EPC CONTRACTOR'S STAMP Name :

Registration Number :
SIGNATURE

Date :

OWNER

EPC CONTRACTOR

SUPPLIER

PROJECT

REDSTONE CSP PROJECT

01 22/12/2022 First issue

C PAULISSEN D HUBERT C ZOLOTAS
REV DATE DESCRIPTION DONE CHECKED APPROVED

CLIENT DOCUMENT NUMBER DOCUMENT NAME

RDST-01-WSR-MMP-CMI-00017 SR Maintenance Guidelines

CLIENT REV.
JC DOCUMENT NUMBER DOCUMENT OWNER

82010 / 49M01 JOHN COCKERILL SHEET 0/12

This Document and the design it covers are the property of John Cockerill. They are merely loaned and on the borrower's express agreement that they will not be reproduced,
copied, loaned, exhibited or used, except in the limited way and private use permitted by any written consent given by John Cockerill to the borrower.
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82010/49M01 01 Technical Specification

TABLE OF CONTENTS

1. Reference documents .................................................................................................... 3

2. Foreword........................................................................................................................ 4
3. Safety instruction ........................................................................................................... 4
4. Maintenance activities .................................................................................................... 5
4.1 Shift inspection ........................................................................................................... 5

4.2 Monthly scheduled maintenance ................................................................................ 5

4.3 Periodical scheduled maintenance ............................................................................. 5

4.4 Overhaul inspection .................................................................................................... 5

4.5 Legal inspection ......................................................................................................... 5

4.6 Major overhaul............................................................................................................ 5

5. General maintenance schedule...................................................................................... 6

6. Detailed notes regarding maintenance and cleaning ...................................................... 6
6.1 Foreword .................................................................................................................... 6

6.2 Heat exchangers and piping preventive maintenance................................................. 7

6.2.1 Routine maintenance ........................................................................................................................ 7

6.2.2 Major overhaul maintenance ............................................................................................................. 7

6.3 Tanks preventive maintenance ................................................................................... 7

6.4 Pressure relief / gate / globe / check / control valves and rupture discs preventive
maintenance ...................................................................................................................... 8

6.4.1 Routine maintenance ........................................................................................................................ 8

6.4.2 Major overhaul maintenance ............................................................................................................. 8

6.5 Instrumentation preventive maintenance .................................................................... 9

6.5.1 Routine maintenance ........................................................................................................................ 9

6.5.2 Major overhaul maintenance ............................................................................................................. 9

6.6 Casing and backstay system preventive maintenance.............................................. 10

6.6.1 Routine maintenance ...................................................................................................................... 10

6.6.2 Major overhaul maintenance ........................................................................................................... 10

6.7 Framework and support preventive maintenance ..................................................... 11

6.7.1 Routine maintenance ...................................................................................................................... 11

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6.7.2 Major overhaul maintenance ........................................................................................................... 11

6.8 Crane and Suspended Platform ............................................................................... 11

6.9 Thermal Shields ....................................................................................................... 12

6.10 Steel structure (main and secondary) ..................................................................... 12

6.10.1 Main steel structure ......................................................................................................................... 12

6.10.2 Secondary steel structure ................................................................................................................ 12

6.11 Electrical Cabinets and Cables ............................................................................... 12

6.12 Lightning Rods........................................................................................................ 12

7. Remedy instructions .................................................................................................... 12

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1. REFERENCE DOCUMENTS

Main documents related to maintenance activities are listed below.

A short description of each document is as follows :

- 46M01 : O&M Manuals of each equipment

- 49M02 : General maintenance schedule
- 49M03 : Procedure for heat exchanger panel removing and replacement
- 49M04 : Procedure to replace a tube of a heat exchanger panel
- 49M05 : Procedure to describe maintenance of equipment installed inside receiver
- 49M06 : Procedure to describe maintenance of casing panels
- 49M07 : Procedure to describe maintenance on receiver roof
- 57M05 : Procedure to describe operation & maintenance of crane and nacelles

