to the relatIvely low carbon content.
Increased resistance to pitting and sensitization is provided by the addition of molybdenun.
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2870040960 9-4.2 Piping Deslan Invrovement -
To reduce susceptibility to IGSCC further, the recirculation M-system has been redesigned to reduce the total nunber of welds and the nunber of fleid welds. Design improvements of the replacement pipe and safe ends incorporate :
1.
Use of bent pipe for 12-inch risers to eliminate 20 welds.
2.
Use of extra long tangent 28-inch elbows to reduce the number of welds by 4.
3.
Deletion of end caps by using 12-inch Induction bent pipe and a reducer on the ends of the 22-inch headers to reduce the nuTber of welds by 2 and to eliminate the crud traps formed by the end caps.
4.
Deletion of header sweepolets by using a header with extruded outlets.- This eliminates 8 welds. The stress indices for the extruded outlets are lower than those for the original sweepolets.
5.
Use of a single forged piping fitting to replace the RHR return tee, cross and reducer. This-eliminates 2 welds.
6.
Elimination of the bypass IInes connections. This eliminates 2 welds since the Decon connections are still needed.
7.
Use of seamless pipe to eliminate the longitudinal welds during manufacture.
8.
Elimination of the header cross tie and equallzer valves and respective bypass lines. This eliminates 4 welds.
9.
Elimination of the creviced regions of the recirculation safe-ends.
The new design incorporates features to facilitate 151, reduce radiation buildup and minimize Installation time.
In addition to the above described work scope related to IGSCC mitigation, the following engineered modifications are planned:
l.
Redesign and upgrade of the bottom head drain to eliminate crud traps, thereby reducing future radiation bulldup.
2.
Replacement of a portion of the RWCU piping (elbow spool inside the drywell and piping outside drywell up to the RWCU regenerative heat exchanger).
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3.
Removal of the Rtu Head spray line.
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4.
Deletion of pipe whip restraints associated with the elimination of the arbitrary Intermediate pipe breaks.
Changes are anticipated to the Technical Specifications for the following:
1.
Deletion of the recirculation loop cross tie connection y
piping.
N 2.
Ek imination of LLRT requirenents for valves associated with th! Head Spray piping which is to be removed..
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Mirdr changes to the bases.
5.0 Health Physics Control
( ' A Job specific radiation protection program has been formulated to assure that reasonable steps will be taken to reduce radiation exposure and contamination.
l 6.0 Codes and Standards G
1.
The Recirculation, RHR piping and pentetrations will be designed in accordance with the ASME BCPV Code,Section III 1980 Edition up to and including the Winter 1981 Addenda.
New supports for the Recirculation and RHR piping will be h'
designed to ASME Section III, Subsection NF, 1980 Edition up to including the Winter 1981 Edition up to and including the Winter 1981 Addenda. Modifications to existing supports will be designed to USAS B31.1, 1967 Edition. Piping material was purchased in accordance with ASME Section III, 1980 4
Edition up to and including the Winter 1981 Addenda. Welding will be performed in accordance with ASME Section IX,1980 Edition up to and including the Winter 1981 Addenda.
Nondestructive examination will be performed in accordance with ASME SectJon V, 1980 Edition up to and including the Winter 1981 Addenda for welds to new piping and equipment and
+b USAS B31.1'--1967 for welds to reused piping equipment. The replacement' work is being performed in accordance with ASME Section XI, 1980 Edition uri to and including the Winter 1981 Addenda. All pipe replacement work ccmpiles with UFSAR requi rewncs. The elimination of pipe whip restraints per R
the appilcation of AIB elimination criteria per NUREG 1061 will require prior NRC approval.
2.
The Preservice nondestructive examination will be performed in accordance with ASME Section XI 1980 Edition up to and g
including Winter 1981 Addenda as detailed in the Peach Bottom Inservice Inspection (ISI) program.
/
3.
The Unit 3 replacement program will be reviewed with the ANII prior to irrplementation.
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2870040960
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4.
In addition to the Code required welder qualification tests, welder proficiency will be demonstrated on full scale neckups of the. piping prior to working on actual piping In the contairvnent.
5.
An ASME Section XI hydrostatic test for the recirculation and RHR piping will be performed in conjunction with that to the reactor pressure vessel. A separate hydrostatic test will be performed for the RWCU system.
6.
An Integrated lea'K rate test (ILRT) will be performed.
7.
- The replacement penetration pressure test will be perfonned in conjunction with the containment Integrated leak rate test (ILRT).
7.0 Quality Assurance / Quality Control The replacement work will be controlled by Chicago Bridge and Iron's (CBI) Quality Assurance Program. The program utilized CBI's standard manuals, namely, " Nuclear Quality Assurance Manual for Repairs and Alterations", and, " Nuclear Quality Assurance Manual for ASME Section III Products". Both of these programs have been approved by an ASME survey team. CBI's Quality Assurance and Quality Control activities will be subject to audit by PECo's Engineering & Research Department Quality Assurance Organization.
