Work Package Template

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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 • askepri@epri.com • 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).
NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY
PERSON ACTING ON BEHALF OF ANY OF THEM:
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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
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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.
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:
Work Package Templates. EPRI, Palo Alto, CA: 2007. 1012288.
iii
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)
v
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
vi
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
Garry Waggoner TXU
vii
CONTENTS
1 INTRODUCTION ....................................................................................................................1-1
1.1 Purpose and Scope........................................................................................................1-1
1.2 Background ....................................................................................................................1-1
1.3 Report Structure and Overview......................................................................................1-1
1.4 Glossary of Terms and Acronyms..................................................................................1-2
1.4.1 Industry Definitions and Nomenclature .................................................................1-2
1.4.2 Acronyms ..............................................................................................................1-7
1.5 Key Points ......................................................................................................................1-8
2 WORK PACKAGE TEMPLATES ...........................................................................................2-1

2.1 Introduction ....................................................................................................................2-1
2.2 Benefits of Work Package Templates ............................................................................2-3
2.3 Work Package Templates ..............................................................................................2-4
2.4 How to Use the Templates.............................................................................................2-4
2.5 Planning Walkdowns......................................................................................................2-5
3 WORK PACKAGE TEMPLATE FORMAT .............................................................................3-1

3.1 Task Overview ...............................................................................................................3-1
3.2 Pre-Job Considerations..................................................................................................3-2
3.3 Contingency Considerations ..........................................................................................3-4
3.4 Detailed Work Instructions .............................................................................................3-6
3.5 Post Maintenance Testing..............................................................................................3-8
3.6 Feedback Mechanisms ..................................................................................................3-9
3.7 References...................................................................................................................3-11
4 REFERENCES .......................................................................................................................4-1
A WORK PACKAGE TEMPLATE – BELT DRIVEN EQUIPMENT ......................................... A-1

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
x
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
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
xi
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
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
xii
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
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
xiii
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
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
xiv
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
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
xv
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
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
xvi
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
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
K WORK PACKAGE TEMPLATE – STEAM TRAPS .............................................................. K-1
xvii
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
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
xviii
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
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
xix
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
xx
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).
1-1
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.
1-2
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.
Contacts – Two conducting parts that interact to make or break a circuit.
1-3
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
1-4
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.
1-5
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
1-6
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
OSHA – Occupational Health and Safety Administration
1-7
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

Targets information that will lead to improved equipment reliability.
1-8
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.
Key O&M Cost Point

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
2-1
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.
Key O&M Cost Point

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
efficiently than starting from scratch.
2-2
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
maintenance activities.
2-3
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.
2-4
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.
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.
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.
2-5
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.

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)
6. Notebook.
2-6
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.
3-1
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.
3-2
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
d. Experience from other utility experiences
3-3
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 Development – Contingency Considerations
3-4
This section of the work package provides information related to contingencies that may arise
during the course of the maintenance activity. Scope expansion due to unforeseen or newly
discovered deficiencies during the course of maintenance activities happens. It is unlikely
(numerous possibilities) and infeasible (cost restrictive) to develop contingencies for all possible
scenarios. 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, operating history and other
intelligence. Key considerations should be made in the areas of:
1. Potential scope expansion – Once a piece of equipment is opened for maintenance or
inspection there is always the potential for work scope to increase. A review of previous
maintenance history on the piece of equipment will provide valuable information to assist
in development of contingencies.
2. 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. This can be required for
determination of whether parts should be replaced, scope expansion, engineering support
for repair methods, etc.
3. Identify rapid or emergency actions to place equipment in compensatory configurations
or conditions.
4. 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. 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 parts should be flagged as contingent in
the work package. It will be necessary to make a decision as to whether the parts should
be on site to support the maintenance activity. Procurement should be notified of the
contingent parts requirements so availability and lead times can be determined. 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. 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.
Key Technical Point

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, operating history and other intelligence.
Key O&M Cost Point

The planner should be aware that contingency parts may or may not be
necessary to support the job. This can be a significant financial decision
since most contingency parts tend to be high cost items that are not
maintained in normal inventory.
3-5
3.4 Detailed Work Instructions
Figure 3.4
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. 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. The amount of detail that exists in this section can vary. This can
be affected by the skill level of the craft, supervisory oversight provided and the work activity it
self.
The work package developer should not assume that the craftsman knows everything about the
work activity. The developer can assume that each craftsman possesses the following skill set.
1. Can read engineering drawings
2. Can read and understand work instructions
3. Understands the proper application and use of hand tools.
4. Can use measurement equipment.
3-6
The draftsman will possesses many other skill sets but this will vary by craftsman based on the
amount of training received, experience level and past work experience.
The amount of detail required can also be affected by the amount of supervisory oversight
provided. Oversight may be either form supervisors within the maintenance organization,
engineering support or vendor support. 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. 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.
The dominant factor n the level of detail required in the work instructions is the task itself.
Tasks that are complex or less frequently performed will require a greater level of detail. Other
factor that can affect the level of detail required include:
1. The availability of approved, detailed procedures to perfo5rm the work activity.
2. Risk to the unit (trip, transient)
3. Personnel Safety
4. The requirement for special controls (Confined work space)
5. The requirement for special skills (Welding, rigging, etc)
NOTES are provided to give amplifying or clarifying information. NOTES should only contain
administrative information. NOTES should not direct any physical actions required by the
maintenance craftsman. NOTES should precede the step to which they apply.
CAUTIONS are provided to heighten attention to step(s) that if improperly performed may result
in equipment damage, injury to personnel, and impact to unit operation or adversely affect plant
systems. CAUTIONS should precede the step to which they apply.
To assist the craftsman in recognizing critical steps in the work instructions special symbols or
annotations (Bomb or firecracker symbols, stop signs, etc) have been used to minimize the
potential for errors.
The work templates contained in this report provided varying levels of detail.
3-7
3.5 Post Maintenance Testing
Figure 3.5
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. Post
maintenance testing is performed to verify that all components and systems are capable of
performing their intended functions following maintenance activities. It will also verify that
original deficiencies have been corrected and that no new deficiencies were introduced during
the maintenance activity. 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, a procedure or a
subsequent work order package.
Post maintenance testing may be performed with the equipment operating under normal
operating conditions or specific test conditions. Post maintenance testing provides an initial
break-in or run-in period for adjustments, calibrations and/or monitoring of equipment
performance characteristics. (E.g. vibration, temperature, flow, etc)
3-8
Post maintenance testing should include documentation of results for future reference and
trending.
3.6 Feedback Mechanisms
Figure 3.6
Work Package Development – Feedback Mechanisms
Feedback provides information related to the quality of work in the field, processes that support
work, and observation of work practices and conditions in the plant. Feedback is a vital link
between the job-site and the organization. Feedback can be obtained through a variety of
mechanisms. (E.g. direct observation of work performance, work package feedback sheets, post
job reviews, Corrective Action Program, informal communications, etc) These methods of
providing feedback on maintenance activities have been used with varying degrees of success.
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, support worker performance, improve job productivity and identify
opportunities to strengthen human performance and reduce errors. It can identify problems with
procedures, work packages, equipment, work performance and training of personnel.
3-9
Feedback should be obtained as soon as practical following the maintenance activity. It should
focus on both improvement opportunities as well as recognizing those things that went well.
Some typical items that should be considered for feedback include:
1. Unanticipated surprises
2. Unanticipated error precursors/traps
3. Industrial safety issues or hazards
4. Equipment condition
5. Personnel issues (lack of resources, incorrect resources, training inadequacies)
6. Work Order/Package quality
7. Procedure quality
8. Quality of supervision
9. Quality of vendor support (if applicable)
10. Quality of planning and scheduling
11. Adequacies of tools, parts, resources
12. Inter-departmental support
13. Obstacles to work performance
14. Things that went well
15. Good catches

Feedback is a credible source of information that can result in the
improvement in the organization of work, support worker performance,
improve job productivity and identify opportunities to strengthen human
performance and reduce errors.
3-10
3.7 References
Figure 3.7
Work Package Development - References
This section of the work package is the maintenance craftsman’s resource library. This section of
the work package should provided sufficient supplemental information necessary to complete the
maintenance activity satisfactorily. 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. The package
would become too bulky and could very likely turn off the craftsman to useful information
contained within. However, 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 some cases, if they exist, whole or portions of procedures may be referenced. If portions of
procedures are included as reference the planner should be careful to include the initial
conditions, precautions and limitations applicable to that procedure to ensure that portion of the
procedure is applied appropriately and under the proper circumstances.
References may be included in whole, in part or noted for easy reference and access. Typical
references may include:
3-11
Included in package:
1. Approved procedures related to work activity (if they exist)
2. Vendor drawings
3. Complete parts list with appropriate stock numbers
4. MSDS sheets for chemicals that will be used
5. Electrical drawings (if applicable)
6. Copy of the equipment clearance/tag out
7. Operating Experience
8. Any permits required (Confined space, hot work, etc)
Referenced or noted:
1. Industrial Safety Manual

2. Detained Post maintenance procedure (if it exists)
3. Hot Work Permit Procedure
4. Confined Work Space Procedure
5. Chemical Control Procedure
6. Foreign Material Control Procedure
7. Technical support Procedures (Packing, torque, welding, etc)
8. Equipment vendor technical manual
9. Specific component vendor technical manual (Coupling, Mechanical seal, etc)
3-12
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, RP-
2243-1.
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. Container (bags) for temporary storage of studs and nuts
B. Loctite
C. Emery cloth
D. Steel wool
E. 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. Force gauge
B. Belt tensioner
C. Sheave Groove Gauge
D. Torque wrenches
E. Combination wrenches
F. Socket set
G. 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
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 and the use of the tube cleaning equipment.
2.7 Identify Clearance/Tag out Boundary
A. Motor to fan, compressor, cooler, AHU, etc

B. Power to inlet and outlet dampers (if applicable)
C. Power to common plenum/duct equipment (if applicable)
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.
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 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
3.3 Identify rapid or emergency actions to place equipment in likely
A-3
compensatory configurations or conditions
3.4 Develop material list for potential contingency and consumable parts
A. Bearings
B. Shaft
Develop work instructions, utilize existing procedures when applicable

Provide expected actions in proper sequence for task.
Identify Notes and Cautions where needed
A. NOTIFY Operations prior to beginning work

B. ENSURE an appropriate clearance/tag out is in place to perform work safely
C. ENSURE all parts expected to be used are available and in hand
D. ENSURE all tools necessary to perform the job are available
E. ENSURE appropriate personal safety equipment is worn on the job
4.1 Disassembly
NOTE
Bag or tag parts for traceability.
A. REMOVE as applicable:
a. Guards
b. Covers
c. Access Ports
d. Bolts, screws and/or fasteners
CAUTION
Do not pry belts off of sheaves as this may damage belts and sheaves.
NOTE
Belts should not ride in the bottom of a sheave groove.
A-4
B. REDUCE sheave center-to-center distance between the motor sheave and the driven
sheave to allow removal of belts.
C. LIFT belt(s) off sheave
4.2 Inspections
NOTES
1. Worn or damaged parts should be repaired or replaced if required
2. Old and new belts should be inspected prior to use
3. Wear on one side of a belt is an indication of improper sheave alignment.
4. Belts that are hard and brittle are typically a result of lack of tension.
5. Spin burns or glazed shinny side walls is an indication of belt slippage.
A. INSPECT belts for:

A. Cover fabric ruptures
B. Cracks
C. Slip burn areas
D. Separation of plies
E. Ruptures
F. Worn belt sides
NOTES.
1. Sheaves with burrs, rough spots or corrosion may be cleaned.
2. Sheaves with cracks or dished sides should be replaced.
3. If sheave is dished greater than 1/32”, the sheave should be replaced.
A-5
G. INSPECT sheaves for:
a. Burrs
b. Rough spots
c. Corrosion
d. Pitting
e. Cracks
f. 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.
H. INSPECT shaft for rough spots, burrs, or other damage or degradation.

I. INSPECT bearings for any defects or misalignment
J. INSPECT bearing set screws are tight
NOTE
Some pillow block bearings require lubrication. Refer to vendor for approved
lubricants.
CAUTION
Do not apply excessive pressure when lubricating to prevent damage to bearing seals.
K. LUBRICATE bearings (if required)

L. INSPECT the following for unusual wear:
a. Shaft coupling
b. Housings
c. Mounting bases
d. Fan wheel
A-6
4.3 Alignments
4.3.1 Sheave alignment

CAUTION
Do not roll or pry belts off of sheaves as this may damage belts and sheaves.
NOTE
Sheaves should be placed as close to the bearings as possible to create less shaft
deflection and bearing stresses.
A. ALIGN motor sheave to driven sheave

a. Laser alignment
b. Straight edge alignment
c. String alignment
4.3.2 Shaft/Bearing Alignment (required only if shaft or bearing is replaced)
A. INSPECT bearing and ensure it is centered in its housing

B. VERIFY Shaft is level, in the same plane (prime mover and driven unit)
C. ADJUST bearings as needed to achieve shaft s in the same plane.
D. For fans: ENSURE fans are centered radially and axially.
E. TIGHTEN bearing hold down bolds (snug tight)
F. POSITION dial indicators on shaft at pillow block bearing.
G. LOOSEN pillow block hold down bolts
H. OBSERVE dial indicators for movement to determine if shaft was preloaded.
a. For vertical movement add or delete shims as necessary on pillow block bearing
or adjust flange bearings
b. For horizontal movement, adjust bearings as necessary
I. REPEAT dial indicator test for shaft preload until acceptable results are achieved
J. TORQUE bearing hold down bolts when satisfactory shaft alignment is achieved.
K. RECHECK alignment
A-7
4.3.3 Adjusting belt tension
NOTES
1. Ideal belt tension is the lowest tension that will prevent prolonged belt squeal on
startup and excessive vibration during operation.
2. Refer to vendor manuals for appropriate belt tensions
3. The shaft deflection method is a recommended method for belt driven HVAC
equipment.
4. After installation of new belts, belts should be tensioned to maximum allowable
force to allow for break-in stretch
5. Over tensioning belts shortens belt and bearing life.
6. Under tensioning belts can cause premature belt ware or fan failure.
7. Some fans have resonant frequencies that must be avoided.
8. For multiple belt sets do not mix old and new belts.
9. The most common reason for belt failure is under tension.
4.3.3.1 Shaft deflection method
A. INSTALL dial indicator at closest accessible location to the centerline of sheave.

B. APPLY tension to belt until shaft movement is detected not to exceed 0.001 inch
C. MEASURE belt span to +/- 1 inch
D. DIVIDE span by 64 to obtain deflection
NOTES
1. For a banded belt, Average force equals total force divided by the number of
belt ribs.
2. Deflection force should be measured as close to the center between the two
sheave axis.
E. MEASURE force in pounds required to deflect each of the belts a distance equal to the
deflection distance
F. CALCULATE average force
4.3.4 Reassembly
A. INSTALL all bolts, screws and fasteners (torque as specified)
NOTE
If work was performed inside a plenum ensure are materials taken into plenum have
been removed.’
A-8
B. INSTALL guards, covers and access ports
5.0 Determine PMT and PMT considerations
A. Vibration testing is recommended for all corrective maintenance

B. Flow testing is recommended for sheave replacements if flow is critical to proper
operations of equipment or supported equipment cooling.
C. Additional belt tension adjustments may be required to achieve acceptable vibration
levels or to eliminate belt squeal
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. Industrial Safety Manual

B. Applicable vendor technical manuals (Belts, sheaves, bearings, driven equipment)
C. Foreign Material Control Procedure
D. Material Safety Data Sheets
E. Chemical Traffic Control Procedure
A-9
B
WORK PACKAGE TEMPLATE - BOILER FEED WATER
PUMP
1.0 Task Overview
1.1 Component type
This work instruction is applicable to a single stage, pack-less boiler feed water pump.
Ensure the unique boiler feed water pump identifier is used to designate which boiler feed water
pump is being worked.
1.3 Scope
This work instruction provides instructions for the disassembly and assembly of a single stage,
pack-less boiler feed water pump. It also provides steps for the removal and installation of
subsystems. Various inspections, cleaning and lubrication information is also provided.
A. Grease (for gear type coupling installation)

B. Containers (bags) for temporary storage of parts
C. Clean rags
D. Oil drain pan
E. Bearing oil (as per vendor manual)
F. Silicon grease
B-1
G. Anti seize
H. Permatex
I. Cleaning solvent (Isopropyl alcohol, acetone, act.)
J. Rubber gloves
K. Duct tape
A. Various gaskets (case to cover, bearing brackets, etc)

B. Various O-rings (Stuffing box bushing, cover, etc)
C. Various seals
1.6 Special tools
A. Chain falls, rigging, hoists, slings etc

B. Combination wrenches
C. Allen wrenches
D. Various sockets
E. Plasti-gage for bearing clearances
F. Bearing heater for coupling hub
G. Tempilstick (as per vendor manual for coupling hub)
H. Cribbing (to support rotating element, if removed)
I. Coupling puller
J. Dial indicators
K. Feeler gauges
L. Inside and outside micrometers
M. Torque wrenches (various)
N. Alignment equipment
2.0 Pre-job Brief
This work is typically performed during an outage period. However, if it can be performed with
the unit on line other considerations are reduced load operation, and working around thermally
hot components.
B-2
A. Performance of this work will open various piping systems and a major piece of plant
equipment. Appropriate measures (covering pipe ends, covering casing) should be taken
to prevent foreign material from entering the system.
A. If pump uses EPT O-Rings, they are susceptible to deterioration and failure if they come
in contact with petroleum based products.
B. Depending on material some pump shafts are susceptible to stress corrosion cracking.
Refer to vendor manual for proper chemicals that may be used on shaft.
A. Equipment Clearance Orders

B. Open Flame Permits/Hot Work Permits
C. Chemical Control
D. Transient Fire Load Permit (cleaning solvents, oil, grease, rags, etc)
work being performed.
NOTE
MFW pump prime mover may be either an electric motor or a steam driven turbine.
Prime mover shall be cleared as part of clearance/tag out boundary
B-3
A. Motor breaker or steam supply valve
B. Motor heater breaker (if applicable)
C. Pump supply valve
D. Pump discharge valve
E. Pump vent valve
F. Pump drain valve
G. Lube oil supply breaker (if applicable)
H. Lube oil supply and discharge valves (if applicable)
I. Cooling water supply and discharge valves
appropriate.