JC Reference Project Reference Title

82010_46M01 RDST-01-WSR-MMP-CMI-00016 SR Operating And Maintenance Manual

82010_49M02 RDST-01-WSR-MMP-CMI-00018 SR General Maintenance & Inspection

Schedule

82010_49M03 RDST-01-WSR-MMP-CMI-00019 SR Procedure for Heat Exchanger Panel

Replacement

82010_49M04 RDST-01-WSR-MMP-CMI-00020 SR Procedure for tubes replacement of a

heat exchanger panel

82010_49M05 RDST-01-WSR-MMP-CMI-00021 SR Internal Equipment Maintenance

82010_49M06 RDST-01-WSR-MMP-CMI-00022 SR Casing Panels Maintenance

82010_49M07 RDST-01-WSR-MMP-CMI-00023 SR Roof and Cladding Maintenance

82010_49P01 RDST-01-WSR-YDY-CMI-00001 SR Sequences & Controls

82010_49P02 RDST-01-WSR-YLI-CMI-00001 SR List of Set Points

82010_49P08 RDST-01-WSR-YID-CMI-00001 SR Functional Description

82010_49P11 RDST-01-WSR-GIO-CMI-00001 SR Salt Survey

82010_57M05 RDST-01-WSR-MMP-CMI-00036 Maintenance Crane and Nacelle - USER

AND MAINTENANCE MANUAL

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2. FOREWORD

The following specification covers the general maintenance of a Molten Salt CSP Solar Plant
Receiver which is part of the JOHN COCKERILL (JC) scope of supply. Guidelines are given
for each type of equipment but the details of operation of each component are not mentioned:
they can be found in the dedicated section of document 82010_46M01 “SR Operating and
Maintenance Manual” (OMM) prepared specifically for the solar receiver.

Depending on the maintenance organization of the plant, it is required to keep record of each
maintenance activity and operation, device by device, in order to allow prediction of required
overhaul or risk of failure of specific device. Management of spare parts will also be easier
and predictable. Log sheets are to be prepared for each equipment.

This procedure is to be read along with document 82010_49M02 “SR General Maintenance
and Inspection Schedule”.

3. SAFETY INSTRUCTION

When maintenance is required on any item of the Molten Salt Solar Receiver or its auxiliaries,
it is mandatory to check that there is no remaining pressure inside, upstream or downstream
the device to maintain, to check that the system is cold and check that the device is properly
isolated from upstream and downstream systems. That instruction must be mandatorily
followed because of the risk of personal injury.

Note that in addition, all safety instructions that can be found in the OMM of Molten Salt Solar
Receiver equipment, components or Molten Salt Solar Receiver auxiliary systems have to be
followed as well (see document 82010_46M01 “SR Operating and Maintenance Manual”).

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4. MAINTENANCE ACTIVITIES

4.1 Shift inspection

Visual inspection of the whole Solar Receiver and its auxiliaries, by a competent
person.

The purpose of the inspection is to detect any abnormal operation of the equipment
and to decide if and where some maintenance or repair are required.

Point of observation: tightness of molten salts circuit, tightness of circuit enclosures,

abnormal noise of motor and actuators,…

4.2 Monthly scheduled maintenance

Scheduled maintenance is required on some equipment according to the general
maintenance schedule.

These are typically greasing, oiling, resetting of measurement device as required,...

Inspection and data record are also included in the monthly scheduled maintenance
activity.

Each equipment has to be checked, more in detail than during the shift inspection.

4.3 Periodical scheduled maintenance

Some components need inspection and/or maintenance every 6 months or yearly or
other, see general maintenance schedule 82010_49M02.

4.4 Overhaul inspection

The overhaul inspection and maintenance require an outage of the unit. It can be
organised during the scheduled outage of the Solar Receiver.

The inspection includes internal visit of the Solar Receiver, inside of the pressure part.

4.5 Legal inspection

According to the country regulations specific inspections and tests are mandatory, in
presence of the Authorities. Such operation has to be combined with the yearly overall
inspection or a major overhaul.

4.6 Major overhaul

A major overhaul of the Molten Salt Solar Receiver is recommended every 3 years of
operations. The inspection includes deep investigations of the behaviour of each
component, with dismantling and replacement of parts, as required.

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5. GENERAL MAINTENANCE SCHEDULE

The general maintenance schedule 82010_49M02 gives a summary, easy to read of the
maintenance activities on a daily basis. It has to be read together with the relevant sections of
the dedicated O&M Manuals.

6. DETAILED NOTES REGARDING MAINTENANCE AND

CLEANING

6.1 Foreword
This section gives overall recommendations for the Molten Salt Solar Receiver
maintenance.

These can be considered as guidelines for the Operating & Maintenance staff.

In addition to these general guidelines, specific maintenance instructions given by the

supplier of the specified components must be followed.

It is important to distinguish the routine maintenance from the major overhaul

maintenance.

The routine maintenance is performed by the operators every day while the Molten
Salt Solar Receiver is in operation.

On the other hand, major overhaul maintenance must be performed after 16000
operating hours or at least every three years. The Molten Salt Solar Receiver must be
cold and drained in order to enable the maintenance of the whole equipment. Make
sure that heliostats are not focused onto the Molten Salt Solar Receiver during
maintenance operations.

Special attention must be given to:

- a very important aspect of the overall Molten Salt Solar Receiver maintenance : the
salt composition. Please refer to document 82010_49P11.

