siemens - Public Service Commission

EXAMPLE 

August 23,2007 

Mr. Jim Gannon 

Enercon Services, Inc. 

500 Townspark Lane 

Kennesaw, GA 30144 

Subject: 

Progress Energy Florida, Inc. 

Crystal River Discharge Canal Cooling Study 

Request No. xxxO7-0 1 

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Dear Mr. Gannon: 

You are invited to submit a proposal for the evaluation and conceptual design of cooling options 

for Progress Energy's Crystal River South and Crystal River Unit 3 sites. Two (2) signed copies 

of the proposal (one priced and one unpriced) shall be sealed and marked "CONFIDENTIAL" 

and submitted to Deborah Hanna, Progress Energy Florida, Inc., 15760 W. Powerline Street 

(SA2C), Crystal River, FL 34428-6708. No copies of the proposal shall be distributed to any 

other Progress Energy personnel. Your proposal must be received no later than close of business 

September 29, 2007. If your proposal is received after that day or time, it will not be considered 

for the described work. Telephoned or faxed proposals or proposal information are unacceptable 

and will not be considered. No modifications to the proposal will be accepted after the bid due 

date and time specified above unless specifically requested in writing and approved by Progress 

Energy. 

It is intended that a Contract in the form of the attached sample Contract will be awarded for this 

scope of work and quotations shall be made accordingly, unless the successful Vendor has an 

existing Master Contract with Progress Energy, in which case a Work Authorization will be 

released against that Master Contract incorporating the details of this Request for Proposal. 

Progress Energy does not obligate itself to accept the lowest or any other bid and specifically 

reserves the right to reject any and all bids. Vendors are advised that all bids will be opened and 

__-. evaluated solely by Progress Energy. All information contained in the bids submitted to Progress 

Energy and Progress Energy's evaluation, including any Vendor's relative position to the 

successful Vendor, is considered exclusive information of Progress Energy and will not be made 

available to any of the Vendors. All unsucce~stul Vendors will be notified by Progress Energy in 

writing of the award of the work to anothcr firm. 

. I _-_ 

KCA -_-_- 

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LLF? _..___I 

5GA __,_.--- All requests for clarifications, interpretations or decisions on discrepancies pertaining to any of the

EXAMPLE 



Request No. xxxO7-0 I 

proposal documents or related project data fumished as part of the proposal documents shall be made 

directly to Deborah.Hanna@pgnmaiI.com, (352) 563-2943, x4547. 

It is the Vendor's responsibility to advise his potential subcontractors, suppliers, and other subvendors 

that information will be available only through the Vendor and that no direct contacts 

with Progress Energy by other firms shall be initiated. Information exchange shall be between 

Progress Energy and Vendor, and Vendor and his potential subcontractors. No work shall be 

subcontracted without the approval of Progress Energy. Subcontract work and proposed 

subcontractors must be identified in Vendor's proposal. 

Please acknowledge receipt of this proposal and your bidding intentions by completing the 

attached Acknowledgement and General Information forms. The forms are to be completed in 

their entirety so that Progress Energy has all the information necessary make the contract award. 

Bids will not be considered when submitted on forms other than those provided. Please fax the 

completed Acknowledgement & General Information forms to Deborah Hanna at (352) 563-4464 

before the close of business on September 4,2007. Progress Energy will host a walk through of 

the applicable Crystal River areas on September 6, 2007 from 1 to 3 PM. The walk through will 

be followed by a question and answer session to ensure all the potential vendors understand the 

scope of this work. 

PROGRESS ENERGY FLORIDA, INC. 

By: 

Deborah Hanna 

Lead Contract Management Specialist 

Attachments: 

Acknowledgement 

General Information 

Scope and Other Requirements 

PEF-NCK-00582

TABLE OF CONTENTS 

Cover Letter & Invitation to Bid 

Acknowledgement Form 

General Information Form 

Scope and Other Information 

I. Background 

11. Vendor Scope of Work 

111. Owner Scope of Work 

IV. Technical Details 

V. References 

VI. PEF Contacts 

VII. Work Control 

VIII. Schedules 

IX. Quality Assurance 

X. Technical Documentation & Submittal Requirements 

XI. Deliverables 

XII. Additional Information 

XIII. Attachments 

Attachment A - Bid Requirements 

Attachment B - Alternatives Analysis Report Outline 

Attachment C - PEF Technical Documentation 

PEF Safety Plan 

Site Land Use Classification Map 

Applicable Sections of the Site Certification Application 

Historical Data of Circulating Water Temperatures 

Helper Cooling Tower Performance Curves 

Modular Cooling Tower Performance Curves 

Local Annual Windrose 

Request for Information Form 

PEF-NCR-00.583

ACKNOWLEDGEMENT 

To : 

Deborah Hanna 


15760 W. Powerline St. (SA2C) 

Crystal River, FL 34428-6708 

Fax: 3 52-563-4464 

In regards to: Progress Energy Florida, Inc. 


Request No. xxxO7-0 1 

I acknowledge receipt of the subject proposal package and have indicated my bidding intentions 

as follows: 

0 I have reviewed the proposal documents and will not be submitting a bid for this work. 

I have reviewed the proposal documents and intend to submit a bid for this work. 

0 I plan to attend the facility walkthrough and solicitation discussion on September 6, 2007. 

(Signature) 

(Title) 

(Date)

GENERAL INFORMATION 

In the evcnt that your Proposal is accepted and a Contract is awarded to the firm whose full legal 

company name appears herein below, Mr./Ms. 

, whose title is 

, will be executing the Contract on behalf of the firm. 

Should this person's title not indicate that he/she is a corporate officer (president, vice president, 

or corporate secretary), an affidavit signed by a corporate officer shall be provided along with the 

bid, stating that the person whose name appears above is duly authorized to execute contracts on 

behalf of the firm. 

The Contractor is: (select appropriate line and complete information) 

An Individual: 

A Corporation of the State of 

A Partnership consisting of: 

A Joint Venture comprised of: 

Full Legal Company Name 

Business Address 

Mailing Address 

(if different) 

Contact Name 

Contact Phone 

Contact E-Mail 

Company Website 

Federal Tax ID Number 

2

Contractor's Liccnse Number (if applicable) 

State of Issuance 

In accordance with the Federal Acquisition Regulation section 52.2 19, please check all that apply 

to your company. Please provide supporting documentation or certification to confirm the status 

for any categories checked under Small/Diverse Vendors. 

[ ] Certified small business* [ 3 HUBZone, 8(a) or disadvantaged business* 

[ ] Veteran-owned business* [ ] Minority-owned business * * 

[ ] Service-disabled veteran-owned business* [ ] Women-owned small business * * 

[ 3 Not a Small Business 

* As defined by the Small Business Administration (SBA): ivww.sba.cov 

* * Certified by Progress Energy and as defined by SBA. 

Register online at W\VM .pronress-enere\i.coni/suDplierdiversitv 

BY: 

NAME (printed): 

TITLE: 

DATE: 

3 

PEF-NCR-00586

SCOPE AND OTHER REQUIREMENTS 

I. Background 

Progress Energy Florida, Inc. (PEF) plans to increase the electrical power output of its nuclear 

reactor - Crystal River Unit 3 (CR3) - located in Crystal River, FL via an Extended Power 

Uprate (EPU) scheduled for completion in 201 1. The planned changes will increase the licensed 

core power from 2568 MWt (903 MWe) to 3014 MWt (1080 MWe), an electrical improvement 

of roughly 20%. A direct result of the augmented electrical generation will be an increase in heat 

rejected from the circulating water system through the once-through condensers and into the 

discharge canal. Without mitigation, the corresponding increase in dissipated heat is expected to 

affect the permitted discharge temperature limit of 96.5 O F. 

CR3 shares a common discharge canal with two adjacent coal-fired units, CRl (400 MW) and 

CR2 (500 MW). The common discharge canal currently has 36 cells of helper (mechanical draft) 

cooling towers plus 67 additional modular cooling towers that operate during the summer months 

to cool a portion of discharge canal water to comply with permit limits. However, even with the 

helper and modular cooling towers, high discharge canal water temperatures periodically cause 

CR1 and CR2 to de-rate so as not to exceed the permitted National Pollutant Discharge 

Elimination System (NPDES) limit. After the 201 1 EPU implementation, operation of CRI and 

CR2 will be further impacted by the increase in discharge canal water temperature without any 

mitigation. 

PEF developed and submitted a Site Certification Application (SCA) to the Florida Department 

of Environmental Protection (FDEP) as part of the EPU permitting process. One of the possible 

mitigating actions submitted in the SCA was the use of additional cooling towers. Applicable 

sections of the SCA are included in Attachment C. Although cooling towers were mentioned in 

the SCA, the use of cooling towers may not be the best altemative. As a result, this Request for 

Proposal (RFP) has been developed to determine the best thermal mitigation alternative. 


The Scope of Work is divided into two phases. Phase I is to evaluate alternatives for reducing 

the discharge canal water temperature in order to (1) accommodate the planned thermal increase 

associated with CR3’s EPU, (2) minimize the effect on full-load operation of CRI and CR2 and 

potentially eliminate necessary de-rates of either unit, and (3) comply with all existing and 

proposed environmental permits, including re-circulating water from the discharge canal to the 

intake canal to offset increased condenser flow from CR3’s EPU and address 316(b) 

requirements. The goal of this study is to evaluate the potentially viable altematives, compare 

the alternatives, and recommend the most cost effective and technically feasible alternative. The 

Study Report will be structured using the outline provided in Attachment B. Phase 11 of this 

work scope is to develop a conceptual design, general cost estimate (f25%) and high-level 

4 

P EF-NCR-00 5 8 7

schedule for the Prqject’s implementation. 

Phase I 

The alternatives analysis shall contain sufficient design consideration (e.g., equipment sizing, 

quantity, and materials) to determine whether it is technically and economically feasible to 

implement each alternative. The following list provides the expected alternatives, in whole or in 

combination, for this evaluation. 

Evaluation of cooling alternatives, including, but not limited to, the following: 

New Cooling Towers 

Modifying Existing Cooling Towers 

o Upgrade Helper Cooling Towers (fans, stacks, or fill)’ 

o Eliminate Modular Cooling Towers 

3 Evaporative Cooling 

3 Inlet/Discharge Chillers 

3 Air Spargers/13ubblers2 

Analysis of each alternative including, but not limited to, the following: 

Economic Cost Estimate (including the basis for the estimate) 

Schedule Analysis 

Quantity and Size of Equipment 

Infrastructure Requirements (e.g., electrical needs) 

Proposed location(s) considered for the alternative 

Site Impacts (e.g., environmental, operational and maintenance) 

Advantages and Disadvantages Relative to Other Options 

Identify environmental impacts for each alternative3 

Wetlands Mitigation 

2 Biota Impingement and Entrainment Issues 

Preparation of an Alternatives Summary Report comparing the alternatives and an on-site 

presentation (to plant personnel) of the selection results. 

Phase I1 

The recommended alternative shall be developed into a conceptual design, which shall contain 

sufficient detail to prepare a request for proposal (RFP) package for the final equipment 

procurement and design. Section X of this document identifies the level of detail expected in the 

conceptual design report. PEF expects that the conceptual design can be used as the stand alonc 

engineering design input document for the final design. 

This work is NOT nuclear safety related and does not need to be completed under the Vendor’s 

’ Helper Cooling Tower upgrades were evaluated previously (additional References - Bechtel Cooling Water Study). 

Bubble cooling was previously reviewed (additional References - John Cooper & Associates Engineering 

Evaluation). 

PEF will perform detailed review of 316(b) impacts; Vendor is not expected to coordinate any interaction with 

permit agencies. PEF expects the Vendor to identify possible environmental impacts, as well as solutions, for each 

alternative. 

5 

PEF-NCR-00588

Appendix B program. 

The technical details and requirements for each of the items associated with this scope of work 

are discussed in the following sections. 


PEF personnel will work with the selected Vendor in obtaining additional information (e.g., 

wetland surveys, civil engineering drawings, and plant electrical drawings) to support the 

evaluation. The selected Vendor should expect a one day turn around time for on site delivery of 

drawings and an additional one to two days time for off site delivery. PEF personnel will 

coordinate the Vendor’s CR site indoctrinations, badging, and specific training, as required. 

After the Phase I altemative selection, an economic analysis will be performed using PEF’s inhouse 

EESY+ software. PEF will input the Vendor’s supplied data into EESY+ and provide the 

output results for incorporation into the final study report. The Vendor will review the EESY+ 

input for accuracy and review/incorporate the output results into the study. 


Vendor shall conduct a thorough review of design altematives to reduce the discharge canal 

water temperature and satisfy the stated Project objectives following CR3’s EPU. This 

evaluation shall include a technical analysis of design variables such as discharge canal 

temperature variation, ambient temperatures, and environmental restrictions. Specific data 

related to the unit operations following the EPU are included below. Additional information will 

be supplied by PEF after contract award and requested by the selected vendor. 

0 CRl full-load operation 

s 245,000 gpm Circulating Water Flow (actual) 

a -I 7 OF Circulating Water Temperature Rise Through Condenser 

0 CR2 full-load operation 

a 308,000 gpm Circulating Water Flow (actual) 

s -14 OF Circulating Water Temperature Rise Through Condenser 


s 832,000 gpm Circulating Water Flow 

s -1 7 OF Circulating Water Temperature Rise Through Condenser 

s .768 MBtuhr of Additional Heat Dissipated due to EPU 

0 (Hamon) Helper Cooling Towers operation . 

3 4 blocks of 9 cells 

3 686,000 gpm Total Water Flow 

a 89.5 OF Design Outlet Temperature (based on 103 OF inlet and 81 OF wet bulb) 

(Aggreko) Modular Cooling Tower operation 

s 67 individual cells 

s 180,000 gpm Total Water Flow 

6 

PEF-NCR-00589

a 90 '1: Design Outlet Temperature (based on 103 O F inlet and 81 OF wet bulb) 

Project Objectives 

a Allow Full-Load Operation of CRl, CR2 and CR3 during Summer 

=, Plan for Maximum Design Intake Water Temperature of 91 OF 

Comply with 96.5 OF Point of Discharge (POD) 3-hr Rolling Average 

3 Maintain a maximum Permitted Discharge Flow Rate of 1,320,000 gpm (or 1,897.9 

Mgpd) by returning cooled discharge canal water (approximately 152,000 gpm) to the 

intake canal. 

Additional Data 

Intake canal cannot be blocked due to barge traffic. 

3 Though additional cooling capacity is only required during summer months, recirculating 

water flow back to the intake canal is necessary year round. 

=, The return water from discharge to intake canals will be designed for most efficient 

and cost effective mitigation of biota entrainment and impingement. 

V. REFERENCES 

The following reference documents are provided as part of this RFP. These documents are 

located in Appendix C. 

1. PEF Safety Plan 

2. Site Land Use Classification Map 

3. Applicable Sections of the Site Certification Application 

4. Historical Data of Circulating Water Temperatures 

5. Helper Cooling Tower Performance Curves 

6. Modular Cooling Tower Performance Curves 

7. Local Annual Windrose 

8. Request for Information Form 

Additional documents will be provided following contract award. Other data that may be 

provided to facilitate technical evaluations, as requested. 

Site civil engineering drawings 

Site electrical drawings 

Wetland surveys 

Site Certification Application 

Bechtel Cooling Water Study 

John Cooper & Associates Engineering Evaluation 


Contractual: Deborah Hanna 

Telephone: (352)563-4547 

E-mail: Deborah.Hanna@pgnmaiI.com 

Technical: 

Mark Gillespie or Mark Hickman 

7 

PEF-NCR-00590

Telephone: 

Email: 

(352) 795-0504 x6926 or (352) 563-2943 x4233 

mark.gillespie@pgnmail.com or inark.hickmaii:ir2u~nmail.com 


The majority of the work is expected to be completed at Vendor’s facility. However, one cubicle 

with 2 desks and 2 chairs will be provided (if requested) at Crystal River for the selected 

Vendor’s use. Vendor shall be responsible for all office supplies, equipment and personnel 

protective equipment (e.g., hard hat, safety glasses and safety shoes). Vendor shall be 

responsible for identifying personnel that need access on Site and shall coordinate temporary 

badges and training so as not to impact the schedule of work. 

The selected Vendor shall establish a Request for Information (RFI) Log to track information 

transmitted between PEF and Vendor. The RFI form (see Attachment C) will be completed for 

all questions on the Project that need formal clarification. RFI’s shall be used to resolve any 

questions related to Project scope, schedule or cost. Additionally, RFI’s may be used to request 

drawings or other documents not accessible to Vendor or to document equipment or system 

specifications. 

Vendor shall conduct weekly status meetings/teleconferences with PEF Project personnel. 

Vendor shall distribute an agenda (with input from PEF) prior to the meeting, take minutes and 

distribute the minutes after the meeting. PEF personnel will have an opportunity (1 working day 

minimum) to comment on the meeting minutes before they are submitted as final. Minimum 

topics to be covered at each meeting are: 

Safety topic 

Earned value status (cost vs. schedule) 

Projected Estimate at Completion (EAC) 

AccomplishmentsMilestones 

Issueshlequest for Information 

Scheduled accomplishments for next week 

Number of personnel working on the project (last week and next week) 

The Vendor shall conduct a Phase I completion and 90% project completion review meetings 

with PEF personnel at CR. Vendor shall distribute an agenda (with input from PEF personnel) 

prior to the review, take minutes and distribute the minutes after the review. PEF personnel will 

have an opportunity (4 working days minimum) to comment on the review meeting minutes 

before they are submitted as final. Minimum topics to be covered at each review are: 

Safety topic 

Earned value status (cost vs. schedule) 

Projected EAC 

Accomplishments 

Presentation of completed documents for approval 

Issues 

General discussion (question & answers) 

8 

PEF-NCR-0059 1

Vendor shall perform technical evaluation of cooling alternatives and complete a conceptual 

design of the recommended solution. Interaction between PEF and Vendor is expected to clarify 

any comments on altematives as well as to identify site restrictions that may not have been 

considered. 

Vendor shall attend a mandatory Kick-Off Meeting prior to the start of work, to be set up when 

the contract is issued. 

VIII. Schedule 

The following sequence of activities identifies the formal reviews and deliverables for the work. 

Vendors are required to submit a schedule with the required time line completed. The stated 

scope of work is required to be complete by January 3 1, 2008. 

RFP sent to Vendors 

September 4,2007 


October 5,2007 


< 1 Week After NTP 

- 5 Weeks After NTP 





- Submit Acknowledgement & General Information Forms 

- Walkdown and RFP Discussion at Crystal River 

- Proposals Due [Approx. 4 WEEKS TO PREPARE] 

- Contract Award Notice to Proceed (NTP) 

- Kick-Off Meeting (at Crystal River Site) 

- Phase I Completion Review (Alternative Selection on or 

before this review) and Presentation of Report (at Crystal 

River Site). 

- Conceptual Design Draft (90% Completion) Report 

- PEF comments on Draft Report 

- Final Report 

- Presentation of Report (at Crystal River Site) 

The selected Vendor is required to change this time line into a schedule that contains meaningful 

milestone and deliverable dates within one week of NTP. Project completion must not exceed 

January 3 1, 2007. 

Vendors are encouraged to identify any dates that can be improved in the above schedule. 


Quality Assurance (QA) and Quality Control (QC) shall be accomplished under Vendor’s 

internal QA/QC Program. Vendor’s QA/QC Program shall be submitted to PEF for review with 

their proposal. 

X. Technical Documentation and Submittal Requirements 

Phase I 

Finalize the list of alternatives to be evaluated and obtain Alternative Evaluation List approval 

from PEF Project Manager. Complete the altematives analysis and draft the Alternatives

Summary Report. lhe selected Vendor shall work with PEF personnel to determine a 

recommended alternative for implementation after the alternative analysis is complete. A 

preliminary draft of the Phase I alternatives summary report shall be submitted to PEF for review 

and comment 5 days prior to final document submittal and presentation at Crystal River. The 

final Alternatives Summary Report shall be approved by PEF before starting the conceptual 

design. The final alternatives analysis will identify additional testing and information that is 

required in order to complete the conceptual design (i.e. underground utilities location, soils 

sampling, etc.). 

Five copies of the final Altematives Summary Report shall be supplied to PEF. 

Phase I1 

The Vendor shall then develop a Conceptual Design of the selected alternative. The design shall 

have sufficient detail that the information can be used as the primary input for the detailed 

design. PEF personnel will supply site specific criteria for Vendor inclusion in the conceptual 

design document as identified below. At a minimum, the Conceptual Design will include the 

fo I lo w i ng : 

Provide a detailed scope description. The description should include the boundaries and 

interfaces with existing systems (i.e., site electrical, helper and modular cooling towers). 

Identify the location(s) for installation and reason for selection, including any testing data 

that was used to aid in the site selection. 

0 Identify any exclusions or caveats that were considered during alternative selection. 

Identify applicable codes and standards. 

o State design conditions such as seismic loads, wind speeds, thermal and dynamic 

loads, system pressure and temperatures, and chemical considerations. 

Identify installation requirements that are unique to the proposed design, installation, 

and/or startup of the equipment. Include specific direction if field routing is not 

acceptable. 

Identify any assumptions made during the alternative selection. 

o State environmental conditions anticipated during storage, construction, and 

operation. 

o Identify environmentally sensitive areas near the construction areas. Identify the 

environmental permitting requirements for the construction. 

o Identify any interface requirements including definition of the functional and 

physical interfaces involving structures, systems and components. 

Identify any precautions or limitations that need to be considered in completing the 

design. 

o Identify environmental considerations (e.g., maximum particulate carry over 

during evaporative processes). 

Provide installation sketches and marked up drawings for electrical, I&C, and mechanical 

systems. Develop P&ID of recommended system(s). 

Provide installation sketches and marked up drawings with civil/structural details. 

Provide calculations developed during the altemative evaluation and selection process. 

0 Provide suggested component and equipment selection and specifications. 

o Identify the performance requirements of the selected alternative systems and 

10 

PEF-NCR-00593

equipment, such as capacity, rating, and system output. 

o Identify material requirements such as electrical insulation properties, protective 

coating and corrosion resistance. 

o State mechanical requirements such as vibration, stress, shock, and reaction 

forces. 

o Identify Structural requirements covering items such as equipment, foundations 

and pipe supports. 

o Identify hydraulic requirements such as pump net positive suction heads, 

allowable pressure drops, and allowable fluid velocities. 

o Identify electrical requirements such as source of power, voltage, conduit 

requirements, electrical insulation and motor requirements. Provide the electrical 

power supply for each component and calculation of the total electrical power 

required for the project. 

o State the on-site electrical power source that will be used to supply the project. 

List the major pieces of electrical equipment to be procured and installed in order 

to provide electrical power to the major electrical components. 

o Identify of the electrical power routing from the main distribution switchgear to 

transformer(s) and load center(s) to be used for the project. 

o Provide layout and general arrangement requirements. 

o Additional requirements such as inadvertent activation prevention devices, such as 

switch covers, key lock switches and other human factors considerations (Le. 

handwheel locks) may be provided by PEF personnel. 

Identify operational requirements and sequencing under various conditions, such as plant 

start-up, normal plant operation, plant shutdown, plant emergency operation, special or 

infrequent operation, and system abnormal or emergency operation, including postulated 

accident conditions. PEF personnel will assist in determining these criteria. 

State instrumentation and control requirements, including indicating instruments, 

controls, and alarms for operation, testing, and maintenance. Other requirements such as 

the type of instrument, installed spares, range of measurement, and location of indication 

should also be included. PEF personnel will identify desired instrumentation and alarms. 

The instrumentation and controls should be similar to existing equipment monitoring and 

control schemes. 

Access and administrative control requirements for plant security (PEF personnel to 

identify). 

If applicable, state redundancy, diversity and separation requirements of structures, 

systems, and components. 

Identify the failure effects on the requirements of structures, systems, and components, 

including a definition of those events and accidents that they must be designed to 

withstand (Le. hurricane winds). 

Identify system and component test requirements and the conditions under which they 

will be performed. 

Identify accessibility, maintenance, repair, and in-service inspection requirements for the 

equipment, including the conditions under which these will be performed (PEF personnel 

to assist). 

Identify the on-site transportability requirements such as size and shipping weight, 

11 

PEF-NCR-00594

limitations. 

Identify the fire protection or resistance requirements. 

State that the design is to identify the handling, storage, and shipping requirements of 

procured material. 

Identify safety requirements for preventing personnel injury including such items as 

restricting the use of dangerous materials, escape provisions from enclosures, and 

grounding of electrical systems. Identify plant procedures that address these hazards (i.e. 

Chemical Control). PEF personnel will assist in identifying site requirements and 

procedures. 

Provide an Affected Documents List of site drawings and procedures. 

Provide an estimate of new drawings that will be generated during the detailed design 

phase. 

Prepare a Conceptual Design Report Package. 

Drawings shall be performed and submitted in US standard units (i.e. feet, Ibs, kips, inches). All 

engineering drawings and calculations will be reviewed and approved by a registered 

Professional Engineer. 

Five copies of the final conceptual design documents shall be supplied to PEF. 

XI. 

Deliverables 

Phase I 

Kickoff meeting agenda and minutes 

List of alternatives to be analyzed 

Weekly meeting agenda, status, & minutes 

Draft Alternatives Summary Report (5 copies) 

Final Alternatives Summary Report (5 copies) and Presentation 

Phase I1 

Updated project schedule 


Draft Conceptual Design Report (5 copies) 

Final Conceptual Design Report (5 copies) and Presentation 

XII. Additional Information 

PEF will hold a pre-bid meeting with interested Vendors to clarify questions and expected scope. 

The meeting will be held on September 6, 2007 from 1 to 3 pm. 

XIII. Attachments 

A. Bid Requirements 

B. General Study Outline 

C. PEF Technical Documentation 

12 

PEF-NCR-00595

Attachment A. Bid Requirements 

Vendor shall provide the following information with their proposals. 

1. Company’s resume providing qualifications and references that demonstrate Vendor’s 

capability to complete the work. 

2. Vendor’s organization chart identifying how this work will be managed as well as interface 

points with PEF. 

3. Resumes of personnel intended to be used on this project. These resumes will be evaluated 

as part Vendor’s qualification to accomplish the stated scope of work. 

4. Commitment to start work within ten (10) days of the Notice to Proceed. 

5. Company safety statistics. 

6. Classification of each type person associated with the work scope. 

7. Hourly billing rates for each classification (straight timelovertime or all-hours rate) 

8. Billable travel and living expenses. 

9. Estimated man-hours for each personnel classification. 

10. This contract will be completed as a Time & Materials contract, divided into two phases. 

Provide a maximum not-to-exceed contract dollar amount for each phase of the work 

described in this RFP. 

1 1. Provide a description of the suggested approach the Vendor will take to complete this work. 

The approach description should: 

be consistent with the estimated cost and schedule, 

include the expected manpower (by classification) needed for each phase of the work, 

demonstrate that the Vendor understands the work scope & schedule requirements, 

identify what work will be completed at Crystal River and the work to be completed at 

the Vendor’s facility, 

include potential problems that could affect the project cost or schedule, 

include methods to control contract costs, 

describe the Vendor’s earned value system that will be used to monitor and report project 

cost (this description should demonstrate that the Vendor has the capability to properly 

identify, monitor, collect, analyze, and report project costs), 

identify opportunities to improve the project’s completion. 

12. Provide a schedule for accomplishing this scope of work that contains the sequence of 

activities in Section VIII. 

13. QA/QC Program Manual &/or Procedures to be followed in completing the work. 

14. Health & Safety (H&S) Plan or agreement to comply with the PEF’s H&S Plan. 

SPECIAL REQUIREMENTS : 

Confidentiality: 

All RFP drawings, specifications, and contractual documents will remain the property of 

Progress Energy and are to be returned in good condition within ten (1 0) days after the date set 

PEF-NCR-00596

for receiving bids. WP documents shall not be reproduced or used for any purpose other than 

for the preparation of a proposal in accordance with this request. The information contained in 

these documents is proprietary and confidential and shall be maintained in strict confidence. 

RFP Interpretation: 

An interpretation request shall be made to Progress Energy if a Vendor is in doubt as to the true 

meaning of any part of the drawings, specifications, or contractual documents. Modification of 

the documents will be made only by written addendum issued to each Vendor as described 

below. 

RFP Exceptions: 

If a Vendor's proposal contains any deviations or exceptions, those deviations or exceptions must be 

specifically identified on a single separate attachment to the proposal in order to be considered in the 

evaluation. If not so identified, the deviations or exceptions will not be considered part of the 

proposal. Conditional proposals based on Vendor-generated clarifications may not be accepted. If a 

Vendor takes any exceptions in addition to those submitted in accordance with this section, that 

Vendor's proposal may be rejected by Progress Energy. 

RFP Approved Equal Evaluation: 

Submittals by Vendor for evaluation of products as "approved equal" shall be made to the 

appropriate designated individual listed in the Request for Proposal at least ten (10) days prior to 

the proposal due date. Results of evaluations will be provided no later than seven (7) days prior 

to the proposal due date. Submittals made later than ten (1 0) days prior to the proposal due date 

will not be considered. 

RFP Addenda: 

Progress Energy reserves the right to amend or clarify requirements herein by Addenda. An 

addendum may be issued at any time prior to the date for receipt of proposals and may be mailed 

or otherwise delivered to all Vendors who have been invited to bid. Request by a Vendor for 

extension of the proposal due date shall be received by Progress Energy at least one week prior to 

the then scheduled date. If revisions or clarifications are of magnitude to warrant, in the opinion 

of Progress Energy, the extension of the date set for receipt of proposals, an addendum will be 

issued announcing the new date. Failure of a Vendor to acknowledge receipt of any addendum in 

the space provided on the proposal form may result in rejection of that proposal. 

Safety: 

Progress Energy is committed to using safety conscious contractors. To this end, Progress 

Energy collects safety-related data voluntarily provided by all persons performing or desiring to 

perform Progress Energy work. This data is compiled and made available to Progress Energy 

employees via Progress Energy's intranet. This intranet system is accessible by non-Progress 

Energy employees, and thus, so will be any safety-related information you provide. In providing 

the safety-related information requested herein, to Progress Energy or to any other person doing 

business, directly or indirectly, with Progress Energy, the undersigned contractor explicitly 

authorizes Progress Energy to disclose said information to non-Progress Energy persons and 

hereby releases Progress Energy and its agents and employees from any cause of action or claim 

PEF-NCR-00597

for damages related to said disclosures. 

Nuclear Requirements: 

This work is NOT classified as Nuclear Safety Related and does not need to be accomplished 

under the vendor’s Appendix B Program.

Attachment B. Alternatives Analysis Report Outline 

1. Title/Signature Page 

i. Contact Information 

2. Executive Summary 

3. Table of Contents 

4. Introduction 

i. Project Description 

ii. Preliminary Scope Statement 

iii. References 

iv. Existing Unit Overview 

5. Design Criteria 

i. Design Objectives 

ii. Design Parameters 

6. Evaluation of Alternatives 

i. General Descriptions 

0 Equipment 

General layout 

ii. Technical Evaluation 

0 Operating parameters 

Ability to meet project requirements 

iii. Economic Analysis 

0 Equipment 

0 Site preparation 

Installation/construction 

Operating costs 

iv. Environmental Issues 

0 Location / site preparation 

Operating 

0 Potential mitigation actions required 

v. Estimatcd Cost 

0 Equipment 

Site Preparation 

0 Installation / construction 

Operation 

Maintenance 

vi. Estimated Schedule 

7. Recommended Solution 

8. Attachments

Attachment C. PEF Technical Documentation 








8. Request for Information Form


PEF-NCR-0060 1

~ ~~ 

ProgressEnergy 

I 

Information 

Use 

NUCLEAR GENERATION GROUP 

STANDARD PROCEDURE 

VOLUME 99 

BOOK/PART 99 

SAF-NGGC-2172 

INDUSTRIAL SAFETY 

REVISION 8 

SAF-NGGC-2172 

REV. 8 

I 

Page I of 55


SECTION 

PAGE 

1.0 PURPOSE ............................................................................................................ 3 

2.0 REFERENCES ...................................................................................................... 3 

3.0 DEFINITIONS ....................................................................................................... 6 

4.0 RESPONSIBILITIES ............................................................................................. 8 

5.0 PREREQUISITES ................................................................................................. 8 

6.0 

PRECAUTIONS AND LIMITATIONS .................................................................... 8 

7.0 SPECIAL TOOLS AND EQUIPMENT ................................................................... 8 

8.0 ACCEPTANCE CRITERIA .................................................................................... 8 

9.0 INSTRUCTIONS ................................................................................................... 9 

9.1 Practice and Philosophy .................................................................................. 9 

9.2 Safety Meetings ............................................................................................... 9 

9.3 General Rules .................................................................................................. 9 

9.4 Personal Safety Protection ............................................................................ 11 

9.5 Hearing Conservation .................................................................................... 14 

9.6 Respiratory Protection ................................................................................... 15 

9.7 Confined Spaces ........................................................................................... 15 

9.8 Asbestos ........................................................................................................ 15 

9.9 Lead ............................................................................................................... 16 

9.10 Heat Stress .................................................................................................... 16 

9.11 Hazardous Chemicals .................................................................................... 16 

9.12 Electrical Safety ............................................................................................. 16 

9.13 Rubber Insulating Gloves .............................................................................. 17 

9.14 Handling, Use, and Storage of Portable Compressed Gas Cylinders ........... 18 

9.15 Rigging ........................................................................................................... 19 

9.16 Safe Sling Operations .................................................................................... 19 

9.17 Fall Protection ................................................................................................ 20 

9.18 Ladders .......................................................................................................... 21 

9.19 Scaffolding ..................................................................................................... 22 

9.20 First Aid Including Bloodborne Pathogens ..................................................... 22 

9.21 Safety Showers and Eyewash Stations ......................................................... 23 

9.22 Office Safety .................................................................................................. 23 

9.23 Compressed Air Use ...................................................................................... 23 

9.24 Work Over Water ........................................................................................... 24 

SAF-NGGC-2172 

REV . 8 

PEF-NCR-00603 

I Page 2 of 55


SECTION 

PAGE 

9.25 Pedestrian Safety .......................................................................................... 24 

9.26 Motor Vehicle Safety ...................................................................................... 24 

9.27 Trenching ....................................................................................................... 25 

9.28 Hydrolazing .................................................................................................... 25 

9.29 Job Safety Analysis ....................................................................................... 26 

9.30 Ergonomics .................................................................................................... 26 

10.0 RECORDS ..................................................................................................... 26 

ATTACHMENTS 

1 . BNP Personal Protective Equipment Designated Area Diagram and Site Hazard 

Assessment ................................................................................................. 27 

2 . HNP Personal Protective Equipment Designated Area Diagram and Site Hazard 

Assessment .............................................................................................................. 32 

3 . RNP Personal Protective Equipment Designated Area Diagram and Site Hazard 

Assessment .............................................................................................................. 37 

4 . HE&EC Personal Protective Equipment and Hazard Assessment ........................... 42 

5 . CR3 Personal Protective Equipment Designated Area Diagram and Site Hazard 

Assessment .............................................................................................................. 44 

6 . NGG Hazard Assessment PPE Matrix .................................................................... 49 

7 . Pneumatic Tool Safety Device Exemption ............................................................... 51 

8 . Personal Protective Equipment Waiver Form ........................................................... 52 

REVISION SUMMARY ......................................................................................................... 53 

PEF-NCR-00604

1.0 PURPOSE 

This procedure provides guidance and responsibilities for safe work practices for the Progress Energy 

nuclear generation group. 

2.0 REFERENCES 

2.1 

2.2 

2.3 

2.4 

2.5 

2.6 

2.7 

2.8 

2.9 

2.10 

2.11 

2.12 

2.13 

2.14 

2.15 

2.16 

2.17 

2.18 

2.19 

2.20 

2.21 

FRM-CPL-470, Power Generation, Distribution and Transmission Standard Annual Inspection 

Checklist Energy Supply Form 

29 CFR 1904, Recording and Reporting Occupational Injuries and Illness 

29 CFR 1910, Occupational Safety and Health Standards for General Industry 

29 CFR 1926, Occupational Safety and Health Standards for Construction Industry 

ANSI 241-1999 American National Standard for Personal Protection Protective Footwear 

ANSI 287.1 - 1991 American National Standard for Personal Protection - Personal Footwear 

ANSI 289.1 - 1997 Personnel Protection - Protective Headwear for Industrial Workers 

ANSI 2358.1-2004 American National Standard for Emergency Eyewash & Shower Equipment 

MNT-NGGC-0004, Scaffolding Control 

OPS-NGGC-1301, Equipment Clearance 

SAF-SUBS-00001, Health & Safety Guidance Document Introduction 

SAF-SUBS-00002, OSHA Recordkeeping 

SAF-SUBS-00003, Fire Prevention, Control and Evacuation 

SAF-SUBS-00004, Hearing Conservation 

SAF-SUBS-00005, Process Safety Management of Highly Hazardous Chemicals 

SAF-SUBS-00006, Hazardous Waste Operations and Emergency Response (HAZWOPER) 

SAF-SUBS-00007, Respiratory Protection 

SAF-SUBS-00008, Confined Space 

SAF-SUBS-00010, First AidlEmergency Medical Response 

SAF-SUBS-00011, Wheel Rim Service 

SAF-SUBS-00012, Asbestos Exposure Control


2.22 

2.23 

2.24 

2.25 

2.26 

2.27 

2.28 

2.29 

2.30 

2.31 

2.32 

2.33 

2.34 

2.35 

2.36 

2.37 

2.38 

2.39 

2.40 

2.41 

2.42 

2.43 

2.44 

2.45 

SAF-SUBS-00013, Lead Exposure 

SAF-SUBS-00015, Bloodborne Pathogens 

SAF-SUBS-00016, Hazard Communication 

SAF-SUBS-00017, Laboratory Safety 

SAF-SUBS-00018, Trenching and Excavation 

SAF-SUBS-00019, Fall Protection 

SAF-SUBS-00020, Power Generation, Distribution & Transmission 

SAF-SUBS-00021, Slips, Trips, and Fall Safety 

SAF-SUBS-00022, Stairway and Ladder Safety 

SAF-SUBS-00023, Compressed Gases 

SAF-SUBS-00024, Flammable and Combustible Liquids 

SAF-SUBS-00025, Personal Protective Equipment 

SAF-SUBS-00026, Marking Industrial Hazards 

SAF-SUBS-00027, Industrial TruckslForklifts 

SAF-SUBS-00029, General Machine Guarding 

SAF-SUBS-00030, Hand and Power Tool Safety 

SAF-SUBS-00031, WeldinglHot Work Safety 

SAF-SUBS-00033, Employee Incident Investigation 

SAF-SUBS-00034, Cranes and Rigging 

SAF-SUBS-00035, Diving Operations 

SAF-SUBS-00036, Scaffolding Safety 

SAF-SUBS-00039, DOT Motor Carrier Safety (FMCSR) Driver Qualification Process 

SAF-SUBS-00041, Contractor Safety 

SAF-SUBS-00042, Chemical Control 

SAF-NGGC-2172 

REV. 8 

Page 5 of 55


2.46 

2.47 

2.48 

2.49 

2.50 

2.51 

2.52 

2.53 

2.54 

2.55 

2.56 

2.57 

2.58 

2.59 

2.60 

2.61 

2.62 

SAF-SUBS-00043, DOT Motor Carrier Safety (FMCSR) Drug & Alcohol Program 

SAF-SUBS-00044, Exposure Assessment Guideline 

SAF-SUBS-00047, DOT Motor Carrier Safety (FMCSR) Driver and Supv. Responsibilities 

SAF-PGNC-00048, Protective Grounding Guidelines 

SAF-SUBS-00055, Electric Arc Flame Resistant Clothing Guideline 

SAF-SUBS-00060, Corporate Health & Safety Audit and Self-Assessment Programs 

SAF-SUBS-00062, Safety Council Meetings 

SAF-SUBS-00203, Ergonomics 

CHE-NGGC-0045, NGG Chemical Control Program 

LEG-SUBS-00001 , Reporting Procedure for Personal Injuries, Vehicle Accidents, Claims, and 

Damages 

ACGIH - Threshold Limit Values (TLVs) for Chemical Substances & Physical Agents, current 

edition 

SAF-NGGC-2175, Electrical Safety and ARC Flash Protection 

SAF-NGGC-2174, Confined Space Entry Procedure 

CAP-NGGC-0200, Corrective Action Program 

SAF-ESGX-00002, Energy Supply Fall Protection Procedure 

SAF-SUBS-00065, Safety Manual 

SAF-PGNF-00065, Accident Prevention Manual 

3.0 DEFINITIONS 

3.1 ACGIH 

American Conference of Governmental Industrial Hygienists 

3.2 ANSI 

American National Standards Institute 

I I I - 

PEF-NCK-00607


3.3 dBA 

Noise level in decibels measured on the A weighted scale of a standard sound-level meter or 

noise dosimeter at slow response. 

3.4 HEBEC 

Harris Energy and Environmental Center 

3.5 Hydrolazing 

High-pressure water washing at greater than 5000 psig 

3.6 Immediate Hazard 

3.7 MDLS 

3.8 MSDS 

3.9 NCR 

3.10 OSHA 

Hazard that has the potential to severely injure an individual or do significant damage to 

safety-related equipment. Examples of these hazards include, but are not limited to a leaking fuel 

tank, a severed high voltage electrical line, or damaged structural member. 

Materials Dedication and Laboratory Services 

Material Safety Data Sheet 

Nuclear Condition Report 

Occupational Health and Safety Administration 

3.1 1 Unsafe Act 

An action taken by a person or persons which is a departure from safe work practice, a task error, 

or an oversight, and which is correctable given proper knowledge, training, or leadership. 

3.12 Unsafe Condition 

A physical situation, circumstance, or situation which in itself creates the potential for accident or 

injury without the addition of an unsafe act being committed. 

SAF-NGGC-2172 REV. 8 

Page 7 of 55

4.0 

RESPONSIBILITIES 

4.1 

Site Vice-president 

Responsible for the implementation of this procedure. 

4.2 

Managers and Supervisors 

Responsible for ensuring all personnel under their supervision are fully aware of the hazards 

associated with the job, work procedures involved, special precautions, and personal protective 

equipment requirements and the requirements contained within this procedure. 

4.3 

Employees 

Responsible for maintaining the highest regard for safety while planning and conducting work. 

Employees are also responsible for ensuring that a safe work environment exists for themselves 

and their coworkers and for following the requirements contained within this procedure. 

4.4 

Occupational Health and Safety Section 

Responsible for providing information and guidance to employees regarding industrial hygiene 

and safety issues. 

4.5 

Designated Representatives 

Responsible for ensuring SAF-SUBS-00041, or site procedure is implemented for their contractor 

5.0 

PREREQUISITES 

As designated in this procedure. 

6.0 

PRECAUTIONS AND LIMITATIONS 


7.0 

SPECIAL TOOLS AND EQUIPMENT 


8.0 

ACCEPTANCE CRITERIA 

N /A 

SAF-NGGC-2172 

REV. 8 

Page 8 of 55

9.0 INSTRUCTIONS 

9.1 Practice and Philosophy 

9.1 ,I All employees shall use approved procedures and established safe practices when 

performing their duties. Employees should report all industrial safety related deficiencies 

and make recommendations as to how a safer working environment can be attained. 

Before undertaking a task, the employee should be satisfied and confident that the task 

can be done without subjecting himself or others to any unsafe condition or hazard. An 

employee should also assist his coworkers in ensuring their safety. Employees are 

required to comply with this procedure as well as all plant procedures, programs, and 

safety rules, which assure OSHA compliance. 

9.2 Safety Meetings 

9.2.1 All employees are expected to attend monthly safety meetings in accordance with 

SAF-SUBS-00062. When schedule conflicts do not permit attendance at assigned safety 

councils, each employee will arrange to make up the council meeting and notify their 

council secretary. Makeup meetings may include: 

9.3 General Rules 

Attending another council meeting 

Viewing videotape of a meeting 

Reviewing the Presentation Package for the meeting. 

9.3.1 

9.3.2 

9.3.3 

9.3.4 

Each supervisor shall determine through inspections conducted on at least an annual 

basis that each employee is complying with the safety related work practices required by 

this and other safety related procedures. This determination must be documented using 

FRM-SUBS-00470 or other similar means. 

It is the responsibility of each person to be observant of unsafe acts or conditions and to 

document these observations utilizing site observation procedures or the Corrective 

Action Program. When unsafe acts or conditions pertaining to personnel safety are 

observed, they should be promptly corrected if possible. If not possible, mark them in 

some way as to prevent others from inadvertently coming into contact with the hazard. 

Personal injuries, property damage, and near misses shall be reported and investigated in 

accordance with the Site Accident Investigation and Corrective Action Program. All First 

Aid reports shall be sent to the Site Occupational Health and Safety Specialist. 

The person in charge of the job or crew shall conduct a pre-job briefing before the start of 

each day or when significant work changes occur. Briefings should be conducted in 

accordance with site procedures 


Page 9 of 55


9.3.5 Red and black (danger) barrier ribbon (or equivalent to meet intent) is used to identify 

imminent hazards which, if not avoided, will result in death or serious injury. A sign 

identifying the person in charge, the hazard, and contact phone number must be posted in 

areas where red and black barrier ribbon is used if the area is not immediately occupied 

and controlled by the work group using the barrier ribbon. Personnel shall not cross the 

boundary without permission of personnel working on the job. Red and black barrier 

ribbon shall not be used as a substitute for approved railing, floor hole covers, or a hole 

watch. 

9.3.6 Yellow and black (caution) barrier ribbon (or equivalent to meet intent) shall be used for 

potential hazards which, if not avoided, could result in minorlmoderate injury. A sign 

identifying the hazard should be posted when barricading a work area with caution ribbon 

if the area is not immediately occupied and controlled by the work group using the barrier 

ribbon. 

9.3.7 When working overhead, keep tools and small materials not in use, in belts or in an 

appropriate container. Consider utilizing tool lanyards when the possibility exists for tools 

to be dropped onto employees working below. Use a bucket andlor hand line to raise and 

lower tools, and materials. Do not throw anything up to or down from any elevated work 

position. 

9.3.8 When possible, do not stand where you could be struck by tools or materials accidentally 

dropped from above. 

9.3.9 Smoking is not permitted in radiation control areas, or in areas which contain flammables 

such as gasoline, oil, acetylene, hydrogen, solvents, or paint that is stored or in use. 

Smoking is also prohibited in all buildings on site and in all company vehicles. 

9.3.10 Use extreme caution and appropriate protective clothing when handling or transporting 

acids, caustics, hot water, or other chemicals; or when working around steam systems 

(see Attachment 6 NGG Hazard Assessment Matrix). Use MSDS for use of hazardous 

chemicals. 

1, Assure cargo is properly distributed and adequately secured on or within 

transportation vehicle. 

2. Prevent cargo from leaking, spilling, blowing or falling from transportation vehicle. 

3. Cargo must be secured to prevent shifting within the transportation vehicle to an 

extent that stability or maneuverability is affected. 

9.3.1 1 Handrails should be used when ascending or descending stairs. 

9.3.12 Each site should implement an Emergency Evacuation Plan in accordance with 

SAF-SUBS-00003 or site procedures. 

9.3.13 Each employee should know the location of the nearest exit from the area in which he is 

working, should rapid evacuation be necessary. 

PEF-NCR-006 1 1


9.3.14 When machining on contaminated lathes in the hot machine shop (i.e., grinding, cutting, 

boring, turning, and polishing), employees should dress in short-sleeved scrubs or paper 

PCs with elastic wristbands, and surgeon's gloves. Employees shall dress in accordance 

with their appropriate RWP while they prepare, set up, and perform work on the work 

piece. 

9.3.15 All hand and power tools shall be inspected in accordance with site procedures and 

manufacturers' recommendations before and after each use . Damaged and/or defective 

tools shall be removed from service immediately and repaired or discarded. 

9.3.16 Each person is responsible for maintaining a high standard of housekeeping within the 

areas under hidher control and for cleaning up the work area at the conclusion of each 

job or work day. 

9.3.17 Air hoses supplying pneumatic tools and exceeding 1/2" ID must be equipped with a 

safety device to reduce pressure in the event of failure. Where a pneumatic tool will not 

operate with a safety device in place, the proper operating condition of the tool has been 

verified, the proper air hose size has been verified, the proper safety device size and 

operational condition has been verified, and no other usable tool is available on site, an 

exemption to this requirement may be granted by completing Attachment 6, Pneumatic 

Tool Safety Device Exemption. This should be considered a solution of last resort. 

9.3.18 Drill motors and powered saws without installed guards shall be stored in tool rooms with 

bits and blades removed or sheathed to prevent puncture and/or laceration hazards. 

9.4 Personal Safety Protection 

9.4.1 Each Site has designated areas where personal protective equipment will be worn. Refer 

to specific site procedures or Attachments 1, 2, 3, 4 or 5 to identify areas. Proper 

protective clothing and equipment shall be worn while performing jobs that are potentially 

hazardous from a chemical, radiological, or physical aspect. Protective clothing for jobs 

involving hazardous chemicals shall be utilized in accordance with the appropriate MSDS. 

9.4.2 Shirt sleeves, lanyards, ties, jewelry, hair, etc., will be properly secured when working in 

the plant while working around operating or moving equipment. 

9.4.3 Finger rings, loose chains, metal wrist bands, other metal jewelry or key rings shall not be 

worn while working around moving machinery, on energized lines and equipment, or 

when performing any other hands-on activity where these articles may present a hazard.


9.4.4 Hard hats should be worn while headsets are in use whenever an overhead or bumping 

hazard exists. If a supervisor deems this impossible, the employee must be a safe 

distance from the hazard and must don the hat immediately following task completion. 

Attachment 8 Personal Protective Equipment Waiver form or the FRM-SUBS-01086 PPE 

waiver form (link to the form can be found in SAF-SUBS-00025) shall be used to 

document the waiving of the requirement for a hard hat by the supervisor 

9.4.5 Travel directly from dress-out area to contaminated work area and directly from 

contaminated work area back to dress-out area without hard hat is allowed IF NO HEAD 

INJURY HAZARDS EXIST IN THE TRAVEL PATH. 

9.4.6 Caps and other headwear that interferes with the capability of the suspension of hard hats 

shall not be worn under the hard hat (this does not include non-flammable welding caps 

or liners designed to be worn under hard hats for cold weather protection.). 

9.4.7 Prior to welding, cutting, or brazing employees shall have eye protection with the required 

shade number for that job. Safety glasses shall be worn under welding hoods. 

9.4.8 Do not look at a welding arc unless a welding shield with suitable lens is used. Where 

feasible and necessary, welding screens shall be used to protect employees in adjacent 

work areas from the potential effects of the welding arc, in accordance with 


9.4.9 Flame retardant PCs shall be worn while stick welding, arc-gouging and cutting activities 

involving oxygenlacetylene. Flame retardant PCs should be evaluated for use when 

performing other types of hot work. 

9.4.10 Shoes shall be appropriate for the activity being performed. Reinforced toe protection 

approved by ANSI 241-1 999 (steel toe, composite, etc.) is required when work conditions 

warrant. This includes areas where there is a danger of foot injuries due to crushing, 

falling or rolling objects or objects piercing the sole and where feet are exposed to 

electrical hazards. 

1. The sole of the shoe must provide a substantial degree of puncture and slip 

resistance. 

2. Upper construction of the shoe shall be substantial, non-porous material such as 

leather. 

3. Employees actively involved with work where there are foot hazards shall wear 

toecap safety shoes in accordance with ANSI-Z41-1999 and the site hazard 

assessment. 

4. Only boots or shoes with discrete heels shall be worn to help prevent slipping 

when climbing poles and towers. 

9.4.1 1 All employees, contractors and visitors will wear gloves while engaged in maintenance, 

operational and other physical work activities that could pose a potential hand injury in 

industrial areas (see Attachment 6 NGG Hazard Assessment PPE Matrix). 

SAF-NGGC-2172 

REV. 8 Page 12 of 55


9.4.12 Supervisors may exempt (during the pre-job brief) glove use in those cases where gloves 

interfere with the work being performed and adequate protection is provided. 

9.4.1 3 The hazard of wearing gloves while operating rotating machinery must be assessed to 

determine if hand protection presents a greater risk to the worker. 

9.4.14 Each site is responsible for conducting and documenting a personal protective equipment 

hazard assessment (see Attachments 1, 2, 3, 4, 5, and 6). 

9.4.15 Safety Equipment shall be used in accordance with the Site Personal Protective 

Equipment Hazard Assessments (see Attachments 1, 2, 3, 4, 5, and 6). 

9.4.16 Clothing worn must conform to good safety practices. Shorts, tank shirts, T-shirts without 

sleeves, cut-off shirts, or fishnet type shirts are generally not permitted. 

9.4.1 7 Employees working with exposed energized electrical conductors or equipment that has 

potential for electric arcs shall wear clothing in accordance with SAF-NGGC-2175. 

9.4.18 Personal protective equipment waivers may be granted on a case-by-case basis by the 

job supervisor or site Occupational Health and Safety Specialist. Use Attachment 8 

Personal Protective Equipment Waiver form or FRM-SUBS-01086 PPE Waiver Form (link 

can be found in SAF-SUBS-00025 Personal Protective Equipment) to document the 

waiver. 


Page 13 of 55

~~ 

9.5 Hearing Conservation 

9.5.1 

9.5.2 

Each site will implement a continuing effective hearing conservation program as outlined 

in SAF-SUBS-00004. 

Areas greater than 85 dBA shall be posted with the following sign or alternative language 

that identifies the hazard and meets the intent for level of protection: 

CAUTION 

Hearing Protection Required 

When Working in This Area 

While Machinery is Operating 

9.5.3 

9.5.4 

9.5.5 

Individuals will be responsible for adhering to hearing protection signs and using adequate 

hearing protection equipment where required by elevated sound levels. 

Managers and supervisors shall ensure that personnel working in designated hearing 

protection areas wear adequate hearing protection. 

Hearing protection is required in those areas not posted when, due to the nature of the 

work being performed, there exists noise levels greater than 85 dBA. Hearing protection 

should also be considered whenever unmeasured noise levels appear to be excessive. 

Supervisors may contact the site Occupational Health and Safety Specialist for assistance 

in making sound level determinations. 

. SAF-NGGC-2172 

REV. a Page 14 of 55

9.6 Respiratory Protection 

9.6.1 The use of respiratory protection related to radiation safety is specified and controlled in 

accordance with the site respiratory protection procedure. 

9.6.2 The use of respiratory protection related for non-radiological purposes must be in 

accordance with the SAF-SUBS-00007 or site procedures. 

9.6.3 Respirators shall be used when engineering controls cannot reduce personal exposure to 

airborne non-radiological hazard(s) to concentrations below OSHA established 

Permissible Exposure Limits (PELS) andlor ACGIH Threshold Limit Values (TLVs). 

9.7 Confined Spaces 

9.7.1 Each site will implement a confined space entry program in accordance with 

SAF-NGGC-2174. 

9.7.2 A confined space may contain a life-threatening atmosphere or condition. An area is 

referred to as a confined space if it meets all three of the following criteria: 

9.8 Asbestos 

any space not intended for continuous human occupancy, 

any space having a limited means of access and egress (Le., tanks, vessels, vaults, 

pits), 

is large enough and so configured that an employee can bodily enter and perform 

assigned work. 

9.8.1 Asbestos removal shall be performed in accordance with SAF-SUBS-00012 or site 

procedures. 

9.8.2 Asbestos may be present in the plant in many forms. Some of these forms include but 

are not limited to the following: insulation such as pipe, duct, boiler wall, electrical cable 

insulation, and arc chutes; building materials such as transit board, ceiling and floor tile, 

roofing materials, acoustic and fireproofing insulation, and friction and mechanical 

products including brake shoes, clutch lining valve packing, and gasket material. All of 

these materials shall be treated as suspect asbestos containing material until 

appropriately licensed personnel determine otherwise. If material is presumed to be 

asbestos work must proceed according to the site asbestos exposure control program. 

9.8.3 All asbestos containing materials that needs to be removed shall be removed only by 

appropriately trained personnel. 


Page 15 of 55

9.9 Lead 

9.9.1 Lead removal shall be performed in accordance with SAF-SUBS-00073 or site 

procedures. 

9.9.2 Lead may be present in the facilities in the form of: paint and coatings, as well as in bricks 

and blankets used for radiological shielding. All lead or suspect lead containing material 

shall be treated as containing lead unless determined otherwise. 

9.10 Heat Stress 

9.10.1 Each site shall implement a heat stress procedure in accordance with SAF-SUBS-00032 

or site procedures. 

9.10.2 Use extreme care when working in hot environments. Length of time in a work area, 

special clothing, and adequate fluid intake should be considerations when determining 

stay times for work in hot environments. 

9.1 1 Hazardous Chemicals 

9.1 1 .I All employees shall be trained on the hazards associated with the chemicals with which 

they work, the personal protective equipment to be used, the location of the MSDS, the 

labeling procedures, and the location of the Hazard Communication Program. Training 

shall be in accordance with SAF-SUBS-00016 and CHE-NGGC-0045 as applicable. 

9.1 1.2 Employees should consult with their supervisor, the MSDS, and follow CHE-NGGC-0045 

prior to using any new or potentially hazardous chemicals. 

9.1 1.3 Handling of flammablelcombustible substances shall be in accordance with 


9.12 Electrical Safety 

9.12.1 Work performed on electrical equipment will be performed in accordance with 

SAF-NGGC-2175. 

9.12.2 All electrical hand tools will be provided with adequate shock protection; that is, three 

prong plugs or a double insulated frame. 

9.12.3 No electrical hand tool that is considered unsafe will be reissued until repaired. Any tool 

which is not working properly will be repaired and tested prior to issue or discarded. 

SAF-NGGC-2172 

REV. a I Page 16 of 55

9.12 Electrical Safety 

9.12.4 Electrical equipment will be inspected and has the current quarterly inspection color code 

(if applicable) visible on the cord, is equipped with a ground fault circuit interrupter (GFCI) 

or ground continuity monitor (GCM) or is double insulated in accordance with site 

procedures. 

9.12.5 Extension cords and cables may not be used in place of permanent wiring of a structure. 

Avoid "daisy-chaining" multi-strip power devices or using these devices in conjunction with 

an extension cord. 

9.12.6 All electrical hand tools will be inspected for defects prior to use. 

9.12.7 When erecting scaffolding, ladders, or similar equipment in the vicinity of electrical 

equipment with the potential for an electrical arc or if an electrical arc is observed, STOP 

WORK and notify the Superintendent - Shift Operations. Certain areas in the plant have 

been markedlidentified where this potential for arcing exists (e.g., around isophase bus 

ducts). 

9.13 Rubber Insulating Gloves 

9.13.1 Rubber insulating gloves shall be inspected and air tested prior to each use. 

9.13.2 Rubber insulating gloves shall be periodically tested by the a test laboratory and stamped 

with an expiration date. Gloves will not be used beyond the stamped expiration date. 

9.13.3 Rubber insulating gloves shall always be used with the appropriate glove protectors. 

9.13.4 Low voltage gloves are rated for 1,000 volts maximum. High voltage gloves are rated for 

17 kV maximum. Class 00 gloves are rated at 500V maximum. 

9.13.5 Low voltage gloves shall be red or yellow in color. High voltage gloves shall be black in 

color. At sites where Class 00 gloves are used they will be white or blue in color. 

SAF-NGGC-2172 

REV. 8 

Page 17 of 55 I 

PEF-NCR-006 18

9.14 Handling, Use, and Storage of Portable Compressed Gas Cylinders 

9.14.1 Cylinders shall be used in accordance with SAF-SUBS-00023 and SAF-SUBS-00031. 

9.14.2 Cylinders not used in a 24-hour period shall be placed in storage. 

9.14.3 Cylinders shall be stored at least 20 feet from flammable and combustible liquids and 

easily ignitable forms of materials such as wood, paper, oil, and grease. 

9.14.4 Cylinders shall be stored where they will not be exposed to excessive rise in temperature 

or physical damage. 

9.14.5 All cylinders shall have their valves closed while in storage and during transit. Empty 

cylinders should be tagged or labeled as being empty. 

9.14.6 Cylinder caps shall be in place except when cylinders are in service or connected ready 

for service. 

9.14.7 Cylinders shall be securely restrained to prevent tipping at all times 

9.14.8 Welding or cutting work shall not be physically supported by compressed gas cylinders. 

9.14.9 Gas shall not be transferred from one cylinder to another or mixed with another gas in a 

cylinder, except for approved cascading systems. 

9.14.10 Leaks from valves or fittings on compressed gas cylinders, with the exception of Freon 

cylinders, should be stopped by closing of the valve or taken outdoors away from sources 

of ignition and slowly emptied. Leakage through a valve outlet may be temporarily 

stopped by attaching a regulator. The cylinder should have a note attached in such a way 

as to indicate the nature of trouble. The cylinder shall be stored separately from the other 

used cylinders. When the vendor picks up the used cylinder they shall be advised of the 

leaking cylinders. 

9.14.11 Cylinders should be located at a safe distance from the welding or be appropriately 

protected so that they will not be exposed to sparks, slag, or misdirection of the torch 

flame or overheating from hot materials of processing. 

SAF-NGGC-2172 

REV. 8 

Page 18 of 55

9.14 Handling, Use, and Storage of Portable Compressed Gas Cylinders 

9.14.12 Cylinders not having fixed hand wheels should have keys or handles on valve stems while 

these cylinders are in service. In multiple cylinder installations, only one key or handle is 

required for each manifold. 

9.14.1 3 Compressed gas cylinder valves should be opened slowly. 

9.14.14 Before a regulator is removed from a cylinder valve, the cylinder valve should be closed 

and the gas released from the regulator. 

9.14.15 As oxygen under high pressure may react violently with oil or grease, every possible 

precaution should be taken to prevent oxygen from coming in contact with oil or grease. 

Oxygen cylinders, valves, regulators, hose, and other apparatus shall be kept free from oil 

or grease and should not be handled with oily hands, oily gloves, or with greasy 

equipment. 

9.14.16 Acetylene cylinders must be kept in an upright position at all times. 

9.14.17 Acetylene, propane, methane, ethylene and hydrogen should not be used in torches or 

other devices without reducing the pressure through a suitable regulator. 

9.15 Rigging 

9.15.1 Rigging shall be inspected, and performed in accordance with SAF-SUBS-00034 or site 

rigging procedures. 

9.16 Safe Sling Operations 

9.16.1 Slings shall be inspected, and used in accordance with SAF-SUBS-00028 or site rigging 

procedures. 

9.16.2 Damaged or defective slings shall not be used. 

9.16.3 Slings shall not be shortened with knots, bolts or other makeshift devices. 

9.16.4 Slings shall not be kinked. 

9.16.5 Loads lifted in a basket hitch shall be balanced to prevent spillage 

9.16.6 Slings shall be securely attached to the load. 

9.16.7 Suspended loads shall be kept clear of all obstructions. 

9.16.8 Personnel shall be kept clear of suspended loads and loads about to be lifted. 

9.16.9 Hands and fingers shall not be placed between sling and load while sling is being 

tightened around load. 

9.16.10 Tag lines shall be employed to guide loads and prevent excessive sway during load 

movement. 

SAF-NGGC-2172 

REV. 8 

Page 19 of 55

9.17 Fall Protection 

9.17.1 Fall protection should be used in accordance with SAF-ESGX-00002, SAF-SUBS-00019, 

SAF-SUBS-00021 and site procedures. 

9.17.2 All fall protection users must be properly trained and qualified as directed in SAF-ESGX- 

00002. 

9.17.2 Safety harnesses and lanyards shall be inspected by each user prior to use. 

9.17.3 Full body harnesses with shock absorbing lanyards shall be used when working at 

unprotected elevations above six feet. 

9.17.4 Lanyards shall not be tied to themselves in a choked manner. If the anchorage point is 

too large for the lanyard to hook directly on, the employee shall use an anchorage strap or 

other approved attachment device to attach to the anchorage point. Note: Lanyards with 

an installed D-Ring can be connected back to the D-Ring. 

9.1 7.5 Escorts of contractors and vendors shall ensure fall protection requirements are followed. 

9.17.6 Occupied elevated fixed ladder access points and floor openings shall be guarded by a 

floor cover, guardrail or other substantial physical barrier, or shall be constantly attended 

to prevent personnel from falling into openings. 

9.1 7.7 Employees shall wear properly tied-off safety harnesses whenever working in manlifts or 

aerial lifted baskets. It is not required for employees to tie-off in manlifts that move only in 

the vertical direction and have OSHA approved handrails, midrails and toeboards. 

9.17.8 A safety harness is not to be used to support any employee. It is a back-up safety device 

only in case the employee slips or falls. 

9.1 7.9 When utilizing personal fall protection, employees shall select appropriate anchorage 

points as indicated in Attachment 2 or Attachment 3 in SAF-ESGX-00002. 

9.17.10 Climbing on insulated pipes, pipe hanger components, and instrument lines is prohibited, 

except where the nature of the work is such that no damage is expected and other 

options are determined as not being feasible. 

9.17.1 1 Climbing on cable trays is to be minimized. In cases where access to equipment can 

ONLY be attained by climbing on or through cable trays, the access will be permitted 

while exercising maximum caution. The possible damage to insulation, instrument lines, 

and power cables make strict compliance with this rule mandatory. 


Page 20 of 55

9.18 Ladders 

9.18.1 Ladders should be erected, used and stored in accordance with SAF-SUBS-00019, 

SAF-SUBS-00022 and SAF-SUBS-00036 or site procedures. 

9.18.2 Ladders shall be inspected in accordance with the site's maintenance inspection 

programs AND prior to each use by the ladder user. At a minimum, the following items 

should be included in the inspection: 

Missing or damaged components (e.g., cracked side rails, bent or damaged 

rungs, missing non-slip material on feet of ladder, loose or missing rivets, screws, 

or bolts, etc.) 

All fasteners are secure 

All moving parts are in good working order 

Side rails and rungs are free from dirt, oil or other foreign material. 

Defective ladders shall be removed from service for repair or destruction and tagged or 

marked, "Dangerous, Do Not Use" or other suitable verbiage. 

9.18.3 Step ladders shall be used appropriately with legs fully extended and locked, and shall not 

be used as extension ladders. 

9.18.4 Portable rung and cleat ladders shall, where possible, be used at such a pitch that the 

horizontal distance from the top support to the foot of the ladder is one-quarter of the 

working length of the ladder (the length along the ladder between the foot and the top 

support). The ladder shall be so placed as to prevent slipping, and it shall be tied off, or 

held in position. Ladders shall not be used horizontally as platforms, runways, or 

scaffolds. 

9.18.5 When working on a ladder resting against a pole or round structure, always secure the 

ladder at the top. Until this is done, have someone hold the ladder. 

9.18.6 The top of a ladder used to gain access to a roof or working platform shall extend at least 

three feet above the roof or platform, where possible. 

9.18.7 Ladders shall not be placed in front of doors opening toward the ladder unless the door is 

blocked, locked, or guarded. 

9.18.8 Ladders shall not be placed on boxes, barrels, or other unstable bases to gain additional 

height. 

9.18.9 Fall protection shall be utilized when working off a ladder 6 feet from the surface on 

which the ladder is resting, Le, ladder set up on floor level with a fall potential nearby 

below the floor level. 

9.18.10 Employees shall not climb ladders with tools, materials or anything else in their hands. 

I SAF-NGGC-2172 REV. 8 

PEF-NCR-00622

9.19 Scaffolding 

9.19.1 All scaffolds shall be erected and used in accordance with SAF-SUBS-00036 or 

MNT-NGGC-0004. 

9.19.2 All scaffolding and their supports shall be capable of supporting at least four times the 

intended load. 

9.19.3 When work on a specific scaffold requires the use of personal fall protection because of 

the scaffold's construction (incomplete rails), the fall protection requirements shall be 

specified on the scaffold tag. 

9.19.4 Working on scaffolding during high winds, storms or when snowlice is present on 

scaffolding is prohibited. 

9.19.5 Scaffold information tags shall be attached to all scaffolds. These information tags shall 

include pertinent hazard information relevant to work to be performed on the scaffold 

(e.g., exposed hot pipes, overhead hazards, special fall protection systems and 

requirements, etc.) and shall be reviewed by all scaffold users prior to climbing the 

scaffold. 

9.20 First Aid Including Bloodborne Pathogens 

9.20.1 Every accident, no matter how minor, must be reported promptly to your supervisor or the 

person in direct charge of the work and the site Occupational Health and Safety 

Specialist. Individuals working at an NGG site who do not report to the site must report all 

injuries occurring at the site to their CBO supervisor or site contact (so that For-Cause 

FFD testing requirement can be evaluated) and to the site Occupational Health and 

Safety Specialist as soon as possible. 

9.20.2 Accident reports shall be completed in accordance with LEG-SUBS-00001 , 

SAF-SUBS-00002, SAF-SUBS-00033, or site procedures. 

9.20.3 Injured employees requiring emergency medical treatment shall call the control room at 

X5555 to obtain assistance. HE&EC shall call 91 1. 

9.20.4 Exposure incidents for employees, who have had contact with blood or other body fluids, 

shall be handled in accordance with SAF-SUBS-00015 or site procedures. 

9.20.5 In the event of area contamination with blood or other body fluids that pose the potential 

for presence of bloodborne pathogens, contact the site group that is trained for clean-up 

and decontamination of bloodborne pathogen containing materials. 

I SAF-NGGC-2172 I REV. a I 

PEF-NCR-00623

9.21 Safety Showers and Eyewash Stations 

9.21 .I Safety showers and eyewash stations are provided at appropriate locations throughout 

the plants and the HE&EC. These eyewash stations shall be maintained in accordance 

with SAF-SUBS-00010 or site procedures. 

9.21.2 Portable eyewash stations are available from Materials Control, and shall be used in 

areas where caustic or acid compounds, or other chemicals which are hazardous to the 

eyes, are used and fixed eyewash stations are not available. 

9.21.3 Drench hoses meeting the requirements of ANSI 2358.1-2004 Emergency Eyewash and 

Shower Equipment may be used in lieu of a portable eyewash station andlor emergency 

showerleyewash station. 

9.21.3 Weekly inspections (activation) of safety showers and eyewash stations shall be 

performed in accordance with site procedures. 

9.21.4 It is each employee’s responsibility to be familiar with the location and operation of safety 

showers and eyewash stations prior to beginning any job where their use may be 

necessary. 

9.22 Office Safety 

9.22.1 Repairs to any office machinery shall be made by qualified personnel only. 

9.22.2 Only one drawer of a file cabinet should be opened at time and should not be opened and 

left unattended. When possible, stand to the side of the cabinet when opening drawers 

and do not rely on file drawer stops to prevent drawer from falling out. Ensure filing 

cabinet top drawers are not overloaded as to allow tipping of the cabinet when drawers 

are opened. 

9.22.3 Tilting in chairs which raises the chair’s feet from the floor is prohibited. 

9.22.4 Standing on swivel chairs is prohibited. 

9.22.5 Use caution when lifting loads. Ensure a clear path is available prior to moving loads. 

Use the legs, bend at the knee, keep the back straight and lift by straightening the legs. 

Carry loads close to the body. Twisting the torso should be avoided when carrying a load. 

Change the position of your feet to change direction. 

9.22.6 Electrical extension cords should not be used as a substitute for permanent wiring. When 

extension cords are a temporary necessity, they should be taped down, clipped to the 

back of desks or covered with a rubber passageway if they cross walkways. Avoid “daisychaining” 

multi-strip power devices or using these devices in conjunction with an 

extension cord. 

9.23 Compressed Air Use 

9.23.1 Compressed air greater than 30 psi shall not be used for cleaning. 

9.23.2 Air hoses exceeding %“ ID must be equipped with a safety device to reduce pressure in 

the event of failure when used with pneumatic tools (Reference Attachment 6, Pneumatic 

Tool Safety Device Exemption). 

PEF-NCR-00624

9.23 Compressed Air Use 

9.23.3 Job-made air hose connects shall be constructed in accordance with manufacturers' 

recommendations. At least two securing bands should be used when making hose 

connects. 

9.24 Work Over Water 

9.24.1 All employees who work over or near water, or where danger of drowning exists without 

the protection of guardrails, fall protection, etc., shall wear U.S. Coast Guard approved life 

jackets or buoyant work vests. All equipment shall be inspected prior to and after each 

use for defects. Defective equipment shall not be used. 

9.24.2 Ring buoys with an appropriate amount of attached line shall be provided and readily 

available for emergency rescue operations during times when employees are working in 

areas above water. 

9.24.3 At least one lifesaving skiff shall be immediately available at locations where employees 

are working over or adjacent to water and are not tied off to prevent them from falling into 

the water. Reactor cavities (when flooded) and spent fuel pools are exempt from this 

requirement. Bodies of water which may be too small or otherwise inappropriate for 

accommodation of a skiff should be evaluated for alternatives. 

9.25 Pedestrian Safety 

9.25.1 Pedestrians should observe crosswalk markings; stay within the lines and to the right. 

9.25.2 Pedestrians should wait for all traffic to come to a complete stop. 

9.25.3 Pedestrians should check both ways and allow enough time to cross safely. 

9.25.4 Handrails should be used when ascending or descending stairs. 

9.26 Motor Vehicle Safety 

9.26.1 Compliance with DOT driving regulations shall be in accordance with SAF-SUBS-00039 

and SAF-SUBS-00047. 

9.26.2 Employees shall not attempt to get on or off a moving vehicle. 

9.26.3 Any employee operating a company vehicle licensed for off-site use shall ensure that a 

first aid kit and a fully charged fire extinguisher are installed. 

9.26.4 Seat belts and shoulder harness shall be used when operating company vehicles, if 

so-equipped. 

SAF-NGGC-2172 

. REV. a 

Page 24 of 55

9.26 

Motor Vehicle Safety 

9.26.5 Employees shall ride in or on only properly protected area of vehicles in motion - never on 

bumpers, tail gates, running boards, fork-lift forks, fenders or other hazardous locations. 

9.26.6 Employees will obey all site, local and state regulations when operating vehicles. 

9.26.7 Employees will obey posted speed limits and other traffic regulation signs on site. 

9.27 

Trenching 

9.27.1 At any excavation site there shall be a competently trained person, who is capable of 

identifying existing and predictable hazards and who shall have the authority to take 

prompt corrective action to eliminate them on the site. Through training, this individual 

shall be able to determine soil classifications and select protective systems to be used. 

9.27.2 ALL trenches and excavations greater than 5 feet in depth must be sloped, benched or 

shored. Trenches and excavations must be either sloped back to its proper angle to 

achieve a stabilized slope, properly benched or must be shored with a protective system. 

(However, some excavations and trenches less than 5 feet in depth may be sloped or 

shored dependent upon the examination of the competent person.) 

9.27.3 Trenches and excavations DO NOT require sloping or shoring when: 

Excavations are made entirely in stable rock 

Excavations are less than 5 feet in depth and examination of the ground by the 

competent person provides no indication of a potential cave-in. 

9.27.4 All work in excavations shall be performed in accordance with SAF-SUBS-00018 and/or 

site procedures. 

9.28 

Hydrolaring 

9.28.1 Persons performing hydrolazing shall be trained in hydrolazing hazards prior to 

performing work. 

9.28.2 Only dual trigger hydrolazing guns may be used with wands less than 36 inches in length. 

The release of either trigger must immediately shut off the hydrolazing gun. 

9.28.3 Access to the area where hydrolazing is being conducted shall be restricted to minimize 

the number of persons exposed. 

9.28.4 Persons performing hydrolazing shall wear Kevlar gloves, rubber gloves, face shields, and 

rubber boots with steel toes and metatarsal guards, as a minimum. Personal protective 

equipment requirements may be modified by the job supervisor or site Occupational 

Health and Safety Specialist based upon the hazard analysis of the specific job. 

SAF-NGGC-2172 

REV. 8 

Page 25 of 55

9.29 Job Safety Analysis 

9.29.1 Job supervisors or their designee shall perform a written Job Safety Analysis (JSA) on 

projects or work activities that they deem warrant an additional safety barrier. The JSAs 

will include, at a minimum, job steps, hazards associated with the work activities, 

measures to be taken to minimize or eliminate the hazards and a person responsible for 

the measure. It is the responsibility of the job supervisor to complete the JSA and ensure 

employees know and understand the expected safe work practices for any job evaluated 

by the JSA. 

9.29.2 Jobs that may require a JSA include, but are not limited to, the following: 

9.30 Ergonomics 

New or infrequently performed jobs 

Jobs that require extensive manual handling of material 

Jobs with a high risk of injury or damage to equipment (consider using internal 

and external OE to determine if job may need a JSA) 

Jobs with a history of injury or near misses (consider using internal and external 

OE to determine if job may need a JSA) 

Jobs that entail long-term repetitive actions 

Critical jobs with perceived time constraints. 

9.30.1 Ergonomics is the multi disciplinary study of the interaction between people and their 

working environment. The working environment includes the physical environment (e.g. 

temperature, light) and the tools and equipment that are used for performing the job (e.g., 

including workstations, computers, hand tools, etc.). Failure to address ergonomics in 

designing or performing work can reduce the comfort and efficiency of employees and 

lead to workplace injuries and illnesses. 

9.30.2 Refer to SAF-SUBS-00203 for further guidance. The purpose of this guidance is to 

provide an effective process to identify, evaluate and control ergonomic risk factors that 

can lead to employee discomfort. 

10.0 RECORDS 

10.1 All OSHA-required records shall be kept in accordance with: 

- 29CFR1904 

- 29CFR1910 

- 29CFR 1926 

- SAF-SUBS-00002

ATTACHMENT 1 

Sheet 1 of 5 

BNP Personal Protective Equipment Designated Area Diagram 

29 CFR 1910 Subpart I 

Certification of Hazard Assessment - 7 September 2006 

I 

I 

ENP SITE MAP 

0 Safety Glasses Rquried in Yafltenace shops 

* HardHdsandSafetyGlwewes NolReguiredonOerignated 

Tnvel M to Conbd Rm. 

SAF-NGGC-2172 

REV. 8 

Page 27 of 55

ATTACHMENT 1 

Sheet 2 of 5 


BNP Personal Protective Equipment Site Hazard Assessment 

This hazard assessment covers typical work situations in various areas of the Brunswick Nuclear 

Plant. The Site PPE Designated Area Diagram on page 1 of this Attachment designates areas 

where hard hats and safety glasses shall normally be worn regardless of work taking place (shaded 

areas). 

Tasks shall be evaluated by supervision and specific personal protective equipment (PPE) identified 

and used in accordance with that evaluation and this assessment. The Job Safety Analysis (JSA) 

Process (see section 9.30 of this procedure) can be used as a tool in determining PPE 

requirements. Some types of PPE are addressed in other program documents such as procedures 

and guidance documents. Non-routine tasks that are not addressed in this hazard assessment 

must be evaluated on a case-by-case basis and appropriate PPE identified and used. The site 

Occupational Health and Safety Specialist is available to provide assistance in performing these 

evaluations. 

