117 - · pdf file117 section: mi 3.10 ... title boiler feed pump inspection program power...

117 SECTION: MI 3.10

TITLE: Critical Pump Inspection and Repair Program

POW€R SUPPLY DATE: 411/201 I (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE 6 of7

VII. SAFETY

Daily inspections should be made and any irregulaties in the operation of a pump should be reported immediately. This applies particularly to changes in the sound of a running pump, abrupt changes in bearing temperatures, oil level, and stuffing box leakage. A check of the pressure gages and of the flow meter should be made dally.

If recordlng instruments are provided, a daily check should be made to determine whether the motor cavity temperafure, vibratron pressure or power consumption indicate that further inspection Is required.

Recording Instrumentation should be maintained to ensure it is in good operating wnditians and properly calibrated.

Monthly The free movement of stuffing box glands should be checked and packing should be inspected to determine whether it requires replacement. Grease lubricated kan'ngs should be checked to see that hey contain the correct amount of grease.

Two years intetval Each pump shall be dismantled, cleaned, inspected and reprace wear components as needed.

Six vears interval Each pump shall be pulled and overhauled every 6 to 8 years. Impellers, shafts. shroud and bearing shall be inspected for cracks and erodon.

Before any attempt to inspect the pump, the following precautions must be observed:

rn Be sure that the eleckical supply is isolated from the pump rriotor, Jock out power supply to driver and tag.

0 It is important that proper lockoutttagout procedures are followed to prevent injury or equipment damage from energy sources.

rn Make sure pump is compteteJy depressurized.

0 Close suction and dischame valves and tag.

118

VIII. DOCUMENTATION

IX. APPfNOlCES

SECTION: MI 3.qO

AI1 critical pump inspection documentation Including work scow, maintenance plans, cMltractor inspecf'on reports, etc, will be malntafned at a central sewer.database.

TiTLE: Critical Pump Inspection and Repair Program

PUWER SUPPLY DATE: Mll2Ol I (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 7 of7

Use care when dismantlirig a drained pump on a hot boiler;

SECTION: MI 3-11

TITLE: Boiler Feed Pump Inspection Program

POWER SUPPLY DATE 4/l/2011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 1 of4

I. OVERVIEW

11. RESPONSIBILITIES

A. Power Supply Services

BOILER FEED PUMP INSPECTION PROGRAM

Boiler Feed Pumps pump (BFP) from the condensate system to the boifer system (tioiler drum}. OG&E has many boiler types-with different pressure tequirernents. Most of the larger unit 8FPs are driven by i steam turbine (covered In the steam'turblne MI) and the smaller units are driven by electn'c motors (covered in the electric motor MI): Most pumps are rated at about 60% of full unit (2 pumps per unit X 6O%], which provides extra h t e r pumping capacity (more than needed at full load). Efficiency is important on the BFP's but wilt be evaluated along with repair cost (both repair and removal and assembly cast).

Specify interval frequency of each BFP component Inspection, as appropriate.

Review reports from last inspection.

Develop scope of work.

Determine workforce requirements (is. Plant, dutside vendors at plant, shop work).

Develop specialized parts (unusual to all outages) needs and availability @e. new type shaft, volutes, seals).

Provide project lead with support from plants.

Inspect and prepare extra work affer initial inspections (on site or at external location if parts are shipped offsite),

Provide a single potnt contact for vendors.

Provide a detailed list of normal pads needed for Inspection (Le. gaskets, bolts).

119

120

B. Plant

SECTION: Mi 3.1 I

a Inspect overhead crane before each outage and provide documentation or provide a moMle crane as necessary.

TITLE Boiler Feed Pump Inspection Program

POWER SUPPLY DATE 41112011 (Rev 2) MECHAMCAL INTEGR1TY MANUAL

PAGE: 2of4

Ill. PROCEDURES

I Responsible for supplylng tabor and planning functions for maintaining he physlcal equipment condition including weekly, monthly, and other routine preventatwe maintenance activities as recommended In the 08rM manuals furnished by the OEMs.

o Maintains the equipment as necessary to insure safe, reliable operation while In service.

The purpose of this process is fa outllne procedures for maintaining gas turbines by developing, implementlng, and maintaining a site-specific and comprehensive mechanical integrity program which falls under elght major tasks:

0

Planning and scheduling Performance testlng Mechaniwl diagnostic (is. vibration, hroscopic) Material and Parts control program Disassembly and reassembly As found and as left dimensions Trafning employees on maintenance, Inspection and testing Documentation

I

I 1 A. CRITICAL

EQUIPMENT LIST A Uitical equipment list must be site specfic, SFP's have different configurations consisting of number of stages, pressure and flow requirements, take off water supplies (Le. atternperator sprays). There are spare volutes for certain pump location {some may fit on different plants OF units within a plant).

I

I I B. CRITICAL

MAINTENANCE PROCEDURE DEVELOPMENT

The maintenance procedure will be unit specific. Each BFP will have its own procedure according to the physical configuration. fhe procedure will also vary due to the amount of work required from the Inspection, OEM

I

SECTION: MI 3.1 1

TITLE Boiler Feed Pump Inspection Program

POWER SUPPLY DATE: 4lV2011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 3 of4

IV. INSPECTWN FREQUENCY

V. MAINTENANCE TRAINING

..

recommendations, and previous inspection reports.

OGE has several manufactures of pumps (Le. Byron Jackwon, Ingersoll Rand, Pacfica).

Geneml procedures for each BFP are covered In the OEM Technical Manuals. OEM Techniwl Manuals may not include alI necessary debited Information. Technical Field Assistance (TFA) is available from the OEM and may be utilized as necessary.

The needed information at the plants includes disassembly procedures along with data measurement sheets. Tolerance allowance on each' measurement and how to obtah each measurement. Installation procedures as found and as leff measurements.

Cleaning, NDE and evaluations of all parts of the BFP must b specified in advance. A generic scope c a n be provided but each inspection may require different combinations of procedures.

Procedures shalt be readily available to the personnel who are responsible for repairing, Inspecting, testing, or maintaining the equipment.

8FP volutes inspection frequencies shall be 8 years. This provides much less failures mechanically and will keep the effidency to good levels. Longer intervals requIre much more internal repair (Le. water washing out of parts, shaff, and jotnt faces). Shorter intervals will be heavy in the disassembly and reassembly cost and offset other savings.

dost of the tmining is provfded as OJT. Boiler Feed >ump training classes are available by the OEM or other ;ources,

'erformance test should be run to determine the

121

SECTIOM: MI 3,Ii

TKL€ Boiler Feed Pump Inspection PmgmlTl

POWER SUPPLY DATE: 4w20l1 (Rev 2) MECHANICAL INTEGRITI MANUAL

PAGE: 4 of4

TESTING, AND RECORD KEEPirjG

VII. DEFIQENCIESI CORRECTWE ACTIONS

VIIL APPENDICES INDEX

degradation of the units before the budgeting cycle starts. Walk around vibration data should be collected monthly or at cycles when the 8FP is online.

I Temperature or pressure variations (available in operational data], larger than n o m l , should trisger an investigation of muse and reevaluated the inspections intervals.

a OEM Techniml Bulletins will also affect the 'inspecbschedule as problems surface from other similar BFP's in h e OEM feet

0 Dowrnentafion (adage reports and shop reports) will be stored electronically on a shared drive designated by PSS.

If deflclencies are seen uslng Performance testing, predictive maintenance, OEM bullefins, or operating Dbsewation, PSS will leAd in the evaluation of solution of the problem.

122

SECTION: MI 3.12

TITLE: Pressure Vessel Inspection Program

POWER SUPPLY DATE 41112011 (Rev 2) MECHANlCAt. INTEGRITY MANUAL

PAGE: 1 o f 5

I. OVERVIEW

. RESPONSIB1UTIES

A. Power Supply semi ces

B. Power Plant

PRESSURE V€SSEL INSPECTION PROGRAM

Ressure vessel equipment to be inspected shall be defined as any closed vessel other than a bailer. Pressure vessels containing Steam, hot water, gas, or air supplied from an external source or the indirect appkatIon of heat are included. Also, "hot water supply heaters" are inctuded in the inspection program. Pressure shall be internal to the vessel and greater than A5 pslg. Pressure vessels as defined shall not be portable. AH such pressure vessels shall be designed and fabricated per the requirements of ASME Boiler and Pressure Vessel Code Section VIfl, Division 1. fnspe'ctions of pressure vessels shall be pe,hrmed in compliance with NBlC and Oklahoma Boiler and Pressure Vessel Safety Act. Each pressure vessel as defined above shall be registered with the state of Oklahoma, assigned an Oklahoma number, and issued a Certificate of Operation.

Develop and provide work scopes for inspection of pressure vessel equipment

Maintain a11 pressure vessel inspection reports and records

Verify all inspection findings are addressed as recommended in inspection report and documented for the next Inspectton.

Ensure that pressure vessel inspections, repairs, and testing of -pressure vessel equipment are conducted and documented as required by state jurisdiction.

Provide O W E Inspectors to ensure compliance with scopes of work

Create requisitions and include pressure vessel inspection work scopes.

123

124 SECTION: MI 3,12

TITLE Pressure Vessel Inspection Proflmrpl

POWER SUPPLY DATE: 41112011 (Rev 2) MECHAPtlCAL INTEGRITY MANUAL

PAGE: 2of5

C. Supply Chain

lit. PROCEDURES

0 Provide detailed planning and scheduling to ensure Inspection Contractor, and inspection related activities are coordinated with other unif work activiks scheduled during the outage.

0 Provide detailed planning and scheduling to ensure all identified pressure vessel equipment deficiends are addressed in accordance with Inspection Contractor's recommendations.

Coordinate the bld review process with Power Supply Services and Plants.

Notiv Power Supply Services of all exceptions taken to the scope of work technical requirements and assist to resolve.

The purpose of a pressure vessel inspection procedure is ta implement a pmosss to ensure pressure vessel equipment is maintained according to ASME, NBIC, state, other applicable d e s and industry standards as part of the overall comprehensive Mechartid Integrity Program.

I. wilt Identify the pressure vessel equipment and provide all necessary supporting documentatton to ixrrtplete each inspection

2. Plant will review and verify the listing of pressure vessels scheduled for inspection priur to the start of the budgeting process.

3. psS will provide the plant a detalled Inspection work scope as per Oufage Readiness Index (QRI) prior to the scheduled unit outage.

4. Supply Chain will coordinate the bld review process with PSS and Plant members. Successful inspection service group and necessary crafts shall be selected.

5. psS will mordinafe a pre-inspection meeting at the plant to clarify inspection requirements such as scaffolding, insulation removal, surface preparation, re-insulatbn, efc. In addition, all other plant requirements will be discussed such as security, safety. etc. All contractors, PSS, and appropriate

125 SECTION: Ml3.12

TITLE Pressure Vessel Inspection Program

POWER SUPPLY DATE ss1112011 (Rev 2) MECHANICAL lNTEGRtIY MANUAL

PAGE: 3 of5

1V. CRITICAL EQUIPMENT LIST

V. INSPECTION FREQUENCY

6.

7.

8.

9.

plant personnel will be in attendance.

PSS lns~ectors will oversee the overall work quarity of the Contrac!or(s] and ensure all work is accomplished as per work scope. PSS Inspectors will convey any deficiencies requiring immediate affentbn or additional work requirements to the Plant.

- PSS will coordinate an exit interview meeilng with the Plant and Inspedon Contractor at completion of the work to discuss preliminary results of the pressure vessel equipment inspection,

- PSS wlll coordinate a pressure vessel final repod revi~w 'meeting with the Piant and deveJop an action plan for addressing lnspection Contractor's recommendations.

I_ PSS will insert the pressure vessel inspection final report into the appropriate database in the year completed. psS will also insert in the database the action plan for addressing the recommendations and budgetary esthates in the future years to be cornpJeted.

A compilation of pressure vessel equipment to be maintained, inspected, and tested must be developed for Each plant site. A partial list of pressure vessel equipment is shown here:

a Deaemtor and Deaerator Storage Instrument Air Receiver Tank Hot Water Supply Tank

0 Continuous Blow Down Tank 0 Feedwater Heater

HzTank Security Ak Tank

inspections of ASME Code stamped pressurn vessels ;hall be based on NBIC and Oklahoma boiler and

SECTION: MI 3.12

TITLE Pressure Vessel Inspection Program

POWER SUPPLY DATE: 4II1201 I (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 4of5

VI. INSPECTION TESTING TECHNIQUES

pressure vessel safety act requirements.

FeedMer heater plugged tubes are documented by location, quantify, and date p!ugg,ed on the respective tube map for each heater (see I&M 'Closed Feedwater Heater Mechanical and Performance Testing"). Once the heater has a total af 10% plugged tubes, an NDE of the remaining tubes shall be performed to determine the tube wall thickness. This information shall be used to perform 'insurance plugging' of tubes having a remaining wall approximately 40% of original average wall thickness. Feedwater heaters experiencing frequent tube leaks shall be examined for fube thickness before running unit in the 'warn season".

Following are the testing techniques that may be utilized for pressure vessel inspections. Not all techniques are necessarily utilized for every Inspection.

,Uuztraxlnic Inspection run - Nondestructive test method in which beams of hIgh frequency sound waves are introduced Into a material and are reflected back from discontinuities. Used for vessel wall thickness measurements and the location of internal defects, such as laminations or seams in material.

VldeoscoDic lnspedion W) - Used for tnaccesslble loations of vessels allowing Identification of cracks, erosion, corrosion damage, and gerieral gross deformation.

Stress AnalvsislFinite Element Analysis - Serves to identify whether a gIven vessel nozzle load or wall thinning condition will pass to be *fit for service' with weight, thermal, and pressure stress under safe opemting conditions.

Acoustic Emissions - Not a 'stand alone" NDE method, but a fest conducted to screen for possible advanced tank crack propagation. Referenced In ASME Section V, Article 12

A.No recommended adon 8.Visual external examination

126


.- TITLE: Pressure Vessel Inspection

Program POWER SUPPLY DATE: 41112011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE 5ofS

VII. REPAIRS& ALTERATI 0 N S

VIII. SAFETY CONCERNS

fX. APPENDICES INDEX

C.Further evaluation by NDT (Non Destructive

D.Follow-up by NDTliittemal inspection E Very ache. Immediate follow-up by

Testing)

NDThntemal inspection

AI[ repairs and alterations shalt first have the pemlsslon from an AI prior to performing any work. Repairs and alterations shall be performed in accordance with NBlC and ASME Section VI11 Dwlsion 1.

