ATTACHMENT 2

GAS TURBINE 7FA MAINTENANCE

Contractors Planned Maintenance Scope of Work for Gas Turbine

The outage release time shall be defined as the point in time when the unit lock out tag out is complete and the unit is off turning gear. Outage duration excludes time for water wash, DLN tuning, performance testing or non-supplied work scope hold points.

All acceptance points at the completion of the outages described below shall be covered at the point in time the Contractors work is mechanically complete and releases the unit for turning gear.

The Contractor shall complete a HGPI and MI of the gas turbine in accordance with current turbine OEM guidelines in effect during this contract. The Contractor shall conduct a Minor and Major Inspection of the covered generator in accordance with current generator OEM guidelines in effect during this contract.

Gas Turbine (GT) Scheduled Maintenance

1) Hot Gas Path Inspection

a) Planning

i) Contractor shall meet with Austin Energy at least 180 days prior to start of outage to confirm dates and review work scope (both planned and unplanned).

(1) Confirm availability of parts to be supplied under the scope of this contract. This shall include the following by part serial number:

(a) Repairs and refurbishment cycles

(i) Number of times

(ii) When

(iii) What

(b) Total Factored Fired Hours on the part

(c) Total Factored Fired Starts on the part

(d) Part manufacturer and date of manufacture

(2) Verify/inventory any special tools and/or customer required parts.

ii) Contractor shall meet with Austin Energy at least 90 days prior to outage start to review work scope and schedule.

iii) Contractor shall meet with Austin Energy at least 30 days prior to outage:

(1) Review work scope and outage

(2) Confirm parts and special tools

(3) Review Level 3 proposed outage schedule and work scope. The proposed outage schedule shall be provided in a Microsoft Project file.

(4) Take pre-shutdown data

(5) Identify Project Manager and Field Engineers.

b) Preparation

(i) The contractor will adhere to Contractor Work Requirements, Lock Out/Tag Out procedures.

c) Disassembly

Contractor shall perform the services described below.

i) Document all abnormal, as-found conditions on an appropriate data sheet or form, with illustration such as sketch or digital image to be submitted, discussed, and confirmed by the authorized Austin Energy representative.

ii) Turbine Compartment

(1) Remove turbine compartment roof.

(2) Remove exhaust and inlet duct access panels.

iii) Combustion Section:

(1) Remove flame detectors.

(2) Remove spark plugs.

(3) Remove the gas fuel flex hoses.

(4) Remove the fuel nozzle/end cover assemblies.

(5) Remove the Cap Assembly from the cover and casing assembly.

(6) Remove combustion liners and crossfire tubes.

(7) Remove flow sleeves.

(8) Remove outer crossfire tubes.

(9) Remove outer combustion casings.

iv) Turbine Section:

(1) Take opening compressor and turbine rotor position checks.

(2) Remove upper-half cooling and sealing air piping.

(3) Remove turbine thermocouples.

(4) Place mechanical support jacks under unit casings.

(5) Remove turbine casing bolts and 1st stage nozzle top key and clamps.

(6) Remove upper-half turbine casing.

(7) Remove transition pieces.

(8) Take 1st stage nozzle radial concentricity checks.

(9) Remove upper-half 1st stage nozzle.

(10) Remove upper-half, 1st stage nozzle support ring.

(11) Take turbine rotor float (thrust clearances).

(12) Take turbine clearance checks.

(13) Remove lower-half 1st stage nozzle, key, and nozzle clamps.

(14) Remove lower-half 1st stage shroud blocks.

(15) Remove lower-half 2nd and 3rd stage nozzle radial retaining pins.

(16) Remove lower-half 2nd and 3rd stage nozzle segments.

(17) Remove upper-half 2nd and 3rd stage nozzle radial retaining pins.

(18) Remove upper-half 2nd and 3rd stage nozzle segments.

(19) Remove 1st and 2nd stage buckets.

(20) Remove UH/LH 3rd stage shroud blocks.

d) Inspection

i) Combustion component Inspections:

(1) Fuel nozzle inspection.

(2) Clean and inspect gas fuel injectors.

(3) Reassembly of injectors to end covers.

(4) Inspect and test spark plugs.

(5) Inspect and test flame detectors.

(6) Inspect combustion caps and liners.

(7) Inspect crossfire tubes and retainers.

(8) Inspect combustion chamber flow sleeve.

(9) Inspect combustion outer casings.

(10) Inspect transition pieces.

ii) Inspect 1st, 2nd, and 3rd stage nozzles.

(1) Nozzle cracking

(2) Nozzle foreign object damage.

(3) Corrosion or erosion of nozzles.

(4) Nozzle and Diaphragm seal conditions for continued service.

iii) Inspect 1st, 2nd, and 3rd stage buckets.

(1) 1st stage buckets

(a) Cracks

(b) Dents

(c) Missing metal

(d) Corrosion

(2) Inspect Radial Seal Pin Grooves.

(3) Inspect Wheelspace Seal/Angle Wings.

(4) Perform eddy current inspections (ECI) on the 1st and 2nd stage turbine wheels per TIL’s 1280 and 1540.

