Calculation M-93-038, Impact of Pipe Clamp on Calvert ... · the acceptability of the clamp design....

ENCLOSURE (6)

CALCULATION M-93-038 (25 pages)

Calvert Cliffs Nuclear Power Plant, LLCDecember 6, 2013

DESIGN ENGINEERING AND CONFIGURATION CNG-FES-015MANAGEMENT FORMS Revision 00006

FORM 3, ENGINEERING CHANGE NOTICE (ECN)Page I of I

ECN No.: rCP-1l3-000947-TCN-03-CNw001 Rev. No.: 0000

INITIA'TION

Parent Product ID:

Parent Product Type:

Title:

Site (check on4):

Safely Classification

M p-93-038

calculation

Revision No. 01

Component Cooling Pu~mp Room Piping - Unit 2

CCNPP

E UNIT I

I] SR

'" NM P

ZUNIT 2

IZ NSR

[3 REG

[- COMMON ED ISFSI

ED Augmented Quality

B, I)I.gCRIPTION OF CIiA(,NI-,;:

A PIPE CLAMP IS FIIrNG INSTALLED PER BC]'- 13-000947 Rlv. 0 TO SHAL, A THRU-WAI.L IEAK IN lIJ I PIPING AI"APPROXIMATIELY NODi 290 xkS SiHOWN ON DWG 91374 SFIET 1.

C. JUJSTIFICATION:

AN IVAI.UATIIN WAS PFRFOI:•NII'D IN ViNI)OF, DOCUMFNT ILD-CALC-0013 Rr:v. 0 (ITAc't:!o) T FOUND

1"1117 INSI'ALLATiON OF TIlE PIPE CLAMP ACCF!PT\I3I.E WITH REGARD TO PIP' SfTRE.SS, PIPE SUPPORT 1.OADS AND

I)ISPI.ACEME!r"S, AND HEAT EXCHANGER NOZZLE LOADS.

USEI ADDITIONAL SHEETS AS REQUIRED Check if additional shects used [

[ Cancelled

[ [NMP Onlyl Change existing p usting Iro Document _ from "C" to "R" to avoid duplicate posting.

R ElVIE W AN1) APPROVAL:.... •n~ .... ., ; II

Electronic Signature (Primed Nanweand Situture) Datc:

Is Design Verification Required?

If yes, Design Verification Form is

Z Yes F1 No

DJ Attnched [] Filed with: ECP-13-000947 Rev. 0

Independent Reviewer:

El Electronic Signature

Approval:

E] Electronic Signature

Michael Tompkins (ILD, Inc1) . ..-................___ . -. •.. ; -

(Prinlcd Nanic and Signature)

L. ' ...... ... ... .... ... ... , .

.-0'tinted Name add Signamrcl •

Datle:

bate:

ILD Calculation Cover Sheet

Date: 11/5/2013 Calculation No: ILD-CALC-0013

Revision No: 0

Impact of Pipe Clamp on Calvert Cliffs Nuclear Power Plant ComponentCalculation Title: Cooling Water Piping Stress

Project Number: 1002-0040

Revision History: Include general descviplion as well as pages changed, added, superseded, orvoided.

Rev 0: Initial Issue

Calculation Type: [I Safety Related E] Non-Safety Related

Design VerificationRequired?: El No E] Yes (See ILD-EP-0015)

IDV was performed in combination with IDV of CCNPPECP-13-00947. See ECP-13-00947 for record of IDV.

Namne/Signature Required below.

Preparer: Michael Morgan.. Date:

Reviewer: Michael Tom pki nsf.. .- < Date: ,.///•'

Design Verifier: Bob Stakenborghs Date: k(s'i

Approver: Lindsey Dziuba , Date: L

Total Number of Pages 3,00.9

Page 1

ILD-CALC-0013 REV 0Job #1002-0040

-/LD

ILD-CALC-0013 REV 0

November 8, 2013

Impact of Pipe Clamp on Calvert Cliffs Nuclear Power Plant

Component Cooling Water Piping Stress

Table of Contents

1.0 Purpose and Scope ........................................................................................................................... 4

2 .0 D e sig n In p u t ...................................................................................................................................... 4

3 .0 A ssu m p tio n s ..................................................................................................................................... 5

4.0 Methodology and Acceptance Criteria ........................................................................................ 6

5.0 Documentation of Computer Code ............................................................................................. 9

6.0 Calculations and Results ....................................................................................................... 9

7 .0 C o n clu sio n ...................................................................................................................................... 23

8 .0 R e fe re n ce s ...................................................................................................................................... 2 3

9 .0 A ttach m e nts ................................................................................................................................... 24

List of Attachments

Attachment A: M E101 Benchmark Input (ILD-CALC-0013_R0_BM.inp) ............................................ 7 pages

Attachment B: M E101 Pipe Clamp Input (ILD-CALC-0013_ROCLAMP.inp) ...................................... 7 pages

Attachment C: M E101 Pipe Separation Input (ILD-CALC-0013_RO S.inp) ......................................... 7 pages

Attachment D: ME101 Benchmark Output (ILD-CALC-0013 _RO0BM.out) .................................... 981 pages

Attachment E: ME101 Pipe Clamp Output (ILD-CALC-0013_ROCLAM P.out) ............................... 981 pages

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ILD-CALC-0013 REV 0Job #1002-0040

Attachment F: ME101 Pipe Separation Output (ILD-CALC-0013 R0 S.out) .............. 1001 pages

Attachm ent G : CCNPP Correspondence ............................................................................................. 1 page

Revision History

Rev. 0 - Initial Issue,

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ILD-CALC-0013 REV 0Job #t1002-0040

1.0 Purpose and Scope

During the early-September 2013 forced Unit 2 shutdown a pin-hole leak was identified on the

Calvert Cliffs Unit 2 Salt Water (SW) pipe line 12"-U1-2011. The SW pipe with the hole is connected

to the discharge of Component Cooling Water (CCW) heat exchanger No. 21. In order to mitigate

the adverse effects of the hole in the piping, a clamp is being installed to seal the pipe (Ref. 8.1).

This calculation will evaluate the impact of the clamp weight on the Component Cooling Water salt

water piping stress, pipe support loads, and heat exchanger nozzle loads. Additionally, the loads on

the piping and supports are evaluated for thrust loads that would occur in the event of a pipe

separation at the location of the leak. This calculation does not evaluate the local stress on the

piping due to the installation of pipe clamp. That evaluation will be completed in ILD-CALC-0014

(Ref. 8.4). ILD-CALC-0014 will use the piping forces and moments from this evaluation to determine

the acceptability of the clamp design. This calculation is safety related.

2.0 Design Input

2.1 The model input for all existing piping and the applicable stress results are taken from

CCNPP Calculation M-93-038 Rev. 1 (Ref. 8.2). A review of the outstanding calculation

comments on M-93-038 Sheet 6 was completed, and it was verified that there is no impact

on this analysis. Also, a review of existing calculation change notices against M-93-038 was

performed. There is no impact on this calculation, In the thermal stress analysis (Eqn.

13/14) defined by TEA (thermal evaluation analysis control word) in the M-93-038 input, the

load case SEISDB was not excluded. The thermal analysis shouldn't include seismic loads

and therefore, has been excluded from the TEA input for correctness. Since this analysis

does not change any thermal cases, there is no affect on the analysis.

2.2 The salt water cooling piping layout and node numbers are given on CCNPP Drawing 91374

Sheet 1 (Ref. 8.3)

2.3 The pipe clamp assembly weight is approximately 233.7 lbs per CCNPP Calculation CA08093Rev. 0 (Ref. 8.1 Attachment E). Therefore, the use of 240 lbs in the ME101 model will be

bounding.

2.4 The piping code of record for the CCW salt water piping is USAS B31.1 1967 (Ref. 8.5).

2.5 Pipe supports SK-42075 and SK-42076 have a minimum margin of 20% using loads 15%

greater than those given in M-93-038 per CCNPP Calculation CA00700 (Ref. 8.6) and

CA00702 (Ref. 8.7). The design basis calculations for these supports are C-93-058 (Ref. 8.14)

and C-93-059 (Ref. 8.15).

2.6 Pipe Support 5K-42073 has a minimum load ratio of 0,89 for the south-side base plate bolt

interaction per CCNPP calculation C-93-056 (Ref. 8.16). The support was analyzed with adesign load of ±11,000 lbs in the x-direction, 1,500 lbs in the positive y-direction, and 4,710

lbs in the negative y-direction. The loads were qualified using faulted loads compared

against normal load allowables. A review of the as-built modifications for this support (Ref.

8.17 through 8.20) was performed, and there is negligible affect on this analysis.

2.7 Per Ref. 8.1, the through-wall leak Is located on 12" diameter class U-1 piping. The

operating pressure of U1 piping is 35 psig per Piping Class Summary Sheet M-601 (Ref. 8.9).

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ILD-CALC-0013 REV 0Job #1002-0040

Per Piping Class Sheet M-600 (Ref. 8.10), the piping is standard weight. The internal area of

standard 12" pipe is 0.7854 ftW per Crane Technical Paper No. 410 (Ref. 8.11) when using the

nominal wall thickness.

2.8 Correspondence with CCNPP plant personnel indicates that the maximum flow rate through

the salt water piping is 7,000 gpm (see Attachment G).

2.9 The maximum density of salt water of salt water is 64.1 Ibm/ft 3 per ASME PTC 12.2 Appendix

I (Ref. 8.12). Using a larger density corresponding to a temperature less than typical

operating temperatures is more conservative. The density assumes normal salinity of sea

water (see Section 3.3).

3.0 Assumptions

3.1 The pipe clamp weight is added as a single mass to node point 290 (Ref. 8.3). Per Ref. 8.1,

the installed clamp CG will be approximately 13 inches downstream of valve 2-CV-5206,

Node 290 is 5 inches downstream of the centerline of the valve and between 0.5 and 1.5

inches downstream of the valve flange. The next closest node is node 286, which is 38

inches downstream of the valve centerline. Node 290 is sufficiently close to the actual

clamp mounting location to approximate any stress induced on the piping by the installation

of the pipe clamp. Additionally, since node 290 has an assigned SIF of 1.3 and the clamp is

installed on a straight run of pipe (no additional SIF) the calculated stress is conservative at

this location.

3.2 In order to model the event of a full circumferential pipe break, a two inch dummy element

was added between Node 286 and 290 for the pipe separation model (Attachment C). This

element was given a low stiffness (modulus of elasticity of 1 psi) to allow the ends of thepiping created by the "break" to move independently. This dummy element has no impact

on the pipe loads or movement. It only serves to connect the piping upstream of the break

to the remaining piping of the model.

3.3 The salinity of the salt water in the piping is assumed to be of normal concentration. This is

a reasonable assumption since CCNPP salt water is taken from the Chesapeake Bay and not

a high-salinity source.

3.4 Only supports near the clamp are evaluated for this analysis since they will bear the vast

majority of load induced on the system by the clamp and postulated break. The remaining

pipe supports are deemed acceptable by judgment due to their relatively distant proximity.

* Support SK-42076 Is nearest to the installation location of the clamp. This support's

restraint direction is in the global Y-direction.

* Support SK-42075 Is the nearest support with restraint in the global Z-direction. It

also provides support in the global Y-direction.

* Support SK-42073 is the nearest support with restraint in the global X-direction. It

also provides support in the global Y-direction.

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ILD-CALC-0013 REV 0Job #1002-0040

4.0 Methodology and Acceptance Criteria

CCNPP Calculation M-93-038 Rev. I (Ref. 8.2) is the calculation of record for the Unit 2 CCW system

salt water piping. M-93-038 uses the Bechtel-developed software ME101 (see Section 5.0) to

calculate the code stresses and support loads in accordance with the CCNPP code of record for this

piping, USAS 831.1 1967 (see Section 2.4).

4.1 Benchmark

Calculation M-93-038 only gives the maximum computed stresses in the salt water piping.

Therefore, the exact input used previously will be rerun to determine the loads and stresses at

node 290 for comparison purposes. The benchmark ME101 input file (ILD-CALC-

0013 RO BM.inp) is in Attachment A.

4.2 Pipe Clamp Installation

In order to evaluate the impact that the added weight of the pipe clamp has on the piping

system, a weight of 240 lbs is added to node 290 (Assumption 3.1 and Design Input 2.3). No

other changes are made to the model. The results are compared against those in the

benchmark model to determine how the clamp affects pipe stresses and support loads. The

ME101 input file (ILD-CALC-0013 ROCLAMP.inp) for the pipe clamp installation is in

Attachment B.

4.3 Pipe Separation

A third model was developed to postulate pipe movements should the salt water piping have

a circumferential break at node.290. In order to do this, a dummy element with low stiffness

was added in between Nodes 286 and 290 (see Section 3.2). On each end of the dummy

element, an axial thrust load is imposed to account for loads induced by the salt water flowing

from the break. The ME101 input file for the pipe separation case is in Attachment C (ILD-

CALC-0013_ROS.inp).

