Text

Proposed Inservice Inspection Alternative HNP-ISI-ALT-HDPE-01, Version 3.0
	ML15274A197
Person / Time
Site:	Hatch
Issue date:	10/01/2015
From:	Pierce C; Southern Co, Southern Nuclear Operating Co
To:	; Document Control Desk, Office of Nuclear Reactor Regulation
References
	NL-15-1754
	Download: ML15274A197 (87)
	v • d • e

Charles R. Pierce Regulatory Affairs Director October 1, 2015 Docket Nos.: 50-366 Southern Nuclear Operating Company, Inc.

40 Inverness Center Parkway Post Office Box 1295 Binningham, AL 35242 Tel 205.992.7872 Fax 205.992.7601 U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, D. C. 20555-0001 Edwin I. Hatch Nuclear Plant-Unit 2 SOUTHERN<<\\

UCLEA A SOUTHERN COMPANY NL-15-1754 Proposed lnservice Inspection Alternative HNP-ISI-ALT-HDPE-01, Version 3.0 Ladies and Gentlemen:

Southern Nuclear Operating Company (SNC) originally submitted proposed lnservice Inspection Alternative HNP-ISJ-AL T-HDPE-01, Version 1.0 by letter dated March 6, 2014. Based on subsequent conversation with the Nuclear Regulatory Commission (NRC), SNC withdrew Version 1.0 of this Alternative, and submitted Version 2.0 on Septembe~ 19, 2014, providing additional information for the Alternative. During the course of NRC review of Version 2.0, several changes to the proposed Alternative were identified and agreed upon between NRC and SNC. This Jetter resubmits Enclosures 1 and 2 of this Alternative as Version 3.0, incorporating the following changes from Version 2.0:

, Proposed Alternative,

Introduction:

deleted reference to 14 inch nominal diameter as "estimated."

, Proposed Alternative, Material: last paragraph - Revised paragraph reference to reflect 2015 Edition of Section IX, and added alternative test requirements if the pending change to QF-143.2.3.2 is not accepted by the NRC

, Proposed Alternative, Design, 1st paragraph: the last sentence has been removed due to the submittal of more detailed drawings showing the layout for this piping

, Proposed Alternative, Design, 41h paragraph: revised to past tense

, Proposed Alternative, Design, 5th paragraph: changed to past tense

, Proposed Alternative, Design, last paragraph: - added statements regarding sealing of conduits between Unit 2 Div II and Div I valve pits

, Fabrication and Installation, first paragraph: last sentence revised to read: "... in accordance with the requirements of the original Construction Code and ASME Section XI."

U.S. Nuclear Regulatory Commission NL-15-1754 Page2

, Fabrication and Installation, Fusing Procedures, last sentence changed to reference Enclosure 7 of September 19, 2014 submittal

, 11 OO(a), Footnote 4: deleted the sentence discussing 14-inch nominal diameter as "estimated"

, 1100(b), last sentence: revised to read "... will meet the requirements of the original Construction Code and ASME Section XI."

, 2000, Footnote 7: deleted reference to 14DR7 as "preliminary."

, 2221, Footnote 8: modified to refer to Enclosure 5 of September 19, 2014 submittal

, Table 2520(a)-2: Item 5, short term strength: for clarity, added "or ASTM 01598" under Test Method, as this method is invoked by the version of ASTM F714 referenced in Supplement 1

, Table 3210-1: conservatively revised maximum allowable ring deflection for DR7 to 3% to agree with the current proposal for a revision to Section Ill Appendix XXVI, Table XXVI-3210-1

, Table 3210-3: added previously truncated values for Modulus of Elasticity for 1 0 year and 50 year load durations

, 4231 (c): added visual inspection of machined surfaces and verification by direct measurement of required wall thicknesses as agreed during the RAI process

, 4412(a)(2): clarified fusion joint protection requirements as agreed during the RAJ process

, 4412(a)(3): added requirement for using isopropyl alcohol for cleaning fusion surfaces as agreed during the RAJ process

, Supplement 1: added ASTM 01598-2009 to the Table of Referenced Standards

, Supplement 3, 3-143.2.4.2, Footnote 13: revised paragraph reference to reflect 2015 Edition of Section IX, and added alternative testing requirements in the event the pending revision to Section IX, QF-143.2.3.2 is not accepted by the NRC

, Supplement 5: Periodic Pressure Test, (b)(1) revised to reflect lSI pressure test at 1.1 x Design Pressure In addition, all references to regulation 1 OCFR50.55a(a)(3)(i) are changed to 1 OCFR50.55a(z)(1) due to the regulation change. While the September 19, 2014 letter contained eight separate enclosures, only Enclosures 1 and 2 are being updated and included in this package. Enclosures 3-8 of the September 19, 20141etter were only included to assist the NRC in their review of Enclosures 1 and 2 and were not intended to form the basis of the NRC's Safety Evaluation.

Some of the information originally provided in Enclosure 3 - 8 of the September 19, 2014 letter has since become outdated. All requirements or information originally provided in the September 19, 20141etter (including all enclosures) can be considered superseded by the requirements contained in Enclosures 1 and 2 to this letter unless otherwise specified.

U. S. Nuclear Regulatory Commission NL-15-1754 Page3 To provide sufficient time to complete material procurement and planning of the PSW piping replacement and to provide assurance of the planned approach, SNC respectfully requests NRC review and approval of the attached Version 3.0

{Enclosures 1 and 2) of the lSI Alternative by November 16, 2015.

This letter contains no NRC commitments. If you have any questions, please contact Ken McElroy at {205) 992-7369.

Respectfully submitted, c.({.~

C. R. Pierce Regulatory Affairs Director CRP/RMJ/Iac

Enclosures:

1. Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 1 0 CFR 50.55a{z){1 ), Version 3.0.

2. Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a{z){1 ), Version 3.0.

cc:

Southern Nuclear Operating Company Mr. S. E. Kuczynski, Chairman, President & CEO Mr. D. G. Bost, Executive Vice President & Chief Nuclear Officer Mr. D. R. Vineyard, Vice President-Hatch Mr. M. D. Meier, Vice President-Regulatory Affairs Mr. D. R. Madison, Vice President-Fleet Operations Mr. B. J. Adams, Vice President-Engineering Mr. G. L. Johnson, Regulatory Affairs Manager-Hatch RTYPE: CHA02.004 U.S. Nuclear Regulatory Commission Mr. L. D. Wert, Regional Administrator {Acting)

Mr. R. E. Martin, NRR Senior Project Manager-Hatch Mr. D. H. Hardage, Senior Resident Inspector-Hatch

Edwin I. Hatch Nuclear Plant - Unit 2 Proposed lnservice Inspection Alternative HNP-ISI-AL T-HDPE-01, Version 3.0 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 }, Version 3.0 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a{z)(1 ), Version 3.0 Plant Site-Unit:

Edwin I. Hatch Nuclear Plant (HNP) - Unit 2.

Interval Dates:

Fourth lnservice Inspection (lSI) Interval -January 1, 2006 through December 31, 2015. Fifth lSI Interval -January 1, 2016 through December 31, 2025.

Requested Date for Approval is requested by November 16, 2015.

Approval:

The affected piping consists of Division II Plant Service Water (PSW) from the Turbine Building isolation valve box to the Reactor Building. This is Class 3 ASME Code 1 0-inch diameter piping which is buried and unlined. The function of this piping Components is to supply PSW to the drywall and the reactor building coolers. Both Unit-1 Affected:

and -2 PSW buried piping were installed at the same time with the design and installation being performed per B31.7-1969-USAS Code for Pressure Piping.

The applicable Code edition and addenda (for the fourth lSI interval) is ASME Applicable Section XI, "Rules for lnservice Inspection of Nuclear Power Plant Code Edition Components," 2001 Edition through the 2003 Addenda (Reference 1). The and Addenda:

installation process will be performed during the fifth lSI interval and as described below, will be to the 2007 Edition through the 2008 Addenda (Reference 2).

Applicable During the process of replacing this carbon steel piping, Article IWA-4000, Code subparagraph IWA-4221 (b) requires that items used during a Requirements:

repair/replacement activity meet the construction code.

Southern Nuclear Operating Company (SNC) has decided to replace the carbon steel piping described above with high density polyethylene (HOPE) piping. Article IWA-4000, subparagraph IWA-4221 (b) requires th~t items and materials for any ASME repair/replacement activity meet the construction code.

Reason for The use of HOPE piping for ASME applications is a recent technology Request:

improvement and was not available in the 1960's or 1970's to meet the construction code. There are no provisions in ASME Section XI or in an approved Code Case for installing HDPE Piping as a replacement for carbon steel during a repair/replacement activity. SNC is therefore submitting an lSI Alternative requesting approval to use HDPE piping for this repair/replacement activity.

This lSI Alternative applies to replacement of the HNP Unit 2 Division II PSW carbon steel supply piping from the Turbine Building isolation valve box to a new Proposed below-grade vault outside the Reactor Building, with HDPE piping produced with Alternative:

PE4710 material of cell classification 445574C with a 14 inch nominal diameter. Maximum operating temperature of the system is 97°F, and maximum operating_pressure is 190 psig. The Design Temperature is 123°F with a Design E1-1 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Pressure of 180 psig. This proposed lSI Alternative and supporting details in provide the technical basis and detailed requirements for the use of HOPE piping. These details include material, design, fabrication, installation, as well as examination and testing of HOPE piping, which are summarized as follows.

MATERIAL SNC will be responsible for surveying, qualifying, and auditing Polyethylene Material Organization(s), to verify that the organization's Quality Assurance Program conforms with the Alternative Technical Requirements (ATR) and to the SNC Quality Assurance Program requirements. Should SNC elect to use an ASME HOPE Certificate Holder to perform material supply, fitting fabrication, or installation, SNC will audit the Certificate Holder as a Repair/Replacement Organization in compliance with 1 0 CFR 50 Appendix 8, the SNC Quality Assurance Program, and the HNP Section XI Repair/Replacement Program.

SNC will perform all of the functions required by this lSI Alternative that are not performed by the Polyethylene Material Organization or ASME HOPE Certificate Holder. SNC may elect to perform any other Quality Program functions that would normally be the responsibility of the Polyethylene Material Organization or ASME HOPE Certificate Holder. Such functions performed by SNC will be described in the HNP Repair/ Replacement Program.

All HOPE material will, to the extent practical, be produced from a single batch of Dow Chemical, DGDA-24921 resin (cell cla,ssification of 445574A2) with a minimum PENT rating of 2,000 hours0 days 0 hours 0 weeks 0 months . HOPE piping items will include straight pipe, fabricated mitered elbows with segments thicker than the connecting pipe, and flange adapters rated for the design conditions. All HDPE-to-HDPE connections will be made using the butt thermal fusion process and HNP Fusing Procedure Specifications (FPS).

All polyethylene material product forms from different suppliers will be tested for fusibility using HNP fusing procedures in accordance with Section 2300 of. The testing will be performed at the manufacturing facility and witnessed by SNC, or will be performed at the plant by SNC. The Joint fusibility testing will include each HOPE Material Manufacturing facility and each HOPE source material supplied by different Material Manufacturers, in all combinations of suppliers and in all nominal diameters and thicknesses to be fused in production. In addition, all joint testing will use the same fusing machine make and carriage model to be used for joining the materials in production. Square-butt joint test coupons will be made at the pressure and temperature extremes of the HNP fusing procedure to verify fusibility of the material. Testing of the specim'ens will be by High Speed Tensile Impact Test (HSTIT) and Guided Side-1 The "BK" suffix (or "C" for cell classification) applies to the resin after carbon black has been added, typically by the Material Manufacturers to DOW specifications. When discussing the bare resin as in these cases, the "BK" suffix is not yet applicable and the cell classification has an "A" designation in place of "C".

2 Suffix designator "A" applies to the bare resin; suffix designator "C" applies to the same resin with carbon black added to the resin manufacturer's specifications.

E1-2 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Bend Testing.

Note: SNC reserves the option to perform only HSTIT testing in the event Regulatory questions with regard to the adequacy of that test method are resolved. In addition, use of Guided Side-Bend Testing as depicted in Enclosure 2, Supplement 3 is contingent upon NRC acceptance of a pending change to ASME Section IX, QF-143.2.3.2. If the change is not accepted, the test specimen will be bent to an angle of 60 deg +1-10 deg as indicated in QF-143.2.3.2 and Figure QF-463(d) of the 2015 Edition of ASME Section IX.

DESIGN SNC will be responsible for the design of all structures and piping required to complete this project. SNC may enlist the services of experienced outside organizations to accomplish the design. The design elements for HOPE piping are limited to buried HOPE piping systems constructed of straight pipe, mitered elbows, square-butt and mitered fusion joints, and metal to polyethylene flanged connections. Short non-buried segments of HOPE piping will extend into subgrade vaults to allow for flanged connection to the metallic piping. The design life of the system will be 50 years.

Design of the HOPE piping will be accomplished in accordance with Section 3000 of Enclosure 2. The duration of load will be specified for each load case, and the physical and mechanical properties will be selected based on the maximum duration of load. Accessibility to permit future inservice examination and pressure drop testing will be provided in the design of the metallic/HOPE connections for the piping which will be located in below-grade vaults. Design loading will be as defined in USAS B31.7-1969, and will be based on a Design Factor, DF, of 0.50. Loads to be evaluated will include maximum and minimum internal design pressure and temperature under all service conditions, and the number of equivalent full range temperature cycles. The modulus of elasticity value (E) used in the plant specific analysis will be established considering the most current data available relative to its dependence on stress at the time of approval of the piping stress analysis. 3 Also evaluated will be detailed pipe routing and interface connections, as well as loading due to saturated soil, buoyancy, and flotation; vertical pressure due to surcharge loads; permanent ground movement, frost heave (if applicable) and soil settlement; seismic wave passage and seismic soil movement; building anchor motions and number of seismic cycles for seismic design; and thermal expansion and contraction.

A conceptual design package was prepared with a summary submitted to the Regulator during the fourth quarter of 2014. The conceptual design package included physical layout, preliminary calculations, vault locations and layouts, and dimensional requirements for the HOPE piping, including allowances for surface damage and repair by blending.

3 Within the design stress range of HOPE for buried Class 3 piping systems (i.e. s BOO psi/S 25% Sy), latest EPRI testing indicates that modulus of elasticity will not vary significantly with stress levels.

E1-3 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 A summary of completed as-designed calculations was provided to the Regulator during the third quarter of 2015 to validate the structural integrity of the proposed installation under all load conditions.

Other facets of design, including but not limited to Appendix R fire protection, associated civiVstructural modifications, and excavation and backfill using a flowable fill cement mixture, will be addressed under SNC design procedures in accordance with the existing design and license basis for HNP. Also, there are existing conduit runs between the Unit 2 Division II and Division I PSW valve pits. The Unit 2 Division I PSW valve pit contains safe shutdown path 1 equipment; therefore, SNC will ensure that the conduit runs are adequately sealed such that water from the Unit 2 Division II valve pit cannot reach the Unit 2 Division I PSW valve pit to impact safe shutdown path 1 equipment.

FABRICATION and INSTALLATION Piping items and appurtenances will be fabricated and installed in accordance Section 4000 of Enclosure 2, and will be constructed from polyethylene materials that meet the requirements of Section 2000. Methods of fabrication and installation will be by thermal butt fusion and flanged joints. Branch connections will not be permitted in polyethylene material, and all metallic interface items will be fabricated and installed in accordance with the requirements of the original Construction Code and ASME Section XI.

Inspection and Repair of Material All polyethylene material will be visually inspected upon receipt at the plant site and again during installation. Indentations of 0.040" or less in pipe and pipe segments may be accepted provided the remaining pipe wall thickness is greater than toesign* After receipt at the site, gouges or cuts greater than 0.040" will be removed by grinding or machining such that the cavity has a minimum taper of 3:1 (half-width of the overall area to depth) without any sharp edges, provided the remaining wall thickness remains in excess of toesign* Alternatively, the damaged portion will be removed and discarded.

Fusing Procedures SNC is responsible for developing all fusing procedures to be used on this project. SNC will include in the fusing procedure specification essential parameters that are in addition to the essential variables typically included in commercial HOPE fusing procedures. Any change in these essential parameters will require re-testing at the procedure extremes in accordance with 2300 of Enclosure 2. Essential parameters include material batch lot, product form, manufacturing facility, nominal diameter, nominal thickness, fusing carriage make and model, machine slope exceeding 20 degrees, and fusing ambient temperature less than 50 oF or greater than 125 °F. SNC will ensure that the fusibility verification tests required by Section 2300 of Enclosure 2 are performed and accepted prior to approval of an FPS. A sample Fusing Procedure Specification was shown in Enclosure 7 to the September 19, 2014 submittal.

E1-4 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Fusing Machine Operator Qualification Test SNC, or its approved Certificate Holder, will conduct the tests required by this Alternative to qualify the performance of fusing operators who apply the fusing procedures. Each fusing machine operator will receive a minimum of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months of training covering the principles of the fusion process and the operation of the fusing equipment. The make and model of each fusing machine carriage to be used in production will be tested in accordance with Section 2300 of Enclosure 2 on all diameters and thicknesses to be fused. Fusing machine operators will be qualified by testing on the same machine model and same size and thickness of piping to be fused. A data acquisition device will be attached to the fusing machine for verifying compliance with the fusing procedure, and specimens will be cut from the test joint and tested by the guided side-bend test method. (Refer to Note above, under "Material.")

Fusing Requirements Precautions will be taken to prevent contamination of the joint during the fusing process. The joints will be protected as required to prevent all deleterious contamination including rain, snow, dust, fine particulate and wind during fusing operations. Fusing will not be performed on wet surfaces or surfaces containing dust or fine particulate. Fusing will not be performed at ambient temperatures less than 50°F or greater than 125°F, unless an environmental enclosure is used to control work area temperature between 50°F and 125°F. At temperatures between 1 oooF and 125°F, extended cooling times will apply prior to removal of the fusing machine carriage from the fused joint.

Items to be joined will be fitted, faced, aligned, and retained in position during the fusing operation using appropriate fusing machines. The alignment surface mismatch will be less than 1 0% tfab min of the items being fused, and items of different outside end diameters will not be fused together. Every joint fusion will have a data acquisition device attached to the fusing machine to ensure that the proper fusing parameters and procedures were followed for each joint. If any parameter is outside the approved range, the fused joint will be removed and replaced in compliance with the FPS or the item will be scrapped. Failure of a recorder to operate properly during the fusion process will also cause removal and replacement of the fused joint.

EXAMINATIONS and TESTS Required Examinations A visual examination will be performed of all external surfaces upon receipt of polyethylene material at the plant, for visual evidence of flaws imposed during packaging, transport, and handling. In addition, visual examination will be performed of all accessible external surfaces of piping after placement in the burial trench. Each fused joint will be visually inspected on accessible surfaces to verify proper fusion bead and cleavage configuration in accordance with Section 5000 of Enclosure 2. In addition, the data acquisition record for the fused joint will be compared with the applicable HNP Fusing Procedure Specification to verify parameters and procedures were followed in making each fused joint.

All fused joints will also be 1 00% volumetrically examined using the phased E1-5 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 array or other qualified ultrasonic technique with encoded (position and amplitude) data recording in accordance with 5000 of Enclosure 2. Any indication of a defect during the volumetric examination will cause rejection of the joint.