B-4
A. Rotating element
B. Coupling (as per vendor manual)
C. Wear ring
D. Bearings


F. ENSURE all rigging, hoists, chain falls, slings etc. are available and have been inspected
prior to use
4.1 Preparations
A. VERIFY clearance/tag out is correctly in place

B. LOCATE and ENSURE proper piece of equipment is being worked per the work
instruction
C. ENSURE appropriate laydown areas are prepared for temporary storage of removed
components
CAUTION
Instrumentation and associated cabling can be easily damaged. Care must be exercised
during disassembly to prevent damage to either instruments or cables.
B-5
D. REMOVE instrumentation (temperature, vibration, etc)
CAUTION
Ensure insulation does not contain asbestos. If asbestos is present, asbestos abatement
must be used to remove insulation.
E. REMOVE insulation and store appropriately

F. REMOVE any piping, equipment supports and other interferences as required
4.2 Removal of Subsystems
NOTE
Removed piping ends should be covered after removal to prevent entry of foreign
material.
A. REMOVE seal water piping (if pump covers are to be removed)

B. REMOVE instrumentation (if not previously removed)
NOTE
Oil systems may contain orifices. Care should be taken to ensure these are recognized,
marked and saved for reinstallation.
C. REMOVE oil piping (if bearing housings are to be removed)
4.3 Disassembly
NOTE
Engineering may require as found alignment data prior to disassembly.
A. MEASURE as-found coupling alignment (if required)

Horizontal offset
Vertical offset
Angular face alignment
B-6
NOTE
Matchmark spool piece to hubs. Match mark coupling hubs and diaphragm packs.
B. REMOVE coupling guard

C. REMOVE spool piece (if present)
NOTES
1. Match mark couplings prior to removal.
2. If coupling hub is to be removed from pump shaft heat will be required.
Hot work permit required.
3. Various types of coupling arrangements are used in the industry. Follow
applicable vendor disassembly instructions for removal.
D. REMOVE coupling
E. DISASSEMBLE thrust end (depending on pump design some components may or may
not be present) (Refer to vendor manual)
a. Thrust deflectors
b. Thrust bearing housing
c. Journal bearing
d. Oil seal
e. Thrust bearing assembly
f. Bearing housing bracket
g. Stuffing box (bushings, o-rings, etc)
F. DISASSEMBLE thrust end (depending on pump design some components may or may
c. Journal bearing
d. Oil seal
G. REMOVE pump cover and gasket
NOTE
If rotating element is to be removed, protective sleeves should be placed on shaft to
protect bearing surfaces.
B-7
H. REMOVE rotating element
NOTE
If impeller is to be removed, this is typically an interference fit over a drive key. Heat
will be required for removal. Obtain a hot work permit.
CAUTION
Do not exceed vendor recommendations on max temperature allowed. Rotate heat for
even distribution keeping flame away from shaft.
CAUTION
If during the removal process the impeller binds on the shaft, allow shaft and impeller
to cool and then repeat heating removal steps. Attempting to continue with removal
can damage shaft.
I. REMOVE impeller
J. REMOVE wear ring
4.3.1 Cleaning, Inspection, Lubrication
NOTE
During cleaning steps follow guidance of MSDS sheets, chemical control procedures
and temporary storage of combustible materials.
A. CLEAN parts with appropriate cleaning solution and dry with lint free rags
NOTES
1. Any worn or defective parts should be replaced.
2. If bearings are found wiped or degraded the oil sump strainer and oil drain
piping should be inspected and cleaned as required.
B. INSPECT parts for wear, erosion and corrosion

a. Rotating element
b. Casing internals
c. Bearing bracket covers
d. Bearings (inboard, outboard, thrust bearings)
e. Bearing housings
B-8
f. Oil deflectors
C. INSPECT pump shaft
a. NDT (optional based on need, UT length, PT journal bearing area, PT
under coupling area.
b. Shaft runout
c. Radial end wear ring and thrust end wear ring
d. Inboard and outboard stuffing box bushings
NOTE
All flanges and gasket surfaces should be free of dirt, grit, grease, oil or other visible
contaminants.
D. CLEAN gasket mating surfaces (honing may be required)

E. CLEAN bolts and threaded holes
F. LUBRICATE threads of studs/bolts with never seize.
4.3.2 Reassembly
A. REPLACE wear ring
***** If impeller was removed *****
NOTES
1. Proper heating of impeller requires slow even heat distribution.
2. Temperature of impeller should be monitored during heating. Do
not exceed vendor temperature limits.
B. INSTALL impeller
***** If shaft was removed *****
NOTES
1. Shaft should be rotated at various stages of reassembly to detect
any binding.
2. Pre-lube bearings before rolling shaft.
C. INSTALL pump gasket and cover
B-9
D. INSTALL rotating element (shaft and impeller)
NOTES
1. During reassembly appropriate torque techniques should be
followed.
2. Lubricate o-rings with approved lubricant prior to installation.
3. Measure bearing clearances after installation of bearings.
Clearance should be within vendor requirements.
E. REASSEMBLE thrust end (depending on pump design some components may or may
c. Journal bearing
d. Oil seal
F. REASSEMBLE thrust end (depending on pump design some components may or may
c. Journal bearing
d. Oil seal
G. ENSURE shaft rotates freely
H. CENTER rotating element axially
I. CHECK Thrust Disc Face alignment
J. ASSEMBLE outboard and inboard bearings
K. SET thrust bearing end play
L. ASSEMBLE
a. Oil deflectors
b. Stuffing box covers
c. Fill lube oil tank (vendor recommended oil)
d. Ensure shaft rotates freely
NOTE
Observe match marks
B-10
A. INSTALL coupling
B. INSTALL spool piece
C. PERFORM cold alignment
D. INSTALL coupling guard
NOTE
If boiler feed pump lube oil sense line was disconnected, backfill line to purge air
E. INSTALL subsystems
Oil piping
Seal water piping
Instrumentation
A. RELEASE clearance/tag out

B. CHECK for leaks (oil, water)
C. When pump is capable of being run
a. PERFORM vibration testing
b. MEASURE inboard and outboard bearing temperatures (vendor
recommendation)
D. Hot alignment (if required)
B-11
E. Work site cleanup
REINSTALL any interferences removed to support access to work
REINSTALL insulation
CLEAN work area to original pre-maintenance conditions
F. RETURN unused parts to storeroom

identified.
7.0 References

B. Applicable vendor technical manuals (boiler feed pump, coupling, bearings)
F. Hot work procedure
G. Storage of temporary combustibles
B-12
C
WORK PACKAGE TEMPLATE – HEAT EXCHANGER
1.0 Task Overview
1.1 Component type
This work instruction is applicable to a single pass horizontal heat exchanger. However, many
aspects are applicable to U-tube type heat exchangers.
Ensure the unique heat exchanger identifier is used to designate which heat exchanger is to be
worked on.
1.3 Scope
This work instruction provides instructions for the disassembly of a heat exchanger, cleaning,
pressure testing, repairs of tube and tube to tube sheet leaks and reassembly.
A. Container (bags) for temporary storage of studs and nuts

B. Tube plugs (type as specified by vendor)
C. Isopropyl Alcohol, Acetone or DI water
D. Clean rags
E. Thread Lubricant
F. Flat scraper
G. Emery cloth
H. Marker to identify problem tubes
I. Buckets
C-1
A. Gasket material
B. Studs
C. Nuts
D. Washers
E. Zincs (if applicable)
1.6 Special tools
A. Rotary grinder, with bits and disks

B. Stainless steel brush
C. Eyebolts, slings chokers, come-a longs
D. Endplate removal fixture (if specified for the heat exchanger)
E. Tube cleaning equipment (pump, hoses, cleaners)
F. Borescope (Tube fouling inspection if required)
G. Leak testing equipment
H. Rolling tool
I. Torque wrenches
J. Wooden blocks to support end plate of hinge type design
K. Pop-a-Plug hydraulic equipment (if this method of tube plugging is used)
L. Lighting (Low voltage or GFIC protected)
M. Ventilation fans (if needed)
N. Personal protective equipment (hard hat, eye glasses, safety shields, gloves, breathing
dust masks, etc)
2.0 Pre-job Brief
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. Load reduction may
be required to perform heat exchanger maintenance. Ensure running equipment has adequate
flow to ensure proper cooling of the equipment. Running equipment should be monitor
frequently, especially following removal of the heat exchanger. Running equipment
temperatures should be stabilized prior to disassembly of the heat exchanger in the event the heat
exchanger must be returned to service.
C-2
A. House keeping should be maintained clean to minimize potential for safety hazards
B. All parts (nuts, bolts, washers, studs, etc) should be suitably identified and stored to
ensure proper orientation and reinstallation.
A. House keeping at the job site should be maintained to minimize the potential for foreign
material from entering the heat exchanger. The heat exchanger end bell should be
inspected for cleanliness prior to closure.
A. Unnecessary personal safety hazards may result if proper housekeeping is not maintained.
B. Tube cleaning equipment operates under extremely high pressure and can cause serious
personal injury. Personnel operating tube cleaning equipment should be trained and
familiar with operating of equipment.
C. Ensure the end of the heat exchanger where cleaners are shot out is appropriately covered
to prevent personal injury due to a missile.
D. Work area should be roped off or marked appropriately for hazards present on the job.
E. Tube cleaning equipment shall have a “deadman’s” switch controlled by the operator.
F. Cleaning solvents can be volatile. Ensure MSDS (Material Safety Data Sheets) have been
reviewed and appropriate guidance followed for the handling, temporary storage and
disposal on any applicable materials used.
G. Some heat exchanger fluid systems contain various corrosion inhibitor chemicals. MSDS
sheets should be reviewed for any applicable precautions and requirements.
H. Ensure any load lifting equipment is in good repair and of proper load bearing size for
loads to be lifted.
I. Nuts, bolts, studs, washers and any disassembled parts should be identified and stored
properly to ensure control and availability for reinstallation.
A. Define appropriate Clearance/Tag Out boundary and ensure all planned work activities
are with in the identified clearance/tag out boundary.
B. Identify if any chemical use permits are required for special chemicals or solvents.
(Chemical Control Procedure, Material Safety Data Sheets)
C. Transient fire loads should have appropriate permits.
C-3
2.5 Identify Environmental Considerations
A. Review appropriate MSDS sheets and in-house chemical use procedures for any special
chemicals or solvents used.
B. Identify reporting limits and requirements for any accidental release of chemicals or
solvents to the environment
C. Identify and special handling or temporary short-term storage requirements for any
specials chemicals or solvents required.
D. Some heat exchangers contain corrosion inhibitor chemicals. When draining heat
exchangers ensure MSDS sheets are reviewed for any applicable precautions and
requirements.
2.7 Identify Clearance/Tagout Boundary
A. Inlet and outlet valves and bypass valves for the tube process fluid
B. Inlet and outlet valves and bypass valves for the shell process fluid
C. Tube side drain and vent valves
D. Shell side drain and vent valves
E. Power to electronic corrosion control equipment (if applicable)
A. Tube plugging activities

B. Tube to tube sheet leak repairs
C. Coating repairs
D. Corrosion/Erosion repairs
C-4
C. Contact vendor for any clarification of vendor information or additional vendor
D. Engineering should be notified of any erosion/corrosion problems identified

A. Tube plugs (type as per vendor)

B. Coating materials


4.1 Disassembly:
A. ENSURE FME requirements are in place, work area is clean and appropriate work
boundaries have been established
B. REMOVE insulation if heat exchanger has insulation on heat exchanger channel heads
end plates to allow access to studs.
C. STORE insulation for personal safety and preservation of insulation.
C-5
CAUTION
Heat exchanger end plates are extremely heavy. Ensure lifting equipment is
appropriate for load being lifted. If end plate is moved to a location for temporary
storage, ensure it is adequately secured to prevent accidental rolling or tipping.
NOTES
1. Some end plates require special lifting rigs. Refer to vendor manual.
2. Some end plates are on hinges. When end plate is swung open ensure blocks
are positioned under end plate to minimize forces on the hinges.
3. Results of inspection could require scope change to the work instructions to
correct identified discrepancies
D. REMOVE end plate studs and remove end plates at each end of heat exchanger.
E. SECURE end plates to an adequate fixture.
F. REMOVE and discard end plate gaskets
CAUTION
Lighting should be either low voltage or protected by Ground Fault Circuit Interrupter
(GFCI)
NOTES
1. Establish any Confined Space Work requirements if applicable.
2. 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.
G. INSTALL adequate lighting in heat exchanger

H. PERFORM inspection of heat exchanger
a. Corrosion
b. Erosion
c. Fouling
d. Coatings
e. Zincs
f. Debris or foreign material
g. General cleanliness
h. Evidence of vibration (chafing, score marks, bright metal, weld cracks, etc)
i. Leak indications beneath Heat exchanger or else where
j. Tube plug degradation (improper installation, looseness, missing)
k. Tube end splitting
C-6
l. Failed or cracked welds
m. Vibration damage
4.2 Cleaning:
NOTES
1. Some cleaners have limited lifetime (10-15 shootings) Ensure adequate
number of cleaners is available.
2. Appropriate ventilation and/or personal safety equipment may be
A. REMOVE all loose corrosion from tube sheet and inside surface of heat exchanger
B. CLEAN tubes using tube cleaning system or hyrolazing equipment.
C. ENSURE all cleaners are removed from heat exchanger following cleaning if used
D. CLEAN heat exchanger channel heads
4.3 Heat Exchanger Testing:
NOTES
1. Heat exchanger testing for tube integrity can be performed by either
Eddy Current Testing (ECT) or performance of a leak test.
2. Leak tests can be performed using system pressure or with leak test
equipment using either water. Air, helium etc.
A. PERFORM ECT (Typically a function of specialized ECT personnel)
***** “OR” *****
4.3.1 Leak Testing
4.3.1.1 Leak Testing using System Pressure
A. OBTAIN temporary lift of clearance/tag out boundary on shell side of heat exchanger.
B. PRESSURIZE slowly (fill and vent) shell side of heat exchanger to system pressure.
C. MAINTAIN heat exchanger shell side at system pressure for approximately 30 minutes
D. INSPECT tube sheet for leaks
E. RECORD any leaks identified and characterize as to whether the leak is a tube or tube to
sheet leak
C-7
F. RELIEVE system pressure slowly
G. RE-ESTABLISH clearance boundaries
4.3.1.2 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. OBTAIN necessary temporary lifts on clearance/tag out to install pressure testing

equipment
B. INSTALL a relief valve with a set pressure less than or equal to design pressure of shell
or tube design pressure, whichever is lower
C. 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.
D. ATTACH pressure gage to leak testing equipment

E. INSTALL pressure testing equipment
F. PRESSURIZE HX to test pressure
G. MAINTAIN heat exchanger shell side at system pressure for approximately 30 minutes
H. INSPECT tube sheet for leaks
I. RECORD any leaks identified and characterize as to whether the leak is a tube or tube to
sheet leak
J. RELIEVE system pressure slowly
K. REMOVE pressure testing equipment
L. INSTALL original equipment clearance/tag out boundary
4.4 Leak Repairs
4.4.1 Tube to Tube-Sheet Leaks
A. MEASURE inside diameter (ID) of problem tubes

B. COMPARE ID of problem tubes to acceptance criteria
C. IF ID is less than acceptance criteria THEN:
C-8
a. CLEAN inside diameter of problem tubes (depth determined by vendor manual)
CAUTION
Do not damage tube sheet or coatings during cleaning process
b. ROLL each tube to acceptance criteria

c. MEASURE ID of rolled to verify acceptance criteria
D. PERFORM leak test again after all problems tubes are rolled and meet acceptance
criteria.
E. IF ID was greater than acceptance criteria THEN REFER to engineering for appropriate
corrective actions to take for repair.
4.4.2 Tube leaks
NOTES
1. Tube maps should be generated to show which tubes have been
plugged.
2. Ensure adequate plugging margin for the heat exchanger will not
be exceeded after plugging operations.
3. There are various types of tube plugs; driven plugs, welded plugs,
Pop-a Plugs. Refer to vendor manual for type of plug to use.
4. If tube stabilization is required (e.g. rod or wire stabilization)
refer to vendor manual.
A. IDENTIFY problem tubes to be plugged
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, heavy hammering may result in damage to tube sheet.
C. INSTALL tube plugs into each end of the problem tubes
C-9
NOTE
Leak tests should be re-performed following any tube or tube to tube sheet leak repair.
4.5 Reassemble Heat Exchanger
A. REMOVE all tolls, equipment, etc from heat exchanger channel head
B. CLEAN the inside surfaces of the heat exchanger channel heads
C. VERIFY heat exchanger channel heads are free of foreign material and other objects
CAUTION
Do not damage gasket sealing surfaces during cleaning process.
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. VERIFY sealing surfaces are free of foreign material and no leak paths exist.
F. CLEAN threads on studs and bolts to remove foreign material, rust, corrosion and burrs
G. VERIFY threads and studs are clean and damage free
H. INSTALL a new gasket
I. POSITION end plate to heat exchanger channel head flange
J. INSTALL all studs and nuts and snug tight
K. TORQUE flange nuts as required (refer to vendor tech manual)
A. RELEASE clearance/tag out for return to service (Operations)

B. VERIFY no leaks observed at sealing services
C. INSTALL insulation (if applicable)
D. CLEAN work area
E. DISPOSE of any special chemicals or solvents used appropriately
F. RETURN unused parts to stores
C-10
Identify mechanism to provide work order feedback for improvements and errors.

identified.
C. Ensure tube plugging maps are updated
7.0 References
Identify typical references needed to perform the identified work
A. Heat Exchanger Vendor Tech manual

B. Tube cleaning or Hydrolazing Equipment Tech Manual
C. Tube Plugging Instruction
D. Tube Sheet Map
E. Tube Rolling Instruction
F. Material Safety Data Sheets
G. Chemical Control Procedures
H. Foreign Material Control
I. Corrosion Control
C-11
D
WORK PACKAGE TEMPLATE – LOW VOLTAGE
BREAKER OVERHAUL
NOTE
This work instruction is written based on a generic low voltage breaker overhaul.
Breaker design varies by manufacturer. This work template is based on information
associated with Westinghouse, General Electric and ABB low voltage circuit breakers.
Various components listed in each subsection may or may not be installed on a given
breaker. Refer to specific breaker technical manual for components installed.
CAUTION
Refer to specific vendor manual for breaker being overhauled.
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.
1.0 Task Overview
1.1 Component type
This work instruction is applicable to Low Voltage breakers (typically 225 – 600 VAC).
Ensure the unique breaker identifier is used to designate which breaker is to be worked on.
1.3 Scope
This work instruction provides instructions overhaul of Low Voltage breakers (225 – 600 VAC).
D-1
A. Light oil Lubricant (Vendor approved)

B. Cleaning brushes (no metal)
C. Clean lint free rags
D. Soft bristle brush (Non metal)
E. Approved solvent or isopropyl alcohol
F. Degreasing solvent (vendor approved e.g. Varsol)
G. Silver plate cleaner for contacts (vendor approved e.g. Tarnex)
H. Glass cleaner (ammonia based)
I. Anti-oxidizing lubricant
J. Scotch-brite
K. Fine sandpaper
L. Molybdenum Disulfide
NOTE
The part list is based on parts that would be replaced during a typical breaker
overhaul regardless of breaker manufacturer.
A. Stationary and Moving main contacts

B. Arc chutes
C. Auxiliary switch
D. Shunt trip device and shunt coils
E. UV device and coil
F. Various fasteners, clips, etc (Typically supplied as kits)
G. Spring assemblies
H. Operating mechanism components (Oscillator assembly, motor cutoff switch lever, trip
shaft return spring)
1.6 Special tools
A. Proper breaker lifting device/hoist

B. Flat, low dolly for breaker transport
C. Power supply (appropriate voltage to check breaker control components)
D. Multimeter (to measure control circuit voltages and low resistance)
E. Vacuum cleaner
D-2
F. 500 to 1000 volt megger
G. Breaker Rack Out Tool/Wrench
H. Overcurrent trip device test set (with timer)
I. Amptector Trip Unit Test Set
J. Spring force scale (~ 50 oz)
K. Electrician’s tools (sockets, combination wrenches, screwdrivers, pliers, etc)
L. Feeler gauges
M. Dial Caliper
N. Extra fine files
2.0 Pre-job Brief
A. Operations must be notified of impending breaker to be removed for maintenance.
A. Housekeeping at the job site should be maintained to minimize the potential for foreign
material from entering the MCC/LCC or associated buss work.
B. Work area should be roped off to preclude personnel from entering a potential shock
hazard area and temporary storage of removed breaker baskets/buckets.
A. There are potential hazards of electrical shocks and/or burns whenever working in or
around electrical equipment. Awareness to electrical hazards should be observed in the
field, or at the workbench/test area.
B. Appropriate Personal Protective equipment should be worn to preclude shock or arc flash
injuries. (As per Facility Electrical safety Manual, NFPA 70E, OSHA, etc)
C. 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. When working inside a breaker, always keep hands clear of moving breaker parts.
E. Never place hands inside a breaker until the breaker closing springs have been verified to
be DISCHARGED.
F. Ensure hands, tools, test leads and other objects are clear of any moving breaker parts to
prevent injury to personnel or damage to the breaker.
G. Do not insert a breaker into the cubicle unless the arc chutes are installed.
D-3
H. A breaker lifting device/hoist should be used to remove and install a breaker from its
cubicle.
I. A low dolly should be used to move the breaker to its work location to prevent the
possibility of tipping.
J. Older breakers may have arc chutes that contain asbestos. The presence or absence of
asbestos should be verified prior to performing any work on arc chutes.
D-4
A. Specific breaker to be clean and inspected

