Project Management Guidance When Upgrading Steam Turbines at Nuclear and Fossil Power Plants

Project Management Guidance when Upgrading
Steam Turbines at Nuclear and Fossil Power Plants
1014717
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Project Management Guidance
when Upgrading Steam Turbines at
Nuclear and Fossil Power Plants
1014717
Technical Update, January 2007
EPRI Project Manager

A. Grunsky
ELECTRIC POWER RESEARCH INSTITUTE

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Sequoia Consulting Group, Inc.
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CITATIONS
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This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Project Management Guidance when Upgrading Steam Turbines at Nuclear and Fossil Power
Plants. EPRI, Palo Alto, CA: 2007. 1014717.
iii
REPORT SUMMARY
Background
Many power producers upgrade steam turbines to gain megawatts (MW) instead of installing
new capacity for a variety of reasons. The engineering challenges encountered—when managing
procurement and adequately analyzing plant support systems affected by this upgrade—are
becoming more pronounced.
Utilities are continuing to pursue license renewal applications and power uprates; these
initiatives are being undertaken on an aging fleet of nuclear and fossil power plants. Many plants
are facing the necessity of upgrading their steam turbines to support these initiatives. However,
industry expertise to support such activities has diminished since the days of plant
construction—there are fewer qualified vendors/equipment manufacturers, materials may have
changed, and owners are usually not staffed for this major undertaking.
Objectives
• To provide a comprehensive look at the potential effects, lessons learned, and work processes
that steam turbine upgrades have on plant auxiliary systems, which include the steam and
feedwater cycle
• To serve as a companion document to the Web database, accessible to EPRI members,
containing utility feedback on the effects of turbine upgrades on other plant systems
• To support utilities in their efforts to upgrade steam turbines by providing a source of
knowledge to increase staff awareness and appreciation of the major design, procurement,
installation, and operation issues that need to be considered
Approach
In 2004, the EPRI Steam Turbine Generator Research Program initiated a project to document
the effects that turbine upgrades have had on auxiliary systems and components that typically
interface with the steam turbine at fossil and nuclear power plants. The information relevant to
this project involved organizations that had actually installed upgraded steam turbines. As such,
a series of on-site visits was conducted as a means for interviewing key engineering,
maintenance, and steam-supply-system personnel.
v
Similar to the interviewing and data compilation, a separate effort was undertaken to define an
effective process for upgrading a steam turbine and a way to address the various project
management issues encountered during a steam turbine upgrade. This report was developed
using information from a project led by EPRI Plant Support Engineering regarding the
replacement of key plant components. It addresses those process issues that, based on feedback
obtained through the site visits, were sometimes overlooked during the implementation of each
respective utility steam turbine upgrade project.
Results
The results of this project provide users with two key sources of information regarding steam
turbine upgrades. As one of the sources, this report provides the user with the process elements
that are included in the upgrade of a major component (such as a steam turbine) and industry
guidance on how to implement the overall process. This report also provides the user with key
project management issues to consider during the duration of the steam turbine upgrade project
to ensure that the overall project is completed in a safe, timely, and cost-effective manner.
The second source of information is a database, which is cross-referenced in this report, that
provides the user with a compilation of the various effects that steam turbine upgrades have had
on plant systems and components and assemblies adjacent or inherent to the steam turbine.
EPRI Perspective
The information contained in this guideline represents a significant collection of human
performance information, including techniques and good practices, related to the upgrade of
steam turbines common at both fossil and nuclear power plants. An assemblage of this
information provides a single point of reference for plant engineering and maintenance
personnel, both in the present and in the future. Through the use of this guideline, in close
conjunction with the industry guidance provided by the Institute of Nuclear Power Operations
(INPO) and owners groups, EPRI members should be able to significantly improve and
consistently implement the processes associated with upgrading steam turbines and increasing
the output of their plants. This will subsequently help members achieve increased output,
reliability, and availability of their steam turbine generator components on which the upgrades
are performed.
Keywords
Steam turbine
Upgrade
Components
Turbine generator
vi
ACKNOWLEDGMENTS
EPRI wishes to acknowledge the following industry representatives who contributed valuable
information on lessons learned and effects of turbine upgrades on power plants:
Daniel Schaeffer AmerenUE
Bob Tomala Exelon Corporation
Bill Newsom Mitsubishi
Lew Shuster Reliant Energy
Dan Rothas Siemens-Westinghouse
James Wieters South Carolina Electric and Gas Co.
Bob Bjune South Texas Project
David Brahms Southern California Edison
Russell Chetwynd Southern California Edison
Jerry Best Tennessee Valley Authority
Gary Zia Tennessee Valley Authority
EPRI would also like to thank members of the Turbine-Generator Users Group (TGUG) for their
assistance during the review of this report.
vii
CONTENTS
1 INTRODUCTION ....................................................................................................................1-1
1.1 Introduction .....................................................................................................................1-1
1.1.1 Background .............................................................................................................1-1
1.1.2 Overall Objectives ...................................................................................................1-1
1.2 Scope of This Report.......................................................................................................1-2
1.2.1 Role of a Database in the Upgrade Process ...........................................................1-2
1.2.2 References to Quality Assurance Implementation Standards .................................1-2
1.3 Definitions of Key Terms .................................................................................................1-2
1.4 Acronyms ........................................................................................................................1-3
2 PROJECT MANAGEMENT AND PROCESS OVERVIEW ....................................................2-1

2.1 Development of the Generic Process..............................................................................2-1
2.2 Key Issues and Report Structure ....................................................................................2-3
2.3 Project Management for Replacing Major Plant Components ........................................2-3
2.3.1 General Guidance ...................................................................................................2-3
2.3.2 Managing Design and Technical Issues..................................................................2-5
2.3.2.1 Project Management Interface Controls ..........................................................2-5
2.3.2.2 Managing the Concurrent Engineering Processes ..........................................2-7
2.3.2.3 Other Design Considerations...........................................................................2-8
2.3.3 Evaluating Industry Experience ...............................................................................2-8
2.3.4 Establishing and Managing the Project Budget.......................................................2-9
3 SYSTEM AND COMPONENT DESIGN ISSUES ...................................................................3-1

3.1 Understanding the Reasons for the Steam Turbine Upgrade .........................................3-1
3.2 System and Component Design Relationship.................................................................3-2
3.3 Establishing System Operating Parameters and Design Requirements .........................3-3
3.3.1 System Normal Operating Conditions .....................................................................3-3
3.3.2 System Accident Operating Conditions ...................................................................3-3
ix
3.3.3 Plant Seismic Demands ..........................................................................................3-3
3.3.4 Environmental Conditions........................................................................................3-4
3.3.5 System Design Margins...........................................................................................3-4
3.3.6 System Safety Classifications .................................................................................3-5
3.4 Establishing Design Inputs for the Steam Turbine ..........................................................3-6
3.4.2 Establishing Steam Turbine Performance Requirements........................................3-6
3.4.3 Establishing Steam Turbine Physical Requirements ...............................................3-7
3.4.4 Determining Component Safety Classification ........................................................3-8
3.4.5 Spare and Replacement Parts ................................................................................3-8
3.5 Adjacent/Interfacing System Components and Plant Design Modification......................3-9
3.5.1 Steam Turbine Interface Points ...............................................................................3-9
3.5.2 Anticipated Effects of Steam Turbine Upgrades....................................................3-12
3.6 Generating Design Output Documents .........................................................................3-13
3.6.1 System Design Output Documents .......................................................................3-13
3.6.2 Steam Turbine Design Output Documents ............................................................3-13
3.7 Design Verification ........................................................................................................3-14
3.8 Design Review and Approval ........................................................................................3-14
3.9 Configuration Management ...........................................................................................3-16
4 DEVELOPING BID SPECIFICATIONS AND REQUESTS FOR PROPOSALS ....................4-1

4.1 Developing the Bid Specification for the Replacement Component................................4-1
4.1.1 Specifying Technical Requirements ........................................................................4-2
4.1.1.1 Specifying System Design Basis Requirements ..............................................4-2
4.1.1.2 Specifying Steam Turbine-Specific Requirements...........................................4-2
4.1.2 Specifying Quality Requirements ............................................................................4-3
4.1.3 Specifying Supplier Documentation Requirements .................................................4-5
4.2 Developing the Request for Proposal..............................................................................4-6
4.3 Developing the Installation/Construction Specification....................................................4-7
4.4 Developing Service Specifications and Contracts...........................................................4-8
5 SUPPLIER QUALIFICATION AND SELECTION, BID EVALUATION, AND

PURCHASING...........................................................................................................................5-1
5.1 Supplier Selection and Qualification................................................................................5-1
5.1.1 Selection of Procurement Sources ..........................................................................5-1
x
5.1.2 Supplier Qualification Status ...................................................................................5-2
5.1.3 Supplier Quality Program Capabilities.....................................................................5-2
5.2 Bid Evaluation and Award ...............................................................................................5-3
5.2.2 Obsolescence of the Replacement Component ......................................................5-5
5.3 Purchasing Issues and Considerations ...........................................................................5-5
5.3.1 Licensee/Owner Schedule Demands ......................................................................5-5
5.3.2 Manufacturing Lead Times ......................................................................................5-6
5.3.3 Commercial Terms and Conditions .........................................................................5-6
5.3.4 Procurement Document Preparation, Review, and Change Control .......................5-7
5.4 Handling Exceptions to the Purchase Order ...................................................................5-7
5.4.1 Technical Exceptions...............................................................................................5-7
5.4.2 Commercial Exceptions...........................................................................................5-8
5.5 Acceptance Planning.......................................................................................................5-9
5.6 Validity of Supplier Documentation and Certificates .....................................................5-10
5.6.1 Supplier Certification .............................................................................................5-10
5.6.2 Supplier Documentation ........................................................................................5-12
6 FABRICATION ISSUES .........................................................................................................6-1

6.1 Establishing Witness and Hold Points.............................................................................6-1
6.2 Manufacturing Surveillance .............................................................................................6-1
6.3 Witnessing Tests and Inspections...................................................................................6-2
6.3.1 Establishing Acceptance Criteria.............................................................................6-2
6.3.2 Nondestructive Examination....................................................................................6-3
6.3.3 Shop Testing/In-Process Testing and Inspection ....................................................6-3
6.4.4 Final Product Testing...............................................................................................6-4
6.5 Handling Manufacturing Nonconformances ....................................................................6-4
6.6 Obtaining Required Documentation ................................................................................6-5
6.7 Cleanliness Requirements and Special Controls ............................................................6-6
7 SHIPPING AND HANDLING ISSUES ....................................................................................7-1

7.1 Determining the Optimum Shipping Method ...................................................................7-1
7.2 Transportation Routing....................................................................................................7-2
7.3 Packaging for Shipping ...................................................................................................7-2
7.4 Need for Sensing/Monitoring Devices During Shipment .................................................7-3
xi
7.5 Customs Requirements and Homeland Security Issues .................................................7-3
7.6 Lifting/Handling Issues ....................................................................................................7-4
8 RECEIPT INSPECTION ISSUES ...........................................................................................8-1

8.1 Developing Appropriate Inspection Attributes .................................................................8-1
8.1.1 Reviewing Documentation Received.......................................................................8-1
8.1.2 Testing/Inspecting Component Attributes................................................................8-2
8.1.3 Testing/Inspecting Supporting/Auxiliary Items.........................................................8-2
8.2 Site-Specific Testing and Inspection Requirements........................................................8-2
9 STORAGE AND STAGING ISSUES ......................................................................................9-1

9.1 Storage Level Determination and Requirements ............................................................9-1
9.2 On-Site Storage/Staging Capabilities..............................................................................9-3
9.3 In-Storage Maintenance Activities...................................................................................9-4
9.4 Licensee/Owner Lifting and Handling Capabilities ..........................................................9-5
9.5 Materials Management....................................................................................................9-5
10 INSTALLATION ISSUES ...................................................................................................10-1

10.1 Pre-Installation Requirements .....................................................................................10-1
10.1.1 Determining the Optimum Access Route ............................................................10-1
10.1.2 Establishing Lifting/Rigging Requirements ..........................................................10-1
10.1.3 Developing a Lift Plan..........................................................................................10-2
10.2 Interferences ...............................................................................................................10-2
10.3 Expertise Needed to Install the Equipment .................................................................10-3
10.4 Sequence of Installation Steps....................................................................................10-3
10.5 Special Tools Required ...............................................................................................10-3
10.6 Special Quality Control Requirements ........................................................................10-4
10.7 Personnel Safety/ALARA Issues.................................................................................10-4
10.8 Post-Installation Testing ..............................................................................................10-4
11 DEVELOPING THE MAINTENANCE STRATEGY FOR THE UPGRADED STEAM

TURBINE .................................................................................................................................11-1
11.1 Inputs Regarding Preventive Maintenance .................................................................11-1
11.1.1 Steam Turbine Manufacturer...............................................................................11-1
11.1.2 EPRI Preventive Maintenance Basis Database ..................................................11-1
11.1.2.1 EPRI Preventive Maintenance Optimization Process ..................................11-1
xii
11.1.2.2 Abbreviated PM Task Evaluation Process...................................................11-3
11.2 Preventive Maintenance Experience with Upgraded Steam Turbines ........................11-5
11.3 Establishing a Life Cycle Management Plan ...............................................................11-5
11.4 Determining Critical Spares.........................................................................................11-5
11.5 Establishing Condition Monitoring Requirements........................................................11-6
11.6 Revising Operating Practices and Procedures............................................................11-6
12 DISPOSAL OF REPLACED EQUIPMENT ........................................................................12-1

12.1 Disposal Facility Capabilities.......................................................................................12-1
12.2 Decontamination vs. Long-Term Storage....................................................................12-2
12.3 General Environmental Concerns ...............................................................................12-2
12.4 Opportunity to Refurbish/Salvage Replaced Component............................................12-2
12.5 Shipping and Handling Issues with Contaminated Equipment....................................12-3
13 BIBLIOGRAPHY ................................................................................................................13-1
13.1 Regulations and Regulatory Guidance........................................................................13-1
13.2 Implementing Standards .............................................................................................13-1
13.3 Industry Guidance .......................................................................................................13-2
13.4 EPRI Technical Reports ..............................................................................................13-2
xiii
LIST OF FIGURES
Figure 2-1 Generic Process for Considering Key Issues when Upgrading a Steam
Turbine ...............................................................................................................................2-2
Figure 3-1 System and Component Design...............................................................................3-2
Figure 5-1 Supplier Selection and Bid Evaluation......................................................................5-4
Figure 11-1 PM Optimization Process .....................................................................................11-2
xv
LIST OF TABLES
Table 2-1 Typical Project Team for Implementing a Turbine Upgrade ......................................2-6
Table 3-1 Typical Component Performance Requirements/Characteristics ..............................3-7
Table 3-2 Typical Steam Turbine Physical Requirements/Characteristics ................................3-8
Table 3-3 Types and Examples of Key Interfaces ...................................................................3-10
Table 3-4 Typical Scope of Design Review for a Steam Turbine Upgrade..............................3-14
xvii
1
INTRODUCTION
1.1 Introduction
1.1.1 Background
Many power producers upgrade to more efficient and higher-flow-capacity steam turbines
instead of installing new generating capacity for a variety of reasons. The marginal cost and
regulatory issues associated with additional fleet capacity through upgrades are significantly less
than those of new generating capacity. The engineering challenges encountered with adequately
analyzing plant support systems affected by upgrades are becoming more pronounced.
Utilities are continuing to pursue license renewal applications and power uprates; these
initiatives are being undertaken on an aging fleet of nuclear and fossil power plants. Many plants
are facing the necessity of upgrading their steam turbines to support these initiatives. However,
industry expertise to support such activities has diminished since the days of plant
construction—there are fewer qualified vendors/equipment manufacturers, materials may have
changed, and owners are usually not staffed for this major undertaking.
1.1.2 Overall Objectives
This project will provide a comprehensive look at the potential effects of steam turbine upgrades
on plant auxiliary systems, including the steam and feedwater cycle. The steam turbine upgrades
could include new rotors, diaphragms, and buckets in the high pressure (HP)/intermediate
pressure (IP)/low pressure (LP) sections of the turbine or in only one section of the turbine (HP,
IP, or LP). The upgraded turbine will have increased section efficiencies and increased MW
output. How these upgrades affect the steam cycle (for example, from increased pressure or
flow), the generator (for example, increased MW output), the boiler/reactor feedpumps, or any
system that supports the operation of the steam turbine will be the focus of this project.
The overall objective of this project is to compile utility feedback regarding the effects of turbine
upgrades on their auxiliary plant systems into a database accessible to EPRI members from the
Internet. To address the generic project management issues associated with a turbine upgrade,
this report will serve as a companion document to the database and will be appropriately cross-
referenced. These two deliverables will enable owners to be “intelligent customers” when faced
with upgrading steam turbines to implement a power uprate and support license renewal and
plant life extension. This project will support utilities in their efforts to upgrade steam turbines
1-1
Introduction
by providing a source of knowledge to increase staff awareness and appreciation of the major
design, procurement, installation, and operation issues that need to be considered.
1.2 Scope of This Report
1.2.1 Role of a Database in the Upgrade Process
A basic premise of this task is that owners have already performed the appropriate cost-benefit
and technical analyses to reach the decision to upgrade the steam turbine. As such, this document
and the companion database do not provide any further guidance on how these analyses should
be performed and the decision-making process that is most effective. When the decision to
upgrade is made, this database will be a valuable source of information to project managers and
systems owners involved in ensuring that the project is completed efficiently and with the
desired results.
1.2.2 References to Quality Assurance Implementation Standards
Throughout this report there are a number of references to certain QA implementation standards
as a means of establishing a basis for the guidance provided. Although the ANSI N45.2 daughter
standards are often referenced, the user of this report should recognize that other QA
programmatic and implementation guidance may be equally applicable. This report recognizes
that these American National Standards Institute (ANSI) standards do not apply to owners of
fossil power plants, but the intent of the standards may still be applicable and useful. The intent
of this report is not to exclude any particular QA guidance but rather to present, in generic terms,
guidance on implementation that is most applicable to power plant owners.
1.3 Definitions of Key Terms