In addition their code related work will be inspected by an Authorized Nuclear Inspector.
8.0 Training 8.1 fiockup Training 3.1.1 Plasma Arc Cutting and Machining Operations Operators for either the Plasma Arc Cutting or machining operation will be trained on mockups simulating expected drywell conditions.
Operators shall demonstrate their ability to perform the required operation (s) in the drywell.
8.1.2 Welding Processes Welders will be required to demonstrate an ability to make quality welds under expected drywell conditions prior to perfonning work inside the I
drywell.
Physical restraints such as space, position, and obstructions, etc. will be mocked-up full scale.
Additionally, welders will be required to practice using 316NG material prior to performing 316NG welds in the drywell.
. 2870040960 8.2 Welder Qualification Each welder and welding operator will be required to pass appilcable code welding tests by producing test coupons in accordance with specified welding procedures. Test coupons will be examined non-destructively and/or destructively to prove each welder's capability.
8.3 Health Physics All personnel involved in the pipe replacement work will be required to receive training and pass the necessary tests adwinistered by PECo Nuclear Training Section. Training is provided in two categories - General Enployee Training (GET) and General Respiratory Training (GRT). GET provides the individual with training in radiation contamination and its reduction, nuclear plant rules, Radiation Work Pennit's dostnetry, and dressing out in Anti-C clothing. GRT provides the Individual with training in the use and fitting of protective respiratory gear.
9.0 Piping Analyses 9.1 Nuclear Class 1 Component Evaluation Based on ASME Section III The piping will be analyzed in accordance with the rules of NB-3600 of ASME Section III Boller and Pressure Vessel Code 1980 Edition through winter 1981 addenda.
The following will be evaluated in the analysis of the piping systen:
a)
The pipe minintm wall thickness will be detennined such that there is adequate wall thickness for the various design and operating pressures defined in the design specification. Pressure design will be in accordance with the rules in NB-3640, 3654, 3655, 3656, and 3657.
b)
Prinary stress Intensity limits of Equation (9) In NB-3652, 3654, 3655, and 3656 will be net.
c)
Prinary plus secondary stress intensity range Ilmits will be net for the pressure, tanperature, and earthquake duty cycles defined in the design specification.
Primary plus secondary stress intensity range limit will be net by satisfying the requirenent of Equation (1) in NB-3653-1.
If the stress range calculated by Equation (10) exceeds 3 Sm, the sinplified Elastic-Plastic analysis Equations (12) and (13) will be satisfied.
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2870040960 d).
The cunulative usage factor will be met for the B pressure, temperature, and earthquake duty cycles defined in the design specification. The cunulative usage will be evaluated in accordance with NB-3653-6.-
9.2 Piping Stress Analysis Due to the change in the piping configuration, the recirculation. piping and connecting portions of the RHR piping will be reanalyzed. The recirculation piping and the RHR suction and return piping between the tee connection and the drywell penetration will be included in the analyses.
Thermal-Expansion Analysis Three thermal conditions have been selected for analysis.
These three thermal conditions will be used to simulate the service levels contained in NB-3600.
Selsmic Analysis The recirculation piping and connecting RHR piping will be modeled as a lunped mass system with enough details to accurately predict piping dynamic response up to a frequency of 33 Hz.
The weight of the piping contents plus insulation will be added to the weight of the pipe in the form of a unifonnly-distributed load CIbs/ft). The weight of punps and valves will be included in the mass model. For the punp motors and valve operators, the extended mass will be modeled as an additional weight at the respective center of gravity.
The stiffness of each support will be included in the piping mathematical model.
The earthquake analysis will be performed using the response spectra method. The dynamic analysis utilizes response spectrun curves for the site based on ground motion accelerations of 0.05g (design earthquake) and 0.12g (maximun credible earthquake).
The forces and moments due to earthquake differential anchor movements will be determined by a static analysis with the movement at supports as input.
2870040960
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9.3 Pipe Support Deslon The pipe support design will optimize the use of existing support hardware to minimize the nurber of the new components to be procured, to minimize drywell changes, and to simpilfy installation.
In addition, the supports will be designed to minimize the necessity for welded attachments to the piping.
The existing hangers were designed and purcha. sed to the-requirements of USAS B31.7 and the existing snubbers were designed and purchased to the requirements of the ASME Section III,. Subsection NF.
Existing hangers and snubbers will be re-evaluated to the code to which they were purchased.
If any new recirculation or RHR piping supports are required, they will meet the materials, design fabrication, and erection requirements of ASME Section III, Subsection NF.
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