- high velocities achieved during some transient operation (such as emergency

draining of the receiver) which can lead to Acoustically Induced Vibration (AIV) on the
piping system. After such event, revise pipe supports. Notice supports are acting
correctly, revise for any lifting support. Perform visual inspection for high vibration /
noise identification on the lines during this operation.

NB : This section is only valid for equipment of JC supply.

For equipment supplied by others, please refer to their maintenance
specification.

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6.2 Heat exchangers and piping preventive maintenance

6.2.1 Routine maintenance
Look for leaks on pipes inside the Solar Receiver tower.
Look for damaged pipe insulation.
From the outside, with the suspended platform, inspect the black coating on the
tubes and measure its optical properties (absorptivity).
For thermocouple on tubes, bolt thread is greased with high temperature grease
type Molykote Cu (+1100 °C), screw is fitted in the housing on delivery. Cu based
grease is unalterable with time, operating temperature is between 500 and 600°C.
Screw to be re-greased during maintenance and replacement.

6.2.2 Major overhaul maintenance

From the outside, with the suspended platform, inspect exterior aspect for
leakages or tubes deformation. Inspect also the black coating on the tubes and
measure its optical properties (absorptivity). In case maintenance team wishes to
check tube thickness, procedure is as follows:
- Remove smoothly the coating locally where the thickness measurement will be
done by using sandpaper
- UT examination shall be performed to check the tube thickness
- Coating repair is normally not required as the surface preparation for the
thickness measurement is really limited
Along the time, absorptivity of the black coating is decreasing. Operator of the
plant will decide when it is necessary to recoat all the heat exchangers due to the
absorptivity of the coating which is not good anymore. Decreasing rate will depend
on many factors such as the site conditions and the operating parameters of the
receiver. Therefore it is not possible to predict with accuracy the lifetime of the
coating but usually it is about 2 years.
Check for proper tightness of the seals around the tube panels on the Upper Oven
Box and Lower Oven Box.

6.3 Tanks preventive maintenance

Caution: When an inspection of the receiver is required, all tank manholes must
be opened and the tank must be vented carefully with air (on both sides)
for a couple of days, prior to entering the tank.

It is mandatory that the inspector be accompanied by someone standing

outside ready to give the alarm in case of trouble.

Note that NOx atmosphere is a safety hazard.

Entering a tank filled with NOx can quickly be fatal.

Inspect interior for rusts residues or damaged equipments or pipes.

Inspect bolts and nuts of internal parts. Re-torque and tack weld where needed.

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Notes:

o Before closing access doors in order to restart the Solar Receiver, make absolutely
sure that nobody is inside and that no foreign equipment are remaining inside.

o New gaskets should be used when closing doors.

6.4 Pressure relief / gate / globe / check / control valves and rupture discs
preventive maintenance
6.4.1 Routine maintenance
Look for leaks (flanges, bellows and packings).

Check state and operation of valve pressure switches and rupture disc pressure
switches.

Listen for leaking pressure relief valves while the Molten Salt Solar Receiver is in
service.

Grease regularly stems of valves.

For electrical actuators, check heating resistance.

Grease the gearboxes.

All valves should be operated from time to time (at least once a year).
They must be completely opened and closed. In case of motorised valve, check
limit and torque switch during this operation.

6.4.2 Major overhaul maintenance

Control valves and valves operating under cavitation or flashing conditions, must
be dismantled for inspection.

- In case of erosion on the seat itself, this seat should be replaced or relapped.
- In case of erosion of the plug, the valve is still tight but this erosion should be
monitored at the next maintenance period.

It is necessary to check that limit switches on the valves are well tightened up.

Follow the valve manufacturer recommendation for detailed maintenance

operations.

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6.5 Instrumentation preventive maintenance

6.5.1 Routine maintenance
Except a visual inspection, no special maintenance is required on the instruments
themselves (except otherwise stated by the manufacturer).

In particular, check if instruments do not vibrate.

In case of doubt on instruments (readings from local instruments and transmitters

are different for instance), the following sequence of operations applies :
a) Check programming parameters of “smart” transmitter.

b) Check auxiliary equipment of the transmitter : pressure lines, isolating

valve, manifolds, electrical wiring, etc.

Note that zero errors are usually caused by incorrect mounting of the
transmitter, by equalising vessels at different heights, by dirty valves, or
dirty pressure compartments in the measuring cell.

c) Check the transmitter itself.

Adjust zero and span if necessary (please refer to manufacturer's

instructions).

Note that this value is completely independent of the transmitter itself.

Heat tracing and ovenboxes heaters must be in perfect working condition. Test by
resistance measurement must be carried out.

6.5.2 Major overhaul maintenance

Close the transmitter isolation valve if any. Disconnect the flange of the transmitter
which in not equipped with diaphragm.