(5) Inspect Shroud Tips

(6) Inspect Shroud Blocks

(7) Inspect 2nd and 3rd Stage Diaphragm Segments

(8) Take 1st stage nozzle ellipticity (flattening) checks.

iv) Compressor/IGV

(1) Clean and NDT IGV airfoils for cracks and erosion. Document, report, and discuss all results with the authorized AE representative.

(2) Check all airfoils for angle, lift, and backlash. Check both fully open and fully closed positions. Check for binding and movement. Document, report, and discuss all results with the authorized AE representative.

e) Reassembly

i) Turbine/Combustor

(1) Install lower-half 1st stage nozzle, key, and nozzle clamps.

(2) Install lower-half 2nd and 3rd stage nozzle segments.

(3) Install lower-half 2nd and 3rd stage nozzle radial retaining pins.

(4) Install Row 1 and Row 3 Shroud Blocks.

(5) Take and record turbine clearances.

(6) Install upper half 1st stage nozzle support ring.

(7) Install upper half 1st stage nozzle.

(8) Take and record 1st stage nozzle concentricity.

(9) Install upper-half 2nd and 3rd stage nozzle segments.

(10) Install upper-half 2nd and 3rd stage nozzle radial retaining pins.

(11) Install upper-half turbine casing.

(12) Thrust check

(13) Install upper-half 1st stage nozzle clamps, key, and shims.

(14) Install Transition Pieces and replace access cover.

(15) Install Turbine thermocouples.

(16) Install upper-half cooling and sealing air piping.

(17) Remove jacks and supports from under Turbine casing.

(18) Take and record final rotor position checks.

(19) Install outer combustion chambers and outer crossfire tubes.

(20) Install flow sleeves/replacement piston ring, crossfire tubes, and combustion liner assemblies.

(21) Install spark plugs.

(22) Assemble the fuel nozzle/end cover to the fuel nozzle casing.

(23) Assemble the cap to the fuel nozzle and casing assembly.

(24) Assemble the fuel nozzle casing to the combustion casing.

(25) Install tertiary cooling lines and atomizing air purge lines.

(26) Install diffusion passage and atomizing air purge lines.

(27) Install primary, secondary, tertiary, and quaternary gas fuel lines.

(28) Install flame detectors and cooling water manifolds.

(29) Install turbine compartment roof.

(30) Reassemble inlet and exhaust duct panels.

(31) Reassemble turbine compartment roof components and side panels.

f) Startup Checks

i) After any activity or evolution that compromises the integrity of a previously complete and functional system, equipment, or device, the Contractor shall restore those items to the proper configuration and verify correct and complete by measurement and test.

ii) Clean up all lube oil and water spills.

iii) Make a visual inspection of the unit, check to ensure that the following has been completed:

(1) Check that all removed piping has been reinstalled properly.

(2) Check that all removed conduit has been reinstalled and electrical connections have been made.

(3) Confirm proper operation of all devices. Document, report, and discuss any abnormal or unexpected findings with the authorized Austin Energy representative.

(4) Correct any gas, oil, and water leaks observed.

(5) Inspect inlet and exhaust duct plenums for cleanliness and secure shut.

(6) Verify all means and devices used to by-pass safeguards, alarms, and the like, including hard-wired and software jumpers (e.g., points off scan), as well as the purposeful set-point changes, have been removed and/or returned to the safe and normal operating configuration. The authorized AE representative on shift must confirm the log/record indicates all items are restored and then countersign in agreement.

(7) Remove locks and sign-off of the applicable Lock Out/Tag Out tags and forms.

iv) Reconnect power to all systems disabled at start of job.

v) Re-arm the fire protection system.

vi) Perform pre-cranking checks as follows:

(1) Record all panel counter readings.

(2) Check operation of the emergency lube oil pump.

(3) Perform a visual inspection to verify oil is flowing in bearing drains.

(4) Block out generator excitation and generator breaker equipment.

vii) Place unit on turning gear for two to eight hours until gap voltages on bearing vibration probes are steady and no longer change.

(1) Observe for leaks, abnormal noises, or control issues. Document, report, and discuss any abnormalities or issues to the authorized Austin Energy representative.

viii) Crank the unit and perform the following checks:

(1) Observe pickup RPM of speed sensors versus time.

(2) Inspect for casing air leaks.

(3) Observe and record vibration levels.

(4) Observe and record maximum crank speed.

(5) Check starting means for proper operation.

(6) Listen for abnormal noises. Document, report, and discuss any abnormalities to the authorized Austin Energy representative.

(7) Check temperature of lube oil in bearing drains or at the bearing header and tank.

(8) Observe all panel pressure gauge readings for abnormalities. Document, report, and discuss any abnormalities to the authorized Austin Energy representative.

(9) Trip unit using the emergency trip and listen for abnormal noises from gas turbine and associated equipment during shutdown. Document, report, and discuss any abnormalities to the authorized Austin Energy representative.

(10) Observe proper drop-out RPM of speed sensors.

ix) Initiate a start and perform the following zero to full-speed-no-load checks:

(1) Observe applicable firing check parameters.

(2) Observe and record acceleration rates.

(3) Record full set of vibration readings.

