Work Package Template

Effective December 6, 2006, this report has been made publicly available in accordance with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export Administration Regulations. As a result of this publication, this report is subject to only copyright protection and does not require any license agreement from EPRI. This notice supersedes the export control restrictions and any proprietary licensed material notices embedded in the document prior to publication. Work Package Templates 1012288 Work Package Templates 1012288 Technical Update, February 2007 EPRI Project Manager L. Rogers ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 • USA 800.313.3774 • 650.855.2121 • [email protected] • www.epri.com DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). 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ORGANIZATION(S) THAT PREPARED THIS DOCUMENT Electric Power Research Institute (EPRI) This is an EPRI Technical Update report. A Technical Update report is intended as an informal report of continuing research, a meeting, or a topical study. It is not a final EPRI technical report. NOTE For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or e-mail [email protected]. Electric Power Research Institute, EPRI, and TOGETHER SHAPING THE FUTURE OF ELECTRICITY are registered service marks of the Electric Power Research Institute, Inc. Copyright © 2007 Electric Power Research Institute, Inc. All rights reserved. NC 28262 Principal Investigator J. Palo Alto.CITATIONS This document was prepared by Electric Power Research Institute (EPRI) Nuclear Maintenance Applications Center (NMAC) 1300 W. EPRI. CA: 2007. West This document describes research sponsored by the Electric Power Research Institute (EPRI). 1012288.T. Harris Boulevard Charlotte. This publication is a corporate document that should be cited in the literature in the following manner: Work Package Templates. iii . . REPORT SUMMARY This Work Package Templates Guide provides fossil plant maintenance personnel with assorted inspection. “Maintenance Work Package Planning Guidance for Fossil Power Plant Personnel” The appendices contain work package templates for a variety of different plant equipment. E. Limitorque SB actuator. Approach An introduction to work packages provides insight into the work package process.g. minor repair and overhaul. minor repair or overhaul templates for various pieces of plant equipment. The format is consistent with the provided in EPRI Technical Report 1014547. testing. vendor information and other site-specific information relevant to the work activity. benefits that can be realized from the use of work packages and guidance on how to use the work package templates. This guide will assist plant maintenance personnel in improving the efficiency. These templates will be provided for common maintenance activities by component and in a standardized format. reliability and reducing the maintenance costs for associated with maintenance on selected pieces of equipment. inspection.g. In many cases. Various types of maintenance activities are embedded in the templates. The generic work package templates may then be used with site-specific information to develop site-specific work packages referencing site-specific procedures. “Maintenance Work Package Planning Guidance for Fossil Power Plant Personnel” Currently there is no means to share lessons learned from maintenance activities among fossil utilities and to benefit from the efficiencies learned from using enhanced/optimized work packages. (E. The templates can be found useful to any maintenance organization regardless of the current level of work package development and planning. There are some templates that are directed at specific equipment due to their widespread use. Low voltage breakers and steam traps) In some cases a particular design may be featured. (E. work packages are repeatedly prepared for equipment that is common among most fossil power plants. Gould 3196 pump) Some templates cover a wide range of equipment vendors and types. A proposed format for developing work packages is provided. Objectives The objective of this report is to provide a series of work package templates for common pieces of equipment found in most fossil plants. roll wheel pulverizer) v . Background In parallel with this Technical Update EPRI developed the following document that formed the basis for the template format utilized within this report: • Technical Report 1014547. A compilation of work package templates that provides information for the development of specific work orders will improve the efficiency and technical adequacy or work packages. Most templates are generic with respect to the piece of equipment.g. The focus of the report is to provide a work package template format and example templates from which site specific work packages may be developed. tools and equipment. pre-job briefs. detailed work instruction/sequence. It provides information for inspections. identification or parts. minor repairs or overhauls of equipment.Results This technical report provides an overview of work package development. Considerations are given to task overview. feedback mechanisms and proposed references. contingencies. a work package template format and work package templates for various pieces of equipment common to most fossil power plants. The report provides templates for numerous pieces of equipment that are found in most fossil power plants using a standardized format. Keywords Work Control Work Planning Work Package Work Order Templates Work Instruction vi . The development of site-specific work package templates that can be utilized repeatedly for maintenance activities can increase the overall effectiveness and efficiency of the maintenance organization and reduce overall maintenance costs. .ACKNOWLEDGEMENTS EPRI wishes to acknowledge the members of the Task Advisory Group: Charlie Cassise Clarence Nail Charlie Leveridge David Brawner Bill Hilton Ken McDonald Steve Blair Regan Hallford George Lum Joe Tyner David Egner Howard Ray Garry Waggoner Detroit Edison Dynegy East Kentucky Power Cooperative Entergy Hoosier Energy Rural Electric Coop... Inc Hoosier Energy Rural Electric Coop. Inc Hoosier Energy Rural Electric Coop. Inc PNM Southern Company Southern Company TVA TVA TXU vii . . ...................................................................................................................................................................................................................... Identifies general and specific hazards..................................................................................1 Task Overview .............................................................................4 Detailed Work Instructions ..................3-1 3........................................................................2-4 2.....1 Component type................3-11 4 REFERENCES ........................................4....................................................................................................................2 Background .......................................................1 Introduction ...............2 Benefits of Work Package Templates ......................................................................1-1 1...................1-8 2 WORK PACKAGE TEMPLATES ........................................0 Task Overview ....................................... A-2 ix .....................................................................3 Report Structure and Overview...............................................4 Develop list of know consumable materials to be used................2-3 2........................................................................... A-1 1..........................................................................2 Equipment tag or unique equipment identifier................................................4 Identify permits required...................................................................................................................................3 Work Package Templates ..........................................CONTENTS 1 INTRODUCTION ........2-5 3 WORK PACKAGE TEMPLATE FORMAT ...............................................................................................................................................3-4 3....................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ............................... A-1 1...............................................................1 Purpose and Scope................................................................5 Develop a list of know parts to be replaced .....................................3-1 3...................................................................................3-2 3.......................................5 Planning Walkdowns...2-1 2..........2-4 2..................................................................................................4...........................................................................................................................................................................................................................................3 Scope ................. A-1 1...............................................2 Acronyms .7 References..2 Pre-Job Considerations....................................................................... A-1 1......................................................................................3 Contingency Considerations ................3-8 3...............6 Special tools.............................................................................. A-2 2.........................1-7 1.......4 Glossary of Terms and Acronyms..................................................................................... A-2 2...................3-9 3..1-1 1......................1 Evaluate potential for generation or equipment risk hazards .......1-1 1.......................................1-1 1......................... A-1 1................................3-6 3.................. A-2 2..................3 Job Safety Analysis.......................................... A-1 2................5 Post Maintenance Testing..........................1-2 1...............................4-1 A WORK PACKAGE TEMPLATE – BELT DRIVEN EQUIPMENT ...............6 Feedback Mechanisms ................5 Key Points ....................... A-2 2.......1-2 1..............2-1 2.................................................................. A-1 1.............0 Pre-job Brief ....... A-1 1.........................4 How to Use the Templates............................1 Industry Definitions and Nomenclature ........................................... ..................................................................................... A-8 4...................... A-3 3.... A-9 B WORK PACKAGE TEMPLATE .................................... B-2 2....3.....................................................0 Pre-job Brief .............3 Scope ............................................................................................. B-4 x .....................................................1 Identify potential scope expansion and actions due to scope expansion..................0 References.................................................7 Identify Clearance/Tag out Boundary............................................................................ B-1 1...5 Identify Environmental Consideration .......................... A-7 4.................................................................................................................2 Inspections ...................4 Develop list of know consumable materials to be used........0 Contingency Considerations ....................1 Disassembly.......................................................................2 Equipment tag or unique equipment identifier....... B-3 2...................................................... Identifies general and specific hazards............................. A-3 3....................................................................5 Identify Environmental Consideration ........1 Shaft deflection method.............................................................0 Detailed Work Instructions ............. B-1 1....................0 Contingency Considerations .............................4 Reassembly.. B-2 2................................................................... B-3 2..........3 Job Safety Analysis.................6 Identify Operating Experience........................................3.....................................4 Identify permits required......................................2...........................................................................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ......... A-3 3....... B-1 1.... B-3 2...............................................................1 Evaluate potential for generation or equipment risk hazards ....................... B-1 1................ B-3 2........................3...........................................1 Sheave alignment......................................3.......................................... A-3 2............... A-3 2.................................... B-3 3....................................7 Identify Clearance/Tag out Boundary..3 Alignments ....................1 Identify potential scope expansion and actions due to scope expansion..................... A-8 4............................0 Determine PMT and PMT considerations ................1 Component type......................... A-9 7.......... A-7 4........ A-5 4.......................................................................................................0 Task Overview .3..............................................................2 Shaft/Bearing Alignment (required only if shaft or bearing is replaced .......................................................................................2 Identify individuals to contact in case certain events occur... B-1 1.................................... A-4 4............... A-3 3. B-1 1..................5 Develop a list of know parts to be replaced ...................0 Feedback Mechanisms .....................................3. A-4 4................................ A-3 3............................................................................6 Special tools.................................................................................................................6 Identify Operating Experience. B-4 3.......................................................................................... B-2 1.............................. A-7 4...............................4 Develop material list for potential contingency and consumable parts..2 Identify individuals to contact in case certain events occur... B-3 2.............BOILER FEED WATER PUMP....................................................... B-4 3..................... A-9 6..................................................................................................... B-2 2...............................3 Adjusting belt tension .........3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ................. A-4 4.......... A-8 5.............. ..............................................................5 Identify Environmental Considerations........................1 Identify potential scope expansion and actions due to scope expansion.......2 Cleaning: .................... B-6 4..................................2 Reassembly............... C-1 1...................................................................................................... C-7 4...............................1 Cleaning.... C-1 1.................... C-5 3...........1 Evaluate potential for generation or equipment risk hazards ......................................... Inspection............................................3 Job Safety Analysis............................ C-5 4..................................................0 Pre-job Brief .......................................................................................................... B-8 4.0 Feedback Mechanisms .....................0 References..... Identifies general and specific hazards. B-5 4.............................................. B-5 4............... B-12 C WORK PACKAGE TEMPLATE – HEAT EXCHANGER ............................. C-2 2...........................................1................. C-3 2.....4 Develop material list for potential contingency and consumable parts............. C-3 2............. C-7 4...................0 Contingency Considerations ..................................................................... C-1 1..............................3 Heat Exchanger Testing:..................................... C-2 2................................................................................................................................................................... Lubrication ... C-5 4......0 Detailed Work Instructions .................................................................................................................. C-3 2...2 Identify Foreign Material Exclusion (FME) potential and mitigation ............................ C-4 3........................................................... C-1 1.. B-5 3..........................5 Develop a list of know parts to be replaced ....................................................................3.............................. B-11 6................3 Disassembly..0 Detailed Work Instructions ............................................7 Identify Clearance/Tagout Boundary..... C-4 2..........................3...................1.............................................................4 Develop list of know consumable materials to be used................ C-1 1......................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions . C-7 4.......1 Leak Testing using System Pressure ...........................................................3.............................3 Scope ........................ C-1 1.....................................3...................................1 Component type......................................3....................1 Disassembly:.................................... B-5 4................................................2 Identify individuals to contact in case certain events occur..................................2 Removal of Subsystems ...........................3....................................... C-4 3.............................................................................................................. C-8 xi .... B-6 4.................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions .................................................................................................................... C-5 4............................ C-4 3....................................... B-9 5......4 Identify permits required......................................... C-2 2........................... C-4 2............................2 Leak Testing using Hydro Pump ...................................1 Preparations............................ B-12 7...........................................2 Equipment tag or unique equipment identifier........................................................................1 Leak Testing.................................................................................6 Special tools..............6 Identify Operating Experience............... C-4 3...4 Develop material list for potential contingency and consumable parts............................................................... C-2 1................................... C-7 4.......................................0 Task Overview .......................................................................0 Determine PMT and PMT considerations ..... ................7 Inspections....................................................... D-17 4....1 Identify potential scope expansion and actions due to scope expansion................ D-19 5............. C-10 5............................................................4 Identify permits required........................................ C-8 4......0 Determine PMT and PMT considerations ..... D-1 1....6 Disassembly................................ D-3 2........................... D-5 3.........4.............5 Electrical Tests..................................10Final Breaker Assembly ............. D-5 4............................................................................................................................. D-3 2................................5 Develop a list of know parts to be replaced .......0 Feedback Mechanisms ......................................................................................................................................................................................... D-10 4....................................... C-11 7......... Cleaning and lubrication.0 Pre-job Brief .................................................2 Equipment tag or unique equipment identifier......... D-5 3.............................. D-3 2...............7 Identify Clearance/Tagout Boundary............ D-19 xii .................................................4 Leak Repairs .................................................................... D-4 2...2 Mechanical/Electrical Operation............................................................ C-9 4..........6 Identify Operating Experience...............................................................................4....................................................................................................................................................4 Develop list of know consumable materials to be used........................................ D-7 4................. D-2 1..................................................................................... D-5 3......8 Reassembly ............................................................1 Initial Testing and Inspections..........4...........................0 Determine PMT and PMT considerations ...................2 Identify Foreign Material Exclusion (FME) potential and mitigation ........................ D-4 2........................2 Identify individuals to contact in case certain events occur..... D-5 4...................................................................... D-2 1................................ D-9 4................................................................0 References........................ Adjustments and Tests ........3 Scope ...................................................................1 Component type........ D-5 3.............0 Detailed Work Instructions ......................................................................................... D-3 2.......5 Identify Environmental Consideration ..................................... D-9 4...............................................4 Operating Mechanism Inspection........................0 Task Overview ........................................................ D-6 4..................................................... D-11 4..............1 Evaluate potential for generation or equipment risk hazards .... D-5 3...........................4 Develop material list for potential contingency and consumable parts....... D-2 2................................................3 Contact Inspections and Adjustment.........5 Reassemble Heat Exchanger ....1 Tube to Tube-Sheet Leaks.............................. Identifies general and specific hazards........ C-8 4.................. D-1 1........................................................................................................................................2 Tube leaks.................................................... Tests....................................................... D-4 2....................... D-15 4..............9 Post overhaul Inspections........ C-11 D WORK PACKAGE TEMPLATE – LOW VOLTAGE BREAKER OVERHAUL ...................3 Job Safety Analysis................ D-1 1..........3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ...............6 Special tools.... D-1 1..................................0 Contingency Considerations ......................................... C-10 6............................... D-8 4....................................................................................................................................................... D-1 1........................................................................... ..................................................2 Load Center Switchgear Cleaning and Inspection: .........................................................0 Pre-job Brief ...........0 Pre-job Brief ................................................................................................................................................................................ E-2 2............................................................ E-11 7...1 Evaluate potential for generation or equipment risk hazards ......................................................................6................................................................................4 Develop list of know consumable materials to be used...................................... E-3 3...F-1 1...........F-2 xiii ......6 Identify Operating Experience. E-3 2.................................................................................0 Task Overview ...................................................................0 Detailed Work Instructions .................................................. E-1 1.... E-1 2.......................F-2 2. E-1 1.......3 Scope ... E-4 4.............................. E-11 F WORK PACKAGE TEMPLATE – LIMITORQUE SMB ACTUATORS .....................................F-1 1........................ Identifies general and specific hazards.2 Identify Foreign Material Exclusion (FME) potential and mitigation .......6 Special tools..............................................................................................0 References......................... E-1 1.............................................................................................4 Develop material list for potential contingency and consumable parts.. E-8 5...........................................................0 Feedback Mechanisms ..........1 Load Center Breaker Clean and Inspect....................................................1 Identify potential scope expansion and actions due to scope expansion...................... E-3 2........ E-2 2.............................................6 Special tools...................2 Equipment tag or unique equipment identifier.......... D-20 E WORK PACKAGE TEMPLATE – MOTOR CONTROL CENTER/LOAD CONTROL CENTER (MCC/LCC) INSPECTION AND CLEANING ...0 Contingency Considerations .............................................................................................................. E-3 2.................................... E-2 2..........................................................................................................F-2 1..............................................................................3 Scope ..................... E-4 3......... E-4 3...1 Component type.......................................... E-5 4........................F-1 1...............2 Identify individuals to contact in case certain events occur...............7 Identify Clearance/Tagout Boundary........................................... E-1 1...............0 Task Overview ................................ E-1 1........................................................................................................................................0 Feedback Mechanisms .......... E-2 2..........................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ................................. E-4 4........................................................0 Determine PMT and PMT considerations ........................................................5 Develop a list of know parts to be replaced ...............F-1 1.................................................4 Identify permits required..... E-3 3........................................0 References.................................................................................................................................................................................5 Develop a list of know parts to be replaced .....4 Develop list of know consumable materials to be used.......................................................................3 Job Safety Analysis............................................................2 Equipment tag or unique equipment identifier.......F-1 1......5 Identify Environmental Consideration .....................................................F-1 1..... D-20 7........................ E-1 1.................................... E-3 3................................................................. E-10 6....1 Component type......................... E-1 1..................................................................... ...........................................................................F-4 3.....................................12......3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions .....................................10 Valve stem lubricant Inspection ....................................................................................................................................F-5 3.2 Setting the Torque Switch .......8 Install Limit/Torque Switch Compartment Cover .....................F-5 4........................F-14 7........................................ G-1 1..................F-9 4...............................F-13 4.......................................12 Switch Adjustments.........................................................F-2 2...............4 Develop material list for potential contingency and consumable parts....................13..6 Identify Operating Experience........................F-14 5..........F-6 4.F-4 2..................F-11 4.........................................2 Stem Nut Installation ........................................F-8 4................1 Component type................................3 Limit Switch Compartment Inspection ...............F-7 4.........F-12 4................13 Replace Stem Nut .............................................................5 Identify Environmental Consideration ..........................................................................F-12 4........ G-1 1....................F-8 4..............................................................................................................7 Motor Termination inspection..1 Evaluate potential for generation or equipment risk hazards ..F-4 2.........................12...1 Preparations..................................4 Torque Switch Inspection..........1 Stem Nut Removal ........4 SMB-00 Torque Switch ..F-15 G WORK PACKAGE TEMPLATE – ELECTROSTATIC PRECIPITATOR..............2 Identify Foreign Material Exclusion (FME) potential and mitigation ............................F-5 3................................................12.............................................................................................................................................................................................................F-4 2.......................................................13.......................................................................1 Setting the Limit Switch ............................2 Equipment tag or unique equipment identifier.............................F-11 4..............................................0 Feedback Mechanisms ..................... G-1 1.................................................... Identifies general and specific hazards..............................................................................................................................1 Identify potential scope expansion and actions due to scope expansion..........................5 Limit Switch Inspection..............................................................0 Task Overview ........................ G-1 1...............................F-5 4.................................................4 Identify permits required........0 References..F-3 2..F-3 2............12....2...............................................................................................0 Determine PMT and PMT considerations ....................................................................3 SMB-000 Double Torque Switch ...............9 Main Gearcase Lubrication Inspection.......F-7 4..............................F-10 4....................2 Identify individuals to contact in case certain events occur...............3 Scope ...F-9 4.......... G-1 xiv ...............................F-4 3..................................F-4 3..................................F-6 4.............................F-13 4................3 Job Safety Analysis..........................................................................................................................................................................6 Limit Switch Gear Box Grease Inspection................................................................................F-14 6...2 External Inspection of Actuator/Valve ...............................................0 Detailed Work Instructions ........................................................F-5 4......F-6 4.....................F-13 4....................11 Motor Inspection................0 Contingency Considerations ..........................................................................7 Identify Clearance/Tag out Boundary.................................................. ...................5 Develop a list of know parts to be replaced .............................. H-2 1....................... G-4 4....... G-17 H WORK PACKAGE TEMPLATE – PULVERIZER OVERHAUL............ Emitter/Collector Rapper/Vibrator).............................4 Upper Housing (Tension Insulators and Housings..............................................0 Contingency Considerations ..........................................................................................................7 Control Cabinets (Emitter Control Cabinets........4 Develop list of know consumable materials to be used...........0 Pre-job Brief .. H-2 2........ H-1 1...................... G-2 2.......................................... G-4 3.. G-16 5............................. H-3 2.............................................3 Scope ..........................................3 Job Safety Analysis..................................................................................... G-2 2...... G-2 2....................................... H-3 2...........................2 Equipment tag or unique equipment identifier....................... G-2 2....................................0 Feedback Mechanisms ..............7 Identify Clearance/Tag out Boundary.......... G-8 4.............................. G-5 4..................2 Pre-maintenance checks (prior to clearance/tag out on precipitator)...... Identifies general and specific hazards.......1 Component type............................................................ G-17 6.......................................................................................1 Evaluate potential for generation or equipment risk hazards ..................... H-1 1................................................................0 Determine PMT and PMT considerations ..............................................................................................1 Shutdown for Maintenance ............................ H-1 1.............................3 Lower Precipitator Maintenance.....................1 Evaluate potential for generation or equipment risk hazards ...................................5 Develop a list of know parts to be replaced ..........................................6 Special tools................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ................................... Rapper Control Cabinets) .....................................................................4 Identify permits required.......................................................................................... Identifies general and specific hazards........................ Coffin........................................................... Cans........................................................................................... G-3 2.............0 References.................................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ....... G-4 4................5 Penthouse (aka............................................. G-3 2........ G-4 3.................................4 Develop material list for potential contingency and consumable parts........................................2 Identify Foreign Material Exclusion (FME) potential and mitigation .................................5 Identify Environmental Consideration . G-2 1........................0 Pre-job Brief ............. H-1 1........ G-12 4..... G-17 7........... G-14 4....2 Identify individuals to contact in case certain events occur.................0 Task Overview .................................................................1..................................0 Detailed Work Instructions ................. G-12 4......................... G-2 2...........................................3 Job Safety Analysis...........6 Identify Operating Experience............................................ H-3 xv . H-1 1................................. H-1 1..........1 Identify potential scope expansion and actions due to scope expansion.................... G-4 3................................ G-3 2......... Doghouse) Insulator compartment inspections .... G-5 4................................................... H-3 2.................... G-3 3.................................................4 Develop list of know consumable materials to be used...............................6 Special tools..........................................................6 Transformer/Rectifier (TR) ................................................................. G-1 1. G-4 3.................................... ........................I-2 2.............. Identifies general and specific hazards.................................................................0 Pre-job Brief ............... H-3 2.................... H-4 4..I-4 xvi ..........................3 Develop material list for potential contingency and consumable parts....3 Job Safety Analysis............................................................... H-5 4...................................