Ameren Illinois Electric Quality Assurance Program Keith Lowry Superintendent, Electric Quality Assurance

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1 Ameren Illinois Electric Quality Assurance Program Keith Lowry Superintendent, Electric Quality Assurance May 15, 2015

2 Development of Quality Assurance Process Illinois Commerce Commission Reliability and Performance Recommendation Issued in 2008 Overall Objectives Ensure the safety of the electric distribution facilities for both the public and employees. Continually improve system reliability and ensure facilities are designed and constructed in accordance with Ameren Standards and NESC code.

3 Development of Quality Assurance Process Ameren Illinois Process Development Ameren Objectives 1. Ensure new and existing design standards comply with NESC requirements 2. Ensure engineering application of the design standards comply with Ameren design criteria and NESC requirements 3. Ensure that facilities are constructed as designed

4 Development of Quality Assurance Process Ameren Illinois Process Development Ameren Objectives 4. Identify and correct compliance issues to continually improve reliability of Ameren electric distribution facilities. 5. Determine the effectiveness of the QA process through meaningful measure and review of process performance.

5 Development of Quality Assurance Process Ameren Illinois QA Organizational Structure Part of Ameren Illinois Divisional Operations Sr. Director Division Operations Manager Electric Training and Quality Assurance Superintendent Quality Assurance Quality Assurance Analyst (2) Quality Assurance Auditor (4)

6 Quality Assurance Auditor Responsibilities Audit construction work in field Standards Compliance National Electrical Safety Code Compliance Avian Protection Safety Workmanship

7 QA Work Process Flow Analysts Sends Audit Requests to Operating Centers for 10 Random Work Requests. QA Automatically Receives 100% of Distribution MAP Projects Auditors receive job packets; Reviews plans and schedules and routes work. Auditors perform inspection of job in field for compliance to engineering design, construction quality, safety issues, Ameren Standards, and/or NESC violations. Auditors in office prepares Field Reports and photos for each job and sends package to Analyst for report preparation. Analyst prepares QA Audit Summary (Excel spreadsheet and PowerPoint presentation) from Field Reports and photos turned in by Auditors. Sets up Audit Review Meeting, and sends reports to areas within 10 days.

8 QA Work Process Flow Auditors conduct Audit Review Meetings where audit findings are discussed. Auditor notifies Analyst of any revisions needing to be made to reports. Analyst closes audit by finalizing Summary Report, uploads Corrective Action Data to final Report and prepares audit packet for document retention. Engineering or Operations then responsible for coordinating the corrective action to comply with proper Ameren Standard Construction or NESC code requirements. Engineering or Operations responsible for entering completion data into CA Report. CA Report Monitored by Il. Division Management for completion of issues.

9 Field Report Form Field Audit Date: Circuit # : DOJM W/R #: Job Description / Address: Audit OK Audit Review Ameren Crew Division: Contractor Crew AMI-MAP Audit MAP Audit North 6 South Contractor Crew Name: Operating Center: City: Auditor: WR From: John Hudson Dan Petrone OC Phil Langdon Evon Pickens DDC Keith Lowry PDC Ameren Operations Supervisor: Audit Completion Date: Facility Count Data: Total Facilities on WR: Facilities with : Facilities w/o : * Design Date: * Build Date: Pole Location / Number Key Number Comments Photo Corrective Action

10 QA Key Sheet 14 Cable Terminals Ameren Standard NESC Code Key # Description Corrective Action Auditor Notes NESC 215 C Steel secondary riser not grounded. All metal secondary conduits--either newly installed or transferred--shall now be effectively grounded per DCS NESC 215C Ground steel riser per Ameren Standards. Start making this call after 7/8/14. Only call when a pole or conduit has been replaced or transferred. QA bulletin article dated October 30, NESC Terminal pole lacks label or legible label. NESC 372 Install or replace labeling on pole for correct switch number ** NESC 217 A2c ** NESC 239 G Riser bracket spacing above ground and between lowest two brackets is less than 8'. DCS **, NESC 217 A2c Top of riser is less than 40" above communications. DCS **, NESC 239 G1 Correct riser bracket spacing to meet the required 8' separation required by Ameren Standards and NESC Code. Refer to Engineering to recommend corrective action ** Note Cable shield or conduit bushing is missing at top of conduit on single phase riser pole. DCS ** Note 9 Install conduit coupling/bushing or cable shield as required by Ameren Standards. Based on from Harry Hayes to Keith, begin citing now for 1-ph only--not for 3-ph (since 3-ph is more stable). Corrective action (Install conduit coupling or cable shield) if constructed after January 1, QA bulletin dated October 30, 2013.