(4) Observe and record temperature suppression set point.

(5) Observe and record pickup time of all appropriate electrical speed relays.

(6) Adjust full-speed-no-load rpm to specifications.

(7) Check digital set point

(8) Take a complete set of running data and record on operating data form.

x) On-Line Checks

(1) Take a set of load data and record at pre-selected loads and base load.

(2) Check for air, oil, gas, and water leaks.

(3) Contractor shall be responsible for repairing all air, oil, gas, and water leaks which are a result of their work scope both planned and unplanned.

xi) Shutdown Checks

(1) Note and record coast-down time.

(2) Listen for abnormal noises from gas turbine and associated equipment during coast down.

(3) Observe unit vibration readings during coast-down. Document, report, and discuss any abnormalities to the authorized Austin Energy representative.

g) Perform DLN Tuning

2) Major Inspection

a) Planning

i) Contractor shall meet with Austin Energy at least 180 days prior to start of outage to confirm dates and review work scope (both planned and unplanned).

(1) Confirm availability of parts to be supplied under the scope of this contract. This shall include the following by part serial number:

(a) Repairs

(i) Number of times

(ii) When

(iii) What

(b) Total Factored Fired Hours on the part

(c) Total Factored Fired Starts on the part

(d) Part manufacturer and date of manufacture

(2) Verify/inventory any special tools and/or customer required parts.

ii) Meet with Austin Energy at least 90 days prior to outage start to review work scope and schedule.

iii) Meet with Austin Energy at least 30 days prior to outage:

(1) Review work scope and outage.

(2) Confirm parts and special tools.

(3) Review Level 3 proposed outage schedule and work scope. The proposed outage schedule shall be provided in a Microsoft Project file.

(4) Take pre-shutdown data.

(5) Identify Project Manager and Field Engineers.

b) Preparation

(i) Contractor and Austin Energy to review and agree on what items need to be locked-out and tagged for safe work conditions. Contractor to sign-on to the applicable Austin Energy applied Lock Out/Tag Out tags and forms, then attach the Contractor’s own locks.

(ii) As an integral part of the Lock Out/Tag Out process, Contractor shall maintain a log/record of all means and devices used to by-pass safeguards, alarms, and the like, to include but not be limited to hard-wired and software jumpers, as well as the purposeful control system set-point changes. The authorized Austin Energy representative on-shift must countersign all additions and removals.

c) Disassembly

i) All abnormal, as-found conditions must be documented on the appropriate data sheet or form, with illustration such as sketch or digital image, and then confirmed by the authorized Austin Energy representative.

ii) Preliminary Steps:

(1) Remove the starting means coupling.

(2) Check Torque Converter to Generator alignment.

(3) Check Turbine-Generator alignment.

(4) Remove the instrumentation.

iii) Turbine Compartment

(1) Remove turbine compartment roof.

(2) Remove exhaust and inlet duct access panels.

iv) Combustion Section

(1) Remove the air purge supply line to the purge module.

(2) Remove flame detectors.

(3) Remove the spark plugs.

(4) Remove the gas fuel flex hoses and manifolds.

(5) Remove the cooling and sealing air pipe.

(6) Remove the fuel nozzle/end cover assemblies.

(7) Remove the Cap Assembly from the cover and casing assembly.

(8) Remove combustion liners and crossfire tubes.

(9) Remove flow sleeves.

(10) Remove outer crossfire tubes.

(11) Remove outer combustion casings.

v) Turbine Section

(1) Take and record as found Compressor and Turbine Rotor position checks.

(2) Remove upper-half piping.

(3) Remove inlet plenum upper half.

(4) Remove turbine compartment upper half.

(5) Place mechanical support jacks under unit casings and inlet bellmouth.

(6) Remove the exhaust frame.

(7) Remove upper-half exhaust frame and air cone.

(8) Remove turbine casing bolts and 1st stage nozzle top key and clamps.

(9) Remove upper-half turbine casing.

(10) Remove transition pieces.

(11) Take 1st stage nozzle radial concentricity checks.

(12) Remove upper-half 1st stage nozzle.

(13) Remove upper-half 1st stage nozzle support ring.

(14) Take and record as found Turbine clearances.

(15) Remove lower-half 1st stage nozzle key and nozzle clamps.

(16) Remove lower-half 1st stage nozzle.

(17) Remove lower-half 2nd and 3rd stage nozzle radial retaining pins.

(18) Remove lower-half 2nd and 3rd stage nozzle segments.

(19) Remove upper-half 2nd and 3rd stage nozzle radial retaining pins.

(20) Remove upper-half 2nd and 3rd stage nozzle segments.

(21) Remove 1st, 2nd, and 3rd stage buckets

(22) Remove 1st and 2nd stage shroud blocks.

vi) Compressor Section

(1) Remove upper-half inlet casing.

(2) Remove mid-compressor casing.

(3) Remove compressor discharge casing.

(4) Remove upper-half inner compressor discharge casing.

(5) Take and record as found rotor thrust and compressor clearances.

(6) Remove bellmouth and disassembly IGV rack/actuator.

(7) Remove Compressor-Turbine Rotor.