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ...................2 Identify individuals to contact in case certain events occur............................................................................................................ H-9 4.........................I-3 3..........I-4 4....6 Identify Operating Experience.......................................3 Scope ................................1 Evaluate potential for generation or equipment risk hazards ............................................................................. H-11 I WORK PACKAGE TEMPLATE – DAMPERS .............. H-11 5......................... H-4 2............. H-5 4.........................................................................................................................................5 Identify Environmental Consideration ........................2 Equipment tag or unique equipment identifier....................................................................I-2 2............7 Identify Clearance/Tag out Boundary..................................................4 Roll Wheel Assembly Installation ....I-1 1...........................................5 Develop a list of know parts to be replaced ............................................................................... H-4 3.....................................1 Inlet Damper Clean/Inspection....................................................3 Grinding Ring Segment Removal and Replacement................................................... H-7 4..........2 Identify individuals to contact in case certain events occur............................................................................I-3 3....................................................................1 Component type.......................................................................2... H-4 3...................................0 Detailed Work Instructions ...................................................................4 Develop list of know consumable materials to be used...............0 Task Overview .....I-1 1.........4 Identify permits required... H-3 2.............I-2 2...................................................................................................5 Identify Environmental Considerations..................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ...........................4 Final Reassembly...........................I-3 2.......................I-3 3.................................6 Identify Operating Experience.................................0 Contingency Considerations ...I-2 2.......................................................7 Identify Clearance/Tag out Boundary..............................................I-1 1...... H-4 3..................4 Develop material list for potential contingency and consumable parts......................0 Contingency Considerations ..................................0 References................................2 Roll Wheel Assembly Removal ..........0 Determine PMT and PMT considerations ...6 Special tools........1 Identify potential scope expansion and actions due to scope expansion...........................1 Prerequisites ..........I-3 3................................................................................ H-4 3......I-4 4.. H-5 4........................I-1 1.................................................I-3 3.......................................................................I-2 2................................................ H-11 6..........................................................................1 Identify potential scope expansion and actions due to scope expansion..I-1 1......I-3 2..................................................0 Feedback Mechanisms .................................................................. H-11 7.....................................................4 Identify permits required.............................I-2 2..........I-1 1.................................................................................0 Detailed Work Instructions ....................................................I-1 1.......................................................................................................................... ......3 Pump Disassembly .............. J-7 4.....................................................................................................................................................1 Identify potential scope expansion and actions due to scope expansion..................... 3196) .....................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ......................................................................................................4 Reassembly ...........................................................................................................0 Contingency Considerations ..........................................0 References.......................4 Identify permits required.....................2 Identify individuals to contact in case certain events occur.............................................................................0 Feedback Mechanisms .....................................5 Develop a list of know parts to be replaced .............................................................................................................................................I-6 4.......................................3 Scope ..... J-3 3....................I-6 4.......................................................................................................................... J-4 3.................................1 Evaluate potential for generation or equipment risk hazards .........................5 Pump Reassembly .................................I-7 6.........................................................................................................................................0 Pre-job Brief ................................... J-6 4..................................... J-3 2....0 Feedback Mechanisms .......................................................0 Determine PMT and PMT considerations ........................ J-1 1..........................0 Determine PMT and PMT considerations ................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ....................................................................6 Special tools................................................................. J-7 4.......................... J-16 7................ J-5 4... J-1 1...................................................................... J-3 2...............................7 Final Pump Assembly .........0 Detailed Work Instructions ...................0 References.... J-16 K WORK PACKAGE TEMPLATE – STEAM TRAPS ..................................................................................1 Component type............................3 Job Safety Analysis.......4 Develop material list for potential contingency and consumable parts..................................1 Preparations.................................J-1 1........ J-4 3......................... J-3 2.........................................2 Equipment tag or unique equipment identifier.......................2 Damper Bearings .................. J-15 6................................................2 Preparation for pump removal.....................6 Pump Installation............................................................................................................................................. J-3 2.......................................................................................................I-8 J WORK PACKAGE TEMPLATE – CENTRIFUGAL PUMP (PROCESS................ J-11 4. J-5 4............................ J-2 2...............................................3 Lubrication.......................... K-1 xvii ........................... J-4 4.............................................................................. J-2 2..... J-4 4................... J-1 1.....................5 Identify Environmental Consideration ......................... Identifies general and specific hazards.................. J-1 1.....................................................................................................6 Identify Operating Experience......................................................................................... J-4 3..........................................................I-7 5.................... J-2 1................................4 Pump Inspection .............. J-2 2. J-14 5............ J-2 2.........0 Task Overview .............................................4........ J-1 1........................7 Identify Clearance/Tag out Boundary. J-4 3....4 Develop list of know consumable materials to be used.........................................................I-7 7............................................................................... ........ K-1 1....... K-4 4............................0 Pre-job Brief ...2......................................................2 Ball Float Steam Trap ...................................5 Identify Environmental Consideration ............................................................................................................ K-3 2.....................3 Job Safety Analysis...............L-1 1......... K-8 4................................L-1 1..................................................... K-4 4......................... K-3 2..............................................1 Component type. K-9 4...0 References...................................3 Scope .. K-2 2........................L-1 1.............................................................................................1 Identify potential scope expansion and actions due to scope expansion....0 Detailed Work Instructions ..........................................4 Develop list of know consumable materials to be used........................................................................................L-2 xviii .. Identifies general and specific hazards.......................................................................... K-3 3.................................. K-3 2.................................................... K-6 4........................0 Task Overview .............................. K-1 1.....2 Equipment tag or unique equipment identifier.......... K-2 2..........................0 Task Overview .......................................................................................................... K-1 1......................3 Balance Pressure Steam Trap . K-4 4......... K-9 4.......................6 Identify Operating Experience............................................ K-2 2........................2........... K-10 6..1 Evaluate potential for generation or equipment risk hazards ........................... K-3 3....4 Identify permits required...............................................................1...................... K-10 5......................................0 Feedback Mechanisms ............................................................. K-11 7.4 Develop material list for potential contingency and consumable parts.......................4 Develop list of know consumable materials to be used............................................................6 Special tools.............................................................. K-2 2................................................................ K-7 4........2................................................................................................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ..............................1 Testing Steam Traps. K-1 1......... K-4 3..........................................2 Identify individuals to contact in case certain events occur......... K-1 1.........................................7 Identify Clearance/Tag out Boundary............................................5 Develop a list of know parts to be replaced .............................................6 Special tools..... K-11 L WORK PACKAGE TEMPLATE – GATE AND GLOBE VALVES ....................................................................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ........................................2...........................................................................................................L-1 1......................................................................................................................................................5 Develop a list of know parts to be replaced .........2........................................................................................2....................................................................... K-7 4.............. K-2 1....2 Steam Trap Maintenance.........2 Equipment tag or unique equipment identifier...........................L-1 1...................................................L-1 1.......4 Thermostatic Steam Trap............................................................1 Thermodynamic Steam Trap......................................................................................5 Inverted Bucket Steam Trap ..............................................3 Scope ....................L-1 1...................... K-3 3..............6 Liquid Expansion Steam Trap ..............1 Component type.......................... K-2 2...........................................................................0 Determine PMT and PMT considerations ............................................................ K-3 3........0 Contingency Considerations ................ .....................M-1 1......................................0 Pre-job Brief ....6 Identify Operating Experience.......................................................0 Pre-job Brief ............2 Inspections .....................................1 Identify potential scope expansion and actions due to scope expansion...........6 Identify Operating Experience............ Identifies general and specific hazards..................................................L-4 4....M-4 3...........................4 Develop list of know consumable materials to be used...L-4 3...............1 Evaluate potential for generation or equipment risk hazards ..................................................................L-4 4................................................................................................................................................................0 Detailed Work Instructions ........3 Valve repairs .........................................M-1 1.............................0 Feedback Mechanisms ......1 Component type.........2......................................................................................L-7 5............................................................................5 Develop a list of know parts to be replaced ..................................................6 Special tools.........M-3 2.....................L-2 2......0 Determine PMT and PMT considerations .....................................................................L-6 4.......................................L-3 2.5 Identify Environmental Consideration ....................................................................................................................L-2 2............................................M-2 1.........................................................................................................................L-3 3.................2 Identify individuals to contact in case certain events occur...........................................................................................................................................M-3 2...........................L-3 3....0 References.........4 Identify permits required.................................................................................................M-3 2.........2 Identify Foreign Material Exclusion (FME) potential and mitigation ........................5 Identify Environmental Consideration ...................................................L-5 4....4 Reassembly ..................4 Identify permits required................L-4 4...........................................................L-2 2.........................................M-1 1.............L-7 7.................................................L-7 6....................................................................0 Contingency Considerations ................................ Identifies general and specific hazards....................................................................L-3 2...............................................................................0 Contingency Considerations ......0 Task Overview ....................................L-8 M WORK PACKAGE TEMPLATE – MULTI-STAGE VERTICAL PUMP .............M-4 3.............................................3 Scope ...........................................................2 Identify Foreign Material Exclusion (FME) potential and mitigation ................................2 Identify individuals to contact in case certain events occur....................3 Job Safety Analysis.................L-3 3........M-1 1............7 Identify Clearance/Tag out Boundary.M-4 3...........3 Job Safety Analysis...........................L-2 2............................................M-4 xix .....................................................................................................................4 Develop material list for potential contingency and consumable parts.........................................................7 Identify Clearance/Tag out Boundary............................................................................M-1 1........................M-3 2..M-2 2..M-2 2......M-2 2.......1 Identify potential scope expansion and actions due to scope expansion................3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ..................................2 Equipment tag or unique equipment identifier...M-1 1............................L-2 2....L-3 3......................1 Evaluate potential for generation or equipment risk hazards .M-3 2........................................................................1 Disassembly...................................................... ...8.....................................................................................3............................................................................................................................................... N-1 N......0 Feedback Mechanisms .M-10 4................M-11 4......3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions ............................................... N-2 N................................................................M-12 6..............................1 Assembly of pump bowls...............................................2 Key Human Performance Points ..............................8............................................5 Disassembly or Bottom column section .........................................M-4 3.................................M-6 4.........................................................................................................................................................M-13 N LISTING OF KEY INFORMATION ....................M-7 4...M-13 7............8...............1 Key O&M Cost Points .........M-5 4..3 Disassembly and removal of discharge head .....................................6 Impeller Bowl disassembly ..................................8.......................M-10 4..................................................................2 Assembly of lower line shaft and column to pump assembly ......M-11 4.....6 Final Assembly ....................2 Motor Removal..................................5 Installation of discharge head..0 Detailed Work Instructions ......0 References.............................8..............M-12 5...............................................................8............M-12 4......................................M-7 4...................................................................................................M-4 4................................................................................................................................................M-11 4......................................1 Preparations............M-5 4.................. N-1 N.....M-6 4............................................................................8 Pump Assembly ................. N-3 xx .........M-5 4..........................................M-8 4.........................................3 Installation of lower pump assembly in pump well .......................................................7 Inspection of Pump components .................................0 Determine PMT and PMT considerations ....4 Installation of line shafts and columns................4 Develop material list for potential contingency and consumable parts................3 Key Technical Points ............4 Disassembly of columns and line shafts ............................................... Work packages can increase the efficient use of resources. minor repairs and overhauls. work packages are repeatedly prepared for equipment that is common among most fossil power plants.3 Report Structure and Overview Section 2 of the report provides basic work package related information. 1. For maintenance organizations that may have less structures processes the templates will provide a firm foundation for developing work packages. improve overall maintenance and equipment reliability. These templates can then be used as guides to develop site specific work packages.1 Purpose and Scope The purpose of this report is to provide fossil plant maintenance organizations with some generic work package templates. In many cases. These templates will be provided for common maintenance activities by component and in a standardized format. The templates cover a wide range of equipment types as well as a variety of maintenance activities including inspections. Section 3 presents the format of a generic work packages and discusses the contents of each section. 1. minor repairs. The templates contain information that can be used by maintenance organizations no matter what the current level of work planning or work package development may exist.1 INTRODUCTION 1. increase overall productivity and enhance human performance error reduction. Information includes the benefits that can be realized from the use of work packages and how to use work packages. 1-1 . inspections.g. and overhauls). The appendices provide numerous work package templates on a wide range of plant equipment and various levels of maintenance activities (E. Maintenance organizations that have processes in place can find information that will enhance their current processes. There are numerous EPRI products listed that provide greater detail on the operation and maintenance of key plant equipment. A compilation of work package templates that provides information for the development of specific work orders will improve the efficiency and technical adequacy or work packages. Section 4 provides a list of key references used in developing many of the work package templates.2 Background Currently there is little to no means to share lessons learned from maintenance activities among fossil utilities and to benefit from the efficiencies learned from using enhanced/optimized work packages. 1 Industry Definitions and Nomenclature Air Circuit Breaker – A circuit breaker whose primary circuit interrupts current in air verses vacuum.This term refers to energizing the ESP during an outage period at ambient temperatures. 1-2 . oil or gas.4. this device prevents the reclosing of the circuit breaker as long as the device that initiated the opening is maintained in the position for opening. The object is to verify the electrical integrity of the bus section.4 Glossary of Terms and Acronyms 1. to obtain electrical readings of voltage and current. The advantage of this type of measurement is to relate the internal integrity of the ESP bus sections to one another as to electrode damage or extent of ash buildup. Air load . Antipump device – After an opening operation. Alignment .Figure 1-1 Work Package Template Overview 1.A condition where the axis or center lines of two shafts are in line or coaxial. and to determine whether spark over occurs before reaching a specific limit of the TR set rating. Collecting surface plate design differs between manufacturers. The insulators are either a ceramic bar or a shaft type and are usually secured to the hopper wall. into or through which an arc is directed to extinction. classifies the coal.Anti-sway insulator . Coal pulverizer .A rotating vane assembly for the separation of coal particles. Centrifugal Fan – A fan rotor or wheel within a scroll-type housing and including driving mechanism supports for either belt drive or direct connection. Auxiliaries – Devices which perform secondary functions as adjuncts or refinements to the primary function of the circuit breaker.Is the term for the sheet metal collector plate that serves as the point of deposition for the particulate that is negatively charged within the gas passage of the ESP. Classifier. Collecting surface . Classifier. Contacts – Two conducting parts that interact to make or break a circuit. Auxiliary Switch – A switch which is mechanically operated by the operating mechanism for indication.A brinelled bearing is one in which a dent has been formed in one of the races by a ball. Hierarchy is: parts make components. but all are secured to the shell of the ESP at ground potential and serve as the positive anode of the gas passage. Arc Chute – A confined space or passageway. Some designs connect directly between the collecting plates and the lower.An ESP which is installed downstream of the air heaters. which position and retain the discharge electrodes. and equipment makes systems. Many components make up equipment. dynamic . stationary . lined with an arc resistant material. interlocks or other control functions and reflects the open or closed status of the breaker. Bus – A conductor or group of conductors that serve as common connection for two or more circuits. 1-3 . components make equipment. HV frames. Also called a coal mill. HV frames. Closing Spring Charging Motor – A motor that is energized automatically by internal limit switches to charge the closing springs electrically. dries the coal. Arcing contacts – The contacts of the circuit breaker on which the arc is drawn after the main and intermediate (if used) contacts have parted.A machine that reduces the size of coal particles. and transports the coal to the boiler piping. Brinelled bearing . Cold-side ESP . from swinging or drifting out of alignment. Component – A generic technical part. Bell Alarm – An alarm that features one normally open and one normally closed contact activated by the auto-trip indicator.A combination of a vane and cone section designed to maintain and control the desired fineness of the coal leaving the mill.These insulators are used to prevent the bottom. to enhance corona characteristics. with the sides of each hopper being steep sloped. Four-train geared limit switch .A lever that is operated to allow manual operation of the Limitorque actuator using the handwheel. Each rotary drum switch contains four contacts. Finger Tight . and blowers. exhausters. Baffles are usually placed in the hoppers.a facility that removes fly ash from the flue gas by producing an electric charge on the fly ash and collecting it electrostatically. ventilators. Declutch Lever. Damper – A device used to vary the volume of air passing through an air outlet. It is shaped to provide a corona discharge when the impressed voltage breaks the gas down at the electrode surface. the discharge electrode is a smooth round wire slightly larger than 0. The other two rotors are set at some intermediate position depending on the application. Barbed wire is also frequently used in part. The typical shape is pyramidal. or all of the ESP. The outlet opening is sized so that fly ash may be easily removed by an ash removal system. Axial. Frame Size – The maximum continuous current rating (In amps) of a circuit breaker for all parts except the coils of the direct acting overcurrent trip device.The rotor-type. Hoppers . voltage applied to the discharge electrode is of negative polarity. Tube axial. Typically. In many weighted-wire designs. Fan – Any device that produces a current of air by the movement of a broad surface can be called a fan.Internal elements in the transition or ductwork to produce the desired velocity contour at the inlet and outlet face of the precipitator (for example. Discharge electrode . They can vary widely in style and shape. This breakdown of the gas creates corona tufts on the discharge surface. Propeller. and Vane axial.electrostatic precipitator (ESP) . One rotor is set to trip at the full open position of the valve. turning vanes or perforated plates).Hoppers located at the bottom of the precipitator casing and are used to collect the material that has been collected and that falls off of the internal components that are cleaned. they extend below the dust level to minimize undesirable gas leakage 1-4 . four-train geared limit switch employs four rotary drum switches.54 mm) in diameter. Drawout feature – An option available on circuit breakers which allows the circuit breaker to be disconnected and r4emoved from the switchboard without de-energizing the switchboard.Refers to the HV component that ionizes the process gases and creates the electric field. Critical speed – The speed of a rotating system that corresponds to a natural frequency of the system. The declutch lever will automatically disengage upon operation of motor. air inlet.Corrective Maintenance – All maintenance performed to correct a breakdown or failure. or duct. Fans are also called compressors. two of these contacts open electric circuits and two of the contacts close electric circuits. and one rotor is set to trip at the full close position of the valve. ESP . There are several types: Centrifugal.1 in. (2. When the rotor is properly set to trip at the desired position.Refers to the tightening of a fastener without the aid of a wrench. Discharge Electrodes of the rigid and rigid frame or mast variety are also widely available. Gas distribution devices . which periodically impart a shock to the collecting surfaces to help dislodge the collected material into the hopper system. and stator are the preferred general terms. Key-interlock system .A weatherproof. but it is more important to know that reliability of rapper operation holds priority over timing. and hazards and controls that provide a heightened level of awareness of significant aspects of the task. and poke holes to unclog the hopper outlets. a stator. a panel.These are devices. Long-Time Delay Trip Element – The element of a direct acting overcurrent trip device that functions with a purposely delayed action (typically 2-1000 seconds) on an overcurrent condition. Housing – The housing for a fan is the stationary element that guides the air or gas before and after the impeller. which carries a belt or chain. A housing can also be called a casing. Intermediate contacts – Contacts in the main circuit which part after the main contacts have parted and before the arcing contacts have parted. The final collection efficiency of the precipitator is often determined by how well this process is conducted. housing.below the collection plates. The object is to dislodge the material from the collector surface in small clumps or patches without building excessive dust layer thicknesses. Isolation Damper – A damper installed in a system that is capable of stopping or diverting flow from one portion of the system to another. Hoppers are also equipped with access doors.A system of locks that prevents opening the ESP access doors while the precipitator is energized. strike plates for manually rapping the hopper walls. For fans. Inspection – Any activity performed to find a failure or breakdown. Journal bearing – A cylindrical bearing. 1-5 . and other aspects of this system. Operating Mechanism – The part of the mechanism that actuates all the main circuit contacts of the switching device either directly or by the use of pole-unit mechanisms. generally located at the top of the ESP or bottom of the collecting plates. Typically. Main Contacts – Contacts that carry all or most of the current of the main circuit. Pre-Job Brief – An interactive dialogue between those involved in the work to ensure that all understand the scope of what is to be accomplished. procedural steps. gas-tight enclosure over the precipitator to contain the HV insulators. roles and responsibilities. casing. a scroll. Overcurrent Protection – A form of protection that operates when the current in the main circuit exceeds a predetermined value. Rappers (Collecting surfaces) . Penthouse . See sheave. a ring. hoppers are equipped with level detectors to alarm high levels and hopper heaters that are used to reduce corrosion and to keep the material fluidized. or a volute. Pulley –A wheel attached to a shaft. impact force. This is a complex part of precipitation. (304. These components involve a specially wound transformer that supplies a RMS secondary voltage sized on the basis of gas passage spacing and discharge electrode design.Rappers (High voltage) . When fastener preload values are required. Test Position – The position where the primary disconnecting devices of the removable element are separated by a safe distance from those in the housing. Snug Tight .Is the term for the HV transformer and rectifier that provides the electrical energy for a given precipitator area.A device for physically grounding the HV system prior to personnel entering the precipitator. The shunt trip device is used to open an electrically operated breaker under normal conditions. Short-time delay trip element – A direct-acting trip device that functions with a purposely delayed action (typically 0.500 volts ac (45 kV dc average) is utilized for the 9 in.300 volts ac (65 kV dc average) for most of the 12 in. The starter consists of two contactors mounted on a common base and mechanically interlocked. Two-trained geared limit switch . subsequent torquing will be necessary. Reversing Starter . TR set . The most common type consists of a conductor. two of these contacts open electric circuits and two of the 1-6 . When the rotor is properly set to trip at the desired position.07 – 1 second) on an overcurrent condition. Whether the buildups observed during outage inspections are detrimental can usually be determined by an analysis of electrical readings during periods of operation. two-train geared limit switch employs two rotary drum switches.The reversing starter electrically changes the operation of the electric motor from one direction of rotation to the other. (228.8 mm) wide gas passage of rigid electrode precipitators. Each rotary drum switch contains four contacts. 77. Some or all of the secondary disconnecting devices are in operating contact. See pulley. Safety grounding device . Often used synonymously with Journal bearing. the other attached to the HV voltage system using an insulated operating lever. one end of which is grounded to the casing. Torque Switch – A device designed to protect the actuator in open and close directions.A wheel attached to a shaft. which carries a belt or chain. An RMS secondary voltage of about 53. The discharge electrodes will generally exhibit irregular coatings of various size and shape. Sheave .6 mm) wide gas passage of most weighted-wire precipitators. in such a manner that brings faces together uniformly and ensures that the fastener(s) cannot be loosened by hand. The object is to keep the buildups on these electrodes from affecting the corona discharge pattern. or a group of fasteners.The rotor-type.These rapper devices impart a vibration or shock to the HV frame supporting the discharge electrodes. Shunt Trip Device – A circuit breaker attachment that utilizes a solenoid to rotate the trip shaft to open (trip) the circuit breaker. It is usually better to operate with some buildup than employ excessive rapping forces that can result in failure of discharge electrodes. Sleeve bearing – A bearing that carries lubricant for the shaft rotating within it.Refers to the tightening of a fastener. An important part of these measurements is the indicated voltage at the threshold of corona current. approved procedures may be referenced and may suffice as work instructions. permits. V-I curve .Refers to using "skill of the craft" to tighten a fastener with a hand wrench to a degree of tightness that is acceptable to the craftsman with no further verification. vendor manuals. safety analysis.2 Acronyms CAP – Corrective Action Program ESP . these curves sometimes can be developed during operating periods. Undervoltage Trip (Release) – A release that operates when the voltage of the main circuit is equal to or less than the release setting.Electrostatic Precipitator FME – Foreign Material Exclusion ICS – Industrial Control and Systems ID – Inside Diameter LCC – Load Control Center MCC – Motor Control Center MSDS – Material Safety Data Sheet NEMA – National Electrical Manufactures Association NFPA – National Fire Protection Association OD – Outside Diameter OSHA – Occupational Health and Safety Administration 1-7 . drawings. While normally obtained during air load. Wrench Tight .4. for example). When applicable. Work Instruction – Instructions for performance of the work to be accomplished. 1.contacts close electric circuits. Work Package – A compilation of documents including the work order.Usually refers to a plot of secondary voltage versus secondary current for a single TR set in which the shape of the plotted curve might indicate a number of internal operating characteristics of the precipitator. the level of detail of which is dependent on the assigned planning level. and the other rotor is normally set to trip at the full close position of the valve. work instructions. weld process sheets. One rotor is normally set to trip at the full open position of the valve. and any other supporting material (that is. operating experience. The Key Points are shown in the following way: Key O&M Cost Point Emphasizes information that will result in reduced purchase. O&M Costs. 