Power Generation Division Vendor Qualification, Audit …dnhiggins.com/docs/Attachment I - Vendor Qualification, Audit, and... · PGD Vendor Qualification, Audit and Surveillance

PGD-ALL-DE-MA-1301141010

Page 1 of 105 Rev. O 11-28-12

PGD Vendor Qualification, Audit

and Surveillance Plan

Power Generation Division

Vendor Qualification, Audit and Surveillance Plan

Rev. O 11-28-2012

Revision History Rev Date Who Description

- 11-11-09 JVP First Issue of PGD Draft

A 11-13-09 JVP Changes per J. Mulligan

B 11-18-09 JVP Add ST Appendices

C 5-3-10 JVP Add Pump Repair Vendor Capability Survey App. C

D 6/08/2010 DT Modified Environmental Section

E 7-19-10 JVP Modified SGFT appendix J per Arash K.

F 11-30-10 ALD Modified SGFT appendices L, M, N, O, per J. Mulligan

G 04-04-11 ALD Add Appendix P per J. Mulligan

H 8-26-11 MDR Changes to Instructions for Use, added pre-surveillance checksheet

J 03-07-2012 RAS Added Appendix Q

K 6-12-12 JVP Update File name to incl. “surveillance”, include links to process maps in Op Model, add Appendix R

L 6-28-12 JVP Revise with input from Vendor Surveillance team

M 9-21-12 JVP Add Appendix S

N 10-15-12 JVP Add vendor scorecard into text, insert link to ST vendor score card in App E, add App T with link to scorecard

O 11-28-12 JVP Fix Links, revise verbiage to match new vendor surveillance process, p. 20 and 21, add App T, revise Pre-Shop Visit Checksheet per G. Griffith. Include links to Vendor Surv. SharePoint site


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Table of Contents Vendor Qualification

Item Description Hyperlink

1 Instructions for use Instructions_for_Use

2 Vendor Qualification Audit Survey Vendor Qualification Audit Survey

3 Quality system overview Quality_System_Overview

4 Quality Organization questions

1 Quality Assurance Organization

5 Purchasing system questions

2 Control of Procured Articles

6 Manufacturing Questions 3 Control of Manufactured Article

7 Inspection and testing questions 4 Inspection Measuring/Test Equipment

8 Document control

5 Drawing and Change Control

9 Non-conforming items – questions

6 Nonconforming Articles

10 Inspection and testing questions 7 Completed Item Inspection and Testing

11 Handling and preservation questions 8 Handling, Storage, Packaging, Preservation & Delivery

12 Environmental Stewardship 9 Environmental Stewardship


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Table of Contents: Vendor Surveillance


Appendix Instructions for use Instructions_for_Use

Appendix Supplier Performance Evaluation Report (Scorecard)

Supplier Performance Evaluation Report

Checklist Vendor Surveillance Checklist Vendor Surveillance Checklist

App A Electric Motor Repair Vendor Capability Survey

Motor Vendor Survey

App B Gearbox Repair Vendor Capability Survey

Gearbox Vendor Survey

App C Pump Repair Vendor Capability Survey

Pump Repair Vendor Survey

App D ST Component Approval Form Rev B ST Component Approval Form Rev B

App E FPL/NEER PGD Supplier Performance Evaluation Report (ref. Excel file)

FPL/NEER PGD Supplier Performance Evaluation Report

App F ST Quality Assurance Nonconformance Report Form (ref. Excel file)

ST Quality Assurance Nonconformance Report Form

App G Pre-Audit Questionnaire – Suppliers of Steam Turbine Repair Services

Pre-Audit Questionnaire – Suppliers of Steam Turbine Repair

App H ST Supplier Qualification Checklist ST Supplier Qualification Checklist

App I ST Supplier Trip Report ST Supplier Trip Report

App J

Steam Generator Shop Audit Check Sheet Steam Generator Shop Audit Check Sheet

App K

Steam Generator Heat Treatment Audit Questions


App L

Steam Generator Shop Audit Check Sheet Specific checkpoints for Honeycomb SCR catalyst

Steam Generator Shop Audit Check Sheet Specific checkpoints for Honeycomb SCR catalyst

App M

Steam Generator Materials Site Inspection Check Sheet Specific checkpoints for Honeycomb SCR catalyst

Steam Generator Materials Site Inspection Check Sheet Specific checkpoints for Honeycomb SCR catalyst


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App N

Steam Generator Shop Audit Check Sheet Specific checkpoints for waterfall coated CO catalyst

Steam Generator Shop Audit Check Sheet Specific checkpoints for waterfall coated CO catalyst

App O

Steam Generator On-site Materials Check Sheet Specific checkpoints for waterfall coated CO catalyst

Steam Generator On-site Materials Check Sheet Specific checkpoints for waterfall coated CO catalyst

App P Steam Generator Structural Steel Fabricator/Erector Vendors

Steam Generator Structural Steel Fabricator/Erector Vendors

App Q Traveling Water Screen Shop Audit Check Sheet

Traveling Water Screen Shop Audit Check Sheet

App R Rotor Shop Balance Audit Check Sheet

Rotor Balance Shop Audit Check Sheet

App S Basket Strainer Shop Audit Check Sheet Specific checkpoints

Basket Strainer Shop Audit Check Sheet Specific checkpoints

App T

Generator Equipment Component Repairs, Refurbishment, Rewinds, or Site Services Vendor Capability Survey

Generator Equipment Component Repairs, Refurbishment, Rewinds, or Site Services Vendor Capability Survey


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Vendor Qualification Purpose: The purpose of this document is to create a standardized procedure for evaluating and qualifying (including requalification) of vendors who provide parts and services for major pieces of equipment Instructions for Use: Instructions for Suppliers: The Supplier is to complete the quality section questionnaire, Items 2 through 12 as identified in the table of contents above as well as supply approved supporting documents. In addition, if the Supplier checks “NO” or “N/A” on any check sheet, the rationale needs to be explained in the comments section. (Gray shaded areas are to be filled in by FPL/NEER Company Representative.) Additionally, the appropriate questionnaire related to the product or service to be provided shall be filled out and returned to the FPL/NEER Company Representative. Instructions for FPL/Nextera Company Representative: Once the Questionnaire is returned to the appropriate FPL/NEER Company Representative, the questionnaire and the supporting quality documents and comments shall be reviewed. Following the review, an audit of the Supplier’s quality system and facility shall be performed on a mutually agreed upon date. During the audit, the FPL/NEER Company Representative shall use the questionnaire and appropriate appendix checksheet as a guideline, verifying compliance to the quality system. This document is also used as the standard when performing routine shop surveillance audits on previously “qualified” vendors. (See Appendix for more details and for instructions of use). Documents created from this process shall be placed here so they are available for future reference: Vendor Qualification Documents - All Documents Definition of Responsibilities: For roles and responsibilities for the various tasks defined in this process document, refer to the process maps and flowcharts in the Operational Model (PGD\Development\Manufacture\Flowcharts). Use the following links: Process Map for Vendor Qualification: http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca802714da

Flowchart for Manage Procurement: http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca8013137d

Flowchart for Manage Vendor QA/QC Plan: http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca80131317

http://cafe.nexteraenergy.com/sharepoint/pgd/VendorSurveillance/Forms/AllItems.aspx?RootFolder=%2Fsharepoint%2Fpgd%2FVendorSurveillance%2FVendor%20Qualification%20Documents&FolderCTID=0x012000D320D4CC5DFB8F4AB5DB9BFD36396C4E&View=%7bEC6131DB-AE84-4400-8395-A4FD42BD176F%7d

http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca802714da

http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca8013137d

http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca80131317


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Vendor Qualification / Audit Survey

THIS SECTION FOR FPL USE ONLY

Survey Request Date: Date Received:

Reviewed For FPL By: Review Date:

Date Audit Scheduled Audit Site Contact

Approved Not Approved Conditional Approval (state conditions)

Conditions:

Supplier Name: Phone:

Mailing address

Shipping Address Fax:

Form Completed By: E-Mail:

Title

Phone:

Products/Services:

Technical Contact: E-Mail:

Title:

Phone:

Quality Assurance Contact: E-Mail:

Title:

Phone:

Manufacturing Contact: E-Mail:

Title:

Phone:


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Quality System

Identify the specifications your current procedures are based on:

ISO9001-2000 CSA Z299.3-1985 MIL-Q-9858A EASA – Q Other Yes No N/A 1. Is the Company Registered?

2. What System? Who is the Registrar? When was the last external surveillance?

3. Do you have a company and Quality Department organizational chart?

4. Do you have a Quality Manual and/ or published directive?

If any of the above answered yes, please provide copies.

5. Do you maintain a list of measuring/testing equipment? Please provide copies.

6. Are there documented procedures, which provide for indoctrination and training for personnel whose activities affect quality?

Total Sq. Ft Manufacturing Area Total Number of Personnel

Total Inspection Personnel Total Engineering Personnel

Total Production Personnel Total Prod. Eng. Personnel


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Quality Assurance Organization 1 QUALITY ASSURANCE ORGANIZATION

YES *NO N/A This Section For FPL Use Only

Result

from Audit OK NG

1.1 Quality Assurance organization's authorities and responsibility clearly defined in writing.

1.2 QA organization clearly has the authority to withhold items that have not met acceptable quality standards.

1.3 QA organization has direct access to appropriate levels of company management so that problems and conflicts can be efficiently and effectively resolved and corrected (Provide copy of Organizational Chart).

1.4 Are internal audits performed on a regular basis?

1.5 There is a system for continual maintenance and updating of a Quality Assurance Manual.

1.6 The Quality Assurance organization operates a defect prevention program (corrective / preventive action system).

1.7 The Quality Assurance organization prepares and issues periodic reports and maintains records relative to item acceptance/rejection, disposition, rejected items, quality costs and other factors.