Note that opening a flange not equipped with isolation valve is a safety
hazard because NOx can escape.

Follow the instrument manufacturer recommendation.

In case of wrong programming of these smart transmitters (span, set, ...), the
Molten Salt Solar Receiver protections could be modified.

JC could not be held responsible for these wrong settings.

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6.6 Casing and backstay system preventive maintenance

6.6.1 Routine maintenance
A routine maintenance of the expansion joint is necessary. These joints ensure casing
airtightness around each casing openings (i.e. piping and hangers of heat
exchangers).

This maintenance will ensure the tightness of the joint in the clamping area.

A visual inspection of the joints must be performed each month. It will include:

- The detection of any discoloration of the joint fastening systems.

- The detection of any mechanical damage made to the joints by an external

aggression,

- The general cleanliness of the joint: Nothing can lay on the joint; nothing can
prevent a good air circulation around the joint.

Casing airtightness between each casing panels will be checked. Screwing of casing
flanges bolts and/or replacement of “ladder type” gasket is required in case of leakage.

Check for proper tightness of the seals around the heat exchangers on the Upper and
Lower oven boxes.

Check the insulation of the casing panels to detect eventual cracks or damages.

6.6.2 Major overhaul maintenance

Check for loose fixation screws.

Check for loose hangers of heat exchangers.

It is performed by listening noise they produce while hitting them with a hammer.
Readjust them if necessary.

Check for casing corrosion. Check for cracks in the welds of the casing.

Open the upper and lower Oven boxes for visual inspection. Check for insulation
damages, visual inspection of electrical resistances, etc.

Visual check of the backstay system. Verify that all axes are still in position and
secured.

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6.7 Framework and support preventive maintenance

6.7.1 Routine maintenance
During normal Molten Salt Solar Receiver operation, check regularly that pipes
hangers are between hot and cold positions.

In case of wrong setting, hangers must be reset in cold conditions as soon as

possible (20°C in tanks).

Check loose hangers by hand (using a hammer).

Check the calcium-silicate supports and especially after a seism. In case of

damages, a replacement of the calcium-silicate material may be required.

6.7.2 Major overhaul maintenance

Clean sliding supports and hangers using compressed air.

Check for loose screws on steel structure.

Check for loose hangers of pipes at all levels. It is performed by listening to the
noise they produce while hitting them with a hammer. Readjust them if necessary.

Check for potential damages (cracks) on Calcium-Silicate supports.

Note that an extra scaffolding/ladder may be needed to check too high parts of
steel structure.

6.8 Crane and Suspended Platform

Refer to the O&M Manual of the manufacturer 82010_57M05.

Warning: note that the lift motor and the crane motor are fed from the same electrical
board (normal lighting & small power distribution board 01BLL30GH001). In the case
of a simultaneous usage of both equipment at full load, no other heavy tools (welding
machine,…) must be used and connected to the same board.

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6.9 Thermal Shields

Major overhaul maintenance

From the outside, with the suspended platform, inspect thermal shields panels for potential
cracks or damages. Check the panels fixation.

6.10 Steel structure (main and secondary)

6.10.1 Main steel structure
Main beams and columns to be checked in order to ensure they are still in good
conditions (no excessive deformations, connections still in contact, bolts not
untightened)

6.10.2 Secondary steel structure

6.10.2.1 Grating
Every grating panel must have at least 4 clips well tightened. No excessive
gaps between grating is acceptable.

6.10.2.2 Ladder and handrails

Every ladder and handrails connections must be checked. No excessive
vibration is accepted.

6.11 Electrical Cabinets and Cables

When the main power is OFF in electrical cabinet, clean the filters/cooling unit/heaters.

When the main power is ON (the receiver is in operation), perform a thermal survey
(with thermal camera) inside the electrical cabinets and on all the receiver power and
I&C cables to ensure the good electrical operation.

Check the pressure of the fire protection system and make sure that the fire
extinguishers are not expired.

6.12 Lightning Rods

Check the electrical continuity.

From the outside, with the suspended platform, inspect the rods for potential
deteroriation due to overheating caused by too high solar flux from solar field.

From the inside of receiver, check the rods bolted connection.

7. REMEDY INSTRUCTIONS

In case of failures or abnormal situations related to the process of the Molten Salt Solar
Receiver, sequences and control loops (logics) of the Receiver are designed and programmed
to automatically remedy to any specific situation. The appropriate alarm and/or trip are
automatically triggered. Refer to the documents 82010_49P01 “SR Sequences & Controls”,
82010_49P02 “SR List of Set Points” and 82010_49P08 “SR Functional Description” for the
description of the logics.

JOHN COCKERILL
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