Component – A piece of equipment—such as a vessel, pump, valve, core support structure,
relay, or circuit breaker—that is combined with other components to form an assembly.
Components typically are designated with an identification number.
Equipment designer – The organization in the owner’s supply chain that is responsible for
designing the equipment so that it is suitable for the intended applications.
Fabricator – The organization in the licensee’s supply chain that is responsible for fabricating
parts, assemblies, and subcomponents needed to manufacture the replacement component.
Manufacturer – The organization in the licensee’s supply chain that is responsible for
manufacturing and assembling the replacement component to the extent required by the licensee.
Power uprate – An uprate that is distinctive from a performance upgrade in that the increase in
power output is achieved by increasing the inlet temperature or mass flow into the turbine,
thereby providing more available energy to the original turbine components and increasing
output. The term power uprate is commonly used to indicate an increase in reactor thermal
power.
1-2
Introduction
Source verification – Activities witnessed at the supplier’s facilities by the purchaser or its agent
for specific items to verify that a supplier of a commercial-grade item controls the critical
characteristics of that item, as a method to accept the item.
Standard receipt inspection – Activities conducted upon receipt of items, including
commercial-grade items, in accordance with ANSI N45.2.2-1978 or ANSI/ASME NQA-1-1986
and NQA-2-1986 to check such elements as the quantity received, part number, general
condition of items, and damage.
Steam turbine performance upgrade – An upgrade that seeks to provide additional output by
extracting more work from the available energy or to reduce the operating heat rate by more
efficient use of the available energy. Within the context of this guideline, an upgrade is
considered as a practical (or commercially available) retrofit action, which involves the
replacement of selected components on a portion of an existing turbine steam path with more
aerodynamic and thermally efficient designs.
Supplier – The organization furnishing a commercial-grade item or basic component. This could
include an original equipment manufacturer, part manufacturer, or distributor.
Witness/hold points – Means to ensure that source verification activities are witnessed by utility
personnel or their agents.
1.4 Acronyms
ALARA as low as reasonably achievable
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing Materials
CFR Code of Federal Regulations
EPIX equipment performance and information exchange
FCC Federal Communications Commission
FSAR final safety analysis report
INPO Institute of Nuclear Power Operations
ISO International Organization for Standardization
LOCA loss-of-coolant accident
NDE nondestructive evaluation/examination
NMAC Nuclear Maintenance Applications Center
NP nuclear power
NPSH net positive suction head
NRC nuclear Regulatory Commission
NSSS nuclear steam supply system
1-3
Introduction
PM preventive maintenance
PMDB preventive maintenance database
QA quality assurance
RCM reliability centered maintenance
RTF run-to-failure
SMART system monitoring and reporting tool
SSC system, structure, or component
TIL technical information letter
TR technical report
1-4
2
PROJECT MANAGEMENT AND PROCESS OVERVIEW
2.1 Development of the Generic Process
Figure 2-1 represents a generic process that a project team should follow when upgrading a
steam turbine at a nuclear or fossil power plant. The process is structured like a typical bar chart
with each activity shown in approximate chronological order, and the duration of each activity is
roughly shown to depict overlaps of various activities throughout the process.
2-1
Project Management and Process Overview
Identify Scope of
• Establish Design Inputs
Steam Turbine • Establish System Requirements
Components to be • Generate Design Outputs
Replaced • Design Verification
• Configuration Management
Design Issues Section 3 Translate Design

Requirements into
Develop Request for Procurement
Proposal and Section 4 Requirements
Specifications
Bid Evaluation, Manufacture in
Supplier Qualification Accordance with
Qualified Design
and Selection
Section 5 Purchasing Fabrication
Issues Issues
Section 5 Section 6 Shipping
and
Communicate Section 7 Handling Section 8
Requirements Receipt
to the Supplier
Inspection
Component Acceptance Storage/Staging
• Manufacturing Surveillance Issues
• Witness/Hold Points
• Verification After Receipt Section 9
Section 10
Installation Issues
Develop Component Maintenance Strategy
• Division of Responsibilities
Section 11
• Work Planning
• Project Duration & Schedule
• Supply Chain Management
• Risk & Contingency Management
Disposal of
• Project Cost Control Replaced
• Project Team Composition & Components
Management
Section 12
• Senior Management Support
Project Management
Section 2.3
Figure 2-1
Generic Process for Considering Key Issues when Upgrading a Steam Turbine
2-2
2.2 Key Issues and Report Structure
Figure 2-1 illustrates that the process should follow a logical sequence of events that affords the
project team an ample opportunity to evaluate all aspects of the upgrade and interface points
between the steam turbine and adjacent equipment/operating systems. The categorization of key
issues is based upon the typical delegation of activities when upgrading a turbine among the key
organizations involved (for example, design engineering, procurement engineering, purchasing,
QA, and organizations in the supply chain).
Figure 2-1 also depicts the overall flow of information and the primary purpose of each element
of the process. Each process element is also cross-referenced to the corresponding section in this
report where detailed implementation guidance is provided.
Figure 2-1 also illustrates the following key points:

• Certain aspects of the design of the replacement component require an iterative process most
effectively performed through close collaboration with the equipment designer/manufacturer.
• The design of the replacement component should concurrently consider other aspects of the
project to include the maintainability of the equipment and installation.
2.3 Project Management for Replacing Major Plant Components
2.3.1 General Guidance
One of the keys to success when upgrading a major plant component such as the steam turbine is
the ability to manage the entire project to ensure that it remains on schedule and under budget
and that the upgraded component remains suitable for its intended application. Although the
main focus of this report is on the turbine itself, the project manager must have an appreciation
for the entire scope of work associated with upgrading the component. This involves the
modification of various interface system components, each controlled with appropriate site-
specific design changes processes. Figure 2-1 illustrates that project management activities span
the duration of the project and include many issues that are not necessarily directly related to the
replacement component nor are they technical in nature. Some of these issues may include the
following:
• Division of responsibilities – Assigning roles and responsibilities among the various internal
and external organizations associated with the design, procurement, manufacture,
installation, maintenance, and operation of the steam turbine.
• Work planning – Coordinating the numerous work activities associated with the steam
turbine and interfacing system components.
2-3
• Project duration and schedule – Establishing a project scope, total duration, and milestones
so that all activities are appropriately planned and scheduled. The project manager should
consider the following issues when establishing an overall project schedule for a steam
turbine upgrade:
– Pre-design activities – Walkdowns, inspections of existing component, conceptual design
studies
– Pre-award activities – Design engineering activities, specification development, bid
evaluation
– Manufacturing lead time
– Shipping duration
– Receiving and staging duration
– Demolition schedule
– Installation schedule
– Post-installation testing and startup activities
– Turnover activities
Once each of these major elements has been planned, the licensee’s work-planning
organization should be used to establish the overall project schedule and milestones in
accordance with existing utility/site procedures.
• Supply chain management – Interfacing with the various organizations in the supply chain to
ensure that each has the necessary capabilities and can implement those controls in a
consistent manner with regard to the replacement component and other system components
needing replacement or modification.
• Risk and contingency management – Developing plans for addressing unexpected issues that
arise throughout the duration of the overall project and means for estimating the risks
associated with implementing various corrective actions.
• Project cost control – Ensuring that the turbine upgrade project remains within the allowable
budget.
• Project team composition and management – Ensuring that the appropriate individuals are
available to support the turbine upgrade project, including members from the supply chain.
• Senior management support – Ensuring that senior management is aware of the project
scope, budget, and progress so as to provide the necessary support throughout the duration of
the turbine upgrade work activities.
2-4
• Configuration management – Ensuring that the appropriate design change control processes
are implemented effectively and that the as-built configuration of the upgraded turbine is
accurately represented and conveyed in design output documents (operations and
maintenance [O&M] procedures will change as a result of the upgrade).
• Training – Ensuring that personnel associated with the O&M of the steam turbine are
provided with adequate training, if their existing level of training is deemed inadequate for
the safe and reliable performance of the equipment.
2.3.2 Managing Design and Technical Issues
One of the key responsibilities of the project manager is to manage design issues so that the
upgraded turbine remains suitable for its intended application(s), it subsequently performs
reliably, and adjacent system components are modified as needed to sustain reliable system
performance. Successful project managers recognize the importance of maintaining a close
interface with both internal and external organizations.
2.3.2.1 Project Management Interface Controls
Because engineering (including the design) occurs sequentially and in an iterative manner, some
expertise and awareness of parameters affecting the turbine through all stages of its life should
be considered during the design phase. However, concurrent engineering is based on the
observation that there is no necessary condition forcing that expertise to occur only at the
required stage. Indeed, it is often the case that many kinds of expertise (both internal and external
to the utility, for example, a performance test engineer) are essential at almost every stage of
product development and usage. As such, the project manager should solicit and be provided
with a variety of expertise concurrently in each stage of the sequential process.
To ensure that the required expertise is available, the project manager should create a team
whose members combine to provide the required expertise. This team should be a
multidisciplinary group that guides a component replacement from beginning to end. INPO
information suggests the most successful teams, for nuclear steam turbine upgrades, include a
senior reactor operator during the entire process. For steam turbine upgrades at fossil power
plants, a senior person from operations should be considered for inclusion on the team. Table 2-1
lists the typical organizations that may compose the project team and the estimated extent to
which they would be involved.
2-5
Table 2-1
Typical Project Team for Implementing a Turbine Upgrade
Organization Composing Anticipated Level of Involvement

Project Team
Engineering (design, systems, High (except PE)
component, and procurement)
Maintenance Medium
Installer High
Project manager High
Quality assurance (QA)/quality Medium
control (QC)
Work High
controller/planner/scheduler
Licensing Low
Operation (senior/station reactor High

operator or equivalent)
Senior management Medium

Component supplier High
Plant security Low
Training Low (higher for maintenance personnel)
Supply chain Low (during actual purchasing)

Health physics Project dependent (based on
application)
Chemistry management Low (project dependent – based on
application)
ANSI N45.2.11 describes implementation guidance for the control of both external and internal
interfaces encountered during the design of a component. It suggests that for either type of
interface, the project manager should perform the following:
• Identify the interface
• Establish responsibilities
• Establish appropriate lines of communication
• Establish procedures to control the flow of design information
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2.3.2.2 Managing the Concurrent Engineering Processes
Successful project managers recognize the importance of considering various aspects of the
replacement as the design of the upgraded turbine and design modifications of adjacent system
components progress. This process is often referred to as concurrent design because the design
evolves throughout the project and occurs in concurrent engineering environments. EPRI report
TR-107372, Guideline for Reverse Engineering at Nuclear Power Plants, describes concurrent
design in the following manner:
A systematic approach to the integrated, concurrent design of products and their related
processes, including manufacturing and support. Causes developers to consider from the
outset, all elements of the product life cycle.
In a very general way, engineering occurs in a sequential manner. Design must occur largely
before manufacturing the replacement component; testing and inspection commence after
manufacturing has started. Then, the turbine components are shipped, stored, installed, started,
operated, and maintained.
For the purposes of this report, when upgrading a major plant component such as the steam
turbine, the project manager should factor the following aspects of the component use into its
design to the extent feasible:
• Enhancing the ease of installation – The project team should consider, during the design of
the turbine upgrade, how and where the new components will be installed—even if only
conceptually. Layouts and lifting/rigging plans should be communicated to potential
component manufacturers so that appropriate features can be designed onto the component to
facilitate the safe handling and installation of the item. Walkdowns should also be considered
as a means to share installation concerns with potential manufacturers during the design
phase of the replacement project. Examples of design features that can enhance the ease of
installation of major plant components may include:
– Welded lifting lugs
– Protective shields/plugs/caps
– Internal bracing/padding
• Maintainability – The project team should work with potential suppliers to design any
enhancements to the turbine that will support future maintenance activities. Accessibility,
maintenance, repair, and in-service inspection requirements for the plant (including the
conditions under which they will be performed) should be communicated to potential
suppliers. This may result in special instrumentation, physical reconfiguration of the
equipment, or allowance for accessibility.
2-7
• Enhancing turbine performance monitoring – The project team and potential manufacturers
should examine ways in which the performance of the steam turbine will be most effectively
monitored. Together, the following aspects should be considered:
– Ability to inspect equipment
– Instrumentation and enhancements to support equipment performance monitoring
– Test requirements, including in-plant tests and the conditions under which they will be
performed
• Need for special tooling – During the design of the steam turbine upgrade, the project team
and potential suppliers should determine if there are any requirements for special tooling—
either during the manufacture or operation of the steam turbine. In some cases, the design can
be modified early in the process to negate the need for special tooling.
2.3.2.3 Other Design Considerations
ANSI N45.2.11 suggests that the project manager consider the following parameters during the
design of the steam turbine upgrade:
• Personnel requirements and limitations, including the qualification and number of personnel
available for operation, maintenance, testing, and inspection and permissible personnel
radiation exposures for specified areas and conditions
• Transportability requirements such as size and shipping weight, limitations, and Federal
Communications Commission (FCC) regulations
• Fire protection or fire resistance requirements
• Handling, storage, and shipping requirements
• Requirements to prevent undue risk to the health and safety of the public
• Safety requirements for preventing personnel injury (including such items as radiation
hazards), restricting the use of dangerous materials, escaping provisions from enclosures, and
grounding of electrical systems
2.3.3 Evaluating Industry Experience
During the design phase of the steam turbine upgrade, the project manager should consider
researching industry experience related to the steam turbine and the performance of potential
manufacturers of the steam turbine. There exists a wealth of industry experience regarding the
replacement of steam generators, steam turbines, and generators. In general, the project team
should consider the following sources for researching industry experience:
• INPO operating experience
• Nuclear Regulatory Commission (NRC) bulletins and/or 10CFR21 notices
• Technical information letters (TILs)
• Technical bulletins
2-8
• Original equipment manufacturer (OEM) publications/papers on upgrades

• Peer review/readiness review team (internal and external peers)
• Other utility experience with similar component replacement and steam turbine upgrades (for
benchmarking)
2.3.4 Establishing and Managing the Project Budget
Although not the primary focus of this report, the project team should be aware of budget
constraints throughout the duration of the project. Development of detailed bid specifications
(for equipment and installation), proper selection of the turbine upgrade supplier, and proper
scoping and management of adjacent system design modification work all contribute to ensuring
that the overall project budget is realistic and remains manageable.
2-9
3
SYSTEM AND COMPONENT DESIGN ISSUES
3.1 Understanding the Reasons for the Steam Turbine Upgrade
As noted in Section 1 of this report, many plants are facing the necessity of upgrading key
components such as the steam turbine to support initiatives such as license renewal applications
and power uprates. Before any design activities are undertaken, engineering personnel should
fully understand why the component is being upgraded. Although the reason(s) may not have a
significant effect on implementing the generic process described in this report, it will in most
cases affect the scope of the owner’s design and procurement processes.
As noted in Section 1 of this report, one of the basic premises in this report is that utility
personnel have already performed a replace vs. repair/refurbish analysis in accordance with site-
specific procedures. This report assumes that a turbine upgrade has been determined to be the
most cost-beneficial option. As such, the replace vs. repair analysis is not included in the generic
process provided in Section 2 and is not discussed in any further detail in the remaining sections
of this report.
Listed next are some of the most common reasons that a major plant component such as the
steam turbine would be upgraded. In some cases, upgrade may be the best option for a
combination of the following issues:
• End of life – The component has reached the end of its design life and can no longer perform
design functions and cannot support plant license renewal.
• Component obsolescence – The component is obsolete and cannot be maintained properly.
– The original manufacturer is no longer in business or does not manufacture an identical
component.
– Newer technologies have replaced those inherent to the original component.
– Spare/replacement parts are either obsolete or no longer available.
• Power uprate – The original component design is inadequate to support a power uprate.
• Degraded performance – The original component performance has degraded over time,
adversely affecting its availability or reliability.
3-1
System and Component Design Issues
• Improving/enhancing steam turbine performance and reliability – In some cases, a

component will be upgraded not only to restore system performance, but also to improve its
reliability. Similarly, a component may be replaced to improve upon a less reliable design.
And, in some cases, a component is upgraded to enhance system output performance and
improve equipment reliability. The project team should clearly understand the goals of the
steam turbine upgrade and subsequently communicate those objectives to potential suppliers
as early in the design phase as possible.
3.2 System and Component Design Relationship
Figure 3-1 illustrates that the design issues encountered during the upgrade of a major plant
component, such as the steam turbine, include those directly related to the steam turbine as well
as those associated with adjacent/interfacing system components. In many cases,
adjacent/interfacing system components require some design modifications in order to make the
upgraded steam turbine suitable. These plant design modifications are just as important to the
success of the project as the design modifications to the steam turbine.
• Normal Operating Conditions

• Accident Operating Conditions
• Plant Seismic Demand
• Environmental Conditions
• System Design Margins
• System Safety Classification
System Operating Parameters

