Location, Layout & ConstructionNatural Perils The facility is subject to potential high winds and tornados – Munich Re Tornado

Zone 4

Exposure (from external facilities)

Stand alone facility

Spacing Between Plant Areas & Site Layout

Units are arranged in side-by-side configuration in 2 groups of 6. Unit centerline separation is 20’ and case-to-case is 10’-10”. Each unit is 9’-3” wide. Separation between unit 6 & 7 is 33 ft.

Within Unit Spacing

The generating sets are all located in an engine hall connected by a small corridor and fire door to the Admin office/Control Room and Maintenance Shop

Construction Building construction is noncombustible with multiple fire walls and a corridor feature to separate the engine hall from the Admin/Maintenance building

The entire building is of steel frame, sheet metal wall and roof, non-combustible ISO 3 type construction.

Fire Separation

The generating sets are all located in an engine hall connected by a small corridor and fire door to the Admin office/Control Room and Maintenance Shop.

A 2-hr firewall separates the Engine Hall and the Switchgear rooms. The Office/Control Room and Mechanical Room are separated from the Maintenance Shop by a 2-hr firewall.

A concrete firewall separates them and they have individual containment pits

Fuel Storage & HandlingFuel Storage: Layout & Diking

There are no large fuel oil tanks at this site. Fuel for the diesel fire pump is located in a double wall tank on the fire pump skid.

Fuel Handling Natural gas is provided from a single supplier (with a compressor station nearby) via 2 independent pipelines. The pipelines come from the same compressor source, but operate at different pressures. The gas is regulated from 700 psig at the pipeline to 105 psig into the engine hall.

Control & Protection SystemsControl Systems, ESD & Interlocks

At 20% LEL, all units are tripped and main fuel shut-off valve for plant closes.On an engine hall fire alarm (from UV/IR sensors), units are tripped and main fuel gas valve into plant closes. All fans are shut off and vents are closed.

BoilerTurbine or ICE (Internal Combustion

Engine)GeneratorTransformer

Operational Reliability & RedundancyUtilities Reliability

Outside the engine hall in a packaged enclosure is an auxiliary “Black-Start” diesel generator rated at 450KW and a CAT 625 hp engine

Process Flow Configuration

GSU 1 serves engines 1-6 and GSU 2 serves engines 7-12.

Plant Utilisation

Rubart Station is a peaking/load following generating station using

Proven Technology

The CAT G20 generator sets are the first serial units for the V-20 configuration. The design is based on the proven G16 design

OperationsManning, Training & Experience

Mechanics are all qualified and trained by the OEM Caterpillar. There is no service agreement with CAT. Sunflower personnel perform all preventative maintenance of the generator sets. Major overhaul work will be performed by OEM representatives

There are usually 8 employees stationed at Rubart (4 Engine Operators, 1 Mechanic, 1 I&C Tech, 1 Admin, and 1 Supervisor).

Supervisors, operators and mechanics are experienced in power generation equipment. OEM training has been provided to plant operators.

A Caterpillar Technical Field Advisor is on-site M-F for 2 years from 10/2014 that provides technical assistance to the mechanics and operators.

Operating & Emergency Procedures, P&IDPlant Monitoring & Routines

All procedures follow OEM guidelines from Caterpillar and the other OEMs as well as Sunflower Electric routines where applicable.

Work Permit System

Sunflower has a complete written permit program that is adequately enforced and administered. The program includes most typical work permits. Contractors are required to adhere to this program. Permits are controlled and sign-off by the Shift Supervisor.

Safe Work Practices &

Safety Critical By-Pass HandlingPlant Condition, Housekeeping & Order

Housekeeping was observed to be good in general throughout the plant.