B. Control power fuses (if required)
A. Defective parts identified in breaker inspection

C. Contact supervision if any problem is identified that prevents following work instructions

A. Complete spare breaker (Tested)

B. Complete spare Operating Mechanism

Prerequisites to starting maintenance
D-5
F. RECORD cubicle number, breaker serial number, model, type of overloads and breaker
nameplate data.
NOTE
Frequency of overhaul for low voltage circuit breakers depends on the environment
and operating conditions. Frequency may be between 1 – 3 years depending on
conditions. Factors affecting frequency include: high humidity, high ambient
temperature, dusty or dirty atmosphere, corrosive atmosphere, frequency of switching
operations, frequency of fault operations, and age of equipment.
4.1 Initial Testing and Inspections
A. (If installed) VERIFY breaker is open and closing springs discharged.
NOTE
Do not use excessive force when racking out breaker.
B. CHECK for smooth roller operation during breaker removal.
NOTE
Use appropriate lifting device to remove breaker from cubicle.
CAUTION
Voltage will be present at switchgear bus stabs.
C. REMOVE breaker from cubicle.
NOTE
Draw out interlocks vary by vendor (Most common are listed)
D. CHECK drawout device interlocks (if installed)

a. Racking mechanism (levering) interlock
D-6
b. Trip Interlock
c. Manual Lockout device check
d. Closing spring interlock
e. CONNECT, TEST, DISCONNECT, REMOVE interlocks
E. INSPECT the general condition of the breaker.
a. Dirt, dust
b. Grease hardening, darkening
c. Cracking
d. Melting
e. Burn marks
f. Broken, bent, missing parts
a. Corrosion
F. REMOVE Arc chutes
a. Burning
b. Cracks
G. INSPECT Pole unit bases
a. Dirt
b. Carbon Tracks
c. Cracks
4.2 Mechanical/Electrical Operation
NOTE
If breaker has a undervoltage (UV) device it must be energized or mechanically
defeated.
A. MANUALLY CYCLE breaker several times and check for smooth operation.
B. CHECK operation of breaker indicators and breaker operation counter.
C. ELECTRICALLY CYCLE breaker and check for smooth operation and excessive arcing
in electrical devices.
D-7
4.3 Contact Inspections and Adjustment
CAUTION
Some tests in this section require opening and closing of breaker. Ensure hands, test
instruments and cables and other devices are clear of moving parts.
A. INSPECT breaker contacts

a. Cracking
b. Burning
c. Heat stress
d. Excessive scarring/galling
e. Corrosion
f. Pitting
g. Discoloration (Over heating)
h. Silver plating for flaking or peeling
i. Repair or replace any damaged or degraded components
j. Measure contact tips for wear (replace if less than vendor recommendation)
NOTE
Refer to vendor specification for contact gap.
CAUTION
If gap adjustments are required care should be taken not to over adjust. Over
adjusting will increase closing force
B. Gap Adjustments
a. Contact gap – MEASURE and adjust as required (As per vendor technical
manual)
b. Contact sequence gap – MEASURE and adjust as required (As per vendor
technical manual)
D-8
4.4 Operating Mechanism Inspection
A. INSPECT operating mechanism
a. General cleanliness (dirt, dust, corrosion, etc)
b. Loose, broken parts
c. Loose, missing retainers, snap rings, etc
d. Wear and binding in mating surfaces
e. Latch and roller surfaces for wear
CAUTION
Tests require opening and closing of breaker. Breaker contacts open quickly. Ensure
hands and equipment are clear of moving parts.
f. Trip bar or shaft

1. Freedom of movement
2. Determine trip force
g. CHECK Operating mechanism alignment
h. CHECK Arc contact alignment
i. CHECK tripping load
4.5 Electrical Tests
NOTE
1. Refer to vendor manual for electrical devices installed and to be tested.
2. Refer to vendor manual to acceptance criteria.
CAUTION
Do not measure insulation resistance of a solid state Over Current Trip Device
(OCTD).
D-9
A. MEASURE Primary circuit insulation resistance (Line to Load, Phase to Ground, Phase
to Phase)
B. MEASURE Control Wiring insulation resistance
C. MEASURE Contact resistance (Each phase)
D. MEASURE Undervoltage (UV) Device Pickup
E. CHECK Control Circuit
F. CHECK Shunt Trip Device
NOTE
Overcurrent device may be electro mechanical or solid state.
G. CHECK Overcurrent Trip Device

a. Long time delay
b. Short time delay
c. Instantaneous
d. (If installed) Ground fault test
e.
NOTE
Breaker disassembly differs by breaker and vendor. Refer to vendor manual for
specific disassembly information.
4.6 Disassembly
A. Primary disconnects
B. Secondary disconnects
C. Frame assembly – charging motor, closing springs, trip shaft/bar
D. Pole unit bases
E. Contact structure – stationary, moving contacts
NOTE
Not all breakers have the auxiliary components listed. Refer to vendor technical
manual for specific components installed on breaker being overhauled.
D-10
F. REMOVE auxiliary subcomponents
a. Auxiliary switch
b. Control relay
c. Closing solenoid (solenoid operated breakers)
d. Bell alarm device
e. Amptector unit (if installed)
f. Anti-pump relay
g. Reset micro switch
h. Shunt Trip Device
i. Undervoltage (UV) Trip Device
j. Electric lockout device
k. Fuse Trip Device
l. Current limiting fuses
m. Reverse current trip attachment
n. Closing spring release device
o. Motor cutoff switch
p. Latch check switch
G. REMOVE operating mechanism
4.7 Inspections, Tests, Cleaning and lubrication
NOTE
1. Parts should be cleaned with an approved cleaning solvent or isopropyl alcohol

and clean lint free rags.
2. Damaged or degraded parts below vendor acceptance criteria should be
replaced.
CAUTION
Some older arc chutes contain asbestos. So not sand or attempt repair unless arc
material is known.
A. INSPECT/CLEAN arc chutes

a. Burns
b. Cracked ceramic
c. Carbon deposits
d. Erosion
D-11
B. INSPECT/CLEAN/LUBRICATE primary disconnects
a. Overheating
b. Excessive/abnormal wear
c. Broken/weak springs
C. INSPECT/CLEAN/LUBRICATE secondary disconnects
a. Cracks
b. Damage around mounting holes
c. Move without binding
D. INSPECT/CLEAN frame assemblies
a. Corrosion
b. Bends
c. Cracked welds
E. INSPECT/CLEAN contact structure
a. Contacts for pitting, corrosion, loss of silver plating
b. Contact springs for corrosion, damage or excessive heat
F. INSPECT/CLEAN pole unit bases
a. Cracks
b. Burns
c. Carbon tracks
d. Warping
e. Overheating
NOTE
During disassembly of the operating mechanism it is recommended that notes, scribe
marks and other aids be used to aid in ensuring that the subcomponents (spacers,
retainers, bearing, etc. are reassembled correctly.
CAUTION
Handle bearings carefully.
G. INSPECT/CLEAN operating mechanism

a. Remove components from shaft working from one end towards middle
b. Springs – inspect for breaks, cracks, weakness, and other defects.
c. Bearings – proper lubrication, freedom of movement
d. Latches – Wear, cracks
e. Trip bar/shaft – freedom of movement
f. Pins – cracks, worn, alignment through linkages
D-12
g. Welds – cracks
h. General appearance – corrosion
i. (If installed) Levering device – wear, damage
NOTE
Not all breakers have the auxiliary components listed. Refer to vendor tech manual for
specific components installed
H. INSPECT auxiliary subcomponents

a. Auxiliary switch
1. CHECK for proper operation
2. CHECK insulation for cracks, discoloration or other defects
3. MEASURE contact resistance
4. DISASSEMBLE and clean switch
5. REPLACE contacts if badly burned or pitted
6. REASSEMBLE switch
b. Closing solenoid (solenoid operated breakers)
1. INSPECT coil
2. MEASURE coil resistance
INSPECT/DISASSEMBLE/CLEAN Control Relay
1. INSPECT for freedom of movement
2. INSPECT insulation for cracks, discoloration or other defects
3. DISASSEMBLE/CLEAN coil
4. INSPECT coil for signs of overheating
6. INSPECT plastic components for cracks
7. INSPECT control relay arc chutes (cracks, erosion, carbon deposits)
8. INSPECT plunger core for distortion or warping
9. INSPECT contacts for burning and pitting
b. INSPECT/DISASSEMBLE/CLEAN Shunt trip device
c. DISASSEMBLE/CLEAN coil Inspect Wiring and connections
1. Cracks/brittleness
2. Pinched wires
3. Broken wires
4. Loose connections
5. Broken lugs
d. INSPECT/CLEAN phenolic covers, insulated pushrods, etc.
1. Cracks
D-13
2. Carbon tracking
3. Dirt/dust/grease
e. INSPECT/DISASSEMBLE/CLEAN Undervoltage (UV) device
2. INSPECT for overheating
3. MEASURE UV coil resistance
4. INSPECT latch, latch pin and trip lever for excessive wear
6. LUBRICATE/REASSEMBLE UV coil
f. INSPECT Electric Lockout device
4. INSPECT coil for signs of overheating
g. INSPECT Bell alarm device
1. INSPECT for freedom of operation
h. Primary fuses
1. VERIFY proper type
2. VERIFY proper rating
3. CLEAN outside of fuse
i. Fuse trip device
1. DISASSEMBLE the device
3. REASSEMBLE, LUBRICATE friction points
j. Solid State Overcurrent Trip Device (SS OCTD) actuator
2. MEASURE actuator coil resistance
3. INSPECT plastic components for cracks
4. ENSURE permanent magnet has sufficient strength to hold device in
reset position
k. Solid state current sensor
1. INSPECT for overheating
2. INSPECT wiring for cracks and other visible damage
3. CLEAN terminations
l. Electro-mechanical overcurrent trip device
1. INSPECT the device for corrosion, defective parts, missing or defective
springs, magnet lamination separation
2. CLEAN the trip device
3. REMOVE and clean reset valve and filter
4. LUBRICATE moving parts
m. CLEAN/INSPECT Anti-pump relay
1. Freedom of operation
2. Contacts – pitting, burns, excessive wear
3. MEASURE coil and contact resistance
4. LUBRICATE friction points
D-14
n. CLEAN/INSPECT Reset Micro switch
o. CHECK Overcurrent trip Switch
1. Freedom of operation
2. Insulation condition
3. Overheating of coil
4. Plastic components – cracking
5. Plunger – distortion
6. Contacts
7. LUBRICATE friction points
4.8 Reassembly
NOTE
1. Refer to notes taken during disassembly to aid in reassembly
2. During reassembly frequent checks should be performed to ensure all
components installed operate freely without binding.
3. Use a mixture of isopropyl alcohol with molybdenum disulfide for lubricating
various components. (Pivot points, bearings, bushings, sliding points, etc) As
per approved by vendor technical manual.
4. During any lubrication, old lubricant should be removed prior to applying new
lubricant.
CAUTION
During reassemble keep hands clear of moving parts
CAUTION
Do not allow lubricants to be deposited on latch faces
D-15
CAUTION
Do not lubricate Overcurrent devices
A. Operating Mechanism
a. LUBRICATE the following components
1. Latch faces
2. Trigger faces
3. Trip pan felt pad
4. Trip bar/shaft pivot points and bearing surfaces
5. Spring charge indicator
6. Cam surfaces
7. Closing spring pins
8. Oscillator bar/bushing
b. REPLACE all retainers/fasteners
c. INSTALL operating mechanism on breaker platform
d. ALIGN and INSTALL closing solenoid assembly
e. INSTALL contact structure (Main stationary and moving contacts)
f. INSTALL Pole Unit bases
g. INSTALL frame assembly – operating mechanism, levering device, closing
springs, charging motor, trip shaft/bar, frame rollers
NOTE
1. For a given breaker not all subcomponents will be present based on individual
vendor design.
2. Refer to vendor technical manual for installation sequence of subcomponents to
prevent interferences.
3. Refer to vendor technical manual for any required specification, measurements
or clearances that are required during installation
B. INSTALL Auxiliary Subcomponents

a. Auxiliary switch
b. Control relay
c. Closing solenoid (solenoid operated breakers)
d. Bell alarm device
e. Amptector unit (if installed)
f. Anti-pump relay
g. Reset micro switch
h. Shunt Trip Device
i. Undervoltage (UV) Trip Device
j. Electric lockout device
k. Fuse Trip Device
D-16
l. Current limiting fuses
m. Reverse current trip attachment
n. Closing spring release device
o. Motor cutoff switch
p. Latch check switch
C. INSTALL primary disconnects
D. INSTALL secondary disconnects
4.9 Post overhaul Inspections, Adjustments and Tests
A. Mechanical Inspections and Tests
CAUTION
If gap adjustments are required care should be taken not to over adjust. Over
adjusting will increase closing force
CAUTION
Tests require opening and closing of breaker. Ensure hands, test instruments and
cables and other devices are clear of moving parts.
a. Contact gap – MEASURE and ADJUST as required (As per vendor technical
manual)
b. Contact sequence gap – MEASURE and ADJUST as required (As per vendor
technical manual)
c. Operating mechanism – CHECK tripping load, alignment check
d. UV Device – CHECK clearances, gap measurement and operation
e. Fuse Trip device – MEASURE and ADJUST device
f. Shunt Trip device – MEASURE clearance between trip bar and trip lever
g. Reverse Current Trip – CHECK operation and armature travel
h. CHECK Trip latch overlap
i. CHECK Drawout device interlocks
B. Electrical Inspections and Tests
NOTE
For megger voltage refer to vendor technical manual.
D-17
CAUTION
Do not megger wiring of Solid State Trip Unit
a. Wiring insulation resistance measurements (Megger except contacts)

1. MEASURE Primary circuit insulation resistance (Line to Load, Phase to
Ground, Phase to Phase)
2. MEASURE Control circuit insulation
3. MEASURE Contact resistance (Multimeter)
b. TEST Under Voltage Device – CHECK Dropout and breaker closure
c. TEST Control Circuit – CHECK for proper operation
d. TEST Shunt Trip Device – VERIFY trip function
e. TEST Bell alarm – VERIFY proper operation
f. 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.
CAUTION
Refer to vendor technical manual for proper test currents when testing overcurrent
trip devices. Excessive test currents will pit contacts.
g. Electro-mechanical Overcurrent Trip Device

1. REMOVE current limiting fuses
2. INSTALL test bar
3. CHECK electro-mechanical overcurrent trip device – Proper operation
and travel, long time delay, short time delay, instantaneous trip)
4. ADJUST electro-mechanical overcurrent settings to vendor specification
as required.
NOTE
Depending on Amptector installed it may be necessary to defeat either/both, ground
fault elements and discriminator circuits. Refer to Amptector vendor technical manual
for SS OCTD unit installed.
h. Solid State Overcurrent Trip Device (SS OCTD)

1. VERIFY settings, wiring and connections
2. CHECK SS OCTD – Proper operation and travel, long time delay, short
time delay, instantaneous trip)
D-18
3. ADJUST SS OCTD unit settings to desired specification as per vendor
manual
i. (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.
CAUTION
Refer to vendor technical manual for proper test currents when testing overcurrent
trip devices. Excessive test currents will pit contacts.
4.10Final Breaker Assembly
NOTE
Catch debris removed from contacts.
A. REMOVE any debris deposited on contacts form breaker overcurrent testing

B. INSTALL arc chutes and insulators
C. PERFORM final breaker visual inspection for loose components, damaged wiring,
etc.
A. MANUALLY OPERATE breaker to verify proper operation during open and close
operation.
B. VERIFY breaker indications reflect proper status of breaker.
C. VERIFY breaker cannot be closed with UV device de-energized.
D. CONDUCT electrical testing to confirm no short circuits were created during inspection
or maintenance.
E. REMOVE all test leads and equipment from breaker.
F. INSTALL breaker in cubicle test position
G. ELECTRICALLY CYCLE breaker in the test position open and close to verify correct
operation
H. (If installed) VERIFY any key interlocks or mechanical interlocks are functioning
properly
I. CLEAN work area
J. DISPOSE of any special chemicals or solvents used appropriately
K. RETURN unused parts to stores
D-19

identified.
7.0 References
A. Breaker Vendor Tech manual

B. Applicable wiring drawings
C. Facility Electrical Safety Manual
E. Chemical Control Procedures
F. Foreign Material Control
D-20
E
WORK PACKAGE TEMPLATE – MOTOR CONTROL CENTER/LOAD
CONTROL CENTER (MCC/LCC) INSPECTION AND CLEANING
1.0 Task Overview
1.1 Component type
This work instruction is applicable to 480 volt Load Center Breakers, starters, Motor Control
Center/Load Control Center (MCC/LCC) cubicles/cabinets, and buss work and hardware.
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.
1.3 Scope
This work instruction provides instructions for the cleaning and inspection of 480 volt
MCC/LCC Breakers, starters, MCC/LCC cubicles/cabinets, and buss work and hardware.
A. Electrical contact cleaner (non-residue)

B. Cleaning brushes (no metal)
C. Clean rags
D. Approved cleaner (non-residue)
A. Light bulbs
B. Power and control fuses
C. Starter contactor kits
1.6 Special tools
A. Analog Multi-meter
B. Low resistance Ohm Meter
E-1
C. Electrician’s Tool Box
D. Vacuum cleaner
E. 500 to 1000 volt megger
F. Breaker Lifting device
G. Breaker Rack Out Tool
2.0 Pre-job Brief
A. Operations must be notified of impending Load Center Work with sufficient time to place
alternate equipment into operation or realign power supplies.
A. 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.
B. Work area should be roped off to preclude personnel from entering a potential shock
hazard area and temporary storage of removed breaker baskets/buckets.
A. There are potential hazards of electrical shocks and/or burns whenever working in or
around electrical equipment
B. Appropriate Personal Protective equipment should be worn to preclude shock or arc flash
injuries. (As per Facility Electrical safety Manual, NFPA 70E, OSHA, etc)
C. Personnel working on breakers should have received the proper training and be qualified
to work on this equipment.
D. Use of compressed air is not recommended for cleaning. Compressed air only distributes
contaminants to other surfaces. If air is used, remove arc covers from contactors and seal
openings to control circuits present. Compressed air should also be dry and free from oil
E. Many vendors do not recommend burnishing contacts. The filing of contacts removes the
silver finish and shortens useful life. Emory cloth should not be used to burnish contacts.
E-2
C. Transient fire loads should have appropriate permits.
A. Specific breaker to be clean and inspected

B. Control power fuses (if required)
C. MCC/LCC supply breaker (If MCC/LCC is being cleaned)
A. Defective parts identified in breaker inspection

B. Defective parts identified during starter inspection
C. Defective parts identified during bus work inspection
E-3

C. Contact supervision if any problem is identified that prevents following work instructions

A. Overload heaters
B. Starter coils
C. Pushbuttons
D. Switches
E. Terminal blocks
F. Complete starter kits

Prerequisites to starting maintenance

NOTE
Frequency of maintenance for low voltage circuit breakers depends on the
environment and operating conditions. Frequency may be between 1 – 3 years
depending on conditions. Factors affecting frequency include: high humidity, high
ambient temperature, dusty or dirty atmosphere, corrosive atmosphere, frequency of
switching operations, frequency of fault operations, and age of equipment.
E-4
NOTE
If breaker has experienced a fault a thorough inspection of the breaker should be
performed prior to returning it to service.
NOTE
It is cost effect to perform load center cleaning with basket/bucket maintenance.
4.1 Load Center Breaker Clean and Inspect
CAUTION
Check the line side of the breaker for voltage. If voltage is present use extreme caution.
NOTE
If working around energized low voltage equipment appropriate electrical safety
equipment should be worn. (e.g. gloves, eye protection)
NOTE
If an arc has occurred in the breaker compartment it is possible some organic
insulating materials may have deteriorated. (Evidenced by soot, debris or carbon
tracks)
A. CHECK incoming line terminals to verify that the equipment is de-energized

