Work Package Template

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Work Package Templates

1012288

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.

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Work Package Templates

1012288

Technical Update, February 2007

EPRI Project Manager L. Rogers

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DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.

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.

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CITATIONS

This document was prepared by

Electric Power Research Institute (EPRI)

Nuclear Maintenance Applications Center (NMAC) 1300 W.T. Harris Boulevard

Charlotte, NC 28262 Principal Investigator J. West

This document describes research sponsored by the Electric Power Research Institute (EPRI). This publication is a corporate document that should be cited in the literature in the following manner:

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REPORT SUMMARY

This Work Package Templates Guide provides fossil plant maintenance personnel with assorted inspection, minor repair or overhaul templates for various pieces of plant equipment. This guide will assist plant maintenance personnel in improving the efficiency, reliability and reducing the maintenance costs for associated with maintenance on selected pieces of equipment.

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, “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. In many cases, work packages are repeatedly prepared for equipment that is common among most fossil power plants. 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. These templates will be provided for common maintenance activities by component and in a standardized format.

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. The generic work package templates may then be used with site-specific information to develop site-specific work packages referencing site-specific procedures, vendor information and other site-specific information relevant to the work activity.

Approach

An introduction to work packages provides insight into the work package process, benefits that can be realized from the use of work packages and guidance on how to use the work package templates. The templates can be found useful to any maintenance organization regardless of the current level of work package development and planning.

A proposed format for developing work packages is provided. The format is consistent with the provided in EPRI Technical Report 1014547, “Maintenance Work Package Planning Guidance for Fossil Power Plant Personnel”

The appendices contain work package templates for a variety of different plant equipment. Various types of maintenance activities are embedded in the templates; testing, inspection, minor repair and overhaul. Most templates are generic with respect to the piece of equipment. There are some templates that are directed at specific equipment due to their widespread use. (E.g. Limitorque SB actuator, Gould 3196 pump) Some templates cover a wide range of equipment vendors and types. (E.g. Low voltage breakers and steam traps) In some cases a particular design may be featured. E.g. roll wheel pulverizer)

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vi Results

This technical report provides an overview of work package development, a work package template format and work package templates for various pieces of equipment common to most fossil power plants. 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. 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. The report provides templates for numerous pieces of equipment that are found in most fossil power plants using a standardized format. It provides information for inspections, minor repairs or overhauls of equipment. Considerations are given to task overview, pre-job briefs, contingencies, detailed work instruction/sequence, identification or parts, tools and equipment, feedback mechanisms and proposed references.

Keywords

Work Control Work Planning Work Package

Work Order Templates Work Instruction

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ACKNOWLEDGEMENTS

EPRI wishes to acknowledge the members of the Task Advisory Group:

Charlie Cassise Detroit Edison

Clarence Nail Dynegy

Charlie Leveridge East Kentucky Power Cooperative David Brawner Entergy

Bill Hilton Hoosier Energy Rural Electric Coop., Inc Ken McDonald Hoosier Energy Rural Electric Coop., Inc Steve Blair Hoosier Energy Rural Electric Coop., Inc

Regan Hallford PNM

George Lum Southern Company

Joe Tyner Southern Company

David Egner TVA

Howard Ray TVA

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1.0 Task Overview ... A-1 1.1 Component type... A-1 1.2 Equipment tag or unique equipment identifier... A-1 1.3 Scope ... A-1 1.4 Develop list of know consumable materials to be used... A-1 1.5 Develop a list of know parts to be replaced ... A-1 1.6 Special tools... A-1 2.0 Pre-job Brief ... A-2 2.1 Evaluate potential for generation or equipment risk hazards ... A-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... A-2 2.3 Job Safety Analysis, Identifies general and specific hazards... A-2 2.4 Identify permits required... A-2

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2.5 Identify Environmental Consideration ... A-3 2.6 Identify Operating Experience ... A-3 2.7 Identify Clearance/Tag out Boundary... A-3 3.0 Contingency Considerations ... A-3 3.1 Identify potential scope expansion and actions due to scope expansion... A-3 3.2 Identify individuals to contact in case certain events occur... A-3 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... A-3 3.4 Develop material list for potential contingency and consumable parts... A-4 4.0 Detailed Work Instructions ... A-4 4.1 Disassembly ... A-4 4.2 Inspections ... A-5 4.3 Alignments ... A-7 4.3.1 Sheave alignment... A-7 4.3.2 Shaft/Bearing Alignment (required only if shaft or bearing is replaced ... A-7 4.3.3 Adjusting belt tension ... A-8 4.3.3.1 Shaft deflection method... A-8 4.3.4 Reassembly... A-8 5.0 Determine PMT and PMT considerations ... A-9 6.0 Feedback Mechanisms ... A-9 7.0 References... A-9

B WORK PACKAGE TEMPLATE - BOILER FEED WATER PUMP... B-1

1.0 Task Overview ... B-1 1.1 Component type... B-1 1.2 Equipment tag or unique equipment identifier... B-1 1.3 Scope ... B-1 1.4 Develop list of know consumable materials to be used... B-1 1.5 Develop a list of know parts to be replaced ... B-2 1.6 Special tools... B-2 2.0 Pre-job Brief ... B-2 2.1 Evaluate potential for generation or equipment risk hazards ... B-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... B-3 2.3 Job Safety Analysis, Identifies general and specific hazards... B-3 2.4 Identify permits required... B-3 2.5 Identify Environmental Consideration ... B-3 2.6 Identify Operating Experience ... B-3 2.7 Identify Clearance/Tag out Boundary... B-3 3.0 Contingency Considerations ... B-4 3.1 Identify potential scope expansion and actions due to scope expansion... B-4 3.2 Identify individuals to contact in case certain events occur... B-4

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3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... B-5 3.4 Develop material list for potential contingency and consumable parts... B-5 4.0 Detailed Work Instructions ... B-5 4.1 Preparations... B-5 4.2 Removal of Subsystems ... B-6 4.3 Disassembly ... B-6 4.3.1 Cleaning, Inspection, Lubrication ... B-8 4.3.2 Reassembly... B-9 5.0 Determine PMT and PMT considerations ... B-11 6.0 Feedback Mechanisms ... B-12 7.0 References... B-12