11 Summary Report Part 1 Audit Date Circuit No. DOJM No. Audit w ith No 08/04/2014 J IPMS Yes Crew Ameren or Contractor Operating Center City Auditor Description of Job Div. Repair service w ire and NESC service clearance at 502 Wabash Avenue. Ameren VI N Belleville Belleville Keith Low ry 08/04/2014 Q IPMS N/A Three phase distribution to serve Memorial Hospital at 1404 Cross Street. Ameren VI N Belleville Shiloh Keith Low ry 08/04/2014 Q IPMS N/A Three phase distribution to serve Memorial Hospital at 1404 Cross Street. Ameren VI N Belleville Shiloh Keith Low ry

12 Summary Report Part 2 Completion Date Type of Violation NESC/Ameren Standard Violation Findings Photo Corrective Action Date Div. Notified Repairs are Needed Responsible Corrective Action Entry Party (ex. Eng./Ops) NESC/Ameren Violation Responsible Party 08/06/2014 N/A N/A None N/A None N/A N/A N/A 08/06/2014 Ameren ** ** Riser Pole Center deadend on pole is attached less than 1' - 6" above the top mounting bolt as required in Ameren Standards. DCS ** ** 232 No action required. Construct all future projects per Ameren standard. N/A N/A N/A 08/06/2014 Ameren ** Riser Pole Less than #2 cu betw een concentric neutral and system neutral. DCS ** 231 Correct connection from the cable concentric neutral to the system neutral, minimum w ire size is #2 copper as required by Ameren Standards. 08/25/2014 Contractor JF Electric

13 Corrective Action Report Part 1 Div. Operating Center Audit Date DOJM of Audit Description of Job NESC/Ameren Standard Violation Findings Crew Ameren or Contractor Date Div. Notified Repairs are Needed Responsible Corrective Action Entry Party (ex. Eng./Ops) VI N Belleville 08/04/2014 IPMS Three phase distribution to serve Memorial Hospital at 1404 Cross Street ** Riser Pole Less than #2 cu between concentric neutral and system neutral. DCS ** Ameren 08/25/2014 Contractor VI N Belleville 08/04/2014 IPMS VI N Belleville 08/04/2014 IPMS Three phase distribution to serve Memorial Hospital at 1404 Cross Street ** Three phase distribution to serve Memorial Hospital at 1404 Cross Street Riser Pole Lightning arrester cap not installed correctly. DCS ** Ameren 08/21/2014 Contractor Padmount transformer Work not completed according to construction prints and not noted on print. Transformer not installed. Ameren 08/21/2014 Engineering

14 Corrective Action Report Part 2 Corrective DOJM / OAS No. Corrective Action * Required Date Completed * Required Completed By (Ameren or Contractor) * Required Contractor Required Repairs - Number of manhours not charged to us. Comments

15 QA Audit Review Meeting Participants Participants Division Manager Operations Manager Electric Superintendent Field Supervisors Supervising Engineers Electric Distribution Design Supervisors Ameren Standards Representative

16 QA Audit Review Meeting Agenda Agenda Review of Summary Report Discuss findings Includes pictures, standards and NESC documentation Review of Corrective Action Report Open Discussion

17 QA Audit Review Meeting Report

37 2014 Top 10 Standard Stirrup clamp installed when not required ** Poly-guard spiral wrap and/or staples 191 not installed to secure street light conductor to pole ** Non-standard install of a single phase 120 padmount transformer cable training or grounding installation ** Wildlife cover installed incorrectly on 117 transformer bushing ** Non-standard grounding of a single 88 phase overhead transformer

38 2014 Top 10 Standard Pole top pin not installed correctly 83 or missing anti-split bolt Underground cables or equipment 77 missing tagging or use of non-standard labeling materials Non-standard terminal pole ground Overhead or down guy not insulated or 74 insulators not properly installed to meet NESC codes Pole size and/or class changed from 69 design and not noted on print

39 2014 Top 5 NESC 1. NESC 372 UG Primary cable is missing tagging or 71 has inadequate or incorrect tagging 2. NESC 234 B1 a Horizontal clearance of wires, cables 52 or conductors from other supporting structures 3. NESC 385 Padmounted equipment lacks a 45 permanent and legible outside label 4. NESC 215 C5 Placement of guy insulator in 45 overhead guy 5. NESC 235 C Vertical clearance between conductors 20 at the support

40 QA Results Annual Violation Totals Total Facilities Audited Without Ameren and Contractor Total Facilities Audited by Year PCT With PCT Total Facilities Audited Without PCT With Ameren % % % % Contractor % % % % Annual Total % % % % PCT

41 QA Results Annual Violation Totals Ameren Only Total Facilities Audited by Year Total Facilities Audited Without PCT With PCT Total Facilities Audited Without PCT With PCT Division % % % % Division % % % % Division % % % % Division % % % % Division % % % % Division 6N % % % % Division 6S % % % %

42 QA Results Annual Violation Totals Total Facilities Audited Without Contractor Only Total Facilities Audited by Year PCT With PCT Total Facilities Audited Without PCT With Contractor A % % % % Contractor B % % % % PCT

43 QA Results - Rework Ameren and Contractor Total Requiring Rework Total Requiring Rework PCT Total Requiring Rework PCT Ameren % % Contractor % % Annual Total % %

44 QA Results - Rework Ameren Only Requiring Rework Total Requiring Rework PCT Total Requiring Rework PCT Division % % Division % % Division % % Division % % Division % % Division 6N % % Division 6S % % 44

45 QA Results - Rework Contractor Only Requiring Rework Total Requiring Rework PCT Total Requiring Rework PCT Contractor A % % Contractor B % %

46 QA Path Forward Establish team from engineering and operations areas to identify barriers to building to standards and recommend process changes. Initiate process changes in areas of communications, stocking materials and standards feedback Further develop QA Reports to enhance feed back to management and divisions

47 Questions

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