MaintenanceOrganisation & Planning

A site specific emergency plan was not been fully completed. A recommendation was made to finalize and implement a site specific Emergency Action Plan and review emergency response procedures with the area emergency responders

Qualifications & Contractors

Caterpillar has provided training to all operators and mechanics on the servicing of the G20 generator sets. Burns & McDonnell (the lead engineering firm) provided training on the BOP equipment

Supervisors, operators and mechanics are experienced in power generation equipment. OEM training has been provided to plant operators.

A Caterpillar Technical Field Advisor is on-site M-F for 2 years from 10/2014 that provides technical assistance to the mechanics and operators.

Mechanical, Electrical & InstrumentationSpare Parts & Repairs

Only frequently used spare parts will be kept on hand. There will be one spare turbo cartridge (includes turbo and bearings in an easily exchanged package). There are no plans to have a spare crankshaft onsite. CAT has stated it would take 6 weeks to fabricate a new crank. As there are 11 other engines available for power production, having one engine out of service for this time seems acceptable. There are no spare engines or generators available at this time.

InspectionOrganisation & Procedures

All procedures follow OEM guidelines from Caterpillar and the other OEMs as well as Sunflower Electric routines where applicable.

Boiler & Piping InspectionTurbine & Generator Inspection

Internal Combustion Engines (ICE's)

Mechanics are all qualified and trained by the OEM Caterpillar. There is no service agreement with CAT. Sunflower personnel perform all preventative maintenance of the generator sets. Major overhaul work will be performed by OEM representatives

Transformers & Electrical SystemsRecords & AnalysisSafety & Loss PreventionSafety Awareness & SMS Auditing

The Safety Supervisor and staff conduct training and auditing for HLS, as well as the Mid-Kansas sites. Rubart is visited by a member of the safety team multiple times a month.

Management of Change

A formal program to document and approve changes is called “Document Change Request” or DCR. The DCR defines what the change is and contains all the supporting information for the change. Manager approval is required to initiate the change.

Control of Ignition Sources

Hot work is done in the Maintenance Shop when possible. Flash protection is utilized when working on electrical switchgear.

Smoking is only allowed outside and at least 10 ft from building access points (blue sky policy).

Risk Management & Contingency Planning

Maintenance is planned and based on OEM recommended frequencies.

Fire ProtectionFire & Gas Detection

The engine hall is protected at the ceiling level by automatic sprinklers. There is no additional spot protection at the engine/generator level. UV/IR fire detectors are located on the engine hall wall to monitor the aisle space between each engine set. Smoke detectors (photo & ionization) are located in the ceiling space. Methane detectors are located over the gas valve train at each unit.

Smoke detectors are located in the return air ducts and fixed temperature detectors in the ceiling. The area is protected by an OH Grp 1 pre-action sprinkler.

Firewater Supply & Distribution

A well provides water to the site. The well can fill the firewater tank within 8 hours.240,000 gal.

Fixed Firefighting Sysetm

The engine hall is protected at the ceiling level by automatic sprinklers. There is no additional spot protection at the engine/generator level

Manual Firefighting

Personnel at Rubart will be trained for incipient fires only. Fire extinguishers appear to be in adequate number at this time. A fire monitor nozzle is located next to a

Systems hydrant near the GSUsFire Protection Maintenance & Testing

The plant is not operational to date, so IT&M has not been discussed. Equipment was getting readied for acceptance testing. Acceptance certificates will be supplied and kept on file.

Emergency ResponseFire Brigade & Mutual Aid

Distance- 15miles, response time – 20 min

Emergency Planning

The Emergency Response Plan was said to be in progress, but has not been implemented. A recommendation was made to finalize and then educate and train Rubart staff on the emergency response procedures.

Security & Surveillance

The facility is entirely fence-enclosed. The main gate is closed and accessed by a card reader or call button. The site is extremely well covered with inside and outside video cameras that include IR and radar to monitor motion. Video feeds to the Rubart Control Room and the Garden City S2 Control Room.

The site is staffed 7am – 5:30pm M-F. After hours all doors are locked and the Garden City S2 Control Room monitors and controls the station.