Supervision can, on a case-by-case basis, adjust the requirements for PPE for a defined task after 

personnel hazards have been clearly determined. Waivers to PPE requirements may be granted on 

a case-by-case basis by the job supervisor provided that there are no hazards in the work area 

requiring such PPE or it is deemed that a higher risk of injury or illness exists by using that PPE. 

The PPE waiver shall be documented on Attachment 8 of this procedure or on FRM-SUBS-01086, 

PPE Waiver (link to this form is found in SAF-SUBS-00025 Personal Protective Equipment). 

MINIMUM PPE REQUIREMENTS 

IF, industrial-type work is to take place in areas not addressed on the Site PPE Designated Area 

Diagram, THEN minimum PPE requirements include, but are not limited to, safety glasses, 

appropriate work shoes, and appropriate gloves for the task. 

Some areas that are shown on the map in this attachment as areas typically not requiring PPE 

usage may be designated by supervision to require certain PPE as based upon tasks and 

subsequent hazards introduced due to those tasks. These areas shall be controlled in order to 

protect employees dedicated to the task as well as those in close proximity. Controls shall be 

established through methods such as guarding, barricading and posting, or other equivalent means. 

SAFE WALK PATH 

"Safe Walk Path" is defined as that designated travel path which, after hazard evaluation, has been 

deemed safe for traversing to and from certain areas without the use of PPE. 

The accepted "designated safe walk path" is that pathway from the RCA SPA entrance to the 

control room. 

Personnel will follow the "designated safe walk path" established by management. This path may 

be altered by supervision and posted for PPE use accordingly to ensure personnel safety during 

times of ensuing work at close proximity to pathway. 

NOTE: Employee training on proper use of Personal Protective Equipment is provided in General 

Employee Training (GET), General Employee Retraining (GER) and in Continuing Training (CT). 

Training for contract personnel should be provided by the contractor. 

SAF-NGGC-2172 


ATTACHMENT 1 

Sheet 3 of 5 



1910.133 EYE AND FACE PROTECTION 

Those areas requiring the use of safety glasses with side shields are designated on the BNP 

Personal Protective Equipment Designated Area Diagram located on sheet 1 of this attachment 

(shaded areas). Other areas may be designated “Safety Glasses Required”, as determined by 

supervision, based upon a Job Safety Analysis. 

Where designated, protective eye and face devices shall meet the criteria specified in ANSI 287.1- 

1989, “American National Standard Practice for Occupational and Educational Eye and Face 

Protection”. Eye protection lens material must be made of polycarbonate as a minimum. The 

manufacturer’s emblem and a ”+” must be on the lens to designate “High Impact” lens on all nonprescription 

safety glasses purchased after August, 2003 (prescription high impact lens will not 

have 287 stamped on them). Prescription safety lenses must have the + next to the manufacturing 

lab’s monogram. Prescription safety frames must meet the High Impact Standard and shall be 

marked “287-2 or “Z87+”. REMOVABLE side-shields must be marked 287. 

Safety Glasses are not required in offices, control rooms, designated warehouse areas, auxiliary 

building tool room, locker rooms, HP work area and instrument issue room. 

Dark glasses shall not be worn inside buildings unless medically prescribed. 

Persons working in full face respirators in contaminated areas may travel directly to and from dressout 

areas and their work locations without safety glasses provided no eye injury hazards exist within 

the travel path. 

The job supervisor and employee(s) must determine the need for eye protection based upon the 

risk of eye injuries from those items listed in the NGG Hazard Assessment PPE Matrix (Attachment 

6). 

1910.135 HEAD PROTECTION 

Those areas requiring the use of hard hats are designated on the BNP Personal Protective 

Equipment Designated Area Diagram located on sheet 1 of this attachment (shaded areas). Other 

areas may be designated “Hard Hat Required“, as determined by supervision, based upon specific 

job hazard evaluations. 

Where designated, protective helmets shall meet the criteria specified in ANSI 289.1-1986, 

”American National Standard for Personal Protection-Protective Headwear for Industrial Workers- 

Requirements“. 

The job supervisor and employee(s) must determine the need for head protection based upon the 

risk of head injuries from those items listed in the NGG Hazard Assessment PPE Matrix 

(Attachment 6). 


areas and their work locations without hard hat provided no head injury hazards exist within the 

travel path. 

Per manufacturers‘ recommendation, hard hat liners should be replaced annually and the entire 

hardhat hat replaced not greater than 5 years from the date it was placed into service. Individuals 

are responsible for maintaining the 1 (one) and 5 (five) year periods. 

SAF-NGGC-2172 


ATTACHMENT 1 

Sheet 4 of 5 



Areas Exempt from General Hard Hat Requirements (when overhead lifting or any other head 

injury hazards exist, head protection must be worn): 

Crane, forklift or other vehicles with 

overhead protection 

Laboratories 

Locker Rooms 

Bath and Shower Rooms 

ToolRooms 

Radwaste Control Room 

Designated Warehouse Areas (except 

when required by task) 

Shopareas 

HP Work Area 

Main Control Room Complexes 

Offices 

Switchgear Rooms 

BatteryRooms 

1910.95 HEARING PROTECTION 

Wear approved hearing protection in areas 285 dBA. These areas will be designated or posted: 

“Caution Hearing Protection Required“ 

Due to varying plant conditions, there may be times when hearing protection will be required in 

areas not posted as “Hearing Protection Required”. 

SAF-NGGC-2172 


ATTACHMENT 1 

Sheet 5 of 5 



1910.136 FOOT PROTECTION 

Foot Protection ("hard foe safety shoes"or "foot guards'? is required when carrying or handling 

materials such as heavy packages, objects, parts or tools, which could be dropped onto the feet. 

When used, protective footwear shall meet the criteria specified in ANSI 241-1999, "American 

National Standard for Personal Protection - Protective Footwear". 

The job supervisor and employee(s) must determine the need for foot protection based upon the 

risk of foot injuries from those items listed in the NGG Hazard Assessment PPE Matrix (Attachment 

6). 

The Site Occupational Health and Safety Specialist will work with supervision to determine 

individuals whose jobs require that they wear hard toe safety shoes. In accordance with the 

supervisor's guide to standard company attire, PROGRESS ENERGY will pay for hard toe safety 

shoes that are required for PROGRESS ENERGY employees whose work activities require that 

they wear them. 

Foot guards, available from the tool rooms, can provide metatarsal protection. This equipment shall 

be worn when operating air or electric paving breakers, tamps, jackhammers, hydrolazers, etc. 

(See "Foot Protection" Matrix in Attachment 6) 

Employees requiring special shoes due to a medical condition shall provide their supervisor a note 

from their physician prior to wearing the footwear on site. 

1910.138 HAND PROTECTION 

Hand Protection (gloves) is required to prevent cuts, abrasions, burns, and skin contact with 

hazardous chemicals. 

The job supervisor and employee(s) must determine the need for hand protection based upon the 

risk of hand injuries from those items listed in the NGG Hazard Assessment PPE Matrix 


The type of gloves selected for a particular task shall be based on the degree of protection 

necessary for the specific hazard and for the level of risk to the worker's hands. 

Appropriate hand protection must be worn when employees' hands are exposed to hazards that 

could cause burns, cuts, abrasions, splinters, electrical shock, chemicals, or blood borne pathogen 

exposures. For hands-on-work in industrial work areas, gloves shall always be used, unless there is 

a valid reason not to wear them. 

Finger rings, loose chains, metal wrist bands, body jewelry or key rings shall not be worn while 

working around moving machinery or when performing any other hands-on activity where these 

articles may present a hazard. Additional requirements, as addressed in SAF-NGGC-2175 

Electrical Safety, apply for working on, or near energized electrical components. 

SAF-NGGC-2172 

REV. 8 Page 31 of 55 

PEF-NCR-00632

ATTACHMENT 2 

Sheet 1 of 5 

HNP Personal Protective Equipment Designated Area Diagram 



Dlt 

011 

STEAM GENERATOR 

STORAGE FACILITY 

1- -;-- 

1- 

SEWAGE 

TREATMENT 

PLANT 

- 

COOLING TOWER 

MAFEYP INTAKE 

STRUCTURE 

.,I,.", . I . . 


Page 32 of 55

ATTACHMENT 2 

Sheet 2 of 5 

HNP Personal Protective Equipment Site Hazard Assessment 


This hazard assessment covers typical work situations in various areas of the Harris Nuclear Plant. 

The Site PPE Designated Area Diagram on page 1 of this Attachment designates areas where hard 

hats and safety glasses shall normally be worn regardless of work taking place (shaded areas). 








evaluations. 

















“Safe Walk Path” is defined as that designated travel path which, after hazard evaluation, has been 


The accepted “designated safe walk path” is the established pathway from the 26l’elevation to the 

Turbine Building via the concrete slab between the tank farm and Turbine Building, the elevator 

itself and the stairway adjacent to the elevator. Another ”safe walk path” exists on the 314’ 

elevation of the Turbine Building, consisting of the painted walkway leading to the north stairway 

from the Main Control Room and Operations Building. 

Personnel will follow the “designated safe walk path” as established by management. This path may 

be altered by supervision and posted for PPE use accordingly, to ensure personnel safety during 






Page 33 of 55 

PEF-NCR-00634

ATTACHMENT 2 

Sheet 3 of 5 




Those areas requiring the use of safety glasses with side shields are designated on the HNP 


(shaded areas). Other areas may be designated "Safety Glasses Required", as determined by 



1989, "American National Standard Practice for Occupational and Educational Eye and Face 

Protection". Eye protection lens material must be made of polycarbonate as a minimum. The 

manufacturer's emblem and a 'I+" must be on the lens to designate "High Impact" lens on all nonprescription 



lab's monogram. Prescription safety frames must meet the High Impact Standard and shall be 

marked "287-2" or "287+". REMOVABLE side-shields must be marked 287. 


building tool room, locker rooms, HP work area and instrument issue room. 







6). 

191 0.1 35 HEAD PROTECTION 

Those areas requiring the use of hard hats are designated on the HNP Personal Protective 


areas may be designated "Hard Hat Required", as determined by supervision, based upon specific 



"American National Standard for Personal Protection-Protective Headwear for Industrial Workers- 

Requirements". 






travel path. Individuals may also travel from the Waste Processing Building 261' dress-out area to 

the PAL door or directly to the Spent Fuel Pool FME Area with a hard hat. 

Per manufacturers' recommendation, hard hat liners should be replaced annually and the entire 



SAF-NGGC-2172 

REV. 8 

Page 34 of 55

ATTACHMENT 2 

Sheet 4 of 5 





Shop areas and yards (except when 

required by task) 

Offices 

Locker Rooms 



ToolRooms 

HP Work Area 

e Bath and Shower Rooms Main Control Room Complex 



Radwaste Control Room Complex 

Stairwell from Main Control Room 

Complex to the Ops Building 

Auxiliary Control Panel Room 

A&B EDG Control Panel Rooms Secondary Sample Station (TB 240' 

Elev.) 

Battery Rooms 


Laboratories 

Spent Fuel Pool Area 



"Caution Hearing Protection Required" 

The entire Turbine Building is designated a "Hearing Protection Required" area during operation. 


areas not posted as "Hearing Protection Required". 

Due to very high noise levels, some plant areas will require two (2) sets of hearing protection. This 

will consist of one set of earplugs AND earmuffs. These areas will be designated by signs stating: 

"Caution - Double Hearing Protection Required" 


Page 35 of 55

191 0.1 36 FOOT PROTECTION 

ATTACHMENT 2 

Sheet 5 of 5 



Foot Protection (“hard toe safety shoes”or “foot guards’? is required when carrying or handling 


When used, protective footwear shall meet the criteria specified in ANSI 241-1999, “American 

National Standard for Personal Protection - Protective Footwear”. 



6). 



supervisor’s guide to standard company attire, PROGRESS ENERGY will pay for hard toe safety 





(See “Footwear Protection” Matrix in Attachment 6) 










necessary for the specific hazard and for the level of risk to the worker’s hands. 

Appropriate hand protection must be worn when employees‘ hands are exposed to hazards that 








I SAF-NGGC-2172 REV. 8 Page 36 of 55 I 

PEF-NCR-00637

ATTACHMENT 3 

Sheet 1 of 5 

RNP Personal Protective Equipment Designated Area Diagram and Site Hazard Assessment 



Crosshatched areas indicate PPE -Required Areas (hard hat and safety glasses at a 

minimum). 

SAF-NGGC-2172 

. REV.^ 

Page 37 of 55

ATTACHMENT 3 

Sheet 2 of 5 

RNP Personal Protective Equipment Site Hazard Assessment 


This hazard assessment covers typical work situations in various areas of the Robinson Nuclear 

Plant. The Site PPE Designated Area Diagram on page 1 of this Attachment designates areas 

where hard hats and safety glasses shall normally be worn regardless of work taking place (shaded 

areas). 

NOTE: For ease of recognition, there is a “Green Line” painted around the power block which 

indicates the general “hard hat and safety glasses required area”. 








evaluations. 








IF industrial-type work is to take place in areas not addressed on the Site PPE Designated Area 









“Safe Walk Path” is defined as that designated travel path which, after hazard evaluation, has been 


The accepted “designated safe walk path” is that pathway outside the “Green Line” to the south of 

the TB between the TB and the Switchyard and then to the east of the TB between the TE? and PAP 

East to the TB elevator or NE stairwell. This “designated safe walk path” allows workers to travel to 

and from the control room without wearing hard hat and safety glasses provided there is no 

industrial work taking place in or near the path. 

Personnel will follow the “designated safe walk path” as established by management. This path may 

be altered by supervision and posted for PPE use accordingly, to ensure personnel safety during 





SAF-NGGC-2172

ATTACHMENT 3 

Sheet 3 of 5 




Those areas requiring the use of safety glasses with side shields are designated on the RNP 


(shaded areas). Other areas may be designated “Safety Glasses Required”, as determined by 





manufacturer’s emblem and a “+” must be on the lens to designate “High Impact” lens on all nonprescription 




marked “287-2” or “287+”. REMOVABLE side-shields must be marked 287. 


building tool room, locker rooms, HP work area, instrument calibrationlrespirator decon room, and 

the calibrated instrument issue room. 







6). 


Those areas requiring the use of hard hats are designated on the RNP Personal Protective 


areas may be designated “Hard Hat Required”, as determined by supervision, based upon specific 



“American National Standard for Personal Protection-Protective Headwear for Industrial Workers- 

Requirements”. 




During refueling outages, individuals may normally travel between the RCA Entrance dress-out area 

and the entrance to the CV without wearing a hard’hat. Hard hats will be provided at the SOP for 

donning prior to entering the CV. Hard hat requirement for this area may be changed based on 

adjacent work. 



travel path. 

Per manufacturers’ recommendation, hard hat liners should be replaced annually and the entire 



I GF-NGGC-2172 I REV. 8 I Page 39 of 55 I 

PEF-NCR-00640

ATTACHMENT 3 

Sheet 4 of 5 





Offices 

Shop Areas and Yards Areas (except 


O&M and Auxiliary Building Tool Rooms 

From Dress-out area to CV entrance 

(during refueling outages) 

Instrument Calibration Facility 




Safeguards Room 

4160 Switchgear Room 

NB Battery Room 

Spent Fuel Pool Area 

Tool Decon Area in the Radwaste 

Building 

Hagan Room 

a 

a 

a 

0 

a 

a 

0 

0 

a 

0 

a 

a 

0 

Control Rooms 



Laboratories 

HP Work Area (except when required by 

task) 

Respirator Decon Facility 

Cable Spread Room 

Spent Fuel Building Roof (when roof is 

open) 

EllE2 Room 

Control Rod Drive Room 

C Battery Room 

Sorting Area in the Radwaste Building 

WWDS Room 

Locker Rooms 



"Caution Hearing Protection Required" 

The entire Turbine Building is designated a "Hearing Protection Required" area during operation. 


areas not posted as "Hearing Protection Required". 



"Caution - Double Hearing Protection Required"


ATTACHMENT 3 

Sheet 5 of 5 



Foot Protection (“hard foe safety shoes”or “foot guards’? is required when carrying or handling 



National Standard for Personal Protection - Protective Footwear”. 



6). 








(See “Foot Protection” Matrix in Attachment 6) 











Appropriate hand protection must be worn when employees’ hands are exposed to hazards that 








SAF-NGGC-2172 

I 

REV. 8 

Page 41 of 55 

PEF-NCR-00642

ATTACHMENT 4 

Sheet 1 of 2 

HE&EC Personal Protective Equipment and Hazard Assessment 

29 CFR 1910 Subpart 1 

Certification of Hazard Assessment for E8EC - 7 Sept 2006 

This hazard assessment covers typical work situations in various areas of the Energy and 

Environmental Center (E&EC). Tasks shall be evaluated by supervision and specific personal 

protective equipment (PPE) identified and used in accordance with this assessment. Non-routine 

tasks addressed in this hazard assessment must be evaluated on a case-by-case basis and 

appropriate PPE identified and used. 

29 CFR 1910.133 EYE AND FACE PROTECTION: 




manufacturer’s emblem and a ”+” must be on the lens to designate “High Impact” lens on all nonprescription 




marked “287-2” or “Z87+”. REMOVABLE side-shields must be marked 287. 




6). 

29CFR 1910.135 HEAD PROTECTION 


“American National Standard for Personal Protection-Protective Headwear for Industrial Workers- 

Requirements“. 




Per manufacturers’ recommendation, hard hat liners should be replaced annually and the entire 





“Caution Hearing Protection Required” 

Due to varying conditions, there may be times when hearing protection will be required in areas not 

posted as “Hearing Protection Required”. 

Due to very high noise levels, some areas will require two (2) sets of hearing protection. This will 

consist of one set of earplugs AND earmuffs. These areas will be designated by signs stating: 

“Caution - Double Hearing Protection Required” 

SAF-NGGC-2172 

REV. 8 Page 42 of 55 

PEF-NCR-00643

ATTACHMENT 4 

Sheet 2 of 2 

HEBEC Personal Protective Equipment and Hazard Assessment 

29 CFR 1910 Subpart 1 


Foot protection (hard toe safety shoes) shall be worn when carrying or handling materials such as 

heavy packages, parts or tools, which could be dropped onto the feet. 

When used, protective footwear shalt meet the criteria specified in ANSI 241-1999, “American 

National Standard for Personal Protection - Protective Footwear.” 

A pre-job brief should be performed to determine the need for foot protection based upon the risk of 

foot injuries from the items listed in Attachment 6. 

E&EC supervision, along with the Occupational Health and Safety Specialist will work with 

management to determine those individuals whose jobs may require that they wear hard toe safety 

shoes. In accordance with the supervisor’s guide to standard company attire, supervision and 

management will determine, on a case by case basis, whether PROGRESS ENERGY will pay for 

safety shoes that are required based upon the job duties of each employee. 

29 CFR 1910.138 HAND PROTECTION 
















PEF-NCR-00644

ATTACHMENT 5 

Sheet 1 of 5 

CR3 Personal Protective Equipment Designated Area Diagram 



=.--a 

/- 

--I 

SAF-NGGC-2172 

REV. 8 

Page 44 of 55

ATTACHMENT 5 

Sheet 2 of 5 

CR3 Personal Protective Equipment Site Hazard Assessment 


This hazard assessment covers typical work situations in various areas of the CR3 Nuclear Plant. 

The Site PPE Designated Area Diagram on page 1 of this Attachment designates areas where hard 

hats and safety glasses shall normally be worn regardless of work taking place (shaded areas). 








evaluations. 






PPE Waiver (link to this form is found in SAF-SUBS00025 Personal Protective Equipment). 











"Safe Walk Path" is defined as that designated travel path which, after hazard evaluation, has been 

deemed safe for traversing to and from certain areas without PPE. 

The accepted designated "Safe Walk Path" is that pathway, demarcated by a Green Line from the 

119' Turbine Building roll up door to/from the elevator access 124' landing and to/from the Cold 

Machine shop andlor East stairwell leading to the 95' TB and access to the 95' Control Complex. 

Personnel may use the Safe Walk Path for traversing without PPE. 

To ensure personnel safety during times of ensuing work in or at close proximity to pathway, this 

path may be altered by supervision and posted for PPE use accordingly. 




SAF-NGGC-2172 


ATTACHMENT 5 

Sheet 3 of 5 




Those areas requiring the use of safety glasses with side protectors are designated on the CR3 


(shaded areas). Other areas may be designated "Safety Glasses Required", as determined by firstline 

supervision, based upon specific job hazard evaluations. 


1989, "American National Standard Practice for Occupational and Educational Eye and Face 

Protection". Eye protection lens material must be made of polycarbonate as a minimum. The 

manufacturer's emblem and a "+" must be on the lens to designate "High Impact" lens on all nonprescription 



lab's monogram. Prescription safety frames must meet the High Impact Standard and shall be 

marked "287-2" or "Z87+". REMOVABLE side-shields must be marked 287. 







6). 


Those areas requiring the use of hard hats are designated on the CR3 Personal Protective 


areas may be designated "Hard Hat Required", as determined by supervision, based upon specific 



"American National Standard for Personal Protection-Protective Headwear for Industrial Workers- 

Requirements". 






travel path. 

Per manufacturers' recommendation, hard hat liners should be replaced annually and the entire 



SAF-NGGC-2172 

R€V. 8 

Page 46 of 55

ATTACHMENT 5 

Sheet 4 of 5 





Offices 

Control Rooms 

Shop Areas and Berm (except 


Locker Rooms 



Around the Spent Fuel Pool 

when open 

Instrument Calibration Facility 

Maintenance Support Building 

Laboratories 

Control Rod Drive Room 



95’ Control Complex 

Cable Spread Room (bump cap 

instead) 

NBlC Battery Rooms 

RB 160’ and 180’ adjacent to, or over 

refuel poolhncore pit 

Hot & Cold Tool Rooms 

Outage Support Building 

Chemistry Count Rooms 

MTF (unless posted) 

Designated Warehouse areas 

(except when required by task) 


Wear approved hearing protection in areas >85 dBA. These areas will be designated or posted: 

“Caution Hearing Protection Required” 

The entire Turbine Building is designated a “Hearing Protection Required” area during modes 1-4. 


areas not posted as “Hearing Protection Required”. 



“Double Hearing Protection Required Except for Walkthroughs“ 

Nonstop pass through of “DOUBLE HEARING PROTECTION REQUIRED” areas without the 

second level of hearing protection is allowed. 

In non-posted areas, notify Health Physics to determine if work activity noise level is sufficient (> 

85db) for the use of hearing protection. In areas posted “DANGER - High Noise Area”, contact HP 

for additional requirements. 

SAF-NGGC-2172 

REV. 8 

. Page47of55


ATTACHMENT 5 

Sheet 5 of 5 



Foot Protection (“hard foe safety shoes”or “foot guards’? is required when carrying or handling 



National Standard for Personal Protection - Protective Footwear“. 



6). 








(See “Foot Protection” Matrix in Attachment 6) 




See Site Specific Procedure AI-100 for additional requirements under the Hand Protection (Use of 

Gloves) policy. 



The job supervisor and employee(s) to determine the need for eye protection based upon the risk of 

hand injuries from those items listed in the NGG Hazard Assessment PPE Matrix (Attachment 6). 




could cause burns, cuts, abrasions, splinters, electrical shock, chemicals, or blood borne pathogens 







1

ATTACHMENT 6 

Sheet 1 of 2 

NGG Hazard Assessment PPE Matrix 




Tasks requiring eye and face protection have been identified in the matrix below 

Flying particles, 

pressurized liquid and 

air, and steam 

Particles 

Molten metal 

Liquid chemicals 

Acid or caustic liquids 

Chemical gases or 

vapors 

Solid chemicals 

Light radiation 

(welding) 

~~ 

Light radiation 

(oxylacetylene cutting) 

Light radiation (other) 

Electrical contact 

Grinding, sanding, chipping, descaling, 

hammering, chiseling, drilling, etc.; 

escaping compressed air steam, or 

hydraulic fluids under pressure. 

Open sand blasting 

Hot sparks during an arcing flash; 

welding, cutting or other operation 

resulting in hot sparks.(For welding, 

cutting, and brazing see light radiation 

below.) 

Water treatment chemicals, cleaning 

solvents, laboratory chemicals, liquid 

nitrogen 

Water treatment chemicals, battery 

acid, laboratory chemicals. 

Laboratory chemicals and their byproducts, 

also, per chemical labels, IE 

Xylene from paint vapors, etc. 

Caustics, laboratory chemicals, 

pesticideslherbicides 

Electric arc or gas welding, arc gouging, 

etc. 

Gas torch cutting or brazing 

Infrared, laser, x-ray diffraction, TEM, 

SEM, etc.) 

Exposed energized conductors 

Safety glasses with side shields or goggles 

high risk exposures in this category, includt 

face shield with hardhat.) 

Sandblasting hood 

Safety glasses with side shields or 

goggles and face shield with hardhat. 

Safety glasses wl side shields or goggles. 

(For severe exposures in this category, 

include a face shield.) 

Safety glasses wl side shields or goggles. 

(For severe exposure include face shield). 

Per MSDS, e.g., air tight goggles or full 

face shield depending on exposure levels. 

For low exposure levels, safety glasses 

with side shields are allowed. 

Safety glasses wl side-shields or goggles. 

(Chemical resistant face-shield if splash 

hazard exists when adding to a liquid) 

Welding hood wl dark lens and safety 

glasses. (For specific guidance refer to 

SAF-SUBS-00031.) 

Welding hood with dark lens (and safety 

glasses) or goggles with dark lenses. (For 

specific guidance refer to SAF-SUBS- 

00031 WeldinglHot Work Safety.) 

See equip. manual or site Occupational 8, 

Safety Specialist for guidance. 

Refer to SAF-NGGC-2175 

29 CFR 1910 Subpart I29CFR 1910.135 HEAD PROTECTION 

Instances when protective helmets are required have been identified in the matrix below. 

Falling objects 

Bumping Hazards 

Electrical contact 

Tools and materials used overhead. 

Plant structures, equipment, etc. 

Exposed Energized conductors. 

Hard hat 

Hard hat 

Refer to SAF-NGGC-2175 

SAF-NGGC-2172 

REV 8 

Page 49 of 55

ATTACHMENT 6 

Sheet 2 of 2 

NGG Hazard Assessment PPE Matrix 


Instances when protective footwear is required have been identified in the matrix below. 

tools and materials barrels spools of 

29 CFR 1910.138 HAND PROTECTION 

Instances when hand protection is required have been identified in the matrix below. 

chemical contact 

dermatitis 

Chemical burns 

ammonium hydroxide, ethylene glycol), 

pesticides, coatings, lab chemicals, solvents, 

I oils, greases, caustics, alcohols, and asbestos. 

I Water treatment chemicals, acids, caustics. 

I Health & Safety Specialkt 

I Per MSDS or Site Occupational 

SAF-NGGC-2172 

REV. a 

Page 50 of 55

ATTACHMENT 7 

Sheet 1 of 1 

Pneumatic Tool Safety Device Exemption 

1) Specifically Identify Tool: 

Verified By: 

Date: 

2) The proper operating condition of the tool has been verified. 

Verified By: 

Date: 

3) The proper air hose size has been verified. 

Verified By: 

Date: 

4) The proper safety device size and operational condition has been verified. 

Verified By: 

Date: 

5) No other usable tool is available on site. 

Verified By: 

Date: 

6) Exemption Granted. 

Supervisor: 

Date: 

NOTES: 

SAF-NGGC-2172. REV. 8 

Page 51 of 55

~~ 

ATTACHMENT 8 

Sheet 1 of 1 

Personal Protective Equipment Waiver Form 

Please maintain a copy of this attachment at the job site for the duration of the work 

taking place under this waiver. 

Effective 

Job Description: 

Supervisor (print): 

Hard Hat 

In accordance with the site hazard assessment, the work governed by this waiver is 

taking place where there is not risk of injury from falling objects or exposed electrical 

conductors. 

0 Safety Glasses 


taking place where there is not risk of eye injury from flying particles, metal, chemicals, 

acids or caustics, or light radiation. 

0 Other (specify): 


taking place where there is not risk of injury from (specify hazard) 

Therefore the use of 

is waived. 

0 Compensatory MeasureslComments 

Approved by (supervisor’s signature): 

-SAF-NGGC-2172 REV. 8 

Page 52 of 55

~ 

~ 

~ 

7- Revision Summary 

Section 

Description of Change 

2.61 

Added reference 

-~ 

2.62 I Added reference 

3.8 1 Added MSDS 

4.2 

4.3 

9.1.1 

9.3.1 

9.3.2 

9.3.4 

9.3.5 

9.3.6 

9.4.6 

9.3.10 

9.3.15 

9.3.16 

9.4.1 

9.4.4 

9.4.7 

9.4.9 

~- - 

9.4.10 

9.4.12 

9.4.18 

~~ ~ 

9.5.3 

9.5.4 

-~ 

9.5.6 

9.7.1 

~ 

9.8.2 

9.8.3 

9.14.1 

9.14.3 

9.14.4 

9.14.5 

Added “and the requirements contained within this procedure.” 

Added “and for following the requirements contained within this procedure.” 

Added “this procedure as well as 

Changed ”may“ to ”must” and added “or other similar means.” 

Changed working for clarification 

Deleted “Pre-job briefings at the HE&RC need only be conducted when special WORK 

hazards exist.” 

Replaced “tape“ with “ribbon”. 

Changed “should” to “shall.” 

Added “or liners designed to be worn under hard hats for cold weather protection.” 

Added “Use MSDS for use of hazardous chemicals.” 

Added “and manufacturers’ recommendations’ 

Deleted section 

Changed “should” to ”shall” and “shall be utilized in accordance with the appropriate 

MSDS.” 

Chancled “unfeasible” to impossible”. 

Safety glasses shall be worn under welding hoods. 

Added “9.4.9 Flame retardant PCs shall be worn while stick welding, arc-gouging and 

cutting activities involving oxygenlacetylene. Flame retardant PCs should be considered 

by supervisors when performing other types of hot work.” 

Changed “should” to “shall“. 

Added “and adequate protection is provided.” 

Chancled “safety representative” to “Occupational Health and Safety Specialist” 

Added “by elevated sound levels.” 

Chancled “are expected to” to “shall” 

Deleted section 

Deleted “or site procedures“ 

Changed “however, may be, and may” to If, is, must”. 

Added “that needs to be removed” and “only”. 

Changed “if any electrical arc is observed” to “with the potential for an arc or in an 

electrical arc is observed” and Added “(e& around isophase bus duct) 

Added “Avoid “daisy-chaining” multi-strip power devices or using these devices in 

conjunction with an extension cord. 

Replaced ”should” with “shall” 

Replaced “should” with “shall” 

Replaced “should” with ”shall” 


I SAF-NGGC-2172 REV. 8 Page 53 of 55 I 

PBF-NCR-00654

~~ ____ 

Section 

Description of Change 

Revision Summary 

9.14.8 


9.14.9 Replaced “should” with “shall” 

9.14.11 Added “or be appropriately protected ’ 

9.14.15 


9.17.1 

Added SAF-ESGX-00002 Energy Supply Fall Protection Procedure 

9.17.2 Added “All fall protection users must be properly trained and qualified as directed in 

SAF-ESGX-00002 Energy Supply Fall Protection Procedure.” 

9.17.4 Added “other approved attachment device“ 

9.17.9 

Change wording from “such as piping with 3” diameter or greater, structural angles 

greater than or equal to 4x4 or shall comply with site requirements” to “as indicated in 

SAF-ESGX-00002 Energy Supply Fall Protection Procedure.” Deleted “Unacceptable 

anchorages: Instrument lines, electrical conduit, PVC piping, and fire suppression 

piping.” 

9.18.2 Added “At a minimum, the following items should be included in the inspection: 

~~ ~ 

~ 

Missing or damaged components (e.g., cracked side rails, bent or damaged rungs, 

missing non-slip material on feet of ladder, loose or missing rivets, screws, or bolts, 

etc.) 

All fasteners are secure 

All moving parts are in good working order 

Side rails and rungs are free from dirt, oil or other foreign material 

And “or other suitable verbiaae.” 

9.20.1 

Added “and the site Occupational Health and Safety Specialist. Individuals working at 

an NGG site who do not report to the site must report all injuries occurring at the site to 

their CBO supervisor or site contact (so that For-Cause FFD testing requirement can be 

evaluated) and to the site Occupational Health and Safety Specialist as soon as 

possible.” 

9.20.3 

Changed “the appropriate site emergency number” to “X5555” 

9.21.2 

Added “or other chemicals which are hazardous to the eyes,” 

9.21.3 Added “Drench hoses meeting the requirements of ANSI 2358.1-2004 Emergency 

Eyewash and Shower Equipment may be used in lieu of a portable eyewash station 

andlor emeraencv showerlevewash station.” 

9.22.1 


9.22.6 Added “Avoid “daisy-chaining” multi-strip power devices or using these devices in 

conjunction with an extension cord. 

9.24.3 

Added “Bodies of water which may be too small or otherwise inappropriate for 

accommodation of a skiff should be evaluated for alternatives.” 

9.26.2 

Changed “should” to “shall”. 

9.26.3 

Changed “should” to “shall”. 

9.26.7 

Added “and other traffic regulation signs” 

9.27.1 Reworded “At any excavation site there shall be” 

9.29.1 

Added “at a minimum,” 

Attachments Reworded for consistency and clarity. 

1,2,3,4,& 5. 

Attachment 2, qeplaced HNP site map 

page 1 

SAF-NGGC-2172 

REV. a 

Page 54 of 55

Section 

~ 

Attachment 3, 

Daqe 1 

Attachment 5, 

paw 1 

Numerous 

2.60 

I Description of Change 

Replaced RNP site map 

Replaced CR3 site map 

Revision Summary 

. . 

Replaced “Safety Representative” with “Occupational Health and Safety Specialist” 

Added reference to 2.60 SAF-ESGX-00002 Energy Supply Fall Protection Procedure 

11 I Added Attachment 11.8 Personal Protective Equipment Waiver Form 


Page 55 of 55


PEF-NCR-00657

' 

LEGEND 

n Crystal River Nuclear Unit 3 Site LOCatlOn 

REFERENCE 

FLUCFCS 

1 2006 SoUhmrf Flonda Water Managemen1 Asnal 

2 Crptal Rmr unt 3 Sile Location by Gddsr Arsocldlar 1°C 

3 FLUCFCS by Golder Arrocialer Inc 

DRAFT 

540 0 540 

p 

SCALE 16000 Frat 

PROXCl 

PROGRESS ENERGY FLORIDA, CRYSTAL RIVER 

NUCLEAR UNIT 3 UPRATE PROJECT 

1llLE 

FLORIDA LAND USE, COVER, AND FORMS 

CLASSIFICATION SYSTEM MAP 

@&CPI~~ 

~.np. em.1. 

FROfCIN" Olldpill S,.bLE^ll"Ullh I yt 

ns,m s I ".Yl

Applicable Sections of the Site Certification Application

June 2007 2- 1 0738953 I 

2.0 SITE AND VICINITY CHARACTERISTICS 

2.1 Site and Associated Facilities Delineation 

2.1.1 Site Location 

Progress Energy Florida’s CR3 is part of the larger Crystal River Energy Complex (CREC) located in 

Citrus County, Florida. The CREC is comprised of 4,738 acres and includes a single nuclear unit 

(CR3) and four coal-fired units, CR I, 2, 4, and 5. CR3 and the four coal-fired units lie in the 

developed area of the site. 

CR3 is in the southern (and center) part of CREC and comprises approximately 26.86 acres. This 

26.86 acre site and certain related facilities are the subject of this application. These CR3 facilities 

are shown on Figure 2.1.2-2. CR 1 and 2 are located along the southern boundary of the CREC in 

between the intake and discharge canals. CR 4 and 5 are located approximately 0.5 mile north of 

CR3. CR I, 2, 4 and 5 are not affected by this application. 

The CREC is located in all or portions of Sections 31, 32, 33, 34, and 35, Township 17, Range 16. 

CR3 is located in Section 33, Township 17, Range 16 (Figure 2.1.1-1). CR I and 2 are located in 

Section 33, Township 17, Range 16, and CR 4 and 5 are located in or portions of Sections 28 and 33, 

Township 17, Range 16. 

2.1.2 Existing CREC Site Uses 

CR3 is an 838 MW pressured water reactor which began commercial operation in 1977. CR3 is not 

currently certified under the PPSA. CR 1 and 2 were built in the 1960s and produce 379 and 486 

MW, respectively. CR 4 and 5 were built in the early 1980s and produce 717 and 720 MW, 

respectively. CR 4 and 5 were certified under the PPSA in 1980. The CREC also contains office 

buildings, warehouses, coal storage areas, ash storage, transmission, and substation facilities which 

support the various units (Figure 2.1.2- I). 

Cooling water for CR I, 2, and 3 is withdrawn from an intake canal which connects to Crystal Bay 

and the Gulf of Mexico (Figure 2.1.2-2). Florida Department of Environmental Protection (FDEP) 

National Pollution Discharge Elimination System (NPDES) permit FL0000159 (Appendix IO. 1.2) 

PEF-NCR-00660

June 2007 2-2 0738953 1 

limits the combined condenser flow from CR I, 2, and 3 to 1,898 million gallons per day (MGD) 

during the period of May 1 through October 3 I , and 1,613.2 MGD during the remainder of the year. 

CR 1 and 2 

The cooling water intake structures for CR 1 and 2 are located on the north bank of the intake canal. 

The design intake flow for CR I and 2 is 638,000 gallons per minutes (gpm), or 919 MGD. 

CR3 

The cooling water intake structure for CR3 is located approximately 400 ft east of the intake for CR 1 

and 2. A chain link fence extends across the entire width of the intake canal upstream of the intakes 

for CR I and 2. The fence restricts access to CR3 and collects floating or partially submerged debris. 

CR3 has four pump bays and seven traveling screen bays separated from the pump bays by a common 

plenum. An eighth traveling screen bay provides service water. Similar to CR 1 and 2, the traveling 

screen trays are three meters wide and have 9.5 millimeter (mm) (318 inch) mesh. They are operated 

once every eight hours and cleaned by a front spray wash system. The screenwash trough slopes to 

the west were material is collected in a sump prior to discharge to the intake canal. The trough 

receives combined wash water from all screens. 

CR3 operates with four circulating water pumps, eac'h rated 170,000 gpm. The design intake flow for 

CR3 is 680,000 gpm or 979 MGD. The three units have a maximum permitted flow of 1,898 MGD 

and a total nameplate rating of 1,854.8 MW. Additionally, CR3 has a low flow nuclear services water 

pumping capacity of 10,000 to 20,000 gpm, depending on system demand. 

Cooling water for CR 1, 2, and 3 is withdrawn by a common intake canal south of the units that 

extends into the Gulf of Mexico. The 14-mile-long intake canal is dredged to a depth of 

approximately 20 feet (ft) to also accommodate coal barges which unload and dock on the south side 

of the canal, just west of the intakes for CR 1 and 2 (Figure 2. I .2-2). The intake canal is defined by 

northern and southern dikes. The northern dike continues along the channel for another 5.3 miles. 

There are openings in the dikes at irregular intervals to allow north-south boat traffic in the area of 

CREC. Movement of water into the canal is tidally influenced; at the mouth of the canal, current 

velocities ranged from 0.6 to 2.6 feet per second (fps) when last measured in 1983-1984 (Golder 

2005). 

PEF-NCR-0066 1

June 2007 2-3 0738953 1 

The hcad of the common discharge canal for all units is located just north of the discharge from CR3. 

The canal extends west for approximately 1.6 mile to the point of discharge, where it opens into a 

bay. The dredged channel, bordered to the south by a spoil bank, continues for another 1.2 miles. 

Water in the discharge canal is maintained by dredging to a depth of approximately IO ft. 

Helper cooling towers currently line the northern bank of the discharge canal and receive a portion of 

the circulating water flow from CR I, 2, and 3 including cooling tower blowdown from CR 4 and 5. 

The helper cooling towers are operated as necessary to ensure that the discharge temperature does not 

exceed 96.5"F (as a three-hour rolling average) at the point of discharge into the Gulf of Mexico. In 

February 2006, PEF received approval from the state of Florida to install modular cooling towers 

which CR 1 and 2 operate during the warmest times of the year. CR 4 and 5 are closed-cycle units 

that withdraw water for cooling tower makeup from the discharge canal, downstream of CR I, 2, and 

3 and discharge cooling tower blowdown to the discharge canal (Figure 2.1.2-2). 

CR 1, 2, and 3 are authorized to operate via several common environmental permits issued by the 

FDEP and other agencies (Appendices 10.1.2 and 10.4). Figure 2.1.2-1 depicts the site layout and 

Figure 2.1.2-2 is an aerial photograph of CR3. 

2.1.3 Adjacent Properties 

CR3 is located within the CREC and is adjacent to CR 1 and 2. The intake canal is located south of 

CR3 and the discharge canal is located north of CR3. PEF operates a mariculture center 

approximately one mile east of CR3. The Crystal River Mariculture Center is a multi-species marine 

hatchery originally established in the early 1990s to mitigate fisheries impacts related to the oncethrough 

cooling water system at Crystal River Units 1, 2, and 3. The Mariculture Center operations 

focus on the successful husbandry, culture, grow-out, harvest, and release into local waters of those 

selected species. Land use surrounding the CREC is predominantly undeveloped land. Active mines 

are located to the north and east of CREC. 

. The Central Florida Barge Canal is located approximately 3.2 miles north of CR3. There is 

relatively low-density residential housing north of the Central Florida Barge Canal and east of U.S. 

Highway 19 

PEF-NCR-00662

June 2007 1 0738953 

SECTION 3 

3.0 THE PLANT AND DIRECTLY ASSOCIATED FACILITIES ............................... 3- 

3.1 

...................................................... 

........................ 3- 

Other Onsite Projects ..................................... 3-2 

3.2 

3.3 

3.4 

Fuel ............................ ........................................ 

......................... 3-4 

3.5 

Plant Water Use ....................................................... 

.................................................. 3- 12 

.................................................................. 3-12 

3.6 

3.7 

3.8 

3.9 

Chemical and Biocide Waste ............................................. 

Solid and Hazardous Waste ............................................ 

On-Site Drainage System ........................ 

................................. 3-12 

................................. 3-13 

3.10 

............................................................. 

LIST OF TABLES 

Table 3.4.1- I 

Table 3.4.1-2 

Potential PM and PMlo Emissions 

Physical, Performance and Annual Emissions for the SCT 

LIST OF FIGURES 

Figure 3.2. I - I 

Figure 3.2.1-2 




CREC Property Boundary 

CRECICR3 Site Layout 

Location of CR3 Air Emission Sources 

CR3 Uprate Project SCT Layout 

CR I, 2, 3 NPDES Discharge Points 

APPENDICES 

Appendix IO. 1.5 

PSD Permit Application 

Golder Associates 

PEF-NCR-00663

June 2007 3- 1 0738953 1 

3.0 THE PLANT AND DIRECTLY ASSOCIATED FACILITIES 

3.1 Background 

PEF plans to add 180 MW of electrical generation resources to its system in order to continue to 

provide reliable, safe, and cost-effective service to its customers. The CR3 Uprate Project is an 

innovative application of technological advancements and efficiencies that will increase the power 

output of the plant approximately 180 MW, from 900 MW to 1,080 MW. The extra power output 

will result from using more highly enriched fuel which will result in increased thermal MWs 

produced in the reactor core. The additional heat will raise the temperature exchange between the 

primary and secondary systems, creating more steam for turning the turbines. 

To safely proceed with the uprate, modifications to supporting equipment are necessary to 

accommodate the additional heat created from the more highly enriched fuel and to accommodate all 

designed conditions in the plant. 

The uprate project will occur over two phases. The first phase (Phase 1) will occur during a 2009 

planned refueling outage and scheduled steam generator replacement. The improvement to the 

turbine line components will increase the efficiency of power production resulting in decreasing 

consumer costs. The existing steam turbine high-pressure rotor was designed in the 1960s and is a 

multi-piece assembly which causes more drag than current technology deems necessary. PEF will 

replace the outdated rotor with current rotor blade technology, a single piece model, which will 

effectively decrease the drag factor. Replacing the outdated turbine technology will enable the 

turbines to increase megawatt output by 40 MW with the same steam input. 

Phase I1 will take place during the 201 1 planned refueling outage. The second phase will result in an 

additional 140 MW of power and include alterations that will elevate temperatures within the reactor 

and the use of the enriched uranium fuel. In order to ensure that fusion reactions inside the core are 

maintained safely, cooling water flow rates will be increased and adjustments will be made to the 

safety systems. A larger pumping capacity than currently exists in the water flow system supplying 

the steam generators is required in order to elevate the flow rate. Therefore, modifications to or 

replacement of pumps and heat exchangers will occur. In order to determine appropriate replacement 

and modification needs, an engineering evaluation will be conducted to characterize the most cost 

effective upgrade necessary for each motor and pump to achieve the optimal flow rate. 


PEF-NCR-00664

June 2007 3-2 0738953 1 

3.1.1 Description of Other Onsite Proiects 

There are a number of projects which are currently being implemented at CR3 over the next several 

years. Several of the projects are ongoing and are described below as current and base-line conditions 

and may be referenced throughout the SCA. None of these projects are the subject of this SCA. 

Main step-up transformer replacement. The main step-up transformer will be replaced 

due to degradation which has led to recent on-line failures which adversely impact plant 

avai labi I ity. 

Measurement Uncertainty Recapture. Since 2002, CR3 has been licensed to 2,568 MWt 

based on maintaining a standard two percent measurement uncertainty margin to the 

requisite analyses and system evaluations performed at 2,6 19 MWt. Relatively recent 

guidance allows a reduction of this margin based on improved instrumentation so the 

plant can be licensed to operate at a slightly higher power level. The application for this 

increase was submitted to the NRC on April 25, 2007 to allow a restart from the 2007 

outage at this slightly higher power level. This project can be implemented with existing 

permits and regulatory approvals. 

CR3 License Renewal. The license renewal is a comprehensive assessment of CR3 

operations to demonstrate compliance with NRC regulatory requirements. The 

relicensing process will allow an additional 20 years of plant operation beyond the 

current CR3 licensed operating period of 40 years. It is anticipated that the License 

Renewal Application will be submitted to the NRC early in 2009. 

Steam Generator Replacement Project (SGRP). The once-through steam generators will 

be replaced in 2009 due to long-term degradation that will not support reliable operation 

to the end of plant life. The project will necessitate the utilization a number of 

undisturbed areas for lay-down areas, transportation off-loading and equipment assembly 

areas. Many of these same areas will also be utilized to support the CR3 Uprate Project. 

The appropriate environmental permits to authorize the disturbance of these areas will be 

obtained separate from the site certification process. 

3.1.2 Description of CR3 Uerate Pro-iect 

The project that triggers the need for this application is power level upgrades scheduled for 2009 

through 2012. The most substantial of the plant modifications will be installed during the refueling 

outages scheduled for 2009 and 201 1. While not all the final decisions have been made, the current 

plans include: 

In 2009, CR3 is planning to refurbish the low pressure turbines and electrical generator. 

Several main feed-water heat exchangers and main steam re-heaters will be modified or 

replaced. The net impact of these modifications is a substantially more efficient 

secondary plant. Thus, while the NRC licensed power level will remain constant; the 

electrical generation will be increased and the heat released to the environment will be 

Golder Associates

June 2007 3-3 0738953 1 

lessened. The net generation increase from current levels is expected to be approximately 

40 MW. 

Leading up to 201 1 CR3 seek NRC license changes to allow operation at the increased 

output. It will be necessary to make a large number of smaller, yet substantial, 

modifications to assure long term reliability of all plant systems at the conditions 

necessary to support this higher licensed power level. The most environmentally 

significant of these modifications is an increase in circulating water flow and an increase 

in discharge temperatures. The higher, licensed power level is currently anticipated to 

result in a net electrical generation increase of 180 MW above current levels. 

3.2 Site Layout 

The CREC contains four coal-fired steam electric generating units - CR 1, 2, 4, and 5, and a single 

nuclear unit - CR3. The CREC is the largest power-producing complex in the state of Florida with a 

total generating capacity of 3,140 MW. Figure 3.2.1-1 provides the property boundary and Figure 

3.2.1-2 provides the general layout ofthe various facilities within the CREC. 

3.3 Fuel 

The CR3 Uprate Project will not significantly alter fuel utilization as part of any of the above 

referenced projects. The primary fuel involved is the nuclear fuel used directly in power production. 

There will be no change in the nature of the fuel; no increase in maximum fuel enrichment and no 

substantial change in fuel assembly mechanical design will be required. There will be increases in the 

size of the refueling batch necessary to supply the necessary energy to support operation at the higher 

power levels. 

Diesel fuel is used in a number of emergency generators. The main station emergency generators 

may be increased in capacity which will increase fuel use. However, these generators are for standby 

use only. Other than testing, these diesels, as well as a number of others, which power fire and 

emergency feedwater pumps, etc, are not routinely operated. Diesel fuel is delivered and unloaded as 

needed. The size of storage and refilling frequency is not expected to change significantly. There is 

no expected increase in use of other fuels. 

Golder Associates

June 7007 3 -4 0738953 I 

3.4 Air Emissions and Controls 

3.4. I Air Emission Twes and Sources 

The entire CREC, including the nuclear unit’s associated process equipment, is currently addressed 

under the site’s Title V (TV) air operating permit. This permit (Final Permit No. 0170004-015-AV) 

is active until December 31, 2009, when renewal is required. The TV permit addresses four coalfired 

fossil fuel steam generating units; two natural draft cooling towers; a helper mechanical draft 

cooling tower; a modular cooling tower; coal, fly ash and bottom ash handling facilities and 

relocatable diesel-fired generators. Although CR3 (the nuclear generating unit) is not considered an 

emission generating unit under the TV permit, certain emissions units associated with CR3 are 

appropriately considered. 

The CREC is classified as an existing major facility. A “major facility” is defined as any 1 of 28 

named source categories that have the potential to emit 100 tons per year (TPY) or more or any other 

stationary facility that has the potential to emit 250 TPY or more of any pollutant regulated under 

CAA. “Potential to emit” means the capability, at maximum design capacity, to emit a pollutant after 

the application of control equipment. A modification to an existing major facility that results in a 

significant net emissions increase equal to or exceeding the significant emissions rates (SER) listed in 

Section 62-212.400, Table 62-212.400-2, F.A.C., is classified as a major modification and will bc 

subject to the PSD preconstruction permitting program for those pollutants that exceed the PSD 

SERs. The procedures for determining applicability of the Prevention of Significant Deterioration 

(PSD) permitting program to the project are specified in Rule 62-212.400(2), F.A.C. For each 

regulated pollutant, PSD is triggered as a result of a modification at an existing unit if the difference 

between the projected actual emissions and the baseline actual emissions equals or exceeds the SER 

for that pollutant, as defined at Rule 62-210.200(243), F.A.C. 

. 

The scope of the proposed project includes an uprate of 40 MW associated with equipment 

modifications made during the 2009 refueling outage and 140 MW to be added after upgrades to the 

reactor during the 201 1 refueling outage. The uprate will increase the output from CR3 and the 

associated circulating intake water flow rate will also increase. lhe air emission impacts associated 

with increased intake water flow (Le., increased flow through additional new cooling towers) will 

trigger PSD for particulate matter (PM), but not for PM less than IO microns (PMlo). Other regulated 

air emissions (e& NO, and SOz) will not be affected, as there will be no additional fuel combustion 

sources (e.g., additional diesel generator capacity) that may trigger PSD for these pollutants. 


PEF-NCR-00667

June 2007 3-5 0738953 1 

The project design is still evolving; however, as stated above, the engineering and design data 

currently indicate that the Project will be characterized as a major source subject to PSD. Therefore, 

this SCA addresses Best Available Control Technology (BACT) for PM emissions, which are the 

significant emission increase of concern. Federal PSD requirements are contained in 40 CFR 5 1.166, 

Prevention of Significant Deterioration of Air Quality. The state of Florida’s PSD regulations are 

found in Rule 62-212.400, F.A.C. 

The types and sources of air emissions associated with the CR3 Upgrade Project will consist of a new 

mechanical draft cooling tower to be designated the South Cooling Towers (SCT). PM and PMlo 

emissions will result from cooling tower operation in the form of drift. Drift is water aerosols emitted 

from the cooling tower containing dissolved minerals from the water circulating in the cooling tower. 

The dissolved minerals become PM, including PMlo, when the water in the drift is evaporated. 

Cooling tower drift will be controlled using mist eliminators that will be designed to limit drift to no 

more than 0.0005 percent of the circulating water rate of the cooling tower. 

In addition to adding a cooling tower to remove the incremental heat required to be dissipated by the 

uprate project, PEF is considering replacement of the existing modular cooling towers with additional 

permanent cooling towers (the South Cooling Tower (SCT)). Based on the relative design heat 

dissipation rates, approximately 1 1 additional cells similar to the existing permanent helper cooling 

tower cells will be required to replace the modular cooling tower in full. Coupled with the six cells 

required to dissipate the incremental heat rejected due to the uprate project, a total of 17 cells would 

be required. The status of the existing modular cooling tower is unknown, therefore, in order to 

present a worst-case air quality assessment, it is assumed that the new SCT will include a safety 

factor (of at least one cell) and consist of 18 cells arranged in a 9 by 2 configuration. The estimated 

cooling water flow into the proposed 18 cell SCT is estimated at approximately 342,306 gpni. Again, 

this estimate assumes that the existing bank of modular towers would be replaced by the proposed 

SCT associated with this uprate project, which may not necessarily be the case. 

Figure 3.4.1-1 presents the proposed location of the air emission sources. Estimated hourly emission 

rates, as a result of the proposed cooling tower addition are presented in Table 3.4.1-1, for both PM 

and PMlo emissions. In addition, the proposed cooling tower design parameters and annual PM/PMlo 

emissions estimates are provided in Table 3.4.1-2 for the maximum operating load. That is, the 

information presented is for the proposed cooling tower design that represents the worst-case 

emissions and flow characteristics. Appendix IO. 1.5, the PSD Application, presents the basis for the 


PEF-NCR-00668

June 2007 3 -6 073899 1 

emission rates and maximum annual emissions of regulated pollutants, as well as unit performance. 

As indicated, PSD review is triggered for PM (i.e., due to cooling tower impacts associated with the 

uprate). 

3.4.2 Air Emission Controls 

State-of-the-art air pollution control equipment will be installed on the project to minimize air 

emissions. The control techniques proposed for this project are based on an evaluation of economic, 

energy, and environmental impacts and have been determined to represent BACT on similar projects. 

The following subsection presents a summary of the Control Technology and the BACT analysis, 

which is presented in the PSD permit application in Appendix 10.1.5. 

3.4.3 Control Technologv DescriptioniBest Available Control Technology 

BACT review is required under FDEP rules and EPA regulations pertaining to PSD. Federal 

regulations are codified in 40 Code of Federal Regulations (CFR) Parts 5 I. 166 and 52.2 1, and FDEP 

has adopted PSD rules in Rule 62-212.400, F.A.C. The BACT review is part of the evaluation of 

control technology under the Florida PSD rules. BACT is applicable to all pollutants for which PSD 

review is required and is pollutant-specific. It is an emission limitation that is based on the maximum 

degree of reduction for each regulated pollutant, which is determined to be appropriate after taking 

into account energy, environmental, economic impacts, and other costs. BACT cannot be any less 

stringent than the federal New Source Performance Standards (NSPS) applicable to the source under 

evaluation. 

The FDEP and EPA have established a policy for BACT review in which the most stringent control 

alternatives are evaluated first. The alternatives are either rejected based on technological, 

environmental, energy or economic reasons or they are proposed as BACT. This procedure is 

referred to as the “top-down‘‘ approach. For the project, BACT is applicable for emissions of PM. 

Appendix 10.1.5 of the SCA for the project contains a complete PSD Application. The PSD 

Application includes the BACT evaluation for the project and addresses those pollutants for which 

BACT is applicable. A discussion of the environmental, economic, and energy aspects of alternative 

control techniques and methods are included. The remainder of this section briefly describes those 

control technologies that are proposed for the CR3 Uprate Project. 


PEF-NCR-00669

June 2007 3-7 0738953 1 

PM emissions will be emitted from the cooling towers in the form of drift. Cooling tower drift will 

be controlled through the use of mist eliminators that will be designed to limit drift to no more than 

0,0005 percent of the circulating water rate of the cooling tower. This level of control represents the 

best that is currently available. The total circulation water use will be limited to 1.8 E 1 1 gallons per 

year, based on 8,760 hours per year at a maximum circulation rate of 342,306 gallons per minute 

(gpm). 

3.4.4 Design Data for Control Eauiument 

Design information for the air pollution control equipment is presented in Section 5.0 of Appendix 

10.1.5 (PSD Application). 

3.4.5 Design Philosophy 

The project minimizes air pollutant emissions by using efficient design and state-of-the-art air 

pollution control equipment that will meet a BACT emission rate. In addition, by maximizing the 

megawatt output per unit of cooling water consumed, the air pollutant emissions per megawatt output 

are minimized. Collectively, the design of the CR3 Uprate Project will incorporate features that will 

make it one of the most efficient and lowest emitting, with respect to the amount of air emissions 

emitted per M Ws produced. 

3.5 Plant Water Use 

The primary water use for the CR3 Uprate Project will be an increase in cooling water flow through 

the CR3 condenser to cool the increased heat rejected by the CR3 condenser. The quantitative water 

use diagram for the existing CR 1, 2, and 3 is shown in Figure 2.3.4-4. This figure does not show the 

evaporative losses from the existing HCTs, however, that evaporation is estimated to range up to a 

maximum of only about 9,957 gpm. The only significant change in flow rates anticipated as a result 

of the CR3 Uprate Project is that of the potential increase of condenser cooling water flow for CR3 by 

up to about 150,000 gpm. 

A new SCT has been proposed both to offset the increased circulating water rejected heat and to 

replace the existing modular HCT. A small portion of the increased flow associated with the uprate 

project (up to about 1,288 gpm) will be evaporated in the recirculating portion of the new SCT, which 

will be used year-round to dissipate the increase in rejected heat. The new SCT has also been

June 2007 3-8 0738953 I 

designed to avoid any increase in flow into the intake canal from Crystal BayiGulf of Mexico, and to 

avoid any increase in heat load or temperature rise leaving the discharge canal to Crystal BayiGulf of 

Mexico. For the purpose of this SCA, a conservative and conceptual design plan for the South 

Cooling Tower has been proposed. Detailed design will be addressed as part of the NPDES renewal 

process in 2009. 

3.5.1 Heat Dissipation Svstem 

In Section 2.3.4, the design value of the existing heat rejection rate via the condenser cooling water 

for CR3 was quantified as 5.88 Billion Btu per hour. CR3 currently produces approximately 900 

MWe (megawatts electrical) and 2,609 MWt (megawatts thermal). The net result of the uprate 

project will be to increase CR3’s output to approximately 1,080 MWe and 3,014 MWt. These 

quantities can all be converted to Btu per hour by the formula 1 watt = 3.4 12 14 I Btu/hour. The result 

is shown in the table below, Heat Dissipation System Comparison. The difference between MWt and 

MWe is the amount of heat produced by the unit that is not converted to electricity and which is 

therefore rejected via the condenser cooling water system. The net increase in heat rejection is 225 

MWt, which is equivalent to 0.768 Billion Btu per hour, and represents an increase of about 13.2 

percent relative to the current baseline heat rejection rate of 5.88 Billion Btu per hour for CR3, and 

about seven percent for the design three-unit heat rejection rate of 10.91 Billion Btu per hour 

currently leaving the discharge canal. 

The size and shape of the discharge thermal plume varies with plant and meteorological conditions. 

The thermal plume is generally proportional to the amount of heat rejected, which is a function of the 

product of the flow rate and the temperature rise. PEF is proposing additional recirculating cooling 

towers to remove the increased rejected heat anticipated by the uprate project (0.768 Billion 

Btuihour), therefore, the size of the thermal plume will not increase beyond existing conditions. 

As described in Section 2.3.4, CR 1, 2 and 3 currently operate both permanent and modular HCTs. 

The permanent HCT consists of four separate tower structurcs, each containing nine cells. 


PEF-NCR-0067 1

June 2007 3 -9 0738953 1 

I 

Heat Dissipation System Comparison 

I 

Pre-Existing 

(Baseline) Unit 3 

Post-Uprate 

Unit 3 

MWe 

MWt 

Billion Btu per hour (electrical) 

Billion Btu per hour (thermal) 

Increase in Billion Btu per hour 

(electrical) 

Increase in Billion Btu per hour 

(thermal) 

900 1,080 

2,609 3,014 

3.070 3.685 

5.83 1 6.599 

Base 0.615 

Base 0.768 

Each cell has a water flow rate of 19,017 gpm, and a heat dissipation rate of 0.127 Billion Btu per 

hour. To achieve the dissipation of the increase of 0.768 Billion Btu per hour, a preliminary estimate 

indicates that a cooling tower consisting of six cells, similar to the permanent HCT cells, would be 

required. A six-cell cooling tower would be approximately 50 ft wide by 300 ft long by 55 ft tall, or 

roughly 2/3 the size of one of the existing permanent HCT. 

PEF has the option during the uprate of increasing either the CR3 condenser cooling water flow rate, 

or temperature rise, or both. The amount of heat that the new cooling towers must dissipate is 

independent of the specific choice of flow rate and temperature rise. If the CR3 flow rate is held 

constant at the existing 680,000 gpm, the temperature rise is expected to increase from 17.5 O F to 

19.8 OF for CR3, and the overall temperature rise for the 3-unit flow rate of 1,318,000 gpm prior to 

the use of HCT is expected to increase from 16.7 to 17.9 OF. The use of the existing HCT and the 

new SCT in the helper mode would then reduce the combined discharge temperature down to 

7.7 OF, assuming the full use of all HCT and ignoring the HCT evaporation. This is the same 

temperature rise that would be expected under the same conditions with the existing plant 

configuration. 

Similarly, if the condenser cooling water flow rate for CR3 is increased to 830,000 gpm, and to 

1,468,000 gpm for all three units, the delta T for CR3 will be reduced to approximately 14.3 OF, 

whereas the combined three-unit temperature rise will decrease from 16.74 OF to 15.03 O F prior to the 

use of HCT. The use of the existing HCT and the new six-cell cooling tower in the helper mode 

would then reduce the combined discharge temperature rise down to 6.46 OF. This is a temperature 

1.24 O F less than would be expected under the same conditions with the existing plant configuration, 

and is less because the three-unit flow rate has been increased by 150,000 gpm, which is about 


p EF-NCR-0067 2

June 2007 3-10 0738953 1 

1 1.4 percent of the present three-unit flow rate. Although the flow rate has been increased, the rate of 

heat rejection remains at the existing level, as evidenced by the reduction in temperature rise. 

However, in order to avoid incremental intake entrainment impacts due to the uprate, PEF proposes to 

increase the size of the new SCT and to run a portion of the facility in the recirculating mode (i.e., 

with the cold water return routed back to the intake canal rather than to the discharge canal). At the 

maximum expected condenser cooling water flow rate increase of 150,000 gpm, the size recirculating 

portion ofthe SCT thus need to be eight cells (flow rate of 152,136 gpm). 

In addition to adding the new cooling tower to remove the incremental heat required to be dissipated 

by the uprate project, PEF could potentially replace the existing modular cooling towers with an 

additional permanent HCT. Based on the relative design heat dissipation rates, approximately 1 I 

additional cells equivalent to the existing permanent HCT cells would be required. Coupled with the 

six cells required to dissipate the incremental heat rejected due to the uprate project, this means a total 

of 17 cells would be required, assuming additional cells were not required for intake canal flow 

reduction. The break point for this is the six-cell flow rate of 114,102 gpm; at a condenser cooling 

water flow rate increase less than 114,102 gpm no additional recirculation for intake flow reduction is 

needed. If the condenser cooling water flow rate increase exceeds 114,102 gpm additional 

recirculating cells are required for intake flow reduction. In the worst case, at the maximum increase 

of 150,000 gpm, this would entail two additional recirculating cells. However, the other result of 

increasing the flow rate is that the discharge temperature is reduced. Because the HCT are designed 

solely to reduce the discharge temperature to not exceed a value of 96.5 OF on a rolling three-hour 

average, the reduced temperature rise results in the fact that less cooling is needed from the HCT. 

The resultant amount of reduction in HCT heat transfer is about 0.5 Billion Btu per hour, which is 

equivalent to about four cooling tower cells. Thus, while this case requires two extra cells for intake 

flow reduction, it decreases the number of helper cells required by four. In summary, the two cases 

are described in the following table: 


PEF-NCR-00673

June 2007 3-1 1 0738953 1 

Case 

Required number of cells in 

recirculating mode 

Required number of cells in 

helper mode 

Total number of required cells 

Minimum condenser cooling 

water flow increase (0 gpm) 

6 

II 

17 

Maximum condenser 

cooling water increase 

(1 50,000 gpm) 

8 

7 

15 

PEF may propose to install the new permanent SCT, between the intake and the discharge canal as 

shown in Figure 3.5.1-1, which will include a safety factor (ofat least one cell) and consist of 18 cells 

arranged in a 9 by 2 configuration. Depending on the final amount of the increase in condenser 

cooling water, between six and eight cells will be operated full time in the recirculating mode, and 

from 12 to 10 respectively would be operated in the helper mode as required. 

Figure 3.5.1-1 provides a simplified water use diagram showing the expected division of flow for the 

latter case. The flow from eight cells is estimated to be 152,136 gpm, which is more than the 

potential maximum CR3 condenser cooling water flow rate increase of 150,000 gpm. Therefore, the 

CR3 Uprate Project should actually cause some slight reduction in entrainment relative to the existing 

conditions. 

Through-screen velocity is anticipated to increase from 1.45 fps (max at MLW) to as much as 

2.02 fps (max at MLW) with the CR3 Uprate Project. This is because the four existing cooling water 

pumps will be modified to deliver as much as 207,778 gpm each. This increased velocity could result 

in an increase in impingement mortality. The installation and operation of the proposed recirculating 

six to eight cells of the SCT will slightly reduce entrainment impacts due to the slightly reduced 

overall intake flow from Crystal Bay, and may also reduce impingement mortality by reducing the 

number of organisms available to be impinged. 

PEF intends to request modification of the NPDES permit to authorize the operation of the new SCT 

and an increase in circulating water flow at CR3 from 680,000 gpmi923 MGD to as much as 830,000 

gpm/l,l95 MGD. Overall, the proposed CR3 Uprate Project will not increase flow to the intake canal 

from Crystal Bay and there will be no net increase in the thermal discharge at the NPDES POD. The 

CR3 Uprate Project will not have a negative impact to fisheries or the aquatic environment. 

Golder Associates

June 2007 I 0738953 1 

SECTION 5 

5.0 EFFECTS OF PLANT OPERATION ....................................................................... 5-1 

5.1 Effects of the Operation of the Heat Dissipation System 

........ 5-1 

5.1.1 Temperature Effect on Receiving Body of Water ........................................ 5-1 

5.1.2 Effects on Aquatic Life ..................................................... 5-1 

5.1.3 Biological Effects of Mo n .................................................. 5-3 

5.1.4 Effects of Offstream Cooling ....................................................................... 5-3 

5.2 Effects of Chemical and Biocide Discharges ........................ 

5.2.1 Industrial Wastewater Discharges ................... 

5.2.2 Cooling Tower Blowdo ................................. 5-3 

5.3 Impacts on Water Supplies ........ 

............................................ 5-4 

5.3.1 Surface Water 

5.3.2 Groundwater ................. 

5.3.3 Drinking Water ............. ...................... 5-4 

5.3.4 Leachate and Runoff .... 

5.3.5 Measurement Programs ................................................... 5-4 

5.4 SolidHazardous Waste Disposa 

5.4.1 Solid Waste .................................................................................................. 5-5 

5.4.2 Hazardous Wastes ...................................................... ........... 5-5 

5.5 Sanitary and Other Waste Discharges ............... ............................... 5-5 

5.6 Air Quality Impacts ........................................... ............................... 5-5 

5.6.1 Impact Assessment .............. .................................................. 5-5 

5.6.1.1 Regulatory Applic .............................................................. 5-5 

5.6.1.2 Analysis Approach and Assumptions ........................................... 5-6 

5.7 

5.8 

5.9 

5.10 

5.1 1 

5.12 

5.13 

........................... 5-8 

Noise Impacts ..................... 

5.7.1 Impacts .......................... .................................................................... 5-8 

Changes to Non-Aquatic 

5.8.2 Monitoring .................................................................................................. 5-10 

Other Plant Operation Effects ............................. 

................ 5-10 

5.9. I Operations Traffic ...................... ................................... 5-10 

5.9.2 Effect of Train Operations ................ ............................................... 5-12 

Archaeological Sites 

Resources Committe 

Variances ................................................................................................................. 5-12 

References ........................................................................... 5-13 

LIST OF TABLES 

Table 5.9.1-1 

Table 5.9.1-2 

Roadway Capacity Analysis Summary 

Intersection Capacity Analysis Summary 


PEF-NCR-00675

June 2007 II 0738953 1 

LIST OF FIGURES 



Operations Noise Map 

2013 Build Traffic Volumes 


PEF-NCR-00676

June 2007 5- 1 0738953 1 

5.0 EFFECTS OF PLANT OPERATION 

5.1 Effects of the Operation of the Heat Dissipation System 

5. I. 1 Temperature Effect on Receiving Body of Water 

As described in Section 3.5, the final condenser cooling water flow rate for CR3 has not been 

determined, however, the potential will range up to a maximum expected flow rate of 830,000 

gpm from the current 680,000 gpm. The corresponding flow rate for CR I, 2, and 3 will thus 

range up to 1,468,000 gpm (potential maximum). The use of the proposed new SCT will ensure 

that the heat rejection rate from the three units will be limited so as not to exceed the present 

maximum rate of 10.91 Billion Btu per hour at the POD. Because the temperature rise is 

proportional to the heat rejection rate, the full load temperature rise at the maximum expected 

flow rate, without the use of the HCT but using the recirculating portion of the new SCT, will be 

13.79 "F. 

Since the discharge temperature from CR 1,2 and 3 prior to use of the new SCT is estimated to 

range between the present value of up to 16.74" F, to a future value between 13.79 " F and 16.74 O 

F, there is not expected to be any measurable impact due to change in combined flow discharge 

temperature. Also, because the total quantity of heat rejected via the discharge canal at the POD 

is not changing, the shape and extent of the thermal plume (the location and amount of acreage 

enclosed within each temperature isotherm) is not expected to change with the CR3 Uprate 

Project. 

5.1.2 Effects on Aquatic Life 

PEF has been in the process of quantifying baseline aquatic impingement and entrainment 

impacts at the CREC in order to develop a Comprehensive Demonstration Study (CDS) for 

submittal to the FDEP in compliance with the federal Clean Water Act 316(b) rule. However, the 

U.S. Court of Appeals for the Second Circuit recently remanded most of the substantive portions 

of the USEPA's July 2004 3 l6(b) Rule. PEF anticipates that EPA will re-promulgate the Phase I1 

3 I6(b) regulations at some time in the future. In the interim, PEF intends to continue to evaluate 

impingement and entrainment impacts associated with the CR3 Uprate Project within the CREC 

existing monitoring program. This data will be used to evaluate impacts and identify measures to 

reduce aquatic impacts during the next CREC NPDES pennit renewal (scheduled in late 2009). 


PEF-NCR-00677

June 2007 5-2 0738953 1 

The magnitude of any changes in overall facility effects due to the uprate project is expected to be 

small. 

There are no expected changes in effects on aquatic organisms due to changes in the release of 

heat, because there is no change in the quantity of heat as measured in Btu per hour, and because 

the temperature rise associated with the release of heat will be the same as, or slightly reduced 

from, the current discharge temperatures. 

As described in Section 3.5, the total quantity of water withdrawn from the Gulf of Mexico 

through the intake canal will not be increased by the uprate project; therefore, the total rate of 

entrainment should also not increase. In fact, since the amount of cooling water that will be 

recirculated by the six-cell portion of the new cooling towers (152,136 gpm) exceeds the potential 

increase in cooling water flow associated with the uprate project (150,000 gpm), the net inflow 

into the intake canal from the Gulf of Mexico is estimated to decrease slightly with the uprate 

project. 

Impingement mortality is generally considered a function of both through-screen velocity and of 

total flow rate. Although the uprate may cause the through-screen velocity to increase by as 

much as 22 percent (from 1.65 fps maximum to 2.02 fps maximum), the actual concentration of 

impingeable organisms is more likely controlled by the velocity entering the intake canal, as that 

is the velocity those organisms must overcome to escape impingement. As described in Section 

2.3.4, the existing intake canal velocity which corresponds with the maximum through-screen 

velocity (at MLW) is estimated to be about 1.3 fps. Since the uprate project will actually reduce 

the overall cooling water flow into the intake canal from 1,318,000 gpm to at most 1,315,684 

gpm (1,468,000 gpm - 152,136 gpm), the maximum intake canal velocity would be expected to 

be reduced slightly, on the order of about 0.002 fps. 

Based on the discussion above, PEF proposes to continue to evaluate the entrainment and 

impingement impacts associated with CREC ongoing facility operations as well as the impacts 

associated with the CR3 Uprate Project. PEF intends to quantify aquatic impacts to offset 

impacts during the CREC NPDES renewal (scheduled for submittal in 2009) process. Pending 

the outcome of the ongoing studies, PEF will propose the best technology available for 

minimizing impacts. Based on current information, the proposal may include a physical barrier, 

diversion technology or expanded onsite restoration (Le., expansion of the Mariculture Center). 


PEF-NCR-00678

June 2007 5 -3 0738953 I 

5.1.3 Bioloeical Effects of Modified Circulation 

The CR3 uprate project is not expected to cause any significant modification to water circulation 

in the site vicinity. The existing condition includes the circulation pattems superimposed by the 

CREC on the ambient environment. As described in section 5.1.2 above, the magnitude of the 

change to the velocity entering the intake canal is estimated to be a reduction of approximately 

0.002 fps. Changes of this magnitude are not measurable. 

5.1.4 Effects of Offstream Cooling 

Because the new SCT withdraws water from the discharge canal, it is withdrawing water that has 

already been screened and passed through a condenser. Therefore, that withdrawal of water will 

not cause any increase in impingement mortality or entrainment relative to the existing levels. 

5.2 Effects of Chemical and Biocide Discharges 

5.2.1 Industrial Wastewater Discharges 

Compliance with applicable state and federal discharge regulations and water quality standards 

for industrial wastewaters, is presently being achieved through the implementation of the CR 1,2, 

and 3 NPDES permit. The CR3 Uprate Project will not cause any changes in the quantity or 

characteristics of industrial wastewaters generated by the facility; therefore, no change in that 

compliance achievement status due to the uprate project is expected. 

5.2.2 Cooling Tower Blowdown 

The proposed new SCT associated with the CR3 Uprate Project will not generate any 

“blowdown”. Additionally, the evaporation associated with the recirculating portion of the new 

SCT is not expected to exceed 1,718 gpm, an amount that will not significantly increase the TDS 

of the cooling water discharge. At this maximum expected evaporation rate, the change in TDS 

concentration assuming an existing value of 28,000 mg/L would only be about 37 mg/L or 0.1 

percent. This effect is insignificant relative to the natural range of TDS of 7,000 mg/L (31,000- 

24,000) as shown on Figure 2.3.4-6. 

Golder Associates


PEF-NCR-00680

Figure 2.3.4-5 Once Through Cooling Water Flow 

2,000 

I 

1 -Average . Maximum - - - Limit I 

1,800 

1,600 

1,400 

600 

400 

200 

0 

5/18/2007 4:OO PM Table 2.3.4-1 .XIS Figure-2.3.4-5 

PEF-NCR-0068 1

Figure 2.3.4-7 Once Through Cooling Water Temperatures 

105 

100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

+Average Intake 

Average Discharge 

--- 

Maximum Intake 

Maximum Discharge 

45 

- 

40 

511 812007 4:02 PM Table 2.3.4-1 .xis Figure-2.3.4-7 

PEF-NCR-00682


PEF-NCR-00683

HOf YRlER TEnPERATURE 

1 110.0 OF 

2 108.0 OF 

3 106.0 'F 

4 104.0 OF 

6 103.0 "F 

6 102.0 OF 

1 100.0 OF 

8 98.0 OF 

9 98.0 OF 

10 94.0 OF 

I1 92.0 OF 

12 90.0 Of 

DESIGN CONOIT13NS 

URTERFLOY 

RELATIVE Hunioi1i 

COLD HRlER 

I101 URTER 

WET BULB 

mnonEmis PRESSURE 

ii~ifio. uscm 

66 89.60 i: OF 

103.00 OF 

81.00 'F 

IO13 nn. 

PERFORMRNCE CURVES COLD WRTER TEMPERRTURE RS R FUNCTION 

OF HE1 BULB AIR TEMPER9TURE RNO HOT WRTER TEMPERATURE 

HATERFLOH 

I7 I750 .USGPM 

246 U.6. HIWHAI 27. YES1.ERIOGEWRlER H.J. OB807 US1 

CRYSTRL RIVER - BFISE OFFERlNG 

OHNER'S HRRG[N - ON[ TOWER 

nmcn 1990 

10410 HUT578 .' 

PEF-NCR-00684


PEF-NCR-006 8 5

- 

a, 

0, 

C 

e 

6 

a, 

-0 

? 

a, 

m 

C 

e 

ci 

a, 

-a 

I 

(3 

Y 

a, 

0: 

C 

e 

u 

a, 

U 

0 

7 

- I

Local Annual Windrose

_,.I _.. 

5/24/2007 2 3 7-1 TPA Annual Windrose doc 

,,.' 

_,. 

....... .............. 

iNORTH--. 

,_,.- ....................... 

.... 

.._................_..' 

.... .......... 

........ ............ 

.*.. ...... .......... ..; SOL.?TH"' 

WIND SPEED 

(Knots) 

17-21 

m 11-17 

7-11 

4-7 

1-4 

Calms: 13.40 

Average Wind Speed 5.73 Knots 

Calm Winds 13.4 % 

Note: 1 knot = 1.151 miles per hour. 

Figure 2.3.7-1. 

Annual Wind Rose for 2001 to 2005 

Tampa International Airport (Station No. 12842) 

Source: National Climatic Data Center. 2001-2005. 

PEF-NCR-00688

5/24/2007 2 3 7-2 TPA Winter Windrosc.doc 

WIND SPEED 

(Knots) 

u >=22 

m 17-21 

m 11-17 

m 7-11 

0 4-7 

m 1-4 

Calms: 13.17 

Average Wind Speed 

5.74 Knots 

Calm Winds 

13.17 Yo 


Figure 2.3.7-2. 