In-process Destructive Testing In addition, in-process destructive testing will be performed on 10% of all fused joints made on each machine used during installation at the site in accordance with Section 4460 of Enclosure 2. Testing of the specimens will be by High Speed Tensile Impact Test and Guided Side Bend Test. (See Note above, under "Materials.") Failure of a test specimen will cause additional sampling of joints made since the previous acceptable tests using that machine.

Qualification of Volumetric Examination Procedures Written ultrasonic examination procedure(s) will be qualified in accordance with 5000 of Enclosure 2 by performance demonstration testing. Demonstration testing will be witnessed by an Authorized Nuclear lnservice Inspector who has experience with lSI ultrasonic examinations, and also by a Regulatory representative. The witnessing of this qualification by the Regulatory representative may only be waived by the USNRC. The demonstration test specimen(s) for volumetric examinations will be fabricated from the same polyethylene material (PE471 0) being installed, will contain a joint representative of the joint to be examined including the same fusing variables and parameters, and will include fabrication type flaws. The demonstration specimen scanning and joint surfaces will be representative of the production surfaces to be examined. The procedure demonstration will be considered acceptable if 1 00%

of the detectable relevant flaws are identified. Successful demonstration will validate the appropriateness of using ultrasonic examination, including the frequency range specified in the procedure, in lieu of radiographic examination for the fused joints.

Qualification of Examination Personnel All personnel qualified to perform visual examinations on this project, excluding the visual examinations for leakage, will receive the 24 hour2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months training as required for the fusing machine operator. All personnel qualified for visual inspections will be qualified as VT-1 or VT-2 inspectors in accordance with ASME Section XI and ANSI/ASNT CP-189, as applicable. In addition, all VT-1 inspectors will be given a practical examination using physical samples of visually acceptable and unacceptable polyethylene pipe fused joints. A sample set with flaws representative of unacceptable conditions will be used. The written visual examination procedure will be used and a passing grade of 80% detection of the intended flaws will be required for qualification for VT-1 visual inspection of polyethylene piping.

Volumetric examination personnel will demonstrate their capability to detect flaws using the qualified procedure in a blind performance demonstration conducted on a specimen set containing surface-connected and subsurface flaws. Detection of at least 80% of the intended flaws in the performance demonstration test set is required to qualify for ultrasonic examination of HOPE E1-6 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 fused joints. Personnel qualification will be in accordance with Section 5000 of.

PRESSURE TESTING Prior to initial operation, the installed system will be hydrostatically tested at 1.5 times the Design Pressure + 1 0 psig for 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months in accordance with Section 6000 of Enclosure 2. The test pressure will then be decreased by 1 0 psi and held for at least one hour. All fusion joints will be un-insulated and exposed for inspection during the test. Each fused joint and all accessible external exposed surfaces will be examined for leakage while at 1.5 times design pressure. For long sections of piping, the hydrostatic testing will be accomplished by testing in smaller subsections. Upon a satisfactory test of each smaller subsection the piping will be buried. The one-hour hold.at decreased pressure must have no make-up water added and must experience no reduction in pressure greater than 5% of the test pressure. This one hour hold will serve as the Preservice Examination for the installed piping.

INSERVICE INSPECTION For all polyethylene piping installed under this lSI Alternative, lnservice Inspection will include an isolated pressure decay test performed at least once each lSI Inspection Interval (for the remaining life of the plant) to verify maintenance of structural integrity throughout the design life of the system. This testing will be performed in accordance with Supplement 5 of Enclosure 2, and will reaffirm the following: 1) absence of detrimental slow crack growth, 2) absence of detrimental cold fusion in joints, and 3) adequacy of design modulus of elasticity based on time in service, temperature and operating stresses.

Basis for Use:

One additional enclosure is associated with this lSI Alternative:

1. Enclosure 2 is the HNP Unit 2 Alternative Technical Requirements (ATR) which describes the technical details for material procurement, design, fabrication, installation, as well as the examination and testing of HOPE piping for Division II PSW. The ATR incorporates lessons learned from two domestic nuclear plants as well as changes to address regulatory concerns. It is a package that reflects the latest industry efforts related to HOPE applications at nuclear power facilities.

The ATR references ASME Section XI. Such references apply to ASME Section XI, 2001 Edition with 2003 Addenda for material and initial design, and to ASME Section XI, 2007 Edition through the 2008 Addenda for installation, examination and testing. includes several Supplements: Supplement 1 identifies applicable standards that are referenced, Supplement 2 applies to the Ultrasonic Examination of High Density Polyethylene, Supplement 3 defines the requirements applicable to Fusing Qualifications, Supplement 4 provides the Code Data report form to document these E1-7 to NL-15-1754 Scope of Plant Service Water Replacement using the Proposed Alternative to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Code activities, and Supplement 5 provides details of the lnservice Inspection pressure testing activities applicable for the duration of plant life. In addition, two Nonmandatory Supplements are included:

Supplement A applies to Fusing Machine Operator Qualification Training and Supplement B provides examples of Unacceptable Fusion Bead Configurations. Version 3.0 of Enclosure 2 is included with this submittal.

The September 19, 2014 submittal of this Alternative included six additional enclosures. Enclosures 3-8 of the September 19, 2014 letter were only included to assist the NRC in their review of Enclosures 1 and 2 and were not intended to form the basis of the NRC's Safety Evaluation. Some of the information originally provided in Enclosure 3

- 8 of the September 19, 2014 letter has since become outdated. All requirements or information originally provided in the September 19, 20141etter (including all enclosures) can be considered superseded by the requirements contained in Enclosures 1 and 2 to this letter (NL 1754) unless otherwise specified.

Based on the detailed technical information provided with this alternative, SNC is confident that this alternative will provide an acceptable level of quality and safety. Therefore, it is requested that the NRC authorize this proposed alternative in accordance with 1 OCFR50.55a(z)_(1j.

Duration of The implementation of HOPE piping will be performed during the fourth and Proposed fifth lSI Intervals. The use of HOPE material plus periodic pressure testing as Alternative:

described in this Alternative provides HNP with high quality Division II PSW QiQing for the remaining ot>_erationallife of the plant.

Precedents:

1. Safety Evaluation Report for Relief Request 13R-1 0, Use of Polyethylene Pipe in Lieu of Carbon Steel Pipe in Buried Essential Service Water System (TAC No. MD6792) at Callaway Plant, Unit 1, dated November 7, 2008 (ML083100288).

2. Safety Evaluation Report for Relief 06-CN-003, Use of Polyethylene Material in Buried Service Water Piping (TAC NOS. ME0234 and ME0235) at Catawba Nuclear Station, Units 1 and 2, dated May 27, 2009 (ML091240156).

References:

1. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,Section XI, 2001 Edition with the 2003 Addenda.

2. ASME Boiler and Pressure Vessel Code,Section XI, 2007 Edition with the 2008 Addenda.

Status:

Awaiting NRC approval.

E1-8

Edwin I. Hatch Nuclear Plant - Unit 2 Proposed lnservice Inspection Alternative HNP-181-AL T-HDPE-01, Version 3.0 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ),

Version 3.0 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Alternative Technical Requirements Hatch Nuclear Plant-Unit 2 Partial HDPE Replacement for Div II Plant Service Water Piping Note: All paragraph, figure and table number references in this document refer to this ATR unless otherwise noted as ASME Section III, ASME Section V, ASME Section XI, etc.

1000 GENERAL REQUIREMENTS llOOSCOPE This Alternative Technical Requirements (ATR) applies to Hatch Nuclear Plant (HNP)

Unit 2 Division IT Plant Service Water (PSW) supply piping from the Turbine Building isolation valve box to a new sub grade vault located outside of the Reactor Building. This ATR is proposed as an lSI alternative to the Construction Code and ASME Section XI requirements under Alternative HNP-ISI-AL T -HDPE-0 1.

(a) These Requirements address replacement of the existing buried and unlined carbon steel Class 3 NPS 10 piping with IPS4 14 HDPE piping produced with PE4710 material of cell classification 445574C. Design conditions are as follows:

Condition Temperature, op Pressure, psig Normal operating 95 140 Maximum Operating 97 190 Design 123 180 (b) Except as otherwise stated, the provisions of this ATR will apply in lieu of IW A-4000, ASME Section XI, 2001 Edition through 2003 Addenda, and ASME Section XI, 2007 Edition through 2008 Addenda.

(1) The requirements ofiW A-4140 through IW A-4170, and IW A-43005 will apply.

(2) The requirements of 6000 will be used in lieu of IW A-4500.

(3) Use of this ATR will be identified on the NIS-2 or NIS-2A data report form.

All modifications to existing metallic materials or items that interface with polyethylene material will meet the requirements of the original Construction Code and ASME Section XI.

4 NPS is the common term used for steel piping, IPS is the common term used for plastic piping; both are dimensionally equivalent.

5 10CFR50.55a limitations shall apply.

E2-1 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 1200 RESPONSffiiLITIES (a) The Owner, Southern Nuclear Operating Company (SNC) will perform all of the functions required by this ATR that are not performed by the Polyethylene Material Organization. SNC may elect to perform any other Quality Program functions that would normally be the responsibility of the Polyethylene Material Organization. Such functions performed by SNC will be described in the HNP Repair/ Replacement Program.

(b) SNC will make all necessary provisions for the Authorized Inspection Agency to perform the inspections necessary to comply with this ATR. All references herein to "Inspector" apply to the Authorized Nuclear Inservice Inspector.

(c) SNC will be responsible for surveying, qualifying, and auditing the Polyethylene Material Organization, to verify that the organization's Quality Assurance Program conforms with this ATR and to the SNC Quality Assurance Program requirements.

(d) Satisfactory completion of the survey and audit will allow the Polyethylene Material Organization to supply material to HNP for a period of three years. After the three-year period, a triennial audit will be performed, if necessary for continued supply of material.

(e) Should SNC elect to use an ASME HDPE Certificate Holder to perform material supply or fabrication, SNC will audit the Certificate Holder as a Repair/Replacement Organization in compliance with 10CFR50 Appendix B, the SNC Quality Assurance Program, and the HNP Section XI Repair/Replacement Program. The Certificate Holder will then be responsible for (a) through (d) as delineated in the HNP Repair/ Replacement Program.

(f) SNC will be responsible for design of the HDPE piping in accordance with this ATR.

(g) SNC will be responsible for fabrication, fusing, installation, inspection and testing of the HDPE piping in accordance with this ATR and applicable design requirements.

E2-2 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 2000 MATERIAL All HDPE material will, to the extent practical, be produced from a single batch of Dow Chemical, DGDA-2492 resin meeting the requirements stipulated herein. HDPE piping items will include only 14 DR7 6' 7 straight pipe, fabricated mitered elbows with segments thicker than the connecting pipe, and flange adaptors rated for the design conditions. All HDPE-to-HDPE connections will be made using the thermal butt fusion process.

2200 POLYETHYLENE MATERIAL REQIDRE:MENTS (a) Natural compound, pigment concentrate compound, polyethylene compound and polyethylene material will conform to the requirements of this ATR.

(b) Conformance with ASTM Standards referenced in Supplement 1 and herein will be limited as specified in this ATR. In the event of conflict between a referenced standard and this ATR, the requirements of this ATR will take precedence.

(c) Natural compound, pigment concentrate compound, polyethylene compound, and polyethylene material will be marked in accordance with the marking requirements in 8000 and the applicable ASTM standard.

2220 SPECIFIC COMPOUND REQIDREMENTS 2221 Requirements for Certification of Polyethylene Compound (a) General

( 1) Polyethylene Compound will comply with and be certified in accordance with this ATR and Table 2221-1.

(2) The required value for each property will be as specified in Table 2221-1.

( 3) The standard for determining the required value for properties will be as specified in Table 2221-1.

( 4) The test method for determination of the required value for the physical property will be as specified in Table 2221-1.

(b) Polyethylene compound used for the manufacture of polyethylene material will meet the requirements of the polyethylene compound manufacturer and Table 2221-1.

(c) Polyethylene compound will be black except as provided in 2231(b).

(d) Polyethylene compound is the combination of natural compound and pigment concentrate compound as follows:

( 1) When polyethylene compound is combined by the Polyethylene Compound Manufacturer, polyethylene compound is the polyethylene source material.

(2) When polyethylene compound is combined by the Polyethylene Material Manufacturer, natural compound and pigment concentrate compound are the polyethylene source materials.

6 DR= Dimension Ratio= (Outside Diameter)+(thickness) 7 This pipe size and DR are subject to change based on design requirements.

E2-3 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 (3) When polyethylene compound is combined by the Polyethylene Material Manufacturer, the Natural Compound Manufacturer will provide the Polyethylene Material Manufacturer with a formulation that specifies the weight ratio (proportions) of natural compound and pigment concentrate compound, and with processing equipment setting recommendations that produce polyethylene compound in accordance with Table 2221-1.

(e) Polyethylene compound will exceed 2000 hr Pennsylvania Edge-Notch Tensile Test (PENT) per ASTM F14738 and will have an independent listing that is published in PPI TR-4, Table I.A.13. The independent listing will identify the following:

(1) A standard grade hydrostatic design basis (HDB) rating of at least 1,600 psi at 73°F.

(2) A standard grade HDB rating of at least 1,000 psi at 140°F.

( 3) A hydrostatic design stress (HDS) rating of at least 1,000 psi for water at 730F.

(4) Standard grade HDB ratings and HDS ratings will be determined in accordance with PPI TR-3, Parts A, D, and F.

(5) A material designation ofPE4710 in accordance with PPI TR-4, Table-I.A.13.

(6) The unique trade name or designation for the polyethylene compound.

(7) The Polyethylene Natural Compound Manufacturer.

(f) The Polyethylene Material Manufacturer of polyethylene pipe will have a dependent listing for black polyethylene compound that is published in PPI TR-4, Table I.A.l3. The black polyethylene compound will exceed 2000 hr Pennsylvania Notch Tensile Test (PENT) per ASTM F1473 and the dependent listing will identify the following:

( 1) A standard grade hydrostatic design basis (HDB) rating of at least 1,600 psi at 73°F.

(2) A standard grade HDB rating of at least 1,000 psi at 140°F.

(3) A hydrostatic design stress (HDS) rating of at least 1,000 psi for water at 73°F.

(4) Standard grade HDB and HDS ratings in accordance with PPI TR-3, Parts A, D andF.

(5) A unique trade name or designation to the polyethylene compound that is published in PPI TR-4, Table I.A.13.

(g) The Certificate of Analysis (C of A) Report will identify the trade name or designation assigned to the polyethylene compound by the Polyethylene Compound Manufacturer that is published in PPI TR-4.

8 Dow Chemical, DGDA-2492 BK resin has a PENT value >10,000 hr (see Enclosure 5 to September 19, 2014 submittal)

E2-4 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (h) The Certified Polyethylene Test Report (CPTR) will identify the trade name for the polyethylene compound assigned by the Polyethylene Material Manufacturer that is published in PPI TR-4, Table I.A.13, and will identify the following:

( 1) The C of A Report trade names for the natural compound and the pigment concentrate compound, or (2) The C of A Report trade name for the polyethylene compound (i) Color polyethylene compound will contain color and ultraviolet (UV) stabilization in accordance with ASTM 03350 Code E. Color polyethylene compound color and UV stabilization duration requirements shall be specified in the Design Specification. Color polyethylene compound will be used for color stripes only on safety related polyethylene pipe, to differentiate it from non-safety material.

2222 Natural Compound (a) Natural compound will meet requirements specified by the Natural Compound Manufacturer.

(b) Natural compound will be combined with pigment concentrate compound in accordance with 2221(d).

(c) The Natural Compound Manufacturer will assign a unique trade name or designation to the natural compound.

2223 Pigment Concentrate Compound (a) Black pigment concentrate compound will meet requirements specified by the Natural Compound Manufacturer.

(b) Black pigment concentrate compound will be combined with natural compound in accordance 222l(d)(3).

(c) The Pigment Concentrate Compound Manufacturer will assign a unique trade name or designation to the pigment concentrate compound.

(d) Color pigment concentrate compound will be in accordance with 223l(b) 2230 SPECIFIC MATERIAL REQUIREMENTS (a) This section identifies the specific requirements applicable to the various product forms permitted by this ATR.

(b) All fabrications produced by fusing will be produced using HNP fusing procedures and performed by SNC or by a Certificate Holder audited and approved by SNC in accordance with 1200. Only fusing procedures and fusing machine operators trained and tested in accordance with this ATR will be used.

(c) All fused joints will be examined in accordance with Section 5000 of this ATR.

2231 Polyethylene Material-Pipe (a) Polyethylene pipe will be manufactured in accordance with this ATR and ASTM F714. Elevated temperature sustained pressure test per ASTM F714 will be successfully E2-5 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 completed by the pipe manufacturer at least twice annually during manufacture of pipe supplied for this project.

(b) Pipe will be black and will be manufactured by extrusion. With the exception of color stripes per this section, unless otherwise specified by the Natural Compound Manufacturer black pipe will contain 2 wt% to 3 wt% carbon black that is well dispersed through the pipe wall. Samples will be taken from pipe and tested in accordance with ASTM 01603 or ASTM 04218.

( 1) A single green color stripe may be coextruded into the pipe outside surface.

The depth of the color stripe into the pipe outside surface must not infringe upon minimum wall thickness of Design* The color stripe will not project above the pipe outside surface and will not be covered in whole or in part by black pipe material.

(2) Where natural compound and pigment concentrate compound are combined by the Polyethylene Material Manufacturer, the Polyethylene Material Manufacturer will use the same natural compound with black pigment concentrate compound and with color pigment concentrate compound if optional color stripes are coextruded into the pipe outside surface.

( 3) Where black polyethylene compound and color polyethylene compound are used to extrude pipe with optional color stripes, coextruded into the outside surface, the black polyethylene compound and color polyethylene compound will use the same natural compound.

(c) Pipe print line marking will be applied in accordance with ASTM F714 during extrusion using heated indentation.

(d) Prior to shipment of the pipe, testing for fusibility of the material will be performed in accordance with 2300, unless SNC or its designee elects to perform the testing.

2232 Polyethylene Material-Flange Adapter (a) Flange adapters will only be fabricated from pipe by machining, using polyethylene materials meeting the requirements of 2231.

(b) The configuration will be in accordance with 4520.

(c) The pressure rating, PR, will be determined in accordance with 3132.

(d) The dimensions and surface appearance will be verified and the pressure rating confirmed by testing in accordance with ASTM F2206.

(e) Prior to shipment of flange adaptors, testing for fusibility of the material will be performed in accordance with 2300 of this Article, unless SNC or its designee elects to perform the testing.

2233 Polyethylene Material-Mitered Elbows (a) The polyethylene material used for mitered elbows will be pipe meeting the requirements of 2231.

(b) The configuration of the mitered elbow will meet the dimensional requirements of the specifications listed in Supplement 1, and the additional requirements of 3132.1.

(c) Prior to shipment of mitered elbows, testing for fusibility of the material will be performed in accordance with 2300, unless SNC or its designee elects to perform the testing.

(d) The Data Report Form NM(PE)-2 (Supplement 4) will be used for this product form.

E2-6 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 2300 POLYETHYLENE MATERIAL FUSING VERIFICATION TESTING 2310 GENERAL (a) All polyethylene material product forms will be tested for compliance with the HNP Fusing Procedure Specification (FPS) described in Supplement 3, 3-221 and as specified herein.

(b) The polyethylene materials tested will be from the same Polyethylene Material Manufacturer's manufacturing facility using the same method of manufacture as the polyethylene materials to be used in production.

(c) Joint fusibility testing will include each lot of polyethylene source material to be used in production supplied by the same or different polyethylene Material Manufacturers in all combinations of suppliers and in all diameters and thicknesses to be fused in production.