1.8 The Quality Assurance organization maintains a system for the use and control of inspection stamps.

1.9 The Quality Assurance organization trains employees in the application of Quality Assurance methods.

1.10 Software is properly safeguarded to prevent unauthorized changes.

1.11 Verify policy for document control and retention of shop records are maintained a minimum of 5 years.

1.12 Supplier remarks:

1.13 Auditors remarks:


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Control of Procured Articles

2 CONTROL OF PROCURED ARTICLES YES *NO N/A This Section For FPL Use Only

Result

from Audit OK NG

2.1 The Quality Assurance organization has a system for quality evaluations of potential suppliers.

2.2

The Quality Assurance organization has a program for continuing Quality Assurance approval of your suppliers.

2.3 Purchase orders clearly describe the work to be performed.

2.4 Purchase orders clearly specify acceptance criteria.

2.5 The Quality Assurance organization reviews all customer orders.

2.6 Purchase orders include provisions for customer’s source inspection and audit.

2.7 Purchase orders specify documentation requirements.

2.8 The Quality Assurance system requires that suppliers have adequate Quality Assurance programs.

2.9 The Quality Assurance organization operates a source inspection system and Audit System.

2.10 The Quality Assurance organization operates a receiving inspection system.

2.11 Procured articles are inspected to assure compliance with applicable specifications.

2.12 Receiving/inspection records reflect a quality history of suppliers.

2.13 Manufacturer’s identification is maintained on raw materials or in correlated records.

2.14 Is there a system in place for “age control” when applicable.

2.15 Measuring devices, inspection gauges and test equipment are available to source inspectors and receiving inspectors and adequate for the inspection and test purposes required.

2.16 The identification and proper handling of purchased articles is assured.

2.17 A positive means of identification of all raw stock is


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used.

2.18 A system is used that assures only inspected materials will be used.

2.19 Control is maintained over any design changes which may be required at their subcontractors.

2.20 All purchase orders are screened for inclusion of applicable requirements.



*USE THE “REMARKS” SPACE WHEN "NO" IS INDICATED AND AN EXPLANATION IS REQUIRED

(Continued on the following page)


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Control of Manufactured Article

3 CONTROL OF MANUFACTURED ARTICLE YES *NO N/A This Section For FPL Use Only

Result

from Audit

OK NG

3.1 In-process inspection is performed by Quality Assurance.

3.2 Applicable drawings and specifications are referenced in inspection records.

3.3 Applicable drawings, engineering orders/changes, and specifications are available to Inspection.

3.4 Special processes are accomplished in adequate facilities, by competent trained personnel, in accordance with applicable procedures.

3.5 Inspection gages and test equipment, capable of performing required inspections, are available and controlled.

3.6 Inspection equipment is stored in a manner that precludes damage and loss of accuracy.

3.7 Sampling inspection is performed to approve plan when applicable.

3.8 The selection of articles and characteristics subject to sampling inspection and the selection of Acceptable Quality Levels are documented.

3.9 A system is maintained for indicating the inspection status of in process articles.

3.10 All necessary inspections and tests are provided to assure compliance with customer’s requirements.

3.11 The identification and handling of fabricated articles are controlled.

3.12 There is a system that prevents the unauthorized use of materials that have not yet been inspected.

3.13 Criteria for supplier selection is based on past performance records.

3.14 There is a system for the proper identification of the inspection status of in-process materials.

3.15

3.16



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Control of Manufactured Article, cont’d

3 CONTROL OF MANUFACTURED ARTICLE YES *NO N/A This Section For FPL Use Only

Result

from Audit




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Inspection Measuring/Test Equipment

4 INSPECTION MEASURING/TEST EQUIPMENT YES *NO N/A This Section For FPL Use Only

Result

from Audit

OK NG

4.1 Quality procedures assure that inspection measuring/test equipment are periodically inspected and recalibrated to required accuracy, at established intervals.

4.2 Production tooling which is in use as a medium of inspection is inspected at intervals that assure the maintenance of required accuracy.

4.3 A system is in place for modification of inspection/test equipment to latest engineering changes.

4.4 Calibration system complies with the requirements of MIL-STD-45662 or ISO-10012 or equivalent (Calibration System Requirements).

4.5 Working standards of required accuracy that are periodically calibrated and traceable to the National Institute of Standards and Technology, are maintained in a suitable atmosphere.

4.6 New, reworked or modified test/inspection equipment is inspected and calibrated prior to use.

4.7 All inspection measuring equipment are identified and traceable to individual records attesting to last calibration, calibration due date, and by whom calibration was performed.

4.8 Records are maintained as a basis for periodic recalibration of inspection measuring equipment.

4.9 Inspection impounds or identifies un-calibrated or past due test equipment, tools, or fixture to preclude their use.

4.10 Equipment and manufacturing devices used for inspection purpose are stored in a manner which precludes damage and loss of accuracy.

4.11 Subcontractors are required to have a system which ensures the accuracy of their test and measuring equipment.

4.12 Requests for proposal and/or contracts are reviewed by Quality Assurance to identify any unusual precision measurement requirements.



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Inspection Measuring/Test Equipment, cont’d

4 INSPECTION MEASURING/TEST EQUIPMENT YES *NO N/A This Section For FPL Use Only

Result

from Audit

4.13

4.14

4.15

4.16





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Drawing and Change Control

5 DRAWING AND CHANGE CONTROL YES *NO N/A This Section For FPL Use Only

Result

from Audit

OK NG

5.1 There are documented procedures describing drawing and change control.

5.2 A control exists for withdrawal of obsolete documents.

5.3 The control system prevents the use of unauthorized documents

5.4 The control system verifies that changes are incorporated at specified change points.

5.5 There is sufficient documentation to produce articles in conformance with design and engineering requirements.

5.6

5.7

5.8

5.9





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Nonconforming Articles

6 NONCONFORMING ARTICLES YES *NO N/A This

Section For FPL Use Only

Result

from Audit

OK NG

6.1 There is a system that provides for control of non-conforming materials.

6.2 There is a method for identifying and correcting conditions that cause repetitive discrepancies.

6.3 Corrective actions on non-conforming articles are initiated and closed out promptly.

6.4 Receiving records are used to initiate corrective action on non-conforming parts.

6.5 Manufacturing inspection records are used to initiate corrective action of non-conforming articles.

6.6 Corrective action extends to purchased products.

6.7 Analyses are made to identify trends toward product deficiencies.

6.8 Discrepant materials are promptly and adequately identified and separated from normal work operations.

6.9 Adequate holding areas for nonconforming materials are available and used.

6.10 Written procedures are used for approval of repair, rework and disposition.

6.11 There are procedures for controlling non-conforming supplies.

6.12

6.13

6.14





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Completed Item Inspection and Testing 7 COMPLETED ITEM INSPECTION AND TESTING YES *NO N/A This

Section For FPL Use Only

Result

from Audit

OK NG

7.1 All finished goods are inspected by Quality Assurance to ensure that contract requirements have been met.

7.2 Drawings, written instruction and procedures are readily available to all final inspection personnel.

7.3 Re-inspection and retest is documented on all items that have been reworked, repaired, or modified after initial product.

7.4

7.5

7.6

7.7

7.8





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Handling, Storage, Packaging Preservation & Delivery


8 HANDLING, STORAGE, PACKAGING PRESERVATION & DELIVERY

YES *NO N/A This Section For FPL Use Only

Result

from Audit

OK NG

8.1 There are adequate work inspection instructions for the handling, storage and delivery of material.

8.2 Articles are handled so as to prevent damages and deterioration (long term as well as short term storage /packaging.)

8.3 Transfer procedures are provided to prevent commingling, contamination, or loss.

8.4 Stamps, labels, or other acceptable media are used to indicate and identify, condition, and inspection status of articles.

8.5 Provisions are made to prevent unauthorized use of un-inspected articles.

8.6

8.7




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Environmental Stewardship

9 ENVIRONMENTAL STEWARDSHIP YES NO N/A NextEra Use Only

Result from Audit

OK NG

9.1 Are your construction activities in accordance with applicable regulatory/permit requirements?

9.2 Do you have all required Permit/Plans required to complete construction activities, e.g., SPCC, Storm water Construction, SWPPP, etc.?

9.3 Do you have a process to respond, report and clean up spills?

9.4 Do you have a contract set up with certified vendors to respond to large spills?

9.5 Do you have a process to properly store, manage, handle and dispose of hazardous, non-hazardous, universal and construction waste, e.g., aerosol cans, solvents, oily rags, paints, etc.?

9.6 Do you have a process for ensuring the most environmentally friendly chemicals/products are used?

9.7 Do you have a SWPPP or any other Plan to ensure construction activities do not pose a threat to nearby water bodies or drinking water sources?

9.8 Do you have a SWPPP or any other Best Management Plan to ensure pollution control measures are in place?

9.9 Are all employees trained and understand all regulatory requirements/permits/Plans?

9.10 Do you have a process for following regulatory requirements regarding maintaining and storing records, e.g., shipping, training, etc.?

9.11 Do you have a process for completing and maintaining on-going site inspections during construction activities?

9.12 Do you have procedures for activities which include environmental considerations?

9.13 Do you have a process for reporting dead or injured endangered or species of special interest?

9.14 Do you have a process for ensuring good housekeeping is maintained during construction activities?

9.15 Suppliers

Remarks:


Supporting documentation that is required to be submitted as part of the pre-qualification process:

1. Line items marked “Yes” provide High Level Process Overview with submittal. 2. Line items marked “No” or “N/A” provide detailed explanation of answer with submittal.


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Surveillance Audit Plan Purpose:

The purpose of this document is to create a standard for performing shop surveillance audits on “qualified”

vendors. Shop surveillance is typically required in the following situations: first time a vendor is performing the

work, when critical equipment/work is being performed (i.e. P91 work, heat treatment) or when a request is made

from a stakeholder (i.e. Power Plant, Central Maintenance, Execution Team, Etc). Prior to every outage, there

will be a meeting between the Outage Manager and the Fleet Teams where it will be determined which jobs

require vendor surveillance. The Fleet SME responsible for the audit should follow the Vendor Surveillance

process flowchart which is located in the Operational Model.