Section 3.4 and Design Requirements
Design Inputs for the
Section 3.3
Replacement Component
• Performance Requirements
• Physical Requirements
• Safety Classification Configuration Management Section 3.9
• Spare/Replacement Parts
Design Approval Section 3.8
Design Modification of
Adjacent/Interfacing System
Components
Steam Turbine Section 3.5
Replacement
Components
Design
Output
Design Documents
Section 3.6
Verification
Section 3.7
Figure 3-1
System and Component Design
3-2
3.3 Establishing System Operating Parameters and Design Requirements
3.3.1 System Normal Operating Conditions
The project team should communicate to potential turbine manufacturers the following
information, as applicable:
• System flow, pressure, and temperature
• Interface requirements, including the definition of the functional and physical interferences
involving systems, structures, and components (SSCs)
• Structural requirements covering such items as equipment foundations and pipe supports
• Hydraulic requirements such as pump net positive suction head (NPSH), allowable pressure
drops, and allowable fluid velocities
• Electrical requirements such as source of power, voltage, raceway requirements, electrical
insulation, and motor requirements
• Access and administrative control requirements for plant security
• Redundancy, diversity, and separation requirements of related SSCs
Note that in some cases it may also be beneficial to communicate these same system parameters
experienced during off-normal operating conditions.
3.3.2 System Accident Operating Conditions
For nuclear licensees, system operating conditions following a design basis accident should be
considered and provided to potential suppliers. Failure affects requirements of SSCs, including a
definition of those events and accidents that the SSCs must be designed to withstand that should
also be communicated to potential component manufacturers during the design of the item.
3.3.3 Plant Seismic Demands
The project team should ensure that plant-/site-specific seismic loads are communicated to
potential suppliers during the upgrade design of the steam turbine. Seismic demands vary from
plant to plant, and it is important for potential suppliers to understand the loads to which the
particular steam turbine will be subjected.
3-3
3.3.4 Environmental Conditions
During the design of the component, it is important for the project team to convey various
environmental conditions to which the steam turbine will be subjected. First and foremost, the
suppliers should be aware of the basic plant location, layout, and arrangement requirements for
the replacement component. Consideration should be given to environments during the
following:
• Anticipated storage – Temperature, humidity, atmospheric pressure, and exposure to airborne
contaminants
• Normal operation – Ambient conditions, wind loads, and an indoor/outdoor unit
3.3.5 System Design Margins
The project team should confirm the design margins associated with both the system in which
the steam turbine is installed and the steam turbine itself. Any changes to design margins should
be documented on design outputs such as calculations, drawings, specifications, system
descriptions, design basis documents, and the final safety analysis report (FSAR) (for nuclear
licensees). In many cases, the resulting effect on actual design margins may not be ascertained
until after the steam turbine has been upgraded.
The following is a list of design margin issues that may arise during a steam turbine upgrade
project and that may require a margin review by either the utility engineering organization or the
turbine manufacturer:
• Generator cooling – Can the present system accommodate it, or will heating problems limit
the capability to take maximum advantage of the upgrade?
• Isophase bus duct – Is it sized for cooling and current-carrying capacity for the upgrade?
• No-load disconnect – Is it properly sized for upgrade capacity?
• Exciter size – Is the exciter oversized, or will it also become a limiting factor in terms of
taking advantage of a turbine upgrade?
• Main transformer size – Is the existing transformer already sized for 100% power output, or
does it have additional current-carrying capability?
• Steam generator degradation (fossil or nuclear) – Has plugging or fouling degraded the steam
generator or boiler to a point where it may limit the potential benefits of a turbine upgrade?
• Turbine moisture extraction drains – The increase in mass flow and the increase in thermal
efficiency both contribute to increased moisture extraction flow to the hot well. The casing
drain size needs to be checked to ensure that moisture will drain as designed.
3-4
• Steam extraction and drain flows – Are both sized sufficiently to handle the consequential
effects, which can be expected from changes to the turbine flow path? The project team
should consider including in their specification that the upgrade OEM should match existing
steam extraction flow, temperatures, and enthalpy. If matching is not possible, the supplier
should provide a calculated heat-balance diagram showing the effects on changes in the
extraction conditions on the entire cycle.
• Condenser limits – Will the improvement in turbine efficiency be significantly affected by
seasonal changes on condenser back pressures? Will increased steam flow adversely affect
tube vibration between tube supports?
• Control valve positioning – What additional changes may be required to accommodate the
upgrade of an HP turbine? The project team should recognize that the objective is to operate
at the optimum valve point.
• Feedwater pumps and condensate pumps – The entire thermal cycle should be analyzed,
including the condenser neck expansion joint, generator hydrogen purity (may have used up
the margins, which relates to the capability curve and matching purity to the upgraded
turbine), and the electrical loading on the buses.
• Heater tubes – In general, an analysis should be performed to determine adverse effects on
efficiency resulting from deposits of copper and/or silica from the heater tube materials
because this may be an issue when meeting performance guarantees and could affect
efficiency by 2%.
• Turbine-generator (T-G) shaft torsional response – Assuming that the current/original
components have had no issues with torsional vibration, have the replacement components
been appropriately analyzed so that no abnormal torsional vibration responses will be seen on
the T-G shafts due to the changeout of the upgrade shafts/components?
Experience has shown that utilities considering a steam turbine upgrade should invest in a plant
heat balance re-analysis as a part of the upgrade evaluation.
3.3.6 System Safety Classifications
The project team at a nuclear power plant should confirm the safety classification of the system
in which the steam turbine will be installed and the classification boundaries. This information is
typically documented in the updated final safety analysis report (UFSAR), system descriptions,
system design bases documents, technical specifications, and system diagrams and drawings.
3-5
3.4 Establishing Design Inputs for the Steam Turbine
ANSI N45.2.11 provides the following guidance regarding the establishment of design inputs:
Applicable design inputs, such as design bases, regulatory requirements, codes and
standards, shall be identified, documented and their selection reviewed and approved.
Changes from specified design inputs including the reasons for the changes shall be
identified, approved, documented and controlled.
When upgrading the steam turbine, it is important to understand the current design bases
requirements of the system in which it is installed. This may be different from the requirements
originally specified in the original component purchase specification because there may have
been design modifications performed during the life of the steam turbine. Furthermore, the
project team should understand the objectives of the steam turbine upgrade and whether one of
the objectives is to increase system output performance by virtue of replacing the various steam
turbine subcomponents.
3.4.2 Establishing Steam Turbine Performance Requirements
Steam turbine design functions and operability will vary under various conditions such as plant
startup, normal plant operation, plant shutdown, plant emergency operation, special or infrequent
operation, and system abnormal or emergency operation. These conditions and corresponding
performance requirements should be understood by the project team and communicated to
potential steam turbine suppliers. These may include any of the following:
• Instrument and control requirements, including indicating instruments, controls, and alarms
required for operation, testing, and maintenance. Other requirements include the type of
instrument, installed spares, range of measurement, and location of indication.
• Component design and safety functions. (Appendix A of EPRI report 1008256 may be
referenced for additional information.)
• Capacity, including such items as changes in steam flow and generator power factor curves.
• Material requirements including compatibility, electrical insulation properties, protective
coating, and corrosion resistance.
• Mechanical requirements such as vibration, stress, shock, and torsional and reaction forces.
• Component failure mechanisms, failure modes, and effects. (Appendix B of EPRI Report
1008256 may be referenced for additional information.)
3-6
In some cases, the steam turbine performance requirements cannot easily be ascertained from
existing documentation and can be obtained only by inspection or measurement of the actual
component. In these cases, the project team may need to gain access to the equipment during an
outage to make the necessary inspection or measurement. Depending on plant operating status,
the project team may need to plan these outage activities months before the upgrade of the steam
turbine.
Given the outputs resulting from modification of adjacent/interfacing system components and the
subsequent system operating parameters, the project team establishes steam turbine technical
requirements to the degree deemed necessary to ensure that all design basis requirements are
met. In many cases, the manufacturer is provided latitude to design/offer an upgrade that meets
the requirements of the design requirements they have been provided. The degree to which the
project team is involved in the actual design of the upgrade will vary, depending on its
complexity and its plant-specific functions.
In most cases, the project team must understand and communicate steam turbine-specific
performance requirements to potential suppliers in order to ensure that system performance
requirements are met. In some cases, it may also be necessary for the project team to determine,
select, and specify physical requirements for the steam turbine and its parts. For example, it may
be necessary to clearly specify the location of test instrumentation, type of instrumentation,
and/or the location and functions of existing plant or high-accuracy temporary instrumentation.
When specifying to this level of detail, it may be helpful to consider the services of an outside
performance consultant to assist the utility if needed.
Table 3-1 provides a listing of typical steam turbine performance requirements that should be
considered, as applicable, during the design of the replacement.
Table 3-1
Typical Component Performance Requirements/Characteristics
(See EPRI Report 1008256)
Flow rate Operating range Rotational direction
Horsepower/shaft power Pressure drop Speed

Load rating Pressure rating Temperature rating
3.4.3 Establishing Steam Turbine Physical Requirements
Table 3-2 provides a listing of typical steam turbine physical requirements that should be
considered, as applicable, during the design of the replacement.
3-7
Table 3-2
Typical Steam Turbine Physical Requirements/Characteristics
(See EPRI Report 1008256)
Balance Leachable halogen content (of Surface finish

nonmetallic items)
Composite metal hardness Load rating Surface hardness
Dimensions (to within Material of construction Tensile strength

manufacturer’s tolerance)
Ductility Mounting Thermal conductivity

Durometer hardness (of Permeability Torque/torsional vibration
nonmetallic items) response
Elasticity (of nonmetallic items) Plating Viscosity (of lubricants)
Fatigue resistance Shear strength Wall thickness
General configuration or shape Spring constant Weight
Homogeneity (of material)
3.4.4 Determining Component Safety Classification
The project team at a nuclear power plant should confirm the safety classification of the steam
turbine being upgraded in order to determine the extent to which 10CFR50, Appendix B
requirements apply. If the steam turbine is not classified as safety related, the project team
should still determine whether other QCs and requirements are applicable and whether those
requirements are relevant during the design process. Safety classification of components varies
from plant to plant, depending on original licensing commitments and subsequent
implementation of component categorization programs. The project team should determine
which of the following categorization methodologies have been used to determine the current
classification of the component being replaced:
• Deterministic/functional safety classification (safety related or non-safety related)
• Categorization per 10CFR50.65 (Maintenance Rule)
• Categorization per INPO AP-913 (critical components)
• Risk-based categorization per 10CFR50.69 (high safety significant or low safety significant)
3.4.5 Spare and Replacement Parts
As noted earlier in this report, it is often beneficial to consider a maintenance strategy during the
design of the steam turbine upgrade. Subsequently, the project team should consider establishing
with potential suppliers the scope of spare and replacement parts necessary to execute the
anticipated maintenance as well as the frequency with which those items should be made
available. EPRI report 1011861, Considerations for Developing a Critical Spare and
3-8
Replacement Items Program at a Nuclear Power Plant, should be considered as a guide for
determining critical spares for a steam turbine.
During the design and prior to procurement of the steam turbine, consideration should be given
to establishing means for proactively obtaining from potential suppliers certain design
information such as materials and dimensions/tolerances of certain spare/replacements parts.
Having this part-level information provided during the procurement of the component will make
acceptance of these items in the future easier and with less engineering involvement. An example
of this is procuring a number of spare turbine blades/buckets for each row during the upgrade
process. This will enable dimensional measurements later without needing to disassemble the
turbine. Also, a spare LP turbine blade can be a standard for frequency testing of future
replacement blades.
3.5 Adjacent/Interfacing System Components and Plant Design

Modification
3.5.1 Steam Turbine Interface Points
A key consideration when upgrading a major plant component such as the steam turbine is the
identification of all interface points between the steam turbine with the existing system and
auxiliary systems associated with the existing component. Identification of interfaces should
begin as early in the design as possible to ensure that the upgraded steam turbine will not
interfere with existing equipment and that operating parameters of interfacing systems are
adequate to enable the upgraded steam turbine to perform as designed. Interfaces should be
categorized into the following areas as summarized in Table 3-3.
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Table 3-3
Types and Examples of Key Interfaces
Type of Interface Examples for Consideration
Structural Strength of foundation

Physical interferences with existing structures
Footprint configuration
Maintenance of existing accessibility
Potential modifications to crane
Rigging and loading
Turbine lay-down area
Structural movements as they relate to expansion joints
Mechanical Piping size, location, and method of connection

Adequacy of flow, pressure, and fluid temperature to and
from new component
Pipe hangers
Adequacy and alignment of bearings, gearboxes, and
couplings
Material compatibility
Compatibility of fluids with the new component
Direction of rotation of mating rotating elements
Torsional strength of centerline components
Adequacy of the thrust bearings (seismic)
Review of stresses in the couplings
Turning gear refurbishment
Verification of lift pump capacity
Interface with main shaft driven oil pump
Relief valve capacities and set points
Adequate flow to all bearings
Stress levels due to a catenary line change (bearing
pedestals)
Alignment hardware/shaft train alignment
Load rejection effects – what will the terminal speed be?
Condenser
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Table 3-3 (cont.)

Types and Examples of Key Interfaces
Type of Interface Examples for Consideration
Electrical Physical location of power cable and wiring

Adequacy of existing drive mechanisms
Adequacy of power supply
Compatibility with existing voltage and current inputs
Compatibility with existing circuit inputs and circuit breaking
capability
ISO phase bus duct
Short circuit analysis
Protective relay upgrade
Generator output breakers
Excitation system
Instrumentation and control (I&C) Compatibility with existing equipment performance monitoring
equipment
Physical location of instrumentation tubing, wiring, and cables
Adequacy of input signals
Maintaining accessibility of existing instrumentation and
indicators
Control logic review
Establishment of environment conditions for I&C cabinets
Re-scaling instrumentation
Potential set-point change
Other Adequacy of the crane and other lifting devices

Restoration time for flushing new systems that were installed
or modified (need for temporary installation of fine mesh
screens and potential of steam blows)
Turbine insulation review
Adequacy of fire protection system
The project team should consider verifying all interface points in the field through the use of
walkdowns as well as performing calculation reviews and reviews of appropriate engineering
outputs (for example, drawings, design basis documents, and system descriptions).
3-11
3.5.2 Anticipated Effects of Steam Turbine Upgrades
When upgrading a major plant component such as the steam turbine and after identifying all of
the interface points with existing SSCs, the project team should analyze any adverse effects the
steam turbine could have on interfacing equipment performance and design margins. This
analysis should be a logical follow-up for determining interface points and should be categorized
by discipline as noted in the preceding tables.
For example, an upgraded steam turbine may exhibit a different thrust force on a rotating shaft
than the existing component. One possible effect that should therefore be anticipated may
include the need to upgrade the thrust bearings so that the additional load can be accommodated
without premature wear or excessive vibration.
In another example, as operating conditions change for the upgraded equipment, some plants
have experienced significant amounts of foreign material (which had been inadvertently in these
systems for years) suddenly break loose due to higher flow rates and/or increased vibration. This
dislodging of material subsequently caused flow-related problems and prevented the upgraded
steam turbine from achieving anticipated performance requirements.
In some cases, the potential effects may not be as simple as these examples. The owner’s
engineering organization should evaluate the interface points carefully for effects that are not
simply “once removed” from the component. For example, an upgraded steam turbine may
require a different size intake line at the point of attachment to the upgraded turbine, which
subsequently requires relocating some anchors and duct supports. By moving the anchors and
duct supports, different loads and movement are exhibited on an existing expansion joint located
further upstream in the line. The expansion joint therefore may require modification or
replacement, even though it is not directly adjacent to or interfacing with the upgraded steam
turbine.
EPRI report TR-106230, Main Turbine Performance Upgrade Guide, states the following
general issues when considering an upgrade:
• Generator cooling – Can the present system accommodate it, or will heating problems limit
the capability to take maximum potential advantage of the upgrade?
• Exciter size – Is the exciter oversized, or will it also become a limiting factor in terms of
taking advantage of a turbine upgrade?
• Main transformer size – Was the existing transformer already sized for 100% power output,
or does it have additional current-carrying capacity?
• Steam generator degradation – Has plugging degraded the steam generator to a point where it
may limit the potential benefits of a turbine upgrade?
• Steam extraction and drain flows – Are both sized sufficiently to handle the consequential
effects, which can be expected from changes to the turbine flow path?
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• Condenser limits – Will the improvement in turbine efficiency be significantly affected by

seasonal changes on condenser back pressures?
• Control valve positioning – What additional changes may be required to accommodate the
upgrade of an HP turbine?
The report also recommends that utilities invest in a balance-of-plant re-analysis as part of an
upgrade evaluation. The consequences of an uprate—in regard to taking future advantage of an
upgrade, or vice versa—should also be considered.
As noted in Section 1 of this report, a compilation of effects resulting from various steam turbine
upgrades at fossil and nuclear power plants is provided in a separate database. The effects
contained in this database encompass many of the general issues noted previously.
3.6 Generating Design Output Documents
3.6.1 System Design Output Documents
In the majority of cases, when a major plant component such as the steam turbine is upgraded,
design modifications to adjacent/auxiliary SSCs to accommodate the new component are
necessary. Typically, the project team will develop the following design outputs associated with
affected system components, depending on the extent to which those system components have
been modified:
• Revised calculations supporting the design of the replacement component
• Revised system drawings
• Revised system descriptions
• Revised technical specifications and FSARs
3.6.2 Steam Turbine Design Output Documents
The design of the steam turbine upgrade should be a collaborative effort between the project
team and the equipment designer. As noted in the preceding sections, the project team should
establish certain physical and performance design requirements for the steam turbine and
communicate those to the equipment designer/manufacturer in a bid specification. Given these
inputs, the equipment designer/manufacturer should be provided latitude to design/offer a
component upgrade that meets the requirements of the design requirements they have been
provided. Section 4 of this report provides guidance for developing the bid specification and
refining it after a qualified supplier has been selected. Typically, after the steam turbine has been
upgraded, designed, and manufactured, the equipment supplier will provide the following design
output documents:
• Component assembly drawings
• Component maintenance guidance
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• Recommended spare parts lists

• Component operating guidance
3.7 Design Verification
Section 6 of ANSI N45.2.11 provides implementation guidance for performing design

verification, which would be required to ensure that the new upgraded design is suitable for its
intended application(s). The ANSI standard describes three methods for accomplishing design
verification—design reviews, alternative calculations, and qualification testing. Special care
should be taken when the upgraded steam turbine is installed in a seismically qualified system.
3.8 Design Review and Approval
The project team should consider formal design reviews of the proposed turbine upgrade to
ensure that the upgrade will be suitable and that the modifications will achieve the performance
parameters specified. Table 3-4 provides a list of typical issues that may be included in a
comprehensive internal design review process for a turbine upgrade project.
Table 3-4
Typical Scope of Design Review for a Steam Turbine Upgrade
(Courtesy of SCE&G, VC Summer)
General Area for Design Review Issues Reviewed
Turbine layout • Compatibility with existing

components
Performance considerations • Heat balance review
• Design features
• Water removal
• Erosion
Operation constraints • Uprate capability
• Maximum flow passing
• Temperature/pressure variations
• Startup ramp
• Heatup/cooldown provisions
Design • General criteria
• Life
• Limits
• Analysis – FEA
• Critical flow size
• Features/changes
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Table 3-4 (cont.)