C WORK PACKAGE TEMPLATE – HEAT EXCHANGER ... C-1

1.0 Task Overview ... C-1 1.1 Component type... C-1 1.2 Equipment tag or unique equipment identifier... C-1 1.3 Scope ... C-1 1.4 Develop list of know consumable materials to be used... C-1 1.5 Develop a list of know parts to be replaced ... C-2 1.6 Special tools... C-2 2.0 Pre-job Brief ... C-2 2.1 Evaluate potential for generation or equipment risk hazards ... C-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... C-3 2.3 Job Safety Analysis, Identifies general and specific hazards... C-3 2.4 Identify permits required... C-3 2.5 Identify Environmental Considerations... C-4 2.6 Identify Operating Experience ... C-4 2.7 Identify Clearance/Tagout Boundary... C-4 3.0 Contingency Considerations ... C-4 3.1 Identify potential scope expansion and actions due to scope expansion... C-4 3.2 Identify individuals to contact in case certain events occur... C-4 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... C-5 3.4 Develop material list for potential contingency and consumable parts... C-5 4.0 Detailed Work Instructions ... C-5 4.1 Disassembly: ... C-5 4.2 Cleaning: ... C-7 4.3 Heat Exchanger Testing:... C-7 4.3.1 Leak Testing... C-7 4.3.1.1 Leak Testing using System Pressure ... C-7 4.3.1.2 Leak Testing using Hydro Pump ... C-8

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4.4 Leak Repairs ... C-8 4.4.1 Tube to Tube-Sheet Leaks... C-8 4.4.2 Tube leaks... C-9 4.5 Reassemble Heat Exchanger ... C-10 5.0 Determine PMT and PMT considerations ... C-10 6.0 Feedback Mechanisms ... C-11 7.0 References... C-11

D WORK PACKAGE TEMPLATE – LOW VOLTAGE BREAKER OVERHAUL ... D-1

1.0 Task Overview ... D-1 1.1 Component type... D-1 1.2 Equipment tag or unique equipment identifier... D-1 1.3 Scope ... D-1 1.4 Develop list of know consumable materials to be used... D-2 1.5 Develop a list of know parts to be replaced ... D-2 1.6 Special tools... D-2 2.0 Pre-job Brief ... D-3 2.1 Evaluate potential for generation or equipment risk hazards ... D-3 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... D-3 2.3 Job Safety Analysis, Identifies general and specific hazards... D-3 2.4 Identify permits required... D-4 2.5 Identify Environmental Consideration ... D-4 2.6 Identify Operating Experience ... D-4 2.7 Identify Clearance/Tagout Boundary... D-5 3.0 Contingency Considerations ... D-5 3.1 Identify potential scope expansion and actions due to scope expansion... D-5 3.2 Identify individuals to contact in case certain events occur... D-5 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... D-5 3.4 Develop material list for potential contingency and consumable parts... D-5 4.0 Detailed Work Instructions ... D-5 4.1 Initial Testing and Inspections ... D-6 4.2 Mechanical/Electrical Operation... D-7 4.3 Contact Inspections and Adjustment... D-8 4.4 Operating Mechanism Inspection... D-9 4.5 Electrical Tests... D-9 4.6 Disassembly ... D-10 4.7 Inspections, Tests, Cleaning and lubrication... D-11 4.8 Reassembly ... D-15 4.9 Post overhaul Inspections, Adjustments and Tests ... D-17 4.10Final Breaker Assembly ... D-19 5.0 Determine PMT and PMT considerations ... D-19

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6.0 Feedback Mechanisms ... D-20 7.0 References... D-20

E WORK PACKAGE TEMPLATE – MOTOR CONTROL CENTER/LOAD CONTROL CENTER (MCC/LCC) INSPECTION AND CLEANING ... E-1

1.0 Task Overview ... E-1 1.1 Component type... E-1 1.2 Equipment tag or unique equipment identifier... E-1 1.3 Scope ... E-1 1.4 Develop list of know consumable materials to be used... E-1 1.5 Develop a list of know parts to be replaced ... E-1 1.6 Special tools... E-1 2.0 Pre-job Brief ... E-2 2.1 Evaluate potential for generation or equipment risk hazards ... E-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... E-2 2.3 Job Safety Analysis, Identifies general and specific hazards... E-2 2.4 Identify permits required... E-3 2.5 Identify Environmental Consideration ... E-3 2.6 Identify Operating Experience ... E-3 2.7 Identify Clearance/Tagout Boundary... E-3 3.0 Contingency Considerations ... E-3 3.1 Identify potential scope expansion and actions due to scope expansion... E-3 3.2 Identify individuals to contact in case certain events occur... E-4 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... E-4 3.4 Develop material list for potential contingency and consumable parts... E-4 4.0 Detailed Work Instructions ... E-4 4.1 Load Center Breaker Clean and Inspect ... E-5 4.2 Load Center Switchgear Cleaning and Inspection: ... E-8 5.0 Determine PMT and PMT considerations ... E-10 6.0 Feedback Mechanisms ... E-11 7.0 References... E-11

F WORK PACKAGE TEMPLATE – LIMITORQUE SMB ACTUATORS ...F-1

1.0 Task Overview ...F-1 1.1 Component type...F-1 1.2 Equipment tag or unique equipment identifier...F-1 1.3 Scope ...F-1 1.4 Develop list of know consumable materials to be used...F-1 1.5 Develop a list of know parts to be replaced ...F-2 1.6 Special tools...F-2 2.0 Pre-job Brief ...F-2