(d) All joint testing will use the same fusing machine make and carriage model to be used for joining the materials in production. See 432l(c).

(e) Joint fusibility testing will be performed by the Polyethylene Material Manufacturer unless SNC or its designee elects to perform the testing.

(f) Fusibility testing results will be included in the CPTR.

2320 FUSING PARAMETERS FOR TESTING One square-butt joint will be made at each of the following conditions to verify fusibility at the pressure/temperature extremes of the fusing procedure:

(a) Interfacial pressure of 90 psi minimum and heater temperature of 450°F minimum; heater removal (dwell) time kept to a minimum (must not exceed the specified maximum).

(b) Interfacial pressure of 60 psi maximum and heater temperature of 450°F minimum; heater removal (dwell) time kept to a minimum (must not exceed the specified maximum).

(c) Interfacial pressure of 90 psi minimum and heater temperature of 400°F maximum; heater removal (dwell) time at the maximum permitted.

(d) Interfacial pressure of 60 maximum psi and heater temperature of 400°F maximum heater removal (dwell) time at the maximum permitted.

E2-7 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 2330 TESTING A minimum of four specimens will be removed from fused pipe test coupons at intervals approximately 90 deg apart for each type of test to be performed. Testing of the specimens will be by High Speed Tensile Impact Test in accordance with 3-144 of Supplement 3, and9 Guided Side Bend Testing in accordance with 3-143 of Supplement

3.

2400 REPAIR OF MATERIAL Repair by the Material Manufacturer of manufactured or fabricated polyethylene pipe and fittings will not be permitted. Polyethylene pipe or fittings with gouges, cuts or other surface conditions greater than 0.040" or any indentation resulting in a wall thickness of less than trab min will be unacceptable, and will be rejected and scrapped.

2500 GENERAL REQIDRE:MENTS FOR QUALITY TESTING AND DOCU:MENTATION (a) The Polyethylene Source Material Manufacturer will ensure that polyethylene compound is certified in accordance with 2221.

(b) Acceptance of individual lots of polyethylene source material will be in accordance with 2510.

2510 Certificate of Analysis (C of A) Report The following subparagraphs contain requirements for C of A Report and related traceability documentation.

2511 Polyethylene Compound.

(a) Polyethylene compound will be qualified per 2221.

(b) The Polyethylene Compound Manufacturer will test polyethylene compound in accordance with Table 2511-1 and will provide a C of A Report and related traceability documentation to the purchaser of the lot.

(c) The C of A Report will include the certified test results in accordance with Table 2511-1 (d) The C of A Report and related traceability documentation will include the following information:

( 1) the name of the Polyethylene Compound Manufacturer, (2) the manufacturing location,

( 3) an identification code that is unique and traceable to the specific lot, (4) the Polyethylene Compound Manufacturer's trade name for the polyethylene compound as published in PPI TR-4, 9 SNC reserves the option to do only HSTIT testing if NRC concerns with that test method as expressed in August 2014 (ref: ASME Letter Ballot 14-1440) are resolved.

E2-8 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 (5) the shipping method or type of container(s) for the lot such as railcar or boxes and additional information such as a railcar number if shipped by rail or the name of the commercial carrier and number of boxes if shipped by commercial carrier, (6) the lot weight of polyethylene compound, (7) the date of shipment, (8) other information that identifies the purchaser (customer), purchaser order, purchaser contact, purchaser delivery location, and contact information for the Polyethylene Compound Manufacturer, 2512 Natural Compound (a) The Natural Compound Manufacturer will test natural compound in accordance with Table 2512-1. The Natural Compound Manufacturer will provide a C of A Report and related traceability documentation to the purchaser of the lot.

(b) The C of A Report will include the certified test results in accordance with Table 2512-1.

(c) The C of A Report and related traceability documentation will include the following information:

( 1) the name of the Natural Compound Manufacturer, (2) the manufacturing location,

( 3) an identification code that is unique and traceable to the specific lot, (4) the Natural Compound Manufacturer's trade name for the natural compound, (5) the shipping method or type of container(s) for the lot such as railcar or boxes and additional information such as a railcar number if shipped by rail or the name of the commercial carrier and number of boxes if shipped by commercial carrier, (6) the lot weight of natural compound, (7) the date of shipment, (8) other information that identifies the purchaser (customer), purchaser order, purchaser contact, delivery location, and contact information for the Natural Compound Manufacturer, 2513 Pigment Concentrate Compound (a) The Pigment Concentrate Compound Manufacturer will test pigment concentrate compound in accordance with Table 2513-1. The Pigment Concentrate Compound Manufacturer will provide a C of A Report and related traceability documentation to the purchaser of the lot.

(b) The C of A Report will include the certified test results for the lot in accordance with Table 2513-1.

(c) The C of A Report or related traceability documentation will include the following information:

E2-9 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0

( 1) the name of the Pigment Concentrate Compound Manufacturer, (2) the manufacturing location,

( 3) an identification code that is unique and traceable to the specific lot,

( 4) the Pigment Concentrate Compound Manufacturer's trade name for the pigment concentrate compound, (5) the shipping method or type of container(s) for the lot such as railcar or boxes and additional information such as a railcar number if shipped by rail or the name of the commercial carrier and number of boxes if shipped by commercial carrier, (6) the lot weight of pigment concentrate compound, (7) the date of shipment, (8) other information that identifies the purchaser (customer), purchaser order, purchaser contact, delivery location, and contact information for the Pigment Concentrate Compound Manufacturer, 2520 Certified Polyethylene Test Report for Polyethylene Material-Pipe (a) The Polyethylene Material Manufacturer-Pipe:

( 1) will certify the Certificate of Analysis Report values by testing a sample from the polyethylene source material lot in accordance with Table 2520(a)-1, (2) must not use the material when certification testing does not verify C of A Report values, (3) will test pipe in accordance with Table 2520(a)-2 and will provide a Certified Polyethylene Test Report (CPTR) and the Compound C of A Report(s) to SNC or its designee.

(b) The CPTR will include the following per lot:

( 1) certified test results for the lot in accordance with Tables 2520(a)-1 and -2, (2) the name of the Polyethylene Material Manufacturer,

( 3) the manufacturing location,

( 4) an identification code that is unique and traceable to the specific lot,

( 5) the ASTM standard for pipe manufacture, (6) the specification for the polyethylene compound, (7) the shipping method and the name of the commercial carrier,

( 8) the lot length, (9) the date of shipment, (10) other information that identifies the purchaser (SNC), purchaser order, SNC contact, delivery location, and contact information for the Polyethylene Material Manufacturer,

( 11) a certification that the polyethylene material was made from only virgin polyethylene source material, and that no scrap or reground polyethylene material was used, E2-10 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 No.

2 3

4 5

6 7

8 9

10 11

( 12) certification of slow crack growth resistance (greater than 2000 hr PENT per ASTM F1473 completed on a compression molded plaque at 2.4 MPa and 80°C per Table 2221-1 for the polyethylene compound),

( 13) results of fusibility testing performed in accordance with 2300, Table 2221-1 Certification Requirements for Polyethylene Compound Property, Units Density, g/cmJ High load melt flow rate, g/10 min.

Carbon black, %

Slow Crack Growth resistance (parent material), hr Required Value (a) 0.956 to 0.968 w/2 to 3% carbon black (b) 0.947 to 0.955 w/o carbon black or pigment 4 to 20 2 to 3

>2,000 Thermal Stability, °F

>428 (>220)

(OC)

Tensile strength at yield, psi (MPa)

?:3500 (?:24.24)

Tensile elongation at

?:400 break,%

HOB at 73°F (23°C),

1,600 (11.03) psi (MPa)

HOB at 140°F (60°C), psi (MPa)

HDS for water at 73°F (23°C), psi (MPa)

Thermoplastic pipe materials designation code 1,000 (6.90) 1,000 (6.90)

PE4710 Requirement Standard ASTM03350 Polyethylene Compound Manufacturer Quality Program ASTM 03350 and Table 2221-1 ASTMD3350 ASTMD3350 ASTMD3350 ASTM03350 ASTM 02837, PPI TR-3 and PPI TR-4 ASTM 02837, PPI TR-3 and PPI TR-4 ASTM 02837, PPI TR-3 andPPITR-4 Listed in PPI TR-4 Test Method ASTM 01505 or ASTM 0792 or ASTM 04883 ASTM 01238, Condition 190/21.6 ASTM 04218 or ASTM 01603 ASTM F1473 at 2.4 MPa and 80°C in air ASTM03350 ASTM 0638, Type IV at 50 mm/min. (2 in./min.)

ASTM 0638, Type IV at 50 mm/min. (2 in./min.)

ASTM 02837, PPI TR-3 andPPITR-4 ASTM 02837, PPI TR-3 andPPITR-4 ASTM 02837, PPI TR-3 and PPI TR-4 NA General Note: Only SI units are provided in Tables 2221-1, 2511-1. 2512-1, and 2520(a)-1 when the applicable ASTM Standards do not provide U.S. Customary units.

Table 2511-1 Minimum Quality Testing Requirements for Polyethylene Compound Lots No.

Test Test Standard Test Frequency Test Timing C of A reports test results High load melt flow ASTM Dl238 and Once per lot NA Yes rate, Condition Table 2221-1 190/21.6, g/10 min.

2 Density ASTM 0792 or ASTM Once per lot Before lot Yes 01505 or ASTM 04883 shipment and Table 2221-1 3

Tensile strength at ASTMD638and Once per lot Before lot Yes yield and tensile Table 2221-1 shipment elongation 4

Thermal stability ASTM 03350 and Once per lot Before lot Yes Table 2221-1 shipment 5

Carbon black ASTM 01603 or ASTM Once per lot Before lot Yes content 04218 and Table 2221-1 shipment E2-11 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Table 2512-1 Minimum Quality Testing Requirements for Natural Compound Lots No.

Test Test Standard Test Frequency Test Timing C of A reports test results High load melt flow ASTMD1238 Once per lot NA Yes rate, Condition 190/21.6, g/10 min.

2 Density ASTM 0792 or ASTM Once per lot Before shipment Yes 01505 or ASTM 04883, and Table 2221-1 3

Tensile strength at ASTMD638 Once per lot Before shipment Yes yield and tensile elongation 4

Thermal stability ASTMD3350 Once per lot Before shipment Yes Table 2513-1 Minimum Quality Testing Requirements for Pigment Concentrate Compound Lots No.

2 Test Carbon black content (black only)

Color and UV stabilizer (color only)

Test Standard ASTMD1603 or ASTMD4218 ASTMD3350 Test Frequency Every 24 hr during lot production Every 24 hr during lot production E2-12 Test Timing Every 24 hr after acceptable product has been produced for given production lot Every 24 hr after acceptable product has been produced for given production lot C of A reports test results Yes Yes to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Table 2520(a)-1 Minimum Quality Testing Requirements for Polyethylene Source Material CPTR No.

Test Test Standard Test Frequency reports test results High load melt flow rate, ASTM 01238 Once per lot upon receipt at Yes Condition 190/21.6, g/10 min.

the processing facility 2

Density ASTM D792 or ASTM Once per Jot upon receipt at Yes D1505 and Table 2221-1 the processing facility 3

Carbon black concentration ASTM 01603 or Once per Jot upon receipt at Yes percentage for black ASTM D4218 the processing facility polyethylene compound or black pigment concentrate compound 4

Slow Crack Growth resistance, Greater than 2,000 hr per Once per Jot prior to Yes hr [Note(l)]

ASTM Fl473 completed on shipment of polyethylene a compression molded material plaque at 2.4 MPa and 80°C in Table 2221-1 5

Thermal stability [Note (I)]

Greater than 428°F (220°C}

Once per Jot prior to Yes ASTM D3350 and shipment of polyethylene Table 2221-1 material Note:

(1) In no case may any individual test result, used to establish this value in accordance with the reference industry standard, be Jess than the minimum required value listed in this table.

Table 2520(a)-2 Minimum Quality Testing Requirements for Polyethylene Material - Pipe Manufacturing CPTR No.

Test/Requirement Standard/ Acceptance Test Method Test Frequency reports test Criteria results Workmanship ASTM F714 NA Hourly or once per Yes length, whichever is Jess frequent during ongoing production 2

Outside diameter ASTMF714 ASTM D2122 Hourly or once per Yes

[Note (1)]

length, whichever is Jess frequent during ongoing production 3

Toe-in ASTMF714 ASTM 02122 Once per shift during Yes

[Note (I)]

ongoing production 4

Wall thickness ASTMF714 ASTM D2122 Hourly or once per Yes

[Note (1)]

length, whichever is Jess frequent during ongoing production 5

Short term strength ASTM F714 ASTM 01598, At the beginning of Yes ASTM 01599 or production and ASTMD2290 weekly thereafter during ongoing production 6

Carbon black Para. 2231 (b)

ASTM 01603 or At the beginning of Yes content ASTM 04218 production and weekly thereafter during ongoing production Note:

(1) Sample conditioning must be as specified in ASTM F714.

E2-13 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 3000DESIGN 3100SCOPE The design rules of this section are limited to buried, polyethylene piping systems constructed of straight pipe, mitered elbows, square-butt and mitered fusion joints, and metal to polyethylene flange adapters.

3110 NOMENCLATURE A= cross-sectional area of pipe at the pipe section where the evaluation is conducted, in.2 As= shear area of thrust collar at the section where the evaluation is conducted, in.2 a=

difference in thickness between pipe walls at a tapered transition joint, in.

Ba-trench width, ft.

B 1 = stress index, Table 3311-1 B2= stress index, Table 3311-1 B'= burial factor b = total length of taper at a tapered transition joint, in.

c = the sum of mechanical allowances, installation allowance, erosion allowance and other degradation allowance, in.

c' =length of counter bore at a tapered transition joint, in.

D =average outside diameter of pipe in accordance with ASTM F714, in.

DR = dimension ratio of pipe = average outside diameter of the pipe divided by the minimum fabricated wall thickness = D/trab min Epipe =modulus of elasticity of pipe per Table 3210-3, psi E' =modulus of soil reaction, psi (data is HNP specific)

E'N =modulus of soil reaction of native soil around trench, psi (data is HNP specific)

Fa= axial force due to the specified Design, Service Level A, B, C, or D applied mechanical loads, lb (N)

Fac =axial force range due thermal expansion and/or contraction and/or the restraint of free end displacement, lb Fav =axial force due to the non-repeated anchor motion, lb Fae= axial force range due to the combined effects of seismic wave passage, seismic soil movement, and building seismic anchor motion effects, lb F c= axial force due to fully constrained thermal contraction, lb.

FE= axial force due to fully constrained thermal expansion, lb.

Fs= soil support factor, per Table 3210-2 fo = ovality correction factor, per Table 3221.2-1 GSR = Geometric Shape Rating g= acceleration due to gravity, ftls2 hhub = thickness of thrust collar hub, in.

H= height of ground cover, ft Hgw= height of ground water above top of the pipe, ft.

i= stress intensification factor, per Table 3311-1 K = bedding factor K' =Design and Service Level longitudinal stress factor from Table 3223-1 L= deflection lag factor E2-14 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 M= resultant bending moment due to the specified design, Service Level A, B, C, or D applied mechanical loads, in.-lb Me= resultant moment range due thermal expansion and/or contraction and/or the restraint of free end displacement, in.-lb MIF resultant moment due to the non-repeated anchor motion, in.-lb Mr-resultant moment range due to the combined effects of seismic wave passage, seismic soil movement, and building seismic anchor motion effects, in.-lb N = number of equivalent full range temperature cycles P = internal design gage pressure, plus pressure spikes due to transient events, psig P a= Design or Service Level A, B, C, or D pressure, psig PIF piping system internal Design Pressure at the specified Design Temperature Tv, both being specified in the piping Design Specification, not including the consideration of pressure spikes due to transients, psig Pr-vertical soil pressure due to earth loads, lb/ft2 P 8w= pressure due to ground water above the top of the pipe, lb/ft2 Phydro= external hydrostatic pressure, equal to earth plus groundwater pressure plus surcharge load, psi PL= vertical soil pressure due to surcharge loads, lb/ft2 P m = mitered elbow pressure rating, psig PR = fitting pressure rating, psig R = buoyancy reduction factor r1 '= radius of curvature at the beginning of a tapered transition joint, in.

r2 '= radius of curvature at the end of a tapered transition joint, in.

r3 '= radius of curvature at the thrust collar hub, in.

S = allowable stress, per Table 3131-1, psi SA= allowable secondary stress range value as defined in 3133 and given in Table 3133-1 psi Scomp= allowable side wall compression stress per Table 3220, psi T = temperature, op T IF Design Temperature, op Tgrouna-temperature of soil around pipe, op TwateF temperature of water running through pipe, op tvesign= minimum required wall thickness, in.

tfab min= minimum fabricated wall thickness in accordance with ASTM F714 (called minimum wall thickness in Table 9 of ASTM F714), in.

tm;n= minimum wall thickness for pressure, in.

t' =wall thickness of thrust collar pipe section, in.

W p=: weight of empty pipe per unit length, lb/ft Ww= weight of water displaced by pipe, per unit length, lb/ft w = width of thrust collar hub, in.

Z= section modulus of pipe cross section at the pipe section where the moment is calculated, in. 3 a= coefficient of thermal expansion of pipe, 1/°F L1P= differential pressure due to negative internal pressure of pipe, psi AT =Twater-T ground. op L1Teq= equivalent temperature rise, op E2-15 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0

( ea)Earthquake = strain in the pipe from earthquake wave computer analysis e50n= maximum soil strain due to seismic wave passage v= Poisson's ratio 0= change in diameter as a percentage of the original diameter, commonly called the change in ring diameter Omax= maximum allowable change in diameter as a percentage of the original diameter, commonly called the change in ring diameter, per Table 3210-1 Pdry= density of dry soil, lb/ft3 Psaturated= density of saturated soil, lb/ft3 UAIF tensile stress range in the pipe due to the range of thermal expansion and contraction and/or the restraint of free end displacement, psi UE= tensile stress in the pipe due to an earthquake, psi usw= circumferential compressive stress in the sidewalls of pipe, psi Urc= tensile stress in the pipe due to fully constrained contraction, psi are= tensile stress in the pipe due to fully constrained expansion, psi 3120 DESIGN LIFE (a) The design life of the system will be 50 years.

(b) The duration of load will be specified for each load case, and the polyethylene pipe physical and mechanical properties will be based on the duration of load.

3125 EXAMINATION & TESTING ACCESS Accessibility to permit future inservice examination and pressure drop testing will be provided in the metallic/HDPE flange connection vault designs for the piping.

3130 DESIGN AND SERVICE LOADINGS Design loads will be as defined in USAS B31. 7-1969 Paragraph 3-701. Loads applied to buried polyethylene pipe will include, as a minimum, the following based on a Design Factor, DF, of 0.50:

(a) Maximum internal Design Pressure Pv, for pressure design in accordance with 3131 and 3132; and, if applicable, maximum negative internal pressure for evaluation in accordance with 3221.2.

(b) Maximum and minimum temperature T, and the number of equivalent full range temperature cycles (N) for the selection of allowable stress and design for temperature effects in accordance with 3300.

(c) Vertical soil pressure PE, due to saturated soil, buoyancy, and flotation, for the designs in accordance with 3200.

(d) Vertical pressure due to surcharge loads PL for the design in accordance with 3200.

(e) Permanent ground movement, soil settlement, for design as nonrepeated anchor movements in accordance with 3300.