Instructions for Use: Instructions for FPL/NEER Company Representative: Shop Surveillance Audit for specific job: Prior to the audit, Fleet SME will have the vendor complete the pre-shop surveillance checksheet in this procedure to ensure the framework for all pertinent items/issues related with scheduling, performing and communicating results is established. Once the documents are complete, the audit shall be performed on a mutually agreed upon date between the shop and the Fleet SME/Designee. During the audit, the FPL/NEER Company Representative shall use the questionnaire and appropriate appendix checksheet, verifying compliance. (For example: if an request was made to perform an shop surveillance on a pump repair, the assigned Fleet SME would follow the process, use the pre-shop surveillance checksheet prior to performing the audit, and then utilize the Appendix C pump repair checklist to follow when performing the audit at the shop.) The results are then to be communicated to all stakeholders and shop personnel. Documents created from this process shall be placed here so they are available for future reference: Vendor Surveillance Documents - All Documents Definition of Responsibilities: For roles and responsibilities for the various tasks defined in this document, refer to the process maps and flowcharts in the Operational Model (PGD\Development\Manufacture\Flowcharts). Use the following links: Flowchart for Vendor Surveillance: Future link to revised flowchart in Op Model

PGD-ALL-DE-MA-1301141321 Vendor Surveillance Process Flowchart..ppt Flowchart for Manage Procurement: http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca8013137d

http://cafe.nexteraenergy.com/sharepoint/pgd/VendorSurveillance/Forms/AllItems.aspx?RootFolder=%2Fsharepoint%2Fpgd%2FVendorSurveillance%2FVendor%20Surveillance%20Documents&FolderCTID=0x012000D320D4CC5DFB8F4AB5DB9BFD36396C4E&View=%7bEC6131DB-AE84-4400-8395-A4FD42BD176F%7d

http://pgdapps/DMRetriever/?instanceID=09008dca80318b08



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Supplier Performance Evaluation Report (Scorecard) Purpose:

The purpose of this document is to create a standard for rating a vendor’s performance using the “FPL/NEER

PGD Supplier Performance Evaluation Report”. Instructions for Use: The scorecard is an Excel file located in the same directory as this document, and is linked to from Appendix E. This scorecard should be completed for all jobs where vendor surveillance was used as well as any others jobs where the scorecard is deemed to be required by either Central Maintenance (CM) or the Fleet Team. FPL/NEER Company Representative who performed the vendor surveillance shall complete the Vendor scorecard, and it shall then be forwarded to Fleet SME (if the surveillance was not performed by the Fleet SME) and a representative of the CM execution team for further input and review. With consensus between the Fleet Team and CM, the scorecard is finalized and placed on the SharePoint Site located at: Vendor Performance Evaluation Reports (Scorecards) - All Documents Definition of Responsibilities: For roles and responsibilities for the various tasks defined in this document, refer to the process maps and flowcharts in the Operational Model (PGD\Development\Manufacture\Flowcharts). Use the following links: Flowchart for Vendor Surveillance: Future link to revised flowchart in Op Model

PGD-ALL-DE-MA-1301141321 Vendor Surveillance Process Flowchart..ppt Flowchart for Manage Procurement: http://myportal.fplu.fpl.com/irj/servlet/prt/portal/prtroot/com.fpl.imb.portal.dfcdocument.Attach?id=09008dca8013137d

http://cafe.nexteraenergy.com/sharepoint/pgd/VendorSurveillance/Forms/AllItems.aspx?RootFolder=%2Fsharepoint%2Fpgd%2FVendorSurveillance%2FVendor%20Performance%20Evaluation%20Reports%20%28Scorecards%29&FolderCTID=0x012000D320D4CC5DFB8F4AB5DB9BFD36396C4E&View=%7bEC6131DB-AE84-4400-8395-A4FD42BD176F%7d

http://pgdapps/DMRetriever/?instanceID=09008dca80318b08



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Appendices

For Fleet Team Use for Shop Surveillance Audits


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Vendor Pre-Shop Surveillance Checksheet – Used to prepare for the Shop Surveillance Audit 1 Identify CTQ specifications for scope of work to be followed.

2 Name of Shop being Audited

3 Address of Shop

4 Equipment being audited

5 Service being audited

6 List specific elements of the work that will be monitored to ensure success?

7 Names of Fleet personnel to complete surveillance

8 Method(s) to perform surveillance Remote Onsite

9 Surveillance Schedule Full Time Part Time

10 List schedule of dates to be onsite

11 Conduct Readiness Review with shop (This is to ensure supplier is prepared to meet contract commitments prior to start of work) Checklist of elements to be covered during readiness review. Suggested attendees: Fleet Team Rep, Central Maintenance Project Manager, Central Maintenance Supervisor, and Vendor Representative. Complete

Not Complete

Not Applicable

aa.

QA \ QC plan with established Hold Points and review methodologies.

bb. Schedule Review

bb.1

Component schedules (schedule detail should have no activity longer than 10% of total shop duration)

bb.2

Site component priorities (what do we need back first)

bb.3

Planned work schedules i.e. 7/24’s, 6/10’s, etc

bb.4

Shop visit schedule

bb.5 Participate in FMEA (for major critical equipment)

bb.6

Conduct a LEAN workout – with the Supplier 60 days prior to execution. (review of the project in an effort to eliminate waste)

cc. Consideration of competing\conflicting shop work

d Material status


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d.

dd.1 Material not yet received

dd.2 Material dimensions verified

dd.3 Material composition verified

ee. Pre job inspection

ff. Status of any specialized resources

ff.1 Equipment – available and personnel trained on use

ff.2. Tooling – available, condition, number of spares

g.

Review protocol for authorization of “Extra Work” i.e. anything that would result in a change in billing.

h. Planned or available contingencies (FMEA workout)

ji.

Transportation and loading plan (individual or batch shipping, team drivers, permits, etc. Who will make transportation arrangements, permissible delivery times)

12. Establish surveillance reporting plan

Distribution List:

a. Stakeholders Name

b. Stakeholders Department

c.

Frequency of report

#Days/Week

d. At least 10% of total shop schedule (i.e. 30 day schedule update every 3 days, 10 day schedule update every day) Any change to schedule or cost to be reported immediately upon discovery.

13.

Method(s) Delivered (Form of communication) - Check all Email Conference Call Private Call

14. The following content shall be included in the update report (At the minimum) Included

Not Included

a. QA\QC status

b. Schedule status

c. Extra Work pending disposition

d. Photos

e. Disposition of Non-Conformance Reports

f. Resource Issues

g. Special Tooling, manufacturing or machining issues / problems / breakdowns


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h. Other (Please specify)

15. Extra Work

a. Is Extra Work Required? (Y/N)

b. Clarify protocols for authorization of any “Extra Work”

c. - Identify Execution Team interface.

All elements of Surveillance Plan should be reviewed with all identified stakeholders (i.e. CMGM, PGM, Product Manager, Project Manager, Outage Supervisor and Cost Specialist prior to the start of the job)


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Appendix A

Motor Repair Vendor Capability Survey


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Motor Repair Vendor Capability Survey

Question Vendor Response

1 a Provide 5 references for large AC motor repair / rewind HP > 400HP

Customer #1

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #2

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #3

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #4

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #5

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross


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2 a Provide the following information describing any presently active "Blanket" Large Motor Refurbishment/Repair Contracts you hold.

Comments, if any :

Customer

Types of Service(s)

Duration of Present Contract

Customer

Types of Service(s)


b What benefits would be realized for a contract of 2 or more years in length?

c What FPL-FPLE does to facilitate a good business relationship with your company?

3 a Identify the number of motors repaired in the last twelve (12) months

200 hp

200 hp Vertical

200 hp West'hse

1000hp Total

1000hp Vertical

1000hp West'hse

4 a Based on a precursory review of the specification, what does FPLE Specs requires that adds unnecessary cost to the price of refurbishments/repairs? Please explain

5 a Describe any industry or other certification(s) your employees hold for motor repair.

b Describe any training programs, internal or external, that you provide for your employees.

c Are minimum qualifications established for personnel to perform specific critical repair tasks?

6 a How many employees do you have in the following departments :

Te

ar

Dow

n

Win

din

g

Assem

bly

(Me

ch.)

Ma

chin

e

Shop

Weld

F

ab

Coil

Mfg

.

Qualit

y

Inspectio

n

Engin

eer

/

Te

ch

Support

Full Time Staff

Part Time Staff

Contractors

Approximate Person-hrs per week (total)


Page 29 of 105 Rev. O 11-28-12



6 b Total Number of Employees at your facility?

c Resumes of Critical Expertise

If none, enter "0" in Name Column Vibration Expert Quality Mgr. Elect. Engineer

Name

Total Years of Motor Experience

Years in Present Position

School/Degree/Formal Training

Other Motor Mfg. / Repair Companies Employed by :

Mech. Engineer Lead Machinist Lead Winder

Name

Total Years of Motor Experience


School/Degree/Certifications/Formal Training

Other Motor Mfg. / Repair Companies Employed by :

d Provide names and technical resumes of any technical consultants you use or have on retainer.

7 a Describe the standard services provided with the return of a refurbished / repaired motor.

b Place an "X" in the box for any of the following special motor repair services provided by your company at YOUR facility.

Spin

Castin

g

of

Babbitt

Brg

s.

Fo

rm C

oil

Mfg

. T

hru

7kV

Sta

tor

/ R

oto

r C

ore

Sta

ckin

g

Roto

r R

e-

barr

ing

Ultra

sonic

Inspectio

n o

f B

earin

gs

Ele

ctr

ical

(Win

din

g)

Re-d

esig

n

Dye

Penetr

ate

Te

stin

g

Mo

dal

Analy

sis

/

Imp

act T

est

c List any other special motor repair services provided by your company at YOUR facility.

d Provide any special services that could be provided at our plants (e.g. Laser alignment, motor problem diagnostics, etc.)