Pressure vessel Inspections are usually accomplished during scheduIed unit outages. Beause of this, other maintenance work may be occurring at areas adjakenf to where pressure vessel inspeclions are occumng. Coordination of work activities between the fnspecfion Contractor and QGE members needs to occur to ensure overall safety of personnel.

Scaffolding may be utilized at pressure vessel t o d o n s during the inspection at the plant. Contractors and OG€ members should ensure scaffolding has been Inspected daily before using and all applicable codes and OG+E plant standards are complied with.

Most, if not all of these defined pressure vessels will be Pemitted Confined Spaces. All Confined Space guidelines need to be adhered to as per applimble OSHA guidelines and OWE standards.

SECTION: MI 3.13

TITLE Pulverizer Inspection Program

POWER SUPPLY DATE: 41112017 (Rev 2) MECHANICAL INTEGRIUTY MANUAL

PAGE: I of 14

I. OVERVIEW

11. RESPDNSIBILtTfES


8. Plant

PULVERIZER INSPECTION PROGRAM

The Pulverizer is he compnenf of the ovemlJ Power Generation System that provides the fuel sour#, coal, to the boiler. The Pulverizer Inspection Program includes criteria for the teesting and inspections necessary fdr the continued saTe and reliable operation of the pulverizer. The rnechaniwl integw and performance of the pulverizer ,directIy affects the optimum combustion necessary for the boiler to operate safely and reliably. Optjmum combustion on a coal fired unit is of paramount importance In mahtaining heat rate, unit-wpacity and unit avalabiIIty, To achieve and maintain optimum phformance of the pulverizer, various tests and inspections are pedormed at intervals fhroughout the year. Discrepancies found during fhese tests or inspections are either corrected immediately or planned for Mure outages to ensure the safe operation and mechanfml integrity of the pulverizer.

Prepamfion, revision, and review of any mechanbl design changes to the pulverizers.

Develop and provide detailed work scopes to the plants as necessary.

Assist the plant as necessary to resolve pulverizer mechanical and perfomance issues.

Reviews testing and inspection reports, provldes corrective action recommendations to the plants when necessary.

Provides OG+E 1nspet;tors as necessary to ensure compliance with work scopes.

Ensure members who repair and maintain the

128

SECTION: MI 3.13

TiTLE: Puiverizer Inspection Program

POWER SUPPLY DATE 4111201 1 (Rev 2) MECHANICAL INTEGRlIY MANUAL

PAGE: 2 of 14

C. Contractor

111. CRITICAL EQUIPMENT

INTERVAL FREQUENCY AND DESCRIPTION OF INSPECTIONS AND

pulverizers are adequately trained.

9 Ensures all testing, inspection, and repair requirements are being performed as necessary.

0 Ensures #at all testing, Inspection, and maintenan- activities performed by OG&E personnel or conbador are documented and maintained in plant filed records and SAP.

Ensure all tests, Inspections, and -repah are perfbrmad In accordance with applwble oodes, industry standards, UGE standards, and design specifiwtions.

4ll tests, Inspeclions, and repairs are performed in xmrdance with applicable mdes, industry standards, 3GE standards, and design specifications.

Cone Inverted Cone Classifier Blades Deflector Extenslon Ring Journals Floor Bowl Gearbox Lower Radial and Thrust searing HotlCold Air Dampers 'HotlCold Air Gates Diive Motor Burner Llne Orifice Discharge Valves Air Flow Transmitter Pressure Transrnitler Pulverizer Temperature Ouffet Thermocouples

The following outlines inspectlons and tests for nalntaining pulverizers in optimum operating and mfo-mance condition, The Inspection of each

129

SECTION: MI 3.13

TlTLE: Pulverizer Inspection Program

POWER SUPPLY DATE 4M12011 (Rev 2) MECHANlCAt IEITEGWTY MANUAL

PAGE 3 of14

TESTS pulverizer shall at a rninlmum have an inspectior performed either by calendar date or acfual run timt hours. The adual run time hours shall take prededena over the calendar date:

Inspections:

The Inspection of each puIverirer shall at a minimum have a 3000 Hour Inspection performed eiiher bq calendar date or actual run tlme. Other inspection: rriay be required to analyze problems and take wrrective actions when necessary.

3000 Hour fnsaection

Description of some inspection details:

Ring-to-Roll measurement to ensure proper grinding capability.

Classifier bfade timing i o optimize coal fineness and fuef balance.

Levelness of floor. Ensure no high spofs on the ffoor that would affect Ring-to-Roll measurement.

Extension ring and cone condifion. Ensure no holes due to coal erosion.

Journal spring compression set for proper grinding of mal.

Inlet duct, expansion joint and turning vane condition.

Alr flow transmitters, pressure transmitters and pulverizer thermocouples shall be calibrated and checked for accuracy.

Burner line discharge valves shall be inspected for erosion io prevent valve from


TITLE: Pulverizer Inspection Program

POWER SUPPLY DATE: 4112011 (Rev 2) MECHANICAL fNTEGRIlY MANUAL

PAGE 4 of 14

sealing.

See Amendix A for a sample checklist of ,the "3000 Hour Pulverizer hspectlon" criteria.

HotlCald Air Darnaer and Gate InsDection

Inspection of hot and Gold air dampers shall be performed to ensure dampers will seal and stroke correctly to provide the air needed based on air flow curve for the pulverizer. This MI1 only be perFormed when boiler is not in operation. (Normally accomplished during outage).

Inspection of hot and cold air gates shall be performed to ensure gates will seal off to prevent a temperature influence of inlet air to the pulverizer during operaffon. This Inspecdon shall only t ake place when boiler is not in opemtion. (Normally accornplishd during outage).

Tests:

Coal Fineness Test

After every 3000 Hour Inspection an Isokinefic Coal Fineness test shall be performed to ensure the pulverizek is meeting the 75% on €he 200 mesh screen and less than 0.3% on the 50 mesh screen For proper coal fineness. Results shall be reviewed by the Process Engineer.

Air Flow Test

Primary Air flow test to the pulverizer shall be performed every 5 years. The exception to this interval would be replacement of an air flow transmitter requiring calibration and verification by air flow testing.

Clean Air Flow Test

SECTION: MI 3.13

TITLE: Pulverizer lnspectlon Program

POWER SUPPLY DATE: 4111201.t (Rev 2) MECHANICAL 1NTEGRlM MANUAL

PAGE 5 of 14

A Clean Air Flow Test shall be performed if the fuel velocity through burner lines is not adequate (detemined during performance testing). The Clean Air Flow Test will indicate whether OF not there is a worn orifice in a burner line which ne& replaced to regain the needed air flow velocity.

Motor Circuit Evaluator (MCEI

The following motor tests shall be pedormed at a minimum during outages on the pulverizer drive motor:

a Resistance to Ground. Capa.citance to Ground.

e Phase Resistance. I Phase Inductance, rn Polarization hdex (PI)

Dielectric Absorption Ratio (DAR).

Mer analysis by the Reliability Technician, results shall be reviewed by the Plant Maintenance Engineer and PSS to develop a corrective action plan for discrepancies if necessary.

Performance Test

The Performance Test of the pulverizer will be performed using the Isokinetic Method for determining the proper amount of coal, air, and fineness through each burner line.

Journal Spring Test

Spring testing will be performed during the 3000 Hour Inspection or when pulven'zer pehrmance dictates. Spring compression is set at I 9 tons utilizing mlibrated pressure gauges.

Lube Oil Analysis [Triboloqv)

132

133 H SECTION: MI 3.13

TlTLE: Putverizer Inspection Program

POWER SUPPLY DATE 4W2011 {Rev 2) MECHANICAL INTEGRIPT MANUAL

PAGE: 6 of 14

V. REPAIR PROGRAM

Quarterly oil samples of pulverizer shall be taken by the Reliability Technician and sent to a designated lab for analysis.

The Plant Maintenance Engineer and PSS shall review the report for abnormal results and recommend further inspections of the gearbox, lower radial bearing and thrust bearing if necessary.

SPECIAL NOTE: It should also be noted that if indication in the control morn shows low oil pressure for a pulverizef, the ail filter may need to be replaced and inspected for pluggage. If OB filter pluggage is due to metal fragments, the pulven'zer gearbox, tower radial bearing and thrust bearing need to be inspected.

Motor & Gearbox Vibrafion DatalAnalwis

Vll5ratiop data shall be obtained on a monthly basis on the D.rive Motor, Gearbox and Journal Assemblies by the Reliability Technician.

Drive Motor - Vibration data shall be taken from the inboard and outboard bearings.

Gear box - Vibration data shaIl be taken at the inboard and axial at the output shaft.

Journal Assemblies - Vibration data shall be taken at the cap area.

After analysis by the Reliability Technician, results shall be reviewed by the Plant Malntenance Engineer and PSS to develop a corrective action plan for discrepancies if necessary.

All maintenance repairs of puIverizers shall be performed in accordance with applicable codes, industry standards, OG+E standards, and design

134 SECTfON: MI 3.15

TITLE: Pulverizer Inspection Program

POWER SUPPLY DATE: 41112011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE 7 of34

VI. DOCUMENTATION

I VII. APPENDICES INDEX

specifications by OG*E trained personnel andIor designated contmctors.

Should a discrepancy be found during any tests or inspection and cannot h repaired at that time a notification shall be wn'tten so that €he repair wn be perfomd at a later time, This only applies to repairs that will not affect the performance of the pulverizer and boiler combustion.

All testing resub, 3000 Hour Inspection results, and repair records shall be maintained in a database locat@ on the bG+E selver andlor SAP.

A. 3000 Hour Pulverizer Inspection Form (Sample).

SECTION: MI 3.13 135 TITLE: Pulverizer fnspecfion Program

POWER SUPPLY DATE: 4111201 I (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 8 of t4

Appendix A

3000 Hour Puiverizer Inspection Criteria Form

. . - - . .. .-. .- . . . . . . . . . . __ -. .

SECTlOEI: MI 3.13

TITLE: Pulverizer Inspectlon Program

POWER SUPPLY DATE: 41112011 (Rev 2) MECHANICAL INTEGRtTY MANUAL

PAGE: 9 of 14

Grinding Zone I Journals

Journal: Serial #:

Wear (desired: 4’’) Clearance from bawl Heel: @&e& W’) Toe:

Check forTmnp Iron: Condition of Deflector Plates:

Oil Leak. Note Wear, etc.:

Check Face for Cracks: Button Clearance: @aired: SuskTouching)

Deflection Clearance: (Desired: 5’’)

1 I I I

I 1

I I

L I

I I

1

t 1

1 1

1 I I 1 I I

I 1

1 t 1 I 1 1

JouxnaI Imp ection: (%sua1 Inspec~on of Spring, .-.) - Gap between Spring & Canister: Trunion Thrust End (I3ushing Ret.) Trun. Ring (no more than % (3/8 max) h t

Rubbing: Y I N

wear (outer) Wear (inner)

Free End Trun. Ring Wear [outer) (718” Plate) Thrust war (inner) Does Roll Turn I Spin? Y / N Eccentrics: 3 ? Y / N

On #6 Mills - Check Bushings: Other Comments on Roll / J o m I :

E NO:


TULE: Pulverizer Inspection Program

POWER SUPPLY DATE 41112011 (Rev 2) MECHANICAL MTEGRITY MANUAL

PAGE: 10 of 14

Journal:

Wear (dcssired: 4’’)

Condition of Deflector Plates:

. .

Grinding %ne I Journah

Serial #

Clearance from bowl Heel: @aired: 3’’) Toe:

Check for Tramp Iron:

Oil LRaks: Note wear, etc.:

Check Face for Cracks: Button Cleclmce: (Desired: Just Touching)

Deflection Clearance: (Desired: W’>

Journal Inspection: (Visual Inspection of Spring, . ..) -- Gap between Spring & Canister: Trunion Thrust End (Bushing Ret) Trur~ Ring {no more than % (3/8 ma) l k u s t

Rubbing: Y / N

Wear (outer) Wear (inner)

FreeEnd Trun.Ring Wmr (outer) (718” Plate) Thrust Wear (inner)

DoesRoIITum/Spin? Y I N Ecccnkk: 3 ? Y / N

On #6 Mills - Chcck Bushings: Other Commenu on Roll /Journal:

If NO:

138 SECTION: MI 3.P3

TITLE: PuIverizer tns,pedion Program

POWER SUPPLY DATE: N112017 (Rev 2) MECHANICAL INTEGRIlT MANUAL

PAGE 11 of14

Grinding Zone I Journals

Journal: Serial #:

Wear (desired: 4”) Qearance from bowl Heel: (Daired: W’) Toe:.

Condition of Deflector Plates: Check for Tramp Iron:

03 Leaks: Note Wear, etc.:

Check Face for Crack Button Clerancc: (Desired: Just Touching)

Deflection C l h m e e : (Desired: 5”)

\ I 1 i I I

\ \

I I t

t I

I I

Journal Taspection: (Visual Inspection of Spring., -Gap between Spring & Canister: Rubbing: Y 1 N Trunion Thrust End (Bushing RetJ Tm. Ring (no more than !4 (318 max} Tbrust

Wear (outer) Wear (inner)

Free End Tnm. Ring Wear (outer) (W8” Plate) Thrust Wear (her)

DoesRollTumISpin? Y / N Eccentrics: 3 ? Y / N If NO:

On f#6 Mills - Check Bushings: Other Comments on Roll I Journnl:


TlTL€. PuIvrtrirer Inspection Program

POWER SUPPLY DATE: r1111201f (Rev 2) MECHANICAL INTEGRIPC MANUAL

PAGE 42 Of 14

Condition of: FloorDepth:

FloorAnde:

4 Floorwear:

(Measure to Top of Keystock) @aired: 4 2/87

@mired: 20")

Condition of: Bowl: Gaps: Y I N

0 WeldOverlay: Y I N

Condition of: Extension Ring:

0 Keystock: Y I N Height I Width: . Any Missing?

Condition of Clamping Ring

Vane WheevKicker Plate Clearance: (Desired: %")

Condition of: Vanewheel:

a BoltsBroken? Y I N 0 BoItsMissing'l Y / N

VmcsMissing? Y I N

If No Overlay- b There Cracking in Segments? Verticaf: Horizontal:

1 4 0 SECTIOEI: MI 3.1 3

TITLE Pulverizer Inspection Program

POWER SUPPLY DATE MECHANICAL INTEGRIIY MANUAL

PAGE

ru11201 I (Rev 2)

13 of14

HotlCold Air. Gates, nampers, Ductwork

Condition of Hot Air Gate &k Seals: -. -

Hot Air Dampers:

Cold Air Dampers:

ResuIts of Dampet Stroke:

Condition of: rn Discharge Valves:

%charge Valves Fully Rmacted:

Condition oE Ductwork Expansion Joints: Turning Vanes: Venturi: Thamocouple: Lower Floor: scrapers: Seal Plates: Tapsclear: Y 1 N

SECTION: MI 3.13

TITLE Pulverizer Inspection

POWER SUPPLY DATE MECHANICAL INTEGWTY MANUAL

PAGE

Prqram

HdCald A h Gates; Dampers, Ductwork

Raised Inkit?:

Condition: / I \

mrzlhg vanes \ /

i

------

Temp Air Dan

S e d P1:

SECTION: MI 3.74

TITLE: Fan Inspection Program

POWER SUPPLY MECHANICAL DATE 41mo11 (Rev 2) JHTEGRIIY MANUAL

PAGE 1 of7

FAN INSPECTION PROGRAM

Fired steam generators require large draft fans to move air into the furnace and to remove the combustion products. Draft fans are primary auxllian’es that support boiler operation for all types at fuel and firing methods. Drafk fans are typidty used in four principal applications: forced draft (FD), primary air (PA), induced draR (ID) and gas recirculation (GR).