(f) Seismic wave passage and seismic soil movement, building anchor motions, and number of seismic cycles for seismic design in accordance with 3400.

E2-16 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 (g) Ground movement caused by frost heave (if applicable) for design for expansion and contraction in accordance with 3311.

3131 Pressure Design of Pipe 3131.1 Minimum Required Wall Thickness. The minimum required wall thickness of straight sections of pipe for pressure design will be determined by the following:

toesign= tmin + C The value of c will include an allowance for anticipated surface damage during installation.

where Sis from Table 3131-1

___fd2 tmin= (2S +Po)

The value of trab min will be greater than or equal to tnesign*

3131.2 Allowable Service Level Spikes Due to Transient Pressures. The sum of the maximum anticipated operating pressure plus the maximum anticipated Service Level B pressure spikes due to transients will be no greater than 1.2 times the piping system Design Pressure, P0. The sum of the maximum anticipated operating pressure plus the maximU;m anticipated Service Level C and D pressure spikes due to transients will be no greater than 2 times the piping system Design Pressure, Po.

3132 Pressure Design of Joints and Fittings (a) Polyethylene pipe will be joined using the butt fusion process. All connections to metallic piping will be flanged joints contained in isolated sub-grade vaults.

(b) The design of pipe fittings (mitered elbows and flange adapters) will ensure the fitting has the capacity to withstand a pressure greater than or equal to the Design Pressure, Po, of the attached pipe. The Pressure Rating (PR) of the fitting will be determined as follows:

2 xs PR = GSR x DR_ 1 ;:::: P0 where GSR =1.0 for straight pipe and flange adapters, GSR = 0.8 for mitered elbows DR5.6 to DR9, and GSR = 0.75 for mitered elbows DR9.5 to DR13.5 (with all segments less than or equal to 22.5 degree direction~ changes per fusion).

(c) Flanged connections will include a metallic backup ring and will provide a leak tight joint up to and including the piping hydrostatic test pressure. In addition, the maximum surge pressure per 3131.2 will not cause permanent deformation of the pipe.

3132.1 Pressure Design of Miter Elbows (a) The design pressure rating of the mitered elbow, Pm, will be calculated as the lesser of Equations (1) and (2), provided below (reference Fig. 3132-1).

E2-17 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (1)

(2) where S is from Table 3131-1 (b) Pm will be greater than or equal to P0. Alternatively, the mitered elbow will be at least one standard dimension ratio (SDR) lower than that of the attached straight pipe.

The maximum DR permitted for mitered elbow segments is 13.5.

(c) The minimum fabricated wall thickness of the reinforced sections of the mitered elbow will be 2: 1.25 trab min of the attached straight pipe. The additional wall thickness will be provided by enlarging the pipe OD while maintaining the pipeline ID, or by reducing the pipe ID while maintaining the pipeline OD.

(d) The fabrication tolerance of the fitting angular direction will be +/-3 degrees. Mitered joints of 3 degrees or less (angle aelb in Figure 3132-1) will not require re-design consideration as mitered elbows.

(e) Mitered elbows will comply with the requirements of USAS B31.1.0-1967, Paragraph 104.3.3, as invoked by USAS B31.7-1969 Paragraph 3-704, with the following exceptions: (a) wall thickness will be determined as outlined in (c) above and ND 3644 (e) will be replaced with butt fusion joints in accordance with this ATR.

3133 Allowable Stress Range for Secondary Stress The allowable secondary stress range, SA, is given in Table 3133-1.

(a) The SA value (see Table 3133-1) will be based on the higher of the Design Temperature or the maximum Level A orB temperature.

(b) The SA will be selected based on (1) the total number of temperature cycles or (2) the number of equivalent full range temperature cycles, N, as determined in 3133( d).

(c) The maximum number of permitted equivalent full range temperature cycles, N, is 100,000.

(d) The number of equivalent full range temperature cycles, N, is determined as follows:

E2-18 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 where ATE :::maximum temperalure change experience by the pipe, Of (etC)

Nr,""number of cycles at maximum temperature change 4 Te:

N,, N2...** Nn"' number of cycles at lesser lemperalures changes, 6 T 1* 4 T2 *.**, 4 T n 3200 SOIL AND SURCHARGE LOADS 3210 RING DEFLECTION The soil and surcharge loads on a buried polyethylene pipe will not result in a pipe diameter ring deflection, n, beyond the limit of !lmax per Table 3210-1.

(U.S. Customary Units)

Fs is per Table 3210-2.

(U.S. Customary Units)

Pr-

[psatumted X Hgw + Pdry X (H-Hgw)]

Epipe will be taken at the maximum life specified in the Design Specification, K= 0.1, and L = 1.25 to 1.5, or 1.0 if using soil prism pressure.

3220 COMPRESSION OF SIDEWALLS The circumferential compressive stress in the sidewalls O'sw due to soil and surcharge loads will not exceed Scamp per Table 3220.

(U.S. Customary Units)

O'sw =

_f,f.E+ Pl.) X DR 2 X 144

< Scomp 3221 External Pressure 3221.1 Buckling Due to External Pressure. The following will be met to ensure the pipe does not fail due to the effects of applied external pressure and possible negative internal pressure (a) When the depth of cover is greater than 4ft (1.25 m) or one pipe diameter, whichever is larger, the external pressure from ground water (flooding), earth loads, surcharge loads, and air pressure (due to negative internal pressure at minimum internal gage pressure) on a buried polyethylene pipe will not cause the pipe to buckle. The following equation will be met:

E2-19 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 PE+PL +Pgw R X B' X E' X Epipe Phydro = 11P+

144

~ 2.8 3

12(DR-1)

(U.S. Customary Units)

In addition, the requirements of 3221.2 will also be met.

(b) When the depth of cover is less than 4ft (1.25 m) or one pipe diameter (whichever is larger), the pipe will withstand the combined external pressure of ground water (flooding), earth, surcharge and air without credit for the surrounding soil. In this case the following equation will be met:

/o~p: ( 1 )3 (1-J) DR-l (U.S. Customary Units) v = 0.45 for all loads.

In this case, the requirements of 3221.2 do not need to be met.

The buoyancy reduction, R, and burial, B', factors are R = 1 - 0.33 X. (Hg../H)

(US Customary Units)

B' =

1 1 + 4 X exp(-.065 X H) 3221.2 Effects of Negative Internal Pressure. When the depth of cover is greater than 4 ft (1.25 m) or one pipe diameter (whichever is larger), the pipe will withstand the external air pressure resulting from negative internal pressure at the design minimum internal gage pressure without credit for the surrounding soil. This will be ensured by meeting the following equation:

v is defined in 3221.1 3222 Flotation AP s.foEpe (- * - ),

(1-t}~ DR - 1 Buried polyethylene pipe will have sufficient cover or be anchored to the ground to prevent flotation by groundwater. To ensure this occurs, the following relationship will be satisfied:

(U.S. Customary Units)

Ww< Wp + (PE x D/12) 3223 Longitudinal Stress Design 3223.1 Longitudinal Applied Mechanical Loads. Longitudinal stresses due to axial forces and bending moments resulting from applied mechanical loads will not exceed K' X S, E2-20 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 where (s, xp;: ~)+2(s, x

~)+(B2x~) ~ K'xS The value of K' is given in Table 3223-1. The values of B1, B2 are given in Table 3311-1 and S is per Table 3131-1.

3223.2 Short Duration Longitudinal Applied Mechanical Loads. For the assessment of short duration loads (less than five minutes), the allowable stress, S, may be replaced by one of the following two alternatives:

(a) 40% of the material tensile strength at yield at temperature coincident with the load under consideration, or (b) the values in Table 3223-2 3300 TEMPERATURE DESIGN 3310 MINIMUM TEMPERATURE The polyethylene material will not be used at a temperature below the manufacturer's limit, but in no case will the temperature be less than minus 50°F.

3311 Design for Expansion and Contraction 3311.1 Fully Constrained Thermal Contraction.

The stress resulting from the assumption of fully constrained thermal contraction of the buried pipe when T water<T ground. increased by the stress due to axial contraction from Poisson's effect, will be determined as follows:

I vPDI cr~e= fi>>pcaAT - 2t 3311.2 Fully Constrained Thermal Expansion. The stress resulting from the assumption of fully constrained thermal expansion of the buried pipe when T water> T ground.

will be determined as follows:

Ure =IEpipe X a X ~11 3311.3 Combined Thermal Expansion and Contraction Stress The combined thermal expansion and contraction stress will be limited to SA.

ICTrc I+ICTrel ~ ~

SA is per 3133.

3311.4 Alternative Thermal Expansion or Contraction Evaluation. As an alternative to 3311.1 and 3311.2, the soil stiffness may be accounted for to calculate pipe expansion and contraction stresses. The stresses will satisfy the following equation:

iMc Fac S

O"AJt =z+A ~ A SA is per 3133.

E2-21 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 3312 Non-repeated Anchor Movements The effects of any single non-repeated anchor movements will meet the requirements of the following equation:

...i!t1J2.... +....f.aD__ < 2S Sis per Table 3131-1.

3400 SEISMIC DESIGN Z

A 3410 SEISMIC INDUCED STRESSES The stresses in the buried polyethylene piping system due to soil strains caused by seismic wave passage, seismic soil movement, and building seismic anchor motion effects, where applicable, will be evaluated. The stresses will satisfy the following equation:

SA is per 3133.

Seismic wave passage, seismic soil movement, and building seismic anchor motion loads will be combined by square root sum of the squares.

3500 OTHER DESIGN CONSIDERATIONS Other facets of design, including but not limited to detailed pipe routing and interface connections, Appendix R fire protection, associated civil/structural modifications, and excavation and backfill, will be addressed under SNC design procedures in accordance with the existing design and license basis for HNP.

The following design tables reflect preliminary values applicable to the detailed design.

These may be revised and updated based on the actual pipe thickness selected for the design.

TABLE 3131-1 LONG-TERM ALLOWABLE STRESS, S FOR POLYETHYLENE (psi)

(Values reflect a design factor, DF, of0.50.)

Temperature

<50 yrs eF)

<73 800 95 694 100 670 110 626 125 561 GENERAL NOTE: The stresses listed in Table 3131-1support a 50 yr operating life.

E2-22 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Table 3133-1 SA, Allowable Secondary Stress Limit (psi)

Number of Equivalent Full Design Temperature E'~E' 0.1 0.2 0.4 0.6 0.8 1.0 1.5 2.0 3.0 5.0 Range Temperature Cycles, N N :51000 1000 < N :510000 10000 < N :5 25000 25000 < N :5 50000 50000 < N :575000 N>75000 10Qop 3440 2300 1950 1730 1630 1530 110°F 3280 2190 1870 1650 1540 1470

Values interpolated from standard table.

Table 3210-1 Maximum Allowable Ring Deflection !lmax DR

!lmax (%)

7.3 3.0 7

3.0 Table 3210-2 Soil Support Factor, Fs (12*Bd)/D, in/in 1.5 2.0 2.5 3.0 0.15 0.30 0.60 0.80 0.30 0.45 0.70 0.85 0.50 0.60 0.80 0.90 0.70 0.80 0.90 0.95 0.85 0.90 0.95 0.98 1.00 1.00 1.00 1.00 1.30 1.15 1.10 1.05 1.50 1.30 1.15 1.10 1.75 1.45 1.30 1.20 2.00 1.60 1.40 1.25 TABLE 3210-3 4.0 0.90 0.92 0.95 1.00 1.00 1.00 1.00 1.05 1.08 1.10 l25°F*

3020 2032 1735 1540 1435 1365 MODULUS OF ELASTICITY OF POLYETHYLENE PIPEEpip* (psi)

Load Temperature (°F)

Duration

5 73 95*

100 110 0.5 hr 82000 63550 59900 52500 1 hr 78000 60450 56900 49900 10 hr 65000 50400 47500 41600 24 hr 60000 46500 43800 38400 100 hr 55000 42650 40200 35200 1000 hr 46000 35650 33600 29400 1 yr 40000 31000 29200 25600 10 yr 34000 26350 24800 21800 50 yr 29000 22500 21200 18600

Values interpolated from standard table.

E2-23 125*

44300 42100 35100 32400 29700 24850 21600 18350 15650 5.0 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Table3220 ALLOWABLE SIDE WALL COMPRESSION STRESS Scomp (psi)

Service Level K'

Temperature Scamp (OF)

50 73 100 115 125 1180 1015 815*

704*

630*

Values interpolated from standard table.

Table 3221.2-1 Ovality Correction Factor,fo Percent-Ovallty Ovality Correction Factor 1%

0.91 2%

0.84 3%

0.76 5%

0.64 6%

0.59 Table 3223-1 Table 3223-2 c

1.33 Short Duration (<5 minutes) AUowable Longitudinal Tensile Stress Temp, oF S, psi go 100 115 125 1200 940 81 0*

730*

Values interpolated from standard table.

(a): Constant OD, 5-Segment, Reinforced (b): Constant ID, 5-Segment, Reinforced 90 Degree Elbow 90 Degree Elbow Figure 3132-1: Nomenclature for Mitered Elbows E2-24 D

1.33 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Table 3311-1 STRESS INDICES, FLEXffiiLITY, AND STRESS INTENSIFICATION FACTORS FOR PE PIPING COMPONENTS [NOTE (1) (2) (6)]

Primary Stress Flexibility Stress Index Flexibility factor Intensification Description Characteristic k

Factors Sketch B1 B2 h

i Straight Pipe 0.5 1.0 N/A 1.0 1.0 NIA Butt Fusion Joint 0.5 1.0 NIA 1.0 1.0 N/A (1+cot6)

~~*

Miter Elbow Note DR-1 In-plane Loading:

1.7

'-A s ;;:: r(l + tan a) 0.69 1.1 or hx (5)

~

[Note (3) and (4)]

t.(1 +cote) 2r R scote c--"2 Machined Metallic to PE 0.5 1.0 N/A 1.0 1.0 See Fig. 4520-1 Bolted Flange Connection Notes to Table:

(1)

The following nomenclature applies to this Table only for use in determining stress indices, stress intensification factors, and flexibility factors Do r

R e s

t.

=

Nominal outside diameter, in Mean radius of pipe (in) (matching pipe for elbows and tees)

Nominal bend radius of elbow or pipe bend, in One-half angle between adjacent miter axes, deg Miter spacing at center line, in DR

=

Nominal wall thickness of pipe, (trab min) in (matching pipe for elbows and tees)

Pipe Dimension Ratio = DJt.

(2)

The stress indices i and the flexibility factors k shall not be taken as less than 1.0. They are applicable to moments in any plane for fittings except as noted.

(3)

One-half miter angle (6) is limited to::; 11.25°.

(4)

The flexibility factor k is only applicable for in-plane bending moment loading.

(5)

The 82 stress indices for mitered elbows are dependent upon the DR and shall be as follows:

1.25 for DR 6*

1.38 for DR 7 1.42 for DR7.3*

Values extrapolated (DR6) or interpolated (DR7.3) from standard requirements (6)

All abutting piping fittings of differing DR's shall meet 4231 E2-25 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 4000 FABRICATION AND INSTALLATION 4100 GENERAL REQUIRE:MENTS 4110 INTRODUCTION (a) Fabrication and installation shall be in accordance with this section and will use polyethylene materials that comply with the requirements of 2000. Methods of fabrication and installation will be by thermal butt fusion and flanged joints. Use of threaded or adhesive joints with polyethylene material will not be permitted.

(b) Only thermal fusion circumferential butt joints and miter joints may be used for pressure boundary fusion joints. See Fig. 4110-1.

Fig. 4110.1 THERMAL FUSION BUTT JOINT (c) Branch connections will not be permitted in polyethylene material.

(d) All metallic interface items will be fabricated and installed in accordance with the requirements of the original Construction Code.

(e) Hereinafter all requirements specified in this section apply to fabrication and installation of polyethylene material.

4120 Examinations Visual examination activities specified by 4130 or in 5000, will be performed by personnel and procedures qualified in accordance with 5400.

4130 REPAIR OF MATERIAL All polyethylene material will be inspected upon receipt. Any material not meeting the surface acceptance criteria of 2400 will either be scrapped or repaired in accordance ~ith 4131. All polyethylene material external surfaces will be given an additional visual examination after placement in the burial trench for visual evidence of flaws imposed during fabrication and installation. For pipe larger than IPS 4, any indentation greater than 0.040" will be unacceptable. Indentations of 0.040" or less will be acceptable provided the remaining pipe wall thickness is greater than toesign*

E2-26 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 4131 Elimination of Surface Defects Pipe surface gouges or cuts greater than 0.040" in pipe greater than IPS 4 will be removed by grinding or machining in accordance with the following requirements:

(a) The cavity has a minimum taper of 3:1 (half-width of the overall area to depth) without any sharp edges.

(b) The remaining wall thickness is in excess of tnesign*

(c) As an alternative to (1) and (2), the damaged portion may be removed and discarded.

4132 Additional Requirements - Flange Adapters (a) Damage in the pipe section in the transition between the pipe section and the hub section, will necessitate flange adapter replacement.

(b) Damage in the flange face (hub) may be repaired by machining only provided after the repair the minimum hub dimensional requirements of ASTM F2880 are satisfied.

4200 FORMING, FITTING, AND ALIGNING 4210 CUTTING, FORMING, AND BENDING 4211 Cutting Material will be cut to shape and size by mechanical methods.

4212 Forming and Bending Processes The material will not be cold or hot formed or bent except as follows:

(a) During installation, a pipe radius of curvature greater than or equal to thirty (30) times the outside diameter is permitted for piping with DR equal to or less than 13.5 except as restricted by (b).

(b) During installation all pipe within two outside diameters of a flange connection or mitered elbow (measured from the pipe to fitting fused joint) will not have a radius of curvature less than one hundred (100) pipe outside diameters.

4213 Minimum Thickness of Fabricated Items If any operation reduces the thickness below the minimum required to satisfy the rules of 3000 and 4130, the material will be scrapped.

4230 FITTING AND ALIGNING 4231 Fitting and Aligning Methods Items to be joined will be fitted, faced, aligned, and retained in position during the fusing operation using appropriate fusing machines.

(a) Items of different outside diameters will not be fused together except as provided in (c).

(b) The alignment surface mismatch must be less than 10% trab min of the items being fused.

E2-27 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (c) For items with different DRs, the item with the smaller DR will be counterbored and tapered to equal the wall thickness, or its outside diameter will be machined and tapered to equal the wall thickness of the item with the larger DR and will comply with Fig.

4230-1 (a) or (b). Machined surfaces will be visually examined to verify absence of porosity or other deleterious surface conditions, and required wall thicknesses will be verified by direct measurement.