B. CHECK out-going terminals to ensure no feedback condition exists.
C. CYCLE breaker in test position and CHECK for undue noise or vibration that may
loosen bolted connections.
D. INSPECT the internal condition of the breaker basket/bucket.
a. Heat Stress
b. Cracking
c. Melting
d. Burn marks
e. Discoloration
f. Dirt, dust, debris
E-5
NOTE
Use of a vacuum cleaner verses air blowing is preferred. Using air to blow out a Load
Center basket/bucket typically moves dust around. Dust may settle inside relays, over
current devices or other components with contacts causing overheating or improper
operation.
E. 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. It is recommended that alcohol and Freon not be used as cleaning
agents.
F. CLEAN inside of basket/bucket using and approved solvent or contact cleaner. WIPE
bus bars, insulators, cables, etc.
G. INSPECT bucket/basket interior for moisture, condensation build-up or signs of
previous wet conditions.
H. REPAIR any identified sources showing in leakage.
I. INSPECT the bucket/basket interior for any signs of overheating or discoloration.
J. INSPECT load center basket/bucket components for any signs of visibly worn, cracked
or missing parts.
a. INSPECT Breaker for:
i. Broken disconnects
ii. Bent or damaged interlock arms
iii. Missing components
iv. Line and load connections for overheating
v. Line and load connections for missing or defective parts
vi. MANUALLY OPERATE to ensure freedom of movement
b. INSPECT Starter
i. Wiring
ii. Contacts
iii. Freedom of movement of electrical contactors
c. CHECK Fuses
i. Proper size (rating)
ii. Proper voltage
iii. Fit into clips snuggly with no damage or deterioration
iv. If fuses are in a holder, blades fit securely into stabs
v. Discoloration
vi. Corrosion
d. INSPECT Aux contacts
i. Burns
ii. Discoloration
iii. Pitting
E-6
iv. Corrosion
v. Resistance checks
e. INSPECT Insulators
i. Cracks
ii. Electrical tracking
f. INSPECT Arc chutes
i. Chipped or broken components
ii. Pitting
iii. Burning
K. REPAIR or REPLACE any damaged or degraded parts
NOTE
If desired and Insulation resistance test may be conducted during the wiring
inspection.
L. INSPECT internal load center basket/bucket wiring

g. Tightness
h. Cracked or flaking insulation
i. For chafing against metal surfaces during vibration
j. Discoloration
k. Corrosion
l. Broken/cracked lugs
m. (If warranted) MEGGER wiring to determine condition of circuit breaker
insulation to ground and phase to phase.
M. REPAIR or REPLACE and damaged or degraded components.
N. CLEAN and INSPECT instrumentation and controls
a. Pushbuttons, switches, meters, lights, control devices etc
i. Damage (missing/broker parts)
ii. Proper ratings
iii. Loose connection
iv. Deterioration
v. Switches move freely and are in good working order
O. REPAIR or REPLACE any damaged or degraded components.
P. Breaker Operating Mechanism
a. CLEAN mechanism
b. CHECK for proper alignment of basket/bucket (plume and square)
c. INSPECT mechanism for any damage, excessive wear or degraded conditions.
(Cracks, loose parts (latches), distortion, missing/broken cotter pins, worn cams,
roller surfaces, etc)
d. LUBRICATE mechanism with light oil (as approved by vendor technical
manual)
E-7
NOTE
Use of contact cleaners is not recommended by some vendors because of the potential
of sticking on magnetic pole faces. Refer to appropriate vendor manual.
Q. Starter Contactor
a. INSPECT starter contacts for excessive pitting or arcing

b. HOLD A phase started contactor CLOSED.(made up state)
c. MEASURE resistance across starter contacts.
d. Reading should be less than 0.005 Ohms (typical reading)
NOTE
It is recommended that contacts be replaced in pairs to avoid misalignment and uneven
contact pressure.
e. IF reading is greater than 0.005 Ohms, THEN REPLACE contacts.

f. REPEAT (a – d) for B and C phases
R. (If applicable) TEST installed electrical accessory devices.
a. Under-voltage device
b. Shunt trip
c. Over-current device
d. Auxiliary switch contacts
4.2 Load Center Switchgear Cleaning and Inspection:
A. Prerequisites to performing maintenance

a. NOTIFY Operations prior to beginning work
b. ENSURE an appropriate clearance/tag out is in place to perform work safely
c. ENSURE all parts expected to be used are available and in hand
d. ENSURE all tools necessary to perform the job are available
e. ENSURE appropriate personal safety equipment is worn on the job
B. VERIFY by unique load center identifier that the appropriate load center is being worked
and it is appropriately tagged out.
C. (If applicable) CHECK all door interlocks for proper operation.
D. POSITION each breaker in the load center to the “OPEN” position.
E-8
CAUTION
Wear appropriate electrical protective equipment until the bus has been verified de-
energized.
E. VERIFY load center bus is de-energized (appropriate range multi-meter)

F. Breaker to Bus Resistance measurements
a. MEASURE A phase from line side of breaker to the bus bar
b. RECORD resistance reading (typical less than 0.005 Ohms)
c. REPEAT (a – b) for B and C phases
d. 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.
G. REMOVE each breaker basket/bucket.

H. TAG each load center breaker basket/bucket as to location in load center it was removed
from.
I. VACUUM thoroughly each load center cubicle slot to remove dirt and debris from
basket/bucket and rear of load center.
J. 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.
K. INSPECT MCC/LCC for any signs of wetness, condensation or leaks.

L. SEAL off any identified leaks from conduits and PROVIDE an alternate drain source.
CAUTION
Do not sand or remove any plating on any bus bar, splice bar or terminal lug.
E-9
NOTE
Some vendors do not require any servicing of bus connections for the life of the
MCC/LCC. Refer to vendor manual before making any bus changes to bus splice
joints. Ensure recommended vendor torque values are used if bus joints are tightened.
M. INSPECT all components in each load center cubical bus bars

a. Arcing
b. Burning
c. Heat stress
d. Excessive scarring
e. Corrosion
f. Pitting
g. Cracking
h. Discoloration
i. Insulating materials
j. Repair or replace any damaged or degraded components
N. INSPECT rear stabs on cubicle’s basket/bucket
a. Arcing
b. Corrosion
c. Discoloration, overheating
d. Pitting
e. Missing parts
O. INSPECT load center grounding cable
P. INSPECT seals and latches on load center rear doors.
Q. REPAIR or REPLACE defective or degraded components
R. SECURE doors on load center (Prior to energizing the MCC/LCC)
S. INSPECT exterior MCC/LCC cabinets for
a. Missing screws, bolts, nuts, fasteners, retainers and keepers
b. Rust and corrosion
c. Unused openings
d. Conduits for proper fit, no cracks or leaks
e. IF MCC/LCC is composed of multiple cabinets, THEN INSPECT sealer
between joints
T. REINSTALL each breaker basket/bucket in its proper location.
U. ENSURE the handle on each breaker is in the “OPEN” position
V. CLEAN outside of load center with vacuum and approved cleaner
A. PERFORM electrical testing to confirm no short circuits were created during inspection
or maintenance.
B. RELEASE clearance/tag out for return to service (Operations)
C. CYCLE the breaker in the test position open and close several times to VERIFY correct
operation
E-10
D. (If installed) VERIFY any key interlocks or mechanical interlocks are functioning
properly
E. CLEAN work area
F. DISPOSE of any special chemicals or solvents used appropriately
G. RETURN unused parts to stores

identified.
7.0 References
A. Breaker Vendor Tech manual

B. Applicable wiring drawings
C. Facility Electrical Safety Manual
D. NFPA 70E
E. NEMA Standards Publication No. ICS 2, Annex A (Maintenance of Motor Controllers
After a Fault Condition)
F. OSHA Standards – 29 CFR Part 1910 Subpart S - Electrical
G. Material Safety Data Sheets
H. Chemical Control Procedures
I. Foreign Material Control
E-11
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.
1.0 Task Overview
1.1 Component type
This work instruction is applicable to Limitorque SMB actuators.
Ensure the unique valve identifier is used to designate which valve actuator is being worked.
1.3 Scope
This work instruction provides instructions for cleaning, inspections, and limited setup of
Limitorque SMB actuators.
A. Lubricant, limit switch (Mobile 28, Vendor approved)

B. Lubricant, gear case (NLGI Grade 0, Vendor approved)
C. Lubricant, valve stem (Graphite type, Vendor approved)
D. Electrical-type cleaning solvent (e.g. CRC Lectra Clean)
E. Clean lint free rags
F-1
A. Gaskets
B. Seals
C. Limit switches
D. Torque switch
1.6 Special tools
A. Megger (500V to 1000V range)

B. Multimeter (volt-ohm)
C. Electrician’s toolbox
D. Drill
2.0 Pre-job Brief
A. Generation
a. 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.
b. If the valve stem is to be lubricated during the maintenance it should be isolated.
Proper lubrication requires stroking of valve to access stem threads.
B. Equipment Risk/Damage
a. Do not lift the operator by the handwheel.
b. Do not pull or force the declutch lever up or down.
c. Do not engage the declutch lever while the motor is running
d. Do not use valve wrenches or cheater bars to operate handwheel
e. Do not plug motor – alternate motor starts and stops to open or close the valve
more tightly
f. Do not pump grease into motor
g. Do not pinch wires between switch compartment cover and switch compartment
flange
C. Do not exceed motor duty cycle. (Refer to vendor manual for number of strokes per hour
for either AC or DC operated motors)
F-2
A. Performance of this work will open actuator to environment. Appropriate measures

should be taken to prevent foreign material from entering the actuator.
A. Beware of electrical hazards. Power should be removed before working on actuator or

opening limit switch compartment.
B. There is a potential for high pressure fluid, gas, etc. to be on the valve when performing
maintenance. The actuator mounting bolts should not be removed from the valve unless
the stem is secured.
C. If maintenance is being performed on the actuator while installed on the valve, ensure the
valve is not under thrust or torque load.
D. Do not remove the spring cartridge cap, housing cover or stem nut from the actuator if
the valve is under load.
E. Do not use cheater bars, wheel wrenches, pipe wrenches or other devices on the actuator
handwheel or declutch lever.
F. All MANUAL handwheel engagements must be followed by an electrical valve stroke.
G. Do not engage handwheel during maintenance activities unless direct to do so by the
work instruction or the supervisor.
H. Do not engage the handwheel unless one of the following conditions exists:
a. Valve is in the mid position
b. Valve is in the open position
c. Control switch is NOT in the closed position
I. The following actions should be avoided to prevent potential actuator/motor damage
a. Do not use oversized motor thermal overloads
b. Check limit switch settings and motor direction prior to operating the actuator
electrically following maintenance
c. Do not force the declutch lever into the motor position. The declutch lever
returns to the motor position when the motor is energized.
d. Do not depress the declutch lever during motor operation to stop valve travel.
e. 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. Do
not lift the actuator/gearbox or actuator/valve combinations with only the
eyebolts.
F-3
A. Equipment Clearance Orders

B. Chemical Control
C. Transient Fire Load Permit (cleaning solvents, oil, grease, rags, etc)
A. Power to actuator motor (at motor control center)

B. Power to space heaters if powered from other than motor source
C. Isolation valves (inlet and outlet side) of valve being worked
D. Bypass valves around isolation valves (if installed)
appropriate.
F-4


A. Limit Switch Gear Box


E. REVIEW and UNDERSTAND the scope of work before the start of any field activities.
F. 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.

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. ENSURE contact mounting screws are tight
D. NOTE as found torque switch setting
E. INSPECT base phenolic material for signs of cracking
F. ENSURE electrical connections are tight
G. ENSURE mounting bolts are tight and in good condition
H. ENSURE dial is properly aligned with actuating link
I. ENSURE dial face is not loose
J. 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
NOTES
Lubricant should be reddish to rust brown.
Lubricant viscosity should be soft to slightly fluid
1. Lubricant should not contain dirt or other contaminants
B. ENSURE lubricant level is just above the top of the small gears.
C. ADD lubricant (e.g. Mobile 28) to proper level as required.
NOTE
If lubricant was added to the top of a four train switch, lubricant in lower gear box and
cartridge assembly must be inspected.
D. INSPECT cover gasket and replace as required.
NOTES
Gasket should not protrude under finger base mounting surface. Trim as required
Do not over tighten cover mounting screws.
E. INSTALL gear box gasket and cover
4.7 Motor Termination inspection
A. INSPECT motor terminations for overheating and degradation
4.8 Install Limit/Torque Switch Compartment Cover
A. CLEAN gasket seating surfaces on compartment and compartment cover

B. INSPECT compartment cover gasket (Clean or replace)
C. APPLY a light coat of bearing grease on compartment/cover surfaces
D. 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.
E. INSTALL switch compartment gasket and cover
F-8
4.9 Main Gearcase Lubrication Inspection
A. 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. EXTRACT a representative grease sample from the worm gear and the motor pinion
gear area.
C. INSPECT grease samples for contaminants. (dirt, metal particles, water, etc)
D. IF lubricant contains dirt, water or other foreign material THEN:
i. FLUSH actuator with a degreaser/cleaner (e..g. Exxon Varsol #18)
ii. REPACK actuator with proper lubricant (e.g. NLGI-0 grade) to proper
level
NOTE
If lubricant must be must be added to achieve proper level then:
1. Main gearcase should be filled to a level that covers the worm gear.
2. Main gearcase void should be approximately 20-25% to allow for thermal
expansion.
3. Motor pinion compartment should be filled to a level that covers the motor
pinion gear.
4. Motor pinion compartment void should be approximately 40-50% to allow for
thermal expansion.
5. Ensure lubricant added is the same type lubricant currently in the actuator. Do
not mix lubricants in the actuator.
E. ADD lubricant to proper level in the main gearcase. (If required)

F. ADD lubricant to proper level in the motor pinion compartment. (If required)
G. GREASE the housing top flange and handwheel grease zerk fittings.
H. ENSURE grease relief tube is clean and free of grease (If installed)
I. INSTALL pipe plugs removed on main gear case and motor pinion compartment.
J. CLEAN and INSPECT declutch shaft and handwheeel shaft areas.
K. LUBRICATE the declutch and handwheel shaft.
CAUTION
To stoke valve it must be isolated from process stream so that process stream is not
purtubated during the lubrication process.
4.10 Valve stem lubricant Inspection
F-9
CAUTION
If valve is stroked by hand, it must stroked electrically when power is restored prior to
returning valve to service.
A. STROKE the valve as required to allow for thorough stem cleaning, inspection and
lubrication.
B. VERIFY that the Locknut is tight and properly staked.
C. CLEAN and INSPECT all accessible portions of the valve stem threads.
D. APPLY a thin coat of lubricant (e.g. Graphite type) Threads should appear slightly wet.
E. CLEAN and INSPECT the stem nut area.
F. VERIFY stem nut is tightly secured by the locknut.
G. APPLY a thin coat of lubricant to accessible threads in the stem nut area.
4.11 Motor Inspection
A. INSPECT motor leads for signs of overheating, cracked insulation, loose wires or other
damage/defects that would prevent proper operation.
NOTE
AC motors should be meggered at 1000V. DC motors should be meggered at 500V.
CAUTION
Limit switch cover should be installed prior to performing a megger on the motor.
B. MEGGER the actuator motor from the Motor Control Center (MCC).
C. ENSURE megger reading meets acceptance criteria. (Typically greater than 1 Megohm
is normal, Reference vendor tech manual)
NOTE
Phase to Phase resistance readings should be the same.
D. CHECK phase to phase resistance of the motor windings.

E. (DC motors) CHECK armature brushes for proper contact and wear
F-10
4.12 Switch Adjustments
4.12.1 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, replace the entire gear box. Do not repair
limit switch gear box.
A. VERIFY power is off.
NOTE
After valve is stroked by hand, it must stroked electrically when power is restored
prior to returning valve to service.
Note direction of Intermittent Gear Shaft for rotor to be set.
B. MANUALLY OPEN valve to the full open position

C. TURN Set Rod clockwise (CW) until it reaches the stop position.
D. The contacts on the Rotor to be set should be in the open position.
E. IF the contacts on the Rotor to be set are not in the open position THEN
a. 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.
b. The rotor is set at the correct position for contact opening.
F-11
c. GO to Step G.
F. IF the contacts on the Rotor to be set are already in the open position THEN
a. TURN the Intermittent Gear Shaft in the OPPOSITE direction noted during
performance of Step B (above) until the Rotor turns and the contacts close.
b. TURN the Intermittent Gear Shaft in the direction noted during the
performance of Step B (above) until the Rotor turns and the contacts open.
c. The rotor is set at the correct position for contact opening.
G. BACK OFF Set Rod until it stops
H. ENSURE that the Intermittent Gear Shaft is tight and will not rotate. Do not force.
I. MANUALLY CLOSE the valve to the full close position.
J. PERFORM steps (C – H) to set the tripping position on the other rotor.
4.12.2 Setting the Torque Switch
NOTE
Torque settings must be made with the switch mounted in the actuator.
CAUTION
Do not attempt to remove either the spring cartridge cap or the housing cover from the
actuator while the valve is torque seated.
4.12.3 SMB-000 Double Torque Switch
A. VERIFY power is OFF

B. LOOSEN Pan Head Screws
NOTE
The higher the torque number setting the higher the torque output of the actuator.
C. SET the striker for open or close operation. (Match the edge of the Striker with the
desired number) to the desired torque setting
D. TIGHTEN Pan Head Screws
F-12
4.12.4 SMB-00 Torque Switch
A. VERIFY power is OFF

B. LOOSEN Machine Screw
NOTE
The higher the torque number setting the higher the torque output of the actuator.
C. SET the pointer, for open or close direction torque switch, at the desired torque
setting
D. TIGHTEN Machine Screw
4.13 Replace Stem Nut
CAUTION
Do not remove the Locknut with the actuator under load or with pressure under the
valve.
4.13.1 Stem Nut Removal
NOTE
The locknut is typically staked in two places
A. LOCATE stakes and spot with a drill.

B. REMOVE Locknut
C. CLEAN up all metal particles.
NOTE
If valve is stroked by hand, it must be stroked electrically when power is restored prior
to returning valve to service.
F-13
D. MANUALLY ROTATE handwheel to close valve.
E. ROTATE Stem Nut for the remainder of the length of the valve stem, when stem nut
splines are free from Drive Sleeve.
4.13.2 Stem Nut Installation
A. Installation on Keyed Shaft

a. LOWER stem nut onto drive sleeve until Stem Nut is seated
b. INSTALL the Key
c. INSTALL the Locknut
d. STAKE in two places (180 degrees apart)
B. Installation on Threaded Shaft
a. ROTATE Stem Nut onto the shaft until the Stem Nut splines engage the Drive
Sleeve splines
b. MANUALLY ROTATE handwheel to the open valve position until the Stem
Nut is seated.
c. INSTALL locknut
d. STAKE the top threads above the locknut in two places (180 degrees apart)

B. ELECTRICALLY STROKE valve to ensure it functions properly open and closed.
C. VERIFY limits are set correctly.
D. IF valve was torque seated THEN
a. OPERATE valve electrically to seat the valve
b. ENSURE tight shutoff by tripping the torque switch contacts.
E. Work site cleanup - CLEAN work area to original pre-maintenance conditions
F. DISPOSE of any generated waste products properly.
G. RETURN unused parts to storeroom

identified.
F-14
7.0 References

B. Foreign Material Control Procedure
C. Material Safety Data Sheets
D. Chemical Traffic Control Procedure
E. Storage of temporary combustibles (transient fire loads)
F. Vendor Technical Manual
F-15
G
WORK PACKAGE TEMPLATE – ELECTROSTATIC
PRECIPITATOR
NOTE
This work instruction contains information regarding cleaning, inspection and
limited maintenance on a Dry Electrostatic Precipitator (ESP). This instruction
can be used in whole or in part based on the desired work to be performed. The
work instruction is based on a generic ESP. Some components may or may not
be present on all ESP’s. For some specific inspections and maintenance on some
components, refer to the appropriate vendor technical manual.
1.0 Task Overview
1.1 Component type
This work instruction is applicable to a dry Electrostatic Precipitator.
Ensure unique equipment identifier is used to designate which precipitator is being

worked.
1.3 Scope
This work instruction describes the cleaning, limited preventative maintenance and
testing of an ash collecting precipitator.

