Guidance for the Use of Reverse-Engineering Techniques Revision 1 to EPRI TR-107372 3 0 0 2 0116 7 8 2018 TECHNICAL REPORT Electric Power Research Institute 3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 USA 800.313.3774 • 650.855.2121 • [email protected] • www.epri.com 9889751 9889751 Guidance for the Use of Reverse- Engineering Techniques Revision 1 to EPRI TR-107372 3002011678 Final Report, May 2018 EPRI Project Manager M. Tannenbaum All or a portion of the requirements of the EPRI Nuclear Quality Assurance Program apply to this product. ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA 800.313.3774 ▪ 650.855.2121 ▪ [email protected] ▪ www.epri.com 9889751 DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR (B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT. REFERENCE HEREIN TO ANY SPECIFIC COMMERCIAL PRODUCT, PROCESS, OR SERVICE BY ITS TRADE NAME, TRADEMARK, MANUFACTURER, OR OTHERWISE, DOES NOT NECESSARILY CONSTITUTE OR IMPLY ITS ENDORSEMENT, RECOMMENDATION, OR FAVORING BY EPRI. THE FOLLOWING ORGANIZATIONS, UNDER CONTRACT TO EPRI, ASSISTED IN PREPARATION OF THIS REPORT: Electric Power Research Institute (EPRI) Sequent Consultants, Incorporated NOTE For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or e-mail [email protected]. Electric Power Research Institute, EPRI, and TOGETHER…SHAPING THE FUTURE OF ELECTRICITY are registered service marks of the Electric Power Research Institute, Inc. Copyright © 2018 Electric Power Research Institute, Inc. All rights reserved. 9889751 ACKNOWLEDGMENTS The following organizations, under contract to the Electric Power Research Institute (EPRI), prepared this report: EPRI 1300 W. WT Harris Blvd Charlotte, NC 28262 Principal Investigator Marc H. Tannenbaum Sequent Consultants, Incorporated 163 Pleasant Street, Suite 4 Attleboro, MA 02703 Investigator M. P. Tulay This report describes research sponsored by EPRI. EPRI would like to thank the following individuals who participated in the technical advisory committee and made contributions to the development of this report. Their valuable insights and experience were essential to the successful completion of this project. Harry Medsger Areva NP Edward Wynne AZZ Nuclear Jason Heilbrun Curtiss-Wright Nuclear Division Aleks Lulgjuraj Curtiss-Wright Nuclear Division Bhavesh Patel Duke Energy Sam Yousif Dynamic Solutions George Shampy Entergy Jeff Rehg Exelon Nuclear Craig Irish Irish Partners Consulting Al Lafleur NextEra Energy, Incorporated This publication is a corporate document that should be cited in the literature in the following manner: Guidance for the Use of Reverse-Engineering Techniques: Revision 1 to EPRI TR-107372. EPRI, Palo Alto, CA: 2018. 3002011678. iii 9889751 Mike Williams NextEra Energy, Incorporated Milton Conception Paragon Energy Solutions Doug VanTassel Paragon Energy Solutions Greg Keller Rolls-Royce Nuclear Services William Ware Southern Nuclear Joshua Schneider Tennessee Valley Authority Jeff Jacobson U.S. Nuclear Regulatory Commission Jonathan Ortega-Luciana U.S. Nuclear Regulatory Commission Jim Garrison United Controls International In addition, the following individuals are acknowledged for participating in team meetings, providing content, or previewing the report. Taylor Smith Areva NP Nathan Morris AZZ Nuclear Marie Nemier Curtiss-Wright Nuclear Division Tad Gray Curtiss-Wright Nuclear Division Sebastian Larrea Dominion Energy Paul Saksvig Dominion Energy Jon Thomas Duke Energy Barry Geiger Entergy George Shampy Entergy Syed Jaffery Exelon Nuclear Tim Rogers Exelon Nuclear Uldrick Jean Exelon Nuclear Al Lafleur NextEra Energy, Incorporated Clyde McCullough NextEra Energy, Incorporated Juan Antonio Muñoz Tirado Nucleonova Waylon Waters NuSource Joe Garguilo Paragon Energy Solutions Steve Letourneau Rolls-Royce Nuclear Engineering Services Bob Roach Tennessee Valley Authority Tim Sheil Tennessee Valley Authority Marcus Ledford United Controls International Luis Sanchez United Controls International Rich McIntyre U.S. Nuclear Regulatory Commission Paul Prescott U.S. Nuclear Regulatory Commission iv 9889751 The following individuals were ongoing members of the Task Group that