Fig.4230-1 T41per-.d Tnnltion Joint

ct.

t'..., t r.~~ _ ofth1Mer component c*,.CI 2 St' c"vnlues are after factng 03S< [__!!._] < 060 (b - e")

r.*.. =OOSt' rz'-. "" OOSt' (a) Reinforcement on Inside Diameter a

~~~~~~-t I'

tC:ab -

of thmncr component c'a"'2.SI' c'\\-alues ore after foong 03S< [-!......] <060 (b - c.-1 r.*-*o.ost' r:*-

O.OSt' (b) Reinforcement on Outside Diameter E2-28 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 4240 JOINT END TRANSITIONS The joint end transitions of items will provide a gradual change in thickness from the item to the adjoining items and will comply with 4231(c) and Fig.4230-l(a) or (b).

4300 FUSING QUALIFICATIONS 4310 GENERAL REQillREMENTS 4311 Types of processes permitted Only HNP Fusing Procedure Specifications that are verified as capable of producing fused joints by testing in accordance with 2300 of this ATR may be used for fusing pressure retaining material. The records required by 4320 will be prepared.

4315 Fusing Operator Training (a) Each fusing machine operator will receive a minimum of 24 hr of training, covering the principles of the fusion process and the operation of the fusing equipment. There will be a two part test at the end of this training:

(1) The written theoretical knowledge part of the test will cover such topics as: safety, fundamentals of the fusing process, and recognition of typical joint imperfections.

(2) The practical knowledge portion will include hands-on training using equipment make and models to be used in production.

(3) Successful completion of this training will be documented on the performance qualification record.

( 4) Performance qualification testing will be performed and documented in accordance with this ATR and Supplement 3.

(b) Non-mandatory Supplement A provides guidance for the training program.

4320 FUSING QUALIFICATIONS, RECORDS, AND IDENTIFYING STAMPS 4321 Required Qualifications (a) SNC (or approved Certificate Holder) is responsible for the fusing to be performed on this project. SNC will develop the fusing procedures and ensure that the tests required by 2300 to verify fusibility of the FPSs for use on this project are satisfied prior to approval of the FPS. SNC (or approved Certificate Holder) will also conduct the tests required by Supplement 3 of this ATR to qualify the performance of fusing operators who apply these procedures. Only fusing procedures tested in accordance with 2300 will be used.

(b) Procedures and fusing machine operators used to join pressure parts will meet the testing, training and qualification requirements of this ATR. Mitered joints will be fused using HNP Fusing Procedures with fusibility verified by square-butt fusing in accordance with 2300. During production, pressure settings will be adjusted to compensate for the non-circular cross-section of the mitered joint. Personnel performing miter-joint fusing will be qualified using square-butt fusing of pipe segments with the same nominal OD and ID as the mitered joint segments. (Square butt joints are necessary for taking destructive test specimens for fusibility verification and performance qualification testing.)

E2-29 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 (c) The make and model of each fusing machine carriage to be used in production will be tested in accordance with 2300 on all diameters and thicknesses to be fused. As an alternative to testing by the supplier or fabricator, the testing-or applicable portions thereof-may be performed by SNC (or its approved Certificate Holder) prior to fabrication or production. Machines to be used on slopes exceeding 20 degrees will be tested at the maximum slope (and estimated maximum drag) to be applied. The tested machine make(s) and model(s) and maximum slope of use will be documented in the fusing procedure specification (FPS).

4322 Maintenance and Certification of Records SNC will maintain records of all fusing procedures tested in accordance with 2300 and of the fusing machine operator qualification tests, showing the date and results of each test and the identification mark assigned to each fusing operator. These records will be reviewed, verified, and certified by SNC (or its approved Certificate Holder) and will be available to the Inspector.

4322.1 Identification of Joints by Fusing Operator Each fusing operator will apply the identification mark assigned to him adjacent to all permanent fused joints. The marking will be 1 ft (0.3 m) or less from the fusion bead and will be done with permanent metallic paint marker or stenciling marker.

4323 Fusing Prior to Qualification No production fusing will be performed until after the FPS which is to be used has been tested and verified in accordance with 2300. Only fusing procedures tested and operators qualified in accordance with this ATR and Supplement 3 will be used. Only fusing machine models tested in accordance with 4321(c) and 2300 will be used for production.

4340 GENERAL REQIDREMENTS FOR PERFORMANCE QUALIFICATION TESTS 4341 Conformance to Supplement 3 All fusing operator performance qualification tests will be in accordance with Supplement 3 and this ATR using HNP Fusing Procedure Specifications that have been tested in accordance with the requirements of 2300.

4342 Additional Requirements (a) The pipe size tested will be the size and thickness selected for the piping.

(b) A data acquisition device will be attached to the fusing machine for recording the data concerning the joint as required by 3-131 of Supplement 3.

(c) The visual examination required by 3-305 of Supplement 3 will be performed over the entire inside and outside surfaces of the coupon.

(d) Bend specimens will be tested in accordance with 3-143 of Supplement 3. The specimens must not crack or separate in the fused joint.

E2-30 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 4400 RULES GOVERNING MAKING, EXAMINING, AND REPAIRING FUSED JOINTS 4410 PRECAUTIONS TO BE TAKEN BEFORE FUSING 4411 Identification, Storage and Handling of Materials SNC (or its approved Certificate Holder) will be responsible for control of the materials that are used in the fabrication and installation of components. Suitable identification, storage, and handling of material will be maintained.

4412 Cleanliness and Protection of Fusing Surfaces (a) Precautions will be taken to prevent contamination of the joint during the fusing process.

( 1) The surfaces of the heaters used for fusing will be free of scale, rust, oil, grease, dust, fine particulate and other deleterious material.

(2) The joint will be protected from the above and all other deleterious contamination including rain, snow, dust, fine particulate and wind during fusing operations. Fusing may not be performed on wet surfaces or surfaces containing dust or fine particulate.

(3) 70% (minimum) isopropyl alcohol solution will be used for cleaning all film, oil or other foreign material from machined fusion surfaces.

(b) Fusing will not be performed at ambient temperatures less than 50°F or greater than 125°F, unless an environmental enclosure is used to control work area temperature between 5Qop and 125 op_ For ambient fusing temperatures between 100°F and 125°F, minimum cooling time shall be 13 minutes per in. of thickness.

4420 RULES FOR MAKING FUSED JOINTS 4421 Heating Cycle (a) Immediately prior to inserting the heater plate between the faced ends to be joined, the temperature will be verified to be within: the required range by measuring at four locations approximately 90 degrees apart in the fusing zone, on both sides of the heater plate.

(b) Care will be taken upon heater removal to ensure uniform flat heated surfaces on both pipe ends of the joint prior to fusing together.

4422 Surfaces of Fused Joints Fused beads will usually remain intact after completion of fusing.

(a) When required, fused beads may be removed, but only after the visual inspection required by 521 O(b) is completed and documented. The entire surface at the removed bead locations must be inspected and must meet the acceptance criteria of 5322 after bead removal.

(b) The finished joint must be suitable for required visual and volumetric examinations.

E2-31 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 4423 Joint Transitions When items of different diameters are fused together, there will be a gradual transition between the two surfaces in accordance with 4231(c).

4440 FUSING DATA ACQIDSITION RECORDER The fusing machine will have a data acquisition recorder attached to it for each joint fused. The data acquisition record produced by the device will include the information specified in Supplement 3. In addition, job information related to the joints such as job number, joint number fusing machine operator, date and time will be recorded. The data acquisition device must be capable of a minimum of one (1) day of butt fusion joint information and capable of downloading this information as a permanent record.

(a) Failure o~ a recorder to operate properly during the fusion process will cause removal and replacement of the fused joint.

(b) The data acquisition records will be compared to the FPS to ensure that the proper butt fusing parameters and procedures were followed for each joint. If any parameter is outside the approved range, the fused joint will be removed and replaced in compliance with the FPS or the item will be scrapped.

(c) Verification of fusing parameters and variables not included in the data acquisition record will be documented in accordance with the SNC (or approved Certificate Holder's) Quality Assurance Program.

4450 REPAIR OF FUSED JOINTS 4451 General Requirements (a) Indications of defects in fusion joints detected by the examinations required by 5000, or by the tests of 6000, will cause rejection of the joint. Repair of a fused joint is not permitted. All unacceptable joints will be removed and replaced.

(b) Fusion beads are not required to remain intact. Damaged fusion beads will be evaluated to verify no infringement upon the fusion joint or adjacent base material.

Damaged portions of fusion beads will be removed if necessary to perform this evaluation.

4452 Elimination of Surface Defects Surface defects may be removed by grinding or machining in accordance with the requirements of 4131. The removal area will be re-examined and will meet the acceptance criteria of 5322.

4460 IN-PROCESS PRODUCTION TESTING (a) A sampling of butt fusion joints produced at the site will be removed and destructively tested to verify soundness. This will include the first production fusion joint produced each week on each fusing machine plus a representative sampling of additional butt fusion joints such that a minimum of 10% of the butt fusion joints produced on each machine are tested.

E2-32 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (b) Four test specimens will be removed from each fused joint at intervals approximately 90 deg apart for each test to be performed. Testing of the specimens will be by High Speed Impact Test in accordance with 3-144 of Supplement 3, and10 by Guided Side Bend Testing in accordance with 3-143 of Supplement 3.

(c) Failure of any test specimen will cause two fusion joints produced on that machine since the previous successful in-process production test to be removed and tested in a similar manner. Failure of any of those specimens will cause rejection and removal of all butt fusion joints produced on that machine since the previous successful in-process production test.

4500 MECHANICAL JOINTS 4510 BOLTING AND THREADING 4511 Thread Engagement The threads of all bolts-or studs must be engaged in accordance with the design. Flange bolting will be engaged as required by 4520.

4512 Thread Lubricants Any lubricant or compound used in threaded joints will be suitable for the service conditions and must not react unfavorably with either the service fluid, polyethylene material or any other material in the system 4520 FLANGED JOINTS (a) Only flanged connections are permitted for joining of polyethylene pipe to metallic pipe or piping items. The polyethylene flange connection will be constructed using a polyethylene flange adapter having a DR ratio equal to the attached polyethylene pipe, and joined by butt fusion to the attached pipe.

(b) The polyethylene flange adapter will be connected to the metal flange using a metallic backing ring. The backing ring will have a pressure rating equal to or greater than the mating metal flange.

(c) Before tightening, flange faces will be parallel within 1/16 in./ft measured across any diameter; flange bolt holes will be aligned within 1!8 in. maximum offset. Damage to the gasket seating surface on the polyethylene flange that would prevent the gasket sealing will be evaluated per 4132(b). Use of a gasket is optional.

(d) The flange will be joined using bolts of a size and strength that conforms to the requirements of ASME B16.5 or ASME B16.47 Series A, as applicable. Bolts or studs will usually extend completely through their nuts. Any bolts or studs wpich fail to do so will be considered acceptably engaged if the lack of complete engagement is not more than one thread. Flat washers will be used under bolt heads and nuts.

10 SNC reserves the option to perform only HSTIT testing in the event the regulator questions with regard to the adequacy of that test method are resolved.

E2-33 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (e) In assembling flanged joints, the gasket, if used, will be uniformly compressed to the proper design loading. Special care will be used in assembling flanged joints in which the flanges have widely differing mechanical properties. Tightening to a predetermined torque is recommended. If used, no more than one gasket may be inserted between contact faces in assembling a flanged joint. The gasket material will be selected to be consistent and compatible with the service requirements of the piping system.

(f) See Fig. 4520-1 for a typical flange configuration r19 4520-1 TRANSffiON FLANCEARRANCEMENT Metallit" flim1e Metallic pipe Gasket (optional)

t~~

.....,.. +........

4600 PIPE SUPPORTS All installed supports for polyethylene piping will meet the requirements of the Construction Code and the following:

(a) Piping will be supported, guided, and anchored in such a manner as to prevent damage thereto. Point loads and narrow areas of contact between piping and supports will be avoided. Suitable padding will be placed between piping and supports where damage to piping may occur.

(b) Valves and equipment that could transmit excessive loads to the piping will be independently supported to prevent such loads.

E2-34 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 5000 EXAMINATION 5100 GENERAL REQUIREMENTS FOR EXAMINATION 5110 PROCEDURES, QUALIFICATION, AND EVALUATION 5111 General Requirements (a) Nondestructive examinations shall be conducted in accordance with the examination methods of Section V, except as modified by the requirements of this ATR.

(b) Visual examinations will be conducted in accordance with ASME Section XI, IW A-2210.

(c) The volumetric examination will be in accordance with Section V, 2010 Edition, Article 4 and Supplement 2 of this ATR, and demonstrated as specified herein.

(d) SNC will be responsible for reviewing procedure and demonstration results to validate that the range of the essential variables of the procedure were included in the demonstration.

(e) All personnel qualified to perform visual e.xaminations required by this ATR, excluding the VT-2 visual examinations of 5210(d), will receive the training as required for the fusing machine operator in 4315. The training will include review and understanding of the inspection requirements of this section, including the visual inspection acceptance criteria of 5320. This training will also include the use of a fusing machine to make a fused joint. Qualification as a fusing machine operator is not required. This training will be documented on an NDE qualification record.

5112 Nondestructive Examination Procedures All nondestructive examinations performed under this Article will be performed in accordance with detailed procedures, which have been proven by actual demonstration to the satisfaction of the Inspector. Procedures, records of demonstration of procedure capability, and personnel qualification will be available to the Inspector on request.

5113 Volumetric Examination Procedures (a) The ultrasonic examination will include the joint volume required by 5220 and the joint to base material interface up to 'A in. from the joint centerline into the joint base material (see Fig. 5220-1).

(b) The ultrasonic examination will be performed using an appropriate method (PAUT or TOFD) and encoded (position and amplitude) examination techniques.

(c) A written ultrasonic examination procedure will be developed in accordance with the format described in Supplement 2 and qualified by performance demonstration per 5114.

The ultrasonic examination procedure will:

( 1) Contain a statement of scope that specifically defines the limits of procedure applicability (e.g., minimum and maximum thickness, minimum and maximum diameter, scanning access).

E2-35 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (2) Specify which parameters are considered essential variables. The procedure will specify a single value or a range of values for the essential variables.

( 3) List the examination equipment, including equipment manufacturer and model or series.

( 4) Define the scanning requirements such as beam angles, scan patterns, beam direction, maximum scan speed, extent of scanning, and access requirements.

(5) Contain a description of the calibration method (e.g., actions required to ensure that the sensitivity and accuracy of the signal amplitude and time outputs of the examination system, whether displayed, recorded, or automatically processed, are repeated from examination to examination).

(6) Contain techniques for data interpretation and plotting.

5114 Qualification of Volumetric Examination Procedures (a) All volumetric examination procedures will be qualified and demonstrated to the satisfaction of the Inspector and a Regulatory Representativell using specimens conforming to the following requireme1_1ts:

( 1) The specimens will be fabricated from the same polyethylene material (PE4710) being installed.

(2) The demonstration specimen( s) will contain a joint representative of the joint to be examined (i.e. butt joint).

( 3) The demonstration specimen scanning and joint surfaces will be representative of the production surfaces to be examined as specified in the ultrasonic examination procedure.

( 4) The demonstration specimens will include relevant actual or simulated fabrication type flaws (e.g., lack of fusion, inclusions) consistent with the type of production joint to be examined.

(5) The demonstration set will include specimens with through-wall flaw sizes including the smallest flaw size of 0.040 in. (1mm) or 10% of the thickness (or maximum permitted by design), whichever is larger, and the largest flaw size between 30% and 90% of the thickness.

(b) The demonstration set will include at least one each minimum and maximum flaw size at each of the following locations: inner diameter (I.D.) surface-connected, outside diameter surface -connected, and embedded flaw. All flaws shall be separated by a minimum of 1 in.

(c) The demonstration will be considered acceptable if 100% of the above flaws are identified.

11 Witnessing of the demonstration by a Regulatory Representative may only be waived by the USNRC.

E2-36 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 5120 TIME OF EXAMINATION OF COMPLETED FUSED JOINTS Non-destructive examination of fused joints will be conducted:

(a) After the completion of the cooling period, and (b) Before the joint becomes inaccessible in the burial trench.

5200 EXAMINATIONS 5210 VISUAL EXAMINATION Visual examinations will be performed on the following:

(a) A VT -1 visual examination of all external surfaces, during receipt inspection at the plant, for visual evidence of flaws imposed during packaging, transport, and handling.

(b) A VT -1 external visual examination of all fused joints, including review and verification of data acquisition records for the joint in accordance with 4440.

(c) A VT -1 Visual examination of all accessible external surfaces of piping after placement in the burial trench for visual evidence of flaws imposed during fabrication and installation.

(d) A VT-2 visual examination of all piping and fused joints, during the hydrostatic test in accordance with 6224.

5220 ULTRASONIC EXAMINATION All fused joints will be volumetrically examined.

(a) The examination volume will include 100% of the area of interest shown in Figure 5220-1.

(b) Each joint will also be examined 360 de g. using the techniques demonstrated in 5114.

Figure 5220-1 FUSION PIPE JOINT EXAMINAnON VOLUME A

1/4 in. (6mm) from -f centerrme Examination volume A-8-C-D 5300 ACCEPfANCE STANDARDS 5310 GENERAL REQUIREMENTS B

L 114 in. (6mm) from r -centernne D

Unacceptable fusion joints will be removed. Repair of unacceptable fusion joints will not be permitted.

E2-37 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 5320 VISUAL EXAMINATION ACCEPTANCE CRITERIA OF EXTERNAL SURFACES 5321 Fused Butt Joints Joints will meet the following:

(a) Fused butt joints must exhibit proper fusion bead configuration. Nonmandatory Supplement B depicts unacceptable thermally fused bead configurations.

(b) There must be no visible evidence of cracks in the cleavage or incomplete fusion as evidenced by cleavage extending beneath the OD surface of the piping. The cleavage between fusion beads must not extend to or below the OD pipe surface (see Fig. 5321-1). When cleavage depth cannot be visually verified, pit or depth gages will be used to verify compliance, or else the joint will be rejected.

(c) Fusion joints, except for J11iter joints, must not be visually angled or offset by 3 degrees or more. The ovality offset must be less than 10% trab min of the fused items.

(d) The data acquisition record for the fused joint must be compared with the FPS to verify parameters and procedures were followed in making the fused joint.

FIG. 5321-1 POLYETHYLENE PIPE BUTT FUSION JOINT O.D. BEAD CC ROSS SECTION VIEW>

Cal V'IIU8Dy Acuptable (Un ifonn bead around pipe)

(cJ Y*ually Acceptable (Nonunifonn bead around plpelocallzad diameter mlamatch leas than 101l6 of the wall)

(b) Vi1Ually Ai:Ciptab..

(Nonunlfonn bead around pipe)

Cleawge tip aha II not meet or extend below pipe aurfaca (d) ViMJally Urutt:aptable (Nonu nifo nn/U nifo nn bead around pipe - V-G roove too deep at pipe-tangent)

Note: Actual bead configurations may vary for mitered joints.

5322 Material Surfaces Surfaces of all material must meet the requirements of 4131.