The two axial thrust loads are oriented in the model such that their actions serve to push the

piping apart at the break, simulating the thrust of salt water leaving the system in the event of

a break. Per Ref. 8.8, the thrust load due to the blowdown of a fluid jet can be calculated from

the conservation of momentum as follows:

T = 144(AE)(Po - P.) + pV 2AE Equation 1

Where: T = Thrust Load (Ibs)

AE = Area of the Pipe Opening (ft2)

P, = Stagnation Pressure of the Liquid (psi)

Pý = Atmospheric Pressure (psi)

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ILD-CALC-0013 REV 0Job #1002-0040

p = Density of the Fluid (Ibm/ft3 )

V = Velocity of the Fluid (ft/sec)

4.4 Acceptance Criteria

4.4.1 Pipe Stress

The results of the analysis are considered acceptable if the calculated pipe stress is

less than the given allowable. The pipe stress allowables for A53 Gr B Welded

(material for node 290) and A377 GR 30 are as follows:

Table 4-1 - USAS 831.1 1967 Allowable Stresses (A53 GR B Welded)

ALLOWABLE STRESSDESIGN (PSI)

CONDITION LEVEL

SUSTAINED

LOADS 1.0 x SH 12,700

EQN. 11

OCCASIONAL

LOADS B 1.2 x SH 15,240

EQN. 12

OCCASIONAL

LOADS D 2.4 x SH 30,480

EQN. 12

THERMAL

EXPANSION 1.0 x SA 19,050

EQN. 13

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ILD-CALC-0013 REV 0Job #1002-0040

Table 4-2 - USAS B31.1 1967 Allowable Stresses (A377 GR 30)

DESIGN ALLOWABLE STRESSDESPSI)

CONDITION LEVEL

SUSTAINED

LOADS 1.0 x SH 3,000

EQN. 11

OCCASIONAL

LOADS B 1.2 x SH 3,600

EQN. 12

OCCASIONAL

LOADS D 2.4 x SH 4,800"

EQN. 12

THERMAL

EXPANSION 1.0 x SA 19,050

EQN. 13

*Per M-93-038 page 13 Note 2, Sy for Gray Cast Iron Gr. 30 is not

available, so pipe stresses are compared with SH/0.625 = 4,800 psi.

4.4.2 Pipe Supports

Per Refs. 8.6 and 8.7, the nearest pipe supports (SK-42076 and SK-42075) have a

minimum of 20% margin when using loads 15% greater than given in Ref. 8.2 (see

Section 2.5). Therefore, if the loads due to the added weight of the clamp system

increase less than 20%, then they will be acceptable by inspection. If the load

increases are greater, the supports will need to be evaluated in more detail. If the

two closest supports' load increases are acceptable, then the supports further away

are deemed acceptable by judgment (Assumption 3.4).

The closest support that restrains the piping in the X-direction is SK-42073. The

components with the least margin in support SK-42073 are the South-side base plate

bolts. Their maximum interaction ratio is 0.89 (ratio of tension to allowable plus

ratio of shear to allowable). The load ratios for all other components in the support

are much less. The maximum design load for this support is ±11,000 lbs in the x-

direction, 1,500 lbs in the positive y-direction, and 4,710 lbs in the negative y-

direction (Ref. 8.16). If the load increases are bound by the maximum analyzed

design loads, then the results are acceptable.

4.4.3 Heat Exchanger Nozzle

The CCW Heat Exchanger nozzle loads were evaluated in M-93-038 Attachment 11

and 14. Since it has been shown that the nozzle loads are acceptable at those levels,

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ILD-CALC-0013 REV 0Job # 1002-0040

if the results of this analysis give loads less than the previously evaluated loads, then

the nozzle is acceptable.

Table 4-3 - CCW Heat Exchanger 21 Outlet Nozzle Loads at Node 350 (Ref. 8.2 Attachment 14 Page 2)

Load Force (Ibs) Moment (ft-lbs)Case Fx Fy Fz Mx My Mz

Norm 11,161 3,711 3,096 9,003 11,964 30,500

Upset 12,643 4,102 3,620 10,306 12,671 34,609Faulted 13,731 4,429 6,785 18,886 24,510 37,625

5.0 Documentation of Computer Code

This calculation uses the computer software ME101 version N9 developed by Bechtel to analyze

piping structures. The software input was developed at ILD's Baton Rouge offices and run on

CCNPP's computers. CCNPP maintains ME101 as safety related under their Quality Assurance

Program. ME101 was validated under CCNPP calculation CA04657 Rev. 6 (Ref. 8.13). The program

input and output are as specified in Sections 4.0 and 6.0. The output files contain the date the input

file was run, and therefore, that date applies to the corresponding input file as well. The models

were run on CCNPP computer station PCG7147 in accordance with Ref. 8.13.

6.0 Calculations and Results

6.1 Benchmark

The ME101 model output for the benchmark evaluation is in Attachment D (ILD-CALC-

0013_ROBM.out). The reported maximum stresses are the same as given in M-93-038

(stresses for node 135 were not given in M-93-038 but are listed here for completeness),

repeated in Table 6-1 below.

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ILD-CALC-0013 REV 0Job #1002-0040

Table 6-1 - Maximum Pipe Stress (Benchmark)

LOCATION MAXIMUM ALLOWABLE COMPUTED

DESIGN OF MAXIMUM COMPUTED STRESS

CONDITION LEVEL END ELEMENT STRESS(PSI) (PSI) ALLOWABLE

SUSTAINED SHLOADS 440 435 MEON.S 440 1,263 3,000 0.421

-EQN. 11 440

SUSTAINED SH

LOADS 135 135 4,752 12,700 0.374

EQN. 11 140

OCCASIONAL 1.2 SH

LOADS B 440 435 M 2,843 3,600 0.790

EQN. 12 440

OCCASIONAL 1.2 SH

LOADS B 135 135 6,341 15,240 0.416

EQN. 12 140

OCCASIONAL 2.4 SH

LOADS D 440 435 M 4,193 4,800 0.874

EQN. 12 440

OCCASIONAL 2.4 SH

LOADS 0 135 135 7,642 30,480 0.251

EQN, 12 140

THERMAL SA

EXPANSION 180 180 17,239 19,050 0.905

EQN. 13 197

Two additional nodes are of interest for the installation of the pipe clamp. The benchmark

stresses at node 290 (the location of the clamp installation) and node 395 (the nearest non-

heat exchanger pipe anchor) are given below.

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ILD-CALC-0013 REV 0Job #1002-0040

Table 6-2 - Pipe Stress at Node 290 (Benchmark)




SUSTAINED SHLOADS 290 286 1,141 12,700 0.090EQN. 11 290

OCCASIONAL 1.2 SH

LOADS B 290 286 1,463 15,240 0.096

EQN. 12 290

OCCASIONAL 2.4 SHLOADS D 290 286 1,704 30,480 0.056EQN. 12 290

THERMAL SA

EXPANSION 290 286 5,635 19,050 0.296

EQN. 13 290

Table 6-3 - Pipe Stress at Node 395 (Benchmark)




SUSTAINED SH

LOADS 395 390 1,031 12,700 0.081

EQN. 11 395

OCCASIONAL 1.2 SH

LOADS B 395 390 1,711 15,240 0.112

EQN. 12 395

OCCASIONAL 2.4 SH

LOADS D 395 390 2,211 30,480 0.073

EQN. 12 395

THERMAL SA

EXPANSION 395 390 4,991 19,050 0.262

EQN. 13 395

The two nearest pipe supports are SK-42076 and SK-42075. The benchmark loads for these

supports are as follows. The loads and displacements exclusively due to the postulated

thermal cases are not repeated here since there is no effect on those analyses.

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ILD-CALC-0013 REV 0Job #1002-0040

Table 6-4 - Benchmark SK-42075 Loads and Displacements (Y-Dir)

Load Force (Ibs) Displacement (in)

Case FX FY FZ FA DX DY DZ DA

WTOP 0 -5,758 0 -5,758 0.000 0.000 0.000 0.000

SEISOB 0 822 0 822 0.000 0.000 0.000 0.000

SEISBD 0 1,540 0 1,540 0.001 0.000 0.000 0.000

MAXNRM 0 -4,467 0 -4,467 0.023 0.000 0.000 0.000

MINNRM 0 -7,562 0 -7,562 -0.035 0.000 0.000 0.000

MAXUPS 0 -3,645 0 -3,645 0.023 0.000 0.000 0.000

MINUPS 0 -8,384 0 -8,384 -0.035 0.000 0.000 0.000

MAXFLT 0 -2,903 0 -2,903 0.023 0.000 0.000 0.000

MINFLT 0 -9,940 0 -9,940 -0.045 0.000 0.000 0.000

Table 6-5 - Benchmark SK-42075 Loads and Displacements (Z-Dir)



WTOP 0 0 143 143 0.000 0.000 0.000 0.000

SEISOB 0 0 1,871 1,871 0.000 0.000 0.000 0.000

SEISBD 0 0 3,245 3,245 0.001 0.000 0.000 0.000

MAXNRM 0 0 7,358 7,358 0.023 0.000 0.000 0.000

MINNRM 0 0 -5,711 -5,711 -0.035 0.000 0.000 0.000

MAXUPS 0 0 9,229 9,229 0.023 0.000 0.000 0.000

MINUPS 0 0 -7,582 -7,582 -0.035 0.000 0.000 0.000

MAXFLT 0 0 10,603 10,603 0.023 0.000 0.000 0.000

MINFLT 0 0 -8,956 -8,956 -0.045 0.000 0.000 0.000

Table 6-6 - Benchmark SK-42076 Loads and Displacements


Case FX FY FZ FA DX i DY DZ DA

WTOP 0 -7,522 0 -7,522 -0.004 0.000 0.003 0.000

SEISOB 0 1,109 0 1,109 0.007 0.000 0.006 0.000

SEISBD 0 2,069 0 2,069 0.012 0.000 0.011 0.000

MAXNRM 0 -5,736 0 -5,736 0.024 0,000 0.018 0.000

MINNRM 0 -8,674 0 -8,674 -0.047 0.000 -0.027 0.000

MAXUPS 0 -4,628 0 -4,628 0.031 0.000 0.024 0.000

MINUPS 0 -9,783 0 -9,783 -0.054 0.000 -0.033 0.000

MAXFLT 0 -2,972 0 -2,972 0.036 0.000 0.039 0.000

MINFLT 0 -11,006 0 -11,006 -0.078 0.000 -0.038 0.000

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ILD-CALC-0013 REV 0Job #l1002-0040

Table 6-7 - Benchmark SK-42073 Loads and Displacements (X-Dir)



WTOP -366 0 0 -366 0.000 0.000 -0.001 0.000

SEISOB 1,579 0 0 1,579 0.000 0.000 0.001 0.000

SEISBD 2,738 0 0 2,738 0.000 0.000 0.001 0.000

MAXNRM 5,277 0 0 5,277 0.000 0.000 0.041 0.000

MINNRM -7,470 0 0 -7,470 0.000 0.000 -0.064 0.000

MAXUPS 6,856 0 0 6,856 0.000 0.000 0.041 0.000

MINUPS -9,049 0 0 -9,049 0.000 0.000 -0.065 0.000

MAXFLT 8,825 0 0 8,825 0.000 0.000 0.050 0.000

MINFLT -10,208 0 0 -10,208 0.000 0.000 -0.143 0.000

Table 6-8 - Benchmark SK-42073 Loads and Displacements (Y-Dir)



WTOP 0 -2,068 0 -2,068 0.000 0.000 -0.001 0.000

SEISOB 0 326 0 326 0.000 0.000 0.001 0.000

SEISBD 0 605 0 605 0.000 0.000 0.001 0.000

MAXNRM 0 -562 0 -562 0.000 0.000 0.041 0.000

MINNRM 0 -2,995 0 -2,995 0.000 0.000 -0.064 0.000

MAXUPS 0 -235 0 -235 0.000 0.000 0.041 0.000

MINUPS 0 -3,321 0 -3,321 0.000 0.000 -0.065 0.000

MAXFLT 0 926 0 926 0.000 0.000 0.050 0.000

MINFLT 0 -3,600 0 -3,600 0.000 0.000 -0.143 0.000

6.2 Pipe Clamp Installation

The ME101 model output for the evaluation of the effect of the pipe clamp system weight is in

Attachment E (ILD-CALC-0013_ROCLAMP.out). Table 6-9 summarizes the comparison of the

maximum pipe stresses that include the clamp weight to the piping allowables.

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ILD-CALC-0013 REV 0Job #1002-0040

Table 6-9 - Maximum Pipe Stress (Pipe Clamp Installed)


DESIGN OF MAXIMUM COMPUTED STRESS ---------


SUSTAINED SH

LOADS 440 435 M 1,263 3,000 0.421

EQN. 11 440

SUSTAINED SH

LOADS 135 135 4,752 12,700 0.374

EQN. 11 140

OCCASIONAL 1.2 SH

LOADS B 440 435 M 2,838 3,600 0.788

EQN. 12 440

OCCASIONAL 1.2 SH

LOADS B 135 135 6,313 15,240 0.414

EQN. 12 140

OCCASIONAL 2.4 SH

LOADS D 440 435 M 4,186 4,800 0.872

EQN. 12 440

OCCASIONAL 2.4 SH

LOADS D 135 135 7,596 30,480 0.249

EQN. 12 140

THERMAL SA

EXPANSION 180 180 17,239 19,050 0.905

EQN. 13 197

The maximum pipe stresses have negligible change due to the addition of the pipe clamp. The

stresses at node 290 are given below.

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ILD-CALC-0013 REV 0Job #1002-0040

Table 6-10 - Pipe Stress at Node 290 (Pipe Clamp)




SUSTAINED SH

LOADS 290 286 1,279 12,700 0.101

EQN. 11 290

OCCASIONAL 1.2 SH

LOADS B 290 286 1,625 15,240 0.107

EQN. 12 290

OCCASIONAL 2.4 SHLOADS D 290 286 1,887 30,480 0,062EQN. 12 290

THERMAL SA

EXPANSION 290 286 5,635 19,050 0.296

EQN. 13 290

Table 6-11 - Pipe Stress at Node 395 (Pipe Clamp)


DESIGN OF MAXIMUM COMPUTED STRESS --...---


SUSTAINED SH

LOADS 395 390 1,036 12,700 0.082

EQN. 11 395

OCCASIONAL 1.2 SH

LOADS B 395 390 1,722 15,240 0.113

EQN. 12 395

OCCASIONAL 2.4 SH

LOADS D 395 390 2,227 30,480 0.073

EQN. 12 395

THERMAL SA

EXPANSION 395 390 4,991 19,050 0.262

EON. 13 395

The sustained and occasional pipe stresses have increased by approximately 10%, but all pipe

stresses due to the addition of the pipe clamp remain well within allowables.

The following tables give the pipe support loads due to the addition of the pipe clamp system.