FD and ID fans consist of axial and centrifugal fans. The periodic Fan inspection is essential fo ensure continued compliance with all applicable cpdes, industry standards and design specifmuons throughout the life of the operating unit. ThIs program prqvldes guidelines for conducting field inspections of fan wheels. an extension of any preventive maintenance strategy for a draft fan. A maintenance department can realize hyo benefits from a welldesigned and properly implemented fan inspection program.

First, it offers personnel a way to identify cracking or erosion problems for early corrective actions, before the damage escalates into major problems with a potential for catastrophic failure.

Second, k can help in establishing a database. Well documented records along with blade maps and photographs can help maintenance department begin a material history file on the fan wheel.

PSS will ensure fan Inspection deficiencies have:been completed in awrdance with maintenance manual and specificatl ons.

0 PSS and plant qualified personnel will jointty coordinate fan inspections and NDE.

Vibration monitoring.

Motor cumnt analysis.

PSS wilt maintain all fan Inspection reports and

142


TITLE: Fan Inspection Progmrn

POWER SUPPLY MECHANICAL DATE: 44112011 (Rev 2) 1NTEGRITY MANUAL

PAGE: 2of7

111, FAN INSPECTiON MAINTENANCE G UlDAN CE

A. Maintenance Issues

B. Condition Monitoring

1V. FAN INSPECTlON TECHNIQUES

ZcurdXn a centril server database,

0 Provide defalled planning to ensure Fan Inspection deficiencies are completed In accordance with maintenance manual. Work in conjunction wiih PSS.

0 Performs regular oil analysis.

Make repairs as needed.

Fan inspection program is to provide preventive maintenance guldance to assist in improving the reliablity of Fans. In addiff on, thls section also pmvides guidelines for conducting field inspections of fan wheefs.

Maintenance issues that are most often cited include bearing and alignment problems, lubrication, vibration problems (resulting h m improper balancing or buildup of deposits), and erosion and wear of blades from enhined particles. Also reported are problems with dampers, particularly on Row control dampers.

Condition monitoring is the use of advanced technologies to determine equipment condition and, potentially predld failure. It includes technologies such as the blowing:

0 Vibraffon measurement and analysis

Nondestfilctive examination (NDE) Infrared themogmphy Motor current analysis.

oil aMIySIS

The goal of condition monitoring is to identify changes in the condition of the fan, motor, or auxiliary that could lndlcate some potenfiat failure. Physical characteristics are measured, recorded, and analyzed so that trends can be identified.

~

Inspection Methods An inspection program is an essential componenk of any maintenance stdegy associated with boiler fan units. It can be used to establish a dabbase for fan wheel repair and as a means to identrfy the cracklng or erosion problems before the problem escalates €0 catastrophic failure. Four of the most

144 SECTION: Mi 3.$4

TtTLE: Fan Inspection Program

POWER SUPPLY MECHANICAL DATE: 41~12041 (Rev 2) lNTEGRlTY MANUAL

PAGE: 3 of7

V. INSPECTION AREAS

common Jnspedipn methods hat are ?rpicatly used in boiler fan units are listed below:

- OyettOry) Magnetic Partide Testing -Visual Inspection - Ultrasonic Inspection - nLiquid Penetrate

Visuai fnspectIons WT) Qualified pe:rsoniiel are to conduct the visual inspection ofthe rotating elements, weld joints, blade surfaces, and hubs. A visual inspction. Indudes but not limited to checking for vistble cracks and surface discontinuities.

jWetlDrvl-Maqnefic Particle Tasting Magneffc particle feting is a NDE (Non-Destructive harnlnation) fechnique that can be used €0 identify any cracks that exist on the suiface of ferromagnetic materials. ThIs can be further broken down into fhe categories of wet fluorescent msgne'tic particle testing (WFMT) and dry magnetic particle testing @lT).

Ultrasonic Inspection Ubsonlc testing (UT) is a fechnique hat can be used to detect any cracks or voids below the surface of a material. ThIs technique is used to determine the thickness of a fan surface or housing which is subjected to an erosive envlronrnent. It also Used €0 Inspect for voids in fan hubs, whtch are manufactured from cast iron and cast steel.

Liquid Penetrant The liquid penetrant (PT) testing method is used to detect surface cracking of materials. The PT method is typically used in tight spaces and is only effective where the discontinuity is open to the component surface approximately ten minutes.

Recommended areas ta be inspected during visual and magnetic particle examhatfons Include the following:

* The entire length of every weld joining €he fan blades to the center plate and slde plate.

Splice welds on the side and center plates.


TITLE Fan Inspection Program

POW€RSUPPLY MECHANICAL DATE: 4/1120-l1 (Rev 2) INTEGRITY MANUAL

PAGE: 40f7

Welds attaching stiffeners to center plates, hubs, and/or shaR

We!& in fabricated hubs.

* WeIds attaching balance weights to the side plates or center plate.

Pad welds used in place of balance weights.

0 Seal welds of botted-on erosion liners. These welds are not struc2u'kl; however, cmcks beginning in these seal welds may propagate into th*e structural weld or component. These cracks may also form an area on which erbske gas streams may mmntrate.

Cracks in eroslon liners made of some hardened material are common but normally not considered to be detrimental to the fan operation.

Insoaction Frequency The final step in implementing an inspection program is to determine the interval for conducting visual and Nondestrucdve examinations.

Daily checks During walk down, operators to check for the following:

Foundation cracks or loose anchor bolts, I Motor vibration

Motor amp readings 0 Bearlng temperatures

Missing insulatlan Check all air and gas ductsfor leakage,

Monfhlv Intemls Vibration analysis Oil analysis

Two years Intervals Routine Inspections: This includes utilizing various inspection iechnlques as needed, instrumentation dibration, stroking the dampers, lube oil system, wear and eroslon inspection of blades and inlet- vanes.


TitLE Fan Inspection Program

POWER SUPPLY MECHANICAL DATE 4l11201-l (Rev21 INTEGRITY MANUAL

PAGE 5 of?

B. Burn Hazards

C. Electrical

E, Cleaning Operations

F. Fan Movement

Fow veam . Ititewals 0 Replace bearings and bladas as needed.

(Refer to Appendix A: Inspection Frequency)

Fans are mfating equipment, and appmpriaie tag-orrl procedures should be followed before any inspection or maintenance is started.

Fan housings are confined spaces that may be filled with harmful gases. Confined space enfry procedures, including alr checks, should be-followed before entq.

The lubrication 011 of all fans and motors provides iubrication and coofing of the bearings, and the temperature of the oil may be high enough to present a bum hazard. ID fans operate at elevated temperatures and may retain heat for a long period a h being shut down.

The fan motor and fan auxiliaries are electrical and therefore present the risk of electrical shock. Before work on any electrical equipment is performed, the equipment should be de-energized and properiy tagged out

Some testing and inspection, such as vibration and performance testing, require the fans to be running during the tests. Access doors should never be opened with the fan running. On fhe downstream side, releasing the door may result In explosive opening. On the upstream side, the inflow may be sufftcknt to suck in materials such as tools and clothing. Special precautions must be observed while perfomhg these tests.

Respiratory health is the primary concern when personnel are involved in abrasive blast cleaning operations, A correct and fully functioning air supply and hood are essential and must be used at all times by personnel engaged in this operation; heavy duty gloves, a helmet or hood, and upper body covering should be standard items as well.

Even when a fan is focked out electrically, it may be subject to "windmilling.' Therefore, the impeller should be secured to physically restrict rotational movement. When personnet need to climb on the wheel to perform work or an inspection, the

147 SECTION: MI 3,d4


POWER SUPPLY MECHANICAL DATE: 4l112011 (Rev 2) INTEGRIPI MANUAL

PAGE 6 of?

wheel should be rnechanimlly secured.

Before a fan is sfarted, it should be ensured that all personnel have exited the fan housing, Inletboxes, inlets, and discharge ductwork. In addition, all material and took should be removed from the housing,

In order to perform the required repairs and inspections on fans, which have been taken off-line, access by scaffoldlng andor ladders wilt be required as well as adequate Ilghting. It is irnporhnt to properly secure alt ladders, scaffolding and walk boards to eliminate potential accidents.

A Fan Inspection Frequency.

POWER SUPPLY MECHANICAL INTEGRITY MANUAL

Inspect foundation, pedestals, and anchor bolts Inspect expansion Joints

148

X X

SECTtON: MI 3.14


DATE 4/1/2011 (Rev 2)

PAGE: 70f7

Inspect main drive motor Inspect fluid drive Inspect and replace blade bearings as needed

Appendix A

Fan Inspection Frequency

X X

X

Task

I

Inspect and replace control studs as needed Inspect and replace slide bearings as needed Inspect and replace rotating unlon as needed Inspect and replace shaft bearings as needed lnspact and rebulld vartable inlet vanes as needed

X X X X X


TITLE: Electrical Switchgear Inspectian Program

POWER SUPPLY DATE N112015 (Rev 2) MECHANICAL INTEGRIlY MANUAL

PAGE: 1 O f 4

I. OVERVIEW

11. RESPONSIBJLfTtES


B. P?ant

ELECTRICAL SWITCHGEAR INSPECTION PROGRAM

An Electrid Switchgear Inspectjtion Program is needed tc ensure the safe and reliable operation of switchgear at the Generafing Plants. Electrical switchgear inspectjon and maintenance is essential to ensure continued compliance ta NFPA codes, industry standards and design specifications throughout the life of the operating unit. In addibon, severity of senice, plant operation {number of sfadsand clearing d faults), and environmental conditions of service may affed frequency of inspection and malntenance of switchgear. Failure of plant switchgear M n impact both member safety and equipment reliability. Discrepancies found during the Switchgear Inspection are either corrected immediately during the outage or in the future to ensure safe operation and mechanical Integrity of equipment.

Overall coordinator of the Electrical Switchgear Maintenance and Inspection Program for Power Supply including most predictive and outage related Tnspedion activities.

Develop and provide Electrical Switchgear inspection work scopes to the plants.

Maintain Electrical Switchgear Inspection reports and records.

Make recommendations to correct Inspection deficiencies determined in accordance with the Inspection Confractor's recornmendattons,

Schedules Mure inspections based on condition assessments, operational experiences, OEM recommendations, test results, and other predictive mainfenance activities.

Provides OWE Inspectors fo ensure compliance with work scope.

- Responsible for supplying labor and pfaanning


TITLE: ElecfricaI Switchgear I n s p ~ t i ~ n Program

POWER SUPPLY DATE: 4!112014 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 2uf4

C. Suppiy Chain

Il l . CRITICAL EQUIPMENT LIST

I

IV. PROCEDURE

functions for rnajntaining the physical equipment condition includlng weekly, monthly, and other routine preventative maintenance activities as recommended in the OgM manuals furnished by the OEMs.

Maintains the equipment as necessary to insure &e, reliabfe operafion of the equipment while in servia.

Create requisitions with attached Switchgear Inspection work scopes.

Provide detailed pianning and scheduling as per Outage Readiness Index (ORI) guidelines to ensure that all of the Inspection Contmctor activities are coordlnated with other unit work activities scheduled during the outage.

Coordinate any bid review process with Power Supply Services and Plants.

H e c b b l switchgear, for the purpose of the ElectricaI Switchgear Inspection Program, shalt consist of the foltowing equipment:

Medium Voltage Switchgear

Medium voltage power circuit breakers, bus, relaying, starters, switches, instrument transformers, cables and !eminations used to transfer or switch power equlpment rated above 1000 V ac to 15KV ac.

-ow Voltaqe Switchsear

low voltage power circuit breakers, bus, relaying, panel 3oards, MCCs, starters, switches, instrument transformers, =aMes, trip devices, etc., used to transfer or switch power squipment rated at 600 V ac and befow.

The purpose of the Electrical Switchgear Inspection procedure is to implement a process fo ensure that electrical ;witchgear and other associated equipment is maintained as 3art of the overall mmprehensive Mechanical Integrity 'rog ra 117.

SECTION: MI 3.15

TITLE Electrical Switchgear Inspection Program

POWER SUPPLY PATE: 41212011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE 3 of4

1. .will identify .the equipment requiring inspection, inspection requirements, and inspection frequency interval In the Electrical Switchgear Inspection Program dowment PSS will maintain this document a central server location.

2 Plant Will review the requirements in the Electrical Switchgear database each year prior to the start of the budgeiing process to identify any inspections that have been scheduled and will require budgeting of material, services, or internal labor by the plant@).

3. psS will provide the plant a detailed work scope compliant with the Outage Readiness Index (ORI) prior to the inspe3on scheduled at the plant.

4. S U D P ~ Chain will coordinate the M d review process with PSS and the Generation Plant,

5. psS wit1 oversee the overall work quality of the Contractor(s) and ensure all work Is accomplished as per work scope. psS wilt convey any deficiencies requlring immediate attentian or additional work requirements to the Plant.