8 a Identify experience repairing

Westinghouse 1000 hp horizontal and vertical motors. Discuss known upgrades for oil leaks and vibration problems for these types of machines.


Page 30 of 105 Rev. O 11-28-12



8 b How do you obtain technical details and design information from major motor OEM's; specifically Westinghouse and Reliance?

c Describe any alliances you have with motor or sub-component OEM's, including the scope of the agreement.

d Describe the typical process for obtaining replacement parts from motor OEM's, specifically Westinghouse and Reliance.

e List and describe any authorized distribution agreements you hold with motor OEM's for "new" replacement motors.

9 a Identify specific references you use in determining acceptable tolerances for critical motor fits and performance parameters.

10 a Describe any products (motors, motor components, motor testing equipment, other electrical equipment etc.) designed and manufactured by your company (as the OEM).

b List and describe what you consider to be your company's three (3) most accomplished projects or endeavors regarding motor manufacturing, repair or refurbishment.

11 a Provide the specifications for your balancing equipment (Make, Type, Length OD and Weight of Part, etc.)

b Is your equipment graduated to balance to ISO 'G' levels?

c Describe your internal residual imbalance acceptance criteria for specific types and speeds of rotating equipment.

12 a What type of vibration equipment do you use? (Make, Model, Units)


Page 31 of 105 Rev. O 11-28-12



12 b What are your standard vibration acceptance criteria for specific types and speeds of induction motors?

c Do you have the capability of transferring vibration data electronically for analysis through software such as RBM Ware? or other software?

d Do you have the capability to use proximity probes to measure shaft displacement for vertical machines?

13 a Under what circumstances do you believe a fully-loaded test is required?

b Can you load test a motor in the vertical position? If so, what are the limits? Can you perform a heat run in accordance with IEEE 112 Primary-superposed equivalent loading method?

c Dynamometer capabilities for horizontal machines.

Dyno Make / Type

Duty Min hp @ 3600 rpm

Max hp @ 3600 rpm

Min hp @ 900

rpm

Max. hp @ 900

rpm

Dyno #1

Dyno #2

Dyno #3

d Power Supply / Test Panel Capability Amps Continuous @ 1.0 pu of Tap

Amps - Starting @ 1.0 pu of Tap

Voltage Regulation

% from Tap

575 Volt tap

4000 Volt tap

6600 Volt tap

e Can you perform locked rotor tests? Provide description of limitations, method and equipment used.

f Describe equipment used to perform NL test on TEWAC or other motors with water-cooled components. Does the equipment have the capability of regulating/monitoring flow and fluid temperature?


Page 32 of 105 Rev. O 11-28-12



14 a Describe your Measurement and Test Equipment calibration program. If calibrations are performed externally, do you audit the calibration vendor?

b Provide information on the following MTE. (highest capacity units) Make Model

Max Volt, if

applicable

Size, Rating or other

description

Meggar

Surge Tester

DC Hi-pot Test Set

AC Hi-pot Test Set

Core Loss Test Set

Capacitance / Doble / Power Factor Test Set

Off-line Partial Discharge Processor

Low Resistance Ohmmeter

Thermography Equipment

Strobe Light

Growler

c Identify any additional motor related Measurement and Test Equipment you have at YOUR facility.

15 a Do you have "in-house" TIG Welding Capabilities?

b Do you have brazing rings or induction brazing equipment for rotor repairs?

c Describe processes/equipment (plating, flame spray, welding, etc) you have available for shaft (journal) repairs? What is the preferred method?


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16 a Provide descriptions of the following machine tools at YOUR facility.

Number available Size(s) Aggregate Capacity

Additional Description

Horizontal Mill

Vertical Mill

Vertical Boring Mill

Horizontal Boring Mill

Turning Lathes

Surface Grinding Equipment

Planar Surface Standard

Indexing Chucks

b Identify any additional motor repair related Machine Tools you have at YOUR facility.

17 a Provide description of ovens Make Height Width Depth # of Water Suppression Nozzles

Energy Source

Burn-Out (Charring) Oven #1


Drying / Curing Oven #1


b Describe any additional Winding Removal or Baking Equipment available at YOUR facility.

c What is your preferred / recommended method for winding removal for specific sizes of machine?

18 a Provide description of Resin Treating Equipment

Size

Resin (Make, Product #,

Base, Temp Class )

Controls (Automated or

Manual)

VPI Tank # 1

VPI Tank #2

Dipping Tank (Over-coating existing windings)

b Are coils manufactured at your facility or by an external supplier? Provide Name (s).

c Do you have a clean room for winding motors? If "in-house" coil facility is available, provide specifications (make, model, capacity) of the following coil manufacturing equipment.

c Diamond Coil Looping Machine


Page 34 of 105 Rev. O 11-28-12



Diamond Coil Spreader

Turn Taping Machine

Conventional or Robotic Taping Machines

d Identify any Trademarks or patented insulation systems your company holds.

e Provide the following information on your standard 7kV stator insulation system for Global VPI winding

Manufacturer Type / Model / Part Number

Temperature Class

Groundwall Insulation

Slot Wedges

Lead Cable

Series Coil Connection Insulation

Strand / Turn Insulation

f Identify any qualification or characteristic testing you have performed on your standard stator insulation system(s). (e.g. Thermal Life, Voltage Endurance, NEMA Sealed Winding Tests, etc.)

g How are the joints between the phase coil leads and the cable connections sealed? Describe.

h How are the areas where the coil leads exit the knuckle sealed? Describe

i Provide a comprehensive list of ALL in-process testing performed on medium-voltage form coils up to the point that the resin treatment is performed.

j Do you prefer to attach motor leads before or after VPI process?

19 a List the approximate square footage and lift capacity for each department in your facility.

Coil

Mfg

.

Win

din

g

Insta

llatio

n

La

rge

Mo

tor

Assem

bly

Sm

all

Mo

tor

Rep

airs

Pa

rts

Con

ditio

nin

g

Ma

ch

ine

Sh

op

We

ldin

g/F

ab

Sh

op

Are

a

QC

Inspe

ctio

n

/ T

est A

rea

Area (thousands of sq.ft.)

Lift Capacity (Tons)

Hook Height (at top of travel)


Page 35 of 105 Rev. O 11-28-12



b Describe equipment used to press large shafts in/out of induction rotors.

c List size of Paint Spray booth(s). Is all painting performed such that over-spray is controlled?

20 a Provide a comprehensive tabulation of process procedures or work instructions that you have developed AND IMPLEMENTED. Provide Document Control number, title of procedure, origination date, revision number, approximate number of pages, and implementation status. Note : Attached excerpts from your Quality documents are acceptable and preferred. Information not on the listing but requested above can be handwritten in the margins). If an internal register is NOT available, or proprietary, please complete the table below.

Doc. No. Procedure / Work Instruction Title Rev. # or Rev.

Date

Original Date

# of Pages

Implementation Status


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Appendix B

Gearbox Repair Vendor Capability Survey


Page 37 of 105 Rev. O 11-28-12



Gearbox Repair Vendor Capability Survey


1 a Provide 5 references for large gearbox repair customers

Customer #1

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #2

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #3

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #4

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #5

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross


Page 38 of 105 Rev. O 11-28-12



2 a Provide the following information describing any presently active "Blanket" Gearbox Refurbishment/Repair Contracts you hold.

Comments, if any :

Customer

Types of Service(s)


Customer

Types of Service(s)




3 a Identify the number of gearboxes repaired in the last twelve (12) months

< 500 KW

<1000kW <2000kW

2000hp

4 a Based on a precursory review of the specification, what does FPLE Specs requires that adds unnecessary cost to the price of refurbishments/repairs? Please explain

5 a How many employees do you have in the following departments :

Te

ar

Dow

n

Assem

bly

(Me

ch.)

Ma

chin

e

shop /

gear

cuttin

g

Qualit

y

Inspectio

n

Engin

eer

/

Te

ch

Support

Full Time Staff

Part Time Staff

Contractors


6 A List any other special motor repair services provided by your company at YOUR facility.

b Provide any special services that could be provided at our plants (e.g. Laser alignment, motor problem diagnostics, etc.)

c How do you obtain technical details and design information from major OEM's?

d Describe any alliances you have with motor or sub-component OEM's, including the scope of the agreement.

e Describe the typical process for obtaining replacement parts from motor OEM's.



Page 39 of 105 Rev. O 11-28-12



b What are your standard vibration acceptance criteria for specific types and speeds of induction motors?

c Do you have the capability of transferring vibration data electronically for analysis through software such as RBM Ware? or other software?

8 a Under what circumstances do you believe a fully-loaded test is required?

c Dynamometer capabilities for machines.

Dyno Make / Type Duty max KW @ 30 rpm based

on 1200RPM input

Max. KW @ 30 rpm based on 1800 RPM

input

Dyno #1

Dyno #2

Dyno #3

d What size regen Dyno is installed

e Which brand / model gearboxes do you have tooling for to perform a dyno test

9 a Do you have "in-house" TIG Welding Capabilities?

b Describe processes/equipment (plating, flame spray, welding, etc) you have available for shaft (journal) repairs? What is the preferred method?


Number available Size(s) Aggregate Capacity


Horizontal Mill

Vertical Mill



Turning Lathes



Indexing Chucks

Hobbing machines

Form grinding machines (what AGMA quality can be produce on

that machine?)

11 a Provide description of ovens Make Height Width Depth # of Water Suppression

Nozzles

Energy Source

Heat treating Oven #1

Heat treating Oven #2

12 a Facility Crane capacities

Crane ( 1) capacity and Height under hook




Page 40 of 105 Rev. O 11-28-12



b Trucking capacity & average distance traveled

c Does the facility have on-line continuous oil monitoring capability

d Is the repair facility climate controlled year round?

e Does the facility have a clean room for assembly?

f Does the facility have the ability to Nital Etch test gears prior to reuse?

g Does the facility have the ability to check gear profiles?

h Does the facility have the abililty to regrind gears?

i List size of Paint Spray booth(s). Is all painting performed such that over-spray is controlled?