Typical Scope of Design Review for a Steam Turbine Upgrade
(Courtesy of SCE&G, VC Summer)
General Area for Design Review Issues Reviewed
Bucket design • Off-resonance operation

• Steam bending stress
• Attachment selection
• Hook shear
• Wheel neck tension
• Rim tangential stress
• Overspeed capability
Torsional analysis • Sub- and super-harmonic
responses
Critical speeds and rotor balancing
Bearings • Pedestal loading
• Transient loads
• Clearances
• Thrust loads
Coupling • Torsional increases with uprate
Material selection and specification • Rotor

• Blade
• Blade rings
• Hardware
Special processes • Flame hardening
• Bucket/wheel shot peening
• Welding
Stress corrosion cracking • Chemistry
Installation, inspection, and • Changes in these areas due to

maintenance newer equipment design or size or
improved material properties
Design approval may be required from numerous organizations associated with the steam turbine
upgrade. Also, separate design approvals may be warranted at both the system and component
levels. For example, the project team may need design approval from certain organizations for
the entire steam turbine and its effects on the system in which it is installed. The project team
will subsequently approve the design of the actual components selected for the upgrade project.
3-15
It is important that the project manager understand the level of approval necessary and the
roles/responsibilities of the various organizations involved in the design and installation of the
steam turbine components. Listed next are different types of design approvals that may be
relevant when replacing a major plant component:
• Internal approval of design modifications
• Internal approval of component manufacturer’s design according to existing plant procedures
(typically should precede fabrication but may not be completed until after the supplier
selection and the completion of their design)
• External approvals from federal, state, and local agencies
• Regulatory approvals and permits
3.9 Configuration Management
Section 7 of ANSI N45.2.11 provides implementation guidance for document controls. When
upgrading a steam turbine, it is important that all related design output documents and O&M
procedures are updated to reflect the as-installed configuration.
3-16
4
DEVELOPING BID SPECIFICATIONS AND REQUESTS
FOR PROPOSALS
When upgrading a major plant component such as the steam turbine, the project team is typically
responsible for preparing the specification used to procure the subcomponents necessary. This
specification is initially communicated to potential suppliers in a request for proposal (for
example, a bid request). Once a particular manufacturer has been selected to furnish the
upgraded steam turbine components, the specification may be revised to reiterate
manufacturer/component-specific design information and will typically be communicated to the
selected supplier with a purchase order.
Owners may be responsible for preparing an installation specification, which is provided to the
organization leading the construction/replacement effort. This may or may not be the
manufacturer of the steam turbine. Often the size and complexity of the steam turbine
components, and when the components are installed, will dictate the degree to which the owner’s
own maintenance organization is involved in the actual installation.
EPRI report 1009841, Guidelines for Reducing the Time and Cost of Turbine-Generator
Maintenance Overhauls and Inspections, Volume 4: Turbine-Generator Component
Procurement Specifications, contains detailed guidance for developing specifications for the
following steam turbine components and related overalls:
• Turbine-generator blading
• Fossil HP/IP/LP rotors
• Nuclear HP/LP turbine rotors
• Generator rotor rewinds
• Replacement generator rotors
4.1 Developing the Bid Specification for the Replacement Component
The bid specification level of specificity will vary and will be dependent upon the complexity of
the upgraded steam turbine components and the system in which they will be installed. Care
should be taken not to develop the bid specification with a preconceived notion of one particular
steam turbine upgrade design. The bid specification should be specific enough to adequately
communicate all necessary system design requirements and anticipated steam turbine-specific
needs but broad enough to allow multiple suppliers to bid.
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Developing Bid Specifications and Requests for Proposals
4.1.1 Specifying Technical Requirements
Because the technical requirements specified are a translation of the design requirements, they
may be grouped into the same categories as described in Section 3 of this report—design basis
requirements and steam turbine-specific design attributes.
4.1.1.1 Specifying System Design Basis Requirements
System design basis requirements would typically include, as applicable to the actual steam
turbine being upgraded, any of the following:
• System normal operating conditions
• System accident operating conditions
• Plant seismic demands
• Environmental conditions
• System and component safety classifications (for nuclear licensees)
• Requirements exceeding industry/code requirements
• Description of all interface points and work associated with connecting interfaces
The project team should ensure that current operating data (and not the original heat balance) are
used to create an as-built heat balance when communicating system operating parameters to
potential bidders.
4.1.1.2 Specifying Steam Turbine-Specific Requirements
Steam turbine-specific design attributes should also be specified and could typically include any
of the following:
• Component performance requirements
• Margins for meeting existing extraction points (typically within 1/2%)
• Component technical requirements:
– Noun description of the items with modifiers sufficient to distinguish the item from other
similar items.
– Industry codes and standards, including applicable revision level. The specific applicable
sections of codes and standards should be referenced wherever possible.
– Material specifications.
4-2
Other technical procurement requirements that may be specified include the following:
• Special manufacturing/fabrication processes
• Nondestructive examination/evaluation (NDE)
• Storage and staging requirements to prevent degradation
• Request for spare and replacement part information
• Means of design verification
• Plant-specific drawings/supplier drawings and revision level
• Qualification parameters to maintain compliance to a qualification report or seismic
conditions
• Shelf life requirements
• In-storage maintenance requirements
The extent of the technical description on the procurement document is dictated by the
procurement conditions, the role of the supplier in the equipment design, the complexity of the
steam turbine upgrade, manufacturing processes used in the components’ production, and the
bounding conditions the steam turbine is required to satisfy.
4.1.2 Specifying Quality Requirements
The quality requirements for upgraded steam turbine components should be developed and
specified in the procurement document to invoke the necessary supplier controls over
manufacturing, design, and purchasing activities that ensure that the specified technical
requirements are met. The specification should also delineate anticipated QA program
responsibilities between the project team and various organizations in the supply chain.
Quality requirements do not take the place of or substitute for technical requirements.
Components that are technically inadequate can be produced under an acceptable quality
program but will remain technically inadequate for the application.
The quality requirements specified for upgraded steam turbine components should be contingent
on the component’s role in performing critical functions, complexity in design, manufacturing
processes for production qualification requirements, and special processes. Specific quality
requirements may be imposed to focus resources on controlling/imparting certain
component-specific design attributes critical to its performance and reliability.
When specifying quality requirements, it is necessary to understand the supplier’s use of

subsuppliers and material sources to ensure that appropriate quality requirements are passed on
and specified correctly through the supply chain. The owner’s specific quality commitments
from its QA program and FSAR (for nuclear licensees) should be included, as necessary, to
ensure compliance to regulatory requirements.
4-3
For nuclear licensees, the quality requirements for commercial-grade components used in nuclear
safety application require special consideration. Commercial-grade purchases should not have
nuclear-unique standards imposed in the purchase documents (for example, 10CFR50, Appendix
B, and 10CFR21). However, special acceptance requirements may be required (see EPRI report
NP-5652, Guideline for the Utilization of Commercial Grade Items in Nuclear Safety-Related
Applications).
Typically, the quality requirements specified on the procurement document will include the
following:
• Quality assurance program requirements – These could be the specification of either a
nuclear or commercial QA program, depending on the capabilities of the supplier of the
component. Supplier QA programs (such as ANSI N45.2, 10CFR50 Appendix B, ASME
Section III, NCA 3800, and ASME/ANSI NQA-1), are typically recognized as nuclear QA
programs capable of providing the owner with a basic component. Many suppliers have to
obtain certification to the ISO 9000 Quality Management System, which should also be
considered when procuring from a commercial (nonnuclear) supplier. Evidence of the
supplier’s QA program commitments is often requested so that the project team can review
approved quality program manuals or procedures.
• Frequency and types of supplier audits – These should be specified to inform potential
suppliers of the need for any performance-based audits/commercial-grade surveys in addition
to those they have already undergone.
• Source verifications (including witness and hold points) – Source inspections and the
witnessing of in-process tests should be specified for manufacturing processes affecting
design/performance attributes where the quality cannot be confirmed by other available
methods. (For guidance on the other methods available, see ANSI N45.2.13, “Quality
Assurance Requirements for the Control of Items and Services for Nuclear Power Plants,”
and EPRI NP-5652, Guidelines for the Utilization of Commercial Grade Items in Nuclear
Safety-Related Applications.) Source verification should be tailored to any important
design/performance attributes, such as the performance of a test and inspections by the
supplier. For example, penetrant testing may be required to verify weld quality, or a
performance test may be required to verify the head and capacity of a pump. Special quality
requirements can be imposed on a commercial supplier because these types of requirements
are used in many nonnuclear applications. Potential suppliers should also be made aware of
the frequency of anticipated source inspections and the degree to which resident inspectors
will be present during the manufacturing process (for example, the level of intrusiveness
anticipated by the project team). The project team should consider the use of industry
operating experience as a means for determining the scope and frequency of source
verification activities.
• Receiving inspections – These should be communicated to the supplier so that it is aware of
the scope of verification activities that the project team will perform after the steam turbine
components are shipped. The primary value in communicating this type of information is to
allow the supplier the opportunity to coordinate any special logistical support and resources
needed to facilitate the receiving inspections.
4-4
• Other special quality requirements may include any of the following:

– Qualification testing, including mockups
– Access requirements for inspection/audit/surveillance
– Personnel qualification and certification
– Defect reporting according to 10CFR21 for nuclear suppliers
– Dedication methodology according to EPRI NP-5652
– Performance of subsupplier’s inspection/audit/surveillance/sampling according to
established procedures or recognized standards
– Special processes and/or cleanliness requirements
– Field verification by the turbine upgrade OEM of all interface points (may be scheduled
and integrated into an upcoming outage to minimize operational impact)
The quality requirements specified should be commensurate with the technical requirements
specified.
4.1.3 Specifying Supplier Documentation Requirements
Supplier documentation is required to furnish the project team with objective evidence that the
technical and quality requirements of items have been met. Documentation should be considered
a tool in the verification of an item’s technical adequacy and quality compliance but should not
be used without confirmation of its validity (see EPRI NP-5652, ANSI N45.2.13, or ANSI
N45.2.2).
Supplier documentation requirements should correlate with the specified technical and quality
requirements and be specific as to the content. Care should be taken not to request excessive or
meaningless documents or test reports that are not applicable to the item. Certificates of
conformance should not rely solely on generalized statements (such as “this item meets the
requirements of the purchase document”), should be validated by the project team, and should
contain specific statements.
The types of supplier documentation typically specified should include, as applicable, the
following (including consideration of quantity and type of medium):
• Supplier drawings, procedures, and specifications – This general category may include the
following:
– Deviation notices
– QC reports (nonconformance reports)
– Submittals to explain the design basis of the upgraded component and outputs of analyses
performed by the upgrade OEM (SCC margins, fatigue margins, and turbine missile
analysis [assume the maximum turbine valve testing intervals])
– Maintenance manuals
4-5
– Designer’s station manual

– Conformed drawings/as-built drawings
The project team should be clear about the type of units depicted on drawings
(International System of Units vs. English units), and types of standards (Deutsches
Institut für Normung [DIN], American Society of Mechanical Engineers [ASME]).
• Supplier instruction manuals (including maintenance recommendations)
• Qualification reports
• Certified material test reports
• Nondestructive test reports
• Personnel certifications
• Inspection reports
• QA manuals
• Performance test reports
• Certificates of Conformance/Compliance
• Recommended spare/replacement parts lists
Retention time of records should also be specified as well as the quality and legibility of the
records where necessary to ensure future reproduction capability.
4.2 Developing the Request for Proposal
At this stage of the project, the project team should have completed a conceptual design study
and should have a basic understanding of the scope of the upgrade to be installed and the
resulting system performance parameters to be achieved by upgrading certain steam turbine
components. Also at this point the project team should have developed the bid specification for
the replacement components, which will become an integral piece of the request for proposal.
However, it is not uncommon to have selected at this point a supplier and particular steam
turbine components demonstrated to be suitable for the plant application. As such, the project
team should compile known design basis and system operating parameters and communicate
them to potential component suppliers in a request for proposal or what is commonly referred to
as a bid spec.
The project team should communicate to potential bidders the following information:
• The scope of upgrade work (equipment only or equipment and installation)
• The component being replaced, including all known design and performance parameters
about the existing steam turbine
4-6
• The bid specification for the steam turbine replacement components, including any of the
following:
– Technical requirements (system design basis requirements, component-specific
requirements, and system performance requirements that the project team wants to
enhance by virtue of replacing certain subcomponents)
– Quality requirements
– Supplier documentation requirements
• Anticipated supplier interface, including walkdown planning, pre-bid meetings, and a bid
submittal schedule
• Schedule for a steam turbine upgrade
• Type of bid (for example, fixed price, lump sum, and time and material)
• Commercial terms and conditions
4.3 Developing the Installation/Construction Specification
The level of detail and scope of the installation/construction specification will vary depending
upon who is responsible for installing the replacement components constituting the steam turbine
upgrade. In some cases, the project team will install the components and, as such, should develop
work packages necessary in accordance with existing site-specific procedures.
In some cases, the manufacturer of the upgrade components will be the installer. When this is the
case, the specification provided to the manufacturer may include both refined procurement and
installation requirements. Work done in this manner is often referred to as a
design/procure/install contract or a turnkey contract.
When upgrading a major plant component such as the steam turbine, the project team should
consider the following issues for inclusion in the installation/construction specification:
• Scope of components/subcomponents to be demolished
• Limits of demolition (typically communicated on a drawing)
• Sequence of demolition/installation steps
• Description of all interface points and work associated with connecting interfaces
• Description of design modifications necessary on adjacent/ancillary systems
• Scope of work considered being of low safety significance that could be handled in the field
• Appropriate plan/section drawings, schematics, and flow diagrams depicting the removal of
the old components and the installation of the replacement
• Lifting and rigging plans for both the old and new components
4-7
• QCs that are required during the installation of the replacement steam turbine components:
– NDE
– Witness and hold points for inspection and testing during the installation process
– In-process testing required as the replacement component is being installed
• Scope of supporting/ancillary equipment needed for a steam turbine upgrade (for example,
procurement responsibilities for items such as weld wire and insulation)
• Post-installation testing requirements for verification of design performance parameters
• Personnel qualification requirements for craft labor, inspectors, and riggers employed during
the installation of the new component
• Special tools or scaffolding required to install the new steam turbine components
• Codes and standards applicable to the work associated with installing the replacement steam
turbine components
• Personnel safety issues and as low as reasonably achievable (ALARA) concerns (for nuclear
licensees)
• Requirements for the submittal of an installation plan and schedule
• Description of organizational interfaces and roles/responsibilities among
members/organizations composing the installation team
• Performance acceptance criteria for the new steam turbine components
• Access routing and special considerations for moving the components into their designated
positions
• Special lifting/handling requirements
• Storage/staging requirements (such as power, air, and lighting)
Many of these installation issues are discussed in more detail in Section 10 of this report. They
are listed here so that they can be appropriately communicated in the specification document.
4.4 Developing Service Specifications and Contracts
In some cases, the project manager will be required to develop specifications to procure various
services in support of the steam turbine upgrade and system design modifications. Service
specifications should include the following general requirements:
• Scope of work
– Type of service needed
– Applicable industry codes and standards
4-8
• Quality requirements
– Personnel certifications
– Inspection reports
– QA manuals
– Performance test reports
• Supplier documentation requirements
– Certificates of Conformance/Compliance
– Personnel qualification certificates
• Commercial terms and conditions (see Section 5 of this report for additional guidance)
4-9
5
SUPPLIER QUALIFICATION AND SELECTION, BID
EVALUATION, AND PURCHASING
5.1 Supplier Selection and Qualification
5.1.1 Selection of Procurement Sources
Section 4 of ANSI N45.2.13 states in general that the selection of a supplier should be based on
evaluation of their capability to provide items in accordance with the requirements of the
procurement documents. The standard also requires that procurement source evaluation and
selection measures include integrated actions involving one or more organizations (for example,
engineering, construction, manufacturing, operations, maintenance, purchasing, or QA) based
upon the item being procured.
Methods to be used in evaluating supplier sources along with the results should be documented
and include one or more of the following:
• Evaluating the supplier’s history of providing a product that performs satisfactorily in actual
use.
• The supplier’s current quality records supported by documented qualitative and quantitative
information, which can be objectively evaluated.
• The supplier’s technical and quality capabilities as determined by a direct evaluation of its
facilities and personnel and the implementation of its QA program. Note that in some cases
suppliers, such as utility engineering organizations, may have lost technical depth and
expertise over the last 20 years due to a lack of new plant construction throughout the
domestic power industry.
5-1
Supplier Qualification and Selection, Bid Evaluation, and Purchasing
5.1.2 Supplier Qualification Status
ANSI N45.2.13 states in part that the licensee is responsible for the:
Evaluation of supplier’s quality assurance program to assure that it is appropriate and