6.. psS will coordinate an exit intenriew meeting with the Plant and Inspection Contractor at completion of the work to discuss results of the Inspection.

7. psS Will maintain all InspectiodRepair Reports at a central server tocation.

Frequency of lnspedions will be determined by equipment condition, outage schedules, unusual operating expen'ences, predictive maintenance technologies, previous inspection recommendations, etc. Inspections will be scheduled on a rolling ten year plan and each unit will be identified within the plan.

For medium and [ow voltage equlpment within the power plants the maintenance practices will as a minimum conform to the Malntenance of Equipment Subject to Long

SECTION: MI 3.15

TITLE Electricat Switchgear Inspection Program

POWER SUPFLY DATE: 41112051 (Rev 2) MECffANICAL. INTEGRITY MANUAL

PAGE: 4of4

VI. DOCUMENTATlON

Vlf. APPENDICES INDEX

Intervals Between Shutdown information In the mos recent edition of the NFPA 70B “Recommended Practice foi Electrical Equfpmnt Maintenance.

OGE personnel or conhctoE will perform annual visual anc infrared inspections of equipment connections, cublcles cable spJm, bus connections, terminations, tape coverings etc.

Protective relaying will be cleaned and tested on every

Breakers, switches, starters and other switching devices will be inspected and tested on a four f4J year basis. This Inspection interval may be adjusfed at certain locations in a plant due tu environmental conditions dictating more frequent inspections. Plant equipment s h ~ u l d h placed in€o two groups and one group of equipmen! should be tested on each two year maintenance outage to spread out the required resources over the four year interval.

other switchgear related items such as bus, instrument transformers, Insulators, bus connector torque, etc. will be inspected coincident with fhe outage schedules for the switching devIces above.

year scheduled maintenance outage.

Equipment condition assessmenfs determined during the hour year maintenance interval may dictate shorter maintenance cycles, increased O&M expenses, or switchgear replacement and subsequent mpital budget expenses. These adjustments to maintenance intervals and expenses Will be tracked in the tolling ?O year budget borecast.

411 Electrical Switchgear Inspection documentation including mrk scopes, maintenance plans, contractor inspection reports, efc. will be maintained at a central server database.

U SECTION: MI 3,16

TITLE: Steam Turbine Valve Inspection Program

POWER SUPPLY DATE: iWII207 I (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 1 Of4

I. OVERVIEW


A. Power Supply S e wices

5. Plant

STEAM TURBINE VALVES INSPECTlON PROGRAM

Steam turbine valves (STV) are the safeguard and controller of steam turbines (main turbines and BFPT) in our generating facilities, The vqlves accomplish two fundamental functions. They control the amount of steam that enters a turbine or may be used as a shut off (on or off) when a fuhine is shut down. The aduab'on of these valves may be e l e d r i ~ ~ y d m u l i c or mechanical. The proper operaffon of these valves is provided by proper maintenance and online festing. Leaking or malfunctioning valves can Muse unsfable shutdown of :uhines or Jack of conht can muse unstable running :onditions (both will upset the electrical grid). The Jalves consist of Throttle valves (usually he shut off mlves to the turbine but may be used for cantmi during sfart up), and Governor valves (usually used to control the amount of steam to the turbine during operatbrr. Hot Reheat valves used to stop the steam flow to the IP turbine.

- Schedule each S W component inspection, as appropriate.

Specify Interval frequency STV, as appropriate.

0 Maintains all S W Inspection Reports.

Review previous S W Inspection Reports to ensure corrective recommendations are planned and scheduled for the n ~ x t outage.

0 Develop scope of work as necessary.

Provide project lead with support from plants as necessary.

Review reports from last inspection.

SECTION: MI 3.1 6

TITLE Steam turbine Valve inspection Program

POWER SUPPLY DATE 4~112011 (Rev 2) MECHANICAL W E G R I M MANUAL

PAGE 2 of4

~

111. PROCEDURES

A. CRITICAL EQUIPMENT LfST

B. CMTICAL MAINTENANCE PROCEDURE DEVELOPMENT

a Inspect overhead crane before each outage anc provide documentation or provide a mobile crane as necessary.

0 Plans and schedufes STV inspections as pel intern1 frequency.

9 Test e l v e s durfng operations to determine reliability.

The purpose of this process is to outline procedures for maintaining steam turbines valves by developing, mplementing, and matntalnhg a slte-specific and mrnprehensive mechanical integrii program whlch falls mder seven major tasks:

Planning and schedulhg 0 Operational testing

Material and Parts c o n h l program Disassembly and reassembly

b As found and as left dimensions Training empioyees on rnairrtenance, Inspection and testing Documentation

4 critical equipment list must be site specific. STV have lifferent canfiguratlons consisting of number of valves ier unit and lowtion, pressure and flow requirements.

ihe maintenance procedure will be unIt specific. Each jTV will have its own procedure accordi,ng to the ihysical configuration. OEM recommendations and irevious Inspection reports.

s General procedures for each S W are covered in the OEM Technical Manuals. OEM Technical Manuals may not include all necessary detailed information. Technical Field Assistance (TFA] is available from the OEM and may be utilized as necessary.

154

155 SECTION: MI 3.3 6

TITLE: Steam Turbine Valve Inspection Program

POW€R SUPPLY DATE 411 1201 d (Rev 2) MECHANICAL 1NTEGRIM MANUAL

PAGE 3 of4

1V. INSPECTION FREQUENCY

V, MAINTENANCE TRAINING

VI. INSP€CTION, TESTING, AND RECORD KEEPING

The needed information af the plants incrude: disassembly procedures along with dak measurement sheets. Tolerance allowance or each measurement and how to obtain ea& measuremknt. Reassembly procedures as founc and as left measurements.

Cleaning, NDE and evaluations of all park of thE STV must be specified in advance. A generic scope an be provided but each inspectton may require different combinations of procedures.

Procedures shall be readily avatlable to the personnel who are responsible for repairing, inspedting, testing, or malntahing the equipment.

SlV inspe'dtion frequencies shall be every other outage (2 years between outage) 4 year cycle. This is per OEM recommendation.

Most of the training is provided as OJT or vendor ;chools. S W training classes are available by the OEM 3r other sources.

3peralional test should be run to determine the ability of he STV to work as needed. These test need to happen mce per wee'k and will require coordination between the lispatcher and other plants.

Malfunctioning valves will require attention kfore the scheduled maintenance interval.

OEM Technical Buletins will also affect the inspect schedule as problems surface fmm other similar STV in the OEM fleet.

a Documentation (repair from previous outages) will be stored electmnically on a shared drive designated by PSS.

SECTlOFI: MI 3.1 6

V11. DEFICIENCIES! CORRECTIVE wnms

TITLE Sfeam Turbine Vatve Inspection Program

POWER SUPPLY DATE: 41112011 (Rev 2) MECHANICAL fNTEGRIlY MANUAL

PAGE: 40f4

If decie-ncks ,ape seen using Performance testing, OEM bulletins, or operating observation, PSS will lead in the evaluation of soldion of the problem.

Vltl. APPENDICES INDEX

c ; 56

157 SECTION: MI 3.A7

TITLE: Cathodic Protection Inspection Program


PAGE: q O f 5

t. OVERVIEW


CATHODIC PROTECTlON INSPECTION PRUGRAM

Cathodic Protection Systems within QGE facilities require maintenance and inspedon services fo insure carrosion of piping and other protected structures is controlled.

Inspections and maintenance requirements will in general consls~ of routine monitoring of the cathodic protection TmnsformerlRe&er, (TR), sets for voltage and currents, maintenance of fhe TF3 sefs, wbles, piping connections, etc. to insure that the cothodic protection system remalns in good working order.

Identifimation and replacement of severed conductors, exhausted anode beds, faulted transformers, etc. Will be accomplished as problems are identified.

Preventive Maintenance 8 Manitnrinq

Preventive maintenance and monitoring, consists of ongoing tasks performed on a routine, (monthly, quarterly or annual), basis. These functions wilt be prevenhtive or predictive in nafure and are deslgned to assess, predict, and prevent failures of the Cathodic Profedion System between major inspections.

Esmples of Preventive maintenance and monitoring tasks-are listed in Section VI.

Malor Inspections, Testina, 8 Rematrs

Major InspectiondAssessments andor Refurbishments and Repairs wifl be accomplished on a five (5) schedule. A Cafhodic Protection Contractor will perform the on-slte assessment and will determine what major repairs are required. A brief listing of major inspection requiremenfs is listed In section V.


7YTl.E: Cathodic Protection Inspection Program

POWER SUPPLY PATE 41112011 (Rev 2) MEGHANICAL INTEGRITY MANUAL

FAG€: 2of5


B. Plant

C. Supply Chain

e

4

e

0

0

Overall coordlnafor of the Cathodic Profedon lnspection Programs for Power Supply.

Develop and provide detailed Inspection work scopes +nd or specifications for the plants.

Maintains Cathodic Protection testing and Inspection' reports.

Makes recommendations to correct Inspection deficiencies deterrnlned in accordance with the testing and fnspectian report recamrnendatfons,

Specify inspection interval frequency based on wndition assessments, test resuIts or other maintenance activities.

Ensures compliance Wib issued Testing, Inspection, and Repalr Scopes of Work andlor specifications.

Responslble for supplying labor and planning functions for maintatnlng the physical equipment condition including required routine preventative maintenance activities.

Maintains monitoring equipment, MCC feeders, cables, TR sets, etc. necessary to insure safe, reliable operation of the Cathodic Protection Systems while in service.

Create requisitions with attached fnspedion work scopes andlor repat specifications.

Provide detailed plannlng and scheduling as required to ensure that all maintenance activities are accomplished at the proper intervals.

Coordinate the bid review process wIth Power Supply Services and Plants.


TITLE Cathodic Protection Inspection Program


PAGE 3of5

111. CRlTlCAL EQUIPM€NT UST

IV. PROCEDURE

~ ~ ~ ~

Below is a listing of types of Cathodic protection equipment within OGE Energy power pfants. This listing is not alI inclusive not necessarily found at all locations.

TR set power supply CIjlP. 480V MCC) 8 TR set ( d l lilled transfomedRectifier)

Andes (Typically impressed current systems with buried an6de beds)

8 Bun'ed cables, (Power cables, ground cables, anode cables, pipe or structure attachments)

The purpose of the Cathodic Protection Inspection Program is to implement a process to ensure equlpment Is maintained as part of the overall comprehensive Mechanical Infegrity Program.

- PSS will identify the equipment requiring Inspection, inspection requirements, and inspection frequency interval in the Cathodic Protection Inspection Progmm document. PSS will maintain this document at a centrat server lowtion.

- Plant will review the requirements in the Cathodic Projection Inspection Program each year prior to the start of the budgeting process to identify any MaJor Inspec&ns andlor repaits fhat have been scheduled and will require budgeting by the plaot(s).

- PSS will maintain a defailed work scope andor specifidon for inspections or repairs.

Supcllv Chain will coordinate fhe bid review process with PSS and the Generation Plant.

_I PSS wilt oversea the overaJl work quality of the cathodic protection vendors and ensure a11 work is accomplished as per work scope or specifmtions. - PSS will convey any deficiencies requiring immediate attention or additional w o k requirements to the Planf.

PSS will maintain all Cathodic Protection - InspectionlRepair Reports at a central server

SECTION: MI 3.17

TlTLE: Cathodic Protection inspection Program

POWER SUPPLY DATE #If2011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 40f5

M i i o n ,

7. Prant .will maintain cathodic protection inspection reports -for equipment replacdreconditioned on site in SAP:

V. MAJOR ASSESSMENT AND TESTING

Major Assessment

6 Record rectifier output, both voltage and current, by reading the rectifier meters - If existing meters are'riot in op'erating order, a portable meter is q u l r e d .

Verifying rectifier meters by measuring the output with portable test instrumentation, calibrate the rectiner meter H required.

0 Recdrd the input current and voltage to the r-jctifier, record the redtifier tap seff ing.

Record the structure fa reference potential at the rectifer (should appropriafe instrumenWon exist) or measurewith portabJe test equipment and a reference 'electrode. The tester should intempt the M e r output and not the structure potential shift with the rectifier ori and Off.

Compare data with industry wide expected values td dgterrriine If corrective actions are necessary.

0 Additional structure fa reference electrode measurements should also I% taken throughout the syst6n1 to ensure thatprotective potentials are at their desiied limits. The rectifier output should be increased or decreased by changing tap settings to achieve the desire value. - Measure individual anode currents where possible.

I Identify new or unprotected systems that may I

SECTION: Mi 3.17

TKLE: Cathodic Protection Inspection Program

POWER SUPPLY DATE: * l u l n o l l (Rev 2) MECHANICAL iNTEGRIW MANUAL

FAGE 5 of5

VI. PREVENTIVE MAINTENANCE ACTIVlPl ES

411, DOCUMENTATION

'111. APPENDICES lMDEX

need protection.

L Major inspection vendor,must issue maintenance, repair, or refurbishment requirements based on analysis of data.

Preventive maintenance and monitoring, consists of ongoing tasks performed to prevent failures of the cathodic protection system between major inspections.

Monthly

Check TR sets.

Measure and record incoming ac voltage and current, investigate if. power is off, or currents imbalanced (three phase units).

Record rectifier output - dc voltage and current where shunts are available.

Visually look for leaking oll on oil filled 'transformers.

Measure and record individual anode currents where possible.

Bi-Annuat

0 Clear transformer and check oil. Check for proper level. Check for wa€er in oil.

All Cathodic Protection Inspection documentation Including work scopes, maintenance p h s , contractor inspection reports, etc. will be maintained at a centml sewer database.

161

SECTION: MI 3.18

TITLE Painting & Coating Inspection Program

POWER SUPPLY DATE 4112011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE 1 of5

I* OVERVIEW



8- Plant

C. Supply Chain

162

PAINT1 NGICOATING INS PECTiON PROGRAM

Establishment of a PainfinglCoatings Inspection Program permits planning and prioritiiffon of coatings rnaiqtenance wqrk as needed to ensure the integrity and performance of structures and equipment throughout the life of the aperating unit Failure of Cirtlcal structures can impact bofh member safety and equipment failure. A mating monitoring prcgram enables eady identifmtion and detection of potential problems on coatings systems and aids in establishing a long-term, cost effective coatings maintenance program.