Winter Wind Rose for 2001 to 2005 


Source: National Climatic Data Center. 2001 -2005. 

pEF-NCR-00689

,,.I 

,,I' 

5/24/2007 2.3.7-3 TPA Spring Windrose doc 

................. .... '._ 

,.,. 

........ 

--J 

.... 

.-,*.~ 10?/0 

........... 

~ 

L...,,. 

........ 

WIND SPEED 

(Knots) 

m 17-21 

m 11 -17 

7-11 

4-7 

1-4 

Calms: 10.49 


Calm Winds 


6.39 Knots 

10.49 % 

Figure 2.3.1-3. 

Spring Wind Rose for 200 1 to 2005 


Source: National Climatic Data Centcr. 200 1-2005. 

PEF-NCR-00690

5/24/2007 2.3.7-4 TPA Surnrner Windrose doc 

WIND SPEED 

(Knots) 

El >=22 

m 17-21 

m 11-17 

l--i 4-7 

m 1-4 

Calms: 17.98 


Note: 1 knot = 1.15 1 miles per hour. 

Figure 2.3.7-4. 

Summer Wind Rose for 2001 to 2005 


Source: National Cllmatic Data Center. 2001 -2005. PEF-NCR-0069 1

5/24/2007 2 3 7-5 TPA Fall Windrose doc 

........... 

:NORTH........ 

................. .... ._.. 

,..- .-- .,,- 

WIND SPEED 

(Knots) 

17-21 

m 11-17 

7-11 

4-7 

m 1-4 

Calms: 11.99 


5.78 Knots 



Figure 2.3.7-5. 

Fall Wind Rose for 2001 to 2005 


Source: National Climatic Data Center. 2001-2005. 

PEF-NCR-00692

RFI Number: 

Discharge Canal Thermal Mitigation Project Request for Information (RFI) Form 

Date: 

Contractor's Project Manager 

Initiator: 

Approval: 

Description of Request, Issue, Concern 

Suggested resolution: 

Scope 

I I Schedule I I cost I I Safety 

Progress Energy Direction, Resolution, Clarification 

4pproval 

Project Manager 

Procurement Siecialist: 

PEF-NCR-00693

Kennwort: 

Job Name: 

Auftragsnummec 10588 

Order-No.: 

Index I gultig ab: 

Gsue I Cate: 

1 tistellt s 314 

\ 

~12.01.2004 Gerdemnn 

ReoSred 

Geprijft S 314 12.01.2004 Weinzierl 

Amroved 

Freigegeben S 314 12.01 -2004 Winlder,F.J 

kleased 

F r e igeg e be n 

Kunde I AbnahmegeseUschaft 

Weased CustMnerlAcceptanceauth 

Abteiturtgloeparbnent "/Date "?I ELBms 

gez. Gerdemann 

gez. Weinzierl 

gez. Winkler 

Unterschrift I siar=" 

Siemens AG 

paw= Generation (E)

Inhattsverzeichnis I Table of contents 

Auftragsnummer: 10588 

ader-M. 

Blatt-Nr. Bauteil 

Sast-Na 

TYP: 

Type: 

Werkstoff 

h@ml?al 

TLV 

FINChaSeSpktWlbll 

Datum 

oaa 

Index 

ksun 

121120 

Turbinenw elk 

Turbhe shaft 

NiaMOV 

PD 10325UB 

121300 

Turbiienheufer 

Turbine rotor 

131110 

Leitschaufeln Stufe 1-8 L+R 

Stationary blades stage 1-0 L+R 

9238 01 

131301 

Leitschaufeln (gefrast) 

Stationary blades (nsled) 

9238 01 

1321 20 

Laufschaufeln Sufe 1-8 L+R 

%tor bMeS Stage 1-8 L e 

X20Crl3 

9238 01 

132301 

Laufschaufeln (gefrast) 

!MorMedes (Riled) 

X20Cf13 

9238 01 

161140 

Lebchaufeltrager ( El TTEzIGElIGE2) 

Gui Made carrier (-rEllrrcvcEirm) 

GX4CfNil3-4 

PEF-NCR-00695

Qualitats prufblatt/Quality Test Sheet 

Index: o 

&Watt Qoh..t k..: Nr: 121120 

Datum: w: 

minahme 

aecpsaon 

1 

1.1 

1.2 

1.3 

1.4 

1.5 

Ruefungen beim Lleferanten 

Tests at supplier 

Mass-und Sihtpruefung 

Dmensional and visual inspection 

cherrische zusamnsetzung 

Chenical corrposition 

higchanische tigemchaften 

Mechanical properties 

uhaschalpruefung - Nach demvergueten 

Ub-asonic test - After quallly heat treabnent 

DokumntationskontroL 

Checkof documtation 

PEF-NCR-00696

Qu alitats p r u f blattlQuality Te s t She et 

jennwort: 

2b -1: 

iuftrags-H.: 1- 

rdor no.: 

bugruppe: 

IS. c*.m 

' 

Index: 0 GBlatt Nr: 121300 

QIWt m.: 

Datum: 

Date: 

matt: 1 

m: ol 

von2 

riifungen 

.Ita 

Manforderunp 

st Spec" 

Mung durch: 

Tesmd bv 

lemeOS 

1 

1.1 

3.1 

3.2 

Ruefungen nach dem Rehen der Uchtbaender des 

Turbtneniaeufers 

Tests after turning of seal strips on turbine rotor 

Mass- und SiihtpnrefUng 

h-process dmnsionai and visual inspection 

Pruefungen waehrend und nach dem Beschaufeln des 

Turbinenheufors 

Tests during and after blading of turbine rotor 

SchaufeCuJntrok 

h-process blading check 

Pruefungen tum. waehrend und nach dam Wuchten des 

Turbineniwufws 

Tests to, durirjg and after balancing of turbine rotor 

Schleuderpruefung - Turbinenlaeufer - 1.20 x Nenndrehzahl. 2 

nin. 

mer speed te.st - ~urbine mtor- I ~ x O "inai speed. 2 nin. 

Wuchtpruefung - Turbine.n$eufer - Schw ingungsanatyse. 

RBstunwucM 

Bakince test - Turbine rotor - Vbration analyses. rerreinhs 

inbalance 

eichnung I Drawing 

eichnung I b mg 

(undensonderforderung 

hbx" speck1 requirement 

PEF-NCR-00697

Kennwort 

Job h a : 

Auftrags-Nr.: 10588 

o.&, m.: 

Baugruppe: 

0.s 0.- 

Qualitiits pruf blattlQuality Test Sheet 

I 

Index: 0 QBiatt GSh0.t )h: Nr: 1~1300 

TLV: 

FuIChasa Swcnl8tlon: 

Datum: 

1y.: 

Blatt: Rp.: 2 von2 d 

I 

Priifungen 

laat. 

irch: 

I 

emn! 

4 Ruefungen vor dem Versand des Turblnenlaeufers 

Tests before shlpment exfactory of turbine rotor 

4.1 Pund- und Ranlaufpruefung - Vor dem Versand 

fBdiC and axlal run out check - Before despatch 

eichnung I Draw mg 

P 

undensonderf orderung 

ith 6ctensbn shaft clrstomer special 

quLemt 

4.2 

Mdpruefung - Vor dem Versend des Turbinenlaeufen 

FMI ispection - Before despatch of turbne rotor 

I 

I 

Siemens AG 

RMferGeneratknIffi) 

PEF-NCR-00698

Qualit~tsprufbla~Quality Test Sheet 

hnnwort 

ib Wma: 

iuftrags-Nr.: 10588 

rd.r k 

hugruppe: 12800 

Da. a.40.: 

'rllfungen 

ma- 

rinanforderung 

861 Spec" 

Mung durch 

Tatad tw 

iemns 

- 

3ilnahm 

Index: 

TLV: 9238 

- 

01 

.clRcltlon: 

emrkungen 

ndex 

GBlatt Fk: 131110 

Qaheat ND.: 

Datum: o*.: 

Blatt: m: I ot vonl 

l 

Pruefungen des Vormaterlala 

Tests long-lead materlal 

1.1 

Uxznische Zusamnensekung - Schmehanatyse 

Chenical conpsition - M analysis 

LV 

1.2 

~hanische 6genschaften 

Machanical properties 

LV 

1.3 

Sichtpruafung 

Visual inspectan 

LV 

1.4 

tvhspruefung 

amensDnal Inspection 

!&hnung I Raw ng 

KV 

2 

Warenelngangspruefung (Vormaterial) 

ihceiving incpedin (Re-material) 

2.1 

tbkumentatbmrkontrde 

Checkof docurnentation 

LV 

X 

--- 

.I I-- 

CI

Qu alitgts prtifb IaWQuality Test Sheet 

Cennwort: 

obNnn.: 

iuftrags-N.: 1- 

rdbr M 

hugruppe: 12800 

m. 

Wfu nge n 

’oat. 

1 Pruefungen waehrend der Fertiiung 

Tests durlng manufacturing 

ImtbrW: 

’iifanforderung 

lat.Pecrcaml 

urch: 

w 

iemns 

Index: 

TLV: 9238 01 

Furchib sp.Cmatlon: 

QBlatt M: 131301 

m.: 

Datum: 

D.*: 

Blatt: 1 

P.P.: 

vonl 

OI 

hdex 

- 

1.1 Ma&prllfung 

Olmensional inspection 

w3.004 

2 Pruefungen nach der Fertigung 

Tests after manufacturing 

2.1 SiCh@fGfUng - 100 % 

Visual inspection - 100 % 

443.001 

2.2 

iberpdfung dar Dob~~~~ntatiOn auf VoPstBndi- und F5c-M 

-3.001 

Fnal check of documentatbn for correctnebs and conpletenea 

Siemens AG 

I - 

rd) 

I 

Wer Generation (PG)

Kennwort: 

Job "0: 

AuRrags-N.: 

etm m.: 

1ossS 

Baugruppe: 14600 

h.. &Ab.: 

PrOfungen 

T.Sb 

Fnjfun durch: 

T€s& bv 

QualitiltsprufblattlQuality Test Sheet 

Index: 

Q-matt Nr: 132120 

Q.h..t No2 

Datum: 

DQO: 

TLV: 9238 01 Blatt: 1 of vonl 

Purchaw 

wltkaUon: 

hdex 

1 

1.1 

1.2 

1.3 

1.4 

2 

2.1 

Ruefungen des Vormaterials 

Tests long-lead material 

ChenjSche Zusamnensetzung - Schmebanatyse 

chenical composition - Melt anatysk 

Mechanische tigenschaften 

Mechanical properties 

sic~fung 

VBd h S w 

kesspruefung 

Umenskmal 

Wareneingangsprucr ng (vormc I 

RaceMng Inspection (Re-materlrl) 

LV 

LV 

LV 

eichnung I Drawing 

LV 

PEF-NCR-0070 1

QualitatsprufblaWQuality Test Sheet 

bnnwort: 

Ib m.: 

ruftrags-Nr.: 

.d.rnp: 

VXJ~I 

laugruppe: 14600 

IS. 

Index: QBlatt Nr: 132301 

Q.h..t m.: 

Datum : 

Db: 

rIifungen 

DSW 

1 

Ruefungen waehrend der Fertlgung 

Tests during manufacturing 

rrch: 

V 

emens 

- 

niahme 

rlkk” 

emerkungen 

“3 

1.1 

MaCpnlfung 

~nsional inspection 

M43.004 

P 

2 

Ruefungen nrch der Fertigung 

Tests after manufacturlng 

2.1 

SichtpKifU- - 100 % 

viwl inspection - 100 % 

M43.001 

X 

2.2 

iberptiifung der Dok”tati0n auf Volktf~ndig- und RcicMigkeit 

M43.001 

P 

Fnal check of documentation for correctness and conpletenesr 

PEF-NCR-00702

QualitSts pr UfblatUQuality I Test Sheet 

Index 

QBlatt Nr: 161140 

a..h..t I(a: 

mtum: 

M.: 

Blatt: I vonl of 

Irch: 

Y 

iam3m 

iinahme 

acpa6on 

1 

Ruefungen balm Lleferanten 

Tests at suppller 

1.1 

chenische 2tim"Sekung - Schmebanatyse 

chemjcal conposltion - Melt analysis 

LV 

1.2 

1.3 

wchanische tigenschaftefl 

MBchanical properties 

zersmngsfrele mung 

Nondestructive test 

LV 

LV 

1.4 

Mass- und SihtpMfUng 

anrtnsional and visual hspection 

Leichnung I Draw hg 

2 

2. 

Wareneingangspruefung 

kmMng inspection 

m- und Slchtpruefung w Wrend der Fertigvng 

Umensional und visual hspectan - h process 

Zeichnung I Draw in9 

X

POTENTIAL SUB-SUPPLIER LIST 

SIEMENS 

FOR INFORMATIONAL PURPOSES ONLY 

Modmuaton Frujecf 

APRIL 16,2W7 

'r 

PAGE I Main Supplier Lisf -2007-2 

SIEMENS CONFlOENTlAL PROGRESS ENERGY SERVICE COMPANY, LLc-cRYST4L RIVER UNIT #3 

REOUESTNO SO22007 

USE THIS DOCUMEMSOELYFOR THEFVRPOSE GWEN. RENRN UPQN REQUEST. 

DONOTDISCLOSE REPRODUCEOR USE OTHERWISE

SIEMENS 

McdernaalKm prolecf 

CONFIDENTIAL 

P~GE 2 Main Supplier Lul-2007-2 

,, 

SIEMENS CONFlOENilAL PRffiRESS ENERGY SERVICE COMPANY. LLc-CRYSTfiL RIVER UNIT #3 


USE THIS OOCUMEMSOELYFOR THE FWRPOSE GNW RENRN UWN REQUEST. 

DO NOTOISCLOSE REPROOUCEOR USE OTHERWISE WHOLnTHE WRmEN CONSENTOFSLE~~ENSPOWER GENERATIP"'"- 

~EF-NCR-00705

SIEMENS 

Potential field Sub-Sutmlier List 

Mcdmnalm Pro~ecl 

AWIL 16.2W7 

CONFl DENTlA L Do 

r 

PAGE3 

SIEMENSCONFIOENTIAL 

Main Suppk Le!-2037-2 

R?ffiR&SS ENERGY SERVICE COMPAW, LLCGQYST~ RIVER UNITE 

REQUESTNO SD22007 

USE THIS DOCUMENTSOLELIFOR THE WRWSE GIVEN. RWRN UPON REQUEST. 

NOTDISCLOSE REPRODUCEOR USE OTHERWSE tnT~om THE WRITTEN CONSENTOFSIEMENSPOWER GENEWTIONINC. 

PEF-NCR-00706

SUSQUEHANNA STEAM ELECTRIC STATION 

TURBINE RETROFIT/GENERATION UPRATE: 

DECISION FACTORS FOR LONG TERM RELIABILITY 

AND IMPROVED PERFORMANCE 

Co-Authors 

John A. Bartos, PPL Susquehanna, LLC 

Michael S. Corski, PPL Susquehanna, LLC 

Lawrence E. Olah, PPL Susquehanna, LLC 

Michael IK Smiarowski, Siemens Westinghouse Power Corporation 

INTRODUCTION/ABSTRACT 

Nuclear power is a cost-effective source of electric power. According to Robert Smock, editor 

of Power Engineering Magazine, “with almost 400,000 MW of new capacity needed to meet 

demand growth over the next 20 years, nuclear power must contribute to this need and it is 

evident that electrical utilities must increase capital investment in electrical facilities.”’ Nuclear 

Plant operators are relicensing and retrofitting the plants to achieve maximum output and useful 

life from the plants. PPL’s Susquehanna Steam Electric Station (SSES) Units 1 and 2, a Boiling 

Water Reactor Plant in Benvick, PA, with a 1100 MWe nominal rating per unit, is such a plant 

looking to operate at peak efficiency and reliability for its operating life. 

The Susquehanna Station was faced with long term maintenance issues on its original disc type 

OEM low-pressure (LP) turbines (circa 1982). The original LP rotors suffered from stress 

corrosion cracking (SCC) in the disc/keyway and blade attachment areas, which is a common 

design issue on certain rotor designs. Even though all six of the original disc type Unit #1 and #2 

LP rotors were replaced with the current monoblock design in 1986 and 1988 respectively, there 

were still concerns that these monoblock LP rotors would develop SCC in the blade attachment 

areas. In addition, another significant long-term maintenance issue was LP casing erosion on the 

current operating LP turbines, which PPL also wanted to address. 

A team was formed to investigate the long-term options for the Susquehanna plant to both 

increase performance and reduce long term maintenance on the turbines. In November 1999, 

PPL issued requests for bids to replace the six (6) low-pressure turbines with an option to replace 

the two (2) high-pressure turbines. Upgraded erosion resistant materials options were also part 

of PPL’s request for the LP construction. 

Although many factors are considered when developing an effective contract, the keyhnique 

factors PPL used in the selection process of the turbine retrofit were: 

1 

Smock, Kobert, W , Power Engineermg, July 2001 (Vol 105, no 7), p 3

Performance Improvement 

Proven Technology and Reliability (includes Material SelectionKomposi tion and 

PI acement) 

Additional contributing factors that were involved in contract discussions between both PPL and 

the turbine supplier were: 

Performance Warranty/Testing Criteria 

Scope of Supply 

Installation Scope and Duration 

Equipment Warranty 

Design Alternatives Incorporating Current and Potential Future Station Uprates (in 

essence, Strategic Planning) 

On January 23, 2001, PPL awarded the turbine retrofit contract to Siemens-Westinghouse Power 

Corporation (SWPC). The new turbines will use Advanced Disc Design LP rotors and have 

upgraded casing materials for erosion resistance. The HP turbine retrofit provides a portion of 

the additional MWe’s and optimizes the turbine to the uprated steam conditions. This paper will 

share, to the extent possible, the details on the key decision factors to provide insight regarding 

the magnitude and breadth of such a project. 

LP ROTOR DISC CRACKING EXPERIENCE 

Several manufacturers’ turbines with shrink fit discs on solid rotors, such as at the original 

turbines at Susquehanna Steam Electric Station (SSES), had a history of disc inside diameter 

cracking in the keyway areas, Such disc cracking is a well-known problem in the industry 

caused by stress corrosion. Three basic factors: susceptible material, wet corrosive environment, 

and high tensile stress at the surface are necessary to support stress corrosion cracking. In this 

design, the original keyway provided a location for steam contaminants to concentrate, thereby 

creating a corrosive environment. Most importantly, the geometry of the keyway and the shrink fit 

of the disc onto the rotor shaft contributed to high tensile stress at the disc surface. 

Disc cracking has been an issue on many low-pressure turbine rotor designs with shrink fit discs, 

with some exceptions, such as the Siemens design. This has led to replacement, or planned near 

term replacement, of many nuclear low-pressure turbine rotors. Susquehanna, in fact, had replaced 

the original disc type LP turbine rotors after only nominally 4 years of operation, with in-kind 

monoblock replacements supplied by the OEM. The replacement monoblock rotors had a six-year 

inspection interval. This inspection interval was later extended to eight years. In addition to the LP 

rotor inspection, a boresonic inspection is required every 10 years. 

PEF-NCR-00708

OTHER LONG TERM RELIABILITY ISSUES 

Disc keyway cracking was the most serious risk to long term reliability and economical operation of 

the original Susquehanna LP turbines which led to their replacement. On the current operating LP 

turbine, the main concerns that were a challenge to long term operation were: 

Dovetail Cracking: Dovetail cracking is stress corrosion cracking that occurs at the rim of a turbine 

disc, which is the attachment for the turbine blades. This type of failure is not as serious because it 

cannot generate missiles that would be potentially dangerous to plant safety systems. Nevertheless, 

this is becoming a significant industry concern and is causing some utilities to implement repair 

programs to prevent further damage to their turbine rotors. Typical repair costs could be $5 million 

per rotor and may require extended refueling outages to implement. The current SSES LP turbine 

rotors, which are a monoblock design, have not exhibited dovetail cracking. A crack mitigation 

program was in process at Susquehanna. The dovetail inspection and crack mitigation programs 

were discontinued after the decision to replace the turbines was formally approved. 

Inner Casing Erosion: Casing erosion was also a serious long-term reliability issue on the current LP 

turbines at Susquehanna Steam Electric Station. Many nuclear operators, especially BWRs, are 

considering replacement or have replaced their older turbine rotors and inner casings because of 

high cost repairs associated with the severe erosion and loss of generation. Again, this was a major 

consideration in the turbine retrofit. 

TURBINE BID REQUEST ISSUANCE AND MmESTONE DATES 

In November 1999, PPL Susquehanna LLC issued a request for bids to four vendors for retrofit LP 

turbines at the Susquehanna site. This bid request also gave the bidders flexibility to quote on 

options such as improved materials, high-pressure turbine components, and installation services. 

Bids were received in late February 2000 with PPL project evaluations extending through November 2000. 

The selection process entailed: 

0 Technical Evaluations 

0 Design Considerations and Clarification Meetings with Vendors 

Options Assessments 

Internal Meetings to Discuss Potential Future Station Uprates and Other Equipment Limitations 

The evaluation period was extended by these considerations plus the need to analyze and 

incorporate information from an LP turbine inspection during the Spring 2000 Unit 1 refuel outage. 

In addition, meetings were held with the vendors submitting quotations to ensure their offerings 

were accurately being evaluated. 

A letter of intent was issued to Siemens Westinghouse on November 17*, 2000. After two months 

of detailed negotiations and contract language review, the project agreement between PPL and 

Siemens Westinghouse Power Corporation (SWPC) was signed on January 23,2001.

PERFORMANCE lMPROVEMENT/AWARD DECISION 

The decision was made to proceed with the retrofit of the HP and LP rotors and inner casings. This 

would not only resolve the dovetail cracking concerns, but would additionally minimize future 

casing erosion problems. PPL’s technical specification sought “a more efficient steam path for the 

main steam turbine, including all related accessories and auxiliaries required for a complete and 

operable system, to be installed as a replacement for the existing steam paths.”2 An additional 

annual average of 50 W e output gain for each unit is anticipated from the advanced technology 

turbine train. 

Although there were no long-term maintenance reasons to retrofit the HP turbines, a decision was 

made to proceed with their retrofit because the increased W e that the HP turbine added to the total 

project upgrade justified their retrofit. 

PROVEN TECHNOLOGY AND RELIABILITY 

In conjunction with the increased performance provided by the improved technology turbine 

train, a proven, reliable turbine design was given equal importance as a success factor. Again, 

PPL’s turbine specification stipulated that the retrofit turbine equipment “must maintain the 

existing unit availability while eliminating stress corrosion cracking (SCC) in both the blade 

attachment and disdkeyway areas, eliminating erosion of turbine stationary parts, while 

providing an increase in time between maintenance interval^."^ Meeting this criterion is 

discussed below. 

SWPC’s LP Advanced Disc Rotor and Turbine Design Highlights 

The retrofit LP design completely replaces the original rotors and inner casings, with minor 

structural modifications to the LP exhaust hoods. The figure below shows a representative LP 

steam path cross-section that will be used at Susquehanna. SWPC will be providing its 13m2 LP 

turbine design, which refers to the approximate exhaust area of each LP flow. The retrofit 

turbines will be designed to fit into the existing turbine bearings and operate with all the existing 

auxiliary systems. The SSES original seven blade stage LP design will be replaced with nine 

blade stages. 

The LP rotor features the SWPC advanced disc design. The Susquehanna LP rotors will use a 

three disc per flow design, which was introduced to the US. market at the Siemens 

Westinghouse upgrade of the Limerick Generating Station turbines in 199811 999. This advanced 

disc design LP rotor is the standard product offering for large nuclear LP rotor retrofits. As part 

of the SWPC best practices initiatives after uniting the respective Siemens and Westinghouse 

organizations in 1998, this advanced disc LP rotor design has become the standard offering for 

such applications. 

‘Technical Specification for the Replacement of the Main Turbine M-1549 rev. 1, Nov. 1999, p.3. 

Ibid, p.3.

Figure 1 -Advanced Disc Design LP Turbine Cross Section 

PPL benefited from previous application and analyses performed on the Limerick project to 

assess the design claims of the SWPC advanced LP disc design. Two major points that were 

highlighted by a previous independent evaluation of SWPC design claims were: 

Pertaining to SCC in the Disc Inlet: 

The SPC (SWPC) design addresses those areas in other manufacturers’ designs that have led 

to early retirement of those rotors due to SCC in their shrunk-on discs.4 

Pertaining to SCC in the Blade Attachment Area: 

SPC stresses are low compared to similar stresses which we have calculated for other 

manufacturer’s designs in the equivalent areas. The lower stress states combined with the 

manufacturing procedure which results in residual compressive stresses in the periphery of 

the disc should provide good resistance to SCC in the attachment area.5 

Noteworthy LP Turbine Design Features 

Other noteworthy design features that were incorporated into the LP turbine design are as 

summarized as follows: 

‘ “Limerick LP Turbine Replacement Rotor Proposed by Sicmcns Power Corporation Evaluation of Margin With 

Respect to Disc SCC”, MPR Report, December 1995. 

Ibid. 

PEF-NCR-007 1 1

Integrally shrouded stationary and rotating drum stages. In addition, interstage 

sealing is accomplished through the “see-thru” or parallel seal strip arrangement. 

Free standing LP rotating section blades (3 stages per flow) with 46-inch last 

stage blades 

Flame hardened leading edges of the LP freestanding rotating blades to mitigate 

moisture erosion. 

Forward leaning last stage stationary blades for improved last stage rotating stage 

flow distribution. 

Moisture removal slots in the last stage stationary blade ring to reduce moisture 

erosion. 

Boroscopic inspection ports in the inner casing, to allow for blade inspection 

without casing disassembly. 

Asymmetric steam extraction locations to allow compact design and match 

existing extraction pipe locations. 

Features that contributed to the increased performance improvement are: 

0 Able to use larger back-end blading 46-inch. 

Flexibility to increase number of blade stages. 

0 Optimized turbine design for the available steam conditions or uprate. 

Surface Stress Management To Avoid Stress Corrosion Cracking (SCC) 

In addition to careful selection of materials and strength levels, several techniques are used to 

further enhance resistance to SCC: 

0 

0 

All of the LP discs receive special heat treatment to impart residual compressive 

stress on the disc surfaces. 

Disc 1 (innermost) is shot peened on its side surfaces and in areas of the blade 

grooves and entering slots. Keyways, located only on this first disc, which are in 

fact cylindrical for pin insertion, are bored, rolled, and honed. 

Disc 2 is shot peened on its side surfaces and in the caulking piece grooves. 

Disc 3 has no additional shot peening, but the last row of rotating blade roots are 

rolled. 

LP Inner Casing Erosion and Material Composition and Placement 

The existing Susquehanna LP turbines had shown increasing signs of LP casing erosion 

of their carbon steel inner casing components. Such casing erosion was a repair cost 

problem at Susquehanna and is a potential issue at other BWR power plants. Therefore, 

PPL included a request in its bid specification for options to improve the composition of 

the inner casing materials. SWPC standard design nuclear LP turbines have, as a 

minimum, the blade path constructed from erosion resistant material such as an ASTM 

A487, gr. CA6NM and A276, type 403, which are used in the construction of the blade 

rings and carriers. After evaluating inner casing options that included up to an all 

PEF-NCR-007 12

stainless steel inner casing construction, PPL selected the hybrid inner casing design 

which included upgraded materials in the high velocity areas. The dark shaded areas on 

Figure I represent the use and placement of erosion resistant materials. 

Maintenance IntervalsNalve Testing 

PPL stipulated in its specification that the retrofit turbine components have at a minimum a 10- 

year inspection interval. SWPC LP turbines of such design as selected for Susquehanna, have 

been approved by the NRC for 10-year inspection intervals. It is worth noting that from a 

turbine design standpoint, the SWPC LP design could justify maintenance intervals up to 

100,000 operating hours, which is typically over 12 calendar years. 

Also, reducing the frequency of control valve testing often results in operating cost savings. A 

majority of turbine vendors can offer turbine equipment that requires only quarterly valve 

testing. SWPC’s full arc admission design HP turbines support such a testing regimen, while 

requiring less power reduction due to the fill arc all reaction design, as compared to partial arc 

and impulse designs. 

The main points of an LP casing retrofit that contribute to the reliability and extended 

maintenance intervals are: 

1. 

2. 

3. 

4. 

5. 

Entire steam path is replaced which minimizes/eliminates the need for repairs in the 

future. 

Existing original SSES LP casings represented 20+ year old technology where issues are 

increasing, e.g. steam wash, erosion, etc. 

Entire turbine is ready for 40+ years service life that fits into license extension plans. 

Proactive approach to eliminate future concerns, which are a real possibility with reuse of 

existing LPT components. 

Design is for 100,000 equivalent operating hour (EOH) inspection intervals/lO year 

approval from the NRC. 

Advanced Disc Type LP Rotors in Service 

Thirty-three (33) nuclear units are in service worldwide, which use the Siemens Advanced disc 

technology LP rotors introduced since 1972. Siemens has not experienced the extensive stress 

corrosion cracking of disc-type rotor as other suppliers and no Siemens-design LP rotor required 

replacement due to SCC concerns.6 In fact, recent replacement of Siemens disc design LP rotors 

have been solely for performance improvement reasons due to the availability and application of 

i m proved b I ade technology . 

Oeynhausen, H., Roettger, G., Meade, W., Termuehlen, H. “Replacement of Nuclear LP Turbine Rotors and Inner 

Casings”, American Power Conference Proceedings, April 1-3, 1997, p. 1. 

pEF-Nc~-00713

There are six operating units in the United States with the advanced disc design LP turbines, 

which are listed below: 

SWPC OEM 

0 Grand Gulf Nuclear Station (Three LPs) 

0 Comanche Peak Steam Electric Station1 (Two LPs) 

Comanche Peak Steam Electric 2 (Two LPs) 

Retrofits 

0 

0 

Limerick Generating Station 1 (Three LPs) 

Limerick Generating Station 2 (Three LPs) 

Palisades Nuclear Station(Tw0 LPs which are formerly the Connecticut Yankee LP 

turbines) 

Susquehanna Steam Electric Station 1 & 2 (Six LPs on order for 2003/2004 installation) 

It is interesting to note that the LP turbines operating at the Palisades Nuclear Station in South 

Haven, Michigan were the first application of the Siemens advanced disc design LPs in the 

United States. These were originally installed at the now decommissioned Connecticut Yankee 

(CY) Atomic Power Station in 1987. These turbines were removed from CY and inspected and 

modified for installation at the Palisades site in 1998/1999. The rotors were given a full 

ultrasonic inspection at this time and showed no indications due to SCC. 

High Pressure (HP) Turbine Design Highlights 

As mentioned earlier, the Hp turbine was retrofitted for the performance improvement benefit. 

Some of the design highlights of the HP turbine include: 

0 

0 

Mono-block design without bore 

Stainless steel inner casing and blade carriers in existing outer casing, bearings, flow 

guide, etc. 

SWPC inlet “L” seal design, providing sealing between the inner and outer casing. 

Single piece inlet admission ring 

Full reaction blade path 

Advanced blade designs using SWPC’s “3DS” blading. 

Five strip inter-stage seals. 

Existing seven blade stage design will be replaced with 12 blade stages per flow. 

PEF-NCR-007 14

Figure 2 - HP Turbine Comparison (Upper: SWPC Design: Lower: Original) 

PERFORMANCE WARRANTY/PEFWORMANCE TESTING CRITERIA 

Since the majority of this project’s economic justification was based on increased generation, a 

performance warranty was established to provide an added incentive to achieve the generation 

improvement. To adequately/fairly enforce this performance warranty, it was imperative that the 

achieved megawatt improvement be accurately measured. SWPC and PPL mutually agreed to 

performance test language and procedures as part of the final contract negotiations. PPL agreed 

to SWPC’s recommendation that a pre-test be performed prior to the turbine upgrade, and that a 

post-test be performed after the new turbine components are installed. By implementation of a 

“pre and post” test, after each respective reheling outages, the net MWe improvement provided 

from the turbine alone is verified. This method of testing is felt to be the most accurate and 

mutually beneficial test method since steam cycle inefficiencies, not easily quantified, will be 

comparable in each test. 

INSTALLATION SCOPE AND DURATION 

Originally, PPL requested that installation be considered as an option. The initial belief in the 

early stages of the project evaluation was that installation would be similar to an LP rotor 

replacement, which PPL had experienced with their Units 1 & 2 LP rotor replacement years 

earlier, in 1986 and 1988, respectively. After detailed discussions and a transfer of “lessons 

learned” between PPL and SWPC, PPL installation personnel agreed that such a project was akin 

to a construction effort as opposed to a more familiar maintenance outage. The LP turbine 

retrofit will require cutting and rewelding of all inlet and extraction piping, in addition to the 

installation and alignment of the new turbine components. The HP turbine retrofit will require 

specialty machining to modify and reuse the original outer casing. 

After the PPL and SWPC team mutually reviewed the installation workscope and respective 

responsibilities, a comprehensive installation specification was developed for the project. 

Defined installation services for the retrofit high pressure and three low-pressure turbines per 

PEF-NCR-007 15

unit were therefore included in the total project effort. Using SWPC’s experience on both its 

own units and most recently at the Limerick Turbine Retrofit Project, it is estimated that the 

Susquehanna turbine train retrofit could be accomplished in 38-days, turning gear to turning 

gear. 

Such aggressive installation outage durations, which were unheard of just a few years ago, are 

possible with an entire LP casing change-out due to the following: 

0 Reduced risk of encountering components that require repair, which would increase 

outage critical path. 

0 LP turbine lower-half components can be pre-aligned and installed as a single unidlift. 

0 Dedicated and experienced (owner and vendor) project teams that are committed to 

thorough and rigorous pre-planning. 

This approach has been already proven by the successful Limerick 1 & 2 installations. In fact, a 

number of participants in the Susquehanna project have previous experience from the Limerick 

installations. 

CONCLUSIONS 

As with most major purchase decisions, the key issues are product features, price, and 

performance. SWPC’s advanced disc design LP turbines and its full reaction Hp turbine 

provides the reliability and performance improvement that PPL required, with features that 

addressed their long-term maintenance concerns. 

A turbine retrofit project is a major undertaking for both the plant owner and the turbine vendor. 

For PPL, the Susquehanna Turbine RetrofidGeneration Uprate project began as a project 

evaluatioduprate program and transformed into a strategic planning initiative for PPL. Long 

term maintenance issues were considered as well as current and future electric power market 

conditions. Turbine retrofit decisions had to consider the long-term operation, including uprate 

plans, for the life of the station. 

From a project evaluation standpoint, PPL took a global perspective to assure that all alternatives 

were properly assessed and considered and all bidders were evaluated fairly. 

From a long-term reliability standpoint, the Susquehanna station project goal is to address the 

long-term maintenance issues and provide significant performance improvements using the latest 

design turbine technology. Through a team approach and flexibility, the project is poised to 

provide excellent value to all the project stakeholders. The increased asset value of the project 

has not gone unnoticed by the shareholders of PPL as well. 

The first Susquehanna turbine retrofit installation, on Unit #2, is planned for March 2003 with 

the Unit 1 installation scheduled one year later. The project team plans to share and report the 

successes and lessons-learned from those installations in such a similar industry-wide format and 

forum.

~ ~~ 

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CON FI DENTI AL PEF-NCK-0073 8

Date: 04/09/2007 

Subject: Employment Resume 

Don Cunningham 

Address 1288 Eden Park Court 

Altamonte Springs, FI., 32714 

Hm Ph: (407) 294-2486 

Office: (407) 736-3540 

don.cunninaham@swpc,siemens.com 

- 

EXPERl EN CE: 

8/2/02 to Present: Siemens Power Generation 

Steam Turbine Mod and Up-grades ( 024 ) 


Responsibilities Include: 

Assist Steam Turbine and Gas Turbine marketing during final stages of negotiations 

In General, receive contract transfer from marketing and implement the contract. 

Single point contact for SPG with the customer and internal resources for the duration of 

the contract. 

Represent SPG at customer meetings and provide monthly project status reports 

Coordinate internal resources ( Engineering, Purchasing, Transportation, Drafting, Order 

Management, Field Service, etc ) to respond to commercial and technical issues. 

Perform project management of forced outages for large steam turbines, gas turbines 

and generators. 

Attend Customer Witness Points with the customer. 

Initiate invoices. 

Initiate and implement contract change orders. 

Use SPG systems to obtain quotations and large proposals for up-ratings and normal 

outage work. 

Initiate FDR’s, EFAR, Warranty Claims, RFQ’s, WRITS, QIRS, PWCS, etc. 

Perform schedule tracking function for all internal resources. 

Initiate and complete negotiations to close out the project with a satisfied customer. 

Assume the correct commercial and technical positions with the customers to bring 

about the best resolution possible when SWPC is being taken advantage of. 

Constantly monitor the bottom line to achieve project margin and ebit. 

Createhpdate and present monthly project status ( Commercial and Technical ) 

EXPERl EN CE: 

4/9/01 to 8/2/02: Siemens Westinghouse Corp. 

Power Projects Implementation - A5 

Project Engineer 


2A -DON CUNN~GHAMRESUME..DOC 

PEF-NCR-00739

Supply of Equipment Contracts for new Combined Cycle Power Plants 

Interpret and apply the contract within the SWPC organization 

Single point interface for the customer and their A/E 

Provide all contract deliverables in the proper format and on time 

Provide timely response to customers technical and commercial questions and 

concerns. 

Manage various SWPC organizations to provide contract deliverables 

Manage quotation process for contract change orders ( DCCD's) 

Manage Field service to perform unit installation and commissioning 

Perform plant turnover to Warranty or O&M group 

Monthly progress meetings with the customer 

Use various databases available to complete my scope of work 

( PID/IDENERSR/ERS/LN,/DCCD/EFAR,FDR etc.) 

4/9/98 to 4/9/01: Alstom Power Generation - ABB 

Industrial Service Department 

Customer Service Manager 


Provide technical support to a group of 36 customers. Industrial steam turbine and 

utility combined cycle plants. 

Provide solutions to customer technicakommercial problems 

Attend customer meetings, make technical presentations and produce quotations for 

service outages, unit up-ratings and new products. 

Schedule and coordinate requests for field service engineers, outages, major parts 

orders and shop repairs. 

In office, outage/project manager with commercial and financial responsibility to 

insure project success. 

Coordinate and manage required support outage support personal including 

customer, manufacturing and repair facilities, finance, contracts, design engineering, 

outside contracts and vendors and parts suppliers. 

Provide short term and long term financial forecast and business plans. Update 

forecast and plans on a quarterly basis. 

Contact negotiations 

Verification of accurate invoiciQng and timely payment of same 

Processing and resolution of warranty claims and deficiencies 

Personal evaluation and interview of prospective employees 

3/97 - 4/98: Westinghouse lntemational Service Co. 

Power Generation Department 

Customer Service Assistant - S. America Region 


Provide technical support for over 80 customers located in S. America. Utility steam 

turbines and combined cycle facilities. 

Provide field service support for new combined cycle installations 

2A - DON CUNNINGHAM RESUME..DOC 

PEF-NCR-00740

Provide solutions to customers technical problems 

Schedule and coordinate requests for field service engineers, outages and major 

parts orders. 

Coordinate with related departments, customers, manufacturing facilities and repair 

shops, finance, outside contractors, vendors and parts suppliers. 

Verification of accurate invoicing for service and parts and timely payment of same 

Processing of warranty claims 

7/95 - 3/97: Westinghouse Elec. Corp. 

Power Projects Implementation 



Project engineer for the development of two, turn - key, combined cycle power 

plants. The Whitewater facility in Wisconsin and the Cottage Grove facility in 

Minnesota. 

Verify technical accuracy of the contract with regard to the Westinghouse 

manufactured/purchased items ( Turbines, Generators and Auxiliary components ). 

Respond to owners technical and commercial questions 

Schedule responsibility to ensure on time delivery of drawings, specifications and 

manufacturing schedules for the turbines, generators and auxiliary components 

Interface with architectural engineer to provide engineering for primary equipment 

interface points for mechanical, electrical and controls scopes. 

Schedule and follow manufacture of primary components to ensure timely delivery to 

site and insure quality of manufacturing efforts. 

Traveled to the site and performed the installation of the Whitewater combined cycle 

power island scope. 

Field scope at the Whitewater facility included installation of the two turbines and 

generators and the auxiliary components. CT was a 501F and ST was a 100MW 

single case design. Performed the mechanical and electrical scope from the pouring 

the foundations through unit commissioning. 

6/89 - 7/95: Westinghouse International Service Corp. 

Power Generation Division 

Field Service Engineer - International 

Responsibilities include: 

0 

Installation of Turbinedgenerators and auxiliary equipment in new combined cycle 

power plants. Major installations include Sithe - Cardinal combined cycle plant in 

Ontario, Canada. The llsan Combined cycle plant in S. Korea. 

Major and minor service outages for large and small utility steam turbines and 

generators and auxiliary components. 

Major and minor service outages on Combustion Turbines, generators and CT 

auxiliaries. 

Service work performed internationally: Argentina SA. Tuxpan, Mexico, Cairo Egypt, 

Yang Gwang, S. Korea, Cuba. 

2.4 - DUN CI/N"GHAM RE'SUME.DOC

e 

e 

Interface with the customer, contractor and Westinghouse Intl. to make repair 

recommendations and perform detailed supervision for implementation of repair 

scopes 

Produce a final installation or outage report 

Insure outage or installation is performed in a quality manner, on time and under 

budget 

Work with IS0 auditors to perform site inspections 

Areas of special expertise- Blading repairs, unit alignment, H2 cooled generator 

inspections. 

Education 

e 

e 

e 

e 

e 

0 

e 

e 

e 

e 

e 

e 

e 

e 

e 

e 

e 

e 

Bachelor of Science Degree in Mechanical Engineering - Lamar University, 

Beaumont Tx. 3.0 GPA 

Westinghouse Training Program from June of 1988 to June of 1989 

Advanced Combustion Turbine Familiarization Course 

Siemens Project Management Certification completed 

ESI Project Management Certification Completed 

Root cause failure analysis course 

Reliability centered maintenance course 

Balancing course 

Project management training 

SAP Training 

Database training 

Risk Management Training Course - ESI 

Project Leadership, Management and Communication Training Course - ESI 

Time Management Course - ESI 

PMP exam Preparation Course - ESI 

SCORE Release 2 Training 

TXP Introduction Course 

Management Development I 

Computer Skills 

0 

0 

e 

e 

e 

e 

e 

e 

e 

0 

Outlook 

Lotus Notes 

Microsoft Word 

Access 

Excel 

IMS Database 

IDEA 

PI D 

LN Databases 

Sure Track Scheduling 

2A - DON CUNNIhfGHAM .Q.ESUME.DOC 

PEF-NCR-00742

SIEMENS 

Commercial Exceptions 

Mcdernaabon Proled Page f Commercial fixceplions- 2'337.2 

April 16, 2W7 Semens Confidential Propress Energy Swvice Company LLC-CryslalR!verUnil#3 

4 

Rquesl No S022W7 

Use fhis document solely fcr the purpose given. Return upon request. 

DO not disclose repmduce or ise otherwise withouf lhe wrinen consent OfSiemens Power Generaoon Inc. 

CON FI D ENTIA1 

- 

PEF-NCR-00743

CRAFT LABOR EXTRA WORK RATES 

SIEMENS 

Modernizalion Projed 

April 16, 200 7 

Page 1 


CraH Labar Rsles- 2007-2 

Prqress Energy Service Conpany, U.C.Crysla1 River Unil #3 

Request No SD22W7 

Use this doihnenl solely for the purpose given Relum upon request 

Do nor disclose reproduce or use otherwise wilhoul the wrinen consenl ofSiemenz Power GeneraUOn Inc 

CO N FI 0 ENTl AI 

L

INSTALLATION CONDITIONS 

I 

Modernizelion Project 

April 16, 2007 

Page 1 Inslalialion Ccmdifans- 2007.2 

. Semens Conlideolial 

Pmsress Enwgy Service Company, LLC-Crystal River Unif #3 

Rquesl No SO22007 

Use this document solely forthe putpore given. Re" 

upon request. 

Do no1 disclose repmduce or use otherwise wllhoor the wrinen consent of Siemens Power Generauon hc. 

CONFIDENTIAL

SIEMENS 

Modernnabon Projecl Pdge 2 Inslalialion Cmdittons- 2007-2 

April 16, 2W7 Semns Confidential 

Prcgress Emgy Servce Company, UC-Cryslal River Unit #3 

Request No SD22W7 

Use chis documenl solely forthe purpose given Rerurn upon request 

Do not d~sclose reprodrlce or &e ornerwwe withom che wrinen consenf 01 Semens PoHer GeneraOon Inc 

CONFIDENTIAL

SIEMENS 

Modernnabon Project Page 3 lnslalhlion Condrtms- 2007-2 

April 76, 2W7 , Siemens Confidenlial Prcgress Enwgy Sw&e Company, UC-Wslal River Unit $3 

Requesl No 5022007 

Use thls document solely for rhe purpose given. Return upon request. 

Do not disclose repmdude or use ofhemlse withoui fhe wrinen consent ofsiemens Power Generatton lnc. 

CONFIDENTIAL 

PEF-NCR-00747

SIEMENS 

Request No SKI22037 

Use this document solely for the purpose given. Return upon request. 

Do not disclose reprodice or use otherwise wirhoul the written consent of Siemens Power Qenerauon hC. 

CONFIDENTIAL 

PEF-NCK-00 74 8

SIEMENS 

Modemnation Pro]& Page 5 

April 16, 2007 

Siemens Conhdenfial 

Use fh!s documenr solely for fhe purpose prven Rerum upon requen. 

Do not d sclose repmdke or use orherw!se Wrfhom [he wnnen consenf of Semens Po~er Generauon Inc. 

CON FI D ENTIA 1 

lnslalhbon Condrtons- 2007.2 

Prqress Energy Servxe Company LLC-Wlal River Unrl #J 

Requesl No 5022007

Use rhJ documenr solely for rhe purpose given Rerum upon request 

Do nor disclose repnduce or use orherwise wrrhou7 (he urn" consenr of Slemens Pouer Generauon lnc 

CONFI DENTI A1 

SIEMENS

SIEMENS 

April 16, 2007 

use thlsbocument so/s/y for rhe purpose given. Rerum upon requea 

DO not disclose reproduce or use otherwise wlrhom the wrltten consent of Semens Power Qeneration lnc. 

CONFIDENTIAL 

Prosress Enwgy ServQe Corrlpany, LLC-C2yslalRw~v Unif M 

Request No SO22007

SIEMENS 

,. ._ - _. . - . . , 

April 16. 2W7 

Prcgress Energy Servtce Company, LLC-Cqslel River Unil W 

Reguesl No SD22W7 

Use this ,document solely for the purpose given. Return upon request 

Do not disclose reproduce or use othenvlse withom the written consent ofSlemens Power Generation InC 


PEF-NCR-00752

SIEMENS 

Modemriation Frojwt c page9 lnsfalhfion Condilms- 2007-2 

April 16, 2047 Siemens Confidenbai 

Progress Energy Service Company, UC-ClystaiRivw Unit #3 

Request No SO22007 

Use ati9'documenf solely for fhe purpose given. Refurn upon request. 

Do nor disclose reproduce or use ofhenvise wifhoul the Wrlffen consent of Slemens Power Generation Inc. 

CON F I DENTI AI- P EF-NCR-007 5 3

a 

Siemens Contract #I 45569 

Work Authorization #50 

Executive Summary 

August 8,2007 

Turbine Generator Retrofit 

Purchase & Installation 

Progress Energy 

I 

PEF-NCR-00754

iemens 

Contract ummary: 

ontents: 

D 

B 

b 

D 

D 

D 

D 

D 

B 

D 

D 

b 

B 

D 

Scope 

Schedule 

Comparison of Bid Price 

Negotiated Savings 

Comparison of BNP Pricing 

System Bundling 

Performance Incentives 

Warranty 

Liquidated DamagedDis-Incentive 

Limits of Liability/Extension of Insurance 

2009 Performance Guarantee 

2011 Performance Guarantee 

100 Day Performance Guarantee 

Project Review Team 

PEF-NCR-00755

iemens Contra 

roiect Schedule 

C 

0 

:t Summary: 

0 

Siemens has a mday clearance window for the 

2009 refueling outage scope of work and a mday 

clearance window for the 201 1 refueling outage 

scope of work. 

The Project Schedule consists of three distinct 

schedules: 

+ Engineering Deliverable Schedule 

+ Manufacturing Schedule 

o Installation Schedule 

All three shall be submitted for owner review and 

approval within 60 days of contract award. 

9 . 

>_ 

.. 

4& 

Siemens Contract Summary: 

Comparison of Pricinq - from Bid Submittals ($000’~) 

Equipment Prices Alstom Siemens 

HP & LP Turbines 

Generator 

Exciter 

Field Installation 

Total Cost 

CONFIDENTIAL 

paogress Energy

ontrac t Sum mar 

Savings ($000's) 

Alstom 

Siemens 

unt 

Price after Discount 

Evaluated Added Scope 

B HP turbine gland steam spillover valve 

B Machining steam lead inlet flanges 

B Rotor lifting beam 

B Extended warranty 

b Extended property insurance 

, Total Evaluated Price 

CONF


Corporate Bundling- 11 Rotors 

PEF-NCR-00760

Warranty 

PEF-NCR-00762

PEF-NCR-00763

Limits of Liability

emens Contract Summary: 

3e - 

MegaW atts 

5 Energy 

PEF-NCR- 00765


201 I Delta Target Output - Performance Guarantee 

131.3 133.3 135.3 137.3 139.3 141.3 1152.7 154.7 156.7 158.7 160.7 162.7 

Megawatts Gained 

e t 

@ Progress Energy

ct Summary 

ance Guaran tee 

For I00 davs of Continuous Operation 

- 

Contractor4places at risk for each 

outage (2009, 201 I) RE-J;~~BE 

The 4 00 day period begins after completion of 

commissioning and Unit has reached 100% \ 

power 

The unit must be removed from services 

based on the Contractor's Instruction Manual 

. '. 

I 

I 

I 

PEF-NCK-00767

0 


Proiect - Review Team 

0 

Project Manager - Ted Williams 

Project Technical Lead - Scott Deahna 

Legal - Dave Conley 

Tax - Paul Matthews 

Financial - Gerry Dowd 

Audit - Elwyn Wood 

Contracts - Tony Owen 

Executive Sponsor - Danny Roderick 

-q 

L&?zz ProgressEnergy 

6 \ 

PEF-NCR-00768

CONFIDENTIAL 

@Crystal 

River Unit 3 Extended Power Uprate Project, Turbine Generator Retrofit Proposal Evaluation 

Progress Energy issued Crystal River Unit 3 (CR3) Turbine Generator Retrofit Request for Proposal # 

SD22007 on February 16, 2007, The request for proposal was issued to Siemens Power Generation, Alstom 

Power Systems, Mitsubishi Heavy Industries and Westinghouse Nuclear (Toshiba). The CR3 turbine 

generator was originally supplied by Westinghouse Power Generation (Le. Siemens). The CR3 low pressure 

turbines were retrofit in 1996 with Brown Boveri (i.e. Alsiom) turbines. CR3 Turbine Generator Retrofit 

Proposals were received from Siemens Power Generation (Siemens) and Alstom Power Systems (Alstom) on 

April 16,2007. 

_- 

Siemens Proposal Summarv: - _ _ .__ 

- - ^------.I,

Alstom Initial ProuosalS-ummaw: 

.. - - 

0 

I 

I 

1 

I I I j ' 

. 

.. ... . ~.. . 

Alstom Amended Pro~osal Summaw: 

I 

I 

I

02/28/2007 12: 24 412-374-4811 

. \ ; : * 

W EC-LICENSING PAGE Bl 

Mr. Tony Owen 

F,v,~ J.P. Sechrist 

Fam 919-546-6750 Pages: 

Rei 

batel February 28,2007 

cc: 

l Ugmt 0 FL Review Plssse h a n t D Please Reply 0 Please 

e Comments: 

Mr. Owen, 

Westinghouse appreciates your inclusion of our company on this request for bid. 

, Under our new parent company Toshiba, Westinghouse now has additional 

capabilities and is Interested in these types of opportunities. Unfortunately, 

Toshiba's unfamiliarity with the' Siemens Turbine-generator and the lead times 

required for forging would not allow us to support Progress Energy's desfred 

schedule for delivery of the components specified in the bid request. As a result, we 

-will not be submitting a bid for this work.

02/28/2607 12:24 412-374-4011 

I~ I. , - 

W EC -LI CENS I NG 

PAGE 02 

ACKNOWEDCEMENT 

Mr. Tony Owen 

Progrcss Energy Service Company, LLC 

P. 0. Box IS51 (PEB 2C3) 

Raleigh, NC 27602 

Fax: 919-546-6750 

PROGRESS EN€RGY SERVICE COMPANY, Uc 

CRYSTAL RIVER WCLEAR PLANT, UNlT #3 

REQUESTNO. SD22007 

I acknowlcdgc reccipt of the subject proposal package and have indicated my bidding intcntions as follows: 

X 

I have reviewed tbe proposal documents and will not be submitthq ~IM for this work. Proposal 

documents arc being returned under separate cover, 

0 

1 have reviewed be proposal documeors and intend to submit a J&j for this work and will mskc 

nrrangements to contact or visit the site as requested. 

e 

0- (Signature) 

Manager. Major Proprams aroun 

(Title) 

February 28.2007 

(Date) 

PEF-NCR-00773

Siemens Contract Negotiations 

05103107 

Those in attendance were: 

Tony Owens 

Scott Deahna 

Ted Williams 

Mike Morin 

Dan Smith 

Mike O'Leary 

Shay Foley 

Kebris Miller 

AI Batista 

Puneet Bahl 

Steve Blevins 

Don DiAntonio 

HPT should be acceptable for 2009-201 1. All components can meet 1165MVA based on current 

installed. 

Major Components core iron, stator, exciter, rotor can meet 1200 MVA. Other Aux. components 

are under evaluation e.g. H2 gas cooler. Can scope prior to avoid. Blower should be OK by may 

need to be modified. Bushings need to determine by June 8'. 

0 - 

Need to identify critical path efficiencies. Challenge 69 day duration target 58 days. Can a 

midsection replacement be estimated? 

Use 95'F for the gas SC Cooling 

Siemens Engineering Comments 

Turbine Rotor weight and TEGO Babbit. 

Installed on similar type frame supports. 

Babbit will support higher loads and temps. No new bearings required if needed will be included 

by Siemens not PGN. 

Generator frame design can meet 75 psig requirement. Original design 60 psig. Seal oil system 

Mods are included in base price. 

Laser alignment of LPT Included 

Gen Alignment should be included 

HP needs to be checked 

New Canto nary Curves will require alignment 

Generator exciter front foot alignment. 

300 amp rating power amp drawers need to be verified @ 1200 MVA and single failure capability 

to carry full excitation. 

Do not anticipate TGV control problems with full arc control. 

Need generator Neutral analyzed for shorts transients. Protective relay set points will be provided. 

I'EF-NCR-00774

Siemens Scope of Supply Comments 

Generator bushings need to be replaced for 1165 MVA. 

Need to be evaluated for 1200MVA and included in base cost list. 

At minimum new H2 seal rings not necessarily new performance seals. Need new seals for Rotor 

replacement. Labyrinth seals. 

Item 3 

Item 4 

(included) 

(included) 

(included) 

Item 5 

Item 6 

Item 7 

Confirmed to be in base price 

Larger gland steam spill over valve include 

HP turbine flextallic gasket modification 

HP turbine erosion protection. 

Rebabbit bearings as contingency risk 

Lead free rupture disks 

Lower generator leads box/Asbestos 

Included 

New Tech Manual provide 

No Environment Monitor in proposal 

Include flux probes, do not use slot couplers 

instead use bus couplers 

[included] Fiber Optic Vibration Monitoring 

[in base price] Gas discharge RTDs (24) 

(2) New terminal boards included 

Siemens Contract Negotiations 

Instruments and piping under generator should not be replaced. 

Hz Cooler included price will be evaluated prior to contract award. 

MSR installation 21 days parallel critical path. 

Millwrights, Crane Operator, rigging, 

TEI to install MSRs, Siemens to manage Scaffolders, HP, insulation, handlers. 

Need Scaffold/lnsulation resource loaded plans. Siemens to check with contracts personnel 

Barge costs are more than rail costs. No concern with last blade removalhnstallation and factory 

balance. 

Any seal surface machine field work scope is included in base cost 

Siemens responsible for dehumidifier and no delays. 

Generator Core Iron loop test requires 416OV-3MW 850 amps single phase. Site to provide 

Dower.

Siemens to provide requirements for oil flushes and should be included as part of the base project 

costs. No adder 

Ventilation testing requirements need pressure taps in 8 areas back to manifold. Requires 114 , 

113 speed in air to verify proper ventilation. Need to include in scope for outage and build into 

critical path. Aux. Steam to Main Steam back feed to spin turbine. Need operating experience to 

justify. Performed as part of 1990 mid section replacement and orifices needed adjustment. 

Siemens Commercial Comments 

Proposal costs include return of rotor to seed program. 

interchangeable. Same warranty applies. 

No risk with availability and is 

Overall Megawatt output secondary heat balance reactor power. Incentive and penalty deadband. 

Use existing higher accuracy heat balance and Megawatt instrumentation. 

Need date for final data for LPT design, CR3 to provide MSR drain reroute and FWHE design 

Specs. 

Retained component study $look Tab 1 C. 

How many hours and rate to establish costs? Support equipment. 

Need to breakout Digital Voltage Regulators ($625)0 and why do we need hardened cabinets. 

Includes installation and start up testing. 

Evaluate "traveling craft labor" adder 

All costs are firm fixed price for year of installation 

Estimate fixed assuming all are traveling 

CR3 provide onsite training and vendor for badges. 

Siemens Final Notes 

HP LP hold points witness points should not be limited. 

Final Design is independent and Siemens has right to change design. 

Need to establish scope of liability with respect to uprate interface fit up 8 modification of as found 

conditions. 

Siemens will participate in design review mtgs. 

Amendment to be written by Siemens by Friday. 5/18/07 

We owe our notes and actions to Dan by next Friday 5/11/07. 

PEF-NCR-00776

2P Pg. 1 of 3 

iemens Proposal #SD22007, CR3 Turbine Generator Retrofit 5/3/07 Review Meeting 

n Items Continued: 

Siemens to provide proposal amendment letter by 05/18/07. 

Siemens to provide 1200 MVA generator component evaluation by 06/08/07. 

Siemens to address project schedule: 

Generator field installation schedule is 69 days, including 48 days for generator stator winding and core iron 

replacement working 24 x 7. Siemens to review generator schedule to identify a ten day reduction. If 

generator outage schedule does not fit inside revised plant steam generator replacement schedule, then 

evaluate stator midsection replacement. Siemens mentioned the possibility of a seed stator frame becoming 

available. 

0 

Siemens to include the following io the proposal at current price point: 

1. Generator main lead bushing replacement. 

2. Replace generator H2 seal rings and seal strips on H2 gland, bearing oil catcher and outer oil seal. 

3. Generator Ventilation Testing. Add description of requirements. 

4. Complete rotor lrain center he 

laser alignment and generator fiame foot loading alignment. 

5. Replacement of the HP turbine gland steam spillover control valve with larger capacity valve. 

6. Machining of the HP turbine steam lead inlet flanges for flexitalic gasket modification. 

7. Rebabbit HP turbine and generator bearings due to new rotor journals. 

8. New style LP turbine lead free rupture discs. 

9. Lowering of the generator leads box to clean and pump sealing groove. 

10. A complete new technical manual for the turbine generator (excluding the AEH controller volumes) 

and electronic spare parts catalog. 

11. Material to support lube oil flush. 

12. Seal oil skid modifications to support 75psi generator H2 pressure. 

13. The Generator Neutral Transformer will be included in the Siemens electrical evaluation for 

1200MVA generator short circuit conditions. Generator protective relay set points will be provided. 

14. All LP cylinder alignment and installation features (material and modifications) to install new turbines 

are included in proposal. 

15. All HP turbine cylinder steam seal surfaces will be checked and machined as necessary. 

16. The Generator Neutral Transformer Will be included in the Siemens electrical evaluation for 

1200MVA generator short circuit conditions. Generator protective relay set points will also be 

provided. 

17. AI1 LP cylinder alignment and insrallation features (material and modifications) to install new turbines 

are included in proposal. 

18. All HP turbine cylinder steam seal surfaces wil be checked and machined as necessary. 

Siemens to review the following conceptsrisues: 

Project Mananement: PE desires “turnkey” project management with minimal PE support responsibilities. 

Siemens to provide millwrights, riggers, welders, pipe fitters, crane operators and winders. TEI may provide 

the craft to install the MSRs. Siemens overall project management to include control of additional support 

provided by PE (mechanics, electricians, I&C, Mold, insulators, pipe fitters, health physics, laborers, 

space attendants, fire watch, etc.). This will eliminate any delays due to ‘‘support requirements by 

to discuss this concept with their contracts personnel and provide their position. 

PEF-NCR-00777

0 A-2 

It 

1 

1.1. 

CR3 Allov 600 PWSCC Mltiaation Proiecf 

Pressurizer and Sume Line Modiflcations 1 

Description C. X. A. and E Proposal Section 

Project Description 

IntroductionlProject Background: 

Crystal River Unit 3 will be undertaking a series of component replacement and reinforcement activities 

during the 15th refueling outage (RFO15) currently scheduled for late 2007. These activities are 

intended to reduce the risk of Alloy 600/82/182 Primary Water Stress Corrosion Cracking (PWSCC) 

associated with the Pressurizer and Surge Line. When complete, all susceptible componentdregions 

in the Pressurizer and Surge Line will have been replaced, reinforced or will have been reconfigured 

such that no Alloy 600/82/182 will be performing a Reactor Coolant Pressure Boundary function. 

The Bidder is requested to submit a comprehensive proposal based on the requirements contained 

herein and on the previous experience of the Bidder with similar proposals and/or projects. The Bidder 

is requested to bid the scope of work described to optimize the overall Alloy 600 Mitigatlon program for 

Prooress Enerav. 

C 4.0 

1 I Evaluation (NDE). and demobilization activities associateiwith the modification of the following I I I 

12'1' 

1.2.1.1. 

A A 

1 .L.C. 

1*23' 

1.2.3.1. 

components: 

Pressurizer Relief Valve Butt Welds (total of 3) 

Pressurizer Spray Line Extension Pin and Safe End 

Pressurizer Vent Nozzle 

Pressurizer Sample Tap Nozzle 

Pressurizer Lower Level Tap Nozzles (total of 3) 

Pressurizer Thermowell 

Pressurizer Surge Line Nozzle Butt Weld 

Hot Leg Surge Line Nozzle Butt Weld 

The Relief Valve Butt Welds are to be modified by removing the existing Alloy 82/182 welds and 

flanges and replaclng with equivalent flanges attached with Alloy 52/152 welds. 

The bidder may propose a weld inlay technique for these locations. 

The Sorav line Extension Pin and Safe End and attachment welds are to be replaced with Allov 690 

components attached with Alloy 52/152 welds. 

The Vent, Sample Tap, and Lower Level Tap Nozzles are to be modified using a half-node 

replacement methodology employing Alloy 690 components attached with Alloy 521 52 welds. 

The preferred half-nozzle replacement methodology is to use a mid-wall weld as opposed to an 

external weld build-up and attachment weld. The proposal may contain either methodology at the 

Bidder's discretion. 

C 4.0 

C 4.0 

m 

, A 

L 4.u 

C 4.0 

A 4.0 

'C (Conforml -The Bidder meets the requirement in the manner indicated. 

X /ExMDL~o~~ - An approach which does not meet the requirements or a requirement the Bidder declines to meet. 

A @h"q) - An approach which is substantially different kom the suggested approach but whldr meets the slated requirements. 

E (Enhancement) -An element not required by the Requirements Documents but offered for consideration. 

PEF-NCR-00778

a Pg. 2 of 3 

Turbine Testing: Proposal pricing includes 

r ASME PTC 6 turbine Derformance testing. Following 

discussion the prevailing approach is not to perform a full ASME PTC 6 performance test. Consideration is to 

use the PTC 6 - 2004 Atemate Test. Key parameters will be megawatt output and reactor thermal. PE will 

have high accuracy instruments for feedwater flow, main steam pressure, main steam RTD’s, condenser back 

pressure and high accuracy megawatt meters. This approach will reduce the price by the amount included to 

perform the full PTC 6. 

Performance bonus / penalty clause should have a performance dead band. Review dollars tied to performance 

testing result. The fact that the multiple changes to the plant will make exact megawatt contribution from a 

single source difficult to evaluate. A deadband of +/- 0.7% (test accuracy) has been discussed as an amount to 

account for these uncertainties and then a bonus could be considered for megawatts achieved above that value. 

Siemens to review tbe following conceptslissnes: 

Is replacement of the generator WTA voltane remlator required to support the 1200MVA generator rating 

excitation requirements? WTA power amp drawers are uprated from 200 amps to 300 amps. Are the power 

amp drawers fully redundant at 300 amps? Siemens to unbundle the Digital Voltage Regulator and price it 

semrately. Provide basis for recommending the EM1 I RFI hardened cabinets. Verify the estimated cost for 

~&cluding~ation 

- 3 - I- and startup support. 

- 

istinn nenerator rotor 

ens. Transportation costs are included in the current price to 

return the-existing CR3 generator rotor back to Charlotte. The Shipping and Handling estimated cos~ate 

high. Heavy hauling on site is largest cost portion. Agree to review transportation and handling plan. Evaluate 

Mammoat (bundled contract) for on site heavy hauling. 

The final Secondary Plant design configuration must be provided to Siemens to support turbine blade path 

design. This includes the MSR drains re-route and feed water heater specifications. Siemens to provide a date 

when the information is needed for the final turbine steam path design. 

Siemens to evaluate the rem 

basis for this cost 

re-consider the m 

peripherals and include as baseline to the overa!! project. 

~. 

and support systems for EPU impact. The 

o perform the study. PE requests Seimens to 

er work required to define the turbine 

Provide basis for consideration of adding thegenerator “Performance Plus H2 Seal Package” to proposal. 

Document advantages / benefits associated Vtith this seal package. Provide a list of users with large 

generators equipped with performance plus seal insta!led. 

Siemens will provide dehumidification for generator and no delays of high pot testing due to winding 

moisture. Electrical Power required for generator core iron loop test wil be by PE. 

..’ 

I 

erator instnunentation will include h’tallation of two flux probes, fiber optic vibration probes and 24 Gas 

charge R7’D’s With new terminal bods. Flux probes and fiber optic vibration pickups will be monitored 

using portable test equipment. Include providing the required portable test equipment for monitoring. Partial 

discharge slot coupler pickups are not required.


A 

AREVA 

RFP No. 562764&568414RlC 

Page A-l 

APPENDIX A 

PROGRESS ENERGY TABLE OF CONFORMANCE 

- 

Alloy 

AREVA NP PROPRIETARY 

600 Mitigation 

AREVA NP Proposal 

1232104 

PEF-NCR-00780

iemens Proposal #SD22007, CR3 Turbine Generator Retrofit 5/3/07 Review Meeting 

en Items Continued: 

Siemens to review the following conceptslissues: 

The extra charge for traveling personnel was defined as the per diem and mobilization costs that could occur 

to bring in some of the Siemens ''regular" craftsman similar to AREVA specially welders. This will be further 

defined by Siemens. 

Progress Energy access to the manufacturing facilities cannot be limited to just five visits for HP and LP 

turbines. 

LP turbine construction "is f d design dependent and Siemens reserves the right to make changes to the 

number and style of components noted above without impact to performance guarantee values." "Price" to be 

added to the statement. 

.

A 

AREVA 

August 11,2006 RFP No. 5627648568414RIC 

- 

Page 95 

13.0 TERMS AND CONDITIONS 

13.1 GOVERNING AGREEMENT 

13.2 VALIDITY 

AREVA NP PROPRIETARY 

i. 

-. 

Alloy 600 Mitigation 

AREVA NP Proposal 

1 232 1 04 

PEF-NCK-00782

f 

I 

Crystal River 3 Generator Cross Section

0 

Based upon seminar information and CR3 power uprate project the following work scope 

pecommended: 

,&*b 

CR3 Recommended work scope for 16R. 

In field Stator rewind 

Stator End Iron Replacement 

Factory rotor and exciter rewind 

Output boltinflushing replacement 

New Hydrogen Seals and Duplex Oil Filters 

Hydrogen Cooler drop in tube sheet 

Digital voltage regulator 

Based upon attendance at Seminar the following items are considered as part of TG Bid 

Spec and work for 16R in 2009. 

0 

In field Stator rewind 

Stator End Iron Replacement 

Factory rotor and exciter rewind 

Output boltinghushing replacement 

-.New Hydrogen Seals and Duplex Oil Filters 

Hydrogen Cooler drop in tube sheet 

Digital voltage regulator 

The following estimates should be used for scheduling purposes based best performance 

durations 

Core Replacement 18 days 

Stator Rewind < 20 days 

Rotor Rewind 29 days 

Exciter Rewind 28 days 

J Strap Change out 15 days 

Balancing 20 moves < 24 hours 

Coil Lead time 9 months minimum prefer one yew 

Shipping of components requires dedicated rail and at least 5 days on each end. 

PEF-NCR-00784

Siemens Generator Workshop 

Feb 57,2007 

Charlotte NC 

Mark Pringle - Director Charlotte Fort Payne Operations 

Opening Remarks and Agenda 

Power Uprates and retrofit and upgrade capabilities 

Tour of Siemens Turbine Generator Service center 

Andrew Medla - Director Generator Engineering 

Generator Developments and Implications for Operating Fleet 

Overview of World Wide Operations and facilities 

Computational Tools 

3D Finite element analysis of turbine blading, Improved efficiencies and reliability in 

severe thermal cycles, load following 

Computational Fluid Dynamics, allows for increased cooling less heating, allows for 

increased design capabilities, then compared to actual field data results. 

New design 2200 MVA 50 Hz, new design technologies and materials directly applicablc 

to uprates and upgrades. 

0 

Objectives - Speed, Dependable Generation, Life Extension, Capacity Increase 

Strategy - Fast Rewinds, Airkiquid Cooled upgrades, stacked cote replacements 

Core Replacement 18 days 

Stator Rewind < 20 days 

Rotor Rewind 29 days 

Exciter Rewind 28 days 

J Strap Change out 15 days 

Balancing 20 moves 24 hours 

Coil Lead time 9 months minimum prefer one year 

Shipping of components requires dedicated rail and at least 5 days on cach cnd. 

Performance Plus Seal State of Art Carbon seal technology greatly reduces oil 

consumption by a factor 50: 1. Can be used with increased H2 pressure up to 75 psig. 

How do we increase MVAK loading capability on existing machines? Additional 

windings. Who should pay for upfront design (vendor or industry)? 

Mark Pringle - Director Cbarlotte Fort Payne Operations 

Generator Factory Services 

* 

Quality Culture, Manufacturing technologies, Upgradeflprates, Repairs

Safety, Reliability (> 400 gedexciter in 5 years), Dependability (>90% on time), Trust 

(open and transparent) 

Typically Generator Rewind performed in 12 weeks, with customer input reduced time 

less than 6 weeks. 

Only 84% on time in 2006, Target for 2007 is 96%. 

Rotor and Exciter Seed Program. Purchase old machines completely refurbish and sell to 

customers with credit exchange program. CR3 components readily available on the shelf. 

Are they shelf ready for power level uprate? 

Dennis Cadwell - Director Steam Turbine Generator Specialty Services 

Field Service capabilities use same engineering organization as factory services. 

Specialty tooling and services must meet same quality and technical requirements as in 

the factory. 

Inspectioflesting 

MaintenancelRepairs 

Rewinds - RIG1 FLEX Rapid Field Rewind 20 days 

Mark Musulin - Project Manager Beaver Valley Nuclear Stator Rewind and Rotor 

Modernization 

Gas Inner cooled, stator rotor replacement 

Original 1026 MVA, 0.9 pf 

New Rating 1070 MVA, 0.92 pf 

Why rewind? 

Insulation limited to 30 years design life 

Extend inspection frequency from 6 to 10 years 

Upgrade RTD, fiber Optic, 

Shorted pole, Original design end winding vibrations 

Core End Iron heating issues 

Coordinate with RSG and RVCH 

Increased Operating capabilities 

Scheduled to avoid future outage duration impact 

New Improved components and monitoring capabilities 

Scope of work was Siemens H2 cooled RIG1 Flex 

ANSI class F Insulation 

Flux probe 

. 7' 

'L '\4D, fiber optics 

PEF-NCR-00786

0 

H2 gland seal rings 

Bearing refurbishment 

Turbine Generator Window 57 days 

Actual Rewind duration 37 days, this rewind time only does not include disassembl) 

reassembly and other scheduled maintenance 

Resource Impact 

Determined to perform 6 months prior to outage 

Design Calcs and set points 

Project management, design, field, test engineers 

Laborers and technicians all supplied by Siemens 

Integrated effort with site personnel for support organizations 

Extensive testing 

QA coil 

EL Cid 

Hi pot 

Core tightening 

Loop heat thermo-vision 

RTD and fiber optic 

Ventilation testing 

Ventilation testing requires rolling turbine with Aux steam, risk that may nccd to 

shutdown readjust and re-perform. Why does it need to be done? 

Challenges 

Short planning period 

Loop Heat power supply (4160v 700 amps) 

Lay down area 

Clearances and back feed requirements 

Equipment security screening, inspected at factory and closed with seals by security 

Ventilation test 

Chemical control first time use of site of most chemicals 

Lessons Learned 

e 

Support work 

Material receipt 

Coils skids disposal 

Lumber for platforms, FME for all screws used 

Loop heat power supply 

Core Hot Spot acceptance criteria

0 

Time for cleaning, painting 

Belly cover installation 

Fresh crew for reassembly 

Ops must own ventilation test 

Obtain MSDS and chemical list early 

Replace bushings and CTs 

Tom Schubert - Manager Global Generator Service Engineering 

Industry Trends and fleet demographics 

Global Overall Electrical yearly output 9% Increase over 5 years 

Average US base load is currently 32 years in service 

This base 20-40 years in service equates to approximately 80% of total base load 

30-40 years is approximately 45% of US base load 

Typical Life Cycle for large frame generators is 30-40 years 

Alex Christodoulo - Manager Generator Services Engineering 

Modernizing and Servicing generator stators 

Overview of Water and Hydrogen cooled stator 

Recommended maintenance to extend life cycle an additional 30 years 

0 

Stator Windings - End connection strand cracking, End winding loosening, parallel ring 

looseness, and phase lead cracks. These are caused by thermal stresses and age 

degradation, mechanical forces caused by electromagnetic forces in natural fiequency 

ranges. Transient damage caused by severe fault etectro-mechanical stresses. These 

mechanisms can today be controlled by the advancement of material composition and 

design modeling. Generator is designed to withstand a 3 phase short. 

Stator Core - Only 5 Major core losses over last 50 years, foreign object 5, Over fluxing 

5, Looseness 3, Installation 1, Unknown 1. 

Recommended Maintenance 

El-cid < 1 OOmilliamp - look for hot spots with thermo vision inspection 

Shorted laminations - grind out make field repairs or terminate 

Core Looseness and Length - through bolts may bottom out need to add more iron plates 

Core End Iron heating - new designs are more adequately cooled 

End Shield laminations - end shield replacement 

3 Options 

Onsite Stator rewind and corc refurbishment 

Onsite Stator rewind and core replacement with donut stacking replacement 

Onsite replacement with seed or new components 

PEF-NCR-00788

0 

Advanced Hydrogen Cooled Stator 

Dynamically tuned - 

Brazed connections 

New Materials ANSI Material Type F 

Advance support plate construction, and bolting output connectionshushings 

Generator Uprate Studies 

More Copper in stator slots 

More ventilation today’s designs 

Higher rated exciters 

If required, new forgings for rotors, more core iron added by donut stacking replacement 

Bill Gardner - Manager Generator Rotor and Exciter Engineering 

Modernizing and Servicing hydrogen generator rotors 

0 

Rotor Retaining Ring tooth top cracking repairs requires rotor rewind and possibly new 

forging. Two Mods Short and Long Ring Modifications. Short Mod for small cracks 

grinds out existing flaws and leaves in compression vice tensile stresses. Long Ring 

Modification removes entire tooth top, re-establish a new shrink fit area, fillet 

enlargement. CR3 performed Long Ring Modification. Provides best start stop cycle 

operation of 10,000 cycles compared to 1,000 cycles for short mod. 

Randy Whitener - Engineer Generator Services Engineering 

Air cooled generator rotor update 

N/A 

Kip Madeira -Manager Exciter Services 

Modemizing and servicing exciters and collectors 

CR3 Exciter 16 1 C average 32 Years 

Domestic Exciter Unplanned outages (50%) 

Age related -banding separation, phase leads, insulation, bearings 

Ops and Maint - FME 

Localized overheating causing lifting of end winding 

Severed flexible lead riser laminations 

Diode wheel Component Cleanliness 

Fuse resistance checks 

a 

Eric McDonald - Manager Advanced Products Development 

Automatic Voltage Regulators Upgrades 

Analog WTA and Power System Stabilizers are obsolete and at age for replacement 

upgrade. Upgrades can remove single point vulnerabilities. 

PEF-NCR-00789

0 

Brushless Exciter Replacement Voltage Regulator (RG3) 

Designed in a modular package to replace WTA (Plug and Play) 2 days 

Sam Farley - Senior Engineer Generator Services Engineering 

Modemizing Generator auxiliaries, hydrogen seals, water and hydrogen systems 

Seal Rubs, Oil ingress 

Segmented Carbon Seal design installed in 2003, 

Loss of oil pressure good to 75 psig minimizes hydrogen loss on loss of seal oil 

Duplex filters reduces single point vulnerability 

Hydrogen purity monitors 

King Chan - Senior Engineer Generator Services Engineering 

Modemizing Generator and Exciter coolers 

Coolers are specifically designed for machine output. Over designed causes condensation 

and corrosion within generator. Under designed causes overheating. Need to redesign or 

replace cooler as part of generator uprate. Must stay within original shell constraints. 