Page 15 of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-12 - SK-42075 Loads and Displacements with Pipe Clamp Installed (Y-Dir)



WTOP 0 -5,829 0 -5,829 0.000 0.000 0.000 0.000

SEISOB 0 832 0 832 0.000 0.000 0.000 0.000

SEISBD 0 1,559 0 1,559 0.001 0.000 0.000 0.000

MAXNRM 0 -4,538 0 -4,538 0.023 0.000 0.000 0.000

MINNRM 0 -7,633 0 -7,633 -0.035 0.000 0.000 0.000

MAXUPS 0 -3,706 0 -3,706 0.023 0.000 0.000 0.000

MINUPS 0 -8,465 0 -8,465 -0.035 0.000 0.000 0.000

MAXFLT 0 -2,955 0 -2,955 0.023 0.000 0.000 0.000

MINFLT 0 -10,030 0 -10,030 -0.045 0.000 0.000 0.000

Table 6-13 - SK-42075 Loads and Displacements with Pipe Clamp Installed (Z-Dir)



WTOP 0 0 130 130 0.000 0.000 0.000 0.000

SEISOB 0 0 1,890 1,890 0.000 0.000 0.000 0.000

SEISBD 0 0 3,277 3,277 0,001 0.000 0,000 0.000

MAXNRM 0 0 7,345 7,345 0.023 0.000 0.000 0.000

MINNRM 0 0 -5,723 -5,723 -0.035 0.000 0.000 0.000

MAXUPS 0 0 9,235 9,235 0.023 0.000 0.000 0.000

MINUPS 0 0 -7,613 -7,613 -0.035 0.000 0.000 0.000

MAXFLT 0 0 10,622 10,622 0.023 0.000 0.000 0.000

MINFLT 0 0 -9,000 -9,000 -0.045 0.000 0.000 0.000

Table 6-14 - SK-42076 Loads and Displacements with Pipe Clamp Installed



WTOP 0 -7,649 0 -7,649 -0.004 0.000 0.003 0.000

SEISOB 0 1,127 0 1,127 0.007 0.000 0.006 0.000

SEISBD 0 2,103 0 2,103 0.012 0.000 0.011 0.000

MAXNRM 0 -5,864 0 -5,864 0.024 0.000 0.018 0.000

MINNRM 0 -8,801 0 -8,801 -0.047 0.000 -0.027 0.000

MAXUPS 0 -4,736 0 -4,736 0.031 0.000 0.024 0.000

MINUPS 0 -9,928 0 -9,928 -0.054 0.000 -0.033 0.000

MAXFLT 0 -3,064 0 -3,064 0.036 0.000 0.039 0.000

MINFLT 0 -11,168 0 -11,168 -0.078 0.000 -0.038 0.000

Page 16 of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-15 -SK-42073 Loads and Displacements with Pipe Clamp Installed (X-Dir)



VVTOP -402 0 0 -402 0.000 0.000 -0.001 0.000

SEISOB 1,593 0 0 1,593 0.000 0.000 0.001 0.000

SEISBD 2,763 0 0 2,763 0.000 0.000 0.001 0.000

MAXNRM 5,241 0 0 5,241 0.000 0.000 0.041 0.000

MINNRM -7,506 0 0 -7,506 0.000 0.000 -0.064 0.000

MAXUPS 6,834 0 0 6,834 0.000 0.000 0.041 0.000

MINUPS -9,100 0 0 -9,100 0.000 0.000 -0.065 0.000

MAXFLT 8,813 0 0 8,813 0.000 0.000 0.050 0.000

MINFLT -10,269 0 0 -10,269 0.000 0.000 -0.143 0.000

Table 6-16 -SK-42073 Loads and Displacements with Pipe Clamp Installed (Y-Dir)



WTOP 0 -2,044 0 -2,044 0.000 0.000 -0.001 0.000

SEISOB 0 323 0 323 0.000 0.000 0.001 0.000

SEISBD 0 599 0 599 0.000 0.000 0.001 0.000

MAXNRM 0 -538 0 -538 0.000 0.000 0.041 0.000

MINNRM 0 -2,971 0 -2,971 0.000 0.000 -0.064 0.000

MAXUPS 0 -215 0 -215 0.000 0.000 0.041 0.000

MINUPS 0 -3,294 0 -3,294 0.000 0.000 -0.065 0.000

MAXFLT 0 944 0 944 0.000 0.000 0.050 0.000

MINFLT 0 -3,570 0 -3,570 0.000 0.000 -0.143 0.000

There is negligible difference in displacement due to the pipe clamp system. Additionally, the

load increases are less than 20% for SK-42075 and SK-42076. The load increases for support

SK-42073 remain within the maximum analyzed design load. Per Section 4.4, these loads are

acceptable.

The HX 21 outlet nozzle loads (absolute value) for the piping with the clamp installed are given

in Table 6-17. All loads are less than the originally analyzed loads in Table 4-3.

Table 6-17 - CCW Heat Exchanger Outlet Nozzle Loads at Node 350 (Clamp Installed)

Load Force (Ibs) Moment (ft-lbs)

Case Fx Fy Fz Mx My MzNorm 9,766 3,300 2,684 7,832 10,138 26,556

Upset 11,078 3,651 3,152 9,002 11,015 30,198

Faulted 12,042 3,945 5,914 16,487 21,338 32,872

Page 17 of 24

ILD-CALC-0013 REV 0Job #1002-0040

6.3 Pipe Separation

The thrust load to be applied at each end of the dummy member is calculated using Equation1:

T = 144(AE)(Po - P"') +POV 2AE

The pipe's fluid velocity is calculated from the volumetric flow rate and internal pipe area

(Design Input 2.7 and 2.8).

V Q _ (7000gal/mrin)(O.1337ft 3/gal)(1min/60sec) - 19.86ft/sec Equation 2

AE (0,7854ft2

)

Where: Q = Volumetric Flow Rate (gal/min)

The thrust load is therefore:

T = 1 44(0.7854ft 2 ) (35ps) + (64.llbM/ft 3)(19.86ft/sec) 2(O'7854ft 2)32 .2 lb'-ft = 4,575 lbf322lbf-.svc 2

Therefore, using 4,600 lbf of thrust on each end of the dummy member conservatively bounds

deviations from the input (larger internal pipe diameter, etc.). Note that this thrust isconservative because it is the steady state thrust load that would be developed if the piping

separated and steady state flow were allowed to develop from the open end. Since the ends

will be encapsulated by the seal, steady state flow could not develop from the pipe ends (and

spray outward).

The ME101 model output for the evaluation of the effect of pipe separation is in Attachment F

(ILD-CALC-0013_RO0S.out). Table 6-18 summarizes the comparison of the maximum pipe

stresses due to pipe separation at node 290 to the piping allowables.

Page 18 of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-18 - Maximum Pipe Stress (Pipe Separation)




SUSTAINED SH

LOADS 440 435 M 1,263 3,000 0.421

EQN. 11 44D

SUSTAINED SH

LOADS 335 M 335 B 5,968 12,700 0.470

EQN. 11 335 M

OCCASIONAL 1.2 SH

LOADS B 440 435M 2,839 3,600 0.789

EQN. 12 440

OCCASIONAL 1.2 SH

LOADS B 335 M 335 B 7,579 15,240 0.497

EQN. 12 335 M

OCCASIONAL 2.4 SH

LOADS D 440 435 M 4,187 4,800 0.872

EQN. 12 440

OCCASIONAL 2.4 SH

LOADS D 335 M 335 B 8,865 30,480 0.291

EQN. 12 335 M

THERMAL SA

EXPANSION 180 180 17,707 19,050 0.930

EON. 13 197

The maximum pipe stresses increase due to the separation of the piping due to increased

displacements. Additionally, node 335M replaced node 135 as the highest stress node with

SH equal to 12,700 psi. However, all stresses remain below allowables and therefore

acceptable. Since the nodes near the break are free moving, there are negligible stresses at

those locations. The pipe stress for node 395 is as follows.

Page 19 of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-19 - Pipe Stress at Node 395 (Pipe Separation)




SUSTAINED SH

LOADS 395 390 1,581 12,700 0.124

EQN. 11 395

OCCASIONAL 1.2 SH

LOADS B 395 390 2,335 15,240 0.153

EQN. 12 395

OCCASIONAL 2.4 SH

LOADS D 395 390 2,889 30,480 0.095

EQN. 12 395

THERMAL SA

EXPANSION 395 390 3,100 19,050 0.163

EQN. 13 395

The following tables give the pipe support loads due to pipe separation.

Table 6-20 - SK-42075 Loads and Displacements with Pipe Separation (Y-Dir)

Load Force (Ibs) I Displacement (in)


WTOP 0 -5,298 0 -5,298 -0.001 0.000 0.000 0.000

SEISOB 0 773 0 773 0.000 0.000 0.000 0.000

SEISBD 0 1,447 0 1,447 0.001 0.000 0.000 0.000

MAXNRM 0 -4,422 0 -4,422 0.022 0.000 0.000 0.000

MINNRM 0 -6,415 0 -6,415 -0.039 0.000 0.000 0.000

MAXUPS 0 -3,648 0 -3,648 0.022 0.000 0.000 0.000

MINUPS 0 -7,188 0 -7,188 -0.039 0.000 0.000 0.000

MAXFLT 0 -2,859 0 -2,859 0.022 0.000 0.000 0.000

MINFLT 0 -8,337 0 -8,337 -0.049 0.000 0.000 0.000

Page 20.of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-21 - SK-42075 Loads and Displacements with Pipe Separation (Z-Dir)

Load Force (Ibs) ....... Displacement (in)


WTOP 0 0 -935 -935 -0.001 0.000 0.000 0.000

SEISOB 0 0 1,781 1,781 0.000 0.000 0.000 0.000

SEISBD 0 0 3,089 3,089 0.001 0.000 0.000 0.000

MAXNRM 0 0 4,929 4,929 0.022 0.000 0.000 0.000

MINNRM 0 0 -5,364 -5,364 -0.039 0.000 0.000 0.000

MAXUPS 0 0 6,710 6,710 0.022 0.000 0.000 0.000

MINUPS 0 0 -7,145 -7,145 -0.039 0.000 0.000 0.000

MAXFLT 0 0 8,018 8,018 0.022 0.000 0.000 0.000

MINFLT 0 0 -8,624 -8,624 -0.049 0.000 0.000 0.000

Table 6-22 - SK-42076 Loads and Displacements with Pipe Separation



WTOP 0 -7,048 0 -7,048 -0.030 0.000 0.009 0.000

SEISOB 0 994 0 994 0.013 0.000 0.006 0.000

SEISBD 0 1,855 0 1,855 0.022 0.000 0.011 0.000

MAXNRM 0 -5,908 0 -5,908 -0.023 0.000 0.045 0.000

MINNRM 0 -8,287 0 -8,287 -0.114 0.000 -0.009 0.000

MAXUPS 0 -4,914 0 -4,914 -0.010 0.000 0.052 0.000

MINUPS 0 -9,281 0 -9,281 -0.127 0.000 -0.015 0.000

MAXFLT 0 -3,695 0 -3,695 -0.001 0.000 0.072 0.000

MINFLT 0 -10,400 0 -10,400 -0.150 0.000 -0.031 0.000

Table 6-23 - SK-42073 Loads and Displacements with Pipe Separation (X-Dir)



WTOP -3,739 0 0 -3,739 0.000 0.000 0.000 0.000

SEISOB 2,114 0 0 2,114 0.000 0.000 0.001 0.000

SEISBD 3,667 0 0 3,667 0.000 0.000 0.001 0.000

MAXNRM -3,739 0 0 -3,739 0.000 0.000 0.041 0.000

MINNRM -9,040 0 0 -9,040 0.000 0.000 -0.068 0.000MAXUPS -1,624 0 0 -1,624 0.000 0.000 0.042 0.000

MINUPS -11,155 0 0 -11,155 0.000 0.000 -0.069 0.000

MAXFLT -72 0 0 -72 0.000 0.000 0.055 0.000

MINFLT [ -12,707 0 0 -12,707 0.000 0.000 -0.148 0.000

Page 21 of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-24 -SK-42073 Loads and Displacements with Pipe Separation (Y-Dir)

Load Force (Ibs) _ Displacement (in)

Case FX FY FZ FA DX DY DZ DAWTOP 0 -2,165 0 -2,165 0.000 0.000 0,000 0.000

SEISOB 0 346 0 346 0.000 0.000 0.001 0.000SEISBD 0 641 0 641 0.000 0.000 0.001 0.000MAXNRM 0 -857 0 -857 0.000 0.000 0.041 0.000MINNRM 0 -2,947 0 -2,947 0.000 0.000 -0.068 0.000

MAXUPS 0 -511 0 -511 0.000 0.000 0.042 0.000

MINUPS 0 -3,293 0 -3,293 0.000 0.000 -0.069 0.000MAXFLT 0 568 0 568 0.000 0.000 0.055 0.000MINFLT 0 -3,588 0 -3,588 0.000 0.000 -0.148 0.000

There is negligible difference in displacement due to pipe separation for supports SK-42075

and SK-42073. The movements for SK-42076 increased more significantly. A review of Ref.

8.15 indicates that the design of this pipe support allows free movement in the pipe's axial

direction (Global Z). Additionally, there is a 0.5 inch gap on either side of the pipe in the

Global X-direction. Since all displacements in the X-direction are less than 0.5", these

movements are acceptable.

With the exception of the loads for SK-42073 and the Maximum Faulted load for SK-42076,

the load increases are less than 20%. In the case of the Maximum Faulted load for SK-42076,the load is negative and less than the Minimum Faulted load, and therefore bounded by the

acceptance criteria. Per Section 4.4, these loads are acceptable.

For support SK-42073, the loads in the y-direction remain within previously analyzed values

and are acceptable. The maximum x-direction load is -12,707 lbs which is greater than the

previous maximum analyzed load of 11,000 lbs. Increasing the bolt interaction load ratio(Design Input 2.6) by the ratio of load increase to design load:

(-12,707)/(-11,000)*0.89 = 1.028 > 1.0

However per Ref. 8.16, the support was analyzed using faulted loads compared against normalload allowables. Additionally, conservatisms exist in both this analysis and the original

support analysis. If the faulted allowables were used and conservatisms removed, the bolts

are acceptable by inspection.