1-8 . Key Human Performance Point Denotes information that requires personnel action or consideration in order to prevent injury or damage or ease completion of the task. The Key Points are organized into three categories: Human Performance. or maintenance costs. Key Technical Point Targets information that will lead to improved equipment reliability.1. and Technical. key information is summarized in Key Points. operating. EPRI personnel who reviewed and prepared this guide selected the information included in these Key Points. Each category has an identifying icon to draw attention to it when quickly reviewing the guide. The primary intent of a Key Point is to emphasize information that will allow individuals to act for the benefit of their plant.5 Key Points Throughout this guide. Key Points are bold lettered boxes that highlight information covered in the text. (E. Key O&M Cost Point To best meet the competitive challenge the continually improving maintenance organization is finding ways to work smarter. It is not enough. Working smarter means being ready for the expected and the unexpected. The amount of detail required will different from one maintenance organization to another based on many factors. efficiently and safely. Today’s environment is a competitive one that is ever changing and expanding at an increasing rate to keep up with the demands of electrical generation. The craftsman requires guidance. With complexity there is the growing need for better training and better resources for the maintenance craftsman to be able to perform their work. work packages provide an opportunity to incorporate controls and barriers to mitigate the potential for error or to mitigate the consequences of error. nor is it an effective strategy to meet competitive challenge through doing less. This measure may be the quickest but it is not necessarily the wisest. but with the increase in efficiency and reliability has come complexity. Without this guidance a task may take longer to perform. experience and skill level of craftsman. Technology has lead to more efficient and reliable equipment. Training.g. resources. efficiently and safely. Working smarter means being ready for the expected and the unexpected. An effective maintenance organization possesses the ability to adapt to a dynamic. it may be performed incorrectly or incompletely. quality and safety. In addition. All available work may not be performed while the equipment is available for maintenance. With the complexity of plant equipment it is no longer feasible to rely on the memory of the craftsman to ensure the inspections and corrective maintenance are performed correctly. These inefficiencies may lead to increased equipment unavailability and downtime during the maintenance activities as well as increase the likelihood of reduced reliability due to poor maintenance or missed opportunities to perform required maintenance. Taking advantage of new technologies has been one method that has proven to be successful. Work packages provide the maintenance craftsman with the level of detail necessary to perform a work activity correctly. If a maintenance task is to be performed correctly it must contain sufficient detail. To best meet the competitive challenge the continually improving maintenance organization is finding ways to work smarter.1 Introduction Maintenance is the most critical function when it pertains to product output. etc) Although the level of detail may vary to basic content of the work package from one facility to another to another should 2-1 . quick changing environment. One of the resources that can aid the craftsman in this area is the work package.2 WORK PACKAGE TEMPLATES 2. tools required.g. Key O&M Cost Point The labor resource is one of the largest and expensive within the maintenance department. The work package will be the primary tool used to manage all aspects of the maintenance activity: labor resources. Key Technical Point The use of developed work package templates allows the maintenance organization to move from the fire-fighting mode of performing work to an operational mode that is structured and proactive. In the case of corrective maintenance it is very probable that an overhaul work package template could be modified to meet the particular needs of the corrective maintenance far more efficiently than starting from scratch. It will provide the how to for work execution. Scope of work to be performed. etc. a significant amount of money is being wasted. spending significant amounts of time searching for spare parts. a measure of organizational effectiveness. proper equipment clearance. (E. step by step guidance on how the work is to be accomplished) Key Human Performance Point Work packages provide the maintenance craftsman with the level of detail necessary to perform a work activity correctly. 2-2 . The work package will serve as the backbone of a proactive maintenance organization. It can be easily modified accommodate the current needs. lacking the proper skills and tools for the craftsman or always feeling rushed to perform repairs at the sacrifice of quality. is to pull together the resources defined within the work package. When equipment inspections are required a pre-developed package can be retrieved and used to perform the inspection. If the labor resource is not being utilized effectively and efficiently. a significant amount of money is being wasted.possess some basic similarities. parts. The use of developed work package templates allows the maintenance organization to move from the fire-fighting mode of performing work to an operational mode that is structured and proactive. human performance. If the maintenance organization finds itself in a position of constantly reacting to emergencies and unplanned shutdowns. other than the work itself. If the labor resource is not being utilized effectively and efficiently. information input to a variety of maintenance functions and a valuable source of feedback for continuous improvement. efficiently and safely. then the maintenance organization is functioning in a “fire-fighting” mode. The majority of the preparation planning was done far in advance. parts required. The labor resource is one of the largest and expensive within the maintenance department. safety and error free considerations. The major activity left. The same applies for corrective maintenance and overhauls. Key O&M Cost Point The work package template will provide the maintenance organization with a more accurate and efficient tool for the scheduling and execution of maintenance activities. Templates can be readily modified to suit particular maintenance activities. regardless of which craftsman performs the work 2. Estimation variances. etc. Can provide improvement in safe working practices. improving the safe working practices and reviewing the stores re-credits can offer areas of improving work order templates. The maintenance organization will be more responsive to meeting emerging work needs. Works order templates contain all planned information including parts.The work package is the communications vehicle for the maintenance organization to perform its overall function. This includes NOTE’s and CAUTION’s that can protect both equipment and personnel as well as provide additional information to enhance the effectiveness of the maintenance activity. Work packages can assist the maintenance craftsman in reducing errors. The issues facing the organization today appear to overshadow the longer term priorities. additional tips or instructions. resources requirements. The work package template will provide the maintenance organization with a more accurate and efficient tool for the scheduling and execution of maintenance activities. Templates can be used as training tools.2 Benefits of Work Package Templates The first impression may be that work package templates will take resources from other critical maintenance functions with very little benefit in return. 4. 2-3 . Not only does it provide the craftsman with the necessary instructions on how to perform the work but it also provides the acceptable maintenance standards and behaviors expected during the performance of the work When the work package is properly implemented it helps ensure that the maintenance is performed consistently and correctly. They can be used in their entirety or in part based on the particular needs. 1. 2. 3. 7. Work package templates can take a lot of the work out of the planning function so that it can be focused more on other improvements. It will move from a fire-fighting mode to a mode that is more structured and proactive. work instructions. Like most new processes the initial effort may appear overwhelming. 8. Following are some of the benefits that can be realized from a system of work package templates. 6. Provides step-by-step sequence of work instructions. 5. Templates can also be used to store trouble shooting guides for specific symptoms/fault modes. 4 How to Use the Templates The degree of formalization of work processes between fossil plants will differ. to encompass a wide range or work tasks required on a particular type of equipment regardless of the manufacturer of the equipment. The templates provide what to inspect and in addition provide guidance to the craftsman of what the inspection should entail.2. In the case of low voltage air operated circuit breakers the task is more feasible. Key considerations during the review should include: 1. the work package templates may provide alternative methods.3 Work Package Templates The work package templates in this report are generic. roll wheel verses a tube or ball mill). The items in this section are directly applicable to the type of work being performed and may assist in the prevention of errors during maintenance. They were designed. Although their function is identical the inspections and overhauls of the different types would be different. There are a few exceptions such as Limitorque actuators and Gould 3196 process pumps. notes or cautions or other information that will be of benefit to the way maintenance is performed. Some plants may possess very detailed and formalized procedures for the conduct of maintenance activities. All breakers have a frame. It is difficult to create a generic work package template. the templates may be used to enhance existing products. operating mechanism. Tolerances and specifications are left to the specific site. 2. in most cases. 2-4 . Pre-job brief – In this section there are items that may be considered when performing pre-job briefs prior to maintenance activities. In less formalized processes the work package templates will provide a foundation for the development of specific work packages for the templates provided as well as a process that can be used to develop specific work packages on other pieces of equipment. either procedures or work packages.g. In organizations with more formalized processes. 2. contacts and protective devices. human performance considerations. Circuit breaker design is similar enough between manufacturers to allow for a work package template to be created. There will of course be differences in certain devices between manufacturers. In facilities where more formalized processes exist. Inspection activities – When items are required to be inspected most procedure tell what is to be expected. At the other end of the spectrum will be plants that develop and redevelop work instructions only as they are needed upon equipment failure. Of course there will be a wide range of processes used between these two extremes. the work package templates contained in this report will prove to be of value. Regardless of the level of sophistication of the work process being used by any given maintenance organization. 3. Personnel safety and equipment protection – Throughout the templates there are notes and cautions used to raise awareness to potential personnel safety issues or to maintenance issues that could affect the reliability of the maintenance being performed. For example a coal pulverizer may use one of many mechanisms to perform its function. (E. Also due to differences in design some templates reference a particular design type. Due to their wide spread use in the industry more detail is provided. drawings and other engineering documents. laser alignment. struts. double-dial) 2. repairs and overhauls. During the walkdown considerations should typically include: 1. hangers).g. 2-5 . the templates will provide a solid foundation from which facility specific work packages can be developed.5 Planning Walkdowns An important step in the planning process is the planning walkdown. Are there interferences that must be removed to support the maintenance activity? Can they be removed safely? Will their removal impact operating equipment? Pipes? Supports? Hangers? Insulation? Etc. Will the work impact other equipment in the area? Will operating equipment in the work area require special considerations with respect to potential impact on the operating equipment or personnel safety? This is of special note when the maintenance is being performed with the unit on line. There will be short term costs associated with the development of the specific work packages but the long term gains will outweigh these costs. Does the work instruction encompass the scope of work to be done? Have new items been identified that should increase the scope? Conversely are the items that should be removed from the scope of the work package? 2. For example there may be tolerance criteria for a measurement taken on a piece of equipment. 3. Appropriate acceptance criteria should be obtained from the vendor technical manual.g. Because the work packages templates are generic it is recommended that during specific work package development that appropriate references be used. Another example of the generic nature of the work packages would be equipment alignment. etc. The effort taken to perform a thorough walkdown of the work area will enhance the work package and enable it to be used more effectively. work platforms). Each facility will differ with respect to where equipment is located. The planning walkdown is essential for the development of pre-job considerations and contingencies. Key O&M Cost Point There will be short term costs associated with the development of the specific work packages but the long term gains will outweigh these costs. References include vendor technical manuals. This is an important step in developing the finalized work package for the maintenance activity. It will help expedite repairs and minimize equipment unavailability. Each plant will be different based on the method that is used in their training or the technology available (E.g. accessibility to equipment (E. The work package will appropriately call for an alignment but it is left at the discretion of the particular facility as to how the alignment is to be accomplished. The thoroughness and consistency of walkdowns can be improved through the use of a checklist.In organizations that do not possess formalized procedures or work packages for equipment inspections. laydown areas. interferences (E. pipe supports. rigging supports. Are facilities available? Electrical. 2-6 . 7.g. cranes. Is there sufficient space in the work area to carry out the maintenance safely? Is there room for scaffolding. They also make excellent reference materials during pre-job briefs. During the walkdown there are tools that should be available to the planner to achieve the greatest benefits from the walkdown. Digital voice recorder. Laser pointer. etc. water. Are there any personnel safety considerations? 8. What special permits may be required? Confined Workspace? Transient combustible storage? Etc. These are of benefit when sitting down and completing the work package. 9.? 5.4. forklift access. 4. Key Human Performance Point The planning walkdown is essential for the development of pre-job considerations and contingencies. phones? 10. Notebook. Are there physical limitations to performing the work safely? 6. Small digital camera. proper rigging sites. 3. It is much easier than taking written field notes. The results of the walkdown should be incorporated into the work package. These include: 1. 2. leak identification) 6. Measuring tape. laydown areas. What is the status of environmental conditions at the work site? Lighting? Temperature concerns? Hot pipes? Rotating machinery? Etc. (Excellent for pointing out details in pictures. air. It also provides an opportunity to validate materials and special tooling needs. Strong flashlight 5. ladders. E. Equipment tag or unique identifier – describes the exact piece of equipment to be worked indicated by a unique equipment identifier. (e. Component type – describes the type of equipment that is to be worked. floor elevation. 3-1 . 1A Boiler Feedwater Pump. 2.Task Overview This section of the work package provides general information regarding the task. The section consists of the following sub-sections. Breaker 42317 1A Boiler Feedwater Pump) 3.g. 1.1 Task Overview Figure 3-1 Work Package Development . room. etc) Proving a drawing of the equipments location and a picture of the equipment should be included in the package if available.g. Location of Equipment – Provide a brief description of where the equipment is located.3 WORK PACKAGE TEMPLATE FORMAT 3. building. (E. Each piece of equipment should have a Bill of Materials (BOM). (E. grease. 6. etc) that will be used during performance of work. Craftsman skills required – The types of craftsman to be used during the maintenance activity should be identified. etc) 5. rags.g. 3-2 . List of know parts to be replaced – provides a list of parts that will be used during the performance of the work based on the scope of work described. Inspection. repair.4. Scope – describes in general the type of work to be performed on the piece of equipment. personnel and the environment are not impacted as a result of the maintenance activity. List includes typical journeyman’s tools. cleaning solvents. 8. overhaul. oil. test. safety equipment and specialty tools required to perform the scope of work. 7. 3.2 Pre-Job Considerations Figure 3-2 Work Package Development – Pre-job Considerations This section of the work package provides a significant amount of information necessary to ensure equipment. Tools/Special tools – provides a list of tools that will be required to perform the scope of work properly and safely. The section consists of the following subsections. List of known consumables – a list of consumable products (e.g. (E. This may include precautions for working a piece of equipment on line. To protect these assets administrative programs have been developed. personnel or the environment. (E. Typical permits that may be required during maintenance include. Experienced personnel proving experiences and expertise. especially the Corrective Action Program c. 6.Review any relevant plant specific or industry related operating experience applicable to the work being performed. chemicals. Experience from other utility experiences 3-3 . Operations experience can be drawn from various sources including: a. 5. etc) as well as mitigation of the release of hazardous substances used during maintenance to the environment. Work activities should be evaluated to determine if the potential exist to inadvertently affect equipment in the area.g. Identify environmental considerations – This section is concerned with the identification of environmental hazards that may be imposed on the worker (e. platform board was left in condenser waterbox following waterbox cleaning) This section provides information related to certain tasks during maintenance where foreign material could be introduced as well as measures that should be taken during maintenance to prelude the introduction of foreign material into the equipment being worked. Consideration should also be given to equipment in the immediate vicinity of the work location. lethal gases. 3. From previous performance of work orders d. Identify Foreign Material Exclusion (FME) potential and mitigation – Foreign material introduced into a piece of equipment or system during maintenance can have severe impact on plant operations. etc. lighting. Hot Work Permit. Equipment Clearance Order/Tag Out. precautions that should be taken during the course of maintenance to preclude potential damage to equipment being worked. Review operating experience . scaffold was built with a scaffold bar running through the handwheel of a piece of nearby equipment) 2. combustible atmospheres. Job Safety Analysis – Maintenance tasks can represent hazards to both equipment and personnel.g. From on-site experiences. Identify permits required – Many maintenance activities may prove hazardous to the equipment. This section provides information that should be considered with regard to performing a job safely and correctly to minimize the potential for causing injury to personnel or equipment damage related to the maintenance being performed. Transient Combustible Control.1. Chemical Traffic Control/MSDS. Evaluate potential for generation or equipment risk hazards – This section provides considerations concerning the effect the maintenance may have on the plant.g. Confined Space Entry. temperature. especially during prejob briefs b. effects on system lineups. The review of operating experience can help reduce risk to both personnel and equipment by learning from past mistakes or problems that have been encounter in the industry or at the given facility. 4. Vendor bulletins f.3 Contingency Considerations Figure 3-3 Work Package Development – Contingency Considerations 3-4 . Key Human Performance Point The review of operating experience can help reduce risk to both personnel and equipment by learning from past mistakes or problems that have been encounter in the industry or at the given facility. Identify Clearance/Tag Out Boundary – This section provides general information with respect to how a piece of equipment may be removed from service to ensure that both personnel injury and equipment damage is prevented. This is provided as general information ONLY. due to differences in design. 3. etc) to ensure that equipment is properly isolated and placed in a condition such that maintenance can be performed safely. vendor. Each site.e. must use its knowledge of the system along with applicable drawings (piping. wiring. Key considerations should be made in the areas of: 1. 4. Key O&M Cost Point The planner should be aware that contingency parts may or may not be necessary to support the job.This section of the work package provides information related to contingencies that may arise during the course of the maintenance activity. 2. Identify rapid or emergency actions to place equipment in compensatory configurations or conditions. This can be a significant financial decision since most contingency parts tend to be high cost items that are not maintained in normal inventory. This can be required for determination of whether parts should be replaced. The level of effort placed on contingency planning should be commensurate with the scope and significance of the maintenance activity. The planner should attempt to anticipate necessary contingencies based on previous work experience. Procurement should be notified of the contingent parts requirements so availability and lead times can be determined. It is unlikely (numerous possibilities) and infeasible (cost restrictive) to develop contingencies for all possible scenarios. Potential scope expansion – Once a piece of equipment is opened for maintenance or inspection there is always the potential for work scope to increase. This will allow a cost effective decision to be made with respect to whether the parts should procured or expedited to support the maintenance activity. engineering support for repair methods. The parts should be flagged as contingent in the work package. Early identification of parts and contingent parts also allows sufficient time to determine parts obsolescence issues. Engineering can then be informed of the need for part evaluations to support the maintenance activity. Develop material list for contingency and consumable parts – The planner should be aware that contingency parts may or may not be necessary to support the job. The planner should attempt to anticipate necessary contingencies based on previous work experience. etc. operating history and other intelligence. Key Technical Point The level of effort placed on contingency planning should be commensurate with the scope and significance of the maintenance activity. A review of previous maintenance history on the piece of equipment will provide valuable information to assist in development of contingencies. operating history and other intelligence. 3. scope expansion. 3-5 . It will be necessary to make a decision as to whether the parts should be on site to support the maintenance activity. This can be a significant financial decision since most contingency parts tend to be high cost items that are not maintained in normal inventory. Identify individuals to contact in case of certain events – The craftsman should be provided information in the work package on who should be notified if problems are encountered during the performance of the maintenance activity. Scope expansion due to unforeseen or newly discovered deficiencies during the course of maintenance activities happens. This can be affected by the skill level of the craft.3. 3-6 . supervisory oversight provided and the work activity it self. 3. 2. The work package developer should not assume that the craftsman knows everything about the work activity.4 Work Package Development – Detailed Work Instructions This section of the work package provides the detailed sequence of steps required to perform the maintenance activity satisfactorily. 1. The developer can assume that each craftsman possesses the following skill set. 4. Can use measurement equipment. The amount of detail that exists in this section can vary. Can read engineering drawings Can read and understand work instructions Understands the proper application and use of hand tools.4 Detailed Work Instructions Figure 3. This section also includes notes and cautions to provide the maintenance craftsman with amplifying information and alert them to critical attributes related to equipment or personal safety. rigging. 4. CAUTIONS are provided to heighten attention to step(s) that if improperly performed may result in equipment damage. transient) Personnel Safety The requirement for special controls (Confined work space) The requirement for special skills (Welding. The amount of detail required can also be affected by the amount of supervisory oversight provided. 3. detailed procedures to perfo5rm the work activity. engineering support or vendor support. NOTES should only contain administrative information. experience level and past work experience. Other factor that can affect the level of detail required include: 1.The draftsman will possesses many other skill sets but this will vary by craftsman based on the amount of training received. 2. Oversight may be either form supervisors within the maintenance organization. Tasks that are complex or less frequently performed will require a greater level of detail. CAUTIONS should precede the step to which they apply. Engineering and vendor support during a work activity will typically be known to the package developer and can be taken into account during package development. stop signs. 5. Supervisory support from within the maintenance organization is not as clear and should not be assumed to be present during the work activity with regard to the level of detail that should be included in the work package. etc) have been used to minimize the potential for errors. The work templates contained in this report provided varying levels of detail. To assist the craftsman in recognizing critical steps in the work instructions special symbols or annotations (Bomb or firecracker symbols. injury to personnel. NOTES should not direct any physical actions required by the maintenance craftsman. and impact to unit operation or adversely affect plant systems. Risk to the unit (trip. The dominant factor n the level of detail required in the work instructions is the task itself. NOTES should precede the step to which they apply. The availability of approved. 3-7 . etc) NOTES are provided to give amplifying or clarifying information. calibrations and/or monitoring of equipment performance characteristics.5 Work Package Development – Post Maintenance Testing This section of the work package provides post maintenance tests as well as activities that should be perform post maintenance to return the work location to pre-work conditions or better. a procedure or a subsequent work order package. It will also verify that original deficiencies have been corrected and that no new deficiencies were introduced during the maintenance activity.5 Post Maintenance Testing Figure 3.3. Post maintenance testing is performed to verify that all components and systems are capable of performing their intended functions following maintenance activities.g. vibration. The tests performed should be commensurate with the maintenance work performed and the importance of the equipment to facility safety and reliability. Post maintenance testing may be specified in the current work order package. (E. flow. temperature. Post maintenance testing provides an initial break-in or run-in period for adjustments. Post maintenance testing may be performed with the equipment operating under normal operating conditions or specific test conditions. etc) 3-8 . Post maintenance testing should include documentation of results for future reference and trending. etc) These methods of providing feedback on maintenance activities have been used with varying degrees of success. and observation of work practices and conditions in the plant. processes that support work. The maintenance organization should take advantage of as many of these mechanisms as possible. Each will provide a different perspective and insight into the maintenance work process. Feedback is a credible source of information that can result in the improvement in the organization of work. 3-9 . informal communications.g. post job reviews. direct observation of work performance. It can identify problems with procedures. Feedback is a vital link between the job-site and the organization. (E.6 Feedback Mechanisms Figure 3. Corrective Action Program.6 Work Package Development – Feedback Mechanisms Feedback provides information related to the quality of work in the field. support worker performance. improve job productivity and identify opportunities to strengthen human performance and reduce errors. Feedback can be obtained through a variety of mechanisms. equipment. work packages. 3. work package feedback sheets. work performance and training of personnel. Inter-departmental support 13. Adequacies of tools. Procedure quality 8. Quality of vendor support (if applicable) 10. training inadequacies) 6. parts. incorrect resources. Some typical items that should be considered for feedback include: 1. Quality of supervision 9. Unanticipated error precursors/traps 3. Work Order/Package quality 7. It should focus on both improvement opportunities as well as recognizing those things that went well. resources 12. Unanticipated surprises 2. Obstacles to work performance 14. Things that went well 15.Feedback should be obtained as soon as practical following the maintenance activity. 3-10 . support worker performance. improve job productivity and identify opportunities to strengthen human performance and reduce errors. Quality of planning and scheduling 11. Industrial safety issues or hazards 4. Good catches Key Human Performance Point Feedback is a credible source of information that can result in the improvement in the organization of work. Equipment condition 5. Personnel issues (lack of resources. However. It is not possible to place all the resource information that may be used during the course of the maintenance activity into the work package. References may be included in whole.7 References Figure 3.7 Work Package Development . In some cases. If portions of procedures are included as reference the planner should be careful to include the initial conditions. if they exist.References This section of the work package is the maintenance craftsman’s resource library. Typical references may include: 3-11 . the work package reference section should contain sufficient information that will be accessed during the maintenance activity and provide reference information in sufficient detail to allow the craftsman to easily retrieve the reference if required. in part or noted for easy reference and access. precautions and limitations applicable to that procedure to ensure that portion of the procedure is applied appropriately and under the proper circumstances. This section of the work package should provided sufficient supplemental information necessary to complete the maintenance activity satisfactorily. The package would become too bulky and could very likely turn off the craftsman to useful information contained within.3. whole or portions of procedures may be referenced. Approved procedures related to work activity (if they exist) Vendor drawings Complete parts list with appropriate stock numbers MSDS sheets for chemicals that will be used Electrical drawings (if applicable) Copy of the equipment clearance/tag out Operating Experience Any permits required (Confined space. 9. etc) Equipment vendor technical manual Specific component vendor technical manual (Coupling. 8. 7. 3. hot work. 4. 7. 2. Industrial Safety Manual Detained Post maintenance procedure (if it exists) Hot Work Permit Procedure Confined Work Space Procedure Chemical Control Procedure Foreign Material Control Procedure Technical support Procedures (Packing. torque. 6. Mechanical seal. welding. 2. 8. 3. 5. 4. 5. etc) 3-12 .Included in package: 1. etc) Referenced or noted: 1. 6. 4 REFERENCES 1. Electrostatic Precipitator Guidelines, Vol. 1: Design Specifications, Vol. 2: Operation and Maintenance, Vol. 3: Troubleshooting. EPRI, Palo Alto, CA: 1987. CS-5198, RP2243-1. 2. Heat Exchanger: An Overview of Maintenance and Operations, EPRI, Palo Alto, CA; 1997. TR-106741. 3. HVAC Fans and Dampers Maintenance Guide, EPRI, Palo Alto, CA; 1999, TR-112170. 4. Maintenance Work Package Planning Guidance, EPRI, Palo Alto, CA; 2005, 1011903. 5. Circuit Breaker Maintenance, Vol 1: Low Voltage Circuit Breakers, Part 1, ABB K-Line, EPRI, Palo Alto, CA; 1993. NP-7410. 6. Circuit Breaker Maintenance, Vol 1: Low Voltage Circuit Breakers, Part 2, GE-AK Models, EPRI, Palo Alto, CA; 1992. NP-7410. 7. Circuit Breaker Maintenance, Vol 1: Low Voltage Circuit Breakers, Part 3, Westinghouse DB Models, EPRI, Palo Alto, CA; 1992. NP-7410. 8. Circuit Breaker Maintenance, Vol 1: Low Voltage Circuit Breakers, Part 4, Westinghouse DS Models, EPRI, Palo Alto, CA; 1992. NP-7410. 9. Electrostatic Precipitator Maintenance Guide, Vol. 1, EPRI, Palo Alto, CA; 2003, 1007456. 10. Electrostatic Precipitator Maintenance Guide, Vol. 2, EPRI, Palo Alto, CA; 2003, 1007690. 11. Pulverizer Maintenance Guide, Vol 2, B&W Roll Wheel Pulverizers; EPRI, Palo Alto, CA; 2004. 1009508. 12. Belt Drive & Bearings Reference Guide, Emerson Power Transmission Manufacturing. 13. Power Zone 4 Low Voltage, Metal-Enclosed Drawout Switchgear, Class 6037, Instruction Bulletin, Square D, 1999-2003. 14. Limitorque SMB Series/SB Series Installation and Maintenance, Flowserve Corporation, 2004. FCD LMAIM1401-00. 15. Evolution Series E 9000 Motor Control Centers, Installation and Maintenance Guide, General Electric, 2001. DEH-40472 Rev 3. 16. Medium Voltage Motor Control Center, Installation and Maintenance Manual, ABB Power T&D, Nov 1998. Bulletin No. 1B3.2.7-7B. 17. Advantage Motor Control Centers, Installation and Maintenance Manual, Cutler Hammer, 2004. 1.B.8922-1A. 18. Guideline to Good Practices for Planning, Scheduling and Coordination of Maintenance or DOE Nuclear Facilities, US Department of Energy, 1993. DOE-STD-1050-93. 19. Guideline to Good Practices for Types of Maintenance Activities at DOE Nuclear Facilities, US Department of Energy, 1993. DOE-STD-1052-93. 4-1 20. Military Handbook, Maintenance and Operation of Central Heating Plants, US Department of Defense, 1995. MIL-HDBK-1125/1. 21. Goulds Pumps, Goulds Vertical Turbine Pumps, Bulletin 3A.1, ITT Industries, 2004. 22. Thermostatic Steam Traps, Module 11.2, SC-GCM-80, Spirax-Sarco Limited, 2005. 23. Mechanical Steam Traps, Module 11.3, SC-GCM-81, Spirax-Sarco Limited, 2005. 24. Thermodynamic Steam Traps, Module 11.4, SC-GCM-82, Spirax-Sarco Limited, 2005. 25. Testing and Maintenance of Steam Traps, Module 11.14, SC-GCM-80, Spirax-Sarco Limited, 2005. 26. Steam Survey Guide, ORNL/TM-2001/263, Oak Ridge National Laboratory, Greg Harrell, 2002. 27. Inspect and Repair Steam Traps, Steam Tip Sheet #1, DOE/GO-102002-1503, Steam, US Department of Energy, 2002. 4-2 A WORK PACKAGE TEMPLATE – BELT DRIVEN EQUIPMENT 1.0 Task Overview 1.1 Component type This work instruction is applicable to various belt driven types of equipment. It is applicable but not limited to air handling units (AHUs), fans, coolers, compressors, vacuum pumps, etc. 1.2 Equipment tag or unique equipment identifier Ensure unique equipment identifier is used to designate which piece of belt driven equipment is worked. 1.3 Scope This work instruction describes the disassembly, inspection, shaft/bearing alignment, sheave alignment, belt tension adjustment and reassembly of belt driven equipment. 1.4 Develop list of know consumable materials to be used A. B. C. D. E. Container (bags) for temporary storage of studs and nuts Loctite Emery cloth Steel wool Grease (if applicable for bearing lubrication) 1.5 Develop a list of know parts to be replaced A. Belts B. Sheaves C. Shims 1.6 Special tools A. B. C. D. E. F. G. Force gauge Belt tensioner Sheave Groove Gauge Torque wrenches Combination wrenches Socket set Allen wrenches A-1 H. Straight edge I. Dial indicators J. Level 2.0 Pre-job Brief 2.1 Evaluate potential for generation or equipment risk hazards A. Some fans have resonant frequencies. Belts should be adjusted appropriately to avoid fans potentially running at resonant frequencies. B. Some belts do not recommend the use of belt dressings. This could cause premature belt failure. (refer to belt manufacture with respect to belt dressings) C. It is recommended that belt tension be checked within 24 to 48 hours of installing new belts due to belt break-in stretch. D. If ventilation fans are being worked, resulting ventilation line-ups to support work can cause significant d/p’s across doors or other accesses posing a personnel safety hazard. 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. If work is performed inside plenums foreign material exclusion areas should be established. 2.3 Job Safety Analysis, Identifies general and specific hazards A. Some fans are located in common plenums and may require securing redundant fans to allow work to proceed safely. B. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. 2.4 Identify permits required A. Equipment Clearance/Tag out Orders B. Confined Work Space (if applicable) C. Chemical Control Procedures (handing and disposal) A-2 grease. oil.7 Identify Clearance/Tag out Boundary A. AHU. Inspections of any components may result in the need to repair or replace components as appropriate. C. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work.1 Identify potential scope expansion and actions due to scope expansion A.0 Contingency Considerations 3. Motor to fan. etc B. Contact engineering if flow tests or vibration monitoring can not meet acceptable limits within the scope of work D. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. solvents. B. Contact planner if scope growth is identified during work instruction performance B. Handling and disposal of chemicals (E.2. 2.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment. compressor.3 Identify rapid or emergency actions to place equipment in likely A-3 .g. Power to inlet and outlet dampers (if applicable) C. 3. cleaning solvents) B. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E.5 Identify Environmental Consideration A. Power to common plenum/duct equipment (if applicable) 3. etc) should be in accordance with approved chemical control procedures 2.g.2 Identify individuals to contact in case certain events occur A. cooler. Shaft 4. Covers c. utilize existing procedures when applicable Provide expected actions in proper sequence for task. Bearings B.4 Develop material list for potential contingency and consumable parts A. REMOVE as applicable: a. C. Access Ports d.compensatory configurations or conditions 3. screws and/or fasteners CAUTION Do not pry belts off of sheaves as this may damage belts and sheaves.0 Detailed Work Instructions Develop work instructions. B. Guards b. E. NOTE Belts should not ride in the bottom of a sheave groove. A. Bolts. D. Identify Notes and Cautions where needed A.1 Disassembly NOTE Bag or tag parts for traceability. A-4 . NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn on the job 4. Spin burns or glazed shinny side walls is an indication of belt slippage. A-5 .2 Inspections NOTES 1. 5. 4. Belts that are hard and brittle are typically a result of lack of tension. the sheave should be replaced. C.B. If sheave is dished greater than 1/32”. Cracks C. Sheaves with cracks or dished sides should be replaced. Sheaves with burrs. 2. 3. rough spots or corrosion may be cleaned. Worn belt sides NOTES. 1. Ruptures F. Worn or damaged parts should be repaired or replaced if required Old and new belts should be inspected prior to use Wear on one side of a belt is an indication of improper sheave alignment. 2. Separation of plies E. Slip burn areas D. INSPECT belts for: A. Cover fabric ruptures B. REDUCE sheave center-to-center distance between the motor sheave and the driven sheave to allow removal of belts. 3. LIFT belt(s) off sheave 4. A. Shaft coupling b. Housings c. Burrs b.G. Corrosion d. K. or other damage or degradation. CAUTION Do not apply excessive pressure when lubricating to prevent damage to bearing seals. Pitting e. Fan wheel A-6 . Dished sides NOTE Major shaft defects can sometimes be discovered by rotating shaft by hand and listening/feeling for unusual noises and/or rough spots. INSPECT bearing set screws are tight NOTE Some pillow block bearings require lubrication. I. H. Refer to vendor for approved lubricants. LUBRICATE bearings (if required) L. Rough spots c. INSPECT sheaves for: a. INSPECT bearings for any defects or misalignment J. INSPECT shaft for rough spots. INSPECT the following for unusual wear: a. burrs. Cracks f. Mounting bases d. 3.3. A. NOTE Sheaves should be placed as close to the bearings as possible to create less shaft deflection and bearing stresses. K.2 Shaft/Bearing Alignment (required only if shaft or bearing is replaced) A. Straight edge alignment c. For horizontal movement. String alignment 4. LOOSEN pillow block hold down bolts OBSERVE dial indicators for movement to determine if shaft was preloaded. G. in the same plane (prime mover and driven unit) ADJUST bearings as needed to achieve shaft s in the same plane. For fans: ENSURE fans are centered radially and axially. adjust bearings as necessary I. TORQUE bearing hold down bolts when satisfactory shaft alignment is achieved. E. REPEAT dial indicator test for shaft preload until acceptable results are achieved J. For vertical movement add or delete shims as necessary on pillow block bearing or adjust flange bearings b. RECHECK alignment A-7 . H.1 Sheave alignment CAUTION Do not roll or pry belts off of sheaves as this may damage belts and sheaves. B. F. C. ALIGN motor sheave to driven sheave a. a.3 Alignments 4. D. TIGHTEN bearing hold down bolds (snug tight) POSITION dial indicators on shaft at pillow block bearing. INSPECT bearing and ensure it is centered in its housing VERIFY Shaft is level.4. Laser alignment b. Some fans have resonant frequencies that must be avoided. Under tensioning belts can cause premature belt ware or fan failure.1 inch DIVIDE span by 64 to obtain deflection NOTES 1. D.4 Reassembly A.3. C. screws and fasteners (torque as specified) NOTE If work was performed inside a plenum ensure are materials taken into plenum have been removed.3. 6. After installation of new belts. 4.001 inch MEASURE belt span to +/.3 Adjusting belt tension 1. INSTALL dial indicator at closest accessible location to the centerline of sheave.’ A-8 . Deflection force should be measured as close to the center between the two sheave axis. belts should be tensioned to maximum allowable force to allow for break-in stretch Over tensioning belts shortens belt and bearing life. The most common reason for belt failure is under tension. CALCULATE average force 4. Average force equals total force divided by the number of belt ribs. Refer to vendor manuals for appropriate belt tensions The shaft deflection method is a recommended method for belt driven HVAC equipment. B.3. 8. For multiple belt sets do not mix old and new belts. 2. APPLY tension to belt until shaft movement is detected not to exceed 0. 2. For a banded belt. NOTES Ideal belt tension is the lowest tension that will prevent prolonged belt squeal on startup and excessive vibration during operation. 7. 3. E. MEASURE force in pounds required to deflect each of the belts a distance equal to the deflection distance F.4. INSTALL all bolts. 5.3.1 Shaft deflection method A. 4. 9. driven equipment) Foreign Material Control Procedure Material Safety Data Sheets Chemical Traffic Control Procedure A-9 . C. B. D.B. sheaves. C. E. Industrial Safety Manual Applicable vendor technical manuals (Belts. Initiate any corrective action program documents necessary to resolve any problem areas identified.0 Determine PMT and PMT considerations A.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. 7. Vibration testing is recommended for all corrective maintenance B. Additional belt tension adjustments may be required to achieve acceptable vibration levels or to eliminate belt squeal 6. Perform post job review B.0 References A. Flow testing is recommended for sheave replacements if flow is critical to proper operations of equipment or supported equipment cooling. bearings. covers and access ports 5. INSTALL guards. . 1 Component type This work instruction is applicable to a single stage. E.4 Develop list of know consumable materials to be used A.BOILER FEED WATER PUMP 1. Grease (for gear type coupling installation) Containers (bags) for temporary storage of parts Clean rags Oil drain pan Bearing oil (as per vendor manual) Silicon grease B-1 .3 Scope This work instruction provides instructions for the disassembly and assembly of a single stage. 1.0 Task Overview 1.2 Equipment tag or unique equipment identifier Ensure the unique boiler feed water pump identifier is used to designate which boiler feed water pump is being worked. cleaning and lubrication information is also provided.B WORK PACKAGE TEMPLATE . 1. pack-less boiler feed water pump. C. 1. Various inspections. F. It also provides steps for the removal and installation of subsystems. pack-less boiler feed water pump. B. D. J. etc) B. However. D. Various seals 1. and working around thermally hot components. H. Chain falls. N. if removed) Coupling puller Dial indicators Feeler gauges Inside and outside micrometers Torque wrenches (various) Alignment equipment 2. M.) Rubber gloves Duct tape 1. I. H.5 Develop a list of know parts to be replaced A. slings etc Combination wrenches Allen wrenches Various sockets Plasti-gage for bearing clearances Bearing heater for coupling hub Tempilstick (as per vendor manual for coupling hub) Cribbing (to support rotating element. B-2 .6 Special tools A. F. bearing brackets. act. I.1 Evaluate potential for generation or equipment risk hazards This work is typically performed during an outage period. etc) C. acetone.G. G. if it can be performed with the unit on line other considerations are reduced load operation. Anti seize Permatex Cleaning solvent (Isopropyl alcohol. Various O-rings (Stuffing box bushing. E.0 Pre-job Brief 2. K. Various gaskets (case to cover. K. B. cover. hoists. C. rigging. J. L. D. Appropriate measures (covering pipe ends. oil. 2. solvents. Equipment Clearance Orders Open Flame Permits/Hot Work Permits Chemical Control Transient Fire Load Permit (cleaning solvents. Handling and disposal of chemicals (E. Performance of this work will open various piping systems and a major piece of plant equipment. Refer to vendor manual for proper chemicals that may be used on shaft. rags. etc) should be in accordance with approved chemical control procedures 2.g. B. cleaning solvents) B. C. covering casing) should be taken to prevent foreign material from entering the system. grease.2 Identify Foreign Material Exclusion (FME) potential and mitigation A.3 Job Safety Analysis.5 Identify Environmental Consideration A. Identifies general and specific hazards A.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed. they are susceptible to deterioration and failure if they come in contact with petroleum based products.4 Identify permits required A.g. Prime mover shall be cleared as part of clearance/tag out boundary B-3 . grease. If pump uses EPT O-Rings. B. 2.2. Depending on material some pump shafts are susceptible to stress corrosion cracking. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E. etc) 2. oil. 2.7 Identify Clearance/Tag out Boundary NOTE MFW pump prime mover may be either an electric motor or a steam driven turbine. C. G. 3. B.1 Identify potential scope expansion and actions due to scope expansion A. D. Motor breaker or steam supply valve Motor heater breaker (if applicable) Pump supply valve Pump discharge valve Pump vent valve Pump drain valve Lube oil supply breaker (if applicable) Lube oil supply and discharge valves (if applicable) Cooling water supply and discharge valves 3.0 Contingency Considerations 3. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work.A. Contact engineering if flow tests or vibration monitoring can not meet acceptable limits within the scope of work D. Contact vendor for any clarification of vendor information or additional vendor assistance is required B-4 . F. B.2 Identify individuals to contact in case certain events occur A. Inspections of any components may result in the need to repair or replace components as appropriate. C. Contact planner if scope growth is identified during work instruction performance B. H. E. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. I. B-5 .4 Develop material list for potential contingency and consumable parts A.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. VERIFY clearance/tag out is correctly in place B. E. D. hoists. are available and have been inspected prior to use 4. Rotating element Coupling (as per vendor manual) Wear ring Bearings 4. LOCATE and ENSURE proper piece of equipment is being worked per the work instruction C. C.0 Detailed Work Instructions Develop work instructions. B. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn on the job ENSURE all rigging.1 Preparations A. ENSURE appropriate laydown areas are prepared for temporary storage of removed components CAUTION Instrumentation and associated cabling can be easily damaged. F. chain falls. utilize existing procedures when applicable Provide expected actions in proper sequence for task. C. Identify Notes and Cautions where needed A. B. Care must be exercised during disassembly to prevent damage to either instruments or cables. slings etc.3. D. MEASURE as-found coupling alignment (if required) Horizontal offset Vertical offset Angular face alignment B-6 . REMOVE oil piping (if bearing housings are to be removed) 4. Care should be taken to ensure these are recognized. asbestos abatement must be used to remove insulation. C.2 Removal of Subsystems NOTE Removed piping ends should be covered after removal to prevent entry of foreign material. REMOVE instrumentation (if not previously removed) NOTE Oil systems may contain orifices. REMOVE seal water piping (if pump covers are to be removed) B. If asbestos is present. A. etc) CAUTION Ensure insulation does not contain asbestos. E.3 Disassembly NOTE Engineering may require as found alignment data prior to disassembly.D. marked and saved for reinstallation. equipment supports and other interferences as required 4. REMOVE instrumentation (temperature. REMOVE insulation and store appropriately F. vibration. A. REMOVE any piping. REMOVE coupling guard C. Thrust bearing housing c. etc) G. DISASSEMBLE thrust end (depending on pump design some components may or may not be present) (Refer to vendor manual) a. Various types of coupling arrangements are used in the industry. 2. Thrust deflectors b. Journal bearing d. Stuffing box (bushings. Journal bearing d. Follow applicable vendor disassembly instructions for removal. Thrust bearing assembly f. B-7 . etc) F. Stuffing box (bushings. Thrust bearing assembly f. Bearing housing bracket g. Bearing housing bracket g. D. Hot work permit required. REMOVE pump cover and gasket NOTE If rotating element is to be removed. Match mark coupling hubs and diaphragm packs. REMOVE coupling E. protective sleeves should be placed on shaft to protect bearing surfaces. o-rings. REMOVE spool piece (if present) NOTES 1. Match mark couplings prior to removal. B.NOTE Matchmark spool piece to hubs. Oil seal e. Thrust bearing housing c. If coupling hub is to be removed from pump shaft heat will be required. o-rings. Oil seal e. 3. DISASSEMBLE thrust end (depending on pump design some components may or may not be present) (Refer to vendor manual) a. Thrust deflectors b. Heat will be required for removal.1 Cleaning. erosion and corrosion a. chemical control procedures and temporary storage of combustible materials. allow shaft and impeller to cool and then repeat heating removal steps. Bearings (inboard. CAUTION If during the removal process the impeller binds on the shaft. I. Rotate heat for even distribution keeping flame away from shaft. REMOVE impeller J. Inspection. thrust bearings) e. INSPECT parts for wear. this is typically an interference fit over a drive key. Any worn or defective parts should be replaced.3. B. Casing internals c. Bearing housings B-8 . REMOVE rotating element NOTE If impeller is to be removed. CLEAN parts with appropriate cleaning solution and dry with lint free rags NOTES 1. Attempting to continue with removal can damage shaft.H. Bearing bracket covers d. outboard. CAUTION Do not exceed vendor recommendations on max temperature allowed. 2. Lubrication NOTE During cleaning steps follow guidance of MSDS sheets. REMOVE wear ring 4. A. Rotating element b. Obtain a hot work permit. If bearings are found wiped or degraded the oil sump strainer and oil drain piping should be inspected and cleaned as required. REPLACE wear ring ***** If impeller was removed ***** NOTES 1. LUBRICATE threads of studs/bolts with never seize. grease. Temperature of impeller should be monitored during heating. 4. Pre-lube bearings before rolling shaft. INSTALL impeller ***** If shaft was removed ***** NOTES 1. Oil deflectors C. oil or other visible contaminants. Shaft runout c. grit. b. PT under coupling area.2 Reassembly A. CLEAN gasket mating surfaces (honing may be required) E. Proper heating of impeller requires slow even heat distribution. Inboard and outboard stuffing box bushings NOTE All flanges and gasket surfaces should be free of dirt. Do not exceed vendor temperature limits. 2. PT journal bearing area. UT length. B. 2. D.f. Radial end wear ring and thrust end wear ring d. C. INSTALL pump gasket and cover B-9 . INSPECT pump shaft a.3. NDT (optional based on need. CLEAN bolts and threaded holes F. Shaft should be rotated at various stages of reassembly to detect any binding. Thrust bearing housing c. Journal bearing d. ASSEMBLE a. Thrust deflectors b.D. Ensure shaft rotates freely NOTE Observe match marks B-10 . Clearance should be within vendor requirements. ASSEMBLE outboard and inboard bearings K. etc) F. Stuffing box (bushings. o-rings. Journal bearing d. REASSEMBLE thrust end (depending on pump design some components may or may not be present) (Refer to vendor manual) a. 3. CHECK Thrust Disc Face alignment J. o-rings. Lubricate o-rings with approved lubricant prior to installation. Oil seal e. SET thrust bearing end play L. Fill lube oil tank (vendor recommended oil) d. E. Thrust deflectors b. INSTALL rotating element (shaft and impeller) NOTES 1. During reassembly appropriate torque techniques should be followed. REASSEMBLE thrust end (depending on pump design some components may or may not be present) (Refer to vendor manual) a. Oil deflectors b. Stuffing box covers c. etc) G. Thrust bearing assembly f. CENTER rotating element axially I. Stuffing box (bushings. Bearing housing bracket g. Measure bearing clearances after installation of bearings. 2. Thrust bearing housing c. Bearing housing bracket g. Oil seal e. ENSURE shaft rotates freely H. Thrust bearing assembly f. 0 Determine PMT and PMT considerations A.A. B. backfill line to purge air E. RELEASE clearance/tag out B. INSTALL coupling INSTALL spool piece PERFORM cold alignment INSTALL coupling guard NOTE If boiler feed pump lube oil sense line was disconnected. PERFORM vibration testing b. Hot alignment (if required) B-11 . CHECK for leaks (oil. D. When pump is capable of being run a. INSTALL subsystems Oil piping Seal water piping Instrumentation 5. water) C. C. MEASURE inboard and outboard bearing temperatures (vendor recommendation) D. Work site cleanup REINSTALL any interferences removed to support access to work REINSTALL insulation CLEAN work area to original pre-maintenance conditions F. 7. coupling. Industrial Safety Manual Applicable vendor technical manuals (boiler feed pump. E.0 References A. D. C. G. Initiate any corrective action program documents necessary to resolve any problem areas identified. Perform post job review B. B. bearings) Foreign Material Control Procedure Material Safety Data Sheets Chemical Traffic Control Procedure Hot work procedure Storage of temporary combustibles B-12 . F.E. RETURN unused parts to storeroom 6.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. C. H.2 Equipment tag or unique equipment identifier Ensure the unique heat exchanger identifier is used to designate which heat exchanger is to be worked on. However. Container (bags) for temporary storage of studs and nuts Tube plugs (type as specified by vendor) Isopropyl Alcohol. cleaning. B. D.4 Develop list of know consumable materials to be used A. F. Acetone or DI water Clean rags Thread Lubricant Flat scraper Emery cloth Marker to identify problem tubes Buckets C-1 . E.1 Component type This work instruction is applicable to a single pass horizontal heat exchanger. many aspects are applicable to U-tube type heat exchangers.C WORK PACKAGE TEMPLATE – HEAT EXCHANGER 1. 1. pressure testing.0 Task Overview 1.3 Scope This work instruction provides instructions for the disassembly of a heat exchanger. 1. G. I. repairs of tube and tube to tube sheet leaks and reassembly. 1. come-a longs Endplate removal fixture (if specified for the heat exchanger) Tube cleaning equipment (pump. K. F. C.6 Special tools A. slings chokers. eye glasses. Running equipment should be monitor frequently. D.1 Evaluate potential for generation or equipment risk hazards If this work is being performed with the unit on line it is possible that the heat exchanger being worked may be supporting cooling to various pieces of running equipment. C. hoses. gloves. C-2 . breathing dust masks.0 Pre-job Brief 2. safety shields. N. E. Rotary grinder. E. etc) 2. I. D. with bits and disks Stainless steel brush Eyebolts. especially following removal of the heat exchanger. L. M. J. Load reduction may be required to perform heat exchanger maintenance. Gasket material Studs Nuts Washers Zincs (if applicable) 1. Ensure running equipment has adequate flow to ensure proper cooling of the equipment. Running equipment temperatures should be stabilized prior to disassembly of the heat exchanger in the event the heat exchanger must be returned to service. B. G.1. B.5 Develop a list of know parts to be replaced A. cleaners) Borescope (Tube fouling inspection if required) Leak testing equipment Rolling tool Torque wrenches Wooden blocks to support end plate of hinge type design Pop-a-Plug hydraulic equipment (if this method of tube plugging is used) Lighting (Low voltage or GFIC protected) Ventilation fans (if needed) Personal protective equipment (hard hat. H. F. 2.3 Job Safety Analysis. I.4 Identify permits required A. MSDS sheets should be reviewed for any applicable precautions and requirements.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. The heat exchanger end bell should be inspected for cleanliness prior to closure. studs. etc) should be suitably identified and stored to ensure proper orientation and reinstallation. G. Nuts. Some heat exchanger fluid systems contain various corrosion inhibitor chemicals. E. Transient fire loads should have appropriate permits. B. (Chemical Control Procedure. Ensure MSDS (Material Safety Data Sheets) have been reviewed and appropriate guidance followed for the handling. Tube cleaning equipment shall have a “deadman’s” switch controlled by the operator. Personnel operating tube cleaning equipment should be trained and familiar with operating of equipment. studs. Identifies general and specific hazards A. temporary storage and disposal on any applicable materials used. bolts. B. House keeping at the job site should be maintained to minimize the potential for foreign material from entering the heat exchanger. Identify if any chemical use permits are required for special chemicals or solvents. 2. D. Work area should be roped off or marked appropriately for hazards present on the job.A. Ensure the end of the heat exchanger where cleaners are shot out is appropriately covered to prevent personal injury due to a missile. bolts. washers. C. H. All parts (nuts. Tube cleaning equipment operates under extremely high pressure and can cause serious personal injury. washers and any disassembled parts should be identified and stored properly to ensure control and availability for reinstallation. Ensure any load lifting equipment is in good repair and of proper load bearing size for loads to be lifted. Cleaning solvents can be volatile. Unnecessary personal safety hazards may result if proper housekeeping is not maintained. 2. C-3 . Material Safety Data Sheets) C. House keeping should be maintained clean to minimize potential for safety hazards B. Define appropriate Clearance/Tag Out boundary and ensure all planned work activities are with in the identified clearance/tag out boundary. Tube plugging activities Tube to tube sheet leak repairs Coating repairs Corrosion/Erosion repairs 3. Inlet and outlet valves and bypass valves for the tube process fluid Inlet and outlet valves and bypass valves for the shell process fluid Tube side drain and vent valves Shell side drain and vent valves Power to electronic corrosion control equipment (if applicable) 3.2 Identify individuals to contact in case certain events occur A. D. 2. Review appropriate MSDS sheets and in-house chemical use procedures for any special chemicals or solvents used. D. Some heat exchangers contain corrosion inhibitor chemicals. B.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment. Identify reporting limits and requirements for any accidental release of chemicals or solvents to the environment C. 2.7 Identify Clearance/Tagout Boundary A. B. D. B. E.1 Identify potential scope expansion and actions due to scope expansion A. When draining heat exchangers ensure MSDS sheets are reviewed for any applicable precautions and requirements.5 Identify Environmental Considerations A. Contact planner if scope growth is identified during work instruction performance C-4 . C.2. C.0 Contingency Considerations 3. Identify and special handling or temporary short-term storage requirements for any specials chemicals or solvents required. work area is clean and appropriate work boundaries have been established B.0 Detailed Work Instructions Develop work instructions. Tube plugs (type as per vendor) B. C. Coating materials 4.4 Develop material list for potential contingency and consumable parts A. utilize existing procedures when applicable Provide expected actions in proper sequence for task. B. REMOVE insulation if heat exchanger has insulation on heat exchanger channel heads end plates to allow access to studs. C. D. Engineering should be notified of any erosion/corrosion problems identified 3. ENSURE FME requirements are in place. Contact vendor for any clarification of vendor information or additional vendor assistance is required D. STORE insulation for personal safety and preservation of insulation. Identify Notes and Cautions where needed A.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. C-5 . C. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance.B. E.1 Disassembly: A. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn on the job 4. Zincs f. weld cracks. SECURE end plates to an adequate fixture. INSTALL adequate lighting in heat exchanger H. F. Results of inspection could require scope change to the work instructions to correct identified discrepancies D. bright metal. Tube plug degradation (improper installation. Debris or foreign material g. 3. G. REMOVE end plate studs and remove end plates at each end of heat exchanger. Ensure lifting equipment is appropriate for load being lifted. etc) i. Leak indications beneath Heat exchanger or else where j.CAUTION Heat exchanger end plates are extremely heavy. Coatings e. Some end plates require special lifting rigs. Tube end splitting C-6 . PERFORM inspection of heat exchanger a. Erosion c. Evidence of vibration (chafing. Refer to vendor manual. 2. 2. General cleanliness h. If metal tube plugs are used in the heat exchanger the tube sheet should be inspected in the area of these plugs for tube plug initiated stresses. When end plate is swung open ensure blocks are positioned under end plate to minimize forces on the hinges. Corrosion b. score marks. Fouling d. If end plate is moved to a location for temporary storage. E. missing) k. Some end plates are on hinges. REMOVE and discard end plate gaskets CAUTION Lighting should be either low voltage or protected by Ground Fault Circuit Interrupter (GFCI) NOTES 1. NOTES 1. looseness. ensure it is adequately secured to prevent accidental rolling or tipping. Establish any Confined Space Work requirements if applicable. B. Air. D. MAINTAIN heat exchanger shell side at system pressure for approximately 30 minutes INSPECT tube sheet for leaks RECORD any leaks identified and characterize as to whether the leak is a tube or tube to sheet leak C-7 . C. Leak tests can be performed using system pressure or with leak test equipment using either water. PERFORM ECT (Typically a function of specialized ECT personnel) ***** “OR” ***** 4. Appropriate ventilation and/or personal safety equipment may be A. REMOVE all loose corrosion from tube sheet and inside surface of heat exchanger CLEAN tubes using tube cleaning system or hyrolazing equipment. Vibration damage 4. A.3. D.1 Leak Testing 4. Heat exchanger testing for tube integrity can be performed by either Eddy Current Testing (ECT) or performance of a leak test. 2. ENSURE all cleaners are removed from heat exchanger following cleaning if used CLEAN heat exchanger channel heads 4. Failed or cracked welds m. OBTAIN temporary lift of clearance/tag out boundary on shell side of heat exchanger. helium etc. 2.l.1 Leak Testing using System Pressure A. C. Some cleaners have limited lifetime (10-15 shootings) Ensure adequate number of cleaners is available. PRESSURIZE slowly (fill and vent) shell side of heat exchanger to system pressure.3 Heat Exchanger Testing: NOTES 1. B. E.2 Cleaning: NOTES 1.1.3. 2 Leak Testing using Hydro Pump CAUTION Leak test pressure shall not exceed the design pressure of either the shell or tube side of the heat exchanger A. REMOVE pressure testing equipment L.3. whichever is lower C. A.1 Tube to Tube-Sheet Leaks D. IF ID is less than acceptance criteria THEN: C-8 . RELIEVE system pressure slowly K.F. COMPARE ID of problem tubes to acceptance criteria C. F. G. RELIEVE system pressure slowly G. RE-ESTABLISH clearance boundaries 4. MEASURE inside diameter (ID) of problem tubes B.4.1. E.4 Leak Repairs 4. I. ATTACH pressure gage to leak testing equipment INSTALL pressure testing equipment PRESSURIZE HX to test pressure MAINTAIN heat exchanger shell side at system pressure for approximately 30 minutes INSPECT tube sheet for leaks RECORD any leaks identified and characterize as to whether the leak is a tube or tube to sheet leak J. H. INSTALL a relief valve with a set pressure less than or equal to design pressure of shell or tube design pressure. INSTALL original equipment clearance/tag out boundary 4. OBTAIN necessary temporary lifts on clearance/tag out to install pressure testing equipment B. ENSURE area is roped off for personal protection CAUTION Head pressure effects must be accounted for if the pressure gauge elevation is significantly different from heat exchanger elevation. driven plugs.g. Pop-a Plugs.a. CLEAN inside diameter of problem tubes (depth determined by vendor manual) CAUTION Do not damage tube sheet or coatings during cleaning process b. CLEAN both ends of tubes to be plugged CAUTION If driven plugs are used. B. Ensure adequate plugging margin for the heat exchanger will not be exceeded after plugging operations. IDENTIFY problem tubes to be plugged CAUTION Do not damage tube sheet or coatings during cleaning process. welded plugs. C.2 Tube leaks NOTES 1. 3. There are various types of tube plugs. ROLL each tube to acceptance criteria c. heavy hammering may result in damage to tube sheet. INSTALL tube plugs into each end of the problem tubes C-9 . IF ID was greater than acceptance criteria THEN REFER to engineering for appropriate corrective actions to take for repair. 4. Refer to vendor manual for type of plug to use. A. MEASURE ID of rolled to verify acceptance criteria D. If tube stabilization is required (e. 2. PERFORM leak test again after all problems tubes are rolled and meet acceptance criteria. Tube maps should be generated to show which tubes have been plugged. 4. E.4. rod or wire stabilization) refer to vendor manual. 5 Reassemble Heat Exchanger A. C. REMOVE all tolls.0 Determine PMT and PMT considerations A. F. VERIFY heat exchanger channel heads are free of foreign material and other objects CAUTION Do not damage gasket sealing surfaces during cleaning process. equipment. VERIFY sealing surfaces are free of foreign material and no leak paths exist. E. K. D. G. D. CLEAN the gasket sealing surface on both channel heads and both end plates using a flat scraper and fine emery cloth NOTE A leak path is a defect across the gasket sealing surface E. corrosion and burrs VERIFY threads and studs are clean and damage free INSTALL a new gasket POSITION end plate to heat exchanger channel head flange INSTALL all studs and nuts and snug tight TORQUE flange nuts as required (refer to vendor tech manual) 5. J. B. RELEASE clearance/tag out for return to service (Operations) VERIFY no leaks observed at sealing services INSTALL insulation (if applicable) CLEAN work area DISPOSE of any special chemicals or solvents used appropriately RETURN unused parts to stores C-10 . H. CLEAN threads on studs and bolts to remove foreign material. rust.NOTE Leak tests should be re-performed following any tube or tube to tube sheet leak repair. 4. I. etc from heat exchanger channel head B. CLEAN the inside surfaces of the heat exchanger channel heads C. F. Perform post job review B. B. H.6. C. I. C. F. Initiate any corrective action program documents necessary to resolve any problem areas identified. Heat Exchanger Vendor Tech manual Tube cleaning or Hydrolazing Equipment Tech Manual Tube Plugging Instruction Tube Sheet Map Tube Rolling Instruction Material Safety Data Sheets Chemical Control Procedures Foreign Material Control Corrosion Control C-11 . E.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors. D. Ensure tube plugging maps are updated 7. G. A.0 References Identify typical references needed to perform the identified work A. . This work template is based on information associated with Westinghouse. General Electric and ABB low voltage circuit breakers.3 Scope This work instruction provides instructions overhaul of Low Voltage breakers (225 – 600 VAC). 1. CAUTION This maintenance should only be performed by properly trained maintenance personnel who have received specialized training and demonstrated proficiency in the overhaul of the specific type of breaker being overhauled.D WORK PACKAGE TEMPLATE – LOW VOLTAGE BREAKER OVERHAUL NOTE This work instruction is written based on a generic low voltage breaker overhaul. Refer to specific breaker technical manual for components installed.2 Equipment tag or unique equipment identifier Ensure the unique breaker identifier is used to designate which breaker is to be worked on. Various components listed in each subsection may or may not be installed on a given breaker. 1. Breaker design varies by manufacturer. CAUTION Refer to specific vendor manual for breaker being overhauled. D-1 . 1.1 Component type This work instruction is applicable to Low Voltage breakers (typically 225 – 600 VAC).0 Task Overview 1. D. I. 1. G.1. trip shaft return spring) 1. B. etc (Typically supplied as kits) Spring assemblies Operating mechanism components (Oscillator assembly. Light oil Lubricant (Vendor approved) Cleaning brushes (no metal) Clean lint free rags Soft bristle brush (Non metal) Approved solvent or isopropyl alcohol Degreasing solvent (vendor approved e. B.4 Develop list of know consumable materials to be used A. Stationary and Moving main contacts Arc chutes Auxiliary switch Shunt trip device and shunt coils UV device and coil Various fasteners. D. D.g.g. Varsol) Silver plate cleaner for contacts (vendor approved e. F. clips.6 Special tools A. L. C. F.5 Develop a list of know parts to be replaced A. low dolly for breaker transport Power supply (appropriate voltage to check breaker control components) Multimeter (to measure control circuit voltages and low resistance) Vacuum cleaner D-2 . B. E. Tarnex) Glass cleaner (ammonia based) Anti-oxidizing lubricant Scotch-brite Fine sandpaper Molybdenum Disulfide NOTE The part list is based on parts that would be replaced during a typical breaker overhaul regardless of breaker manufacturer. K. E. motor cutoff switch lever. E. J. G. C. Proper breaker lifting device/hoist Flat. H. C. H. 0 Pre-job Brief 2. G. M. Work area should be roped off to preclude personnel from entering a potential shock hazard area and temporary storage of removed breaker baskets/buckets. N. Identifies general and specific hazards A. B. NFPA 70E. pliers. B. 500 to 1000 volt megger Breaker Rack Out Tool/Wrench Overcurrent trip device test set (with timer) Amptector Trip Unit Test Set Spring force scale (~ 50 oz) Electrician’s tools (sockets. (As per Facility Electrical safety Manual. 2. etc) Feeler gauges Dial Caliper Extra fine files 2. G. test leads and other objects are clear of any moving breaker parts to prevent injury to personnel or damage to the breaker. J. H. Appropriate Personal Protective equipment should be worn to preclude shock or arc flash injuries. Operations must be notified of impending breaker to be removed for maintenance. When working inside a breaker. tools. etc) C. E. Ensure hands. I. combination wrenches. Awareness to electrical hazards should be observed in the field. Housekeeping at the job site should be maintained to minimize the potential for foreign material from entering the MCC/LCC or associated buss work. D-3 .3 Job Safety Analysis. Never place hands inside a breaker until the breaker closing springs have been verified to be DISCHARGED. always keep hands clear of moving breaker parts.F. 2. F. There are potential hazards of electrical shocks and/or burns whenever working in or around electrical equipment.1 Evaluate potential for generation or equipment risk hazards A. K. Personnel working on breakers should have received the proper training and be qualified and proficient for work on the specific type of breaker being overhauled D. screwdrivers.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. OSHA. or at the workbench/test area. L. Do not insert a breaker into the cubicle unless the arc chutes are installed. Material Safety Data Sheets) 2. Identify and special handling or temporary short-term storage requirements for any specials chemicals or solvents required.4 Identify permits required A.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment. Older breakers may have arc chutes that contain asbestos. I. Identify if any chemical use permits are required for special chemicals or solvents. J. The presence or absence of asbestos should be verified prior to performing any work on arc chutes. B. Identify reporting limits and requirements for any accidental release of chemicals or solvents to the environment C. 2. (Chemical Control Procedure. 2. Define appropriate Clearance/Tag Out boundary and ensure all planned work activities are with in the identified clearance/tag out boundary. A breaker lifting device/hoist should be used to remove and install a breaker from its cubicle.H. B. D-4 . A low dolly should be used to move the breaker to its work location to prevent the possibility of tipping. Review appropriate MSDS sheets and in-house chemical use procedures for any special chemicals or solvents used.5 Identify Environmental Consideration A. Specific breaker to be clean and inspected B. Identify Notes and Cautions where needed Prerequisites to starting maintenance A.