Make more small tubes more surface area. Drop in cooler design. Fabricated and 

pressure tested in shop. Fin design less expensive, helical design more efficient but can 

be debris trap. 

e 

Glenn Gamble- Manager Generator Modernization 

Responding to Forced Outages 

Forced Outage Plan- What Happened, How did it Happen, How much and How Long, 

Need forced outage checklist 

Collect data- MW/MVA, pf, voltage current Hz vibration, trends 

Mode of Operation - Base , Start Up, Load change 

Auxiliary Equipment data and trends - Water skid, seal oil, voltage regulator, Exciter 

Hydrogen system 

System data - One line diagram, SWYD, relays, control scheme 

Records - Oscillographs, Sequence of events, operator interviews, last outage data 

SMEs input 

Root cause investigation photos, videos, quarantine area and equipments 

Take samples 

Mechanical failure typically leads to electrical failure 

Define Scope identify options 

Know your inventory, know the vendors inventory 

The decision of what and when to repair is the critical path

February 16,2007 

Siemens Power Generator, Inc. 

7309 Egypt Lake Drive 

Tampa, FL 33614 

Attention: Dan Smith 

PROGRESS ENERGY FLORIDA, MC. 

CRYSTAL RIVER NUCLEAR PLANT, UNIT 3 

TURBINE GENERATOR REPLACEMENT & RETROFIT 

REQUEST NO. SD22007 

Dear Mr. Smith: 

You are invited to submit a proposal for Replacement of the Turbine Generator and the performance of related 

work (see the Scope attached for additional details) for Progress Energy's Crystal River Nuclear Power Station, 

Unit 3 site located at 15760 West Powerline Street in Crystal River, Florida 34428. Two (2), signed copies of 

the proposal (one priced and one unpriced) shall be sealed and marked "CONFIDENTML" and submitted to 

Tony Owen, Progress Energy Service Company, LLC, P. 0. Box 1551 (PEB 2C1), Raleigh, NC 27602. 

Overnight delivery should be sent to410 S. Wilmington Street (PEB 2C3), Raleigh, NC 27601. The proposal 

must bc sealed and marked as noted above in a separate envelope inside the overnight envelope. No copies of 

the proposal shall be distributed toany other Progress Energy personnel by the bidder. Your proposal must be 

received no later than 12:OO noon, March 30,2007. If your proposal is received after that day or time, it will 

not be considered for the described work. Telephoned or faxed proposals or proposal information is 

unacceptable and will not be considered. No modifications to the bidder's proposal will be accepted after the 

bid due date and time specified above unless specifically requested by Progress Energy in writing. 

Bidder is requested to complete, sign, and return the General Information form attached in its entirety and to 

furnish information requested by this form. Bids will not be considered when submitted on forms other 

than thosc provided. 

It is intended that a Contract in the form of the attached specimen Contract will be awarded for this Work and 

quotations shall be made accordingly, unless the successful bidder has an existing Master Contract with 

Progress Energy. in which case a Work Authorization will be released against that Master Contract 

incorporating the details of this Inquiry. 

a 

Progress Energydoes not obligate itself to accept the lowest or any other bid and specifically reserves the right 

to reject any and all bids. Bidders are advised that all bids will be opened and evaluated solely by Progress 

Energy, AI1 information contained in h e bids submitted to Progress Energy and Progress Energy's evaluation, 

including any bidder's relative position to the successful bidder, is considered exclusive information of 

Progress Energy and will not be made available to any of the bidders. AI1 unsuccessful bidders will be notified 

by Progress Energy in writing of the award of the work to another firm. 

Progress Energy Service Company, LLC 

P.O. @ox 1551 

Ralcigli, NC 77602 

All requests for clarifications, interpretations or decisions on discrepancies pertaining to the commercial aspect 

PEF-NCR-0079 I


of the proposal documents or related project data fumished as part of the proposal documents shall be made 

directly to Tony Owen, Tonv.owen@pgnmail.com (919) 546-2933 by the bidder only. 

All requests for clarifications, interpretations or decisions on discrepancies perhining to the technjcal aspect of 

the proposal documents or related project data furnished as part of the proposal documents shall be made 

directly to Scott T. Deahna at the Crystal River Nuclear Plant (CNP) at (352) 563-2943, extension 4234, or 

email address Scott.deahna@Pfznmail.com by the bidder only. 

It is the bidder’s responsibility to advise his potential subcontractors, suppliers, and other subvendors that 

information will be available only through the bidder and that no direct contacts with Progress Energy by 

subtier firms shall be initiated. Information exchange shall be between Progress Energy and bidder, and bidder 

and his potential subcontractors. No work shall be subcontracted without the approval of Progress Energy. 

Subcontract work and proposed subcontractors must be identified in bidder’s proposal. 

As a prerequisite for consideration of a bidder’s proposal, bidder must contact the site of the proposed work, 

discuss job conditions with Progress Energy’s designated representntive, become acquainted with thc technical 

requirements of the work and all available information and local conditions which may possibly occur in the 

course of the work, and make his choice of methods and equipment accordingly. Contact appointments must 

be made with Scott Deiihna at the Crystal River Nuclear Plant. No site visits will be allowed without prior 

appointment with the above named person. 

Please acknowledge receipt of this proposal and your bidding intentions by complehg the attached 

Acknowledgement and faxing to Tony Owen at (919) 546-6750 by two business days. 

RGY SERVICE COMPANY, LLC 

Supply Chain Management 

Attachments to this RFP: 



Scope and Other Requircmcnts 

Sample Contract 

Bid Specification 

Table of Conformance 

Safety Evaluation Forin 

Attachments to Bid Specificalions 

10.1 CR3 Turbine Generator Operating Data (Electronic Only) 

10.2 MUR Power Uprate PEPSE Analysis (Electronic Only) 

10.3 CR3 P&ID’s (Electronic Only) 

10.4 CR3 Turbine Generator Layout Drawings (Electronic Only) 

2

OPC 

ST 

1 POD 

#1 

080009 

BATES NOS. PEF-NCR- 

00793 THROUGH 

PEF-NCR-00869 

NON-RESPONSIVE

etto:Is by qua;ity managen-ent 

organizatwf Gesrnbed telow: 

88 :he group office "Business Excellence, Quality Management" 

(BE) :e" to thc%v"gemen: rep:eren:a:!vc" and Sup3o~t; 

thP Group ErQclltbde Mana?Qment by pe'fnf!?lng the Carpidle 

qcaliiy !ai& defined 111 tk? Slernens Guallty b?dil?qEmet:t 

.. Mandatory E:FmelltS 

This otfice covers ?he toilowitg top:cs' process nwr.ageiiient. 

qmliiy managxnwr system and hiivners QYCeiliCCB program. 

a Qualityafficeswithln divisionsand within major function/ 

process owners are set u? to adme and siippor: the Reads 

a! these iunits with respect Io the es:ahlishment and Implemei;ta!ion 

o! lhe sperif!c cualilv r?.dn?gemer;t wasures. 

They repcrt diiectly ?a trier managament. The:, fields of d q 

ind au?hori!y are defined and c!oiumen:ed in internil ruli-s 

tor the reSpQC!!vr area of si-tlvlty. 

The organ:zar;onal UI:& may, on 3 cdse-by-cxc. or tempcrary 

basis. appOint Quality Coardinators anu'lor Quality Committees 

tor sppcific OM dutirc. ThQy sre in charge of roordtna1,ng. advw 

in;g arid wpportmg the:r respec!lVe fuxtions for qual3y matters. 

Documentation structure 

According to qtcaiity system and product rstcy reauwexmt5, 

the ~rocesse; for prMd-ct and S ~NIC~ ieaiizdtlcn. such ar custamer-related 

procerres. mnrketmg R sales. propo.rzls, ;xCCilflun. 

~OJK? mnqment and service operations, controi of mearunnrj 

and montoring de,virer, arpdescrihec I!: thew ?rtnciples.;pec:Iic 

QtA mnuals. process manuals, and KnO&?dgC baser and imp:emwted 

in contor-mce with thcse documents (sec iigiirc hcioiv 

01 our dorumen tation 5 trurture). 

Q'4 JWBmL."l.tiii* 

Stnulure 

Con ti nu ou s improvement 

Wa1.t). snd satety are ~rerfiiuisite; lot lhe produrb diid beNiCe5 

dereloped. produced and SUpplled. We enfC.rce the Iniarcbement 

prxesses through the Slemenrw,dP top. Qiiality prqram. 

All lop. aclivlties are fo:used on CiiSIomri 5srlsk:;on snd on 

incieasinq me Ecoiicmi: Value Added of our company. 

To m?a;ure qua:itysystem performance. the qroup USES Customer 

and employee tipmion s!:tveys. Internal acdin and wvtews. 

scli.assessnients sccorai*g 10 8usiiiess Ex:rl:en:e Uodels, 

pr~es; and prodscl;service verifications. 

Ana:yses Of data and pCr?O:ma"CQ IndlGWS. WkICh alS@ PrOVldQ 

areas of imp:oven:enl lor the QM sys:em, we applled 

PEF-NCR-00871

Quality Management Manual (QMM 602) 

Siemens Power Generation Page: 1 of 11 

QMM 602 

Quality Management Manual 

for 

Siemens Power Generation 

Proj. Code 

ZEN000 

Type of 

Doc. 

CH02 

Contents Code 

0087 

hnav 7006 Edition 

PEF-NCR-00873



General 

This Quality Management Manual will be revised if necessary. 

Copies are uncontrolled, unless otherwise marked. 

Reservation of Proprietary Riqhts 

The reproduction, transmission or use of this document or its contents is not permitted without express written 

authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration 

of a utility model or design, are reserved. 

Preparation, Review and Release 

Released by: Reviewed by: Prepared by: 

PGNoqes PG BE21Gomez PG BE211Dr. SchmittlHaacklAnqermeyer 

O.U./Name O.U./Name 0.U.lName 

2001-05-16 2001 -05-03 2001 -05-03 

Date Date Date 

Voges Gomez Sc hmittlHaacUAngermeyer 

O.U. = organizational unit 

Editorial revisions were introduced in 0312006. The Declaration of Policy was revised on the basis of the latest 

organizational restructuring, and will be maintained as a separate document in future; a corresponding reference 

to this effect was added under Section 2.1. All processes described in the manual to date retain their 

validity. 

sgd. Kruger, PG BE31 

May 2006 Edition 

PEF-NCR-00874



Table of Contents 

1 Quality management system 

1.1 General requirements 

1.2 Documentation requirements 

1.2.1 General 

1.2.2 Control of documents and records 

2 

2.1 

2.2 

2.3 

2.3.1 

2.3.2 

2.4 

2.4.1 

2.4.1.1 

2.4.1.2 

2.5 

2.5.1 

2.5.2 

Management responsibility 

Management commitment and quality policy 

Customer focus 

Planning 

Quality objectives 

Quality management system planning 

Responsibility, authority and communication 

Responsibility and authority 

Management representative 

Quality management organization 

Management review 

Review input 

Review output 

4 5 

4 5.1 

4 5.2 

4 5.2.1 

4 5.2.2 

5.2.3 

4 

4 5.3 

5 5.4 

5 5.5 

5.5.1 

5.5.2 

5 

5 

6 

6 

6 

6 

6 

Measurement, analysis and improvement 

General 

Monitoring and measurement 

Customer satisfaction 

Internal audit 

Monitoring and measurement of processes 

and products 

Control of nonconforming product 

Analysis of data 

Imp roveme nt 

Continual improvement 

Corrective and preventive action 

10 

10 

10 

10 

10 

10 

11 

11 

11 

11 

11 

3 

3.1 

3.2 

3.3 

4 

4.1 

4.2 

4.2.1 

4.2.2 

4.2.3 

4.3 

4.3.1 

4.3.2 

4.3.3 

4.3.4 

4.3.5 

4.3.6 

4.3.7 

4.4 

4.4.1 

4.4.2 

4.4.3 

4.5 

4.5.1 

4.5.2 

4.5.3 

4.5.4 

4.5.5 

4.6 

Resource management 6 

Provision of resources 6 

Human resources 

Competence, awareness and training 7 

Infrastructure and work environment 7 

Product realization 

Planning of product realization 

Customer-related processes 

Determination of requirements related to 

the product 

Review of requirements related to the product 

Customer communication 

Design and development 

Design and development planning 

Design and development inputs 

Design and development outputs 

Design and development review 

Design and development verification 

Design and development validation 

Control of design and development changes 

Purchasing 

Purchasing process 

Purchasing information 

Verification of purchased product 

Production and service provision 

Control of production and service provision 

Validation of processes for production and 

service provision 

Identification and traceability 

Customer property 

Preservation of product 

Control of monitoring and measuring devices 

7 

7 

7 

7 

7 

7 

8 

a 

a 

8 

a 

a 

8 

8 

8 

8 

9 

9 

9 

9 

9 

9 

9 

10 

10 


p~~-NCR-00875


Siemens Power Generation 

. 

Page: 4 of 11 

Distribution of the documents is controlled eiiher 

CONFIDENTIAL 

May 2006Ed1t1on 

PEF-NcR-oo~~~


Siemens Power Generation Page: 5 of 11


Siemens Power Generation Page. 6 of 17 

__ 

_.


Siemens Power Generation Page. 7 of 11 

____ 

.- --- 

._- .-._I - 

. .. 

-. . .- --- - ..._ .



- - -- 

Mav 2006 Edition 

CON FI DENTI A L PEF-NCR-008 8 0



E



. . . . . . . . . . . 

, . 

- _._- 

._ .................... 

. .



. . . . .....- _.-. 

............ 

, , 

CONFl DENTI A1 


PEF-NCR-00883

April 10, 2008 

Mr. Dick Miller c/o 

Bechtel Power Corp. 

5275 Westview Drive, 4B 1 

Ferderick, MD 2 1703 

Subject : 



Request No. DH07-003 

Dear Mr. Miller: 



of the proposal (one priced and one unpriced) shall be sealed and marked "CONFIDENTIAL'' 




September 29,2007. If your proposal is received after that day or time, it will not be considered 




Energy. 







evaluated solely by Progress Energy. All information contained in the bids submitted to Progress 



available to any of the Vendors. All unsuccessful Vendors will be notified by Progress Energy in 

writing of the award of the work to another firm. 

All requests for clarifications, interpretations or decisions on discrepancies pertaining to any of the



Request No. xxxO7-01 

proposal documents or related project data fumished as part of the proposal documents shall be made 

directly to Deborah.Hanna@pgnmail.com, (352) 563-2943, x4547. 








attached Acknowledgement form. Bids will not be considered when submitted on forms other 

than those provided. Please fax the completed Acknowledgement form to Deborah Hanna at 

(352) 563-4464 before the close of business on September 4,2007. Progress Energy will host a 

walk through of the applicable Crystal River areas on September 6,2007 from 1 to 3 PM. The 

walk through will be followed by a question and answer session to ensure all the potential 

vendors understand the scope of this work. 


Deborah Hanna 


Attachments: 




PEF-NCR-00886


To : 

Deborah Hanna 




Fax: 352-563-4464 





as follows: 


I have reviewed the proposal documents and intend to submit a bid for this work. 

0 I plan to attend the facility walkthrough and solicitation discussion on September 6, 2007. 

(Signature) 

(Title) 

(Date) 

1


In the event that your Proposal is accepted and a Contract is awarded to the firm whose full legal 

company name'appears herein below, Mr./Ms. 



Should this person's title not indicate that he/she is a corporate officer (president, vice president, 


bid; stating that the person whose name appears above is duly authorized to execute contracts on 




A Corporation of the State of: 







Contact Name 

Contact Phone 




2

Contractor's License Number (if applicable) 


In accordance with the Federal Acquisition Regulation section 52.2 19, please check all that apply 


for any categories checked under Smallhliverse Vendors. 

[ 3 Certified small business* [ 3 HUBZone, 8(a) or disadvantaged business* 

[ ] Veteran-owned business* [ ] Minority-owned business * * 

[ 3 Service-disabled veteran-owned business* [ ] Women-owned small business * * 

[ ] Not a Small Business 

* As defined by the Small Business Administration (SBA): wwwsba.gov 


Register online at www.progress-enerw.com/supplierdiversifi 

BY: 


TITLE: 

DATE: 

PEF-NCR-00889 

3


I. Background 








affect the permitted discharge temperature limit of 96.5 O F. 






CRl and CR2 to de-rate so as not to exceed the permitted National Pollutant Discharge 

Elimination System (NPDES) limit. After the 201 1 EPU implementation, operation of CRl and 


mitigation. 





the SCA, the use of cooling towers may not be the best alternative. As a result, this Request for 



The Scope of Work is divided into two phases. Phase I is to evaluate altematives for reducing 


associated with CR3’s EPU, (2) minimize the effect on full-load operation of CRl and CR2 and 



intake canal to offset increased condenser flow from CR3’s EPU and address 3 16(b) 



Study Report will be structured using the outline provided in Attachment B. Phase I1 of this 

work scope is to develop a conceptual design, general cost estimate (+25%) and high-level

schedule for the Project’s implementation. 

Phase I 



implement each alternative. The following list provides the expected altematives, in whole or in 


0 Evaluation of cooling alternatives, including, but not limited to, the following: 

3 New Cooling Towers 

3 Modifying Existing Cooling Towers 



3 Evaporative Cooling 

3 InletDischarge Chillers 

3 Air Spargers/Bubblers’ 

0 Analysis of each alternative including, but not limited to, the following: 

Economic Cost Estimate (including the basis for the estimate) 

Schedule Analysis 

Quantity and Size of Equipment 

Infrastructure Requirements (e.g., electrical needs) 

Proposed location(s) considered for the alternative 

Site Impacts (e.g., environmental, operational and maintenance) 

Advantages and Disadvantages Relative to Other Options 

0 Identify environmental impacts for each alternative3 

=3 Wetlands Mitigation 

3 Biota Impingement and Entrainment Issues 

0 

Preparation of an Alternatives Summary Report comparing the alternatives and an on-site 


Phase I1 




conceptual design report. PEF expects that the conceptual design can be used as the stand alone 




Bubble cooling was previously reviewed (additional References - John Cooper & Associates Engineering 

Evaluation). 



alternative. 

5







evaluation. The selected Vendor should expect a one day tum around time for on site delivery of 


coordinate the Vendor's CR site indoctrinations, badging, and specific training, as required. 

After the Phase I alternative selection, an economic analysis will be performed using PEF's inhouse 

EESY+ software. PEF will input the Vendor's supplied data into EESY+ and provide the 


input for accuracy and reviewhncorporate the output results into the study. 


Vendor shall conduct a thorough review of design altematives to reduce the discharge canal 

water temperature and satisfy the stated Project objectives following CR3's EPU. This 






s 245,000 gpm Circulating Water Flow (actual) 

s -1 7 "F Circulating Water Temperature Rise Through Condenser 


3 308,000 gpm Circulating Water Flow (actual) 

s -14 O F Circulating Water Temperature Rise Through Condenser 


s 832,000 gpm Circulating Water Flow 

s -17 OF Circulating Water Temperature Rise Through Condenser 

s .768 MBtdhr of Additional Heat Dissipated due to EPU 

0 (Hamon) Helper Cooling Towers operation 

s 4 blocks of 9 cells 

9686,000 gpm Total Water Flow 

s 89.5 OF Design Outlet Temperature (based on 103 OF inlet and 81 "F wet bulb) 

0 (Aggreko) Modular Cooling Tower operation 

3 67 individual cells 


6

90 OF Design Outlet Temperature (based on 103 OF inlet and 81 OF wet bulb) 

0 Project Objectives 

s Allow Full-Load Operation of CRl, CR2 and CR3 during Summer 

s Plan for Maximum Design Intake Water Temperature of 91 O F 

s Comply with 96.5 O F Point of Discharge (POD) 3-hr Rolling Average 

s Maintain a maximum Permitted Discharge Flow Rate of 1,320,000 gpm (or 1,897.9 


intake canal. 

0 Additional Data 

3 Intake canal cannot be blocked due to barge traffic. 



s The return water from discharge to intake canals will be designed for most efficient 


V. REFERENCES 













0 Site civil engineering drawings 

0 Site electrical drawings 

0 Wetland surveys 

0 Site Certification Application 

0 Bechtel Cooling Water Study 

0 John Cooper & Associates Engineering Evaluation 



Telephone: (352)563-4547 

E-mail: Deborah.Hanna@pgnmail .com 

Technical: 

Mark Gillespie or Mark Hickman 

7

Telephone: 

Email: 

(352) 795-0504 x6926 or (352) 795-6486 x4233 

mark.gillespie@pgnmail.com or mark.hickman@,Panmail.com 








The selected Vendor shall establish a Request for Information (MI) Log to track information 











0 Safety topic 

0 Earned value status (cost vs. schedule) 

0 Projected Estimate at Completion (EAC) 

0 Accomplishments/Milestones 

0 IssuesRequest for Information 

0 Scheduled accomplishments for next week 

0 Number of personnel working on the project (last week and next week) 








0 Projected EAC 

0 Accomplishments 

0 Presentation of completed documents for approval 

0 Issues 

0 General discussion (question & answers) 

8



any comments on alternatives as well as to identify site restrictions that may not have been 

considered. 



VIII. Schedule: 



scope of work is required to be complete by January 3 1,2008. 

RFP sent to Vendors 

September 4, 2007 

September 6, 2007 



Summary Report. The selected Vendor shall work with PEF personnel to determine a 








Five copies of the final Alternatives Summary Report shall be supplied to PEF 

Phase I1 





following: 

0 Provide a detailed scope description. The description should include the boundaries and 

interfaces with existing systems (i.e., site electrical, helper and modular cooling towers). 

0 Identify the location(s) for installation and reason for selection, including any testing data 



0 Identify applicable codes and standards. 



0 Identify installation requirements that are unique to the proposed design, installation, 


acceptable. 

0 Identify any assumptions made during the alternative selection. 


operation. 



o Identify any interface requirements including definition of the functional and 

physical interfaces involving structures, systems and components. 

0 Identify any precautions or limitations that need to be considered in completing the 

design. 

o Identify environmental considerations (e.g., maximum particulate carry over 

during evaporative processes). 

0 

0 

0 

0 

Provide installation sketches and marked up drawings for electrical, I&C, and mechanical 

systems. Develop P&ID of recommended system(s). 

Provide installation sketches and marked up drawings with civiI/structural details. 

Provide calculations developed during the alternative evaluation and selection process. 

Provide suggested component and equipment selection and specifications. 

o Identify the performance requirements of the selected alternative systems and 

10

equipment, such as capacity, rating, and system output. 

o Identify material requirements such as electrical insulation properties, protective 

coating and corrosion resistance. 

o State mechanical requirements such as vibration, stress, shock, and reaction 

forces. 

o Identify Structural requirements covering items such as equipment foundations 

and pipe supports. 

o Identify hydraulic requirements such as pump net positive suction heads, 

allowable pressure drops, and allowable fluid velocities. 

o Identify electrical requirements such as source of power, voltage, conduit 

requirements, electrical insulation and motor requirements. Provide the electrical 

power supply for each component and calculation of the total electrical power 

required for the project. 

o State the on-site electrical power source that will be used to supply the project. 

List the major pieces of electrical equipment to be procured and installed in order 

to provide electrical power to the major electrical components. 

o Identify of the electrical power routing from the main distribution switchgear to 

transformer(s) and load center(s) to be used for the project. 

o Provide layout and general arrangement requirements. 

o Additional requirements such as inadvertent activation prevention devices, such as 

switch covers, key lock switches and other human factors considerations (Le. 

handwheel locks) may be provided by PEF personnel. 

Identify operational requirements and sequencing under various conditions, such as plant 

start-up, normal plant operation, plant shutdown, plant emergency operation, special or 

infrequent operation, and system abnormal or emergency operation, including postulated 

accident conditions. PEF personnel will assist in determining these criteria. 

State instrumentation and control requirements, including indicating instruments, 

controls, and alarms for operation, testing, and maintenance. Other requirements such as 

the type of instrument, installed spares, range of measurement, and location of indication 

should also be included. PEF personnel will identify desired instrumentation and alarms. 

The instrumentation and controls should be similar to existing equipment monitoring and 

control schemes. 

Access and administrative control requirements for plant security (PEF personnel to 

identify). 

If applicable, state redundancy, diversity and separation requirements of structures, 

systems, and components. 

Identify the failure effects on the requirements of structures, systems, and components, 

including a definition of those events and accidents that they must be designed to 

withstand (i.e. hurricane winds). 

Identify system and component test requirements and the conditions under which they 

will be performed. 

Identify accessibility, maintenance, repair, and in-service inspection requirements for the 

equipment, including the conditions under which these will be performed (PEF personnel 

to assist). 

Identify the on-site transportability requirements such as size and shipping weight, 

PEF-NCR-00897 11

limitations. 

Identify the fire protection or resistance requirements. 

State that the design is to identify the handling, storage, and shipping requirements of 

procured material. 

Identify safety requirements for preventing personnel injury including such items as 

restricting the use of dangerous materials, escape provisions from enclosures, and 

grounding of electrical systems. Identify plant procedures that address these hazards (Le. 

Chemical Control). PEF personnel will assist in identifying site requirements and 

procedures. 

Provide an Affected Documents List of site drawings and procedures. 

Provide an estimate of new drawings that will be generated during the detailed design 

phase. 

Prepare a Conceptual Design Report Package. 

Drawings shall be performed and submitted in US standard units (Le. feet, lbs, kips, inches). All 

engineering drawings and calculations will be reviewed and approved by a registered 

Professional Engineer. 

Five copies of the final conceptual design documents shall be supplied to PEF. 

XI. 

Deliverables: 

Phase I 

Kickoff meeting agenda and minutes 

List of alternatives to be analyzed 


Draft Alternatives Summary Report (5 copies) 

Final Alternatives Summary Report (5 copies) and Presentation 

Phase I1 

Updated project schedule 


Draft Conceptual Design Report (5 copies) 

Final Conceptual Design Report (5 copies) and Presentation 

XII. Additional Information: 

PEF will hold a pre-bid meeting with interested Vendors to clarify questions and expected scope. 

The meeting will be held on September 6,2007 from 1 to 3 pm. 

XIII. Attachments : 

A. Bid Requirements 

B. General Study Outline 

C. PEF Technical Documentation 

12

Attachment A. Bid Requirements 

Vendor shall provide the following information with their proposals. 

1. Company’s resume providing qualifications and references that demonstrate Vendor’s 

capability to complete the work. 

2. Vendor’s organization chart identifying how this work will be managed as well as interface 

points with PEF. 

3. Resumes of personnel intended to be used on this project. These resumes will be evaluated 

as part Vendor’s qualification to accomplish the stated scope of work. 

4. Commitment to start work within ten (10) days of the Notice to Proceed. 

5. Company safety statistics. 

6. Classification of each type person associated with the work scope. 

7. Hourly billing rates for each classification (straight time/overtime or all-hours rate) 

8. Billable travel and living expenses. 

9. Estimated man-hours for each personnel classification. 

10. This contract will be completed as a Time & Materials contract, divided into two phases. 

Provide a maximum not-to-exceed contract dollar amount for each phase of the work 

described in this RFP. 

1 1. Provide a description of the suggested approach the Vendor will take to complete this work. 

The approach description should: 

0 be consistent with the estimated cost and schedule, 

0 include the expected manpower (by classification) needed for each phase of the work, 

0 demonstrate that the Vendor understands the work scope & schedule requirements, 

0 identify what work will be completed at Crystal River and the work to be completed at 

the Vendor’s facility, 

0 include potential problems that could affect the project cost or schedule, 

0 include methods to control contract costs, 

0 describe the Vendor’s earned value system that will be used to monitor and report project 

cost (this description should demonstrate that the Vendor has the capability to properly 

identify, monitor, collect, analyze, and report project costs), 

0 identify opportunities to improve the project’s completion. 

12. Provide a schedule for accomplishing this scope of work that contains the sequence of 

activities in Section VIII. 

13. QNQC Program Manual &/or Procedures to be followed in completing the work. 

14. Health & Safety (H&S) Plan or agreement to comply with the PEF’s H&S Plan. 

SPECIAL REQUIREMENTS: 


All RFP drawings, specifications, and contractual documents will remain the property of 

Progress Energy and are to be returned in good condition within ten (1 0) days after the date set

for receiving bids. RFP documents shall not be reproduced or used for any purpose other than 

for the preparation of a proposal in accordance with this request. The information contained in 

these documents is proprietary and confidential and shall be maintained in strict confidence. 

RFP Interpretation: 

An interpretation request shall be made to Progress Energy if a Vendor is in doubt as to the true 

meaning of any part of the drawings, specifications, or contractual documents. Modification of 

the documents will be made only by written addendum issued to each Vendor as described 

below. 

RFP Exceptions: 

If a Vendor’s proposal contains any deviations or exceptions, those deviations or exceptions must be 

specifically identified on a single separate attachment to the proposal in order to be considered in the 

evaluation, If not so identified, the deviations or exceptions will not be considered part of the 

proposal. Conditional proposals based on Vendor-generated clarifications may not be accepted. If a 

Vendor takes any exceptions in addition to those submitted in accordance with this section, that 

Vendor’s proposal may be rejected by Progress Energy. 

RFP Approved Equal Evaluation: 

Submittals by Vendor for evaluation of products as “approved equal” shall be made to the 

appropriate designated individual listed in the Request for Proposal at least ten (1 0) days prior to 

the proposal due date. Results of evaluations will be provided no later than seven (7) days prior 

to the proposal due date. Submittals made later than ten (1 0) days prior to the proposal due date 

will not be considered. 

RFP Addenda: 

Progress Energy reserves the right to amend or clarify requirements herein by Addenda. An 

addendum may be issued at any time prior to the date for receipt of proposals and may be mailed 

or otherwise delivered to all Vendors who have been invited to bid. Request by a Vendor for 

extension of the proposal due date shall be received by Progress Energy at least one week prior to 

the then scheduled date. If revisions or clarifications are of magnitude to warrant, in the opinion 

of Progress Energy, the extension of the date set for receipt of proposals, an addendum will be 

issued announcing the new date. Failure of a Vendor to acknowledge receipt of any addendum in 

the space provided on the proposal form may result in rejection of that proposal. 

Safety: 

Progress Energy is committed to using safety conscious contractors. To this end, Progress 

Energy collects safety-related data voluntarily provided by all persons performing or desiring to 

perform Progress Energy work. This data is compiled and made available to Progress Energy 

employees via Progress Energy’s intranet. This intranet system is accessible by non-Progress 

Energy employees, and thus, so will be any safety-related information you provide. In providing 

the safety-related information requested herein, to Progress Energy or to any other person doing 

business, directly or indirectly, with Progress Energy, the undersigned contractor explicitly 

authorizes Progress Energy to disclose said information to non-Progress Energy persons and 

hereby releases Progress Energy and its agents and employees from any cause of action or claim

for damages related to said disclosures. 


This work is NOT classified as Nuclear Safety Related and does not need to be accomplished 

under the vendor’s Appendix B Program. 

15

1. 

2. 

3. 

4. 

5. 

6. 

Attachment 6. Alternatives Analysis Report Outline 

Title/Signature Page 

i. Contact Information 



Introduction 

i. Project Description 

ii. Preliminary Scope Statement 

iii. References 

iv. Existing Unit Overview 

Design Criteria 

i. Design Objectives 

ii. Design Parameters 

Evaluation of Altematives 

i. General Descriptions 

0 Equipment 

0 General layout 

ii. Technical Evaluation 

0 Operating parameters 

0 

Ability to meet project requirements 

iii. Economic Analysis 

0 Equipment 

Site preparation 

0 Installatiodconstruction 

e Operating costs 

iv. Environmental Issues 

0 Location / site preparation 

0 Operating 

0 Potential mitigation actions required 

v. Estimated Cost 

0 Equipment 

0 Site Preparation 

0 Installation / construction 

0 Operation 

0 Maintenance 

vi. Estimated Schedule 

7. Recommended Solution 

8. Attachments 

16

Attachment C. PEF Technical Documentation 





5. Helper Cooling Tower Performance Cunies 




PEF-NCR-00903 17


18


19

Applicable Sections of the Site Certification Application 

20


PEF-NCR-00907 

21


22


23

Local Annual Windrose 

24

I 

RFI Number: 

Date: 

Initiator: 

Discharge Canal Thermal Mitigation Project Request for Information (RFI) Form 

Contractor's Project Manager 

Approval: 

Date that response is needed by to prevent Project impact: 

I 

Progress Energy Direction, Resolution, Clarification 

I 

Approval: 

Project Manager: 

~~ ~ 

[Procurement Specialist: 

PEF-NCR-009 1 1 

25

April 10, 2008 

Attn: 

Subject : 




Dear Mr. 



of the proposal (one priced and one unpriced) shall be sealed and marked "CONFIDENTIAL" 




September 29,2007. If your proposal is received after that day or time, it will not be considered 




Energy. 







evaluated solely by Progress Energy. All information contained in the bids submitted to Progress 



available to any of the Vendors. All unsuccessful Vendors will be notified by Progress Energy in 


PEF-NCR-009 I2




All requests for clarifications, interpretations or decisions on discrepancies pertaining to any of the 

proposal documents or related project data hrnished as part of the proposal documents shall be made 

directly to Deborah.Hanna@pgnmail.com, (352) 563-4547. 








attached Acknowledgement form. Bids will not be considered when submitted on forms other 

than those provided. Please fax the completed Acknowledgement form to Deborah Hanna at 

(352) 563-4464 before the close of business on September 4, 2007. Progress Energy will host a 

walk through of the applicable Crystal River areas on September 6,2007 from 1 to 3 PM. The 

walk through will be followed by a question and answer session to ensure all the potential 

vendors understand the scope of this work. 


By: 

Deborah Hanna 


Attachments: 



Scope and Other Requirements


To: 

Deborah Hanna 




Fax: 352-563-4464 





as follows: 


0 I have reviewed the proposal documents and intend to submit a bid for this work. 

0 I plan to attend the facility walkthrough and solicitation discussion on September 6,2007. 

(Signature) 

(Name) 

(Title) 

(Date) 

1


In the event that your Proposal is accepted and a Contract is awarded to the firm whose full legal 

company name appears herein below, Mr./Ms. 



Should this person’s title not indicate that he/she is a corporate officer (president, vice president, 


bid, stating that the person whose name appears above is duly authorized to execute contracts on 




A Corporation of the State of: 







Contact Name 

Contact Phone 




2



In accordance with the Federal Acquisition Regulation section 52.219, please check all that apply 


for any categories checked under Small/Diverse Vendors. 

[ 3 Certified small business* [ ] HUBZone, 8(a) or disadvantaged business* 

[ 3 Veteran-owned business* [ ] Minority-owned business * * 

[ 3 Service-disabled veteran-owned business* [ 3 Women-owned small business * * 

[ 3 Not a Small Business 

* As defined by the Small Business Administration (SBA): ww.sba.gov 


Register online at www.progress-energv.com/suDulierdiversit 

BY: 


TITLE: 

DATE: 

PEF-NCR-009 16 3


I. Background 








affect the permitted discharge temperature limit of 96.5 OF. 






CRI and CR2 to de-rate so as not to exceed the permitted National Pollutant Discharge 

Elimination System (NPDES) limit. After the 201 1 EPU implementation, operation of CRl and 


mitigation. 





the SCA, the use of cooling towers may not be the best alternative. As a result, this Request for 



The Scope of Work is divided into two phases. Phase I is to evaluate alternatives for reducing 


associated with CR3’s EPU, (2) minimize the effect on full-load operation of CR1 and CR2 and 



intake canal to offset increased condenser flow from CR3’s EPU and address 3 16(b) 



Study Report will be structured using the outline provided in Attachment B. Phase I1 of this 

work scope is to develop a conceptual design, general cost estimate (+25%) and high-level

schedule for the Project’s implementation. 

Phase I 



implement each alternative. The following list provides the expected alternatives, in whole or in 


0 Evaluation of cooling alternatives, including, but not limited to, the following: 

New Cooling Towers 

Modifying Existing Cooling Towers 



Evaporative Cooling 

Inlet/Discharge Chillers 

Air Spargers/Bubblers2 

0 Analysis of each alternative including, but not limited to, the following: 

3 Economic Cost Estimate (including the basis for the estimate) 

3 Schedule Analysis 

z Quantity and Size of Equipment 

s Infrastructure Requirements (e.g., electrical needs) 

3 Proposed location(s) considered for the alternative 

3 Site Impacts (e.g., environmental, operational and maintenance) 

3 Advantages and Disadvantages Relative to Other Options 

0 Identify environmental impacts for each alternative3 

z Wetlands Mitigation 

s Biota Impingement and Entrainment Issues 

0 Preparation of an Alternatives Summary Report comparing the alternatives and an on-site 


Phase I1 




conceptual design report. PEF expects that the conceptual design can be used as the stand alone 




* Bubble cooling was previously reviewed (additional References - John Cooper & Associates Engineering 

Evaluation). 



alternative. 

PEF-NCR-00918 

5







evaluation. The selected Vendor should expect a one day turn around time for on site delivery of 


coordinate the Vendor’s CR site indoctrinations, badging, and specific training, as required. 

After the Phase I alternative selection, an economic analysis will be performed using PEF’s inhouse 

EESY+ software. PEF will input the Vendor’s supplied data into EESY+ and provide the 


input for accuracy and reviewhcorporate the output results into the study. 


Vendor shall conduct a thorough review of design alternatives to reduce the discharge canal 

water temperature and satisfy the stated Project objectives following CR3’s EPU. This 





0 CRl full-load operation 


3 -1 7 OF Circulating Water Temperature Rise Through Condenser 





3 832,000 gpm Circulating Water Flow 


j .768 MBtu/hr of Additional Heat Dissipated due to EPU 

0 (Hamon) Helper Cooling Towers operation 

3 4 blocks of 9 cells 


3 89.5 O F Design Outlet Temperature (based on 103 OF inlet and 81 OF wet bulb) 

0 (Aggreko) Modular Cooling Tower operation 

3 67 individual cells 


6

. 

3 90 O F Design Outlet Temperature (based on 103 OF inlet and 81 OF wet bulb) 

0 Project Objectives 

3 Allow Full-Load Operation of CR1, CR2 and CR3 during Summer 

3 Plan for Maximum-Design Intake Water Temperature of 91 OF 

3 Comply with 96.5 OF Point of Discharge (POD) 3-hr Rolling Average 

3 Maintain a maximum Permitted Discharge Flow Rate of 1,320,000 gpm (or 1,897.9 


intake canal. 

0 Additional Data 

3 Intake canal cannot be blocked due to barge traffic. 



3 The return water from discharge to intake canals will be designed for most efficient 


V. REFERENCES 







5, Helper Cooling Tower Performance Curves 






0 Site civil engineering drawings 

0 Site electrical drawings 

0 Wetland surveys 

0 Site Certification Application 

0 Bechtel Cooling Water Study 

0 John Cooper & Associates Engineering Evaluation 

7



Telephone: (352)563-4547 

E-mail: Deborah. Hanna@pgnmail. com 

Technical: 

Telephone: 

Email: 

Mark Gillespie or Mark Hick” 

(352) 795-0504 x6926 or (352) 563-2943 x4233 

mark.gillespie@pgnmail.com or mark.hickman@pnnmail.com 








The selected Vendor shall establish a Request for Information (RFI) Log to track information 













0 Projected Estimate at Completion (EAC) 

0 Accomplishmentshlilestones 

0 Issues/Request for Information 

0 Scheduled accomplishments for next week 

0 Number of personnel working on the project (last week and next week) 






Safety topic 


PEF-NCR-0092 1 

8

0 Projected EAC 

0 Accomplishments 

0 Presentation of completed documents for approval 

Issues 

0 General discussion (question & answers) 



any comments on alternatives as well as to identify site restrictions that may not have been 

considered. 



VIII. Schedule: 



scope of work is required to be complete by January 3 1,2008. 

0 RFP sent to Vendors 

0 September 4, 2007 

0 September 6,2007 


0 October 11,2007 

0


Quality Assurance (QA) and Quality Control (QC) shall be accomplished under Vendor’s 

internal QNQC Program. Vendor’s QNQC Program shall be submitted to PEF for review with 

their proposal. 

X. Technical Documentation and Submittal Requirements . 

Phase I 

Finalize the list of alternatives to be evaluated and obtain Alternative Evaluation List approval 

from PEF Project Manager. Complete the alternatives analysis and draft the Alternatives 

Summary Report. The selected Vendor shall work with PEF personnel to determine a 








Five copies of the final Alternatives Summary Report shall be supplied to PEF. 

Phase I1 





following: 

0 Provide a detailed scope description. The description should include the boundaries and 

interfaces with existing systems (Le., site electrical, helper and modular cooling towers). 

0 Identify the location(s) for installation and reason for selection, including any testing data 



0 Identify applicable codes and standards. 



0 Identify installation requirements that are unique to the proposed design, installation, 


acceptable. 

0 Identify any assumptions made during the alternative selection. 


operation. 



10


AR WA-06-2792 

Mr. Danny Roderick 

Director - Site Operations 


Crystal River Nuclear Plant 

15760 West Power Line Street 

Crystal River, FL 344284708 

Subject: 

Proposal for CR-3 Engineering Design and Licensing Measurement 

Uncettainty Recapture (MUR) Power Uprate Project 

Attachment: 1. 

AREVA NP Proposal for 'MUR Power Uprate Project" 

Dear Mr. Roderick: 

AREVA NP Inc. (AREVA NP), an AREVA and Siemens company, is pleased lo provide you 

the attached proposal for CR-3 Engiwering Design and Licensing MUR Power Uprate 

Project. We look forward to your favorable acceptance of this proposal and appreciate this 

opportunity to work with you on this project. 

The attached submittal is a non-priced version of our proposal for your technical review. The 

priced version will be hand carried and presented at the executive meeting on Monday, 

October l€ith. 

This proposal is valid until December 15, 2006 except that AREVA NP reserves the right to 

withdraw or amend at any time prior to approval by Progress Energy and subsequent written 

acceptance by an authorized representative of AREVA NP. 

This proposal is proprietary to AREVA NP. If you have any questions conceming this 

proposal, please contact Dallas Scott at (434) 832-2937 or me at (434) 832-2948. 

Sincerely, 

cc: 

Jim Terry - CR-3 

Ted Williams - CR-3 

Debbie Hanna -CR-3 

Skip Hudson - AREVA 

Dallas Scott - AREVA 

Ed - Kane - AREVA 

AREVA NP INC. 

3315 Old Fot.rl RMd. P.O. B CX lW35. Lynchburp. VA 24y160935 

Tel.: (134) B32.30C-Y~ Fax: (454) 1324040 www.meva.cm 

Dennis A. Napior 

Manager, NSSS Engineering Services 

Nuclear Engineering 

PEF-NCIi-00924

Engineering Design and Licensing 

For CR-3 

Measurement Uncertainty Recapture (MUR) 

Power Uprate Project 

For CR-3 Nuclear Power Station 

Proposal Request from: 


AREVA Proposal 

#4161 OS4 

Dated: October 11, 2006 

Validity: December 15,2006 

Prepared By: 

AREVA NP Inc. 

331 5 Old Forest Road 

P.O. Box 10935 

L ync hb urg, Virginia 24506-0935 

Thl) prcgowl Including any armngr wmod IO or perlaining IheroUI. ia hr pcpq d AREVA. h conalns conllamllal inlormalbn “3 it provided 10 

ROQ~ EnrW on wndllon Ihal d. or m rppraaenMnsr by rwanng fir PropcM. agw nd Io rcprc-jKa OT apy in whob w In part 01 lo turnkh hlwmatbn 

h0mnbelhOnwnn~permlrslon. 0(10~keany~o1tnaPropculanort~anlorlhoovalu~andtlrPropnat

AREVA NP InC. 

Proposal #4 161084 

PROPRIETARY 


Executjve Summary ................................................................................................................................... .iV 

........................................................................................................................ 1 

......... 

_. 

--> 

....... ., 

........ 

J 

...... 

k 

3.0 COMMERCIAL ....................................................................................................................... 45 

CR-3 MUR Power Uprafe Project ii Progress Energy 

CR-3 Nuclear Power Slation

.............................. 

~ 

..,..,...,....._.... 

AREVA NP Inc. 

Proposal #4161084 

PROPRIETARY 


Attachment 1 Respmslbiliiy Tables Licensing Activities ........................................................................... 48 

Attachment 2 Responsibility Table Engineering Changes ..(.................................................................... 56 

Attachment 3 2006 Master Services Rates ........................................................................................ 59 

Figure 1 Proposed Canfiguration .............................................................................................................. 23 

Figure 2 Project Schedule ..................I...~......1__._..................................,...,.,........,,....................,...,..,....... 37 

Figure 3 - Caldon EC Schedule ............................................................ ~ 38 

~ 

CR-3 MUR Power Upmte Project iii Progress Energy 

CR-3 Nuclear Power Station 

CON FI ENTl At PEF-NCR-00927

AREVA NP Inc. 


- 


PROPRIETARY 


CR-3 Power Uprate Project -, iv Progress Energy 


CON FI DENTI AL

AREVA NP Inc. 

Proposal #4 161 084 

PROPRIETARY 


CR-3 Power Uprate Project -I V Progress Energy 


CONFl DENTIAL 

PEF-NCR-00929

AREVA NP Inc. 


PROPRIETARY 


... 

.e 

CR-3 Power Uprate Project vi Progress Energy 

CR-3 Nuclear Power Station

AREVA NP Inc. 


PROPRIETARY 

Introduction 

0 1.0 INTRODUCTION 

CR-3 Power Uprate Project 1 Progress Energy 


AREVA NP Inc. 


PROPRIETARY 

Work Scope 

2.0 WORKSCOPE 

.............. '1 

... ... . . 

CR-3 Power Uprafe Project 2 Progress Energy 


'.

AREVA NP Inc. 


PROPRIETARY 

Work Scope 

CR-3 Power Uprate Project 3 . Progress Energy 

CR3 Nuclear Power Station 

CONFl DENTI AL

AREVA NP Inc. 


PROPRIETARY 

Work Scope 

CR-3 Power Uprate Project . 4 Progress Energy 


CONFIOENTIAL

AREVA NP Inc. 


PROPRIETARY 

Work Scope 

CR-3 Power Uprare Projecf 5 Progress Energy 

CR-3 Nuclear Power Sfation 

GO N F 1 0 ENTl AL

AREVA NP Iflc. 


PROPRIETARY 

Work Scope 

Cff-3 Power Uprate Project 6 Progress Energy 



PEF-NCR-00936

AREVA NP Inc. 

Proposal#4161084 

PROPRIETARY 

Work Scope 

CR-3 Power Uprafs Project 7 Progress Energy 


CON Fl DENTI AL 

PEF-NCR-00937

CR-3 Power Uprate Project a Progress Energy 


AREVA NP hc. 


PROPRIETARY 

Work Scope 

"*"-i ............. r 


CR-3 Nuclear Power Slation 

CONFIDENTIAL 

PEF-NCR-00939

AREVA NP Inc. 


PROPRIETARY 

Work Scope 



CONFl DENTIAL 

PEF-NCR-00940

AREVA NP Inc. 


PROPRIETARY 

Work Scope 

* . 

CR-3 Power Uprare Project 11 



CONFIDENTIAL 

PEF-NCR-0094 1

AREVA NP lnc. 


PROPRIETARY 

Work Scope 



CON FI OENTIAL 

PEF-NCR-00942

AREVA NP Inc. 


PROPRIETARY 

Work Scape 


CR-3 Nuclear Power Srdrion

AREVA NP Inc. 


PROPRIETARY 

Work Scope 



CONFIDENTIAL 

PEF-NCR-00944

AREVA Inc. 

Proposal #4 161 084 

PROPRIETARY 

Work Scope 

CR-3 Power Uprare Project 15 Progress Energy 


CONFIDENTIAL 

PEF-NCR-00945

AREVA Inc. 


PROPRIETARY 

Work Scope 

CR-3 Power Uprate Pro]ect 16 Progress Energy 


CONFl OENTIAL 

PEF-NCR-00946

ARE VA lnc. 


PROPRIETARY 

work scope 

0 SYSTEM REVIEW SUMMARY 

Cff-3 Power Uprafe Projecf. 17 Progress Energy 


CONFIDENTIAL

AREVA Inc. 


PROPRIETARY 

Work Scope 

2.1.4 Llcenslng Report Preparation 



CONFIDENTIAL

AREVA lnc. 


PROPRIETARY 

Work Scope 

e 

CR-3 Power Uprats Project 19 Progress Energy 


CONFIDENTIAL 

PEF-NCR-00949



CONFl DENTIAL

~~ 

ARWA Inc. 


PROPRIETARY 

Work Scope 



CONFIDENTIAL 

PEF-NCR-0095 1

AREVA Inc. 


PROPRIETARY 

Work Scope 



AREVA Inc. 

Proposal #4 I6 I084 

PROPRIETARY 

Work Scope 

~~ 



GO N FI 0 ENTl AL 

PEF-NCR-00953

AREVA Inc. 


PROPRIETARY 

Work Scope 



CON F1 DENTI AL 

PEF-NCR-00954

AREVA Inc. 


PROPRIETARY 

Work Scope 



CONFl DENTIAL

AREVA Inc. 

Proposal #4 I6 7084 

PROPRIETARY 

Work Scope 

I 


Cl?-3 Nuclear Power Station 

_ - 

CON Fl DENTI AL 

PEF-NCR-00956

AREVA Inc. 

Proposai#4161084 

PROPRIETARY 

Work Scope 

t 

REDACTED 

I 

-. _- - -- 



CR-3 Power Uprate Project 28 Ppgress Energy 


CONFl DENTIAL

AREVA Inc. 


PROPRIETARY 

.. - . 

Work Scope 

.. . . . 

ED ACTED 

, I 

CR-3 Power Uprate Pmiect 29 Progress Energy 


C 0 N FI D ENTI AL 

PEF-NCR-00959

AREVA Inc. 


PROPRIETARY 

Work Scope 

7 

s 

-_ -. ._ . 

CR-3 P owr Uprate Project 30 Progress Energy 


CO N F I D ENTl AL 

PEF-NCR-00960

AREVA lnc. 


PROPRIETARY 

Work Scope 

.- - 

01 

.. . . - 

_- 

.. 

.- 

--i 


CR-3 Nuclear Power Stafion 

4 s 

CONFIDENTIAL PEF-NCR-0096 1

AREVA Inc. 


PROPRIETARY 

Work Scope 

I 

1 

, . 

1 

CR-3 Power Uprate Projecr 32 Progress Energy 


CONFl DENTI AL

AREVA Inc. 

Propose1 #4161084 

PROPRIETARY 

Work Scope 

CR-3 Po wet Uprate Project 33 Progress Energy 


CONFIDENTIAL 

PEF-NCR-00963

AREVA Inc. 


PROPRIETARY 

Work Scope 

. - . 

CR-3 Power Uprate Project 34 



.. 

CONFIDENTIAL 

PEF-NCR-00964

AREVA Inc. 


PROPRIETARY 

work scope 

0 ' . . . .. 

I -1 

...... ""1 

..._- 

1 ....* 

CR-3 Power Uprate Project 35 



CON FI D ENTl AL

A REVd inc. 


PROPRIETARY 

Work Scope 

2.8 Schedule 

CR-3 Power Uprats Project 36 



.. 

CONFl DENTIAL

AREVA NP Inc PROPRIETARY . PENGO7-1370.0 Rev 0 


1.0 INTRODUCTION . . ..... . ................................ .... ....... . ............ . ............. 1 

8 

r 

Thls Proposal, lnduding any drawings submilted or pertaining Ihoreb. is the property of AREVA NP Inc. I1 contains 

confldentlal information and Is loaned lo the Buyer on umdilion that the Buyer, or he Buyer's representative, by receiving 

this Proposal. agrees rot lo reproduce or copy in whole or in part or to fumish infmtlon from It lo others wllhoul 

permission, or lo make any use of the Proposal other lhan the evaluallon of AREVA NPs Proposal. The Buyer agrees to 

return thfs Proposal. If requested. 

Page i 

PEF-NCR-00968 

W.

AREVA NP Inc P ROPRl ETARY - PENG07-1370.0 Rev 0 

a 3 .O WORKSCO p E .. .. , , . , . . .. . . , ... . .. .. . 

a CONFIDENTIR!, 18 

0 -a t s - 

,........, ........, , .,. ,.., ...,.......................- 

- I 

e0 

W 

this Proposal, agrees not to reproduce or copy in whole or in part or to furnish iniomtion from It to o ~lm without 

permission, or to make any use of the Proposal other than the evaluaUon of AREVA NPs Proposal. The Buyer agrees to 

return this Proposal, if requested. 

Page ii 

PEF-NCR-00969

AREVA NP Inc PROPRIETARY PENG07-1370.0 Rev 0 

This Proposal, including any drawings submitted or pertalnlng thereto. Is the property of AREVA NP Inc. It mntains 

confidential information and is loaned to the Buyer on condition that the Buyer, or the Buyefs representative. by receiving 

lhis Proposal, agrees nol to reproduce or copy In whole or in part or to furnish Information from It to others without 

permission. or to make any use 01 the Proposal other than the evaluation of ARNA NP's Proposal. The Buyer agrees to 

return this Proposal. if requested. 

Page iii

ktum this Propsat, If requested. 

Page iv 

p~p-~CK0097 1

AREVA NP lnc 

PROPRlETARYfl’ p n m f RENG07-1370.0 Rev 0 

I . , uv 

I I I e a 

6.0 REQUIRED INPUTS ....................,...,....................... ........,............,.................... 

66 

This Proposal. induding any drawings submltted or pertaining thereto, is the property of ARWA NP Inc. It contains . 

confldential information and is loaned to the Buyer on condition that the Buyer. or the Buyefs representative. by receiving 

this Proposal, agrees not lo reproduce or copy in whde cr in part of fo furnish information from it to others without 

permission. or to make any use of the Proposal other than the evaluation of AREVA NPs Proposal. m e Buyer agrees to 


Page v 

pEF-NCK-00972

AREVA NP inc PROPRl ETARY PENG07-1370.0 Rev Q. 

7.0 SCHEDULE ........................................................................................................ 69 

8.0 QUALITY ASSURANCE ................................................................................... -70 

9,O AREVA NP TEAM PROPRIETARY INFORMATION ......................................... 71 

10.0 COMMERCIAL ITEMS ....................................................................................... 72 

~- 

This Proposal. induding any dramngs submitted or pertalnlng thereto. is the properly of ARNA NP Irk. It wntalns 

confidential information and Is loaned to the Buyer on condition that the Buyer, or the Buyer's representative, by receiving 

this Proposal, agrees not lo reprodue of copy in whole or in part or to fumish informabon from it to others wrthouf 

permission, or lo make any use of the Proposal other than the evaluation of AREVA NP's Proposal. The wer agrees to 

retum this Proposal. if requested. 

Page vi 

PEF-NCli-00973

AREVA NP Inc PROPRIETARY PENG07-1370.0 Rev 0 

11.0 REFERENCES ................................................................................................... 78 

12.0 CONTACTS ........................................................................................................ 80 

AlTACHMENT 1 . PROPOSED PROJECT SCHEDULE............... ............................. 1-1 

ATTACHMENT 2 OPTIONAL WORKSCOPE ............................................................. 2-1 

ATTACHMENT 3 EXCEPTIONS TO PROGRESS ENERGY FLORIDA REQUEST FOR 

PROPOSAL ..................................................................................................... -3-1 

ATTACHMENT 4 WORLEYPARSONS PROJECT STRUCTURE .............................. 4-1 

ATTACHMENT 5 PROGRESS ENERGY FLORIDA REQUIRED FORMS .................. 5-0 

AlTAC H M ENT 6 RESUMES.. .................................................................................... .6-0 

This Proposal, induding any drawlngs submitted or pertaining thereto, is the property of AREVA NP Inc. It canlains 

wdtdenlial information and Is loaned lo the Buyer on condition bat the Buyer, or the Buyer‘s represenlatlve, by receiving 

this Proposal, agrees not to reproduce or mpy in whole or In part or lo furnish informalion from it to others without 

permission. or to make any use of the Proposal other than the evaluation of AREVA NP’s Proposal. The Buyer agrees to 


Page vii 

I’EF-NCR-OO~~~

OPC 

1 st POD 

#1 

080009 

BATES NOS. PEF-NCR 

00975 THROUGH 

PEF-NCR-0 12 10 

REDACTED

SIEMENS 

INSTALLATION DIVISION OF RESPONSIBILITIES 

A d 16,2007 

. . __ -. -. . . . -. - 

Prcgress Energy Service Cmany, UC-Dyslal River Unit U 

Request No 5022007 

PEF-NCR-012.11

SIEMENS 

Modernnabon Pwnf 

Apnl 16 xx17 

Page 2 

Semens Confidenlial 

Pnqress Energy S-ce 

Inslallalm DOR - 2W7 2 

Company UC-Cryslal RIVW UndM 

Requesl NO SD22W7 

& CONFIDE!JTI! 1 

Use fhis document solely for rhe purpose given Refurn upon requesf. 

Do nor disclose reproduce or use ofhemrse wlfhoul the wrlnen consenf of Siemens Power Generation Inc 

1 , ~ ~ - ~ ~ 12 ~ - 0 1 2

SIEMENS 

Modernnabon Prop4 Page 3 Installahn DOR- 2037-2 

April 16, 2007 

Smmns Conlrdenliel 

Use this documenr solely for lhe purpose given. Rerurn upon requesr. 

00 nor discloss repmduce or use otherwise wirhom the wrlnen consenr ofSlemens Power Generalron Inc. 

progress Energy Servce Conpafly, UC-Cryslal Rwet Unll kj 

Request No SD2Mo7

I .- . -.. .,. Awl 16. 2007 Pqress Energy Swce Company. LLC-*tal RIVM Unit #3 

Request No So22007 

Use (his documenr solely for the purpose given Relurn upon requesr 

Do not disclose reproduce or use olherwlse wrrhoul [he Wrlnen consen1 of Siemens Power Generalion Inc 

PEL7-NCR-0 12 14

SIEMENS 

____ 

Mcdernaation Projcct Page 5 installatmn DOR- 2W72 

Apnl 16 2007 Semens Conbdentml 

Prosress Encrgy Servhe Company LLC-Crystal River Und #3 

Requesl No 5022007 

Use rhls documenr solely for rhe purpose given Rerurn upon request 

Da nor disclose reproduce or use orherwise wtrhout rhe wrinen consenr of Siemens Power Generaaon Inc

w 

a

SIEMENS 


... _. . . 

April 16. Mo7 

Rogress G%sgy Swm Cowany LLCCrystalffNW unflX3 

Use his Documen? SOMY For he Purpose Given Rerum Upon Requesr 

00 NOI olsclose Repmduce or Use Ohemlse WrthoUI The Wrinen Consent of Siemens Power Generation fnc 

Ifj CONFIDENTi?! p ~ _NCR-012’9 

k

SIEMENS 

Mcdwnaafion Roj& 

April 16, 2037 

' 

Page 2 Table dConfenls- 2W7-2 


Rcgress Gh?qy Swm Company, LLCCrysral RNM Und a3 

Use Tnrs Documenr Solely For me Purpose Gwen Rerum Upon Request 

Do Nor Discrose Ropmdxe Or Use Omewrse W!rhouI The Wnnen Consenr Of Siemens Pwer Generatlon hc. 

I'EF-NCR-O 1220

EXPERIENCE LIST 

SIEMENS

SIEMENS 

PAOE 2 


GeneratcxErpenencc Lis1 - 2007.2 

Frqress Energy Servm Company. LLC-Crystal RNW Und Lu 

REQUESTNO SD2Mo7 

USE MIS OOCUHEKTSOLELYFOR MEPURPOSE GIVEN. RETURN UPON REOUEST. 

DO NOTOISCLOSE REPROOUCEOR USE OTHERWSE WTHOUTTHE m(mENCONSEMOFSIEMENSf0WER 

GEMERATMMINC. 

PEF-NCR-0 1222

USE THIS WCUHEKTSOLELYFOR THE PURPOSE OffW. RENRN UWN REQUEST. 

DO NOTOISCLOSE REPROOUCE OR USE OTKERWSE WHOW THE #ROTEN CONSENTOF SIEMENS POWER GWERP. W N INC 

SIEMENS

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Apnll6, Mo7 

Seemens Conlidenliai 

Pngress Dlqy Serve Company. LLCGryslai RNW Und U.3 

REQUESTNO SD22W7 

USE THIS WCUMNTSOLELYFOR THEPURWSE GNW RENRN UWN REQUEST. 

DO WTDISCLOSEREPRODUCEOR USE OTNERWSE WHOLTTHE WRrTrEN CONSENTOFSIEMENSPOWER GENERAlWNINC 

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Rcgress Energy SWKS Company. LLC-Crystal RNW Und X3 


I’EF-NCR-O 1225

Modernnabon hied 

Apnll6, XO7 

PAGE6 

Semns Confidenhal 

Generator Expenenm Lid - 2007-2 

Rcgress Energy Servroe Company LLC-CWal RNW Und U3 

REWESTNO SD22W7 

USE THIS WCUMEmSOLELYFOR THEPURPOSE GNW RETURN UPONREQUEST. 

DO NOTDISCLOSE REPRODUCE OR USE OTHERWISE WHOLIT THE WRrrrEN CONSEKTOFSIEMENS PQWERGENER4TK)NINC. 

PEF-NCR-0 1226

SIEMENS 

t&XkrIIQabon Ro,d 

Apnl16, 2097 

PAQE 7 

Semens Confidentral 

Generelor Exparencs Lis1 - 2007.2 

Rcgress Energy Save Company. LLC-Cfystal RNW Und %j 

REQUESTNO 50223.77 

USE THIS WCUMENTSOl€LYFOR THEPURPOSEONE4 RENRN UPON REOUEST. 

w NOTDISCLOSE REPRODUCE OR USE OTHERWISE WITHOUT THE “ E N CONSENT OF SIEMENS POWER GENERPmN INC. 

~EF-NCR-O 1227

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Aprrl 16. 2037 

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propress Enwgy Seyoe Company LLC-Crystal RNW Unn #3 

REQUESTNO S ~ m 7 

USE THIS WCUMEMSOLELYFOR THEPURPOSE GNW RENRN UWNREQUESr 

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ProgreJs Enegy Servm Company, LLCCtysfal RNS Unit #3 

REQMSTNO SO22007 

USE THIS OOCUMEMSOLELYFOR THEPURPOSEGNW. RETLIRNUPONREOUEST. 

DO NOTDISCLOSE REPRODUCEOR USE OTHERWSE WllfOL'T WE r"ENC0NSEMOFSlEHENS POWER GENERATION/NC. 

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SIEMENS 

McdwnrzeOon Prolecl PAOE 10 Generalor Experrnce Lis1 - 2007-2 

Aprd 16. 2007 

Semens Conf!dential 

Rcgress Energy Serve Company, LLCCryslal RNW Unrl X3 


USE THIS OOCUKMSOLELYFOR THEPURPOSE GNEN RETURN UWN REQUEST. 

Do NOTDISCLOSE REPROOUCEOR USEOTNERWISE WTNOVTTHE WR~ENCON~EHTOFSI~ENSPOWER 

GENEMTION~NC. 

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MODERNIZED EXPERIENCE LIST 

HP Nuclear Turbines 

SIEMENS


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MODERMU~ONPRWCT 

APRll 16,2007 

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MODBRMWONPROJRCI 

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ALL MODS EXPERIENCE LIST 

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APRTL 16.2007

SIEMENS

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February 16,2007 

Attention: 



TURBME GENERATOR REPLACEMENT & RETROFIT 


Dear Bidder: 

You are invited to submit a proposal for Replacement of the Turbine Generator and the performance of related 

work (scc the Scope attached for additional details) for Progress Energy's Crystal kver Nuclear Power Station, 

Unit 3 site located at 15760 West Powerline Street in Crystal Rwer, Florida 34428. Two (2), signedcopies ofthe 

proposal (one priced and one unpriced) shall be sealed and marked "CONFIDENTIAL" and submitted to Tony 

Owen, Progress Energy Service Company, LLC, P. 0. Box 155 1 (PEB 2C1), Raleigh, NC 27602. Overnight 

delivery should be sent to 410 S. Wilmington Street (PEB 2C3), Raleigh, NC 27601. The proposal must be 

sealed and marked as noted above in a separate envelope inside the ovemight envelope. No copies of the proposal 

shall bc distributed to any other Progress Energy personnel by the bidder. Your proposal must bc rcccivcd no 

later than 12:OO noon, March 30, 2007. If your proposal is received after that day or time, it will not be 

considered for the described work. Telephoned or faxed proposals or proposal information is unacceptable and 

will not be considered No modifications to the bidder's proposal will be accepted after the bid due date and time 

specified above unless specifically requested by Progress Energy in writing. 

Biddcr is rcquested to complcte, sign, and return the General Information form attached in its entirety and to 

furnish all information requested by this form. Bids will not be considered when submitted on forms othcr than '. 

b .- 

those provided. I: .: 8 i . J 

It is intended that a Contract in the form of the attached specimen Contract will be awarded for this Work and 

quotations shall be made accordingly, unless the successful bidder has an existing Master Contract with Progress 

Energy, in which case a Work Authorization will be released against that Master Contract incorporating the 

details of this Inquiry. 

' 

r:-: 

Progress Energy docs not obligate itself to accept the lowest or any other bid and specifically reserves the right to 

reject any and all bids. Bidders are advised that all bids will be opened and cvaluated solely by Progress Energy. 

All information contained in the bids submitted to Progress Energy and Progress Energy's evaluation, including 

any biddcr's relative position to the successful bidder, is considered exclusive dormation of Progress Energy and 

will not be made available to any of the bidders. All unsuccessful bidders will be notified by Progress Energy in 


; v3 , 

C) 

'\ 

-_, , .J (3 

.J (L 

c > 

L L

All requests for clarifications, interpretations or decisions on discrepancies pertaining to the commercial aspect of 

the proposal documents or related project data furnished as part of the proposal documents shall be made duectly 

to Tony Owen, Tonv.owen@,pmail.com (919) 546-2933 by the bidder only. 

All requests for clarifications, interpretations or decisions on discrepancies pertaining to the technical aspect of 

the proposal documents or related project data furnished as part of the proposal documents shall be made duectly 

to Scott T. Deahna at the Crystal River Nuclear Plant (CNP) at (352) 563-2943, extcnsion4234, or email address 

Scott,deahna@” ail.com by the bidder only. 


information will be available only through the bidder and that no direct contacts with Progress Energy by subtier 

firms shall be initiated. Information exchange shall be between Progress Energy and bidder, and bidder and his 

potential subcontractors. No work shall be subcontracted without the approval of Progress Energy. Subcontract 

work and proposed subcontractors must be identified in bidder’s proposal. 

As a prerequisite for consideration of a bidder‘s proposal, bidder must contact the site of the proposed work, 

discuss job conditions with Progress Energy’s designated representative, become acquainted with the technical 


course of the work, and make his choice of methods and equipment accordingly. Contact appointments must be 

made with Scott Deahna at the Crystal River Nuclear Plant. No site visits will be allowed without prior 


Please acknowledge receipt of this proposal and your bidding intentions by completing the attached 

Acknowledgement and faxing to Tony Owen at (9 19) 546-6750 by two business days. 

PROGRESS ENERGY SERVICE COMPANY, LLC 

By: 

Tony Owen 

Supply Chain Management 





Sample Contract 



Safety Evaluation Form 

Attachments to Bid Specifications 

10.1 CR3 Turbine Generator Operating Data (Electronic Only) 

10.2 MUR Power Uprate PEPSE Analysis (Electronic Only) 

10.3 CR3 P&ID’s (Electronic Only) 

10.4 CR3 Turbine Generator Layout Drawings (Electronic Only) 

2


Mr. Tony Owen 


P. 0. Box 1551 (PEB 2C3) 


Fax: 919-546-6750 


CRYSTAL RIVER NUCLEAR PLANT, UNIT #3 


I acknowledge receipt of the subject proposal package and have indicated my bidding intentions as follows: 

I have reviewed the proposal documents and will not be submitting p bid for this work. Proposal 

documents are being returned under separate cover. 

X 

I have reviewed the proposal documents and intend to submit a bid for this work and will make 

arrangements to contact or visit the site as requested. 

(Nante) 

3 

PEF-NCR-0 1245

GENERAL IhTORMATION 


CRYSTAL RIVER NUCLEAR PLANT, UNIT #3 


Contractor visited the site [XI and/or contacted [ X ] the site on March 13,2007 and discussed job conditions 

with Scott Deahna to acquaint himself with the technical requirements of the work and all available information 

and local conditions which may impact pricing of the subject Inquiry No.SD22007. 

In the event that your Proposal is accepted and a Contract is awarded to the fm whose full legal company 

name appears herein below, Siemens Power Generation, Inc. Mr.. Craig Weeks, whose title is President 

Global Service Division , will be executing the Contract on behalf of the firm. Should this person's title not 

indicatc that he/she is a corporate officer (president, vice president, or corporate secretary), an affidavit 

signed by a corporate officer shall be provided along with the bid, stating that the person whose name appears 

above is duly authorized to execute contracts on behalf of the firm. 

Thc Contractor is: (select appropriate line and complctc information) 



A Partnership consisting of 

A Joint Venture comprised of 

Delaware 

Full Legal Company Name Siemens Power Generation, Inc. 

Business Address 4400 Alafava Trail 

Orlando, Florida 32826 



Contact Name 

Contact Phone 81 3-931-5004 


Company Websitc 

Dan Smith Key Account Manaeer 

dan.i.smith@siemens.com 

Siemens.com 

Fedcral Tax ID Number 13-3987280 

Contractor's License Number (if applicable) CGC059151 State of Issuance FL. 

4 

PEF-NCR-0 1246

111 accordaiice with the Federal Acquisition Rcgulatio~~ sectioli 52.219, please check all that apply to yoiir 

coinpauy. Please provide suppoitillg doculnenlatioll or certification to coilfiri~l the status for auy categories 

checked iiiider Siiiall/Diverse Vendors. 

[ I Certified small business* [ ] IiUBZone, 8(a) or disadvantaged business* 

[ ] Veteian-owned bw.iiiess* [ ] Minority-owned busiuess * * 

[ ] Service-disabled veteran-owiied busiiiess* [ ] Women-owned sinall busiiiess * * 

[XI Not a Siiiall Business 

* 

* * Ceitified by Piogress Energy and ns defiiied by SBA. 

As defiiied by the Sinall Business Atlmiiiistration (SBA): \!\:\\ 

,.hn.~.i)\ 

Register oiiline at ~ ~ ~ ! ! ~ ~ i ~ i ~ ~ ~ - ~ i i cr\ili ~ ~ ~ ~ , ~ ~ ~ t i i ' ~ i i ~ ~ ~ ~ l i ~ i ( l i \ 

By; 

. I 

,,/,;,'l'

SCOPE AND OTHER REOUIREMENTS 


CRYSTAL EWER NUCLEAR PLANT, UNIT #3 


SCOPE: (See Section 1 of the Sample Contract) 

The Crystal River Unit 3 Nuclear Power Station (CM), located near Crystal River, FL presently generates 903 

MWe at 100% reactor power (2568 MWt). 

CR3 is planning to implement an extended reactor power uprate of 17% during the fall 20 1 1 refueling outage. 

The CR3 steam generators will be replaced during the fall 2009 refueling outage. CR3 is also planning an 

“appendix K’ fcedwater flow measurement uncertainty recovery (MUR) uprate of approximately 1.6% reactor 

power during the fall 2007 refueling outagc. 

The intent of the CR3 extended power uprate (EPU) project is to retrofit the low pressure turbines, moisture 

separator reheaters, feedwater heat exchangers, generator and the exciter during the fall 2009 refueling outage. 

The high pressure turbine will be designed and retrofit during the fall 20 1 1 refueling outage to support the reactor 

thermal uprated conditions. 

SCHEDULE: 

The replacement of the turbine generator at the Crystal River Unit 3 site is scheduled for completion during the 

fall 2009 refueling outage. Implementation of an extended reactor power uprate of 17% is scheduled to bc 

completed during the fall 20 1 1 refueling outage. 

TERMS AND CONDITIONS 

Terms and Conditions will be in accordance with the Samplc Contract. 

EXECUTION OF PROPOSAL: 

The full corporate firm or individual name and exact address shall appear on your proposal form. The signature must 

be that of a corporatc oficer or authorized person followed by their title. The signature(s) of all authorized pcrsons 

signing the Proposal shall be in ink and in longhand. 

BIDDERS PROPOSAL: 

Bidder IS rcquircd to submit two (2) signed copies (one priced and one unpriced) and onc (1) clcctronic copy of thc 

entire proposal giving complete descriptive information covering Bidder’s solution, including engineering, 

construction, procurement, testing, and related work proposed to be hished which meets or exceeds all functional 

requirements of PE’s RFP. Also, acknowledge that PE shall have permission to make additional copies of Bidder’s 

proposal, attachments, and any other submitted materials. The proposal form and any other requested attachment that 

contains prices must be submitted in a sealed envelope separate from the other submittals requested herein. Bidder’s 

proposal as appropriate shall include the following: 

6

a. A cover letter with an inventory of the contents of the complete proposal. 

b. A clear dcscription of your company's solution proposed to meet all functional requirements of the 

Rcquirements Documents and the methods used to perform those functions. 

c. The Bidder shall complete the Table of Conformance for the Scope(s) of Work contained herein, and by 

rcsponding to each section, heading and subheading in the order they appear. The Bidder shall indicate for 

each whether your proposed solution will conform or deviate. The heading or subheading includes all 

paragraphs up to the next heading or subheading. Bidder may respond to individual paragraphs undcr such 

headings or subheading. Sections, headings, and subheadings are those numbered, in bold print andor 

underlined. In preparing the Table of Conformance, Bidder may use either Microsoft Word or Microsoft 

Excel; bidder is encouraged to utilize the redlining technique in Microsoft Word appropriate (Le., sample 

contract document). 

Further, the Bidder shall provide details of nonconformance, such as an exception, alternate or enhancement 

(see below) on the Tables of Conformance. If the Bidder fails to supply the Tablcs of Conformance, PE will 

assume the Bidder's proposed system is in conformance with the Scope@) of Work and all other documents 

furnished with this RFP, and if the Bidder is the successful Bidder, the Bidder shall be required to meet all 

requirements without exception. The only acceptable classifications in the Tables of Conformance (to be 

indicated by letter) are: 

C (Conform) - The Bidder meets the requirement in the manner indicated. 

X (Exception) - An approach which does not meet the requirements or a requirement the Bidder declines to 

meet. 

A [Alternate) - An approach which is substantially different from the suggested approach but which incets the 

stated requirements. 

E (Enhancement) - An element not required by the Requirements Documents but offered for consideration 

The technical response as expressed in the Tables of Conformance shall be such as to enable PE's personnel 

to make a thorough and complete evaluation and arrive at a sound determination as to whether or not the 

solution proposed and described will satisfi the rcquirements of PE. The proposal should be specific, 

detailed, and completc to clarify and hlly demonstrate that the Bidder has a thorough understanding of the 

requirements for and technical problems inherent in the performance for the described Work. It should also 

dcmonstratc that the Bidder has a valid and practical solution for such problcms. 

Statements that the Bidder understands the Scope(s) of Work or that Bidder can or will comply with all 

requirements and statements paraphrasing the requirements or parts thereof are considered insufficient. 

Phrases such as "Standard procedures will be employed," "Well-known techniques will be used," etc., will be 

considercd insufficient. The proposal must be sufficient to indicate how the Bidder proposes to comply 

with all requirements and procedures to be exercised. Clarity and completeness of the technical approach will 

be given much attention. Only written data submitted with the proposal and subsequent clarifications will be 

considered. Orally submitted data will be considered. 

All information pertinent to a particular requirement item of the Scope@) of Work must be given in each place 

in the proposal at the expense of some (but not excessive) redundancy if necessary. 

d. 

e. 

Answer all questions proposed by PE. The response to each question shall be cross-referend to LheBidder's 

proposal where applicable. 

Bidder shall acknowledge that discounts provided by hardware suppliers to Bidder, at the time of submitting 

Bidder's proposal, shall also apply to the actual hardware that will ultimately be furnished PE, regardless of 

1 

PEF-NCR-0 1249

sizc or quantity. Further, in the event any greater discounts are received by Bidder at the time of delivery, 

Bidder shall proportionally pass such discounts on to PE. 

c 

Provide a preliminary milestone schedule for accomplishing this work. 

SPECIAL REOUIREMENTS: 

Familiaritv with Laws: 

The bidder is assumed to be familiar with all federal, state, and local laws, ordinances, and regulations which may in 

any manncr affcct those engagcd or employcd in the work, the materials or equipment in the work or the conduct ofthc 

work. PE should be immediately contacted for clarification if a Bidder should discover provisions in any drawings, 

specifications or contractual documents contrary to or inconsistent with any such law, ordinance or regulation. 


All drawings, specifications, and contractual documents will remain the property of Progress Energy and are to be 

returned in good condition within ten (10) days after the date set for receiving bids. These documents shall not be 

reproduced or used for any purpose other than for the preparation of a proposal in accordance with this request. 

The information contained in these documents is proprietary and confidential and shall be maintained in strict 

confidence. 

Interorctation: 

I 

An interpretation request shall be made to Progrcss Energy if a bidder is in doubt as to the true meaning of any 

part of thc drawings, specifications, or contractual documents. Modification of the documents will bc made only 

by written addendum issued to each bidder as described below. 

Exccotions: 

If a bidder's proposal contains any deviations or exceptions, those dcviations or cxccptions must bc spccifically 

identified on a sinale separate attachment to the proposal in order to be considered in the evaluation. If not so 

identified, the deviations or exceptions will not be considered part of Lhe proposal. Conditional proposals based 

on bidder-generated clarifications may not be accepted If a bidder takes any exccptions in addition to thosc 

submitted in accordance with this section, that bidder's proposal may be rejected by Progress Energy. 

Sample contract documents are not included for bidders possessing a Master Contract with Progress Encrgy. All 

other biddcrs, if successful, will review and rcdline the enclosed SAMPLE contract format. Any exceptions to thc 

contract documents must accompany the proposal as detailed above and the exceptions will be considered in the 

bid evaluation process. 

Aoproved Equal Evaluation: 

Submittals by bidder for evaluation of products as "approved equal" shall be made to the appropriate designated 

individual listed in the Request for Proposal at least ten (10) days prior to the proposal due datc. Results of 

evaluations will be provided no later than seven (7) days prior to the proposal due date. Submittals made later 

than tcn (1 0) days prior to the proposal due date will not be considcred. 

Addenda: 

Progress Energy reservcs the right to amend or clarifL requirements herein by Addenda. These may be issued at 

any time prior to thc date for receipt of proposals and may be mailed or othenvise delivered to all bidders who 

8

have been invited to bid. Request by a bidder for extension of the proposal due date shall be received by Progress 

Energy at least one week prior to the then scheduled date. If revisions or clarifications are of magnitude to 

warrant, in the opinion of Progress Energy, the extension of the date set for receipt of proposals, an addendum 

will be issued announcing the new date. Failure of a bidder to acknowledge receipt of any addendum in the space 

provided on the proposal form may result in rejection of that proposal. 