Page 41 of 105 Rev. O 11-28-12



Appendix C

Pump Repair Vendor Capability Survey


Page 42 of 105 Rev. O 11-28-12






1 a General capability of the repair facility. Can the facility support ?

Shop

Location

Date of visit

Evaluation performed by

Large Horizontal Pumps

Large Vertical Pumps

Number of horizontal pumps which can be

worked simultaneously

Number of vertical pumps which can be

worked simultaneously

2 a Provide references for large pump repair (BFP / CWP)

Customer #1

Type of Service

Address

Technical Contact

Phone and/or email

b Customer #2

Type of Service

Address

Technical Contact

Phone and/or email

3 a On site shop observations

Crane capacity

Entry bay door configuration

Notes on record keeping area

Notes on QA/QC inspection area

Work order sample review

Random inspection


Page 43 of 105 Rev. O 11-28-12



of micrometer for calibration tag

Weld rod storage area review

Shop testing capabilities

List major machine capabilities

List of what pump OH tasks are outsourced

Field service capability

Ability to perform parts dimensional

mapping

Material stock observations

Shop cleanliness

General observations

4 a Reporting Capabilities – obtain sample reports for

As found inspection – dimensions and

pictures

NDE sample report

Revised scope of supply and quote

As built inspection – dimensions and

pictures

Field set-up sample report

Alignment sample report


5 a Process / Record Keeping – review record keeping area for

Welder qualification record review

Equipment calibration record review

Customer pump reports and data

review

Review process for documenting modifications

Review process to document non conformances



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Appendix D

ST Supplier Component Approval Form


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ST Supplier Component Approval Form

COMPONENT APPROVAL FORM –

[Supplier Name]

5/30/2014

* Instructions:

1) Modify file name to reflect supplier name, enter supplier name on this form.

2) Fleet Team Member to enter name and date at the bottom of this form.

3) Check boxes to identify which components the Supplier is capable of performing work on. When applicable enter remarks in the box provided. E.g. can work on hydrogen seals but requires additional supervision.

4) File this form in the Cafe under the applicable Suppliers’ records.

Check off below the specific components that Supplier is Qualified for:

Rotors Diaphragms / Blade Rings

Hydrogen Seals / Casings Oil Deflectors

Steam Glands/ Packing Cases Governor Table

Valves –Main and Reheat Stop/Throttle Control Rotors

Valves – Main Control and Intercepts

Bearings – Specify if Thrust or Journal

Brg Types:

Valve actuators Endshields/ Bearing brackets

Blade / Bu ket replacement Turning Gear

Reverse Engineering Balance Bal Type:

Shells / Cylinders / Casings

REMARKS, if any :

APPROVED BY: DATE:

http://cafe.fpl.com/sharepoint/pgd/techservices/turbfleet/TeamWIG/ST%20WIG%20Action%20Items/


Page 46 of 105 Rev. O 11-28-12




Page 47 of 105 Rev. O 11-28-12



Appendix E

FPL/NEER PGD Supplier Performance Evaluation Report

See file: PGD-ALL-DE-MA-1301141011 FPL-NEER PGD Supplier Performance Evaluation Report..xls

http://pgdapps/DMRetriever/?instanceID=09008dca80318af0



Page 48 of 105 Rev. O 11-28-12



Appendix F

ST Quality Assurance Nonconformance Report (NCR) Form

go to Excel file: PGD-ALL-DE-MA-1301141012 ST Quality Assurance Nonconformance

Report (NCR) Form .xls




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Appendix G

Pre-Audit Questionnaire For Suppliers of ST Repair Services


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Pre-Audit Questionnaire for Suppliers of Steam Turbine Repair Services Pleas respond for consideration as supplier of steam turbine component repairs.

Supplier Data

Vendor Name

Vendor Location (State)

Vendor Shipping Address

Vendor Mailing Address

Vendor Phone

Vendor Fax

Engineering focal point

Quality Assurance focal point

General Manager focal point

Vendor's website address

Approximate Sq. Footage

Supplier's Capability Refer to the adjacent ATTACHMENT 1 worksheet and list in-house capabilities.

List only equipment owned & operated by your facility. Note if automated or manual as applicable.

Acceptable to substitute Appendix 1 format as long as the proper data is provided.

Write N/A if there is no need to apply for the product in question.

Subcontractors Refer to ATTACHMENT 1 and provide a list of processes

that will be performed outside your facility for the product being evaluated.

Include names and locations of intended subcontractors.

Quality Systems Reference Quality Programs or Certifications implemented that apply to products furnished to Florida Power & Light. (ISO, ASME, AS etc.)

List audits completed by external registrant in the last 12 months.

Quality Program Registrant Last Audit


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People Provide a summary of personnel:

Summary (Total Number of Employees):

Function # of employees

Management

Engineering

Quality Assurance/QC

Shop/Production

Marketing/Admin

Labor Union representation? (y/n)

References/Relevant Experience List customers willing to serve as references: List customers who have recently procured products similar to those being evaluated:

Name Company Phone


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Appendix G, Attachment 1 Supplier Capability Matrix

Process IN-HOUSE Capability?

Sub-vendor for

Outsource?

Reverse Engineering (specify if blades, stationaries, valve components, etc)

Blade and Stationary Manufacture (equipment, OEM types, etc)

Valve Restoration Capabilities

Lifting Capability (crane capacities)

Rotor Capability - Max length between centers of Lathe and Max swing on Lathe

Cleaning (Grit Blast Typical)

FPI

MPI

X-Ray

Dimensional Measuring Equipment (e.g. CMM, Layout tables, etc)

Is there a Level 3 Inspector on site?

Fusion Welding (incl # of Booths, methods, e.g. TIG, MIG, etc)

Peening

Heat Treat (include size and # of furnaces)

Process IN-HOUSE Capability?

Sub-vendor for

Outsource?


Page 53 of 105 Rev. O 11-28-12



Conventional Machining (List Types, e.g. horizontal mill, vertical boring, etc)

Diaphragm and Blade Ring Capability (e.g. Vertical Mill max height and max swing)

Additional Machining Capabilities (i.e. chemical, electrical, waterjet, etc.)

Surface Grinding

Moment Weighing

Coating

Large Rotor Balancing (List whether Low Speed or High Speed, etc)

Do written procedures exist for disassembly, Inspection, reassembly, etc? For which Steam Turbine components (e.g. valves, rotors, etc)

Does a Quality Assurance employee maintain surveillance over shop procedures?


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Appendix H

ST Supplier Qualification Checklist


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ST Supplier Quality checklist Instructions: The Quality Checklist form is to be completed by the Turbine Fleet Team during an arranged audit of the shop. The quality checklist is comprised of a series of questions regarding the quality, process, and capability of the shop. There are areas for comments for each line item. Form Completion instructions: 1) The check list consists of 39 line items in which the Auditor should verify as applicable and time allows (if verify answer of yes, if not verified no or N/A). The results of each line item audit are recorded in the Comments section. 2) Subsequent audits should be listed as revisions to the quality checklist. Updates to the quality checklist are needed when changes to the Vendors quality, process, or capability occur. 3) The completed "Quality Checklist" should be filed under the CAFÉ website under the applicable supplier records folder.


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Acti

vit

y #

Activity Type

Audit Activity

Successfully

Verified? (Y, N, or

N/A)

Comments From Auditor

1 Quality Verify if Supplier is ISO Qualified. Note the registrant.

2 Quality

Verify if a Quality Manual exists. If yes, ask to review a typical process (e.g. Approval of Sub-Vendors, Processing NCR's, etc)

3 Quality

Verify if supplier has a "process" for dispositioning discovery items. Ask for specifics, like which disciplines are involved (e.g. inspector writes up dimensional findings, engineering dispositions, results sent to customer, etc).

4 Quality

Verify that an NCR/corrective/preventive action system exists and is utilized for non-conformances., refused shipments, turnbacks, customer complaints, etc. Explain who is authorized to review and approve nonconformances.

5 Quality

Verify that Quality Assurance has performed a survey of all vendors used to assist in the overhaul repair of turbine hardware. Do they perform receiving inspections of the work they sub out?

6 Quality

Randomly pick a job package (e.g. traveler, shop router, data sheets, etc) in the shop and ensure records are traceable back to the specific customer and related P.O. or work request.

7 Quality

Randomly pick a job package (e.g. traveler, shop router, data sheets, etc) in the shop and record whether there is adequate verification of final inspection data (i.e. does Machinist record dimensions or does a Quality person take the final dim, or does Qual just sign off, etc).

8 Quality

Randomly pick a job package in the shop and make an assessment of whether the written documents and instructions have sufficient detail to


Page 57 of 105 Rev. O 11-28-12



perform the operations (e.g. disassembly, inspection, reassembly, etc) or are they relying on "tribal knowledge" to complete operations.

9 Quality

Verify hardware is not stacked or piled on top of other hardware, and protective packaging is used to prevent handling damage.

10 Quality

Verify if a policy exists for record retention of shop work packages (router sheets, quality inspections, etc).

11 Quality Verify that supplier provides Final Reports of their work. Request an example and review.

12 Quality Verify if tool control exists so that tooling has calibration records.

13 General

With a copy of the suppliers PreAudit Questionnaire, perform some spot

checks of capabilities they listed (e.g. crane capacity, lathe equipment, weld

booths, balance machine, etc).

14 General

Chose a component (e.g. LP rotor, Diaphragm, Stop Valve, etc) and ask

supplier to go out to the shop and "walk the process" they will use for refurbishment. Idea is to have a

representative shop router in hand.

15 Balance Equipment

Are there maintenance and calibration records for the balance equipment.