satisfies the requirements for the items or services being purchased.
If the replacement component is being procured from a supplier with whom the licensee/owner
has already procured other items, the licensee/owner should verify the supplier’s qualification
status by reviewing the approved supplier’s list (typically maintained by the QA organization). If
the replacement component is being procured from a new supplier, the QA organization should
be advised so that an initial qualification evaluation (for example, an audit or commercial-grade
survey) can be performed.
5.1.3 Supplier Quality Program Capabilities
The project team should ensure that the supplier has the technical capabilities to meet the
specification requirements and a QA program to ensure that those capabilities are implemented
consistently. Project teams should recognize that supplier QA program capabilities vary
significantly among suppliers. Furthermore, a supplier’s commitment to a given QA program
does not in itself ensure reliable performance of the manufactured component. Ideally, the
supplier’s program is capable of meeting the licensee’s/owner’s requirements. If it is not, the
project team is responsible for addressing those shortcomings to achieve the necessary level of
QA.
The results of a supplier evaluation should be documented in a report that is made available to
engineering personnel for assessment of the supplier’s capabilities. The supplier evaluation is
important because it serves to:
• Confirm that the supplier has the necessary technical capabilities and QCs
• Properly implement capabilities and controls
5-2
Section 2 of ANSI N45.2.13 requires that the licensee establish measures for the control of the
procurement of a replacement component, including appropriate planning. The ANSI standard
states in part:
Planning shall result in the documented identification of methods to be used in

procurement activities, sequence of action and milestones indicating the completion of
these activities, and the preparation of applicable procedures prior to the initiation of each
individual activity listed below. Planning shall provide for the integration of the
following:
1. Procurement document preparation, review, and change control
2. Selection of procurement resources
3. Bid evaluation and award
4. Purchaser control of supplier performance
5. Verification (for example, surveillance, inspection, or audit) activities by the

purchaser
6. Control of nonconformances
7. Corrective action
8. Acceptance of item or service
9. Quality assurance records
10. Audit of procurement program
Another factor that should be considered that is not explicitly described in ANSI N45.2.13 is the
division of QA programmatic responsibilities between the project team and various organizations
in the supply chain. These factors are discussed in more detail in the following section.
5.2 Bid Evaluation and Award
Section 5 of ANSI N45.2.13 states in general that a licensee should establish a documented
system for reviewing and evaluating the bids and awarding of contracts. This established process
should be used for the evaluation of bids for replacement components. Figure 5-1 illustrates the
general process for supplier selection and bid evaluation that is implemented by most
licensees/owners of power plants.
5-3
Figure 5-1 illustrates that the owner’s QA organization is typically responsible for the initial
qualification and screening of potential suppliers. After requests for proposals are issued, the bid
evaluation is performed jointly by the owner’s purchasing organization and engineering
organization.
Bid evaluations should be made by individuals or organizations designated to evaluate the

following subjects, as applicable to the type of procurement and replacement component:
• Technical considerations
• Quality assurance requirements
• Supplier’s personnel
• Supplier’s production capability
• Supplier’s past performance
• Alternate designs for consideration
• Evaluations of exceptions to the bid
• Schedule adherence
Supplier
Quality
Organization Engineering
Organization
Establish List of Qualified
Suppliers Eligible to Bid
Develop Bid
Specification
Purchasing
Organization
Issue Bid
Specification to
Eligible Suppliers
Bids
Perform Perform
Commercial Bid Technical Bid
Evaluation Evaluation
Select Supplier and

Purchase Component
Figure 5-1
Supplier Selection and Bid Evaluation
5-4
Other factors, though not quality related, that should be considered may include any of the
following:
• Warranties
• Equipment purchase price and price adjustments
• Supplier experience/reputation/recognition in the nuclear industry
• Manufacturing facility location
• Ease of doing business
• Commercial terms and conditions
5.2.2 Obsolescence of the Replacement Component
Another issue that the project team should consider during the supplier selection and bid
evaluation phase of the project (and an issue not specifically addressed in existing ANSI
standards) is the potential for obsolescence of the replacement steam turbine components and
their spare parts. The project team should evaluate the technologies associated with the
replacement components and assess whether the technologies proposed by the supplier are
current and appropriate for the components. The project team should also be aware of technical
issues/concerns with the components that may have caused performance degradation in the past.
Care should be taken to select technologies and materials that are suitable for the plant
application but not necessarily excessive for the sake of being state of the art.
5.3 Purchasing Issues and Considerations
The project team should recognize that not all issues will be presented and resolved during the
bid evaluation phase and some may arise after the contract has been awarded. Ideally, the project
team should attempt to resolve issues as early in the process as possible. The issues noted below
are included in Section 2 of this report with respect to the overall project management
responsibilities of the project team but are reiterated next to emphasize the importance of
resolving them prior to the start of fabrication.
5.3.1 Licensee/Owner Schedule Demands
One of the first nontechnical issues that should typically be addressed as soon in the procurement
process as possible is the schedule for design, manufacturing, shipping, receiving, and installing
the steam turbine replacement components. All licensees/owners should have a process for
planning and scheduling work activities in the plant, but, for a steam turbine upgrade and
subcomponent replacement, the process is often much more involved and extensive than when
planning and scheduling routine maintenance activities.
5-5
5.3.2 Manufacturing Lead Times
Another major issue affecting the selection of a supplier and, subsequently, the procurement of
the steam turbine upgrade components is the manufacturing time. It is most often the case that
the manufacturer does not have the components readily available in stock and must manufacture
the components so that they are suitable for the owner’s particular application and they meet all
of the requirements in the design/procurement specification(s). A primary consideration affecting
manufacturing lead time is the criticality of each upgrade component and the resulting level of
QCs that the project team deems necessary.
The project team should consider investigating the supplier’s ability to manufacture and deliver
the steam turbine upgrade components prior to the bid phase and during the initial qualification
of the primary supplier (and possibly subsuppliers). By the time a supplier has been selected and
a purchase order is being placed, the project team should need only to confirm lead times with
the supplier to ensure that the components can be delivered to meet the demands of the site.
5.3.3 Commercial Terms and Conditions
Negotiating commercial terms and conditions is typically not within the scope of either the
design engineering or procurement engineering organizations. As such, the purchasing
organization should take the lead role in resolving these types of issues. Special commercial
considerations may include:
• Delivery, title, and risk of loss
• Warranty limitations
• Limitations of liability
• Indemnity
• Nuclear financial protection
• Transferring/shipping/routing of equipment
• Transfer of responsibility during shipment, receipt, storage/staging, and installation
• Type/schedule/frequency of document reviews
• Quantified level of oversight by the project team
• State laws
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5.3.4 Procurement Document Preparation, Review, and Change Control
The development of the procurement specification should be a continuation and refinement of

the bid specification. The procurement specification should be finalized upon completion of the
bid evaluation and qualification and selection of the supplier of the steam turbine upgrade
components. When a supplier has been selected and the supplier has offered a suitable steam
turbine upgrade design package, the detailed procurement specification can be completed.
Criterion IV of 10CFR50, Appendix B states in part:
Measures shall be established to assure that applicable regulatory requirements, design

bases, and other requirements which are necessary to assure adequate quality are suitably
included or referenced in the documents for procurement of material, equipment, and
services, whether purchased by the applicant or by its contractors or subcontractors.
In essence, what the regulation requires is that the procurement specification translate the design
requirements established by the project team into procurement requirements.
When the supplier has been selected by virtue of bid evaluation, the licensee’s/owner’s
engineering organization should refine the bid specification as needed so as to clearly
communicate necessary technical and quality requirements commensurate with system and
component design requirements and the supplier’s capabilities to meet them. In most cases, the
licensee’s/owner’s existing processes and procedures should be used to prepare, review, and
control changes of the procurement documents needed for the replacement component.
Additional guidance is provided in Section 3 of ANSI N45.2.13.
5.4 Handling Exceptions to the Purchase Order
In those cases when the purchase order is awarded to a manufacturer through competitive bids, it
is less likely that the manufacturer will take exceptions to the requirements of the purchase order.
This is because the supplier will have already had an opportunity to evaluate the licensee/owner
requirements during the bid process, and any issues regarding their ability to meet those
requirements should have already been communicated to the project team and resolved.
Technical and commercial exceptions to purchase order requirements tend to be more of a
problem when the purchase order is awarded sole source and without competitive bidding. In
these cases, the manufacturer may be seeing the owner requirements for the first time when the
purchase order is awarded. Ideally, there will not be exceptions; but in reality, the project team
should be prepared to address them in a timely manner.
5.4.1 Technical Exceptions
The licensee’s/owner’s design and procurement engineering organizations should take the lead in
resolving technical exceptions to the purchase order. In some cases, input from O&M may be
helpful in resolving a technical exception and reaching a feasible solution to the issue. Under no
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circumstances should a purchasing agent or nontechnical personnel attempt to resolve a technical

exception to the purchase order. Instead, the issue should be directed to the appropriate
engineering organization.
Although the project team should strive to prevent exceptions to purchase order requirements
through good planning and supplier selection techniques, in most cases, the licensee’s/owner’s
existing process for resolving purchasing issues should be used as needed. Technical exceptions
that may arise during the specification and procurement of steam turbine upgrade components
could include the manufacturer’s inability to meet the following requirements:
• Steam turbine component performance requirements
• Steam turbine component technical requirements
– Requirements described in industry codes and standards
– Physical and chemical material properties, in accordance with American Society for
Testing Materials (ASTM) and/or ASME
– Dimensional requirements, including tolerances
• Special manufacturing/fabrication processes
• Shipping, packaging, and storage requirements
• Request for spare and replacement part information
• Means of design verification
• Shelf life requirements, if applicable
• In-storage maintenance requirements
5.4.2 Commercial Exceptions
The licensee’s/owner’s purchasing organization should take the lead in resolving commercial
exceptions to the purchase order. In some cases, input from engineering, QA, and O&M may be
helpful in resolving a commercial exception and reaching a feasible solution to the issue.
As noted in the preceding section, the project team should strive to prevent exceptions to
purchase order requirements through good planning and supplier selection techniques, and in
most cases, the licensee’s/owner’s existing process for resolving purchasing issues should be
used as needed. Commercial exceptions that may arise during the specification and procurement
of a major plant component could include the manufacturer’s inability to meet any of the
requirements listed in Section 5.3.3 of this report.
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5.5 Acceptance Planning
Ideally, acceptance planning should begin during the specification and procurement of the
replacement component. This affords the project team an opportunity to plan the types of
verifications and their schedules with the selected manufacturer (and third-party organizations, if
needed) in advance of final design and fabrication. When the supplier and final steam turbine
upgrade design have been selected, however, the project team should finalize the scope and
frequency of acceptance activities, including any of the following:
• Additional or ongoing audits of organizations in the supply chain
• Source verification activities (witness and hold points)
• Receipt test/inspection activities
• Post-installation tests/inspections
Section 10 of ANSI N45.2.13 states in part that the licensee shall:
Establish the method of acceptance of an item or service being furnished by the supplier.
Prior to offering the item or service for acceptance, the supplier shall verify that the item
or service being furnished complies with the procurement requirements. Where required
by code, regulation or contract requirement, documentary evidence that items conform to
procurement documents shall be available at the nuclear power plant site prior to
installation or use of such items regardless of acceptance methods.
When upgrading a major plant component such as a steam turbine, it is recommended that all of
the acceptance activities listed previously be used to some extent due to the typical complexity
and safety significance of the item. Of these methods, any of which may be chosen by the project
team, source verification involves acceptance during the fabrication of the replacement item and
is discussed in more detail in this section of the report.
Section 6 of ANSI N45.2.13 states in general that a licensee should retain the responsibility of
monitoring and evaluating supplier performance to the specified requirements of the
procurement document. The methods provided may include the following:
• Establishing an understanding between the project team and the supplier of the provisions
and specifications of the procurement documents
• Requiring the supplier to identify planning techniques and processes to be used in fulfilling
procurement document requirements
• Reviewing documents that are generated or processed during activities fulfilling procurement
requirements
• Identifying and processing necessary change information
• Establishing an exchange method of document information between the project team and the
supplier
5-9
Depending on the complexity or scope of the steam turbine upgrade, the project team should
initiate pre- and post-award activities. These activities may take the form of meetings or other
forms of communication to establish the following:
• An understanding between the project team and the supplier of the upgraded steam turbine
subcomponents
• The intent of the project team in monitoring and evaluating the supplier’s performance
• The planning, manufacturing techniques, tests, inspections, and processes to be used by the
supplier in meeting procurement requirements
Project team notification points, including hold and witness and hold points, should be identified
and documented based upon mutual agreement between the supplier and the project team. These
activities should be implemented as early as practicable in the procurement process. The depth
and necessity of pre- and post-award activity depends on the uniqueness, complexity,
procurement frequency with the same supplier and past supplier performance for the specific
component covered by the procurement document.
5.6 Validity of Supplier Documentation and Certificates
5.6.1 Supplier Certification
After a supplier’s QA program capabilities and implementation have been evaluated and found
to be acceptable and contractual terms have been established, the project team may request
certification from that supplier as objective evidence that the specified QCs were implemented
and that purchase requirements have been met.
Section 4 of this report discusses the types of quality requirements that may be specified for a
replacement component and the types of documentation that are typically furnished by the
manufacturer/supplier.
5-10
ANSI N45.2.13 Section 10 provides the following guidance regarding the receipt of a supplier’s
Certificate of Conformance:
Where not precluded by other requirements, documentary evidence may take the form of
written certificates of conformance which identify the requirements met by the items.
Where certificates of conformance are used, the following minimum criteria shall be met:
a. The certificate should identify the purchased material or equipment, such as by the purchase
order number.
b. The certificate should identify the specific procurement requirements met by the purchased
material or equipment, such as codes, standards, and other specifications. This may be
accomplished by including a list of the specific requirements or by providing, on-site, a copy
of the purchase order and the procurement specifications or drawings, together with a suitable
certificate. The procurement requirements identified should include any approved changes,
waivers, or deviations applicable to the subject material or equipment.
c. The certificate should identify any procurement requirements that have not been met, together
with an explanation and the means for resolving the nonconformances.
d. The certificate should be attested to by a person who is responsible for this quality assurance
function and position are described in the purchaser’s or supplier’s quality assurance
program.
e. The certification system, including the procedures to be followed in filling out a certificate
and the administrative procedures for review and approval of the certificates, should be
described in the purchaser’s or supplier’s quality assurance program.
f. Means should be provided to verify the validity of supplier certificates and the effectiveness
of the certification system, such as during the performance of audits of the supplier or
independent inspection or test of the items. Such verifications should be conducted by the
purchaser at intervals commensurate with the supplier’s past quality performance.
Receipt of supplier documentation in general, and a Certificate of Conformance in particular,

should be an integral part of the acceptance plan for the upgraded steam turbine components.
However, acceptance of an upgraded steam turbine component based solely on the receipt of
supplier documentation is not recommended. Instead, the project team should consider using all
of the means available to ensure that the item is conforming to its design requirements and will
perform all of its design functions. These acceptance methods, as detailed in ANSI N45.2.13,
should be considered initially during the development of the specification, during the bid
evaluation, and continuing throughout fabrication, receipt, and installation.
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5.6.2 Supplier Documentation
The project team’s engineering personnel should interface closely with the supplier to ensure that
the design is suitable for the upgraded component’s intended application. Design interface
should result in a qualified and suitable final component design, and the supplier should be
required to furnish the documents necessary to demonstrate the suitability of the design as well
as supporting information regarding its installation, operation, and maintenance. These
documents, which constitute design outputs from the supplier and typically requested by the
project team in the final procurement specification, may include any of the following:
• Supplier drawings, procedures, and specifications
• Supplier instructional manuals (including maintenance recommendations)
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6
FABRICATION ISSUES
6.1 Establishing Witness and Hold Points
Witness and hold points should be established to ensure that the project team has an opportunity
to witness and verify the conformity of upgraded steam turbine components to their respective
design requirements as the components are being manufactured, fabricated, and assembled.
Witness and hold points communicate the following to the manufacturer:
• What attributes of the component need to be verified before fabrication resumes
• When in the manufacturing process those critical attributes can most effectively be verified
After the witness and hold points are determined and the critical attributes to be verified are
identified, the project team and the supplier should coordinate how best to verify the conformity
of the product. This may involve witnessing a test, inspection, or special manufacturing process
or examining selected programmatic QCs.
6.2 Manufacturing Surveillance
When planning requires licensee/owner source verification, it should be implemented to monitor,

witness, or observe manufacturing at the organization in the supply most appropriate to evaluate
the activities. Source surveillance may require the assignment of personnel to a supplier’s
facility, which may necessitate the use of inspection personnel external to the utility’s
engineering or QC organizations.
Manufacturing surveillance is a type of source verification that affords the project team an
opportunity to observe a special process that renders or imparts a critical attribute to the
upgraded steam turbine component. Processes that are typically observed may include any of the
following:
• Welding
• Assembling
• Insulating
• Coating
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Fabrication Issues
• Heat treating
• Machining
• Testing
The level of manufacturing surveillance should be based on the following factors:

• Uniqueness of the upgraded component – Unique and highly specialized components will
typically require more surveillance to ensure that the unique design features conform with the
established, qualified design.
• Supplier capabilities/certification – Adequate supplier certification/capabilities can negate the
need for additional surveillance by the project team. Conversely, if the supplier’s capabilities
are lacking, the project team should consider increased surveillance activities to ensure that
the component conforms to its design requirements.
• Utility’s participation – The project team has the option of using contract employees to
perform this activity if it is cost beneficial.
• Safety significance/criticality, functions, and reliability of the replacement components.
6.3 Witnessing Tests and Inspections
Similar to manufacturing surveillance, source inspection should be implemented in accordance

with plans to perform inspections, examinations, or tests at predetermined points. Source
inspection may require the assignment of personnel to a supplier’s facility. The following types
of tests and inspections should be considered when replacing a major plant component:
• Material hardness
• Tensile tests
• Hydrostatic tests
• Leak rate test
• Material chemical content verification
• Calibration
• Operability
• Pressurization
6.3.1 Establishing Acceptance Criteria
Prior to witnessing or, in some cases, actually conducting the test or inspection, the project team
should coordinate with the manufacturer to establish the acceptance criteria for the activity. In
essence, the acceptance criteria for a given inspection/test are the manufacturer’s design criteria
with some allowable tolerance ranges. The test/inspection should verify that the manufactured
component or part thereof is in fact conforming to its required design values.
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Fabrication Issues
6.3.2 Nondestructive Examination
The project team should be aware of NDE required either by ASTM material standards or other
industry material standards used to fabricate the upgraded steam turbine components.
Additionally, the project team should determine which, if any, of these examinations and
evaluations should be witnessed during source inspection. The scope of the NDE will vary
among components, and requirements should be specified in the procurement specification as
discussed in Section 4 of this report. Typical NDE witnessed by the project team during the
replacement of a major plant component may include any of the following:
• Ultrasonic calculations
• Ultrasonic applications
• Eddy current testing
• Liquid penetrant testing
• Magnetic particle testing
• Radiographic applications
Additional guidance regarding nondestructive examination and evaluation is provided in

numerous EPRI technical reports and source documents.
6.3.3 Shop Testing/In-Process Testing and Inspection
In many cases, with the design and fabrication of a large, complex steam turbine component, the
manufacturer performs numerous in-process tests as the component is being assembled. In most
cases, these tests and inspections are performed at the manufacturer’s facility, thus the
terminology shop testing is often used to refer to these types of verification activities. The
in-process test or inspection is a means for the manufacturer to verify the acceptability of certain
attributes of the upgraded component that may otherwise be difficult or costly to verify after the
entire steam turbine is reassembled. They may also be performed to verify the acceptability
and/or operability of a discrete assembly or subcomponent prior to it being installed in the steam
turbine. Depending on the function of the discrete assembly or subcomponent and its safety
significance to the overall performance of the steam turbine, the project team should establish
means to verify some or all of these verification activities as the upgraded component is being
installed. Examples of in-process testing and inspections include verification of the following:
• Dimensions, tolerances, and fits between mating parts and subassemblies
• Configuration of new components to ensure correct match-up in the field to mating
equipment
• Testing of attributes resulting from special manufacturing processes
• Operability of a subcomponent or assembly
• Input/output values
• Electrical continuity
6-3
Fabrication Issues
One example of shop testing that is critical in large steam turbine procurement relates to
verifying that tuned LP rotor blades have proper frequencies to avoid resonance vibration and
subsequent fatigue damage in operation. Typically, manufacturers approach this at two levels:
• Testing of the first production rotor assembled in a spin-pit test facility with appropriate
instrumentation to detect blade frequencies
• Production testing of 100% of blades in a test fixture designed to simulate root fixity (and
comparison of those data against an acceptable range)
Plant owners need to ensure that both types of tests are conducted on tuned blades and that there
is an opportunity to review the spin-pit test results. Also, the records of all individual blade
frequency test results should be considered part of the documentation that accompanies the
component delivered. This must be negotiated prior to the award of a contract to avoid the
manufacturer later taking the position that the data are proprietary if a blade failure occurs and an
independent root-cause analysis is necessary.
6.4.4 Final Product Testing
Final product testing may be required by either the project team or an industry code/standard as a
means to ensure that the upgraded component performance meets established design
requirements prior to being released for shipment. Final product testing may not be feasible for
all steam turbine upgraded components and may not be applicable. The project team should
coordinate with the manufacturer and should be fully aware of the degree to which the upgraded
turbine will be assembled and tested before leaving the manufacturing facility.
In lieu of final product testing prior to shipment, the project team may opt for testing after the
upgraded component is installed in the steam turbine. When final product testing is deemed
necessary, the project team should clearly specify the type of test and applicable codes/standards
by which the test will be conducted in the final procurement specification.
6.5 Handling Manufacturing Nonconformances
ANSI N45.2.13 Section 8 states in general that the project team and the supplier should establish
and document measures for the identification, control, and disposition of items that do not meet
procurement document requirements. The requirements for handling nonconformances are not
limited to nonconformances discovered after receipt of the item, and, as such, the requirements
would apply for any nonconformances discovered during the manufacture of any upgraded steam
turbine components as well.
The project team should establish the most appropriate process or procedure for handling
nonconformances discovered with the steam turbine component. Nonconforming items should
typically not be released for shipment, with expectations that the item will be corrected after its
receipt on site.
6-4
Fabrication Issues
Nonconformances should be handled in accordance with the following sequence of actions:

1. Review the type and extent of the nonconformance.
2. Notify the project team of the nonconformance (if it is occurring without the owner present).
3. Accept the disposition of the nonconformance (acceptance by the owner).
4. Verify that the nonconformance was dispositioned properly.
5. Maintain records, as appropriate.
6.6 Obtaining Required Documentation
As noted in Section 4 of this report, the project team should specify the types of documentation
needed to ensure that technical and quality requirements have been met by the manufacturer and
other organizations in the supply chain, as applicable. Documentation should be considered a
tool in the verification of an item’s technical adequacy and quality compliance but should not be
used without confirmation of its validity (nuclear licensees should reference EPRI NP-5652,
ANSI N45.2.13, or ANSI N45.2.2).
The types of supplier documentation typically specified should include, as applicable, the
following:
• Supplier drawings, procedures, and specifications
• Supplier instruction manuals
• Personnel certifications
• QA manuals
• Certificates of Conformance/Compliance
The owner’s QA organization should typically be responsible for ensuring that all of the
documentation specified has been received. Receipt may take place during fabrication, during
final product testing, or during receipt of the steam turbine upgraded components. In some cases,
documentation specific to a particular assembly or subcomponent may be received separately,
based on requirements specified in the design/procurement specification.
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Fabrication Issues
6.7 Cleanliness Requirements and Special Controls
The project team should determine if there are any cleanliness requirements exceeding those
customary for fabrication of the steam turbine components or those requirements already
included in related industry codes or standards.
Criterion IX of 10CFR50, Appendix B states in full:
Measures shall be established to assure that special processes, including welding, heat
treating, and nondestructive testing, are controlled and accomplished by qualified
personnel using qualified procedures in accordance with applicable codes, standards,
specifications, criteria, and other special requirements.
As such, the project team should ensure that if special processes have been specified and are
necessary to impart, render, or control critical attributes of the steam turbine upgraded
components, the appropriate and correlating special QCs are in place to ensure that those
processes have been implemented properly. Again, if there are special QCs, the owner’s QA
organization should typically be responsible for ensuring that those activities are implemented by
the steam turbine manufacturer or other organization in the supply chain, as applicable.
6-6
7
SHIPPING AND HANDLING ISSUES
ANSI N45.2.2 Section 4 covers the requirements for the loading and shipment of items that
would be applicable for a steam turbine upgrade project. The standard describes environmental
protection during transit, procedures to minimize damage in transit, precautions required when
handling items during loading and transit, and identification and inspection of overseas
shipments.
7.1 Determining the Optimum Shipping Method
When upgrading a major plant component such as a steam turbine, the method(s) of shipping the
upgraded components from the point of manufacture to the site should be evaluated and
determined prior to or during the manufacture of the items. The following key issues should be
considered:
• Cost and schedule constraints
• Physical size, weight, and overall configuration of the replacement components (large size
may prohibit the use of some transportation means)
• Types of shipping methods (for example, truck, railway, ship, aircraft, or barge)
• Components’ susceptibility to damage during shipment
• Manufacturer’s packaging of the components
In general, the mode of transportation used should be consistent with the protection classification
of the item and with the packaging methods employed. Section 4.2 of ANSI N45.2.2 provides
additional guidance when selecting and using open carriers, closed carriers, and special
shipments.
7-1
Shipping and Handling Issues
7.2 Transportation Routing
ANSI N45.2.2, Section 4.2.2 states in general that the conveyance used for transport should be
certified to be structurally adequate to take the loads imposed during loading, while traveling,
and during unloading. Prior to shipment, the project team should ensure safe transit by
investigating the route. The following issues should be considered when transporting upgraded
steam turbine components:
• Cost and schedule constraints
• Physical size, weight, and overall configuration of the replacement component (large size
may preclude the use of certain routes)
• Component’s susceptibility to damage during shipment
• Modifications or upgrades that may be needed
– Replacing railroad ties or rails
– Improving the load-bearing capacity of roadbeds or bridges
– Deepening or widening waterways to accommodate the load
• Need for escorts (The use of escorts may be specified to accompany shipments, when
additional surveillance is required during transit of certain items.)
7.3 Packaging for Shipping
The need for physical protection of items due to movement or contact with other items is much
more of a concern when the item is in transit than when the item is in storage or after it has been
installed in the plant. Therefore, a reduced level of packaging may be adequate when the
component is staged on site. Consideration should be given to how much of the packing
materials should be discarded when the upgraded component is staged for installation and
protection from physical damage is no longer a concern. In some cases, the packaging used
during shipping has to be removed in order to move the item into place and maneuver it through
the access route established in the plant.
The following issues should be considered when determining the type and extent of packaging
for upgraded steam turbine components during shipping:
• The manufacturer’s recommended means for packaging the component to provide adequate
protection during shipment
• Physical size, weight, and overall configuration of the upgraded component
• Component’s susceptibility to damage during shipment
• Security requirements and inspections at points of shipment, entry, and/or receipt
7-2
One area of particular consideration in selecting packaging for replacement of steam turbine
components is corrosion protection. Precaution should be taken to avoid contact with humid air
or creating a situation where condensation occurs on the rotor surfaces, especially in areas near
salt water. Typically, rotors are wrapped in airtight packaging with desiccant to remove moisture.
7.4 Need for Sensing/Monitoring Devices During Shipment
ANSI N45.2.2, Section 4.2.3 states in part:
Use of impact recording meters shall be specified on shipments of heavy or relatively

large items incorporating delicate factory-installed instrumentation. Meters, when
specified, shall be installed prior to loading (to record any rough handling during
loading). Procedures shall be established to interpret recorded data and to thoroughly
check the integrity of an item when there is evidence of rough handling. A notice that
impact recording meters are being used shall be prominently displayed. Special recording
meters with operating time limits greater than the expected transit time shall be specified
or, if the expected transit time exceeds the operating time limit of the recorders being
used, provisions shall be made to service the meters during transit.
Given this guidance, the project team should consider the following issues/factors when
determining the need for sensing/monitoring devices during shipment of steam turbine
replacement components:
• Physical size and weight of the component
• Type and fragility of instrumentation incorporated on the component
• The component’s susceptibility to damage
• The mode(s) of transportation being considered
7.5 Customs Requirements and Homeland Security Issues
Section 4.5 of ANSI N45.2.2 provides guidance regarding shipments from countries outside the
United States. Care should be taken to ensure that current homeland security requirements are
also met. The following issues should be considered when transporting steam turbine
replacement components from overseas:
• Special requirements for overseas shipment required by either the United States or the
country of origin
• Inspections required at point of shipment
• Inspections required at point of entry
• Special packaging needed to accommodate inspections during transport
• Requirements for special identification and markings
7-3
• Mode(s) of transportation being used and requirements specific to those modes

• Requirements for special permits or documentation
7.6 Lifting/Handling Issues
When lifting and handling a large replacement component for a steam turbine, the following
issues should be considered:
• Loading – The weight, lifting points, or center of gravity indicated on the crate, skid, or
package by the shipper should be used to ensure proper handling during loading, transferring
between carriers, and unloading.
• Rigging – Rigging requirements should be established by the project team prior to transport
and handling of the manufactured component. Care should also be taken to ensure that
carbon steel rigging equipment does not come in direct contact with stainless steel—except
when attached to lifting lugs, eyes, or pads—in order to avoid surface damage. Many
OEMs/suppliers are obtaining components from international sources, and thus most are
using metric units for sizing rigging and lifting components. Special care should be taken not
to mismatch U.S./English unit-sized components to metric unit-sized components. Users
should account for these differences for future maintenance activities by addressing these
issues in the plant lifting and rigging program.
• Handling precautions – Austenitic stainless steel and nickel-based alloy materials should be
handled in such a manner that they are not in contact with lead, zinc, copper, mercury, or
other low-melting elements, alloys, or halogenated materials.
• Package/preservation coating – Packages and/or preservative coatings should be visually
inspected after loading, and damaged areas should be repaired prior to shipment. Items
shipped with desiccants should be inspected after loading to ensure that sealed areas are
intact.
• Sealed openings – Sealed openings should be visually inspected after loading to ensure that
closures are intact. Materials used for resealing should be in accordance with ANSI standards
or owner procedures.
• Stacking – Where special care is deemed necessary to avert damage, written instruction
covering the location and stacking limits of the crates or boxes on the transport vehicle
should be specified. These instructions should be marked on the container.
• Theft and vandalism – Precautions should be taken to minimize the possibility of theft and
vandalism during the shipment of the component.
• Bracing – The type of bracing and tie-down methods to be used with the mode of
transportation selected for special shipments of replacement components should be specified
by the project team.
EPRI report 1007914, Lifting, Rigging, and Small Hoist Usage Program Guide, and 1009706,
Rigger’s Handbook, should be used as references for establishing and applying appropriate
lifting and handling requirements.
7-4
8
RECEIPT INSPECTION ISSUES
As noted in Section 5 of this report, receipt inspection should be an integral part of the
acceptance plan when replacing a major plant component. The project team should use care
when developing a receipt inspection plan to ensure that appropriate physical and performance
attributes are adequately verified and that a steam turbine replacement component is not
damaged in any way during the conduct of receiving activities. ANSI N45.2.13 Section 7 states
in part:
When planning requires (licensee) receipt inspection, it shall be implemented and

coordinated with source verifications performed. During receiving inspection, emphasis
shall be placed on assuring that items have not sustained damage in shipment that would
influence subsequent fabrication, construction, installation or end use. Sampling may be
utilized during receiving inspection when conducted in accordance with established
procedures or recognized standards. These measures shall also include provisions for
dispositioning (for example, accept, reject, or hold) and handling of items received and
services performed.
It should be used to supplement the QA and verification activities that have taken place prior to
and during the manufacture of the component and should be performed to verify that the supplier
has met all requirements of the purchase order.
8.1 Developing Appropriate Inspection Attributes
The inspection attributes may be instructions to verify the receipt of certain supplier
documentation, which typically should have been described in the final procurement
specification. In most cases, the furnished supplier documentation provides objective evidence
that certain physical and/or performance attributes of the steam turbine replacement component
have been verified as conforming to the manufacturer’s design. When certain component
attributes have not been verified prior to receipt or in cases where additional assurance is needed
to verify the conformity of a particular component attribute, the project team may opt to verify a
particular physical or performance attribute of the component through a test or inspection.
8.1.1 Reviewing Documentation Received
ANSI N45.2.13 Section 7 states in part:
Receiving inspection measures shall include provisions for receiving documentation

(such as drawings, certifications, test results and other materials) offered as objective
evidence in satisfaction of requirements.
8-1
Receipt Inspection Issues
8.1.2 Testing/Inspecting Component Attributes
When receiving activities are used to verify either physical and/or performance attributes of the
steam turbine components (that have not already been verified by the supplier through an audit
or source verification), the project team must establish the appropriate acceptance criteria prior to
verifying the component attribute(s). These acceptance criteria should represent the
manufacturer’s design criteria for the item and include tolerances as allowed by the item’s
design.
8.1.3 Testing/Inspecting Supporting/Auxiliary Items
In some cases, the project team may be responsible for testing/inspecting supporting or auxiliary
items, which may include any of the following:
• Spare/replacement items for the steam turbine component
• Tools needed to install the steam turbine component
• Installation materials (such as bar stock, shims, and blocks)
• Consumables used during installation (such as weld rods, lubricants, and rags)
Similar to testing/inspecting the steam turbine component itself, if receiving activities are used to
verify physical and/or performance attributes of supporting or auxiliary items, the project team
should first establish the appropriate acceptance criteria. These acceptance criteria should
represent the supplier’s/manufacturer’s design criteria for the item and should typically include
tolerances.
8.2 Site-Specific Testing and Inspection Requirements
Depending on site-specific procedures and requirements, there may be cases where special
testing and inspection requirements must be met when procuring components for a steam turbine
upgrade. Typically, these special requirements should be established through close coordination
between the engineering and QA organizations. The special testing and inspections requirements
should be determined as early in the procurement process as possible.
8-2
9
STORAGE AND STAGING ISSUES
9.1 Storage Level Determination and Requirements
Nuclear licensees have used ANSI N45.2.2 guidance for many years in establishing the
necessary controls to package, ship, receive, store, and handle incoming components and
replacement parts. Section 2.7 of the ANSI standard provides detailed guidance on how to
classify a procured item with respect to protective measures to prevent damage, deterioration, or
contamination of the item. To assist the user of this report, the following excerpt is provided
regarding the categorization of components that may be replaced at a nuclear power plant. ANSI
N45.2.2 Section 2.7 states in part:
Level A – Items classified to Level A are those that are exceptionally sensitive to
environmental conditions and require special measure for protection from one or more of
the following effects: temperatures outside required limits, sudden temperature changes,
humidity and vapors, gravitational (g) forces, physical damages, and airborne
contamination (such as, rain, snow, dust, dirt, salt spray, and fumes).
The following shall be used as a guide for classifying items intended for this level of
classification:
(1) Special electronic equipment and instrumentation.
(2) Special materials, such as chemical, that are sensitive to environment.
(3) Special nuclear material (fuel) and sources. The requirements of the NRC fuel license and
conditions and other governmental agencies shall be met.
Level B – Items classified to Level B are those that are sensitive to environmental
conditions and require measures for protection from the effects of temperature extremes,
humidity and vapors, acceleration forces, physical damage, and airborne contamination
and do not require special protection required for Level A items.
classification:
(1) Instrumentation
(2) Electrical penetrations
(3) Batteries
(4) Welding electrode and wire
(5) Control rod drives
9-1
Storage and Staging Issues
(6) Motor control centers, switchgear and control panels