Progress Energy is committed to using safety conscious contractors. To this end, Progress Energy collects safetyrelated 

data voluntarily provided by all persons performing or desiring to perform Progress Energy work. This 

data is compiled and made available to Progress Energy employees via Progress Energy's intranet. This intranet 

system is accessible by non-Progress Energy employees, and thus, so will be any safety-related information you 

provide. In providing the safety-related information requested herein, to Progress Energy or to any other person 

doing business, directly or indirectly, with Progress Energy, the undersigned contractor explicitly authorizes 

Progress Energy to disclose said information to non-Progress Energy persons and hereby releases Progress 

Energy and its agents and employees from any cause of action or claim for damages related to said disclosures. 

Progress Energy subscribes to the "BROWZ" system and will expect the successful bidder to track safety and 

insurancc certificates in the "BROWZ" system. 


This work is classified as NON-SAFETY RELATED. 

All site assigned personnel of the successful bidder who are to be grantcd unescorted access to the plant site are 

required to attend a prerequisite security/radiation training class prior to entering radiation controlled areas. 

When Contractor's employees must apply for unescorted access, the screening of Contractor employees will be 

pcrformcd by Owncr in accordance with the latest revision of the document titled "Nuclear Worker Screening 

Requirements for Unescorted Access," the current revision of which is attached to this Contract. The document 

contains instructions to the Contractor with respect to providing employees for screening by Owner. Owner will 

send Contractor revisions to the document, and Contractor shall acknowledge receipt of the revision in writing. In 

the event Contractor performs screening at Owner's request, Contractor grants to Owner the right to audit all 

documcntation resulting from Contractor's employee screening process on its own behalf or in conjunction with 

thc U.S. Nuclear Regulatory Commission. 

Bidder's attention is specifically directed to the stringent security, fitness-for-duty, health physics, ALARA, and 

quality check provisions which apply to this work. These criteria are defined in the attached specimen Contract. 

Award of Contract / Right to Reiect ProDosals: 

PE will award the contract to the Bidder submitting the best evaluated proposal which complies with the requirements 

herein. PE will utilize Bidder's Tables of Conformance, all requested attachments, references, and other information 

provided in its process of evaluating Bidder's proposal. PE may, in its sole discretion, reject any or all proposals 

received or waive minor defects, irregularities or informalities therein. 

a. Upon reaching the award decision, PE may elect to issue a Letter of Intent to the successful Bidder. Bidder 

shall include a statement within its proposal as to its commitment to start work immediately and continue 

performance of such work upon receipt of such letter. 

b. The successful Bidder may bc required to b ish corporate guaranties from each of its corporatc ownerships 

up to and including the parcnt corporation. Such documents will be due upon exccution of the contractual 

document. Bidder shall include a statement within its proposal acknowledging Bidder's understanding and 

9

Schedule Risk: 

agreement to h ish such corporate guaranties in the form fiunished with this RFP. 

Timely completion of the replacement turbine generator at the Crystal River Unit 3 Site by the fall 2009 

refueling outage and implementation of an extended reactor power uprate of 17% during the fall 20 1 1 

refueling outage is critical to the success of this project. Therefore, the selected bidder will be asked to place 

profit at risk to demonstrate understanding and ownership of the schedule. 

Irrevocable Standbv Letter of Credit: 

Bidder shall affirm on the proposal form its ability and willingness to finish, in PE's favor, an irrevocable standby 

Letter of Credit per the Contract. The Letter of Credit shall remain in full force and effect during the term of the 

contract and may be engaged by PE in the event of Bidder's default under any such contract. 

Insurance: 

Furnish proof of valid insurance per contractual requirements. 

Alternate Bid Formats: 

A bid based on the rcquircments noted herein is required; however, PE encourages Bidder to propose an alternative bid 

process, 

10

PROPOSAL INCLUSIONS: 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

Classifications of each type person you intend to bill for. 

Hourly billing rates for each personnel classification (may be straight timelovertime or all-hours rate) 

Billable travel and living expenses. 

Estimated man-hours for each personnel classification. 

Provide a maximum not-to-exceed contract dollar amount to accomplish the work. 

Resumes of people you intend to use on this project. 

Provide the earliest date that you could start work on this project. 


Rcdlined copy of Sample Contract. 

Completed Table of Conformance. 

Complete Contractor Safcty InformatiodChccklist Form. 

11 

PEF-NCR-01253

..ll-.l-l_l..--l.-l-- 

I - 


Contractor's Safety In~~Pmatiorl/ChecI~l~st Form 

PURPOSE: Please supply the following safety tnformation foi your company. Safety IS important to Progress Energy arid 

will be used as criteria in selecting contractois NOTE: 1NCOMPLE'PE FORMS CANNOT BE PROCESSED. 

IC%ON 1; TO BE COMPLETED 8Y THE CONTRACTOR 1 

. ........ 

.... _- 

-- __ .- 

S3!?!Y..jZ!'O9 ral* 

Please provide your cirrrent written safety inanual (diskette or CD-ROM, if possible) (Nota: 

Unless there are changes to the manual, resvbmission is not neccssary foi annual reviews). 

Does your company have a high level CorpOratQ officer responsible for safety compliance? 

Title. Director, Ettvivoiirnental Wealth aitd SaFety 

- 

-- 

- your company have a formal safety program to assure compliance yth.safety regiilatiorts? 

Does program ii'CWe: . 

e Job hazard ___--I__.__. analvsis and coiitrol . 

. 0 Medical management of work related injuries and illnesses 

* On-site supervision to ensirre con,pliance with safety regctlations and Progress Energy 

s?!etY..P.o!icles 

Pre-qualification and management of subcontractors to ensure conipliance with safety 

regulations -. and Progress Energy Safety policies 

Does your company hold periodic crewlteam safety meetings? - 

0 How Often? Site Safoty Meetings are helrf wookly. 

-- 

Does your company provide and docuineut requited initial and roftcshor training to prepare 

employees to perform duties if) compliance with safety regiilations? NOTE: If a contract is 

awarded, the DR will need this documentation prior to commonceinent of work for Progress 

Enerov. 

CDmpliance History 

Has a serioiis. willful or repeat OSHA citation been issued to your company within the last thiee 

yeais? (Please check the OSHA web site at http://www osha.aov/pls/iiiiis/establishnient, htnil ) 

If yes, please provide a copy of the citation and 8 certification of abatement. 

l.l.lllllll.ll 

Has your company andlor aiiy of its officers beei 

any vlolation of any federal or 

state occupational health and safety laws? 

ff yes, please attach a description of this case, including its resolution. 

Line & Service Contractors: Is your Federal Motor Carrier Safety Rating Satisfadory? (Can be 

louncl at h t t j , ~ ~ . ~ ~ ) If ~ not, ~ ~ state ~ ~ what ~ : the ~ rating is (Unsatisfactory or 

Conditloital). 

- __I__ 

__ 

Kwurds: =lev, fiediUi ad *!Y 

wdaw daurnenl, SAI'W8S OW341 

FKM-%US 00478 

Apph to: Pragrea Energy Carolinas, I N , Pmgresr Energy Fiorlda, inc ; Piwresr Cwigy Mice Company, 11c: Rev 5 74% 

Page 1 of 3 

Au-rHoruzm COPY 

PEF-NCR-0 1254

I number of cases involving Days.:& 

Rates are calculaled as follows. 01 Rate= #&SHA Recordabte cnwries X 200.000 DART Rate- eases involsincr OART X 200.000 

# employee hours #employee hours 

Please have an authorized ropresentative of the company who is responsible for your company's safety program sign on 

the line below certifying that the information provided above is cuirent and accurate. Providing false information may result 

in termination of the contract. 

I SECTION 2:,l&B~kOMPLETEB 

6Y . THE PROdRESS ENERGY DR 0R"cONTRACT SERVICES 

..3 

....__I 

rrint Name, Location and Phone of Dosignatetl Rep: -.....- 

....- 

rsECTroN 3: TO BE COMPLETED iY mi! HEALTH AND smry SUPPORT ... . . 

Key"&: wfcky; kalth and &eky gu'hoce dccultr?nt, %k-SUBs.WWP 

FRt.I-ULBS-F04/8 

Applies ta: Progrcss I new mol nas, fw.: Pmgress Energy FiorMa, Inc.; Prop25 Energy SetvkeCMnpaly, LLC Rev 5 YB 

bQC 2 Of 3 

AUTHORIZED COPY 

PEF-NCR-0 1255

OPC 

ST 

1 POD 

#1 

080009 


01256 THROUGH 

PEF-NCR-01283 

NON-RESPONSIVE

Hello Bob and Greg; 

I have scheduled the Crystal River Site Admin Building Conf Rm. 1 for our next meeting the 

afternoon of Monday July 3 1, 2006. Mr. Dan Roderic (Director - CR3 Nuclear Plant Operations) 

will be available from 1PM to 3PM. We have the room all afternoon. 

The previous site visitor access forms were only good for 2 weeks. Please have everyone who 

plans to attend sign the attached form and retum scanned copy or fax to me at (352) 563-4450 

Background: 

The Crystal River 3 Nuclear Power Station (CR3) is considering a 17% reactor thermal (20% 

electrical) power uprate in 201 1. The unit steam generators will be replaced during an 85 day 

outage during 2009. The CR3 electric generator is H2 inner cooled (60 psig), 989 MVA, 0.9 PF. 

CR3 presently generates 900 MW at 100% reactor power. The generator rotor weight is 365,000 

Lbs. 

Issue 1, Electric Generator 

0 Is it possible to uprate a 989 MVA H2 inner cooled generator to 11 OOMVA by increasing 

the H2 pressure, etc? What are the uprate limitations for H2 inner cooled machines? 

What are the largest Alstom H2 inner cooled generators? 

0 Discuss level of generator disassembly required for Alstom to obtain field measurements 

to bid a generator retrofit design. 

Issue 2, Plant Integrated Solution 

Turbine retrofit solutions integration and SIGMA Energy Solutions proposal PEC-06-00 1, dated 

April 28, 2006. 

0 Discuss SIGMA Energy Solutions capability and experience. 

0 Discuss Alstom “retrofit solutions integration” information presented at Chicago 

conference. 

0 Discuss Alstom “one stop shop” capabilities. 

0 Discuss Chicago conference paper - case study “Oskarshamn 3”. What Alstom group 

performed this plant integration study? How are they associated with SIGMA? 

Issue 3, High Pressure Turbine 

If the HP turbine is retrofit in 2009, it will operate significantly throttled until 201 1. The 

increased throttling losses may be greater than the technology efficiency gains. It may be cost 

effective to retrofit the HP turbine in 201 1. 

0 Discuss above. 

0 Discuss nuclear HP turbine retrofit design technology and estimated performance 

improvement. 

0 Discuss HP turbine retrofit schedule duration requirements. 

0 Discuss level of HP turbine disassembly required for Alstom to obtain field 

measurements to bid a HP turbine retrofit design. 

Issue 4, Low Pressure Turbines 

0 Discuss nuclear LP turbine retrofit design technology and estimated performance 

improvement above existing ABB DS 492 design. 

PEF-NCR-0 1284

Spec 

Page 

Crystal River Unit 3 

Nuclear Power Station 

Replacement Turbine Generator 

# Section Reference Table of Conformance - Technical Comments 

of 1.6% reactor power is planned during the fall 2007 refueling outage. 

Retrofit the low pressure turbines, moisture separator reheaters. generator and 

exciter during the fall 2009 refueling . outage - which will begin in September and will 

have a duration of approximately 80 days. 

Design and retrofit the high pressure turbine during the fall 2011 refueling outage to 

support the reactor thermal uprated conditions. 

An extended reactor power uprate an additional 15.4% reactor power during the fall 

2011 refueling outage. 

Total extended power uprae from present will be 17%. 

Design life - 40 years. 

Provide a proposal for replacement of high pressure and low pressure turbines. 

Objective: To obtain a replacement steam path that produces maximum power from 

the steam supplied by steam generators after implementation of a 17 percent power 

I 

P5 

I 

P6 

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Section Reference 

I 

P7 

1.2.1 

1.2.2 

I 

I 




Table of Conformance - Technical 

Submit various generator stator uprate options including: 

- Rewinding with hydrogen inner cooled winding, 

- Rewinding with water cooled winding, or 

- A complete midsection replacement 

The generator rotor forging is expected to be reused and rewound in the shop 

An exnted rotor spin balance is required 

The exciter and voltage regulator shall be evaluated for modification or 

I I 

replacement to support the generator uprated capability. 

Provide details of all field measurements required. 

Identify required field measurements as required to support final design or final 

machining. 

Provide schedule for performing required field measures. 

Identify long lead time materials. 

I OBJECTIVES 

I 

Generator Capability: 

Provide a state-of-the-art turbine generator design that will maximize the electrical 

(MW,) output and reliability. 

Contribute to a maximum overall availability and efficiency for the NSSS-turbine- 

I generator combination. 

1.2.3 1 I Provide ease of maintenance and increase outage inspection intenrals to a 

1.2.4 

1.2.5 

1.2.6 

1.2.7 

minimum of 10 years over a 40 year design life. 

Provide minimum IS1 intervals of 10 years. 

Eliminate Stress Corrosion Cracking (SCC) as a maintenance issue, including all 

areas subject to SCC such as rotor bore, disklwheel bore, blade root radii, blade 

attachment, etc. 

Eliminate or severly reduce wear due to moisture erosion. 

Provide a rated generator MVA capability that will have a minimum performance 

capability of 1080 MW, real power output while concurrently providing 430 MVAR 

1.2.8 I 1 Refurbish or replace the generator exciter and automatic voltage regulator to 

I I I I reliably support the uprated generator capability. 

1.2.9 1 I Provide moisture separator reheaters that maximize the performance of the uprated 

I I I I I steam cycle. 

I PROPOSAL PRICING 

131 

Purchaser has milestone to purchase rotor forgings and other long lead time 

materials during 2007 to support 2009 installation schedule 

Evaluate and present Bid Proposal Pricing in the following formats: 

Bid the followina Wok ScoDe seoaratelv: 

Comments 

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SedionReference / 6 / / < / (II / Table of Conformance - Technical 


1 High pressure turbine retrofit. 

I I Low pressure turbine retrofit. 

I I Generator stator and rotor rewind. 

for nuclear power plant workers. 

1.3.2 

I I 

i 

I .4 

QA CONDITION 

NON-SAFETY RELATED. 

i 

(1.5.3 I 

i 

- i 

- Generator stator hydrogen (H2) inner cooled winding, and 

water (H20) cooled winding options should be provided 

Generator stator midsection replacement (optional scope). 

Exciter I voltage regulator modification I replacement. 

MSR vessel replacement. 

Turnkey Installation and commissioning service for proposed solution. 

- Installation shall be performed in accordance with NRC 72 hour work week rule 

Combine the total Work Scope (proposed solution) in one bid. 

The Replacement Turbine Steam Paths to be provided are classified as 

Evaluation of any design basis requirements of rotating machineiy will be required 

I I HP Turbine Model: Please refer to page 6 of the Specifications. 

11.5.4 I I I HP Turbine Steam Chests: Please refer to page 6 of the Specifications. 

11.5.5 I I I LP Turbine Model: Please refer to page 6 of the Specifications. 

I 

Comments 

46 

411012008 P = Paragraph No

spec 

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# 

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3 

- 






Moisture Separator Reheaters (MSRs) 

Generator Rewind 

Feedwater Heaters 

Installation of Phase 2 is scheduled for the R17 refueling outage beginning in 

October 2011. 

Phase 2 will include installation of: 

A new HPT 

Remaining balance of plant modifications (main feedwater condensate and 

booster pumps, turbine bypass valves, etc.) 

Phase I 

Phase 2 

Extended Power 

Parameter 

Present Value MUR Uprate Uprate (EPU) 

OTSG Thermal Power 2584 Mwth 2625 MVdth 3030 MWm 

OTSG lntlet Pressure 989.0 psia 1015 7 psia 1015psia 

OTSG Inlet Temperature 457.7 "F 458 41 "F 

460 "F 

OTSG Inlet Enthalpy 

439.2 btu/lbm 440 0 btuAbm 441.7 btunbm 

OTSG Outlet Pressure 923.4 psia 923 4 psia 964 psia 

OTSG Outlet Temperature 591.00 "F 594 5 "F 

582 "F 

OTSG Outlet EnthalDv 1250.4 btullbm 12500 btullbm 1237.4 btdlbm 

Main Feed Pump Discharge 1010 psia 1044 1 psia 1083 psia 

Pressure 

Final Feedwater Flow 

Turbine Throttle Pressure 

Turbine Throttle Flow 

Turbine Control Valve 

Positions 

GV-1 

GV-2 

GV-3 

GV4 

10.854 Mlblhr 

902.72 psia 

10.365 Mlblhr 

45% (6.5") 

100% (14") 

100% (14" 

15% (2.25") 

11.012 Mlblhr 

902.04 psia 

10.530 Mlb/hr 

TED 

Comments 

, 

13.00 Mlblhr 

I 

930 psia 

TED

Spec 

Page 

I 





n Section Reference Comments 

Turbine Backpressure Design Point - Design Point - Design Point - 

2.0 in hg abs. 2.7 in hg abs. 

2.7 in hg abs. 

(seasonal range (seasonal range 

(Ref. HES condenser analysis 

,5- 3.5) 

(seasonal range 

1.5 

report) 

- 3.5) 

2.0 - 4.0) 

If there are issues or questions regarding the above, please note an exception (X) 

and provide an explanation on the attached sheet. 

Refer to Attachment 10.1 for CR3 Turbine Generator Plant Operating Data from 

01 131 12007 

Refer to Attachment 10.2 for CR-3 MUR Power Uprate PEPSE Analysis. The CR3 

PEPS1 model can be electronically transmitted upon request. 

CR3 Condenser Performance Analysis: 

The EPU turbine back pressure design point should correspond with 75F circulating 

water inlet temperature. 75F circulating water inlet temperature is the CR3 seasonal 

average temperature. Refer to Section 1.6, page 9 of Specifications. 

SCOPE OF SUPPLY 

The scope of supply shall include, as determined by the Seller, the following: 

TURBINE 

For the replacement of the high pressure and low pressure turbine steam path and 

associated equipment, the following shall be furnished: 

TheDesign 

Engineering 

Equipment 

Fabrication and Assembly 

Specify all necessary material and any other components requiring replacement for 

compatibility with the replacement steam path. 

4/10/2008 

Evaluate the feasibility of reusing existing: 

Equipment 

Controls 

Turbine supenrisoly instrumentation bearings 

Hoodsprays 

Provide written evaluations for reused components justifying the reuse of these 

components, OR 

Provide new replacement components that are compatible with the new design. 

HP Turbine and Steam Chests: 

Assumptions: Turbine valves, steam chests and HP turbine outer cylinder will be 

reused. 


PEI.'-NCR-O 1289 

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# Section Reference 

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Comments 

I 

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PEF-NCR-01290 

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Comments 

Doc #250846 

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PEF-NCR-01291

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Comments 

I I I I I I Four complete replacement moisture separator reheater vessels with two stages of 

PI 

P2 

P3 

P4 

P5 

P6 

P7 

1 

I 

reheat and four pass tube bundles shall be included in the Seller‘s scope of supply. 

MSR moisture separation and tube bundles should be designed to optimize the 

turbine steam cycle to achieve the best performance within the existing shell 

envelope. 

Existing nozzle configuration and piping should be reused to the extent possible. 

The MSR shall be designed in accordance with Electric Power Research Institute 

(EPRI) NP-3692 “Procurement and Operation Considerations for Moisture 

Separator Reheaters.“ 

439 SS tube material shall be specified. 

MSR instrumentation package shall be included. 

INSTRUMENTATION AND CONTROLS 

The turbine AEH control system is expected to be reused. Refer to Section 1.7.5 of 

the Bid Specification for more information. 

The turbine supervisory instrument system is a Bently Nevada 3300 system and is 

expected to be reused. Refer to the Bid Specification for more information. 

Pickup mounting details will be provided by the Owner to support retrofit design. 

Refer to the Bid Specification, page 12 for more information. 

Generator rotor flux probes will be reused or replaced. Refer to page 12 of the Bid 

Specification for more information. 

Recommend new generator monitoring systems (rotor flux monitor, stator end turn 

vibration monitor, stator partial discharge monitor, etc.) as appropriate. 

Fumish all electrical components and associated auxiliary equipment required to 

support: 

0 the turbine replacement 

0 the MSR replacement, and 

0 generator modifications. 

Fumish a MSR instrumentation package, and 

Fumish a generator instrumentation package. 

Evaluate existing electrical and control systems and interfaces to verify existing 

capabilities and compatibility, specifically: 

0 Turbine speed control system (AEH Electro-Hydraulic Control System). 

0 Auxiliary instrumentation and controls. 

Design equipment to ensure that all of the interfacing systems, structures, and 

components shall be reused, if possible, and shall operate with minimal 

modification of the systems. 

Doc a50846 

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# Section Reference Table of Conformance - Technical 

Spec 

Page 

Comments 

I 

Furnish all electrical components and associated auxiliary equipment required to 

supporl the following if the existing electrical and instrumentatiodcontrol systems 

are not usable: 

the turbine replacement 

the MSR replacement, and 

generator modifications. 

GeneratodRotor monitoring instruments may require replacement or rescaling. 

Provide evaluation for Buyer approval. 

Furnish all instrumentation including instrument pipingltubing, root valves, 

thermowells. and accessories required for: 

the turbine generator and 

the MSR replacement and/or modification. 

Recommend any instrumentation upgrades considered appropriate. 

If Seller chooses to supply alternate control systems, the alternate systems shall be 

modern digital systems that fully meet U.S. nuclear industry requirements for: 

scope of supply. 

redundancy, and 

EPRl recommendations 

Completely describe any such offering. 

All instrumentation provided shall be wired to terminal blocks in dust-tight and dripproof 

terminal boxes (NEMA 4) accessible from outside the turbine-generator 

hniininn 

Provide all wiring, raceway, terminal blocks, and junction boxes for these items. 

All electrical conduit furnished shall be rigid galvanized steel conduit supplied in 

ANSI standard sizes in nominal English units (inch sizes) at all BuyerlSeller terminal 

points. 

I Rigid galvanized steel conduit furnished in accordance with IEC standards is I 

acceptable for conduit within Seller's terminal points. 

Provide each instrument connection to the main process lines with an isolation 

(root) valve. 

Provide Instrument venVdrain connections with an isolation valve. A valve or drain 

plug is not acceptable. 

All instrumentation tubing and accessories supplied shall be stainless steel. 

All thermocouples furnished shall be iron-constantan. 

All RTD's furnished shall be 100 ohm platinum. 

Any transmitters to be provided shall use a 4-20 ma signal range. 

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I I c 1 2 I e I Crystal River Unit 3 

I I I I modification of the systems, strhures. and components. 

I I I I I I Hood sprays. 

I I 1 I Main shaft and bearings. 




I I I I 

Wiring shall be connected to 600 volt barrier type molded terminal blocks for 

extension during installalion at the plant site where termination of Buyer's wiring is 

required 

Seller-to-Seller terminations shall be Seller's standard. 

Buyer's connections made on terminal blocks and on internal devices shall be by 

means of flanged spade or ring type insulation-gripping insulated terminals. 

Dedicated termination points shall be provided for connection of all cable shield 

drain wires. 

All thermocouple wiring shall be terminated on appropriate thermocouple type 

terminal blocks. 

lntemal wiring shall have no splices in any circumstance, nor shall more than two 

wires be terminated on one terminal ooint 

All terminal blocks shall be properly marked and identified for all internal and 

external wiring. 

I I I I 

All cables shall be fire retardant. 

Contacts for switches to be connected to Buyets equipment (i.e., plant annunciator, 

plant computer system, plant supplied control room indicators, etc.) shall be double 

pole-double throw or equal, and rated for 125 VDC, 0.3 amperes inductive load 

minimum. 

EVALUATION OF EXISTING COMPONENTS 

Evaluate existing mechanical and electrical systems and interfaces to verify existing 

caoabilities and ComDatibilitv. 

Design the equipment to ensure that all of the interfacing systems, structures, and 

components shall be reused, if possible, and shall operate with minimal 

Turbine foundation. 

Phvsical interface with steam chest and aovemor valves 

Steam systems - location, size and compatibility. 

HPT cross under piping to MSR. 

MSR cross over piping to LPT. 

Extraction steam nozzle sizes and locations. 

Gland seal steam. 

Gland steam exhaust. 

4 - Support systems 

Turbine lube oil system. 

EHC - electro-hydraulic control system. 

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Comments 

Furnish and deliver all spare parts required during construction. 

Shipment to the job site shall be the responsibility of the Seller. 

SCOPE OF SUPPLY BY OTHERS 

Access to Systems Design Information: Identification of the required information is 

the Sellets responsibility. 

Purchaser shall receive or duplicate necessary documents such as drawings, 

procedures, specifications, etc. 

Modifications to existing mechanical systems, components, including piping and 

hangers as required for the new installation. 

Modifications to existing turbine control systems, instrumentation and electrical 

systems as required for compatibility with replacement equipment. Owner shall 

describe any such modifications as described in Section 1.7.5. 

Modifications to existing generator interface systems and equipment such as 

generator cooling water supplies, generator busses, generator breakers, main 

transformers and protective relaying as required for compatibility with replacement 

equipment. 

Any existing parts that require replacement as a result of disassembly of the 

existing components for final installation will be supplied by the Owner. 

Disposal of removed components that shall not be reused. 

Operation personnel to perform shutdown, startup, draining, filling, isolation. and 

other normal system operating functions. 

Safety clearance and tagging of all equipment. 

Removal, inspection, and installation of instrumentation. 

Electric power, lighting, water, compressed air, and overhead crane facilities. 

Removal and installation of insulation. 

All electrical disconnects and terminations required to perform work. 

Construction and removal of scaffolding. 

Radiation protection technicians if required. 

Unescorted access training for Contractor's personnel. 

Preparation of post installation test procedures. 

Supply of test instrumentation. 

Performance of post installation tests and preparation of associated test reports. 

SCOPE OF SERVICES 

Design, fabrication, shipping, inspection and factory testing of equipment, including 

implementation of Quality Control procedures to ensure completed equipment 

satisfied the specification and design requirements. 

Factory assembly of stationary components to validate dimensional and 

configuration interface with retained systems, structures and components. 

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Engineering and design for any required modification of interfacing or retained 

systems, structures and components. 

Start-up testing and tuning of excitation system. 

Drawings and manuals. 

Calculation of heat balances and revision of the Thermal Kit. 

Quality Assurance and Quality Control documentation. 

Shipping and handling. 

Review of post installation test procedures. 

Field support for post-installation tests and review of associated test reports. 

SCHEDULE 

Provide expected equipment delivery schedules (lead times) and anticipated 

installation schedule durations. 

REQUIRED BID DOCUMENTATION 

Submit a complete proposal fully describing all of the proposed equipment and all 

services to be furnished. 

All documents shall be in English and in U.S. measurement units. 

To include the following: 

Technical product description including but not limited to rotor design, rotor design 

life, steam path design, susceptibility to street corrosion cracking, erosion-corrosion 

resistance, materials of construction, inter-stage sealing, codes and standards. 

Requirements for Seller inspection of existing equipment including owner support 

required. 

Provide separate Heat Balance Diagrams for the Phase 1 installation and the 

Phase 2 installation. 

Include a new guarantee diagram with the new MSRs, HP and LP turbine 

components. 

Performance guarantee estimate. 

Generator capability cuwe. 

Generator cooling requirements. 

Generator excitation requirements 

Furnish a list of all equipment and materials including special tools and spare parts 

required for construction. 

Outline drawings of the turbine-generator unit giving approximate weights, principal 

dimensions, and showing main piping connections. 

Equipment warrantee information. 

A project level milestone schedule including forging milestones and long lead time 

material requirements. 

Proposed installation schedule that starts with the time when the turbine is taken off 

turning gear and ends with the time that it goes back on turning gear @e.. days to 

install the equipment). 

Comments 

PEF-NCR-01297


1.11.11 

1.11.12 

1.11.13 

1 .I 1 .I4 

1.11.15 

1.11.16 

I 





Additional optional scope of supply as defined by Contractor. 

Identification and interfaces with remaining components. 

The evaluation of retained interface components. 

Specify any modifications required to existing equipment including but not limited to 

exhaust hoodsldiffusers. packing casings, vacuum alarm, bearings, turbine lube oil 

system, and turbine supervisory instrumentation to allow installation of new 

equipment. 

Recommended inspection interval for each major part (Rotor and Cylinder) 

including scope of inspection. 

Provide details of the new component construction. The contractor shall describe 

the materials proposed to be used for the major parts of the equipment, such as 

rotors, blades (all stationary and rotating rows), and casings, to be supplied using 

either an ASTM designation or the closes ASTM designation. 

Comments 

#NAME? 

1.11.17 

Factory and field balancing of rotors and vibration standards used. 

1.11.18 Steam chemistrylpurity requirements. 

1.11.19 

Organizational structure of labor for turnkey installation including crafl labor, 

supervision, technical direction and project management. 

1 .I 1 -20 

Provide recommended test methodologies including acceptance testing based on 

the alternative test as defined in the latest edition of ASME Performance Test Code 

PTC-6. 

1.1 1.21 

Absolute backpressure limitations including alarm values. 

1.11.22 

Performance effect of annual variation in condenser absolute backpressure. 

LSB exhaust loss curve and total exhaust loss curve. 

1 .I 1.23 

Summary of retrofit experience with similar equipment and technology.. 

Identify "first of a kind scope. 

1 .I 1.24 

Seller's service facilities that are applicable to the equipment covered in these 

specifications and their locations. 

1.11.25 

Recommended test procedurehning procedure for exciter. 

Recommended test procedureltuning procedure for voltage regulator. 

1.12 REQUIRED DOCUMENTATION AFTER AWARD 

Refer to Section 1 .I2 of the Specifications, Items No. 1 through 40, for a complete 

I I I I I 1 I I listina ofreauired documentation after award. 

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I I I I Purchaser - Owner Reoresentative I I I I Buyer - Owner Representative I 

P = Paragraph No 

I'EF-NCR-01298 

14

#I I Section Reference / 6 


Seller - Firm proposing to supply the subject equipment 

Contract - Equipment and Service Supply Contract 

OSTG - Once Through Steam Generator 

W O - ValvesWideOpen 

STG - Steam Turbine Generator 

TBD - To Be Determined 

Comments 

PI 

P2 

P3 

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Comments 

LP turbine shall be designed with a normal operating backpressure of at least 

Guarantee the turbine-generator gross electrical output (Mw,) uplift after 

installation of the turbine and MSR steam paths at 2625 MWt backpressure, and 

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Comments 

I 

- Turbine Stage Moisture Removal Effectiveness 

- LP Turbine Exhaust Loss Curve 

- Generator Loss 

Phase 2 Installation: HPT. Balance of Plant Modifications Guarantee 

Guarantee the turbine-generator gross electrical output (MW,) uplift after 

installation of the HPT steam paths at 3030 MWt backpressure, and makeup in 

a r c " with the rantract ouarantee heat balance 

This performance improvement results directly and exclusively from the scope of 

supply defined in this specification. 

Provide a revised thermal kit for the revised turbine designs that includes the 

following but not limited to: 

- Heat Balance Diagrams with the new HPT and balance of plant components at 

WO, 100% MWth (guarantee point), 75%, 50% and 25%. The baseline and 

guarantee HBDs will provide the basis for the thermal performance warranty. 

- Net Heat Rate 

- Turbine Expansion Line for each Heat Balance 

- HP Turbine expansion line end points 

- First Stage Pressure vs. Flow 

- Extraction Stage Pressure vs. Flow 

- Gland Leakages and Mechanical Losses 

- Heat Rate and Load Correction Curves for 

o Exhaust Pressure, 

o Throttle Pressure, 

o Throttle Temperature, 

o ReheaterllD 

- Turbine Stage Moisture Removal Effectiveness 

Turbine Performance 

The Sellets heat balance shall be based on the operating parameters specified 

on the Buyers heat balance for nominal full load conditions. 

Specific requirements for the design include: 

- HP turbine throttle pressure and temperature, 

- HP turbine throttle enthalpy, 

- HP turbine throttle flow, and 

- Final feedwater temperature 

Values for feedwaler heater performance at uprated conditions as well as 

extraction line pressure losses can be obtained from the Buyers heat balance. 

Values for MSR performance shall be provided based on the proposed new 

desian 

PEF-NCR-01301 

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The turbine shall be designed with a mass flow margin of 2% above the steam 

flow required to achieve the guaranteed output at the throttle pressure specified in 

the Buyer's heat balance diagram for nominal 100% load to account for 

I I I manufacturer's tolerances. 

1 The design shall allow for an additional 1% flow margin for a total of 3% flow 

margin. 

The turbine shall be capable of stable operation at 100% of rated steam flows 

and rated conditions with one or more low pressure turbines operating at choked 

I 1 flow conditions. 

I I The turbine govemor valves shall be capable of controlling stable main steam 

I headeroressure 

Generator Performance Requirements: 

The generator shall be designed to produce a minimum of 1080 MW real power 

concurrent with 430 MVAR overexcited reactive power at 100% reactor thermal 

output power. 

The generator shall be suitable for operation at rated MVA, power factor, and 

frequency at t5% of rated voltage in accordance with the standards of performance 

established for operation at normal rating. 

Permissible variation at the generator terminal voltage shall be in accordance 

I I I with lEEEC50.13 

1 I The maximum temperature rise for any generator component shall be in 

I accordance with IEEE C50.13 for Classk. 

1 The total temperatures as determined by any of the methods given in ANSlllEEE 

i 

I I I applicable standards shall not exceed 1 IO" C for the stator coils and for the field 

when operating at full loads, and over the full range of power factors. 

The generator open circuit terminal voltage wave deviation factor shall not exceed 

10% as defined by ANSlllEEE standard. 

Stalting from stabilized temperature at rated conditions, the generator field windings 

shall be capable of operating at 130% of rated armature current for one minute in 

accordance with IEEE C50.13 standard requirements. 

Starting from stabilized temperature and rated conditions, the generator field 

windings shall be capable of operating at 125% of rated load field voltage for one 

minute in accordance with IEEE C50.13 standard requirements. 

The stator windings shall satisfactorily withstand normal maintenance high potential 

tests without damage. 

The generator shall be capable of continuous operation at any load up to its rated 

maximum out put and shall withstand all expected operating transients resulting 

I from rapid load changes and transmission line fault conditions. 

Comments 

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Comments 

In accordance with IEEE C50 13, the generator shall be capable of wthstanding 

(without mechanical damage) any type of short circuit at its terminals for limes not 

exceeding the short time thermal capabilities, when operating at rated voltage and 

power factor as well as 5% over voltage, provided the maximum phase current is 

limited by external means to a value which does not exceed the maximum phase 

current obtained from the three phase fault 

a Generator Operating Frequency Requirements, 

Must be able to withstand frequency excursions between 59 5 Hz and 60 5 Hz 

indefinitely 

- Must be able to withstand frequency excursions between 58 5 Hz and 59 5 Hz 

for 60 seconds 

- Must be able to withstand frequency excursion between 60 5 Hz and 61 8 Hz 


Must be able lo withstand frequency excursions between 58 0 Hz and 58 5 Hz 


Must be able lo wlthstand frequency excursions between 57 5 Hz and 58 0 Hz 

fnr 1 wrnnd 

I 1 Generator Operating Voltage Requirements: 

a Must be able to withstand terminal voltages within +/- 5% of rated nominal 

I 

voltage indefinitely. 

I a Must be able to withstand terminal voltage deviations between 5% and 10% (+/-) 

I for 10 seconds. 

I I Generator Operating Overexcitation Requiements: 

I 

I 

I a Must be able to withstand Volts per hertz conditions less than 116% (of 

generator nominal voltage and frequency) for 1.5 seconds. 

a Generator overexcited stator currents less than 150% of nameplate rating for at 

least 5 seconds. 

MSR Performance Reauirements: 

I Four complete replacement moisture separator reheater vessels with two stages of 

I 

I 

reheat and four pass tube bundles. 

MSR moisture separation and tube bundles should be designed to optimize the 

turbine steam cycle to achiecve the best performance within the existing envelope. 

Existing vessel supports, nozzle configuration and piping should be reused to the 

extent possible. 

Turbine Design Requirements: 

Identify evely interface between the new steam flow path and the existing 

equipment where mating to existing parts is a consideration. 

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Section Reference Table of Conformance - Technical Comments 

27 

27 

27 

P2 

P3 

P4 

P5 

Identify components that cannot be utilized with the replacement design and which 

therefore must be replaced 

Consider options and other components recommended for replacement based on 

optimization of performance, component life, reduced maintenance and other 

operational measures as defined elsewhere in this Specification, as well as cost 

considerations. 

Design all equipment for a minimum of 40 years of service with a IO-year minimum 

inspection interval. 

Consider inspection ports for bore scope inspection technique. 

Cite experience and analytic bases that demonstrate satisfactory performance and 

long-term reliability for 40 plus years of troublefree service. 

Erosion resistant materials shall be used in all areas susceptible to erosion, 

including turbine blading and nozzles. 

Moisture removal provisions andlor protective shields shall also be utilized where 

appropriate. 

Any blade coatings utilized in the wet steam of the LP turbine shall have 

demonstrated proven experience under conditions similar to those encountered in 

1 I the CR3 turbine. I 

I I I Provisions shall be incoroorated into the turbine desiqn to minimize erosion of the I 

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I 1 I I I I 

Provide a missile analysis report. Turbine missiles shall be considered in the design 

I I 

of the turbine and turbine control system to limit the overall probability that a turbine 

I missile event will occur and cause unacceptable damage. 

P7 I I I Provide adequate damping in the overall turbine generator design to minimize 

peaking at critical speeds. 

Provide the following information to the Buyer to address site specific 

characteristics: 

Minimum separation of the lateral natural frequencies (critical speeds) of the 

complete turbine-generator assembly from operating and test speeds (above and 

below). 

Separation between torsional natural frequencies of the complete turbinegenerator 

shaft and anticipated exciting line frequencies under normal operating 

conditions or under upsets (e.g., loss of load or loss of generation on the system). 

Verify by testing blade frequencies of tuned modes in accordance with Seller's 

standard practice. Calculation of blade frequencies should include: 

The effect of centrifugal forces, 

Metal temperatures,

Spec 

Page 






I 1 I 

I 1 I e Root fixity factors, and 

e Blade grouping devices (i.e., covers. lashing lugs, etc.) 

Provide Campbell diagrams for each stage. 

Rotor couplings shall be integral with the shaft and shall be compatible with existing 

components. 

The couplings shall withstand shocks during operation, including generator short 

circuit and synchronizing out of phase without exceeding the minimum yield stress 

of the coupling or bolting. 

The rotor design shall minimize stress concentrations. 

Describe the method of rotor fabrication including: 

e Whether a center bore is included, and 

e The reasons for including or not including the center bore. 

Comments 

I 

I 

I 

Turbine rotor and blade materials and fabrication techniques shall have proven high 

resistance to Stress Corrosion Cracking (SCC). Consider: 

Effects of material strength, 

e Heat treatment, 

e Temper embrittlement of low alloy steels, and 

Sensitization of stainless steels. 

At time of manufacture, rotors shall be dynamically balanced at rotational speeds 

from 0 to 120 percent of rated speed on the manufacturer's test stand. 

Shaft vibration during final field operational runs shall not exceed IS0 Standard 

7919 Part 2 limits and IS0 Standard 10816 Part 2 for non-rotating parts. 

Provide to Owner the total loading imposed on the foundations by the components 

supplied. 

Design replacement rotors to maximize practical compatibility with existing journal 

and thrust bearings. 

New bearings, if required, should be designed with adequate lubrication from the 

existing turbine lubricating oil system. 

If the existing lubricating oil system is inadequate, propose modifications to the 

existing system. 

The design shall maintain the current frequency of 

e Overspeed Protection system testing, 

e The quarterly Main Turbine Valve testing, and 

e The Main Turbine Valve disassemblylinspection frequency. 

Provide all connections required to perform an ASME Performance Test Code 

(PTC) 6, alternative test, on all Sellel's furnished equipment and piping. Seller is 

not responsible for PTC 6 connections in the Owner's supplied piping. 

Generator Design Requirements: 

Generator design is an alternate synchronous speed rated according with the 

I I requirements of this specification and driven by the turbine described herein. 


PEF-NCR-01305 

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I 

The upgraded generator shall be of nonsalient pole design. with the existing 

cylindncal rotor and revolving field 

Identify every interface between the new rewind generator and the existing 

systemlequipment 

ComDonents that cannot be utilized with the new design and which must be 

replaced are to be identified for Buyer approval. 

A design evaluation of the existing generator design is required to determine if the 

proposed . . generator uprate can be accomplished with the existing hydrogen inner 

cooled coiling system or optional stator water cooled system will be required. 

Identify all interface between the new generator winding and rotor upgrade and the 

existing equipment such as hydrogen cooling system, exciter, voltage regulator 

where these subsystems can be utilized. 

Options shall consider components recommended for replacement based on 

optimization of performances, component life cycle status, reduced maintenance, 

ai well as cost effectiveness. 

The stator and rotor insulation shall be of Class F per IEEE C50.13 with Class B 

temperature rise in accordance with this Specification. 

Evaluation shall be required to determine if the following replacement or 

refurbishment are warranted: 

Generator retaining ring, 

Generator main leads and high voltage bushings, 

Hydrogen coolers with its control and supply system (required design pressure) 

Rotor collector rings, 

Rotor field windings, 

Current transformers, 

Rotating exciter and exciter field control (including cooling system), 

Rotor coils end turns, 

Rotor retaining leads, 

Generator surge protection and RF monitoring. 

All temperature sensors shall be wired to the existing terminal blocks according to 

the existing layout, with similar number of sensors. 

Any recommendation for upgrading temperature sensors designllayout requires 

Buyer approval. 

Generator rewinding evaluation shall include an analysis of the existing grounding 

system. 

If the existing design and grounding condition can not be utilized, a new grounding 

system shall be recommended for Buyer approval. 

If new generator retaining rings are recommended, the non-magnetic material shall 

be 18Mn-18Cr type material. 

Comments 

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An optional stator cooling system shall be considered if additional generator output 

power could be gained and analysis could show improvements in the generator 

performance. 

In the Bid Proposal, cite experience and analytic bases that demonstrate 

I satisfactory performance and long-term reliability for 40 plus years of trouble-free 

I 

I 

services for the generatorlsubsystems. 

Any components that do not meet the 40 years expected design life shall be 

explicitly detailed in the bid proposal. 

On site torsional vibration testing for the new upgraded turbine generator should be 

included if analysis deems necessary. 

MSR Design Requirements: 

Comments 

The MSRs shall be designed, fabricated, inspected and tested in accordance with 

HE1 Standards for Power Plant Heat Exchangers and ASME Section Vlll Division 1. 

MSRs and drain tanks shall be certified to ASME Section Vlll and shall be Code 

I symbol stamped. 

The MSR shall be designed in accordance with Electric Power Research Institute 

I (EPRI) . . NP-3692 “Procurement and Operation Considerations for Moisture 

Separator Reheaters.“ 

Moisture separator reheater tube material shall be type 439 stainless steel. 

Tube-to-tubesheet joint shall be rolled and welded. 

Specify MSR overpressure protection requirements in accordance with the 

requirements of ASME Section VIII. 

I Relief valves shall be specified for overpressure protection on the Selleh piping or 

equipment in accordance with ASME Code requirements. 

I 

I 

Minimum plate thickness for baffles and support plates shall be in accordance with 

HE1 Standards for Power Plant Heat Exchangers. 

Describe the minimum plate thickness for baffles and support plates in the Proposal 

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MATERIALS, 

Specify materials selected for manufacture of the Equipment. 

Justify these materials for their respective applications as part of the Bid Proposal. 

Utilize materials that are resistant to stress corrosion cracking and erosion for use 

in the manufacture of the equipment. 

Provide the proposed materials list, which shall designate: 

The equipment material selection @e., ASTM designation, any supplements or 

equivalents), 

Chemical comDosition. and 


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5.2 

Phvsical nrnnertics 

Materials and equipment as determined by the Seller and subject to the approval of 

Buyer. 

Materials used in the manufacture of the stationary parts, and the rotor and blades 

shall be consistent with current technology so as to provide the maximum amount of 

service under the specified service conditions. 

The use of asbestos materials or materials containing asbestos shall not be 

permitted. 

All nonmetallic materials in Supplier furnished piping systems shall be noted to the 

Engineer for review and comment. 

Steam path components shall not be made of copper or copper based alloys such 

as bronze or brass. 

Steam path components shall not contain lead. 

Identify, as a part of this Bid, any parts with cobalt. 

Turbine steam path structural materials shall have satisfactory proven experience 

with the main steam chemistry requirements specified herein. 

MOISTURE EROSION PROTECTION 

Moisture erosion protection is required in all areas subject to erosion. 

The location and type of moisture erosion protection shall be identified and 

described. 

Where cladding is used, the type and extent of such cladding and its purpose shall 

be described. 

Where shot peening is used, the extent of such shot peening and its purpose shall 

be described. 

Where hard surfacing, such as flame hardening, induction hardening or material 

inserts are used, the extent of such hard surfacing and its purpose shall be 

described. 

This moisture Drotection could include but not be limited to: 

- 1 

1 

5.3 

The leading edge of the high moisture stages free standing rotating blade rows 

The water removal provisions at every steam extraction lmtm 

The horizontal and vertical joints and sealing surfaces of every stationary part 

where steam leakage can occur. 

Other areas subject to moisture erosion such as casing surfaces, extraction 

nozzle connections and rotor sealing surfaces. 

PIPING 

All piping fumished shall be provided in ASME standard sizes in nominal English 

units finch sizes) at all BuverlSeller terminal Doints 

All weld end preparations. socket weld couplings, threaded connections 

(mechanical and electrical), flange sizes and ratings. at Buyer/Supplier terminal 

points shall comply with ASME standards in English units. 

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Comments 

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Selleh field erected piping shall be designed, fabricated, tested and inspected to 

ASME 831.1. 

Materials shall resist erosionlcorrosion. 

A minimum corrosion allowance of 1/116 shall be provided for all carbon steel 

GENERAL 

All of the castings and forgings used in the construction of this unit shall be of high 

quality and have the necessaty casting processing, radiographic testing, magnetic 

particle inspections, and sonic testing performed that are outlined in the currently 

applicable ASTM specifications. or their equivalent. 

All DiDina furnished bv the Seller shall be tested in accordance with ASME 831 .l. 

Safety relief valves shall be tested in accordance with ASME Code Section VIII. 

All heat exchangers, tanks and pressure vessels, except the turbine casings. main 

steam piping and valves, reheat piping and valves, and the generator coolers, shall 

be hydrostatically tested in accordance with ASME Section VIII, shall be Code 

stamped and registered with the National Board. 

ASME Code Data Forms shall be submitted. 

Shafl vibration during the final field operational runs shall not exceed IS0 Standard 

7919 Part 2 limits and IS0 Standard 10816 Part 2 for non-rotating parts. 

Certified material test reports (CMTR) shall be provided in accordance with the 

referenced codes and standards: 

for large cast steel components; 

for shafts for eauiment over 100 HP: 

for heat exchanger heads, shell, tubesheets and tubes; 

for tank shells: 

for steam piping, valves and piping components; 

and for stainless steel piping, valves and components. 

As a minimum for hardware, all materials, components, and welds shall be 100% 

visually inspected. 

The inspections shall be documented, performed by qualified inspectors, and 

oerformed before oaintina of the item 

Acceptance shall be based upon the workmanship and inspection requirements in 

the codes and standards, such as ASTM, to which the item is made. 

The contract price shall include all tests and inspections normally conducted by 

manufacturers, subcontractors, and material suppliers and all other tests and 

inspections which may be so specified herein. 

Weld testing procedures shall be defined in the Quality Procedures and shall satisfy 

applicable &des and standards. 


PEF-NCR-0 1309 25

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Comments 

33 

i.1.10 

I I I to, the following: 

I 

I 

The weld testing program shall be administered by a welding inspector certified in 

compliance with the American Welding Society (AWS) or Engineer approved equal. 

Conduct shop tests of the work as required to comply with applicable codes, to 

determine acceptability of workmanship and as specified including, but not limited 

I 

a Pressure testing or NDE of piping systems, pressure vessels and related 

34 

34 

34 

6.2 

i.2.1 

i.2.2. 

j.2.3 

SHOP AND FIELD TESTS 

Major rotating parts shall have chemical and physical analysis. 

Charpy impact tests and fracture appearance transition temperature (FATT) tests 

are required for turbine wheels and rotor materials. 

Mechanical inspection for rotor shaft and body including: 

a Material, chemical and physical properties tests, 

I I I I I 1 UTtests. 

a Magnetic particle and UT of bore (if applicable), 

a Surface finish tests of slots 

The rotor and buckets shall be magnafluxed in accordance with Supplier's 

Doc #250&16 

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j.2.4 I 1 The high pressure turbine casing shall be either hydrostatically tested or equivalent 

$2.5 

P1 

I P2 

I 

I 

I I I I I acceptance tests. 

I PTC-6. 

I I I I I I 

I 

non-destructive examination (NDE). 

Turbine Performance Acceptance Test 

Turbine acceptance tests will be performed in accordance with the requirements of 

the latest edition of ASME Performance Test Code PTC-6 alternative test to 

determine the performance of the replacement turbine generator. 

Tests will be performed for Phase 1 and Phase 2 of the extended power uprate 

project. 

The performance test will be prepared and conducted by the Buyer. 

The Seller shall provide technical direction. assistance and witnessing of the 

The Buyer and Seller will jointly determine the technical aspects of the acceptance 

I tests with mutually agreed test methodology, procedures, and plans. 

The Seller shall submit with the bid documentation, acceptable test methodologies 

for Owner review including a recommendation based on the alternative test. 

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Comments 

34 - 

34 - 

34 - 

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35 

I I I I I I I I not be limited to, installation drawings, installation instructions, welding information, I I 

I 

bill of materials, etc. 

18.2 I I I Provide instructions for balancing the equipment following the installation. 

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Seller shall identify all lubricants and chemicals required for installation. 

1 

Comments 

alloys shall not contribute to corrosion during packaging, shipping or storage. 

Objectionable chemicals within the expendable materials are lead, merculy. 

chloride, fluoride, sulfur, copper and zinc. 

Submit a MSDS for each preservative chemical or material used to the Purchaser. 

The center of gravity and/or lifting points for large and heavy equipment shall be 

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PEF-NCK-013 16 

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ALST6)M 

I Power Systems 

May 30,2007 

- I 

c3 

I ' 1 , 

N 


P.O. Box 1551 (PEB 2C3) 


ATTN: 

RE: 

Mr. Tony Owen 

Crystal River Nuclear Plant Unit #3 - Request No. SD22007 

Amendments to Alstom Proposal No. 844T0467 

Dear Mr. Owen: 

PROPRlnARY AND CONFIDENTIAL 

Alstom Power Inc. Copyright 2007 

Alstom Power Inc. 

2800 Waterford Lake Drive 

Midlothian, VA 23112 

(804) 763-7000 

PEF-NCR-0 13 I 7

c 

PROPRIETARY AND CONFIDENTIAL 





(804) 763-7000 

PEF-NCR-0 13 18




P ROPRl ETARY AND CONFl D ENTIA1 


f? CONFIDENJIP,! 

(804) 763-7000

PROPRIETARY AND CONFIDENTIAL 





(804) 763-7000

” 

. . 

v 

111 Crystal River Nuclear Plant, Unit 3 111 

Turbine Generator Replacement and Retrofit 

Project 

Request No. SD22007 

ALSTOM Power Ref: 844’110467 

PROPRIETARY STATEMENT 

This proposal and any drawings, data, photographic material or descriptive matter set out herein are the 

proprietary, confidential and copyright property of ALSTOM and must not be disclosed, loaned, copied or used 

for manufacturing, tendering or for any other purpose without their written permission. 0 2007 

ALSTOiM 

PEF-NCR-0132 

1

Commercial Volume( Unpriced) 

PEP-NCR-0 I322 

Document last updated 16-04-2007 1 1 :35 EDT

c 

Commercial Volume (U n pr iced) 

2Scope ot Supply 

0 

3 Commercial Commentary 7 

4 Validity 12 

5 Terms of Payment 

6 Price Schedule 

7 Retrofit Experience 

13 

15 

17 

0 CONFIDENTIA! 

PEF-NCR-0 1323

OPC 

1 st POD 

#1 

oaooo9 


0 1324 THROUGH 


REDACTED

Alstom Proposal # SD22007, CR3 EPU Turbine Generator Retrofit Meeting Notes, 05/15/07: Pg. 1 of 7 

Outape Schedule: 2009 outage schedule is 75 days for Hp and LP turbine replacement, generator mid-section replacement and MSR replacement. 

Schedule driver is shop rewind of generator rotor (60 days, 45 days in shop). 

ODtional Scope: Generator Stator f eld rewind-with H20 cooled winding. Stator core iron is not replaced. 

Cost: total estimated cost reduced t&%KTEDT Generator Rating: stator rating reduced to 1162.5 MVA. 

Schedule: 2009 outage schedule will not decrease due to off site rotor rewind. 

Meeting Summary Hivhlights: 

e AIstom proposal amendment letter requested by June 1,2007. 

0 Generator rotor replacement is required to improve the 75 day schedule and to increase MVA rating to 1200MVA. Generator rotor 

replacement will be 2011. Requested Alstom to price new rotor vs. rewind rotor. 

e Requested Alstom to consider 2007 open and close of HP tclrbine and generator to be R&D cost by them. 

e Requested Alstom to quote 57”LSB LP turbine option. 

e Support systems for water cooled stator skid and static excitation system are additional cost. Alstom requested to provide support system 

requirements. 

e Control Room impacts for water cooled stator skid and static excitation system (voltage regulator) are additional cost. Alstom requested to 

provide control room impact details. 

e Include laser alignment of entire train, including generator alignment and generator frame foot loading @g. 110). 

e Include Re-striping all bearing pedestal oil seals. 

0 Include HP and LP turbine bearing be rebabbitted in base scope due to new rotor journals. 

e Include machining of all HP Turbine cylinder interface locations as f ~d$ t:,install t *’ new .,-. parts. 

t ,,; i‘p-i 

e Need to provide Installation “Division of Responsibilities”.

Alstom Proposal # SD22007, CR3 EPU Turbine Generator Retrofit MeetinP Notes, 05/15/07: Pg. 2 of 7 

General Notes: 

0 HP Turbine and Generator must be opened in 2007 for field measurements. Is open and close cost included? 

- Re: Requested Alstom to consider this R&D-cost to them. 

0 Evaluate performance of larger 16.8M2 (57”LSB) LP Turbine. 

.Re: - Alstom presented performance curve for 47” and 57” LSB. 57” performs be 

Average benefit of 57” LSB is approximately 3MW/year. Cost is 

Canyon and performance was much better than expected. 

CONFIDENTIP.!. 

In. Hg. Both perform the same above 2.7 In. Hg. 

Note: the 57”LSB was installed at Diablo 

0 Heat balance indicates low feed water temperature between 2009 and 2011 (pg. 201,207,208). What is plant impact? 

- Re: Ted say’s reactor is not affected. Lower feedwater temperature is in Alstom heat balance and would not be corrected for in a plant performance 

test. Areva would have to evaluate / model the Alstom heat balance for EPU. 

0 PE must verify generator frame 75 psi H2 pressure rating for generator stator rewind. 

- Re: This is responsibility of PE. Will need Siemens support to document. 

0 Support systems for water cooled stator skid and static excitation system are additional cost. 

- Re: Alstom requested to provide requirements. See engineering issues. 

Evaluate control room impact for new systems. 

- Re: Alstom requested to provide requirements. Pump controls and annunciator inputs. 

Scope of Supply Comments: 

HP Turbine: 7 stage, full impulse design 

0 New nozzle plates are fitted into existing nozzle box. Existing nozzle plates may need destructive removal. Is machining or repairs to the 

existing nozzle box included? 

- Re: Contingency repairs will be extra scope. 

0 New inner and outer glands are provided. New gland seals machined for rotor clearance. Are both inner and outer glands type 405 ss (pg. 

19)? 

- Re: Alstom stated the HP turbine outer glands are poJ included. Proposal was in error. Inner glands are stainless steel.



0 Governor pedestal stub shaft will be reused. Eccentricity run out will be corrected. Will a spacer be provided to correct axial position if 

needed? 

- Re: Yes, if needed based on field measurement. 

LP Turbine: 10 stage, reaction design 

0 Inner cylinder is reused. Blade carriers are replaced. Discuss interface between new blade carriers and existing inner cylinder (pg. 37). 

- Re: Spring back seals. Pg. 50 

0 Blade carriers are ductile cast iron with 12% CR ring inlays. How is the ring inlays installed in the blade carriers (pg. 5 l)? 

Re: keeper bolt at horizontal joint. 

0 L-0 blades have snubbers. Why not free standing? 

Re: Improves vibration response characteristics. 

Generator Mid-Section: 1173 MVA, Capability Curve pg. 77 

0 Verify main leads between stator and bushings are replaced. Not shown on pg. 75. 

Re: Yes. Drawing in error. 

Discuss phase dropper and bushing connection installation (pg. 98 / 99). 

Re: Interface between H20 cooled portion and H2 cooled portion of main lead. 

Stator Water Skid: 

0 What are the plant requirements to support installation? 

Re: Alstom to provide support system requirements. Cooling water 154 M3h (2500 KW), Demineralized water supply, Power supplies, 

Instrument and controls cabling, control room impacts include pump controls and annunciators. The support systems are not Alstom scope. 

Generator Stator Rewind: 1162 MVA, Capability Curve pg. 121 

Scope includes core iron loop test (pg. 117). What are the power supply requirements? Core loop test is not identified in testing section 

2.4.3.29 (pg. 143). 

- Re: Core loop test is in scope. PE provides power 4160V, 1 phase, ???? Amps. 

Alstom has core iron repair capability by insulation material injection up to 5 inches deep. Siemens el cid test data glitches are near surface issues. 

PEF-NCR-0 1345



Generator Rotor Rewind: 

0 Any repairs to rotor winding are included (pg. 156) 

Re: Yes 

0 Siemens technical advisory TA 2005-001 , Modification of rotor baffle assembly, must be included. May need to get parts from Siemens. 

- Re: Included. Alstom has parts. 

0 A bearing charge will not apply for shop balancing (pg. 154) 

Re: Agreed. 

0 Asbestos abatement in the shop will not be extra cost @g. 156) 

- Re: Agreed. 

Static Excitation System: 

0 Generator bus supply through transformer rated at 7,500 amps @ 500volts. 

Re: Yes 

0 Installation of new transformer (44,200 lbs), electrical cabinets and all electrical connections are included. 

Re: Yes. Transformer foundation (if needed) is not included. 

0 What is the auxiliary power supply requirement for field flashing and is installation included? 

480V, 3 phase, approx. amps (standard bus bkr) for field flashing. 2 x 480V, 3 phase for cabinet air conditioners, 2 x 125VDC control power. 

0 P400AVR digital voltage regulator. What is the control room impact of this system? Are control room modifications included? 

- Re: Control Room impact needs to be provided and is not included in scope. 

0 Pg. 171 states the collector is rated for 3,500 amps. Explain this rating compared to the generator excitation requirements. 

Re: Typo error. Should be 7,500 amps. 

0 Pg. 172 and 177 states new collector assembly housing or modification of existing exciter housing. Is either of these options included? 

- Re: New housing is included in scope of supply. 

0 Pg. 178 and 179 indicate the collector assembly is cooled by ambient air and the ambient air limit is 45C (113F). Are air coolers an option? 

- Re: Possibly. Recommendation not made. 

Can the existing exciter air coolers be reused with the new collector assembly fan? 

Re: Alstom can evaluate. 

include the following scope of supplv at no additional cost: 

0 Include laser alignment of entire train, generator alignment and generator frame foot loading (pg. 1 IO). 

0 Include Re-striping all bearing pedestal oil seals.

Alstom Proposal # SD22007, CR3 EPU Turbine Generator Retrofit MeetinP Notes, 05/15/07: Pg. 5 of 7 

Engineering: Comments: 

0 Provide estimated megawatt output vs. condenser pressure curve for the 57” LSB (16.8M2) LP turbine. Include on curve provided for the 

47” LSB (12.9M2) LPturbine provided in proposal (pg. 209). 

- Re: See pg. 2. Paul will email curve. 

0 47” LSB LP turbine appears to choke at 2.2 In Hg. 47” LSB appears marginal for 1100 MWe output with 4 exhaust flows. 

&Correct. 

0 Has a 57”LSB LP turbine been retrofitted into a Westinghouse turbine frame? References are on pg. 43. 

- Re: Diablo Canyon. Actual performance was much greater than predicted. Guaranteed 35 MW. Obtained 46 at unit 1 and 50 at unit 2. 

0 Why was a full impulse HP turbine design selected? Is design constrained due to reuse of existing inlet nozzle box? 

- Re: Standard design in Europe. 

0 Should HP and LP turbine bearing be rebabbitted due to new rotor journals? 

Re: Request to include in proposal. 

0 Why is bearing 5 loaded greater than bearing 4 following retrofit (pg. 196)? 

Re: Unknown at meeting. 

0 Pg. 538 discusses bearing pedestal modification for reinforcing brackets. What is expected? Are modifications required? 

Re: Bearing strongback to withstand L-0 blade failure by using stronger bolts and heavier strongback if needed. 

Generator rotor rewind will reuse the existing rotor copper winding with new insulation. What is the rewound rotor current capacity rating? 

- Re: 7,720 Amps @ 75 psi H2 gas pressure. 

Generator mid-section replacement is rated at 1173 MVA. What is the rating limiting component? What is the excitation current required? 

Re: Rotor is limiting above 1173 MVA. Excitation requirement is 6,770 amps @ max PF. 

Generator stator rewind is rated at 1162.5 MVA. Excitation current required is 6,845A (pg. 120). What is the rating limiting component? Pg. 

119 states field measurement confirmation is required. What is the risk? The capability curve is shown on pg. 121. Why isn’t the maximum 

power output at unity power factor on the curve? 

Re: Stator core is limiting for 1162.5 MVA stator rewind. 

The generator stator rewind reuses the existing core iron as is. What engineering evaluations were performed to qualify reuse of the existing 

core iron? 

- Re: Engineering models were evaluated. 

Is a generator startup ventilation test requires for either generator options? 

Re: A ventilation test is not required based on experience. 

What are the customer installation requirements for the stator cooling water skid and the static excitation system? Pg. 73 states the water 

skid and water tank control system is not included? What does this mean? 

Re: The proposal statement in not applicable. 

0 What load rating will the lifting beam have? 

- Re: Design rating should be for generator rotor 360,000 lbs. Lifting slings are included. 

PEF-NCR-0 1347

Alstom Proposal # SD22007, CR3 EPU Turbine Generator Retrofit Meeting; Notes, 05/15/07: Pg. 6 of 7 

Installation Comments: 

0 Installation schedule is estimated at 75 days (pg. 548). Generator scope is for mid-section replacement. Schedule driver is rotor rewind in 

shop (60 days, 45 days in shop). Any potential schedule improvement for rotor rewind? 

- Re: 45 days in shop for generator rotor rewind is best effort. Schedule improvement can only be gained by procuring a new rotor. A new rotor can 

not be fabricated in time for the 2009 outage. Generator rotor replacement would be 2011. The stator field rewind schedule is 35-42 days. 

0 Is machining of all HP Turbine cylinder interface locations included (pg. S)? 

- Re: Need to include in scope. 

HP turbine exhaust bowl erosion repair is contingency extra cost item. 

- Re: Contingency repair item. 

0 Complete rotor train laser alignment is included. 

Re: Need to include. 

Destructive removal of bolts is extra work (pg. 544). 

Re: Alstom agreed to eliminate this as extra work item. 

0 New MSR insulation is included (pg. 539). 

- Re: Yes. 

Generator manways and cleaning of stator winding oil will not be ;tra vork (pg. 544). 

- Re: Alstom agreed to eliminate this as extra work item. 

0 Heavy hauling is included (pg. 545). 

- Re: Yes. 

0 Pg. 545, discuss items relating to H2 coolers and turbine end bearing bracket. 

- Re: Alstom agreed to eliminate this as extra work item. 

0 Pg. 546, review personnel numbers identified on table. 

- Re: Asked Alstom to evaluate and explain the personnel numbers on the table. 

Discuss support resources required to be provided by PE. 

Re: Alstom stated their installation cost estimate included all support resources. Need to provide “Division of Responsibilities”. 

PEF-NCR-0 1348


Commercial Comments: 

0 Master Service agreement # 139805 open issue discussion. 

- Re: Alstom needs to provide name of person in Alstom who is responsible to negotiate contract. 

0 MSR material cost is REDACTED J This appears excessive. Explain basis of cost. 

- Re: Alstom agrees it is high but can not cut the cost in half. Alstom can work with other MSR vendors. 

0 HP / LP Turbine material cost is aREDACTEDkThis appears high for LP turbine “blade carrier” solution and reuse of HP turbine nozzle box. 

Explain basis of cost. 

- Re: material cost / Euro / shop utilization. Larger LP turbine with inner cylinder was stated to be approximateljq 

DACTEDbore. 

0 Would Alstom accept total project management responsibility if PE assigned required support labor to Alstom? 

- Re: alstom stated the estimated installation included all support resources. 

0 Proposal states installation is T&M billing. PE prefers fixed cost for total project scope. 

- Re: Can be fixed cost after a defined scope of work is established. PE can provide support resources. 

Propress Energv Ouestions: 

0 EH tubing will be impacted by MSR replacement. 

0 Engineering Change and Work Order Package development. 

0 Radiological support and material decontamination contingency. 

0 O&M replacement of extraction pipe expansion joints? 

0 Any other turbine plant major equipment replacements must be integrated into turbine generator schedule for crane usage and logistics 

coordination.

August 6”, 2007 

JCO7-017 

Project Energy Service Company, LLC 

410 South Wilmington Street (PEB 2C1) 

Raleigh, NC 2760 1 

Attention: 

Reference: 

Tony Owen 

Manager, NGG Major Projects 

Engineering Services Proposal for Secondary Systems Upgrade 

Request for Proposal No. KS 12007 

Enercon Proposal Number: PECR-A07-3007 

Thank you for the opportunity to provide you and Progress Energy with this proposal. We understand the 

importance of this project and have assembled a focused, cost effective approach to support its 

requirements. 

We have attached one (1) priced version and one (1) un-priced version in hardcopy attached to this letter 

along with a CDROM disk which contains electronic copies of both. As called for in your Request for 

Proposal (“RFP”), this disk also contains an electronic copy of the “Table of Conformance”. ENERCON 

holds a current General Services Agreement with Progress Energy, thus additional contract negotiations 

are unnecessary. All work will be performed using these existing terms and conditions. 

The proposal contains all requisite information and is conformance with your RFP. 

Cover Letter with Inventory of Proposal 

0 Executive Summary 

Conformance Acknowledgements 

Separate Proposal for each Major Scoped Task 

o Introduction 

o Scope of Work Description 

o Deliverables 

o Schedule 

o Capabilities and Experience 

o Quality Assurance 

o Commercial and Resource Proposal 

o Assumptions 

Combined Scopes of Work Proposal 

Organizational Support Structure 

0 Appendices 

o Key Personnel Resumes 

o Consolidated Project Schedules 

o Technical Conformance Checklist 

o Organization Charts 

o Completed Safety Information Checklist 

500 Town Park Lane, Suite 275, Kennesaw, GA 30144 (770) 919-1930

I ' 

Our proposal offers a strong team of professionals to support this effort, most with recent Crystal River 

experience. ENERCON is uniquely qualified with an excellent understanding of both the technical and 

operational impacts of Extended Power Uprate as it affects CR3 and able to provide unmatched service 

and quality through the breadth and depth of our organization as needed. 

ENERCON and Progress Energy both enjoy a strong working relationship built on mutual benefit and 

trust. We are confident that our proposal extends that same result and offers the best value and quality. 

If you should have any questions or require any additional information, please do not hesitate to contact 

me at (678) 354-8343 orjcurreriidenercon.com. 

Best Regards, 

(Signuture on Hardcopies) 

Jerry Curren 

Manager of Projects 

Attachment 

Cc: 

Jim Gannon, Client Services Manager 

PECR-A07-3007 

Page 2 

PECR-A07-3007 

August dh, 2007 

PEF-NCR-0135 1

ENERCON SERVICES, INC. 

ENGINEERING SERVICES PROPOSAL FOR 

SECONDARY SYSTEMS UPGRADE TO SUPPORT 

EXTENDED POWER UPRATE 

Request for Proposal (RFP) - KS12007 

Submitted to: 

Tony Owen 



410 Wilmington Street (PEB2C1) 


Submitted on: 

AUGUST gTH, 2007 

PEF-NCR-01352


Proprietary Statement 

PECR-A07-3007 - 11 -


I. 0 EXECUTIVE SUMMARY 1 

2.0 PROPOSAL CONFORMANCE STATEMENTS 3 

3.0 PROPOSED SCOPE OF SERVICES 4 

PECR-A07-3007 August 6*, 2007 

PEF-NCR-0 1354


5.0 ORGANIZATIONAL SUPPORT STRUCTURE 

APPENDIX A - KEY PERSONNEL RESUMES 

APPENDIX B - CONSOLIDATED PROJECT SCHEDULES 

APPENDIX c -TECHNICAL CONFORMANCE CHECKLIST 

APPEND= D - ORGANIZATION CHARTS 

APPENDIX E - SAFETY INFORMATION CHECKLIST 

A 

B 

C 

E 

E 

PECR-A07-3007 -v- August 6*, 2007 

pEF-p;IcP-o 1356

OPC 

1 st POD 

#1 

080009 




REDACTED

CR3 Extended Power Uprate, Secondarv Systems Upgrade, Areva Bid Proposal Review Meeting Pg. 1 of 5 

Meeting Date: 8/28/2007 

1 

The RFP bid specification identified fifteen (15) major tasks. The RFP requested each major task be bid separately and include estimated manhours. 

Combined total work scope pricing and maximum not to exceed pricing was to be identified. A request for proposal ## KS 12007 addendum letter 

was issued on August 14, 2007. The addendum letter added two (2) additional work scopes (item 16 & 17). 

The major task areas included: 

1) Computer models. 

2) MSR replacement and MSR belly drain heat exchanger addition. 

3) Turbine generator modifications. 

4) Deaerator bypass line addition. 

5) Isophase bus duct cooling system. 

6) Feedwater heater and heater drain system modifications. 

7) Secondary service closed cycle cooling system modifications. 

8) Circulating water system modifications. 

9) Condensate pumps and motors. 

10) Feedwater booster pumps and motors. 

I 1) Feedwater control valves and control system stability analysis. 

12) Condenser evaluations. 

13) Electrical distribution calculations. 

14) Mechanical ultimate heat sink calculations. 

1 5) Turbine building structural evaluation. 

16) Intemal flooding analysis due to increased circulating water flow. 

1 7) Plant operating license amendment support. 

Areva I Worley Parsons Proposal Review Notes: 

Proposal includes total work scope and is teaming effort by both companies. 

0 Proposal does not include estimated man hours or cost per task. Proposal includes one fixed cost price for total work scope. 

0 Pg.2, background, states “BOP phase 2 evaluations and implementation will be defined later and are not part of this proposal scope”. 

Verify this is not an accurate statement. All EPU BOP identified work is to be in scope of proposal. BOP Piping Analysis Scope does 

not appear to be included. Areva scoping study report # 5 1-9043794-000 Section 3.4.1.3 “pipe support / water hammer” identifies 16 

piping calculations (ref. App. J) and the main steam pipe hammer calculation M73-1002 need developed or revised. 

PEF-NCR-01604

CR3 Extended Power Uprate, Secondary Systems Upgrade, Areva Bid Proposal Review Meeting Pg. 2 of 5 

Pg.4, Table 1.4-1 ; add “Iso-Phase Bus Duct Electrical Evaluation” to engineering evaluation list. 

Pg. 4, Table 1.4-1; add “Condense Steam Impingement Plate Mods” to EC list. This is an expected output of the HES condenser tube 

vibration analysis. This modification should be scheduled during the 2009 LP turbine modification. 

Pg.5, Table 1.4-1; add “Feedwater Heater CDHE-3”’ 

to equipment specification list. 

Pg.19, EPU PEPSI Model; add MSR belly drain, add deaerator bypass mod, add YUBA estimated feedwater heater TTD’s and DCA’s 

for retained heaters. 

Pg. 19, PEPSI Model; validate MUR PEPSI model against plant data following MUR implementation. PEPSI model will be used as 

equipment design input. 

Pg. 19, PEPSI Model; Siemens will provide preliminary turbine PEPSI model input in September 2007 as requested. PEPSI model to be 

updated with final turbine PEPSI model input after final turbine design is established. 

Pg.20, FATHOM model; add Secondary Cooling System (SC) to list of systems. Need to verify uprated SC system will provide 

sufficient cooling water to specific locations in the system (Le. Generator H2 coolers). System flow control valves should be evaluated. 

The LO Cooler temperature control valve may need to be enlarged. The SC system header pressure control setpoint can be increased 10- 

15 psi due to increasing the generator H2 gas pressure from 60 psig to 75 psig. Ref.Pg.43, SC Pump EC section. 

Pg.22, Condenser Evaluation; Required output of the HES flow induced vibration analysis is to identify tube bundle locations where 

steam impingement plates should be installed. Impingement plate additions were recommended by HES during the CR3 previous 

condenser tube failure analysis. 

Pg.23, Feedwater Heater Evaluation, add “feedwater heater relief valve setpoints and relieving capacity evaluation” to scope of work. 

PEF-NCR-01605

CR3 Extended Power Uprate, secondary Systems Upgrade, Areva Bid Proposal Review Meeting Pg. 3 of 5 

0 Pg.24, Secondary Cooling Maximum; add logistical evaluation for removing existing SC coolers and installing larger heat exchangers 

into turbine building. 

0 Pg.28, Turbine Building Structural Evaluation; Turbine Pedestal Foundation Evaluation will NOT be performed by the turbine 

manufacturer. The turbine manufacturer will provide the increased loading data. The Turbine Generator Pedestal Structural Analysis, 

S95-002 1 , must be revised under this scope of work. Analysis S95-0021, dated June 20, 1995, was performed by Gilbert 

Commonwealth. Same comment Pg.35, Pg. 37, Pg.55, Pg.60 and Pg.61. 

0 Pg. 30, Engineering Change Packages; Areva shall perform all work in accordance with current revision to EGR-NGGC-0005, 

Engineering Change. Same comment Pg.5 1. 

0 Pg. 30, Engineering Change Packages; include “mark-up” of FSAR for each EC to support consolidated EPU FSAR revision. 

0 Pg. 30, Engineering Change Packages; Separate EC packages will be issued for equipment procurement specifications. 

0 Pg.35, LP Turbine Replacement; Turbine Generator Instrument calibration or range changes, including AEH controller scaling, provided 

by the turbine generator OEM shall be included in the EC package. Same comment Pg. 37. Anticipated instrument changes are 

identified on Pg.60 and 6 1. 

0 Pg.35, LP Turbine Replacement; Turbine EC shall include turbine performance test procedure in accordance with ASME PTC 6 - 2004, 

Alternate test for nuclear plant. Same comment Pg. 37. 

0 Pg.38, MSR Replacement, add “MSR relief valve evaluation” to scope of work. 

0 Pg.39, MSR Belly Drains, Evaluate 2 new heat exchangers (2 MSR drain inlets each) rather than 4 new heat exchangers. If feasible, this 

may be less expensive and tie into condensate system better (less piping required). 

PEF-NCR-0 1606


Pg.42, Isolated Phase Bus Duct, include evaluation of bus duct electrical capacity (bus duct rating) in conjunction with the bus duct 

cooling EC. 

Pg.47, Circulating Water Pump EC, include C/D water box flow straighteners and expansion joints. (Larry Sexton working on adding to 

2007 outage scope). 

Pg.49, Equipment Specifications, reliance on original equipment specifications should not be assumed. There should be no additional 

scope to develop the equipment specifications identified. Same comment Pg.60. 

Pg.53, Condenser Evaluation, HES shall provide the condenser evaluation CFD analysis. HES stated the HES CFD analysis is an input 

to the condenser tube bundle tube vibration analysis which is subcontracted by HES. The condenser tube bundle tube vibration analysis 

should be identified as an additional deliverable and should include recommended locations where tube bundle steam impingement 

plates should be installed. 

Pg.53, SC Maximization, final report should include verification of system flow balance and heat loads satisfied. SC system flow control 

valves shall be evaluated. 

Pg.57, PEPSI model, Siemens to provide initial turbine inputs in September, 2007. Siemens to provide final turbine inputs following 

turbine design and submittal of turbine thermal kit. PEPSI model to be verified with plant operating data following MUR power uprate. 

YUBA estimated EPU condition feedwater heater TTD’s and DCA’s to be included in EPU model. Should the EPU model be validated 

and corrected following EPU implementation? 

Pg.57, Electrical Calculations, impact assessment of 54 electrical calculations is included. Revision of these calculations is not included. 

Review optional workscope for ETAP electrical system modeling consolidation. 

Pg.58, Updates. Design Basis Documents and applicable FSAR sections should be “marked up” and included in each EC package. 

PEF-NCR-0 1607


Pg.61 / 62, MSR assumptions, New MSR vessels will be longer. Modifications to piping supports may be required and will not be extra 

work. MSR vendor is to provide revised piping drawings. 

Pg.62, MSR Belly Drain assumptions, location of new heat exchangers as stated in not correct. Need to consider piping runs and 

strategically locate the new heat exchangers. Consider one new heat exchanger for each condensate train each receiving two MSR 

drains. 

Pg.64, Main Generator and Exciter assumptions, SC water piping to the H2 coolers may be impacted; Generator instruments shall be 

reviewed for impacts; turbine supervisory inStrument probe mounting brackets shall be reviewed and modified if required; EH tubing 

mounted to the MSR’s will be impacted. Siemens shall provide all turbine generator vendor drawings to PE for review. How should 

turbine generator VTI be coordinated? 

Pg.67, Mechanical Inputs, A “preliminary” turbine thermal kit should be provided by Siemens in September, 2007. Turbine Generator 

and MSR structural load inputs may not be available in September, 2007. This should not impact schedule. 

Schedule Attachment, review for equipment specifications / procurement EC’s needed by end of October, 2007. Too much equipment is 

identified to be specified by October, 2007. The feedwater heaters (CDHE-3A/B) and the SC heat exchangers Impellers and Motors are 

priority components.