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2.1 Evaluate potential for generation or equipment risk hazards ...F-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ...F-3 2.3 Job Safety Analysis, Identifies general and specific hazards...F-3 2.4 Identify permits required...F-4 2.5 Identify Environmental Consideration ...F-4 2.6 Identify Operating Experience ...F-4 2.7 Identify Clearance/Tag out Boundary...F-4 3.0 Contingency Considerations ...F-4 3.1 Identify potential scope expansion and actions due to scope expansion...F-4 3.2 Identify individuals to contact in case certain events occur...F-5 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ...F-5 3.4 Develop material list for potential contingency and consumable parts...F-5 4.0 Detailed Work Instructions ...F-5 4.1 Preparations...F-5 4.2 External Inspection of Actuator/Valve ...F-6 4.3 Limit Switch Compartment Inspection ...F-6 4.4 Torque Switch Inspection ...F-6 4.5 Limit Switch Inspection...F-7 4.6 Limit Switch Gear Box Grease Inspection...F-7 4.7 Motor Termination inspection ...F-8 4.8 Install Limit/Torque Switch Compartment Cover ...F-8 4.9 Main Gearcase Lubrication Inspection ...F-9 4.10 Valve stem lubricant Inspection ...F-9 4.11 Motor Inspection...F-10 4.12 Switch Adjustments ...F-11 4.12.1 Setting the Limit Switch ...F-11 4.12.2 Setting the Torque Switch ...F-12 4.12.3 SMB-000 Double Torque Switch ...F-12 4.12.4 SMB-00 Torque Switch ...F-13 4.13 Replace Stem Nut ...F-13 4.13.1 Stem Nut Removal ...F-13 4.13.2 Stem Nut Installation ...F-14 5.0 Determine PMT and PMT considerations ...F-14 6.0 Feedback Mechanisms ...F-14 7.0 References...F-15

G WORK PACKAGE TEMPLATE – ELECTROSTATIC PRECIPITATOR... G-1

1.0 Task Overview ... G-1 1.1 Component type... G-1 1.2 Equipment tag or unique equipment identifier... G-1 1.3 Scope ... G-1

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1.4 Develop list of know consumable materials to be used... G-1 1.5 Develop a list of know parts to be replaced ... G-2 1.6 Special tools... G-2 2.0 Pre-job Brief ... G-2 2.1 Evaluate potential for generation or equipment risk hazards ... G-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... G-2 2.3 Job Safety Analysis, Identifies general and specific hazards... G-2 2.4 Identify permits required... G-3 2.5 Identify Environmental Consideration ... G-3 2.6 Identify Operating Experience ... G-3 2.7 Identify Clearance/Tag out Boundary... G-3 3.0 Contingency Considerations ... G-4 3.1 Identify potential scope expansion and actions due to scope expansion... G-4 3.2 Identify individuals to contact in case certain events occur... G-4 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... G-4 3.4 Develop material list for potential contingency and consumable parts... G-4 4.0 Detailed Work Instructions ... G-4 4.1 Shutdown for Maintenance ... G-5 4.2 Pre-maintenance checks (prior to clearance/tag out on precipitator)... G-5 4.3 Lower Precipitator Maintenance... G-8 4.4 Upper Housing (Tension Insulators and Housings, Emitter/Collector -

Rapper/Vibrator)... G-12 4.5 Penthouse (aka. Coffin, Cans, Doghouse) Insulator compartment inspections .... G-12 4.6 Transformer/Rectifier (TR) ... G-14 4.7 Control Cabinets (Emitter Control Cabinets, Rapper Control Cabinets) ... G-16 5.0 Determine PMT and PMT considerations ... G-17 6.0 Feedback Mechanisms ... G-17 7.0 References... G-17

H WORK PACKAGE TEMPLATE – PULVERIZER OVERHAUL... H-1

1.0 Task Overview ... H-1 1.1 Component type... H-1 1.2 Equipment tag or unique equipment identifier... H-1 1.3 Scope ... H-1 1.4 Develop list of know consumable materials to be used... H-1 1.5 Develop a list of know parts to be replaced ... H-2 1.6 Special tools... H-2 2.0 Pre-job Brief ... H-3 2.1 Evaluate potential for generation or equipment risk hazards ... H-3 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... H-3 2.3 Job Safety Analysis, Identifies general and specific hazards... H-3

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2.4 Identify permits required... H-3 2.5 Identify Environmental Considerations... H-3 2.6 Identify Operating Experience ... H-4 2.7 Identify Clearance/Tag out Boundary... H-4 3.0 Contingency Considerations ... H-4 3.1 Identify potential scope expansion and actions due to scope expansion... H-4 3.2 Identify individuals to contact in case certain events occur... H-4 3.3 Develop material list for potential contingency and consumable parts... H-4 4.0 Detailed Work Instructions ... H-5 4.1 Prerequisites ... H-5 4.2 Roll Wheel Assembly Removal ... H-5 4.3 Grinding Ring Segment Removal and Replacement... H-7 4.4 Roll Wheel Assembly Installation ... H-9 4.4 Final Reassembly... H-11 5.0 Determine PMT and PMT considerations ... H-11 6.0 Feedback Mechanisms ... H-11 7.0 References... H-11

I WORK PACKAGE TEMPLATE – DAMPERS ...I-1

1.0 Task Overview ...I-1 1.1 Component type...I-1 1.2 Equipment tag or unique equipment identifier...I-1 1.3 Scope ...I-1 1.4 Develop list of know consumable materials to be used...I-1 1.5 Develop a list of know parts to be replaced ...I-1 1.6 Special tools...I-2 2.0 Pre-job Brief ...I-2 2.1 Evaluate potential for generation or equipment risk hazards ...I-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ...I-2 2.3 Job Safety Analysis, Identifies general and specific hazards...I-2 2.4 Identify permits required...I-2 2.5 Identify Environmental Consideration ...I-3 2.6 Identify Operating Experience ...I-3 2.7 Identify Clearance/Tag out Boundary...I-3 3.0 Contingency Considerations ...I-3 3.1 Identify potential scope expansion and actions due to scope expansion...I-3 3.2 Identify individuals to contact in case certain events occur...I-3 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ...I-3 3.4 Develop material list for potential contingency and consumable parts...I-4 4.0 Detailed Work Instructions ...I-4 4.1 Inlet Damper Clean/Inspection ...I-4

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4.2 Damper Bearings ...I-6 4.3 Lubrication...I-6 4.4 Reassembly ...I-7 5.0 Determine PMT and PMT considerations ...I-7 6.0 Feedback Mechanisms ...I-7 7.0 References...I-8