E2-38 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 5330 VOLUMETRIC EXAMINATION ACCEPTANCE CRITERIA Any indication of a flaw not attributable to configuration that is identified in the examination volume shown in Figure 5220-1 will cause the fused joint to be rejected.

5400 QUALIFICATION AND CERTIFICATION OF NONDESTRUCTIVE EXAMINATION PERSONNEL 5410 GENERAL REQUIREMENTS (a) Organizations performing nondestructive examinations will use personnel qualified in accordance with 5420. When these services are subcontracted by SNC, SNC will verify the qualification of personnel to the requirements of this ATR. All nondestructive examinations will be performed by and the results evaluated by qualified nondestructive examination personnel.

(b) Personnel performing nondestructive examinations required for this ATR will be qualified in accordance with 5420 of this ATR, and the SNC NDE Program. These qualifications will be documented on qualification records.

5420 PERSONNEL QUALIFICATION REQUIREMENTS 5421 Visual Examination (a) Personnel performing visual examinations required by 5210 (a), (b) and (c) will be qualified and certified as a VT-1 visual examiner in accordance with IW A-2300 in addition to (b) and (c), below.

(b) All personnel performing VT -1 visual examinations required by this ATR will receive the same training as required for the fusing machine operator as described in paragraph 5111(c) and Nonmandatory Supplement A. This training shall include the use of a fusing machine to make a fused joint. This joint is not required to be tested for qualification.

This training shall be documented on a qualification record.

(c) All personnel performing VT -1 visual examinations required by this A TR will be given a practical examination of physical samples of visually acceptable and unacceptable fused joints. A sample set including flaws representative of unacceptable conditions (e.g. Figure 5321-1, Non-Mandatory Supplement B) will be used. The visual examination procedure will be used and a passing grade of 80% detection of the intended flaws within the demonstration set will be required. The practical examination will be administered by an individual qualified to Level ill for Visual Examination or their designee. The training and examination results will be documented on a qualification record.

(d) Personnel performing visual examinations required by 5210(d) will be qualified and certified as a VT -2 in accordance with IW A-2300, visual examiner.

5422 Volumetric Examination (a) Personnel performing volumetric examinations required by this ATR will be qualified in accordance with 5410(b).

E2-39 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (b) Volumetric examination personnel will demonstrate their capability to detect flaws by performance demonstration using the qualified procedure in accordance with the following requirements:

(1) The demonstration specimens will be in accordance with 5114(a).

(2) The demonstration specimen set will contain at least one of each minimum and maximum flaw size at each of the following locations: I.D. surface-connected, O.D.

surface connected, and embedded flaw.

( 3) The demonstration will be performed in a blind fashion.

(c) Personnel will be considered qualified for flaw detection, if they report at least 80% of the intended flaws in the performance demonstration test.

(d) SNC will be responsible for reviewing the procedure and demonstration results to validate that the range of the essential variables of the procedure were included in the demonstration.

(e) This examination will be administered by a Level III for Ultrasonic Examination or designee. The practical examination results will be documented on a qualification record.

5423 Certification and Verification Certification and verification of nondestructive examination personnel shall be in accordance with IW A-2300 or the Construction Code.

5500 RECORDS The following nondestructive examination (NDE) records shall be retained by SNC upon completion of construction:

(a) All NDE procedure qualification records.

(b) Visual NDE personnel qualification records and certifications.

(c) Volumetric NDE personnel qualification records identified in paragraph 9.4 of SNT-TC-lA or section 9 of CP-189, including certifications.

(d) All visual NDE examination records and results.

(e) All volumetric NDE examination records and results, including encoded data.

E2-40 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 6000 TESTING 6100 GENERAL REQIDREMENTS 6110 PRESSURE TESTING 6111 Scope of Pressure Testing (a) Prior to initial operation, the installed system will be hydrostatically tested in the presence of the HNP Authorized Nuclear Inservice Inspector.

(b) Bolts, studs, nuts, washers, and gaskets are exempt from pressure testing.

6112 Pneumatic Testing A pneumatic test will not be permitted.

6120 PREPARATION FOR TESTING 6121 Exposure of Joints (a) All fusion joints, including the polyethylene flange adapter side of mechanical joints, will be un-insulated and exposed for inspection during the test.

(b) For long sections of piping, the hydrostatic testing may be accomplished by testing in small subsections of the longer section. Upon a satisfactory test of each small section the piping may be buried. This process will be documented in the HNP Repair/Replacement Program and must be acceptable to the Authorized Inspection Agency.

6200 HYDROSTATIC TESTS The requirement.s of this section apply to all piping systems or piping subassemblies.

6210 HYDROSTATIC TEST PROCEDURE 6211 Venting During Fill Operation The piping subassembly or piping system in which the test is to be conducted will be vented during the filling operation to minimize air pocketing.

6212 Test Medium and Test Temperature (a) Water will be used for the hydrostatic test.

(b) The test will be conducted at an ambient temperature that is within the temperature limits of the system design. The test pressure will not be applied until the piping and the pressurizing fluid are at approximately the same temperature.

6220 HYDROSTATIC TEST PRESSURE REQIDREMENTS 6221 Minimum Hydrostatic Test Pressure The system will be hydrostatically tested at not less than 1.5 times the Design Pressure

+ 10 psi for four hours prior to leakage inspection.

6222 Maximum Permissible Pressure When pressure testing a system, the induced stresses shall not exceed the minimum specified Hydrostatic Design Basis (HDB) for any item in the system.

E2-41 to NL~15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 6223 Hydrostatic Test Pressurization and Holding Time (a) The pressure in the test section will be gradually increased at a rate between 5 psig/min. minimum and 20 psig/min. maximum. Pressure will be held at the test pressure for 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months , during which time make-up water may be added to maintain pressure due to initial expansion.

(b) After the 4 hour4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months hold time, the test pressure will be reduced by 10 psig, and make-up water may no longer be added to maintain pressure. The system pressure will then be monitored for at least one hour, during which time there will be no reduction in pressure greater than 5% of the test pressure. Satisfactory completion of this portion of the test will satisfy pre-service inspection requirements for the portion of HDPE piping being tested.

(c) The total elevated test time greater than normal operating pressure, including initial expansion and time at test pressure, will not exceed 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months . If the pressure test is not completed in that time, the section will be depressurized and not re-pressurized for at least 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months .

6224 Examination for Leakage After Application of Pressure Following the application of the hydrostatic test pressure for the required time in accordance with 6223(a), and upon reduction in test pressure in 6223(b), VT-2 examination for leakage will be performed by personnel qualified in accordance with 542l(d).

(a) Each fused joint and all accessible external exposed surfaces will be examined for leakage while at hydrostatic test pressure.

(b) For items whose external surfaces are inaccessible for direct visual examination, only the examination of the surrounding area (including areas or surfaces located underneath the items) for evidence of leakage will be required.

(c) There will be no leakage at fused joints or through the pressure boundary except as permitted in (d), below.

(d) Leakage of temporary gaskets and seals, installed for the purpose of conducting the hydrostatic test that will later be replaced, may be permitted unless the leakage exceeds the capacity to maintain system test pressure during the required examination.

(e) The examination will be witnessed by the Inspector.

6300 Inservice Testing Inservice pressure testing will be performed in accordance with Supplement 5.

E2-42 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 8000 NAMEPLATES, STAMPING AND DATA REPORTS 8100 GENERAL REQIDREMENTS 8110SCOPE Stamping is neither required nor prohibited. When stamping by an ASME Certificate Holder is required, stamping with the Certification Mark and Designator, and associated data reports for items constructed in accordance with this ATR will be in accordance with the latest regulator-approved edition of ASME Section ill, Subsection NCA-8000. with the following exceptions:

(a) The attachment of nameplates, if required, will be performed using an adhesive or corrosion resistant wire that is compatible with and will not degrade the polyethylene material.

(b) The polyethylene material manufacturer is permitted to apply the standard print line identifier to his piping product using a thermal process.

(c) No indentation stamping is allowed on the polyethylene pipe surface, and all marking will be performed with a metallic paint marker or stenciling marker.

(d) Mitered elbows will be furnished with Data Report Form NM(PE)-2 (Supplement 4) as required by 2233 of this ATR.

9000 GLOSSARY Refer to ASME Section IX, QG-1 09, for definitions applicable to the fusing process. All other definitions will be as given in the latest regulator-approved edition of ASME Section ill, Subsection NCA-9000 with the following additions:

Hydrostatic Design Basis (HDB): one of a series of established stress values for a compound.

Hydrostatic Design Stress (HDS): the estimated maximum tensile stress the material is capable of withstanding continuously with a high degree of certainty that failure of the pipe will not occur. This *stress is circumferential when internal hydrostatic water pressure is applied.

lot: the quantity of:

(a) Polyethylene Source Material documented on the Certificate of Analysis (COA) and related traceability documentation.

(b) Polyethylene Material documented on the Certified Product Test Report (CPTR).

modulus of soil reaction, E': the soil reaction modulus is a proportionality con.stant that represents the embedment soil's resistance to ring deflection of pipe due to earth pressure. E' has been determined empirically from field deflection measurements by substituting site parameters (i.e., depth of cover, soil weight) into Spangler's equation and "back calculating" E'.

polyethylene (PE): a polyolefin composed of polymers of ethylene. It is normally a translucent, tough, waxy solid which is unaffected by water and by a large range of E2-43 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 chemicals. There are three general classifications: low-density, medium-density, and high-density.

void free: free from any detectable voids using the volumetric examination method approved by the SNC or its designee.

E2-44 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 SUPPLEMENT 1 Applicable Standards The PE material standards listed in the following table are applicable to the extent invoked by this ATR.

Referenced Standards Standard Subject Edition ASTM Standards D638 Tensile Properties of Plastics 2010 D792 Density and Specific Gravity (Relative Density)of Plastics 2008 D1238 Melt Flow Rates of Thermoplastics 2010 D1505 Density of Plastics 2010 D1598 Standard Test method for Time to Failure of Plastic Pipe Under 2009 Constant Internal Pressure D1599 Short Term Hydraulic Pressure R2005 D1603 Carbon Black Content of Olefin Plastics 2012 D2122 Determining Dimensions of Thermoplastic Pipe R2010 D2290 Apparent Hoop Tensile Strength 2012 D2837 Obtaining Hydrostatic Design Basis 2011 D3350 Specification for Plastic Pipe & Fitting Material 2012 D4218 Determining Carbon Black Content in PE Compounds R2008 D488 Density Measurement using Ultrasound 2008 F714 Specification for Polyethylene Pipe based on Outside Diameter 2010 F1473 Notch Tensile Test for Slow Crack Growth 2011 F2206 Specification for Fabricated Fittings 2011 F2880 Lap-Joint Type Flange Adaptors 2011a (applies only to flange adaptor hub dimensional requirements)

PPI Documents PPITR-3 Developing Hydrostatic Design, Pressure Design, and Strength 2010a Design Bases, and Minimum Required Strength Ratings PPITR-4 Listing of Hydrostatic Design, Pressure Design, and Strength Latest version Design Bases, and Minimum Required Strength Ratings PPITR-33 Generic Butt Fusion Joining Procedure for Field Joining of 2012 Polyethylene Pipe Other Codes ASME Section Rules for Inservice Inspection of Nuclear Power Plant Note 1 XI Components USAS B31.7 Nuclear Power Piping (Original Construction Code) 1969 USAS B31.1.0 Power Piping (as invoked by USAS B31.7-1969) 1967 ANSJ/ASNT ASNT Standard for Qualification and Certification of 1995 CP-189 Nondestructive Testing Personnel ASME Nondestructive Examination (except for volumetric 2001 Ed w/

Section V examination of fused joints) 2003 Add ASME Nondestructive Examination (for volumetric examination of 2010 Ed Section V fused joints)

Note 1) 2001 Edttion w/2003 Addenda through December 31, 2015; 2007 Edttion w/ 2008 Addenda begmmng January 1,2016 E2-45 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 SUPPLEMENT 2 -Ultrasonic Examination of High Density Polyethylene Paragraph numbers relate to the applicable paragraphs of ASME Section V. 2010 Edition, Article 4, similar to existing Mandatory Appendices of that Article. Skipped and omitted numbers indicate no change to the corresponding paragraphs in Article 4.

2-410SCOPE This Mandatory Supplement describes the requirements to be used to examine fused butt welds in High Density Polyethylene (HDPE) using encoded pulse echo with either the Phased Array (PAUT) or Time of Flight Diffraction (TOFD) ultrasonic technique.

2-420 GENERAL The requirements of ASME Section V, 2010 Edition, Article 4, including Mandatory Appendix ill or Mandatory Appendix V of that Article, as applicable, will apply except as modified herein.

2-421.1 Procedure Qualification. The requirements of Table 2-421 of this ATR (below),

plus ASME Section V, Table T-421 and either Table ill-422 or Table V-421 of Article 4 Appendices, as applicable, will apply.

2-422 Scan Plan A scan plan (documented examination strategy) will be provided showing search unit placement and movement that provides a standardized and repeatable methodology for the examination. In addition to the information in ASME Section V, Article 4 Table T-421 and, as applicable, Table ill-422 or Table V-421 of Article 4 Appendices, the scan plan will include beam angles and directions with respect to the weld axis reference point, weld joint geometry, and number of examination areas or zones.

TABLE2-421 REQIDREMENTS OF AN ULTRASONIC EXAMINATION PROCEDURE FOR HDPE TECHNIQUES Requirement Essential Nonessential (As Applicable)

Variable Variable Scan plan X

Examination technique(s)

X Computer software and Revision X

Scanning technique (automated vs.

X semi-automated)

Flaw characterization methodology X

Flaw sizing (length) methodology X

Scanner and adhering and guiding X

Mechanism Search unit mechanical fixturing X

Device E2-46 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 2-430 EQUIP:MENT 2-431.1 Instrument.

The requirements of ASME Section V, Article 4, T-431 and Appendix ill-431.1, if applicable, will apply. In addition, when using the phased array technique, the following will apply. An ultrasonic array controller will be used. The instrument will be capable of operation at frequencies over the range of at least 1 MHz to 7 MHz and will be equipped with a stepped gain control in units of 2 dB or less and a maximum gain of at least 60 dB.

The instrument will have a minimum of 32 channels. The digitization rate of the instrument will be at least five times the search unit center frequency. Compression setting will be not greater than used during qualification of the procedure.

2-431.2 Data Display and Recording.

When performing TOFD, the requirements of Section V, Article 4, Appendix ill-431.2 shall apply. When performing phased array ultrasonic testing, the following will apply.

The instrument will be able to select an appropriate portion of the time base within which A-scans are digitized. The instrument will be able to display A-, B-, C-, D-, and S-scans in a color palette able to differentiate between different amplitude levels. The equipment will permit storage of all A-scan waveform data, with a range defined by gates, including amplitude and time-base details. The equipment will also store *positional information indicating the relative position of the waveform with respect to adjacent waveform(s), i.e.

encoded position.

2-432 Search Units The requirements of ASME Section V, Article 4 T-432-1, and if applicable Appendix ill-432.1, will apply. In addition, when using the phased array technique, the following will apply. The nominal frequency will be from 1 MHz to 7 MHz unless variables, such as production crystalline microstructure, require the use of other frequencies to assure adequate penetration or better resolution. Longitudinal wave mode will be used. The number of elements used will be between 32 and 128. Search units with angled wedges may be used to aid coupling of the ultrasound into the inspection area.

2-433 Couplant 2-433.1 General The couplant used on HDPE shall not contain oxidizers, grease or motor oils.

2-434 Calibration Blocks 2-434.1.1 Reflectors.

2-434.1.1.1 Side-Drilled Hole (SDH)

The reference reflector will be a maximum diameter of 0.08 in.

2-434.1.2 Material The block will be fabricated from pipe of the same pipe material designation (PE4710) to be used in production.

E2-47 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 2-434.1.3 Quality. In addition to the requirements of ASME Section V, Article 4, T-434.1.3, areas that contain indications that are not attributable to geometry are unacceptable, regardless of amplitude.

2-434.3 Piping Calibration Blocks. The calibration block as a minimum will contain side-drilled holes (SDH) and shall be at least as thick as the component under examination. Alternative calibration block designs may be utilized provided the calibration is demonstrated as required in 2-421.1. The block size and reflector locations will allow for calibration of the beam angles used that cover the volume of interest.

2-460 CALmRATION 2-462.6 Temperature 2-462.6.1 The temperature differential between the calibration block and examination surface will be within 18°F.

2-464 Calibration for Piping 2-464.1 System Calibration for Distance Amplitude Techniques 2-464.1.1 Calibration Block(s). Calibrations will be performed utilizing the calibration block referenced in 2-434.3.

2-464.1.2 Straight Beam Calibration. Not required.

2-464.2 System Calibration for Non-Distance Amplitude Techniques. Calibrations include all those actions required to assure that the sensitivity and accuracy of the signal amplitude and time outputs of the examination system (whether displayed, recorded, or automatically processed) are repeated from examination to examination. Calibration will be by use of the calibration block specified in 2-434.3.

2-467 Calibration Confirmation 2-467.1 System Changes. When any part ofthe examination system is changed, a calibration check will be made on the calibration block to verify that distance range point and sensitivity setting(s) of the calibration reflector with the longest sound path used in the calibration satisfy the requirements of 2-467.3.

2-467.2 Calibration Checks. A calibration check on at least one of the reflectors in the calibration block or a check using a simulator will be performed at the completion of each examination or series of similar examinations, and when examination personnel (except for automated equipment) are changed. The distance range and sensitivity values recorded will satisfy the requirements 2-467.3.

2-467.2.1 Temperature Variations. If during the course of the examination, the temperature between the most recent calibration and component temperature exceeds +/-

18°F, calibration is required.

NOTE: Interim calibration checks between the required initial calibration and the fmal calibration check may be performed. The decision to perform interim calibration checks should be based on ultrasonic instrument stability (analog vs. digital), the risk of having to conduct reexaminations, and the benefit of not performing inteiim calibration checks.

E2-48 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 2-467.3 Confirmation Acceptance Values 2-467.3.1 Distance Range Points. If the distance range point for the deepest reflector used in the calibration has moved by more than 10% of the distance reading or 5% of full sweep, whichever is greater, the distance range calibration will be corrected and the correction noted in the examination record. All recorded indications since the last valid calibration or calibration check will be reexamined and their values will be changed on the data sheets or re-recorded.

2-467.3.2 Sensitivity Settings. If any sensitivity setting for the deepest reflector used in the calibration has changed by 4dB or less, the difference will be compensated for when performing the data analysis, and the correction noted in the examination record. If the sensitivity setting has changed by more than 4 dB, the examination shall be repeated.

2-470 EXAMINATION 2-471 General Examination Requirements 2-471.1 Examination Coverage The examination area of interest is shown in Fig. 5220-1.

2-471.6 Recording. A-scan data will be recorded for the area of interest in a form cop.sistent with the procedure qualification, and recording increments of a maximum of:

(a) 0.04 in. for material <3 in. thick (b) 0.08 in. for material ~3 in. thick.

2-490 DOCUMENTATION 2-492 Examination Records For each examination, the required information of ASME Section V, Article 4 T -492, and either Appendix ID-492 or Appendix V -492 will be recorded. All inspection records, including A-scan recorded data, will be retained in accordance with 5500.