The HX 21 outlet nozzle loads (absolute value) for the piping with the clamp installed are givenin Table 6-25. All loads are less than the originally analyzed loads in Table 4-3.

Page 22 of 24

ILD-CALC-0013 REV 0Job #1002-0040

Table 6-25 -CCW Heat Exchanger Outlet Nozzle Loads at Node 350 (Pipe Separation)

Load Force (ibs) Moment (ft-ibs)

Case Fx Fy Fz Mx My Mz

Norm 9,200 2,984 0 371 2 24,469

Upset 9,716 3,410 516 1,964 2,072 26,879

Faulted 10,095 3,783 895 3,133 3,513 28,977

The magnitude of pipe separation in the event of a circumferential break is calculated from

the resultant displacement between nodes 287 and 288 under normal sustained load

conditions. The resultant movement is approximately 9/64" and will be easily encapsulated

by the length of the clamp.

Table 6-26 - Resultant Pipe Movement Due to Circumferential Break

Displacement (in)

Node DX DY DZ Resultant

287 -0,024 0.000 0.000 0.134

288 -0.004 -0.132 -0.003

7.0 Conclusion

This evaluation determined the acceptability of installing a pipe clamp around a through wall leak in

CCNPP Unit 2 CCW salt water piping with regard to pipe stress, pipe support loads, and nozzle loads.

All pipe stresses are within allowables. Pipe support load increases are bounded by the existing

margin. Nozzle loads due to pipe separation and clamp installation are less than the loads originally

used to qualify the nozzles. Additionally, the pipe clamp is large enough to entirely encapsulate the

piping movement in the event of a full circumferential break in the piping at the location of the leak.

Therefore, there is no adverse impact due to the clamp installation on the piping system.

8.0 References

8.1 ECP-13-000947 Rev. 0

8.2 CCNPP Calculation M-93-038 Rev. 1, "Component Cooling Pump Room Piping - Unit 2"

8.3 CCNPP Drawing 91374 Sheet 1 Rev. 18, "Component Cooling Water Pump Room Piping -

Salt Water Cooling System - Unit 2"

8.4 ILD-CALC-0014 Rev. 0, "Evaluation of 12-U-1-2001 Line Enclosure"

8.5 Calvert Cliffs Engineering Standard ES-040 Rev. 00, "Piping Design Criteria"

8.6 CCNPP Calculation CA00700 Rev. 0, "Modification to Pipe Supports Associated with Salt

Water Piping System"

Page 23 of 24

ILD-CALC-0013 REV 0Job #1002-0040

8.7 CCNPP Calculation CA00702 Rev. 0, "Evaluation of Pipe Supports for Salt Water Piping

System due to Minor Deviation from Design Condition and/or Proximity to Adjacent

Anchor Bolts"

8.8 Moody, F.J.; "Prediction of Blowdown Thrust and Jet Forces;" ASME 1969

8.9 Calvert Cliffs M-601 Piping Class Summary Sheets Rev. 49

8.10 Calvert Cliffs M-600 Piping Class Sheets Rev. 76

8.11 Crane Technical Paper No. 410, "Flow of Fluids Through Valves, Fittings, and Pipe,"

Reprinted 2006

8.12 ASME PTC 12.2-2010, "Steam Surface Condensers"

8.13 CCNPP Calculation CA04657 Rev. 6, "Accepts Version N9 on Individual LAN computers

PCG3004, PCG7147, PCG8521, and PCH0730"

8.14 CCNPP Calculation C-93-058 Rev. 0, "Pipe Support Evaluation for SW Cooling System in the

Component Cooling Pump Room"

8.15 CCNPP Calculation C-93-059 Rev. 0, "Pipe Support Evaluation for SW System in the


8.16 CCNPP Calculation C-93-056 Rev. 0, "Pipe Support Evaluation for SW Cooling System in the






8.19 CCNPP Calculation CA00699 Rev. 0, "Pipe Support Modification for Salt Water Piping

System"

8.20 CCNPP Calculation CA00705 Rev. 0, "Review of Changes to Pipe Supports Configuration"

9.0 Attachments

Attachment A: ME101 Benchmark Input (ILD-CALC-0013 ROBM.inp)

Attachment B: ME101 Pipe Clamp Input (ILD-CALC-0013_R0_CLAMP.inp)

Attachment C: ME101 Pipe Separation Input (ILD-CALC-0013_R0_S.inp)

Attachment D: ME101 Benchmark Output (ILD-CALC-0013_ROBM.out)

Attachment E: ME101 Pipe Clamp Output (ILD-CALC-0013_ROCLAMP.out)

Attachment F: ME101 Pipe Separation Output (ILD-CALC-0013_ROS.out)

Attachment G: CCNPP Correspondence

Page 24 of 24

ENCLOSURE (7)

CALVERT CLIFFS PROCEDURE LR-01 (69 pages)


CENGa joint venture of

Consteltaton ., - eDF

Calvert Cliffs Nuclear Power Plant

TECHNICAL PROCEDURE

LR-01

ON LINE LEAK REPAIRS TO VARIOUS PRESSURE RETAINING COMPONENTS

Revision 00600

This Procedure is EXEMPT from 10 CFR 50.59 / 10CFR 72.48 Reviews

Safety Related

CONTINUOUS USE

WO No.:

General Supervisor-Mechanical Maintenance

ON-LINE LEAK REPAIRS TO VARIOUS UNIT I & 2PRESSURE RETAINING COMPONENTS LR-01, Rev. 00600

Page 2 of 69

TABLE OF CONTENTS

Sections Pages

1.0 P U R P O S E .................................................................................... . . 4

2.0 APPLICABILITY/SCOPE............................................................... 4

3.0 R E F E R E N C E S ............................................................................... . 5

4.0 PR ER EQ U IS ITES ........................................................................... 6

5.0 P R EC A U T IO N S ............................................................................. 9

6.0 PERFO R M A NC E .......................................................... ........ 10

6.1 Leak Repair A ctivity ........................................................... 10

6.2 Post Leak Repair Activity .................................................... 10

7.0 POST-PERFORMANCE ACTIVITIES ...................... 11

8 .0 B A S E S .............................................................................................. 1 1

9 .0 R E C O R D S ................................................................................... . . 1 1

Attachm ent 1, Packing Leaks ........................................................................ 12

Attachment 2, Flange/Bonnet Leaks, Wire Wrap with Cap Nuts andWire Wrap with Slotted Studs and Cap Nuts ........................... 17

Attachment 3, Flange/Bonnet Leak Repairs Using Flat Face PumpingMethod with Slotted Studs/Studs and Cap Nuts ..................... 25

Attachment 4, Flange Leaks: Flange Clamp Method ...................................... 29

Attachment 5, Piping/Fitting Leaks: Enclosures, Sealant Retaining Devices,P erim eter Seals ...................................................................... 34

Attachment 6, Pressure Seal Valve Bonnet Leak Repairs .................... 38

Attachment 7, Pre-Job Leak Repair Data Sheet .............................................. 43

Attachment 8, Post-Job Leak Repair Data Sheet.: ......................................... 45

Attachment 9, Repump Using Existing Penetrations ...................................... 46

Attachment 10, Pre/Post job compressed air repair data ............................... 51

Attachment 11, Compressed air-tubing less than 200 psig repair .................. 54

Attachment 12, Valve Bonnet Gasket Repair (Drill And Tap) ......................... 56

Attachment 13, Valve / Line Kill - Hot Tap Ring ............................................. 63

Attachment 14, Sealant Pumping Procedure .................................................. 68

ON-LINE LEAK REPAIRS TO VARIOUSPRESSURE RETAINING COMPONENTS

UNIT I & 2LR-01, Rev. 00600

Page 3 of 69

LIST OF EFFECTIVE PAGESCumulative Changes 0

Page No. Change No. Page No. Change No. Page No. Change No.

1 26 51

2 27 52

3 28 53

4 29 54

5 30 55

6 31 56

7 32 57

8 33 58

9 34 59

10 35 60

11 36 61

12 37 62

13 38 63

14 39 6415 40 65

16 41 66

17 42 67

18 43 68

19 44 69

20 45

21 46

22 47

23 48

24 49

25 50


Page 4 of 69

1.0 PURPOSE

To provide instructions for temporary leak repairs to on-line components.

2.0 APPLICABILITY/SCOPE

1. This procedure applies to Units I and 2, Safety Related and Non-SafetyRelated components. Patches can only be installed on Non-Safety RelatedCompressed Air Tubing.

2. -This procedure applies to temporary leak repairs, unless otherwise covered byanother approved Mechanical Maintenance technical procedure. Eachattachment will not be used for every repair. Attachments that do not applyshall remain unused.

3. Temporary Repairs to safety related or ASME Section X1 components shall beimplemented under CNG-CM-1.01-1004, Temporary Plant ConfigurationChange Process. Temporary Repairs to non-safety-related, non-ASMESection Xi components shall be implemented under a Work Order andcontrolled by MN-1-110. 1B2242]

4. Design Engineer review shall be completed prior to performance of any leakrepairs made to main steam (System 83) components. [62066]

5. Pressure Boundary repairs on ASME Section XI piping requires NRCapproval. Design Engineering shall be contacted. [522423

6. Leak repair fittings may be replaced with pipe plugs in NSR and non-SectionX1 applications. [813529]

7. Attachment 1, Technical Procedure Step Deletion Screening Form(CNG-PR-1,01-1009), may be used to delete complete steps or partial wordingwithin step(s). This attachment should be completed by the craft

8. All steps within a subsection must be performed in sequence unless otherwisenoted in procedure body.

9. When a conditional step or subsection cannot be performed because thecondition was not met, the step(s) shall be marked N/A.

ON-LINE LEAK REPAIRS TO VARIOUS UNIT 1 & 2PRESSURE RETAINING COMPONENTS LR-01, Rev. 00600

Page 5 of 69

3.0 REFERENCES

3.1 Developmental References:

1. MN-I -110, Procedure Controlled Activities

2. MN-1-101, Control of Maintenance Activities

3. CH-1-100, Controlled Materials Program

4. PM-1 Procurement Program Directive

5. Electric Power Research Institute (EPRI) NP-3111, Testing and Evaluation ofOn-Line Leak Sealing Methods

6. Leak Repairs Inc. (TEAM Inc.) Engineering Repair ProceduresManual ERPM-2

7. EPRI NP-6523-D, On-Line Leak Sealing, A Guide for Nuclear Power PlantMaintenance Personnel

8. USNRC Generic Letter 90-05, Guidance for Performing Temporary Non-CodeRepair of ASME Code Class 1, 2, and 3 Piping. [B2242]

9. Leak Repair Inc. (Team Inc.), Engineering Design Manual, Revision 0, DatedJuly 21, 1989. [B2242]

10. NRC Information Notice 97-73 [11528]

11. MCR 93-047-004-00 [B13529]

12. ES199800191-000 Engineer evaluation to permit air tubing leak repairs

13. 92401 Instrument Tubing lnstallation (M500)

14. CNG-CM-1.01-1004, Temporary Plant Configuration Change Process

15. TRP-3422 TEAM inc Engineering repair procedure Valve / Line Kill -Hot TapRing

16. TRP-3410 TEAM inc Engineering repair procedure, Sealant PumpingProcedure

3.2 Performance References:

1. CNG-CM-1.01-1004, Temporary Plant Configuration Change Process

2. Calvert Cliffs Industrial Safety Manual

3. SA-1-100, Fire Prevention

4. MN-I-110, Procedure Controlled Activities

3.3 Definitions

1. Mainlining - Sealant entering the main process stream


Page 6 of 69

4.0 PREREQUISITES4.1 Responsibilities:

1. System Engineer

* Ensure that a CR has been written.

" The System Engineer and Vendor representative shall inspect theleaking component and review methods to stop leakage, including anassessment of potential hazards to personnel and equipment.

* When valve pressure boundary drilling is necessary, calculations oranalysis shall be provided by leak repair vendor or valve vendor.Alternatively, approval by the valve vendor is acceptable. Calculationsor analysis shall be verified by System Engineer for non-safety relatedcomponents or Design Engineer for safety-related components.Calculations or analysis shall be included in the WO. [B2242]

" System Engineer and Vendor representative shalt determine maximumquantity of sealing compound which may be used and record quantityon Attachment 7, Pre-Job Data Sheet. [B13531]

" The Engineering Services Department could provide the SystemEngineer and the Design Engineer responsibilities as they are calledout with-in LR-01.

2. Design Engineer

Design Engineering involvement in leak repair process is required ifrepair affects a safety related or ASME Section Xl component andCNG-CM-1.01-1004, Attachment 5, Engineering Evaluation, shall becompleted. In non-safety-related, non-ASME Section Xl repairs,Design Engineering involvement is not required, but is recommended ifSystem Engineer needs assistance. [B2242]

Pressure boundary repairs on ASME Section X1 piping componentsneed prior NRC approval. [82242]

Design Engineer review shall be completed prior to performance of anyleak repairs made to main steam (System 83) components. [B20661

3. Vendor

" Vendor shall supply chemical analysis of sealing compounds andmaterial certification for compounds, fittings, clamps, bars, valves,encapsulations, strongbacks and fasteners, if applicable.

* Vendor shall supply details or sketches of enclosures, bars and clamps.

* Vendor Representative shall install sealing device and Inject compoundaccording to attachment listed by System Engineer on Attachment 7,Pre-Job Data Sheet.


Page 7 of 69

4.2 Personnel Requirements

NOTE

Two technicians (minimum) are required for each job. At least one technician should havea minimum of 1-1/2 years of leak sealing experience. Leak sealing contractor should beable to document this experience and to certify it to plant personnel.