J WORK PACKAGE TEMPLATE – CENTRIFUGAL PUMP (PROCESS, 3196) ...J-1

1.0 Task Overview ... J-1 1.1 Component type... J-1 1.2 Equipment tag or unique equipment identifier... J-1 1.3 Scope ... J-1 1.4 Develop list of know consumable materials to be used... J-1 1.5 Develop a list of know parts to be replaced ... J-2 1.6 Special tools... J-2 2.0 Pre-job Brief ... J-2 2.1 Evaluate potential for generation or equipment risk hazards ... J-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... J-2 2.3 Job Safety Analysis, Identifies general and specific hazards... J-3 2.4 Identify permits required... J-3 2.5 Identify Environmental Consideration ... J-3 2.6 Identify Operating Experience ... J-3 2.7 Identify Clearance/Tag out Boundary... J-3 3.0 Contingency Considerations ... J-4 3.1 Identify potential scope expansion and actions due to scope expansion... J-4 3.2 Identify individuals to contact in case certain events occur... J-4 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... J-4 3.4 Develop material list for potential contingency and consumable parts... J-4 4.0 Detailed Work Instructions ... J-4 4.1 Preparations... J-5 4.2 Preparation for pump removal... J-5 4.3 Pump Disassembly ... J-6 4.4 Pump Inspection ... J-7 4.5 Pump Reassembly ... J-7 4.6 Pump Installation... J-11 4.7 Final Pump Assembly ... J-14 5.0 Determine PMT and PMT considerations ... J-15 6.0 Feedback Mechanisms ... J-16 7.0 References... J-16

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1.0 Task Overview ... K-1 1.1 Component type... K-1 1.2 Equipment tag or unique equipment identifier... K-1 1.3 Scope ... K-1 1.4 Develop list of know consumable materials to be used... K-1 1.5 Develop a list of know parts to be replaced ... K-2 1.6 Special tools... K-2 2.0 Pre-job Brief ... K-2 2.1 Evaluate potential for generation or equipment risk hazards ... K-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ... K-2 2.3 Job Safety Analysis, Identifies general and specific hazards... K-2 2.4 Identify permits required... K-3 2.5 Identify Environmental Consideration ... K-3 2.6 Identify Operating Experience ... K-3 2.7 Identify Clearance/Tag out Boundary... K-3 3.0 Contingency Considerations ... K-3 3.1 Identify potential scope expansion and actions due to scope expansion... K-3 3.2 Identify individuals to contact in case certain events occur... K-3 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ... K-4 3.4 Develop material list for potential contingency and consumable parts... K-4 4.0 Detailed Work Instructions ... K-4 4.1 Testing Steam Traps ... K-4 4.2 Steam Trap Maintenance ... K-6 4.2.1 Thermodynamic Steam Trap... K-7 4.2.2 Ball Float Steam Trap ... K-7 4.2.3 Balance Pressure Steam Trap ... K-8 4.2.4 Thermostatic Steam Trap... K-9 4.2.5 Inverted Bucket Steam Trap ... K-9 4.2.6 Liquid Expansion Steam Trap ... K-10 5.0 Determine PMT and PMT considerations ... K-10 6.0 Feedback Mechanisms ... K-11 7.0 References... K-11

L WORK PACKAGE TEMPLATE – GATE AND GLOBE VALVES ...L-1

1.0 Task Overview ...L-1 1.1 Component type...L-1 1.2 Equipment tag or unique equipment identifier...L-1 1.3 Scope ...L-1 1.4 Develop list of know consumable materials to be used...L-1 1.5 Develop a list of know parts to be replaced ...L-1 1.6 Special tools...L-2

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2.0 Pre-job Brief ...L-2 2.1 Evaluate potential for generation or equipment risk hazards ...L-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ...L-2 2.3 Job Safety Analysis, Identifies general and specific hazards...L-2 2.4 Identify permits required...L-2 2.5 Identify Environmental Consideration ...L-3 2.6 Identify Operating Experience ...L-3 2.7 Identify Clearance/Tag out Boundary...L-3 3.0 Contingency Considerations ...L-3 3.1 Identify potential scope expansion and actions due to scope expansion...L-3 3.2 Identify individuals to contact in case certain events occur...L-3 3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ...L-4 3.4 Develop material list for potential contingency and consumable parts...L-4 4.0 Detailed Work Instructions ...L-4 4.1 Disassembly ...L-4 4.2 Inspections ...L-5 4.3 Valve repairs ...L-6 4.4 Reassembly ...L-7 5.0 Determine PMT and PMT considerations ...L-7 6.0 Feedback Mechanisms ...L-7 7.0 References...L-8

M WORK PACKAGE TEMPLATE – MULTI-STAGE VERTICAL PUMP ...M-1

1.0 Task Overview ...M-1 1.1 Component type...M-1 1.2 Equipment tag or unique equipment identifier...M-1 1.3 Scope ...M-1 1.4 Develop list of know consumable materials to be used...M-1 1.5 Develop a list of know parts to be replaced ...M-2 1.6 Special tools...M-2 2.0 Pre-job Brief ...M-2 2.1 Evaluate potential for generation or equipment risk hazards ...M-2 2.2 Identify Foreign Material Exclusion (FME) potential and mitigation ...M-3 2.3 Job Safety Analysis, Identifies general and specific hazards...M-3 2.4 Identify permits required...M-3 2.5 Identify Environmental Consideration ...M-3 2.6 Identify Operating Experience ...M-3 2.7 Identify Clearance/Tag out Boundary...M-4 3.0 Contingency Considerations ...M-4 3.1 Identify potential scope expansion and actions due to scope expansion...M-4 3.2 Identify individuals to contact in case certain events occur...M-4

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3.3 Identify rapid or emergency actions to place equipment in likely compensatory

configurations or conditions ...M-4 3.4 Develop material list for potential contingency and consumable parts...M-4 4.0 Detailed Work Instructions ...M-5 4.1 Preparations...M-5 4.2 Motor Removal ...M-5 4.3 Disassembly and removal of discharge head ...M-6 4.4 Disassembly of columns and line shafts ...M-6 4.5 Disassembly or Bottom column section ...M-7 4.6 Impeller Bowl disassembly ...M-7 4.7 Inspection of Pump components ...M-8 4.8 Pump Assembly ...M-10 4.8.1 Assembly of pump bowls...M-10 4.8.2 Assembly of lower line shaft and column to pump assembly ...M-11 4.8.3 Installation of lower pump assembly in pump well ...M-11 4.8.4 Installation of line shafts and columns...M-11 4.8.5 Installation of discharge head...M-12 4.8.6 Final Assembly ...M-12 5.0 Determine PMT and PMT considerations ...M-12 6.0 Feedback Mechanisms ...M-13 7.0 References...M-13