A. Protective clothing
B. Dust masks
C. Clean rags
D. Duct tape
E. Solvent cleaner (vendor recommended)
G-1
A. Electrical cleaner (no-residue type)

B. Lubricant (non-gumming)
C. Transformer oil (vendor recommendation)
D. Door gasket materials
E. Door seals (as required)
F. Emitter Wires
G. Emitter insulator rubber boots
H. Alignment clips
I. Ground straps
J. Cover and plate gaskets
K. Transformer surge protectors
L. Filters
1.6 Special tools
A. Air monitor
B. Protective clothing, dust masks, eye protection, gloves, hard hat
C. Vacuum cleaner
D. Volt/Ohm Meter (Analog)
E. Amp Meter (Clamp On)
F. Megger
G. Portable lighting
H. Water hose
I. Impact gun
J. Typical mechanic’s tool box
2.0 Pre-job Brief
A. For work performed in precipitator, hoppers, flues and ducts foreign material
exclusion areas should be established.
A. Additional work identified during the performance of this work instruction

requires a scope change to plan newly identified work.
G-2
B. All personnel are responsible for ensuring work is performed per approved
procedure or work instruction.
C. Never touch exposed internal parts of the control system. Operation of the
transformer-rectifier controls involves dangerous high voltage.
D. Never use fingers or metal screwdrivers to adjust uninsulated control devices.
E. Confined space entry permits and precautions for entry into precipitator or flues
F. (If present) Never bypass the safety key interlock system on the precipitator.
Only use powdered graphite to lubricate lock system. Never use oil or grease.
G. Grounding devices should be used when entering the precipitator, transformer-
rectifier switch enclosure or bus ducts. Precipitators can hold high static electrical
charges, up to 15KV following de-energization.
H. 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. Hot dust can
flow like water and severely burn or kill a person standing below the hopper door.
I. Protective clothing should be worn when entering a precipitator or hopper.
J. Be aware of potential high temperatures when entering a precipitator
K. Avoid ozone inhalation. Ozone is a toxic gas that can cause severe illness or
death if inhaled in sufficient quantity. Air-line masks should be used when
entering the precipitator, flues or stack when ozone is present. Precipitator should
be monitored for ozone prior to entry.
L. If high levels of carbon are known to exist on the collecting surface or in the
hoppers, DO NOT open precipitator doors until the precipitator has cooled below
125 degrees F.

B. Confined Work Space
A. Special chemicals
B. Disposal of materials
Review any relevant plant specific or industry related operating experience applicable to
the work being performed and the use of the tube cleaning equipment.
Get a generic Precipitator tag out
G-3
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

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 supervision if any problem is identified that prevents following work
instructions

A. Anti-sway insulator bushings

B. Rapper parts
C. Vibrator parts
D. Through bushing insulators
E. Through bushings
F. Transformer knife blades
G. Transformer receiver clips
H. Transformer ground pads
I. Control cabinets fans

G-4
4.1 Shutdown for Maintenance
A. MAXIMIZE precipitator CLEANUP with full ash removal system and rapper
system operation
CAUTION
Be careful not to violate any EPA limits.
B. REMOVE TR Sets from service as soon as possible after fuel is stopped.

C. MINIMIZE air flow
D. NOTIFY Operations prior to beginning work
E. ENSURE all parts expected to be used are available and in hand
F. ENSURE all tools necessary to perform the job are available
G. IDENTIFY any grounds on Emitter/Transformers
H. LOCATE and ENSURE proper piece of equipment is being worked per the work
instruction
4.2 Pre-maintenance checks (prior to clearance/tag out on precipitator)
NOTES
1. Any deficiencies identified should be added to the scope of the work
instruction for repair or replacement.
2. Procedure for conducting air-load test should be provided in vendor
technical manual. Additional guidance on air load tests may be found in
EPRI document, Electrostatic Precipitator Maintenance, Volumes 1 and
2, E213676.
3. Dirty air-load test is optional but may provide indications of potential
ash build up areas resulting from poor gas flow or inadequate rapping.
G-5
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
NOTE
If collector plate has been eroded away at clip location, it will be necessary to
weld a new clip above or below the eroded area.
j. ENSURE alignments clips are in place on collector plates

k. WELD alignments clips in new areas where plates have been eroded away
l. REPLACE all defective or degraded alignment clips
m. REPAIR or REALIGN the baffle between the collector plates and the
wall (appropriate clearance as per vendor manual)
L. Anti-Sway Bushings
a. INSPECT “Anti-sway” insulator bushings for degradation (stress cracks,
excessive ash buildup, ceramic breaks, ceramic erosion, etc
b. REPLACE any degraded “anti-sway bushings.
NOTE
It is important to identify any air leaks into the precipitator. During operation
cold air in-leakage can mix with hot gases and create a corrosive atmosphere.
M. CLEAN and INSPECT expansion joints for degradation (cracks, holes,

deterioration, etc)
N. REPLACE any expansion joints that can not be repaired
O. CHECK precipitator “box structure” for overall integrity (holes, erosion,
corrosion, etc)
P. REPAIR any precipitator “Box structure” degradation.
Q. INSPECT all doors, sealing surfaces, gaskets and seals.
R. CLEAN doors and sealing surfaces and replace gaskets and seals as required.
S. Chevron area
a. WASH out chevron area
b. INSPECT overall structure including pipes, duct bracing, gussets, turning
vanes, perforated plates (holes open, not blocked), etc for degradation,
erosion, corrosion excessive dust build up and breakage.
c. REPAIR or REPLACE any damaged components
T. Inlet and Outlet Ducts
a. CLEAN and INSPECT outlet duct leaving precipitator to the exhaust
stack for cracks, holes, excessive ash fouling, bent or broken diversion
plates, turning vanes, expansion joints, etc.
b. ASSESS effectiveness of flow distribution devices
c. INSPECT access panels/doors (seals/gaskets) for damage or degradation
d. REPAIR or REPLACE any degraded components
G-10
NOTES
1. Hoppers can pose a serious personnel hazard. They should be emptied
before inspection activities.
2. Scaffolding may be necessary to perform the inspection. This is costly
and presents a safety hazard both during installation and use.
CAUTION
Do not rely solely on level indication instrumentation to ensure hopper is empty.
Visually verify if possible. Tapping on door (hollow ring) may be used.
CAUTION
Safety chains/latches should be installed and functioning properly on hopper
doors
U. Hoppers
a. EMPTY hopper prior to dirty inspection.
b. CHECK hopper insulation/lagging
c. INSPECT lower hoppers for stress cracks, corrosion, erosion, holes and
excessive deposit buildup
d. CHECK for unusual ash build up
e. CHECK for internal obstructions
f. CHECK for signs of air in-leakage
g. REMOVE all foreign material from hopper (weights, wires, etc.)
h. CHECK valves and connections
NOTE
There are many types of hopper level indication systems (gamma radiation,
sound, capacitance, pressure, differential pressure, temperature, etc) Reference
appropriate vendor manual for specific level inspections.
i. CHECK hopper level indication system (including indicator lights if

installed)
j. CHECK hopper doors (seals/gaskets) and poke hole for air leaks or dust
discharge
k. REPAIR any deficiencies noted from hopper inspection
G-11
4.4 Upper Housing (Tension Insulators and Housings, Emitter/Collector -
Rapper/Vibrator)
NOTE
Rapper/vibrators will vary from one facility to another. (Electromagnetic
impulse-gravity impulse, electromagnetic impulse- spring assist, electromagnetic
vibrators, pneumatic, mechanical tumbling hammer) For specific inspections
and repairs, refer to vendor tech manual for installed equipment. General
rapper inspection guidelines are provided below.
A. Emitter and Collector Plate Rapper Inspections

a. INSPECT drive motors
b. INSPECT rapper controls
c. INSPECT rappers for cracks, shaft rubbing or binding, corrosion, leakage
(shaft penetration area) welds, couplings
d. INSPECT rapper penetration boot seals (air and/or water leakage)
e. INSPECT rapper shaft insulators (in installed)
f. INSPECT all rapper ground straps intact (ties rapper rod and housing to
ground)
4.5 Penthouse (aka. Coffin, Cans, Doghouse) Insulator compartment

inspections
CAUTION
Confined Space Entry procedures should be used for entry into penthouse.
A. Penthouse general condition inspection

a. INSPECT structural integrity of enclosure for cracks, corrosion, holes,
etc)
b. INSPECT all penetrations for adequacy of seal and corrosion
c. INSPECT purge air ducting/access doors (seals/gaskets) for leaks and
corrosion
d. INSPECT insulation and lagging
B. VERIFY equipment in the penthouse is de-energized and Clearance/Tag Out
installed
C. CLEAN and INSPECT ground straps (strap and hooks clean, not corroded)
D. REPLACE defective ground straps
E. OPEN penthouse inspection doors
F. VERIFY atmosphere is acceptable for entry
G. INSTALL safety grounds on de-energized equipment
H. RECORD as found condition of penthouse
G-12
I. Through Bushing Insulators
a. CLEAN through bushing insulators
b. INSPECT insulators for stress cracks, wear, or any other abnormality
c. REPLACE degraded insulators
J. High voltage bus duct inspection
a. ENSURE Bus duct is weather tight
b. CHECK grounding jumpers across duct sections installed and tight
c. REMOVE HV bus duct inspection cover
d. INSPECT duct, insulators, thru bushings, bus, connections, etc
e. CHECK Insulators free of any contamination (dust, ash, etc), cracks,
chips, electrical tracking
f. CLEAN insulators with non-abrasive cleaner if required
g. REPLACE any damaged or degraded insulators (also replace insulator
gasket)
h. INSPECT switches(Disconnect or ground switches if installed) for any
corrosion or pitting.
i. CLEAN or REPLACE switches as required.
j. REMOVE any rust or scaling observed
k. IF source of rust or scaling is identified THEN REPAIR.
l. INSPECT seals/gaskets on inspection covers
m. REPLACE seals/gaskets of inspection covers if damaged or degraded.
n. VERIFY duct purge vents (if installed) are not plugged or restricted
K. Tension Insulators and Housing
a. REMOVE tension housing cover, lagging and insulation and inspection
cover
b. CLEAN tension insulators and internals with water
L. ENSURE all surfaces are clean and dry
a. INSPECT housings and tension insulators
b. CLEAN inspection cover (remove old gasket material)
c. INSTALL inspection cover
NOTE
Maintain the integrity of the insulation and lagging. Loss of insulation on the
precipitator will result in cold spots and eventually corrode your electrostatic
precipitator.
d. INSTALL insulation and lagging and cover
M. Emitter Housing
a. REMOVE emitter housing lagging/insulation and inspection plate
b. INSPECT condition of inspection plate, gasket and emitter assembly
c. CLEAN high voltage (HV) emitter insulators and internals with water
d. ENSURE all surfaces are clean and dry
e. INSPECT emitter insulator for stress cracks, breaks and gauling around
seal penetration
G-13
f. CLEAN and INSPECT emitter vibrator assembly
g. TROUBLESHOOT all defective emitter vibrators
h. REPAIR or REPLACE all damaged emitter vibrators as necessary
i. REPLACE emitter insulator boots
j. CLEAN inspection cover (remove old gasket material)
k. INSTALL emitter housing inspection cover
NOTE
Maintain the integrity of the insulation and lagging. Loss of insulation on the
precipitator will result in cold spots and eventually lead to corrosion.
l. INSTALL insulation/lagging
N. Purge Air System

a. INSPECT and REPLACE filters as required
b. CLEAN fans/blowers, motors (lubrication) heaters, dampers, thermostats,
switches, etc
c. REPLACE any defective heaters
4.6 Transformer/Rectifier (TR)
NOTE
Follow approved procedures with respect to the handling and temporary
storage or chemicals used for cleaning.
CAUTION
Safety considerations for TR maintenance
1. Do not perform any maintenance activities on the TR unit will it is

operating
2. Follow all grounding procedures (specified in vendor technical manual)
3. Follow general electrical safe work practices with respect to electrical
shock
4. 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.
G-14
A. CLEAN external surfaces with approved cleaner:
a. Transformer
b. Bus Duct
c. Rectifiers
d. Cooling fans
e. 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.
B. Transfer Switch Cubicle inspection and cleaning

a. INSPECT interior of transformer switching compartments noting any
discrepancies
b. CLEAN interior of transformer switching compartments with approved
cleaner.
c. CLEAN and INSPECT bushings in transfer switch cubicle
d. REPLACE any degraded bushings
e. CLEAN and INSPECT all knife blades and receiver clips
f. REPAIR or REPLACE defective or worn knife blades or receiver clips
g. ENSURE transfer switch cubicle door gasket/seal is in good condition
h. REPLACE defective gasket/seal
i. SECURE transfer switch cubicle
CAUTION
Use proper foreign material controls when working around an open
transformer. All tools and other items shall be secured by lanyard when
working around or inside opening.
C. Transformer interior inspection

a. REMOVE transformer inspection plate
b. CLEAN gasket sealing surface (Discard old gasket)
c. VERIFY “high” winding to bushing bolting connection(s) are tight
G-15
d. VERIFY “low” winding to bushing bolted connection(s) are tight
e. RECORD Oil level
f. OBTAIN an oil sample (approximately a quart)
g. INSPECT oil for suspended debris (silicon fluid is clear, mineral oil is
amber)
h. REPLACE oil removed to the full level (as per vendor technical manual)
i. REINSTALL inspection plate with new gasket.
4.7 Control Cabinets (Emitter Control Cabinets, Rapper Control Cabinets)
A. VERIFY control cabinets are de-energized can Clearance/Tag Out is hung.
NOTE
Eye protection and dust mask should be used when blowing dust out of cabinets.
B. BLOWOUT (Using low pressure air ~40 psig) cabinets, top to bottom (boards,
racks, etc)
C. INSPECT cables, wires and terminations.
D. REPAIR or REPLACE any damaged cables, wires or terminations. (Insulation is
good and terminations are tight)
E. CLEAN and INSPECT cabinet fans and filters
F. REPLACE degraded or damaged fans and filters
G. CLEAN and INSPECT contactors for degradation (overheating, arcing, fly ash
fouling, insulation deterioration, looseness, etc)
H. HOLDING contactors closed, MEASURE resistance across contacts.
I. CLEAN and BURNISH any contacts that do not read 0.0 ohms.
J. VERIFY all pushbuttons and hand switches change contact state.
K. INSPECT cabinet door gasket/seal for any damage or degradation.
L. REPLACE gasket/seal if degradation or damage affect sealing surface.
M. CLOSE cabinet and ensure all latches work properly.
N. REPAIR or REPLACE damaged latches
G-16
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.

B. Initiate any corrective action program documents necessary to resolve any
problem areas identified.
7.0 References
A. Industrial Safety manual

B. Applicable vendor technical manuals (Controls and Precipitator)
C. Confined Space Entry Procedure
D. Foreign Material Control
E. Chemical Control Procedure
F. Material Safety Data Sheets
G. Temporary Storage of transient fire loads
H. 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.
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.
A. Roll Wheel Hub Oil (as per vendor)

B. Gearbox Oil (as per vendor)
C. Grease (as per vendor)
D. High temp RTV (Red)
E. Molycote
F. Heavy oil
G. Permatex
H. Loctite
I. Timbers
J. Saw Blades for Ceramic Saw
H-1
A. Wear plates (Upper Lower, Roller bracket)

B. Grind Ring Segments
C. Throat Vane Segments
D. Roller Bearing Retainer
E. Bearings
F. Bearing Spacers
G. Seals (Roll air and Oil)
H. O-rings
I. Gaskets
J. Wedge Bold Nuts
K. Plugs for jacking bolt holes (if required)
1.6 Special tools
A. Fork lift with personnel work cage

B. Pulverizer Access/Work Platform
C. Inching Air drive Motor
D. Impact Wrench
E. Oxygen-Acetylene Cutting Rig
F. Electric Arc Welder
G. Grinder
H. Chain Hoists
I. Wire and Nylon Slings
J. Turnbuckle
K. Connecting rods
L. Jacks (to raise pressure frame) (Spring frame jacking assembly)
M. 150 ton jack for Grinding Ring Segment removal
N. Ceramic Saw
O. Pulverizer Portable Hydraulic Power Unit
P. Wheel Assembly Handling Tool
Q. Wooden Wedges
R. Torque Wrenches (assorted)
S. Torch and appropriate tips
T. Basic tools from mechanics toolbox
H-2
2.0 Pre-job Brief

established.
A. Pulverizer must be purged and cooled down prior to opening the Pulverizer access
doors.
B. Confined Work Space procedures must be followed when opening Pulverizer
inspection doors and entering the Pulverizer housing.
C. All personnel are clear of the Pulverizer prior to using the Air Inching Drive to
position the Roll Wheel Assembly
D. Additional work identified during the performance of this work instruction
E. Inspect all hoists, slings and other lifting equipment for ant defects and ensure
inspection periods are current prior to use.

B. Confined Work Space
C. Foreign Material Exclusion
D. Chemical Control Procedure
E. Material Safety Data Sheets
2.5 Identify Environmental Considerations
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
H-3
Need a sample clearance for this piece of equipment


C. Contact maintenance Supervisor for inspection and determination of grinding ring
segments replacement.

configurations or conditions
A. Roller Shafts
B. Roll Wheel Tires
H-4


F. ENSURE all rigging, hoists, chain falls, slings etc. are available and have been
inspected prior to use
4.1 Prerequisites
A. LOCATE and ENSURE proper piece of equipment is being worked per the work
instruction
B. VERIFY Pulverizer is shutdown
C. VERIFY Equipment Clearance/Tag Out has been established on Pulverizer to be
worked
D. VERIFY Pulverizer is purged and cooled down for maintenance
E. ERECT Pulverizer/Work platform
CAUTION
Confined Work Space procedures must be established prior to opening and
entering the Pulverizer
F. OPEN Pulverizer for maintenance

G. VERIFY excess coal is removed from Pulverizer (may use outside vendor to
vacuum mill)
4.2 Roll Wheel Assembly Removal
A. PERFORM profile reading on the grinding ring segments
NOTE
Maintenance Supervisor should determine in grindings wheel segments need
replacement.
B. DELIVER grinding ring segment profile readings to maintenance supervisor
H-5
CAUTION
Ensure personnel are clear of the Pulverizer prior to using the air driven motor.
C. ROTATE the mill to loosen the wedge bolt in the grinding ring segment
D. REMOVE cover cone assembly
E. INSPECT gear box cover for corrosive damage
NOTE
Hot work permit required for removal of wedge bolt nut keeper bars.
F. CUT the keeper bar welds

G. REMOVE all wedge bolts and nuts
H. INSTALL wedge bolt jack plate
CAUTION
Ensure personnel are clear of the Pulverizer prior to using the air driven
inching motor.
I. ROTATE the grinding ring segment directly under roll wheel assembly
NOTES
1. Perform the following steps for each wedge bolt.
2. Turnbuckles are to be installed between the wheels and not across the
wheels (as per vendor)
J. INSTALL turnbuckle maintenance fixtures to support roll wheel assembly

K. INSTALL fixture base plate and turnbuckles
L. BOLT base plate to the roller bracket of all three roll wheels
M. REMOVE slack from of turnbuckle linkage
N. INSTALL wood wedges under the roller and between bracket and tire before
proceeding
O. REMOVE seal air piping for each bracket
a. DISCONNECT lower ball joint
b. REMOVE piping from mill
H-6
c. INSTALL covers on bracket seal air openings to prevent entry of foreign
material.
P. RELEASE spring tension and loading force on hydraulic cylinders
Q. REMOVE clevis pins connecting the loading assembly to the spring frame
R. CONNECT spring frame to pressure frame using connecting rods
S. DISCONNECT loading cables
T. INSTALL spring frame jacking assembly
CAUTION
Ensure all personnel are clear from inside the Pulverizer before next step.
U. ENSURE inside of Pulverizer has been cleared of all personnel (Signoff

Required)
V. RAISE the pressure frame (using jacking assembly), springs and spring frame as
high as possible.
W. SECURE spring frame jacking assembly with wire sling and 2 tone chain hoist
from eye bolts in ceiling
X. REMOVE the roll pivot pins
Y. 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
inching motor.
AA. ROLL Wheel Assembly Removal for the remaining wheels Rotate pulverizer to
bring next roll wheel assembly to the door.
BB. REPEAT step [Z] and [A] for remaining wheels.
4.3 Grinding Ring Segment Removal and Replacement
CAUTION
For use of plasma arc cutter, ensure the yoke is grounded to Pulverizer housing.
H-7
CAUTION
Do not cut seat ring.
A. GROUND plasma arc cutter yoke to Pulverizer

B. CUT the first grinding ring segment into several small pieces
C. PRY remaining grinding ring segments loose and REMOVE with segment
handling tool
D. CLEAN the grinding ring seat surface
NOTE
If damage is present contact engineering for resolution.
E. INSPECT grinding ring seat surface for damage

F. CLEAN seating surfaces of new grinding ring segments
G. INSTALL first grinding ring segment over the drive dowel pin and ALIGN it
with wedge bolt holes
NOTES
1. Ensure grinding ring segments are pushed tightly together.
2. Assembled grinding ring segments should align within vendor tolerances
on grinding face contour.
3. It may be necessary to grind the bosses of the last several segments to
achieve proper positioning
H. INSTALL remaining grinding ring segments.
NOTES
4. Torque pattern will be per vendor instructions or a standard torque
pattern such as 1200, 0600, 0300, and 0900.
5. Torque sequence of wedge bolts and nuts should be as per vendor
instructions.
6. Subsequent to 50 hours of Pulverizer operation the Pulverizer should be
removed from service and the wedge bolts re-torqued.
I. INSTALL wedge bolts, washers and nuts

J. TORQUE wedge bolts and nuts per vendor recommendation
K. INSTALL keeper bars and tack weld in place to the seat ring
L. INSTALL plugs in jack bolt holes (if required)
M. INSTALL cone cover assembly (use Permatex in the joint)
H-8
NOTE
RTV should be used around wedge bolts and dowels to prevent coal dust from
entering yoke cavity.
N. INSPECT pressure frame wear plates and replace as required.