1. Personnel requirements for all on line repairs except compressed air tubing.

A. Approved Vendor Technical Representatives (Two)B. Qualified SponsorC. Fire Watch, if requiredD. Qualified Cleanliness Inspector

2. Personnel requirements for compressed air tubing repair

A. Two technicians, at least one qualified TUBE-01, Fabrication andInstallation of Parker CPI and Swagelok Compression Fittings

4.3 Special Tools and Equipment Recommended:

1. Measuring and Test Equipment (M&TE)

M&TE for each type of leak repair is listed in applicable attachment.2. Consumables

Consumables for each type of leak repair are listed in applicableattachment.

3. Other Special Tools & Equipment

Other special tools and equipment for each type of leak repair are listedin applicable attachment.

4.4 Spare Parts Recommended:

Recommended spare parts for each type of leak repair are listed in applicable

attachment.

4.5 Documentation and Support Required:

1. Approved WO2. Approved Engineering Service Package for Safety Related Repairs, if required3. Repair and Replacement Plan for ASME Section XI Repairs, if required4. Radiation work permit (RWP), if required5. Fire Watch, if required

ON-LINE LEAK REPAIRS TO VARIOUS UNIT I & 2PRESSURE RETAINING COMPONENTS LR-0I, Rev. 00600

Page 8 of 69

4.6 INITIAL CONDITIONS

I. Attachment 7, Pre-Job Data Sheet, is complete and leak repair method isapproved.

2. Operations approval on WO and MD-1-100 (if applicable), to start work.CNG-CM-1.01-1004, Attachment 3, Temporary Alteration Form is completeand approved for safety related or ASME Section XI piping. [B2242].

3. Scaffolding is erected, if required.

4. Insulation is removed, if required.

5. Temporary lighting has been installed as required.

6. All working instrumentation (Vendor supplied and CCNPP equipment) hascurrent verifiable calibration record.

7. General area of leaking component has been flagged off and caution signsposted, if required.

8. Fire Watch has been established, if required. [B1528]

9. A page check has been performed.

Prerequisites have been satisfied.

Date:Job Supervisor


Page 9 of 69

5.0 PRECAUTIONS

1. WHEN working in Radiologically Controlled Areas,* RWP requirements and good radiological practices shall be observed.

Fluids shall be treated as contaminated unless certified radiologicalclean by Plant Chemistry,Components shall be treated as contaminated unless certifiedradiologically clean by Radiation Protection.Use of volatile liquids such as alcohol or acetone on contaminateditems can generate airborne radioactivity. Contact Radiation Protectionprior to use of volatile liquids on any contaminated equipment.Exposure rates may change rapidly in specific areas. Take steps tomaintain personnel exposure ALARA.

2. Consumables used in this procedure shall be approved for use according toCNG-EV-1.01-1002, Controlled Materials Management, and consumablematerials considered hazardous (flammable, corrosive, reactive, toxic or listedas a hazardous waste), shall be stored, handled and disposed according toCH-1-101, Hazardous Waste Management.

3. M&TE used in this procedure shall be controlled and calibrated, as applicable,according to MN-2-100, Control and Calibration of Measuring and TestEquipment.

4. Personnel working in area of leak shall wear adequate protective equipment(protective gloves, face shield, safety glasses, appropriate clothing and a selfcontained supply of breathing air if necessary).

5. To prevent over-injection of leak sealing compound, Vendor representativeand System Engineer shall determine maximum quantity of compound used.[B1531]

6. The maximum injection pressure required to inject compound shall not beexceeded during sealant injection.

7. Hole drilling size(s) and location(s) shall be within requirements of calculationsor analysis.

8. Sealant injection process should continue uninterrupted.

9. Injection valve shall always be closed before attaching sealant gun.


UNIT 1 & 2LR-01, Rev. 00600

Page 10 of 69

6.0 PERFORMANCE

6.1 Leak Repair Activity

1. PERFORM leak repair according to attachment selected onAttachment 7, Pre Job Leak Repair Data Sheet OR 10, PreJob / Post Job Compressed Air Repair Data Sheet.

2. IF leak repair is on 1 BDHV-211 piping, THEN PERFORMleak repair PER Attachment 13, Valve / Line Kill Hot TapRing, OR Attachment 14, Sealant Pumping Procedure.

3. IF all answers are no on Attachment 10, THEN PERFORMleak repair per Attachment 11, Compressed Air Tubing LessThan 200 PSIG Repair.

6.2 Post Leak Repair Activity

1. ENSURE Attachment 8, Post Job Leak Repair Data SheetOR Attachment 10 is complete.

2. REMOVE temporary lighting or fixtures installed for thisprocedure,


UNIT I & 2LR-01, Rev. 00600

Page 11 of 69

7.0 POST-PERFORMANCE ACTIVITIES

1. A page check has been performed.

2. Post Maintenance activities shall be conducted per WO instructions.

COMPLETED PROCEDURE

COMPLETED BY: DATE:

RESPONSIBLE SUPERVISOR: DATE:

8.0 BASES

BASIS NUMBER REV. NO. BASISB2242 0 CCSO Letter 90-685, Attachment 3B2066 0 50.59 EvaluationB1528 1 NRC Information Notice 97-73, Fire Hazard in the Use of

Leak SealantB1529 1 MCR 93-047-004-00, Allow Installation of Permanent

Pipe Plugs for Removed Leak Repair Fittings in NSRApplications

B1531 1 SER 5-97, Liquid Leak Sealant Material Migrates IntoReactor Vessel Head Vent System

9.0 RECORDS

1. Records generated by this procedure shall be captured and controlled. Beforetransferring records to Record Management for retention, legibility andcompleteness of the record shall be verified by the transmitting organization.

2. Contents of this procedure shall be retained according toCNG-PR-3.01-1000, Records Management.


Page 12 of 69

ATTACHMENT 1PACKING LEAKS

Page 1 of 5

1.0 PURPOSE

Provides instructions for on-line repair of valve packing leaks.

2.0 DEVELOPMENTAL REFERENCES

Leak Repairs Inc. Procedure Nos. NP-2110, NP-2135, NP-2136, NP-2137

3.0 TOOLS AND EQUIPMENT REQUIRED

1. Air or battery powered drill motor, drill bits and taps

2. Leak Repairs Inc. hydraulic injection equipment (Nuclear) or equivalent

3. Injection valve(s) appropriate size

4. Leak Repairs Inc. Nuclear grade packing, or approved equivalent

5. Pipe plugs made from ASTM A105, A182, or A350 material for NSR and non-Section XI applications, if required [B1I529]

4.0 PERFORMANCE

4.1 Stuffing Box Preparation

1. OBTAIN stuffing box or bonnet wall thickness from equipmentvendor technical manual and drawings.

Nominal wall thickness

2. MEASURE Outside Diameter (OD) of stuffing box and OD ofpacking follower, SUBTRACT and DIVIDE by 2 to determineaverage wall thickness.Stuff. Box OD - Pack. Follower OD + + 2 =

Avg. wall Thick.

3. DETERMINE injection valve size.

Size:


UNIT 1 & 2LR-01, Rev. 00600

Page 13 of 69


Paae 2 of 51/16" NPT

DRILL & TAP SEQUENCE CHART

NOM. WALL THICKNESS

under .262" to .301" to OverSEQUENCE .262" .300" .350" .350"

1: 1/8" Pilot Bit X X X

2: 1/4"' Finishing Bit x X X

3: 1(4" Bottom-Out Bit X

4: I116" NPT Starter Tap X X X

5: 1/16" NPTG Bottom-Out Tap X X

"On wall thickness less then ,262" a hot tap bar will be used.

1/8" NPTDRILL & TAP SEQUENCE CHART

NOM. WALL THICKNESS........._,_,..

under .275"to .351"to OverSEQUENCE .275"" .350" .500" .500"


2: "R" Finishing Bit X X X

3: "R" Bottom-Out Bit X

4: 1/8" NPT Starter Tap X X X

5: 1/8" NPTG Bottom-Out Tap X X

*On wall thickness less than .275", refer to the 1/16" NPT Drill and Tap SequenceChart.

1R4" NPTDRILL & TAP SEQUENCE CHART

NOM, WALL THICKNESS

under .400" to .475" to Over .550"SEQUENCE .400"" .475" .550'

1, 3/16" Pilot Bit X X X

2: "R" Finishing Bit X X X3: 7/16" Bottom-Out Sit x

4: 1/4"NPT Starter Tap X X X5: 1/16" NPTG Bottom-Out Tap x X

'On wall thickness less than .400", refer to the 1/8" NPT Drill and Tap Sequence Chart.


UNIT 1 & 2LR-01, Rev. 00600

Page 14 of 69

ATTACHMENT IPACKING LEAKS

Page 3 of 5

Subsection 4.1 (Continued)

NOTE:

Multiple injection ports may be required, however, the maximum number of ports listed onAttachment 7 shall not be exceeded without concurrence from all approval authorities.

4. LOCATE and CENTER PUNCH stuffing box OD as close topacking box center as possible.

5. SELECT appropriate size pilot drill bit for installed injection valvefrom Drill & Tap Sequence Charts.

. . .. .. .... .~C A UTIO N : .... .

Gland erosion or other circumstances may lead to unexpectedlydrilling through stuffing box wall.

6. DRILL stuffing box, using a positive drill stop to prevent drillingcompletely through stuffing box wall.

7. IF premature drill-through is encountered, LOOSEN packing glandas necessary to redirect fluid or steam flow to allow injection valveinstallation. (MARK N/A if not required)

8. TAP stuffing box following selected Drill & Tap Sequence Chart.

9. INSTALL injection valve into stuffing box tapped hole andTIGHTEN securely.

10. OPEN injection valve.

11. SELECT appropriate size pilot bit and, using a stop and go motion,DRILL through stuffing box, exercising care not to hit valve stem.

WARNING:

Steam may occur when retracting drill and closing injection valve.

12. RETRACT drill and CLOSE injection valve,


UNIT 1 & 2LR-01, Rev. 00600

Page 15 of 69

ATTACHMENT IPACKING LEAKS

Page 4 of 54.2 Sealant Injection

CAUTION:

Follower nuts shall have a full nut thread engagement at all times.

1. CONTACT Operations for current system pressure and temperatureindications.

A. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [B1531]

2. LOOSEN gland follower nuts approximately one quarter of exposedstud length (MARK N/A if not required).

3. ATTACH injection gun to injection valve.

4. OPEN injection valve.

5. INJECT packing until gland rises up and stops at follower nuts.


7. INJECT packing until gland rises up and stops at follower nuts.


9. CLOSE injection valve.

10. TIGHTEN gland follower nuts and compress packing.

CAUTION:

Follower nuts shall have a full nut thread engagement at all times.

11. REPEAT steps 4.2.7 through 4.2.10 until leak is stopped andstuffing box is full OR maximum quantity listed on Attachment 7 hasbeen reached.

12. REMOVE injection gun.

13. LUBRICATE a drill-through plug with an approved lubricant andINSTALL plug into injection valve (MARK N/A if not required),

14. COMPLETE Attachment 8.


UNIT 1 & 2LR-01, Rev. 00600

Page 16 of 69


Page 5 of 5

Iq"

Injection Valve InstallationTypical


Page 17 of 69

ATTACHMENT 2FLANGE/BONNET LEAKS, WIRE WRAP WITH CAP NUTS AND WIRE WRAP WITH

SLOTTED STUDS AND CAP NUTSPage 1 of 8

1.0 PURPOSE

Provides instructions for on-line injection of flange or valve body-to-bonnetconnections that use cap nuts and wire wrap method for injection to stop leaks.


Leak Repairs Inc. Procedure Nos. NP-2117, NP-2119,

3.0 TOOLS AND EQUIPMENT RECOMMENDED

1. Torque Wrench

2. Torque Multiplier, 4 to 1, if required

3. Leak Repairs Inc. Hydraulic Injection Equipment (NUCLEAR) or equivalent

4. Leak Repairs Inc. cap nuts, slotted studs, and injection valves or equivalent

5. Leak Repairs Inc. Nuclear grade sealant compound or approved equivalent

6. Wrapping Wire and/or Cable (appropriate size)

7. Stainless steel pins (provided by Leak Repairs Inc.), or equivalent

4.0 PERFORMANCE

4.1 Preparation

1. VERIFY flange or bonnet stud integrity before beginning work. If studs aredeteriorated, CONTACT System Engineer to determine if flange or bonnetstuds need replacing.

REPLACE: Yes No

Date:System Engineer

2. TORQUE existing studs to value specified on Attachment 7.

All Studs Torqued DatePerformed by


UNIT 1 & 2LR-01, Rev. 00600

Page 18 of 69




3. SELECT and RECORD appropriate repair method:

Method A: Wire wrap and cap nuts.Method B: Wire wrap with slotted studs and cap nuts.

VALVE

Method A: Wire Wrap and Cap Nut MethodTYPICAL


Page 19 of 69



NOTE:

If Method A was selected, proceed to Step 4.2.

If Method B was selected, proceed to Step 4.3.

4.2 METHOD A, Wire Wrap and Cap Nuts

Entire Subsection may be marked N/A if Method B is selected.

1. PERFORM for each cap nut installed.

A. REMOVE nut from one flange or bonnet stud.

B. LUBRICATE exposed stud(s) and Leak Repair injectioncap(s) with an approved lubricant and INSTALL cap nut(s).

C. TORQUE cap nut(s) to value on Attachment 7.

All Cap Nuts TorquedPerformed by

2. INSTALL open injection valves on installed cap nuts.

3. WIRE WRAP flange gap, TYING off wire at intervals, until wire iswithin 1/4 inch to 1/8 inch from edge of flanges.

4. INSTALL cable tensioning device or safety banding. (MARK N/A ifnot required)

ON-LINE LEAK REPAIRS TO VARIOUS UNIT I & 2PRESSURE RETAINING COMPONENTS LR-0I, Rev. 00600

Page 20 of 69




5. ADD injection gun static pressure to Maximum Design Injectionpressure from Attachment 7, Line 14, to obtain maximum injectionpressure.