Overall coordinator of fhe PaintinglCoating Inspection Program for Power Supply.

Develop and provide detailed PaintinglCoating work scopes fo the plants.

Maintains all PalntingEoating lnspectlon reports and records.

Ensures PaintinglCaating work is compIeted in amrdance with work scope specifications. Provides OG+E Inspectors to ensure compliance with work scope.

Schedules future PaintinglCoating Inspections at fhe plant.

Create requis~ions With aftached PaintingEoating work scopes.

Provide detailed planntng and scheduling to ensure coordination of Painting/Coating activities and other plant work activities.

Coordinate the bid review process with Power Supply . I -

Services and Plants.

SECTION: MI 3.18

TITLE Painting Coating Inspection Program

POWERSUPPLY DATE 415/2011 (Rev 2) MECHANICAL INfEGRtTY MANUAL

PAGE: 2of5

163

IIL CRlTICAL EQUIPMENT LIST

IV. PROCEDURE

fhe following areas of the generating plants will be assessed on a periodic frequency to evaluate the overall coatings condition to determine the most cost-effective maintenance strategy:

e

e

b

0

a

E oil e r Sfructu re Precipitator Structure TurbinelGenerator Facilities Switchgear Fai=ilities Ash Conveyor System Ash Storage Facilities Coal Yard Facilities Coal Conveyor Systems Crusher Buildings Cooling Tower Structure

The purpose of the PaintlnglCoating lnspectron Procedure is to implement a process to ensure Painted OF Coated surfaces are maiptained according to applicable ASTM Paint and Coating Standards as part of the overalt comprehensive Mechanical Integrity Program.

1, psS will coordinate the schedulhg and execution of a PaintingKoatings Assessment at specified intervals at all the generating plants. Frequency of assessments will be determhed by the severii of corrosive contingents present at each plant.

2. Painting of structures, equipment, andlor facilities will be budgeted and scheduled as per PaintinglCoating Assessment results at each plant.

3. psS will provide the pjant detailed work scapes for all scheduled PaintinglCoating projects. Work scope will include, at a minimum, surface prepamtlon requirements, paint specificaflons, and apptiwtton specifiations,

1. Supdv Chain will coordinate the bid review process with PSS and Generation Plants.

5. PSS Inspectors will oversee the overall work quality of the PaintinglCoafIng Conb-actor and ensure all work is accomplished as per work scope.

SECTION: MI 3.18

TlTLE: Painting & Coating Inspection Program

POWER SUPPLY DATE: 4W2011 (Rev 2) MECHANICAL INTEGRW MANUAL

PAGE: 3 d 5

V. FAIN'BNGICQATING ASSESSMENT FREC!UENCY

VI. ASTM PAINTING and COATING STANDARDS

Vll. PAINTINGICOATtNG ASSESSMENT CRITERIA

Frequency of assessments will be determined by the severitj of corrosive contingents present at each plant. The presence of coal reclaim systems and cooling towers both confribute to accelerated corrosive conditions of painted surfac~s at a generating plant Hours of service of a untt is another factdr in the degradation mte of painted surfaces due to the operalion of the cooling toweis. Due 'fa the above menlioned factors and the need to develop a rate oi degmdation trend; PaintinglCoatings Assessrnerrts will occur every 2 years at coal plants, while the gas plant assessmenfs will OWUF every 4 years. After a degradation trend of the painted surfaces has been developed, PaintinglCoating Assessrnentintenral frequencies wit! be extended.

The fo!lowing are some of the ASTM Painting and Coating Sfandads relative to the utility industry:

- 03359 - Test Methods for Measuring Adhesion by Tape Test.

D4538 - Terminology Relating to Protective Coating and Lining Work for Power Generation Facilities.

D5498.- Guide for Developing a Training Program for Personnel Performing Coating Work Inspection foi Generation Facitiies.

- D610 - Practice for Evaluating Degree of Rusting on Painted Steel Surfaces.

D6677 - Test Method for Evaluating Adhesion by Knife.

D7108 - Guide for Establishing Qualifications for a Nuclear or Generating Plant Coatings Specialist

- D714 - Test Method for Evaluating Degree of Blistering of Paints.

Following are the inspection criteria identified and assessed juring the PaintinglCoating Assessment of the generating 3lant This infomiation Is necessary to develop a 'aintindcoating Inspection Program to ensure the integrity of

SECTION: MI 3.18

TITLE Painting d CoatIng inspection Program

POWER SUPPLY DATE: rE1112011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE 4of5

165

plant structures and equipment by esbblshing a long-term, cost effective coatings maintenance strategy:

i a L

e

0

Surface Area Substrate Condition Coating Type Visible Coaling Degradation Presence of Lead Service Environment Temperatures Accessibility Factors Coating Thickness Coating Ad heston

~ ~ ~

SAFEIY CONCERNS PaintinglCoatings Assessments are accomplished during normal operating times of the unk No impact to normal work activities' or safety requirements would be anticipated.

Painting of structures andlor equipment will occur while other plant rnajntenance work is being accomplished. Because of this, co-ofdination of work activities between the Painting Contractor and OGE members needs to occur to ensure overall safety of personnel.

Scaffolding may be utilized at locations during Palnfing Projects at the plant. Contractors and OGE members should ensure swffolding has been inspected dally before using and all applicable codes and OG+E plant standards are complied with,

0 Safety Bamer Tape will be utilized at lmflons during the' Painting Projects at tbe plant. Contractors and UGE members shall comply with all safety barrier tape applicable codes and OG+E plant standards. I f safety barrier tape has been Installed improperly or not installed where necessary, please contact the plant Safety Caordinator or Plant Management.

Typical safety requirements will be hard hats, safety glasses andlor goggles, gloves, respirator protection, fall protection.

SECTION: MI 3.18

TmL€ Painting & Coating Inspection Program

POWER SLIPFLY DATE 4111201 1 (Rev 2) M€:CHANICAL INEGRlW MANUAL

PAGE 5 of5

IX . D 0 I: LI M E NTATl 0 N

X. APPENDICES INDEX

166

CUI PaintinglCoatings Assessment documentation will be maintained at a Web-base database that lists groupings, equipment, strucfures, and pictures with corresponding performance Wues" and surface area estimates. This database-wili have the ability to project the performance of exisffng coatlngs and gives unit-wide and specific sitewide perspectives of both cost per square foot and performance per square foot. Forecasted paint fallure anaIyslsThe database will be maintained by both psS and the Plant.

sEcnoN: MI 3.19

TITLE: Crane & Hoist fnspectlon Program

POWER WPPLY DATE: 4112011 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 1 Of7

1, OVERVIEW CRANE AND HOIST INSPECTIOM PROGRAM

A kraneu is a machhe for IiRing and lowering a load and moving it horirontally, with the hoisting mechanism an integral part ofthe machine. Cranes whether fixed OF mobite aredriven manualIy or by power.

A % O W tsanappamtus W c h may be a part of a crane, exerting a force for liRing or lowering.

Cmne and hoist equipment are used extensively in the power plants. This equipment must Ix routinely inspected for safety and reliability. Inspection and maintenance of all such equipment shall conform and comply with the requirements of OSHA

In compliance with:

OSHA29 CFR 1910.179 0) (Overhead a d Ganby Cm-nes) See Attached

OSHA 29 CFR 1926.550 (a)(6) (Cranes and Derricks) A thorough, annual inspection ofthe hokting machinery shall bE made by R competent person, or by a government or private agency recognized by the US. Department of Labor. Tfie employer shall maintain a record of the dates and results of lnspecfions fw each ho;sfing machine and piece of equipment,

Crane and hoist equipment are used for lifting and moving heavy components at several Iocations in the plant. This equipment must be maintained to provide safe and reliable Dperation. It cannot be overemphasized that only quadfied andor licensed individuals operate these devices.

Safety rules and guidance in the use of lifting equipment apply to all operations that involve the use of cmnes and hoists nstalled in or attached to buildings and tu all personnel who use such devices. The proedures shall also document that nspectlons and tests are performed. Equipment deflciencles :hat are autslde acceptable limits shall be corrected before hurther use or necessary means must be taken to ensure safe >peration. Equipment is to be deslgned, built, tested and nstalted according to the latest editions of applicable codes and standards, design specifications and manufacturer's nstructions. AI maintenance materials, spare parts, and qquipmenf shall meet design specifications. Employees nvoked in maintaining the integrity of this equipment shalt be rained In art overview of the process, its hazards, and all

SECTION: MI 3.19

TITLE Crane B Hoist Inspection Program

POWER SUPPLY DATE: 1u112011 (Rev 21 MECHAFIICAL INTEGRlfl MANUAL

PAGE: 2 of?

I t . RESPOMSfBlL1TIES

A. Power Supply S,ervices

B. Power Plant.

prowdures pertaining to the employee's job.

Review hoist and crane inspection contract scape for any needed changes,

Participate in each plant site annual review meeting of hoist and crane inspection results as scheduled by plant

Maintah all manuals for cranes and hoisfs in a central file for easy and quick reference.

Ensure that designated employees receive the required training tobe qualified and competent to operate cmne and hoist equipment in their work areas. This training must be conducted by a qualified instructor who 1s a licensed cmne and holstapemtor

Ensure that crane, hoist, and rigging equipment is inspected by qualified and trained individuals (employees and contracted services}. Preventive maintenance program shall be based on equipment manufacturer's recornmendatrons.

Verify all recommended equipment repairs have been completed and documented before operating equipment. (Operational tests shaII be pe~ormad as required on new or altered equipment.)

Review inspedon service repoFts for timely repairs and long term equipment replacement budget planning.

Verify crane and hoist equipment inspection list is comprehensive and currant

Mark rated load on each side of each crane. Each horst shalI have €Is rated load marked easily visible from the ground or floor.

Maintarn current and complete reports created by crane and holst inspection services group

Conduct exit Interview with inspection services representative after each completion of crane and halst Inspection

168

SECTION: M! 3.19

169 TmE: Crane & Hoist Inspection Program

POWER SUPPLY PATE: a112011 (RQV 2) MECHANICAL INTEGRITY MANUAL

PAGE 3 of? -

C. Supply Chain

Ill. PROCEDURES

rn Lockout and tag all equipment recommended for repairs Immediately after inspection

Review punch out list and verify all recommended repairs to be complete

Provide assistance in negotiating and retainhg crane and hoist inspection services confract

rn Advise of any contract changes and costs

e Review each year the performance of Inspection

The purpose of a cmne and hoist inspection procedure is to rnplenieht a process to ensure crane and hoist equlpment Is maintained according to OSHA and other appliwble codes and ndustry standards as part of the overall comprehensive Mechanical Integrity Progmm.

services group at each plant slte

I . psSwill revlew the inspection contract proposal annually for completeness and mmptiance wilh OSHA

2. Plant wit1 asslst to identify all crane and hoist equipment and provide avallable manufacturer's documentation for a complefe crane and hoist annual condition assessment

3. Suotllv Chain wlll provide an Inspection contractor to perform the annual inspection of crane and hoist equipment. SLIDDIY Chain will obtain a writfen evaluation annually of the contractor's petformama from each plant.

t. will coordinate a schedule with the designated inspection sewices contractor to have all wane and hoist equipment available for Inspection.

i. Plant will take Immediate action io address all reported defects as repotfed by Inspection services contractor

3. Plant will schedule an exit interview Mith €he inspection oontractor and to identify and resolve all found and documented hoist and crane related equipment issues. A schedule with corresponding plan far Immediate action shall be developed including completion target dates.

7. - Plant will document all follow-up repairs

I SECTION: Mi 3.19

TmE: Crane & Hoist Inspection Program

POWER SUPPLY DATE: 4f11201-l (Rev 2) MECHANICAL INTEGRIM MANUAL

PAGE 4of7

IV. CRITICAL EQUIPMENT LIST

V. SAFETY C 0 N C E R N S

VI. APPENDICES INDEX

8 Cranes

Associated Controls and Switches Associated Structure

0 Associated Rigging

Hoists

Crane and hoist inspectioris are usually accomplished when the equipment is nbt being used. This will likely occur putside of scheduled oLitages. Cwrdinaflon of work activities between the Inspection Contractor and QGE members needs to occur to ensure overall sarety of personnel.

e Inspection conhcfor shall perform test opemtions requiring equipment be energized.

All equipment to be repalred shall be locked and tagged.

A OSHA29 CFR 1910.179~)

Related Oocu mentation

INSPECTION AND OPERATION HYDRAULIC CRANES (BM) INSPECTION, T E S T " , AND MAINENANCE.OF OVERhEAD CRANES (I&M) MOBILE CRANE USE WHRE USING SUSPENDED OR A7TACHED PERSONNEL PLATFORMS (l&M) ASMHANSI 830.2, "Overhead and Gantry Cranes (Top Running Bridge, Single or Multipte Girder, Top Running Trolley Hoi,,)-" ASMWANSI 830.5, "Mobile and Lommotive Cranes" ASMEIANSI B30.9, "Slings." ASMUANSI 830J 0, "Hooks." ASMUANSI 830.1 I , "Monorails and Underhung Cranes." ASMUANSI 830.26, "Overhead Hoists (Underbung)." ASMUANSI 630.17, "Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist)." ASMUANSI 830.20, "Below-the-Hook Lifting Devices." ASMUANSI 830.21, "Manually Lever Operated Hoists," Code of Federal Regulation, Tiff e 29, Part I91 0.179, "Overhead and Gantry Cranes." Code of Federal Regulation, Title 29, Part I91 0.1 84, "Slings." Code of Federal Regulation, Titi e 29, Part 1 926.550, "Cranes and Derricks." NFPA 70, Article 61 0, Cranes and Holsts.

17Q

SECTION: MI 3.19

TITLE Crane & Hoist Inspection Program

POWER SUPPLY DATE: 41fl2011 {Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE: 6of7

172

SECTION: MI 3-19

TiTLE Crane B HoEst Inspeetion program

POWER SUPPLY DAT€ 4f12Oll [Rev 2) MECHAMCAL [NTEGRIW MANUAL

PAGE: 7 of7

173

SECTION: MI 3.20

T m E : Freeze Protection Inspection Program

POWER SUPPLY MECHANICAL DATE: 4W201-l (Rev 2) INTEGRITY MANUAL

PAGE O f 1 5

174

fa OVERVIEW

It. DEFlNlTlONS

FREEZE PROTECTION INSPECTION PROGRAM

PIplng and vessels are subject to heat loss when their internal temperature is greater than the surrounding ambient temperature. Thermal insulafion reduces the heat Ioss buf cannot eliminate it Industrial freeze protection systems use heat tracing ‘able and associated equipment fo prevent the freezing of fluids in these expused areas. The heat tracing system cumpensafes for heat losses and maintain a minimum femperafure within an insulated piplng system in the event of a prolonged low fernpemturel low- or no- flow condition.