O. INSPECT intermediate housing wear plates and replace as required
NOTE
If UT testing of seal air piping header is desired, this must be done before
wheels are re-installed.
P. PERFORM UT testing of seal air piping if required

Q. INSPECT seal air piping seals and replace as required
4.4 Roll Wheel Assembly Installation
A. INSTALL top turnbuckle brackets in place on wheel brackets

B. INSTALL bottom turnbuckle fixture brackets on cone cover plate
NOTE
Do not remove assembly from the removal bracket mechanism at this time.
C. INSTALL first roll ring assembly on the grinding ring and center it on a fixture.
NOTE
Turnbuckles are to be installed between the wheels and not across the wheels (as
per vendor)
D. ASSEMBLE turnbuckles to the roller bracket

E. INSTALL wooden wedges under wheel to prevent the wheel from rolling
F. LEVEL the top of the removal bracket along the centerline of the pivot pins to
the center of the mill
G. CONNECT turnbuckle assembly to wheel assembly
H. DISCONNECT roll wheel assembly from removal tool
I. INSTALL roll wheel bracket wear plates
H-9
CAUTION
inching motor.
J. ROTATE Pulverizer (using inching air drive motor) until the next wheel’s
assembly is located at the maintenance hatch.
K. REPEAT above steps for all roll wheel assemblies
L. INSPECT roll pivot pins and pivot blocks. Replace if wear is severe.
M. 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.
CAUTION
Ensure all personnel are clear from inside the Pulverizer before next steps.
N. ENSURE inside of Pulverizer has been cleared of all personnel (Signoff

Required)
O. LOWER pressure frame, springs and spring frame onto roll wheel assemblies.
P. POSITION the wheel assemblies under the pressure frame blocks just prior to
contact. Use turnbuckles and inching air drive motor to position.
Q. LOWER pressure frame while aligning pivot blocks and pivot ring
R. INSTALL seal air piping
SLIDE piping into upper joint
ATTACH lower ball joint
S. CONNECT loading assembly to the spring frame using clevis pins
T. PRESSURIZE hydraulic cylinders to remove slack from loading cables
U. REMOVE turnbuckle assemblies.
NOTES
7. Proper spring loading should be at vendor manual requirements.
8. Hydraulic cylinder loading and spring height should be recorded
for future reference.
V. PRESSURIZE the hydraulic loading cylinders to obtain proper spring loading.

W. MEASURE spring height at various locations
X. RECORD hydraulic cylinder loading and spring height
Y. TIGHTEN top and bottom nuts on loading cylinders
H-10
Z. TIGHTEN top lock nuts on loading cylinder
AA. RELEASE loading hydraulic pressure
BB. REMOVE turnbuckle assemblies
CC. GREASE wheel assembly seals
DD. CHECK oil level in each wheel assembly
4.4 Final Reassembly
A. RELEASE Clearance/Tag out on seal air system

B. CHECK seal air system for leaks
C. CLOSE maintenance hatch and other openings on Pulverizer.
D. REMOVE Pulverizer/Work platform
E. RELEASE Pulverizer/Tag Out on Pulverizer
F. STORE tools used for work
G. CLEAN work area to pre-work conditions
H. RETURN unused part to stores
NOTE
If work was performed inside a plenum ensure are materials taken into plenum
have been removed.’
I. INSTALL guards, covers and access ports
Looking for post maintenance information

7.0 References
A. Industrial Safety manual

B. Confined Work Space Procedure
C. Applicable vendor technical manuals
D. Foreign Material Control
H-11
I
WORK PACKAGE TEMPLATE – DAMPERS
1.0 Task Overview
1.1 Component type
This work instruction is applicable to various dampers.
Ensure unique equipment identifier is used to designate which damper is being worked.
1.3 Scope
This work instruction describes inspection, cleaning, lubrication and minor maintenance
of dampers.
A. Clean lint free rags

B. Grease (e.g. Mobilux EP #2, vendor approved)
C. Cleaning solvent (Vendor approved)
D. Brush
E. Oil (Vendor approved)
A. Gaskets
B. Seals
C. Packing
I-1
1.6 Special tools
A. Mechanic’s tool box

B. Grease gun
C. Can oiler
D. Ladders, scaffolding (depending on location)
E. Safety belts
2.0 Pre-job Brief
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.

established.
A. Conduct a pre-job brief to ensure the scope of the work to be performed is

understood by all personnel.

B. Chemical Control Procedures (handing and disposal)
I-2
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, cleaning materials,
etc) should be in accordance with approved chemical control procedures
A. Motive force to damper (breaker, air supply)

B. Power to FD or ID fan(s)



I-3
A. Bearings
B. Shaft


E. ENSURE appropriate personal safety equipment is worn and used on the job
4.1 Inlet Damper Clean/Inspection
A. DISCONNECT damper linkage from actuator.
NOTE
Reference vendor technical manual for approved cleaning methods: steam
clean, water wash, sandblast, approved solvents
B. CLEAN blades and linkage(s) using vendor approved method of:

a. Dirt/dust/ash/etc
b. Old grease
NOTE
Any damaged or degraded components should be evaluated for replacement.
Work instruction should be amended to perform corrective maintenance.
C. INSPECT the damper components:

a. INSPECT linkages for:
1. Inadequate lubrication
2. Verify free of obstruction or binding
3. Missing or broken parts (pins, bolts, fasteners, etc)
4. Proper alignment
b. INSPECT blades for:
I-4
1. Corrosion
2. Erosion
3. Ash buildup
4. Cracks
5. Warpage
6. Seal along blade edges
7. Binding
8. Bending/buckling
9. Brittle/broken frayed seals (If installed on blades)
NOTE
Seals (if installed) may be either metallic, silicone, rubber or plastic). Seal
tightness may be checked by a smoke test.
c. INSPECT blade seals

1. INSPECT in open and close position for straightness and obvious
surface variations.
2. ENSURE blade seals provide continuous contact along entire
blade length in the closed position.
d. INSPECT blade shaft
1. INSPECT shaft at bushing or bearing pint for wear
2. INSPECT for bowed shaft
e. INSPECT frame for:
1. Corrosion
2. Erosion
3. Warpage that may cause blade binding
f. INSPECT packing glands for leakage
1. Repack glands as required
g. CLEAN accessible external surfaces of the damper unit
h. CHECK damper mountings for loose, broker or missing parts
i. 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.
j. INSPECT inside portion of ductwork at damper for ash build up.
I-5
4.2 Damper Bearings
A. REMOVE damper bearing(s)
NOTE
1. Soak sufficiently to loosen and remove grease/dirt
2. Use a brush to assist in removal of grease/dirt
B. CLEAN bearing(s) by soaking bearing(s) in approved solvent to remove grease

and dirt
C. 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.
D. DISASSEMBLE bearing.
E. INSPECT bearing for damage.
NOTE
If any of the following conditions exist, replace bearing.
a. Broken or cracked rings

b. Dented shields/seals
c. Cracked/broken separators
d. Broken/cracked balls or rollers
e. Flaked/spalled areas on balls, rollers or raceways
f. Discoloration (brownish blue or blue-black areas)
g. Indented/brinelled/etched raceways
4.3 Lubrication
A. LUBRICATE linkages
B. LUBRICATE bearings
C. APPLY small amount of oil to all damper moving components
I-6
4.4 Reassembly
A. INSTALL bearings (if removed)

B. INSTALL linkages (if removed)
C. INSTALL all bolts, screws and fasteners (torque as specified)
D. MANUALLY CYCLE damper open and closed and INSPECT for:
a. Smooth operation of linkage and blades
b. Check for any binding or noise
c. Check completeness of travel
d. Check mechanical stops
E. INSTALL guards, covers and access ports
F. INSTALL linkage to actuator
G. SET Mechanical stops and electrical limits
A. RELEASE Clearance/Tag out on damper

B. ELECTRICALLY CYCLE damper open and close and INSPECT for:
a. Proper operation of linkage and blades
b. Unusual noise
c. Vibration
d. Proper setup of mechanical stops and electrical limits
NOTE
Damper synchronization is accomplished by establishing a reference dimension,
actuating the vanes, and comparing the two sides for balance.
C. VERIFY that dampers are synchronized, for double inlet or outlet damper
configurations.
D. DISPOSE of any generated waste products properly.
E. RETURN any unused spare parts to stores/warehouse

I-7
7.0 References

B. Damper vendor technical manual
C. Actuator vendor technical manual
I-8
J
WORK PACKAGE TEMPLATE – CENTRIFUGAL PUMP
(PROCESS, 3196)
NOTE
proficient) on the type of pump being worked.
1.0 Task Overview
1.1 Component type
This work instruction is applicable to a typical centrifugal process pump. (E.g. Gould 3196 ST,
MT, STX, MTX). A typical Model 3196 STX pump is shown in Figure J.4 in the reference
section of this template.
Ensure the unique pump identifier is used to designate which pump is being worked.
1.3 Scope
This work instruction provides instructions for inspection and repair of a centrifugal process
pump.
A. Acetone
B. Isopropyl alcohol
C. Varsol
D. Clean lint free rags
E. Grease (e.g. Koppers KHP)
F. Pump bearing oil (E.g. MO-2)
G. Silicone grease (E.g. Molycote 55 or 44, Dow Corning 4 or 111)
H. Oil Drain pan
I. Duct tape
J-1
J. Containers (E.g. bags) for temporary storage of parts
A. Gland Gasket
B. Impeller O-Ring
C. Bearing Housing O-Ring
D. Casing Gasket
E. Bearings
1.6 Special tools
A. Mechanics tool box (wrenches, screwdrivers etc)

B. Bearing puller
C. Bearing driver
D. Snap ring pliers
E. Rubber mallet
F. Torque wrenches (various)
G. Allen wrenches
H. Dial indicator
I. Micrometer (inside and outside)
J. Feeler gauges
K. Pyrometer
L. Sling
M. Jacking screws
N. C clamps
O. Shaft wrench
2.0 Pre-job Brief
A. Generation
A. Performance of this work will open pump to environment. Appropriate measures should
be taken to prevent foreign material from entering the pump.
J-2
A. DO NOT allow petroleum based products to contact the EPT O-rings of the mechanical
seal. Petroleum based products will cause the O-rings to deteriorate and fail.
B. Oil drained from the pump should be removed from the work area and properly disposed
of as soon as practical. Other wise, an appropriate transient fire load evaluation should
be performed and proper temporary storage provided.
C. Follow appropriate Material Safety Data Sheet (MSDS) and site approved procedures for
handling and disposal of cleaning chemicals and solvents.
D. Follow approved site procedures for proper draining and disposal of process fluids from
the pump.
A. Equipment Clearance Order

B. Chemical Control Permit
C. Transient combustible material storage permit
A. Pump suction valve

B. Pump discharge valve
C. Pump recirculation valve
D. Pump Vent valve
E. Pump Drain valve
F. Power to motor
G. If installed (Gland seal supply valve)
J-3
appropriate.


A. Impeller
B. Coupling
C. Mechanical Seal


J-4
4.1 Preparations

B. LOCATE and IDENTIFY proper piece of equipment is being worked per the work
instruction
C. ENSURE piping, equipment supports, and other interferences are removed to support
work.
D. IF installed, THEN REMOVE insulation.
4.2 Preparation for pump removal
A. REMOVE coupling guard.
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.
B. DISASSEMBLE coupling
C. IF coupling contains grease, THEN CLEAN grease from coupling.
D. IF required to drain pump casing, THEN DRAIN casing.
NOTE
Cover exposed ends of pipe to prevent entry of foreign material.
E. IF installed, THEN REMOVE gland seal supply and leakoff piping.

F. IF pump had constant level oiler, THEN REMOVE and DRAIN oiler bulb.
NOTE
After draining oil remove from area and properly dispose of or provide temporary
combustible storage.
G. DRAIN oil from pump.
H. REMOVE frame foot hold down bolts.

I. REMOVE pump from casing.
e. REMOVE casing bolts
f. REMOVE casing gasket
J-5
NOTE
Shims that are removed should be marked so they can be replaced in their original
positions.
NOTE
Sling should be used to support pump during removal from casing. Jack screws should
be used to back out pump from casing.
g. REMOVE pump from casing.

h. COVER open casing (Foreign Material Exclusion)
NOTE
Use proper lifting or rigging practices to remove pump from location to work area.
J. MOVE pump to maintenance location.
4.3 Pump Disassembly
A. SECURE pump frame to workbench
NOTE
Coupling hub position should be marked on shaft
B. REMOVE coupling hub.

C. REMOVE impeller from shaft (Impellers are screwed on)
D. REMOVE impeller O-ring
E. IF pump has a packing stuffing box, THEN REMOVE split gland and stuffing box
cover.
NOTE
Mechanical seal location should be marked on shaft
F. IF pump has a mechanical seal, THEN REMOVE mechanical seal.

G. IF installed, THEN REMOVE frame adapter.
NOTE
Disassembly of the power end and it components varies with model. Refer to vendor
technical manual for specific installation.
J-6
H. REMOVE bearings as follows
i. REMOVE bearing housing bolts
j. REMOVE (As a unit) shaft, bearings and bearing housing
k. REMOVE inboard bearing using a bearing puller.
l. REMOVE bearing housing from shaft
m. REMOVE outboard bearing
I. REMOVE inboard and outboard oil seals
J. IF pump has a packed stuffing box, THEN REMOVE packing rings from stuffing box.
4.4 Pump Inspection
NOTE
Age of bearings, mechanical seals, gaskets and O-rings should be taken into account as
to whether they should be replaced regardless of inspection results.
A. CLEAN pump parts as required using isopropyl alcohol or acetone

B. REMOVE burrs as required.
NOTE
Refer to vendor technical manual for acceptable tolerances
C. VISUALLY INSPECT parts for corrosion, erosion or wear.

a. Casing (grooving, pitting)
b. Frame adapter (cracks, gasket surface)
c. Impeller (grooving, pitting, cracking)
d. Shaft (bearing fit, shaft runout)
e. Mechanical Seal
f. Bearing frame (cracks, scale, debris, lubrication passages clear)
g. Inboard Bearing (contamination, damage, overheating, fit etc.)
h. Outboard Bearing (contamination, damage, overheating, fit etc.)
i. Casing Bolts (cracks, damaged threads))
j. Mechanical Seal Gland bolts
k. Labyrinth seals (O-rings for cuts and cracks)
l. Packing studs/nuts (cracks, damaged threads)
D. REPLACE all damaged or degraded parts.
E. LIST parts replaced in work package.
4.5 Pump Reassembly
A. ENSURE bearings are clean and LUBRICATED.

B. LUBRICATE bearing location on coupling end of shaft.
J-7
CAUTION
It may be necessary to heat the bearing to install it on the shaft. If the bearing is heated
DO NOT overheat. Bearing should not be heated more than 250 degrees F.
NOTE
Bearing may be heated using a bearing heater and installed on the shaft by hand.
CAUTION
Gloves should be worn when handing hot bearings
C. IF heat is used, THEN HEAT and INSTALL outboard bearing on coupling 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.
D. IF heat is NOT used, THEN SLIDE outboard bearing onto coupling end of shaft until
firmly seated on shaft shoulder.
NOTE
Drain slots should be positioned at bottom for labyrinth seal
E. LUBRICATE and INSTALL oil seal in thrust bearing housing.

F. LUBRICATE and INSTALL O-ring on bearing housing.
G. SLIDE and LOCK bearing housing onto shaft.
H. LUBRICATE bearing location at impeller end of shaft.
CAUTION
It may be necessary to heat the bearing to install it on the shaft. If the bearing is heated
DO NOT overheat. Bearing should not be heated more than 250 degrees F.
NOTE
Bearing may be heated using a bearing heater and installed on the shaft by hand.
CAUTION
Gloves should be worn when handing hot bearings
J-8
I. IF heat is used, 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.
J. IF heat is NOT used, THEN SLIDE inboard bearing onto impeller end of shaft until
firmly seated on shaft shoulder.
NOTE
Oil seal may be installed in frame adapter or bearing adapter depending on model.
NOTE
Drain slots should be positioned at the bottom for labyrinth seals.
K. INSTALL and LUBRICATE oil seal.
NOTE
Top of thrust bearing housing should be in line with top of frame.
L. INSTALL bearing and shaft assembly into frame

M. IF pump has a shaft sleeve, THEN INSTALL shaft sleeve on to shaft.
N. INSTALL deflector onto shaft OR shaft sleeve.
O. IF pump has a packing stuffing box THEN
a. INSTALL stuffing box cover
b. INSTALL impeller O-ring and impeller on shaft
NOTE
Refer to vendor technical manual for gap clearance
J-9
c. Temporarily ADJUST gap between impeller and stuffing box.
P. IF pump has a mechanical seal, THEN:

a. INSTALL stuffing box cover against frame adapter OR bearing frame.
b. INSTALL impeller O-ring and impeller on shaft
NOTE
Refer to vendor technical manual for gap clearance
c. Temporarily ADJUST gap between impeller and stuffing box.

d. REMOVE impeller and stuffing box cover
e. INSPECT mechanical seal, mechanical seal gland and internals of stuffing box
cover for cleanliness.
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.
f. LUBRICATE and INSTALL stationary O-ring on seat

g. INSTALL stationary seat in gland
h. INSTALL stationary seat in stuffing box cover
i. SLIDE Gland with gasket over shaft
NOTE
Refer to position for mechanical seal marked on shaft during disassembly.
j. SLIDE and LOCK mechanical seal into position on shaft

k. INSTALL stuffing box cover
l. 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. SLIDE and TORQUE mechanical seal gland into position
J-10
4.6 Pump Installation
NOTE
Coupling hub should be positioned at scribe mark made during disassembly
A. INSTALL coupling hub on shaft

B. MOVE pump to plant location.
C. INSPECT casing internals for cleanliness.
D. INSTALL casing gasket against casing shoulder.
E. ENSURE jacking bolts are back all the way out.
NOTE
Use proper rigging techniques during installation or frame assembly to prevent
damage.
F. INSTALL frame assembly into casing
NOTE
If the impeller does not turn freely while tightening the casing bolts, the impeller
should be adjusted using the impeller adjusting bolts.
G. LUBRICATE and INSTALL the frame-casing bolts.
H. TORQUE casing bolts to appropriate vendor specified value.
NOTE
Shaft should be rotated by hand during torque of casing bolts
NOTE
Additional shims may be added as required to avoid pipe strain.
I. REPLACE shims removed during disassembly

J. 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.
K. Adjusting impeller clearance by Feeler Gauge method
J-11
Figure J.1
Impeller Adjustment – Feeler Gauge Method
a. LOOSEN locknuts on impeller adjustment bolts.

b. LOOSEN impeller adjustment bolts several turns.
c. Evenly TIGHTEN bearing housing bolts, while slowly rotating pump shaft by
hand until impeller just starts to rub on casing.
NOTE
Impeller clearances will vary. Refer to vendor technical manual for impeller clearance
gap.
d. 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.
J-12
e. Evenly TIGHTEN impeller adjustment bolts until bearing housing is tight
against the bearing housing bolts
f. 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.
L. Adjusting impeller clearance using Dial Indicator Method
Figure J.2
Impeller Adjustment – Dial Indicator Method
a. LOOSEN locknuts on impeller adjustment bolts.

b. LOOSEN impeller adjustment bolts several turns.
c. Evenly TIGHTEN bearing housing bolts, while slowly rotating pump shaft by
hand until impeller just starts to rub on casing.
NOTE
Impeller clearances will vary. Refer to vendor technical manual for impeller clearance
gap.
d. INSTALL a dial indicator so its tip is positioned on the end of the shaft
e. VERIFY the dial indicator is set to ZERO.
f. LOOSEN each bearing housing bolt 5 – 6 flats.
g. Evenly TIGHTEN impeller adjustment bolts until the dial indicator reads the
desired impeller clearance gap.
h. TIGHTEN the bearing housing bolts. (Finger tight)
J-13
i. Evenly TIGHTEN the bearing housing and the impeller adjusting bolts while
maintaining the desired impeller clearance gap on the dial indicator. (Wrench
tight)
j. TIGHTEN the locknuts on the impeller adjustment bolts (Wrench tight)
k. VERIFY the impeller can be rotated by hand with no indication of rubbing on the
casing.
4.7 Final Pump Assembly
NOTE
Pump may or may not have a constant level oiler.
Figure J..3
Oil Bubbler
A. IF pump has a constant level, THEN FILL bearing housing with proper oil (E.g. MO-2)
as follows:
a. REMOVE oil bubbler
b. ENSURE top tangs in oiler base are level with oil level line marked on side of
pump.
c. REMOVE filler/vent from top of bearing housing.
d. FILL bearing housing with proper oil through the filler/vent UNTIL oil reaches
top of tangs inside the oiler base.
e. FILL bubbler with proper oil.
f. INSTALL bubbler on oiler base.
g. ALLOW bubbler to drain UNTIL bubbling stops.
h. REPEAT steps (f) and (g) UNTIL bubbler remains approximately ¾ full.
J-14
i. ENSURE vent cap vent holes are clear
j. INSTALL vent cap. (Wrench tight)
k. WIPE UP any excess oil.
B. IF pump DOES NOT have a constant level oiler, THEN:

a. REMOVE oil fill plug
b. FILL bearing housing with appropriate oil UNTIL level reaches the middle of
the sight glass.
c. INSTALL oil fill plug. (Wrench Tight)
C. IF gland seal supply and leakoff piping were removed, THEN ENSURE piping is clean
and INSTALL piping (Wrench Tight)
NOTE
Use site specific method for performing pump alignment
D. ALIGN pump to desired tolerances.