Static press. (C.. J + Design Inj. press, () = Max. inject, press.


A. RECORD the following:

System pressure

System temperature

Operations HOLD POINT: Date:

B. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [B1531]

RGS HOLD POINT: Date:


UNIT 1 & 2LR-01, Rev. 00600

Page 21 of 69

ATTACHMENT 2FLANGE/BONNET LEAKS . WIRE WRAP WITH CAP NUTS AND WIRE WRAP WITH



NOTE

First injection gun hose to injection valve attachment is to valve farthest from leak.

CAUTION

Maximum injection pressure or maximum sealant quantity shall not be exceeded.

7. PERFORM sealant injection using Injection Sequence illustration foreach installed cap nut.

A. ATTACH injection gun hose to injection valve and INJECT

sealant.

B. SHUT OFF injection valve and REMOVE injection gun.

A AIV

,.s. ~.


UNIT 1 & 2LR-01, Rev. 00600

Page 22 of 69




8. ALLOW adequate cure time from Attachment 7.


INJECTION VALVE _

SLOT IN CAP NUT

GAP

Method B: Slotted Stud and Cap NutTYPICAL


Page 23 of 69

ATTACHMENT 2FLANGE/BONNET LEAKS..WIRE WRAP WITH CAP NUTS AND WIRE WRAP WITH


4.3 METHOD B, Wire Wrap with Slotted Studs and Cap Nuts

Entire Subsection may be marked N/A if Method A selected.

1. PERFORM for each wire wrap with slotted studs and cap nuts:

A. REMOVE nut(s) and stud from one location only.

B. LUBRICATE slotted stud and contact surface of cap nut withan approved lubricant.

C. INSTALL slotted stud, cap nut and nut (if required).

D. TORQUE cap nut to value from Attachment 7.

All Cap Nuts Torqued:Performed by

2. INSTALL open injection valves on all cap nuts.

3. INSTALL isolation pins on both sides of leaking area. (MARK N/Aif not required)

4. WIRE WRAP flange gap, TYING off wire at intervals until wire iswithin 1/4 inch to 1/8 inch from edge of flanges.

5. INSTALL cable tensioning device. (MARK N/A if not required).

6. ADD injection gun static pressure to Maximum Design InjectionPressure from Attachment 7, Line 14, to obtain maximum injectionpressure.

Static press. +_ + Design inj. press, Q.._) = Max. inject, press.


UNIT 1 & 2LR-01, Rev. 00600

Page 24 of 69






System pressure

System temperature




NOTE:First injection hose to injection valve attachment is to valve farthest from leak.

L ...... ijetin.p r or m m CAUTION

Maximum injection pressure or maximum sealant quantity shall not be exceeded.,.... ..


A. ATTACH injection gun hose to injection valve and INJECTsealant.





Page 25 of 69

ATTACHMENT 3FLANGE/BONNET LEAK REPAIRS USING FLAT FACE PUMPING METHOD WITH

SLOTTED STUDS/STUDS AND CAP NUTSPage 1 of 4

1.0 PURPOSE

Provides instructions for on-line repairs to flange or valve body-to-bonnet connectionleaks using slotted studs or studs and cap nut method without wire wrapping.


Leak Repairs Inc. Procedure NP-2116


1. Torque wrench

2. Torque Multiplier 4 to 1 if required

3. Leak Repairs Inc. Hydraulic Injection equipment (NUCLEAR) or equivalent

4. Leak Repairs Inc. Cap nuts, slotted studs, and injection valves or equivalent

5. Leak Repairs Inc, Nuclear grade sealant compound or approved equivalent

6. Peening gun

7. Pipe plugs made from ASTM Al 05, Al 82 or A350 material for NSR and nonASME Section Xl, as appropriate. [11529]

4.0 PERFORMANCE

4.1 Preparation

1. VERIFY flange or bonnet stud integrity before beginning work. Ifstuds are deteriorated, CONTACT System Engineer to determine ifflange or bonnet studs need replacing. [B22421

REPLACE: Yes No

DATE:System Engineer

2. TORQUE existing studs to value from Attachment 7.

All studs torqued: DatePerformed by


Page 26 of 69

ATTACHMENT 3FLANGEIBONNET LEAK REPAIRS USING FLAT FACE PUMPING METHOD WITH



3. INSPECT flange or bonnet for gaps that would allow sealant toextrude.

A. IF gap(s) are found that sealant may extrude, THENCONTACT RGS for direction to peen gap(s) closed.


Static press. (__J + Design Inj. press. L.) = Max. inject, press.

4.2 Slotted Stud or Stud and Cap Nut Installation

1. REMOVE nut(s) and stud from one location only.

2. LUBRICATE slotted stud or stud and contact surfaces of cap nutwith an approved lubricant.

3. INSTALL a slotted stud/stud and cap nut, and nut, if required.

4. TORQUE cap nut to value on Attachment 7.

5. REPEAT Steps 4.2.1 through 4.2.4 on every other stud.

Number of slotted studs/studs and cap nuts installed:

All Cap Nuts Torqued DatePerformed by

6. INSTALL injection valves on all cap nuts.


UNIT I & 2LR-01, Rev. 00600

Page 27 of 69



4.3. Sealant Injection

1 CONTACT Operations for current system pressure and temperatureindications.


System pressure

System temperature


B. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [1B15311


N OTE:First injection hose attachment is to injection valve farthest from leak.I

CAUTION



A. ATTACH injection gun hose to injection valve and INJECTsealant.


A A A" " : . .i .1I


UNIT 1 & 2LR-01, Rev. 00600

Page 28 of 69




3. PEEN at areas of sealant extrusion.




Page 29 of 69

ATTACHMENT 4FLANGE LEAKS: FLANGE CLAMP METHOD

Page 1 of 5

1.0 PURPOSE

Provides instructions for on-line repairs to flange or valve body-to-bonnet connectionleaks using a clamp device supplied by an approved Vendor.


Leak Repairs Inc. Procedure NP-2114

3.0 TOOLS AND EQUIPMENT

1. Torque Wrench

2. Torque Multiplier 4 to 1, if required

3. Leak Repairs Inc. Hydraulic injection equipment (NUCLEAR) or equivalent

4. Leak Repairs Inc. clamp device, fasteners and injection valves or equivalent


6. Pipe plugs made from ASTM Al05, A182 or A350 material for NSR and non-Section XI applications, if required. EB1529]

4.0 PRECAUTIONS

1. VERIFY flange or bonnet stud integrity before beginning work. If studs aredeteriorated, CONTACT System Engineer to determine if flange or bonnetstuds need replacing. (MARK N/A if not required). [B22421

REPLACE: Yes No

DateSystem Engineer


UNIT 1 & 2LR-01, Rev. 00600

Page 30 of 69


Page 2 of 5

5.0 PERFORMANCE

5.1 Preparation

1. TORQUE existing studs to value on Attachment 7.

All studs torqued: DatePerformed by

NOTE

Design Engineering must review and approve proposed vendor design, materials andmethod of manufacture prior to installation for SR components.

2. APPLY a thin coating of an approved lubricant to all threadedfasteners.

3. INSTALL approved sealant device (clamp),

NOTE

Injection valves on sealant device located directly at leak area shall be left in the openposition until all other valves have been injected with sealant.

4. TIGHTEN device fasteners, ENSURING device pulls up evenly.


Static press. (_) + Design inj. press, (_) = Max, inject, press.


Page 31 of 69


Page 3 of 5

5.2 Sealant Injection



System pressure

System temperature


B. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [B115311


NOTE:

First sealant injection is to injection valve OPPOSITE leak.

CAUTION:

Maximum injection pressure or maximum sealant quantity shall not be exceeded,

2. PERFORM for each injection valve, beginning with injection valveOPPOSITE leak.

A. ATTACH injection gun to injection valve

B. OPEN injection valve and INJECT sealant.

C. CLOSE injection valve and REMOVE injection gun.





Page 4 of 5

CRUNCH GROOVE CLAMP

UNIT 1 & 2LR-01, Rev. 00600

Page 32 of 69

Clamp Device DesignsTYPICAL



Page 5 of 5

UNIT 1 & 2LR-01, Rev. 00600

Page 33 of 69

Injection Gun AttachmentTYPICAL


Page 34 of 69

ATTACHMENT 5PIPING/FITTING LEAKS: ENCLOSURES, SEALANT RETAINING DEVICES PERIMETER

SERALSPage 1 of 4

1.0 PURPOSE

Provides instructions for on-line repairs to piping and-fittings using encapsulationsand sealant retaining devices.


Leak Repairs Inc. Procedures NP-2115, NP-2128, NP-2130, and NP-2133



2. Leak Repairs Inc, Enclosures, sealant retaining devices, strongbacks andinjection valves or equivalent


Sealant Retaining DevicesTypical

ON-LINE LEAK REPAIRS TO VARIOUS UNIT I & 2PRESSURE RETAINING COMPONENTS LR-01, Rev, 00600

Page 35 of 69

ATTACHMENT 5PIPINGFITTING LEAKS: ENCLOSURES, SEALANT RETAINING DEVICES, PERIMETER

SEALSPage 2 of 4

4.0 PERFORMANCE

4.1 Preparation

1. IF hot tap ring is NOT used, THEN TORQUE all flange bolts tovalue on Attachment 7 (MARK N/A if not required).

All flange bolts torqued: Date:Performed by

2. INSTALL soft patch as stopgap measure to slow leak, (MARK N/Aif not required)

3. LUBRICATE all fasteners with an approved lubricant.

4. IF hot tap ring is NOT used, THEN INSTALL sealant retainingdevice with injection valves over leaking component open,

NOTE:

Installation of a Hot Tap Ring (HTR) requires that the HTR be injected with the appropriatesealant, and allowing the sealant to cure prior to performing the drill-thru.

5. IF a hot tap ring is used, THEN INSTALL sealant retaining devicewith injection valve over leaking component.

A. ATTACH the hydraulic injection gun hose to the injectionvalve.

B. INJECT sealant until the HTR has sufficient coverage toallow for the drill-thru.

C. CLOSE the injection valve and remove the hydraulic injectiongun hose.

D. ALLOW sealant time to cure prior to performing the drill-thrustep.

6. TIGHTEN sealant retaining device studs, starting from middle ofside bars, and work outwards until all fasteners are securelytightened.

7. IF a hot tap ring is used, THEN SELECT appropriate size pilot drillbit for installed hot tap ring from Drill & Tap Sequence Charts.


Page 36 of 69

ATTACHMENT 5PIPING/FITTING LEAKS: ENCLOSURES, SEALANT RETAINING DEVICES PERIMETER

SEALSPage 3 of 4

8. IF a hot tap ring is used, THEN ENSURE a positive drill stop isinstalled on the drill to prevent drilling completely through pipe.

9. IF a hot tap ring is used, THEN DRILL through the first pipe wall.

10. IF a hot tap ring is used, THEN REMOVE drill and CLOSE injectionvalve.

NOTE:If perimeter seal enclosure used has a primary and a secondary seal, the primary (inner)

seal should be injected first.

11. ADD injection gun static pressure to Maximum Design InjectionPressure listed on Attachment 7, Line 15, to obtain maximuminjection pressure.

Static press. (__) + Design inj. press. (_ = Max. inject, press.




System pressure

System temperature


B. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [81531]



UNIT 1 & 2LR-01, Rev. 00600

Page 37 of 69

ATTACHMENT 5PIPING/FITTING LEAKS: ENCLOSURES. SEALANT RETAINING DEVICES PERIMETER

SEALSPage 4 of 4

I NOTE:First sealant injection is to injection valve OPPOSITE leak.

t CAUTION,Maximum injection pressure or maximum sealant qua ntity. ,sh.a.ltl no obe exceeded.'

2. PERFORM for each injection valve, beginning with injection valve

OPPOSITE leak.

A. ATTACH injection gun to injection valve.




4. PLUG the back of the injection valve(s) with a Drill-Thru Safety Plug(DTSP) or approved plug.


I


Page 38 of 69

ATTACHMENT 6PRESSURE SEAL VALVE BONNET LEAK REPAIRS

Page 1 of 5

1.0 PURPOSE

Provides instructions for on-line leak repairs to pressure seals on pressure sealvalves.


Leak Repairs Inc. Procedures NP-2142, NP-2143, NP-2144.


1. Air or battery powered drill motor, drill bits and taps

2. Leak Repairs Inc. hydraulic injection equipment (NUCLEAR) or equivalent

3. Leak Repairs Inc. injection valves (appropriate size) or equivalent

4. Leak Repairs Inc. Nuclear grade sealant or approved equivalent

4.0 PERFORMANCE

4.1 Preparation

NOTE:

Dimensions may be obtained from valve manufacturer if required dimensions are not invalve technical manual.

Attachment 6 Worksheet is an example only. Actual injection valve locations aredetermined on a case-by-case basis.

1. Valve dimensions have been obtained and Attachment 6 Worksheethas been completed.

2. Drilling locations and number of installed injection valves has beenapproved by System Engineer or Design Engineer if MD-I-100 isrequired. [B2242]

Date:

System Engineer or Design Engineer

3. DETERMINE injection valve size.


UNIT I & 2LR-01, Rev. 00600

Page 39 of 69


Page 2 of 5


NOM. WALL THICKNESS

under .262" to .301" to OverSEQUENCE .262"* .300" .350" .350"


2: 1/4" Finishing Bit X X X

3: 1/4" Bottom-Out Bit X

4: 1/16"NPT Starter Tap X X X

5: 1/16"NPTG Bottom-OutTap X X

'On wall thickness less than .262" a hot tap bar will be used.


NOM. WALL THICKNESS

under .275" to .351" to Over.SEQUENCE .275"* .350" .500" 500"

1: 3/16" Pilot Bit x x x

2: "R" Finishing Bit X X x


4: 1/8'NPT Starter Tap x x x

5: 1/8" NPTG Bottom-Out Tap X X*On wall thickness less than .275", refer to the 1/16V NPT Drill and Tap SequenceChart.