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. Control power fuses (if required) 3.0 Detailed Work Instructions Develop work instructions. Complete spare Operating Mechanism 4. NOTIFY Operations prior to beginning work D-5 .1 Identify potential scope expansion and actions due to scope expansion A. Contact planner if scope growth is identified during work instruction performance B.2.2 Identify individuals to contact in case certain events occur A. utilize existing procedures when applicable Provide expected actions in proper sequence for task.7 Identify Clearance/Tagout Boundary A.4 Develop material list for potential contingency and consumable parts A. Defective parts identified in breaker inspection 3. Contact supervision if any problem is identified that prevents following work instructions D. Complete spare breaker (Tested) B. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. C.0 Contingency Considerations 3. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. high ambient temperature. Racking mechanism (levering) interlock D-6 . frequency of switching operations. 4. NOTE Use appropriate lifting device to remove breaker from cubicle. corrosive atmosphere. CHECK drawout device interlocks (if installed) a. B. C. D. CAUTION Voltage will be present at switchgear bus stabs. (If installed) VERIFY breaker is open and closing springs discharged. Factors affecting frequency include: high humidity. type of overloads and breaker nameplate data. F. and age of equipment. E. Frequency may be between 1 – 3 years depending on conditions. C.B. REMOVE breaker from cubicle. ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn on the job RECORD cubicle number. dusty or dirty atmosphere. NOTE Frequency of overhaul for low voltage circuit breakers depends on the environment and operating conditions. breaker serial number. CHECK for smooth roller operation during breaker removal. NOTE Do not use excessive force when racking out breaker. frequency of fault operations.1 Initial Testing and Inspections A. model. NOTE Draw out interlocks vary by vendor (Most common are listed) D. REMOVE Arc chutes a.2 Mechanical/Electrical Operation NOTE If breaker has a undervoltage (UV) device it must be energized or mechanically defeated. Burning b. dust b. Broken. C.b. Manual Lockout device check d. INSPECT the general condition of the breaker. ELECTRICALLY CYCLE breaker and check for smooth operation and excessive arcing in electrical devices. Trip Interlock c. Cracks G. A. Dirt b. Carbon Tracks c. MANUALLY CYCLE breaker several times and check for smooth operation. Corrosion F. TEST. a. Burn marks f. Closing spring interlock e. Grease hardening. DISCONNECT. Cracks 4. Melting e. INSPECT Pole unit bases a. REMOVE interlocks E. CHECK operation of breaker indicators and breaker operation counter. B. bent. D-7 . darkening c. Cracking d. CONNECT. missing parts a. Dirt. Discoloration (Over heating) h. Pitting g. Contact sequence gap – MEASURE and adjust as required (As per vendor technical manual) D-8 . Measure contact tips for wear (replace if less than vendor recommendation) NOTE Refer to vendor specification for contact gap. Corrosion f. Gap Adjustments a. Burning c. Silver plating for flaking or peeling i. Cracking b. A. Heat stress d. CAUTION If gap adjustments are required care should be taken not to over adjust. Ensure hands.4. Over adjusting will increase closing force B. test instruments and cables and other devices are clear of moving parts. Excessive scarring/galling e.3 Contact Inspections and Adjustment CAUTION Some tests in this section require opening and closing of breaker. INSPECT breaker contacts a. Repair or replace any damaged or degraded components j. Contact gap – MEASURE and adjust as required (As per vendor technical manual) b. Wear and binding in mating surfaces e. CHECK Operating mechanism alignment h. dust. CHECK tripping load 4. missing retainers. D-9 . snap rings. Latch and roller surfaces for wear CAUTION Tests require opening and closing of breaker. broken parts c.4. CAUTION Do not measure insulation resistance of a solid state Over Current Trip Device (OCTD). INSPECT operating mechanism a. Trip bar or shaft 1. etc d. Refer to vendor manual for electrical devices installed and to be tested. Breaker contacts open quickly.4 Operating Mechanism Inspection A. corrosion. etc) b. 2. Loose.5 Electrical Tests NOTE 1. Determine trip force g. CHECK Arc contact alignment i. Freedom of movement 2. General cleanliness (dirt. Ensure hands and equipment are clear of moving parts. f. Refer to vendor manual to acceptance criteria. Loose. MEASURE Undervoltage (UV) Device Pickup E. B. Long time delay b.A. Refer to vendor technical manual for specific components installed on breaker being overhauled. CHECK Overcurrent Trip Device a. moving contacts NOTE Not all breakers have the auxiliary components listed. CHECK Shunt Trip Device NOTE Overcurrent device may be electro mechanical or solid state. Phase to Ground. CHECK Control Circuit F. MEASURE Control Wiring insulation resistance C. (If installed) Ground fault test e. MEASURE Primary circuit insulation resistance (Line to Load. Primary disconnects Secondary disconnects Frame assembly – charging motor. MEASURE Contact resistance (Each phase) D. D-10 . trip shaft/bar Pole unit bases Contact structure – stationary. Phase to Phase) B. Short time delay c. Refer to vendor manual for specific disassembly information.6 Disassembly A. NOTE Breaker disassembly differs by breaker and vendor. E. D. C. G. closing springs. 4. Instantaneous d. F. Amptector unit (if installed) f. Current limiting fuses m. REMOVE auxiliary subcomponents a. Bell alarm device e. Cracked ceramic c. Electric lockout device k. Motor cutoff switch p. A. Damaged or degraded parts below vendor acceptance criteria should be replaced. Reverse current trip attachment n. Tests. Latch check switch G. INSPECT/CLEAN arc chutes a. Burns b. Undervoltage (UV) Trip Device j. Auxiliary switch b. Carbon deposits d. CAUTION Some older arc chutes contain asbestos. Shunt Trip Device i. 2. Closing solenoid (solenoid operated breakers) d. So not sand or attempt repair unless arc material is known. REMOVE operating mechanism 4. Closing spring release device o. Anti-pump relay g. Parts should be cleaned with an approved cleaning solvent or isopropyl alcohol and clean lint free rags. Control relay c. Erosion D-11 .7 Inspections. Fuse Trip Device l. Cleaning and lubrication NOTE 1. Reset micro switch h. Corrosion b. bearing. corrosion.B. INSPECT/CLEAN/LUBRICATE primary disconnects a. freedom of movement d. weakness. etc. worn. Cracks b. INSPECT/CLEAN contact structure a. Damage around mounting holes c. INSPECT/CLEAN pole unit bases a. INSPECT/CLEAN frame assemblies a. Overheating b. loss of silver plating b. Cracked welds E. G. INSPECT/CLEAN operating mechanism a. Bearings – proper lubrication. Remove components from shaft working from one end towards middle b. Burns c. Excessive/abnormal wear c. scribe marks and other aids be used to aid in ensuring that the subcomponents (spacers. Trip bar/shaft – freedom of movement f. Overheating NOTE During disassembly of the operating mechanism it is recommended that notes. Springs – inspect for breaks. c. and other defects. Warping e. cracks. Move without binding D. damage or excessive heat F. retainers. Contact springs for corrosion. alignment through linkages D-12 . Contacts for pitting. are reassembled correctly. Cracks b. Broken/weak springs C. Pins – cracks. Carbon tracks d. Latches – Wear. Bends c. CAUTION Handle bearings carefully. cracks e. INSPECT/CLEAN/LUBRICATE secondary disconnects a. REASSEMBLE switch b. INSPECT for freedom of movement 2. INSPECT contacts for burning and pitting 10. 1. Pinched wires 3. INSPECT control relay arc chutes (cracks. Welds – cracks h. Closing solenoid (solenoid operated breakers) 1. Auxiliary switch 1. CHECK for proper operation 2. damage NOTE Not all breakers have the auxiliary components listed. INSPECT plastic components for cracks 7. discoloration or other defects 3. INSPECT plunger core for distortion or warping 9. REPLACE contacts if badly burned or pitted 6. CHECK insulation for cracks. Broken wires 4. DISASSEMBLE/CLEAN coil c. INSPECT insulation for cracks. insulated pushrods. Refer to vendor tech manual for specific components installed H. INSPECT for freedom of movement 2. MEASURE contact resistance 4. INSPECT coil for signs of overheating 5. Loose connections 5. carbon deposits) 8. General appearance – corrosion i. MEASURE contact resistance b. Cracks D-13 . INSPECT/DISASSEMBLE/CLEAN Shunt trip device 1. DISASSEMBLE/CLEAN coil Inspect Wiring and connections 1. INSPECT/CLEAN phenolic covers.g. INSPECT insulation for cracks. INSPECT auxiliary subcomponents a. MEASURE coil resistance INSPECT/DISASSEMBLE/CLEAN Control Relay 1. INSPECT coil 2. etc. discoloration or other defects 3. Cracks/brittleness 2. discoloration or other defects 3. DISASSEMBLE/CLEAN coil 4. MEASURE coil resistance 6. erosion. Broken lugs d. (If installed) Levering device – wear. DISASSEMBLE and clean switch 5. missing or defective springs. l. INSPECT for overheating 3. m. 2. MEASURE actuator coil resistance 3. discoloration or other defects 3. INSPECT coil for signs of overheating 5. Freedom of operation 2. k. INSPECT insulation for cracks. magnet lamination separation 2. INSPECT for freedom of operation 3. MEASURE contact resistance Primary fuses 1. CLEAN the trip device 3. CLEAN outside of fuse Fuse trip device 1. LUBRICATE/REASSEMBLE UV coil INSPECT Electric Lockout device 1. j. DISASSEMBLE the device 2. latch pin and trip lever for excessive wear 5. REMOVE and clean reset valve and filter 4. i. CLEAN terminations Electro-mechanical overcurrent trip device 1.e. INSPECT for freedom of movement 2. INSPECT for freedom of movement 2. defective parts. h. MEASURE UV coil resistance 4. INSPECT plastic components for cracks 4. f. LUBRICATE moving parts CLEAN/INSPECT Anti-pump relay 1. excessive wear 3. REASSEMBLE. LUBRICATE friction points D-14 . INSPECT the device for corrosion. INSPECT for overheating 2. MEASURE coil resistance 6. g. LUBRICATE friction points Solid State Overcurrent Trip Device (SS OCTD) actuator 1. VERIFY proper type 2. MEASURE coil and contact resistance 4. burns. Carbon tracking 3. INSPECT latch. INSPECT wiring for cracks and other visible damage 3. Contacts – pitting. ENSURE permanent magnet has sufficient strength to hold device in reset position Solid state current sensor 1. INSPECT for freedom of operation 2. DISASSEMBLE/CLEAN coil 4. VERIFY proper rating 3. INSPECT plunger core for distortion or warping INSPECT Bell alarm device 1. INSPECT for freedom of operation 2. Dirt/dust/grease INSPECT/DISASSEMBLE/CLEAN Undervoltage (UV) device 1. INSPECT plunger core for distortion or warping 6. Overheating of coil 4. bushings. Plunger – distortion 6. bearings. 3. old lubricant should be removed prior to applying new lubricant. CHECK Overcurrent trip Switch 1. (Pivot points. Refer to notes taken during disassembly to aid in reassembly 2.8 Reassembly NOTE 1. sliding points. During any lubrication. CAUTION During reassemble keep hands clear of moving parts CAUTION Do not allow lubricants to be deposited on latch faces D-15 . Freedom of operation 2. Contacts 7.n. CLEAN/INSPECT Reset Micro switch 1. Plastic components – cracking 5. etc) As per approved by vendor technical manual. Use a mixture of isopropyl alcohol with molybdenum disulfide for lubricating various components. LUBRICATE friction points 4. Insulation condition 3. During reassembly frequent checks should be performed to ensure all components installed operate freely without binding. MEASURE contact resistance o. 4. ALIGN and INSTALL closing solenoid assembly e. Reset micro switch h. Refer to vendor technical manual for any required specification. 3. LUBRICATE the following components 1. Fuse Trip Device D-16 . INSTALL frame assembly – operating mechanism. Shunt Trip Device i. Bell alarm device e. Refer to vendor technical manual for installation sequence of subcomponents to prevent interferences. Latch faces 2. Trigger faces 3. measurements or clearances that are required during installation B. INSTALL Auxiliary Subcomponents a. Anti-pump relay g. levering device. Operating Mechanism a. Undervoltage (UV) Trip Device j. Amptector unit (if installed) f.CAUTION Do not lubricate Overcurrent devices A. INSTALL operating mechanism on breaker platform d. REPLACE all retainers/fasteners c. Oscillator bar/bushing b. Cam surfaces 7. INSTALL contact structure (Main stationary and moving contacts) f. frame rollers NOTE 1. INSTALL Pole Unit bases g. 2. charging motor. For a given breaker not all subcomponents will be present based on individual vendor design. Control relay c. trip shaft/bar. Trip bar/shaft pivot points and bearing surfaces 5. Trip pan felt pad 4. closing springs. Electric lockout device k. Auxiliary switch b. Closing spring pins 8. Spring charge indicator 6. Closing solenoid (solenoid operated breakers) d. Fuse Trip device – MEASURE and ADJUST device f. INSTALL primary disconnects D. Over adjusting will increase closing force CAUTION Tests require opening and closing of breaker. Adjustments and Tests A. Motor cutoff switch p. Reverse Current Trip – CHECK operation and armature travel h. Contact sequence gap – MEASURE and ADJUST as required (As per vendor technical manual) c. alignment check d. Contact gap – MEASURE and ADJUST as required (As per vendor technical manual) b. Shunt Trip device – MEASURE clearance between trip bar and trip lever g. Ensure hands. CHECK Drawout device interlocks B. Operating mechanism – CHECK tripping load. a. gap measurement and operation e. CHECK Trip latch overlap i.9 Post overhaul Inspections. Closing spring release device o. UV Device – CHECK clearances. test instruments and cables and other devices are clear of moving parts. Latch check switch C. Mechanical Inspections and Tests CAUTION If gap adjustments are required care should be taken not to over adjust. Electrical Inspections and Tests NOTE For megger voltage refer to vendor technical manual. INSTALL secondary disconnects 4. Current limiting fuses m.l. Reverse current trip attachment n. D-17 . Refer to Amptector vendor technical manual for SS OCTD unit installed. TEST Bell alarm – VERIFY proper operation f. TEST Control Circuit – CHECK for proper operation d. Wiring insulation resistance measurements (Megger except contacts) 1. ground fault elements and discriminator circuits. instantaneous trip) D-18 . TEST Shunt Trip Device – VERIFY trip function e. h. MEASURE Contact resistance (Multimeter) b. instantaneous trip) 4. CHECK SS OCTD – Proper operation and travel. TEST Electric Lockout Device – VERIFY proper operation NOTE If breaker has current limiting fuses these must be removed and test bar installed prior to Overcurrent Trip Device test. INSTALL test bar 3. MEASURE Primary circuit insulation resistance (Line to Load. wiring and connections 2. TEST Under Voltage Device – CHECK Dropout and breaker closure c. REMOVE current limiting fuses 2. Phase to Ground. VERIFY settings. Phase to Phase) 2. Electro-mechanical Overcurrent Trip Device 1. NOTE Depending on Amptector installed it may be necessary to defeat either/both. short time delay. ADJUST electro-mechanical overcurrent settings to vendor specification as required. long time delay. long time delay. CAUTION Refer to vendor technical manual for proper test currents when testing overcurrent trip devices. Excessive test currents will pit contacts. MEASURE Control circuit insulation 3. CHECK electro-mechanical overcurrent trip device – Proper operation and travel. g.CAUTION Do not megger wiring of Solid State Trip Unit a. short time delay. Solid State Overcurrent Trip Device (SS OCTD) 1. VERIFY breaker indications reflect proper status of breaker. C. MANUALLY OPERATE breaker to verify proper operation during open and close operation. CONDUCT electrical testing to confirm no short circuits were created during inspection or maintenance.10Final Breaker Assembly NOTE Catch debris removed from contacts. E. (If required) MEASURE breaker opening and closing times (electrical operation) NOTE If breaker has current limiting fuses these must be removed and test bar installed prior to Overcurrent Trip Device test. A. VERIFY breaker cannot be closed with UV device de-energized. ELECTRICALLY CYCLE breaker in the test position open and close to verify correct operation H. REMOVE all test leads and equipment from breaker. etc.3. RETURN unused parts to stores D-19 . CAUTION Refer to vendor technical manual for proper test currents when testing overcurrent trip devices. D. (If installed) VERIFY any key interlocks or mechanical interlocks are functioning properly I. B. F. INSTALL breaker in cubicle test position G. PERFORM final breaker visual inspection for loose components. DISPOSE of any special chemicals or solvents used appropriately K. CLEAN work area J. ADJUST SS OCTD unit settings to desired specification as per vendor manual i. 4. damaged wiring. INSTALL arc chutes and insulators C. REMOVE any debris deposited on contacts form breaker overcurrent testing B.0 Determine PMT and PMT considerations A. Excessive test currents will pit contacts. 5. 0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors.0 References Identify typical references needed to perform the identified work A. B.6. E. Perform post job review B. A. Breaker Vendor Tech manual Applicable wiring drawings Facility Electrical Safety Manual Material Safety Data Sheets Chemical Control Procedures Foreign Material Control D-20 . C. D. 7. Initiate any corrective action program documents necessary to resolve any problem areas identified. F. Power and control fuses C. Light bulbs B. 1. Electrical contact cleaner (non-residue) Cleaning brushes (no metal) Clean rags Approved cleaner (non-residue) 1.5 Develop a list of know parts to be replaced A.3 Scope This work instruction provides instructions for the cleaning and inspection of 480 volt MCC/LCC Breakers. D. Low resistance Ohm Meter E-1 .1 Component type This work instruction is applicable to 480 volt Load Center Breakers.6 Special tools A. Motor Control Center/Load Control Center (MCC/LCC) cubicles/cabinets. 1. starters. C.0 Task Overview 1. starters. MCC/LCC cubicles/cabinets.4 Develop list of know consumable materials to be used A. and buss work and hardware. and buss work and hardware. B.2 Equipment tag or unique equipment identifier Ensure the unique MCC/LCC identifier or which MCC/LCC breaker identifier is used to designate which MCC/LCC or which MCC/LCC breaker is to be worked on.E WORK PACKAGE TEMPLATE – MOTOR CONTROL CENTER/LOAD CONTROL CENTER (MCC/LCC) INSPECTION AND CLEANING 1. Starter contactor kits 1. 1. Analog Multi-meter B. Compressed air should also be dry and free from oil E. remove arc covers from contactors and seal openings to control circuits present.3 Job Safety Analysis. Electrician’s Tool Box Vacuum cleaner 500 to 1000 volt megger Breaker Lifting device Breaker Rack Out Tool 2. G. Compressed air only distributes contaminants to other surfaces. House keeping at the job site should be maintained to minimize the potential for foreign material from entering the MCC/LCC or associated buss work. 2. OSHA. Operations must be notified of impending Load Center Work with sufficient time to place alternate equipment into operation or realign power supplies.1 Evaluate potential for generation or equipment risk hazards A. D.C. Use of compressed air is not recommended for cleaning. B. (As per Facility Electrical safety Manual. E. Work area should be roped off to preclude personnel from entering a potential shock hazard area and temporary storage of removed breaker baskets/buckets. F. Emory cloth should not be used to burnish contacts. Appropriate Personal Protective equipment should be worn to preclude shock or arc flash injuries.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. Personnel working on breakers should have received the proper training and be qualified to work on this equipment. 2. etc) C.0 Pre-job Brief 2. If air is used. There are potential hazards of electrical shocks and/or burns whenever working in or around electrical equipment B. D. E-2 . Identifies general and specific hazards A. Many vendors do not recommend burnishing contacts. The filing of contacts removes the silver finish and shortens useful life. NFPA 70E. 2. Defective parts identified during starter inspection C. 2. MCC/LCC supply breaker (If MCC/LCC is being cleaned) 3. Identify if any chemical use permits are required for special chemicals or solvents. Review appropriate MSDS sheets and in-house chemical use procedures for any special chemicals or solvents used.0 Contingency Considerations 3. Identify and special handling or temporary short-term storage requirements for any specials chemicals or solvents required. (Chemical Control Procedure.1 Identify potential scope expansion and actions due to scope expansion A.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment.7 Identify Clearance/Tagout Boundary A. Specific breaker to be clean and inspected B. Material Safety Data Sheets) C. Transient fire loads should have appropriate permits.4 Identify permits required A. Identify reporting limits and requirements for any accidental release of chemicals or solvents to the environment C. Control power fuses (if required) C. Defective parts identified during bus work inspection E-3 . B.2. B.5 Identify Environmental Consideration A. 2. Defective parts identified in breaker inspection B. Define appropriate Clearance/Tag Out boundary and ensure all planned work activities are with in the identified clearance/tag out boundary. frequency of fault operations. Frequency may be between 1 – 3 years depending on conditions. Contact supervision if any problem is identified that prevents following work instructions D. NOTIFY Operations prior to beginning work B. utilize existing procedures when applicable Provide expected actions in proper sequence for task. C. D.4 Develop material list for potential contingency and consumable parts A. C.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. Contact planner if scope growth is identified during work instruction performance B. Overload heaters Starter coils Pushbuttons Switches Terminal blocks Complete starter kits 4.3. F. ENSURE an appropriate clearance/tag out is in place to perform work safely C. E.2 Identify individuals to contact in case certain events occur A. ENSURE all tools necessary to perform the job are available E. and age of equipment. ENSURE all parts expected to be used are available and in hand D. dusty or dirty atmosphere. ENSURE appropriate personal safety equipment is worn on the job NOTE Frequency of maintenance for low voltage circuit breakers depends on the environment and operating conditions. frequency of switching operations.0 Detailed Work Instructions Develop work instructions. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. high ambient temperature. E-4 . Identify Notes and Cautions where needed Prerequisites to starting maintenance A. Factors affecting frequency include: high humidity. B. corrosive atmosphere. a. Discoloration f. eye protection) NOTE If an arc has occurred in the breaker compartment it is possible some organic insulating materials may have deteriorated. NOTE If working around energized low voltage equipment appropriate electrical safety equipment should be worn. debris E-5 . CHECK out-going terminals to ensure no feedback condition exists. NOTE It is cost effect to perform load center cleaning with basket/bucket maintenance. (e. Dirt. If voltage is present use extreme caution. Burn marks e. CHECK incoming line terminals to verify that the equipment is de-energized B. (Evidenced by soot. C. Cracking c. gloves. D. CYCLE breaker in test position and CHECK for undue noise or vibration that may loosen bolted connections.g. dust.1 Load Center Breaker Clean and Inspect CAUTION Check the line side of the breaker for voltage.NOTE If breaker has experienced a fault a thorough inspection of the breaker should be performed prior to returning it to service. 4. debris or carbon tracks) A. Heat Stress b. Melting d. INSPECT the internal condition of the breaker basket/bucket. Discoloration vi. REPAIR any identified sources showing in leakage. It is recommended that alcohol and Freon not be used as cleaning agents. condensation build-up or signs of previous wet conditions. J. INSPECT the bucket/basket interior for any signs of overheating or discoloration. INSPECT load center basket/bucket components for any signs of visibly worn. INSPECT Starter i. Freedom of movement of electrical contactors c. Missing components iv. CLEAN inside of basket/bucket using and approved solvent or contact cleaner. etc.NOTE Use of a vacuum cleaner verses air blowing is preferred. Contacts iii. Line and load connections for overheating v. Burns ii. Line and load connections for missing or defective parts vi. Using air to blow out a Load Center basket/bucket typically moves dust around. Corrosion d. blades fit securely into stabs v. Proper voltage iii. over current devices or other components with contacts causing overheating or improper operation. INSPECT Breaker for: i. I. CLEAN (Using a vacuum cleaner) out the load center basket/bucket NOTE Limit use of solvent when cleaning to remove grease and contamination to minimize residue buildup. F. Bent or damaged interlock arms iii. a. Proper size (rating) ii. Discoloration iii. Fit into clips snuggly with no damage or deterioration iv. WIPE bus bars. H. Pitting E-6 . INSPECT bucket/basket interior for moisture. G. CHECK Fuses i. Broken disconnects ii. INSPECT Aux contacts i. Dust may settle inside relays. Wiring ii. cracked or missing parts. E. If fuses are in a holder. insulators. MANUALLY OPERATE to ensure freedom of movement b. cables. Burning K. For chafing against metal surfaces during vibration j. lights. INSPECT mechanism for any damage. Corrosion v. Pitting iii. meters. P. distortion. Chipped or broken components ii. control devices etc i. LUBRICATE mechanism with light oil (as approved by vendor technical manual) E-7 . Cracked or flaking insulation i. excessive wear or degraded conditions. REPAIR or REPLACE any damaged or degraded components. Proper ratings iii. Broken/cracked lugs m. roller surfaces. Loose connection iv. Breaker Operating Mechanism a. INSPECT Arc chutes i. (If warranted) MEGGER wiring to determine condition of circuit breaker insulation to ground and phase to phase. REPAIR or REPLACE any damaged or degraded parts NOTE If desired and Insulation resistance test may be conducted during the wiring inspection. Cracks ii. Damage (missing/broker parts) ii. Pushbuttons.iv. INSPECT Insulators i. Discoloration k. loose parts (latches). Corrosion l. missing/broken cotter pins. switches. worn cams. etc) d. REPAIR or REPLACE and damaged or degraded components. Deterioration v. INSPECT internal load center basket/bucket wiring g. CHECK for proper alignment of basket/bucket (plume and square) c. L. Tightness h. CLEAN and INSPECT instrumentation and controls a. Switches move freely and are in good working order O. M. N. Resistance checks e. Electrical tracking f. (Cracks. CLEAN mechanism b. 005 Ohms (typical reading) NOTE It is recommended that contacts be replaced in pairs to avoid misalignment and uneven contact pressure. c. VERIFY by unique load center identifier that the appropriate load center is being worked and it is appropriately tagged out.2 Load Center Switchgear Cleaning and Inspection: A. Auxiliary switch contacts 4. Starter Contactor a. POSITION each breaker in the load center to the “OPEN” position. (If applicable) TEST installed electrical accessory devices. Reading should be less than 0. ENSURE all tools necessary to perform the job are available e. NOTIFY Operations prior to beginning work b. INSPECT starter contacts for excessive pitting or arcing HOLD A phase started contactor CLOSED. e. IF reading is greater than 0. a. E-8 . C. (If applicable) CHECK all door interlocks for proper operation.NOTE Use of contact cleaners is not recommended by some vendors because of the potential of sticking on magnetic pole faces. REPEAT (a – d) for B and C phases R.(made up state) MEASURE resistance across starter contacts. Under-voltage device b. Over-current device d. ENSURE appropriate personal safety equipment is worn on the job B. Shunt trip c. ENSURE an appropriate clearance/tag out is in place to perform work safely c. Refer to appropriate vendor manual. f. b. Q. D. Prerequisites to performing maintenance a. THEN REPLACE contacts. d.005 Ohms. ENSURE all parts expected to be used are available and in hand d. L. SEAL off any identified leaks from conduits and PROVIDE an alternate drain source. Breaker to Bus Resistance measurements a. TAG each load center breaker basket/bucket as to location in load center it was removed from. WIPE down the interior of each load center cubicle slot using an approved cleaner NOTE Condensation in conduits or dripping from outside sources is a common cause of failure. condensation or leaks. E. RECORD resistance reading (typical less than 0. splice bar or terminal lug. MEASURE A phase from line side of breaker to the bus bar b. REPEAT (a – b) for B and C phases d. VERIFY load center bus is de-energized (appropriate range multi-meter) F. INSPECT MCC/LCC for any signs of wetness. VACUUM thoroughly each load center cubicle slot to remove dirt and debris from basket/bucket and rear of load center. I. H. CAUTION Do not sand or remove any plating on any bus bar. J. REMOVE each breaker basket/bucket.CAUTION Wear appropriate electrical protective equipment until the bus has been verified deenergized. E-9 . G. REPEAT (a – c) for all breakers in the load center NOTE Work from the top of the load center down NOTE Breakers removed from load center should be temporarily stored in a location that will not impede work or be a safety hazard.005 Ohms) c. K. fasteners. retainers and keepers b. Arcing b. Discoloration i. SECURE doors on load center (Prior to energizing the MCC/LCC) S. REPAIR or REPLACE defective or degraded components R. CLEAN outside of load center with vacuum and approved cleaner 5. INSPECT exterior MCC/LCC cabinets for a. Rust and corrosion c. ENSURE the handle on each breaker is in the “OPEN” position V. overheating d. Ensure recommended vendor torque values are used if bus joints are tightened. REINSTALL each breaker basket/bucket in its proper location. INSPECT all components in each load center cubical bus bars a. B. THEN INSPECT sealer between joints T. Q. INSPECT seals and latches on load center rear doors.0 Determine PMT and PMT considerations A. PERFORM electrical testing to confirm no short circuits were created during inspection or maintenance. Insulating materials j.NOTE Some vendors do not require any servicing of bus connections for the life of the MCC/LCC. Burning c. INSPECT load center grounding cable P. Conduits for proper fit. bolts. RELEASE clearance/tag out for return to service (Operations) C. Repair or replace any damaged or degraded components N. Discoloration. IF MCC/LCC is composed of multiple cabinets. nuts. Excessive scarring e. CYCLE the breaker in the test position open and close several times to VERIFY correct operation E-10 . Corrosion f. M. Cracking h. Unused openings d. Heat stress d. U. Missing screws. Missing parts O. Pitting e. Pitting g. Arcing b. INSPECT rear stabs on cubicle’s basket/bucket a. Refer to vendor manual before making any bus changes to bus splice joints. Corrosion c. no cracks or leaks e. Breaker Vendor Tech manual Applicable wiring drawings Facility Electrical Safety Manual NFPA 70E NEMA Standards Publication No. Perform post job review B. G. (If installed) VERIFY any key interlocks or mechanical interlocks are functioning properly E. I.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors. 7. F.Electrical Material Safety Data Sheets Chemical Control Procedures Foreign Material Control E-11 . C. Initiate any corrective action program documents necessary to resolve any problem areas identified.0 References Identify typical references needed to perform the identified work A. A. B. E. ICS 2.D. DISPOSE of any special chemicals or solvents used appropriately G. D. RETURN unused parts to stores 6. H. CLEAN work area F. Annex A (Maintenance of Motor Controllers After a Fault Condition) OSHA Standards – 29 CFR Part 1910 Subpart S . . inspections.1 Component type This work instruction is applicable to Limitorque SMB actuators. 1. 1.2 Equipment tag or unique equipment identifier Ensure the unique valve identifier is used to designate which valve actuator is being worked. B. 1.0 Task Overview 1.4 Develop list of know consumable materials to be used A. gear case (NLGI Grade 0. D. CRC Lectra Clean) Clean lint free rags F-1 . 1. Vendor approved) Electrical-type cleaning solvent (e. Vendor approved) Lubricant. and limited setup of Limitorque SMB actuators. limit switch (Mobile 28.F WORK PACKAGE TEMPLATE – LIMITORQUE SMB ACTUATORS NOTE Personnel performing this work instruction should be qualified (properly trained and proficient) on the type of Limitorque actuation being worked. C.3 Scope This work instruction provides instructions for cleaning. E.g. Vendor approved) Lubricant. valve stem (Graphite type. Lubricant. 5 Develop a list of know parts to be replaced A. Do not lift the operator by the handwheel. C. Do not pump grease into motor g. B. Most valve actuator maintenance is performed when the valve can either be isolated during power operations with no effect on generation or during a schedule plant outage. Gaskets Seals Limit switches Torque switch 1. Do not plug motor – alternate motor starts and stops to open or close the valve more tightly f. c. Do not engage the declutch lever while the motor is running d. If the valve stem is to be lubricated during the maintenance it should be isolated. Do not use valve wrenches or cheater bars to operate handwheel e. D. Do not exceed motor duty cycle. Generation a.1. C. Do not pinch wires between switch compartment cover and switch compartment flange C. b. Megger (500V to 1000V range) Multimeter (volt-ohm) Electrician’s toolbox Drill 2.0 Pre-job Brief 2. Proper lubrication requires stroking of valve to access stem threads. Do not pull or force the declutch lever up or down.1 Evaluate potential for generation or equipment risk hazards A. B. D. b.6 Special tools A. (Refer to vendor manual for number of strokes per hour for either AC or DC operated motors) F-2 . B. Equipment Risk/Damage a. Power should be removed before working on actuator or opening limit switch compartment. F. H. The following actions should be avoided to prevent potential actuator/motor damage a. Check limit switch settings and motor direction prior to operating the actuator electrically following maintenance c. F-3 . Do not use oversized motor thermal overloads b.2. 2. All MANUAL handwheel engagements must be followed by an electrical valve stroke. E. Control switch is NOT in the closed position I. d. C. Do not lift the actuator/gearbox or actuator/valve combinations with only the eyebolts. to be on the valve when performing maintenance. gas. Do not engage the handwheel unless one of the following conditions exists: a. Valve is in the open position c. Appropriate measures should be taken to prevent foreign material from entering the actuator. Do not remove the spring cartridge cap. housing cover or stem nut from the actuator if the valve is under load. If maintenance is being performed on the actuator while installed on the valve. Identifies general and specific hazards A. Do not depress the declutch lever during motor operation to stop valve travel. pipe wrenches or other devices on the actuator handwheel or declutch lever. Do not force the declutch lever into the motor position. Do not engage handwheel during maintenance activities unless direct to do so by the work instruction or the supervisor. e.3 Job Safety Analysis. The actuator mounting bolts should not be removed from the valve unless the stem is secured. There is a potential for high pressure fluid. Eyebolts for lifting actuator should not be left in the actuator during operation. Eyebolts installed during maintenance should only be used to lift the actuator. Performance of this work will open actuator to environment. wheel wrenches. etc. B. Do not use cheater bars. D. ensure the valve is not under thrust or torque load. The declutch lever returns to the motor position when the motor is energized. G. Beware of electrical hazards. Valve is in the mid position b.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. 2.4 Identify permits required A. Equipment Clearance Orders B. Chemical Control C. Transient Fire Load Permit (cleaning solvents, oil, grease, rags, etc) 2.5 Identify Environmental Consideration A. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E.g. cleaning solvents) B. Handling and disposal of chemicals (E.g. solvents, oil, grease, etc) should be in accordance with approved chemical control procedures 2.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed. 2.7 Identify Clearance/Tag out Boundary A. B. C. D. Power to actuator motor (at motor control center) Power to space heaters if powered from other than motor source Isolation valves (inlet and outlet side) of valve being worked Bypass valves around isolation valves (if installed) 3.0 Contingency Considerations 3.1 Identify potential scope expansion and actions due to scope expansion A. Inspections of any components may result in the need to repair or replace components as appropriate. B. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. F-4 3.2 Identify individuals to contact in case certain events occur A. Contact planner if scope growth is identified during work instruction performance B. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. C. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3.4 Develop material list for potential contingency and consumable parts A. Limit Switch Gear Box 4.0 Detailed Work Instructions Develop work instructions, utilize existing procedures when applicable Provide expected actions in proper sequence for task. Identify Notes and Cautions where needed A. B. C. D. E. F. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available REVIEW and UNDERSTAND the scope of work before the start of any field activities. ENSURE appropriate personal safety equipment is worn on the job 4.1 Preparations NOTE Product information, actuator nameplate and motor nameplate, are located on the actuator. Actuator nameplate is typically located opposite the limit switch compartment. Motor nameplate is located on the motor. A. VERIFY clearance/tag out is correctly in place B. LOCATE and ENSURE proper piece of equipment is being worked per the work instruction F-5 4.2 External Inspection of Actuator/Valve A. INSPECT external condition of actuator for: a. General damage or degradation 1. Cracks to mounting flange 2. Cracks to yoke 3. Cracks to gearcase b. Broken or missing parts (bolts) NOTE Slight oil weepage is not a cause for replacing a seal. c. Shaft penetrations for indications of seal leakage d. Oil or grease leakage from gearcase 4.3 Limit Switch Compartment Inspection NOTE Pull switch cover straight away from actuator to prevent damage to interior electrical components. A. REMOVE switch compartment cover and gasket. B. INSPECT switch compartment for: a. Loose parts b. Foreign material c. Oil, moisture, dirt (clean as required) NOTE Wiring should be routed away from space heaters d. Wiring for damage, brittleness, discoloration e. Wire lugs are secure and properly crimped f. Terminations are tight 4.4 Torque Switch Inspection A. INSPECT contact condition and alignment B. CLEAN contacts with electrical-type solvent cleaner F-6 C. D. E. F. G. H. I. J. ENSURE contact mounting screws are tight NOTE as found torque switch setting INSPECT base phenolic material for signs of cracking ENSURE electrical connections are tight ENSURE mounting bolts are tight and in good condition ENSURE dial is properly aligned with actuating link ENSURE dial face is not loose RECORD as left torque switch setting 4.5 Limit Switch Inspection A. INSPECT contact condition and alignment B. CLEAN contacts with electrical-type solvent cleaner NOTES “L” bracket may be bent slightly to achieve proper gap or rotor contact Do not use excessive force to bend “L” brackets CAUTION Circuit should be de-energized prior to adjusting fingers C. CHECK “L” bracket tension on “L” brackets that are made-up i. ENSURE gap exists between “L” bracket and contact finger ii. Gap between finger and “L” bracket should be approximately equal to thickness of “L” bracket D. CHECK “L” brackets that are not made-up a. ENSURE contact fingers touch rotor E. ENSURE each limit switch rotor is secure to its intermittent pinion. F. VERIFY clearance between rotor and limit switch frame to prevent excessive rotor drag G. INSPECT phenolic material of finger base for cracks H. ENSURE electrical terminations are tight. I. ENSURE mounting screws are tight. 4.6 Limit Switch Gear Box Grease Inspection A. REMOVE upper limit switch gear box cover and gasket F-7 INSPECT motor terminations for overheating and degradation 4. C.8 Install Limit/Torque Switch Compartment Cover A. ADD lubricant (e.g. Lubricant viscosity should be soft to slightly fluid 1. NOTES Gasket should not protrude under finger base mounting surface. INSTALL gear box gasket and cover 4. E. D.7 Motor Termination inspection A. D. ENSURE lubricant level is just above the top of the small gears. Lubricant should not contain dirt or other contaminants B.NOTES Lubricant should be reddish to rust brown. E. INSTALL switch compartment gasket and cover F-8 . CLEAN gasket seating surfaces on compartment and compartment cover INSPECT compartment cover gasket (Clean or replace) APPLY a light coat of bearing grease on compartment/cover surfaces ENSURE wires in switch compartment are routed away from moving parts and space heaters CAUTION Care must be taken not to pinch any wires between compartment cover and compartment flange. INSPECT cover gasket and replace as required. Trim as required Do not over tighten cover mounting screws. lubricant in lower gear box and cartridge assembly must be inspected. B. NOTE If lubricant was added to the top of a four train switch. C. Mobile 28) to proper level as required. LUBRICATE the declutch and handwheel shaft. 4. G. 5. 2. CAUTION To stoke valve it must be isolated from process stream so that process stream is not purtubated during the lubrication process.4. Exxon Varsol #18) ii. F. etc) D.. NLGI-0 grade) to proper level NOTE If lubricant must be must be added to achieve proper level then: 1. EXTRACT a representative grease sample from the worm gear and the motor pinion gear area. Motor pinion compartment should be filled to a level that covers the motor pinion gear. water. H. J.10 Valve stem lubricant Inspection F-9 . E. REPACK actuator with proper lubricant (e. C. Motor pinion compartment void should be approximately 40-50% to allow for thermal expansion. (If required) ADD lubricant to proper level in the motor pinion compartment. INSPECT grease samples for contaminants. REMOVE pipe plugs on main gearcase and if available one on the motor pinion compartment NOTE Grease layer at port opening should be cleared so a representative sample can be taken. B. K. Main gearcase void should be approximately 20-25% to allow for thermal expansion.g. (If required) GREASE the housing top flange and handwheel grease zerk fittings. ENSURE grease relief tube is clean and free of grease (If installed) INSTALL pipe plugs removed on main gear case and motor pinion compartment. Main gearcase should be filled to a level that covers the worm gear. water or other foreign material THEN: i.9 Main Gearcase Lubrication Inspection A. CLEAN and INSPECT declutch shaft and handwheeel shaft areas. 4. 3. IF lubricant contains dirt. metal particles. ADD lubricant to proper level in the main gearcase. (dirt. Ensure lubricant added is the same type lubricant currently in the actuator. FLUSH actuator with a degreaser/cleaner (e. Do not mix lubricants in the actuator. I.g. Reference vendor tech manual) NOTE Phase to Phase resistance readings should be the same.CAUTION If valve is stroked by hand. D. cracked insulation. C. CLEAN and INSPECT the stem nut area. (DC motors) CHECK armature brushes for proper contact and wear F-10 . CLEAN and INSPECT all accessible portions of the valve stem threads. A. B. D. VERIFY stem nut is tightly secured by the locknut. G. INSPECT motor leads for signs of overheating. inspection and lubrication. APPLY a thin coat of lubricant to accessible threads in the stem nut area. CHECK phase to phase resistance of the motor windings. STROKE the valve as required to allow for thorough stem cleaning. B. it must stroked electrically when power is restored prior to returning valve to service.g. VERIFY that the Locknut is tight and properly staked. loose wires or other damage/defects that would prevent proper operation. F. CAUTION Limit switch cover should be installed prior to performing a megger on the motor. Graphite type) Threads should appear slightly wet. E. 4. ENSURE megger reading meets acceptance criteria. DC motors should be meggered at 500V. MEGGER the actuator motor from the Motor Control Center (MCC). (Typically greater than 1 Megohm is normal. E. APPLY a thin coat of lubricant (e. C.11 Motor Inspection A. NOTE AC motors should be meggered at 1000V. C.12 Switch Adjustments 4. The rotor is set at the correct position for contact opening. it must stroked electrically when power is restored prior to returning valve to service. NOTE After valve is stroked by hand. F-11 . Do not repair limit switch gear box. Note direction of Intermittent Gear Shaft for rotor to be set. B. VERIFY power is off.12. The contacts on the Rotor to be set should be in the open position. TURN the Intermittent Gear Shaft in the direction noted during the performance of Step B (above) until the Rotor turns and opens the contacts to be set. MANUALLY OPEN valve to the full open position TURN Set Rod clockwise (CW) until it reaches the stop position.4. A. D.1 Setting the Limit Switch NOTE The following can be used to set either a Two-Train or a Four-Trained Geared Limit Switch Each drum switch may be adjusted independently of the other(s) CAUTION If limit switch gear box is damaged or defect. E. replace the entire gear box. IF the contacts on the Rotor to be set are not in the open position THEN a. b. 2 Setting the Torque Switch NOTE Torque settings must be made with the switch mounted in the actuator. IF the contacts on the Rotor to be set are already in the open position THEN a. PERFORM steps (C – H) to set the tripping position on the other rotor. b.F.12. Do not force. SET the striker for open or close operation. GO to Step G. G. c.3 SMB-000 Double Torque Switch A. 4. H. CAUTION Do not attempt to remove either the spring cartridge cap or the housing cover from the actuator while the valve is torque seated. 4. TIGHTEN Pan Head Screws F-12 . MANUALLY CLOSE the valve to the full close position. VERIFY power is OFF B. The rotor is set at the correct position for contact opening. (Match the edge of the Striker with the desired number) to the desired torque setting D. BACK OFF Set Rod until it stops ENSURE that the Intermittent Gear Shaft is tight and will not rotate. c. J. TURN the Intermittent Gear Shaft in the OPPOSITE direction noted during performance of Step B (above) until the Rotor turns and the contacts close.12. I. C. TURN the Intermittent Gear Shaft in the direction noted during the performance of Step B (above) until the Rotor turns and the contacts open. LOOSEN Pan Head Screws NOTE The higher the torque number setting the higher the torque output of the actuator. 12.4. for open or close direction torque switch. B. it must be stroked electrically when power is restored prior to returning valve to service. TIGHTEN Machine Screw 4. LOOSEN Machine Screw NOTE The higher the torque number setting the higher the torque output of the actuator. VERIFY power is OFF B. F-13 . REMOVE Locknut C. at the desired torque setting D. CLEAN up all metal particles.13 Replace Stem Nut CAUTION Do not remove the Locknut with the actuator under load or with pressure under the valve. LOCATE stakes and spot with a drill. SET the pointer. 4. C. NOTE If valve is stroked by hand.1 Stem Nut Removal NOTE The locknut is typically staked in two places A.13.4 SMB-00 Torque Switch A. STAKE the top threads above the locknut in two places (180 degrees apart) 5. Perform post job review B. LOWER stem nut onto drive sleeve until Stem Nut is seated b. MANUALLY ROTATE handwheel to close valve. STAKE in two places (180 degrees apart) B. 4.13. INSTALL locknut d. A. D.2 Stem Nut Installation A.D. G. when stem nut splines are free from Drive Sleeve. RETURN unused parts to storeroom 6. E. IF valve was torque seated THEN a. ROTATE Stem Nut onto the shaft until the Stem Nut splines engage the Drive Sleeve splines b. ROTATE Stem Nut for the remainder of the length of the valve stem. F-14 . INSTALL the Locknut d. Work site cleanup . B.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. OPERATE valve electrically to seat the valve b.0 Determine PMT and PMT considerations RELEASE clearance/tag out ELECTRICALLY STROKE valve to ensure it functions properly open and closed. C. MANUALLY ROTATE handwheel to the open valve position until the Stem Nut is seated. ENSURE tight shutoff by tripping the torque switch contacts. Initiate any corrective action program documents necessary to resolve any problem areas identified. DISPOSE of any generated waste products properly. Installation on Keyed Shaft a. INSTALL the Key c. VERIFY limits are set correctly.CLEAN work area to original pre-maintenance conditions F. Installation on Threaded Shaft a. E. c. C.7. D. E. F. B.0 References A. Industrial Safety Manual Foreign Material Control Procedure Material Safety Data Sheets Chemical Traffic Control Procedure Storage of temporary combustibles (transient fire loads) Vendor Technical Manual F-15 . . 1 Component type This work instruction is applicable to a dry Electrostatic Precipitator.2 Equipment tag or unique equipment identifier Ensure unique equipment identifier is used to designate which precipitator is being worked.G WORK PACKAGE TEMPLATE – ELECTROSTATIC PRECIPITATOR NOTE This work instruction contains information regarding cleaning. 1. C. limited preventative maintenance and testing of an ash collecting precipitator. Some components may or may not be present on all ESP’s. E. 1. The work instruction is based on a generic ESP.0 Task Overview 1. Protective clothing Dust masks Clean rags Duct tape Solvent cleaner (vendor recommended) G-1 . inspection and limited maintenance on a Dry Electrostatic Precipitator (ESP). B. This instruction can be used in whole or in part based on the desired work to be performed. 1. 1.3 Scope This work instruction describes the cleaning. D. refer to the appropriate vendor technical manual. For some specific inspections and maintenance on some components.4 Develop list of know consumable materials to be used A. G. D. C. hoppers.5 Develop a list of know parts to be replaced A.1 Evaluate potential for generation or equipment risk hazards 2. L.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. gloves. dust masks. G.0 Pre-job Brief 2. C. E. Air monitor Protective clothing. I. B. I. Electrical cleaner (no-residue type) Lubricant (non-gumming) Transformer oil (vendor recommendation) Door gasket materials Door seals (as required) Emitter Wires Emitter insulator rubber boots Alignment clips Ground straps Cover and plate gaskets Transformer surge protectors Filters 1.1. For work performed in precipitator.3 Job Safety Analysis. F. B. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. 2. E. G-2 . J. Identifies general and specific hazards A. F.6 Special tools A. flues and ducts foreign material exclusion areas should be established. K. H. H. J. hard hat Vacuum cleaner Volt/Ohm Meter (Analog) Amp Meter (Clamp On) Megger Portable lighting Water hose Impact gun Typical mechanic’s tool box 2. D. eye protection. transformerrectifier switch enclosure or bus ducts. Protective clothing should be worn when entering a precipitator or hopper. Never touch exposed internal parts of the control system. Operation of the transformer-rectifier controls involves dangerous high voltage. Ozone is a toxic gas that can cause severe illness or death if inhaled in sufficient quantity. Disposal of materials 2. Only use powdered graphite to lubricate lock system. D. Never use fingers or metal screwdrivers to adjust uninsulated control devices. Equipment Clearance/Tag out Orders B. Be aware of potential high temperatures when entering a precipitator K. Avoid ozone inhalation. 2. E. Special chemicals B. 2. Never open a hopper door unless the dust level is verified to be below the door. Level should be verified visually from precipitator upper access. I. If high levels of carbon are known to exist on the collecting surface or in the hoppers.B.4 Identify permits required A. (If present) Never bypass the safety key interlock system on the precipitator. G. Air-line masks should be used when entering the precipitator.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment.7 Identify Clearance/Tag out Boundary Get a generic Precipitator tag out G-3 . Never use oil or grease. C. Precipitators can hold high static electrical charges. Confined space entry permits and precautions for entry into precipitator or flues F. All personnel are responsible for ensuring work is performed per approved procedure or work instruction. L.5 Identify Environmental Consideration A. up to 15KV following de-energization. H. Precipitator should be monitored for ozone prior to entry. flues or stack when ozone is present. DO NOT open precipitator doors until the precipitator has cooled below 125 degrees F. J. Grounding devices should be used when entering the precipitator. Hot dust can flow like water and severely burn or kill a person standing below the hopper door. Confined Work Space 2. Contact supervision if any problem is identified that prevents following work instructions D. Inspections of any components may result in the need to repair or replace components as appropriate.1 Identify potential scope expansion and actions due to scope expansion A. I. D. F.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. Anti-sway insulator bushings Rapper parts Vibrator parts Through bushing insulators Through bushings Transformer knife blades Transformer receiver clips Transformer ground pads Control cabinets fans 4. C. utilize existing procedures when applicable Provide expected actions in proper sequence for task. G. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. Contact planner if scope growth is identified during work instruction performance B. B. 3. Identify Notes and Cautions where needed G-4 .2 Identify individuals to contact in case certain events occur A. H. E.0 Detailed Work Instructions Develop work instructions.0 Contingency Considerations 3.4 Develop material list for potential contingency and consumable parts A. C.3. B. MINIMIZE air flow NOTIFY Operations prior to beginning work ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available IDENTIFY any grounds on Emitter/Transformers LOCATE and ENSURE proper piece of equipment is being worked per the work instruction 4.1 Shutdown for Maintenance A. B.2 Pre-maintenance checks (prior to clearance/tag out on precipitator) NOTES 1.4. REMOVE TR Sets from service as soon as possible after fuel is stopped. 3. MAXIMIZE precipitator CLEANUP with full ash removal system and rapper system operation CAUTION Be careful not to violate any EPA limits. F. H. Dirty air-load test is optional but may provide indications of potential ash build up areas resulting from poor gas flow or inadequate rapping. Procedure for conducting air-load test should be provided in vendor technical manual. G-5 . 2. Electrostatic Precipitator Maintenance. C. E213676. Volumes 1 and 2. Any deficiencies identified should be added to the scope of the work instruction for repair or replacement. G. D. Additional guidance on air load tests may be found in EPRI document. E. A. PERFORM dirty air load test NOTES 1. Dirty inspection is primarily for determining location and amounts of ash buildup. It can also be used for the identification of obvious problems for potential scope growth and parts identification. 2. Personnel performing inspection should be careful not to disturb ash buildup. This may cause airborne ash problems as well as lose information causing ash buildup. 3. A pre-job brief should be conducted prior to entry into the precipitator for dirty inspection. 4. Abnormal ash buildup may be indication of poor gas flow or inadequate rapping. 5. Areas identified for high or low gas flow should be evaluated as to whether a fix is required or could be successful. CAUTION Confined Workspace Permit is required for work in lower precipitator. CAUTION Air quality shall be monitored and verified safe for entry. CAUTION Appropriate personal safety equipment shall be worn for entry into the precipitator; hard had, respirator or breathing air, gloves, safety glasses/goggles, etc. B. Dirty Inspection a. VERIFY precipitator is shutdown and a clearance/tag out established to allow entry into the precipitator. b. VERIFY precipitator is cooled down sufficiently to allow personnel to enter safely to conduct a dirt inspection. c. EMPTY hoppers d. REMOVE outer insulator doors e. REMOVE inner doors f. MONITOR air quality of precipitator and ENSURE it is safe to enter. G-6 NOTE Areas of high/low ash deposits (emitters and collector plates) is a potential indication of poor clearances. g. INSPECT internals for ash buildup (0.25 to 0.5 inches can be normal) h. INSPECT internals for possible scouring (indication of high gas flow) i. INSPECT flow control devices for blockage NOTE Rapper transmission force should shake whole discharge emitter or collector plate. Rappers will not shake loose all ash build up at once. It is normal for small amount of ash to build up until a sufficient thickness is obtained to shake loose. C. VERIFY all rappers and vibrators are functioning (transmission force) D. PERFORM a walkdown of the precipitator internals and RECORD the condition of all internal components. a. Rappers – Boots, rod welds, insulators b. Vibrators – insulators c. Plate buildup – color, consistency, thickness d. Wire buildup e. Plates – hanger bolts, plate supports, mounting bolts f. Wires – hanger bolts, arcing shields, bushings, hangers g. Damaged or broken wires – location, probable cause h. High voltage insulators i. Penthouse insulation j. Inlet/outlet ducts – dust condition. Leaks k. Anti-sway bars – brackets l. Inlet perforated plates m. Duct and vane blowers n. Hoppers – cracks, buildup, divider doors o. Transformer set conditions E. INFORM supervision and planning of inspection results and any additional work outside the scope of the current work instruction. G-7 4.3 Lower Precipitator Maintenance CAUTION Ensure appropriate Clearance/Tag out is hung for complete precipitator outage work. A. VERIFY Clearance/Tag out in place for precipitator overhaul. CAUTION Confined Workspace Permit is required for work in lower precipitator. B. ROLL Tee’s or brake connections on bottom of hoppers to allow residual ash material to be removed and washed to drains. C. REMOVE and WASH residual ash to drains. NOTES 1. Ensure appropriate protective clothing is worn. 2. Whether to clean the precipitator is an expensive proposition. However, ensuring a properly functioning precipitator is essential to clean plant operations. The ability to perform a detailed assessment of the precipitator depends on the cleanliness of the precipitator. Some considerations for whether to clean or not include: cost, amount of identified or suspected corrosion (especially high sulfur content coal), high arsenic levels in ash, extent of work that needs to be performed on the precipitator (wire change outs, structural repairs, etc) 3. Cleaning can either be done by dry blasting (air or other materials) or water wash down. Either have their advantages and disadvantages. This is at the discretion of the facility. 4. Cleaning should be done from top to bottom. D. CLEAN the interiors of the precipitator, and chevron and outlet ducts. E. ENSURE all ash deposits are removed from emitter curtains, rapper plates, interior components and interior walls. F. ENSURE all foreign material is flushed through the hoppers G. IF further cleaning is required to remove stubborn deposits, THEN CLEAN these areas using scrapers and brushes NOTE At the discretion of the facility a clean air load test may be performed. This test may be helpful in identifying any misalignment problems with emitters and collector plates. G-8 H. PERFORM clean air load test (if desired, optional) I. PERFORM a detailed inspection of lower precipitator and its internals, repair and replacement of key precipitator components. NOTES Location should be recorded using a map. If reason for emitter wire damage is not determined and corrected it may not be worthwhile replacing broken or damaged wire. Air load readings should identify any potential areas likely to have problems. J. Emitter Wires: a. INSPECT for any dislodged, broken or missing emitter wires b. INSPECT for any degradation that would cause grounds c. REPLACE all broken emitter wires unless a pattern of consistent failure is identified that has not been corrected d. Electrode frame (if installed) CHECK attachment integrity and attachment shunt strap e. Support insulators (if installed) 1. CHECK alignment 2. CHECK for ash buildup 3. CHECK for electrical tracking 4. CHECK for cracking 5. REPAIR or REPLACE any damaged insulators f. REMOVE any material that would cause grounds K. Collector Plates: a. INSPECT collector plates for bends, bows, cracks, holes etc. b. CHECK for misalignment both “across” and “in” the direction of gas flow c. STRAIGHTEN bent or bowed plates d. PATCH (Weld) plates with cracks or holes e. ENSURE alignment rakes are straight and all welds intact f. REPAIR alignment rakes as required g. ENSURE collector plates are separated by the alignment rakes with proper separation. (separation distance specified by vendor technical manual) h. ENSURE proper clearance between emitter wires and collector plates (as per vendor technical manual) i. MEASURE plate thickness (several places near bottom of outlet flow) G-9 c. INSPECT all doors. Q. WASH out chevron area b. Inlet and Outlet Ducts a. S. NOTE It is important to identify any air leaks into the precipitator. k. ceramic breaks. duct bracing. erosion. REPLACE any expansion joints that can not be repaired O. CLEAN doors and sealing surfaces and replace gaskets and seals as required. excessive ash fouling. b. REPLACE any degraded “anti-sway bushings. turning vanes. REPAIR or REPLACE any damaged components T. holes. INSPECT “Anti-sway” insulator bushings for degradation (stress cracks. j. excessive ash buildup. CLEAN and INSPECT expansion joints for degradation (cracks. deterioration. l. m. etc. not blocked). CLEAN and INSPECT outlet duct leaving precipitator to the exhaust stack for cracks. expansion joints. bent or broken diversion plates. ASSESS effectiveness of flow distribution devices c. R. perforated plates (holes open. sealing surfaces. etc for degradation. REPAIR or REPLACE any degraded components G-10 . During operation cold air in-leakage can mix with hot gases and create a corrosive atmosphere. INSPECT access panels/doors (seals/gaskets) for damage or degradation d. ENSURE alignments clips are in place on collector plates WELD alignments clips in new areas where plates have been eroded away REPLACE all defective or degraded alignment clips REPAIR or REALIGN the baffle between the collector plates and the wall (appropriate clearance as per vendor manual) L. M. corrosion excessive dust build up and breakage. Anti-Sway Bushings a. gussets. holes. CHECK precipitator “box structure” for overall integrity (holes. etc) N. REPAIR any precipitator “Box structure” degradation. it will be necessary to weld a new clip above or below the eroded area. etc) P. ceramic erosion. etc b. INSPECT overall structure including pipes. gaskets and seals. Chevron area a. erosion.NOTE If collector plate has been eroded away at clip location. corrosion. turning vanes. CAUTION Safety chains/latches should be installed and functioning properly on hopper doors U. etc. This is costly and presents a safety hazard both during installation and use. sound. EMPTY hopper prior to dirty inspection. b.NOTES 1. holes and excessive deposit buildup d. CHECK hopper doors (seals/gaskets) and poke hole for air leaks or dust discharge k. Scaffolding may be necessary to perform the inspection. pressure. REPAIR any deficiencies noted from hopper inspection G-11 . REMOVE all foreign material from hopper (weights. erosion. CHECK hopper level indication system (including indicator lights if installed) j. wires. CAUTION Do not rely solely on level indication instrumentation to ensure hopper is empty. CHECK for internal obstructions f. Hoppers can pose a serious personnel hazard. i. Hoppers a. CHECK for unusual ash build up e. They should be emptied before inspection activities. etc) Reference appropriate vendor manual for specific level inspections. INSPECT lower hoppers for stress cracks. CHECK valves and connections NOTE There are many types of hopper level indication systems (gamma radiation. capacitance. CHECK hopper insulation/lagging c. CHECK for signs of air in-leakage g. 2. corrosion. temperature. Visually verify if possible. differential pressure.) h. Tapping on door (hollow ring) may be used. INSPECT rappers for cracks. INSPECT purge air ducting/access doors (seals/gaskets) for leaks and corrosion d. pneumatic. (Electromagnetic impulse-gravity impulse. INSPECT insulation and lagging B. corrosion. couplings d. INSPECT structural integrity of enclosure for cracks. INSPECT drive motors b. mechanical tumbling hammer) For specific inspections and repairs.4. INSPECT rapper controls c. A. INSTALL safety grounds on de-energized equipment H. OPEN penthouse inspection doors F. Coffin. electromagnetic vibrators. Emitter and Collector Plate Rapper Inspections a. CLEAN and INSPECT ground straps (strap and hooks clean. A.4 Upper Housing (Tension Insulators and Housings. not corroded) D. General rapper inspection guidelines are provided below. Doghouse) Insulator compartment inspections CAUTION Confined Space Entry procedures should be used for entry into penthouse. corrosion. INSPECT rapper penetration boot seals (air and/or water leakage) e. INSPECT all penetrations for adequacy of seal and corrosion c. Cans. VERIFY equipment in the penthouse is de-energized and Clearance/Tag Out installed C. Penthouse general condition inspection a. RECORD as found condition of penthouse G-12 . refer to vendor tech manual for installed equipment. Emitter/Collector Rapper/Vibrator) NOTE Rapper/vibrators will vary from one facility to another. REPLACE defective ground straps E. holes. electromagnetic impulse. INSPECT rapper shaft insulators (in installed) f. INSPECT all rapper ground straps intact (ties rapper rod and housing to ground) 4. shaft rubbing or binding. etc) b. VERIFY atmosphere is acceptable for entry G.5 Penthouse (aka.spring assist. leakage (shaft penetration area) welds. CHECK grounding jumpers across duct sections installed and tight c. CLEAN high voltage (HV) emitter insulators and internals with water d. Emitter Housing a. CLEAN insulators with non-abrasive cleaner if required g. electrical tracking f. ENSURE all surfaces are clean and dry a. breaks and gauling around seal penetration G-13 . Through Bushing Insulators a. REMOVE any rust or scaling observed k. INSPECT duct. Tension Insulators and Housing a. etc). INSPECT condition of inspection plate. bus. d. lagging and insulation and inspection cover b. j. CLEAN tension insulators and internals with water L. REMOVE tension housing cover. ENSURE all surfaces are clean and dry e. etc e. gasket and emitter assembly c. REPLACE any damaged or degraded insulators (also replace insulator gasket) h. ash.I. REPLACE degraded insulators J. INSPECT emitter insulator for stress cracks. Loss of insulation on the precipitator will result in cold spots and eventually corrode your electrostatic precipitator. thru bushings. or any other abnormality c. wear. INSPECT housings and tension insulators b. cracks. VERIFY duct purge vents (if installed) are not plugged or restricted K. REMOVE HV bus duct inspection cover d. CHECK Insulators free of any contamination (dust. insulators. INSTALL inspection cover NOTE Maintain the integrity of the insulation and lagging. INSPECT seals/gaskets on inspection covers m. chips. High voltage bus duct inspection a. REPLACE seals/gaskets of inspection covers if damaged or degraded. CLEAN or REPLACE switches as required. n. i. connections. INSTALL insulation and lagging and cover M. CLEAN inspection cover (remove old gasket material) c. CLEAN through bushing insulators b. l. INSPECT insulators for stress cracks. ENSURE Bus duct is weather tight b. IF source of rust or scaling is identified THEN REPAIR. REMOVE emitter housing lagging/insulation and inspection plate b. INSPECT switches(Disconnect or ground switches if installed) for any corrosion or pitting. Do not perform any maintenance activities on the TR unit will it is operating 2. REPLACE any defective heaters 4. switches. j. Follow general electrical safe work practices with respect to electrical shock 4. INSTALL insulation/lagging N. l. k. Follow all grounding procedures (specified in vendor technical manual) 3. Loss of insulation on the precipitator will result in cold spots and eventually lead to corrosion. CLEAN and INSPECT emitter vibrator assembly TROUBLESHOOT all defective emitter vibrators REPAIR or REPLACE all damaged emitter vibrators as necessary REPLACE emitter insulator boots CLEAN inspection cover (remove old gasket material) INSTALL emitter housing inspection cover NOTE Maintain the integrity of the insulation and lagging. Purge Air System a. G-14 . CAUTION Safety considerations for TR maintenance 1. thermostats. INSPECT and REPLACE filters as required b. i. etc c. Personnel working on TR unit should be properly trained CAUTION Prior to any maintenance on the TR set the High Voltage (HV) bushing should be grounded using a ground stick. h.f.6 Transformer/Rectifier (TR) NOTE Follow approved procedures with respect to the handling and temporary storage or chemicals used for cleaning. g. dampers. motors (lubrication) heaters. CLEAN fans/blowers. Transfer switch cubicles CAUTION Do not attempt to service or perform any maintenance on the TR set while it is energized. CAUTION Follow all appropriate grounding procedures CAUTION Follow general electrical safety precautions to prevent electrical shock. REPAIR or REPLACE defective or worn knife blades or receiver clips g. Transformer b. C. REPLACE any degraded bushings e. CLEAN and INSPECT bushings in transfer switch cubicle d. CLEAN gasket sealing surface (Discard old gasket) c. Bus Duct c. INSPECT interior of transformer switching compartments noting any discrepancies b. CLEAN interior of transformer switching compartments with approved cleaner. Transfer Switch Cubicle inspection and cleaning a. CLEAN external surfaces with approved cleaner: a. Transformer interior inspection a. B. c. Cooling fans e. SECURE transfer switch cubicle CAUTION Use proper foreign material controls when working around an open transformer. ENSURE transfer switch cubicle door gasket/seal is in good condition h. REPLACE defective gasket/seal i. REMOVE transformer inspection plate b. CLEAN and INSPECT all knife blades and receiver clips f. All tools and other items shall be secured by lanyard when working around or inside opening. Rectifiers d.A. VERIFY “high” winding to bushing bolting connection(s) are tight G-15 . (Insulation is good and terminations are tight) E. REINSTALL inspection plate with new gasket. CLEAN and INSPECT contactors for degradation (overheating. BLOWOUT (Using low pressure air ~40 psig) cabinets. etc) C. REPAIR or REPLACE damaged latches G-16 .7 Control Cabinets (Emitter Control Cabinets. top to bottom (boards. MEASURE resistance across contacts. mineral oil is amber) h. REPAIR or REPLACE any damaged cables. REPLACE degraded or damaged fans and filters G. f. insulation deterioration. CLOSE cabinet and ensure all latches work properly. I. fly ash fouling. g. INSPECT cables. REPLACE oil removed to the full level (as per vendor technical manual) i. wires and terminations. VERIFY all pushbuttons and hand switches change contact state. e. J. NOTE Eye protection and dust mask should be used when blowing dust out of cabinets. HOLDING contactors closed. Rapper Control Cabinets) A. looseness. B. K. VERIFY “low” winding to bushing bolted connection(s) are tight RECORD Oil level OBTAIN an oil sample (approximately a quart) INSPECT oil for suspended debris (silicon fluid is clear. D.0 ohms. M. REPLACE gasket/seal if degradation or damage affect sealing surface. etc) H. CLEAN and BURNISH any contacts that do not read 0. N. racks. L. 4. wires or terminations. CLEAN and INSPECT cabinet fans and filters F. VERIFY control cabinets are de-energized can Clearance/Tag Out is hung. INSPECT cabinet door gasket/seal for any damage or degradation.d. arcing. 5.0 Determine PMT and PMT considerations A. WALKDOWN precipitator external and internal and ensure all maintenance is complete and precipitator is clear of any foreign material. B. ENSURE all ground straps are removed C. ENSURE all personnel are out of the precipitator. D. ENSURE all access doors, inspection ports and other openings are sealed and closed. E. RELEASE clearance/tag out on precipitator F. ENSURE key interlock system is functioning and all TR’s are properly connected. G. PERFORM an air load test prior to boiler light off to ensure: a. ENSURE no grounds b. ENSURE TR sets are sparking at the same level c. ENSURE there is no need to re-enter precipitator. 6.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. Perform post job review B. Initiate any corrective action program documents necessary to resolve any problem areas identified. 7.0 References A. B. C. D. E. F. G. H. Industrial Safety manual Applicable vendor technical manuals (Controls and Precipitator) Confined Space Entry Procedure Foreign Material Control Chemical Control Procedure Material Safety Data Sheets Temporary Storage of transient fire loads EPRI, Electrostatic Precipitator Maintenance Guide, E213676, Volumes 1 and 2 G-17 H WORK PACKAGE TEMPLATE – PULVERIZER OVERHAUL 1.0 Task Overview 1.1 Component type This work instruction is applicable to the overhaul of a Roll Wheel Coal Pulverizer. 1.2 Equipment tag or unique equipment identifier Ensure unique equipment identifier is used to designate which Roll Wheel Coal Pulverizer is being worked. 1.3 Scope This work instruction describes the disassembly, inspection, and reassembly of a Roll Wheel Coal Pulverizer. 1.4 Develop list of know consumable materials to be used A. B. C. D. E. F. G. H. I. J. Roll Wheel Hub Oil (as per vendor) Gearbox Oil (as per vendor) Grease (as per vendor) High temp RTV (Red) Molycote Heavy oil Permatex Loctite Timbers Saw Blades for Ceramic Saw H-1 1.5 Develop a list of know parts to be replaced A. B. C. D. E. F. G. H. I. J. K. Wear plates (Upper Lower, Roller bracket) Grind Ring Segments Throat Vane Segments Roller Bearing Retainer Bearings Bearing Spacers Seals (Roll air and Oil) O-rings Gaskets Wedge Bold Nuts Plugs for jacking bolt holes (if required) 1.6 Special tools A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q. R. S. T. Fork lift with personnel work cage Pulverizer Access/Work Platform Inching Air drive Motor Impact Wrench Oxygen-Acetylene Cutting Rig Electric Arc Welder Grinder Chain Hoists Wire and Nylon Slings Turnbuckle Connecting rods Jacks (to raise pressure frame) (Spring frame jacking assembly) 150 ton jack for Grinding Ring Segment removal Ceramic Saw Pulverizer Portable Hydraulic Power Unit Wheel Assembly Handling Tool Wooden Wedges Torque Wrenches (assorted) Torch and appropriate tips Basic tools from mechanics toolbox H-2 B.4 Identify permits required A.2 Identify Foreign Material Exclusion (FME) potential and mitigation A.3 Job Safety Analysis. E. If work is performed inside plenums foreign material exclusion areas should be established. etc) should be in accordance with approved chemical control procedures H-3 .0 Pre-job Brief 2. B. Identifies general and specific hazards A. 2. Inspect all hoists.1 Evaluate potential for generation or equipment risk hazards 2. C. Equipment Clearance/Tag out Orders Confined Work Space Foreign Material Exclusion Chemical Control Procedure Material Safety Data Sheets 2. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E. E. solvents. D. oil. Confined Work Space procedures must be followed when opening Pulverizer inspection doors and entering the Pulverizer housing. grease.5 Identify Environmental Considerations A. 2. slings and other lifting equipment for ant defects and ensure inspection periods are current prior to use.g. All personnel are clear of the Pulverizer prior to using the Air Inching Drive to position the Roll Wheel Assembly D.2.g. C. cleaning solvents) B. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. Pulverizer must be purged and cooled down prior to opening the Pulverizer access doors. Handling and disposal of chemicals (E.. 6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment. B. C.3 Develop material list for potential contingency and consumable parts A.2. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. Inspections of any components may result in the need to repair or replace components as appropriate. 