16 Cleaning general

Insure appropriate measures are used to control corrosion after cleaning (e.g. machine oil or WD40 applied, etc).

17 Engineering

Inquire and comment on the level of engineering involvement in the creation of job packages (e.g. traveler, shop router, data sheets, etc).

18 Engineering

Verify capability of Reverse Engineering relative to inspection methodology (e.g. CMM, White Light, Laser), and Product Definition (e.g. CAD Software, 3D Modeling capability, drawing generation).

19 Engineering

For Reverse Engineering, review and comment on the suppliers method of determining desired tolerances for part surfaces.


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20 Facility Verify lighting is adequate to examine parts.

21 Facility

Note if facility cleanliness and housekeeping are appropriate to quality requirements of the products in work.

22 Facility

Note any observations of safety concerns, such as: at risk behaviors, equipment hazards, hazardous chemicals, poor ventilation, etc.

23 FPI/MPI

Verify if a procedure exists for qualification and certification of inspection personnel. Ensure at least (1) Level III Inspector is on site or a Level III consultant is on retainer.

24 FPI/MPI

Ensure inspection records traceable to inspected part, and including disposition, classification, and date are kept stored and available for future reference.

25 FPI/MPI

Verify written procedures (technique sheets) exist for inspections detailing pre-cleaning, process parameters, inspection requirements, and post-cleaning.

26 Grit blast Ensure grit blast booths (or tents, etc) are of sufficient size to handle turbine components.

27 Heat treat Verify the level of data and document control for recording charts, TC calibration, furnace control, etc.

28 Marking Verify the proper equipment and methodology exists to adequately perform marking of parts.

29 Machining

Verify if supplier maintains schedules or instructions detailing established process (speeds, feeds, setup, metrology etc.)

30 Material Evaluation

Verify if procedures and equipment exist for evaluating mechanical properties (e.g. hardness test).

31 Metrology

Record info on equipment available (e.g. hand mics, CMM, etc) for inspection and verify that it is sufficient to inspect the critical features of part.

32 Moment Weighing

If they noted in the Pre-Audit Questionnaire that they have the capability, ask to review equipment and procedures. Provide comments.


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33 Coating Verify if written procedures/instructions exist to control the application of any of the coatings.

34 Weld-Fusion

Verify if a supplier has records for each welder and base metal group for which welder is certified (including showing test weld results).

35 Weld-Fusion

Verify if there are established written instructions or schedules which provide welding guidelines such as gas flow, nozzle size, torch nozzle, tip extension, base metal reference and weld wire reqmts.

36 Weld-Fusion Ensure weld wire is properly stored to protect it from the environment, and clearly identified.

37 Weld-Fusion Verify if a procedure exists for qualification of automated welds.


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Appendix I

ST Supplier Trip Report


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ST Supplier Trip Report

Supplier Visit Supplier Name:

Supplier Phone:

Supplier Mailing Address:

Trip Report Completed by:

Title:

Date of Trip:

Phone:

Comments from Trip:


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Appendix J

Steam Generator Shop Audit Check Sheet


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Steam Generator Shop Audit Check Sheet Items to be verified at the Shop audit:

Request and understand the Supplier’s site safety plan and evacuation route (perform a ORM/RAMF).

Current status of components

Manufacturing milestones on schedule

Delivery schedule on target

Supplier concerns or issues

Any contingency plan

Quality Plan review Fabrication to design, validate with the prints

Dimensions

Operational orientation

Labeling

Visually inspect all welds (VT)

Look for undercut, porosity, underfill at start-stops, weld size, arc strikes, and cracks

Adequate penetration

Excessive reinforcement

Inspect surface preparation and painting to specification

Review Suppliers quality plan, supplier shall perform to their procedures and any specific requirements as listed in the specification.

Review if supplier is following their plan.

Review applicable documents to determine the appropriate inspectors are validating and signing off on the required steps.

Review applicable documents for all appropriate check points being reviewed and completed.

Review the Certified Material Test Reports (CMTR’s) for correct specified material mechanical and composition properties.

Review the Weld Procedure Specification (WPS) for compliance.

Review the applicable Weld/Component traveler for the use of the proper weld filler material.

Review the application of the proper weld process used, i.e., Shielded Metal Arc/Gas Tungsten Arc Welding (SMAW/GTAW).

Review the Welder Performance Qualifications (WPQ).

Review the welders’ Weld Process Continuity logs.

Review the Weld/Component traveler for the identification and tracking of the welds identified with a welder that has current certifications and has maintained his/her weld process continuity.

Review the required Nondestructive Examination (NDE) performed.


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Review the NDE personnel certifications (Level II or Level III for the respective examination method and for VT, AWS CWI or ASNT Level II certified).

Review the required Post Weld Heat Treatment (PWHT) performed and PWHT procedures.

FPL comments:

Vendor comments:

Issue report when complete.


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Items to be verified at the Field audit: Type of work performed by the Vendor

Rigging and Installation

Fabrication

Inspection

Other (Explain below)

Current status of completion

Milestones on schedule


Vendor concerns or issues


Review Vendor quality plan, Vendor shall perform to their procedures and any specific requirements as listed in the specification.

Review if Vendor is following their plan.

Review applicable and appropriate documents to determine the Vendor is validating and signing off on the required steps.


FPL comments:

Vendor comments:


Attach executive and comprehensive report.


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Appendix K



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Heat Treatment Audit Questions

1 Which type of furnace is in use and what is it’s' energy source?

2 What shop procedure and protocol is used for the heat treatment process?

3 Are the heat treatment parameters defined within the procedure used & known by the furnace operator? Yes No

4 Is recording equipment calibrated & what is frequency of calibration? Yes No

5 How are the number of burners and thermocouples identified and their respective operation tracking maintained?

6 How are furnace products loaded in furnace?

7 How is temperature loss through the furnace door accounted for and checked?

8 What is the size & capacity of the furnace?

9 Is a valid furnace uniformity test report available? Yes No

10 What shop procedure and protocol is used for the quench process?

11 Are the quench treatment parameters defined within the procedure used and known by the furnace operator? Yes No

12 Is the quench facility functional and how is the temperature gradient measured? Yes No

13 How is the water temperature controlled?

14 How are the heat treatment batches defined & by whom?

15 Are test specimens heat treated together with the material they represent? Yes No

16 How is the recording & traceability of batches performed and documented?

FPL comments:

Vendor comments:


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Appendix L

Steam Generator

Shop Audit Check Sheet Specific checkpoints for Honeycomb SCR catalyst


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Steam Generator Shop Audit Check Sheet Specific checkpoints for Honeycomb SCR catalyst Items to be verified at the Shop audit:







Quality Plan review Fabrication of module frames to design, validate with the prints

Module length versus design and tolerances Module width versus design and tolerances Module height versus design and tolerances Module material versus (temperature) specification


Labeling

Perform an overall visual inspection for mechanical issues (cracks, loose bolts, bent or curved

Visually inspect all module welds (VT)




Visually inspect Raw Material Storage

Adequate provisions to prevent rejected raw materials from being used

Visually inspect Kneading, Extrusion and kneaded material storage for quality and consistency issues

Are there provisions to remove certain particle size contaminations and lumps from kneaded material

Inspect module surface preparation

Verify that no surface treatment is used (paint, galvanization) and that there is no significant rust on the module frames

Extrusion

Visually verify that extruded logs are consistently shaped and sized and that wet log color is consistent; check for significant visual imperfections

Log marking

Verify that vendor applies a unique and traceable code to each log and that this code application is robust, permanent and is readable on the end


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products (calcined logs) before packing into modules

Calcining

Calcining has a big impact on final product performance. Verify (visually, verbally) that there are no obvious inconsistencies that can cause significant spread in temperature or residence time.

Log sizing (“cutting”)

Visually verify that cutting surfaces are clean and smooth. Measure lengths of several cut logs.

Module assembly

Visually verify that logs are sealed per vendor specification and that logs are stacked properly (well arranged, snug fit).

Visually verify that module frames are constructed and welded as specified

Warehouse

Visually verify that finished modules carry the proper quality marks (per spec) and that disapproved materials are quarantined and properly marked. Verify that packaging material meets the spec

Measure and verify module dimensions for a few randomly selected modules (see “fabrication of module frames” above)






FPL comments:

Vendor comments:



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Appendix M

Steam Generator Materials Site Inspection Check Sheet

Specific checkpoints for Honeycomb SCR catalyst


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Steam Generator

Materials Site Inspection Check Sheet Specific checkpoints for Honeycomb SCR catalyst Vendor Audited: Site location: Inspector: Date: Items to be verified during the Site Materials inspection:





Any contingency

Quality review Fabrication of module frames to design, validated with the prints

Module length versus design and tolerances Module width versus design and tolerances Module height versus design and tolerances Module material versus (temperature) specification


Labeling

Perform an overall visual inspection for mechanical issues (cracks, loose bolts, bent or curved parts or (transport) damage in general

Visually inspect all module welds (VT)





Verify that no surface treatment is used (paint, galvanization) and that there is no significant rust on the module

Logs (elements) visual

Visually verify that face an back of extruded logs are consistently shaped and sized and that wet log color is consistent; check for significant visual imperfections and damage or contamination

Module assemblies

Visually verify that logs are sealed per vendor specification and that logs are stacked properly (well arranged, snug fit).

Visually verify that module frames are constructed and welded as specified


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Quality marking

Visually verify that finished modules carry the proper quality marks (per spec).

Verify that packaging material meets the spec

Installation issues due to modules

Module-fit-in-frame issues.

Module sealing issues.

Fit at bottom and top rows issues.