The proper installation and periodic inspection of a freeze protection system is essential to ensure continued operation of the power unif, with minimal freeze damage. This program provides guideHnes for conducting field inspectlons of freeze protection system power supplies, controllers, cable and accessories, an extension of any preventive maintenance strategy for plplng. A mahtenance department can realize hivo benefds from a well-designed and properly Implemented freeze protecfion inspection program in the following ways:

It minimizes cost of repair. It offers maintenance personne! a way to identify potential failures prior to freezing weather, altowkg for early corrective actions on the plant’s tImefmrne, rather than an emergency basis during inclement weather. It can help in estabfishing a database. Well documented records along with blade maps and phofographs mn help maintenance department begin a material history file on the fan wheel.

Constant Wattage ‘‘Series” Heat Trace Cable

4 mineral insulated heating -able used exfensively for hlggh iernperature maintenance, hlgh temperature exposure andlar ’ligh watt densify applications which exceed the limitations of !hennoplastic insulated wbles. The,resistaace configurations available can provide tracing for pipes up to 1 mile (1.6 km) ong from a single power supply point. These cables are 3pproved for use in ordlnary (nonclassified) areas and iamrdous (classified) areas. Operating Volt age: 600 VAC. Vtaxlrnum Maintenance Tempemfure: 932°F

SECTION: MI 3.20

TITLE: Freeze Protection Inspection Program

POWER SUFFLY MECHANICAL DATE: 4l112OlI (Rev 2) INTEGRITI‘ MANUAL

PAGE: 2 of 15

~ ~ ..

Ill. REFERENCES

Constant Wattfane “Zone” Heat Trace Cable

A fiberglassMoropolymer lnsulafed heating cable which includes a continuous series of short, independent heating Circuits, Power output is relatively unchanged by variations in circuit length up to several hundred feet Cable may be cut to Iength and provide consistent and reliable heat outputs regardless of circ;uit length. Cable termhations are required. Cables are not subject to the inrush current associated with self-regulating heating cable, therefore the need for oversized power distribution equipment is eliminated. These cables are approved for use in ordinary areas, hazardous (classifled) areas and Zone 2 classified areas. Operating Vottage: 4201240 VAC, Maximum Maintenance Ternpaatwe: 150°F

!%if-Renulatina Heat Trace Cable

A =able designed to provide freeze protection fo metallic and nonmetallic piping, tanks and equipment The heat oufpput of self-regulating heating cable vades In response to the surrounding conditions along the entire length of a circuit. Whenever .the heat loss of the insulated pipe, tank or equipment Increases (as ambient temperafure drops), the heat output of the cable increases. Conversely, when the heat loss decreases {as the ambient temperature rises or product flows), the cable reacts by reducing its heat output. These cables are approved for use in ordinary areas and hazardous {classified) areas. Opemtting Voltage: 110-120 or 20&277 VAG Maxlrnurn Maintenance Temperature: 15O’F

ANSillEEE Std, 515-2004, Standad for fhe Testing, Design, Insfallation and Maintenance of Heclricai Resistance Heat Tmchg for Industria! ilpplicatioions;

ANSIIIEEE Std, 844-2000, Recommended Pracfice for ff ecfricai Impedance. induction. And Skin Effect Heating of P@elines and Vessels;

ANSUNECA 202-2001, Rewmmended Practice for Installing and Mahfaining Indusfrial Heat Tracing Systems

MFPA 70 Natlonal ElectrIc Code - Article 427: Fixed Uectric Heahhg Equbmenf for P@elh%s 8nd Vessek

SECTION: MI 3.20

TITLE: Freeze Proiedon Inspection Program

POWER SUPPLY MECHANICAL DATE: #1120? 1 (Rev 2) INTEGRITY MANUAL

PAGE 3 of15

1V. RESPONBISIUTIES

k Power Supply Services

B. Plant

V. FREEZE PROTECTION INSPECTION MAINTENANCE GUIDANCE

A Matntenance Issues

PSS electrical, engineer wlll prepare and review freeze protection system maintenance manuals and s p q jfications.

PSS eleclrical engineer will assist PIanf maintenance personnel in the design, and the reviewing, Installation. qperatlon and maintenance' of freeze protectiori systems.

PSS electrim1 snglneer wit1 review and recommend, as appropriate, improvements and new technologies in freeze prohctionlheat tracing products.

Creates and main€ains a master list of h e a t - t d piping and ensures all fines are identified witfi signage.

Perfohmregular inspection and maintenance

Provide detailed planning and schduting to ensure system deficiencies are remedied in accordance with maintenance manual. Work in conjunctidn with PSS electrical enGineer.

Provide detailed planning and scheduling to ensure freeze prgteciion system is not excessively damaged during normal Insulationlvalvelpiphg maintenance. Makes repairs as W e d .

Maintains all freeze protection systems Inspection repods and records.

Freeze protection inspection program is to provide routine and preventive maintenance guidance to asskt in improving :he reliability of,fhe heat-bung systems.

VIany freeze protection @ern problems mn be corrected by mper testing and inspection of each componentl whole

176

SECTDIV: MI 3.20

TITLE Freeze Protection Inspection Program

POWER SUPPLY MECHANICAL DATE: 4li12011 (Rev 2) INTEGRITY MANUAL

PAGE: 4of15

B. Condition Monitoring

VI. FREEZE PROTECTION SYSTEM INSPECTION AND TESTING

system prior to system startup, Addiffonally, proper marking of heat-traced piping and pmper maintenance planning can also prevent unnecessary repairs. Maintenance issues that are most oflen cited include: improper or Inadequate installation of heat trace cabling, sensors, confrolfers or Insulation; inadequate replacement of insulation and lagging after pipinghahe repair; falure of freeze protection system components.

Condition monitodng is the observation of system parameters to determine iquipnient condition and, potentially predict Failure. It includes data oolledon and descriptive statistics to tmck current prpcess variables and give Indications of end of life or failure conditions. VariabJes in a freeze protection system that can be monitored and trended to provide proactive indication of probtems :

heat fmclng cable resisbndconff nulLy heaftracing q b l e capacitance effective pipe ternpemture circuitlsysfern voltage circuitlsystern current ground fault trips alarms - temperature, current, voltage (fosdow} Controller cyclelime

Inspection and Tasfing

r\n Inspection program is an essential component of any maintenance strategy ,associated with elechical freeze ptection systems. l k can be used to establish a database for freeze profedion systems and as a means to identify the 3otentiaI or existing problems before the ZrouMe escalates to kiture. Inspection methods that are typ idy used in baiter Fan units are listed below:

1. Component Testing 2. Initlal Installatiqnlre-installation 3. Maintenance. Troubleshooting and Repair

1. Component Testlng

Many freeze protection system failures are caused by problems that could have been corrected by proper testing and inspection of e&h component and the whole system prior

177

SECTION: Mi 3.20


POWER SUF'PLY MECHANICAL DATE $111201 1 (Rev 2) INTEGRITY MAIJUAL

PAGE: 5 of 15

to system startup. These tests and inspections, MI& are ta & conducted before, during, and after installation, can bE dassified according to the stage atwhlch they are performed:

- Manufacturer Certification - Rewiving - Pre-Installation

Manufacturer artMcation. Afl required heat tracing cable and conhl component shop fesfs should be s@ed in the purchase order. Heater a b l e should undergo ac dielecfric tesfing at the manufacturer's recommended testvoltage. Each section or reel of heater cabie should be fested for Fesistance to ground and insulation resistance bemeen conductors. Parallel cabte should be tested for rnfitinuity of bus wires; series able, for continuity of resjstance wire. Conk01 cabinetslconbollers, with all equipment mounted and wired, should be testd for insulation resistance to the grounded frame and should undergo tests to verib set polnt response and component-system function. Resistaim, ambient tempernre, and relative humidity should be recorded. The continuity of eaqh conductor Jn the cabineflcontroller should be verified. Factory test results paperwork should be included with each component.

Receiving. When received, material type, rating, and quantity should be checked against the purchase order speciftcations, factory tesb and other documents. The physical condition of the material should be checked, and any damage to the packaglng that could affect the =ontents should be wrefully inswed. All heating cable mistance should be measured to verify that insulation ntqw has not been violated. Cable conductor mistan= should also be checked for confom-ity with specmed rating.

Pre-insfa!lation. Just prior to installation heater mble is nspected for physical damage to the outer covering, tested kr insulation resistance if sheathed or shielded, and tested for montinuity. Control cabinets are inspected for physical jamage after being permanently mounted or supported. Zompnent and panel rating, fayout, and function are $ecked against the manufacturer's test report. Molded-se :ircuit breakers associated with the el& heat b u n g 5-m should be checked for &'ng and tested for operabirity ~y turning the breaker on and off several times.

179 SECTION: Mf 3.20


POWER SUPPLY MECHANICAL DATE 411 1201 4 (Rev 2) INTEGRITI MANUAL

PAGE 6 of 15

2. Initial InstafIation/Re-InstaIIation

These tests and inspths, Mich are to be conducted before, during, and aff er installation (or maintenandrepair re- installation), can be classified according to the stage at which they are pehrmed:

- Pre-insulation - Predperational - System startup - OperationaI

Pejnsulafion. Ha b-acing cable and freeze protection momponenl installation should follow manufacturer recommendations with the heating cable installed on clean, smooth piping, .without air gaps bemen the cable and the piplng, wbles nof crossed or shorted out and mtrollers installed at proper lwtions, all not exceeding m - m u m zircuit lengths. installation around valves, piping spool aieces, flanges, etc. should have ample cable length for maintenance without damage to the freeze protection system. The excess cable' should be affixed to these m a s fo work properly. Certain iteWactivities should be miformed in the design stage and during installafion to nelp f-dcillhte maintenance and testing activities:

Muwple terhpeserature sensors should be permanently mounted on critical lines, with the leads available for test on terminal bIocks.

a Ali wires, circuits, panels, and components associated with a single system should be marked and identified to make it pcrsslble to visually follow an individual circuit.

1 The circuit power connection junction box and Sensor lead termination box should be visible and easily accessible for cover removal and testing.

* Terminal blwks should be used for both power leads and sensor wires to facilitate testing. MI heated lines should be clearly marked with warnings of hidden heater cable.

Once the heat tracing system is inspected for oDmplefeness and quaIi of installation, but prior to me installation of nsulation, it should be fested for proper opemiion. Because he controller is often located and installed separately icrm the rest of the heat tracing system, special wre should 3e taken fo ensure mper installation and operability of the

180 SECTlON: MI 3.20


POWER SUPPLY MECHANICAL DATE: MI120 t 1 (Rev 2) INTEGRITY MANUAL

PAGE: 7 off5

controller and of iw intemnmcthg conduit and win'ng. Circuit continuity should be tesfed from the terminal brocks in the control cabinet to verify that all heater wble is instatled and unit connections are complete. Series cable resistance shoukl be measured and recorded. With the heafer cable energized, the voltage and current of each dmit are measured and recorded, and circuit function should be checked by walking the line and feeling the Mire length of pfping for heating without emssively hot or cold spots. The temperature set p i n t is manipulated abve and Mlowthe ambient temperaturn to test the readon of related components such as SCRs, mechanical relays, solid- state controller lights, and thermostat contacts. Scheduling is pafiiculairy important at this phase of testing. In -on €0 the pre-lnsulation tests and inspections oullined here, a number of other tasks inctuding pIpa cleaning, k& repair, and hydra% and pressure testing must be completed pior to pipe iwiulation. To ensure suRiclent tlm for completion of alf testing, m-dul planning ofthe work schedule is required.

Pmopemfional. After pipe insulation and lagging installatton Is complete, proper installation should be verified, with special care ghen fo inspecting supports and hangers for signs of mechan'ml damage %that could adversety affect the heating system. Junction boxes and ;Conduits should be checked for t ighess of seals and covers and for cornpkte tagging and identification. Cable insulation resistance should be reverified guamntee-w litat its integrity has not k e n compromised during pIping insulation. Cable continu'@ and resistance should be decked, and mmparad to prior tests. Major discrepancies could indicate able damage. Ground connections should be checked for compliance with drawings and the manufacture& instructions. Control equipment should be calibrated by adjusUm high andlor low set points to the proper temperatures according to the operations charts. A final inspection should be made to ensure that all freeze profected fines have been marked 'Electrically T m d .

System StaHup. System opemtional tests should be conducted ta ensure compliance with design parameters and verify system readinessfor startup. With the system energized. the voltage and current of each dmit should be measured, mrded, and compared with previous readlngs. If discrepancies are observed, remedlal steps should be taken before testing is continued. Care must be taken to not exceed lhe maximum allowable ternperatm of the heater cable sheath or fiberglass-relnfod pipe. Monitor and alarm circuit operability should be verified by adjusting the set point on

P SECTION: MI 3.20


POWER SUPPLY MECHANICAL DATE 41112011 (Rev 2) INTEGRTTY MAMUAl

PAGE: 8 d m

solid-state contrdlers or by putling jumpers on #errnostat contads, Freeze protection system performance verification tests wn be cortclucbd with noMwving pbzr in the Nplng and with precautions necessary to ensure adequate pressure relief In case a rise in temperaatuie causes an increase In pressure during testing. Tracing perfomlance is verified if the pipe temperature increases even slightly durlng the tes!.

Operational. Once the system is placed in operation, periodic visual inspection should be done to verify that the components will function when needed. As the ambient temperatu~ approaches the fredng paint, extra attention should be focused on the fmeze protection system for proper operation.

3. Mainfenance. Troubleshootinn and Repair

A wtl-managed maintenance program keeps the electric heat tracing systems in satisfadory operating condition through regularly scheduled preventive maintenance inspections and tesfs, catibmtbn of corrtrots, and repair or repiacernent of damaged parts. Where there Is a high risk of mechanical damage, or in corrosive or other hostlle environments, morefrequent ins@lon may be necessary. Freeze protection systems should be thoroughly inspected and functionatly f e d every fall. All inspections and test results should be recorded OR the proper fums, compared wih baseline data, and filed accordingly.