AREVA 


PENG07-1370.1 

AREVA NPO7-025 1 1 

Mr. Tony Owen 

Progress Energy Sewices Company, LLC 

410 S. Wilmington Street (PEB2Cl) 


Subject: AREVA NP Proposal PENG07-1370.1 Addendum for Progress Energy Crystal River Unit 3, 

Extended Power Uprate for Balance of Plant Activities 

CONFIDENTI!! 

AKEVA NP INC. 

33 I5 Old Forest Road, P 0 Box 10935, Lynchburg, VA 24506-0935 

(434) 832-3000 - F ~ X (434) 832-3840 www areva cam 

., P 

22 0“ 

“c‘l LA , , t, r . A - ; PEF-NCR-0 1609 

2 2 3 8 ,p;: 

FPSC’-L‘-,.-, ,, $=‘ __] /

September 4,2007 Page 2 Addendum to Proposal #PENG07- 1370.1 Rev. 1 

AREVA-07-025 11 

I'lii? d\rL.uiiictii coiirilitls inlbriiiarton LII~L is cotil'iJetiti:tl ;ind FropricLiry 10 ,il

September 4, 2007 Page 3 Addendum to Proposal #PENG07- 1370.1 Rev. 1 

AREVA-07-025 1 1 

1111s dtruiiiciii ccii~;atns iiihriiimoii (ha; I, ~(IIIII~I~~I~II;~~ 

aiid proprickir! 10 A1lt.L ,I hi’ 

PEF-NCR-0 16 1 1

CONFIDENTlF.? 

September 4,2007 Page 5 Addendum to Proposal #PENG07- 1370.1 Rev. 1 

AREVA-07-025 1 1 

I'llls (i~~~~iJllIci1~ colltains inlbrliialion that is cw1~dc'i~l~:~l and proprKAary to ,\l

September 4,2007 Page 8 Addendum to Proposal #PENG07-1370.1 Rev. 1 

AREVA-07-025 11 

!'Ills dikxnlcnl coillilins iiilbrniatioii lhar is coill'ikllti;ii ni~d propriot,ir!' 

Lo Allf .VA NI' 

PEF-NCR-0 16 16

CONFIDEMTIP,!.

PEF-NCR-0 1626

Daie TU; 9/4/07 Milestone Project Summary 7- 

External Milestone 4 

Page 2 

I 


I

CR-3 EPU BOP PHASE I IMPLEMENTION 

REDACTED 

Project Summary 

External Milestone 

PEF-NCR-01630

1 Dace Tue 9/4/07 

Milestone Prqed Summary t v 

External Milestone +

Contract Bidders 

Technical Evaluation 

Bid Price Comparison 

AREVA Negotiations and Royalty Agreement 

o Negotiated Price 

D Bidder Selection Basis 

D Payment Milestones 

D Limits of Liability 

D Project review Team 

D 

D 

D 

D 

2 

&$J Qa ProgressEnergy 

PEF-NCR-01636

D 

Computer Model Updates 

o PEPSE- heat rate modeling 

o FATHOM= hydraulic modeling 

o CHECWORKS- FAC modeling 

D MSR Replacement and Belly Drain Heat Exchangers 

D Turbine Generator Upgrade impacts 

o Low Pressure Turbine 

o High Pressure Turbine 

o Main Generator and Exciter 

D Dearator Bypass Line Addition 

D lsophase Bus Duct Cooling System Upgrade 

3 

@ ProgressEnergy 

PEF-NCR-01637

o Replace heaters CDHE3A and 3B 

o Evaluate Existing balance of Heaters 

o Replacement of Valves HDV 101, 102,103,104 

o Replace Piping upstream of HDV 247, 248, 249, and 250 

D Secondary Closed Cycle Cooling 

o Replacement of Heat Exchangers 

o Replacement of SC Pumps and Motors 

o Maximization of the system 

D Circulating Water Pumps and Motors 

D Condensate Pumps and Motors 

4

D 

D 

D 

D 

D 

D 

D 

Feedwater Control Valves 

Condenser Performance and FIV calculations and 

Condenser Baffle Plate Installation EC 

Electrical Distribution System calculations 

Mechanical Ultimate Heat Sink Calculations 

Turbine Building Structural Evaluation 

LAR Support 

5 


PEF-NCR-O 1639

D 

D 

AREVA 

o Completed CR3 MUR 

o Performing CR3 NSSS 

o Team very capable of completing BOP and integrating 

complete study 

o Areva partnered with Worley Parsons, the Original NE for 

CR3 BOP 

ENERCON 

o Conducted Waterford BOP 

D TCI 

o NSSS Set points only in conjunction with Westinghouse 

o No real experience in the conduct of a similar study, helped to 

develop the Specification 

o Did not bid all Tasks 

I 

6 

PEF-NCR-0 1640

D AREVA has full time employees with strong history of 

the B&W design plants. 

o Proven performance on MUR and NSSS 

o Stronger interfaces with vendors 

o Teamed with original N E for BOP at CR3 

8 a CONFIDENTIP.!. 

PEF-NCR-0 1642

Initial Bid 

Bid Clarification - I* 

Bid Clarification - 2** 

1 CONFIDENTIR!. 

*Bidders were asked to review organization, set scope, convert T&M work to 

Fixed Price electrical calculations, Condensate Speed Control Drives 

equipment, etc. 

**Bidders were asked to review hours for Tasks 3 (T/G Mods) and 9 

(Condensate Speed Drives) to determine their alignment with the Toshiba 

design reviews for the equipment. 

9 @ ProgressEnergy 

PEF-NCR-01643

I 

W

Final Fixed Price 

Potential Contingency (Max.) 

Maximum Royalty 

Eva I u at ed P ri ces (fu 11 Royalty/no con ti ng ency) 

Evaluated Price (no Royalty/fuII contingency) 

Eva I ua ted P rice (I /Z Royalty/l /Zconti ngency) 

F f%iiDEEJ:pr 

- . -*,=. e'? 

-7 

11 

PEF-NCR-0 1645

~ 

AREVA 

- 

has a proven track record with Progress for this work 

Tech n ical 

REDACTED 

CONFlDENTIh! 

AREVA is best from a Technical perspective and on average equal 

cost with opportunity- REDACTED - 

12 -- @ ProgressEnergy 

PEF-NCR-0 1646

Payment Milestones are designed to provide an 

incentive to complete scheduled work on time 

and a dis-incentive for failure to meet 

schedule. 

13

Per the reement #I 01659, the LOL 

contract . 

the final amount of the 

14

Project Technical Lead 

Legal 

Audit 

Contracts Lead 

Executive Sponsor 

Scott Deahna 

Dave Conley 

Loyd Graves 

Tony Owen 

Danny Roderick 

15 

PEF-NCR-01649

CR3 Extended Power Uprste, Secondarv Systems Upgrade Bid Proposal Technical Evaluation 

Pg. 1 of 3 

0812 1 IO7 

+he following proposal technical comments were developed by reviewing unpriced copies of each proposal. 

7 

The EWP bid specification identified fifteen (15) major tasks. The RFP requested each major task be bid 

separately and include estimated manhours. Combined total work scope pricing and maximum not to exceed 

pricing was to be identified. 


I) Computer models. 









IO) Feedwater booster pumps and motors. 

11) Feedwater control valves and control system stability analysis. 




. IS) Turbine building siructural evaluation. 

b A request for proposal’# KS 12007 addendum letter was issued on August 14,2007. The addendum letter 

added two (2) additional work scopes and responded to questions by the bidders. 

The additional work scope items included: 


2) Plant operating license amendment support. 

b 

Areva / Worlev Parsons Proposa:’ Review Notes: 

0 Proposal includes total work scope and is teaming effort by both companies. 

Proposal does not include estimated man hours or cost per task. Proposal includes one fixed cost 

price for total work scope. 

Pg.2, background, states “BOP phase 2 evaluations and implementation will be defined later and 

are not pari of this proposal scope”. Verify this is not an accurate statement. All EPU BOP 

identified work is to be in scope of proposal. BOP Piping Analysis Scope does no1 appear to be 

included. Areva scoping study report ## 51-9043794-000 Section 3.4.1.3 “pipe support I water 

hammer” identifies 16 piping calculations (ref. App. J) and the main steam pipe hammer 

calculation M73- 1002 need developed or revised. 

0 Pg.4, Table 1.4-1; add “Iso-Phase Bus Duct Electrical Evaluation” to engineering evaluation list. 

0 Pg. 4, Table 1.4-1; add “Condense Steam Impingement Plate Mods” to EC list. This is an expected 

output of the KES condenser tube vibration analysis. This modification should be scheduled during 

the 2009 LP turbine modification. 

Pg.5, Table 1.4- I ; add “Feedwater Heater CDHE-3NB” to equipment specification list, 

Pg. 19, EPU PEPS1 Model; add MSR belly drain, add deaerator bypass mod, add YUBA estimated 

feedwater heater TTD’s qqd DcA’s for, retained heaters. 

. . - ( , . 

, I ! ,., 

! , ; “, !, ;. . : 

PEF-NCR-0 1650

CK3 Extended Power Uprate, Secondarv Systems Upgrade Bid Proposal lechnical Evaluation 

Pg. 2 01. 3 

0 Pg. IO. PEPS1 Model: validnte MUR PIPSI modcl against plant data following MlJR 

iinplcmcnrati(m. PEI'SI modcl will be used :IS cquipmcnt design input. 

0 1'2. IO. PEP'S1 Moelcl: Siemens will provide prcliminui-y tui.binc PEPSl model input in Septembvr 

2007 ;is ~~cqucstccl. PEPS1 model to be updutccl with final turbine PEPSl niodcl input after final 

turbine clcsign is cwhlishecl. 

0 Pg.20. FAl'HOM model; add Secondaiy ('ooling System (SC) to list 01' systems. Need lo vciit'y 

iipiarcd S(' sysrcni will providc sufficicnt cooling water to specific locutions in Ihc system (i.e. 

(icncriitor I12 coolers). Systcm flow conIi.()l vitlves sholild be evuluarcd. The LO Cooler 

(cmpcixlui.c control vdvc may need lo he cnlaiyrl. The SC system header pressiiic conliul 

sctpoint can be incrcascd 10-15 psi duc to inctrasing thc gcnerator 112 gas prcssiirc from 60 psi? 10 

75 psi:. Rcl'.Pg.43. SC Pump EC scclion. 

0 Pg.29. C'ontlcnser Evaluation: Required oulpiir 01' the HES flow induccd vihratiirn analysis is ro 

iclciitil'y tube bundle lociitions where stcan1 inipingcmcnt plates shctiild he installcd. Impingcmcnt 

I>liiIc &litions were iwommenderl by Hi3 during the CR3 prcvious condcnsei. tiihe failure 

mil y si s. 

0 Pg.2.3, Fccclwatci. Hcii~ci' Evalui1tiorl. :idd "Ceedwiater hcatcr. rclicf valve setpoints and relieving 

capucily cviilu;ition" to scopc ol' woik. 

0 Pg.24. Sccont1;ii.y Cociing Maximum; add logistical cvaluution t'or removing cxisling SC cooIci.s 

iincl itisralling Iiiiy heiit cxchai1gei.s into Iiii.hinc building. 

0 Pz.28. l'iiihnc Building Structuriil Ev;tluation: Turhinc Pcdcstul Foundation Evuluaticin wi II NOI' 

he pcifoimcd I>y thc tuitinc manufacturci'. Thc tuikc munutactiii-el. will provide the incrcased 

Ioiiclirig tlalx The I'iii.binc Generator Pcdcslal Stiwtural Analysis. S95-002 I, must be revised 

undci. this scopc 01' work. Aniilysis S95-002 1 . dated Junc 30, 1905. Wits pciformed by Gilhcil 

C'olni.rlon\+4 t h. 

0 Pg, 30, Ensinccring ChLirigc Packages: Arcva shall pcrl'orm ill1 woik in accoidance with i:uinxI 

rcvision to ECR-NUX-0005, Enginccring Change. Samc comment Pg.5 I . 

0 Pg. 3J. Engineering Changc Packagcs: includc "marl\-up" of FSAK for, cach EC to support 

con s () I i d at c d E P U FS A R rev i si on. 

0 Pg. 30. Engineering Changc Packages; Scp;ii.iitc EC packages will bc issued l'or equipment 

pi"xi'cmcnt spcci I'ical ions. 

0 Pg.35. I,P 'I'iirbinc Rcplacement; Thc Iiiihinc vcndor will no1 perl'orm tiirbiric foundation 

ciiIcu1:itioiis 01' revise clcsigii basis fouridiirion ciilctilations. Calculation SOS-002 I sh,ill be revised 

iinclcr this ivorkscopc. Snmc comnient Pg. 37. Pg.55, Pg.60 and Pg.6 I, 

0 I's.35. 1.1' Tiirhinc Replaccincnt: 7'iii.btiic Geiicriitol' Inslrument culihration 01' wngc chungcs. 

including AEH conlidlci. scaling, proi idctl by Ihc tui-bine gencratoi. OEM shall hc includcd in thc 

I:c' packagc. Sainc commenl Pg. 37. AilIiciI7i1Lcd ins;tiumcnt chan2c.s ;ire iclcntificd on Ps.00 and 

h I . 

0 Pg.35. LAP 'I'urhinc Rcpl;iccmcnt; Tui.Rinc EC' shall includc (iirkiiic pei.timnancc test pi-ocedurc iii 

;Iccoi.d;inc.c with )ISME PTC 6 - 2004. Altcrlliite test tor nuclciir plunt. Same cornrncnt Pg. 37. 

0 Pg.38. MSK Rcplaccincnt, udd "MSR wlict' ~alvcwluation" to scopc 01' woi~k. 

0 Pg,30. MSR Belly Drains. E\/;ilttiitc 2 Iit'\h heat cxtchangei.s (3- MSK di.iiili iillcts tach) rather thiitl ,4 

iic\v hcat cxch;inZci.-i. It' I'casihlc, this may hc Icsh expensive and tit' into condciiwtc system heltvr 

(IChh plplllg I~cc]llll~ccl). 

0 l'y.42. Isola~cd Phasc Bus Duct. tncluclc. ~~\t:ilii;ilion oI' his duct clccti'ic;il ci1p;iciIy (hiis duc~ i'iitiry) 

in con,jiinclioii with thc bus cluct cooling I.:C. 

Pg.17. ('ii.culating Watci' Pump E(', iiii,liidc ('ID \cater box f'loi4 s1i.;Ii~hIci1ci.h Lilicl cupansion 

~OI111h.

. - * 

CR3 Extended Power Umate, Secondarv Svstems Uagrade Bid Pro~osal Technical Evaluation 

Pg. 3 of 3 

e Pg.49, Equipment Specifications, reliance on original equipment speci ficatjons should not be 

assumed. There should be no additional scope to develop the equipment specifications identified. 

Same comment Pg.60. 

a Pg.53, Condenser Evaluation, HES shall provide the condenser evaluation CFD analysis. HES 

stated the HES CFD analysis is an input to the condenser tube bundle tube vibration analysis which 

is subcontracted by HES. The condenser tube bundle tube vibration analysis should be identified as 

an additional deliverable and should include recommended locations where tube bundle steam 

impingement plates should be installed. 

Pg.53, SC Maximization, final report should include verification of system flow balance and heat 

loads satisfied, SC system flow control valves shall be evaluated. 

e Pg.57, PEPS1 model, Siemens to provide initial turbine inputs in September, 2007. Siemens to 

provide final turbine inputs following turbine design and submittal of turbine thermal kit. PEPS1 

model to be verified with plant operating data following hlUR power uprate. YUBA estimated 

EPU condition feedwater heater TTD’s and DCA’s to be included in EPU model. Should the EPU 

model be validated and corrected following EPU implementation? 

e Pg.57, Electrical Calculations, impact assessment of 54 electrical calculations is included. Revision 

of these calculations is not included. Review optional workscope for ETAP electrical system 

modeling consolidation. 

Pg.58, Updates. Design Basis Documents and applicable FSAK sections should be “marked up” 

and included in each EC package. 

e Pg.61 / 62, MSR assumptions, New MSR vessels will be longer. Modifications to piping supports 

may be required and will not be extra work. MSR vendor is to provide revised piping drawings. 

e Pg.62, MSR Belly Drain assumptions, location of new heat exchangers as stated in not correct. 

Need to consider piping runs and strategically locate the new heat exchangers, Consider one new 

heat exchanger for each condensate train each receiving two MSR drains. 

e Pg.64, Main Generator and Exciter assumptions, SC water piping to the H2 cooiers may be 

impacted; Generator instruments shall be reviewed for impacts; turbine supervisory instrument 

probe mounting brackets shall be reviewed and modified if required; EH tubing mounted to the 

MSR’s will be impacted. Siemens shall provide a11 turbine generator vendor drawings to PE for 

,review. How should turbine generator VTI be coordinated? 

8 Pg.67, Mechanical Inputs, A “preliminary” turbine thermal kit should be provided by Siemens in 

September, 2007. Turbine Generator and MSR structural load inputs may not be available in 

September, 2007. This should not impact schedule. 

Schedule Attachment, review for equipment specifications / procurement EC’s needed by end of 

October, 2007. Too much equipment is identified to be specified by October, 2007. The feedwater 

heaters (CDHE-3NB) and the SC heat exchangers Impellers and Motors are priority components, 

PEF-NCR-O 1652

CR3 Extended Power Uurate. Secondarv Systems Upgrade Bid Proposal Technical Evaluation 

Pg. 1 of 3 

08/23/07 

@‘he following proposal technical comments were developed by reviewing unpriced copies of each proposal. 

The RFP bid specification identified fifteen (15) major tasks. The RFP requested each major task be bid 


pricing was to be identified, 


Computer models. 

MSR replacement and MSR belly drain heat exchanger addition. 

Turbine generator modifications. 

Deaerator bypass line addition. 

Isophase bus duct cooling system. 

Feedwater heater and heater drain system modifications. 

Secondary service closed cycle cooling system modifications. 

Circulating water system modifications. 

Condensate pumps and motors. 


11) Feedwater control valves and control system stability analysis. 




15) Turbine building structural evaluation. 

’e! request for proposal # KS12007 addendum letter bas issued on August 14,2007. The addcndum letter 




2) Plant operating license amendment support. . 

Enercon Prooosal Review Notes: 

e 

Proposal includes total work scope. 

Proposal includes estimated man hours per major task. Proposal includes cost per major task as 

well as total not to exceed cost for full work scope. 

Enercon appears qualified to perform work scope based on work references and personnel resumes 

included in proposal. Recommend to review Enercon projecl managemcnt team for power upratc 

project experience. 

BOP Piping Analysis Scope does not appear to be included. Areva scoping study report # 5 1- 

9043794-000 Section 3.4.1.3 “pipe support / water hammer” identifies 16 piping calculations (ref. 

App. J) and the main steam pipe hammer calculation M73-1002 need developed or revised. 

Schedule Comment: Prioritize the 2007 procurement of the 2 feedwater heaters (CDHE-3A/B), the 

2 SC heat exchangers and the SC pumps / motors. All other equipment procurement EC can be 

postponed to 2008. 

Verify existing design basis documents and affected FSAR sections will be “marked up“ for each 

EC. 

PEF-NCR-0 1653

(IHJ i3dendecl I'ower Ulirate, Secondary Systems Upgrade Bid Proposal 'Technical Evaluation 

Pg. 2 of 3 

Pg.5. PEPSE ivlvloclcl. xld Y UBA cstiinatcd feedwiirer hentcr TTD's and DCA's for ixtniiiccl 

hcntcrs: validarc MLiK PEPSE modcl nguinst plnnt d:ita following MllR implementation. Siemens 

will ~~ovidc piclimiiiiiry turbine PEPSF: modcl input in September 2007. PEPSE modcl to hc 

iipdutctl with final tiirbiric PEPSE model input uf'ter finul tuibinc dcsign is cqtablished. 

Pg.3, FATtIOM model: add Sccondi1i.y Coolins Sysrcin (SC) lo list of systcms. Nccd to vcril'y 

iipi-atctl SC sysicin will proviclc sull'icicnt cooling water to specific locutions in the systcrn (it. 

Ckncixtor H3 coolers). System flow control viilvcs should be ci:alu~itcd. 'I'he LO C'oolci. 

tcinpcnituiv control v;iIvc may necd to he cnlargcd. The SC sysrcrn hcudei. prcssure control 

setpoint can I>c inciwscd IO- IS psi duc to inL.irasing the gcncrator H2 gas pressi1i.e I'roni 60 psi: to 

75 psiig. 

e Pg.0. Corniiicrcial arid Resourcc Pi.oposal: icvicw "hilling in accordance with master service 

agiwincnt I'or 'T'&M" vs. thc not lo excccd prices qtiitcd in thc ~~i'upos~ill. 

e Pg.10, ltcin 7; CHWWORKS progi'ani at CK3 will he utilized. 

e Pg. IO, ltcin 8: Find PWSE inodcl after iill ncw ccluipmcnt is spccified is no1 in scope. 

e Pg. IO, Itcin 0; Enercon sitc liaison is expected to ohtiiin dcsign basis iiiI'ormii1ioii. Re1ianc.c on sire 

cngincci.ing to proviclc clcsign basis inl'oriiintion is not desired. 

e I'g. I I. ltcin 13; l'hc propos;il docs not includc :I PEPSE modcl for the 1000 plant condition. The 

2000 plant conl'istii.;ition hciit bnlunce model will be pcrl'ormed by Siemens 1,) support tuibinc 

pcifoimuiicc giiariintec and pcrlixmuncc tcsting. Add, "3-wcon shill1 support this el'l'oit iis needed 

to accuratcl y niodcl thc plant configuriition". I':vuluate having Encrcon ped'oim an indcpeiidcnt 

3000 iriodel to coinpirc with Sicmcns model. 

Pg.30. As\;iiniption item 3 iind 4; a11 viilvcs 011 pipinp associated wilh the new MSR belly drain 

heat cxchiii1gei.s shiill hc cvduated. New vi11 vc\; shall be specified for procurcnicnl iiowcvci. u 

rmcurcmcrit EC s hoii Id not be iqui rci.! 

Pi~oposal requii.cs CK3 plant cablc datuhascs uti II he tipdated by plant engineer in$. 

Pg.24. 'l'iiibinc Vcntloi. Information; will not be ;IS extensive as describcd in thc propo>ill. 'T'hc 

turhiiic vcndoi. will Iwovidc ncw complete tul-hinc gcncrutor instruction manuals iind the turbine 

gcnciuloi. inst:illalion instructions. Thc cxistirig turhine generator vendor diawirig file will haix to 

hc icvicwcd for impuct. A turbine pei.forinancc lest procedure shall he dcvclopcd ilnd sholl he in 

accorduncc with ASME PTC 6 - 2004, Alteimutc tcst for nuclcur plant. 

Pg.3-8, Ttiilinc Cicncraloi. Assumptions The SC piping to thc generator H3 cooIci.s niay he 

impacted: Turbine Cieneraror inslriimcnt and conrrol sctting chaiigcs will he pivviiied hy Sicmcns 

and shiill bc incluclcd in the turbinc EC': Genei'ator Instrumcnts will he impacred arid shall he 

cvaluatctl: Tiiihnc (icncixlor siipporl systems will hc evaluated by Sicmcns. Any inipacr.; 

idciitil'icd hy Siciiieiis shall bc included in the riii.biiic EC. 

Pg.70, 'l-iiilinc Gcnci.atoi' Assumptions 17: (.d~liliiti(>n SOS-002 I. Turbine Gciici:iloi. f'cdcslul 

Stiuciui'al Analysis. shdl bc "iipdiited" using the incthodology contained in tlic ;inaly;i\. A thiw 

diniciisionnl milysis modcl ot the tuibinc pctlcsrnl slructurc is included. 

e Pg.39, Bus Duct Dclivcixbles: Vci.iI'y cvdualion ol' bus duct clccti.iciil c;ipiiciry (hiis clui't rarinp) 

will tic pcifoimxl in con.junction with thc hirs (Iiicr cooling EC. 

e Pg.70. SC Systcin Workscope Item IO: Vcril'y Iiydixiilic evaluation incluclcs hylcin I'lon biil;incc. 

systcni tical lo~i(lh i i i sutisl'icd ~ and sysreiii tlo~+. conliul vi11 vcs aic cvaliiatcd. Nc\te thc SV \ystcin 

pi.c?;surc scrpoinl c;iii hc inci-eascd diic 10 iricrcahing genei.aloi. H1 picssiii'c. 

Pg.50. SC' Systcrn Workscqx Item I I . 7'hc ttiihiic IuIw oil tcmpci'atiii'c coiitir)l ~nI\c: \hoiild he 

i~cplx~cd with ;I 1iiiyc.i. v;iIvc. 

PET-NCR-0 1654

0 

0 

CR3 Extended Power Uprate, Secondarv Systems Upgrade Bid Proposal Technical Evaluation 

Pg. 3 of 3 

0 Pg.60, SC System Work Performed by Others; Enercon should interface with equipment vendors 

0 

to obtain design input information and not rely on PE to perform this function. This comment 

applies to all equipment and all “work by others” sections of the proposal. 

Pg,64, SC system Assumptions; defined work scope does not address interferences to replace the 

major SC components. EC installation instructions must address these issues. 

Pg.94, FW Booster Pump Assumption 15; A larger pump / motor will be specified. Impacts to the 

support pedestal and piping can be expected. 

Pg.99, Condenser Evaluation, HES shall provide the Condenser Evaluation CFD Analysis. The 

HES CFD analysis is an input to the condenser tube bundle tube vibration analysis which is 

subcontracted by HES. The Condenser Tube Bundle Tube Vibration Analysis should be identified 

as a deliverable and shall identify tube bundle locations where steam impingement plates should be 

installed. Impingement plate additions were recommended by HES during the CR3 previous 

condenser tube failure analysis. Steam impingement plates should be installed during the 2009 LP 

turbine replacement. 

0 Pg. I 15, Electrical Distribution Calculations; Review proposal to consolidate existing electrical 

calculations into new ETAP. Evaluate cost of converting vs. updating existing electrical 

calculations. 

Appendix B, Consolidated Project Schedule Coqments: 

October 07 PEPSE model is “initial” EPU model. Final PEPSE model shall be submitted after 

all plant design changes have been specified and inputted into the model. 

MSR drain mod procurement EC can be postponed to 2008. 

0 All turbine generator and MSR schedules shall be compared to and coordinated with the 

equipment vendor’s engineering deliverable schedules. The schedule for issuing the installation 

EC‘packages shall be determined by the owner. 

The turbine pedestal calculation schedule shall be accelerated and will si~pport final calculation 

expeditiously upon receiving final input data from Siemens. 

Deaerator procurement EC can be postponed to 2008. 

0 Isophase Bus Duct procurement EC can be postponed to 2008. 

0 Isophase Electrical Capacity Calculation shall be performed in conjunction with designing the 

bus duct cooling system. 

Turbine Building Structural Evaluation is scheduled to complete by 12/12/07. This does not 

appear feasible.

CONFIDENTlP!-

CONFIDENTIh!. 

PEF-NCR-01658

a CONFIDENTIP.!m 

PEF-NCR-01659

PEF-NCR-01661

PROPRIETARY 

20440-1 2 f3/30/2006) 

This document contains 278 pages including Appendices A through T 

i 

I 

4 

AREVA NP Inc., an AREVA and Siemens company 

zc' '_ '. 

L " . t' 

Page 1 of278

OPC 

1 st POD 

#1 

080009 



PEF-NCR-0 194 1 

REDACTED

-- 

AREVA NP Inc. 

PROPRIETARY 

a CONFIDENTIF. 

Areva man hour est 411 012008

[Prooosed Invoice Milestone 

- Date 

I Invoice Amount I Year Totals 

Note: Bold dates indicate minor schedule changes. 

a CONFIDENTI!! 

PEF-NCR-01943

July 27,2005 


CR3 NUCLEAR PLANT 

ENGINEERING SERVICES FOR SECONDARY SYSTEMS UPGRADE 

REQUEST NO. KS 12007 

Dear Bidder: 

This addendum adds requirements to the above-referenced Request for Proposal and provides 

answers to several questions raised by bidders. The questions and respective answers are 

attached. In addition, the following two new requirements are added to the RFP: 

0 Bidder shall include an analysis of Intemal flooding due to the increased “Circulation 

Water” flow rate of approximately 22%. 

0 

Bidder shall include provisions in their bid for License Amendment input. 

All other terms and conditions remain unchanged. Questions pertaining to this addendum should 

be directed to the appropriate individual listed in the original Request for Proposal. 

RFP Addendum 

Kevision 7/27/2007 

#I13343

Your acknowledgement of receipt of this addendum should be noted on your proposal. Failure 

to do so may constitute grounds for rejection of your bid. 


Tony Owen 

Manager NGG Major Projects 

-- I 

Attachment 

RFP Addendum 

Revision 7I27Q.2007 

#I 13343

Attachment A to Request No. KS12007 

Certain bidders have asked the following questions in regards to RFP No. KS12007, so this addendum is 

in answer to those questions and available to all bidders. A question and answer format has been used. 

Turbine building structural evaluation commentslclarifications: 

Question: Sections 1.2.13 and 1.9.15 discuss "Conduct an evaluation of the Turbine Building structure 

considering the expected additional loads resulting from installation of new and larger equipment" 

and "Perform an evaluation of the Turbine Building structure and supports to identify if any significant 

changes are required to accommodate the expected increases in loads resulting from new and larger 

equipment such as turbine motors, main generator, etc.". Both statements imply there is an evaluation 

for the existing building loads. What calculations cover the existing TB evaluations, and will these be 

made available? 

Answer: Original calculations are Gilbert Commonwealth structural calculations and will be made 

available. Estimate 200 hours to review and revise calculations as necessary. 

Question: The statements in sections 1.2.13 and 1.9.15 ask for an evaluation to see if significant 

changes are required. Please define the term "significant" changes versus others? 

Answer: "Significant changes" in design loads would be those that would not meet current acceptance 

criteria and would require modifications to the existing floor or support columns. 

Question: There is no mention of what to do when changes are required. When changes are required, 

are they included with this scope or handled separately outside of this scope? 

Answer: The modifications would be scope addition and would be priced separately as T&M, if required 

Question: Section 1.12 discusses the schedule for the Turbine Building evaluation (Item 15) and is 

scheduled to be completed 12/13/07. It is noted that a PO will not be submitted to anyone before late 

August. Before the TB evaluation can be done, inputs for the weights and footprints of all equipment 

must be known. This includes major components such as the turbine and MSRs. When will the detailed 

vendor information be available and the locations within the TB be defined? The schedule indicates that 

equipment information will not be known until after the deadline for the TB evaluation, which would 

invalidate the TB evaluation schedule. It appears the schedule needs to be reworked to define 

predecessor activities for all tasks. 

Answer: The weights of the replacement components are readily available and will be provided as part of 

the Owners deliverables within the schedule. 

Electrical commentslclarifications: 

Question: Section 1 9 5 asks for the complete replacement of the existing system with the 2 X 100% 

new system each with 100% motor/fan and cooling coils. while Section 1 2 1 discusses upgrade cooling 

unit to have redundant fadmotor and cooling coils The existing unit can not be upgraded to have 

redundant fans Therefore two 100% new units would be required 

Is the plant replacing the existing cooling unit with two new 100% redundant units or upgrading the 

existing unit with redundant motors to meet the design requirements7 

Answer: Is0 phase bus duct coolers should be replaced with 2 X 100% redundant coolers and fans.


Question: Booster Feed Water pump motors are up-rated to 4000 HP. The 4 KV Aux and startup 

transformers may become overloaded and 4KV switchgear will not likely handle all of EPU load 

requirements. It is recommended that before writing the spec proposal for the FW Booster Pump, an 

evaluation on the power distribution system be performed to determine what voltage class motors are 

required. This should be performed prior to preparing the pumplmotor specification. Should the Bid 

Specification identify the need to prepare a preliminary electrical system design review prior to preparing 

the M Booster Pump motor spec (4KV level)? 

Answer: The Feed Water Booster pump motor replacement and modification should include rerouting the 

load center from the 4160V to the 6900V switch gear. 

Questlon: The draft bid specification identifies the need to revise the Non-Safety 125 VDC calculation 

using the €TAP model. If this calculation will not be affected by the EPU, what is the basis for upgrading 

the 125 VDC calculation using the €TAP program? 

Answer: If 125VDC calculations are not affected then state as such within your exception conformance 

tables for the proposal. 

Question: The bid specification recommends performing the voltage drop and short circuit calculation 

using the SKM software tool. Can CR3 provide the overall plant model in the SKM software 

environment? 

Answer: CR3 will provide modeling as currently exists for electrical load centers. 

Question: The specification limited this scope to a revision of calculation €90-0044. Is it Progress 

Energy’s intention to limit the scope of the €TAP proposal to only one calculation? The ability to 

comprehensively update all the individual calculations using multiple software programs, spreadsheets, 

etc. is limited (especially those calculations performed by other third parties). Would Progress Energy 

support developing an overall plant electrical distribution model using the Progress Energy ETAP 

program to incorporate all design changes from the EPU? 

Answer: Provide a comparison of costs for updating the entire electrical system to ETAP instead of 

revising all current software programs and calculations. Prudence will dictate decision. If costs, resource, 

and schedule are better by modeling the whole system in €TAP then CR3 can support this approach. 

ClarificationIComments to Condensate PumpNFDIMotor Request: 

Question: Suggest separating the pump and motor ECs from the VFDs. These are actually 2 different 

product offerings and if the equipment is combined, it may limit the options available for separating pumps 

from VFD vendors. 

Answer: Condensate Pump and Motor and Control system may be separated and designed as separate 

ECs. 


RFP Addendum 

Revision 7/27/2007 

#I I3343

.. 

Clarlflcation on the 1CS system: 


Queatlon: Is it the intent that the Integrated Control System modifications be performed in-house by 

PEF or other contracted entities? 

Answer: PEF will perform ICs modifications. 

ClarificatiodComment to Equipment Specification and Design Specification definition: 

Question: The terms Equipment Specification and Design Specification appear to be interchangeable. 

Are these reference terms the same in the PEF system? Please clarify if they are not the same. 

Answer: Design Specifications are the requirements for the component or system parameters provided in 

an engineering document. Equipment Specifications are the PEF Engineering Documents that are used 

to order equipment in accordance with EGR-NGGC-0020. Note 4 has the issuance of Equipment 

Specifications developed per NGGC-EGR-0020 also requires generation of an EC per EGR-NGGC -0005 

CIarificationlComment on the Reference to Affected Calculations: 

0 

Question: Section 1.9.14 references more than 5 calculation documents out of the -1500 calculations 

that will need to be revised or evaluated. Are these other affected documents to be included in the 

respective EC package preparation, or are the critical documents determined to be the 5 identified in the 

RF P with any other documents to the scope to be defined later? 

Answer: Additional calculations not identified within the RFP should be identified and may be bid as part 

of a fixed price proposal or identified that they will be addressed separately as T&M. 

ClarificationlComments on the schedule: 

Questlon: A brief review of the schedule noted that there are a number of instances where items are to 

be completed prior to a predecessor task being completed, or, not enough time has been allotted for the 

task based on a projected authorization date. A couple of examples include: the reference to the PEPSE 

model being completed by 9-20-07 when a typical PEPSE analysis and documentation takes 8 weeks to 

complete after the receipt of the turbine thermal kit. As mentioned previously, the turbine building 

structural evaluation is scheduled to be completed prior to the completion of the ordering and ECs for 

turbine items, MSRs, etc. Please clarify. 

Answer: A completed PEPSE Analysis was requested by the TG Vendor in order to perform the Thermal 

Kit Analysis. Subsequent conversations have identified that a completed PEPSE run is not required. 

However, the data sheet in the RFP shows what data will be required by the end of Sept to support the 

LP and HP turbine rotor designs, The weights of replacement components are readily available and can 

be provided for the Structural evaluation in order to meet desired schedule. 

PIIF-NCR-0 1948 

FWP Addendum 

Rcvisiori 7/27/2007 

#I 13343

' 

PROGRESS ENERGY FLORIDA, INC 


ENGMEERING SERVICES FOR SECONDARY SYSTEMS UPGRADE 

REQUEST FOR PROPOSAL NO. KSl2007 

LIST OF BIDDERS: 

1. AREVA NP, Inc. 

7207 IBM Drive 

Charlotte, NC 28262 

Attention: Tom Doering 

(704) 805-2357 

thomas.doering@areva.com 

2. Enercon Services, Inc. 

500 Town Park Lane 

Suite 275 

Kennesaw, GA 30144 

Attention: Jim Gannon 

(770) 919-1930 

j gannon@,enercon.com 

.- 

e 

3. Sargent & Lundy, LLC 

55 East Monroe St. 

Chicago, IL 60603-5780 

Attenlion: Chris Sward 

(3 12) 269-7426 

chris.a.sward@sargentlundv.com 

4, TechCom International Corporation 

440 Goddard 

Irvine, CA 926 18 

Attention: Bob Katebian 

(949) 453-0660 ext. 222 

katebian(i3,tcicom.com 

. ' .- 

5. WorleyParsons 

2675 Morgantown Road 

Reading, PA 19607-9676 

Attention: John Ioannidi 

(61 0) 855-2000 ext. 2493 

iohn.ioannidi@worievoarsons.com 

I 

- 

# 


25790

June 6,2007 

Attention : 




REQUEST FOR PROPOSAL NO. KS12007 

Dear Bidder: 

You are invited to submit a proposal for providing engineering services on secondary system components, 

including preparation of design specifications, equipment specifications, Engineering Change Packages and 

calculations for work necessary to increase the electrical generation by 20% (EPUR). Three per cent of the 

increase in generating capacity is to be achieved by improvements to the secondary plant performance (see the 

Scope attached for additional details). This EPUR will occur at Progress Energy's Crystal River Nuclear Power 

Station, Unit 3 located at 15760 West Powerline Street, Crystal River, Florida 34428. 

You are requested to provide two (2), signed copies of the proposal (one priced and one unpriced) plus one 

electronic copy of each shall be sealed and marked "CONFIDENTIAL" and submitted to Tony Owen, 

Progress Energy Service Company, LLC, P. 0. Box 155 1 (PEB 2C1), Raleigh, NC 27602. Overnight delivery 

should be sent to410 S. Wilmington Street (PEB 2CI), Raleigh, NC 27601. The proposal must be sealed and 

marked as noted above in a separate envelope inside the overnight envelope. No copies of the proposal shall 

be distributed to any other Progress Energy personnel by the bidder. Your proposal must be received no later 

than 12:OO noon, August 6,2007. lfyour proposal is received after that day or time, it will not be considered 

for the described work. Telephoned or faxed proposals or proposal information are unacceptable and will not 

be considered. No modifications to the bidder's proposal will be accepted after the bid due date and time 

specified above unless specifically requested by Progress Energy in writing. 

Bidder is requested to complete, sign, and return the General Information form attached in its entirely and IO 

furnish information requested on this form. Bids will not be considered when submitted on forms other 

than those provided. 

It is intended that a contract in the form of the attached specimen contract will be awarded for this work and 

quotations shall be made accordingly, unless the successful bidder has an existing Master Contract with 

Progress Energy, in which case a Work Authorization will be released against that Master Contract 

incorporating the details of this Inquiry. 

U 257906 

PEF-NCR-0 1950

6 

Progress Energy does not obligate itself to accept the lowest or any other bid and specifically reserves the right 

to reject any and all bids. Bidders are advised that all bids will be opened and evaluated solely by Progress 

Energy. All information contained in the bids submitted to Progress Energy and Progress Energy‘s evaluation, 

including any bidder‘s relative position to the successful bidder, is considered exclusive information of 

Progress Energy and will not be made available to any ofthe bidders. All unsuccessfirl bidders will be notified 

by Progress Energy in writing of the award of the work to another firm. 


of the proposal documents or related project data furnished as part of the proposal documents shall be made 

directly to Tony Owen via e-mail at tony.owen@m”aiI.com or by phone at (919) 546-2933 by the bidder 

only. 

All requests for clarifications, interpretations or decisions on discrepancies pertaining to the technical aspect of 

the proposal documents or related project data furnished as part of the proposal documents shall be made 

directly to Ted E. Williams at the Crystal River Nuclear Plant (CNP) at (352) 563-2943, extension 4356, or 

email address ted.williams0~rmmail.com 

- by the bidder only. 


information will be available only through the bidder and that no direct contacts with Progress Energy by 

subtier firms shall be initiated. Infomation exchange shall be between Progress Energy and bidder, and bidder 

and his potential subcontractors. No work shall be subcontracted without the approval of Progress Energy. 

Subcontract work and proposed subcontractors must be identified in bidder’s proposal. 

As a prerequisite for consideration of a bidder‘s proposal, bidder must contact the site of the proposed work, 

discuss job conditions with Progress Energy’s designated representative, become acquainted with the technical 


course ofthe work, and make his choice of methods and equipment accordingly. Contact appointments must 

be made with Ted Williams at the Crystal River Nuclear Plant. No site visits will be allowed without prior 


Please acknowledge receipt of this proposal and your bidding intentions by completing the attached 

Acknowledgement Form and faxing it to Tony Owen at (919) 546-6750 within two business days. 


Tony Owen 






Sample Contract (if applicable) 



Contractor Safety Checklist 

2 

PEF-NCR-0 195 1


Mr. Tony Owen 


P. 0. Box 155 1 (PEB 2C3) 


Fax: 91 9-546-6750 



ENGINEERMG SERVICES FOR SECONDARY SYSTEMS UPGRADE 

REQUEST FOR PROPOSAL NO. KS I2007 

I acknowledge receipt of the subject proposal package and have indicated my bidding intentions as follows: 

0 

I have reviewed the proposal documents and will not be submittingabid for this work. Proposal 

documents are being retumed under separate cover. 

I have reviewed the proposal documents and intend to submit a bid for this work and will make 

arrangements to contact or visit the site as requested. 

(Sign at ure) 

(‘Title) 

(Date) 

3 

PEF-NCR-0 1952





REQUEST FOR PROPOSAL NO. KS 12007 

Contractor visited the site [ ] and/or contacted [ J the site on 

and discussed job conditions with 

to acquaint himselfwith the technical requirements ofthe work 

and all available information and local conditions which may impact pricing of the subject Inquiry No. 

0 

In the event that your Proposal is accepted and a Contract is awarded to the firm whose full legal company 

name appears herein below, Mr./Ms. 

whose title is 

, will be executing the Contract on behalf of 

the firm. Should this person's title not indicate that he/she is a corporate offcer (president, vice president, or 

corporate secretary), an affidavit signed by a corporate officer shall be provided along with the bid, stating that 

the person whose name appears above is duly authorized to execute contracts on behalf of the firm. 




A Partnership consisting of 

A Joint Venture comprised of 





Contact Name 

Contact Phone 






4 

PEF-NCR-0 1953

In accordance with the Federal Acquisition Regulation section 52.219, please check all that apply to your 

company. Please provide supporting documentation or certification to confirm the status for any categories 

checked under Small/Diverse Vendors. 

[ ] Certified small business* [ ] HUBZone, 8(a) or disadvantaged business* 

[ ] Veteran-owned business* 

[ ] Minority-owned business * * 

[ ] Service-disabled veteran-owned business* [ ] Women-owned small business * * 

[ J Not a Small Business 

* As defined by the Small Business Administration (SBA): ww.sba.rrov 


Register online at w\~.pronress-ener~~.com/suDpIierdiversi 

BY: 


TITLE: 

DATE: 

5 

PEF-NCR-0 1954


CRYSTAL RlVER NUCLEAR PLANT, WIT 3 

ENGMEERMG SERVICES FOR SECONDARY SYSTEMS UPGRAD1 

REQUEST FOR PROPOSAL NO. KS 12007 

LIST OF BIDDERS: 

I, AREVA NP, Inc. 

7207 IBM Drive 

Charlotte, NC 28262 

Attention: Tom Doering 

2. Enercon Services, Inc. 

500 Town Park Lane 

Suite 275 

Kennesaw, GA 30 I44 

Attention: Jim Gannon 

(770) 919-1930 

JganiionCilenercoii.com 

3. Sargent & Lundy, LLC 

55 East Monroe St. 

Chicago, IL 60603-5780 

Attention: Chris Sward 

4. TechCom International Corporation 

11 Redondo 

Laguna Niguel. CA 92677 

Attention: Bob Katebian 

(949) 453-0660 ex1 222 

katebiaii@,tci-comcom 

5. WorleyParsons 

2675 Morgantown Road 

Reading, PA 19607-9676 

Attention: John loannidi 

6 

PEF-NCR-01955

SCOPE AND OTHER REOUIREMENTS 


CRYSTAL RTVER NUCLEAR PLANT, UNiT #3 


- SCOPE: 

The scope ofthis request for proposal (RFP) is to supply engineering services to prepare design specifications, 

equipment specifications, Engineering Change packages and calculations for work necessary to increase the 

electrical generation at Progress Energy’s Crystal River Unit 3 (CR3) by approximately 20% by achieving a 

17% increase in reactor power and a 3% increase due to improvements in secondary plant efficiencies. This 

work includes preparation or revision to specifications for heat exchangers, pumps and valves, and conducting 

engineering design and analysis and is limited to secondary system components. The scope is further detailed in 

the bid specification. 

The Crystal River Unit 3 Nuclear Power Station (CR3), located near Crystal River, FL presently generates 903 

MWe at 100% reactor power (2568 M Wt). 

SCHEDULE: 

Proposals shall be submitted within 28 days following receipt of the proposal request. 

Specific work for this proposal as noted in Section 1.12 must be completed in accordance with the submittal 

due dates as noted in Section 1.12. 

Turbine/generator retrofit for Crystal River Unit 3 is scheduled for completion during the fall 2009 refueling 

outage. Implementation of an extended reactor power uprate of 17% is scheduled to be completed during the 

fall 201 1 reheling outage. 

TERMS AND CONDITIONS 

Terms and Conditions will be in accordance with your Mastcr Contract (or in certain cases the attached sample 

contract). Certain specific terms may be renegotiated for this specific proposal and those agreements will take 

precedent over the Master Contract. 

EXECUTION OF PROPOSAL: 

The full corporate firm or individual name and exact address shall appear on your proposal form. The signature 

must be that of a corporate officer or authorized person followed by their title. The signature(s) of all authorized 

persons signing the Proposal shall be in ink and in longhand. 

BIDDER’S PROPOSAL: 

Bidder is required to submit two (2) signed copies (one priced and one unpriced) and one (1) electronic copy of 

the entire proposal giving complete descriptive information covering Bidder’s solution, including engineering, 

construction, procurement, testing, and related work proposed to be fumished which meets or exceeds all 

functional requirements of Progress Energy’s (PE’s) RFP. Also, acknowledge that PE shall have permission IO 

4

make additional copies of Bidder's proposal, attachments, and any other submitted materials. The proposal form 

and any other requested attachment that contains prices must be submitted in a sealed envelope separate from the 

other submittals requested herein. Bidder's proposal as appropriate shall include the following: 

a. A cover letter with an inventory of the contents of the complete proposal. 

b, A clear description of your company's solution proposed to meet all functional requirements of the 

Requirements Documents and the methods used to perform those functions. 

c. The Bidder shall complete the Table of Conformance for the Scope(s) of Work contained herein, and by 

responding to each section, heading and subheading in the order they appear. The Bidder shall indicate 

for each whether your proposed solution will conform or deviate. The heading or subheading includes all 

paragraphs up to the next heading or subheading. Bidder may respond to individual paragraphs under 

such headings or subheading. Sections, headings, and subheadings are those numbered, in bold print 

and/or underlined. In preparing the Table of Conformance, Bidder must use Microsoft Excel; Bidder is 

encouraged to utilize the redlining technique in Microsoft Excel appropriately (Le., sample contract 

document). The completed Table of Conformance shall be submitted electronically with the proposal with 

an active Excel spreadsheet. 

Further, the Bidder shall provide details of nonconformance, such as an exception, alternate or 

enhancement (see below) on the Tables of Conformance in the comments section. If additional space is 

needed use numerical notation to reference your comments and provide as an attachment. If the Bidder 

fails to supply the Tables of Conformance, PE will assume the Bidder's proposed system is in 

conformance with the Scope(s) of Work and all other documents furnished with this RFP, and if the 

Bidder is the successful Bidder, the Bidder shall be required to meet all requirements without exception. 

The only acceptable classifications in the Tables of Conformance (to be indicated by letter) are: 

C (Conform) - The Bidder meets the requirement in the manner indicated. 

X (Exception) - An approach which does not meet the requirements or a requirement the Bidder declines 

to meet. 

A (Alternate) - An approach which is substantially different from the suggested approach but which meets 

the stated requirements. 

E (Enhancement) - An element not required by the Requirements Documents but offered for 

consideration. 

The technical response as expressed in the Tables of Conformance shall bc such as to enable PE's 

personnel to make a thorough and complete evaluation and arrive at a sound determination as to whether 

or not the solution proposed and described will satisfy the requirements of PE. The proposal should be 

specific, detailed, and complete to clarify and fully demonstrate that the Bidder has a thorough 

understanding of the requirements for and technical problems inherent in the performance for the 

described Work. It should also demonstrate that the Bidder has a valid and practical solution for such 

problems. 

Statements that the Bidder understands the Scope(s) of Work or that Bidder can or will comply with all 

requirements and statements paraphrasing the requirements or parts thereof are considered insufficient. 

Phrases such as "Standard procedures will be employed," "Well-known techniques will be used,'' etc., will 

be considered insufficient. The proposal must be sufficient to indicate how the Bidder proposes to comply 

with all requirements and procedures to be exercised. Clarity and completeness ofthe technical approach 

will be given much attention. Only written data submitted with the proposal and subsequent clarifications 

will be considered. Orally submitted data will not be considered. 

All information pertinent to a particular requirement item ofthe Scope(s) of Work must be given in each 

5 

PEF-NCR-0 1957

place in the proposal at the expense of some (but not excessive) redundancy if necessary. 

d. 

Answer all questions proposed by PE. The response to each question shall be cross-referenced to the 

Bidder's proposal where applicable. 

e, Bidder shall acknowledge that discounts provided by hardware suppliers to Bidder, at the time of 

submitting Bidder's proposal, shall also apply tothe actual hardware that will ultimately be furnished PE, 

regardless of size or quantity. Further, in the event any greater discounts are received by Bidder at the 

time of delivery, Bidder shall proportionally pass such discounts on to PE. 

f. Provide a preliminary milestone schedule for accomplishing this work. 

SPECIAL REOUIREMENTS: 

Familiaritv with Laws: 

The Bidder is assumed to be familiar with all federal, state, and local laws, ordinances, and regulations which may 

in any manner affect those engaged or employed in the work, the materials or equipment in the work or the conduct 

of the work. PE should be immediately contacted for clarification if a bidder should discover provisions in any 

drawings, specifications or contractual documents contrary to or inconsistent with any such law, ordinance or 

regulation. 

Confidentialitv: 

0 

All drawings, specifications, and contractual documents will remain the property of Progress Energy and are to 

be returned in good condition within ten (1 0) days after the date set for receiving bids. These documents shall 

not be reproduced or used for any purpose other than for the preparation of a proposal in accordance with this 

request. The information contained in these documents is proprietary and confidential and shall be maintained 

in strict confidence. 

Interpretat ion: 

An interpretation request shall be made to Progress Energy ifa bidder is in doubt as to the true meaning ofany 

part of the drawings, specifications, or contractual documents. Modification of the documents will be made 

only by written addendum issued to each bidder as described below. 

Exceptions: 

If a bidder's proposal contains any deviations or exceptions, those deviations or exceptions must be specifically 

identified either in the Table of Conformance or on a single separate attachment to the proposal in order to be 

considered in the evaluation. If not so identified, the deviations or exceptions will not be considered part of the 

proposal. Conditional proposals based on bidder-generated clarifications may not be accepted. If a bidder 

takes any exceptions in addition to those submitted in accordance with this section, that bidder's proposal may 

be rejected by Progress Energy. 

Sample contract documents are not included for bidders possessing a Master Contract with Progress Energy. 

All other bidders, if successful, will review and redline the enclosed SAMPLE contract format. Any 

exceptions to the contract documents must accompany the proposal as detailed above and the exceptions will 

be considered in the bid evaluation process. 

Approved Eaual Evaluation: 

Submittals by bidders for evaluation of products as "approved equal" shall be made to the appropriate 

6 

PEP-NCR-0 1958

designated individual listed in the Request for Proposal at least ten (1 0) days prior to the proposal due date. 

Results of evaluations will be provided no later than seven (7) days prior to the proposal due date. Submittals 

made later than ten (1 0) days prior to the proposal due date will not be considered. 

Addenda: 

Progrcss Energy reserves the right to amend or clarify requirements herein by Addenda. These may be issued 

at any time prior to the date for receipt of proposals and may be mailed or otherwise delivered to all bidders 

who have been invited to bid. Request by a bidder for extension of the proposal due date shall be received by 

Progress Energy at least one week prior to the then scheduled date. If revisions or clarifications are of 

magnitude to warrant, in the opinion of Progress Energy, the extension of the date set for receipt of proposals, 

an addendum will be issued announcing the new date, Failure of a bidder to acknowledge receipt of any 

addendum in the space provided on the proposal form may result in rejection of that proposal. 

0 

Progress Energy is committed to using safety conscious contractors. To this end, Progress Energy collects 

safety-related data voluntarily provided by all persons performing or desiring to perform Progress Energy work. 

This data is compiled and made available to Progress Energy employees via Progress Energy's intranet. This 

intranet system is accessible by non-Progress Energy employees, and thus, so will be any safety-related 

information you provide. In providing the safety-related information requested herein, to Progress Energy or to 

any other person doing business, directly or indirectly, with Progress Energy, the undersigned contractor 

explicitly authorizes Progress Energy to disclose said information to non-Progress Energy persons and hereby 

releases Progress Energy and its agents and employees from any cause ofaction or claim for damages related to 

said disclosures. 

PE also requires that Contractor complete the attached Safety Checklist form and contractor must score 

appropriately (green) in order to be awarded contract. 


This work is classified as NON-SAFETY RELATED. 

All site assigned personnel ofthe successful bidder who are to be granted unescorted access to the plant site are 

requircd to attend a prerequisite securityhadiation training class prior to entering radiation controlled areas. 

When Contractor's employces must apply for unescorted access, the screening of Contractor employees will be 

performed by Owner in accordance with the latest revision of the document titled "Nuclear Worker Screening 

Requirements for Unescorted Access," the current revision of which is attached to this Contract. The 

document contains instructions to the Contractor with respect to providing employees for screening by Owner. 

Owner will send Contractor revisions to the document, and Contractor shall acknowledge receipt of the 

revision in writing. In the event Contractor performs screening at Owner's request, Contractor grants to Owner 

the right to audit all documentation resulting from Contractor's employee screening process on its own behalf 

or in conjunction with the U.S. Nuclear Regulatory Commission. 

Bidder's attention is specifically directed to the stringent security, fitness-forduty, health physics, ALARA, and 

quality check provisions which apply to this work. These criteria are dctined in the attached spccimen 

Contract. 

Award of Conhact / Kipht to Keiect Proposals: 

PE will award the contract to the Bidder submitting the best evaluated proposal which complies with the 

requirements herein. PE will utilize Bidder's Tables ofconformance, all requested attachments, references, and 

I 

PEF-NCR-0 1959

other information provided in its process ofevaluating Bidder's proposal. PE may, in its sole discretion, reject any 

or all proposals received or waive minor defects, irregularities or informalities therein. 

a. Upon reaching the award decision, PE may elect to issue a Letter of Intent to the successful Bidder. 

Bidder shall include a statement within its proposal as to its commitment to start work immediately and 

continue performance of such work upon receipt of such letter. 

b. The successful Bidder may be required to fumish corporate guaranties from each of its corporate 

ownerships up to and including the parent corporation. Such documents will be due upon execution of the 

contractual document. Bidder shall include a statement within its proposal acknowledging Bidder's 

understanding and agreement to fumish such corporate guaranties in the form furnished with this RFP. 

Schedule Risk: 

Timely completion of the design work for secondary systems for Crystal River Unit 3 must be completed 

in accordance with the submittal due dates in Section 1.12 of the Bid Specification to support the fall 2009 

refueling outage and implementation of an extended reactor power uprate of 17% during the fall 201 1 

refueling outage is critical to the success of this project. Therefore, the selected bidder will be asked to 

place profit at risk to demonstrate understanding and ownership of the schedule. 

Irrevocable Standby Letter of Credit: 

Bidder shall affirm on the proposal form its ability and willingness to fumish, in PE'sfavor, an irrevocable standby 

Letter of Credit per the Contract. The Letter of Credit shall remain in full force and effect during the term of the 

contract and may be engaged by PE in the event of Bidder's default under any such contract. 

~nsurance: 

Furnish proof of valid insurance per contractual requirements. 

Alternate Bid Formats: 

A bid based on the requirements noted herein is required; however, PE encourages Bidder to propose an altemative 

response.

.:_ 

e 1. 

2. 

Classifications of each type person you intend to bill for. 

Hourly billing rates for each personnel classification (may be straight timdovertime or all-hours rate) 

PROPOSAL INCLUSIONS: 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

Billable travel and living expenses. 

Estimated man-hours for each personnel classification. 

Provide a maximum not-to-exceed contract dollar amount to accomplish the work. 

Resumes of people you intend to use on this project. 

Provide the earliest date that you could start work on this project. 


Redlined copy of Sample Contract if applicable. 

Completed Table of Conformance provided electronically as an active Excel spreadsheet. 

Complete Contractor Safety Information/Checklist Form. 

PEF-NCR-0 196 1

a ProgressEnergy 

Contractor's Safety InformatiodChecklist Form 

RPOSE: Please supply the following safety information for your company. Safety is important to Progress Energy and will 

be used as criteria in selecting contractors. NOTE: lNCOMPLETE FORMS CANNOT BE PROCESSED. 

SECTION 1: TO BE COMPLETED BY THE CONTRACTOR 1 

Contractor Name: 

Address: 

Web Site Address (optional): 

Telephone: 

NAICS Code: 

Scope of Work: 

____ ~ 

Name of Subcontractor(s) if 

applicable: 

Progress Energy Contact: 

I 

~ 

Safety Program 

Please provide your current written safety manual (diskette or CD-ROM, if possible). (Note: 

Unless there are changes to the manual, resubmission is not necessary for annual reviews). 

Does your company have a high level corporate officer responsible for safety compliance? I I I 

I I 

oes your company have a formal safety program to assure compliance with safety regulations? I 

I I I 

Does program include: 

Job hazard analysis and control 

Medical management of work related injuries and illnesses 

On-site supervision to ensure compliance with safety regulations and Progress Energy 

Safety policies 

Pre-qualification and management of subcontractors to ensure compliance with safety 

regulations and Progress Energy Safety policies 

Does your company hold periodic crewlteam safety meetings? 

Howoften? 

Does your company provide and document required initial and refresher training to prepare 

employees to perform duties in compliance with safety regulations? NOTE: If a contract is 

awarded, the DR will need this documentation prior to commencement of work for Progress 

Energy. 

Compliance History 

Has a serious, willful or repeat OSHAcitation been issued to your company within the last three 

years? (Please check the OSHA web site at www.osha.aov/oshstats and click on Establishment 

Search). This site also provides SIC numbers. 

If yes, please provide a copy of the citation and a certification of abatement. 

I I 

Has your company and/or any of its officers been convicted of any violation of any federal or state 

occupational health and safety laws? 

If yes, please attach a description of this case, including its resolution. 

Cine B Service Contractors: Is your Federal Motor Carrier Safety Rating Satisfactory? (Can be 

round at httD:Nivw\Y.safersys.or~ ) If not, state what the rating is (Unsatisfactory or Conditional). I 1 I 

I 

Keyuordi: safety: heallh and safety guidanw daumenl: s ~ - s U B S ~ 1 

App(lrs lo: Prqrerc Energy Csmllnas. lnc : Pfogrrir EwrW Ftaridi, Inc.; NorV) Cardins NolmI Oar Caporobon; Pfogrorr Energy Sanica Company. UC: 

Prqrsar Tdacom Corporatim. Slratbgic RdMurCd SOIUIION Cow.: Earcem Nodh Csralina Narurai Go$ Cap. 

FRMSUBW78 

Rev. 3 Ms 

Pqa 1013 

PEF-NCR-0 1962

~~ ~~~ 

~ 

L 

Using your company's OSHA log for the last 3 years: Yr: 2002 Yr: 2003 Yr: 2004 

e 

Total number of OSHA Recordable injuries and illnesses 

Total number of cases involving Days Away, Restricted or Transferred 

e Total number of fatalities I 

Employee hours worked each year for last three years 

OSHA Incident Rate last three years (01 Rate)' 

Days Away, Restricted or Transferred Rate last three years (DART Rate)' 

Your company's EMR for the last three years 

Rates are calculated as follows: 01 Rate= # OSHA Recordable injuries X 200.004 DART Rate= # cases lnvolvina DARTX 200.000 

#employee hours 

# employee houn 

Please have an authorized representative of the company who is responsible for your company's safety program sign on the 

line below certifying that the information provided above is current and accurate. Providing false information may result in 

termination of the contract. 

Name: 

Signature: 

Title: 

Date: 

I SECTION 2: TO BE COMPLETED BY THE PROGRESS ENERGY DR OR CONTRACT SERVICES 

Print Name, Location and Phone of Designated Rep: 

- Final RxG(realth & Safety Support): I RED YELLOW* 0 GREEN 0 

Signature: 

Comments: 

. 

Recommended Rating (DRKontract Services): 1 RED 0 YELLOW 

Signature: Date: 

I 

I SECTION 3: TO BE COMPLETED BY THE HEALTH AND SAFETY SUPPORT 

Date 

'Necessary improvements to upgrade contractor from Yellow to Green: 

Keywo~dr: uafaty; hrehh end ufary guidm Qwmfflt SAfSUBSQoO41 

FRM-SUBS.00478 

ADDIIW lo: Prwresa EMrW Carolinas. Inc: Pmmess €new Florida, Inc, Norlh Cwllns NutJmI Gas Carpaation, Proorers Energy Servlm Company ILC, Rev 3 2105 

Pfc+ets Tsle&m Caporalan, Stralagic Resou~oe Solull~s Cap, Eastern Noflh CamltM NatufaI Gas Carp Page 2 Ol 3 

PEF-NCR-0 1963

1 

P96 I O-XJN-d3d

Section Referena 

Crystal River Unit 3 Nuclea 

xtended Power Uprate Bid Specification 

of Conformance - Technical 

Table 

1 1 . 1 I 

IIII 

-- 

I 

Prepare an EC to replace the piping upstream of Heater Drain Valves HDV- 

247. -248. -249, and -250 with piping with a higher pressure and temperalure 

rating 

Secondary Services Closed Cycle Coollng System Modifications 

0 Perform an evaluation to determine the maximum capacity and cooling flow of 

the Secondary Cooling Heat Exchangers based on existing space limitations. 

Perform an evaluation to determine the maximum Row by replacing the SC pump 

impellers and motors 

0 Prepare a new specification for the Secondary Cooling Heat Exchangers 1A 

and 18 

0 Prepare an EC to purchase two new SC heat exchangers 

0 Prepare an EC to install two new SC heat exchangers 

0 Revise Secondary Cooling pumps and motors. SCP-1A and -16 specification 

Prepare an EC to purchase two new SC pump impellers and motors 

0 Prepare an EC to install two new SC pump impellers and motors 

Circulating Water System Modifications 

0 Revise specification for Circulating Water Dumps and motors CWP-1A -16. 

1C. and -1D to achieve a nominal flow of 207,400 gpm 

0 Prepare an EC to purchase four new CW pump impellers and motors 

- 

Comments 

I I I I 0 Prepare an EC to install four new CW pump impellers and mot06 and uwrade I I 

the cirwiatina water svstem exnansion iointiat the condenser as reauired I I 

I 

Revise swcification for the Condensate Dum= and motors. CDP-IA and -16 I I 

Condensate pumps and motors 

to achieve the required flow for EPU conditonsinduding incorporation of variable 

speed drives and compatible condensate flow control 

0 Prepare an EC to purchase two new CD pump impellers and motm equipped 

with variable speed drives 

Prepare an EC to install two new CD pump impellers. motors and the 

associated variable speed drives 

Feedwater Booster pumps and motors 

0 Revise specification for the Feedwater Booster pumps and motors. FWP-1A 

and -18 to achieve the required flow for EPU conditions including increasing the 

flow margin to 10% 

0 Prepare an EC to purchase two new feedwater booster pumps and mo:ors 

0 Prepare an EC to install hrro new feedwater booster pumps and motors 

Feedwater Control Valves and Feedwater Control System Stability 

0 Perform an evaluation lo determine if the feedwater control valves and 

feedwater control system are stable under EPU conditions 

Condenser 

Condud an update to existing condenser performance and Row-induced 

vibration calculations. This shall also include an evaluation of waterbox 

temperature limits and shielding designs for internal components. The update is 

to be subcontracted to Heat Exchanger Services 

Electrical Distribution Calculations 

I 

Oocm- 

“7 

2

~ ____, 

Crystal River Unit 3 Nuclea 

xtended Power Uprate Bid Specification 


Table 

0 Perform an evalution of the station auxiliary transformer, startup transformer. 

and the 4KV buses, switchgear, circuit breakers and cabling to support the 

expected increase in the electrical load 

0 Update the following electrical distribution calculatlons to evaluate the 

adequacy of existing power system equipment ratings (auxiliary transformers. 

load centers. motor control centers. swtchaear. cables. etcl to SUDIIO~~ the hiaher 

.. 

system load and identify required upgrade; of the eleckidistribution systeh 

0 Voltage Drop/Short Circuit for AC Electrical System - SKM Software 

Non Safety 125 VDC - ETAP Software 

Mechanical Ultimate Haat Sink Calculations 

0 Update the following Mechanical Ultimate Heat Sink Calculations to reflect EPU 

I conditions 

0 Calculation M97-0133. 'SW Heat Loads During LBLOCA and SW 

Temperature Oecay Times," Rev 11 

0 Calculation M95-0020, "DCHE Performance Evaluation." Rev 1 

0 Calculation M95-044, 'RWIDCIDH Thermal Analysis - DC Temperature 

Calculatian " Rev 1 

. . 

I 0 Calculation M95-0035. "SW System Inventory Transient Analysis." Rev 2 

1 Turbine Building Structural Evalwtlon 

1 0 Perform an evaluation of the turbine building structure and supports for maior 

equipment to identify if any significant changes are required to a&mmodate the 

expected increases in loads resulting from new and larger equipment such as 

I 

Each of the major tasks described in &ion 1.9 should be bid separately 

Each of the computer model updates described in section 1.9 shouw be bid 

separately 

Comments 

I 

I 

Tasks must be completed in accordance with the schedule detailed in section 1.12 

All work will be done in accordance with the: 

Codes and Standards detaded in section 3 1 

0 Regulatory Requtrements detaiid in section 3 2 

Owner Procedures detailed in sectan 3 3 

0 Specifications detailed in sectcon 10.2 

0 PLIDs detailed in section 10 3 

Calculations detailed in section 10 0 

_. 


3




Extended Power Uprate Bid Specification 

Secondary Systems 

June 25,2007 

PEF-NCR-0 1967

Progress Energy Crystal River Unit 3 

Request for Proposal for Engineering Services to Upgrade Secondary System 

6/25/2007 


0 1 . 0 SCOPE ...................................................................................................... 3 

1-1 General .................................................................................................. 3 

1.2 Objectives .............................................................................................. 5 

1.3 Proposal Pricing ..................................................................................... 6 

1.4 QA Condition .......................................................................................... 7 

I . 5 Existing Configuration ............................................................................ 7 

1.6 Operating Conditions ............................................................................. 8 

1.7 Scope of Supply ..................................................................................... 9 

1.8 Scope of Supply by Owner ..................................................................... 9 

1.9 Scope of Services ................................................................................ 10 

1.10 Schedule .............................................................................................. 13 

1.11 

Required Bid Documentation ............................................................... 13 

1 . 12 Required Documentation After Award .................................................. 15 

2.0 DEFINITIONS .......................................................................................... 18 

3.0 REFERENCES ........................................................................................ 18 

3.1 Codes and Standards .......................................................................... 18 

3.2 Regulatory Requirements ............................................. ................ 19 

3.3 Owner Procedures ............................................................................... 19 

4.0 DESIGN REQUIREMENTS ..................................................................... 20 

5.0 MATERIAL REQUIREMENTS ................................................................. 20 

6.0 INSPECTION AND TESTING .................................................................. 20 

7.0 FABRICATION REQUIREMENTS ........................................................... 20 

8.0 INSTALLATION REQUIREMENTS ......................................................... 20 

9.0 SHIPMENT .............................................................................................. 20 

10.0 ATTACHMENTS ...................................................................................... 21 

10.1 Scope of Services Detail ...................................................................... 21 

10.2 Specifications ............... ............................................................... 43 

................................................................................... 43 

10.4 Calculations .......................................................................................... 43 

10.5 Procedures ........................................................................................... 44 

2


Request for Proposal for Engineering Services lo Upgrade Secondary System 

6/25/2007 

1.0 SCOPE 

0 1.1 General 

The purpose of this document is to provide information to prospective bidders 

to supply engineering services to prepare design specifications, equipment 

specifications, Engineering Change packages and calculations for work 

necessary to increase the electrical generation at Progress Energy's Crystal 

River Unit 3 (CR3) station by approximately 20% by achieving a 17% 

increase in reactor power and a 3% increase due to improvements in 

secondary plant efficienaes. This work includes preparation or revision to 

specifications for heat exchangers, pumps and valves, and conducting 

engineering design and analysis and is limited to secondary system 

components. 

The Crystal River Unit 3 Nuclear Power Station, located near Crystal River, 

Florida presently generates 903 MWe at 100% reactor power (2568 MWt). 

CR3 is planning an "Appendix K" feedwater flow measurement uncertainty 

recovety (MUR) uprate of 1.6 % reactor power (to 2609 MWt, 914 MWe) 

during the fall 2007 refueling outage. The CR3 steam generators, low 

pressure turbines, main generator and other significant equipment will be 

replaced during the fall 2009 refueling outage. The fall 2009 refueling outage 

is expected to begin in September 2009 and will have a duration of 

approximately 80 days. During the fall 201 1 refueling outage, CR3 is planning 

to implement an extended reactor power uprate to achieve an additional 

15.4% reactor power (3030 MWI including pump heat, 1080 MWe) and 

additional secondary plant upgrades including replacement of the high 

pressure turbines. The total extended power uprate from present will be 

approximately 20% including the MUR uprate and improvement in thermal 

efficiency. 

The Extended Power Uprate (EPU) at CR3 requires some design changes, 

procurement of new equipment and substantial changes to some existing 

equipment such as the main generator and exciter, LP and HP turbines, 

condensate pumps, feedwater booster feed pumps, circulating water pumps, 

secondary cooling pumps, moisture separator reheaters, low pressure 

feedwater heaters, as well as new and revised calculations and evaluations. 

A proposal to prepare design specifications and installation modifications for 

these design changes is requested. In addition, new systems are required to 

achieve the desired electrical output. These design changes are the addition 

of four Moisture Separator Reheater (MSR) Belly Drain Heat Exchangers; 

valves, piping, and controls for a Deaerator bypass line; and an upgrade of 

the lsophase Bus Duct Cooling System to make the motors and fans 

redundant. In addition to the design specification, equipment Specifications 

are required for the MSR Belly Drain Heat Exchangers, the Deaerator bypass 

line control valve, and the new lsophase Bus Duct Cooling System. 

Equipment that is being substantially changed and requires new or revised 

specifications follows. Specifications shall be prepared as outlined in 

3 

PEF-NCK-0 1969



6/25/2007 

procedure EGR-NGGC-0020. This equipment is being replaced with like 

components that have higher capacities. 

Feedwater Heaters CDHE-3A and -38 (2) 

Heater Drain Valves HDV-101, -102, -103, and -104 (4 valves) 

Secondary Cooling Heat Exchangers 1A and 18 (2) 

Secondary Cooling pumps and motors, SCP-IA and -1 6 (2) 

Circulating Water pumps and motors IA, 18, 1C and 1D (4) 

Condensate pumps and motors CDP-1A and -1 B 

Feedwater Booster pumps and motors FWP-1A and -18 

In addition to preparation of procurement documents for equipment, 

engineering support is required to perform a number of analyses and 

evaluations. Update of the existing computer models and calculations for an 

NSSS output of 3030 MWt (3014 MWt + 16 MWt RCP heat) are required, 

Calculations and analyses shall be prepared as outlined in procedure EGR- 

NGGC-0017. 

PEPSE (thermal performance) 

FATHOM (hydraulic) 

CHECWORKS (flow accelerated corrosion) 

Electrical Distribution System calculations (ETAP and SKM) 

Calculation M97-0133, "SW Heat Loads During LBLOCA and SW 

Temperature Decay Times," Rev 11 

Calculation M95-0020, "DCHE Performance Evaluation," Rev 1 

Calculation M95-0044, "RW/DC/DH Thermal Analysis - DC 

Temperature Calculation," Rev 1 

Calculation M95-0035, 'SW System Inventory Transient Analysis," 

Rev. 2 

Coordination of an update to existing condenser performance and flowinduced 

vibration by Heat Exchanger Services (HES) is required. New 

analyses/evaluatians are required for the feedwater heaters, secondary 

cooling heat exchanger sizing, feedwater control valve stability, and a 

structural evaluation of the turbine building considering the new equipment to 

be installed. 

- 

The third segment of this work scope is to prepare Engineering Change (EC) 

packages for purchase of equipment. The EC's shall be prepared as outlined 

in Procedure EGR-NGGC-0005, "Engineering Change". The following 

Engineering Change packages are required. The requirements of NGGM- 

PM-0020, "Vendor Quality Program for Critical Non-Safety Equipment" apply 

to these components also. 

Feedwater Heaters CDHE-JNB (2) 


Secondary Cooling Heat Exchangers 1A and 16 (2) 

Circulating Water pumps and motors lA, lB, 1C and 1D (4) 

Secondary Cooling pumps and motors, SCP-1A and -1 B (2) 



The final part of this task is to prepare EC's (EGR-NGGC-0005) to install the 

following upgrades. 

Feedwater Heaters CDHE-3A and -38 (2) 

4 

PEF-NCR-01970



@25/2007 


Secondary Cooling Heat Exchangers 1A and 1B (2) 

Circulating Water pumps and motors lA, 18, 1C and 10 (4) 

Secondary Cooling pumps and motors, SCP-1A and -16 (2) 



Moisture Separator Reheater (MSR) Belly Drain Heat Exchange1 

Oeaerator bypass line 

Redundant lsophase Bus Duct Cooling System 

New Low Pressure Turbine rotors and inner casings (2) 

New High Pressure Turbine rotor and inner casing 

New Main Generator and Exciter 

New Moisture Separator Reheaters (4) 

In addition to these upgrades, an EC to replace the piping upstream of Heater 

Drain Valves HDV-247, -248, -249, and -250 with piping with a higher 

pressure and temperature rating is required. 

1 .Z Objectives 

The objective of this proposal request is to oblain bids on engineering 

sewices for work associated with upgrading the secondary systems at Crystal 

River Unit 3 necessary to support the Extended Power Uprate. 

1.2.1, Prepare design specificalions for the addition of MSR belly drain heat 

exchangers, addition of a deaerator bypass line, replacement of the 

condensate pumps, motors and controls with a variable speed design, 

and an upgrade of the lsophase Bus Duct Cooling System to make 

the motors and fans redundant. 

1.2.2. Prepare new equipment specifications for MSR belly drain heal 

exchangers, a deaerator bypass line conlrol valve, and the lsophase 

Bus Duct Cooling System motors and fans. 

1.2.3. Revise existing specifications for Feedwater Heaters CDHE-3A and - 

38, Heater Drain Valves HDV-101, -102, .103, and -104, Secondary 

Cooling Heat Exchangers 1A and lB, Circulating Water pumps and 

molors lA, 18, IC and ID, Secondary Cooling pumps and motors, 

SCP-1A and -1 6, Condensate pumps, motors and variable speed 

drives, CDP-1A and 18, and Feedwater Booster pumps and motors, 

WP-2A and 28. 

1.2.4. Update the existing PEPSE, FATHOM, CHECWORKS computer 

models. 

1.2.5. Updale existing calculations for the Electrical Distribution System 

(Calculation E90-0044), Calculation M97-0133, "SW Heat Loads 

During LBLOCA and SW Temperature Decay Times," Rev 11, 

Calculation M95-0020, "DCHE Performance Evaluation," Rev 1, 

Calculation M95-0044, "RWIOCIDH Thermal Analysis - DC 

Temperature Calculation," Rev 1, and Calculation M95-0035, 'SW 

System Inventory Transient Analysis,' Rev. 2 

1.2.6. Conduct an update to existing condenser performance and flowinduced 

vibration calculations. The update is lo be performed by Heat 

Exchanger Services. 

5



8/25/2007 

1.2.7. Perform an evaluation to determine the maximum capacity and 

cooling flow of the secondary cooling heat exchangers and secondary 

cooling motor, pump, and impellers based on existing space 

limitations. 

1.2.8. Determine if the feedwater control valves and main feedwater pump 

control system are stable under EPU conditions. 

1.2.9. Perform an evaluation of the existing feedwater heaters to 

characterize the existing condition and establish a monitoring program 

following EPU implementation. 

1.2.10. Prepare Engineering Change packages and other associated 

procurement documentation for purchasing new Feedwater Heaters 

CDHE-3NB, Heater Drain Valves HDV-101, -102, -103, and -104, 

Secondary Cooling Heal Exchangers 314 and 38, Circulating Water 

pumps and motors lA, 18,lC and 10, Secondary Cooling pumps 

and motors, SCP-1A and -, Condensate pumps, motors and variable 

speed drives, CDP-1A and 18, and Feedwater Booster pumps and 

motors, FWP-2A and 28. 

I .2.11 Prepare EC’s (EGR-NGGC-005) to install the new Feedwater Heaters 

CDHE3A and -38, Heater Drain Valves HDV-101, -102. -103, and - 

104, Secondary Cooling Heat Exchangers 1A and 18, Circulating 

Water pumps and motors 1 A, 1 B, 1C and 1 D, Secondary Cooling 

pumps and motors, SCP-IA and -18, Condensate pumps, motors 

and variable speed drives, CDP-1A and lB, Feedwater Booster 

pumps and motors, FWP-PA and 28, , MSRs and MSR Belly Drain 

Heal Exchangers, Deaerator bypass line, redundant lsophase Bus 

Duct Cooling System, and High and Low Pressure Turbine rotors and 

inner casings and turbine generator and exciter. 

1.2.12. Prepare an EC to replace the piping upstream of Heater Drain Valves 

HDV-247, -248, -249, and -250 with piping with a higher pressure and 

temperature rating. 