2. Roller Shafts B. Contact planner if scope growth is identified during work instruction performance B.0 Contingency Considerations 3. Roll Wheel Tires H-4 .7 Identify Clearance/Tag out Boundary Need a sample clearance for this piece of equipment 3. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. D.2 Identify individuals to contact in case certain events occur A. Contact maintenance Supervisor for inspection and determination of grinding ring segments replacement. 3.1 Identify potential scope expansion and actions due to scope expansion A. VERIFY excess coal is removed from Pulverizer (may use outside vendor to vacuum mill) 4. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn on the job ENSURE all rigging. B. utilize existing procedures when applicable Provide expected actions in proper sequence for task. LOCATE and ENSURE proper piece of equipment is being worked per the work instruction B. VERIFY Pulverizer is purged and cooled down for maintenance E. Identify Notes and Cautions where needed A.4. B. C. chain falls. hoists. DELIVER grinding ring segment profile readings to maintenance supervisor H-5 . slings etc.2 Roll Wheel Assembly Removal A. VERIFY Equipment Clearance/Tag Out has been established on Pulverizer to be worked D. OPEN Pulverizer for maintenance G. F.1 Prerequisites A.0 Detailed Work Instructions Develop work instructions. E. ERECT Pulverizer/Work platform CAUTION Confined Work Space procedures must be established prior to opening and entering the Pulverizer F. PERFORM profile reading on the grinding ring segments NOTE Maintenance Supervisor should determine in grindings wheel segments need replacement. are available and have been inspected prior to use 4. VERIFY Pulverizer is shutdown C. D. C. DISCONNECT lower ball joint b. REMOVE seal air piping for each bracket a. N. 2. INSTALL turnbuckle maintenance fixtures to support roll wheel assembly INSTALL fixture base plate and turnbuckles BOLT base plate to the roller bracket of all three roll wheels REMOVE slack from of turnbuckle linkage INSTALL wood wedges under the roller and between bracket and tire before proceeding O. I. L. REMOVE all wedge bolts and nuts H. REMOVE cover cone assembly E. Turnbuckles are to be installed between the wheels and not across the wheels (as per vendor) J.CAUTION Ensure personnel are clear of the Pulverizer prior to using the air driven motor. K. Perform the following steps for each wedge bolt. INSPECT gear box cover for corrosive damage NOTE Hot work permit required for removal of wedge bolt nut keeper bars. CUT the keeper bar welds G. ROTATE the grinding ring segment directly under roll wheel assembly NOTES 1. ROTATE the mill to loosen the wedge bolt in the grinding ring segment D. REMOVE piping from mill H-6 . INSTALL wedge bolt jack plate CAUTION Ensure personnel are clear of the Pulverizer prior to using the air driven inching motor. F. M. AA. ROLL Wheel Assembly Removal for the remaining wheels Rotate pulverizer to bring next roll wheel assembly to the door. INSTALL covers on bracket seal air openings to prevent entry of foreign material. RELEASE spring tension and loading force on hydraulic cylinders REMOVE clevis pins connecting the loading assembly to the spring frame CONNECT spring frame to pressure frame using connecting rods DISCONNECT loading cables INSTALL spring frame jacking assembly CAUTION Ensure all personnel are clear from inside the Pulverizer before next step. RAISE the pressure frame (using jacking assembly). W. REMOVE the roll pivot pins Y. ENSURE inside of Pulverizer has been cleared of all personnel (Signoff Required) V.P. c. REPEAT step [Z] and [A] for remaining wheels.3 Grinding Ring Segment Removal and Replacement CAUTION For use of plasma arc cutter. Q. R. BB. ensure the yoke is grounded to Pulverizer housing. SECURE roll pivot blocks to pressure frame assembly Z. Roll Wheel Assembly Removal For each wheel perform the following REMOVE wear plates from roll wheel INSTALL roll wheel removal assembly (jacks) ATTACH lift bracket to roller bracket ASSEMBLE all jackscrews DISCONNECT turnbuckle assembly OPERATE screw mechanism to pivot roll wheel assembly out of the mill LOWER roll wheel assembly to forklift for temporary storage CAUTION Ensure personnel are clear of the Pulverizer prior to using the air driven inching motor. 4. H-7 . SECURE spring frame jacking assembly with wire sling and 2 tone chain hoist from eye bolts in ceiling X. springs and spring frame as high as possible. S. T. U. A. CLEAN the grinding ring seat surface NOTE If damage is present contact engineering for resolution. PRY remaining grinding ring segments loose and REMOVE with segment handling tool D. Torque sequence of wedge bolts and nuts should be as per vendor instructions. 0300. INSTALL remaining grinding ring segments.CAUTION Do not cut seat ring. INSPECT grinding ring seat surface for damage F. J. CLEAN seating surfaces of new grinding ring segments G. I. K. Ensure grinding ring segments are pushed tightly together. 2. 5. 0600. NOTES 4. M. CUT the first grinding ring segment into several small pieces C. Assembled grinding ring segments should align within vendor tolerances on grinding face contour. Subsequent to 50 hours of Pulverizer operation the Pulverizer should be removed from service and the wedge bolts re-torqued. INSTALL wedge bolts. and 0900. GROUND plasma arc cutter yoke to Pulverizer B. Torque pattern will be per vendor instructions or a standard torque pattern such as 1200. washers and nuts TORQUE wedge bolts and nuts per vendor recommendation INSTALL keeper bars and tack weld in place to the seat ring INSTALL plugs in jack bolt holes (if required) INSTALL cone cover assembly (use Permatex in the joint) H-8 . L. It may be necessary to grind the bosses of the last several segments to achieve proper positioning H. 6. E. 3. INSTALL first grinding ring segment over the drive dowel pin and ALIGN it with wedge bolt holes NOTES 1. PERFORM UT testing of seal air piping if required Q. INSTALL top turnbuckle brackets in place on wheel brackets B. CONNECT turnbuckle assembly to wheel assembly H. NOTE Turnbuckles are to be installed between the wheels and not across the wheels (as per vendor) D. INSTALL wooden wedges under wheel to prevent the wheel from rolling F. INSPECT intermediate housing wear plates and replace as required NOTE If UT testing of seal air piping header is desired. INSTALL roll wheel bracket wear plates H-9 . INSTALL bottom turnbuckle fixture brackets on cone cover plate NOTE Do not remove assembly from the removal bracket mechanism at this time. this must be done before wheels are re-installed. C. P.NOTE RTV should be used around wedge bolts and dowels to prevent coal dust from entering yoke cavity. INSPECT pressure frame wear plates and replace as required. INSTALL first roll ring assembly on the grinding ring and center it on a fixture. LEVEL the top of the removal bracket along the centerline of the pivot pins to the center of the mill G. O. INSPECT seal air piping seals and replace as required 4. DISCONNECT roll wheel assembly from removal tool I. ASSEMBLE turnbuckles to the roller bracket E. N.4 Roll Wheel Assembly Installation A. springs and spring frame onto roll wheel assemblies. X. Q. REMOVE turnbuckle assemblies. CAUTION Ensure all personnel are clear from inside the Pulverizer before next steps. NOTES 7.CAUTION Ensure personnel are clear of the Pulverizer prior to using the air driven inching motor. INSTALL seal air piping SLIDE piping into upper joint ATTACH lower ball joint S. K. W. ASSEMBLE roll pivot in the wheel brackets for each roll wheel. NOTE It may be necessary to position the wheel assemblies under pressure frame blocks. LOWER pressure frame while aligning pivot blocks and pivot ring R. CONNECT loading assembly to the spring frame using clevis pins T. ROTATE Pulverizer (using inching air drive motor) until the next wheel’s assembly is located at the maintenance hatch. LOWER pressure frame. V. N. 8. Hydraulic cylinder loading and spring height should be recorded for future reference. Replace if wear is severe. Y. PRESSURIZE hydraulic cylinders to remove slack from loading cables U. PRESSURIZE the hydraulic loading cylinders to obtain proper spring loading. REPEAT above steps for all roll wheel assemblies L. M. POSITION the wheel assemblies under the pressure frame blocks just prior to contact. Use turnbuckles and inching air drive motor to position. INSPECT roll pivot pins and pivot blocks. Proper spring loading should be at vendor manual requirements. ENSURE inside of Pulverizer has been cleared of all personnel (Signoff Required) O. P. MEASURE spring height at various locations RECORD hydraulic cylinder loading and spring height TIGHTEN top and bottom nuts on loading cylinders H-10 . J. 0 Determine PMT and PMT considerations Looking for post maintenance information 6.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. CHECK oil level in each wheel assembly 4. covers and access ports 5. 7. INSTALL guards. TIGHTEN top lock nuts on loading cylinder AA. Initiate any corrective action program documents necessary to resolve any problem areas identified. B. D.0 References A. C. REMOVE turnbuckle assemblies CC. Industrial Safety manual Confined Work Space Procedure Applicable vendor technical manuals Foreign Material Control H-11 . GREASE wheel assembly seals DD.’ I. REMOVE Pulverizer/Work platform RELEASE Pulverizer/Tag Out on Pulverizer STORE tools used for work CLEAN work area to pre-work conditions RETURN unused part to stores NOTE If work was performed inside a plenum ensure are materials taken into plenum have been removed. E. RELEASE loading hydraulic pressure BB. G.Z. H. D.4 Final Reassembly A. B. Perform post job review B. C. F. RELEASE Clearance/Tag out on seal air system CHECK seal air system for leaks CLOSE maintenance hatch and other openings on Pulverizer. . E. Packing I-1 . B.g. lubrication and minor maintenance of dampers. Seals C. Clean lint free rags Grease (e. cleaning.4 Develop list of know consumable materials to be used A. Gaskets B.5 Develop a list of know parts to be replaced A. 1. C.2 Equipment tag or unique equipment identifier Ensure unique equipment identifier is used to designate which damper is being worked. 1.I WORK PACKAGE TEMPLATE – DAMPERS 1.3 Scope This work instruction describes inspection. 1. vendor approved) Cleaning solvent (Vendor approved) Brush Oil (Vendor approved) 1. Mobilux EP #2.1 Component type This work instruction is applicable to various dampers.0 Task Overview 1. D. If ventilation fans are being worked. Some belts do not recommend the use of belt dressings.3 Job Safety Analysis. 2.4 Identify permits required A. Mechanic’s tool box Grease gun Can oiler Ladders. B. E.0 Pre-job Brief 2. B. B. Conduct a pre-job brief to ensure the scope of the work to be performed is understood by all personnel.6 Special tools A.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. D. resulting ventilation line-ups to support work can cause significant d/p’s across doors or other accesses posing a personnel safety hazard. scaffolding (depending on location) Safety belts 2. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. C. This could cause premature belt failure. If work is performed inside plenums foreign material exclusion areas should be established.1. Some fans have resonant frequencies. Identifies general and specific hazards A. (refer to belt manufacture with respect to belt dressings) C. Belts should be adjusted appropriately to avoid fans potentially running at resonant frequencies. It is recommended that belt tension be checked within 24 to 48 hours of installing new belts due to belt break-in stretch. Equipment Clearance/Tag out Orders B.1 Evaluate potential for generation or equipment risk hazards A. 2. 2. Chemical Control Procedures (handing and disposal) I-2 . D. Power to FD or ID fan(s) 3. grease.7 Identify Clearance/Tag out Boundary A. cleaning materials. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E.0 Contingency Considerations 3. C. cleaning solvents) B. Contact planner if scope growth is identified during work instruction performance B. Inspections of any components may result in the need to repair or replace components as appropriate.. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance.g. solvents.g. Motive force to damper (breaker. B. oil.1 Identify potential scope expansion and actions due to scope expansion A. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. etc) should be in accordance with approved chemical control procedures 2. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. Handling and disposal of chemicals (E. 2.2.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions I-3 . 3.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment.2 Identify individuals to contact in case certain events occur A.5 Identify Environmental Consideration A. air supply) B. water wash. D. Dirt/dust/ash/etc b. NOTE Reference vendor technical manual for approved cleaning methods: steam clean.0 Detailed Work Instructions Develop work instructions. Identify Notes and Cautions where needed A. approved solvents B. Missing or broken parts (pins. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn and used on the job 4. Work instruction should be amended to perform corrective maintenance. bolts. Verify free of obstruction or binding 3. CLEAN blades and linkage(s) using vendor approved method of: a. INSPECT blades for: I-4 . utilize existing procedures when applicable Provide expected actions in proper sequence for task. DISCONNECT damper linkage from actuator.1 Inlet Damper Clean/Inspection A. C. sandblast. Shaft 4. C. E. Inadequate lubrication 2. fasteners.4 Develop material list for potential contingency and consumable parts A. etc) 4. Bearings B. B. INSPECT linkages for: 1. INSPECT the damper components: a. Old grease NOTE Any damaged or degraded components should be evaluated for replacement. Proper alignment b.3. 2. Repack glands as required g. INSPECT ductwork to damper seals for tightness CAUTION If inside of ductwork at damper is inspected for ash buildup CONFINED WORKSPACE requirements should be in effect. Corrosion 2. INSPECT shaft at bushing or bearing pint for wear 2. INSPECT blade seals 1. 6. Warpage that may cause blade binding f. d. INSPECT in open and close position for straightness and obvious surface variations. CHECK damper mountings for loose. INSPECT packing glands for leakage 1. ENSURE blade seals provide continuous contact along entire blade length in the closed position.1. 4. 8. 7. INSPECT for bowed shaft e. Seal tightness may be checked by a smoke test. INSPECT frame for: 1. INSPECT inside portion of ductwork at damper for ash build up. INSPECT blade shaft 1. 5. CLEAN accessible external surfaces of the damper unit h. Corrosion Erosion Ash buildup Cracks Warpage Seal along blade edges Binding Bending/buckling Brittle/broken frayed seals (If installed on blades) NOTE Seals (if installed) may be either metallic. 3. Erosion 3. silicone. broker or missing parts i. I-5 . rubber or plastic). j. c. 9. 2. NOTE If any of the following conditions exist. d. D. e. REMOVE damper bearing(s) NOTE 1. Soak sufficiently to loosen and remove grease/dirt 2. E. b. rollers or raceways Discoloration (brownish blue or blue-black areas) Indented/brinelled/etched raceways 4. LUBRICATE linkages B. Use a brush to assist in removal of grease/dirt B. DISASSEMBLE bearing. g.3 Lubrication A. Broken or cracked rings Dented shields/seals Cracked/broken separators Broken/cracked balls or rollers Flaked/spalled areas on balls.2 Damper Bearings A. c. replace bearing. SLOWLY ROTATE outer race noting any rough/sticky spots NOTE If rough/sticky spots persist after repeated cleaning attempts the bearing should be disassembled and inspected. f. INSPECT bearing for damage. a. CLEAN bearing(s) by soaking bearing(s) in approved solvent to remove grease and dirt C. APPLY small amount of oil to all damper moving components I-6 . LUBRICATE bearings C.4. Check completeness of travel d. INSTALL bearings (if removed) INSTALL linkages (if removed) INSTALL all bolts. and comparing the two sides for balance. C. for double inlet or outlet damper configurations. Smooth operation of linkage and blades b. Proper setup of mechanical stops and electrical limits NOTE Damper synchronization is accomplished by establishing a reference dimension. D. Check mechanical stops E. E. D. DISPOSE of any generated waste products properly. Check for any binding or noise c. Initiate any corrective action program documents necessary to resolve any problem areas identified. ELECTRICALLY CYCLE damper open and close and INSPECT for: a. B. I-7 . INSTALL guards. VERIFY that dampers are synchronized.4 Reassembly A. RELEASE Clearance/Tag out on damper B. Perform post job review B. SET Mechanical stops and electrical limits 5. RETURN any unused spare parts to stores/warehouse 6. Unusual noise c. C. screws and fasteners (torque as specified) MANUALLY CYCLE damper open and closed and INSPECT for: a.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A.4. Vibration d. covers and access ports F. Proper operation of linkage and blades b. INSTALL linkage to actuator G. actuating the vanes.0 Determine PMT and PMT considerations A. 0 References A. D. Industrial Safety Manual Damper vendor technical manual Actuator vendor technical manual Material Safety Data Sheets Chemical Traffic Control Procedure I-8 .7. B. C. E. g. H.3 Scope This work instruction provides instructions for inspection and repair of a centrifugal process pump.g. E.4 in the reference section of this template. Koppers KHP) Pump bearing oil (E. MTX). I.J WORK PACKAGE TEMPLATE – CENTRIFUGAL PUMP (PROCESS. 1. 3196) NOTE Personnel performing this work instruction should be qualified (properly trained and proficient) on the type of pump being worked.0 Task Overview 1. 1. 1. F. G. Dow Corning 4 or 111) Oil Drain pan Duct tape J-1 . MT. D.g. A typical Model 3196 STX pump is shown in Figure J. 1. Acetone Isopropyl alcohol Varsol Clean lint free rags Grease (e.g. (E. MO-2) Silicone grease (E.2 Equipment tag or unique equipment identifier Ensure the unique pump identifier is used to designate which pump is being worked. B. Gould 3196 ST.4 Develop list of know consumable materials to be used A. STX. Molycote 55 or 44. C.1 Component type This work instruction is applicable to a typical centrifugal process pump. C. L. E.g. Generation B. K. Performance of this work will open pump to environment. E.0 Pre-job Brief 2.1 Evaluate potential for generation or equipment risk hazards A. M. D. Gland Gasket Impeller O-Ring Bearing Housing O-Ring Casing Gasket Bearings 1. Mechanics tool box (wrenches. Appropriate measures should be taken to prevent foreign material from entering the pump.J. F. C. D. Equipment Risk/Damage 2.5 Develop a list of know parts to be replaced A. B. N. G. O. J. H. B. bags) for temporary storage of parts 1.6 Special tools A. I. J-2 . screwdrivers etc) Bearing puller Bearing driver Snap ring pliers Rubber mallet Torque wrenches (various) Allen wrenches Dial indicator Micrometer (inside and outside) Feeler gauges Pyrometer Sling Jacking screws C clamps Shaft wrench 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. Containers (E. D. oil. Handling and disposal of chemicals (E. Oil drained from the pump should be removed from the work area and properly disposed of as soon as practical.g. Other wise.. 2. B. G.7 Identify Clearance/Tag out Boundary A. E. Pump suction valve Pump discharge valve Pump recirculation valve Pump Vent valve Pump Drain valve Power to motor If installed (Gland seal supply valve) J-3 . DO NOT allow petroleum based products to contact the EPT O-rings of the mechanical seal.2. Follow appropriate Material Safety Data Sheet (MSDS) and site approved procedures for handling and disposal of cleaning chemicals and solvents. grease.4 Identify permits required A.5 Identify Environmental Consideration A. Identifies general and specific hazards A. an appropriate transient fire load evaluation should be performed and proper temporary storage provided. Equipment Clearance Order B. Petroleum based products will cause the O-rings to deteriorate and fail. Transient combustible material storage permit 2. etc) should be in accordance with approved chemical control procedures 2. C. 2. B.3 Job Safety Analysis. Chemical Control Permit C.g. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E. solvents. Follow approved site procedures for proper draining and disposal of process fluids from the pump. C.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed. F. D. cleaning solvents) B. 3. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available REVIEW and UNDERSTAND the scope of work before the start of any field activities. Impeller B.2 Identify individuals to contact in case certain events occur A. ENSURE appropriate personal safety equipment is worn on the job J-4 . Identify Notes and Cautions where needed A. D. E. Contact planner if scope growth is identified during work instruction performance B.0 Detailed Work Instructions Develop work instructions. B. Inspections of any components may result in the need to repair or replace components as appropriate. Mechanical Seal 4.1 Identify potential scope expansion and actions due to scope expansion A. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. F.4 Develop material list for potential contingency and consumable parts A. Coupling C. utilize existing procedures when applicable Provide expected actions in proper sequence for task. C.3. C.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. B.0 Contingency Considerations 3. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. D. NOTE For disc type couplings ensure disc sequence is maintained during removal Either leave a bolt in one bolt hole or tape disc pack to maintain proper sequence. IF coupling contains grease. 4. IF installed. I. REMOVE pump from casing. NOTE Cover exposed ends of pipe to prevent entry of foreign material. G. NOTE After draining oil remove from area and properly dispose of or provide temporary combustible storage. equipment supports. THEN REMOVE insulation. ENSURE piping. LOCATE and IDENTIFY proper piece of equipment is being worked per the work instruction C. DISASSEMBLE coupling C.1 Preparations A. e. REMOVE casing gasket J-5 . IF pump had constant level oiler. THEN REMOVE and DRAIN oiler bulb. REMOVE casing bolts f. THEN CLEAN grease from coupling. H.2 Preparation for pump removal A. REMOVE frame foot hold down bolts. IF required to drain pump casing. IF installed. and other interferences are removed to support work. VERIFY clearance/tag out is correctly in place B.4. THEN DRAIN casing. D. B. DRAIN oil from pump. REMOVE coupling guard. E. F. THEN REMOVE gland seal supply and leakoff piping. D. G. REMOVE pump from casing. J-6 . IF pump has a mechanical seal. NOTE Sling should be used to support pump during removal from casing. THEN REMOVE mechanical seal. h.3 Pump Disassembly A. C. E. SECURE pump frame to workbench NOTE Coupling hub position should be marked on shaft B. 4. THEN REMOVE split gland and stuffing box cover. Jack screws should be used to back out pump from casing. IF installed. REMOVE impeller from shaft (Impellers are screwed on) REMOVE impeller O-ring IF pump has a packing stuffing box. REMOVE coupling hub. COVER open casing (Foreign Material Exclusion) NOTE Use proper lifting or rigging practices to remove pump from location to work area. Refer to vendor technical manual for specific installation. MOVE pump to maintenance location.NOTE Shims that are removed should be marked so they can be replaced in their original positions. g. NOTE Mechanical seal location should be marked on shaft F. THEN REMOVE frame adapter. J. NOTE Disassembly of the power end and it components varies with model. damage. Shaft (bearing fit. damaged threads)) j. LIST parts replaced in work package. REMOVE bearing housing from shaft m. REMOVE bearings as follows i. gasket surface) c. l. 4. shaft runout) e. bearings and bearing housing k. NOTE Refer to vendor technical manual for acceptable tolerances C. a. REMOVE inboard and outboard oil seals J. E.4 Pump Inspection NOTE Age of bearings. lubrication passages clear) g. REMOVE burrs as required. THEN REMOVE packing rings from stuffing box. Impeller (grooving. pitting. REMOVE outboard bearing I. Bearing frame (cracks. cracking) d.) i. fit etc. REMOVE (As a unit) shaft. REMOVE bearing housing bolts j. ENSURE bearings are clean and LUBRICATED. overheating. gaskets and O-rings should be taken into account as to whether they should be replaced regardless of inspection results. Outboard Bearing (contamination. damage. pitting) b. Casing Bolts (cracks. A. Labyrinth seals (O-rings for cuts and cracks) l. Inboard Bearing (contamination. J-7 . Packing studs/nuts (cracks. Mechanical Seal f. VISUALLY INSPECT parts for corrosion. fit etc. overheating. Frame adapter (cracks. damaged threads) D. Mechanical Seal Gland bolts k. CLEAN pump parts as required using isopropyl alcohol or acetone B. mechanical seals.H. erosion or wear. REPLACE all damaged or degraded parts. scale. debris. B.) h. REMOVE inboard bearing using a bearing puller. IF pump has a packed stuffing box. Casing (grooving. LUBRICATE bearing location on coupling end of shaft.5 Pump Reassembly A. 4. NOTE Drain slots should be positioned at bottom for labyrinth seal E. NOTE Bearing may be heated using a bearing heater and installed on the shaft by hand. Bearing should not be heated more than 250 degrees F. F. LUBRICATE bearing location at impeller end of shaft. CAUTION Gloves should be worn when handing hot bearings J-8 . NOTE Bearing may be heated using a bearing heater and installed on the shaft by hand.CAUTION It may be necessary to heat the bearing to install it on the shaft. THEN SLIDE outboard bearing onto coupling end of shaft until firmly seated on shaft shoulder. CAUTION Gloves should be worn when handing hot bearings C. Bearing should not be heated more than 250 degrees F. THEN HEAT and INSTALL outboard bearing on coupling end of shaft until firmly seated on shaft shoulder. H. NOTE It may be necessary to lightly tap bearing using a pipe or driving sleeve to fully seat bearing against shaft shoulder. If the bearing is heated DO NOT overheat. CAUTION It may be necessary to heat the bearing to install it on the shaft. LUBRICATE and INSTALL oil seal in thrust bearing housing. D. IF heat is NOT used. If the bearing is heated DO NOT overheat. IF heat is used. LUBRICATE and INSTALL O-ring on bearing housing. G. SLIDE and LOCK bearing housing onto shaft. INSTALL impeller O-ring and impeller on shaft NOTE Refer to vendor technical manual for gap clearance J-9 . INSTALL deflector onto shaft OR shaft sleeve.I. THEN INSTALL shaft sleeve on to shaft. NOTE Oil seal may be installed in frame adapter or bearing adapter depending on model. L. IF heat is NOT used. IF pump has a packing stuffing box THEN a. N. J. IF heat is used. O. NOTE Top of thrust bearing housing should be in line with top of frame. K. INSTALL bearing and shaft assembly into frame IF pump has a shaft sleeve. M. INSTALL and LUBRICATE oil seal. INSTALL stuffing box cover b. THEN SLIDE inboard bearing onto impeller end of shaft until firmly seated on shaft shoulder. NOTE Drain slots should be positioned at the bottom for labyrinth seals. THEN HEAT and INSTALL inboard bearing on impeller end of shaft until firmly seated on shaft shoulder. NOTE It may be necessary to lightly tap bearing using a pipe or driving sleeve to fully seat bearing against shaft shoulder. SLIDE and LOCK mechanical seal into position on shaft k. INSTALL stuffing box cover l. j. IF pump has a mechanical seal. INSTALL stuffing box cover against frame adapter OR bearing frame. NOTE Care should be taken to minimize dust or other contaminants from settling on seal faces until all parts are assembled and locked into final position.c. P. f. LUBRICATE and INSTALL stationary O-ring on seat INSTALL stationary seat in gland INSTALL stationary seat in stuffing box cover SLIDE Gland with gasket over shaft NOTE Refer to position for mechanical seal marked on shaft during disassembly. mechanical seal gland and internals of stuffing box cover for cleanliness. h. Temporarily ADJUST gap between impeller and stuffing box. THEN: a. i. d. g. Temporarily ADJUST gap between impeller and stuffing box. REMOVE impeller and stuffing box cover e. INSPECT mechanical seal. SLIDE and TORQUE mechanical seal gland into position J-10 . INSTALL impeller O-ring and impeller on shaft NOTE Refer to vendor technical manual for gap clearance c. INSTALL impeller O-ring and impeller on shaft NOTE Refer to vendor technical manual for appropriate torque value for gland stud nuts based on size m. b. E.6 Pump Installation NOTE Coupling hub should be positioned at scribe mark made during disassembly A. F. K. INSTALL coupling hub on shaft MOVE pump to plant location. G. REPLACE shims removed during disassembly J. INSTALL frame assembly into casing NOTE If the impeller does not turn freely while tightening the casing bolts. I. INSTALL frame foot hold down bolts (Wrench tight) NOTE Impeller clearance may be adjusted by either the Feeler Gauge Method OR the Dial Indicator Method. NOTE Use proper rigging techniques during installation or frame assembly to prevent damage. TORQUE casing bolts to appropriate vendor specified value. D. Adjusting impeller clearance by Feeler Gauge method J-11 . the impeller should be adjusted using the impeller adjusting bolts. LUBRICATE and INSTALL the frame-casing bolts. NOTE Shaft should be rotated by hand during torque of casing bolts NOTE Additional shims may be added as required to avoid pipe strain. B. ENSURE jacking bolts are back all the way out. INSPECT casing internals for cleanliness. INSTALL casing gasket against casing shoulder. H.4. C. LOOSEN impeller adjustment bolts several turns.Figure J. Refer to vendor technical manual for impeller clearance gap. J-12 .1 Impeller Adjustment – Feeler Gauge Method a. LOOSEN each bearing housing bolt until desire impeller clearance gap can be obtained between the bearing housing and the underside of the bearing housing bolts. NOTE Impeller clearances will vary. while slowly rotating pump shaft by hand until impeller just starts to rub on casing. c. Evenly TIGHTEN bearing housing bolts. LOOSEN locknuts on impeller adjustment bolts. b. d. LOOSEN impeller adjustment bolts several turns. c. Adjusting impeller clearance using Dial Indicator Method Figure J. Evenly TIGHTEN impeller adjustment bolts until bearing housing is tight against the bearing housing bolts f. while slowly rotating pump shaft by hand until impeller just starts to rub on casing. TIGHTEN the locknuts on the impeller adjustment bolts (Wrench tight) g. VERIFY the impeller can be rotated by hand with no indication of rubbing on the casing. Refer to vendor technical manual for impeller clearance gap. b. TIGHTEN the bearing housing bolts. NOTE Impeller clearances will vary. Evenly TIGHTEN bearing housing bolts. e. (Finger tight) J-13 . Evenly TIGHTEN impeller adjustment bolts until the dial indicator reads the desired impeller clearance gap.2 Impeller Adjustment – Dial Indicator Method a. LOOSEN locknuts on impeller adjustment bolts. g. L. f. d. h.e. INSTALL a dial indicator so its tip is positioned on the end of the shaft VERIFY the dial indicator is set to ZERO. LOOSEN each bearing housing bolt 5 – 6 flats. VERIFY the impeller can be rotated by hand with no indication of rubbing on the casing. c. d. ENSURE top tangs in oiler base are level with oil level line marked on side of pump. Evenly TIGHTEN the bearing housing and the impeller adjusting bolts while maintaining the desired impeller clearance gap on the dial indicator. REMOVE oil bubbler b. MO-2) as follows: a.i. FILL bubbler with proper oil. FILL bearing housing with proper oil through the filler/vent UNTIL oil reaches top of tangs inside the oiler base. INSTALL bubbler on oiler base. ALLOW bubbler to drain UNTIL bubbling stops. g. REMOVE filler/vent from top of bearing housing. f. THEN FILL bearing housing with proper oil (E. e. J-14 .g. TIGHTEN the locknuts on the impeller adjustment bolts (Wrench tight) k. (Wrench tight) j. h. Figure J.7 Final Pump Assembly NOTE Pump may or may not have a constant level oiler.3 Oil Bubbler A. REPEAT steps (f) and (g) UNTIL bubbler remains approximately ¾ full.. 4. IF pump has a constant level. H. J-15 . RELEASE clearance/tag out PERFORM vibration testing IF pump has packing. FILL bearing housing with appropriate oil UNTIL level reaches the middle of the sight glass. THEN ADJUST packing to achieve proper leakoff. INSTALL coupling guard (Wrench Tight) 5. C. IF pump DOES NOT have a constant level oiler. B. VERIFY no system or oil leaks. torque requirements.i. (Wrench tight) k. etc) for installation of coupling depending on coupling type. ALIGN pump to desired tolerances.0 Determine PMT and PMT considerations A. INSTALL oil fill plug. ENSURE vent cap vent holes are clear j. MONITOR inboard and outboard bearing temperatures using a pyrometer. THEN: a. c. (Finger Tight) NOTE Use site specific method for installation of packing NOTE Use site specific method (E. REMOVE oil fill plug b.g. D. G. IF pump has a packing gland THEN: a. ASSEMBLE coupling using information obtained during disassembly. INSTALL packing and lantern ring b. INSTALL vent cap. THEN ENSURE piping is clean and INSTALL piping (Wrench Tight) NOTE Use site specific method for performing pump alignment D. TIGHTEN hold down bolts while assuring alignment tolerances are maintained F. B. WIPE UP any excess oil. (Wrench Tight) C. E. IF gland seal supply and leakoff piping were removed. E. lubricant. INSTALL split GLAND with gland nuts. Perform post job review B. G. 7. equipment supports or other interferences were removed. Work site cleanup . J. B. IF piping.F. THEN INSTALL insulation. THEN REINSTALL these interferences. Industrial Safety Manual Foreign Material Control Procedure Material Safety Data Sheets Chemical Traffic Control Procedure Storage of temporary combustibles (transient fire loads) Vendor Technical Manual (Pump) Vendor Technical Manual (Coupling) J-16 .CLEAN work area to original pre-maintenance conditions I. RETURN unused parts to storeroom 6. DISPOSE of any generated waste products properly. E. C.0 References A. IF insulation was removed.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. H. F. Initiate any corrective action program documents necessary to resolve any problem areas identified. D. G. 4 Typical Model 3196 STX Pump J-17 .Figure J. . B.) K-1 . D. It is essential for inspection personnel to know how each steam trap operates under specific conditions in order to diagnose the problem correctly. Typically numerous steam traps are tested during a given testing.2 Equipment tag or unique equipment identifier Ensure unique equipment identifiers are used to designate which steam traps are being inspected. This can help avoid misdiagnosis and allow proper interpretation of test results.F. 1. thermostatic. thermodynamic. Some test methods require the use of special equipment that will require special training.3 Scope This work instruction describes the testing and repair of steam traps.0 Task Overview 1. 1. Squeeze water bottle Spanners (required for removing regulator devices from traps) Clean rags Thread lubricant Lapping compound (e. If traps require maintenance they should be identified on the data sheets for repair. mechanical.1 Component type This work instruction is applicable to various types of steam traps.4 Develop list of know consumable materials to be used A. C.K WORK PACKAGE TEMPLATE – STEAM TRAPS NOTE Personnel involved in steam trap testing should be familiar with the fundamental operation of the types of traps to be inspected.g. E. Carborundum compound I. orifice. 1. 1. Prior to opening a trap for inspection or repair the steam supply and return lines to condensate should be isolated. Steam lines and traps are HOT. Typically testing/inspection of steam traps is performed with the unit on line. Temperature measurement (Contact thermometer. Testing a. Identifies general and specific hazards A. infrared detection equipment. etc) B. If steam trap requires replacement and is removed from the system. Heat sensitive strips or crayons. pyrometer. C.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. However. Industrial stethoscope or ultrasonic test equipment c. Cover gaskets Strainers Seats Disks 1.1 Evaluate potential for generation or equipment risk hazards A. D. K-2 . Maintenance a. Mechanics toolbox 2. D.0 Pre-job Brief 2. Dangers might include: isolation of vents and protective devices or alarms. In most cases there is little to no risk to the unit or systems during these activities. open pipe ends should be covered to preclude foreign material entering system 2. B. When isolating any section of piping.5 Develop a list of know parts to be replaced A. Ensure isolation valves are turned closed in a gradual way to avoid system shocks. C.6 Special tools A. B. consideration should be given as to whether isolating valves will put any other part of the system or personnel at risk. care should be taken since sections of piping may be isolated to perform testing. Wearing of appropriate personnel safety equipment and work precautions should be observed. Manipulation of any valves or equipment should be performed by Operations personnel.1.3 Job Safety Analysis. Mechanics tool pouch b. When blowing down a steam trap gloves and face shield should be worn. 2. 2 Identify individuals to contact in case certain events occur A. B.1 Identify potential scope expansion and actions due to scope expansion A. 2. Personnel should take necessary precautions and wear appropriate personal safety equipment.7 Identify Clearance/Tag out Boundary A. Outlet isolation to condensate recovery C. K-3 .0 Contingency Considerations 3. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. 2. to depressurize trap) 3. Steam trap testing is performed with the steam system operating. 3.E. Inspections of any components may result in the need to repair or replace components as appropriate. During testing live steam may be released to the environment. Inlet isolation to trap B. Appropriate ear protection should be worn. During trap reassemble ensure all joint faces are clean. B. Equipment Clearance/Tag out Orders 2.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. Contact planner if scope growth is identified during work instruction performance B.5 Identify Environmental Consideration A. The plant is typically a high noise area.4 Identify permits required A. Blowdown valve (If applicable. F. Prior to performing maintenance on steam trap allow the trap to cool to minimize the potential for burns. 