(8) Remove compressor bleed valves and actuators.

vii) Bearings

(1) Remove # 1 bearing cap and bearing.

(2) Take and record # 1 bearing and seals clearances.

(3) Remove # 2 bearing cap and bearing.

(4) Take and record # 2 bearing and seals clearances.

(5) Roll-out the lower bearing halves for inspection.

viii) Lube Oil System:

(1) Drain lube oil reservoir.

(2) Store the lube oil in a suitable container which shall have secondary containment. Clean and vacuum dehydrate oil while in storage container.

(3) Remove both AC Lube oil pumps, disassemble, inspect, replace bearings, and reassemble.

(4) Remove the DC Lube Oil Pump and DC Seal Oil Pump, disassemble, inspect, replace bearings, and reassemble.

(5) Clean and inspect the lube oil reservoir.

d) Inspection

i) Combustion component Inspections:

(1) Fuel nozzle inspection.

(2) Clean and inspect gas fuel injectors.

(3) Reassembly of injectors to end covers.

(4) Inspect and test spark plugs.

(5) Inspect and test flame detectors.

(6) Inspect combustion caps and liners.

(7) Inspect crossfire tubes and retainers.

(8) Inspect combustion chamber flow sleeve.

(9) Inspect combustion outer casings.

(10) Inspect transition pieces.

(11) Inspect flow sleeve and replace piston ring.

ii) Turbine Section

(1) Inspect 1st, 2nd, and 3rd stage nozzles.

(a) Nozzle cracking

(b) Nozzle foreign object damage.

(c) Corrosion or erosion of nozzles.

(2) Inspect 1st, 2nd, and 3rd stage buckets.

(a) 1st stage buckets

(i) Cracks

(ii) Dents

(iii) Missing metal

(iv) Corrosion

(b) Inspect 2nd and 3rd stage buckets.

(i) Cracks

(ii) Missing metal

(iii) Dents

(iv) Air-cooled 2nd stage buckets

(v) Corrosion

(3) Inspect Radial Seal Pin Grooves.

(4) Inspect Wheelspace Seal/Angle Wings.

(5) Inspect Shroud Tips

(6) Inspect 1st, 2nd, and 3rd stage Shroud Blocks

(7) Inspect 2nd and 3rd Stage Diaphragm Segments

(8) Take 1st stage nozzle ellipticity (flattening) checks.

(9) Inspect 1st stage nozzle support ring.

(a) Check for rotor seal damage or wear.

(b) Check nozzle support pad seal fit for galling or fretting.

(10) Clean and inspect turbine casing.

(11) Clean and inspect rotor dovetail and locking ring areas for cracking as required.

(12) Take turbine rotor run out checks.

(13) Clean and measure journal.

iii) Compressor

(1) Clean and inspect compressor rotor. Take run-out checks on coupling and journals.

(2) Clean and inspect rotating compressor blading.

(3) Clean and inspect Inlet Guide Vanes and replace bushings, pinion gears and rack.

(4) Clean and inspect compressor casing.

(5) Clean and inspect compressor stator blades for binding, wear, cracking, and rubs. Replace as necessary.

(6) Perform UT inspection on R-0 blades, R1 blades, and S1 vanes. Per latest

OEM guidance to current TIL. Document and report any abnormalities or indications and discuss with the authorized AE representative.

(7) Take dental molds on R-0 blades. Guidance to current TIL.

(8) Replace RO blades if necessary.

iv) Bearings

(1) Visually and dimensionally inspect bearings (No. 1, 2 and thrust bearing).

(2) Inspect and check the bearing tilt pads. Ensure that the lower pad support pins to not have fretting or excessive wear.

(3) Perform UT bonding check on bearings.

(4) Measure journal diameter at two planes fore and aft. Check for roundness and taper on the journal.

e) Reassembly

i) Bearings

(1) Roll-in the lower half of the bearings.

(2) Reassemble and install the thrust bearing.

(3) Install the upper half of the bearings.

ii) Turbine/Compressor/Combustor

(1) Reassemble 1st, 2nd, and 3rd stage buckets to the turbine wheel.

(2) Install the compressor rub ring.

(3) Install the lower-half 1st stage nozzle, key, and nozzle clamps.

(4) Install the lower half 2nd and 3rd stage nozzle segments.

(5) Install the lower-half 2nd and 3rd stage nozzle radial retaining pins.

(6) Install 2nd and 3rd stage shroud blocks.

(7) Check rotor clearances and thrust. Record results.

(8) Install the compressor discharge casing upper half.

(9) Install upper-half 1st stage nozzle support ring.

(10) Install upper-half 1st stage nozzle.

(11) Check 1st stage nozzle concentricity.

(12) Install upper-half 2nd and 3rd stage nozzle segments.

(13) Install upper-half 2nd and 3rd stage nozzle radial retaining pins.

(14) Install upper-half turbine casing.

(15) Install upper-half 1st stage nozzle clamps, key, and shims.

(16) Install transition pieces and replace access cover.

(17) Install the upper-half forward and aft compressor casings.

(18) Install the upper-half inlet casing.

(19) Install exhaust air cone and exhaust frame.

(20) Reassemble exhaust inner diffuser end cover.