1.2.13 Conduct an evaluation of the turbine building structure considering the 

expected additional loads resulting fmm installation of new and larger 

equipmen!. 

1.3 Proposal Pricing 

Seller shall evaluate and present bid proposal pricing in the following formats: 

1.3.1 Each of the major tasks described in Section 1.9 should be bid 

separately. 

1.3.2 Each of the computer model updates described in Section 1.9 should 

be bid separately. 

1.3.3 Combine the total work scope. 

6 

PEF-NCR-01972



6/25/2007 

4.4 QA Condition 

The equipment identified in this proposal request is classified as non-nuclear 

safely related. The analysis work described in this proposal request is 

classified as non-nuclear safety related except for the revision of the existing 

mechanical calculations and the evaluation of the feedwater block valves. 

1.5 Existing Configuration 

The existing configuration is described in existing drawings, specifications 

and calculations. 

7 

PEF-NCR-0 I973



612512007 

1.6 Operating Conditions 

The existing operating conditions are described in existing drawings, 

specifications and calculations. The following are the operaling conditions 

used to determine the scope of work included in this proposal request. 

Prellmlnaty Operating Conditions 

Parameter 

Current 

Steam Generator Thermal Output 

RCS High Temperature Trip Limit 

2619.4 3020.06 

Feedwater Temperature to SG Inlet 

(OF) 

Turbine Header Pressure (psia) 

MS AP SG Oullet to Header (psid) 

Estimaled SG AP (psid) 

SG Inlet Pressure (psia) 

AP MFWP Oischarge to SG Inlet 

(psid) 

MFWP Discharge Pressure @sia) 

Steam Temperature ( OF) 

Condenser Design Back Pressure 

400 46 1 

900 930 

23.4 34 

35 60 

958.4 1024 

54,8 68 

1013 1092 

584 582 

2.5 f 1 .O 2.7 f 1.0 

PEF-NCR-0 1974



6125/2007 

0 

I .7 


This proposal request is limited to engineering services. Supply of equipment 

is not within the scope of this proposal request. 

1.8 Scope of Supply by Owner 

1.8.1 Access to system design information. Identification of the required 

information is the seller's responsibility. The purchaser shall provide 

VPN access to necessary documenls such as drawings, procedures, 

specifications, etc. 

1.8.2 Access to any electrical equipment panels, cubicles, etc. is only 

permitted with approval of responsible owner personnel in accordance 

with approved procedure% . . . , , . . ... . .. , , . . . . , , , . . .. , . , . .._.. . . . . .. . . . . . .....-.( 

1.8.3 Operations personnel to perform shutdown, startup, draining, filling, 

isolation, and other normal system operating functions. 

1.8.4 Safety clearance and tagging of all equipment. 

1.8.5 Removal and installation of insulation. 

1.8.6 All electrical disconnects and terminations required to perform work. 

1.8.7 Construction and removal of scaffolding. 

1.8.8 Radiation protection technicians if required. 

1.8.9 Unescorted access training for seller's personnel. 

1.8.10 Preparation of post installation test procedures. Supply of test 

instrumentation. Performance of post installation tests and preparation 

of associated test reports, unless speafied within separate contracts. 

Deleted:. 

-) 

9 

PEF-NCR-0 1975



6/25/2007 

0 

1.9 Scope of Services 

This section provides an outline of the scope of supply of engineering 

services for this proposal request. Additional detail can be found in 

Attachment 10.1. 

1.9.1 Computer Models 

Update the following computer models for EPU conditions 

PEPSE 

FATHOM 

CHECWORKS 

1.9.2 MSR Replacement and MSR Belly Drain Heat Exchanger Addition 

Prepare an EC to install four new moisture separator reheaters 

including an evaluation of the MSR relief valves. The supplier 

of the new turbine rotors is providing the new MSRs. 

Add four new MSR belly drain heat exchangers 

o Design Specification 

o Prepare an MSR belly drain heal exchanger specification 

o Prepare an EC to purchase four new MSR belly drain heat 

exchangers 

o Prepare an EC to install 4 new MSR belly drain heat 

exchangers, valves, piping, and controls 

1.9.3 Turbine Generator Modifications 

Prepare an EC to install two new low pressure turbine rotors 

and inner casings 

Prepare an EC to install a new high pressure turbine rotor and 

inner casing 

Prepare an EC to install a new Main Generator and Exciter 

1.9.4 Deaerator Bypass Line Addition 

Prepare a design specification 

Prepare a specification for a new control valve 

Prepare an EC to purchase new control vatve 

Prepare an EC to install new valves, piping, and controls 

1.9.5 Upgrade of the lsophase Bus Duct Cooling System 

Determine the adequacy of the existing isophase bus ampacity 

Prepare a design specification 

Prepare a specification for new lsophase Bus Duct Cooling 

System including fans, motors, and controls 

9 Prepare an EC lo purchase new equipment 

Prepare an EC to install new lsophase Bus Duct Coaling 

System 

10 

PEF-NCR-0 1976



6/25/2007 

1.9.6 Feedwater Heater and Feedwater Heater Drain Modifications 

Replacement of Feedwater Heaters CDHE3A and -38 

o Prepare a feedwater heater specification 

o Prepare an EC to purchase two new third point feedwater 

heaters 

o Prepare an EC to install 2 new third point feedwater 

heaters 

Evaluation of the existing feedwater heaters 

o Characterize the condition of the existing feedwater 

heaters that will remain in service 

o Establish a monitoring program following EPU 

implementation for these feedwater heaters 

Heater Drain Valves HDV-101, -102, -103, and -104, 

o Prepare a valve specification for the first point heater drain 

valves 

o Prepare an EC to purchase four new first point feedwater 

heater drain valves 

o Prepare an EC to install four new first point feedwater 

heater drain valves 

Heater Drain Valves HDV-247, -248, -249, and -250 

o Prepare an EC to replace the piping upstream of Heater 

Drain Valves HDV-247, -248, -249, and -250 with piping 

with a higher pressure and temperature rating. 

1.9.7 Secondary Services Closed Cycle Cooling System Modifications 

Perform an evaluation to determine the maximum capacity and 

cooling flow of the secondary cooling heat exchangers based 

on existing space limitations. Perform an evaluation to 

determine the maximum flow by replacing the SC pump 

impellers and motors. 

Prepare a new specification for the Secondary Cooling Heat 

Exchangers 1A and 18 

Prepare an EC to purchase hvo new SC heat exchangers 

Prepare an EC to install two new SC heat exchangers 

e Revise Secondary Cooling pumps and motors, SCP-1A and - 

1 B specification 

Prepare an EC to purchase two new SC pump impellers and 

motors 

Prepare an EC to install two new SC pump impellers and 

motors 

11 

PEF-NCR-0 1977


Request for Proposal for Engineering Services lo Upgrade Secondary System 

6Q512007 

1.9.8 Circulating Water System Modifications 

Revise specification for Circulating Water pumps and motors 

CWP-IA, lB, IC and ID to achieve e nominal flow of 207,400 

QPm 

Prepare an EC to purchase four new CW pump impellers and 

motors 

Prepare an EC to install four new CW pump impellers and 

motors and upgrade the circulating water system expansion 

joints at the condenser as required. 

1.9.9 Condensate pumps and motors 

Revise specification for the Condensate pumps and motors, 

COP-1A and 1 B to achieve the required flow for EPU 

conditions including incorporation of variable speed drives and 

compatible condensate flow control. 

Prepare an EC to purchase two new CD pump impellers and 

motors equipped with variable speed drives 

Prepare an EC to install two new CD pump impellers, motors 

and the associated variable speed drives 

1.9.10 Feedwater Booster pumps and motors 

Revise specification for the Feedwater Booster pumps and 

motors, FWP-1A and 1 B to achieve the required flow for EPU 

conditions including increasing the flow margin to 10%. 

Prepare an EC to purchase two new feedwater booster pu ps 

and motors 

T 

Prepare an EC to install two new feedwater booster pumps, I 

and motors 

I .9.1 I Feedwater Control Valves and Feedwater Control System Stability 

Perform an evaluation to determine if the feedwater control 

valves and feedwater control system are stable under EPU 

conditions. 

1.9.12 Condenser 

Conduct of an update to existing condenser performance and 

flow-induced vibration calculations. This shall also include an 

evaluation of waterbox temperature limits and shielding 

designs for internal componenls. The update is to be 

subcontracted to Heat Exchanger Services. 

1.9.13 Electrical Distribution Calculations 

Perform an evaluation of the station auxiliary transformer, 

startup transformer, and the 4KV buses, switchgear, circuit 

breakers and cabling to support the expected increase in the 

electrical load. 

Update the following electrical distribution calculations to 

evaluate the adequacy of existing power system equipment 

ratings (auxiliary transformers, load centers, motor control 

centers, switchgear, cables, etc) to support the higher system 

12



6125/2007 

load and identify required upgrades of the electrical distribution 

system. 

o Voltage DroplShort Circuit for AC Electrical System - SKM 

Software 

o Non Safety 125 VDC - €TAP Software 

1.9.14 Mechanical Ultimate Heat Sink Calculations 

Update the following calculations to reflect EPU conditions. 

Calculation M97-0133, “SW Heat Loads During LBLOCA and 

SW Temperature Decay Times,“ Rev 11 

Calculation M95-0020, “DCHE Performance Evaluation,” Rev 

1 

Calculation M95-0044, “RWIDCIDH Thermal Analysis - DC 

Temperature Calculation,“ Rev 1 

Calculation M95-0035, “SW System Inventory Transient 

Analysis,” Rev. 2 

1.9.15 Turbine Building Structural Evaluation 

. Perform an evaluation of the turbine building structure and 

supports for major equipment to identify if any significant 

changes are required to accommodate the expected increases 

in loads resulting from new and larger equipment such as 

turbine rotors, main generator, etc. 

1.10 Schedule 

Proposals shall be submitted within 28 days following receipt of the proposal 

request, 

1.11 Required Bid Documentation 

1.11 .I Seller shall submit a complete proposal fully describing all of the 

services to be fumished. All documents shall be in English and in U.S. 

measurement units. 

1.11.2 Exceptions to the proposal request must be clearly identified. 

1.11.3 A project level milestone schedule identifying the start date of each 

task and sub task, completion date of the tasks, subtasks, and the 

overall completion date. Need dates for information not being 

developed by the seller should be included in this schedule. 

- 

1 ,I 1.4 The seller may offer additional optional scope of supply as defined by 

seller. 

1 .I 1.5 The seller must provide the organizational structure of labor for 

engineering services described in this proposal request including 

supervision, technical direction and project management. The staffing 

levels should be provided for each task identified in the proposal 

request. 

1 ,l 1.6 The seller should describe the project management measures to be 

implemented to control the cost schedule and risks associated with 

this scope of work. 

1.11.7 Any of the work in this proposal that the seller intends to subcontract 

must be clearly identified. The buyer must approve all subcontractors. 

13



6/25/2007 

1 .I 1.8 The seller must provide a summary of experience providing similar 

engineering services and identify any 'first of a kind" scope. For those 

"first of a kind" services, the seller should describe the steps to be 

taken to assure a quality and timely product. 

1 .I 1.9 The seller must identify the location where this work will be conducted 

including a discussion of how the seller will interface with the CR3 

site, 

14 

PEF-NCR-01980

I_ 



6/25/2007 

1.12 Required Documentaffon After Award 

- 

No. 

The following lable summarizes the documentation required by this proposal 

request, 

TASK I SUBTASK I PRIORIN I SUBMITTAL I 

1 

- 

2 

3 

- 

4 

5 

Turbine 

I 

Tu;bine I I I 

Main Generator and 1 Install EC package 13 112-12-08 

Exciter 

Deaerator Bypass 

Line 

lsophase Bus 

1 

Design Specificalion 1 10-03-07 

Equipment Specification 1 10-17-07 

Purchase EC package 2 10-31-07 

Install EC package 3 12-12-08 

Evaluate electrical 4 6-18-09 

Feedwater Heaters 

6 

- 

Heater Drain Piping 

PM-0020) 

Install EC package 3 12-12-08 

15



612512007 

No. 

9 

- 

10 

TASK SUBTASK PRIORITY SUBMITTAL 

DUEDATE , 

SC Modifications Maximization Report I 9-20-07 

SC Heat Exchangers Equipment Specification 1 10-03-07 

Purchase EC package 2 10-31-07 

7 Install EC package 

SC Pump Impellers 

and Motors 

Equipment Specification 

Purchase EC package 

Install EC- package 

CW Pump Impellers Equipment Specification 

8 and Motors 

Purchase EC package 

Condensate Pump 

Impellers, Motors, 

and Variable Speed 

Drives - 

FW Booster Pump 

Impellers and Motors 

3 12-12-08 

1 10-03-07 

2 10-31 -07 

3 12-12-08 

4 6-18-09 

5 7-2-09 

11 

- 

12 

- 

13 

- 

14 

FW Control System 

Main Condenser 

Electrical Distribution 

Non Safety 125 VDC 

Emergency Diesel 

Generators 

Vital 120 VAC 

Safety 125 VDC 

TSC Security Diesel 

Calculation M97- 

0133 


0020 

I and Startup Transformers, 

and 4KV System 

Calculation E9CL0044 

6 1-08-09 

Calculation 6 6-19-08 




Calculation 6 1-08-09 - 

Calculation 4 619-08 

Calculation 4 619-08 

- 

15 

0044 


0035 

Turbine Building 

Structural Evaluation 

Calculation 4 6-1 9-08 

Evaluation 1 12-1 3-07 

16 

PEF-NCK-O 1982

... 



6/25/2007 

Priority Codes: 

1 

2 

3 

4 

5 

6 

Required for specifying equipment for the 2009 refueling 

outage 

Required for ordering equipment for the 2009 refueling 

outage 

Required for installation of equipment for the 2009 

refueling outage 

Required for specifying equipment for the 201 1 refueling 

outage 

Required for ordering equipment for the 201 1 refueling 

outage 

Required for installation of equipment for the 201 1 

refueling outage 

The work products that are required by tasks included in this proposal 

request are computer model updates, design specifications, Engineering 

Change packages for purchase, Engineering Change packages for 

installation, evaluations and plans, specifications, calculations, and purchase 

orders. 

Computer model updates should be completed and the results provided in 

either a calculation or a report. The individual computer model task 

description provides direction on how the results are to be documented. 

The requirements for design specifications are identified in Procedure EGR- 

NGGC-0005, Engineering Change. One component of a design specification 

is the design inputs. Attachment 2 of EGR-NGGC-0005 provides a 

comprehensive list of design inputs to be considered. 

Procedure EGR-NGGC-0005 provides the requirements for preparing an 

Engineering Change for the installation of a design change in the plant. In 

addition to EGR-NGGC-0005. the requirements of MCP-NGGC-0401, 

Material Acquisition (Procurement, Receiving, Shipping), NUA-NGGC-1530, 

Equipment, Pressure Test, Protective Coatings, and Special Process 

Inspections, and NGGM-PM-0020, Vendor Quality Program for Critical Non- 

Safety Equipment apply to the preparation of ECs for purchase of major 

equipment. 

The results of evaluations and plans are to be documented in reports. There 

are no specific procedures that define the content or format. The reports 

should be prepared and documented consistent with professional engineering 

standards. 

Specificalions are prepared and documented in accordance with the 

requirements of EGR-NGGC-0020. Preparation and Control of Specifications, 

Calculations are prepared and documented in accordance with Ihe 

requirements of EGR-NGGC-0017, Preparation and Control of Design 

Analysis and Calculations. 

In some cases, a purchase order may be prepared without completing an EC. 

The information should be prepared and documented as defined in NGGM- 

17



6/25/2007 

PM-0020, Vendor Quality Program for Critical Non-Safety Equipment. The 

tasks where this requirement applies are indentified in the individual task 

descriptions. 


The following definitions shall apply to this Specification: 

Owner - Progress Energy 

Purchaser - Owner Representative 

Buyer - Owner Representative 

Seller - Firm proposing lo supply the subject equipment 

Supplier - Firm awarded the order for the subject equipment 

Contract - Equipment and Service Supply Contract 


3.1 Codes and Standards 

The following codes and standards should be used in developing design and 

equipmenl specifications. Note that only recognized US. standards and 

equivalent International standards will be accepted. A list of applicable 

International codes and standards shall be submitted, in English, for 

Engineets acceptance prior to use. The design, fabrication, materials, 

workmanship, and testing of all equipment shall be in accordance with the 

buyer's standards and applicable codes. In the event of an apparent conflict 

among standards, codes and this specification, the seller shall identify such 

conflict. The Seller shall obtain written resolution of such conflict from the 

purchaser prior to proceeding with work involwng the conflict. When 

standards are referenced in this specification without current or effective 

dates, the latest revision of the standard specification in effect as of the date 

of the Contract shall be considered applicable. Any modifications to the 

standard specifications included herein shall be with the express written 

approval of the purchaser. 

3.1.1 Heat Exchange Institute (HEI) 

a. Standards for Power Plant Heat Exchangers 

b. Standards for Steam Surface Condensers 

3.1.2 Electrical equipment shall be designed, constructed and tested in 

accordance with the following standards: 

a. Institute of Electrical and Electronics Engineers (IEEE): 

i. Standard General Principles for Temperature Limits in the 

Rating of Electrical Equipment and for Evaluation of 

ii. 

iii. 

iv. 

Electrical Insulation, IEEE 1 I 

Neutral Grounding Devices, IEEE 32. 

Recommended Practice for Testing Insulation Resistance of 

Rotating Machinery, IEEE 43 

Test Procedures for Polyphase Induction Motors and 

Generators, IEEE 112A. 

b. American National Standards Institute (ANSI): 

i. National Electric Safety Code, ANSI C2. 

ii. Switchgear, ANSI C37. 

18 

PEE'-NCR-0 1984


Request for Proposal for Engineering Services 10 Upgrade Secondary System 

6/25/2007 

iii. 

Transformers, ANSI C57 

c. National Electrical Manufacturers Association (NEMA): 

i. Enclosures, NEMA 250. 

ii. Motors and Generators, NEMA MG1, MG2. 

iii. Power Circuit Breakers, NEMA SG4. 

d. National Fire Protection Association (NFPA) Standard 70 - 

“National Electrical Code”. 

e. All electrical hardware shall be listed in the Factory Mutual 

Approval Guide or, if not listed in this guide, shall be Underwriters 

Laboratories tisted I 

3.1.3 tnstrumentation, Systems, and Automation Society (ISA), Standards 

and Practices for Instrumentation. 

3.1.4 All work performed and materials provided by the Supplier shall be in 

accardance with Federal, State, County, and Municipal codes, laws, 

and ordinances of the place of installation. 

3.2 Regulatory Requirements 

3.2.1 Crystal River Unit 3 Updated Final Safety Analysis Report 

3.2.2 Crystal River Unit 3 Technical Speafications 

3.3 Owner Procedures 

3.3.1 EGR-NGGC-0003, Design Review Requirements 

3.3.2 EGR-NGGC-0005, Engineering Change 

3.3.3 EGR-NGGC-0007, Maintenance of Design Documents 

3.3.4 EGR-NGGC-0011, Engineering Product Quality 

3.3.5 EGR-NGGC-0012, Equipment Data Base 

3.3.6 EGR-NGGC-0017, Preparation and Control of Design Analysis and 

Calculations 

3.3.7 EGR-NGGC-0020, Preparation and Control of Specifications 

3.3.8 EGR-NGGC-0155, Specifying Electrical/l&C Modification Related 

Tests 

3.3.9 MCP-NGGC-0401, Material Acquisition (Procurement, Receiving, 

Shipping) 

3.3.10 NUA-NGGC-1530. Equipment, Pressure Test, Protective Coatings, 

and Special Process Inspections 

3.3.11 REG-NGGC-0010, 10 CFR 50.59 and Selected Regulatory Reviews 

3.3.12 ADM-NGGC-0107, Equipment Reliability Process Guideline 

3.3.13 NGGM-PM-0018, Project Management Program Manual 

3.3.14 NGGM-PM-0020, Vendor Quality Program for Critical Non-Safety 

Equipment 

3.3.15 AI-550, Infrequently Performed Tests or Evolutions 

3.3.16 EGR-NGGC-0157, Engineering of Plant Oigital Systems and 

Components 

19



6/25/2007 

4.0 DESIGN REQUIREMENTS 

This proposal request is limited to engineering services to prepare design 

documents. Specific design requirements for equipment have not yet been 

established for components within the scope of this proposal request. 

Requirements for design-related work within the scope of this proposal request are 

identified in Section 3. 

5.0 MATERIAL REQUIREMENTS 

No material is requested for supply under this request for proposal. The scope of 

this proposal request is for engineering services only. 

6.0 INSPECTION AND TESTING 

This proposal request is limited to engineering services. No inspection or testing 

requirements apply to this work. 

7.0 FABRICATION REQUIREMENTS 

This proposal request is limited to engineering services. No fabrication 

requirements apply to this work. 

8 .O INSTALLATION REQUIREMENTS 

This proposal request is limited to engineering services. Since physical installation 

of equipment is not within the scope of this proposal request, installation 

requirements do not apply to this work. 

9.0 SHIPMENT 

This proposal request is limited to engineering services. Since supply of 

equipment is not within the scope of this proposal request, shipping instructions do 

not apply to this work. 

20 

PEF-NCR-0 1986



6/25/2007 

0 

10.0 ATTACHMENTS 

10.1 Scope of Services Detail 

Scope of Sewices Detail 

This attachment provides a detailed discussion of specific elements of the engineering 

service so that a proposal can be provided. Numbering is consistent with the line item 

number from section 1.9. 

1.9.1 Computer Models 

PEPSE Computer Model Update 

The CR3 PEPSE thermal heat balance model will require revision for the new operating 

conditions based on the final thermal kit from the selected turbine/generator supplier, 

proposed deaeralor bypass flow and Circulating Water System flow of 207,400 per 

pump. The 3030 MWt PEPSE model will include the following cases. 

e 

Baseline without the MSR belly drain heat exchangers and deaerator 

bypass line modifications 

EPU configuration with the MSR belly drain heat exchangers and the 

deaerator bypass line 

One case with each set of the feedwater heaters removed from service 

(five cases total) and the MSR belly drain heat exchangers and the 

deaerabr bypass line installed 

Procedure EGR-NGGC-OOl7, Preparation and Control of Design Analysis and 

Calculations, applies to this task. 

FATHOM Computer Model Update 

The condensate, feedwater, and main steam systems will require hydraulic analysis 

(FATHOM or equal) based on the new operating conditions at 3030 MWt including pump 

performance data, system configurations, and component pressure drops. The following 

will be included as part of this evaluation. 

Condensate Pump Sizing 

Booster Feedwater Pump Sizing 

Verification of feedwater block (isolation) valve differential pressure 

Procedure EGR-NGGC-0017, Preparation and Control of Design Analysis and 


CHECWORKS Computer Model Update 

The CR3 CHECWORKS model will require updating based on final PESPE results for 

3030 MWt. A preliminary FAC analysis indicates increased wear rates for several critical 

componenls. Detailed review and impact on the CR3 erosion corrosion program will be 

required once the final 3030 MWt PEPSE model is complete. It is recommended that 

21

P 



6/25/2007 

Advanced Run Definitions (ARDs) be developed and input for each relevant component 

or system section breakdown. 


Calculations, does not apply to this task. 

22 

pEF-NCR-0 1988



612512007 

1.9.2 MSR Replacement and MSR Belly Drain Heat Exchanger Addition 

MSR Replacement 

The turbine rotor supplier is providing new moisture separator reheaters. An 

engineering change package is required to be prepared to support installation of the new 

MSRs. As part of the task of preparing the EC package, evaluation of the MSR relief 

valves is required. Procedure EGR-NGGC-0005, Engineering Change applies is this 

task. 

MSR Belly Drain Heat Exchanger Addition 

Current CR3 plant configuration dumps the MSR belly drains directly to the condenser. 

This design negatively impacts plant efficiency because a significant amount of energy is 

dumped to the condenser. The BOP efficiency can be improved and energy recaptured 

by installing heat exchangers in the MSR drains. It is expected that approximately 4 

MWe will be gained in generator output. The figure below illustrates the concept of 

recapluring the energy in the MSR belly drains before dumping to the condenser. 

MSR Belly Draln Flow Diagram 

The existing MSRs are not adequale for 3030 MWt and are being replaced. The 

preliminary PEPSE model for 3030 MWI indicates lhat the MSR shell drain flow is 

expected lo increase from 11% to 13% with a temperature increase to 392 'F from 377 

23 

PEF-NCR-0 1989



612512007 

‘F with the EPU power uprate. Velocity in the 4-in drain line will increase to 9 Wsec from 

7.8 fUsec. 

Instrumentation 8 Controls 

These heat exchangers would be transferring heat from liquid to liquid, and will require 

temperature control valves to regulate condensate flow to the new heat exchangers. 

Local indications for the process variables that are necessary for the heat exchangers 

would include differential pressure across lhe heat exchangers (both MSR drain fluid 

side and condensate side), which would be used to determine fouling or tube plugging, 

and temperatures at the inlet and outlet (both MSR drain fluid side and condensate 

side), to determine effiaencies and heat transfer for the heat exchangers. 

Procedure EGR-NGGC-0005, Engineering Change, Section 9.3.1, provides the list of 

information necessary for a design specification. This information includes the following. 

Scope Description 

References 

Design Input 

Assumptions 

Evaluation 

Interfaces 

Quality Class Determination 

The design specification should also address the operation of the system under upset 

conditions such as a turbine trip, control valve failures, pump trips, etc. 

As part of this task, a new specification for the MSR belly drain heat exchangers is 

required. Procedures EGR-NGGC-0020, Preparation and Control of Specifications, 

MCP-NGGC-0401 , Material Acquisition (Procurement, Receiving, Shipping), NUA-and 

NGGC-1530, Equipment, Pressure Test, Protective Coatings, and Special Process 

Inspections apply to the preparation of specifications. 

Two EC packages are required, one to procure the four new heat exchangers and a 

separate EC package to install the entire design change in the plant. Procedure EGR- 

NGGC-0005, Engineering Change describes the steps necessary lo prepare an EC 

package. 

24 

PEF-NCR-0 1990



685l2007 

1.9.3 Turbine Generator Modifications 

Low Pressure Turbine Replacement 

The new low pressure turbine rotors and inner casings are being procured to increase 

the CR3 electrical output. An engineering change package is required to be prepared to 

support installation of the new low pressure turbine rotors. Procedure EGR-NGGC- 

0005, Engineering Change applies is this task. 

High Pressure Turbine Replacement 

A new high pressure turbine rotor and inner casing are being procured to increase the 

CR3 electrical output. An engineering change package is required to be prepared to 

support installation of the new high pressure turbine rotors. Procedure EGR-NGGC- 

0005, Engineering Change applies is this task. 

Generator and Exciter Replacement 

A new main generator and exciter is being procured to increase output to 1200 MVA, 

430 MVAR, 0.93 power factor, and 1080 MWe with a condenser vacuum of 2.7 inches 

of mercury and a circulating water inlet temperature of 75 OF. An engineering change 

package is required to be prepared to support installation of the new main generator and 

exciter. Procedure EGR-NGGC-0005, Engineering Change applies is this task. 

25 

PEF-NCR-0 199 1



6/25/2007 

1.9.4 Design Specification, Oeaerator Bypass Line 

The Deaerator (FWHE-1) is designed to break up the entering condensate and allow 

entrained gases to escape and be vented off and to provide heat input to the fluid as it is 

passed through the elements. The Deaerator Storage Tank, FWT-1, capacity is 73,000 

gallons to the normal water line. The capacity of this open, deaerating feedwater heater 

assures adequate inventory for the FW Booster Pumps (NPSH) following a large step 

Load decrease in condensate pump flow. At EPU conditions, the expected condensate 

inlet temperature is 277 'F; extraction steam inlet temperature is 344 OF; and outlet 

feedwater temperature is 308 'F. The stated maximum feedwater outlet capacity of the 

deaerator is 11,200,000 Ibshr. The expected condensate flow at EPU conditions is 

13,010,639 IbsAr. 

Preliminary evaluation by the OEM, Crane-Cochrane, indicates that the existing 

deaerator heater is not adequate based on its ability to remove non-condensabfes and 

physical flow limitations. The EPU flow rate of 13,010,639 lbslhr cannot be handled by 

existing internal components (nozzles, trays, piping). To resolve this issue, a portion of 

the condensate flow to lhe deaerator is to be bypassed around FWHE-I and fed directly 

into the deaerator storage tank, M .1. A flow control valve with manual isolation and 

bypass will be used to divert any flow above the maximum deaerator design limit of 

11,200,000 Ibdhr. Based on the preliminary 3030 MWt PEPSE model, the total flow into 

the deaerator will be 13,010,639 fbsihr that is approximately 16% higher than the current 

11,200,000 lbdhr design limit. 

Instrumentation & Controls 

0 

This line will normally carry approximately 1.8~10' lbslhr and the control valve should be 

sized accordingly. The deaerator bypass valve should be closed when condensate flow 

to the deaerator is less than 11.2 x10' Ibs/hr and open to maintain condensate flow lo 

the deaerator within the design limit. Deaerator bypass flow should be measured and 

displayed locally. 

To implement this design change, a design specification, a specification for the control 

valve, an EC package to purchase the control valve, and an EC package to install the 

design change into the plant are required. Procedure EGR-NGGC-0005, Engineering 

Change, Section 9.3.1, provides the list of information necessary for a design 

specification. This information includes the following. 


References 

Design Input 

Assumptions 

Evaluation 

Interfaces 


The flow, temperature, pressure, and injection path of the condensate flow directly into 

the deaerator storage tank will require evaluation to maintain desired deaerator 

performance. An evaluation of the expected concentration of dissolved oxygen content 

and hydrazine injection will be required. Preparation of this design specification must be 

coordinated with the MSR belly drains Heat Exchanger modifications to the deaerator 

drain tank. 

26 

PEF-NCR-0 1992



612512007 

As part of this task, a new specification for the deaerator bypass control valve is 

required. Procedures EGR-NGGC-0020, Preparation and Control of Spedfications, 

MCP-NGGC-0401, Material Acquisition (Procurement, Receiving, Shipping), NUA-and 

NGGC-1530, Equipment, Pressure Test, Protective Coatings, and Special Process 

Inspections apply to the preparation of specifications. 

Two EC packages are required, one to procure the new control valve and a separate EC 

package to install the entire design change in the plant. Procedure EGR-NGGC-0005, 

Engineering Change describes the steps necessary to prepare an EC package. 

27


Request for Proposal for Engineerlng Services to Upgrade Secondary System 

6/25/2007 

0 

0 

1.9.5 Upgrade of the lsophase Bus Duct Cooling System 

The Isolated Phase 6us Duct system includes a forced-air cooler to remove excess heat 

from the bus duct. The heat sink for the cooler is the Secondary Cooling (SC) system. 

The present cooler, furnished by Westinghouse, is a closed air loop design. The existing 

cooler (fan and coils) has no backup capability, nor the ability lo shift to once-through 

cooling mode on a loss of cooling. As a result, in the event of loss of cooling, the 

generator load has lo be reduced to the bus duct self-cool rating of 186OOA in a very 

short period of time. The latest approach for large generation plant bus cooling system 

provides for redundant fans and coolers for optimum reliability. The existing CR3 design 

did not include a solar radiation load factor that is estimated to be a maximum heat input 

in summer month of 66 KW. The net heat input to the force-air cooling system from 

solar radiation is estimated to be 33 KW. Cooler design load should include the solar 

radiation factor. 

At EPU design conditions, the bus duct load will be 33.1 KA. At this load and the peak 

operating conditions, the design heat generation rate in the bus duct will increase to 566 

KW. and the heat removal rate required from the SC system will increase to 466 KW. 

Cooling demand with the solar input is estimated at 500 KW. Instruments on the 

existing cooler are basic. The design does no1 provide operating flexibility or Lo initiate 

corrective actions, in timely manner. To support EPU operating requirements, the entire 

existing cooler is to be replaced with a new cooler that contains redundant fans and 

cooling coils. The new cooler should have following features: 

2.100% cooling capacity fans, motors and cooling coils 

Full access to stand by unit including redundanl fans 

. Upgraded instruments and control 

Heating elements to dry bus duct during start up 

Instrumentation & Controls 

The instrumentation and control equipment for the new coolers should include local 

differential pressure and cooler inlet and outlet temperatures for both air and water. 

Controls should include automatic start of the standby unit. The status of each cooler 

should be displayed on a local panel (run, stop, stand by). 

To implement this design change, a design specification, a specification for the control 

valve, an EC package to purchase the fans. motors and controls, and an EC package to 

inslall the design change into the plant are required. This design specification must 

identify any changes required to the electrical distribution, including load centers and/or 

MCCs, to accommodate lhis change. Procedure EGR-NGGC-0005, Engineering 

Change, Section 9.3.1. provides the list of information necessary for a design 

specification. This information includes the following. 


References 

Design Input 

Assumptions 

Evaluation 

lntedaces 


28



6/25/2007 

As part of this task. a new specification for the fans, motors and controls is required. 

This specification should include a requirement for an evaluation of the effects of 

increased airflow on vibration of the system components. The specification should 

include a requirement for high effiaency motors to offsetthe impact on the electrical 

distribution system. Procedures EGR-NGGC-0020, Preparation and Control of 

Specifications, MCP-NGGC-0401, Material Acquisition (Procurement, Receiving, 

Shipping), NUA-and NGGC-1530, Equipment, Pressure Test, Protective Coatings, and 

Special Process Inspections apply lo the preparation of specifications. 

An evaluation of electrical capability of the existing isophase bus should be completed 

considering the new lsophase Bus cooling capacity. 

Two EC packages are required, one to procure the new isophase bus duct cooling unit 

and a separate EC package to install the entire design change in the plant. Procedure 

EGR-NGGC-0005, Engineering Change describes the steps necessary to prepare an 

EC package. 

29 

PEF-NCR-0 1995



6/25/2007 

1.9.6 Feedwater Heater and Feedwater Heater Drain Modifications 

Performance of all of the feedwater heaters was reviewed by Yuba Heat Transfer to 

delermine the acceptability of the current feedwater heaters to operate at EPU , 

conditions. All heaters exceed either the Heat Exchanger Institute (HEI) recommended 

limits or the Yuba standards in one or more areas. The primary area of concern is the 

high velocity through the extraction steam side nozzles. Although these high velocities 

do not pose an immediate danger of damage to the heaters, they could lead to 

increased flow accelerated corrosion. In addition to the YUBA evaluation, plant FAC 

data indicates accelerated wear on the CDHE-3NB feedwater heaters. It has been 

decided to replace the third point feedwater heaters, CDHE-3A and -36 and Implement 

an upgraded monitoring plan for the remaining feedwater heaters. 

EPU increases the flow rates through all of the feedwater heaters. The flow capacities 

of the existing low pressure heater drain valves were examined to determine if sufficient 

capacity exits for these valves. All of the low pressure heater drain valves are capable 

of the EPU flow rates except for the valves associated with the first point heaters, HDV- 

101, -102, -103, and -104. Therefore, these four valves require replacement. 

A new PEPSE heat balance will be performed to determine the first point heater drain 

valve flow rates at EPU conditions. 

e 

There are four sections of secondary system piping that will likely exceed design 

allowable pressures and temperatures. These sections of piping are the 2-in lines 

upstream of valves HDV-247, HOV-248, HDV-249, and HDV-250. These piping 

segments are on CR3 FD-302.111 Sheet 3 Rev 47, Locations G-6 and C-1. The line 

specification for this piping is 600-4 and has an allowable pressure of 670 psig at 500 O F. 

The EPU operating conditions are expected to be 877.06 psig at 530.87 OF. Therefore, 

this piping will be replaced with piping that is rated for the EPU conditions at these 

locations. 

To implement this strategy, four sublasks are to be accomplished; all related to the 

feedwater heaters and the feedwater heater drains. 

Replacement of Feedwater Heaters CDHE-3A and -38 

A revision to the specification for the third point feedwater heaters is required. A new 

PEPSE heat balance at EPU conditions will be performed to support preparation of this 

revised specification. Procedures EGR-NGGC-0020, Preparation and Control of 



Special Process Inspections apply to the preparation of specifications. 

Two EC packages are required, one lo procure the new third point feedwater heaters 

and a separate EC package to install the new third point feedwater heaters in the plant. 

Procedure EGR-NGGC-0005, Engineering Change describes the steps necessary to 

prepare an EC package. 

Evaluation of the Existing Feedwater Heaters 

30 

PEF-NCK-0 1996



6/25/2007 

A proposal is required to evaluate the current condition of the existing eight feedwater 

heaters that will remain in service and create an upgraded monitoring program for all of 

the feedwater heaters. 

The evaluation of the existing heaters that will remain in service should include an 

assessment of the feedwater heater performance based on the final 3030 MWt PESPE 

model and the feedwater heater relief valve setpoints and relieving capacity. Also, the 

design of the piping between CDHE-3NB feedwater heaters and the associated heater 

drain valves should be reviewed based on 3030 MWt PEPSE model. 

The monitoring program should include base lining the current conditions and an 

inspection afler the first cycle following EPU. An outline of the conceptual program 

follows. 

. Obtain any current CR3 FAC data for feedwater heaters. 

. Establish nozzle inspections for feedwater heaters based on the new FAC 

analysis at EPU conditions. 

Obtain and evaluate original design specifications for stainless steel components. 

Obtain indushy benchmark data 

. Identify additional inspections required for onlineloutage in 2007 to support 

decision 

Establish acceptance criteria including mitigation options 

Review the relief valve sizes to determine if they are adequate at EPU conditions 

. Prepare table of issues and risk potential 

, Replacement of Heater Drain Valves HDV-101, -102, -103, and -104, 

Revision of the existing valve specification for the first point heater drain valves is 

required to reflect the conditions predicted by the PEPSE model at EPU conditions. 

These valves will also be required to operate for two fuel cycles at the Measurement 

Uncertainty Recovery (MUR) power level (2625 MWt). Procedures NGGM-PM-0020, 

Vendor Quality Program for Critical Non-Safety Equipment, EGR-NGGC-0020, 

Preparation and Control of Specifications, MCP-NGGC-0401, Material Acquisition 

(Procurement, Receiving, Shipping), NUA-and NGGC-1530, Equipment, Pressure Test, 

Protective Coatings, and Special Process Inspections are applicab!e to this task. 

Two EC packages are required, one to procure the four new first point feedwater heater 

drain valves and a separate EC package to install these new valves in the plant. 

Procedure EGR-NGGC-0005, Engineering Change describes the steps necessary to 

prepare an EC package. 

Replacement of Piping Upstream Heater Drain Valves HDV-247, -248, -249, and -250 

An EC package is required to replace the piping upstream of Heater Drain Valves HDV- 

247, -248, -249, and -250 with piping the appropriate pressure and temperature rating 

for EPU and MUR conditions. Procedure EGR-NGGC-0005, Engineering Change 

describes the steps necessary to prepare an EC package. 

31



6/25/2007 

1 9.7 Secondary Services Closed Cycle Cooling System Modifications 

The Secondary Services Closed Cycle Cooling System (SC) provides cooling water flow 

to various secondary plant loads including the Turbine Generator, Condensate Pumps, 

Lube Oil Coolers, Air Removal System, Instrument Air System and Station Air System. 

It also provides backup cooling to the Control Complex Chillers upon loss of SW. The 

SC system consists of two main heat exchangers (SCHE-IA, le) and two main pumps 

(SCP-IA, 1 e). 

Currently the SC system is rated for 54 Mbtuhr and the flow rate is 10,000 gpm. The 

new generator heal loads (which account for the majority SC system heal load) are 

expected to produce about 58.9 Mbtulhr based on 1200 MVA and 430 MVAR (0.933 pf). 

Based on the generator heat load increase, the total SC heat for EPU conditions is 

projected to be between 75 Mbtulhr and 80 Mbtulhr. The SC system will need to 

increase its heat removal capacity to handle the increased heat load due to planned 

power uprate and to restore margin. 

By relocating piping and small obslructions, sufficient space is available to install new 

SC heat exchangers with over all dimensions of 66 inches outside diameter and 54 feet 

in length. The actual heat exchanger sizing shall maximize the heat transfer capacity of 

the heat exchangers based on the existing space limitations. Likewise, the size SC 

pump impeller and motor will be increased to maximize SC flow so the new heal 

exchanger specifications must be coordinated with the new SC pump maximum flow 

rate. 

Maximization of the Secondary Services Closed Cycle Cooling System 

Due to the increased heat loads on this system, it is required to maximize the heat 

removal capability of the system, This evaluation must determine the maximum capacity 

and cooling flow of the secondary cooling heat exchangers based on exisling space 

limitations. This evaluation must also determine the maximum SC system flow by 

replacing the SC pump impellers and motors. 

Replacement of the SC Heat Exchangers 

Revision of the SC heat exchanger specification is required. Procedures EGR-NGGC- 

0020, Preparation and Control of Specifications, MCP-NGGC-0401, Material Acquisition 


Protective Coatings, and Special Process Inspections are applicable to this task. 

Two EC packages are required, one to procure the two new SC heat exchangen and a 

separate EC package to install these new heat exchangers in the plant. Procedure 

EGR-NGGC-0005, Engineering Change describes the sleps necessary to prepare an 

EC package. 

Replacement of the SC Pumps and Motors 

Revision of the SC pump and motor specification is required. The specification shoutd 

include a requirement to maximize the motor efficiency to offset the impact on the 

electrical distribution system. Procedures EGR-NGGC-0020, Preparation and Control of 


32 

PEF-NCR-01998

.. 



6/25/2007 


Special Process Inspections are applicable to this task, 

Two EC packages are required, one to procure the two new SC pumps and motors and 

a separate EC package to install these new pumps and motors in the plant. Procedure 

EGR-NGGC-0005, Engineering Change describes the steps necessary to prepare an 

EC package. 

33 

PEF-NCR-0 1999



6/25/2007 

i .9.8 Circulating Water System Modifications 

The current circulating water system Pumps 1A & 1D are 30-pole motors running at 233 

rpm with a stated flow of 167,000 gpm each. Pumps 1C 8 ID are 28-pole motors 

running at 250 rpm with a stated flow of 179,000 gpm each. This provides a total system 

flow of approximately 692,000 gpm for the condenser water boxes and the SC system 

heat exchangers. At these flow rates the condenser water box flow rates are between 

8.4 and 9.0 ft/sec. The limiting design conditions are the water box inlet filters that have 

a design flow limit of 10.5 Wsec. 

Based on the information supplied by HES for the condenser backpressures, and the 

information supplied by Siemens for the turbinelgenerator performance, higher CW flow 

is advantageous in the summer months. Addilionally, there is no significant MWe 

penalty to supply the higher CW flow rates during cold water (winter) conditions. This 

eliminates the need for two-speed motors or variable speed drives. 

To realize higher Circulation Water System flow, new circulating water pump impellers 

and larger motors will be required. The circulating water pump supplier, Flowserve, has 

determined that a 22% increase in flow to 207,400 gpm per pump is achievable. 

Therefore, a revision to the circulating water pump and motor specification is required to 

reflect this higher flow. The specification should include a requirement to maximize the 

motor efficiency to offset the impact on the elecbical distribution system. Procedures 

EGR-NGGC-0020, Preparation and Control of Specifications. MCP-NGGC-0401, 

Material Acquisition (Procurement, Receiving, Shipping), NUA-and NGGC-1530, 

Equipment, Pressure Test, Protective Coatings, and Special Process Inspections are 

applicable to this task. 

Two EC packages are required, one to procure the four new CW pump impellers and 

motors (columns and casings are not being replaced) and a separate EC package to 

install these new pumps and motors in the plant. As pad of the EC package to install the 

new CW pumps, the CW expansion joints at the condenser need to be upgraded to 

accommodate the expected higher pump discharge pressure. In 2007, new expansion 

joints are being installed with Beaudrey flow straightener modifications on the A and B 

water boxes. Flow straightener and new expansion joints will need to be installed on the 

C and D water boxes in 2009. Procedure EGR-NGGC-0005, Engineering Change 

describes the steps necessary to prepare an EC package. 

34 

PEF-NCR-02000



6/25/2007 

0 

1.9.9 Condensate Pump and Motor CDP-1A and -1 B Replacement 

Replacement of the two Condensate pump impellers is necessary to produce the 

required flow at EPU conditions. The calculated condensate system flow conditions at 

uprate are approximately 19,300 gpm at a temperature of 108 OF. The new pump should 

be designed to produce 9670 gpm t 4% margin for a capacity of 10,060 gpm at 800 feet 

total developed head (TDH). The currently installed pumps are six stage Ingersoll-Rand 

pumps with a design flow of 8,000 gpm at 745 feet TDH driven by a 2000 horsepower 

(HP) motor at 1185 rpm through a magnetic drive coupling assembly. The thrust bearing 

is incorporated in the magnetic drive coupling assembly. 

Flowserve has advised that h e existing Ingersoll-Rand six stage pumps can be 

upgraded by replacing the rotating stages while retaining the internal casing to achieve 

the desired flow and TDH. The proposed uprate of Condensate pumps for EPU 

conditions will increase margin from 1.5% (existing) to 4Oh (EPU). 

Concurrent with the replacement of the Condensate pump impellers, elimination of the 

magnetic drive coupling will also be accomplished. A direct driven pump and motor with 

a variable speed digital control system (VSD) is to be procured and installed. Since the 

existing design incorporates the assembly thrust bearing in the magnetic drive coupling. 

the new design will require that the new motor include the thrust bearing assembly. 

Control of condensate flow will be accomplished by powering the new motors through a 

variable speed drive. The existing condensate pump controls are not compatible with a 

direct drive VSD system and require replacement. The current condensate flow 

recirculalion to the condenser (CDV-39) is designed to maintain the minimum CD flow 

requirements (1600 gpm per pump). Changes to the minimum CD pump flow 

requirement are not expected. 

To realize higher Condensate System flow, a design specification, a specification for the 

new Condensate pump impellers and larger motors equipped with variable speed drives, 

an EC package to purchase the impellers, motors and drives, and an EC package to 

install the design change into the plant are required. Procedure EGR-NGGC-0005, 

Engineering Change, Section 9.3.1, provides the list of information necessary for a 

design specification. This information includes the following. 

Scape Description 

References 

Design Input 

Assumptions 

Evaluation 

Interfaces 


Revision to the Condensale pump and motor specification is required to reflect this 

higher flow and to incorporate the variable speed drive into the design. The specification 

should include a requirement to maximize the motor efficiency to offset the impact on the 

electrical distfibution system. The revised CD pump specification should establish the 

requirements for new 6 stage rotating elements suitable for the EPU flow requirements 

(see proposed pump performance curve below). The specification for the new CD pump 

motors should require motors rated for 4000 volts, 1180 rpm, 2500 HP, an integral thrust 

bearing, and compatible with a variable speed drive. The revised specification needs to 

35 

PEP-NCK-0200 1



612512007 

incorporate a variable speed drive compatible with a 4 KV and 2500 HP with the 

capability to be bypassed. The VSD must be capable of providing minimum and 

maximum motor speeds to support system flow requirements at all loads. The 

specifcation must incorporate features that will assure high reliability and require 

compatibility wilh the expected environmental conditions. VSD specifcation should 

include dry type isolation transformer at the input side with 3-phase secondary windings 

that can provide required phase shifting to reduce harmonic currents and voltages 

reflected back to the primary power system. VSD design could include either inductance 

or capacitance coupling at the DC link (between rectifier and inverter circuits). Either 

design can provide reliable operation provided that proper design precaution has been 

taken to eliminate voltage spiking or prevent currenffvoltage harmonics increase at the 

inverter output. The requirements for revised condensate flow control must be included 

in the specification. Procedures EGR-NGGC-0020, Preparation and Control of 



Special Process Inspections are applicable to this task. 

Proposed Condensate Pump Performance Curve 

Two EC packages are required, one to procure the two new CD pump impellers, motors 

and drives, and a separate EC package to install these new impellers, motors, and 

drives in the plant. Procedure EGR-NGGC-0005, Engineering Change describes the 

steps necessary lo prepare an EC package. 

36 

PEF-NCR-02002



6/25/2007 

0 

1.9.10 Feedwater Booster Pumps and Motors, FWP-ZA and -1B 

The 3030 MWt PEPSE model estimated required minimum feedwater system flow at 

uprate to be 14,155.6 gpm per pump. The present design conditions are 12,760 gpm at 

305 OF, 725 feet TDH and 50.37 feet NPSHA. A larger booster feedwater pump and 

motor can provide increased flow and pressure allowing the main feedwater pumps to 

develop a smaller portion of the pressure required at the steam generators. This will 

allow the existing main feedwater pumps and turbine drives to be used for EPU 

conditions. The existing Feedwater Booster pumps and drivers will be replaced to 

realize feedwater flow margins of approximately 10% at EPU conditions. 

Revision of the Feedwater Booster pump (FWP-PA and 28) and motor specification is 

required to reflect the new pump requirements. The revised specification should 

establish the requirements for new Feedwater Booster pumps and motors consistent 

with the performance curve betow supplied by Flowserve. Confirmation that the 

proposed pump performance curve is adequate must be completed. The specification 

for the new Feedwater Booster pump motors should require motors rated for 4000 volts. 

The specification should include a requirement to maximize the motor efficiency to offset 

the impact on the electrical distribution system. Procedures EGR-NGGC-0020, 

Preparation and Control of Specifications, MCP-NGGC-0401, Material Acquisition 


Protective Coatings, and Special Process Inspections are applicable to this task. 

PEF-NCR-02003



6/25/2007 

Two EC packages are required, one to procure the two new Feedwaler Booster pumps 

and motors, and a separate EC package to install these new pumps and motors in the 

plant. Procedure EGR-NGGC-0005, Engineering Change describes the steps 

necessary to prepare an EC package. 

38 

PEF-NCR-02004



6/25/2007 

1.9.1 1 Feedwater Control Valves and Feedwater Control System Stability 

Feedwater flow is regulated by feedwater pump speed and the Startup FW control 

valves, FWV.39 8 FWV-40, from 0 to 15% flow, by feedwater pump speed and the 

Low-Load Flow Control Valves, FWV-37 8 FW-38, from 15 to 50%and by opening 

Feedwater Block Valves, FWV-29 & FWV-30, and feedwater pump speed above 50% 

flow. The switch over to the low-load flow control valves will be at the same mass flow 

rate flow but at a slightly lower percentage of total feedwater flow. The block valves 

opening will be at the same mass flow rate (6x10' Ibmhr) flow but at a slightly lower 

percentage of total feedwater flow. The valve will pulse open to 15% and them ramp full 

open. When the loop feedwater flow demand decreases to 45% of the loop flow range, 

the associated main block valve will receive a close signal. The valve Wil ramp closed 

to 17% open and then pulse to full dosed. The block valves dose of a main feedwater 

isolation actuation signal. 

The initial assessment is that the feedwater flow control and block valves are adequate 

for EPU conditions. The developed feedwater pressure exiting !he feedwater pumps is 

being raised from 1013 psia to 1092 psia. A hydraulic evaluation of the feedwater 

system (FATHOM or equal) is being performed as part of the Phase 1 detailed design. 

Verification of proper operation of the feedwater isolation valves at the maximum 

differential pressure is required after the hydraulic analysis is complete. The feedwater 

control and block valves require furlher evaluation of the MFP runback set point and 

control oscillations after the final PEPSE and hydraulic models are complete. 

The proposal for this task should include 1) an evaluation of the feedwater control 

system setpoints and 2) an evaluation of the stability of the feedwater control system 

and valves over the operating range of the system at EPU conditions. 

1.9.1 2 Condenser Performance and Flow-Induced Vibration Calculations 

Condenser performance requires evaluation using the final PEPSE results for 3030 MWt 

including CW pump flow of 207,400 gpm each. In addition, a baseline case should be 

evaluated for 2568 MWt and existing CW flow for baseline comparisons against current 

plan1 data. A condenser flow-induced vibration evaluation is required using the final 

3030 MWt results. 

These evatuations are to be sub contracted to Heat Exchanger Services. The proposal 

should include the cost for the HES analysis. 

39 

PEF-NCK-02005



6125f2007 

0 

0 

1.9.13 Electrical Distribution System Calculations 

A number of upgrades to the secondary plant will result in an increase in the electrical 

load on the CR3 electrical distribution system, The Redundant lsophase Bus Ouct 

Cooling System, Circulating Water pump motors, SC pump motors, Feedwater Booster 

pump motors, and Condensate pump motors will result in significant load increases on 

the electrical distribution system, An analysis of the distribution system is required that 

must include new load flow, short circuit, motor starting and protection system 

coordination studies. The goal of this calculation revision is lo evaluate the adequacy of 

existing power system equipment ratings (auxiliary transformers, load centers, motor 

control centers, switchgear, cables, etc) to support the higher system load and identify 

required upgrades of the electrical distribution system. 

An initial evaluation of the impact of ekpected electric load increases on the Station 

Auxiliary Transformer, 4KV buses, circuit breakers, switchgear, and cabling is required 

to determine any required equipment replacements. 

The calculation revision will ensure that power system sources and components, such 

as offsite power, transformers, cables and system protection circuits will either continue 

to operate within their designed limits with the load increases expected, or identify 

system changes needed to assure the planned reconfiguration will not affect the plant 

licensing commitments. This study should be completed 2 years prior to the planned 

uprate in 2011 to support procurement of equipment and modification packages as 

required. 

This calculation revision will update existing CR3 electrical distribution calculations. The 

calculations currently utilize €TAP and other computer programs for the analysis as 

folfows. 

Voltage DroplShort Circuit for AC Electrical System - SKM Software 

Non Safety 125 VDC - ETAP Software 

The seller must identify any additional calculations that require revision as a result of the 

EPU upgrades. Procedure EGR-NGGC-0017, Preparation and Control of Design 

Analysis and Calculations, applies to this task. 

40 

PEF-NCR-02006



6/25/2007 

1.9.14 Mechanical Ultimate Heat Sink Calculations 

Update of four nuclear safety related calculations, Calculation M97-0133, "SW Heat 

Loads During LBLOCA and SW Temperature Decay Times," Rev 11, Calculation M95- 

0020, "DCHE Performance Evaluation," Rev 1, Calculation M95-0044, "RWIDCIDH 

Thermal Analysis - DC Temperature Calculation," Rev 1, and Calculation M95-0035, 

"SW System Inventory Transient Analysis,' Rev. 2 is required to reflect EPU conditions. 

A discussion of each of the calculations follows. 

Calculation M97-0133, "SW Heat Loads During LBLOCA and SW Temperature Decay 

Times," Rev 11 

0 

Calculation M97-0133, "SW Heat Loads During LBLOCA and SW Temperature Decay 

Times,'' Rev I needs to be revised to account for increased heat load from the Reactor 

Building Cooling Unit heat loads, the Spent Fuel Heal Exchanger heat loads, and lhe 

Make Up Pump motor heat loads. In addition, an allowance for macrofouling and an 

increase in the allowable number of plugged tubes should be included in this calculation 

update. When revising Calculation M97-0133 for the EPU conditions, the existing 

sensitivity study of tube blockage versus RW inlet temperatures needs to be updated 

since the existing study is based on 0% macrofouling with only 10 tubes plugged per 

SWHE. 

The maximum SWHE shell side outlet temperature for emergency operating conditions 

is 110 OF. Per CR3 Calculation M97-0133, during emergency operating conditions, the 

SWHE shell side outlet temperature must be less than 104 'F no greater than 90 

minutes after a LOCA with LOOP and must be less than 104 'F no greater than 100 

minutes after a LOCA without LOOP in order to maintain the Control Complex air 

temperatures below their design limits. Calculation M97-0133, "SW Heat Loads During 

LBLOCA and SW Temperature Decay Times." Rev 11 must be updated to reflect EPU 

conditions using the new design heat loads for the affected equipment. 



Calculation M95-0020, "DCHE Performance Evaluation," Rev I 

Calcufation M95-0020, "DCHE Performance Evaluation," Rev 1 for the Decay Heat 

Closed Cycle Cooling (DC) System needs to be revised to account for increased heat 

load of the Decay Heat Heat Exchangers and the Makeup Pumps at EPU condilions and 

to reduce the allowable number of plugged tubes to 10% (69 tubes). Also, there are 

inconsistencies between Calculation M95-0044 and Calculation M95-0020 that require 

resolution. The thermal conductivity of the DCHE tubes should be relatively equal; 

however, there is significant difference between the thermal conductivity and the 

maximum shell side velocities for the DCHE design conditions used in these two 

calculations. The existing sensitivity study of tube blockage versus RW inlet 

temperatures needs to be updated when revising Calculation M95-0044, "RW/DC/DH 

Thermal Analysis - OC Temperature Calculation," Rev 1 and Calculation M95-0020, 

"DCHE Performance Evaluation," Rev I for EPU conditions. 

Procedure EGR-NGGC-0017. Preparation and Control of Design Analysis and 

Calculations. applies to this task. 

41 

PEF-NCR-02007



6/25/2007 

Calculation M95-0044, "RWIDCIDH Thermal Analysis - DC Temperature Calculation," 

Rev 1 for the Decay Heat Closed Cycle Cooling (OC) System needs to be revised to 

account for increased heat load of the Decay Heat Heat Exchangers and the Makeup 

Pumps at EPU conditions and to reduce the allowable number of plugged tubes to 10% 

(69 tubes). Also, there are inconsistencies between Calculation M95-0044 and 

Calculation M950020 that require resolution. The thermal conductivity of the DCHE 

lubes should be relatively equal; however, there is significant difference between the 

thermal conductivity and the maximum shell side velocities for the DCHE design 

conditions used in these two calculations. The existing sensitivity study of tube blockage 

versus RW inlet temperatures needs to be updated when revising Calculation M95-0044, 

"RWIDCIDH Thermal Analysis - DC Temperature Calculation," Rev 1 and Calculation 

M95-0020, "DCHE Performance Evaluation," Rev 1 for EPU conditions. 



Calculation M95-0035, 'SW System lnvenlofy Transient Analysis,' Rev. 2 

Calculation M95-0035, "SW System Inventory Transient Analysis,' Rev. 2 needs to be 

updated for EPU conditions including Verification that the SW thermal relief set points 

will not be affected. Procedure EGR-NGGC-0017, Preparation and Control of Design 

Analysis and Calculations, applies to this task. 

1.9.1 5 Turbine Building Structural Evaluation 

0 

The planned secondary system upgrades will result in increased loads on the turbine 

building structure and, in some cases, increased loads for equipment supports. 

Equipment that will result in significant load increases include the new MSRs, MSR drain 

heat exchangers, turbine rotors and casings, main generator and exciter, feedwater 

heaters, SC heat exchangers, larger motors for pumps with larger impellers or new 

pumps, and Condensate pump variable speed drives. An evaluation of the expected 

increase in loads on the supports and structures is required to identify any significant 

physical andlor calculation changes to that are required. 

42 

PEF-NCR-02008



6/25/2007 

10.2 Specifications 

CR3 Piping Specification SP-5206 Rev, 8 

SWHE Heat Exchanger Specification Sheet 

OCHE Heat Exchanger Specification Sheet 

Instrument Data Sheets for HD Control Valves 

lsophase Bus Duct Cooling Specifications 

Specification for Third Point Feedwater Heaters, CDHE-3A and 38 

Circulating Water Pump and Motor Specification 

Secondaty Cooling Pump and Motor Specification 

Condensate Pump and Motor Specification 

Booster Feed Pump and Motor Specification 

10.3 P81D's: 

Flow Diagram Index 302-00&SH-001 

Symbols 302-001-SH- 001 

Main 8 Reheat Steam 302-01 l--SH-OOl 

Main 8 Reheat Sleam 302-01 I--SH-002 

Main 8 Reheat Steam 302-01 1.-SH-003 

Main & Reheat Steam 302-01 1--SH-004 

Feedwaler 302-081 -SH-001 

Feedwaler 302-081 -SH-002 

Feedwater 302-081 --SH-003 

Feedwater 302-081 --SH-004 

Condensate 302-101 -SH-001 

Condensate 302-101 -SH-002 

Condensate 302-101 --SH-003 

Heater Drains 302-1 ll--SH-001 

Heater Drains 302-1 1 l--SH-002 

Healer Drains 302-1 11--SH-003 

Heater Drains 302-1 1 1 --SH-004 

Circulating Water 302-201 -SH-001 

Secondary Services Closed Cycle Cooling 302-221-SH-001 

Secondary Sewices Closed Cycle Cooling 302-221 -SH-002 



10.4 Calculations 

Calculation M87-0002, 'SW Thermai Analysis,' Rev 3 

Calculation M90-0071, 'CR3 FW Booster Pump NPSH Evaluation,' Rev. 

1 

Calculation M950020. "DCHE Performance Evaluation." Rev 1 

Calculation M95-0035, 'SW System Inventory Transient Analysis," Rev. 2 

Calculation M95-0044, "RWIOCIDH Thermal Analysis - DC Temperalure 

Calculation," Rev 1 

Calculation M97.0133, "SW Heat Loads During LBLOCA and SW 

Temperature Decay Times," Rev 11 

43

Progress Energy Crystat River Unit 3 


6125/2007 

Calculation FW 7.1, Feedwater Booster Pump NPSHA and Deaerator 

Volume Check, dated September 19, 1969. 

Calculation DST-1, GAI Design Deaerator Storage Tank Size, dated July 

11,1968. 

Calculation E90-0044, Non Safety Related 8uses Short Circuit, ARC 

Flash and Voltage Drop Analysis Under Normal Plant Operating 

Conditions, Revision 5 

Non Safety 125 VDC 

10.5 Procedures 

EGR-NGGC-0005, Engineering Change 

EGR-NGGC-0012, Engineering Product Quality 

EGR-NGGC-0017, Preparation and Control of Design Analysis and 

Calculations 

EGR-NGGC-0020, Preparalion and Control of Specifications 

MCP-NGGC-0401, Material Acquisition (Procuremenl, Receiving, 

Shipping) 

NUA-NGGC-1530, Equipment, Pressure Test, Protective Coatings, and 

Special Process Inspections 

NGGM-PM-0020, Vendor Quality Program for Crilical Non-Safety 

Equipmenl 

44

~ 

. 

...... 

, - . ~ 

- . . .. ... . . ..'.>..... ........ 

.. __- -. - - . .-.. . .. -. 

LIS- 

~~ 

I -- -.. 

- 

.-..-. ........ 

.. ..-..... 

-. .... -... ~ 

=I..-. - L.1. I 

. . .......... 

......... 

........ 

-. ... - . 

..... . 

. . . . 

--......

April 10,2008 


CR3 NUCLEAR PLANT 



Dear Bidder: 

This addendum adds requirements to the above-referenced Request for Proposal and provides 

answers to several questions raised by bidders. The questions and respective answers are 

attached. In addition, the following two new requirements are added to the RFP: 

0 Bidder shall include an analysis of Internal flooding due to the increased “Circulation 

Water” flow rate of approximately 22%. 

0 Bidder shall include provisions in their bid for License Amendment input. 

All other terms and conditions remain unchanged. Questions pertaining to this addendum should 

be directed to the appropriate individual listed in the original Request for Proposal. 


RFP Addendum 


li I I3343

.. 

Your acknowledgement of receipt of this addendum should be noted on your proposal. Failure 

to do so may constitute grounds for rejection of your bid. 


Tony Owen 

Manager NGG Major Projects 

I -- 

Attachment 

RFP Addendum 

Revision 4/1012008 

#I13343


Certain bidders have asked the following questions in regards to RFP No. KS12007, so this addendum is 

in answer to those questions and available to all bidders. A question and answer format has been used. 

Turbine building structural evaluation commentslclarifications: 

Question: Sections 1.2.13 and 1.9.15 discuss "Conduct an evaluation of the Turbine Building structure 

considering the expected additional loads resulting from installation of new and larger equipment" 

and "Perform an evaluation of the Turbine Building structure and supports to identify if any significant 

changes are required to accommodate the expected increases in loads resulting from new and larger 

equipment such as turbine motors, main generator, etc.". Both statements imply there is an evaluation 

for the existing building loads. What calculations cover the existing TB evaluations, and will these be 

made available? 

Answer: Original calculations are Gilbert Commonwealth structural calculations and will be made 

available. Estimate 200 hours to review and revise calculations as necessary. 

Question: The statements in sections 1.2.13 and 1.9.15 ask for an evaluation to see if significant 

changes are required. Please define the term "significant" changes versus others? 

Answer: "Significant changes" in design loads would be those that would not meet current acceptance 

criteria and would require modifications to the existing floor or support columns. 

Question: There is no mention of what to do when changes are required. When changes are required, 

are they included with this scope or handled separately outside of this scope? 

Answer: The modifications would be scope addition and would be priced separately as T&M, if required. 

Question: Section 1.12 discusses the schedule for the Turbine Building evaluation (Item 15) and is 

scheduled to be completed 12/13/07. It is noted that a PO will not be submitted to anyone before late 

August: Before the TB evaluation can be done, inputs for the weights and footprints of all equipment 

must be known. This includes major components such as the turbine and MSRs. When will the detailed 

vendor information be available and the locations within the TB be defined? The schedule indicates that 

equipment information will not be known until after the deadline for the TB evaluation, which would 

invalidate the TB evaluation schedule. It appears the schedule needs to be reworked to define 

predecessor activities for all tasks. 

Answer: The weights of the replacement components are readily available and will be provided as part of 

the Owners deliverables within the schedule. 

Electrical comments/clarifications: 

Question: Section 1.9.5 asks for the complete replacement of the existing system with the 2 X 100% 

new system each with 100% motorlfan and cooling coils, while Section 1.2.1 discusses upgrade cooling 

unit to have redundant fanlmotor and cooling coils. The existing unit can not be upgraded to have 

redundant fans. Therefore two 100% new units would be required. 

Is the plant replacing the existing cooling unit with two new 100% redundant units or upgrading the 

existing unit with redundant motors to meet the design requirements? 

Answer: Is0 phase bus duct coolers should be replaced with 2 X 100% redundant coolers and fans. 

PEF-NCK-020 15 

RFP Addendum 


#I13343


Question: Booster Feed Water pump motors are up-rated to 4000 HP. The 4 KV Aux and startup 

transformers may become overloaded and 4KV switchgear will not likely handle all of EPU load 

requirements. It is recommended that before writing the spec proposal for the FW Booster Pump, an 

evaluation on the power distribution system be performed to determine what voltage class motors are 

required. This should be performed prior to preparing the pump/motor specification. Should the Bid 

Specification identify the need to prepare a preliminary electrical system design review prior to preparing 

the FW Booster Pump motor spec (4KV level)? 

Answer: The Feed Water Booster pump motor replacement and modification should include rerouting the 

load center from the 4160V to the 6900V switch gear. 

Question: The draft bid specification identifies the need to revise the Non-Safety 125 VDC calculation 

using the ETAP model. If this calculation will not be affected by the EPU, what is the basis for upgrading 

the 125 VDC calculation using the ETAP program? 

Answer: If 125VDC calculations are not affected then state as such within your exception conformance 

tables for the proposal. 

Question: The bid specification recommends performing the voltage drop and short circuit calculation 

using the SKM software tool. Can CR3 provide the overall plant model in the SKM software 

environment? 

Answer: CR3 will provide modeling as currently exists for electrical load centers. 

Question: The specification limited this scope to a revision of calculation E90-0044. Is it Progress 

Energy's intention to limit the scope of the ETAP proposal to only one calculation? The ability to 

comprehensively update all the individual calculations using multiple software programs, spreadsheets, 

etc. is limited (especially those calculations performed by other third parties). Would Progress Energy 

support developing an overall plant electrical distribution model using the Progress Energy ETAP 

program to incorporate all design changes from the EPU? 

Answer: Provide a comparison of costs for updating the entire electrical system to ETAP instead of 

revising all current software programs and calculations. Prudence will dictate decision. If costs, resource, 

and schedule are better by modeling the whole system in ETAP then CR3 can support this approach. 

ClarificationlComments to Condensate PumpNFDlMotor Request: 

Question: Suggest separating the pump and motor ECs from the VFDs. These are actually 2 different 

product offerings and if the equipment is combined, it may limit the options available for separating pumps 

from VFD vendors. 

Answer: Condensate Pump and Motor and Control system may be separated and designed as separate 

ECs. 

RFP Addendum 


#I13343

Clarification on the ICs system: 


Question: Is it the intent that the Integrated Control System modifications be performed in-house by 

PEF or other contracted entities? 

Answer: PEF will perform ICs modifications. 

ClarificationlComment to Equipment Specification and Design Specification definition: 

Question: The terms Equipment Specification and Design Specification appear to be interchangeable. 

Are these reference terms the same in the PEF system? Please clarify if they are not the same. 

Answer: Design Specifications are the requirements for the component or system parameters provided in 

an engineering document. Equipment Specifications are the PEF Engineering Documents that are used 

to order equipment in accordance with EGR-NGGC-0020. Note 4 has the issuance of Equipment 

Specifications developed per NGGC-EGR-0020 also requires generation of an EC per EGR-NGGC -0005 

ClarificationlComment on the Reference to Affected Calculations: 

Question: Section 1.9.14 references more than 5 calculation documents out of the -1 500 calculations 

that will need to be revised or evaluated. Are these other affected documents to be included in the 

respective EC package preparation, or are the critical documents determined to be the 5 identified in the 

RFP with any other documents to the scope to be defined later? 

Answer: Additional calculations not identified within the RFP should be identified and may be bid as part 

of a fixed price proposal or identified that they will be addressed separately as T&M. 

ClarificationlComments on the schedule: 

Question: A brief review of the schedule noted that there are a number of instances where items are to 

be completed prior to a predecessor task being completed, or, not enough time has been allotted for the 

task based on a projected authorization date. A couple of examples include: the reference to the PEPSE 

model being completed by 9-20-07 when a typical PEPSE analysis and documentation takes 8 weeks to 

complete after the receipt of the turbine thermal kit. As mentioned previously, the turbine building 

structural evaluation is scheduled to be completed prior to the completion of the ordering and ECs for 

turbine items, MSRs, etc. Please clarify. 

Answer: A completed PEPSE Analysis was requested by the TG Vendor in order to perform the Thermal 

Kit Analysis. Subsequent conversations have identified that a completed PEPSE run is not required. 

However, the data sheet in the RFP shows what data will be required by the end of Sept to support the 

LP and HP turbine rotor designs. The weights of replacement components are readily available and can 

be provided for the Structural evaluation in order to meet desired schedule. 

pI:,F-NCR-O?O 17 

RFP Addcndum 


#I 13343

CR3 Extended Power Uprate, Secondary Systems Upgrade, Enercon Bid Proposal Review Meeting 

Pg. 1 of5 

Meeting Date: 8/28/2007 

The RFP bid specification identified fifteen (1 5) major tasks. The RFP requested each major task be bid separately and include estimated manhours. 

Combined total work scope pricing and maximum not to exceed pricing was to be identified. A request for proposal # KS 12007 addendum letter 

was issued on August 14, 2007. The addendum letter added two (2) additional work scopes (item 16 & 17). 


1) Computer models. 










1 1) Feedwater control valves and control system stability analysis. 





16) Internal flooding analysis due to increased circulating water flow. 


Enercon Proposal Review Notes: 


Proposal includes estimated man hours per major task. Proposal includes cost per major task as well as total not to exceed cost for full 

work scope. 

0 Enercon appears qualified to perform work scope based on work references and personnel resumes included in proposal. Review 

Enercon project management team for power uprate project experience. 

PEF-NCR-020 18

CR3 Extended Power Uprate, Secondary Systems Upgrade, Enercon Bid Proposal Review Meeting 

Pg. 2 of5 

BOP Piping Analysis Scope does not appear to be included. Areva scoping study report # 5 1-9043794-000 Section 3.4.1.3 “pipe support 

/ water hammer” identifies I6 piping calculations (ref. App. J) and the main steam pipe hammer calculation M73- 1002 need developed 

or revised. 

Schedule Comment: Prioritize the 2007 procurement of the 2 feedwater heaters (CDHE-3-), 

pumps / motors. All other equipment procurement EC can be postponed to 2008. 

the 2 SC heat exchangers and the SC 

Verify existing design basis documents and affected FSAR sections will be “marked up” for each EC. 

Pg.5, PEPSE Model, add YUBA estimated feedwater heater TTD’s and DCA’s for retained heaters; validate MUR PEPSE model 

against plant data following MUR implementation. Siemens will provide preliminary turbine PEPSE model input in September 2007. 

PEPSE model to be updated with final turbine PEPSE model input after final turbine design is established. 

Pg.5, FATHOM model; add Secondary Cooling System (SC) to list of systems. Need to verify uprated SC system will provide sufficient 

cooling water to specific locations in the system (Le. Generator H2 coolers). System flow control valves should be evaluated. The LO 

Cooler temperature control valve may need to be enlarged. The SC system header pressure control setpoint can be increased 10-1 5 psi 

due to increasing the generator H2 gas pressure from 60 psig to 75 psig. 

Pg.9, Commercial and Resource Proposal; review “billing in accordance with master service agreement for T&M’ vs. the not to exceed 

prices stated in the proposal. 

Pg. 10, Item 7; CHECWORKS program at CR3 will be utilized. 

Pg. 10, Item 8; Final PEPSE model after all new equipment is specified is not in scope. 

Pg. 10, Item 9; Enercon site liaison is expected to obtain design basis infomation. Reliance on site engineering to provide design basis 

information is not desired. 

PEF-NCR-020 19

CR3 Extended Power Uprate, Secondary Systems Upgrade, Enercon Bid Proposal Review Meeting Pg. 3 of 5 

Pg. 1 1 Item 12; The proposal does not include a PEPSE model for the 2009 plant condition. The 2009 plant configuration heat balance 

model will be performed by Siemens to support turbine performance guarantee and performance testing. Add, “Enercon shall support 

this effort as needed to accurately model the plant configuration”. Evaluate having Enercon perform an independent 2009 model to 

compare with Siemens model. 

Pg.20, Assumption item 3 and 4; all valves on piping associated with the new MSR belly drain heat exchangers shall be evaluated. New 

valves shall be specified for procurement however a procurement EC should not be required. 

Proposal requires CR3 plant cable databases will be updated by plant engineering. 

Pg.24, Turbine Vendor Information; will not be as extensive as described in the proposal. The turbine lendor will provide new complete 

turbine generator instruction manuals and the turbine generator installation instructions. The existing turbine generator vendor drawing 

file will have to be reviewed for impact. A turbine performance test procedure shall be developed and shall be in accordance with 

ASME PTC 6 - 2004, Altemate test for nuclear plant. 

Pg.28, Turbine Generator Assumptions; The SC piping to the generator H2 coolers may be impacted; Turbine Generator instrument and 

control setting changes will be provided by Siemens and shall be included in the turbine EC; Generator Instruments will be impacted 

and shall be evaluated; Turbine Generator support systems will be evaluated by Siemens. Any impacts identified by Siemens shall be 

included in the turbine EC. 

Pg.29, Turbine Generator Assumptions 17; Calculation S95-002 1, Turbine Generator Pedestal Structural Analysis, shall be “updated” 

using the methodology contained in the analysis. A three dimensional analysis model of the turbine pedestal structure is included. 

Pg.39, Bus Duct Deliverables; Verify evaluation of bus duct electrical capacity (bus duct rating) will be performed in conjunction with 

the bus duct cooling EC. 

e 

Pg.59, SC System Workscope Item 10; Verify hydraulic evaluation includes system flow balance, system heat loads are satisfied and 

system flow control valves are evaluated. Note the SC system pressure setpoint can be increased due to increasing generator H2 

pressure. 

PEF-NCR-0202 O


0 Pg.59, SC System Workscope Item 1 1 ; The turbine lube oil temperature control valve should be replaced with a larger valve. 

0 Pg.60, SC System Work Performed by Others; Enercon should interface with equipment vendors to obtain design input information and 

not rely on PE to perform this function. This comment applies to all equipment and all “work by others” sections of the proposal. 

0 Pg.64, SC system Assumptions; defined work scope does not address interferences to replace the major SC components. EC installation 

instructions must address these issues. 

0 Pg.94, FW Booster Pump Assumption 15; A larger pump / motor will be specified. Impacts to the support pedestal and piping can be 

expected. 

0 Pg.99, Condenser Evaluation, HES shall provide the Condenser Evaluation CFD Analysis. The HES CFD analysis is an input to the 

condenser tube bundle tube vibration analysis which is subcontracted by HES. The Condenser Tube Bundle Tube Vibration Analysis 

should be identified as a deliverable and shall identify tube bundle locations where steam impingement plates should be installed. 

Impingement plate additions were recommended by HES during the CR3 previous condenser tube failure analysis. Steam impingement 

plates should be installed during the 2009 LP turbine replacement. 

0 Pg. 1 15, Electrical Distribution Calculations; Review proposal to consolidate existing electrical calculations into new ETAP. Evaluate 

cost of converting vs. updating existing electrical calculations. 

PEF-NCR-0202 1


Appendix B, Consolidated Project Schedule Comments: 

October 07 PEPSE model is “initial” EPU model. Final PEPSE model shall be submitted after all plant design changes have been 

specified and inputted into the model. 


All turbine generator and MSR schedules shall be compared to and coordinated with the equipment vendor’s engineering deliverable 

schedules. The schedule for issuing the installation EC packages shall be determined by the owner. 

The turbine pedestal calculation schedule shall be accelerated and will support final calculation expeditiously upon receiving final 

input data from Siemens. 


Isophase Bus Duct procurement EC can be postponed to 2008. 

Isophase Electrical Capacity Calculation shall be performed in conjunction with designing the bus duct cooling system. 

Turbine Building Structural Evaluation is scheduled to complete by 12/12/07. This does not appear feasible.

Proposal for 

Design Engineering of 

Power Uprate for the 

Crystal River Three Nuclear Plant 

Prepared for: 

@ RograasEnergy 

Submitted By: 

TechCom International 

440 Goddard 

Irvine, CA 926 18 

August 2,2007 

UNPRICED COPY

Tech Com International 

440 Goddard Phone: (949) 453-0660 

Imine, CA 92618 Fax: (949) 453-0760 

Email: info~,tci-corp.com 

www.tci-corp.com 

Date: August 2,2007 

Mr. Tony Owen 


P. 0. Box 155 1 (PEB 2C3) 


Subject: 

Reference: 

Proposal for Engineering Service for Power Uprate of Crystal River Three Nuclear Plant 

Request for Proposal #KS 12007 from Progress Energy Florida Inc., including addenda dated 

July 27,2007 

Dear Mr. Owen, 

TechCom International (TCI) is pleased to have an opportunity to submit this proposal to support your Power 

Uprate Project. TCI intends to provide the design and engineering deliverables as specified in your Request for 

Proposal #KS12007. The TCI team will ensure the cost efficiency for your project while maintaining your 

schedule and the highest standards of quality that Progress Energy demands. 

