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The purpose of this presentation is: To give an overview of Shanahan Engineering (SE) Maintenance Division To demonstrate our processes for outage execution To demonstrate the capabilities and experience of SE Presentation Objectives are: To update you a potential customer on SE current operating processes & capabilities To understand your strategy for future maintenance To ensure our service is tailored to suit your specific needs and strategies
Citation preview
Maintenance Management
Presentation January 2011
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Introduction
The purpose of this presentation is: � To give an overview of Shanahan Engineering (SE) Maintenance Division
� To demonstrate our processes for outage execution
� To demonstrate the capabilities and experience of SE
Presentation Objectives are: � To update you a potential customer on SE current operating processes & capabilities
� To understand your strategy for future maintenance
� To ensure our service is tailored to suit your specific needs and strategies
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
1) Current Experience & Capabilities
2) SE scope of supply to OEM’s
3) What’s New in Shanahan Engineering Maintenance Division
4) Maintenance Division Organisation Chart
5) Health, Safety & Environment
6) Trade Testing & Competency & Skills Matrix
7) Pre Outage Presentation
8) Training & Buddy System
9) Gas Turbine Mechanical Fitter Training Manual
10) Post Outage Assessment & Reporting
11) Final Comments
Maintenance Management Presentation
Index
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
Recent Examples of
Non MHI Equipment
Maintenance Experience
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Recent Examples of Non MHI Experience
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
� Westfield Power Station - Major Inspection
of GE Frame 6 � Cockenzie Power Station - Overhaul of
Main Steam Valves � Lethabo Power Station, South Africa -
Overhaul of Steam Turbine and Steam
Valves
� Aghada Power Station – Combustion
Inspection GE 9E � Bussi Power Station – Dismantling of GE 9E � Marina Power Station – Overhaul of Alstom
Generator � North Wall Power Station – Overhaul of
Alstom Generator � ESBI Poolbeg - Plant Auxiliary fuel oil line
Scottish Power 1st September 2010 WG GTS Capabilities
• Long term maintenance contracts
• Full O & M services and products
• Field service and outage management
• Supply of new, refurbished and APM® (Advanced Parts Manufacture) parts
• Control systems service, support & trouble shooting
• On line monitoring
• Wind Turbine Maintenance & EPC
• Full O & M services and products
• Steam Turbine component relifing & manufacture
• On site and off site repairs
• Maintenance & construction contractor
• Technical field service supply to OEM’s & Utilities
Company Introduction Company Introduction
Maintenance Services Division including Outage Management
SE Scope of Supply to MPSE
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
SE Scope of Supply to MPSE
Plant no. 1 Plant no. 2 Plant no. 3 Plant no. 4
Contract Expiry 2014
2015 2018 2012
Exclusivity of Supply of Manpower
Yes Yes Yes No
Bulk order Commitment
No Yes Yes No
Contract Type and Expiration
What’s New In
Shanahan Engineering
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
� New Operations Manager and additional Recruiter assigned to Leeds office � Permanent Outage Coordinators assigned to Leeds office
� Core Maintenance Staff Retained, including HSE Manager
� New Recruitment, Recording and Accounting Software (Bond Adapt & RGC) � Implementation of Pre Outage Presentation
� Development of Gas Turbine Mechanical Fitter Training Manual to improve
quality and service
� Use of Gas Turbine skills matrix and competency certificates � Moving to new office facility with workshop area to allow training, trade
testing and fabrication � New offsite central storage facility for Tools and PPE
� Onsite storage facility with contingency PPE
� Collaboration with Wood Group GTS
What’s New In Shanahan Engineering
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
Organisation Chart
MAINTENANCE CREWS MAINTENANCE CREWS
© Shanahan Engineering
Liam Weavers
Human Resources Officer
Anthony Varey
Lead Outage Coordinator
Ronan Norton Outage Coordinator
James McManus
HSE Manager
Paul Mullins IR Manager
Kara De Souza
Human Resources Officer
Emma Wilkins
Administration Officer
Tony Scott
Mechanical Technical Advisor
Harry Anderson Mechanical Foreman
Paul McGinley Mechanical Foreman
Robert Cullen Mechanical Foreman
Ronnie Anderson
Mechanical Technician
Michael Taylor Mechanical Fitter
Jamie Jenkins Mechanical Fitter
Chris Fenwick
Mechanical Technician
Ged Flynn
Rigging Appointed Person
John Dimishky
Inventory Coordinator
Michael Joyce
Senior Mechanical Engineer
Keith Rigney
Operations Manager
James Greaney
Senior Vice President
Fergal Kelly
Business Development Manager
Wood Group GTS
WG HIT (Gas Turbines) WG ST (Steam Turbines)
Matt Swan
Business Development Manager Maintenance Division
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Mechanical Foremen
� IOSH (Managing Safely – Institute of Occupational Hazards)
� SMTD Module 5 (ECITB) � Safety Passport CCNSG � Supervisors Safety Passport CCNSG � Hi Torc
� Abrasive Wheels � Confined Space Awareness � Manual Handling � Counterbalance Forklift
� Trade Test Assessor
Field Staff Training
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Rigging Foremen
� IOSH (Managing Safely – Institute of Occupational Hazards)
� SMTD Module 5 (ECITB) � Safety Passport CCNSG � Supervisors Safety Passport CCNSG � Manual Handling
� Counterbalance Forklift � Trade Test Assessor � Appointed Person
Office Staff Training � Occupational Awareness � First Aid � Defibrillator
� Manual Handling
Field Staff Training
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
�Fresh Eyes Policy. Assess the Risks and eliminate or reduce wherever possible. Raising awareness of working surroundings at all times.