E. TIGHTEN hold down bolts while assuring alignment tolerances are maintained
F. IF pump has a packing gland THEN:

a. INSTALL packing and lantern ring
b. INSTALL split GLAND with gland nuts. (Finger Tight)
NOTE
Use site specific method for installation of packing
NOTE
Use site specific method (E.g. lubricant, torque requirements, etc) for installation of
coupling depending on coupling type.
G. ASSEMBLE coupling using information obtained during disassembly.

H. INSTALL coupling guard (Wrench Tight)

B. PERFORM vibration testing
C. IF pump has packing, THEN ADJUST packing to achieve proper leakoff.
D. MONITOR inboard and outboard bearing temperatures using a pyrometer.
E. VERIFY no system or oil leaks.
J-15
F. IF insulation was removed, THEN INSTALL insulation.
G. IF piping, equipment supports or other interferences were removed, THEN
REINSTALL these interferences.
H. Work site cleanup - CLEAN work area to original pre-maintenance conditions
I. DISPOSE of any generated waste products properly.
J. RETURN unused parts to storeroom

identified.
7.0 References

F. Vendor Technical Manual (Pump)
G. Vendor Technical Manual (Coupling)
J-16
Figure J.4
Typical Model 3196 STX Pump
J-17
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. This can help avoid misdiagnosis and
allow proper interpretation of test results. It is essential for inspection personnel to
know how each steam trap operates under specific conditions in order to diagnose the
problem correctly. Some test methods require the use of special equipment that will
require special training.
1.0 Task Overview
1.1 Component type
This work instruction is applicable to various types of steam traps; thermostatic, thermodynamic,
mechanical, orifice.
Ensure unique equipment identifiers are used to designate which steam traps are being inspected.
Typically numerous steam traps are tested during a given testing. If traps require maintenance
they should be identified on the data sheets for repair.
1.3 Scope
This work instruction describes the testing and repair of steam traps.
A. Squeeze water bottle

B. Spanners (required for removing regulator devices from traps)
C. Clean rags
D. Thread lubricant
E. Lapping compound (e.g. Carborundum compound I.F.)
K-1
A. Cover gaskets
B. Strainers
C. Seats
D. Disks
1.6 Special tools
A. Testing
a. Mechanics tool pouch
b. Industrial stethoscope or ultrasonic test equipment
c. Temperature measurement (Contact thermometer, pyrometer, infrared detection
equipment. Heat sensitive strips or crayons, etc)
B. Maintenance
a. Mechanics toolbox
2.0 Pre-job Brief
A. Typically testing/inspection of steam traps is performed with the unit on line. In most
cases there is little to no risk to the unit or systems during these activities. However, care
should be taken since sections of piping may be isolated to perform testing. When
isolating any section of piping, consideration should be given as to whether isolating
valves will put any other part of the system or personnel at risk. Dangers might include:
isolation of vents and protective devices or alarms. Ensure isolation valves are turned
closed in a gradual way to avoid system shocks.
A. If steam trap requires replacement and is removed from the system, open pipe ends
should be covered to preclude foreign material entering system
A. Steam lines and traps are HOT. Wearing of appropriate personnel safety equipment and
work precautions should be observed.
B. Manipulation of any valves or equipment should be performed by Operations personnel.
C. Prior to opening a trap for inspection or repair the steam supply and return lines to
condensate should be isolated.
D. When blowing down a steam trap gloves and face shield should be worn.
K-2
E. Prior to performing maintenance on steam trap allow the trap to cool to minimize the
potential for burns.
F. During trap reassemble ensure all joint faces are clean.
A. During testing live steam may be released to the environment. Personnel should take
necessary precautions and wear appropriate personal safety equipment.
B. Steam trap testing is performed with the steam system operating. The plant is typically a
high noise area. Appropriate ear protection should be worn.
A. Inlet isolation to trap

B. Outlet isolation to condensate recovery
C. Blowdown valve (If applicable, to depressurize trap)
appropriate.

K-3

A. Complete replacement steam trap (appropriate design)

B. Regulating devices (bellows, bimetallic, etc)
C. Float ball
D. Bucket
E. Cap/Cover bolts, nuts or clamps
F. Orifice

A. NOTIFY Operations prior to beginning work (Operator required if valve manipulations

will be performed during stream trap testing)
B. ENSURE an appropriate clearance/tag out is in place to repair/replace steam trap (If
required)
4.1 Testing Steam Traps
A. Prerequisites
a. ENSURE trap is in operation and at normal operating temperature
b. TEST for hot trap by squirting a little water on trap cover/cap. If hot water will
vaporize immediately.
c. IF trap is cold, THEN IDENTIFY trap for maintenance.
d. 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.
K-4
B. CHECK external condition of trap
a. Supports
b. Insulation
c. Corrosion
d. Leaks
NOTE
It is recommended that at least two methods be used to determine whether the steam
trap is operating properly.
C. PERFORM sound check on traps (Stethoscope or Ultrasonic)
a. LISTEN for trap operation (Is it cycling?)

b. LISTEN for mechanical sounds
c. CHECK for continuous high pitch steam flow
d. CHECK for continuous low pitch condensate flow
e. CHECK for intermittent flow
NOTE
For closed condensate recovery systems there must be a line with discharge valve
available to observe trap discharge.
NOTE
Operations personnel should perform all valve manipulations.
NOTE
If the trap has a strainer up stream of the trap, the strainer blowdown valve can be
opened to divert condensate away from the trap. This will allow only steam to enter
the trap. If the trap is operating correctly it will close and no steam will be observed at
the discharge.
D. PERFORM visual inspections on traps that sound abnormal.

a. CLOSE return line to condensate recovery
b. OPEN discharge valve
c. OBSERVE discharge for flash steam and normal condensate flow
d. OBSERVE discharge for continuous or intermittent flow (trap design dependent.
e. OBSERVE trap for discharge of live steam.
f. IF any abnormal trap observation is observed, THEN IDENTIFY trap for further
testing or maintenance.
K-5
NOTE
Condensate return line pressure must be known to assist in determining if trap is
operating properly.
E. PERFORM temperature check of trap if necessary

a. IF temperature is measured by contact thermometer or heat sensitive strips,
THEN ENSURE location of temperature measurement is clean, upstream and
downstream of trap.
b. RECORD steam supply line pressure.
c. RECORD condensate return line pressure
d. MEASURE supply line temperature
e. MEASURE return line temperature
f. COMPARE return line temperature to expected return line temperature based on
table K.1 – Pipe Line Temperatures at Various Operating Pressures
Table K.1
Pipe Line Temperatures at Various Operating Temperatures
Return Line Return Line

Steam Pressure (psig) Temperature Range (F)
0 (Atmospheric) 212
15 225-238
30 245-260
100 305-320
150 330-350
200 350-370
450 415-435
600 435-465
F. IF trap is not operating properly, THEN IDENTIFY trap for repair or replacement.
4.2 Steam Trap Maintenance
NOTE
Steam trap maintenance can involve either repair or replacement. Repair would be the
preferred option especially when the trap is welded into the system. The body’s of most
steam traps should last the life of the plant.
NOTE
Some steam traps are sealed units and can only be replaced
K-6
NOTE
Use of a thread lubricant is recommend when installing trap covers/caps or strainer
plugs/caps.
4.2.1 Thermodynamic Steam Trap

a. ENSURE an equipment clearance/tag out is in place and the steam trap is
depressurized and cool to the touch.
b. REMOVE cover (Maybe bolted, screw cap or clamped, etc)
c. REMOVE old disc
d. Fitting new disc
1. ENSURE sealing surface is not overly worn or cut.
2. IF sealing surface is overly worn or has minor cuts THEN LAP seating
surface using an approved lapping compound.
3. INSTALL new disc.
a. INSTALL cover with using new gasket.
b. TORQUE cover to vendor specification
c. IF steam trap has and integral strainer, THEN
1. REMOVE strainer plug/cap
2. CLEAN or REPLACE strainer
3. INSTALL plug/cap using new gasket
4. TORQUE plug/cap per vendor specifications
d. IF strainer is not integral to steam trap (e.g. located upstream of trap) THEN
1. ENSURE strainer is inside equipment clearance/tag out boundary.
2. REMOVE strainer plug/cap
3. CLEAN or REPLACE strainer
4. INSTALL plug/cap using new gasket.
5. TORQUE plug/cap per vendor specifications
4.2.2 Ball Float Steam Trap
NOTE
Steam trap operating mechanism typically includes the main valve assembly, pivot
frame and ball float. Some float traps also contain a bimetallic device that operates to
remove air or non-condensable gases.
K-7
A. ENSURE an equipment clearance/tag out is in place and the steam trap is depressurized
and cool to the touch.
B. REMOVE cover
C. IF strainer is integral to trap THEN CLEAN or REPLACE strainer.
D. REMOVE main valve assembly
NOTE
All sealing materials should be replaced. If the seats are of the screw in type, they
should also be replaced
E. REMOVE operating mechanism

F. INSTALL new seat (if applicable)
G. IF trap was blowing through due to float failure THEN REPLACE float.
H. INSTALL operating mechanism
I. INSTALL cover using a new gasket.
J. IF trap has a bimetallic air vent assembly, THEN
a. REMOVE air vent assembly
b. REFURBISH air vent assembly with new parts (gasket. O-ring, seat, etc.)
c. INSTALL air vent assembly
K. IF strainer was not integral to trap THEN:
a. ENSURE strainer is inside equipment clearance/tag out boundary.
b. REMOVE strainer plug/cap
c. CLEAN or REPLACE strainer
d. INSTALL plug/cap using new gasket.
e. TORQUE plug/cap per vendor specifications
4.2.3 Balance Pressure Steam Trap
B. REMOVE cover (Maybe bolted, screw cap or clamped, etc)
C. REMOVE capsule and spacer plate
NOTE
Seats are typically screw type but will vary by vendor.
D. REMOVE valve seat

E. REMOVE strainer screen and CLEAN or REPLACE strainer screen
F. INSTALL new valve seat
G. INSTALL new capsule and spacer
H. INSTALL cover
I. TORQUE cover to vendor specifications.
K-8
4.2.4 Thermostatic Steam Trap
B. REMOVE cover/cap (Maybe bolted, screw cap or clamped, etc)
C. REMOVE disc or bellows assembly.
D. INSPECT seating surface
E. IF seating surface is only slightly worn or has minor steam cuts THEN LAP seating
surface using an approved lapping compound.
F. INSTALL new disc
G. INSTALL cover/cap
H. TORQUE cover/cap to vendor specifications.
I. IF steam trap has and integral strainer, THEN
a. REMOVE strainer plug/cap
b. CLEAN or REPLACE strainer
c. INSTALL plug/cap using new gasket
d. TORQUE plug/cap per vendor specifications
J. IF strainer is not integral to steam trap (e.g. located upstream of trap) THEN
4.2.5 Inverted Bucket Steam Trap

B. DISCONNECT outlet chamber
C. REMOVE cover, valve seat assembly and bucket
D. REMOVE bucket from valve lever
E. REMOVE valve seat
F. INSTALL new valve seat
G. REMOVE check valve (if installed)
H. INSTALL new check valve (if installed)
I. INSTALL new lever
J. INSTALL bucket on valve lever
K. INSTALL valve seat assembly
L. INSTALL cover using new gasket
M. CHECK strainer by:
K-9
NOTE
Liquid expansion steam traps are calibrate at the factory for a set temperature, but can
be adjusted. Amount of adjustment will vary by vendor. Typically the trap may be
adjusted approximately 50 degrees F.
4.2.6 Liquid Expansion Steam Trap
NOTE
Steam trap should be in service during trap temperature adjustment to observe
response.
A. Adjusting trap operating point

a. LOOSEN adjustment locknut
b. 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. ADJUST trap to desired setting
d. TIGHTEN adjustment locknut
B. Changing the temperature element
a. REMOVE trap (typically screw inlet and outlet)
b. REMOVE adjustment locknut
c. REMOVE overload spring
d. REMOVE adjustment nut
e. REMOVE element
f. REMOVE valve seat
g. INSTALL new valve seat
h. INSTALL new element
i. INSTALL new overload spring
j. INSTALL adjusting nut and locknut
k. INSTALL trap
l. ADJUST trap’s operating temperature using 4.2.6.A.
NOTE
Steam traps should be returned to service slowing allowing time for them to warmup.
A. Return steam trap to service

B. Check steam traps for leaks.
C. Retest steam trap for proper operation
K-10

identified.
7.0 References

B. Applicable vendor technical manuals
K-11
L
WORK PACKAGE TEMPLATE – GATE AND GLOBE
VALVES
1.0 Task Overview
1.1 Component type
This work instruction is applicable to general globe and gate valves.
Ensure unique equipment identifier is used to designate which valve is being worked.
1.3 Scope
This work instruction provides generic instruction for the inspection and minor repair of globe or
gate valves.
A. Lapping compound (various grades)

B. Container (bags) for temporary storage of studs and nuts
C. Emery cloth/crocus cloth
D. Isopropyl alcohol or acetone
E. Prussian Blue
F. Thread lubricant
A. Gaskets
B. O-rings
C. Packing
D. Lantern rings (if used)
L-1
1.6 Special tools
A. Lapping blocks (various sizes depending on valve size)

B. Torque wrenches
C. Mechanics tool box
D. Rigging equipment
2.0 Pre-job Brief
A. Foreign material exclusion and practices should be implemented prior to opening a check
valve for maintenance.
A. Additional work identified during the performance of this work instruction requires a
B. Valve to be worked should be isolated, depressurized, cooled and vented prior to work.
C. Maintain work area clean to prevent foreign material from entering open system and to
minimize the potential for unnecessary safety hazards.
D. If valve body is left unattended a cover should be placed over the opening to preclude
foreign material from entering.
E. Handle cleaning chemicals (alcohol, acetone. etc) in accordance with approved plant
procedures and MSDS.
F. Some gaskets may contain asbestos. If gaskets may contain asbestos appropriate asbestos
abatement procedures should be followed.
G. Care should be taken when handling valves and valve parts. Improper handling or undue
forces applied during disassemble and assembly could damage valves and affect
performance.

B. Chemical Control Procedures (handing and disposal)
C. Asbestos abatement procedures (if applicable)
L-2
A. Inlet isolation valve

B. Outlet isolation valve
C. If there is any power operated equipment inside the isolation boundary, then power
should be removed from that equipment.
appropriate.

L-3
A. Seats
B. Disks
C. Bolting material (Nuts, studs, etc)
D. Stem
E. Pressure seal ring (if applicable)


F. DETERMINE rigging requirements, bolts, nuts, stud sizes, laydown areas, etc)
NOTE
The following is a suggested sequence of work. Steps should be modified as required or
worked out of sequence depending on the particular valve being worked.
4.1 Disassembly
NOTE
Some steps may not be applicable depending on the check valve being worked. Those
steps should be NA’d.
A. IF valve has an operator installed, THEN REMOVE operator (AOV, MOV, reach rod,
chain operator, etc)
B. REMOVE other interferences as required to support maintenance. (air supply tubing,
limit switches, hangers, supports, snubbers, etc)
L-4
NOTE
Bonnet bolts, nuts and other small parts removed during disassembly should be
bagged, tagged and stored appropriately for reassembly.
NOTE
If a pressure seal ring is installed, its removal should be as per vendor
recommendations.
CAUTION
Valve should be off the closed seat to ensure any trapped pressure is relieved prior to
removing the bonnet.
C. DISASSEMBLE valve bonnet bolted connections, pressure seal ring bolts OR valve
flange connections from system.
D. MATCH MARK valve bonnet flanges for proper reassembly.
CAUTION
If rigging is used 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.
CAUTION
If the valve being worked is a gate valve and the gate valve discs do not have flow
direction marks, mark the discs with a marker for proper assembly.
E. INSTALL rigging to remove bonnet, stem and disc.

F. REMOVE valve bonnet, stem and disc.
G. COVER exposed piping or open valve to prevent foreign material from entering the
system.
4.2 Inspections
NOTE
Not all valves will contain all parts listed.
A. INSPECT and RECORD degradation, damage, excessive wear, corrosion, erosion,

biofouling, etc for the following valve parts.
L-5
a. Body
b. Seat surfaces
c. Disc
d. Body to bonnet gasket surface
e. Packing surfaces
f. Pins, guides, etc.
g. Bolting materials (bolts, nuts, studs, etc)
h. O-rings/gaskets
B. IF valve is a globe valve, THEN INSPECT disc anti-rotational device and NOTE any
signs of rotation.
C. CHECK seating surfaces using the bluing method.
D. REPAIR or REPLACE all damaged or degraded parts.
4.3 Valve repairs
NOTE
Lapping should be performed per approved plant procedures and training.
CAUTION
Valve seating angles should not be changed during the lapping process.
A. IF seat and disc surfaces are not badly damaged, THEN LAP seats and disc.
B. CHECK seat and disc surfaces for proper fit by bluing method.
C. REPEAT lapping until acceptable bluing is obtained.
D. CLEAN valve internals.
CAUTION
Locking devices or staking of threads is used in some applications to ensure parts do
not vibrate loose. (E.g. bolting on split clamps to attach valve yokes to bodies, setscrews
to pin globe valve stems in place, etc)
E. CHECK appropriate locking devices for tightness.
L-6
4.4 Reassembly
CAUTION
Gasket seating surfaces and pressure seal ring (if installed) should be clean to minimize
the potential for leaks after reassembly.
A. ENSURE gasket seating and pressure seal ring surfaces clean.