(7) Motors and generators
(8) Precision machined parts
(9) Spares, such as gaskets and O-rings
(10) Air handling filters
(11) Computers
Level C – Items classified to Level C are those that require protection from exposure to
the environment, airborne contaminants, acceleration forces, and physical damage.
Protection from water vapor and condensation is not as important as that for Level B
items.
classification.
(1) Pumps
(2) Valves
(3) Fluid filters
(4) Reactor materials
(5) Compressors
(6) Auxiliary turbines
(7) Instrument cable
(8) Refueling equipment
(9) Thermal insulation
(10) Fans and blowers
(11) Cement
Level D – Items classified to Level D are those that are less sensitive to the environment
than Level C. These items require protection against the weather, acceleration forces,
airborne contamination, and physical damage.
classification.
(1) Tanks
(2) Heat exchangers and parts
(3) Accumulators
(4) Demineralizers
(5) Reactor vessel
(6) Evaporators
(7) Steam generators
9-2
(8) Pressurizer
(9) Piping
(10) Electrical cable
(11) Structural items
(12) Reinforcing steel
(13) Aggregates
EPRI report TR-107101, Packaging, Shipping, Storage, and Handling Guidelines for Nuclear
Power Plants, provides additional guidance (for example, component-specific guidance) that
may be helpful when upgrading the steam turbine.
9.2 On-Site Storage/Staging Capabilities
As noted in the previous section, nuclear licensees have used ANSI N45.2.2 guidance for many
years in establishing the necessary controls for storing incoming components and replacement
parts. During this time, however, licensees shifted their capabilities more toward the long-term
storage of spare and replacement parts and less toward the short-term storage/staging of large
components that were originally used to construct the plant. Now, as the need to replace certain
large steam turbine components integral to an upgrade increases, licensees/owners should
evaluate means to once again provide adequate storage/staging facilities for these larger pieces of
equipment.
ANSI N45.2.2 Section 6 provides guidance for establishing appropriate storage levels and
categorizing them in accordance with the four levels discussed in the previous section. To assist
the user of this report, ANSI N45.2.2 states in part:
(1) Level A items shall be stored under special conditions similar to those described for Level B
items but with additional requirements such as temperature and humidity control within
specified limits, a ventilation system with filters to provide an atmosphere free of dust and
harmful vapors, and any other appropriate requirements.
(2) Level B items shall be stored within a fire resistant, tear resistant, weathertight, and well-
ventilated building or equivalent enclosure. Precautions shall be taken against vandalism.
This area shall be situated and constructed so that it will not be subject to flooding: the floor
shall be paved or equal, and well-drained. Items shall be placed on pallets or shoring to
permit air circulation. The area shall be provided with uniform heating and temperature
control or its equivalent to prevent condensation and corrosion. Minimum temperature shall
be 40 °F (4 °C) and maximum temperature shall be 140 °F (60 °C) or less if so stipulated by a
manufacturer.
9-3
(3) Level C items shall be stored indoors or in equivalent environment with all provisions and
requirements as set forth in Level B items, except that heat and temperature control is not
required.
(4) Level D items may be stored outdoors in an area marked and designated for storage, which is
well-drained, preferably gravel covered or paved, and reasonably removed from the actual
construction area and traffic so that possibility of damage from construction equipment is
minimized. Items shall be stored on cribbing or equivalent to allow for air circulation and to
avoid trapping water.
The project team should also consider the following issues related to the storage/staging of steam
turbine components:
• Structural loading capacity of storage/staging areas
• Division of responsibility among organizations in the supply chain and utility organizations
involved in the storage/staging of the steam turbine components to address issues such as:
– Lighting
– Electrical power
– Fire protection
– Compressed air supply
9.3 In-Storage Maintenance Activities
Depending on the length of time the steam turbine component will be in storage or staged prior
to installation, the project team should determine if there are any in-storage maintenance
activities that are needed. The project team should coordinate with the manufacturer to determine
what requirements may apply and how often these activities should be performed.
EPRI report TR-107101, Packaging, Shipping, Storage, and Handling Guidelines for Nuclear
Power Plants, stresses the need to consider in-storage maintenance requirements as a factor
when determining the most appropriate packaging, shipping, storage, and handling of items.
In-storage maintenance activities that may be applicable for a replacement component may
include the following:
• Rotation of shafts
• Lubrication of mating parts, gears, and cams
• Application of corrosion inhibitor
• Recharging inert gaseous blanket
9-4
9.4 Licensee/Owner Lifting and Handling Capabilities
One of the major considerations when replacing steam turbine components during an upgrade is
how the components will be physically moved from their mode of transportation to the
storage/staging area. In many cases, special lifting and rigging is necessary to safely conduct the
move. Detailed guidance is provided in EPRI report 1007914, Lifting, Rigging, and Small Hoist
Usage Program Guide, and should be used as a basis for determining the most appropriate
lifting/handling methods, developing a lift plan, and safely moving the equipment into its
storage/staging area.
The purpose of EPRI report 1007914 is to provide comprehensive guidance to a wide range of
plant personnel associated with lifting and rigging activities. At the user level, the report
provides personnel in power plants with guidelines on safe and effective lifting, rigging, and
small hoist usage practices. At the management level, the report provides guidance for
establishing and/or enhancing a safe and effective lifting and rigging program. As such, the
report provides guidance for developing and implementing programmatic elements such as
personnel training and certification and developing the necessary program documents and
procedures.
9.5 Materials Management
A primary issue that should be addressed by the project team is ensuring that the steam turbine
components and spare or replacement items are controlled and tracked in accordance with
existing site-specific processes. In most cases, this will involve ensuring that each component
has been assigned the correct equipment identifier and that the spare/replacement items have
been assigned appropriate unique stock codes or identifiers.
Care should also be taken to ensure that inventory unique to any replaced components is purged
from the system and disposed of in an acceptable manner.
9-5
10
INSTALLATION ISSUES
10.1 Pre-Installation Requirements
10.1.1 Determining the Optimum Access Route
Prior to installing steam turbine components, the project team should evaluate the possible access
routes available to move each component from its storage/staging area to its final plant location.
The evaluation should consider the following factors:
• Need for any special lifting/handling equipment
• Impact of routing on plant operations, if applicable
• Impact of routing on existing plant equipment and the extent to which plant modifications
may be required to physically move the replacement component into place
• Personnel safety and ALARA considerations (for nuclear licensees)
• Physical space limitations and known interferences
• Ability to change the physical orientation of the steam turbine component during the routing
• Susceptibility of damage to the steam turbine component during the routing
10.1.2 Establishing Lifting/Rigging Requirements
EPRI report 1007914, Lifting, Rigging, and Small Hoist Usage Program Guide, and 1009706,
Rigger’s Handbook, provide generic processes for establishing lifting/rigging requirements that
would be very appropriate for moving a steam turbine replacement component. Report 1007914
states that the first step in the generic process is to ensure that a technical person or group of
technical personnel has adequately planned and evaluated the lift. Under no circumstances
should a lift be conducted relying solely on one individual’s “skill of the craft” knowledge or
experience. As such, the verification of personnel qualification and certification, when
appropriate, is inherent for effectively implementing the process described in this section.
10-1
Installation Issues
The report stresses that to ensure safe and effective lifting, each lift should be planned and
evaluated as needed. Typically, the evaluation should minimally include the following elements:
1. Analysis of the load
2. Determination of the weight of the load
3. Determination of the load’s center of gravity
4. Establishing of the means to stabilize the load
5. Consideration of clearances available and the load path
6. Consideration of the past history of similar lifts and lessons learned
Each step of the process is detailed in the report and should be used when replacing a major plant
component.
10.1.3 Developing a Lift Plan
The lift plan may vary depending on the complexity of the lift, the weight of the load, the
criticality of the equipment being lifted, or the schedule. Lift plans can vary in the level of detail
contained in the plan, the degree to which the utility’s engineering organization is involved in its
development, and the degree to which the plan can be used generically. Some lift plans are
applicable to only one lift, whereas some are generic for a particular type of lifting/rigging
equipment. Lift plans can be grouped into the following types:
• Pre-engineered lift plans with significant engineering involvement
• Pre-planned lifts that are primarily driven by the scope of the work order
• Field-planned lift plans that are developed in the field by craft personnel
• At-the-job lift plans developed solely for one particular lift
The lift plan may constitute a checklist and include sketches or drawings as a means to convey
the conduct of the lift.
10.2 Interferences
Ideally, physical interferences should have been identified during the design phase of the project
when all interface points were identified and evaluated. The project team should consider the use
of optical scanning technology and three-dimensional modeling as tools to assist in identifying
and addressing physical interferences in and around the steam turbine.
However, there may arise cases where the physical layout of the plant does not match drawings,
and as such, an interference may result. In these cases, the project team should implement
existing procedures for resolving nonconformances and, depending on the severity of the
interference, coordinate resolution with various engineering disciplines and organizations as
necessary. There may also be cases when a process interference arises, at which time the project
10-2
Installation Issues
team should coordinate with affected engineering disciplines to determine the extent of the
condition and the scope of modifications needed to resolve the interference.
10.3 Expertise Needed to Install the Equipment
As noted in Section 4 of this report, the project team should determine, during the
design/specification phase of the project, the organization best suited to install the replacement
component. In some cases, the manufacturer of the steam turbine components will also be the
installer. When this is the case, the specification provided to the manufacturer may include both
procurement and installation requirements. Work done in this manner is often referred to as a
design/procure/install contract or a turnkey contract. In these cases, the project team typically
can delegate the authority to the manufacturer to provide the craft labor and technical skills
needed to complete the entire installation. Any shortfalls in personnel availability, expertise, or
certification should be addressed by the project team and met using alternative sources.
10.4 Sequence of Installation Steps
The sequence of installation steps should be closely coordinated between the project team, the
component manufacturer, and the installer (if different from the manufacturer). The sequencing
should begin with the safe shutdown of the steam turbine system because the upgrade is planned
to begin during a system outage. The sequencing should also include the following:
1. All necessary demolition work of existing equipment
2. Interface disconnects, protection, and rerouting, as needed
3. Design modification of existing SSCs to accommodate the new component
4. Handling of the new component as it is moved through its access route
5. Component placement
6. In situ assembly
7. Interface reconnections
8. In-process testing and inspection
9. Integration of activities into overall outage/work schedule (a readiness review is
recommended to ensure that the sequence is feasible)
10.5 Special Tools Required
The project team should have identified any needs for special tools during the installation of the
steam turbine replacement components when the component and equipment manufacturers were
initially being reviewed and selected. In fact, special tools may have been a key criterion in
selecting the type or model of components and the equipment manufacturer(s) as bids were being
evaluated.
10-3
Installation Issues
During installation, the project team should ensure that the appropriate tools are available, have
been inspected, are being used properly, are calibrated, and are being used by qualified/certified
personnel. The use of digital photography can be useful during the installation and assembly of
turbine upgrade components.
10.6 Special Quality Control Requirements
Another issue related to steam turbine upgrades is the need for special QCs during the
installation phase. In most cases, the project team should coordinate QC activities with the QA
organization during the design and specification phase of the project. In some cases, industry
codes and standards will dictate that certain QCs be applied during the installation. The
equipment manufacturer and the installation contractor may also prescribe certain QCs.
As noted in Section 5 of this report, the project team should address the need for QCs during the
development of the installation specification. Typical activities that may require QCs and
documented evidence of satisfactory completion include the following:
• NDE
• Witness and hold points for inspection and testing during the installation process
• In-process testing required as the replacement component is being installed
10.7 Personnel Safety/ALARA Issues
The project team should ensure that personnel safety issues (and ALARA issues for nuclear
licensees) addressed in the installation specification are mitigated during the installation of the
steam turbine replacement components. Typical concerns that may be applicable when upgrading
a steam turbine include the following:
• Working in proximity to equipment being lifted
• High temperature/humidity environment
The project team should ensure that personnel involved in the installation of the steam turbine
components meet all applicable Occupational Safety and Health Administration (OSHA)
requirements.
10.8 Post-Installation Testing
The project team should ensure that post-installation testing of the steam turbine is conducted in
accordance with the requirements specified in the installation specification and/or the
manufacturer’s recommendations. The project team and manufacturer should work closely to
establish the following:
• Baseline performance criteria for the steam turbine
• Means for verifying and measuring the upgraded steam turbine performance
10-4
Installation Issues
• System operating conditions under which the steam turbine will be tested
• Acceptance criteria for meeting established performance standards
• The type of post-installation test most appropriate for measuring performance data
• Procedures and instructions for conducting the post-installation tests
• Qualification requirements for personnel conducting the prescribed tests
• Benefits of pre-service inspections and/or in-service inspections
10-5
11
DEVELOPING THE MAINTENANCE STRATEGY FOR
THE UPGRADED STEAM TURBINE
11.1 Inputs Regarding Preventive Maintenance
11.1.1 Steam Turbine Manufacturer
The project team should coordinate with the steam turbine manufacturer during the design and
procurement phases of the upgrade to begin developing the preventive maintenance (PM)
program for the new steam turbine. The manufacturer should be required to furnish
recommendations regarding the type(s) of any PM activities and their frequency that are different
as a result of the upgrade.
11.1.2 EPRI Preventive Maintenance Basis Database
The project team should research the EPRI Preventive Maintenance Database (PMDB) to
determine if specific guidance has been developed by EPRI for the upgraded steam turbine. As
part of EPRI’s PM Basis Database Program, there is an ongoing effort to develop technical
guides and documentation of industry experience on PM optimization. EPRI’s PM Basis
Database, client/server version 1.5 (product 1010923) includes PM basis modules for 11 turbine-
generator components, which contain information useful in determining PM intervals. Additional
information can be found at www.epri.com by searching the keyword PMDB.
11.1.2.1 EPRI Preventive Maintenance Optimization Process
Figure 11-1 is based on guidance from EPRI report 1002936, Reliability and Preventive
Maintenance: Balancing Risk and Reliability: For Maintenance and Reliability Professionals at
Nuclear Power Plants. It is presented in this report as an example of one approach to PM
optimization, which considers criticality, failure history, vendor recommendations, current PM
tasks, and the acceptability of the EPRI recommendations. The flowchart references both PM
task evaluation and interval evaluation and serves as an introduction to how plant PM
optimization can use these individual processes.
11-1
Developing the Maintenance Strategy for the Upgraded Steam Turbine
START
N Y Are Current Tasks

Is This A
Essentially Equivalent
Critical
To The EPRI Tasks?
Component?
N Y
Check Vendor Are Current Perform
Recommendations Intervals Equal Interval
And Perform PM To EPRI N Evaluation
Task Evaluation Intervals?
And Interval
Evaluation
Y
Has The Failure Y Retain Existing Has The Failure Y

History Been Tasks AndY History Been
Satisfactory? Intervals, But Satisfactory?
Check Template
N For More Cost- N Retain
Effective Choices Current Tasks
Are The EPRI And Intervals
Tasks Cost-
Effective And Adopt The EPRI Review Failure
Acceptable ? Tasks And Causes To Find
Intervals The Failure
Y Mechanisms
N
Experienced. Add
Task Or Improve
Perform PM Task Task Execution.
Evaluation And
Interval
Evaluation
Figure 11-1
PM Optimization Process
(from EPRI Report 1002936)
PM task evaluation selects and evaluates PM tasks to provide adequate protection against
component failures. Evaluation of task intervals is done separately using interval evaluation.
Evaluation of a PM task should be carried out in the context of other tasks that are being
performed on the component.
The main reasons for these evaluations could be:

• To optimize tasks and intervals as part of a programmatic improvement in which a large
number of tasks and components are addressed
• To change individual tasks in response to poor performance or a finding of poor or
consistently good equipment condition
11-2
Evaluating the tasks follows the same general process regardless of the reason for the evaluation.
The PM task evaluation requires the answers to a set of questions. Each question is handled in
two parts. The first (What?) explains what the issue is about and why it is important. The second
(Answer?) shows the user how to get the answer to the question, most often from the EPRI PM
Basis Database.
11.1.2.2 Abbreviated PM Task Evaluation Process