Troubteshooting. Lack of insulation, wet insulation, OF other mechaniwl defidendes previously mentioned are the most obvious and common wuses of system malfunction. These should be checked first and repaired. If the problem is low bat, the voltage should be checked; [ow voltage will muse a reduction In cabb heal output. Symptoms include longer cycling or the controller being on continuously. If the voltage is low under normal operating mnditjons, the power transfomer taps may need to be changed. High voltage, which may occur during plant shutdown, will produce higher heat, wfiicb is evidenced by more rapid cycling. This, however, wilt not cause a problem unless the temperature exceeds the maximum allowed for the cable sheath.

Where systems are operated through controllers, the set points should be checked and controller operatlon verified. Auxiliary relays should also be checked.

The bus leads of parallel able may be tested like any other

182 SECTION: Ml3.20


POWER SUPPLY MECHANICAL DATE: 41112011 (Rev 2) INTEGRIlY MANUAL

PAGE 90f . lS

electrical cable. The problem is fo tocate !he open, or non- heat-producing, sections of both anstant-wattage and variable-wattage mble. Repairs. Where faults occur, it is necessary to determine the muse and then eliminate it fo prevent a recurrence. The damaged circuits may be repaired on site if all fhe following conditions are met:

The repaired unit will perform its designated function without undue change in the electrical loading.

0 The design and construction characteristics (for example, dielectric strength, water resistance, and watt density) of the product are maintained, The method of repair to the heater cable is recommended or approved by the manufacturer. No load hazard will be created in mrryhg out the repair.

Where breakdown results from corrosive acfion, repair is recommended only if the damage is Ilrnited to a small area. If the damage is at more than one point or the damaged area is extensive, the wble should be replaced. Whew the cause of the cornion cannot be removed, then the wble shoufd be rerouted or should be replaced by a cable wpabJe of withstanding the corrosive effects. If possible, the cause of overheating should be determlned. Repairs should be made only when it is reasonably certain that the damage is local, the remahder of the heater cirrxlif is unaffected, and the repaired cable will not be liable to further failure.

A system design fault will normally require replacement of the complete circuit. Where the above conditions cannot be met, replacement heater cable should be spedfied.

If the heater has not been previously electrically energized and if the breakdown in electrical insulation, severed conductors, or ingress of moisture is -used by mechanical damage, repaIr should normally be possibIe. If the fault is found only after the circuit is energized and the damage Is mnfined to a small area, visual inspection of t he heating unit for 3.3 ft {I m) on either slde of the fault should ensure that the electrid insulation is unaffected other than at the point of mechanical damage.

8 Faults due to incorrect Installation, such as air

SEC'RON: MI 3.20


POWER SLIPPLY MECHANICAL DATE: 41d12011 (Rev 2) INTEGRlTT MANUAL

PAGE: -IO of 15

space between cable and pipe, should be apparent and can- be repaired. Electrical -faults or control equipment failure will usually cause overheating at points other than at the ultimate point of failure, and the heater cable should be replaced.

Repalr Techniques Generally, the repair of electric heating cable will take the form of an inline splice or a service connection via a junction box. Techniques recommended by the manufacturer should be adopted, using specified materials and tools.

rn Removal of a damaged section of a heatihg conductor should not alter the total circuit resistance by more fhan 5%.

s Where heater cables are grounded by means of a metal braid, metal sheath. or foil screen, the integrity of the ground must not be impaired by the rep air. The repaired heater circuit should be subjected to a preoperational test as previously described.

Recommended areas to be inspected during visual and electricaVopemtiona1 examinations Include the following:

The entire exposed length of every pipe that is heat fwced I Temperature sensois (RTOlthennocouples)

Temperature rnonitordmntrallers whether centralized or locally installed

r Junction boxes, control cabhets and conduits for both power and control circults Grounding connections

Inspection Freuuencv

me final step in implementing an inspectron program IS to determine the interval for conducting visual inspection and testingldata gathering.

DaerAtins Eauiprnsnt

The subfreezing operating environment of freeze protection quipment is hardly the best to perform either pe~odic or zpair maintenance. Therefore, it is imperative that proper

183

SECTDN: MI 3.20


POWER SUPPLY MECHANICAL DATE MI12011 (Rev 2) INTEGRITY MANUAL

PAGE: of15

1X SAFElY CUNCERNS

A Confiined Space

B. Haadous (Classified) L O M ~ I O ~ S - NEG Article 500

C. EurnHazards

inspections be done on a timely basis to minimize both equipment and member exposure to the efernenfs.

ShiR Intervats

Visual inspections of equipment, heat traced areas

Mon fhlp iniemlslwinter)

Visual Imp-ections of equipment, heat traced areas Record system process variables - temperature, redstance, capacitance, voltage, current Lamptest

Annuaf lntewak

I Visual Inspections of equipment, heat traced areas i Record system process variables - femperature,

resistance, capacitance, voltage, current rn Lamptest I Verffiwtion of protective devices (eg. drcult breakers,

fuses) are properiy sired and matched to the loads Routine component inspections: instrumentation calibration: operating set pdint checkslsettlng; checking, each circuit resistance, capacitance, voltage, current;

(Refer to Appendix A: Inspection Frequency)

Freeze protection systems encompass distributed electrical squipment, therefore appropriate fag-out procedures should be followed before any inspection or maintenance is started.

%me heat traced piping can be inside of or run through mnflned spaces that may be filled with harmful gases. Confined space enfry procedures, including air checks, should be followed befoE entry.

In hazardous areas, the enclosures of any apparatus should not k opened until the circuit has been disconnected from its jotlrm of supply.

fllhile in operation, the process and water temperature may De hish enough to present a burn hazard. PiDinn operated at Aevsed temperatures may retain heat for a Ions period after



POWER SUPPLY MECHANlCAL DATE: 4112013 (Rev 2) INTEGRiTY MANUAL

PAGE 12 of 13

D. Electrical Hazards

E. Opttrational TesBng

F. PiphglHeating Cable lnstilation Hazard

G Scaffotdlng

X . APPENDICES INDEX

being shut-down.

t h e freeze protection system is electrically powered and fherefore presents the risk of electrical contact. Before work on any, electrical equipment is performed, the equipmen! should be de-energized (bth at the source and in the field] and be pmpriy tagged out.

Some testing and inspection, such as temperature readings and heaiing qable tesjing, require the freeze protection system to be running during the tests. Arc-flash potential and operating equipment near the inspection sites need to be recognized. Speclal precautions must be observed wttile performing these tests.

Respiratory health is the primary concern w)len personnel are involved in insulation installation and removal. Piping insulation and wiring sheathlinsulation materials that are unknown must be checked fot asbestos fibers prior to removal. Abrasive bfast cleaning operations may also be done prior fo fieat trace win'nghsulation installation. A correct and fully functioning air supply and hood are essential and must be used at a% times by personnel engaged in blasting operation; heavy duty gloves, a helmet or hood, .and upper body covering should be standard Items as well.

In order to perform any required repairs and inspections on the freeze protedon system, access by zdfolding andfor ladders may be required as well as adequate lighting. It Is important to properly secure all ladders, scaffolding and walk boards to elirnlnate potential accidents.

A. Fieeze Protection System Inspection Frequency.

8. Sample Freeze Protection Installation Record

C: Sample Freeze Protection Inspection and Testing Record

Operator Rounds (cold weather - Monthly

Task each shift) [Nov-Mar) Check Freeze Protection (FP) System is ell’ergired CheFIi Freeze Protedion jiotificatly sIgnage x X

k

POWER SUPPLY MECHANICAL INTEGRITY MANUAL

Annually (Sep ur Oct)

x

SECTtON: MI 3.20

TITLE Freeze Protection Inspection

DATE Lu.112019 {Rev 2) Program

PAGE: 13 Of 45

~- Inspect Freaze Prolected areas formectianIwl damage Inspect.Frseze Protectd areas for eomsIon damage

4 Inspec! FP Sfitem conduifiunclion boxes for damage,

Ameridix A

X X X X . X X .x x X

. . , * . Verify operahkin’r~g of $rotedive equipment (fuses, X

Check opemtlonlrs-calibrate senso&, contmllerS X Inspectkcord open cl@t FP cable continuity! resistanoelcapacitancc--- Inspect e!rcuil groundtng cqnnections X

circuit breakers)

X

weather .tightness 1 Cheek FP System for rernote,ala.ms Me’asurdrecord t’ernpcrature sensor-(RTD. Tic) values X X Measurehecord FP system operating voltage, current X x Measureirecord FP cable opewtlng resistance, X X

X X Perfomtlrecord repIacsments of FP panel lamp fest X X

POWER SUPPLY MECHANICAL lNTEGRIIY MANUAL

SECYIDN; MI 3.20


DATE 4lll2011 (Rev 2)

PAGE f4 of 15

Appendix E3

Freeze Protection Installation Record (Sample)

I InstaIIatian Record

POWER SUPPLY MECHANICAL INTEGRIIY MANUAL


TITLE: Freeze Protection Inspection

DATE: 4111201 1 (Rev 2)

PAGE: 15 of 15

Program

Apwndix C

Freeze Protection Inspection and Testing Record (Sample)

Inspecfion and Testing Records

189 SECTION: 3.21

TITLE: Cooling Tower Inspection and Testing Program

POWER SUPPLY DATE dl12011 (Rev 2) MECHANICAL INTEGRIW MANUAL

PAGE: I ofa

1. OVERVIEW

11. DEFINITIONS

COOLING TOWER INSPECTION AND TESTING PROGRAM

Cooling Towers are used at OG+E generating plants to transfer the thermal energy out of the condenser outlet water emuen€ by evapoorathre cooling. This program wit1 aver two fjlpes of mding towers. These two types are defined by tMair/mter flow path direction. The types this program addresses.are cross flow and counterffow tuwers.

The towers cbnsist of five main secfions. These sections are distribution, heat transfer, drift removal cotledion and air discharge.

Pistribution Svstem: This system consist of the piping, valves, elevated basins and nodes that direct the condenser clrculating outlet wafer Into the heat transfer section.

Heat Tiansfer Svstem: This 5ystem consbts of horizbnfal layers of splash bars known as fill. The fill is made of wood or plastic that breaks up the water droplds to release the heat as the alr flows over this section. Thls heat is removed by evaporative cooling when the water and ak have direct contact.

Drift Removal System: This system consist of drift ellminatoors of either cellular film or baffle style. The entrained water is removed from the air stream after exiting the fill area by forcing the air to take sudden changes in the flow direction. These changes in diredon cause the separation of entrained water due to centrifugal force. The water adheres to the eliminator suiface and enters the cotlectlon system, while the tighter air passes through to the fan stacks,

Collecfion Svstem: This system collects the water after the fieat transfer takes place, and provides suction for the circulating water pumps b direct the flow back through the condenser as a closed

SECTION: 3.21

TITLE Cooling Tower Inspection and Testing Program

POWER SUPPLY DATE: M1201f (Rev 2) MECHANICAL INTEGRlTY MANUAL

PAGE: 2of8

HI. RESPONSl8ILITiES

A. Power Supply Sem'ces

B. Want

system.

b Air Oischame Svstem: This system consists of propeller fans, gearboxes, fan stacks and wood structures that allow the air €0 exits the tower after passingthrough the drift eliminators. The fans are used lo provide the mothe force for the movement ofthe a$ tbrough the tower.

Overall coordhator of the Cooling Tower Inspection and T&iing Program for Power Supply.

Coordinate annual Coating Tower performance test and provide the plantsthe results of these tests.

Schedules annuat offline Cooling Tower Inspections in a reasonable timeline to have any Cooling Tower deficfeencies repaired before they adversely effects unit output.

Ensures Cooling Tower Inspection deflciencies have been-complefed in accordance with Inspection Consultants both internal and external recommendations. Provide work scopes to h e plants based on the results of inspection if needed.

Mahtains all Cooling Tower Inspection and Testing reports and records.

Provides OG+E Inspectors to ensure compliance with work scope.

The Process Englneer will roub'nely monitor fhe m l n g tower performance and investigate tower degradation mile the units are an-he.

Conduct daily checks of the Cooling Towers whIle the unit is online.

SECTION: 3.21

TITLE: CoolIng Tower Inspection and Testing Program

POWER SUPPLY DATE U11201 I (Rev 2) MECHANICAL INTEGRtM MANUAL

PAGE 3 of8

C. Supply Chain

I). Contractors

IV, CRITICAL EQUIPMENT

Create requisitrons with atfached Cooling Tower Inspection work scopes pteviousty supply by PSS.

Ensure all PMOS related to the Cooling Tower are completed per specified schedule described in SAP.

Provide safe access to the Cooling Tower for conducting inspections on the Cooling Towers by both internal and external consultants.

Provide assistance during the inspection which includes but not limited to removal of access doors, providing ladders, or performing minor repalm based cn the inspection,

Scheduled and plan Confractor activities so that fhey are coordinated with other unit work activities sr;heduled during the oubge.

Budget required amounts based on the ten year projected expenditure schedule in Appendix A of this report.

Coordinate the bId review process with Power Supply Services and Plants.

Provide a detailed inspection report Including digital pictures which prioritize repairs needed. This would include immediate, within the next scheduled outage period, and projected useful life left

Provide a CTI certified performance test report.

- Fill m Drift ejiminators

Fans and gearlmxes - Distribution valves and piping I Screens

SECTION: 3.21

TITLE: Cooling Tower Inspection and Testing Program

POWER SUPPLY DATE: 4111201 1 (Rev 2) MECHANICAL INTEGRITY MANUAL

PAGE.: 4 O f 8

V. PROCEDURE

A. Inspection Program

B. Testing Program

The purpose of this procedure is €a outline the implementafhn and maintenance of OG+E Cooling Towers in a prudent manner. The procedures will include four main areas. These areas are listed below:

8 InspecZion and Testing Program Moniforing Progmrn Repalr Control Program Documentation

An offline Cooling Tower inspection shall be performed annually by a qualified cantractor or infernal SME. Nofe: IJn-kthat do not have an outage during the year, will be inspected by isolating the Individual cell or during maintenance outages. Thls Inspection will include both an external and internal assessment of the Cooling Towers. lfems io be inspected externally are as listed below:

Stairways, ladders and fan deck handrails Casing

e Alr entrance louvers 9 Fan deck and stacks

Rofaffng equipment Electrid conduit

Items to be inspected internaliy are listed below:

0 Dlstrlbution system Fit media DrR eliminators

0 Partiiionmlt Air seals Structure

A Cooling Tower performance .3st will be conducted annually by a CTl certified testing company. Results of these tests will be provided to OG+E. These tests will show how the tower Is performing and if there are any deficiencies In the performance of the tower. A list of performance results from these test are listed belw.