(21) Remove casing jacks.

(22) Install turbine compartment aft wall.

(23) Reassemble the upper-half inlet plenum.

(24) Reassemble upper-half piping.

(25) Take final rotor position checks and record results.

(26) Install outer combustion chambers and outer crossfire tubes.

(27) Install flow sleeves, crossfire tubes, and combustion liners assemblies.

(28) Install spark plugs.

(29) Install fuel nozzle/end cover assemblies.

(30) Assemble the cap to the fuel nozzle and casing assembly.

(31) Assemble the fuel nozzle casing to the combustion casing.

(32) Install the cooling and sealing air pipe and air extraction pipe.

(33) Install gas fuel manifolds and flex hose.

(34) Install flame detectors and cooling water manifolds.

(35) Install air purge supply line to the purge module.

(36) Install inlet and exhaust duct access panels.

(37) Install turbine compartment roof sections.

(38) Re-bolt roof sections to sidewall frames, reconnect electrical conduit and wiring and reinstall turbine compartment side panels and/or doors.

(39) Reinstall turbine instrumentation (AE).

(40) Check and record Turbine-Generator alignment.

(41) Reassemble the load coupling-generator flange.

(42) Check the torque converter to generator alignment.

(43) Reassemble the starting means coupling.

(44) Reinstall coupling guards and load compartment cover.

(45) Check IGV angles both fully open and fully closed for position and proper operation.

(46) Install compressor bleed valve and pressure to see that valve operates correctly.

f) Startup Checks

i) After any activity or evolution that compromises the integrity of the previously complete and functional system, equipment, or device, the Contractor shall restore those items to the proper configuration and verify correct and complete by measurement and test.

ii) Clean up all lube oil and water spills.

iii) Make a visual inspection of the unit, check to ensure that the following has been completed:

(1) Check that all removed piping has been reinstalled.

(2) Check that all removed conduit has been reinstalled and electrical connections have been made.

(3) Confirm proper operation of all devices.

(4) Correct any fuel, oil, and water leaks observed.

(5) Inspect inlet and exhaust duct plenums for cleanliness and secure shut.

(6) Verify all means and devices used to by-pass safeguards, alarms to include, but not be limited to hard-wired and software jumpers (e.g., points off scan) as well as the purposeful control system set-point changes, have been removed and/or returned to the safe and normal operating configuration. The authorized AE representative on-shift must review the log/record to confirm all items are restored and then countersign in agreement.

(7) Remove locks and sign-off of the applicable Lock Out/Tag Out tags and forms.

iv) Reconnect power to all systems disabled at start of job.

v) Re-arm the fire protection system.

vi) Perform pre-cranking checks as follows:

(1) Record all panel counter readings.

(2) Check operation of the emergency lube oil pump.

(3) Perform a visual inspection to verify oil is flowing in bearing drains.

(4) Block out generator excitation and generator breaker equipment.

vii) Place unit on turning gear.

(1) Observe for leaks, abnormal noises, or control issues. Document, report, and discuss any abnormalities or issues the authorized Austin Energy representative.

viii) Crank the unit and perform the following checks:

(1) Observe pickup RPM of speed sensors versus time.

(2) Inspect for casing air leaks.

(3) Observe and record vibration levels.

(4) Observe and record maximum crank speed.

(5) Check starting means for proper operation.

(6) Listen for abnormal noises.

(7) Check temperature of lube oil in bearing drains or at the bearing header and tank.

(8) Observe all panel pressure gauge readings for abnormalities.

(9) Trip unit using the emergency trip and listen for abnormal noises from gas turbine and associated equipment during shutdown.

(10) Observe proper drop-out RPM of speed sensors.

ix) Initiate a start and perform the following zero to full-speed-no-load checks:

(1) Observe applicable firing check parameters.

(2) Observe and record acceleration rates.

(3) Record full set of vibration readings.

(4) Observe and record temperature suppression set point.

(5) Observe and record pickup time of all appropriate electrical speed relays.

(6) Adjust full-speed-no-load rpm to specifications.

(7) Check digital set point.

(8) Take a complete set of running data and record on operating data form.

x) On-line Checks

(1) Take a set of load data and record at pre-selected loads and base load.

(2) Check for air, oil, gas, and water leaks.

(3) Contractor shall be responsible for repairing all air, oil, gas, and water leaks which are a result of their work scope both planned and unplanned.

xi) Shutdown Checks

(1) Note and record coast down time.

(2) Listen for abnormal noises from gas turbine and associated equipment during coast down.

(3) Observe unit vibration readings during coast down.

g) Perform DLN Tuning

Generator Maintenance

1) Minor Inspection----to be performed in conjunction with Hot Gas Path Inspection.

a) Shutdown and Preparation (AE)

i) Depressurize and purge generator to air.

ii) Shutdown and tag out lube oil and seal oil pumps (ensure that generator is electrically isolated and grounded).

b) Shutdown and Preparation (Contractor)

i) Perform Rotor Flux Density testing to establish baseline condition.

ii) Measure mechanical run-out of collector rings while on turning gear.