1. Is this a critical, minor, or run-to-failure (RTF) component? – The objective of PM could be
to prevent all or most failures of a component as far as possible or to prevent only some
failures. Components with these two PM objectives may be stated in PM optimization
processes to be “critical” and “minor,” respectively. Both cases lead the user to consider
doing some PM tasks. If neither of these objectives applies to this component, it should be
classed as RTF, which means that no PM tasks of any kind should be performed on it.
The PM objective for critical components is to prevent all or most failures that are known to
occur and are expected to occur at least once in the life of the equipment. Critical
components must therefore have sufficient PM coverage in scope and frequency to address a
wide spectrum of possible failure mechanisms and certainly all the common failure
mechanisms.
Components that lack important functions may simply be allowed to fail if there are no
serious consequences. They can be repaired after they fail, but they would not merit the
expenditure of maintenance resources to prevent the failure. Such components would be
classed as RTF.
However, many components fall between these extremes. For example, they might cause
significant costs when they fail even though such costs are not nearly on the scale of a loss of
production. This could be a result of self or secondary damage, increased waste disposal
costs, additional testing or requalification of other equipment, or significant radiation or other
occupational exposure during repair (more than during PM). All such components are
categorized as minor and they would ideally receive some level of limited PM.
Therefore, components receive a wide range of different levels of PM. It is convenient to

think of the more comprehensive end of this range of PM coverage as corresponding to the
objective of preventing all or most failures. Even within this category, it is possible to
distinguish failures that individually create huge costs every time they occur from those that
can be (barely) tolerated if a high reliability target is reached (for example, where only a
single failure is likely to be experienced in an extended period of operation). The former
category could be referred to as Critical A components, whereas the second category could
be referred to as Critical B components. Both are critical in the sense that they command that
extensive PM effort be made to prevent them. Preventing most failures rather than all of them
is appropriate for redundant equipment where the combination of two or more train failures
would represent a critical loss of function. In this case, each train needs to be maintained at a
high level of reliability, or there is no point in designing in the redundancy. Clearly, in a
11-3
nuclear power context, the level of Critical B PM provided for two-train safety
configurations may easily rival that for Critical A components (which might trip the plant or
result in an in-plant fatality). Logically, the PM requirements become less demanding as the
redundancy level increases above two and as the risk significance of the individual failures
decreases. Even the nuclear power plant Maintenance Rule contains provisions to allow one
or sometimes two failures for some critical components in a two-year period based on the
system performance criteria.
At the other extreme, minor components might need a PM task to address just one or two
catastrophic failure mechanisms if the objective involves preventing expensive damage to the
component or to another component.
In some cases, there are no cost-effective PM tasks for minor components. This does not
mean that these minor components revert to the RTF category. They are still minor
components, but because they are being RTF, the subsequent cost of the impending failure
must be accepted. In some cases, there may not be cost-effective PM tasks for a critical
component. In this situation, a design change may be sought, but if a practical design change
cannot be implemented, once again, the best course of action may be to run this component
to failure—even though it is still a critical component.
2. Which PM tasks are recommended by the EPRI PM Basis Database? – Tasks recommended
by the EPRI PM Basis Database should be compared to existing tasks to obtain candidate PM
tasks. The tasks in the database may not be packaged in the same way as current tasks. That
is, certain line item activities may be performed as part of another task, and tasks that have
similar names may differ appreciably in scope. The purpose of this question is simply to
identify the database recommendations and to identify which task names are really equivalent
to current tasks. Evaluation of the candidates is performed subsequently. If the user does not
have any current tasks, the database recommendations should simply be selected as
candidates. Vendor-recommended tasks for critical components can also be included if the
user knows how these tasks relate to the EPRI tasks.
3. Which tasks give adequate protection? – The expert panel of utility and vendor personnel that
recommended the tasks in the template suggested the complete set of tasks for the given
conditions as being a moderately conservative group of tasks. These could be applied by an
owner with little operating experience or with limited corporate memory of its failure history.
The intention was to address all the failure mechanisms that are known to happen and that are
expected to occur at least once in the life of the equipment. This is also the philosophy of
reliability centered maintenance (RCM).
However, your current PM tasks for a critical component may differ from the tasks
recommended in the EPRI template. In this case, the vendor recommendations for additional
task insights should be reviewed, and the coverage of failure mechanisms should be
investigated using this step of the procedure.
If the past history of failures has been unsatisfactory for a minor component and the EPRI
recommendations are found not to be acceptable, additional evaluation may be necessary.
11-4
11.2 Preventive Maintenance Experience with Upgraded Steam Turbines
As another source of input, the project team should consider the PM experience with the steam
turbine being upgraded. Care should be taken to consider differences in the type of components
and technologies associated with the new component when drawing on past maintenance
experiences.
11.3 Establishing a Life Cycle Management Plan
The project team should consider the use of various EPRI reports to address life cycle
management planning. In addition to a number of source books for specific components, the
following is a list of EPRI reports that should be used when establishing a life cycle management
plan for the replacement component:
• EPRI report TR-104751, Utility Activities for Nuclear Power Plant Life Cycle Management
and License Renewal, June 1995
• EPRI report TR-104326, Nuclear Plant Life Cycle Management Economics, May 1995
• EPRI report TR-106109, Nuclear Plant Life Cycle Management Implementation Guide,
October 1998
• EPRI report TR-108984, Product Life Cycle Management: Adapting the Best Practices of
Other Industries, September 1997
• EPRI report 1009071, Life Cycle Management Planning Sourcebooks, Volume 8: Main
Turbine, January 2004
11.4 Determining Critical Spares
As noted earlier in this report, it is often beneficial to consider a maintenance strategy during the
design of the steam turbine upgrade. Subsequently, the project team should consider establishing
with potential suppliers the scope of spare and replacement parts necessary to execute the
anticipated maintenance, as well as the frequency with which those items should be made
available. EPRI report 1011861, Considerations for Developing a Critical Spare and
Replacement Items Program at a Nuclear Power Plant, should be considered as a guide for
determining critical spares for a given component.
During the design and prior to the procurement of the steam turbine components, consideration
should be given to establishing means for proactively obtaining from potential suppliers certain
design information such as materials and dimensions/tolerances of certain spare/replacement
parts. Having this part-level information provided during the procurement of the component will
make acceptance of these items easier in the future and with less engineering involvement.
11-5
11.5 Establishing Condition Monitoring Requirements
The project team should research the EPRI PMDB to determine if condition monitoring guidance
has been developed by EPRI for the steam turbine. As part of EPRI’s PM Basis Database
Program, there is an ongoing effort to develop templates as an addendum to the PM basis. EPRI
report TR-106857 (Volumes 1–38), Equipment Condition Monitoring Templates: Addendum to
the Preventive Maintenance Basis, provides detailed guidance.
Additional sources of information that may be considered when establishing condition

monitoring requirements for the replacement component are as follows:
• EPRI report TR-107668, Guideline for System Monitoring by System Engineers,
December 1996
• EPRI report 1002964, System Monitoring and Reporting Tool (SMART) Study: Generic
Application Evaluation, September 2001
• EPRI report TR-107434, System Monitoring by System Engineers: 37 System Monitoring
Plans, January 1998
• EPRI report 1000260, SysMon 2.0 User’s Guide: System Monitoring by System Engineers,
37 System Templates, June 2000
• EPRI report TR-106960, End-Use Performance Monitoring Handbook, October 1996
• EPRI report 1003695, Equipment Condition Assessment: Application of On-Line Monitoring
Technology, December 2004
• EPRI report 1000621, Equipment Condition Monitoring Templates: Addendum to the
Preventive Maintenance Basis, TR-106857 (Volumes 1–38), January 2000
11.6 Revising Operating Practices and Procedures
The project team should anticipate revisions to existing operating practices and procedures
commensurate with the scope of the turbine upgrade. In some cases, existing startup practices
will also need modification based on the configuration and capabilities of the upgraded turbine
components.
11-6
12
DISPOSAL OF REPLACED EQUIPMENT
When replacing steam turbine components and internals, much of the technical focus is often on
selecting suitable replacements, procuring the items, and ensuring that they perform in
accordance with design requirements. However, a key phase of any replacement project is the
disposal of the old components after they are removed from the steam turbine. In some cases, the
old component cannot be moved in one piece due to its physical size. In other cases, the aged
equipment is contaminated with radiation and must be handled appropriately.
The project team should develop a means for safely and cost-effectively disposing of the
replaced components. The factors listed next should be considered as early in the design and
procurement processes as feasible to ensure that the necessary personnel, tools, permits, and
resources are available to properly dispose of the old component after it is removed from service.
12.1 Disposal Facility Capabilities
In parallel with the specification and design of the steam turbine upgrade, the project team
should study feasible means of disposing of the replaced equipment and determining the
capabilities of the disposal facility and organization. During this evaluation, the project team
should determine the following regarding the organization’s capabilities:
• Removal from site
• Interface with contracted demolition work
• Transportation capabilities
• Decontamination
• Storage
• Salvaging
12-1
Disposal of Replaced Equipment
12.2 Decontamination vs. Long-Term Storage
The project team should evaluate whether to decontaminate the replaced steam turbine
components or place them in long-term storage. To assist in this evaluation, the project team
should consider the following EPRI reports:
• EPRI report 1003436, Advanced Volume Reduction and Waste Segregation Strategies for
Low-Level Waste Disposal, November 2003
• EPRI report EA-3681, Environmental Settings and Solid-Residues Disposal in the Electric
Utility Industry, August 1984
• EPRI report 1003026, Decontamination of Reactor Systems and Contaminated Components
for Disposal or Refurbishment: Developments and Experience with the EPRI DFD Chemical
Decontamination Process, November 2001
• EPRI report TR-103810, Low-Level Waste Inventory Management Program for Storage and
Disposal: Source Dk 1.0 – Software Description and User’s Manual, April 1994
12.3 General Environmental Concerns
The project team should consider general environmental concerns when planning for the safe
disposal of the removed components and any auxiliary equipment. These concerns may include
the following:
• Hazardous chemicals and materials
• Radioactivity
• State and local permits
• State and local environmental impact studies/statements
12.4 Opportunity to Refurbish/Salvage Replaced Component
The project team should determine if there are opportunities to refurbish the replaced steam
turbine components and use them in other plant applications. In some cases, this may be feasible
if the component age and wear are not significant or when it can be used in a less severe or
safety-significant application. In some cases, the replaced component may be salvaged, donated
to a research and development organization, and/or sold to an interested third party or the turbine
upgrade OEM (obsolete spare and replacement parts may also be sold back to the turbine
upgrade OEM in some cases). Typically, the engineering organization is not responsible for
making these decisions but may be solicited for input.
12-2
Disposal of Replaced Equipment
12.5 Shipping and Handling Issues with Contaminated Equipment
If the replaced equipment will be shipped off-site and it is radioactive, the project team should
consider requirements for special shipping and handling. Care should be taken to ensure that all
federal, state, and local regulations are studied and met by the project team prior to moving the
equipment off-site.
12-3
13
BIBLIOGRAPHY
13.1 Regulations and Regulatory Guidance
10CFR21, Revision 2, Reporting of Defects and Noncompliances. 1995, Office of the Federal
Register, National Archives and Records Administration, U.S. Government Printing Office,
Washington, D.C.
10CFR50, Appendix B, Quality Assurance Criteria for Nuclear Power Plants and Fuel
Reprocessing Facilities. Office of the Federal Register, National Archives and Records
Administration, U.S. Government Printing Office, Washington, D.C.
10CFR50.2, Definitions. Office of the Federal Register, National Archives and Records
Administration, U.S. Government Printing Office, Washington, D.C.
NRC Generic Letter 89-02, “Actions to Improve the Detection of Counterfeit and Fraudulently
Marketed Products,” March 1989.
NRC Generic Letter 89-09, “ASME Section III Component Replacements.”
NRC Generic Letter 89-04, “Guidance on Developing Acceptable Inservice Testing Program.”
NRC Generic Letter 91-05, “Licensee Commercial Grade Procurement and Dedication
Programs,” April 1991.
NRC Regulatory Guide 1.100, March 1976, “Seismic Qualification of Electric and Mechanical
Equipment for Nuclear Power Plants.”
13.2 Implementing Standards
ANSI N18.7/ANS 3.2, “Administrative Controls and Quality Assurance for the Operational
Phase of Nuclear Power Plants,” 1976.
ANSI N45.2, “Quality Assurance Program Requirements for Nuclear Power Plants.”
13-1
Bibliography
13.3 Industry Guidance
AP-913, Equipment Reliability Process Description (Revision 1), Institute of Nuclear Power
Operations. Atlanta, GA: November 2003.
IEEE Std 323-1974, “Qualifying Class 1E Equipment for Nuclear-Power Generating Stations.”
IEEE, Piscataway, NJ.
IEEE Std 344-1987, “Recommended Practice for Seismic Qualification of Class 1E Equipment
for Nuclear Power Generating Stations.” IEEE, Piscataway, NJ.
13.4 EPRI Technical Reports
Advanced Volume Reduction and Waste Segregation Strategies for Low-Level Waste Disposal.
EPRI, Palo Alto, CA: 2003. 1003436.
Considerations for Developing a Critical Spare and Replacement Items Program at a Nuclear
Power Plant. EPRI, Palo Alto, CA: 2005. 1011861.
Critical Component Identification Process – Licensee Examples (Scoping and Identification of

Critical Components in Support of INPO AP-913). EPRI, Palo Alto, CA: 2003. 1007935.
Decontamination of Reactor Systems and Contaminated Components for Disposal or

Refurbishment: Developments and Experience with the EPRI DFD Chemical Decontamination
Process. EPRI, Palo Alto, CA: 2001. 1003026.
End-Use Performance Monitoring Handbook. EPRI, Palo Alto, CA: 1996. TR-106960.
Environmental Settings and Solid-Residues Disposal in the Electric Utility Industry. EPRI, Palo
Alto, CA: 1984. EA-3681.
Equipment Condition Assessment: Application of On-Line Monitoring Technology. EPRI, Palo

Alto, CA: 2004. 1003695.
Equipment Condition Monitoring Templates: Addendum to the Preventive Maintenance Basis,

TR-106857 (Volumes 1–38). EPRI, Palo Alto, CA: 2000. 1000621.
Guidance for Developing and Implementing an On-Line Maintenance Strategy. EPRI,

Palo Alto, CA: 2004. 1009708.
Guideline for System Monitoring by System Engineers. EPRI, Palo Alto, CA: 1996.
TR-107668.
13-2
Bibliography
Guidelines for Reducing the Time and Cost of Turbine-Generator Maintenance Overhauls and
Inspections, Volume 4: Turbine-Generator Component Procurement Specifications. EPRI, Palo
Alto, CA: 2005. 1009841.
Guidelines for Reverse Engineering at Nuclear Power Plants. EPRI, Palo Alto, CA: 1998. TR-
107372.
Guidelines for Technical Evaluation of Replacement Items in Nuclear Power Plants, Revision 1.
EPRI, Palo Alto, CA: 2004. 1008256.
Guidelines for Technical Evaluation of Replacement Items in Nuclear Power Plants (NCIG-11).
EPRI, Palo Alto, CA: 1989. NP-6406.
Guidelines for the Utilization of Commercial Grade Items In Nuclear Safety-Related

Applications. EPRI, Palo Alto, CA: 1988. NP-5652.
Life Cycle Management Planning Sourcebooks, Volume 8: Main Turbine. EPRI, Palo Alto, CA:
2004. 1009071.
Lifting, Rigging, and Small Hoist Usage Program Guide. EPRI, Palo Alto, CA: 2003. 1007914.
Low Level Waste Inventory Management Program for Storage and Disposal: Source
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Project Management Guidance When Upgrading Steam Turbines at Nuclear and Fossil Power Plants

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Project Management Guidance When Upgrading Steam Turbines at Nuclear and Fossil Power Plants

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Project Management Guidance when Upgrading

Steam Turbines at Nuclear and Fossil Power Plants

Technical Update, January 2007

EPRI Project Manager

ELECTRIC POWER RESEARCH INSTITUTE

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Electric Power Research Institute (EPRI)

Sequoia Consulting Group, Inc.

This report was prepared by

Electric Power Research Institute (EPRI)

Sequoia Consulting Group, Inc.

This report describes research sponsored by EPRI.

Daniel Schaeffer AmerenUE

Bob Tomala Exelon Corporation

Bill Newsom Mitsubishi

Lew Shuster Reliant Energy

Dan Rothas Siemens-Westinghouse

James Wieters South Carolina Electric and Gas Co.

Bob Bjune South Texas Project

David Brahms Southern California Edison

Russell Chetwynd Southern California Edison

Jerry Best Tennessee Valley Authority

Gary Zia Tennessee Valley Authority

2 PROJECT MANAGEMENT AND PROCESS OVERVIEW ....................................................2-1

3 SYSTEM AND COMPONENT DESIGN ISSUES ...................................................................3-1

4 DEVELOPING BID SPECIFICATIONS AND REQUESTS FOR PROPOSALS ....................4-1

5 SUPPLIER QUALIFICATION AND SELECTION, BID EVALUATION, AND

6 FABRICATION ISSUES .........................................................................................................6-1

7 SHIPPING AND HANDLING ISSUES ....................................................................................7-1

8 RECEIPT INSPECTION ISSUES ...........................................................................................8-1

9 STORAGE AND STAGING ISSUES ......................................................................................9-1

10 INSTALLATION ISSUES ...................................................................................................10-1

11 DEVELOPING THE MAINTENANCE STRATEGY FOR THE UPGRADED STEAM

12 DISPOSAL OF REPLACED EQUIPMENT ........................................................................12-1

1.1.2 Overall Objectives

1.2 Scope of This Report

1.2.1 Role of a Database in the Upgrade Process

1.2.2 References to Quality Assurance Implementation Standards

1.3 Definitions of Key Terms

2.1 Development of the Generic Process

Design Issues Section 3 Translate Design

2.2 Key Issues and Report Structure

Figure 2-1 also illustrates the following key points:

2.3 Project Management for Replacing Major Plant Components

2.3.1 General Guidance

2.3.2 Managing Design and Technical Issues

2.3.2.1 Project Management Interface Controls

Organization Composing Anticipated Level of Involvement

Operation (senior/station reactor High

Senior management Medium

Training Low (higher for maintenance personnel)

Supply chain Low (during actual purchasing)

2.3.2.2 Managing the Concurrent Engineering Processes

2.3.2.3 Other Design Considerations

2.3.3 Evaluating Industry Experience

• Original equipment manufacturer (OEM) publications/papers on upgrades

2.3.4 Establishing and Managing the Project Budget

3.1 Understanding the Reasons for the Steam Turbine Upgrade

• Improving/enhancing steam turbine performance and reliability – In some cases, a

3.2 System and Component Design Relationship

• Normal Operating Conditions

System Operating Parameters