193 SECTION: 3.21

TITLE: CcoAng Tower Inspection and Testfng Program .

POWER SUPPLY DATE: 4/112011 (Rev 2) MECHANICAL lNTEGRIlY MANUAL

PAGE 5af8

D. Repair Control Program

Cooling Tower Circulating Water Flow Cooling Tower Approach

0 Goofing Tower Range 0 Predicted Cold Water Out Temperalure

Cooling Tower Capacjty Fan Horsepower

Daily, any time the unit is online, the towers will be monitor for proper operation. This inspection checklist should included in SAP as a PMO. ltems to be :heck are listed below

Check levels in all the hot water basins to ensure none of them are overflowing and are bdance within % Inch of each other. Typically overflow cells ts an Indication of node plugage.

Ensures all cooling fans are In serrlce or a reason for the fan to be out of servlce. During certain times of the season the fans wiWbe in de-toe mode.

Verify no oil is leaking out of the rotating equipment that can cause a SPPC concern. Verify the ail levels on the rotating equipment gearboxes.

Perform a cursory inspection around the Cooling Tower to check for damaged tome louvers, casings, staimys, air seak and Cooling Tower level.

Vet@ that €he Cooling Tower screens pressure dmp is not high causing reduction of flow to the condenser.

The plant control operator will monitor the online performance of the tower if an online performance monitoring system is available such as GP Eta-Pro systems.

These rmairs wilt be based on the annual inspections and when warranted scope of works

SECTION: 3.21

TITLE: Coofing Tower Inspection and Testing Program

POWER SUPPLY DATE: 41112013 (Rev 2) IWECH~ICAL INfEGRlTI MANUAL

PAGE: 6of8

E. Documentation

VI. PRWENTIVE MAINTENANCE

will be produced.

R@airs wilt be planned and scheduled to fh 'within'the scheduled unit outage. Only emBrgency repairs that have muse unit output reduction will be done while the unit is online.

AI! repah will have an order developed within the SAP system for tracking purposes.

AI1 Cooling Tower inspedlonsand performance tests will be archive in the company's 1x0s system.

&I inspections and tests wiil hare an order developed for tracking time and cost in the company's enterprise SAP system.

In order to maintah the Cooling Tower in optimum q w a b n . .in addition to the annua! .inspections and :est,ing, some preventive maintenance (PMs) shall be setformed while the equipment is in senrice. A list of .hese PMs and PM orders from our SA? enterprise system are. below:

PM043 and PM037: Calibmtbn of Cooling Tower level switches and blowdown flow done by maintenance annually.

PM023: Grease and verify operation of distribution valves done by operation quarterly. - PM046 Verify condition and operation of Cooling Tower hoist done by maintenance semi- annually.

I PM031: Verify oil levels and leaks in Cooling Tower fan gearboxes done by operation monthly. Note: this requires shutting down the fan to ver i i the correct level in the gear boxes.

195

SECTION: 3.21

TITLE: Cooling Tower Inspection and Testlng Program

POWER SUPPLY DATE 4!112011 (Rev 2) MECHANICAL INTEGRIM MANUAL

PAGE: 7 ofa

Vlt. TFWNING

Vtll. SAFElY

Canduct vibration checks on the Cooling Tower fan gearboxes done by reliability technician monthly.

Conduct the quarterly cooling tower fan and gearbox check per appendix D In this report

0 ,Conduct checks on the PH meter for the Cooling Tower daily by the chemist.

4 Asthis p g m m matures the annual inspection may be performed internally. In order for this to occur, QG+E plant and PSS personnel will be lnvotved in the annual Inspections done by contractors.

I Informal training on performance elements of the Cooling Tower shall be done for plant operations by the Plant Process Engineer in PSS.

I Safety should be the main focus when inspecting, testing or performing daily checks around the Cooling Tower.

0 Some of the areas to watch out for are slipping, falfing, drowning and rotating equipment hazards &ire aroundthe Cooling Towers.

196 SECTION: 3.21

TITLE:

POWER SUPPLY DATE: MECHANICAL INTEGRITY MANUAL

PAGE:

Cooling Tower Inspection and Testing Program 41112011 (Rev 2)

8 of8

Appendix b Quarterly C O d h Q To-r Cheeks

Cooling Tower Maintbnance Program

Coogtng f o w r Fan Ailgnmnt I Runout Readlngs

Unit Pin:

Allgnment I Runout readings: Fan Blade PItch:

As A5 As A0

Found LIR Pound

A Wads 'I

E mlacia 2

C Blade S

D Blade 4

E Wade 5

F BIadr 6

cs BhdU 7

H Blade a 1

t - Some ro~dlngawrro m m a s u r o d TOP t o Bottom l rn-psumd Sad* to Stdr -

CO-fIng Tower In5peatlon C h m o k l l e

1. 2. Cracks In hub mssembty 3. Hubendplay 4. Bl-3Rg 5. Record blade pitch 6. elade clamp botb s e e m 7. 8.

record weIQht% locations ) 9. Coupllng alignment 10. Dlaance balwen motor and drl- shalt coupltng ( when uncoupted )

abuldn't ha- to pull motor shalt to drlw shi t m % n ewpllng. 11. 1ns-t eoupllng y o k u s and rubber busihlnga

I n s m t ImadIng &go of blade4 ( look fer e=ks In blades )

0 - b ~ hold down b t t m secure I mouirt ptata Shm runout ( 4 1 1 1 haws to rem- balance wdghfa Wm-n couplln~ to check runaut

197

I ~ FIRE PROTECTION INSPECTION PROGRAM

Fire protection systems are designed to protect members as well as Company assets. These include automatic and manual systems as well as emergency action plans. This procedure outlines the minimum requlremenfs Power Supply will take to insure the safety of its members and the protection of the Cornpanfs assets.

SECTION: MI 3.22

TITLE: Fire Protection Inspection Program

POWER SUPPLY DATE: 41112011 (Rev 2) MECHAMtCAL INTEGRITY MANUAL

PAGE: I of6

I. OVERVIEW

In CornpJiance w&: 29 CFR, Part 1910, Subpart t (OSHA Fire Protection)

a NFPA'850 (Recommended Practice for Fire Profedon for Elecb-ic Generafing Planf and H9h Vdtage DImcf Cured Converter Stations) NFPA 72 (National Fire Akrm Code) NFPA 25 (Inspectibn, Testing and Maintenance of Wafer-Based Fire Protection Equipment) NFPA 10 (Standard for Portable FIE €xthgujshers) NFPA 12 (Standard for COS Exfnguishing Systems) NFPA 12A (Standard for Halon f301 fire &tingukhing Sysfems) NFPA 13 (Standard for Installation of Spn'nkler System) NFPA 24 (Standard for the Installation of Private Fire Sewice Mains and Thdr Apputienan ces) NFPA 72 (National Fire Ahrm and Signaling Code) NFFA I01 (Ue Safety Code) NFPA 7 05 (Standard for the inskihtiun of Smoke Door Assernbibs and Ofher Opening Pmt&oE.) NFPA 214 (Standard on Water-cooling Towers) NFPA 2001 (Standard on Clean Agent Fire


TITLE Fire Protecfion Inspection Program

POWER SUPPLY DATE #I 1201 I (Rev 2) MECHANICAL INTEGFCITY MANUAL

PAGE: 2of6

It. RESPONSIBIUTIES

A. Power Supp!y Services

B. Plant

C. Supply Chain

.-

Extinguishing Systems)

rn

rn

a

0

8

Preparation, revision, and review of any rne&anical design changes to any fire protection system.

Develop and provide detalled work scopes to the plank as necessary,

Asgist h e plant as necessary to resolve any mechanicat issues.

Reviews and approves inspection reports, provide recommendations to the plants as necessary.

Mainfain all fire protection inspection reports and repairs at a central sewer database.

Verify contracted fire protection inspection services group are in compliance with current OSHA and NFPA requirements.

Ensures all inspections and repairs are being performed as necessary.

Ensures that all inspection and maintenance actiqities performed by OG&E personnel or contractors are documented and maintained in plant records and SAP.

Ensure all inspections and repairs are performed in accordance with applicable codes, industry standards, OGE standards, and design specifimtions.

Provide assistance in negotiating and

199 SECTION Mt 3.22

TfTLE: Fire Profection Inspection Program

POWER SUPPLY DATE: 41112011 (Rev 2) MECHANICAL INTEGRiITI MANUAL

FAGE- 3 of6

JII. CRITICAL EQUIPMENT

lV* INSPECTION INTERVAL FREQUENCY

1 V. INSPECTION DESCRIPTlOM

retaining fire protection inspection services contract.

Advise of any contract changes and costs,

a Review each year the performance of inspection services group at each plant site

NFPA 850, Chapters 7, 8 and 10 idenlify potential hazards listed for the systems below:

e

*

9

Fuel Handling - Gas Fuel Handling - Oil Fuel Handling - Coal Steam Generators Flue Gas Turbine - Generator Electn’cal Equipment Auxiliary Equipment Combustion Turbines Wind Turbines

The inspection of each site shall be performed at a minimum every year. Other inspections may be -equired to evaluate immediate problems and take corrective actions as necessary.

4nnual fnsmction and Testina - In Accordance Nith NFPA 25, Inspection, Tesfjm and Maintenance of W a € er-Based Fire Pro fe c fion Eauipmen f

0 Annual review of emergency action plans. Annual review of member training records. Annual performance testing of each fire pump.

e Annual hydrant flow testing. 0 Annual functional testing of smoke and heal

detectors. Annual inspection of strainers.


TITLE: Fire Protection Inspection Program

POWER SUPPLY DATE 41112O-l I (Rev 2) MECHANICAL INTEGRlrY MANUAL

PAGE 4of6

VI. REPAIR PROGRAM

VI I D 0 CUM E N TAT1 ON

Wl. APPENDICES INDEX

Annual inspection of sprinkler systems. a Annual tn’pping of deluge valves {flow test

on transformers every major outage). Weekly inspection of the suppression system control valves in ihe buildings.

All maintenance repairs shall be performed in accordance with applicable codes, industry standards; OG+E standards, and deslgn specifica€ions.

Should a deficiency be found during the inspection and cannot be repaired at that time, a notifimtion shall be written so that the repair can be performed st a later date.

411 reported deficiencies must 1) have an SAP notification written and resolved, or 2) if determined not necessary, PSS must document the exemption From the NFPA Codes and be approved by the Managing Director of Power Supply Services.

411 inspection reports will be stored electronidly in 3 central database on the Corporate network.

A. Frequency and Detail of Inspection.


TlTLEr Ffre Profectian Inspection Program

POWER SUPPLY DATE 411 1201 7 (Rev 2) MECHANICAL JNTEGRI7Y MANUAL

PAGE: S O f 6

Appendix A

Frequency & Detail of Inspection

Cas EN / Task Plant Plant WD

Coal

4


TITLE: Piping Inspection Program

POWER SUPPLY DATE: 41412011 (Rev 2) MECHANICAL INTEGRIN MANUAL

PAGE: 1 O f 5

1. UVERVIW

. RESPONSIBILITIES

A. Power Supply Sewices

PIPING INSPECTION PROGRAM

Piping equipment Included in this program shall be referred ta as Ynon critic$ power plant plpfng systems and excludes boiler prowr. bolter external pipins, hot reheat, and cola reheat pipiinq. General or auxiliary power plant piping sewick appIications include steam, water, gas, air, oil, and chemical. {Refer fo ASME B31.1, Chapter I, para. 100.1.3 for piping exclusions.) Ameriwn Water Works Association provides for the desjgn and construction of the power plant circulating water pfping.

Piping design, fabrication, and maintenance shall meet or exceed'the requirements of ASME 831.1 ur dher ASME B31 Code Sections as deemed most appliable forthe particular piping senrice.

ASME E31 .I includes the following piping factors: Materials and selection (Including nonmefalllc)

0 Component dimensions 0 Temperaturepressure ratings

Pipe supports 0 Stress limitations due to pressure and

0 Fabrication and assembly rn Exainination, Inspection, and testing e Operatidn and maintenance

temperature

Piping inspection and maintenance shall follow ASME 831 .I, Nonmandaiory Appendix V, "Recommended Practice for Operation, Maintenance, and Modificatbn of Power Piping Systems', guidelines as they apply to plant 'auxiliary" piping.

Develop and provide work scopes for inspectfon and repair of piphg systems as needed

0 Provide OG+E Inspectors to ensure compliance with scopes of work

204 SECTlON: MI 323 TITLE: Piping Inspection Program

POWER SUPPLY DATE: 411!2014 (Rev 2) MECHANICAL INTEGRIN MANUAL

PAGE 2 O f 5

8. Power Plant

C. Supply Chain

111. PROCEDURES

Create requlsjtions and Inctude pipe inspection work scopes.

Maintain all pipe inspection reporfs and records.

Provide delailed planning and scheduring as per Outage Readiness Index (ORI) to ensure Contradots repab adiyities are coordinated with other unit work ach-fies scheduled during the outage.

Coordinate and provide assishnRJo ensure all knowh pjpe deficiencies are addressed.

Verify that DOL ‘Downstream Welded Steam lines” report is completed for weld repairs performed on steam pipe 15 psig service pressure.

Coordinate the bid review process with Power Supply Services and Plants.

Notify Power Supply Services of all exceptions faken to the scope of work technicaf requirements and asstst to resolve.

The purpose of a pipe inspection procedure, is to implement a process to ensure pipe systems are maintained in good condition for reliable and safe service as proposed by ASME Appendix V, local jurisdtcllon, and industry standards as part of the ovemll comprehensive Mechanical integrity Program.

1. psS ,wjtf assist with documentation required to complete an inspection of a selected piping system.

2. vvilf monifor and document all piping systems for damage, leaks, and general condition and schedule inspectionslrepairs as needed.

3. psS will provide technical support and detaifed work swpe as required for general Inspection and repalrs and wrnrnunicate the intent of work scope to Supply Chah for services needed,

117 - · pdf file117 section: mi 3.10 ... title boiler feed pump inspection program power...

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