E2-49 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.. 55a(z)(1), Version 3.0 SUPPLEMENT 3 - Fusing Qualification Requirements 100GENERAL 3-100SCOPE The rules in this Supplement apply to the preparation and qualification of the fusing procedure specification (FPS), and the performance qualification of fusing machine operators.

3-101 Fusing Procedure Specification The Fusing Procedure Specification (FPS) specifies the "variables" and "parameters"12 including ranges, under which fusing must be performed. The FPS prepared will address the applicable fusing process variables and parameters for production fusing, both essential and nonessential, as provided in this Supplement.

3-102 Fusing Performance Qualification Fusing machine operator performance qualification will verify the ability of the fusing machine operator to produce soundly fused joints when following the HNP FPS. The fusing machine operator performance qualification record (FPQ) will document the performance test of the fusing machine operator, and the results of the required mechanical tests.

3-110 Fused Joint Orientation Orientations for fused joints are addressed in 3-203 an? 3-303.

3-120 Test Positions Fused joints may be made in test coupons oriented in the positions addressed in 3-203 and 3-303.

3-130 Data Acquisition and Evaluation 3-131 Data Acquisition Record Requirements The following fusing variables will be recorded for each fused qualification test joint:

(a) heater surface temperature immediately before inserting the heater plate (b) gauge pressure during the initial heat cycle (c) gauge pressure and elapsed time during the heat soak cycle (d) heater removal (dwell) time (e) gauge pressure and elapsed time during the fusing/cool cycle (f) drag pressure (g) joint configuration (h) pipe diameter and wall thickness (i) type of HDPE material (specification and classification) and manufacturer U) FPS used, operator identification, time, date, and fusing machine identification 3-132 Data Acquisition Record Review The data acquisition record for each qualification test joint will be compared to the HNP FPS after completion, and the following will be verified:

12 The term "parameters" is applied to variables or attributes not considered applicable by Section IX, but considered as applicable for nuclear applications.

E2-50 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z}(1 ), Version 3.0 (a) all data required by 3-131 was recorded (b) interfacial fusing pressure was within the FPS range (c) heater surface temperature recorded was within the FPS range (d) butt-fusing pressure applied during the fusing/cool cycle was correctly calculated to include the drag pressure, fell within the FPS range for the applicable size (e.g., pipe diameter), and agrees with the recorded hydraulic fusing pressure (e) butt-fusing pressure was reduced to a value less than or equal to the drag pressure at the beginning of the heat soak cycle (f) fusing machine was opened at the end of the heat soak cycle, the heater was removed, and the ends brought together at the fusing pressure within the time frame specified by the FPS (g) cooling time at butt-fusing pressure met the minimum time specified by the FPS If the recorded data is outside the limits of the HNP FPS, the joint is unacceptable.

3-140 Examinations and Tests 3-141 Visual Examination (a) All fused qualification test joints will receive a visual examination of all accessible surfaces of the fused joint.

(b) Acceptance Criteria (see Figure 3-462 for evaluation examples)

( 1) There must be no evidence of cracking in the cleavage of the beads or incomplete fusing as evidenced by cleavage projecting to or beneath the OD surface of the pipe.

(2) Joints must exhibit proper fused bead configuration (3) Variations in upset bead heights on opposite sides of the cleavage and around the circumference of fused pipe joints are acceptable.

( 4) The apex of the cleavage between the *upset beads of the fused joint must remain above the base material surface. Cleavage will be inspected by depth or pit gauge when depth is not verifiable by direct visual inspection.

(5) The data record for the FPS or fusing machine operator performance qualification test must be reviewed and compared to the FPS to verify observance of the specified variables applied when completing the fused test joint.

(6) Fused joints must not display visible angular misalignment exceeding 3 degrees, and outside diameter mismatch must be less than 10% of the nominal wall thickness.

(c) Visual examination results must be recorded on the FPQ.

3-143 Bend Tests These tests will impart bending stresses to a butt-fused plastic specimen to evaluate the soundness of the fused joint by visual evidence of failure.

3-143.1 Reverse Bend Test (RBT)

(a) Reverse-bend test specimens will be cut to a minimum width of 1.5 times the test coupon thickness for testing and removed as shown in Figure 3-463(a).

(b) One test specimen will be bent to place the inside surface of the joint in tension, and the other test specimen will be bent to place the outside surface of the joint in tension.

(c) The bending process will ensure the ends of the specimens are brought into contact with one another.

E2-51 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (d) Testing will be in accordance with ASTM F2620-09, Appendix X4.

(e) Test results will be recorded on the test record.

(f) A mechanical (e.g. hydraulic) test producing equivalent stresses for the face and root bends may be substituted for the manual test.

3-143.2 Guided Side Bend Test (GSBT) 3-143.2.1 Significance and Use. This test is designed to impart a bending load on a specimen from a butt fusion joint to evaluate its soundness. It is intended for butt fusion joints of HDPE pipe with a wall thickness greater than 1.0 in.

3-143.2.2 Test Specimens.

(a) Test specimens will be removed from the fused test coupon with the upset bead remaining on the outside and inside surfaces. A strip having the full thickness of the test coupon and measuring approximately Yz to 1 in. wide and 18 in. long will be removed along the longitudinal axis of the test coupon, with the joint located in the approximate center of the strip. See Figure 3-463(b ).

(b) The width of the specimens will be planed or machined to 0.25 in. +/- 0.02 in. with a smooth finish on both sides. See Figure 3-463(c).

3-143.2.3 Test Conditions (a) The GSBT will be conducted at a temperature 60°F to 80°F.

(b) The elapsed time of the test will be between 30 sec and 60 sec.

3-143.2.4 Guided Side-Bend Test Procedure 3-143.2.4.1 Jigs. Test specimens will be bent in a test jig consisting of a fixed member with two cross bars to support the specimen while force is applied. A hydraulic ram may be used to supply the bending force with a ram attached to the end of the cylinder. See Figure 3-463(d).

3-143.2.4.2 Bend Procedure. The side-bend test specimen will be positioned with the butt fusion joint in the center of the jig between the support mandrels, and the ram in the center of the fusion bead on the test specimen. The ram will be moved slowly until it makes contact with the test specimen and is positioned in line with the fusion bead. Then the bending force will be applied and deflect the side-bend test specimen. The test is complete when the test specimen is bent to an angle of 90 deg to 12013 deg between the inside surfaces of the specimen or until failure occurs. See Figure 3-463(d).

3-143.3 Acceptance Criteria. The test specimen must not break or exhibit cracking or fractures on the convex (outer) surface at the fusion interface during this test.

3-144 High Speed Tensile Impact Test (HSTIT)

This test method is designed to impart tensile impact energy to a butt-fused PE pipe specimen to evaluate the soundness of the joint.

13 Use of these values is contingent upon NRC acceptance of pending change to ASME Section IX, QF-143.2.3.2. If the change is not accepted by the NRC, the test specimen will be bent to an angle of 60 deg +/-

10 degas indicated in QF-143.2.3.2 and Figure QF-463(d) of the 2015 Edition of ASME Section IX.

E2-52 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 3-144.1 Test Specimens (a) Test specimens will be removed from the fused test coupon with the upset bead.

remaining on the outside diameter and inside diameter surfaces. Specimens for test coupon thicknesses less than or equal to 2 in. will include the full wall thickness of the fused joint. Specimens for test coupon thicknesses 2 in. (50 mm) and greater may be cut into approximately equal strips between 1 in. and 2.5 in. wide for testing with each segment tested individually such that the full cross section is tested.

(b) Test specimens will be prepared by machining to achieve the dimensions given in Figure 3-464, with the upset beads remaining intact.

(c) A smooth surface free of visible flaws, scratches, or imperfections will remain on all faces of the reduced area with no notches, gouges, or undercuts exceeding the dimensional tolerances given in ASTM F2634-07. Marks left by coarse machining operations will be removed, and the surfaces will be smoothed with abrasive paper (600 grit or finer) with the sanding strokes applied parallel to the longitudinal axis of the test specimen.

(d) Mark the test specimens in the area outside the hole with the applicable specimen identification using a permanent indelible marker of a contrasting color, or an etching tool.

(e) Condition the test specimens at 73 op +/- 4 op for not less than 1 hr just prior to conducting the test.

3-144.2 Test Conditions (a) Test Temperature. Conduct the high speed impact test at a temperature of73°F +/- 4°F unless otherwise specified.

(b) Test Speed. The speed of testing will be in accordance with Table 3-144.2 with a testing speed tolerance of +0.5 in./sec to -1 in./sec.

Table 3-144.2 Testing Speed Requirements WaD Thickness Tesdng Speed s 1251n. (32 mm}

6 ln./sec (150 mm/sec}

> 125ln. [32 mm}

4 ln./sec (100 mm/sec}

3-144.3 Test Procedure (a) The machine speed of testing will be set to the rate specified in 3-144.2(b).

(b) Each specimen will be pinned in the clevis tooling of the testing machine, aligning the long axis of the specimen and the tooling with the pulling direction of the test machine.

(c) Testing will be performed in accordance with ASTM F2634.

(d) The test specimen fracture will be evaluated to determine the mode of failure, and the results noted in the test record.

3-144.4 Test Record. The HSTIT will be documented by preparing a test record that includes the following information:

(a) testing speed applied (b) testing temperature observed (c) specimen dimension verification E2-53 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 (d) test machine calibration data (e) test specimen identification (t) test date (g) test operator identification (h) testing failure mode and acceptance/rejection (i) test equipment identification 3-144.5 Acceptance Criteria. Failure mode must be ductile, with no evidence of brittle failure at the fusion interface. See Figure 3-465, illustrations (a) through (d), for evaluation examples.

200 FUSING PROCEDURES SNC will prepare and approve the written fusing procedure specifications (FPS) required for this project in accordance with the following requirements.

3-201 Procedure Specifications 3-201.1 Fusing Procedure Specification (FPS)

(a) The HNP FPS will address all of the essential variables and parameters for each fusing process used in the FPS. The essential and nonessential variables and parameters for fusing are listed in Table 3-254.

(b) No changes are permitted in the essential variables. Changes in essential parameters will require retesting of fusibility in accordance with 2300.

( c )The HNP fusing procedure specifications will be based on the standard industry fusing procedure as tested and reported in the Plastics Pipe Institute (PPn, Report TR-33, supplemented by the testing described in 2300 of this A TR.

3-201.4 Availability of the FPS. The FPS used for production fusing will be available for reference and review by the Inspector when fused joints are made.

3-202 Type of Tests Required 3-202.1 Mechanical Tests 3-202.1.1 Mechanical testing will be in accordance with 2300. High-speed Tensile Impact Test specimens (HSTIT) will be prepared in accordance with Figure 3-464 and tested in accordance with 3-144.1. In addition, Guided Side Bend Tests (GSBT) will be prepared in accordance with 3-143.14 For each test to be performed, four specimens will be removed from fused pipe test coupons at intervals approximately 90 deg apart. If any test specimen fails to meet the applicable acceptance criteria of 3-144.5, or 3-143.3, as applicable, the test coupon will be considered unacceptable.

3-203 Limits of Qualified Positions for Fusing Procedures Testing will be performed in the horizontal position, and will qualify the FPS for a slope of up to 20 degrees. Use of any fusing machine on a slope greater than 20 degrees requires re-testing of the machine in accordance with 2300 at the maximum slope (and estimated maximum drag) to be used in production. (See 4321(c).)

14 SNC reserves the option to perform only HSTIT testing in the event the regulator questions with regard to the adequacy of that test method are resolved.

E2-54 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 3-220 Production Fusing Procedure 3-221 HNP Fusing Procedure All fusing will be performed in accordance with HNP FPSs, and limited to the following parameters. There will be no deviation from these requirements, unless tested in accordance with 2300 of the ATR.

(a) The pipe material is limited to PE4710, cell classification 445574C, produced from DOW DGDA-2492 BK bimodal polyethylene resin.

(b) The axis of the pipe is limited to the horizontal position +/-20 deg. (See 3-203.)

(c) The pipe ends must be faced to establish clean, parallel mating surfaces that are perpendicular to the pipe centerline on each pipe end, except for mitered joints. When the ends are brought together at the drag pressure, there must be no visible gap.

(d) For mitered butt fusion joints, the pipe faces must be at the specific angle to produce the mitered joint. When the ends are brought together at the drag pressure, there must be no visible gap.

(e) The external surfaces of the pipe must be aligned to within 10% of the pipe wall thickness.

(f) The drag pressure must be measured and recorded. The theoretical fusing pressure must be calculated so that an interfacial pressure of 60 psi to 90 psi is applied to the pipe ends. The butt-fusing gauge pressure set on the fusing machine must reflect the theoretical fusing pressure plus drag pressure.

(g) The heater surface temperature must be 400°F to 450°F.

(h) The initial heating must begin by inserting the heater into the gap between the pipe ends and applying the butt fusing pressure until an indication of melt is observed around the circumference of the pipe. Once observed, the pressure must be reduced to drag pressure and the fixture must be locked in position so that no outside force is applied to the joint during the heat soak cycle.

(i) The ends must be held in place until the minimum bead size. is formed between the heater faces and the pipe ends, as shown in Figure 3-221.1. For 14 NPS and larger pipe sizes, the minimum heat soak time of 4.5 min per inch of pipe wall thickness must be obtained.

G) After the proper bead size is formed, the machine must be opened and the heater removed. The pipe end surfaces must be smooth, flat, and free of contamination. The pipe ends must be brought together and the butt-fusing pressure reapplied.

{ic) The maximum time from separating the pipe ends from the heater until the pipe ends are pushed together must not exceed the time given in Table 3-221.2.

(1) The butt-fusing pressure must be maintained until the joint has cooled, after which the pipe may be removed from the joining machine. The minimum cool time at the butt-fusing pressure must be at least 11 min per inch of pipe wall thickness of the thicker member, except that for ambient temperatures between 100°F and 125°F, the cool time must be at least 13 min per inch of pipe wall thickness of the thicker member.

E2-55 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Figure 3-221.1 Required Minimum Melt Bead Size I

"A" minimum melt bead size is required prior to heater removal r--

H

~

e Pipe or fitting a

Pipe or fitting t

e r

~

Pipe (0.0.), in. (mm)

"A" Minimum Melt Bead Size in. (mml

> 8.63 (219) to ~ 12. 75 (324) 1/4 *(6)

> 12. 75 (324) to ~ 24 (610) 3/8 (10) lable 3-221.2 Maximum Heater Plate Removal Time for Pipe-to-Pipe Fusing Field Applications Pipe Wall Thickness, in. 1 Max1mum ~~ater Plate Removal Time. sec.

> 1.18 to 2.5 20 Fabrication Shop 1.18 to1.5 I

40 3-250 Fusing Variables 3-251 Types of Fusing Variables & Fusing Parameters for Fusing Procedure Specifications (FPS)

The variables and parameters 3 are categorized as essential or nonessential.

3-252 Essential Variables & Essential Parameters Essential variables are those that standard industry practice considers will affect the mechanical properties of the fused joint if changed. Essential parameters are additional parameters applicable to the HNP FPS which may affect the mechanical properties of the fused joint if changed. Changes in essential variables will not be permitted. Changes in essential parameters will require re-testing in accordance with 2300 of the ATR when any change exceeds the specified value recorded in the FPS for that variable or parameter (see Table 3-254).

3-253 Non Essential Variables and Parameters Nonessential variables and parameters are those that will not affect the mechanical properties of the fused joint, if changed, and do not require retesting of the FPS when changed.

E2-56 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Paral!l"::tth 3*40Z Jalnts 3*403 Mat~al 3*404 PositJan 3**105 Tbennal Condldons

Ho6 EQuipment H07 Tcdmlg!IC!

Paragraph 2000 2310(c) 2310(c) 2310(c) 2310(d) 4321(c) 4412(b) 4412(b) 4412(b)

Table3-2S4 (a) Fusing Variables Procedure Specification Polyethylene Pipe Butt Fusing Urief of Variabii!S Es!ll!atlal

..l 6 lolftt t\\'IN!

X 2

~.

Pl~.surf:lee_a!p_lfteS\\t X

.l

~ PE*

X 3

~ wan lhldo1clss

X A

CroSS<<CCSonal iii'C!il t

.1

~ Position*

X

.1 ft Heater sll!'f'.xe ~~~nture X

2 t6 lnrerf:lebl aressure X

3 Decrease In lllltlt ~

width X

A lncre:ue In beater removal rime X

.s Decrease 11'1 cool-down time X

.I

~ F11S1111 machine m:mu~c111rer t

.1

~ Shop tD field. or Ylce wrs:a Table3-254 (b) Fusing Parameters Procedure Specification Polyethylene Butt Fusing Brief of Parameters Essential ell from DOW DGDA-2492 BK X

ell Wall thiclmess (nominall

.X ell Diameter (nominall X

ell Cross-sectional area (nomlnall X

ell Change In fusing carriage make or model X

Increase in machine slope X

Decrease in ambient temperature <50°F X

Increase In ambient temperature 100°F-125°F Increase in ambient temperature > 125°F X

300 PERFORMANCE QUALIFICATIONS NonC!SSl!adal X

X X

Nonessential X

This Section lists the essential variables that apply to fusing machine operator performance qualifications. These variables are listed in Table 3-362.

3-301 Tests 3-301.1 Intent of Tests. The fusing machine operator performance qualification tests determine the ability of fusing machine operators to make sound fused joints when following the HNP FPSs.

3-301.2 Qualification Tests. All fusing machine operators will be qualified using a HNP FPS. A fusing machine operator qualified for fusing in accordance with one HNP FPS is also qualified for fusing in accordance with another HNP FPSs within the limits of the E2-57 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 fusing operator essential performance variables given in Table 3-362. Visual and mechanical examination requirements are described in 3-302. Retests and renewal of qualification are given in 3-320.

3-301.3 Identification of Fusing Machine Operators.

Each qualified fusing machine operator will be assigned an identifying number, letter, or symbol by the organization, which will be used to identify production fused joints completed by the fusing machine operator.

3-301.4 Record of Tests. The record of fusing machine operator performance qualification (FPQ) tests will include the qualified ranges of essential performance variables, the type of tests performed, and test results for each fusing machine operator.

3-302 Type of Test Required 3-302.1 Visual Examination. For pipe coupons, all surfaces will be examined visually over the entire circumference per 3-141 before cutting specimens.

3-302.2 Mechanical Tests. Two bend test specimens will be removed from the fused test joint at intervals of approximately 180 de g. Each specimen will be tested by one of the following methods:

(a) Reverse-Bend Test. The specimens will be removed as shown in Figure 3-463, illustration (a), and tested in accordance with 3-143.1.

(b) Guided Side-Bend Test. Each specimen will be removed as shown in Figure 3-463, illustration (b), and prepared and tested in accordance with 3-143.2.

3-303 Limits of Qualified Positions and Diameters 3-303.1 Pipe Positions. Fusing machine operators will be tested with the pipe in the horizontal position, and will be considered qualified for fusing in the horizontal position

+/-45 deg.

3-303.2 Pipe Diameters. Fusing machine operators will be tested for each nom1nal diameter of pipe to be fused in production.

3-305 Fusing Machine Operators Each fusing machine operator will have passed the mechanical and visual examinations prescribed in 3-301 and 3-302.

3-305.1 Testing. Qualification testing will be performed on test coupons in accordance with 3-311 and the following requirements:

(a) The data required by 3-130 will be recorded for each fusing machine operator.

(b) The supervisor conducting the test will observe the making of the fused joint and verify that the FPS was followed.

3-305.2 Examination. Test coupons fused in accordance with 3-305.1 will be evaluated as follows:

(a) The completed joint will be visually examined in accordance with 3-302.1.

(b) After the joint is complete, the data required by 3-130 will be reviewed for compliance with the requirements of the FPS used for the qualification test.

(c) Bend test specimens will be removed and tested and in accordance with 3-302.2.

E2-58 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 3-310 Qualification Test Coupons 3-311 Test Coupons The test coupons will consist of fusing one pipe joint assembly in the horizontal position.

3-320 Retests and Renewal of Qualification 3-321 Retests A fusing machine operator who fails one or more of the tests prescribed in 3-302 during initial qualification, as applicable, may be retested under the following conditions.