N LISTING OF KEY INFORMATION ... N-1

N.1 Key O&M Cost Points ... N-1 N.2 Key Human Performance Points ... N-2 N.3 Key Technical Points ... N-3

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1

INTRODUCTION

1.1 Purpose and Scope

The purpose of this report is to provide fossil plant maintenance organizations with some generic work package templates. These templates can then be used as guides to develop site specific work packages. 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. Maintenance organizations that have processes in place can find information that will enhance their current processes. For maintenance organizations that may have less structures processes the templates will provide a firm foundation for developing work packages. The templates cover a wide range of equipment types as well as a variety of maintenance activities including inspections, minor repairs and overhauls. Work packages can increase the efficient use of resources, improve overall maintenance and equipment reliability, increase overall

productivity and enhance human performance error reduction.

1.2 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. In many cases, work packages are repeatedly prepared for equipment that is common among most fossil power plants. 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. These templates will be provided for common maintenance activities by component and in a standardized format.

1.3 Report Structure and Overview

Section 2 of the report provides basic work package related information. Information includes the benefits that can be realized from the use of work packages and how to use work packages. Section 3 presents the format of a generic work packages and discusses the contents of each section. Section 4 provides a list of key references used in developing many of the work package templates. There are numerous EPRI products listed that provide greater detail on the operation and maintenance of key plant equipment. The appendices provide numerous work package templates on a wide range of plant equipment and various levels of maintenance activities (E.g. inspections, minor repairs, and overhauls).

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1-2

Figure 1-1

Work Package Template Overview

1.4 Glossary of Terms and Acronyms

1.4.1 Industry Definitions and Nomenclature

Air Circuit Breaker – A circuit breaker whose primary circuit interrupts current in air verses vacuum, oil or gas.

Air load - This term refers to energizing the ESP during an outage period at ambient

temperatures. The object is to verify the electrical integrity of the bus section, to obtain electrical readings of voltage and current, and to determine whether spark over occurs before reaching a specific limit of the TR set rating. 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.

Alignment - A condition where the axis or center lines of two shafts are in line or coaxial. Antipump device – After an opening operation, 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.

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Anti-sway insulator - These insulators are used to prevent the bottom, HV frames, which position and retain the discharge electrodes, from swinging or drifting out of alignment. The insulators are either a ceramic bar or a shaft type and are usually secured to the hopper wall. Some designs connect directly between the collecting plates and the lower, HV frames. Arc Chute – A confined space or passageway, lined with an arc resistant material, into or through which an arc is directed to extinction.

Arcing contacts – The contacts of the circuit breaker on which the arc is drawn after the main and intermediate (if used) contacts have parted.

Auxiliaries – Devices which perform secondary functions as adjuncts or refinements to the primary function of the circuit breaker.

Auxiliary Switch – A switch which is mechanically operated by the operating mechanism for indication, interlocks or other control functions and reflects the open or closed status of the breaker.

Bell Alarm – An alarm that features one normally open and one normally closed contact activated by the auto-trip indicator.

Brinelled bearing - A brinelled bearing is one in which a dent has been formed in one of the races by a ball.

Bus – A conductor or group of conductors that serve as common connection for two or more circuits.

Centrifugal Fan – A fan rotor or wheel within a scroll-type housing and including driving mechanism supports for either belt drive or direct connection.

Classifier, dynamic - A rotating vane assembly for the separation of coal particles.

Classifier, stationary - A combination of a vane and cone section designed to maintain and control the desired fineness of the coal leaving the mill.

Closing Spring Charging Motor – A motor that is energized automatically by internal limit switches to charge the closing springs electrically.

Coal pulverizer - A machine that reduces the size of coal particles, dries the coal, classifies the coal, and transports the coal to the boiler piping. Also called a coal mill.

Cold-side ESP - An ESP which is installed downstream of the air heaters.

Collecting surface - 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. Collecting surface plate design differs between manufacturers, but all are secured to the shell of the ESP at ground potential and serve as the positive anode of the gas passage.

Component – A generic technical part. Many components make up equipment. Hierarchy is: parts make components, components make equipment, and equipment makes systems.

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Corrective Maintenance – All maintenance performed to correct a breakdown or failure. Critical speed – The speed of a rotating system that corresponds to a natural frequency of the system.

Damper – A device used to vary the volume of air passing through an air outlet, air inlet, or duct.

Declutch Lever- A lever that is operated to allow manual operation of the Limitorque actuator using the handwheel. The declutch lever will automatically disengage upon operation of motor. Discharge electrode - Refers to the HV component that ionizes the process gases and creates the electric field. It is shaped to provide a corona discharge when the impressed voltage breaks the gas down at the electrode surface. This breakdown of the gas creates corona tufts on the

discharge surface. Typically, voltage applied to the discharge electrode is of negative polarity. In many weighted-wire designs, the discharge electrode is a smooth round wire slightly larger than 0.1 in. (2.54 mm) in diameter. Barbed wire is also frequently used in part, or all of the ESP, to enhance corona characteristics. Discharge Electrodes of the rigid and rigid frame or mast variety are also widely available. They can vary widely in style and shape.

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.

ESP - electrostatic precipitator (ESP) - a facility that removes fly ash from the flue gas by producing an electric charge on the fly ash and collecting it electrostatically.

Fan – Any device that produces a current of air by the movement of a broad surface can be called a fan. There are several types: Centrifugal, Axial, Propeller, Tube axial, and Vane axial. Fans are also called compressors, ventilators, exhausters, and blowers.

Finger Tight - Refers to the tightening of a fastener without the aid of a wrench.