(i) Contractor and Austin Energy to review and agree on what items need to be locked-out and tagged for safe work conditions. Contractor to sign-on to the applicable Austin Energy applied Lock Out/Tag Out tags and forms, then attach own locks.

(ii) As an integral part of the Lock Out/Tag Out process, Contractor shall maintain a log/record of all means and devices used to by-pass safeguards, alarms, and the like, including hard-wired and software jumpers, as well as the purposeful set-point changes. The authorized Austin Energy representative on-shift must countersign all additions and removals.

(iii) Take all electrical measurements (e.g.: insulation resistance, etc.) to establish pre-outage baseline conditions.

c) Generator Climate Control

i) Contractor shall supply all climate control equipment required to maintain a warm dry environment for the generator rotor and stator. This includes all required hoses, scaffold, tarps, and dehumidifier equipment.

d) Generator Disassembly

i) All abnormal, as-found conditions must be documented on the appropriate data sheet or form, with illustration such as sketch or digital image, and then confirmed by the authorized Austin Energy representative.

ii) Turbine End

(1) Unbolt and remove the roof of the collector cab.

(2) Remove bearing caps and outer oil deflectors (both ends).

(3) Remove the upper half bearings, upper half hydrogen seals, and upper half inner oil deflectors (both ends).

(4) Disconnect and remove all piping and wiring from both outer end shields.

(5) Remove the upper half outer end shield.

(6) Remove the lower half hydrogen seals and the lower half inner oil deflectors

(both ends).

(7) Remove the upper half inner end shield.

iii) Collector End

(1) Unbolt and remove the roof of the collector cab.

(2) Remove bearing caps and outer oil deflectors (both ends).

(3) Remove the upper half bearings, upper half hydrogen seals, and upper half inner oil deflectors (both ends).

(4) Disconnect and remove all piping and wiring from both outer end shields.

(5) Remove the upper half outer end shield.

(6) Remove the lower half hydrogen seals and the lower half inner oil deflectors

(both ends).

(7) Remove the upper half inner end shield.

e) Generator Clean and Inspect

i) Clean and inspect generator parts:

(1) Clean bearing assemblies, oil deflectors, hydrogen seals, fan blades, and end shields.

(2) Visually inspect bearing assemblies, oil deflectors, hydrogen seals, and fan blades for damage, pitting, or insulation breakdown. Document, report, and discuss any abnormalities with the authorized Austin Energy representative.

(3) Take and record (as found) readings for bearings, journals, hydrogen seals, and oil deflectors.

(4) Hydrogen seals shall have a 100% blue contact check.

ii) Clean and inspect brush holding rigging.

(1) Clean brush-holding rigging

(2) Visually inspect brush rigging.

iii) Generator visual inspection.

(1) Inspect stator core and windings, field wedges, surface, and inner ends of retaining rings.

(2) Inspect stator end windings, field coil end turns, and upper frame high voltage extension bus leads and connections.

(3) Inspect belly band for tightness, dusting, and greasing. If any issues are noted, further disassembly will be required to check the torque on bolts.

iv) Perform MAGIC (Miniature Air Gap Inspection Crawler) robotic visual inspection with the stator and field gap to inspect stator core laminations, stator wedges, and surface on the inboard ends of the retaining rings.

v) Inspect belly bands for tightness, dusting, and greasing. If any issues are noted,

vi) Disassemble journal bearings and inspect:

(1) Visually inspect

(2) Take and record as found clearances including ball seat contact and pinch checks.

(3) Check for babbit un-bonding using ultrasonic inspection.

(4) Measure insulation resistance on collector end.

vii) Brush Rigging and Collector Rings

(1) Inspect for proper clearance between brush-holder and collector rings.

(2) Inspect for pitting, threading, grooving wear on collector rings.

viii) Stator Winding

(1) 10-minute Insulation Resistance Measurement and Polarization Index

ix) Frame

(1) Check tightness of hold-down bolts and jacking bolts.

(2) Check that compartment interface seals are watertight and intact.

(3) Check that the rubber expansion joint in the load compartment

x) Rotor

(1) 10-minute Insulation Resistance Measurement and Polarization Index.

xi) Alignment

(1) Record vibration data prior to shut down.

xii) Turning Gear

(1) Inspect tooth contact

(2) Tooth wear or damage

(3) Oil feed nozzles clean and free of foreign matter.

xiii) Cooler

(1) Inspect for air leakage at frame sealing.

(2) Cleanliness of tubes on air side and water side.

f) Reassembly

i) Collector End

(1) Roll in lower half bearing and perform twist and tilt check and check bearing clearances.

(2) Assemble the upper-half end shield.

(3) Make a hydrogen tight seal on the end shield. Pump Dow-Corning Q4-2805 into the sealing grooves. Contractor to supply sealant with current expiration date.

(4) Perform a contact check on the horizontal joints of oil deflectors.

(5) Assemble the inner oil deflector.

(6) Assemble the hydrogen seal housing.

(7) Assemble upper-half bearing.

(8) Assemble outer oil deflector in the bearing cap.

(9) Assemble bearing cap.

(10) Check radial clearances.

(11) Install the roof of the collector cab.

ii) Turbine End

(1) Roll in lower half bearing and perform twist and tilt check and check bearing clearances.

