RELIABILITY PROGRAM

Owner: Inspection Department

Responsibility: Area Inspectors

Purpose:  To assure the safe and reliable operation of plant cooling towers.

Description:

Inspection Intervals:

• External (on-stream) inspections will be performed on 24-month intervals.
• Internal inspections will be performed in conjunction with Unit Turnarounds, with a maximum interval not to exceed 120 months.
• Inspections will be initiated by the Area Inspectors.

Coordination:

• Area Inspector advises the Planner of the need for an inspection.
• Planner creates the necessary Work Orders and Requisitions to engage a qualified third-party cooling tower inspection contractor for Internal Inspections.
• Internal Inspections will be performed by qualified third-party personnel experienced in cooling tower repairs, maintenance, and inspection, accompanied by an Authorized Inspector.
• Planner will advise the Area Inspector of pending inspection details.
• External Inspections will be performed by an API Authorized Inspector.

External Inspection:

External Inspection should be performed well in advance of the scheduled outage and shall include:

• Condition of stairways, landings, and accessible structural members.
• Missing wall panels and air leakage points.
• Condition of water and chemical piping, and basin integrity.
• Operations should be consulted regarding the need to perform a Performance Evaluation.
• Rotating Equipment Engineer should be consulted for any needed repairs or upgrades.

Internal Inspection:

Internal Inspection should be performed during Unit Outages unless alternative arrangements are provided. Normal inspection scope should follow the Cooling Tower Institute Cooling Tower Manual and include:

• Structural integrity of the tower.
• Condition of baffles or packing.
• Presence of fouling or biological growth.
• Pump suction screens and partitions.
• Interior decking condition.
• Condition of fans, shrouds, and equipment guards.

Recommendations / Repair:

• Recommendations from External Inspection are to be forwarded to the T/A Planner for inclusion in the T/A Scope. The T/A Planner will transmit the Scope to the Tower Contractor prior to the Turnaround.
• Recommendations from Internal Inspection are to be developed by the Area Inspector and forwarded to the T/A Manager as additions to the T/A Scope.
• Contractor(s) perform repairs according to the approved Work Scope, under the supervision of the Maintenance Supervisor and performed by a qualified third-party cooling tower company.
• An Inspection representative will be assigned to ensure compliance with applicable industry specifications, document repairs, and make recommendations for successive Turnarounds.

Documentation:

• Area Maintenance Supervisor closes out all Work Orders through normal T/A or system protocol (e.g., SAP).
• T/A Report will be developed by the assigned Inspector and stored in the Maintenance Management System (CMMS). Hard copy files will be maintained for documents not compatible with the CMMS.
• Design changes are to be documented by the Designer/Engineer, who shall also update the Equipment Data in the designated records vault.