Four-train geared limit switch - The rotor-type, four-train geared limit switch employs four rotary drum switches. Each rotary drum switch contains four contacts. When the rotor is properly set to trip at the desired position, two of these contacts open electric circuits and two of the contacts close electric circuits. One rotor is set to trip at the full open position of the valve, and one rotor is set to trip at the full close position of the valve. The other two rotors are set at some intermediate position depending on the application.

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.

Gas distribution devices - Internal elements in the transition or ductwork to produce the desired velocity contour at the inlet and outlet face of the precipitator (for example, turning vanes or perforated plates).

Hoppers - 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. The typical shape is pyramidal; with the sides of each hopper being steep sloped. The outlet opening is sized so that fly ash may be easily removed by an ash removal system. Baffles are usually placed in the hoppers; they extend below the dust level to minimize undesirable gas leakage

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below the collection plates. Typically, 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. Hoppers are also equipped with access doors, strike plates for manually rapping the hopper walls, and poke holes to unclog the hopper outlets.

Housing – The housing for a fan is the stationary element that guides the air or gas before and after the impeller. A housing can also be called a casing, a stator, a scroll, a panel, a ring, or a volute. For fans, housing, casing, and stator are the preferred general terms.

Inspection – Any activity performed to find a failure or breakdown.

Intermediate contacts – Contacts in the main circuit which part after the main contacts have parted and before the arcing contacts have parted.

Isolation Damper – A damper installed in a system that is capable of stopping or diverting flow from one portion of the system to another.

Journal bearing – A cylindrical bearing.

Key-interlock system - A system of locks that prevents opening the ESP access doors while the precipitator is energized.

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.

Main Contacts – Contacts that carry all or most of the current of the main circuit.

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.

Overcurrent Protection – A form of protection that operates when the current in the main circuit exceeds a predetermined value.

Penthouse - A weatherproof, gas-tight enclosure over the precipitator to contain the HV insulators.

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, roles and responsibilities, and hazards and controls that provide a heightened level of awareness of significant aspects of the task.

Pulley –A wheel attached to a shaft, which carries a belt or chain. See sheave.

Rappers (Collecting surfaces) - These are devices, generally located at the top of the ESP or bottom of the collecting plates, which periodically impart a shock to the collecting surfaces to help dislodge the collected material into the hopper system. The final collection efficiency of the precipitator is often determined by how well this process is conducted. The object is to dislodge the material from the collector surface in small clumps or patches without building excessive dust layer thicknesses. This is a complex part of precipitation, but it is more important to know that reliability of rapper operation holds priority over timing, impact force, and other aspects of this system.

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Rappers (High voltage) - These rapper devices impart a vibration or shock to the HV frame supporting the discharge electrodes. The object is to keep the buildups on these electrodes from affecting the corona discharge pattern. The discharge electrodes will generally exhibit irregular coatings of various size and shape. Whether the buildups observed during outage inspections are detrimental can usually be determined by an analysis of electrical readings during periods of operation. It is usually better to operate with some buildup than employ excessive rapping forces that can result in failure of discharge electrodes.

Reversing Starter - The reversing starter electrically changes the operation of the electric motor from one direction of rotation to the other. The starter consists of two contactors mounted on a common base and mechanically interlocked.

Safety grounding device - A device for physically grounding the HV system prior to personnel entering the precipitator. The most common type consists of a conductor, one end of which is grounded to the casing, the other attached to the HV voltage system using an insulated operating lever.

Sheave - A wheel attached to a shaft, which carries a belt or chain. See pulley.

Short-time delay trip element – A direct-acting trip device that functions with a purposely delayed action (typically 0.07 – 1 second) on an overcurrent condition.

Shunt Trip Device – A circuit breaker attachment that utilizes a solenoid to rotate the trip shaft to open (trip) the circuit breaker. The shunt trip device is used to open an electrically operated breaker under normal conditions.

Sleeve bearing – A bearing that carries lubricant for the shaft rotating within it. Often used synonymously with Journal bearing.

Snug Tight - Refers to the tightening of a fastener, or a group of fasteners, in such a manner that brings faces together uniformly and ensures that the fastener(s) cannot be loosened by hand. When fastener preload values are required, subsequent torquing will be necessary.

Test Position – The position where the primary disconnecting devices of the removable element are separated by a safe distance from those in the housing. Some or all of the secondary

disconnecting devices are in operating contact.

Torque Switch – A device designed to protect the actuator in open and close directions.

TR set - Is the term for the HV transformer and rectifier that provides the electrical energy for a given precipitator area. 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. An RMS secondary voltage of about 53,500 volts ac (45 kV dc average) is utilized for the 9 in. (228.6 mm) wide gas passage of most weighted-wire precipitators; 77,300 volts ac (65 kV dc average) for most of the 12 in. (304.8 mm) wide gas passage of rigid electrode

precipitators.

Two-trained geared limit switch - The rotor-type, two-train geared limit switch employs two rotary drum switches. Each rotary drum switch contains four contacts. When the rotor is properly set to trip at the desired position, two of these contacts open electric circuits and two of the

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contacts close electric circuits. One rotor is normally set to trip at the full open position of the valve, and the other rotor is normally set to trip at the full close position of the valve.

Undervoltage Trip (Release) – A release that operates when the voltage of the main circuit is equal to or less than the release setting.

V-I curve - 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. An important part of these measurements is the indicated voltage at the threshold of corona current. While normally obtained during air load, these curves sometimes can be developed during operating periods.

Work Instruction – Instructions for performance of the work to be accomplished, the level of detail of which is dependent on the assigned planning level. When applicable, approved procedures may be referenced and may suffice as work instructions.

Work Package – A compilation of documents including the work order, work instructions, and any other supporting material (that is, drawings, vendor manuals, weld process sheets, operating experience, safety analysis, permits, for example).

Wrench Tight - 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.

1.4.2 Acronyms

CAP – Corrective Action Program ESP - 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

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1-8 1.5 Key Points

Throughout this guide, key information is summarized in Key Points. Key Points are bold lettered boxes that highlight information covered in the text.

The primary intent of a Key Point is to emphasize information that will allow individuals to act for the benefit of their plant. EPRI personnel who reviewed and prepared this guide selected the information included in these Key Points.