(2) Assemble the upper-half end shield.

(3) Make a hydrogen tight seal on the end-shield. Pump Dow-Corning Q4-2805 into the sealing grooves.

(4) Perform a contact check on the horizontal joints of oil deflectors.

(5) Assemble the inner oil deflector.

(6) Assemble the hydrogen seal.

(7) Assemble upper-half bearing.

(8) Assemble outer oil deflector in the bearing cap.

(9) Assemble bearing cap.

(10) Check and record radial clearances.

g) Test

i) After generator is re-assembled, perform a 24-hour Air Leak Check test to ensure that the generator is purged or air/oxygen and gas tight.

ii) This test shall be in accordance with OEM standards.

iii) This test shall be completed prior to introducing Hydrogen into the system.

2) Major Inspection

a) Shutdown and Preparation (AE)

i) Depressurize and purge generator to air.

ii) Shutdown and tag-out lube oil and seal oil pumps (ensure the generator is electrically isolated and grounded).

b) Shutdown and Preparation (Contractor)

i) Perform Rotor Flux Density testing to establish baseline condition.

ii) Measure and record mechanical run-out of collector rings while on turning gear.

iii) Contractor and AE to review and agree on what items need to be locked-out and tagged for safe work conditions. Contractor to sign-on to the applicable Austin Energy applied Lock Out/Tag Out tags and forms, then attach the Contractor’s own locks.

iv) As an integral part of the Lock Out/Tag Out process, Contractor shall maintain a log/record of all means and devices used to by-pass safeguards, alarms, and the like, to include but not be limited to hard-wired and software jumpers, as well as the purposeful control system set-point changes. The authorized Austin Energy representative on-shift must countersign all additions and removals.

v) Take and record all electrical measurements (e.g.: insulation resistance, etc.) to establish pre-outage baseline conditions.

c) Generator Climate Control

i) Contractor shall supply all climate control equipment required to maintain a warm dry environment for the generator rotor and stator. This includes all required hoses, scaffold, tarps, and dehumidifier equipment.

d) Generator Disassembly

i) All abnormal, as-found conditions must be documented on the appropriate data sheet or form, with illustration such as sketch or digital image, and then confirmed by the authorized Austin Energy representative.

ii) Remove the roof of the collector cab.

iii) Remove the rear door panels and the center door sill angle (at floor level) of the collector cab.

iv) Uncouple and remove the turning gear and the flex coupling.

v) Remove collector chimney silencer.

vi) Withdraw the collector inlet silencer and lower the field exciter cables into the duct below the cab deck.

vii) Remove the brush rigging and exciter.

viii) Remove shaft ground brushes and vibration probes (Austin Energy).

ix) Remove upper half of the load compartment and load compartment silencer.

x) Remove bearing caps and outer oil deflectors (both ends).

xi) Remove the upper half bearings, upper half hydrogen seals, and upper half inner oil deflectors (both ends).

xii) Disconnect and remove all piping and wiring from both outer end-shields.

xiii) Remove the upper half outer end shield.

xiv) Remove the lower half hydrogen seals and the lower half inner oil deflectors (both ends).

xv) Remove inlet vanes from the upper half inner end shields and remove the upper half inner end-shield.

xvi) Remove fan blades from rotor.

xvii) Uncouple the generator from the turbine.

xviii) Remove any remaining equipment which protrudes above the top surface of the cab deck plate.

xix) Disassemble and remove the walkway from the rear of the cab.

e) Remove the rotor from the stator

i) Provide all tools, equipment, platform, and lifting equipment required to remove the generator rotor from the stator.

ii) Remove the generator rotor, inspect, and reinstall in accordance with OEM guidelines.

f) Generator Clean and Inspect

i) Clean and inspect generator parts:

(1) Clean bearing assemblies, oil deflectors, hydrogen seals, fan blades, and end shields.

(2) Visually inspect bearing assemblies, oil deflectors, hydrogen seals, and fan blades for damage, pitting, or insulation breakdown.

(3) Take and record (as found) readings for bearings, journals, hydrogen seals, and oil deflectors.

(4) Hydrogen seals shall have a 100% blue contact check.

ii) Clean and inspect brush holding rigging.

(1) Clean brush holding rigging

(2) Visually inspect brush rigging.

iii) Generator visual inspection:

(1) Inspect stator core and windings, field wedges, surface, and inner ends of retaining rings.

(2) Inspect stator end windings, field coil end turns, and upper frame high voltage extension bus leads and connections.

(3) Inspect belly band for tightness, dusting, and greasing. If any issues are noted,

iv) Disassemble journal bearings and inspect:

(1) Visually inspect

(2) Take and record as found clearances including ball seat contact and pinch checks.

(3) Check for babbit un-bonding using ultrasonic inspection.

(4) Measure insulation resistance on collector end.

v) Brush Rigging and Collector Rings

(1) Inspect for proper clearance between brush holder and collector rings.

(2) Inspect for pitting, threading, grooving wear on collector rings.