Drawing versus actuals issues

NextEra Resources/FPL comments:

Vendor comments:



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Appendix N

Steam Generator Shop Audit Check Sheet

Specific checkpoints for waterfall coated CO catalyst


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Steam Generator Shop Audit Check Sheet Specific checkpoints for waterfall coated CO catalyst Items to be verified at the Shop audit:







Quality Plan review End product: fabrication of catalyst blocks to design, validate with the

prints

Block length versus design and tolerances Block width versus design and tolerances Block height versus design and tolerances Block material versus specification

Homogeneous cell shapes, dimensions and orientations

Labeling

Perform an overall visual inspection for mechanical issues (cracks, bad welds,dents, bents or curved parts

Determine cpsi (cells per square inch) for several blocks versus specification

Uncoated blocks (if available): visually inspect all third party vendor manufactured blocks

Block length versus design and tolerances Block width versus design and tolerances Block height versus design and tolerances Block material versus specification Perform an overall visual inspection for mechanical issues (cracks,

bad welds,dents, bents or curved parts Look for adequate weld integrity (undercut, porosity, underfill at start-

stops, weld size, arc strikes, and cracks) Visually verify that metal foil cutting surfaces are clean and smooth.

Measure actual block foil depths of several cut logs (usually 2.5” to 3.5”). versus specification. The foil is the catalyst substrate.

Homogeneous cell shapes, dimensions and orientations Determine cpsi (cells per square inch) for several blocks versus

specification Verify that no surface treatment is used (paint, galvanization) and that


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there is no significant rust on the block frames

Visually inspect Raw Material Storage

Adequate provisions to prevent rejected raw materials from being used

Visually inspect Coating Process for quality and consistency issues

Inspect the coating versus specification

Visually inspect the status of the equipment for issues (maintainance, damage, dirty etc.)

Check line speeds versus specification Check drying temperatures and times versus specification

Coated Block marking

Verify that vendor applies a unique and traceable code to each log and that this code application is robust, permanent and is readable on the end products (calcined logs) before packing into modules

Warehouse

Visually verify that finished modules carry the proper quality marks (per spec) and that disapproved materials are quarantined and properly marked. Verify that packaging material meets the spec






FPL comments:

Vendor comments:



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Appendix O

Steam Generator On-site Materials Check Sheet

Specific checkpoints for waterfall coated CO catalyst


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Steam Generator On-site Materials Check Sheet Specific checkpoints for waterfall coated CO catalyst Vendor Audited: Site: Auditer: Date: Items to be verified at the Shop audit:







Quality Plan review Fabrication of catalyst blocks to design, validate with the prints

Block length versus design and tolerances Block width versus design and tolerances Block height versus design and tolerances Block material versus specification

Homogeneous cell shapes, dimensions and orientations

Labeling

Perform an overall visual inspection for mechanical issues (cracks, bent, dents or curved parts or (transport) damage in general

Visually verify that face an back of blocks are consistently shaped and sized and that block color is consistent; check for significant visual imperfections and damage or contamination

Visually inspect block welds (VT, 10 blocks randomly)





Verify that no surface treatment is used (paint, galvanization) and that there is no rust on the block frames

Coated Block marking

Verify that vendor applies a unique and traceable code to each log and that this code application is robust, permanent and is readable on the end products (calcined logs) before packing into modules


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Verify that packaging material meets the spec

Installation issues due to modules

Block-fit-in-frame issues.

Block assembly sealing issues.

Fit at bottom and top rows issues.

Drawing versus actuals issues.

FPL comments:

Vendor comments:



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Appendix P

Steam Generator Structural Steel Fabricator/Erector Vendors


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Steam Generator Structural Steel Fabricator/Erector Vendors Vendor Audited: Site location: Inspector: Date:

1 Do you have a Civil/Structural PE on staff? Yes No

If so, please provide name of engineer.

If not, please provide name of Company to be utilized and Contact Information.

2 Are all structural welds, welders and related operations for carbon steel in conformance with the applicable provisions of the AWS Structural Welding Code, AWS D1.1 as issued by the American Welding Society?

3 Have all welders, welding operators, and tackers been tested and examined by an independent testing laboratory in accordance with the applicable provisions of the AWS code, and have accurate records been maintained by Vendor?

4 Are personnel responsible for visual inspection and acceptance of welding Certified Welding Inspectors qualified and certified in accordance with American Welding Society AWS QC1, Standard for Qualification and Certification of Welding Inspectors?

5 Is the company a qualified installer who participates in the AISC Certification program and is designated an AISC Certified Erector?

6 If so what Category? Advanced Certified Steel Erector [ACSE] Certified Steel Erector [CSE]

7 Is the company a qualified fabricator who participates in the AISC Certification program and is designated an AISC Certified Plant, Category Standard for Steel Building Structures [STD] ?

FPL comments:

Vendor comments:


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Appendix Q

Traveling Water Screen

Shop Audit Check Sheet Specific checkpoints


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Traveling Water Screen Shop Audit Check Sheet Specific Checkpoints VENDOR DATE

LOCATION SCREEN TYPE

JOB NO. SIZE SCREEN

UNIT NO. DIVER

CONTACT

Items to be verified at the Shop audit:



Manufacturing milestones on schedule Delivery schedule on target Supplier concerns or issues Any contingency plan

Quality Plan review Head Section

Capstands ______________________________ Right Left

Thrust bearings ______________________________ Right Left

Spring Suspension ______________________________ Right Left

Take-up rods/screws ______________________________ Right Left

Take-up housings ______________________________ Right Left

Take-up guides ______________________________ Right Left

Take-up bushings ______________________________ Right Left

Take-up roller bearings ______________________________ Right Left

Drive chain idler sprockets ______________________________ Right Left

Drive chain idler brackets ______________________________ Right Left

Frame ______________________________ Right Left

Coating ______________________________


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Right Left Sprockets ______________________________

Right Left Tooth inserts ______________________________

Right Left Head shaft ______________________________

Right Left Shaft keys ______________________________

Right Left Torque tube ______________________________

Right Left

Spray wash system Header ______________________________

Right Left Nozzles ______________________________

Right Left U-bolts ______________________________

Right Left Internal feed pipe ______________________________

Right Left

Splash housing Front

Housing ______________________________ Right Left Doors ______________________________ Right Left

Rear ______________________________ Housing Right Left Doors ______________________________ Right Left

Chain cover ______________________________ Right Left

Intermediate section Frames ______________________________

Right Left Diagonal bracing ______________________________

Right Left Cross bracing ______________________________

Right Left Front post guides ______________________________

Right Left Rear post guides ______________________________

Right Left

Foot Section


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Sprockets ______________________________ Right Left

Foot shaft ______________________________ Right Left

Set collars ______________________________ Right Left

Shaft brackets ______________________________ Right Left

Sprocket bearings ______________________________ Right Left

Extension shoes ______________________________ Right Left

Extension angles ______________________________ Right Left

Track/filler bars ______________________________ Right Left

Boot casings ______________________________ Right Left

Boot plate ______________________________ Right Left

Carrier chain Side bars condition ______________________________

Right Left Side bars thickness ______________________________

Right Left Set collars ______________________________

Right Left Chain pins lube or non-lube____________________________

Right Left Chain rollers ______________________________

Right Left


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Baskets Frames ______________________________

Right Left Straps ______________________________

Right Left Wire mesh ______________________________

Right Left Hard wire ______________________________

Right Left Coating ______________________________

Right Left Seal plates ______________________________

Right Left Attachment bolts ______________________________

Right Left

Visually inspect all welds (VT) Look for undercut, porosity, weld size, arc strikes, and cracks

FPL comments:

Vendor comments:



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Appendix R

Rotor Balance Shop Audit Checksheet


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Appendix S

Basket Strainer Shop Audit Check Sheet

Specific Checkpoints


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Basket Strainer Shop Audit Check Sheet Specific Checkpoints VENDOR

LOCATION

JOB NO.

UNIT NO.

CONTACT

DATE

Items to be verified at the Shop audit:


Current status of components Manufacturing milestones on schedule Delivery schedule on target Supplier concerns or issues Any contingency plan

Quality Plan review Body

Material ______________________________ Exterior coated

Yes No Interior coated

Yes No Nameplate attached

Yes No Centerline dimension ______________________________

Cover/Body Gasket Material ______________________________

Lifting Lugs Yes No

Cover Davit Yes No

Support legs Number ______________________________ Base Plates

Yes No


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Design Code ASME VIII Non Code

ASME VIII Code “U” Stamp Other ______________________________

Inlet Connection Size ______________________________ Flange type

Series A Series B Raised face Flat face

Pressure rating ______________________________ Bolt holes straddle CL

Yes No Outlet Connection

Size ______________________________ Flange type

Series A Series B Raised face Flat face Pressure rating ______________________________ Bolt holes straddle CL

Yes No Basket

Material ______________________________ Perforation Size ______________________________

Visually inspect all welds (VT) Look for undercut, porosity, weld size, arc strikes, and cracks

FPL comments: Vendor comments:



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Return to Table_of_contents

Appendix T

Generator Equipment Component Repairs, Refurbishment, Rewinds, or Site Services Vendor

Capability Survey


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Vendor Generator Capability Survey


1 a Provide 5 references for major generator projects – Stator , field, Exciter or Collector Assembly, Rewinds/Refurbishment/Modifications or Repairs,

Customer #1

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #2

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #3

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #4

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross

Customer #5

Type of Service

Address

Technical Contact

Phone and/or email

Approximate Gross


Page 96 of 105 Rev. O 11-28-12



2 a Provide the following information describing any presently active major generator (stator, rotor, exciter) Rewinds/Refurbishment/Modifications, Repairs or Services Contracts you currently administer.

Comments, if any :

Customer

Types of Service(s)


Customer

Types of Service(s)




3 a Identify the number of generator Rewinds/Refurbishment/Modifications, Repairs or Services Contracts in the last twelve (12) months (for both shop and field services).

Stator

Rotor Exciter Collector Assembly

Field Services

Other

4 a Based on a precursory review of the specifications, what does FPLE Specs requires that adds unnecessary cost to the price of refurbishments/repairs? Please explain

5 a Describe any industry or other certification(s) your employees hold for generator repair.

b Describe any training programs, internal or external, that you provide for your employees.

c Are minimum qualifications established for personnel to perform specific critical repair tasks? If yes what are the qualifications and which individuals are qualified?