The Key Points are organized into three categories: Human Performance, O&M Costs, and Technical. Each category has an identifying icon to draw attention to it when quickly reviewing the guide. The Key Points are shown in the following way:

Key O&M Cost Point

Emphasizes information that will result in reduced purchase, operating, or maintenance costs.

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.

Key Technical Point

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2

WORK PACKAGE TEMPLATES

2.1 Introduction

Maintenance is the most critical function when it pertains to product output, quality and safety. An effective maintenance organization possesses the ability to adapt to a dynamic, quick changing environment. 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. It is not enough, 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. To best meet the competitive challenge the continually improving maintenance

organization is finding ways to work smarter. Working smarter means being ready for the expected and the unexpected. Taking advantage of new technologies has been one method that has proven to be successful. Technology has lead to more efficient and reliable equipment, but with the increase in efficiency and reliability has come complexity. With complexity there is the growing need for better training and better resources for the maintenance craftsman to be able to perform their work. One of the resources that can aid the craftsman in this area is the work package.

To best meet the competitive challenge the continually improving

maintenance organization is finding ways to work smarter. Working smarter means being ready for the expected and the unexpected.

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, efficiently and safely. The craftsman requires guidance. Without this guidance a task may take longer to perform, it may be performed incorrectly or incompletely. All available work may not be performed while the equipment is available for maintenance. 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.

Work packages provide the maintenance craftsman with the level of detail necessary to perform a work activity correctly, efficiently and safely. In addition, work packages provide an opportunity to incorporate controls and barriers to mitigate the potential for error or to mitigate the consequences of error. If a maintenance task is to be performed correctly it must contain sufficient detail. The amount of detail required will different from one maintenance organization to another based on many factors. (E.g. Training, experience and skill level of craftsman, resources, etc) Although the level of detail may vary to basic content of the work package from one facility to another to another should

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possess some basic similarities. (E.g. Scope of work to be performed, parts required, tools required, proper equipment clearance, safety and error free considerations, step by step guidance on how the work is to be accomplished)

Work packages provide the maintenance craftsman with the level of detail necessary to perform a work activity correctly, efficiently and safely.

If the maintenance organization finds itself in a position of constantly reacting to emergencies and unplanned shutdowns, spending significant amounts of time searching for spare parts, lacking the proper skills and tools for the craftsman or always feeling rushed to perform repairs at the sacrifice of quality, then the maintenance organization is functioning in a “fire-fighting” mode. 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. The work package will serve as the backbone of a proactive maintenance organization. It will provide the how to for work execution, information input to a variety of maintenance functions and a

valuable source of feedback for continuous improvement. The work package will be the primary tool used to manage all aspects of the maintenance activity: labor resources, parts, human performance, a measure of organizational effectiveness, etc. The labor resource is one of the largest and expensive within the maintenance department. If the labor resource is not being utilized effectively and efficiently, a significant amount of money is being wasted.

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.

The labor resource is one of the largest and expensive within the maintenance department. If the labor resource is not being utilized

effectively and efficiently, a significant amount of money is being wasted. When equipment inspections are required a pre-developed package can be retrieved and used to perform the inspection. It can be easily modified accommodate the current needs. The majority of the preparation planning was done far in advance. The major activity left, other than the work itself, is to pull together the resources defined within the work

package. The same applies for corrective maintenance and overhauls. 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

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The work package is the communications vehicle for the maintenance organization to perform its overall function. 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, regardless of which craftsman performs the work

2.2 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. Like most new processes the initial effort may appear overwhelming. The issues facing the organization today appear to overshadow the longer term priorities. The work package template will provide the maintenance organization with a more accurate and efficient tool for the scheduling and execution of maintenance activities. Works order templates contain all planned information including parts, resources requirements, work instructions, etc. 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. Following are some of the benefits that can be realized from a system of work package templates.

1. The maintenance organization will be more responsive to meeting emerging work needs. It will move from a fire-fighting mode to a mode that is more structured and proactive.

2. Provides step-by-step sequence of work instructions. 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. 3. Templates can be readily modified to suit particular maintenance activities. They

can be used in their entirety or in part based on the particular needs. 4. Can provide improvement in safe working practices.

5. Estimation variances, additional tips or instructions, improving the safe working practices and reviewing the stores re-credits can offer areas of improving work order templates.

6. Templates can be used as training tools.

7. Templates can also be used to store trouble shooting guides for specific symptoms/fault modes.

8. Work packages can assist the maintenance craftsman in reducing errors. 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

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2-4 2.3 Work Package Templates

The work package templates in this report are generic. They were designed, in most cases, to encompass a wide range or work tasks required on a particular type of

equipment regardless of the manufacturer of the equipment. There are a few exceptions such as Limitorque actuators and Gould 3196 process pumps. Due to their wide spread use in the industry more detail is provided. Tolerances and specifications are left to the specific site. Also due to differences in design some templates reference a particular design type. For example a coal pulverizer may use one of many mechanisms to perform its function. (E.g. roll wheel verses a tube or ball mill). Although their function is

identical the inspections and overhauls of the different types would be different. It is difficult to create a generic work package template. In the case of low voltage air operated circuit breakers the task is more feasible. Circuit breaker design is similar enough between manufacturers to allow for a work package template to be created. All breakers have a frame, operating mechanism, contacts and protective devices. There will of course be differences in certain devices between manufacturers.

2.4 How to Use the Templates

The degree of formalization of work processes between fossil plants will differ. Some plants may possess very detailed and formalized procedures for the conduct of

maintenance activities. 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. Regardless of the level of sophistication of the work process being used by any given maintenance organization, the work package templates contained in this report will prove to be of value. In facilities where more formalized processes exist, the work package templates may provide alternative methods, human performance considerations, notes or cautions or other information that will be of benefit to the way maintenance is performed. 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.

In organizations with more formalized processes, either procedures or work packages, the templates may be used to enhance existing products. Key considerations during the review should include:

1. 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.

2. Pre-job brief – In this section there are items that may be considered when performing pre-job briefs prior to maintenance activities. 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.