(3)

vi) Stator Winding

(1) 10-minute Insulation Resistance with Polarization Index

(2) Winding Copper Resistance

(3) RTD Resistance Check and Insulation Resistance

(4) DC Leakage

(5) DC Hi-pot (if necessary)

(6) Cleanliness of end windings

(7) Evidence of corona

(8) Distortion or overheating

(9) Broken ties/laminations

(10) Evidence of end winding movement

(11) End winding support hardware

(12) Internal cleanliness

(13) Strip heaters clean and operational

(14) Damaged punchings (laminations or core iron)

(15) Stator wedge system (inspection and tap test)

(16) Cleanliness core (blow with clean compressed air)

(17) Hydrogen Coolers (inspect and clean)

(18) EL-CID (Electromagnetic Core Imperfection Detector) Test

(19) Core Loop Test (required if repairs are made to stator core)

(20) Inspect three (3) core belly bands for proper torque. (requires center and outer hydrogen coolers to be removed)

vii) Frame

(1) End Winding Drain Provisions Clear

viii) Rotor

(1) 10-minute Insulation Resistance with Polarization Index

(2) Winding Copper Resistance

(3) AC Impedance Test

(4) Pole Balance Test

(5) Retaining Ring Damage (NDE)

(6) Cleanliness of End Winding

(7) Evidence of End Winding Movement (using a borescope if necessary)

(8) Wedge Movement

(9) Check balance weights on field

(10) Fan Blade Damage or Erosion

(11) Indications of Overheating

ix) Liquid Level Detector

(1) Proper Operation

x) Shaft Sealing System

(1) Excessive Seal Ring Clearance

g) Reassemble Generator

i) Install rotor in stator

(1) Install the belly pan in the stator with fish paper between belly pan and stator core.

(2) Position the rotor on rolling supports as when it was removed from the stator.

(3) Assemble the coupling shoe and secure it to the shaft. Assemble rigging for pulling rotor through stator.

(4) Pull the rotor into the stator until the coupling shoe is close to the end of the stepped punchings (step down iron) on collector end.

(5) Raise the rotor using the roller supports jacking screws until the coupling shoe clears the stator core and is level.

(6) Pull the rotor into the stator until the coupling shoe has completely passed the stepped punchings (step down iron).

(7) Remove the top half of the body rolling support.

(8) Lower the body rolling support using the jacking screws until the weight of the rotor is supported on the coupling shoe and the collector end rolling support.

(9) Disassemble and remove the body rolling support.

(10) Pull the rotor into the stator until the first rotor shoe can be inserted past the stepped punchings (step down iron).

(11) Raise the collector end of the rotor using jacking screws of the collector end rolling support and insert the first rotor shoe between the rotor body and the belly pan.

(12) Lower the collector end of the rotor slightly to take the weight off the coupling shoe and put it on the rotor shoe.

(13) Pull the rotor through the stator until the coupling is between the stator core and the lower half inner end shield (turbine end). Remove the coupling shoe.

(14) Continue pulling the rotor into the stator until the collector end rolling support reaches the front edge of the cab deck.

(15) Raise the collector end of the rotor slightly with the rolling support and insert the second rotor shoe past the stepped punchings (step down iron) between the rotor body and the belly pan.

(16) Jack the collector end of the rotor down until the rolling support is unloaded and the rotor weight is on the two rotor shoes.

(17) Remove the roller support.

(18) Assemble the shaft support sling to the collector end of the stator frame.

(19) Install the turbine end lower half outer end shield.

(20) Raise the rotor slightly above centerline using the shaft jacking device on the turbine end and the shaft support sling on the collector end.

(21) Remove the rotor shoes, belly pan, fish paper, and protective shim (belly pan) from stator.

(22) Install the collector end lower half inner end shield and guide vanes.

(23) Install the collector end lower half outer end shield.

(24) Roll in the lower bearing halves.

(25) Lower the rotor onto the bearings.

(26) Reinstall the fan blades (both ends). Use new locking plates.

(27) Reinstall the upper half inner end shields.

(28) Reinstall the lower half hydrogen seals and lower half inner oil deflectors (both ends).

(29) Reinstall the upper half bearings, upper half hydrogen seals and upper half inner oil deflectors (both ends).

(30) Reinstall the bearing caps and outer oil deflectors (both ends).

(31) Reconnect all piping and wiring to both outer end shields.

(32) Remove the outer end shield support brackets.

(33) Reinstall the upper half load compartment and load compartment silencer

(turbine end).

(34) Reinstall the shaft grounding brushes and vibration sensors (AE).

(35) Reconnect the collector inlet silencer, and field exciter cables.

(36) Reinstall the collector chimney silencer, collector cover, and collector fan.

(37) Reinstall the turning gear and reconnect the flex coupling.

(38) Remove the bridge support brackets and reinstall the cab center door panel sill angle.

(39) Reinstall the cab door panels, walkway, and roof.

(40) Recouple the generator rotor to the turbine load coupling.

(41) Re-install brush rigging items and ensure collector ring brushes are properly seated.

h) Test

i) After generator is re-assembled, perform a 24-hour Air Leak Check test to ensure that the generator is purged or air/oxygen and gas tight.

ii) This test shall be in accordance with OEM standards

iii) This test shall be completed prior to introducing Hydrogen into the system.