NOM. WALL THICKNESS

under .400" to .475" to OverSEQUENCE .400"* .475" .550" .550"


2: "R" Finishing Bit x x x

3: 7116" Bottom-Out Bit . . .. _ X

4: 1/4" NPT Starter Tap _.X X X5: 1/16" NPTG Bottom-Out Tap X X

*On wall thickness less than .400", refer to the 1/8" NPT Drill and Tap SequenceChart.


Page 40 of 69


Page 3 of 5

4.2 Valve Body Preparation

1. LOCATE and CENTER PUNCH valve body at location(s) specifiedon Worksheet.

2. SELECT appropriate size pilot drill bit for injection valve size to beinstalled from Drill & Tap Sequence Chart.

3. DRILL valve body, using a positive drill stop to prevent drillingcompletely through valve body wall.

4. TAP valve body using drill and tap sequence chart.

5. INSTALL injection valve into valve body and TIGHTEN securely.


NOTE:

Valves 4-inches and below, a minimum of two drill and tap holes may be required.

Valves above 4-inches, a minimum of four drill and tap holes may be required.

7. DRILL and TAP additional locations specified, beginningOPPOSITE original location.

8. INSTALL and TIGHTEN injection valves in all drilled and tappedholes,

9. OPEN an injection valve.

10. SELECT appropriate size pilot bit and, using a stop and go motionand injection valve as a drill guide, DRILL through valve body,exercising care not to hit valve pressure seal ring.

11. RETRACT drill and CLOSE injection valve.

12. REPEAT steps 4.2.9 through 4.2.11 for remaining injection valves.


UNIT I & 2LR-01, Rev. 00600

Page 41 of 69


Page 4 of 5

Subsection 4.2 (Continued)13. ADD injection gun static pressure to Maximum Design Injection

Pressure from Attachment 7, Line 14, to obtain maximum injectionpressure.

Static press. Q..) + Design inj. press. Q__) = Max. inject, press.




System pressure

System temperature


B, VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [B1531]


NOTE:

First injection gun attachment and sealant injection is to injection valve OPPOSITE leak.

CAUTION:


2. PERFORM for each injection valve, beginning with injection valveOPPOSITE teak.

A. ATTACH injection gun to injection valve.






UNIT 1 & 2LR-01, Rev. 00600

Page 42 of 69

PRESSURE SEAATTACHMENT 6

kL VALVE BONNET LEAK REPAIRSPage 5 of 5

WORKSHEET

BONNET RE

GASI

RETAI

5p,

AR

Valve EIN #Valve ManufacturerValve SizeDimension "A"Dimension "B"Total number of injection

valves to be installed


ATT-ACHMENT 7PRE-JOB LEAK REPAIR DATA SHEET

Page 1 of 2

UNIT I & 2LR-01, Rev. 00600

Page 43 of 69

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

INITIAL PUMP

Component EIN

Component Description

Pressure Boundary Leak Description

Component Line Class

Design Pressure

Design Temperature

Normal Service Pressure

Normal Service Temperature

LR-1 Attachment Selected

Torque Value, if required

Nuclear Grade Sealant

System Requirements for Sealant

Application

Chemistry Approved

Maximum Sealant Amount Allowed tobe Injected [81531]

Maximum Number Injection Ports

Maximum Design Injection Pressure

Pressure Data Source

Repair/Replacement Plan Number

Temporary Alteration Tag Number, ifrequired

REPUMP

Type: P.O.#:

Cure Time:

System Temperature Range:Pressure Range:

Date: CML#:

tubes

psi


Page 44 of 69

ATTACHMENT 7PRE-JOB LEAK REPAIR DATA SHEET

Page 2 of 2

18. Verify leak repair method or clamping device is designed according to TEAM Inc.(Leak Repair Inc.) Engineering Design Manual, Revision 0, dated July 21, 1989.Verify design inputs used by Leak Repair Inc. are accurate, Design Engineeringshall review for safety related components or for main steam components.[B2242] [B2066]

Design Engineer or System Engineer

19. Verify piping wall thickness is sufficient to withstand forces generated by clamprings and enclosures. [B2242]

Design Engineer or System Engineer

20. Potential impact on downstream equipment has been evaluated. [B1531]

System Engineer

21. Vendor proposal shall be reviewed and approved by System Engineer or, ifMD-I-100 is required, by Design Engineer. Component hangers and restraintsshall be evaluated for additional weight of sealant retaining device. Installation ofadditional supports may be required before sealant retaining device is installed.[B2242]

System Engineer

22. All data has been reviewed and approved by System Engineer or, if required, byDesign Engineer.

Planner Engineer (SE or DES)


ATTACHMENT 8POST JOB LEAK REPAIR DATA SHEET

Page 1 of 1

UNIT 1 &2LR-01, Rev. 00600

Page 45 of 69

1. Amount Sealant Compound Used

2. IF applicable, INSTALL TemporaryAlteration Tags and PROCESS thetemporary alteration per MD-1-100,Temporary Alterations. [B2242]

3. VERIFY leak stopped. If leak stillexists, CONTACT System Engineer foruse of Attachment 9, Repump UsingExisting Penetrations.

4. Work Completed by:

tubes

DateTime

Vendor Representative

NOTE:

Leak stoppage verification in High Radiation Areas may be performed by means other thanvisual re-inspection.

5. RE-VERIFY leak is stopped 24 - 48hours after time in step 3. (MARK N/Aif not required)

RECORD time and date.

Verified By:

DateTime

6. INITIATE Condition Report for WO to perform a permanent repair.

CR/WO Number:


Page 46 of 69

ATTACHMENT 9REPUMP USING EXISTING PENETRATIONS

Page 1 of 5

1.0 PURPOSE

Provide instructions for repumping of existing penetrations.


Leak Repairs Inc. Procedures NP-2138, NP-2149, NP-2145, and NP-2129



2. Leak Repairs Inc. Enclosures, sealant retaining devices, strongbacks andinjection valves or equivalent

3. Leak Repairs Inc. Nuciear grade sealant compound or approved equivalent

4.0 INITIAL CONDITIONS

1. System and Design Engineering has evaluated the recurrent leak and hasdetermined it is safe to repump.

DateSystem Engineer

2. Attachment 7 has been completed for repump.

Initial Conditions have been met.

DateSponsor


Page 47 of 69


Page 2 of 55.0 PERFORMANCE

NOTE:Subsection used for repumplng shall be the same as used for original repair. Subsectionsnot used should be marked N/A.

5.1 Valve Packing1. INSTALL high pressure gland assembly to existing injection valve.

(MARK N/A if not required)

2. INSTALL injection valve into drill through plug.

3 PROCEED with drill-through by opening injection valve and closingvalve after drill through is complete.



System pressure

System temperature




5. ATTACH injection pump to injection valve and INJECT sealant untilstuffing box is filled, gland is fully extended, and leak is containedOR maximum amount of sealant allowed is injected..


7. PLUG back of injection valve OR REMOVE injection valve andINSTALL safety plug.


Page 48 of 69


Page 3 of 5

5.2 Wire Wrap

1. TIGHTEN all flange or bonnet studs wrench tight.

NOTE:If more than one cap nut and stud assembly requires replacement, replacement must be

done one at a time,

2. BEGIN with stud nearest teak, REMOVE existing cap nut and studassembly.

3. CLEAN existing hole in flange assembly and REPLACE with cleancap nut and stud assembly.

4. INSTALL cable tensioning device or banding, if applicable.


A. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11. [B1531]

6. Starting at cap nut and stud assembly in area of least leakage,ATTACH injection gun to injection valve and INJECT sealant untilleak is contained or pressure is obtained.

7. After cure time has elapsed, REPEAT injection at all remaining capnut and stud assemblies until leak is contained or pressure isobtained. (N/A if injecting only one assembly.)

5.3 Pressure Seal Valve Repump

1. INSTALL and TIGHTEN adapters to all existing injection valves, ifapplicable.

2. INSTALL high pressure packing gland assembly at first valve to bedrilled through, if applicable.

3. INSTALL injection valve, if necessary.

4. PROCEED with drill through by opening injection valve and thenCLOSING valve after drill through is complete. REPEAT for allremaining valves.

5. INSTALL hydraulic injection pump on valve 180 degrees from valvewith worst leak.

ON-LINE LEAK REPAIRS TO VARIOUS UNIT I & 2PRESSURE RETAINING COMPONENTS LR-01, Rev, 00600

Page 49 of 69


Page 4 of 5




System pressure

System temperature


B. VERIFY current system operating conditions are withinrequired service pressure and service temperature rangeslisted on Attachment 7, Line 11, [B31531]


7. PUMP until leak is contained or pressure is obtained, REPEAT forall remaining valves,


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Page 5 of 5

5.4 Sealant Retaining Device Repump

I. TIGHTEN all existing bolting wrench tight.

2. ADAPT to existing fitting and DRILL-THROUGH.

3. IF drill-through safety plugs are present, THEN DO the following:(MARK N/A if not required.)

A. FINISH tapping plug,

B. INSTALL injection valve.

C. PROCEED with drill-through.

4. CONTACT Operations for current system pressure and temperatureindications,


System pressure

System temperature




5. INSTALL injection pump to injection valve with least amount ofleakage and INJECT sealant until leak is contained or pressure isobtained.

6. REPEAT as necessary for all remaining valves. (MARK N/A if notrequired.)

7. AFTER cure time has elapsed, REPEAT injection at all remaininginjection valves until leak is contained or pressure isobtained.(MARK N/A if injecting only one assembly)


Page 51 of 69

ATTACHMENT 10PRE JOB/POST JOB COMPRESSED AIR REPAIR DATA SHEET

Page 1 of 3SCOPE:

This Attachment shall be used to identify the job scope and determine if a temporaryrepair patch can be installed under this procedure.

JOB SCOPE:

1. Repair Location:

2. Hole Size:

Actual Maximum Axial Length inches.

Actual Maximum Circumferential Length inches.

3. Tubing out side diameter and material composition:

4, Immediate downstream equipment loads that will be affected duringpermanent repair:

Person Completing Sheet Date:


UNIT 1 & 2LR-01, Rev. 00600

Page 52 of 69


Page 2 of 3

TABLE 1:

Circle the tubing size and determine if the actual maximum axial and circumferentiallengths exceed the allowed maximum lengths stated in the below table[ES199800191]:

TUBESIZE MAXIMUM MAXIMUM ALLOWED(0. D.) ALLOWED AXIAL CIRCUMFERENTIAL

LENGTH (inches) LENGTH (inches)

1/8 inch 0.39 0.13

'A inch 0.78 0.26

3/8 inch 1.18 0.39

1 inch 1.57 0.52

5/8 inch 1.96 0.65

14 inch 2.36 0.79

7/8 inch 2.75 0.92

1 inch 3.14 1.0

APPLICABILITY SCREEN:

The purpose of this screen is to determine if a temporary patch is permitted underthis procedure. Answer the following questions.

1. Is tubing SR?

2. Does actual maximum hole size (Axial or Circumferential) exceedthe criteria of Table 1 for the associated tubing size?

3. For patches that will not be located in the confines of a tubing tray,is there already a patch installed on the same span of tubing(between adjacent tubing supports) as the proposed patch?

YES/NO.

YES/NO

YES/NO

Person completing screen question!s -Date


Page 53 of 69


Page 3 of 3ACTIONS:

If any of the questions are answered YES this procedure cannot be used.

If all answers are NO, then Attachment 11 of this procedure can be used.

1. Patch method used. I or 2.2. IF applicable, INSTALL Temporary Alteration Tags and PROCESS

the temporary alteration per MD-I-100, Temporary Alterations.

3. VERIFY leek stopped.

Verify By:

4. IF leak still exists, THEN CONTACT System Engineer.


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ATTACHMENT 11COMPRESSED AIR TUBING LESS THAN 200 PSIG REPAIR

Page 1 of 2

PATCH TYPE I

SCOPE:

Patch type 1 is typically used in smaller tube leaks. The determining factor as towhether Patch type 1 or Patch 2 will be used is the ability of the neoprene tape toseal the hole. If the hole is too big, the force of air rushing from the hole will preventthe installation of Patch type 1. In those instances, Patch type 2 should be used.

MATERIALS:

1. Neoprene tape

2. Hose clamp.

INSTALLATION GUIDELINES:

1. INSTALL neoprene tape at hole location,

2. WHEN air leak is contained, THEN INSTALL and tighten a hoseclamp over the hole location.

3. IF tubing vibrations is present and hose clamp is impacting againstadjacent tubing, THEN INSTALL tygon tubing 8 inches or less inlength to prevent the hose clamp from damaging the adjacenttubing.


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ATTACHMENT 11COMPRESSED AIR TUBING LESS THAN 200 PSIG REPAIR

Page 2 of 2

PATCH TYPE 2

SCOPE:

Patch type 2 is typically used for larger tube leaks. The determining factor as towhether patch type I or patch type 2 will be used is the ability of the neoprene tapeused in patch type 1 to seal the hold. If the hole is too big, the force of air rushingfrom the hole will prevent the installation of patch type 1. In those instances patchtype 2 should be used.

MATERIALS:

1. Neoprene or Red Rubber Sheets (or equivalent)

2. Hose clamps

INSTALLATIONS GUIDELINES:

1. INSTALL neoprene or red rubber sheet (or equivalent) at the holelocation. (Refer to Table 1 for dimensions)

2. INSTALL hose clamp over hole location and at both ends ofneoprene or red rubber sheet (or equivalent). (Refer to Table 1 fordimensions)

3. IF tubing vibrations is present and hose cdamp is impacting againstadjacent tubing, THEN INSTALL tygon tubing 8 inches or less inlength to prevent the hose clamp from damaging the adjacenttubing.


UNIT 1 & 2LR-01, Rev. 00600

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ATTACHMENT 12VALVE BONNET GASKET REPAIR (DRILL AND TAP)

Page 1 of 7

1.0 PURPOSE

To provide instructions for on-line leak repairs between bonnet and valve body.