The table of contents on the next page provides an inventory of the contents of this proposal. Progress Energy 

may copy any of the enclosed materials, for their exclusive use in the evaluation of this proposal. If there are 

any questions, please do not hesitate to contact me. 

Sincerely, 

Bob Katebian, Ph.D. 

President 

/End. - TCI Proposal dated 8-2-2006 

Page 2 of 16


440 Goddard Phone: (949) 453-0660 

' Imine, CA 92618 Fax: (949) 453-0760 

Email: infoatci-corp.com - www.tci-corP.com 


1. PROPOSED PROJECT SCOPE AND APPROACH ............................................................................. 4 

1.1. Project Scope ........................................................................................ . .................................. 4 

1.2. Approach ................................................................................................ . ................................. 5 

1.2.1. Preliminary Work ................................................................................................................. 5 

1.2.2. Design Specification ............................................................................................................ 5 

1.2.3. Equipment Specifications and EC Purchase Packages ........................................................ 5 

1.2.4. EC Installation Packages ...................................................................................................... 6 

1.3. Support Required ..................................................................................................................... 7 

2. PROJECT ORGANIZATION ............................................................................................................. 8 

2.1 . Proposed Organization ,.......... . . ... . ...... ... ... .. . . , .. . ... .. . .. . .. . . .. . .. .. . . ... . . . , . .... .. . ... . . . . . . .. . .. . .. .. .. . .. . .. .. .. . . . . 8 

3. 

4. 

2.2. Classification of Personnel .................................................................................................... 10 

KEY PERSONNEL .......................................................................................................................... 1 1 

MAN-HOUR ESTMATES AND MILESTONE SCHEDULE ............................................................. 13 

4.1. 

4.2. 

4.3. 

Attachments: 

Project Start Date ................................................................................................................... 1'3 

Project Milestone Schedule ................................................................................................ "., , 1'3 

Estimated Man-Hours for Project Completion ...................................................................... 15 

1 .) General Information Form 

2.) TCI Small Business Certification 

3.) TCI Disadvantaged Business Certification 

4.) Table of Conformance 

5.) Contractor Safety 

6.) TCI Insurance Certifications 

7.) Resumes of Key Personnel 

8.) NOTUSED 

Page 3 of 16 

PEF-NCK-02025


440 Goddard Phone: (949) 453-0660 

Imine, CA 92618 Fax: (949) 453-0760 

Emai I: i nfo@,tc i -corp.co in 


1. PROPOSED PROJECT SCOPE AND APPROACH 

1.1. Project Scope 

TechCom Intemational (TCI) is submitting this proposal for apartial scope ofwork. Based on our expert 

analysis of the project scope, we have determined that it is in Progress Energy’s (PE) interest to split the project 

tasks to ensure that the project is completed on time and with a high degree of confidence in the resulting 

design. 

TCI proposes to complete the following tasks in their entirety: 

Task 4: Deaerator Bypass Line 

Task 5: Isophase Bus Cooling 

Task 7: Secondary Cooling System Modifications 

Task 8: Circulating Water System Modifications 

Task 10: Feedwater Booster Pumps and Motors 

Task 1 1 : Feedwater Control System 

Task 13: Electrical Distribution 

Task 14: Mechanical Calculations 

Task 15: Turbine Building Structural Evaluation 

TCI also acknowledges receipt of the addenda dated July 27, 2007 and proposes to complete both of the 

additional requested tasks. 

Task A: Analysis of Internal flooding due to the Increased Flow Rate 

Task B: License Amendment Input 

TCI has estimated the project cost by including ten (IO) new or revised drawings for tasks 4, 5, 7, 8, 10 and 13. 

Additional drawings will be prepared based on time and material rates. 

Because the specifications for the pump replacements have not been completed as yet, the required motor sizes 

are indeterminate and, therefore the power requirements are indeterminate. This proposal does not include the 

engineering work required to accommodate changes to the electrical distribution system as a result of increased 

pump power requirements. 

Page 4 of 16 

PEF-NCK-02026


440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Email: infoG;tci-corp.com 


1.2. Approach 

TCI will analyze and prepare the engineering documentation required for each task, in our Irvine, CA offices. 

All TCI Engineers utilized on this project will. be trained to the QA program in effect at PE’s Crystal River 

Three Nuclear Plant. 

1.2.1. Preliminary Work 

Throughout the project TCI’s On-Site Engineering Liaison will coordinate with the discipline Lead Engineers to 

locate and transmit the requisite information to begin each of the designated tasks. As required, the On-Site 

Engineering Liaison will conduct system walkdowns at the direction of the discipline Lead Engineers and will 

interface with PE personnel as needed. 

Steps included in the preliminary may include the following subtasks as applicable: 

1. Training 

2. Identify and review of vendor documentation 

3. Walkdown of plant systems 

4. Review and determination the affected plant design documents 

5. Review and updates the affected design calculations 

1.2.2. Design Specification 

In order to complete the required design specifications, TCI staff will perform the following subtasks as 

applicable: 

1. Identify required system interfaces and component changes required 

2. Identify the system component quality classifications 

3. Determine the applicable references for design input and any additional information needed 

4. Provide justification and validation of assumptions 

5. Evaluate effects of the changes on design margins 

6. Confirm that the change conforms to the design basis 

7. Assess changes to the design inputs and design records 

8. Evaluate the interfaces with other system component changes 

9. Confirm that the field conditions match the design 

10. Evaluate impacts to the non-design records 

1.2.3. Equipment Specifications and EC Purchase Packages 

TCI will submit to PE equipment specifications of sufficient detail for PE to procure the necessary components 

required for each task. The packages will include parts lists and TCI will assist by supplying any technical 

information required by PE’s procurement department. 

Page 5 of I6


440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Emai 1 : i rifo@tc i -corp.co in 


1.2.4. EC Installation Packages 

TCI will submit in the PE required format the completed EC installation package that will include the following 

information, as required, for each task: 

1. Precautions and Limitations: 

a. Identify any significant plant conditions, partial turnovers, etc.; 

b. Identify any condition requirements for installation and testing and 

c. Identify precautions and limitations associated with operation. 

2. Installation Requirements: 

a. Specify inspections, engineering hold points, and clearances; 

b. Provide detail required sequencing steps and 

c. Identify applicable installation documents. 

3. Prepare newlchange label requests 

4. EC parts list: 

a. Provide EC parts list by form, sketch BOM , or drawing reference 

b. Provide design parameters required for procurement 

c. Identify long procurement or fabrication lead times 

5. Test Requirements: 

a. Identify component, sub-system, or system functions to be tested; 

b. Identify design inputs/parameters to be tested and acceptance criteria 

c. Identify interface, pre-turnover and post-tumover testing and 

d. Identify the test procedure to be performed 

6. Tumover to Operations: TCI will determine the tumover requirements and develop the turnover 

transition plan. 

7. EC Installation Package Review and Approval: 

a. TCI will determine the required reviewers; 

b. Provide the appropriate review forms and materials to the reviewers; 

c. Collect review comments; 

d. Disposition and incorporate valid comments of each reviewer; 

e. Obtain the concurrence of the reviewers for comment incorporation and 

f. Provide for PE approval and issue the completed EC Installation Package. 

Page 6 of I6 

PEF-NCR-02028

Tech Coin International 

440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Email: info@tci-corp.com 


1.3. Support Required 

In order to ensure the timely and accurate completion of each task, the support of PE will be required in several 

areas. TCI foresees that support will be need in the following areas: 

I. 

2. 

3. 

4. 

5. 

6. 

7. 

This project will require that TCI personnel, located in the Irvine, California office have access through 

electronic means, to the document management system of the Crystal River Three site. This may be in 

the form of a VPN or other type of network access. 

TCI personnel will require training in the QA program and engineering site procedures of the Crystal 

River Three Nuclear Power Plant. TCI anticipates that this training can be done remotely at the TCI 

Irvine offices. 

TCI expects that their On-Site Engineering Liaison will be furnished with the generally acceptable 

level of support including a phone, computer workstation, desk space and other support as required to 

function effectively at the CR3 site. 

PE will grant authority for TCI personnel to obtain any information need for completion of this project 

to be obtained directly from the vendor. 

PE will support TCI as needed for site walkdowns and visits. This includes security badging, escorting 

or other means needed to ensure adequate access to site systems and components. 

TCI expects that PE will be sensitive to the schedule time constraints and to provide for timely review, 

comment and approval of documents submitted by TCI. This includes any third party reviews that may 

be required. 

TCI is proposing to complete only a portion of the workscope as defined in the PE request for 

proposal. Therefore TCI anticipates that PE will direct other firms involved with this project to 

coordinate with and interface with TCI personnel as required. 

Page 7 of I6 

PEF-NCR-02029


440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Email: info@,tci-corp.com 

www.tci-cortxoni 

2. PROJECT ORGANIZATION 

2.1. Proposed Organization 

TechCom International’s goal is to be highly responsive to your RFP for Engineering, Analysis, Construction 

Management and other Services. The following is our analysis of the organization, and required skill sets to 

ensure the successful completion of the project task items, in a timely manner. 

TCI will provide the following personnel, required to complete this project, based on our analysis of the project 

tasks: 

A,) One Project Manager 

B.) One Lead Mechanical Engineer and six Mechanical Engineers. 

C.) One Lead Civil Engineer and two Civil Engineers. 

D.) One Lead I&C Engineer and one I&C Engineer. 

E.) One Lead Electrical and four Electrical Engineers. 

F.) One on-site Engineering Liaison. 

G.) One Project Secretary 

In order to provide the most efficient use of personnel for this project the following duties will be distributed as 

follows: 

1 .) The Project Manager will have the responsibility of planning and scheduling the work, and deliver of 

the work products to PE. 

2.) The Lead Mechanical Engineer will also act as the Project Engineer, since the bulk of the engineering is 

mechanical. He will provide technical management for the project and serve as a technical contact to 

PE at the TCI Irvine office. 

Please refer to figure 1 for the proposed organizational chart. 

Page 8 of 16 

PEF-NCR-02030


440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Email: info@tci-corp.com 


+ 

I 


Project Engineer* 

On Site Engineering Liaison 

Project Secretary 

Lead Mechanical Engineer* + 

Senior Engineers 

And Designers 

Lead Civil Engineer 

1 


And Designers 

1 

Lead Electrical Engineer 


And Designers 

Lead I&C Engineer 

:Senior Engineers 

And Designers 

Figure 2-1: Proposed Organizational Cart 

Note: The Lead Mechanical Engineer will also function as the Project Engineer as required. 

Page 9 of 16 

PEF-NCK-0203 1


440 Goddard Phone: (949) 453-0660 

Imine, CA 92618 Fax: (949) 453-0760 

Email: iiifok2tci-corp.com 


2.2. Classification of Personnel 

TCI uses stringent qualification criteria to ensure that the proposed staff has the experience and education to 

complete the project. Table 2-1 defines the minimum requirements for each classification of personnel to be 

placed on the project. For purposes of classification, a Doctor of Philosophy in a related field may be 

substituted for a Registered Professional Engineering license (RPE). 

Table 2-1 

Minimum Requirements 

Classification 

Years of Applicable 

Education 

Certifications 

Experience 



Advanced Engineering Degree 

Advanced Engineering Degree 

None 

RPE 

25 years 

25 years 

Project Planner/Scheduler I Degree in Related Field I None I 10 years 

Project Secretary 

Lead Engineer 

Sr. Engineer 

High School 

BS in Field 

BS in Field 

None 

RPE in Field 

RPE in Field 

5 years 

20 years 

15 years 

Engineermesigner BS in Field None IO years 

On-Site Engineer Liaison None None 20 years 

Page IO of 16

~ ~~~ 

Tech Com Intern ation a1 

440 Goddard Phone: (949) 453-0660 

Iwine, CA 92618 Fax: (949) 453-0760 

Email: info~,tci-corp.com 


3. KEY PERSONNEL 

TCI is pleased to present our Management and Analysis team for your consideration for the Crystal River 

Power Uprate project. The attached resumes provide a concise overview of a sample of our team’s capabilities 

we have provided a summary of the key qualifications Table 3-1, which includes the available staff for onsite 

and main office support. 

I Table 3-1: 

I 

I 

Name 

Position 

Qualifications of Proposed Staff 

Engineering Support Staff at TCI Main Ofice 

Discipline 

Years of 

Experience 

Degrees 

Earned 

Katebian, Bob, Project Manager All 30 BS EE 

Ph.D. 

MS EE 

PhD Engr 

Professional 

Registrations 

(State) 

(For pay grade 

purposes PhD 

qualifies.) 

Whittle, C B Lead I&C Engineer I&C 25 BS EE, 

(Butch) Jr., PE 

MS EE 

Koleff, William Sr. I&C Engineer I&C 22 BS EE 

Steve, PE 

RPE I&C (CA) 

RPE (FL) 

Pilot, Pete, PE Lead Engineer EE 25 BS EE 

Root, Mike, PE Sr. Electrical Engineer EE/I&C 25 BS EE 

Carmoa, Gil, PE Sr. Electrical Engineer EE 35 BS EE 

MS EE 

MBA 

Grosze, Andrew Sr. Electrical Engineer EE 21 BS EE 

A., PE 

Coupe, Henry Electrical Engineer/ EE 36 BS EE/ 

Designer 

BS Phys 

RPE EE (FL) 

RPE EE (CA) 

RPE I&C (CA) 

RPE EE 

(CA & IL) 

RPE EE (TX) 

Richard Project Engineer & ME 40 BS Eng. 

Bockhorst, PE Lead Mechanical 

Engineer 

Sima, Fred, PE Sr. Mechanical ME 40 MS ME 

RPE ME (CA) 

SRO 

RPE ME (CA) 

Page 11 of I6 

PEF-NCR-02033

~~ 


440 Goddard Phone: (949) 453-0660 

Imine, CA 92618 Fax: (949) 453-0760 

Email: infora),tci-corp.coin 


Table 3-1: 

Name 

Qualifications of Proposed Staff 

Engineering Support Staff at TCI Main Office 

Position 

Discipline 

Professional 

Valandai, 

Parviz, PE 

Troy, Jeff, PhD 

Santa Ana, 

Fabian, PE 

Cheng, Johnson 

Har, Stephen, 

PE 

Sr. Mechanical 

Engineer 


Engineer 


Engineer 

Mechanical 

Engineermesigner 

Mechanical Engineer 

ME 

ME 

ME 

ME 

ME 

I M S M E 

I BSNE 

I 

20 PhD ME (For pay _ _ grade _ 

I MS ME I purposes P ~ D 

BS Env. qualifies.) 

40 BS Eng. RPE ME (CA) 

25 IBSME I 

25 

BS ME WE ME (CA) 

I 

I 

I 

Hadidi, Hassan Lead Civil/Structural CE/ SE 25 BS SE, RPE SE (CA) 

PhD, SE, PE Engineer MS SE, RPE CE (CA) 

PhD CE 

Lu, Tim, PhD, Sr.Civil/Structural CE/ SE 17 BS CE, RPE CE (CA) 

SE, PE 

Engineer 

MS SE, 

PhD SE 

Baker, Ray, PE Sr. Civil Engineer CE 30 BS CE RPE (CA), S.E. 

MS CE (CA) 

On-Site Engineering Staff 

Brannon, James I On-Site Engineer I I&C I30 

NOTES: 

ScientificEngineering Disciplines and Degrees: CE-Civil; Env- Environmental; EE- Electrical; I&C- 

Instrumentation and Control; ME- Mechanical; MBA- Management and Business Administration; MT- 

Management of Technology; N-Nuclear; Phys- Physics; SE- Structural; RPE - Registered Professional 

Engineer. 

Page 12 of 16 

PEF-NCR-02034


440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Email: info~,tci-corp.coin 

www.tci-coi-p.com 

4. MAN-HOUR ESTMATES AND MILESTONE SCHEDULE 

4.1. Project Start Date 

Since time is of the essence, TCI requests that we receive authorization to proceed no later that August 15, 

2007. If this authorization is received, TCI will proceed with a start date of August 20, 2007. Later authorization 

may impact the completion dates of some of the earlier tasks. In any event, TCI will make every effort to 

complete each task by the identified due date. 

4.2. Project Milestone Schedule 

TCI will perform the project tasks based on the schedule of milestones shown in Table 4-1. The Project 

Manager will be responsible for creating a detailed schedule of the project based on the 

I Table 4-1 I 

I 

No. 

1 

TASK 

Project Milestone Schedule 

SUBTASK 

TechCom elects not to bid on this item at this time. 

1 PR1oRITY I DUEDATE 

MILESTONE 

2 TechCom elects not to bid on this item at this time. 


Design Specification 1 10-03-07 

I 4 I Deaerator Bypass Line Equipment Specification I 1 

1 10- 17-07 

- 

Purchase EC package 2 10-3 1-07 

Install EC package 3 12- 12-08 

Isophase Bus Evaluate electrical capacity 4 6- 18-09 

5 10-03-07 

Isophase Bus Duct Equipment Specification 1 10- 17-07 

Cooling System Purchase EC package 2 10-31-07 

Install EC package 3 12- 12-08 


I 

I 

Page 13 of 16 

PEF-NCR-0203 5

. . 


440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Email: info@,tci-corp.coin 


Table 4-1 

No. TASK SUBTASK 

Install EC package 

PRroRrTY 

6 


MILESTONE 

DUE DATE 

12- 16- 10 

10 

11 

12 

FW Booster Pump Equipment Specification 4 6- 18-09 

Impellers and Motors Purchase EC package 5 7-2-09 

Install EC package 6 12- 16- 10 

FW Control System Evaluation 4 4-8- 10 

Stability Analysis 4 6-11-10 

TechCom elects not to bid on this item at this time. 

Electrical Distribution 

Evaluate Station Auxiliary 4 

and Startup Transformers, 

and 4KV System 

Calculation E90-0044 6 

12- 12-08 

1-08-09 

Page 14 of 16

~~~ 

~ ~ ~~ ~ ~~~ ~ 


440 Goddard Phone: (949) 453-0660 

Imine, CA 92618 Fax: (949) 453-0760 

Emai 1: i nfo@,tc i -corp.com 


4.3. Estimated Man-Hours for Project Completion 

Based on our analysis of the tasks, TCI estimates that it will take a total of 53,530 man-hours to complete. 

Table 4-2 provides a breakdown of our estimate based on task and employee classification. 

I Table 4-2 

Estimated Man-Hours for Each Task Proposed Staff Classification 

Page 15 of 16 

PEF-NCR-02037

Tech Coin International 

440 Goddard Phone: (949) 453-0660 

Irvine, CA 92618 Fax: (949) 453-0760 

Emai 1 : info62tc i -corp.com 


ATTACHMENTS: 

1 .) General Information Form 

2.) TCI Small Business Certification 

3 .) TCI Disadvantaged Business Certification 

4.) Table of Conformance 

5.) Contractor Safety 

6.) TCI Insurance Certifications 

7.) Resumes of Key Personnel 

8.) NOTUSED 

Page 16 of 16 

PEF-NCR-02038

PEF-NCR-02039

PEF-NCR-02040

Spec 

Page 

tt 

section Reference 

Crystal River Unit 3 Nuclear Power Station 

tended Power Uprate Bid Specification Table 

of Conformance -Technical 

. Establish a monitoring program following EPU implementation for these 

feedwater healers


Comments 

2

Comments 

I 1 I I I I I I I and 18 to achieve the required now for EPU conditinnS including Increasing the I 

I 

vibration calculation^. This shall also mcl 

mal components The update is 

and the 4KV buses, switchgear. circuit breakers and cabling tu support the 

expected increase in the electricai load 

Update the following eledrical distribution calullations to evaluate the 

adequacy of existing paver system equipment ratings (auxiliary transformers, 

load centers. motor cOntrol Centers switchgear, cables. etc) to support the higher 

. . ,... .. .,. . ..,.. " ,._ 

equipment to identiy 81 any signihcant changes are required to accommodate the 

expected increases in loads resulting from new and larger equipment such as 

turbine rotors. main generator. etc


Spec tended Power Uprate Bid Specification Table 

Page 


# Mion Reference CO"e"tS 

Doc#Z5Oe46 

411012008 

PEF-NCR-02044

Spec 

Page 

# 

Mion Reference 


tended Power Uprate Bid Specification Table 


Comments 

Doc e50846 

411012008 

5

16 

Q 

a

N 

B 

00

CR3 Extended Power Uprate, Secondarv Svstems Upgrade Bid Proposal Technical Evaluation 

Pg. 1 of 6 

08123/07 

Progress Energy issued Request for Proposal No. KS 12007, Engineering Services for Secondary Systems 

Upgrade on June 6,2007. The bidders were Areva NP, Enercon Services, Sargent & Lundy, TechCom 

International and Worley Parsons. Three proposals were received on August 10,2007. Proposals were 

received by Areva / Worley Parsons (combined proposal), Enercon Services and TechCom International. 

The following proposal technical comments were developed by reviewing unpriced copies of each proposal. 

The RFP bid specification identified fifteen (1 5) major tasks. The RFP requested each major task be bid 


pricing was to be identified. 


Computer models. 

MSR replacement and MSR belly drain heat exchanger addition. 

Turbine generator modifications. 

Deaerator bypass line addition. 

Isophase bus duct cooling system. 

Feedwater heater and heater drain system modifications. 

Secondary service closed cycle cooling system modifications. 

Circulating water system modifications. 

Condensate pumps and motors. 


1 1) Feedwater control valves and control system stability analysis. 





A request for proposal ## KS 12007 addendum letter was issued on August 14,2007. The addendum letter 



1) Internal flooding analysis due to increased circulating water flow. 


TechCom International (TCI) Proposal Review Notes: 

0 TCI proposed to perform 9 of the 15 tasks (task ## 4, 5, 7, 8, 10, 11, 13, 14 and 15) and the 2 additional 

tasks. The proposal estimates a total of 41,780 man hours to complete the proposed work scope. 

Estimated man hours are provided for each major task area proposed. 

0 Proposal includes no references to TCI similar previous work experience. 

0 Proposal identifies a project organization of 20 people. The proposal identifies 19 engineering support 

staff at TCI main office in Irvine, CA. 17 resumes were attached. Several of the resumes indicate that 

TCI “proposed staff’ are presently employees of other companies. I verified one person is presently 

employed by Southem California Edison and another is presently employed by Areva. Several 

additional resumes appear to be suspect. 

0 Proposal includes only 10 new or revised drawings for task 4, 5, 7, 8, 10 and 13. 

0 Proposal does not include changes to the electrical distribution system.

CR3 Extended Power Uprate, Secondary Svstems Upgrade Bid Proposal Technical Evaluation 

Pg. 2 of 6 

Areva / Worley Parsons Proposal Review Notes: 

0 

0 

Proposal includes total work scope and is teaming effort by both companies. 

Proposal does not include estimated man hours or cost per task. Proposal includes one fixed cost 

price for total work scope. 

0 Areva (formally Babcock and Wilcox) is NSSS OEM. Worley Parsons (formally Gilbert 

Commonwealth) is CR3 AE. These companies provide the most capability. This is expected 

require less PE project management support and should reduce project risk. 

0 Pg.2, background, states “BOP phase 2 evaluations and implementation will be defined later and 

are not part of this proposal scope”. Verify this is not an accurate statement. All EPU BOP 

identified work is to be in scope of proposal. BOP Piping Analysis Scope does not appear to be 

included. Areva scoping study report # 5 1-9043794-000 Section 3.4.1.3 “pipe support / water 

hammer” identifies 16 piping calculations (ref. App. J) and the main steam pipe hammer 

calculation M73- 1002 need developed or revised. 

0 

0 

Pg.4, Table 1.4- 1 ; add “Iso-Phase Bus Duct Electrical Evaluation” to engineering evaluation list, 

Pg. 4, Table 1.4-1; add “Condense Steam Impingement Plate Mods” to EC list. This is an expected 

output of the HES condenser tube vibration analysis. This modification should be scheduled during 

the 2009 LP turbine modification. 

0 Pg.5, Table 1.4-1; add “Feedwater Heater CDHE-3”’ to equipment specification list. 

0 Pg. 19, EPU PEPSE Model; add MSR belly drain, add deaerator bypass mod, add YUBA estimated 

feedwater heater TTD’s and DCA’s for retained heaters. 

0 Pg. 19, PEPSE Model; validate MUR PEPSE model against plant data following MUR 

implementation. PEPSE model will be used as equipment design input. 

0 Pg. 19, PEPS1 Model; Siemens will provide preliminary turbine PEPSE model input in September 

2007 as requested. PEPSE model to be updated with final turbine PEPSE model input after final 

turbine design is established. 

0 Pg.20, FATHOM model; add Secondary Cooling System (SC) to list of systems. Need to verify 

uprated SC system will provide sufficient cooling water to specific locations in the system (i.e. 

Generator H2 coolers). System flow control valves should be evaluated. The LO Cooler 

temperature control valve may need to be enlarged. The SC system header pressure control 

setpoint can be increased 10- 15 psi due to increasing the generator H2 gas pressure from 60 psig to 

75 psig. Ref.Pg.43, SC Pump EC section. 

0 Pg.22, Condenser Evaluation; Required output of the HES flow induced vibration analysis is to 

identify tube bundle locations where steam impingement plates should be installed. Impingement 

plate additions were recommended by HES during the CR3 previous condenser tube failure 

analysis. 

0 Pg.23, Feedwater Heater Evaluation, add “feedwater heater relief valve setpoints and relieving 

capacity evaluation” to scope of work. 

0 Pg.24, Secondary Cooling Maximum; add logistical evaluation for removing existing SC coolers 

and installing larger heat exchangers into turbine building. 

0 Pg.28, Turbine Building Structural Evaluation; Turbine Pedestal Foundation Evaluation will NO?’ 

be performed by the turbine manufacturer. The turbine manufacturer will provide the increased 

loading data. The Turbine Generator Pedestal Structural Analysis, S95-002 1, must be revised 

under this scope of work. Analysis S95-0021, dated June 20, 1995, was performed by Gilbert 

Commonwealth. 

0 Pg. 30, Engineering Change Packages; Areva shall perform all work in accordance with current 

revision to EGR-NGGC-0005, Engineering Change. Same comment Pg.5 1. 

PEF-NCR-02050

CR3 Extended Power Um-ate, Secondary Systems Upprade Bid Proposal Technical Evaluation 

Pg. 3 of 6 

0 Pg. 30, Engineering Change Packages; include “mark-up” of FSAR for each EC to support 

consolidated EPU FSAR revision. 

0 Pg. 30, Engineering Change Packages; Separate EC packages will be issued for equipment 

procurement specifications. 

0 Pg.35, LP Turbine Replacement; The turbine vendor will not perform turbine foundation 

calculations or revise design basis foundation calculations. Calculation S95-002 1 shall be revised 

under this workscope. Same comment Pg. 37, Pg.55, Pg.60 and Pg.61. 

Pg.35, LP Turbine Replacement; Turbine Generator Instrument calibration or range changes, 

including AEH controller scaling, provided by the turbine generator OEM shall be included in the 

EC package. Same comment Pg. 37. Anticipated instrument changes are identified on Pg.60 and 

61. 

Pg.35, LP Turbine Replacement; Turbine EC shall include turbine performance test procedure in 

accordance with ASME PTC 6 - 2004, Alternate test for nuclear plant. Same comment Pg. 37. 

Pg.38, MSR Replacement, add “MSR relief valve evaluation” to scope of work. 

Pg.39, MSR Belly Drains, Evaluate 2 new heat exchangers (2 MSR drain inlets each) rather than 4 

new heat exchangers. If feasible, this may be less expensive and tie into condensate system better 

(less piping required). 

Pg.42, Isolated Phase Bus Duct, include evaluation of bus duct electrical capacity (bus duct rating) 

in conjunction with the bus duct cooling EC. 

Pg.47, Circulating Water Pump EC, include C/D water box flow straighteners and expansion 

joints. 

Pg.49, Equipment Specifications, reliance on original equipment specifications should not be 

assumed. There should be no additional scope to develop the equipment specifications identified. 

Same comment Pg.60. 

0 Pg.5 1, Deliverables, review of deliverables should not be limited to 10 working days nor limited to 

one review. Depending on the quantity and complexity of the deliverable more than one review 

may be required to support owner acceptance. 

0 Pg.53, Condenser Evaluation, HES shall provide the condenser evaluation CFD analysis. HES 

stated the HES CFD analysis is an input to the condenser tube bundle tube vibration analysis which 

is subcontracted by HES. The condenser tube bundle tube vibration analysis should be identified as 

an additional deliverable and should include recommended locations where tube bundle steam 

impingement plates should be installed. 

0 Pg.53, SC Maximization, final report should include verification of system flow balance and heat 

loads satisfied. SC system flow control valves shall be evaluated. 

0 Pg.57, PEPSI model, Siemens to provide initial turbine inputs in September, 2007. Siemens to 

provide final turbine inputs following turbine design and submittal of turbine thermal kit. PEPSI 

model to be verified with plant operating data following MUR power uprate. YUBA estimated 

EPU condition feedwater heater TTD’s and DCA’s to be included in EPU model. Should the EPU 

model be validated and corrected following EPU implementation? 

0 Pg.57, Electrical Calculations, impact assessment of 54 electrical calculations is included. Revision 

of these calculations is not included. Review optional workscope for ETAP electrical system 

modeling consolidation. 

0 Pg.58, Updates. Design Basis Documents and applicable FSAR sections should be “marked up” 

and included in each EC package. 

0 Pg.61 / 62, MSR assumptions, New MSR vessels will be longer. Modifications to piping supports 

may be required and will not be extra work. MSR vendor is to provide revised piping drawings.

CR3 Extended Power Uprate, Secondarv Systems Upgrade Bid Proposal Technical Evaluation 

Pg. 4 of 6 

e Pg.62, MSR Belly Drain assumptions, location of new heat exchangers as stated in not correct. 

Need to consider piping runs and strategically locate the new heat exchangers. Consider one new 

heat exchanger for each condensate train each receiving two MSR drains. 

e Pg.64, Main Generator and Exciter assumptions, SC water piping to the H2 coolers may be 

impacted; Generator instruments shall be reviewed for impacts; turbine supervisory instrument 

probe mounting brackets shall be reviewed and modified if required; EH tubing mounted to the 

MSR’s will be impacted. Siemens shall provide all turbine generator vendor drawings to PE for 

review. How should turbine generator VTI be coordinated? 

e Pg.67, Mechanical Inputs, A “preliminary” turbine thermal kit should be provided by Siemens in 

September, 2007. Turbine Generator and MSR structural load inputs may not be available in 

September, 2007. This should not impact schedule. 

e Schedule Attachment, review for equipment specifications / procurement EC’s needed by end of 

October, 2007. Too much equipment is identified to be specified by October, 2007. The feedwater 

heaters (CDHE-3NB) and the SC heat exchangers are priority components. 

Enercon Proposal Review Notes: 

e 

e 

e 

e 

e 

e 

e 

e 

e 

0 

e 


Proposal includes estimated man hours per major task. Proposal includes cost per major task as 

well as total not to exceed cost for full work scope. 

Enercon appears qualified to perform work scope based on work references and personnel resumes 

included in proposal. Recommend to review Enercon project management team for power uprate 

project experience. 

BOP Piping Analysis Scope does not appear to be included. Areva scoping study report # 5 1 - 

9043794-000 Section 3.4.1.3 “pipe support / water hammer” identifies 16 piping calculations (ref. 

App. J) and the main steam pipe hammer calculation M73-1002 need developed or revised. 

Schedule Comment: Prioritize the 2007 procurement of the 2 feedwater heaters (CDHE-3A/B), the 

2 SC heat exchangers and the SC pumps / motors. All other equipment procurement EC can be 

postponed to 2008. 

Verify existing design basis documents and affected FSAR sections will be “marked up” for each 

EC . 

Pg.5, PEPSE Model, add YUBA estimated feedwater heater TTD’s and DCA’s for retained 

heaters; validate MUR PEPSE model against plant data following MUR implementation. Siemens 

will provide preliminary turbine PEPSE model input in September 2007. PEPSE model to be 

updated with final turbine PEPSE model input after final turbine design is established. 

Pg.5, FATHOM model; add Secondary Cooling System (SC) to list of systems. Need to verify 

uprated SC system will provide sufficient cooling water to specific locations in the system (i.e. 

Generator H2 coolers). System flow control valves should be evaluated. The LO Cooler 

temperature control valve may need to be enlarged. The SC system header pressure control 

setpoint can be increased 10- 15 psi due to increasing the generator H2 gas pressure from 60 psig to 

75 psig. 

Pg.9, Commercial and Resource Proposal; review “billing in accordance with master service 

agreement for T&M” vs. the not to exceed prices stated in the proposal. 

Pg.10, Item 7; CHECWORKS program at CR3 will be utilized. 

Pg. 10, Item 8; Final PEPSE model after all new equipment is specified is not in scope.

CR3 Extended Power Uprate, Secondarv Systems Upgrade Bid ProDosal Technical Evaluation 

Pg. 5 of 6 

Pg. 10, Item 9; Enercon site liaison is expected to obtain design basis information. Reliance on site 

engineering to provide design basis information is not desired. 

Pg. 1 1, Item 12; The proposal does not include a PEPSE model for the 2009 plant condition. The 

2009 plant configuration heat balance model will be performed by Siemens to support turbine 

performance guarantee and performance testing. Add, “Enercon shall support this effort as needed 

to accurately model the plant configuration”. Evaluate having Enercon perform an independent 

2009 model to compare with Siemens model. 

Pg.20, Assumption item 3 and 4; all valves on piping associated with the new MSR belly drain 

heat exchangers shall be evaluated. New valves shall be specified for procurement however a 

procurement EC should not be required. 

Proposal requires CR3 plant cable databases will be updated by plant engineering. 

Pg.24, Turbine Vendor Information; will not be as extensive as described in the proposal. The 

turbine vendor will provide new complete turbine generator instruction manuals and the turbine 

generator installation instructions. The existing turbine generator vendor drawing file will have to 

be reviewed for impact. A turbine performance test procedure shall be developed and shall be in 

accordance with ASME PTC 6 - 2004, Alternate test for nuclear plant. 

Pg.28, Turbine Generator Assumptions; The SC piping to the generator H2 coolers may be 

impacted; Turbine Generator instrument and control setting changes will be provided by Siemens 

and shall be included in the turbine EC; Generator Instruments will be impacted and shall be 

evaluated; Turbine Generator support systems will be evaluated by Siemens. Any impacts 

identified by Siemens shall be included in the turbine EC. 

Pg.29, Turbine Generator Assumptions 17; Calculation S95-002 1, Turbine Generator Pedestal 

Structural Analysis, shall be “updated” using the methodology contained in the analysis. A three 

dimensional analysis model of the turbine pedestal structure is included. 

Pg.39, Bus Duct Deliverables; Verify evaluation of bus duct electrical capacity (bus duct rating) 

will be performed in conjunction with the bus duct cooling EC. 

Pg.59, SC System Workscope Item 10; Verify hydraulic evaluation includes system flow balance, 

system heat loads are satisfied and system flow control valves are evaluated. Note the SC system 

pressure setpoint can be increased due to increasing generator H2 pressure. 

Pg.59, SC System Workscope Item 11; The turbine lube oil temperature control valve should be 

replaced with a larger valve. 

Pg.60, SC System Work Performed by Others; Enercon should interface with equipment vendors 

to obtain design input information and not rely on PE to perform this function. This comment 

applies to all equipment and all “work by others” sections of the proposal. 

Pg.64, SC system Assumptions; defined work scope does not address interferences to replace the 

major SC components. EC installation instructions must address these issues. 

Pg.94, FW Booster Pump Assumption 15; A larger pump / motor will be specified. Impacts to the 

support pedestal and piping can be expected. 

Pg.99, Condenser Evaluation, HES shall provide the Condenser Evaluation CFD Analysis. The 

HES CFD analysis is an input to the condenser tube bundle tube vibration analysis which is 

subcontracted by HES. The Condenser Tube Bundle Tube Vibration Analysis should be identified 

as a deliverable and shall identify tube bundle locations where steam impingement plates should be 

installed. Impingement plate additions were recommended by HES during the CR3 previous 

condenser tube failure analysis. Steam impingement plates should be installed during the 2009 LP 

turbine replacement.

.. 

CR3 Extended Power Uerate, Secondarv Systems Ueg;rade Bid Proeosal Technical Evaluation 

Pg. 6 of 6 

8 Pg. 115, Electrical Distribution Calculations; Review proposal to consolidate existing electrical 

calculations into new ETAP. Evaluate cost of converting vs. updating existing electrical 

calculations. 

Appendix B, Consolidated Project Schedule Comments: 

October 07 PEPSE model is “initial” EPU model. Final PEPSE model shall be submitted after 

all plant design changes have been specified and inputted into the model. 


All turbine generator and MSR schedules shall be compared to and coordinated with the 

equipment vendor’s engineering deliverable schedules: The schedule for issuing th installation 

EC packages shall be determined by the owner. 

The turbine pedestal calculation schedule shall be accelerated and will support fina calculation 

expeditiously upon receiving final input data from Siemens. 


Isophase Bus Duct procurement EC can be postponed to 2008. 

Isophase Electrical Capacity Calculation shall be performed in conjunction with designing the 

bus duct cooling system. 

Turbine Building Structural Evaluation is scheduled to complete by 12/12/07. This does not 

appear feasible. 

PEF-NCK-02054

, 

Chris A. Sward 


Phone: (312) 269-7426 

FAX: (312) 269-2208 

Email chris.a.s\Ywd~;~s'rsarrenlluiidv com 

Sarge 

Lundy 

August 10, 2007 

Proposal No. 00273-406 

Letter No. SLCR3-2007-015 



Engineering Services for Secondary Systems Upgrade 

Response to Request for Proposal No. KS12007 

Mr. Tony Owen 


P.O. BOX 1551 (PEB-2C1) 

Raleigh, North Carolina 27602 

Dear Mr. Owen: 

After careful consideration of the requirements specified in Request for Proposal No. KS12007 

and the information provided in the bid specification, Sargent & Lundy LLC (S&L) has decided 

not to offer a proposal for the work as described. While we have a good understanding of the 

general scope of the secondary system upgrades through review of the bid documents and our 

meeting with the project team at Crystal River and have the requisite experience from past 

power uprate projects, we can not provide a proposal that meets the requirements of the bid 

documents. There are a significant number of unknowns that affect scope and will impact 

schedule. This includes detailed development of scope for the specified tasks in Article 1.9 as 

well as defining the overall project approach. 

While the bid specification provides a considerable amount of information on the system 

analyses and functional requirements associated with the required plant modifications, it does 

not define the physical scope of the plant changes. In fact for some modifications, there are 

significant decisions still to be made before the full nature and scope is determined. Large 

equipment replacement projects are very complex and widely varied and require a significant 

amount of study and investigation to accurately define the physical scope of work and the 

associated engineering activities required for their implementation. This scoping requires 

walkdowns, drawing and document reviews, study of alternatives, and meetings with 

stakeholders to develop a clear understanding of the exact scope of the plant change, its 

potential impact on plant operation and the extent and nature of engineering required. We firmly 

believe that this scope definition is critical to the overall success of a project but is beyond what 

is reasonable to develop in a proposal. Without such definition, no reliable estimate of 

engineering cost can be provided.

Mr. Tony Owen 





Page 2 

Relative to project approach, it was indicated during our site visit that some unique 

organizational approach was likely necessary due to concerns over the ability of plant staff to 

support reviews. We recognize that there are innovative teaming arrangements that could be 

beneficial for a project of this nature, but the specific terms would need to be established and 

the appropriate policy and procedural changes agreed upon before the impact on engineering 

scope could be determined. Furthermore, the success of the project will be greatly influenced 

by the participation of experienced and knowledgeable plant staff. Reviews and input at the 

appropriate stages of modification development will be critical. 

An additional concern is with schedule. S&L could not commit to the delivery dates specified 

nor agree to the associated commercial risk. The initial project tasks have delivery dates that 

could not be achieved even with the most optimistic contract award date. The heat balance 

analysis will require several months to complete and thus could not be issued by September 20, 

2007. Submittal dates for subsequent tasks such as the equipment procurement specifications 

are also unrealistic as they do not reflect the necessary precedence of the thermal and 

hydraulic analyses that are necessary inputs to equipment sizing and other specification 

requirements. We are also concerned with the large number of deliverables being issued at 

roughly the same time and the overall ability of the project to perform the requisite reviews and 

support the issuance of the documents. 

As an alternative to the all inclusive not-to-exceed approach, S&L suggests an approach that 

has been used successfully on several other large projects of this nature. It is a two step model 

that breaks the work into a scoping effort and then the detailed engineering work (similar to a 

conceptual design -detailed design approach). This model was used for the Brunswick 

Extended Power Uprate and is currently being used for analysis tasks in support of the 

Crystal River steam generator replacement. The first step for each proposed modification or 

major engineering task is to perform a scoping task that will develop the detailed scope of work 

and approach. Scoping tasks are performed under individual work authorizations on a 

time-and-materials basis per the rates and terms of our general services agreement 

(Contract No. 2571 17). After the full scope of a modification is clearly defined and the approach 

agreed upon, a firm fixed-price proposal is offered for development of the modification, and a 

separate work authorization is issued. This model has proven to be mutually beneficial. The 

task scoping efforts are performed at relatively low cost and produce clear understanding of the 

engineering scope. With that understanding and agreement between the organizations the 

amount of contingency needed to accommodate unknowns is greatly reduced, and the work has 

been completed with very few scope changes. 

We consider Progress Energy an important client and regret that we can not support this 

request, but we do not believe that we can offer a proposal consistent with the RFP that is in the 

best interests of Progress Energy and Sargent & Lundy. We would be happy to further discuss 

the approach outlined above or other ways in which S&L can support Progress Energy in their 

power uprate efforts for Crystal River. 

PEF-NCR-02057

Mr. Tony Owen 





Page 3 

Should you have any questions or would like to further discuss our position, please call 

John Regan at 312-269-6566 or me. 

Yours very truly, 

CAS 

Copies: 

J. D. Regan 

File: LAN 

Chris A. Sward 


PEF-NCR-02058

JOB NO. 

PROPOSAL 

"RADIUSED HOLE" MSR- 1 14 

REV* I A f w/ze/os E A.L. 

E 

Tl. 

tP# 

D

I'I 

J

ARRANGEMENT FOR 

STACKING AND JACKING OF 

CHEVRON VANES 

PEF-NCR-02074

CONFIDENVI,' 

PROPOSAL 

STACKING OF CHEVRON VANES

a CONFIDENTlrl!

Yuba 

2121 N. 161" East Ave 

Heat Tulsa, OK 74116 -4802 

Transfer, LLC Phone (918) 234 -6000 

Fax (918) 234-5589 

A Connell 

Limited Partnership 

Company 

SE RVlCES 

Rev. 01/30/2007 

DOMESTIC TRAVEL 

FIELD ENGINEER RATES 

I. Field Engine charge are a fixed fee based on a normal 8 hour working day. 

2. Overtime charges: 

a. All daily time over 8 hours during the normal work week (Monday through Friday) 

shall be considered overtime. 

b. All time on Saturday shall be considered overtime. 

c. All time on Sundays and Yuba holidays shall be considered premium time. 

Year 

- 2007 - 2008 - 

2009 - 2010 

Fixed Feed8 Hr. Day 

Overtime/Hr. 

Premium Time/H r. 

Notes: 

a. Travel time will b 

b. Travel and living expenses will be invoiced at cost, plus 5%. 

c. Timesheets will be provided daily for approval by the customer's representative. 

d. In no event shall either party be liable to the other for consequential, special or 

incidental damages arising in any way out of the performance of this contract. 

PEF-NCR-02079

n 

a. 

TlEi 

Document Number: 07-924 

Proposal Number: 07-M088 

A PROPOSAL TO SUPPLY 

REPLACEMENT CONDENSATE FEEDWATER HEATERS (FWH) 

LP-3N3B 

At 

The CRYSTAL IUVER NUCLEAR POWER STATION 

UNIT 3 

Submitted To 


100 E. DAVIE STREET (TPP-OS) 

RALEIGH, NC 27601 

THERMAL ENGINEERING INTERNATIONAL 

SANTA FE SPRINGS, CALIFORNIA 

A.L. Yarden 

President, 

MSR TechnoIogy & Advanced Programs 

November 27,2007 

PEF-NCR-02080


FOREWORD 

... 

Page 

,.... 1 

INTRODUCTION ....... 2 

1 .O TEI QUALIFICATIONS 

a CONFIDE NTI! ! 

. . . . . . . . 3 

2.0 DESCRIPTION OF THE OFFERED FEEDWATER HEATERS ..e.... 5 

3.0 SUPPLY OF THE" INSULATION 

. . . . . . . . 12 

4.0 COMMERCIAL INFORMATION 

....... 13 

PEF-NCK-0208 I

1. Outline Drawings ....... 19 

2. Data Sheets Per PESC’s Specification .... .,. 20 

3. Copy of ASME Code Certificates ...... 21 

4. Installation List (FWHs and MSRs) ..... .. 22 

5. Drain Coolcr Zone Baffle Arrangement (Sketch H-217) . . .. . 23 

Description of Internal Venting System (EC-19 & EC-20) ..... . . 

6. 24 

7. Impingement Plate Installation (Sketch H-222A) ...... 25

J 

OPC 

1 st POD 

#1 

080009 


02083 THROUGH 


REDACTED

OPC 

ST 

1 POD 

080009 




NON-RESPONSIVE

iermal 

Equipment Incorporated (TEI) 

Contract #XXXXXX 


August XX, 2007 

Moist[ Are Separator Reheaters (MSRs) 


1 

PEF-NCR-02 186

‘El Contract Summary 

on tents: 

a 

a 

a 

0 

a 

0 

a 

0 

Scope 

Payment Milestones 

Performance Incentives 

Warranty 

Performance Liquidated Damages 

Delivery Liquidated Damages 

Limits of Liability 

Project Review Team 

b3 C- Progress Energy 

PEF-NCR-02187

TEI Contract Summary 

Scope of Work: 

Contractor shall provide the necessary management, personnel, 

material and facilities (except as specified to be furnished by 

Owner) and do all things necessary or incidental to the design, 

engineering, fabrication, testing, furnishing, delivery to Owner, of 

four Moisture Separator Reheaters (MSRs) with two stages of 

reheat. 

Progress Enerav 

PEF-NCR-02 188


Payment Milestones: 

Milestone 

Date 

Payment Milestone 

% of Total 

Selling 

Price 

Payment 

Amount 

Sep-07 

NOV-07 

. Net 60 after order of MSR 

. Verification Tube Strip material has been ordered for Owner 

Engineering Design Package- Complete 

Dec-07 

Mar-08 

Oct-08 

Dec-08 

Feb 09 

Jun-09 

Jul-09 

Dec-09 

Provide Fabrication Schedule (Level 2) to Owner 

. Tube production: September - October 2008 

. True Finning: December 2008 - February 2009 

. Forgings arrive TEI 

. Major materials arrive and TEI begins fabrication 

. TEI receives tubes 

Material Receipt provided showing Tube Strip inventoried at Valtimet 

MSR Vessels are readied for shipping 

. MSR Vessels arrive at Crystal River site, offloaded by TEI and are 

received without damage 

. Provisional Acceptance - or - 120 days after installation completion, 

whichever is shorter 

REDACTED 

c> m Progress Enerw 

tr 

PEF-NCR-02189

TEI Contract Summarv 

Performance Guarantees: 

J 

a CONFIDENT^^,! 

REDACTED 

Load 

I Parameter\ I Max Expected I Guaranteed I Max Expected I Guaranteed 

I r I I I 

Note: Tolerances - None 

Instruments readings will be rounded to the nearest integer. 

C- b! Progress Enerav 

PEF-NCR-02 190


Performance Liquidated Damages: 

EDACTED 'I For each one (I) Fo H.P. reheaters above 10 Fo (overall TTD) 

REDACTED 

For each one (I) PS of MSR vessel above 6 PS 

- 

REDACTED 

For each one (1) 

% of M.S. efficiency below 98 % (MS% 

Progress Enerw


Delivery Liquidated Damages: 

1-5 

6-1 I 

12-21 

I 

I 

REDACTED 

I 

~3 C- Progress Enerav 

PEF-NCR-02193

REDACTED 

Corrective Measures: 

- - - . - - - 

Recurring Corrective Measure*: 

PEF-NCR-02 194


Lim its of Lia bi I ity : 

a CONFIDEMTIP.!. 

0 The liability of Contractor (excludina indemnitv 


rkh-NCR-02 196

'El Contract Sumrr iar 

roject Review Team 


Project Technical Lead 

Legal 

Tax 

Financial 

Audit 

Contracts 

Executive Sponsor 

Ted Williams 

Scott Deahna 

Dave Conley 

Paul Matthews 

Gerry Dowd 

Elwyn Wood 

Tony Owen 

Danny Roderick

7Eli 

March 26,2007 

10375 Slusher Drive 

THERMAL ENGINEERING INTERNA TIONAL Santa Fe Springs, CA. 90670 

Phone: 323-838-1 150 

MSR TECHNOLOGY AND ADVANCED PROGRAMS DIVISION F ~ ~ : 323-838-6454 

msr@thermalengint.com 


Crystal River Nuclear Plant 

15760 W. Powerline Street 

Mail Code: SA2C 

Crystal River, Florida 34428-6708 

Attention: 

Subject: 

Mr. Ted E. Williams 

Superintendent, Major Projects 

Power Level Uprate 

A PROPOSAL TO FURNISH REPLACEMENT MOISTURE SEPARATOR 

REHEATER VESSELS FOR CRYSTAL RIVER UNIT #3 

Reference: TEI Proposal 07-M062 

Dear Mr. Williams: 

We are pleased to forward to you our proposal for the new upgraded and modern Moisture Separator 

Reheaters (MSRs) vessels which meet your betterment goal at Crystal River #3. 

It is our conviction that TEI's advanced MSR technology must be presented to Progress Energy highlighting 

TEI design and experience as well as other critical project related elements. TEI, in its many years of unique 

MSR service to the Nuclear Power Industry, has always maintained its tried-and-true design principles and 

proprietary features, while adapting them to the specific plant's architecture and steam conditions. We are 

committed to bring to Progress Energy a high value MSR equipment. 

We trust you will find this proposal worthy of your consideration. 

We thank you for the opportunity to submit this proposal and hope to hear from you soon. 

Sincerely, 

THERMAL ENGINEERING INTERNATIONAL 

MSR Technology & Advanced Programs Division 

A.L. Yarden 

President 

ALYinol06-04

Document Number: 07-248 

Proposal Number: 07-M062 

A PROPOSAL TO FURNISH 

REPLACEMENT MOISTURE SEPARATOR REHEATER (MSR) VESSELS 

AT 

CRYSTAL RIVER UNIT 3 NUCLEAR POWER PLANT 

Submitted To 

PROGRESS ENERGY FLORIDA, Inc. 

CRYSTAL RIVER NUCLEAR PLANT 

15760 W. POWERLINE STREET 

CRYSTAL RIVER, FLORIDA 34428-6708 

THERMAL ENGINEERING INTERNATIONAL (USA), Inc. (TEI) 

10375 SLUSHER DRIVE 

SANTA FE SPRINGS, CA 90670-3748 

A.L. Yarden 

President, MSR Technology 

& Advanced Programs Division 

March 2007


Page 

1 .O INTRODUCTION 

1.1 General 

1.2 Purpose 

Performance 

Re1 iabil ity 

Operability 

1.3 Merits of the Proposed MSR Vessels Replacement 

1.4 Single Source Responsibility - If Installation Is Included 

.. .. 1 

.... 1 

.... 2 

.... 2 

.... 3 

.... 3 

.... 3 

.... 3 

2.0 SCOPE OF SUPPLY And SERVICES 

2.1 Equipment 

2.2 Services 

2.3 Installation 

2.4 Scope - By Owner 

2.5 Assigned Responsibilities During Vessels’ Installation 

A. Pre-Outage activities 

B. Outage Activities - Main Activities For Milestones Identification 

C. Post-Outage Activities 

3 .O COMMERCIAL 

3.1 Selling Prices 

3.2 Terms Of Payment 

3.3 Warranty 

3.4 Guarantee 

3.5 Liquidated Damages 

Turnkey 

Installation by Others 

.... 4 

.... 4 

.... 5 

.... 5 

.. .. 6 

.... 7 

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.... 8 

.... 8 

.... 

.... 9 

.... 9 

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Page 

4.0 TECHNICAL 

4.1 Performance 

4.2 Fitness-For-Purpose 

4.3 Thermohydraulic And Mechanical Design Of The Reheaters 

4.3.1 

4.3.2 

The Existing And The Proposed Reheater Bundles 

Other Reasons For Selecting The Proposed Bundle 

4.3.3 Mechanical Description 

4.3.4 Tubeside Design In The 4-Pass Arrangement Of The High Capacity 

Design 

4.3.5 Condensate Drainage 

4.4 MSR Performance Tests 

4.4.1 Scope 

4.4.2 Determination Of Performance Parameters 

TEI Workscope 

.... i1 

.... 11 

.... 11 

.... 12 

.... 12 

.... 14 

.... 15 

.... 16 

.... 18 

.... 19 

.... 19 

.... 20 

.... 20

1 .O INTRODUCTION 

1.1 General 

TEI - MSR Division is submitting this unsolicited proposal to Progress Energy to 

design, manufacture, ship and install four (4) new Moisture Separation Reheater 

(MSR) vessels, for and at the Crystal River Plant. The new MSRs incorporate 

advanced and improved design features and are fully compatible with the current and 

uprated steam conditions. The new MSRs will be optimized to achieve high 

thermohydraulic performance, smooth and sustained operation, high reliability and 

ease of inspection. TEI, based on a final plant heat balance will fine-tune the design so 

as to match the most favorable turbines’ steam conditions. Such matchings have been 

effectively accomplished by TEI in cooperation with the selected turbine supplier. 

We have recently cooperated directly with Siemens on other projects to arrive at a best 

design conditions for the turbines / MSRs configuration. Over the years, TEI’s 

complete new MSRs have been paired, with Siemens / KWU machines (Grand Gulf & 

Comanche Peak) with W machines (North Anna) with MHI machines (Ikata) with 

GEC machines (Fermi, Kori) with G.E. machines (Duane Arnold, Seabrook). MSR 

replacement reheaters have been fitted to Alstom machines (Ulchin) very successfully, 

too. 

TEI’s record of effectively modernizing OEM MSRs, extend across a wide range of 

turbines makes, types and sizes, as well as various rated power levels and operating 

floor layouts. TEI’s MSR vessels can be commercially procured directly or can be 

placed in a combined turbine/MSR package for contractual convenience and optimized 

project execution. Therefore, at Siemens request, TEI has provided them a similar 

technical proposal to be integrated into their solicited proposal for a turbine/MSR 

package. However, if the MSRs are procured by Progress Energy directly from TEI, 

we will fully and effectively cooperate with the turbine supplier, such as Siemens and 

fully guarantee the attainment of the proposed performance parameters (TTD, AP, 

M.S. efficiency, subcooling level). 

1

Finally, this unsolicited proposal grossly defines and provides the proposed scope of 

supply and work, the offered selling prices, the commercial terms and the technical 

input and descriptions necessary for orientation and evaluation. It is expected that 

additional information will be required by Progress Energy at this or a later time. Such 

will be promptly provided by TEI upon request. 

1.2 

If TEI is selected as an MSR supplier, TEI as a provider of an unsolicited proposal will 

be ready to enter into negotiations to cover all aspects of this procurement, such as: 

scope, costs, technical and Q.A. requirements, project coordination, labor relations, 

etc. It is TEI’s intent to bring maximum value to this project, regardless of TEI’s role, 

being either a direct vendor or a nominated sub-supplier. 

Purpose 

TEI proposes to replace the four (4) existing MSRs at Crystal River 3 (CR-3) with 

completely new highly improved and fully fit-for-purpose MSR vessels. The new 

vessels will be designed to accommodate the contemplated 20% uprate conditions. 

TEI considers such replacement as practical and economically reasonable. It will 

certainly enhance the overall betterment of the secondary steam cycle. TEI proposes 

to undertake the project on a turnkey basis, i.e., it will design, model test, fabricate, 

ship and install all four (4) vessels and crossaround piping spools. 

The proposed MSR system will complement the rest of the uprated and upgraded 

steam plant. The MSR interfaces with major plant components, and its optimal 

performance yields positive effects on the rest of the system. Remarkable 

improvements will be attained by: 

Performance 

(1) Lower TTD - higher superheat 

(2) Lowest pressure drop - practical 

(3) Complete moisture separation 

(4) Low excess steam rate - optimal 

2

1.3 

1.4 

Reliability 

(5) FAC endurance and erosion resistance 

(6) Resistance to and relief from thermally induced stresses (which can lead to 

distortions and cracks) 

(7) Sound 4-pass mechanical partitioning - pressure spike, erosion 

(8) Vibration-free internals structure and tube banks 

Operability 

(9) Steady and smooth operation 

(10) Streamlined transients 

Merits Of The Proposed MSR Vessels Replacement 

The existing MSR vessels are 11 feet in diameter as compared to the typical 12 feet. 

In spite of the available space on the turbine floor, the fairly short MSR and its inlet 

section are very restricted. TEI has concluded that a small increase in overall 

dimensions would result in large increase in performance and reliability. 

Improvements such as the lowering of internal velocities, streamlining the flow paths, 

and increasing the heat transfer area, result in significantly lower overall TTD, 

remarkably lower pressure drop and virtually complete moisture separation. While 

redesigning the new larger vessels, the flow paths and material of construction will be 

made corrosion/erosion resistant. TEI has selected a 12.5 feet diameter as best 

candidate for the proposed replacement along with longer shell which will extend the 

new vessel’s overall length but with the same supports locations as the existing 

vessels. The crossaround nozzles locations stay the same, ready to reconnect to the 

existing piping. With the shell diameter increased to 12-1/2 feet, the internal flow path 

is streamlined to avoid direct steam impingement, sharp turns and to reduce hydraulic 

expansion and contraction losses. 

Single Source Responsibility - If Installation Is Included 

As TEI is responsible for the design, manufacturing and installation, it will make the 

job a turnkey project, from design through manufacturing to installation; as such, it 

will assure complete coordination and a continuous job execution. It will result in a 

single source responsibility for CR-3 and it will provide continuous and consistent 

technical support by TEI’s experienced MSR engineers during all phases of the project 

with additional benefits as follows: 

3 PEF-NCR-02204

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

On the spot engineering resolution to any “as is” deviations or 

nonconformances, thus protecting schedule. 

A single responsibility and expertise in the installation execution and a 

consistent continuity. 

Contingency plans for unexpected bottleneck, delays or obstructions. 

Adjusting, if needed, day to day current work plan to meet any obstacles. 

Assessing potential problems will assure preparedness and expeditious resolution 

of same. 

TEI, as an MSR designer / fabricator will assure careful installation of the 

vessels so as to avoid damage to existing MSR structure. 

Key installation people are veterans of similar jobs with hands-on and recent 

experience. They will do-it-right at CR-3 the first time, since for them it will not 

be the first time. 

TEI’s knowledge of the job provides for responsible, realistic and achievable 

installation schedule. 

TEI when installing its own MSR replacement equipment carries an undivided 

responsibility for the integrity of the vessels and structure. 

TEI is a custom installer of this type of equipment. We are not a general 

construction company. This job will be reviewed week-by-week by TEI’s top 

management; CR-3 will be given direct access to TEI’s corporate management. 

2.0 

SCOPE OF SUPPLY AND SERVICES 

2.1 Equipment 

a. Four (4) complete MSR vessels, built to ASME Code (as shown below), 

delivered to site F.O.B., Nz purged, uninsulated, painted, with integral supports 

to match existing locations. 

b. Eight (8) excess steam flow regulating valves, S.S. trim. 

c. Monitoring, integral instrumentation and matching readout devices. 

d. All required pipe spools, designed to B3 1.1, to match existing cut lines. 

e. Spare gaskets, tube plugs, chevron vanes and sample tube sections. 

f. Complete documents package including: Q.A. documentation file, design 

calculations, operatiodmaintenance manual and equipment drawings.

2.2 Services 

a. Scaled down model testing and a summary report establishing good flow 

distribution. 

b. 

All manufacturing procedures for review and acceptance, such as manufacturing 

and welding procedures, NDE procedures, Q.A. program. 

c. 

d. 

Documents needed for DCP preparation (by others). 

Meetings at the CR-3 Station for orientation, coordination and project support - 

four (4) meetings. 

e. Monthly progress reporting. 

f. 

g. 

h. 

Preliminary installation procedure and crossaround piping isometrics. 

Site installation support - if installation is excluded from TEI scope, ten (10) 

man-weeks. 

Prepare performance test plan and participate in its execution when MSRs are 

back in service. 

i. All needed site surveys. 

j. All engineering analyses. (Vibration and stress analysis, etc.) 

k. Transportation plan. 

2.3 

Installation - Not in Sequence 

The general and major installation activities are: 

a. 

Off-loading major equipment at gate Items 2.1 (a),(b)&(c) to temporary 

storage. 

b. 

Crossaround pipes cutting (flame and/or mechanical) typically two cuts 

per pipe. 

c. 

Removal of existing shells with their insulation to pre-designated onsite 

locat ion. 

d. 

e. 

f. 

g. 

Removal of mechanical and structural interferences. 

Hauling new MSRs by transporters, to crane bay. 

Lifting to turbine floor with turbine crane (175 tons capacity). 

Installing/securing weld piping spools/nozzles as required. 

5

The TEI resources provisions are: 

a. All labor union or unionized. All supervision, Q.A., engineering onsite 

support. 

b. All weld rods or wire. 

c. All tools, lifting trucks, disposable welding machine, special jigs and 

tooling. 

d. All procedures preparation for FME, safety, fire prevention, cleanliness, 

some generic, some plant-specific as applicable. 

2.4 Scope - By Owner 

a. Off-loading at site -(F.O.B. rail) and placing at temporary storage. 

b. Insulation (TEI can provide as an option). 

c. Scaffolding - (Plan by TEI) 

d. Workers’ training for unescorted access during installation. 

e. Removal of I&C and electrical interferences. 

f. Turbine building crane and operator. 

6

B. Outage Activities - Main Activities For Milestones 

Identification 

1. Remove insulation around cut lines 

2. Mark cut lines of all piping 

3. Mark all electrical and structural interferences 

4. Provide protective barriers 

5. Cut all piping interfaces 

6. Install FME barriers 

7. Remove existing vessels to staging area 

8. Prepare new MSRs in staging area 

(*I 9. 

10. 

11. 

12. 

13. 

14. 

15. 

16. 

17. 

Lift / move new MSRs to existing foundation 

Check pre-fabricated pipe spools 

Tack / weld piping spools - remove FME 

NDE functions 

Mount relief valves 

Replace all interferences previously removed 

Remove scrap and clean area 

Routing thermocouples 

Vessel insulation 

(*) At a cost adder for heavy hauling (logger and crane) pass 

through cost +5%. 

CR-3 

X 

X 

pJ 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

C. Post-Outage Activities 

1. Q.A. reports , 

2. A.I. data sheets - as applicable 

3. Demobilization 

- CR-3 

- TEI 

X 

X 

X 

8 

PEF-NCR-02209

4.0 TECHNICAL 

4.1 Performance 

The purposed upgraded 4SR will achieve high performance under current and uprate 

load levels. Such will directly affect positively the L.P. turbines’ longevity and 

efficiency in providing a higher superheated steam to the L.P. turbines, while lower 

pressure drop across the MSR will make additional enthalpy available for conversion 

to power. It has been demonstrated, over the years, that improved MSR performance 

contributes directly to MWe gains. It is certain that this proposed MSR upgrade will 

not only increase electric production gain but also allow the station to uprate the power 

(flow and pressure) to at least 120% without any adverse impact due to vibration, 

FAC, erosion or mechanical design limitations. 

TEI guarantees the attainment of the following performance parameters values: 

- PSID 

Tolerances - none 

Instruments’ readings will be rounded to next integer. 

0 CONFIDENTIIPL 

4.2 

Fitness-For-Purpose 

P Installation by others 

P Architecture 

The new vessels are somewhat larger but they do not alter the turbine floor 

arrangement. Pull space is sufficient, floor loading is within limits, flanged connection 

in the crossover location is the same. Larger MSR vessels by TEI were installed in 

North Anna #2 with no reported problem. Larger MSR vessels are now being 

fabricated by TEI for both reactor units at Almaraz Nuclear Station. 

11

4.3 Thermohydraulic And Mechanical Design Of The Reheaters 

4.3.1 The Existing And The Proposed Reheater Bundles 

In the last 30 years, TEI has been involved in the design and fabrication of reheater 

bundles for service in its own line of MSRs, as well as in Westinghouse, G.E. and 

Alstom MSRs. 

TEI’s design approach is to provide a reheater tube field whose width is greater 

than its height as compared to your OEM “standard” reheater, whose height is 

larger than its width. The benefits of TEI’s design approach are quite evident in 

view of the excessively high pressure differentials across the MSR internals. TEI 

proposes to Progress Energy such a wider design, (High Capacity), as the best 

suitable for CR-3. 

The reasons for such proposed replacement are as follows: 

1. The existing bundles reportedly are deficient in performance (TTD and AP) 

as compared to the original design heat balance. 

2. The existing bundles are, by now, in all likelihood, distorted and may contain 

tubes which are damaged and failing. This trend for decay has shown to be 

accelerating for older bundles. (The ones in CR-3 are about 20 years old). 

3. Continuing maintenance of the existing bundles is costly and time 

consuming. 

4. The existing bundles, due to their excessively “slim” tube layout, caused an 

unacceptable pressure drop, and are susceptible to “lift” during flow spikes 

(valve testing). 

5. The new High Capacity bundles proposed for replacement at CR-3 are very 

effective, and proven to last in hundreds of applications over many years. 

6. The High Capacity bundles are of refined ferritic S.S. tubing. They utilize 

much higher quality material (restricted chemistry) and contain fins of 

premium quality as compared to your existing ones. 

7. The High Capacity bundles are designed to maintain their structural form (no 

deformations) for the remaining plant life so as to eliminate any future tube 

distortion and tube failures. 

12

8. The 4-pass box redesign assures optimum operability, best performance, zero 

leakage and longest life. 

TEI has installed, over the last 26 years, over 400 replacement bundles in scores of 

nuclear plants. These bundles are operating very successfully and are expected to do 

so for the remaining lives of the plants. We believe that Progress Energy can benefit 

from such improved and effective reheaters. 

On the basis of our experience we have selected a working and proven design for 

this proposal which fits the specific conditions of the CR-3 cycle and meets your 

betterment goals, for both 2625 MWth and 3030 MWth loads and beyond. 

We believe your request for a proposal is aimed to procure equipment and 

components which are better - and obviously different - than the current, deficient 

ones. The proposed bundles which are of sound mechanical and thermohydraulic 

design are optimized for CR-3 secondary cycle conditions. 

The offered design for the bundles is a 4-pass High Capacity tube field design with 

3/4” O.D. finned tubes in vertical U-bend orientation, but with an octagonal tube 

field extended to include the side segments of the larger tubesheet internal 

circumference. The tubes are finned with 27 fins/in. 

The octagonal tube field outline has its sides conform precisely to the prescribed 

arrangement of the side outermost tubes while maximizing the total tube count. 

The details of the design are shown in the attached Mechanical Outline Drawings 

NO. 07-M062-010, -021, -01 1 & -012. 

13

4.3.2 Other Reasons For Selecting The Proposed Bundle 

The remarkable features of the 4-pass arrangement were recognized by worldwide 

MSR manufacturers in the mid-’70s. Virtually all original equipment designers of 

MSRs have various patents covering different elements of this fundamental 4-pass 

design (TEI has two). The conception and evolution of the 4-pass came as a result of 

the inadequacy of the 2-pass to provide long-term reliable equipment. In addition, 

the 4-pass proved not only to operate more efficiently, but also to produce a higher 

performance, as compared to the primitive 2-pass. 

The specific features comprising the proposed 4-pass which is considerably 

improved over the existing OEM design are described below and are mentioned 

throughout this technical section. 

The performance advantage of the octagonal High Capacity type field layout vs. your 

existing rectangular one is a sufficient advantage to prefer this type of design. But 

there are other benefits also, such as a heavier bundle which is less susceptible to 

lift; lower number of tube rows which reduces tubeside channeling and which 

increases the cross section of the upper flow channel, thus reducing pressure drop 

and enhancing longitudinal, even cross flow distribution. Moreover, due to larger 

number of tubes, each tube is subject to a lesser heat duty, which is a desired state 

during abrupt change in unit load. 

The replacement reheaters offered here are of customized design which completely 

eliminates existing problems typical to the OEM equipment and furthermore, 

enhances the MSR performance. The design was especially developed by TEI for 

replacement of reheaters in MSRs of the same make as the ones at your CR-3. 

The design includes mechanical features which provide for structural integrity and 

for improved operation. It also provides for easy maintenance. 

14

The design incorporates the state-of-the-art, extensive field experience gained by TEI 

MSR Division over the years. Also, it integrates the results of in-house development 

and testing effort. The demonstrated performance of TEI replacement reheater 

bundles to date shows no evidence of structural andor operational problems, of 

generic nature, which have afflicted original equipment with detrimental 

consequences. Thus, the offered reheater design, within a new larger MSR vessel 

will exceed your requirements. 

4.3.3 Mechanical Description 

(Refer to the attached mechanical Outline Drawing No.07-M062-010 for 

configuration). The replacement reheater tube bundles are obviously, compatible 

with new proposed MSR vessels. 

The offered bundle design provides for integral relief from mismatched thermal 

expansion so that structural deformation is eliminated and service life is greatly 

extended. The header internal design is an improved arrangement to fully satisfy 

reliability, operation and maintenance requirements. It is designed to endure erosion 

and to withstand high spikes of pressure differentials across its pass partitioning 

plates. 

Each tube-to-tubesheet joint is both rolled and welded to provide two structurally 

independent tube joints for increased reliability. Specifically, the features 

incorporated into the proposed designs are as follows: 

A. A larger header with a larger size manway opening for maintenance 

convenience. Strong internal partition construction to withstand sudden 

pressure fluctuations, associated with instantaneous load changing, thus, 

avoiding severe plate deformation. The internally mounted parts, as well as 

the field of tube joints, are totally accessible for inspection, maintenance 

and/or field inspection. Nozzles on the header are dimensionally and 

metallurgically compatible with the existing reheater piping. (Refer to 

Dwgs. No. 07-M062-011 and -012). 

15

B. A flexible tube support system (cage) allows for controlled intermittent 

relief of mismatched thermal expansions between hotter tubes and 

progressively cooler shrouding side plates. This is a most significant design 

feature which preserves the alignment of the tubes with respect to their 

support plates, thereby preventing side plate deformation which leads to tube 

binding, steam bypassing and other consequent failures. 

C. Tube to shrouding side plate design tolerances are precisely set by design, 

and are maintained during fabrication to prevent side-stream steam 

bypassing. Such tolerances remain intact during the equipment service life 

by virtue of the flexible support system design mentioned in B. above. 

D. Sealing bars are welded longitudinally in selected locations along the 

shrouding side plates to further block steam bypassing and to achieve a 

virtually ideal tube bank configuration for an even cross flow. 

E. Tube holes in support plates are “radiused” to facilitate unobstructed 

movement of tubes with respect to their support plates’ holes during reheater 

pressurization and decompression. The support plates enveloping dimensions 

conform to the new tube field, which are 5/8” thick with no exceptions. 

F. An integral temperature sensing grid, comprised of at least 18 

thermocouples welded in proper tube-end locations in each reheater, indicates 

condensatehteam discharge temperature which confirms good system 

operation. The thermocouples are routed to an externally mounted terminal 

box. A portable readout device is also furnished. 

4.3.4 Tubeside Design In The 4-Pass Arrangement Of The High Capacity Design 

This improved 4-pass design, which is much superior to the existing “add-on” 

4-pass, now in CR-3, provides for: 

A higher and self-induced automatic purging of the critical lowermost tube 

legs, which comprise the second pass, to achieve a virtual elimination of 

subcooling at all load levels. It also provides for a high condensation transfer 

rate and uniform tube temperatures. This purging scheme needs no 

“artificial” perforated plate or orifice restrictors at the tubes’ inlets.

e 

e 

e 

A higher structural integrity by stronger construction of the internal 

partitions and the 4th pass box, to endure sudden pressurization and/or 

decompression. This eliminates deformation and rupture failures. 

An easier access for inspection and maintenance, which is possible by a large 

manway and by the ability to remove internal covers, rather than entire 

components. 

A service-worthy full circumference flat surface seal, on the back of the 4- 

pass box. The box is welded to the tubesheet. The flat surface seal is 

subject to considerably lower differential pressure than in your current 

design due to tube pass sequence. 

Tube passes in a “downhill” top-to-bottom sequence of 1,3,4,2 which 

provides a logical thermal head arrangement and a true co-current two-phase 

flow, thus promoting condensate drainage and preserving stable hydraulics in 

the U-bend sections. This arrangement also results in very low pressure drop 

across the internally welded 4-pass box, thus preserving the sealing gasket, 

on top of the box. 

Boffom discharge holes from the 4th pass box. The box is designed also as a 

“sump” to avoid condensate buildup and submergence of lower tubes. 

Since the end pass (4th pass) is nested above the 2nd pass, the maximum 

potential for subcooling, under unlikely worse case conditions, (insufficient 

excess steam during low load, transients and/or full heating steam pressure) is 

considerably reduced. 

The rate of excess steam is regulated by a valve to establish optimal rate. 

This is the highly recommended and best design for the CR-3 MSRs. It provides a 

larger effective surface, but by utilizing the side segments of the circular tubesheet, 

which are not used in the original design. Such tube arrangement reduces the cross 

flow velocity and, as a result, caused a lesser pressure drop across the tube bank. It 

also reduces the susceptibility to local vibration. The lower pressure drop, coupled 

with a comparable heavier bundle, reduces the “lift-off’ tendency of the bundle. 

17

4.3.5 Condensate Drainage 

As mentioned above, the condensate drainage is accomplished in two steps. First, 

the water inventory condensing in the 1 st and 2nd passes is withdrawn from the 

lowermost area of the head via a drain nozzle to the existing drain tank. No excess 

steam is withdrawn at this point. Second, the condensate generated in the 3rd and 

4th passes is discharged into the sump of an internally welded box from which it is 

discharged, together with the excess steam through a discharge pipe and a valve 

directly into the receiving feedwater heater. 

The drain and discharge nozzles are sized properly to allow a fully vented gravity 

flow from the 2nd pass and well established flows from the 4th pass. The sizing, 

which constitutes a very important design requirement, is based on the proven 

Froude Number criterion for the drain nozzle and on a two-phase critical flow design 

procedure for the 4th pass. We do not anticipate any change in the existing 2nd pass 

drain since after the uprate to 3030 MWth power; it will still carry less condensate 

than its original design capacity. 

This method of discharge is a simple and proven method. It is simply to discharge 

the two-phase flow to a feedwater heater through a critical two-phase flow valve. 

This method only requires one valve in the existing pipe line per reheater. It is a 

pressure reducing valve which can be adjusted. 

The desired flow rate can then be determined by monitoring the amount of 

subcooling at the exit of the 4th pass with the thermocouples installed in the header. 

The valve is trimmed to restrict flow until the onset of subcooling occurs and then it 

is trimmed open slightly to provide for more vapor flow. This technique requires 

thermocouples to be installed in discharge legs of the tubes comprising the 4th pass. 

18

4.4 MSR Performance Tests 

4.4.1 Scope 

TEI will provide a sufficient number of internal sensors and provisions for 

the lead wires or pressure tubing to exit the pressure boundary (proprietary - 

see photographs at end of chapter), as well as locally mounted read-out 

devices so as to be able to gather and record data which positively indicates 

internal performance. Performance verification instruments will be installed 

on the four MSR vessels to determine performance parameters. The internal 

sensors will be located in zones which are indicative of the actual 

thermohydraulic events. 

TEI has had a great deal of practical experience in the planning of data 

requirements, hardware, installation, and recording. Our engineering 

Methods Group is highly qualified to evaluate such data and assess its impact 

on plant parameters. 

The performance of the MSRs will be verified by the direct measurements of 

pressures, temperatures and flow rates of steadcondensate around each 

reheater and vessel. All pressure taps will be installed with isolation valves 

supplied by TEI, ready for connecting to the pressure gauges. All 

temperature connections will be fitted with thermowells or thermocouples. 

Annubars or equivalent meters, will be used to measure the steam and 

condensate flow rates. Other data required for heat balance calculations will 

be mutually established with CR-3 personnel. 

TEI will prepare data sheets in a format which allows a complete and a 

consistent recording of all data necessary for the performance verification. 

TEI will coordinate and participate with your plant personnel in recording the 

data and evaluating same, as requested. 

19 PEF-NCR-02220

4.4.2 Determination of Performance Parameters 

1. TTD 

TTD is determined as the difference between the main steam saturation 

temperature and/or the heating steam inlet temperature, and the average cycle 

steam exit temperature above the H.P. reheater bundle. 

2. AP 

For the complete MSR vessel, the pressure drop is determined as the 

difference between the average static pressures measured at the inlet and 

outlet nozzles. 

3. Subcooling 

Subcooling is determined as the difference between the liquid drainage 

temperature and the corresponding steam temperature in the discharge space. 

TEI Workscope 

* TEI will design, procure, fabricate and install - as applicable - all internal 

* 

* 

* 

* 

* 

instrumentation: conduits, valves, read-out devices, integral junction boxes 

and valves integral to the bundles. Tubing extension, wire extension and 

instrument connections will be done by the plant I&C people. 

TEI will furnish all tubing, extension wires, valves and read-out devices. 

TEI will prepare “data sheets” in a format which allows a complete and a 

consistent recording of all data comprising a “data run”. 

TEI will coordinate and participate with CR-3 plant personnel in the 

recording of data and the assembly of plant data to comprise consistent “data 

runs”. 

TEI, in conjunction with CR-3, will reduce and evaluate the collected data. 

TEI will issue to CR-3 an engineering report adequately covering aspects of 

the testing and documentation of results. 

20 PEF-NCR-0222 1

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JOB NO. 

PROPOSAL 

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SIDE SHROUD PLATE 

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qO4/28/05 H A.L. 

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PEF-NCR-0223 1

JOB NO. 

PROPOSAL 

"ACTION" OF 

FLEXIBLE SIDE SHROUD 

PEF-NCR-0223 2

PROPOSAL 

FUNCTION OF 

BY-PASS RESTRICTOR 

PEF-NCR-02233

JOB NO. 

PROPOSAL 

"RADIUSED HOLE" 

04/z8/05 /e 

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a CONFIDENTIAL 

PEF-NCR-02239

a CONFIDENTIP,!. 

PEF-NCR-02240

siemens - Public Service Commission

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