6 a How many employees do you currently employ in the following departments :

Fie

ld

Serv

ices /

Engin

eers

Fie

ld

Serv

ices /

Te

chnic

ians

Te

stin

g

/Engin

eers

&

Te

chnic

ians

Sta

tor

/ ro

tor

Win

din

g /

Te

chnic

ians

Ma

chin

e &

Weld

Fa

b.

Shop

Ma

nage

me

nt

Qualit

y

Inspectn

Engin

eer

/ T

ech

Support

Full Time Staff

Part Time Staff

Contractors


Employee’s which hold more than one function, i.e., Quality and Engineering support.


Page 97 of 105 Rev. O 11-28-12



6 b Total Number of Employees at your facility?

c Resumes of Critical Expertise

If none, enter "0" in Name Column Facility / Operations

Manager Quality Mgr.

Engineering / Technical Support

Manager

Name

Total Years of Generator or Large Rotating Equipment Experience


School/Degree/Formal Training

Other Generator or Large Rotating Equipment Mfg. / Repair Companies

Employed by :

Senior Mech. Engineer

Senior Electrical Engineer

Field Services Manager

Name





Employed by :

Vibration / Balance Facility

Expert Lead Machinist Lead Winder

Name





Employed by :

d Provide names and technical resumes of any technical consultants you use or have on retainer.

7 a Describe your company / facility standard services provided for Generator Components.

b Place an "X" in the box for any of the following special generator repair services provided by your company at YOUR facility or at site.

Re-d

esig

n

/

Mo

dific

atio

n o

n O

EM

Fle

et

Generic

Issues

Roto

r /

Exciter

bala

ncin

g

Sta

tor

/

Roto

r C

ore

S

tackin

g

Specia

l site

serv

ices

ND

E

Inspectio

n

Capabili

tie

s

Bushin

g

ma

nufa

ctu

re,

repair

or

re-b

uild

Fin

ite

Ele

me

nt

mo

delin

g

Mo

dal

Analy

sis

/

Imp

act

Te

st

c List other special generator repairs or services provided by your company at


Page 98 of 105 Rev. O 11-28-12



YOUR facility or at site.

d Describe any special services that could be provided at our plants (e.g. site machining, generator problem diagnostics, etc.)

8 a Identify experience with Westinghouse, Siemens, GE, Mitsubishi, Brush and Toshiba generators and generator auxiliary equipment. Discuss known upgrades for OEM fleet generator issues such as oil leaks (hydrogen seals and oil seals), vibration problems and end winding issues, etc, for the above OEM manufactures.

b How does your company obtain technical details and design information from major Generator OEM's; specifically Westinghouse, Siemens, GE, Mitsubishi and Toshiba?

c What are your company’s capabilities in the area of reverse engineering of parts? List equipment, software and personal experience.

d Describe any alliances you have with Generator or sub-component OEM's, including the scope of the agreement?

e Describe the typical process for obtaining replacement parts from Generator OEM's, specifically Westinghouse, Siemens, GE, Mitsubishi and Toshiba?

f List and describe any authorized distribution agreements you hold with Generator OEM's for "new" replacement parts, services or generators.

9 a Identify specific references you use in determining acceptable tolerances for critical generator equipment fits and performance parameters.

10 a Describe any products (generators, generator components, generator testing equipment, other electrical equipment etc.) designed and manufactured by your company (as


Page 99 of 105 Rev. O 11-28-12



the OEM).

b List and describe what you consider to be your company's three (3) most accomplished projects or endeavors regarding generator manufacturing, repair or refurbishment.

11 a Provide the specifications for your balance bunker equipment (Make, Type, Length, OD and Max Weight able to balance, etc.)

b If your company does not own a balance bunker list who you utilized to balance equipment.

c Is your company considering or actively planning the construction of a balance facility (bunker)

d Is your equipment graduated to balance to ISO 'G' levels?

e Describe your internal residual imbalance acceptance criteria for specific types and speeds of rotating equipment.

f Is your balance facility capable of thermal runs of rotors? If so, what method(s) do you utilize? What is the maximum current rating if you can excite the rotor?

g Is your balance facility equipped with a flux probe to detect rotor turn shorts? What soft ware method is utilized to perform analysis of the flux test?


b What are your standard vibration acceptance criteria for specific types and speeds of rotors and exciters?

c Does the facility/shop have the capability of transferring vibration data electronically for analysis through software such as RBM Ware? or other software?

d Does the facility/shop have the


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capability to use proximity probes to measure shaft displacement for vertical machines?

13 Material Inventory at Facility /Shop –

a Are retaining rings stocked? If so what is the maximum size (dimensions)?

b What critical materials are normally in your facility /shop inventory, such as collector ring billets, oxygen free copper billets, etc? List below.

1.

2.

3.

4.

5.

c What inventory tracking system is utilized for long and short term shelf items (with expiration dates) such as mica tapes, resins, etc?

d How is material certifications handled for key items such as retaining rings, collector rings, oxygen free copper, etc?

14 a Describe your Measurement and Test Equipment calibration program. If calibrations are performed externally, do you audit the calibration vendor?

b Provide information on the following MTE. (highest capacity units) Make Model

Max Volt, if applicable

# of units, Size, Rating

or other description

Megger

Low Resistance /Digital Ohmmeter

DC Hi-pot Test Set

AC Hi-pot Test Set

El-Cid Test Set

Capacitance / Doble / Power Factor Test Set

Tan Delta Test Set

Off-line Partial Discharge Test set

Recurrent Surge Oscillograph (RSO) Test set

Thermograph Equipment

Impedance test set


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c Identify any additional generator related Measurement and Test Equipment you have at YOUR facility.

15 a Do you have "in-house" TIG and Arc Welding Capabilities?

b What brazing processes are Utilized on equipment repairs for Stator, rotor, exciter or other? (i.e., stator series and phase connections, rotor coil – pole to pole jumpers, main lead connections, etc.)

c List the type & rating of brazing equipment utilized in your processes both in the Factory/Facility/Shop and in the Field?

1.

2.

3.

d Describe processes/equipment (plating, flame spray, welding, etc) you have available for shaft (journal) repairs? What is the preferred method?


Number available

Size(s) Aggregate Capacity


Horizontal Mill

Vertical Mill



Turning Lathes



Indexing Chucks

Rotor slotting lathe

Other (Identify type)

b Identify additional Generator repair related Machine Tools at YOUR facility.

17 a Provide description of ovens Make Height Width Depth # of Water Suppression

Nozzles

Energy Source




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b Describe additional Winding Removal or Curing Equipment available at YOUR facility.

c What is your preferred / recommended method for removal of winding for specific manufacturer (OEM) types and sizes of machine?

d Describe the process utilized to remove old turn insulation from rotor coils? If more than one method list all or provide specification.

18 a Provide description of Resin Treating Equipment

Size

Resin (Make, Product #, Base,

Temp Class )

Controls (Automated or

Manual)

VPI Tank # 1

VPI Tank #2

Dipping Tank (Over-coating existing windings)

Other (Identify Type)

b Are stator or rotor coils manufactured at your facility or by an external supplier? Provide Name (s).

c Do you have clean rooms for winding generator components (stator, rotor, or exciter? If "in-house" coil facility is available, provide specifications (make, model, capacity) of the following coil manufacturing equipment.

Diamond Coil Looping Machine

Diamond Coil Spreader

Turn Taping Machine

Conventional or Robotic Taping Machines

Other (Identify Type)

d Identify any Trademarks or patented insulation systems your company holds.

e Provide the following information on your various (voltage rated) standard stator insulation system(s) for Global VPI or B-Staged taped winding systems

Manufacturer Type / Model / Part Number

Temperature Class

Groundwall Insulation


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Slot Wedges

Connection/Parallel rings

(If Utilized) Group or Transposition Insulation

Strand / Turn Insulation

f Identify any qualification or characteristic testing you have performed on your standard stator insulation system(s). (e.g. Thermal Life, Voltage Endurance, NEMA Sealed Winding Tests, etc.)

g What methods are utilized to encapsulate the stator series, phase connections, and connection ring/parallel to bushing connections? Describe or provide process spec.

h Provide a comprehensive list of ALL in-process testing (Electrical, Mechanical & NDE) performed during the manufacturing process of coils both stator and rotor.

i What insulation materials are manufactured in-house for stator, rotor, and exciter and collector assembly equipment? List below:

j List major insulation sub-contractors your company utilizes as a supply / provider. List the materials supplied / provided by each. Only larger items, such as slot liners, retaining ring and collector ring insulation, mica tape, resins, etc.

19 a List the approximate square footage and lift capacity for each department in your facility.

Coil

Mfg

.

Win

din

g

Insta

llatio

n

La

rge

Eq

uip

me

nt

Assem

bly

/

Dis

assem

bly

Are

as

Roto

r &

Sta

tor

Rep

airs

Pa

rts

Con

ditio

nin

g

Ma

ch

ine

Sh

op

We

ldin

g/F

ab

Sh

op

Are

a

QC

Inspe

ctio

n /

Te

st

Are

a

Area (thousands of sq.ft.)


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Lift Capacity (Tons)

Hook Height (at top of travel)

b Number of cranes both fixed and portable – please specify separately.

c List size of Paint Spray booth(s). Is all painting performed such that over-spray is controlled?

20 a Provide a comprehensive tabulation of process procedures or work instructions that you have developed AND IMPLEMENTED. Provide Document Control number, title of procedure, origination date, revision number, approximate number of pages, and implementation status. Note: Attached excerpts from your Quality documents are acceptable and preferred. Information not on the listing but requested above can be handwritten in the margins). If an internal register is NOT available, or proprietary, please complete the table below.

Doc. No. Procedure / Work Instruction Title Rev. # or Rev.

Date

Original Date

# of Pages

Implementation Status


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