Team Industrial Services Inc. Procedure TRP-3009 Rev. 0

3.0 TOOLS AND EQUIPMENT

1. Pneumatic or battery powered drill

2. Hose for Pneumatic too) operation

3. Drill bits

4. Tap(s)

5. Hydraulic Injection Gun

6. Hand tools to install equipment

7. Hydraulic injection Gun (NUCLEAR) or equivalent

8. Ball valves (appropriate size) or equivalent

9. Nuclear grade sealant or approved equivalent

10. High-Pressure Packing Gland (HPPG)


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Page 2 of 7

4.0 PERFORMANCE

4.1 Valve Body Preparation

1. OBTAIN a controlled copy of a cross-sectional drawing of the valveto be repaired.

NOTE:Bail valve type injection valves are the preferred method when installing injection valves.The use of ball valves is dependant on the materials of composition for compatibility withthe leak source system pressure and temperature.

2. OBTAIN the correct amount of ball valve type injection valves.

3. ENSURE Engineering has determined the allowable amount ofsealant required to seal the leak.


UNIT 1 & 2LR-01, Rev. 00600

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Page 3 of 7


1. WHEN the HPPG assembly will be used, THEN refer to theapplicable Team Industrial Services, INC. chart listed below:

"116" NPTDRILL & TAP SEQUENCE CHART

.250" to .300" .301" to .350" Over .350"SEQUENCE Wall Thickness Wall Thickness Wall Thickness

1: 1/8" Pilot Bit (Optional) X, X x

2: "D" Finishing Bft X X X

3: "D" Bottom-Out Bit X

4: 1/16" NPT Starter Tap X X x

5: 1/16" NPT Bottom-Out Tap X X

A wall thickness less than .250" requires the use of a hot tap ring for drilling or some othermethod of sealing the leak is recommended.

18" NPTDRILL & TAP SEQUENCE CHART

.275" to.350" .351'to .50o" Over .500"SEQUENCE Wall Thickness Wall Thickness Wall Thickness

1: 3/16" Pilot Bit (Optional) X X X2: "R" Finishing Bit X X X


4: 1/8"NPT Starter Tap X X X5: 1/8' NPT Bottom-Out Tap X X

On wall thickness less than .275", refer to the 1/16" NPT Drill and Tap Sequence Chart.


.400" to .475" .475" to .550" Over .550"SEQUENCE Wall Thickness Wall Thickness Wall Thickness

1: 3/16" Pilot Bit X X X2: 7/16" Finishing Bit X X X3: 7/16" Bottom-Out Bit X

4: 1/4" NPT Starter Tap X X x5: 1/4" NPT Bottom-Out Tap X X

*On wall thickness less than .400", refer to the 1/8" NPT Drill and Tap Sequence Chart.


UNIT 1 & 2LR-01, Rev. 00600

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Page 4 of 7

NOTE:When determining drill location, refer to a controlled copy of a cross-sectional drawing forthe valve to be repaired.

The location on the valve where injection valves will be installed may be at the bonnet spilt,or below the bonnet split depending on the design of the valve. Valves in which the bonnetprotrudes in to the valve body will have a recessed gasket which may require injectionvalve installation below the bonnet split.

2. DETERMINE drill location on valve body as specified on applicablevalve worksheet.

3, WHEN the HPPG assembly will be used, THEN INSTALL theHPPG assembly.

VALVE BODY WITHOUT RECESS WORKSHEET

Valve EIN #

Fll ValveManufacturer:

Valve Size:

Dimension "A":

Total number ofinjection valvesto be installed:

Location "B" is the drill location


UNIT 1 & 2LR-01, Rev. 00600

Page 60 of 69


Page 5 of 7

VALVE BODY WITH RECESS WORKSHEET

Valve EIN #

ValveManufacturer:

Valve Size:

Dimension ."A"

Dimension "B"

Total number ofinjection valvesto be installed:

E a aaw*


Page 61 of 69


Page 6 of 7

4. LOCATE AND CENTER PUNCH valve body at location(s) specifiedby one of the preceding Worksheets.

5. SELECT appropriate size pilot drill bit for injection valve size to beinstalled from Drill & Tap Sequence Chart (step 4.2.1).

6. DRILL valve body, using a positive drill stop to prevent drillingcompletely through valve body wall.

7. TAP valve body using drill and tap sequence chart.

NOTE:The appropriate size injection valve is dependant on which Team Industrial Services chartwas used to drill the hole.

8. INSTALL injection valve into valve body AND TIGHTEN securely.


10. DRILL AND TAP additional locations specified, beginning oppositeoriginal location.

11. INSTALL AND TIGHTEN injection valves in all drilled and tappedholes.

12. OPEN an injection valve.

13. SELECT appropriate size pilot bit,

14. ENSURE drill stop is set to allow drill through.

15. USING a stop and go motion, AND the injection valve as a drillguide, DRILL through valve body.

16. RETRACT drill AND CLOSE injection valve.

17. REPEAT steps 4.2.4 through 4.2.16 for remaining injection valves.


UNIT 1 & 2LR-01, Rev- 00600

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Page 7 of 7

18. INSERT hydraulic injection gun into injection valve(s).

19. PUMP sealant with hydraulic injection gun until back pressure isfelt.

20. OPEN the injection valve.

CAUTION:

If sealant is believed to have entered the main line the subject valve controls while pumpingsealant with hydraulic injection gun, then the leak repair must be stopped and put in a safecondition. The Control Room and Engineering must be contacted and informed of potentialforeign material inclusion.

21. PERFORM the following to INJECT sealant:

A. PUMP sealant with hydraulic injection gun until all of thefollowing occurs:

" Back pressure is felt.

" The leak is sealed.

" The sealant compressed.

* The amount of sealant as determined by Engineering hasbeen installed.

NOTE:Peening is a method used to reduce the area between two planes. During this type of leakrepair, peening is used to reduce or stop sealant extrusion.

B. IF peening has never been performed the valve bonnet andbody split, THEN peening may be performed to preventsealant extrusion.

C. ALLOW adequate cure time for the sealant.

D. REPEAT steps until leak stops.

22. WHEN evaluation is satisfactory, THEN clean job area.


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ATTACHMENT 13VALVE / LINE KILL - HOT TAP RING

I of 5

1. Purpose

On-stream injection of sealant in order to stop flow.

2. Equipment And Tools

1. Appropriate size Hot Tap Ring (HTR)

2. Injection Valve(s). ENSURE the need for reduced stem leakagewith the following options:

i. Ball valves are the best option. ENSURE the materials ofComposition for compatibility with the service, pressure andtemperature.

ii. A second option is pre-injecting the injection valve to sealaround the shut-off. This may not achieve 100% positiveseal, but may.reduce the leakage significantly.

1. SEAL the end of the injection valve. This may be doneby installing a DTSP on the end of the valve orthreading the injection valve into a drilled and tappedhole prior to performing the Drill Thru.

2. INJECT a compatible sealant into the valve and rotatethe shut-off pin.

3. ALLOW the sealant time to cure,

NOTE:If using a ball valve for injection, a pipe plug will be installed into the back of the valvewhen all injection is completed. Also, the valve handle will be removed when all injectionis completed.

3. Drill-Thru Safety Plugs (DTSP) or approved pipe plugs.

4. Sealant

5. Check the applicable grade. Nuclear Grade 0 Commercial Grade

6. Type: Batch #: ' (if applicable).

7. Type: __ Batch #: __ (if applicable).

8. Hydraulic Injection Gun.


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2 of 5

9. Miscellaneous hand tools (including but not limited to)

i. Hammer

ii. Combination Wrenches

10. Appropriate taps, as needed.

11. Air Drill Motor with Air Hose

12. Appropriate size Drill Bits, as needed,

i. The 148" or 3/16" drill bits are commonly used for thisprocedure.

13. High Pressure Packing Gland (HPPG) assembly, as advised.

NOTE:

A HPPG assembly is advised for:

A. All process leaks other than steam, water and air.

B. AUl leaks with a pressure greater than 650 psig t 44.8 bars

C. All leaks with a temperature greater than 6500 F / 3430 C

There is one HPPG designed for the 1/8" drill bit and another HPPG designed for the3/16" drill bit. Ensure the appropriate size HPPG is used for the drill-thru procedurerequired for the job.

3. Customer to Furnish

I. Scaffolding, platform or ladder, as needed.

2. Plant air supply for small tools, as needed.

3. Purge medium, as needed.

4. Necessary work permits and authorizations.

5. Radiation protection and Health-Physics Service, as required fornuclear applications.


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3 of 5

4. Pre-Job Review

1. REVIEW job requirements AND PERFORM a job walk down withthe customer.

2. VERIFY with the Customer Contact, conditions are as stated on theIntegrated Mechanical Work Permit

3. DISCUSS job schedule, timing, and requirements.

i. To perform the job, if scaffolding will need to be erected

1. Height of scaffold

2. Height and shape of deck

3. Two means of egress are required

ii. Manpower and/or special requirements

1. The customer will supply fire watch, bottle watch, holewatch, and so forth.

iii. When will the job start; do any functions need to becoordinated with other crafts; is shift work required.

4. Decontamination of equipment, if applicable.

i. Does the customer have a means of decontaminatingequipment and tools that may come in contact withchemicals.

ii. If hazardous waste is generated, does the plant have areasfor disposal.


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ATTACHMENT 13VALVE I LINE KILL - HOT TAP RING

4 of 5

5. Procedure

NOTE:A plant Job Hazard Analysis (JHA) is acceptable in lieu of the TEAM JHA as long asall points are covered.

1. COMPLETE TEAM Industrial Services Inc. (TISI) Integrated

Mechanical Work Permit.

2. ENSURE for the valve to be in the closed position.

3. LOCATE a spot on the shoulder of the valve to install the HTR.

4. INSTALL an injection valve.

NOTE:The HTR requires injection to seal around the circumference of the pipe.

5. INJECT the HTR, as required, to obtain a seal.

6. ALLOW time for sealant to cure.

7. DRILL through the injection valve into the system.

i. USE a high pressure packing gland, if applicable.

8. RETRACT the drill bit AND CLOSE the injection valve.

9. ATTACH the hydraulic injection gun hose to the injection valve.

10. BEGIN pumping to provide a positive pressure in the hose.

11. OPEN the injection valve AND INJECT sealant UNTIL:

" Backpressure is felt

" The leak is sealed

" A pre-determined amount of sealant has been injected

12. CLOSE the injection valve AND DISCONNECT the hydraulicinjection gun hose.

13. REPEAT steps 5.9 through 5.12 at all injection port locations, asapplicable.

14. VERIFY the leak has stopped.


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5 of 5

NOTE:It is recommended that an evaluation be made of the location(s) of the existinginjection valve(s), if the leak continues after completing this procedure,

15. ALLOW the sealant time to cure AND REPEAT Steps 5.9 through5.13 in the same sequence utilized on the first sealant injection.

16. PLUG the back of the injection valve(s) with a DTSP or a plantapproved plug(s), if applicable.

17. CLEAN work area.

18. COMPLETE Attachment 8, Post Job Leak Repair Data Sheet.


UNIT 1 & 2LR-01, Rev. 00600

Page 68 of 69

1,

2.

ATTACHMENT 14SEALANT PUMPING PROCEDURE

Page 1 of 2

PURPOSE

Establish injection procedure to be used in conjunction with applicablerepair procedure.

PRE-JOB REVIEW

2.1. Review job requirements and perform a job walk down.

PROCEDURE

3.1. PERFORM Pre-job brief with all participating personnel.

NOTE:If more than 1 injection valve is present, the injection valve which will be injected firstwill be closed and the remaining valves will be opened and used as vents.

If more than 1 injection valve is installed the first injection valve shall be the furthestvalve from area with the worst blow.

3.2, IF more than 1 injection valve is installed, THEN ENSURE injectionvalve which will be injected first is closed.

3.2.1. ENSURE remaining injection valves are open.

3.2.2. ATTACH hydraulic injection gun hose to the closed injectionvalve.

3.3 IF a single injection valve is installed, THEN ENSURE injectionvalve is closed.

3.3.1. ATTACH hydraulic injection gun hose to the closed injectionvalve.

3.4. PUMP hydraulic injection gun UNTIL positive pressure is present inthe hose.


UNIT 1 & 2LR-01, Rev. 00600

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ATTACHMENT 14SEALANT PUMPING PROCEDURE

Page 2 of 2

NOTE:Pumping is to be discontinued if Mainlining is evident.

Bulleted Substeps of Step 3.6 may be marked N/A if condition is not met.

3.5. OPEN the injection valve AND INJECT approved sealant materialUNTIL one of the following occurs:

" Back pressure is felt, leak is sealed and sealant iscompressed.

OR

• A predetermined amount of sealant has been injected.

OR

" Mainlining is evident or sealant extrusion is encountered.

3.6. IF at any time while injecting, sealant extrudes or blows out of anyopen injection valve, THEN CLOSE the valve halfway.

3.7. CLOSE injection valve that has the hydraulic injection gun installed.

3,7.1 REMOVE hydraulic injection gun from injection valve.

NOTE:Additional injection valves will be injected using the criss cross method.

3.8. IF more than 1 injection valve is installed, THEN CLOSE the next

injection valve to be injected.

3.9. IF leak still exists, THEN REPEAT steps 3.2 through 3.7.

3.10. CLEAN work area.

3.11. COMPLETE Attachment 8, Post Job Leak Repair Data Sheet.

ATTACHMENT (2)

REGULATORY COMMITMENT


ATTACHMENT (2)

REGULATORY COMMITMENT

The table below lists the action committed to in this submittal. Any other statements in this submittal areprovided for information purposes and are not considered to be regulatory commitments.

Regulatory Commitment Date

Verify that the installed mechanical clamping device is removed and replaced 4/1/2015by a permanent code repair or component replacement. The mechanicalclamping device will be removed during the Unit 2 refueling outage in 2015 orearlier should a Unit 2 shutdown of sufficient duration occur prior to the 2015refueling outage.

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