2. nuts or clamps Orifice 4. B. ENSURE all tools necessary to perform the job are available E. F. d. Prerequisites a. BLOWDOWN strainer (If installed) NOTE If there are traps in close proximity to the trap being tested those traps should be isolated to assist in eliminating any false signals that may be generated by those traps. Complete replacement steam trap (appropriate design) Regulating devices (bellows. TEST for hot trap by squirting a little water on trap cover/cap. K-4 . c.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. Identify Notes and Cautions where needed A. ENSURE trap is in operation and at normal operating temperature b. ENSURE all parts expected to be used are available and in hand D. E. ENSURE an appropriate clearance/tag out is in place to repair/replace steam trap (If required) C. THEN IDENTIFY trap for maintenance.0 Detailed Work Instructions Develop work instructions. utilize existing procedures when applicable Provide expected actions in proper sequence for task. If hot water will vaporize immediately. bimetallic. IF trap is cold. ENSURE appropriate personal safety equipment is worn on the job 4. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. D.4 Develop material list for potential contingency and consumable parts A. C. NOTIFY Operations prior to beginning work (Operator required if valve manipulations will be performed during stream trap testing) B.1 Testing Steam Traps A. etc) Float ball Bucket Cap/Cover bolts.C. b. f. THEN IDENTIFY trap for further testing or maintenance.B. D. Leaks NOTE It is recommended that at least two methods be used to determine whether the steam trap is operating properly. e. c. NOTE Operations personnel should perform all valve manipulations. OBSERVE trap for discharge of live steam. the strainer blowdown valve can be opened to divert condensate away from the trap. OBSERVE discharge for continuous or intermittent flow (trap design dependent. IF any abnormal trap observation is observed. OPEN discharge valve c. LISTEN for trap operation (Is it cycling?) LISTEN for mechanical sounds CHECK for continuous high pitch steam flow CHECK for continuous low pitch condensate flow CHECK for intermittent flow NOTE For closed condensate recovery systems there must be a line with discharge valve available to observe trap discharge. CHECK external condition of trap a. K-5 . Supports b. If the trap is operating correctly it will close and no steam will be observed at the discharge. d. PERFORM sound check on traps (Stethoscope or Ultrasonic) a. PERFORM visual inspections on traps that sound abnormal. Corrosion d. OBSERVE discharge for flash steam and normal condensate flow d. C. a. NOTE If the trap has a strainer up stream of the trap. CLOSE return line to condensate recovery b. Insulation c. This will allow only steam to enter the trap. e. IF trap is not operating properly. PERFORM temperature check of trap if necessary a. THEN ENSURE location of temperature measurement is clean. RECORD steam supply line pressure. E.NOTE Condensate return line pressure must be known to assist in determining if trap is operating properly. b. c. THEN IDENTIFY trap for repair or replacement. 4.2 Steam Trap Maintenance NOTE Steam trap maintenance can involve either repair or replacement.1 – Pipe Line Temperatures at Various Operating Pressures Table K. MEASURE supply line temperature e. IF temperature is measured by contact thermometer or heat sensitive strips. MEASURE return line temperature f. The body’s of most steam traps should last the life of the plant. upstream and downstream of trap. COMPARE return line temperature to expected return line temperature based on table K.1 Pipe Line Temperatures at Various Operating Temperatures Return Line Steam Pressure (psig) 0 (Atmospheric) 15 30 100 150 200 450 600 Return Line Temperature Range (F) 212 225-238 245-260 305-320 330-350 350-370 415-435 435-465 F. Repair would be the preferred option especially when the trap is welded into the system. NOTE Some steam traps are sealed units and can only be replaced K-6 . RECORD condensate return line pressure d. TORQUE plug/cap per vendor specifications d. a. TORQUE plug/cap per vendor specifications 4. INSTALL plug/cap using new gasket 4. b. screw cap or clamped. ENSURE sealing surface is not overly worn or cut. REMOVE strainer plug/cap 3.g.2. REMOVE cover (Maybe bolted. Fitting new disc 1. REMOVE strainer plug/cap 2. Some float traps also contain a bimetallic device that operates to remove air or non-condensable gases. INSTALL new disc.2 Ball Float Steam Trap NOTE Steam trap operating mechanism typically includes the main valve assembly. TORQUE cover to vendor specification c. ENSURE an equipment clearance/tag out is in place and the steam trap is depressurized and cool to the touch. REMOVE old disc d. etc) c. ENSURE strainer is inside equipment clearance/tag out boundary. 2. IF steam trap has and integral strainer. IF sealing surface is overly worn or has minor cuts THEN LAP seating surface using an approved lapping compound. INSTALL plug/cap using new gasket. b. 2. INSTALL cover with using new gasket.2. 3. K-7 . CLEAN or REPLACE strainer 4. IF strainer is not integral to steam trap (e. THEN 1.1 Thermodynamic Steam Trap a. located upstream of trap) THEN 1. CLEAN or REPLACE strainer 3. 5.NOTE Use of a thread lubricant is recommend when installing trap covers/caps or strainer plugs/caps. 4. pivot frame and ball float. IF trap has a bimetallic air vent assembly. E.3 Balance Pressure Steam Trap A. ENSURE strainer is inside equipment clearance/tag out boundary. b. REMOVE capsule and spacer plate NOTE Seats are typically screw type but will vary by vendor. etc. seat. REMOVE cover C. F. J. e. If the seats are of the screw in type. IF strainer was not integral to trap THEN: a. they should also be replaced REMOVE operating mechanism INSTALL new seat (if applicable) IF trap was blowing through due to float failure THEN REPLACE float. I.) c. H.2. screw cap or clamped. E. THEN a. F. REFURBISH air vent assembly with new parts (gasket. REMOVE strainer plug/cap c. etc) C. K-8 . ENSURE an equipment clearance/tag out is in place and the steam trap is depressurized and cool to the touch. CLEAN or REPLACE strainer d. REMOVE main valve assembly NOTE All sealing materials should be replaced. IF strainer is integral to trap THEN CLEAN or REPLACE strainer. REMOVE cover (Maybe bolted. G. D. ENSURE an equipment clearance/tag out is in place and the steam trap is depressurized and cool to the touch. G. INSTALL air vent assembly K. D.A. REMOVE valve seat REMOVE strainer screen and CLEAN or REPLACE strainer screen INSTALL new valve seat INSTALL new capsule and spacer INSTALL cover TORQUE cover to vendor specifications. H. TORQUE plug/cap per vendor specifications 4. B. B. INSTALL operating mechanism INSTALL cover using a new gasket. O-ring. I. REMOVE air vent assembly b. INSTALL plug/cap using new gasket. IF seating surface is only slightly worn or has minor steam cuts THEN LAP seating surface using an approved lapping compound.2. REMOVE cover. DISCONNECT outlet chamber C. screw cap or clamped. REMOVE strainer plug/cap c. INSTALL new check valve (if installed) I. INSTALL new lever J. CLEAN or REPLACE strainer c. I. INSTALL new disc G. ENSURE an equipment clearance/tag out is in place and the steam trap is depressurized and cool to the touch. CLEAN or REPLACE strainer d. IF strainer is not integral to steam trap (e. TORQUE plug/cap per vendor specifications J. CHECK strainer by: a.g. REMOVE bucket from valve lever E.4 Thermostatic Steam Trap A. e. REMOVE check valve (if installed) H. located upstream of trap) THEN a. e. ENSURE strainer is inside equipment clearance/tag out boundary. REMOVE valve seat F. B. INSTALL cover/cap H.4. CLEAN or REPLACE strainer d. INSTALL plug/cap using new gasket. D. INSTALL cover using new gasket M. TORQUE plug/cap per vendor specifications 4.5 Inverted Bucket Steam Trap A. THEN a. INSTALL plug/cap using new gasket. INSTALL new valve seat G. b. valve seat assembly and bucket D. REMOVE cover/cap (Maybe bolted. REMOVE strainer plug/cap b. B. TORQUE plug/cap per vendor specifications K-9 . b. F. REMOVE disc or bellows assembly. INSTALL plug/cap using new gasket d. ENSURE strainer is inside equipment clearance/tag out boundary. REMOVE strainer plug/cap c. INSPECT seating surface E. ENSURE an equipment clearance/tag out is in place and the steam trap is depressurized and cool to the touch. IF steam trap has and integral strainer.2. INSTALL valve seat assembly L. etc) C. INSTALL bucket on valve lever K. TORQUE cover/cap to vendor specifications. INSTALL new valve seat h. ADJUST trap to desired setting d. REMOVE valve seat g. A. REMOVE overload spring d.A. INSTALL adjusting nut and locknut k. A.2. ADJUST trap’s operating temperature using 4. INSTALL trap l. c. INSTALL new element i. Return steam trap to service B.NOTE Liquid expansion steam traps are calibrate at the factory for a set temperature. LOOSEN adjustment locknut b. but can be adjusted. REMOVE adjustment locknut c. 5. Amount of adjustment will vary by vendor. INSTALL new overload spring j. Retest steam trap for proper operation K-10 . TIGHTEN adjustment locknut B. 4. Changing the temperature element a. Adjusting trap operating point a. REMOVE element f. REMOVE adjustment nut e.2. REFER to vendor technical manual for which direction (CW or CCW) to turn the adjustment nut to raise or lower temperature at which the trap opens. C.0 Determine PMT and PMT considerations NOTE Steam traps should be returned to service slowing allowing time for them to warmup.6 Liquid Expansion Steam Trap NOTE Steam trap should be in service during trap temperature adjustment to observe response. Typically the trap may be adjusted approximately 50 degrees F.6. REMOVE trap (typically screw inlet and outlet) b. Check steam traps for leaks. 6. Applicable vendor technical manuals C. Perform post job review B. 7. Initiate any corrective action program documents necessary to resolve any problem areas identified. Industrial Safety Manual B.0 References A. Foreign Material Control Procedure K-11 .0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. . D. F.0 Task Overview 1. C.1 Component type This work instruction is applicable to general globe and gate valves.L WORK PACKAGE TEMPLATE – GATE AND GLOBE VALVES 1. B. 1. Gaskets O-rings Packing Lantern rings (if used) L-1 . 1.4 Develop list of know consumable materials to be used A.3 Scope This work instruction provides generic instruction for the inspection and minor repair of globe or gate valves. C. 1.2 Equipment tag or unique equipment identifier Ensure unique equipment identifier is used to designate which valve is being worked. B. E.5 Develop a list of know parts to be replaced A. Lapping compound (various grades) Container (bags) for temporary storage of studs and nuts Emery cloth/crocus cloth Isopropyl alcohol or acetone Prussian Blue Thread lubricant 1. D. 4 Identify permits required A. C.3 Job Safety Analysis. C. Care should be taken when handling valves and valve parts. 2. D. etc) in accordance with approved plant procedures and MSDS. D. depressurized. Chemical Control Procedures (handing and disposal) C.1 Evaluate potential for generation or equipment risk hazards 2. Improper handling or undue forces applied during disassemble and assembly could damage valves and affect performance. G.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. B. If valve body is left unattended a cover should be placed over the opening to preclude foreign material from entering. Handle cleaning chemicals (alcohol. Lapping blocks (various sizes depending on valve size) Torque wrenches Mechanics tool box Rigging equipment 2. Some gaskets may contain asbestos. Equipment Clearance/Tag out Orders B. cooled and vented prior to work. Identifies general and specific hazards A. F. If gaskets may contain asbestos appropriate asbestos abatement procedures should be followed. Valve to be worked should be isolated. B.0 Pre-job Brief 2. Foreign material exclusion and practices should be implemented prior to opening a check valve for maintenance. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. acetone. Asbestos abatement procedures (if applicable) L-2 . Maintain work area clean to prevent foreign material from entering open system and to minimize the potential for unnecessary safety hazards.6 Special tools A.1. E. 2. 2. Inlet isolation valve B. Contact vendor for any clarification of vendor information or additional vendor assistance is required L-3 . Contact engineering if flow tests or vibration monitoring can not meet acceptable limits within the scope of work D. C. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E.6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment. Handling and disposal of chemicals (E. solvents.2 Identify individuals to contact in case certain events occur A.0 Contingency Considerations 3. Inspections of any components may result in the need to repair or replace components as appropriate. cleaning solvents) B.1 Identify potential scope expansion and actions due to scope expansion A.7 Identify Clearance/Tag out Boundary A.. Outlet isolation valve C. B.g.2.g. 3. Contact planner if scope growth is identified during work instruction performance B. grease. then power should be removed from that equipment. 3. etc) should be in accordance with approved chemical control procedures 2.5 Identify Environmental Consideration A. If there is any power operated equipment inside the isolation boundary. oil. 3. E. studs. (air supply tubing. etc) B. IF valve has an operator installed. Identify Notes and Cautions where needed A. chain operator. B. A. etc) Stem Pressure seal ring (if applicable) 4. 4. utilize existing procedures when applicable Provide expected actions in proper sequence for task. D. hangers. Steps should be modified as required or worked out of sequence depending on the particular valve being worked. Seats Disks Bolting material (Nuts. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available ENSURE appropriate personal safety equipment is worn on the job DETERMINE rigging requirements. bolts. laydown areas. etc) L-4 . Those steps should be NA’d. stud sizes.1 Disassembly NOTE Some steps may not be applicable depending on the check valve being worked. reach rod.0 Detailed Work Instructions Develop work instructions. supports. THEN REMOVE operator (AOV. limit switches. C. C.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3.4 Develop material list for potential contingency and consumable parts A. F. nuts. etc) NOTE The following is a suggested sequence of work. B. E. REMOVE other interferences as required to support maintenance. MOV. D. snubbers. 2 Inspections NOTE Not all valves will contain all parts listed. CAUTION If rigging is used to remove bonnet. stem and disc. tagged and stored appropriately for reassembly. A. corrosion. erosion. mark the discs with a marker for proper assembly. D.NOTE Bonnet bolts. 4. stem and disc. biofouling. INSPECT and RECORD degradation. L-5 . C. F. nuts and other small parts removed during disassembly should be bagged. its removal should be as per vendor recommendations. G. REMOVE valve bonnet. CAUTION If the valve being worked is a gate valve and the gate valve discs do not have flow direction marks. COVER exposed piping or open valve to prevent foreign material from entering the system. E. damage. INSTALL rigging to remove bonnet. stem and disc rigging should be position such that the lifting force is along the axis of the stem to avoid damage to disc and seat. etc for the following valve parts. CAUTION Valve should be off the closed seat to ensure any trapped pressure is relieved prior to removing the bonnet. pressure seal ring bolts OR valve flange connections from system. DISASSEMBLE valve bonnet bolted connections. MATCH MARK valve bonnet flanges for proper reassembly. excessive wear. NOTE If a pressure seal ring is installed. setscrews to pin globe valve stems in place. D. Body b.3 Valve repairs NOTE Lapping should be performed per approved plant procedures and training. C. CHECK appropriate locking devices for tightness. 4. g. nuts. bolting on split clamps to attach valve yokes to bodies. CAUTION Valve seating angles should not be changed during the lapping process. REPEAT lapping until acceptable bluing is obtained. THEN INSPECT disc anti-rotational device and NOTE any signs of rotation. CHECK seating surfaces using the bluing method. Packing surfaces f. CHECK seat and disc surfaces for proper fit by bluing method. Disc d. REPAIR or REPLACE all damaged or degraded parts. (E. CLEAN valve internals. etc) h. Body to bonnet gasket surface e. IF valve is a globe valve. THEN LAP seats and disc. etc) E. A. C. Seat surfaces c.a. Pins. IF seat and disc surfaces are not badly damaged. O-rings/gaskets B. D. L-6 .g. Bolting materials (bolts. guides. B. CAUTION Locking devices or staking of threads is used in some applications to ensure parts do not vibrate loose. etc. studs. (packing. INSTALL all interferences that were removed during disassembly. ENSURE gasket seating and pressure seal ring surfaces clean. PACK valve stem per approved plant procedures and vendor recommendations. Check local indication and ensure it agrees with actual valve position. G. J. CLEAN all internal parts with isopropyl alcohol/acetone. INSPECT internals of valve for any foreign material. L-7 .4 Reassembly CAUTION Gasket seating surfaces and pressure seal ring (if installed) should be clean to minimize the potential for leaks after reassembly. NOTE Match marks should be observed when installing bonnet. C. NOTE If pressure seal ring is installed it should be installed per vendor recommendations. INSTALL valve operator. D. B. D. H. etc).0 Determine PMT and PMT considerations A.4. Stroke valve and ensure valve operates smoothly. C. F. stem and disk.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. INSTALL valve bonnet. Perform post job review B. flanged connections. Check for any leaks. 6. pressure seal ring or flanges as appropriate per vendor recommendations. body to bonnet. E. ENSURE pipe and valve flange/threads are clean. 5. B. INSTALL and TORQUE bonnet bolts. Initiate any corrective action program documents necessary to resolve any problem areas identified. ENSURE local position indication is correct for valve position. A. I. If limit switches are installed for remote indication verify proper operation. H. E.7. Industrial Safety Manual Applicable vendor technical manuals Applicable valve and actuator drawings Valve Packing Procedure Lapping Procedure Foreign Material Control Procedure Material Safety Data Sheets Chemical Traffic Control Procedure L-8 . D.0 References A. C. F. G. B. g.g. Dow Corning. GP-1) Never-seize or equivalent Neolube or equivalent Silicon spray Solvent (E. acetone. etc) Grease for bearings (E. etc) M-1 . intake cooling water. and screen wash pumps. D.g. raw cooling water. Coating material (E. 1. (E.g.1 Component type This work instruction is applicable to a typical multistage vertical pump. Amerlock 400. 1. 1. C.4 Develop list of know consumable materials to be used A.M WORK PACKAGE TEMPLATE – MULTI-STAGE VERTICAL PUMP NOTE Personnel performing this work instruction should be qualified (properly trained and proficient) on the type of pump being worked.2 Equipment tag or unique equipment identifier Ensure the unique pump identifier is used to designate which pump is being worked. alcohol.3 Scope This work instruction provides instructions for inspection and repair of a multi-stage vertical pump. F. etc) Grease for O-rings (E. E. G. B.g.0 Task Overview 1. etc) 1. H. E.0 Pre-job Brief 2.1. Inside and outside Mic’s (various sizes as required by pump geometry) b. G. C. L.6 Special tools A. J. columns. studs. etc) Rigging Measurement and Test Equipment (M&TE) a.1 Evaluate potential for generation or equipment risk hazards A. Equipment Risk/Damage M-2 . E.5 Develop a list of know parts to be replaced A. washers) Split rings Impeller keys Packing Bottom Bearing Column bearings (ensure proper thickness. D. cap screws. D. Generation B. Feeler gauges d. Mechanics tool box (wrenches. etc) Assorted fasteners (nuts. B. K. Various O-rings and gaskets (Bowl. F. Go/No-Go gauge) Wear rings 1. I. Dial indicator c. column. screwdrivers etc) Puller for bearings and wear rings Go/No-Go gauge for rubber column bearings FME covers for open pump well and discharge flange Cribbing for pump support Timbers for shaft storage V-blocks for shaft runout measurement Pump column saddle support Installed hoist or crane Lifting fixtures (discharge head. H. F. G. Torque wrenches (various sizes based on vendor requirements) 2. B. C. Follow approved site procedures for proper draining and disposal of process fluids from the pump. D. Petroleum based products will cause the O-rings to deteriorate and fail. Appropriate measures should be taken to prevent foreign material from entering the pump. Chemical Control Permit C. 2. M-3 .5 Identify Environmental Consideration A. Handling and disposal of chemicals (E.2. oil. etc) should be in accordance with approved chemical control procedures..6 Identify Operating Experience Review any relevant plant specific or industry related operating experience applicable to the work being performed. Follow appropriate Material Safety Data Sheet (MSDS) and site approved procedures for handling and disposal of cleaning chemicals and solvents.g. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E.2 Identify Foreign Material Exclusion (FME) potential and mitigation A. Identifies general and specific hazards A.4 Identify permits required A. 2. grease. Oil drained from the pump should be removed from the work area and properly disposed of as soon as practical. Transient combustible material storage permit 2. Performance of this work will open pump to environment. an appropriate transient fire load evaluation should be performed and proper temporary storage provided. C. B. cleaning solvents) B. DO NOT allow petroleum based products to contact the EPT O-rings of the mechanical seal.g. Equipment Clearance Order B.3 Job Safety Analysis. 2. solvents. Other wise. 1 Identify potential scope expansion and actions due to scope expansion A. E. H. F.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions 3. B. Inspections of any components may result in the need to repair or replace components as appropriate. Contact supervision for any uncertainties with respect to the repair or replacement of worn or damaged parts identified during work instruction performance.7 Identify Clearance/Tag out Boundary A. C. Contact vendor for any clarification of vendor information or additional vendor assistance is required 3. C. motor half. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work. F. B.2. H. E. G. B. 3.0 Contingency Considerations 3. Pump discharge valve Pump Vent valve Pump Drain valve Power to motor Power to motor space heaters Power to heat tracing (if applicable) Supply and discharge to motor cooling water (if applicable) Lube water supply 3. Contact planner if scope growth is identified during work instruction performance B. I. Impellers Impeller liners Couplings Pump half.4 Develop material list for potential contingency and consumable parts A. shaft) Suction Bell (Pre-coated) Pump bowls (Pre-coated) Columns (Pre-coated) Pump Shaft Complete bowl assembly Discharge head M-4 .2 Identify individuals to contact in case certain events occur A. G. C. D. D. Amerlock 400.2 Motor Removal A. CAUTION Appropriate rigging techniques should be observed during motor removal. etc) 4. D. INSPECT motor cooling lines for any biofouling. NOTE Ensure as-found coupling gap is measured and recorded. F. Coating material (E. M-5 . PROVIDE FME protection for open lines.J. E. NOTE Depending on pump not all parts will be applicable. IF installed. and other interferences are removed to support work. C. utilize existing procedures when applicable Provide expected actions in proper sequence for task. NOTIFY Operations prior to beginning work ENSURE an appropriate clearance/tag out is in place to perform work safely ENSURE all parts expected to be used are available and in hand ENSURE all tools necessary to perform the job are available REVIEW and UNDERSTAND the scope of work before the start of any field activities. E.1 Preparations A. D. LOCATE and IDENTIFY proper piece of equipment is being worked per the work instruction C. ENSURE piping. B. C. REMOVE motor. Identify Notes and Cautions where needed A.g. DISCONNECT motor cooling lines (if applicable) B. 4. Belzona. equipment supports. DISCONNECT coupling. corrosion. silt. E. ENSURE appropriate personal safety equipment is worn on the job 4. etc. D.0 Detailed Work Instructions Develop work instructions. VERIFY clearance/tag out is correctly in place B. THEN REMOVE insulation. ENSURE all rigging to be used is inspected and in good condition prior to use. REMOVE outer column and bearing retainer F. F. INSTALL saddle support and lower pump assembly on to support. E. CAUTION Cover should be installed over pump well when open to prevent foreign material form entering and prevent personnel injury. REMOVE discharge head. D.4 Disassembly of columns and line shafts NOTE All columns should be match marked before they are disassembled. B.3. LIFT pump assembly to relieve pressure off saddle support. LIFT pump and INSTALL saddle support between the outer column upper flange and sole plate I. REMOVE line shaft and coupling. M-6 . C. E.3 Disassembly and removal of discharge head A. C.A through 4. G. H.3.CAUTION Some packing material contains lead. REMOVE saddle support. REPEAT steps 4. INSTALL FME cover for pump well 4. H. D. NOTE The number of columns and line shafts will vary from one installation to another NOTE Shaft should be clean and lubricated prior to sliding coupling along shaft. B. J. REMOVE adjusting plate. pump half coupling and key REMOVE gland and packing REMOVE shaft sleeves and O-Rings REMOVE stuffing box and O-Rings REMOVE bearing REMOVE discharge head to sole plate nuts MATCH MARK column to discharge head. Refer to appropriate MSDS for proper handing and disposal 4. SECURE shaft coupling to prevent sliding down the shaft. LIFT pump assembly until upper flange of next column is high enough to install saddle support. G. DISCONNECT line shaft coupling. I. A.H until all columns and line shafts are removed. SLIDE impeller from shaft and remove impeller key. NOTE Shaft should be clean and lubricated prior to sliding coupling along shaft. Remaining bowls disassembly a. NOTE Shaft should be clean and lubricated prior to sliding impeller along shaft.4. SLIDE next stage impeller from shaft and remove impeller key. REMOVE bowl from pump assembly. b. F. e. INSTALL cover over open pump well. REMOVE upper bowl from pump assembly. REMOVE the last column section and pump from well. NOTE Pump bowls and other parts should be match marked as necessary prior to disassembly to aid in assuring proper reassembly. MOVE pump to predetermined and prepared work area MATCH MARK bottom column section to pump assembly REMOVE bottom column and bearing retainer. c. E. DISCONNECT coupling SECURE coupling to prevent sliding down shaft REMOVE line shaft and coupling 4.6 Impeller Bowl disassembly NOTE The number of impeller bowls differ form one installation to another. B. NOTE Pump assembly should be supported by cribbing. d. b. Impeller bowl designs differ from vendor to vendor. C.5 Disassembly or Bottom column section A. A. D. B. SLIDE impeller from shaft and remove impeller key M-7 . G. REMOVE thrust collar and associated parts. Upper bowl disassembly a. H. REMOVE next bowl from pump assembly. out of tolerance or excessively worn components should be replaced. NOTE Runout tolerances are per facility or vendor recommendation. (e. MEASURE the following shafts for runout and excessive wear in bearing regions. 4. Bottom bearing NOTE Bearing material varies by vendor. Bowl bearing c. a.) C. Column shafts B. All elastomers should be replaced. a. NOTE Because line shafts are typically symmetrical. coating condition. pitting. Line shafts c. MEASURE the following bearings in two directions to ensure eccentricity. Pump shaft b. MEASURE inside diameter of bearings (tolerance as per vendor recommendation) M-8 . cracks. bronze. NOTE All damaged. NOTE Components may be machined. etc. etc. rubber. polished or reconditioned as necessary as long as component tolerances are maintained.c.7 Inspection of Pump components NOTE All pump components should be inspected for general conditions such as excessive wear. they can be inverted. corrosion. A. Top shaft bearing b. if they meet runout tolerances but show excessive wear in the bearing area. REPEAT steps a and b above until last bowl is removed from suction bell and first stage impeller is removed. Inspection of column bearings a.g. c. IF column is cracked or wall thickness is unacceptable. Inspection of columns a. INSPECT discharge head coatings. THEN REPLACE bowl. THEN REPAIR coatings. NOTE If the columns are coated and there is no degradation in the coatings. THEN REPAIR or REPLACE discharge head. IF wall thickness does not meet acceptance criteria. H. c. there is no need to measure wall thickness. MEASURE clearance between bowl wear rings and impeller wear area. d. IF discharge head has cracking. wear rings and impeller liners a. REPAIR any damaged coatings NOTE If the bowls and suction bell are coated and there is no degradation in the coatings. INSPECT impellers for cavitation damage and damage from impeller dragging against impeller liner. b. F. REPAIR any damaged coatings c. etc. Inspection of pump bowls and suction bell a. Inspection of impellers. THEN REPAIR or REPLACE column. G. IF coatings are damaged. erosion. REPLACE bearings that do not meet acceptance criteria. E. MEASURE wall thickness. NOTE All components not meeting vendor tolerances should be replaced. MEASURE column wall thickness is acceptable (per vendor recommendation) e. D. INSPECT stuffing box threaded pipe connections (lube water) for corrosion. INSPECT coatings on all columns b. c. INSPECT impeller liners for damage caused by impeller dragging against liner. Inspection of discharge head a. d.b. d. INSPECT discharge head for cracks. there is no need to measure wall thickness. b. M-9 . b. INPSECT coatings (inside and outside) on all bowls and suction bell. INSPECT columns for any cracks. INSTALL and TORQUE next stage bowl on to previous stage bowl. ASSEMBLE impeller. NOTE After the next stage impeller is installed it should be verified that the impellers seat simultaneously. (Use a feeler gauge and tolerance should be as per vendor technical manual recommendation) c. G. REPEAT (a – e) above for remaining bowls until pump assembly is complete. 4. I. BOTTOM OUT shaft in bottom bearing cavity. INSTALL and TORQUE first stage suction bowl onto suction bell.1 Assembly of pump bowls A. ASSEMBLE remaining suction bowls as follows. IF impellers do not seat simultaneously. C.8 Pump Assembly NOTE Lubricate all nuts and screws with approved lubricant during assembly. INSTALL pump shaft into suction bell. INSTALL O-ring onto previously installed bowl.8. LUBRICATE bottom bearing and affected area of pump shaft. THEN MACHINE either impeller split rings or impeller liner d. e. PACK bottom bearing cavity full of grease. B. thrust collar and associated parts onto the pump shaft. E. NOTE Lubricate all elastomers with approved lubricant during assembly. D. VERIFY impellers seat simultaneously. H. CAUTION Excessive grease in the bottom bearing cavity may hydraulically restrict shaft from lowering into the position required for impeller adjustment.4. f. LUBRICATE suction bell bottom bearing cavity. INSTALL O-ring on suction bell. M-10 . thrust collar and associated parts onto the pump shaft. b. NOTE Torque of nuts and screws is to be accomplished as per plant instructions. ASSEMBLE first stage impeller. F. a. B. lubricated and free of dirt to prevent galling during assembly. POSITION.8. split rings. MOVE pump and lower column assembly to pump well. split rings. C. lubricated and free of dirt to prevent galling during assembly. C.3 Installation of lower pump assembly in pump well A. B. INSTALL and TORQUE line shaft to preceding line shaft. E. etc should be clean. NOTE Columns. B. M-11 . INSTALL and TORQUE lower column to pump assembly. REMOVE pump well cover. 4. couplings.2 Assembly of lower line shaft and column to pump assembly NOTE Keys may be filed or machined to achieve proper fit and prevent binding during assembly. LOWER pump onto saddle support. shafts. INSTALL O-ring onto column. A. F. 4. A. LOWER pump allowing clearance to install saddle support. LUBRICATE and INSTALL bearing into lower column bearing retainer. NOTE Refer to match marks during assembly. ENSURE coupling and key is installed and secured on shaft to prevent sliding during assembly. INSTALL saddle support. couplings. D. E.8. etc should be clean.NOTE Shafts. INSTALL O-ring onto top bowl. keys.4 Installation of line shafts and columns NOTE Repeat the following steps until all line shafts and columns have been assembled. ENSURE coupling and key is installed and secured on shaft to prevent sliding during assembly. D.8. 4. C. keys. INSTALL and TORQUE lower line shaft to pump assembly. ENSURE pump assembly is vertical and firmly supported on cribbing. BUMP motor to ensure proper rotation. TORQUE discharge head to sole plate and discharge head to pipe flange using approved torque methods. LUBRICATE and INSTALL O-ring onto top column. LOWER pump assembly and POSITION saddle support.D. K. INSTALL and TORQUE column to preceding column. PERFORM flow testing to verify that pump lift is satisfactory. Supports. C. INSTALL stuffing box. REMOVE saddle support. C. INSTALL discharge flange gasket. POSITION. F. E. D. INSTALL and TORQUE discharge head to upper column. LIFT pump column assembly to clear saddle support REMOVE saddle support. INSTALL motor. F. throttle bushing and O-rings. REPEAT steps [A] through [H] until all line shafts and columns have been assembled and installed. LIFT pump from saddle support. INSTALL any interferences removed during disassembly. REHANG clearance/tag out on motor. INSTALL and ENSURE gland is square to stuffing box. G. I. M. H. A. M-12 . F. I. E. E. etc) RELEASE clearance/tag out on motor. LUBRICATE and INSTALL bearing into column bearing retainer. RELEASE clearance/tag out B. INSTALL pump packing as per vendor recommendation.6 Final Assembly A. INSTALL motor cooling water lines (if applicable) 5. G. H. G. hangars. D.5 Installation of discharge head NOTE All gasket seating surfaces should be clean and free of debris. 4. INSTALL pump half coupling and adjusting plate.0 Determine PMT and PMT considerations A. B. J.g.8. LOWER discharge head while aligning flange seating surfaces and gasket. (E. 4. INSTALL shaft sleeve and O-rings. L. ADJUST impeller lift per vendor recommendation.8. PERFORM vibration testing C. B. INSTALL lube water lines. H. VERIFY no system leaks. RETURN unused parts to storeroom 6. I.0 Feedback Mechanisms Identify mechanism to provide work order feedback for improvements and errors A. E. C. 7. D. G. IF insulation was removed.NOTE Packing and leak-off flow should be monitored closely during initial break-in following maintenance. F. B.CLEAN work area to original pre-maintenance conditions DISPOSE of any generated waste products properly. K. Work site cleanup .0 References A. D. F. THEN INSTALL insulation. Perform post job review B. MONITOR gland temperature during break-in run. Initiate any corrective action program documents necessary to resolve any problem areas identified. ADJUST packing to achieve proper leak-off flow. Industrial Safety Manual Foreign Material Control Procedure Material Safety Data Sheets Chemical Traffic Control Procedure Storage of temporary combustibles (transient fire loads) Vendor Technical Manual (Pump) M-13 . J. IF heat tracing is installed and was removed. E. THEN INSTALL heat tracing. M-14 .Figure M-1 Cross-section of a typical multistage vertical pump. The labor resource is one of the largest and expensive within the maintenance department.1 2. The planner should be aware that contingency parts may or may not be necessary to support the job. Working smarter means being ready for the expected and the unexpected.2 2.4 3. If the labor resource is not being utilized effectively and efficiently. 2.N LISTING OF KEY INFORMATION N.1 Key O&M Cost Points Key O&M Cost Point Emphasizes information that will result in overall reduced costs and/or increase in revenue through additional or restored energy production. Referenced Section Page Number Key Point To best meet the competitive challenge the continually improving maintenance organization is finding ways to work smarter. This can be a significant financial decision since most contingency parts tend to be high cost items that are not maintained in normal inventory. The work package template will provide the maintenance organization with a more accurate and efficient tool for the scheduling and execution of maintenance activities.3 N-1 .1 2. a significant amount of money is being wasted. There will be short term costs associated with the development of the specific work packages but the long term gains will outweigh these costs. 2 Key Human Performance Points Key Human Performance Point Sometimes it is not necessary to measure the “goodness” of your safety culture. efficiently and safely.2 3.5 3. 2. The planning walkdown is essential for the development of pre-job considerations and contingencies. as it is to recognize signs that are indications of a poor or failing safety culture. improve job productivity and identify opportunities to strengthen human performance and reduce errors. support worker performance. Feedback is a credible source of information that can result in the improvement in the organization of work.6 N-2 . Some of the key indicators of a poor or failing safety culture are easily observable. The review of operating experience can help reduce risk to both personnel and equipment by learning from past mistakes or problems that have been encounter in the industry or at the given facility. Referenced Section Page Number Key Point Work packages provide the maintenance craftsman with the level of detail necessary to perform a work activity correctly.1 2.N. 2.3 Key Technical Points Key Technical Point Targets information that will lead to improved equipment reliability. The planner should attempt to anticipate necessary contingencies based on previous work experience.3 N-3 .N. operating history and other intelligence. Referenced Section Page Number Key Point The use of developed work package templates allows the maintenance organization to move from the fire-fighting mode of performing work to an operational mode that is structured and proactive. 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