Location, Layout & Construction

The facility is subject to potential high winds and tornados Munich

Natural Perils
Re Tornado Zone 4

Exposure
(from external
facilities)
Spacing
Between Plant
Areas & Site
Layout
Within Unit
Spacing
Construction

Fire
Separation

Stand alone facility

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.
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
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, noncombustible ISO 3 type construction.
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 & Handling

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

Control
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.

Boiler
Turbine or ICE
(Internal
Combustion
Engine)
Generator
Transformer
Operational Reliability & Redundancy
Outside the engine hall in a packaged enclosure is an auxiliary
Utilities
Black-Start diesel generator rated at 450KW and a CAT 625 hp
Reliability
Process Flow
Configuration
Plant
Utilisation
Proven
Technology

Operations
Manning,
Training &
Experience

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

Rubart Station is a peaking/load following generating station using

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

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&ID
Plant
Monitoring &
Routines
Work Permit
System

Safe Work
Practices &
Safety Critical
By-Pass
Handling
Plant
Condition,
Housekeeping
& Order
Maintenance
Organisation &
Planning

Qualifications
& Contractors

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

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.

Housekeeping was observed to be good in general throughout the

plant.

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

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 &
Instrumentatio
n
Spare 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.

Inspection
Organisation & All procedures follow OEM guidelines from Caterpillar and the other
OEMs as well as Sunflower Electric routines where applicable.
Procedures
Boiler & Piping
Inspection
Turbine &
Generator
Inspection
Mechanics are all qualified and trained by the OEM Caterpillar.
Internal
There is no service agreement with CAT. Sunflower personnel
Combustion
perform all preventative maintenance of the generator sets. Major
Engines
overhaul work will be performed by OEM representatives
(ICE's)
Transformers
& Electrical
Systems
Records &
Analysis
Safety & Loss Prevention
The Safety Supervisor and staff conduct training and auditing for
Safety
HLS, as well as the Mid-Kansas sites. Rubart is visited by a member
Awareness &
of the safety team multiple times a month.
SMS Auditing
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.

Risk
Management
& Contingency
Planning

Maintenance is planned and based on OEM recommended

frequencies.

Fire Protection
Fire & Gas
Detection

Smoking is only allowed outside and at least 10 ft from building

access points (blue sky policy).

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
Fixed
Firefighting
Sysetm
Manual
Firefighting
Systems
Fire Protection
Maintenance
& Testing

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

The engine hall is protected at the ceiling level by automatic

sprinklers. There is no additional spot protection at the
engine/generator level
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 hydrant near the GSUs
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 Response
Fire Brigade & Distance- 15miles, response time 20 min
Mutual Aid
The Emergency Response Plan was said to be in progress, but has
Emergency
not been implemented. A recommendation was made to finalize
Planning

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.