3-321.1 Immediate Retest Using Visual Examination. When the qualification coupon has failed the visual examination of 3-302.1, retests will be accepted by visual examination before conducting the mechanical testing. When an immediate retest is made, the fusing machine operator will make two consecutive test coupons. If both additional coupons pass the visual examination requirements, the examiner will select one of the acceptable test coupons for specimen removal to facilitate conducting the required mechanical testing.

3-321.2 Immediate Retest Using Mechanical Testing. When the qualification coupon has failed the mechanical testing of 3-302.2, and an immediate retest is conducted, the fusing machine operator will make two consecutive test coupons. If both additional coupons pass the mechanical test requirements, the fusing machine operator is qualified.

3-321.3 Further Training. When the fusing machine operator has undergone additional training or completed additional fusing practice joints, a new test will be made for each fusion test joint that failed to meet the requirements.

3-322 Expiration and Renewal of Qualification 3-322.1 Expiration of Qualification. The performance qualification of a fusing machine operator will be affected when one of the following conditions occurs:

(a) When a fusing machine operator has not completed a fused joint using a qualified FPS for a time period of 6 months or more, their qualification will expire.

(b) When there is a specific reason to question the ability of the fusing machine operator to make fused joints meeting the requirements of this Section, the qualifications of the fusing machine operator will be revoked.

3-322.2 Renewal of Qualification (a) Performance qualifications that have expired under the provisions of 3-322.1(a) may be renewed by having the fusing machine operator fuse a single test coupon and subjecting the test coupon to the testing required by 3-302. A successful test will renew all of the fusing machine operator's previous qualifications. Failure of the test will necessitate additional training and complete requalification per 3-301 through 3-310 for all positions, machines and diameters to be used in production, without impact on previous fusillg performed unless there is other reason to suspect their integrity.

(b) Fusing machine operators whose qualifications have been revoked under the provisions of 3-322.1 (b) may be requalified by fusing a test coupon representative of the planned production work. The fused test coupon will be tested as required by 3-302. A successful test will restore the fusing machine operator's qualification within the qualified range of essential performance variables listed in Table 3-362. Failure of the test will necessitate complete additional training and complete requalification per 3-301 E2-59 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z}(1 ), Version 3.0 through 3-310 for all positions, machines and diameters to be used in production, and any questionable previously fused joints will be rejected and replaced.

3-360 Essential Variables for Performance Qualification of Fusing Operators 3-361 General A fusing machine operator will be requalified whenever a change is made in one or more of the essential variables listed in Table 3-362.

Table 3*362 Essential Variables Applicable to Fusing Machine Operators 400 FUSING DATA 3-401 General Paragraph 3-403 Material 3-404 Position 3-406 Equipment Brief of Variables

.1 CZI Pipe material

.2 CZI Pipe diameter

.3 CZI Pipe thickness

.1 CZI Position

.1 CZI Fusing machine carriage Each fusing variable described in this Article is applicable for procedure qualification when referenced in 3-250 for each specific fusing process. Essential variables for performance qualification are referenced in 3-360 for each specific fusing process.

3-401.1 Essential Variable (Procedure). A fusing condition that may not be changed.

3-401.1.1 Essential Parameters (Procedure). A fusing condition that, if changed, requires retesting in accordance with 2300.

3-401.2 Essential Variable (Performance). A fusing condition that, if changed, will require retesting in accordance with 3-300.

3-401.3 Nonessential Variable (Procedure). A fusing condition that, if changed, will not require retesting, but must be addressed in the FPS.

3-401.3.1 Nonessential Parameter (Procedure). A fusing condition that, if changed, will not require retesting in accordance with paragraph 2300, but must be addressed in theFPS.

3-401.4 Fusing Data. The fusing data includes the fusing variables grouped as joints, pipe material, position, thermal conditions, equipment, and technique.

3-402 Joints 3-402.1 A change in the type of joint from that qualified, except that a square butt joint qualifies a mitered joint.

3-402.2 A change in the pipe O.D. surface misalignment of more than 10% of the wall thickness of the thinner member to be fused.

E2-60 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 3-403 Material 3-403.1 A change to any pipe material other than DOW DGDA-2492 BK (reference paragraph 2000).

3-403.2 A change in the nominal pipe diameter, D.

3-403.3 A change in the nominal pipe wall thickness, t 3-403.4 A change in the nominal cross-sectional area to be fused. (A= xDavgX t) 3-404 Position 3-404.1 For performance, the addition of other fusing positions beyond that qualified. See 3-303.1. For procedures, a change in the slope of the fusing machine carriage to greater than 20 degrees from horizontal (reference paragraph 4321(c)).

3-405 Thermal Conditions 3-405.1 A change in the heater surface temperature to a value beyond the range specified in 3-221.

3-405.2 A change in the interfacial pressure to a value beyond the range specified in 3-221.

3-405.3 A decrease in melt bead size from that specified in 3-221.

3-405.4 An increase in heater plate removal time from that specified in 3-221.

3-405.5 A decrease in the cool time at butt-fusing pressure from that specified in 3-221.

3-406 Equipment 3-406.1 A change in the make or model of fusing machine carriage.

3-407 Technique 3-407.1 A change in fabrication location from the fabrication shop to field applications or vice versa.

3-420 Material Groupings Not applicable to HNP E2-61 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 }, Version 3.0

~

Odlll

Figure 3-461.1 Fusing Positions

~...

I I

1 HdeQ',..,

I

~

Tllbulallon otPodlont lalalats I

I I

I

-a' I

~

I'D II lion dg A

8 c

Figure 3*461.2 Fusing Test Positions OHS Bt.20 90f. 20

.921 ~

~.**-~

lbllntmnedllte E2-62 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Figure 3*462 Cross Section of Upset Beads far Butt-Fused PE Pipe (a) V"~tuaUr ~

(Uniform bead around plpel (c) VlluaDy Acetphble INonunifonn bead around pipe localized diameter miunatch less than 10'JD of the wall)

E2-63 (b) Viaually Acwptable (Nonuniform bead around pipe)

Cleavage tip shall not mHt oreldtnd below pipe eurface (d) Vltually Unecc.ptable (NonunifonnAmlform b&ad around pipe-V-Groow too deep at pipe-tangent) to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Figure 3-463 Bend Test Specimen Removal, Configuration, and Testing

'j

--=---

15t-Ft5f (6.0 ln. (150 mml mln.J (6.0 ln. 1150 mml min.)

~ ~ ~ ~ ~: _-_- -_-_-_-_-_-_-_-_. ~.,.... "'.......

0.. _______ _

Test strap lal Revors..a.nct Test Spodmen Removal !for '-* :s 1 ln. 125 mmll 9.0 ln.!225 mml-r-9.0 ln.l225 mml r11n.(25mml r--------

0 0

lbl Guldtd Slde.a.nd Tnt Specimen Removal [for r...,. > 1 ln. 125 nvnll E2-64 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 F~gure 3-463 Bend Test Specimen Removal, Configuration,and Testing (Conl'd]

t = 0.25 in. +I- 0.02 in.

Width= wan 7 (ct Guided Side-Bend Test Specimen

~

t= 0.25 in. +I- 0.02 in.

R = 0.50 in. +1- 0.02 in.

L------ C.nttrDnt orbuH tuliiOn (dt Guided Side Bend Test Machine Dimensions E2-65 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1}, Version 3.0 Rgure 3*464 HSTIT Specimen Configuration and Dimensions L

1.381n.l35 mmHI+--....;...,_

0 1.031n. Q82 mmJ 11ln1UIII1 Q) PLe$

J z.ool r" SYM j

cso mmr'T""-+- -+--+-~

m 0.40 in. l10.2 mm) l' 00 ;n m

\\_...;\\~

0.20 ln. CS.l mml*+::::::j::::::...J f

I]\\

0.40 ln. (10.2 mm) +---l--=z.-=:25:-:-1n-'. :.._j 151 mml

"- ( of Fuoion

~ln. C23.SmmJ--t-of---~--4.50(113mml---t-~

1~

in. (23.5 mml 14----s~ ln. uao mml Rlf.---* :

GENERAL NOTES*

(11) AD mublned surfac01 125 RNS or bean.

(b) 3 place dimensions tO..OOS ln. (tO.t3 mm).

(c) Z place dimensions tO..OtD ln. (tO.ZS mm).

(d) Frxtlanal dlmendalls t'/u ln. (t0.80 mm).

(e) AU lnterml rad~ R1h ln. (tO.t3 mm).

[I) AU e.-1 radii ~.ln. (10 mm).

(81 Bead remains on altH machinlns.

E2-66 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Figure 3-465 HSTIT Specimen Failure Examples (a) Brittle Rupture (c) Ductne Rupture Adjecent to Fusion lntlff-E2-67 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Supplement 4 Code Data Report Form i

FORM NM(PE)-2 DATA REPORT FOR NONMETALLIC BATCH PRODUCED PRODUCTS REQUIRING FUSING As Required by the Provisions of the ASME Section XI, Code and the Hatch Nuclear Plant Alternative Technical Requirements (ATR) of HNP-ISI-ALT-HDPE-01

1. Manufactured by------------------------------

(name and address of Manufacturer of nonmetallic products) 2.Manufacturedfor ___________________ ~-----------

(name and address of purchaser)

3. (a) Product Identification ----------::---:-:::---=--:-:-:-----:-:=-:---=--:---=-------

(Lot No., Batch No., etc.) (Print String)

(b) Owner ________________________________________________________ _

4. Manufactured according to Material Spec. --.,........,-------,-- Purchase Order No. _____ __

(ASTM) 5.Remarks _____________ --=--:-~-~-~~-~-----------

(brlef description of fabrication)

Certificate of Compliance We certify that the statements made in this report are correct and that the products defined in this report conform to the requirements of the ASME Material specification listed above on line 4. The Certified Material Batch Reports provided for the material covered by this report.

Certificate of Authorization (n/a if Owner) No.

to use the Symbol Certificate of Authorization expires ____ _

(Date)

Date _______ Name-----,----------- Signed----------------

(Certificate Holder)

(Authorized Signature)

Certificate of Inspection I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and employed by of __________ _

have inspected the products described in this Partial Data Report for product in accordance with the ASME Section XI, Division 1 or 2, Code and the Hatch Nuclear Plant Alternative Technical Requirements (ATR) of HNP-ISI-ALT-HDPE-01. By signing this certificate neither the inspector nor his employer makes any warranty, expressed or implied, concerning the products described in this Partial Data Report. Furthermore, neither the inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with this inspection.

Date Signed Commission ________ _

Nat. Board No. and Endorsement E2-68 n

to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Supplement 5 - Section XI Inservice Inspection General This supplement defines the Section XI Inservice Inspection requirements applicable to the installed Class 3 HDPE piping.

Periodic Pressure Test For all piping installed under this ATR, a pressure decay test will be performed at least once each lSI Inspection Interval (for the remaining life of the plant) to verify maintenance of structural integrity throughout the design life of the system. Successful tests will also reaffirm: 1) absence of detrimental slow crack growth, 2) absence of detrimental cold fusion in joints, and 3) adequacy of design modulus of elasticity based on time in service, temperature and operating stresses. 15 This testing will be performed as follows:

a) The HDPE Piping will be physically isolated from the remainder of the system in order to eliminate the possibility of leak-by through adjacent valves.

b) The pressure in the isolated portion of the system will be gradually increased at a rate of between 5 psig/min. and 20 psig/min. until required test pressure is achieved.

1) Test pressure will equal or exceed 1.1 x Design Pressure for this portion of the system.

c) After the system pressure stabilizes, the injection of make-up water will be terminated, and the HDPE portion of the system will be isolated from the test pump.

d) The system pressure will then be monitored for one hour.

Acceptance Criteria During the monitoring period, there must be no reduction in pressure greater than 5% of the test pressure that is not accounted for by temperature change.

15 The Modulus as a Function of Stress presentation provided at the ASME Sec III HDPE Design meeting in August 2014 may alleviate some concerns with the influence of stress on the Modulus of Elasticity.

E2-69 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 Nonmandatory Supplement A FUSING MACIDNE OPERATOR QUALIFICATION TRAINING A-100SCOPE (a) The major portion of the quality of polyethylene piping is determined by the skills of the fusing machine operators. When installing polyethylene piping, the quality of the fusion joints is essential for the piping system.

(b) It is important that the fusing machine operators are trained and competent in the fusing technology employed in constructing polyethylene piping systems. Continued competence of the fusing operator is covered by periodic retraining and reassessment.

(c) This document gives guidance for the training, assessment and approval of fusing operators to establish and maintain competency in construction of polyethylene piping for pressure applications. The fusion joining technique covered by this Supplement is thermal butt fusion. This Supplement covers both the theoretical and practical knowledge necessary to ensure high quality fusion joints.

A-110 REFERENCES The fusion standards in this Supplement are listed Table A-110-1.

A-200 TRAINING A-210 TRAINING COURSE (a) The course should cover all aspects of the butt fusion process including safety, machine evaluation and maintenance, machine oper~tion, FPS guidelines, pressure and temperature setting, data log device operation and set -up, in-ditch fusing techniques, visual examination guidance, and data log record evaluation. The minimum course duration is 24 hr.

(b) The course will be delivered by a competent qualified trainer with a minimum of 3 yr of experience in the butt fusion processes and who has mastered the techniques involved.

(c) The trainer should have a range of fusing machines representative of the equipment encountered on worksites for installing pipes, in order for the trainee fusing operator to become acquainted with the fusing equipment commonly used. The trainee fusing operator may be trained on one of these fusing machines or on a machine from his own company if accepted by the training center. The fusing equipment must comply with the fusing machine manufacturer's specifications or ISO 12176-1, see Table A-110-1.

A-220 OPERATOR ASSESS:MENT The trainee fusing operator who has followed a training course as described above should then pass a theoretical and practical assessment in order to be qualified as a fusing operator for polyethylene systems. The assessor should not be the trainer but should have the same assessment qualifications as the trainer shown above.

A-230 TRAINING CURRICULUM (a) The training course should be comprised of any combination of fusing packages based on the requirements of utility or pipeline operators. These packages may be given as individual modules or combined to suit requirements. The course should include safety training related to the fusing process and equipment.

E2-70 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 (b) All consumables and tools necessary for the training package should be available during the training session. The pipes and fittings to be used should conform to the ASTM product forms permitted by this Supplement.

(c) The lessons should be designed so that the trainee fusing operator learns to master the fusing technique and attains a good working knowledge of the piping system materials and practical problems encountered when fusing pipe in the field. The fusing operator should receive a written manual covering all the elements dealt with in the training.

Standard ASTMF2620 ISO 12176-1 ISOTR 19480 PPITR-33 Table A-110-1 Fusion Standards and Specifications Referenced in Text Subject Heat Fusion Joining ofPE Pipe & Fittings (for reference only)

Plastic Pipe & Fittings - Equipment for Fusion Joining Guidance for Training and Assessment of Fusion Operators Generic Butt Fusion Procedure (for reference only)

Edition 2009 2006 2005 2012 (d) The theoretical course should deal with general information in connection with raw materials, pipes and fittings, and also with theoretical knowledge about preparation, tools and devices, joining components, different materials, different diameter ratios, and correct and incorrect parameters. The safety course should include information concerning the fusing process, such as protective clothing, general safety, regulations for electrical equipment, handling heater plates, etc. Areas of study should include but not be limited to the following:

( 1) Butt fusion joining.

(a) Principles of fusion.

(b) Straight/coiled pipes, service lines, main lines, etc.

(c) Components: pipes, flange adapters, saddle fittings, other fittings.

(d) Butt fusing equipment: manual, semiautomatic and automatic machines.

(e) Joint preparation: cleaning, rounding, alignment, facing, etc.

(j) Butt fusion cycle: diagram showing pressure, time and temperature relationships.

(g) Failure modes: understanding and avoiding possible mistakes.

(h) Test methods: visual examination, high-speed tensile-impact test, bending test, hydrostatic test, data log recording/evaluation, etc.

(2) The trainee fusing operator should be familiar with the butt fusion joining technique and procedure (FPS) by making a sufficient number of butt fusion joints. In some cases, the fusing technique may vary slightly according to diameter, material or other factors. In such cases, the trainee fusing operator should also be made familiar with the various techniques.

( 3) The trainee should start by making a butt joint between two pipes, and should then learn to make butt fusion joints with pipes and fittings such as tees, reducers, etc.

(4) The trainee should learn how to detect and avoid typical fusion defects.

E2-71 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0

( 5) The trainee should learn how to assess the quality of a butt fusion joint by doing a visual examination of the butt fusion joint and comparing it to the visual guidelines published in the pipe manufacturer's heat fusion joining procedure booklet. The trainee should also compare the data log record to the FPS to ensure the proper parameters and procedures were followed in the butt fusion process.

A-300 ASSESS:MENT AND TESTING (a) Training program should end with a theoretical and practical examination (test piece).

(b) The content of the theoretical examination will consist of not less than 20 multiple choice questions about the butt fusion process, fusing machine operation, pipe, quality examination, safety, etc. within a set period of time. A score of 80% or better is considered passing on this examination. Questions to be included but not limited to are:

How do you calculate the fusing machine gage pressure?

What is the proper heater surface temperature range from the FPS?

What is the proper butt fusion interfacial pressure range from the FPS?

How do you calculate the drag pressure?

How do you know when to remove the heater in the heating cycle?

How long do you leave the pipe ends together under pressure in the cooling cycle?

What is the difference between IPS pipe and DIPS pipe?

How do I determine the hydraulic fusing machines total effective piston area?

How is the total effective piston area of the fusing machine used to determine the fusing machines gage pressure for a specific pipe?

How do you adjust the machine to improve the alignment of the pipe after facing?

How much material should be removed from the pipe ends in the facing operation?

How do you determine if the fusing machine conforms to the equipment manufacturer's specifications?

How do you align the pipe in the butt fusing machine?

Can you butt fuse pipe in a ditch?

What is interfacial pressure?

(c) The practical examination will require the trainee fusing operator to make a fusion joint with a hydraulic butt fusing machine with a minimum pipe size of IPS 8 DRll. A data acquisition device must be attached to the fusing machine and the data concerning the joint entered. The data log device will be used to record the joint made by the trainee.

The assessor will observe the butt fusion joint and note if the proper procedure (FPS) was followed. After the joint is complete, the data log record will be reviewed by the assessor and compared to the FPS to ensure the proper procedures were followed. The assessor will then conduct a visual examination of the joint to make sure it satisfies the visual acceptance criteria per Fig. 5321-1.

(d) Trainees who pass the theoretical and practical examination will be documented on a training record. The record should state the technique or techniques and fusing machines that were used. If the fused specimens are used for fusing operator qualification, they will be tested in accordance with 4300.

E2-72 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1), Version 3.0 A-400 REASSESSMENT If the trainee fails one of the examinations, he should retake it after a period not shorter than one week. If the trainee fails the examination for the second time, the trainee should repeat the training course before taking the test again.

If the trainee fails fusing operator qualification testing, retesting will be performed as permitted by Supplement 3.

E2-73 to NL-15-1754 Proposed Alternative Technical Requirements to ASME Section XI Requirements for Replacement of Class 3 Buried Piping in Accordance with 10 CFR 50.55a(z)(1 ), Version 3.0 Nonmandatory Supplement B Fig. B-1 Unacceptable Fusion Bead Configurations Butt Fusion of Ptp.

Unacceptable Appearance -

lo&Ufficient Melt Butt Ft.tslon ot Pipe Unaccep1able Appearance -

Improper Alignment Butt F\\.lsion or Pipe Unacceptable Appearance-Incomplete Face Off E2-74 Butt FU!Jon ot Pipe Unacceptable Appearance -

Inadequate Ron Back 7 ~F\\.1$00~ VShac:tN J, ~

(l lni'ldQMIItj Roll Qat~. ;II ~

Bun Fu'llon ol Pipe Unacceptable Appearance Bun ~Slon ot Pipe~

Unacceptable Appearance-Incomplete Face Off

v t e Letter Sequence Request
TAC:MF6712, (Approved, Closed)
Initiation Request, Request Acceptance... Administration Questions Answers Results Approval Other:
MONTHYEAR2015-12-21 [Table View]

NL-15-1754, Proposed Inservice Inspection Alternative HNP-ISI-ALT-HDPE-01, Version 3.0

Text

Introduction:

Enclosures:

References:

Navigation menu