made significant contributions to the development of the original TR-107372 report published in 1998 by attending meetings, reviewing and commenting on various drafts, and writing portions of the report. Phil Wyckoff American Electric Power A.G. Anuje Baltimore Gas & Electric Abdy Khanpour Carolina Power and Light Tim Miller ComEd Jeff Cain Duke Energy Les Caudill Duke Energy Mark Bollman Duquesne Light Company Chris Beaudet Entergy Operations Leigh A. Aparicio EPRI–Plant Support Engineering John Sipos Florida Power Corporation Ivor MacFarlane Global Supply Group Paul Waterloo HydroAire, Inc. Don Church IES Utilities Gerald Harrelson Johnston Pump Keith Murphy Johnston Pump Larry Tobin New York Power Authority Jim Fitzwilliam Nova Machine Products Craig Irish Nuclear Logistics, Inc. John Moore PECO Nuclear Pramukh Patel PECO Nuclear Gary Gardner Pentas Controls, Inc. John Brown South Carolina Electric & Gas Sujit Roy Southern California Edison Jim Redmon Southern California Edison Jack Simonis Southwest Research Institute John Taylor TU Electric Gayle Creamer TVA Martin Kehoe Union Electric John Winebrenner, Chairman Virginia Power Steven Fellers Wolf Creek Operating Company v 9889751 9889751 ABSTRACT As the marketplace and manufacturing methods evolve, aging equipment and associated spare parts become increasingly difficult to obtain and may eventually become obsolete. In some cases, reverse-engineering techniques can be used to facilitate replacement of existing items while minimizing the need for extensive design changes. However, risk is inherent when applying reverse-engineering techniques as examination of an existing specimen alone may not be sufficient to ensure that the reverse-engineered design includes provisions that address factors such as how the device functions with interfacing equipment or conditions in the installed environment. Therefore, it is important to understand the design functions of the item to which reverse-engineering techniques are being applied. In addition, reverse-engineered items are subject to the same types of design control considerations as other replacement items. Control of design should be documented in an appropriate evaluation. This report was prepared to assist Electric Power Research Institute (EPRI) members and their suppliers in the effective application of the reverse-engineering techniques and associated design controls necessary to accept the use of designs established through reverse-engineering techniques for use in nuclear power applications. Effective use of reverse-engineering techniques and associated design controls prevent introduction of unintended design changes and associated unevaluated failure modes and mechanisms. Keywords Configuration management Duplication Design control Obsolescence Replicate Reverse engineering vii 9889751 EXECUTIVE SUMMARY Deliverable Number: 3002011678 Product Type: Technical Report Product Title: Guidance for the Use of Reverse-Engineering Techniques: Revision 1 to EPRI TR-107372 PRIMARY AUDIENCE: Individuals such as procurement engineers, design engineers, and technicians at licensee and supplier facilities who are involved in the use of reverse-engineering techniques and associated engineering evaluation processes such as equivalency evaluation and design change. SECONDARY AUDIENCE: Individuals such as quality assurance professionals involved in reverse- engineering projects and equipment reliability professionals involved in managing obsolescence. KEY RESEARCH QUESTION What logical process can be followed to successfully apply reverse-engineering techniques in commercial nuclear power facilities? As equipment ages, obtaining the spare and replacement items needed to support maintenance becomes increasingly challenging. Reverse-engineering techniques are employed in military and other critical application industries and have proven to be an effective method for obtaining replacements for obsolete items. Although a significant amount of design input can be obtained through examination of a specimen, application of reverse-engineering techniques for safety-related items includes developing an understanding of the design functions