Ameren Illinois Electric Quality Assurance Program Keith Lowry Superintendent, Electric Quality Assurance May 15, 2015
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.
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
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.
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)
Quality Assurance Auditor Responsibilities Audit construction work in field Standards Compliance National Electrical Safety Code Compliance Avian Protection Safety Workmanship
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.
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.
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 1 2 3 4 5 6 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
QA Key Sheet 14 Cable Terminals Ameren Standard NESC Code Key # Description Corrective Action Auditor Notes 14 00 01 03 NESC 215 C 14-01 Steel secondary riser not grounded. All metal secondary conduits--either newly installed or transferred--shall now be effectively grounded per DCS 14 00 01 03. 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, 2013. NESC 372 14-03 Terminal pole lacks label or legible label. NESC 372 Install or replace labeling on pole for correct switch number. 14 02 01 ** NESC 217 A2c 14-05 14 02 01 ** NESC 239 G1 14-10 Riser bracket spacing above ground and between lowest two brackets is less than 8'. DCS 14 02 01 **, NESC 217 A2c Top of riser is less than 40" above communications. DCS 14 02 01 **, 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. 14 12 01 ** Note 9 14-12 Cable shield or conduit bushing is missing at top of conduit on single phase riser pole. DCS 14 12 01 ** Note 9 Install conduit coupling/bushing or cable shield as required by Ameren Standards. Based on 8-27-13 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, 2014. QA bulletin dated October 30, 2013.
Summary Report Part 1 Audit Date Circuit No. DOJM No. Audit w ith No 08/04/2014 J89-126 IPMS086591 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 Q18-245 IPMS101580 N/A Three phase distribution to serve Memorial Hospital at 1404 Cross Street. Ameren VI N Belleville Shiloh Keith Low ry 08/04/2014 Q18-245 IPMS101580 N/A Three phase distribution to serve Memorial Hospital at 1404 Cross Street. Ameren VI N Belleville Shiloh Keith Low ry
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 03 12 ** ** Riser Pole 245-11 - Center deadend on pole is attached less than 1' - 6" above the top mounting bolt as required in Ameren Standards. DCS 03 12 ** ** 232 No action required. Construct all future projects per Ameren standard. N/A N/A N/A 08/06/2014 Ameren 14 12 05 ** Riser Pole 245-11 - Less than #2 cu betw een concentric neutral and system neutral. DCS 14 12 05 ** 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
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 IPMS101580 Three phase distribution to serve Memorial Hospital at 1404 Cross Street. 14 12 05 ** Riser Pole 245-11 - Less than #2 cu between concentric neutral and system neutral. DCS 14 12 05 ** Ameren 08/25/2014 Contractor VI N Belleville 08/04/2014 IPMS101580 VI N Belleville 08/04/2014 IPMS101580 Three phase distribution to serve Memorial Hospital at 1404 Cross Street. 12 12 01 ** Three phase distribution to serve Memorial Hospital at 1404 Cross Street. 59 40 00 40 Riser Pole 245-11 - Lightning arrester cap not installed correctly. DCS 12 12 01 ** Ameren 08/21/2014 Contractor Padmount transformer 43858 - Work not completed according to construction prints and not noted on print. Transformer not installed. Ameren 08/21/2014 Engineering
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
QA Audit Review Meeting Participants Participants Division Manager Operations Manager Electric Superintendent Field Supervisors Supervising Engineers Electric Distribution Design Supervisors Ameren Standards Representative
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
QA Audit Review Meeting Report
2014 Top 10 Standard 1. 07 00 21 00 Stirrup clamp installed when not required 194 2. 15 74 01 ** Poly-guard spiral wrap and/or staples 191 not installed to secure street light conductor to pole 3. 51 11 04 ** Non-standard install of a single phase 120 padmount transformer cable training or grounding installation 4. 05 12 10 ** Wildlife cover installed incorrectly on 117 transformer bushing 5. 13 00 06 ** Non-standard grounding of a single 88 phase overhead transformer
2014 Top 10 Standard 6. 06 12 01 02 Pole top pin not installed correctly 83 or missing anti-split bolt 7. 59 40 00 40 Underground cables or equipment 77 missing tagging or use of non-standard labeling materials 8. 12 00 10 03 Non-standard terminal pole ground 77 9. 11 00 02 01 Overhead or down guy not insulated or 74 insulators not properly installed to meet NESC codes. 10. 02 00 03 01 Pole size and/or class changed from 69 design and not noted on print
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
QA Results Annual Violation Totals Total Facilities Audited Without Ameren and Contractor Total Facilities Audited by Year 2013 2014 PCT With PCT Total Facilities Audited Without PCT With Ameren 1679 669 39.8% 1010 60.2% 1997 1028 51.5% 969 48.5% Contractor 621 340 54.8% 274 44.1% 2359 1674 71.0% 685 29.0% Annual Total 2300 1009 43.9% 1284 55.8% 4356 2702 62.0% 1654 38.0% PCT
QA Results Annual Violation Totals Ameren Only Total Facilities Audited by Year 2013 2014 Total Facilities Audited Without PCT With PCT Total Facilities Audited Without PCT With PCT Division 1 166 49 29.5% 117 70.5% 198 68 34.3% 130 65.7% Division 2 291 94 32.3% 197 67.7% 594 362 60.9% 232 39.1% Division 3 221 78 35.3% 143 64.7% 204 98 48.0% 106 52.0% Division 4 621 311 50.1% 310 49.9% 482 284 58.9% 198 41.1% Division 5 82 37 45.1% 45 54.9% 202 97 48.0% 105 52.0% Division 6N 83 23 27.7% 60 72.3% 115 34 29.6% 81 70.4% Division 6S 215 77 35.8% 138 64.2% 202 85 42.1% 117 57.9%
QA Results Annual Violation Totals Total Facilities Audited Without Contractor Only Total Facilities Audited by Year 2013 2014 PCT With PCT Total Facilities Audited Without PCT With Contractor A 405 190 46.9% 208 51.4% 1347 929 69.0% 418 31.0% Contractor B 216 150 69.4% 66 30.6% 1012 745 73.6% 267 26.4% PCT
QA Results - Rework Ameren and Contractor Total Requiring Rework 2013 2014 Total Requiring Rework PCT Total Requiring Rework PCT Ameren 1843 686 37.2% 1473 614 41.7% Contractor 513 163 31.8% 765 364 47.6% Annual Total 2356 849 36.0% 2238 978 43.7%
QA Results - Rework Ameren Only Requiring Rework 2013 2014 Total Requiring Rework PCT Total Requiring Rework PCT Division 1 305 169 55.4% 201 110 54.7% Division 2 339 94 27.7% 304 119 39.1% Division 3 283 96 33.9% 154 77 50.0% Division 4 437 186 42.6% 229 112 48.9% Division 5 92 13 14.1% 189 39 20.6% Division 6N 127 34 26.8% 158 66 41.8% Division 6S 260 94 36.2% 238 91 38.2% 44
QA Results - Rework Contractor Only Requiring Rework 2013 2014 Total Requiring Rework PCT Total Requiring Rework PCT Contractor A 423 127 30.0% 556 253 45.5% Contractor B 90 36 40.0% 209 111 53.1%
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
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