B. ENSURE pipe and valve flange/threads are clean.
C. CLEAN all internal parts with isopropyl alcohol/acetone.
D. INSPECT internals of valve for any foreign material.
NOTE
Match marks should be observed when installing bonnet.
NOTE
If pressure seal ring is installed it should be installed per vendor recommendations.
E. INSTALL valve bonnet, stem and disk.

F. INSTALL and TORQUE bonnet bolts, pressure seal ring or flanges as appropriate per
vendor recommendations.
G. ENSURE local position indication is correct for valve position.
H. PACK valve stem per approved plant procedures and vendor recommendations.
I. INSTALL valve operator.
J. INSTALL all interferences that were removed during disassembly.
A. Stroke valve and ensure valve operates smoothly.

B. Check for any leaks. (packing, body to bonnet, flanged connections, etc).
C. Check local indication and ensure it agrees with actual valve position.
D. If limit switches are installed for remote indication verify proper operation.

identified.
L-7
7.0 References

B. Applicable vendor technical manuals
C. Applicable valve and actuator drawings
D. Valve Packing Procedure
E. Lapping Procedure
F. Foreign Material Control Procedure
G. Material Safety Data Sheets
H. Chemical Traffic Control Procedure
L-8
M
WORK PACKAGE TEMPLATE – MULTI-STAGE
VERTICAL PUMP
NOTE
proficient) on the type of pump being worked.
1.0 Task Overview
1.1 Component type
This work instruction is applicable to a typical multistage vertical pump. (E.g. intake cooling
water, raw cooling water, and screen wash pumps, etc)
Ensure the unique pump identifier is used to designate which pump is being worked.
1.3 Scope
This work instruction provides instructions for inspection and repair of a multi-stage vertical
pump.
A. Coating material (E.g. Amerlock 400, etc)

B. Grease for O-rings (E.g. Dow Corning, etc)
C. Grease for bearings (E.g. GP-1)
D. Never-seize or equivalent
E. Neolube or equivalent
F. Silicon spray
G. Solvent (E.g. alcohol, acetone, etc)
M-1
A. Various O-rings and gaskets (Bowl, column, etc)

B. Assorted fasteners (nuts, cap screws, studs, washers)
C. Split rings
D. Impeller keys
E. Packing
F. Bottom Bearing
G. Column bearings (ensure proper thickness, Go/No-Go gauge)
H. Wear rings
1.6 Special tools
A. Mechanics tool box (wrenches, screwdrivers etc)

B. Puller for bearings and wear rings
C. Go/No-Go gauge for rubber column bearings
D. FME covers for open pump well and discharge flange
E. Cribbing for pump support
F. Timbers for shaft storage
G. V-blocks for shaft runout measurement
H. Pump column saddle support
I. Installed hoist or crane
J. Lifting fixtures (discharge head, columns, etc)
K. Rigging
L. Measurement and Test Equipment (M&TE)
a. Inside and outside Mic’s (various sizes as required by pump geometry)
b. Dial indicator
c. Feeler gauges
d. Torque wrenches (various sizes based on vendor requirements)
2.0 Pre-job Brief
A. Generation
M-2
A. Performance of this work will open pump to environment. Appropriate measures should
be taken to prevent foreign material from entering the pump.
A. DO NOT allow petroleum based products to contact the EPT O-rings of the mechanical
seal. Petroleum based products will cause the O-rings to deteriorate and fail.
B. Oil drained from the pump should be removed from the work area and properly disposed
of as soon as practical. Other wise, an appropriate transient fire load evaluation should
be performed and proper temporary storage provided.
C. Follow appropriate Material Safety Data Sheet (MSDS) and site approved procedures for
handling and disposal of cleaning chemicals and solvents.
D. Follow approved site procedures for proper draining and disposal of process fluids from
the pump.
A. Equipment Clearance Order

B. Chemical Control Permit
C. Transient combustible material storage permit
accordance with approved chemical control procedures.
M-3
A. Pump discharge valve

B. Pump Vent valve
C. Pump Drain valve
D. Power to motor
E. Power to motor space heaters
F. Power to heat tracing (if applicable)
G. Supply and discharge to motor cooling water (if applicable)
H. Lube water supply
appropriate.


A. Impellers
B. Impeller liners
C. Couplings Pump half, motor half, shaft)
D. Suction Bell (Pre-coated)
E. Pump bowls (Pre-coated)
F. Columns (Pre-coated)
G. Pump Shaft
H. Complete bowl assembly
I. Discharge head
M-4
J. Coating material (E.g. Amerlock 400, Belzona, etc)


4.1 Preparations

B. LOCATE and IDENTIFY proper piece of equipment is being worked per the work
instruction
C. ENSURE piping, equipment supports, and other interferences are removed to support
work.
D. ENSURE all rigging to be used is inspected and in good condition prior to use.
E. IF installed, THEN REMOVE insulation.
CAUTION
Appropriate rigging techniques should be observed during motor removal.
4.2 Motor Removal

A. DISCONNECT motor cooling lines (if applicable)
B. INSPECT motor cooling lines for any biofouling, silt, corrosion, etc.
C. PROVIDE FME protection for open lines.
NOTE
Ensure as-found coupling gap is measured and recorded.
D. DISCONNECT coupling.
E. REMOVE motor.
NOTE
Depending on pump not all parts will be applicable.
M-5
CAUTION
Some packing material contains lead. Refer to appropriate MSDS for proper handing
and disposal
4.3 Disassembly and removal of discharge head

A. REMOVE adjusting plate, pump half coupling and key
B. REMOVE gland and packing
C. REMOVE shaft sleeves and O-Rings
D. REMOVE stuffing box and O-Rings
E. REMOVE bearing
F. REMOVE discharge head to sole plate nuts
G. MATCH MARK column to discharge head.
H. LIFT pump and INSTALL saddle support between the outer column upper flange and
sole plate
I. REMOVE discharge head.
J. INSTALL FME cover for pump well
4.4 Disassembly of columns and line shafts
NOTE
All columns should be match marked before they are disassembled.
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.
A. LIFT pump assembly to relieve pressure off saddle support.

B. REMOVE saddle support.
C. LIFT pump assembly until upper flange of next column is high enough to install saddle
support.
D. INSTALL saddle support and lower pump assembly on to support.
E. REMOVE outer column and bearing retainer
F. DISCONNECT line shaft coupling.
G. SECURE shaft coupling to prevent sliding down the shaft.
H. REMOVE line shaft and coupling.
I. REPEAT steps 4.3.A through 4.3.H until all columns and line shafts are removed.
CAUTION
Cover should be installed over pump well when open to prevent foreign material form
entering and prevent personnel injury.
M-6
4.5 Disassembly or Bottom column section
A. REMOVE the last column section and pump from well.

B. INSTALL cover over open pump well.
NOTE
Shaft should be clean and lubricated prior to sliding coupling along shaft.
NOTE
Pump assembly should be supported by cribbing.
C. MOVE pump to predetermined and prepared work area

D. MATCH MARK bottom column section to pump assembly
E. REMOVE bottom column and bearing retainer.
F. DISCONNECT coupling
G. SECURE coupling to prevent sliding down shaft
H. REMOVE line shaft and coupling
4.6 Impeller Bowl disassembly
NOTE
The number of impeller bowls differ form one installation to another. Impeller bowl
designs differ from vendor to vendor.
NOTE
Pump bowls and other parts should be match marked as necessary prior to
disassembly to aid in assuring proper reassembly.
NOTE
Shaft should be clean and lubricated prior to sliding impeller along shaft.
A. Upper bowl disassembly

a. REMOVE upper bowl from pump assembly.
b. SLIDE impeller from shaft and remove impeller key.
c. REMOVE next bowl from pump assembly.
d. REMOVE thrust collar and associated parts.
e. SLIDE next stage impeller from shaft and remove impeller key.
B. Remaining bowls disassembly

a. REMOVE bowl from pump assembly.
b. SLIDE impeller from shaft and remove impeller key
M-7
c. REPEAT steps a and b above until last bowl is removed from suction bell and
first stage impeller is removed.
4.7 Inspection of Pump components
NOTE
All pump components should be inspected for general conditions such as excessive
wear, corrosion, cracks, pitting, coating condition, etc.
NOTE
Components may be machined, polished or reconditioned as necessary as long as
component tolerances are maintained.
NOTE
All damaged, out of tolerance or excessively worn components should be replaced. All
elastomers should be replaced.
NOTE
Because line shafts are typically symmetrical, if they meet runout tolerances but show
excessive wear in the bearing area, they can be inverted.
A. MEASURE the following shafts for runout and excessive wear in bearing regions.
NOTE
Runout tolerances are per facility or vendor recommendation.
a. Pump shaft
b. Line shafts
c. Column shafts
B. MEASURE the following bearings in two directions to ensure eccentricity.
a. Top shaft bearing

b. Bowl bearing
c. Bottom bearing
NOTE
Bearing material varies by vendor. (e.g. bronze, rubber, etc.)
C. Inspection of column bearings
a. MEASURE inside diameter of bearings (tolerance as per vendor
recommendation)
M-8
b. REPLACE bearings that do not meet acceptance criteria.
NOTE
All components not meeting vendor tolerances should be replaced.
D. Inspection of impellers, wear rings and impeller liners

a. INSPECT impellers for cavitation damage and damage from impeller dragging
against impeller liner.
b. INSPECT impeller liners for damage caused by impeller dragging against liner.
c. MEASURE clearance between bowl wear rings and impeller wear area.
E. INSPECT stuffing box threaded pipe connections (lube water) for corrosion, erosion,
etc.
F. Inspection of pump bowls and suction bell
a. INPSECT coatings (inside and outside) on all bowls and suction bell.
b. REPAIR any damaged coatings
NOTE
If the bowls and suction bell are coated and there is no degradation in the coatings,
there is no need to measure wall thickness.
c. MEASURE wall thickness.

d. IF wall thickness does not meet acceptance criteria, THEN REPLACE bowl.
G. Inspection of columns
a. INSPECT coatings on all columns
b. REPAIR any damaged coatings
c. INSPECT columns for any cracks.
NOTE
If the columns are coated and there is no degradation in the coatings, there is no need
to measure wall thickness.
d. MEASURE column wall thickness is acceptable (per vendor recommendation)

e. IF column is cracked or wall thickness is unacceptable, THEN REPAIR or
REPLACE column.
H. Inspection of discharge head
a. INSPECT discharge head coatings.

b. IF coatings are damaged, THEN REPAIR coatings.
c. INSPECT discharge head for cracks.
d. IF discharge head has cracking, THEN REPAIR or REPLACE discharge head.
M-9
4.8 Pump Assembly
NOTE
Lubricate all nuts and screws with approved lubricant during assembly.
NOTE
Lubricate all elastomers with approved lubricant during assembly.
NOTE
Torque of nuts and screws is to be accomplished as per plant instructions.
4.8.1 Assembly of pump bowls
A. ASSEMBLE first stage impeller, thrust collar and associated parts onto the pump shaft.
B. INSTALL O-ring on suction bell.
C. LUBRICATE bottom bearing and affected area of pump shaft.
D. INSTALL pump shaft into suction bell.
E. INSTALL and TORQUE first stage suction bowl onto suction bell.
F. ASSEMBLE remaining suction bowls as follows.
NOTE
After the next stage impeller is installed it should be verified that the impellers seat
simultaneously.
a. ASSEMBLE impeller, thrust collar and associated parts onto the pump shaft.
b. VERIFY impellers seat simultaneously. (Use a feeler gauge and tolerance should
be as per vendor technical manual recommendation)
c. IF impellers do not seat simultaneously, THEN MACHINE either impeller split
rings or impeller liner
d. INSTALL O-ring onto previously installed bowl.
e. INSTALL and TORQUE next stage bowl on to previous stage bowl.
f. REPEAT (a – e) above for remaining bowls until pump assembly is complete.
CAUTION
Excessive grease in the bottom bearing cavity may hydraulically restrict shaft from
lowering into the position required for impeller adjustment.
G. LUBRICATE suction bell bottom bearing cavity.

H. BOTTOM OUT shaft in bottom bearing cavity.
I. PACK bottom bearing cavity full of grease.
M-10
NOTE
Shafts, couplings, split rings, keys, etc should be clean, lubricated and free of dirt to
prevent galling during assembly.
4.8.2 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.
A. ENSURE coupling and key is installed and secured on shaft to prevent sliding during
assembly.
B. ENSURE pump assembly is vertical and firmly supported on cribbing.
C. INSTALL and TORQUE lower line shaft to pump assembly.
D. INSTALL O-ring onto top bowl.
E. INSTALL and TORQUE lower column to pump assembly.
F. LUBRICATE and INSTALL bearing into lower column bearing retainer.
4.8.3 Installation of lower pump assembly in pump well
A. MOVE pump and lower column assembly to pump well.

B. REMOVE pump well cover.
C. LOWER pump allowing clearance to install saddle support.
D. INSTALL saddle support.
E. LOWER pump onto saddle support.
4.8.4 Installation of line shafts and columns
NOTE
Repeat the following steps until all line shafts and columns have been assembled.
NOTE
Columns, shafts, couplings, split rings, keys, etc should be clean, lubricated and free of
dirt to prevent galling during assembly.
NOTE
Refer to match marks during assembly.
A. ENSURE coupling and key is installed and secured on shaft to prevent sliding during
assembly.
B. POSITION, INSTALL and TORQUE line shaft to preceding line shaft.
C. INSTALL O-ring onto column.
M-11
D. POSITION, INSTALL and TORQUE column to preceding column.
E. LIFT pump column assembly to clear saddle support
F. REMOVE saddle support.
G. LOWER pump assembly and POSITION saddle support.
H. LUBRICATE and INSTALL bearing into column bearing retainer.
I. REPEAT steps [A] through [H] until all line shafts and columns have been assembled
and installed.
4.8.5 Installation of discharge head
NOTE
All gasket seating surfaces should be clean and free of debris.
A. LUBRICATE and INSTALL O-ring onto top column.

B. INSTALL and TORQUE discharge head to upper column.
C. INSTALL discharge flange gasket.
D. LIFT pump from saddle support.
E. REMOVE saddle support.
F. LOWER discharge head while aligning flange seating surfaces and gasket.
G. TORQUE discharge head to sole plate and discharge head to pipe flange using approved
torque methods.
4.8.6 Final Assembly
A. INSTALL stuffing box, throttle bushing and O-rings.

B. INSTALL shaft sleeve and O-rings.
C. INSTALL pump half coupling and adjusting plate.
D. INSTALL motor.
E. INSTALL any interferences removed during disassembly. (E.g. hangars. Supports, etc)
F. RELEASE clearance/tag out on motor.
G. BUMP motor to ensure proper rotation.
H. REHANG clearance/tag out on motor.
I. ADJUST impeller lift per vendor recommendation.
J. INSTALL pump packing as per vendor recommendation.
K. INSTALL and ENSURE gland is square to stuffing box.
L. INSTALL lube water lines.
M. INSTALL motor cooling water lines (if applicable)

B. PERFORM vibration testing
C. PERFORM flow testing to verify that pump lift is satisfactory.
M-12
NOTE
Packing and leak-off flow should be monitored closely during initial break-in following
maintenance.
D. ADJUST packing to achieve proper leak-off flow.

E. MONITOR gland temperature during break-in run.
F. VERIFY no system leaks.
G. IF insulation was removed, THEN INSTALL insulation.
H. IF heat tracing is installed and was removed, THEN INSTALL heat tracing.
I. Work site cleanup - CLEAN work area to original pre-maintenance conditions
J. DISPOSE of any generated waste products properly.
K. RETURN unused parts to storeroom

identified.
7.0 References

F. Vendor Technical Manual (Pump)
M-13
Figure M-1
Cross-section of a typical multistage vertical pump.
M-14
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 Page Number Key Point

Section
To best meet the competitive challenge the
continually improving maintenance organization is
2.1 finding ways to work smarter. Working smarter
means being ready for the expected and the
unexpected.
The labor resource is one of the largest and
expensive within the maintenance department. If
2.1 the labor resource is not being utilized effectively
and efficiently, a significant amount of money is
being wasted.
The work package template will provide the
maintenance organization with a more accurate and
2.2 efficient tool for the scheduling and execution of
maintenance activities.
There will be short term costs associated with the
2.4 development of the specific work packages but the
long term gains will outweigh these costs.
The planner should be aware that contingency parts
may or may not be necessary to support the job.
3.3 This can be a significant financial decision since
most contingency parts tend to be high cost items
that are not maintained in normal inventory.
N-1
N.2 Key Human Performance Points

Sometimes it is not necessary to measure the “goodness” of your safety
culture, as it is to recognize signs that are indications of a poor or failing
safety culture. Some of the key indicators of a poor or failing safety culture
are easily observable.

Section
Work packages provide the maintenance
craftsman with the level of detail necessary to
2.1 perform a work activity correctly, efficiently and
safely.
The planning walkdown is essential for the
2.5 development of pre-job considerations and
contingencies.
The review of operating experience can help
reduce risk to both personnel and equipment by
3.2 learning from past mistakes or problems that have
been encounter in the industry or at the given
facility.
Feedback is a credible source of information that
can result in the improvement in the organization
3.6 of work, support worker performance, improve
job productivity and identify opportunities to
strengthen human performance and reduce errors.
N-2
N.3 Key Technical Points
Key Technical Point

Targets information that will lead to improved equipment reliability.

Section
The use of developed work package templates
allows the maintenance organization to move
2.1 from the fire-fighting mode of performing work to
an operational mode that is structured and
proactive.
The level of effort placed on contingency
planning should be commensurate with the scope
3.3 and significance of the maintenance activity. The
planner should attempt to anticipate necessary
contingencies based on previous work experience,
operating history and other intelligence.
N-3
Export Control Restrictions The Electric Power Research Institute (EPRI)
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Effective December 6, 2006, this report has been made publicly available in

accordance with Section 734.3(b)(3) and published in accordance with

Work Package Templates

Technical Update, February 2007

EPRI Project Manager

ELECTRIC POWER RESEARCH INSTITUTE

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Electric Power Research Institute (EPRI)

2 WORK PACKAGE TEMPLATES ...........................................................................................2-1

3 WORK PACKAGE TEMPLATE FORMAT .............................................................................3-1

A WORK PACKAGE TEMPLATE – BELT DRIVEN EQUIPMENT ......................................... A-1

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

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

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

E WORK PACKAGE TEMPLATE – MOTOR CONTROL CENTER/LOAD CONTROL CENTER

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

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

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

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

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

K WORK PACKAGE TEMPLATE – STEAM TRAPS .............................................................. K-1

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

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

N LISTING OF KEY INFORMATION ....................................................................................... N-1

1.3 Report Structure and Overview

1.4 Glossary of Terms and Acronyms

1.4.1 Industry Definitions and Nomenclature

Key O&M Cost Point

Key Human Performance Point

Key Technical Point

Key O&M Cost Point

Key Human Performance Point

If the maintenance organization finds itself in a position of constantly reacting to

Key Technical Point

Key O&M Cost Point

2.2 Benefits of Work Package Templates

Key O&M Cost Point

2.4 How to Use the Templates

Key O&M Cost Point

2.5 Planning Walkdowns

Key Human Performance Point

3.2 Pre-Job Considerations

Key Human Performance Point

3.3 Contingency Considerations

Key Technical Point

Key O&M Cost Point

3.6 Feedback Mechanisms

Key Human Performance Point

1. Industrial Safety Manual

1.1 Component type

1.2 Equipment tag or unique equipment identifier

2.0 Pre-job Brief

2.1 Evaluate potential for generation or equipment risk hazards

2.2 Identify Foreign Material Exclusion (FME) potential and mitigation

A. If work is performed inside plenums foreign material exclusion areas should be

2.3 Job Safety Analysis, Identifies general and specific hazards

2.4 Identify permits required

A. Equipment Clearance/Tag out Orders

2.6 Identify Operating Experience

2.7 Identify Clearance/Tag out Boundary

A. Motor to fan, compressor, cooler, AHU, etc

3.0 Contingency Considerations

3.2 Identify individuals to contact in case certain events occur

* If impeller was removed *

* If shaft was removed *