3. Inspection activities – When items are required to be inspected most procedure tell what is to be expected. The templates provide what to inspect and in addition provide guidance to the craftsman of what the inspection should entail.

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In organizations that do not possess formalized procedures or work packages for equipment inspections, repairs and overhauls, the templates will provide a solid

foundation from which facility specific work packages can be developed. There will be short term costs associated with the development of the specific work packages but the long term gains will outweigh these costs.

There will be short term costs associated with the development of the specific work packages but the long term gains will outweigh these costs. Because the work packages templates are generic it is recommended that during specific work package development that appropriate references be used. References include vendor technical manuals, drawings and other engineering documents. For example there may be tolerance criteria for a measurement taken on a piece of equipment. Appropriate acceptance criteria should be obtained from the vendor technical manual. Another example of the generic nature of the work packages would be equipment alignment. 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. Each plant will be different based on the method that is used in their training or the technology available (E.g. laser alignment, double-dial)

2.5 Planning Walkdowns

An important step in the planning process is the planning walkdown. This is an important step in developing the finalized work package for the maintenance activity. The planning walkdown is essential for the development of pre-job considerations and contingencies. Each facility will differ with respect to where equipment is located, accessibility to equipment (E.g. work platforms), laydown areas, interferences (E.g. struts, pipe supports, hangers), rigging supports, 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. It will help expedite repairs and minimize equipment

unavailability. The thoroughness and consistency of walkdowns can be improved through the use of a checklist. During the walkdown considerations should typically include:

1. 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. 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.

3. 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.

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4. Is there sufficient space in the work area to carry out the maintenance safely? Is there room for scaffolding, ladders, laydown areas, proper rigging sites, forklift access, cranes, etc.?

5. Are there physical limitations to performing the work safely?

6. What is the status of environmental conditions at the work site? Lighting? Temperature concerns? Hot pipes? Rotating machinery? Etc.

7. Are there any personnel safety considerations?

8. What special permits may be required? Confined Workspace? Transient combustible storage? Etc.

9. Are facilities available? Electrical, water, air, phones?

10. It also provides an opportunity to validate materials and special tooling needs. Key Human Performance Point

The planning walkdown is essential for the development of pre-job considerations and contingencies.

The results of the walkdown should be incorporated into the work package.

During the walkdown there are tools that should be available to the planner to achieve the greatest benefits from the walkdown. These include:

1. Digital voice recorder. It is much easier than taking written field notes.

2. Small digital camera. These are of benefit when sitting down and completing the work package. They also make excellent reference materials during pre-job briefs.

3. Measuring tape. 4. Strong flashlight

5. Laser pointer. (Excellent for pointing out details in pictures, E.g. leak identification)

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3

WORK PACKAGE TEMPLATE FORMAT

3.1 Task Overview

Figure 3-1

Work Package Development - Task Overview

This section of the work package provides general information regarding the task. The section consists of the following sub-sections.

1. Component type – describes the type of equipment that is to be worked.

2. Equipment tag or unique identifier – describes the exact piece of equipment to be worked indicated by a unique equipment identifier. (e.g. 1A Boiler Feedwater Pump, Breaker 42317 1A Boiler Feedwater Pump)

3. Location of Equipment – Provide a brief description of where the equipment is located. (E.g. building, floor elevation, room, etc) Proving a drawing of the equipments location and a picture of the equipment should be included in the package if available.

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4. Scope – describes in general the type of work to be performed on the piece of equipment. (E.g. Inspection, test, repair, overhaul, etc)

5. List of known consumables – a list of consumable products (e.g. rags, cleaning solvents, oil, grease, etc) that will be used during performance of work.

6. 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. Each piece of equipment should have a Bill of Materials (BOM).

7. Tools/Special tools – provides a list of tools that will be required to perform the scope of work properly and safely. List includes typical journeyman’s tools, safety equipment and specialty tools required to perform the scope of work.

8. Craftsman skills required – The types of craftsman to be used during the maintenance activity should be identified.

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, personnel and the environment are not impacted as a result of the maintenance activity. The section consists of the following subsections.

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1. Evaluate potential for generation or equipment risk hazards – This section provides considerations concerning the effect the maintenance may have on the plant. This may include precautions for working a piece of equipment on line, effects on system lineups, precautions that should be taken during the course of maintenance to preclude potential damage to equipment being worked, etc. Consideration should also be given to

equipment in the immediate vicinity of the work location. Work activities should be evaluated to determine if the potential exist to inadvertently affect equipment in the area. (E.g. scaffold was built with a scaffold bar running through the handwheel of a piece of nearby equipment)

2. 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. (E.g. 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.

3. Job Safety Analysis – Maintenance tasks can represent hazards to both equipment and personnel. 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.

4. Identify permits required – Many maintenance activities may prove hazardous to the equipment, personnel or the environment. To protect these assets administrative programs have been developed. Typical permits that may be required during maintenance include; Equipment Clearance Order/Tag Out, Confined Space Entry, Hot Work Permit, Transient Combustible Control, Chemical Traffic Control/MSDS.

5. Identify environmental considerations – This section is concerned with the identification of environmental hazards that may be imposed on the worker (e.g. temperature, lighting, lethal gases, chemicals, combustible atmospheres, etc) as well as mitigation of the release of hazardous substances used during maintenance to the environment.

6. Review operating experience - Review any relevant plant specific or industry related operating experience applicable to the work being performed. 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. Operations experience can be drawn from various sources including:

a. Experienced personnel proving experiences and expertise, especially during pre-job briefs

b. From on-site experiences, especially the Corrective Action Program c. From previous performance of work orders

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3-4 e. Vendor bulletins

f. 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. Each site, due to differences in design, must use its knowledge of the system along with applicable drawings (piping, wiring, vendor, etc) to ensure that equipment is properly isolated and placed in a condition such that maintenance can be performed safely.

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.

3.3 Contingency Considerations

Figure 3-3

Work Package Template

Work Package Templates

Work Package Templates

CITATIONS

REPORT SUMMARY

ACKNOWLEDGEMENTS

CONTENTS

1

INTRODUCTION

2

WORK PACKAGE TEMPLATES

3

WORK PACKAGE TEMPLATE FORMAT