�Handsafe – A new initiative based on raising awareness of potential hand hazards and reducing the potential risks. Includes implementation of standardised gloves and criteria for use of each type.
�Care & Custody – Implemented by outage coordinators and foremen, includes role call before and after each shift and implementation Fresh Eyes Policy from a management perspective.
�Safe Work Policy, encouraging employees not to put themselves or fellow workers at risk by adopting un-safe work practices.
� Encouraging Reporting of all accidents, incidents and near misses to Company Foreman and the Outage Safety Officer.
� Tool box talks given at the start of each shift focusing on the potential risks of specific tasks to be carried out during that shift.
Health, Safety & Environment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Recruitment & Assignment Process
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
1. Industry wide advertisement (British Isles) 2. Completion of application forms 3. Review & shortlist of most suitable applications 4. Trade Test of short listed applicants 5. Reference check of applicants 6. HR & IR check of applicants 7. Qualification check and validation of applicants 8. Personal health screening check 9. Identify shortfall in training 10. Enter into company database (using Bond Adapt Software) 11. Prepare Competency Form including skills matrix 12. Prepare Shanahan Trade ID card 13. Assignment to outage based on qualification, skills matrix and outage scope 14. Pre outage induction and familiarisation 15. Buddy System Training 16. Post outage assessment with SE and MPSE 17. Repeat steps 11 to 17 based on post outage assessment
Recruitment & Assignment Process
ENSURING BEST IN CLASS SERVICE ENSURING BEST IN CLASS SERVICE
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Trade Test Certificate
SE Trade Test Assessors are qualified to ECITB standard
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
1. D
Pre Employment Check List
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Competency Profile - Form
WORK HISTORY WITH SHANAHAN ENGINEERING (continued)
SKILLS MATRIX
Gas Turbine
5
Mitsubishi 701DA
5
Mitsubishi 701F
5
Transition Alignment
4
Rotor Blading
5 Rotor Alignment
4 Bypass Spindle Overhaul
5
Bearing Assembly &
Disassembly
5
Heavy Bolt Removal
5
Blade Ring Assembly
4
Combuster Internals
(based on Turbine
Inpection)
5
Skills Matrix Key:
0: No Experience
1: Low Experience
2: Little Experience
3: Moderate Experience
4: Good Experience
5: Very Good Experience
GE - Fife, Scotland, 6FA Hot Gas Path Outage Manpower - Mechanical Fitter
Rotek Outage – Lethabo - Mechanical Fitter
Teesside Outage - Feb 2009 - Mechanical Fitter
Saltend Emergency Outage - Mechanical Fitter
Teesside Emergency Outage - Mechanical Fitter
Saltend Planned Combustion Inspection April 09 - Mechanical Fitter
Teesside Emergency Outage July 2009 - Mechanical Fitter
Teesside Planned Outage August 2009 - Mechanical Fitter
Teesside Outage Nozzle Change - Mechanical Fitter
Teesside Crawl-Through Works December 2009 - Mechanical Fitter
Saltend Nozzle Change January 2010 - Mechanical Fitter
Huntstown Combustor Inspection April 2010 - Mechanical Fitter
Teesside Combustion Inspection Emergency - Mechanical Fitter
Damhead Creek Scheduled Outage June 2010 - Mechanical Fitter
Teesside - Combustion Inspection May 2010 - Mechanical Fitter
Teesside Nozzle Change Out - Mechanical Fitter
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Competency Profile - Certificates
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Competency Profile - Certificates
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Competency Profile - Certificates
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Outage Skills Matrix
Pre-Outage Familiarisation Presentation
Saltend GT2 Outage – August 2010
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Presentation Scope
� Purpose and Objectives � Health and Safety
� Outage Work Scope
� Schedule Overview � Organisation
� Working Time and Break Times � Roles and Responsibilities
� Lessons Learned, incidents to be avoided � Lessons Learned, Caution Points
� Final Comments
Pre-Outage Familiarisation Presentation
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Purpose and Objectives
The purpose of this presentation is:
• To give an overview of the outage scope and organisation
• To stress the importance of quality of workmanship & reputation
• To highlight the impact of past mistakes, and how we can avoid them in the future.
Our Objectives are:
• To have a safe & successful outage for all parties
• To continue to improve & deliver a quality service
• To ensure we maintain a strong reputation
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
� Consider safety first at all times. Please do not put yourself or your fellow worker at risk by adopting un-safe work practices.
� Report all accidents, incidents and near misses to your Company Foreman and the Outage Safety Officer.
�Take immediate action to correct any workplace health risk and report it to your Company Foreman and the Outage Safety Officer.
� Understand the Risks in your workplace. Assess the Risks and eliminate or reduce wherever possible. Be aware of your surroundings at all times.
� Ensure there is a safe system of work in place, STOP if you have any doubts.
� Always wear the correct PPE (Minimum - Hard hat, boiler suit, safety glasses, boots, gloves).
� Maintain a clean work place – good housekeeping can reduce Slips, Trips and Falls.
� Ensure proper storage of oil, chemicals and gases etc.
Health, Safety & Environment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Saltend Unit 2 Outage Work Scope:
• GT Turbine Inspection
• GT Rotor Replacement
• Steam Valve Inspection
• GT Expansion Joint Repair
Pre-Outage Familiarisation Presentation
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Schedule Overview:
Pre-Outage Familiarisation Presentation
Day 1 Sat 28/8/10 Outage Start
Day 5 Wed 1/9/10 Turbine Cylinder Cover Off
Day 7 Fri 3/9/10 Compressor Casing Off
Day 10 Mon 6/9/10 GT Rotor Out
Day 11 Tue 7/9/10 GT Rotor In (new rotor)
Day 16 Sun 12/9/10 Compressor Casing On
Day 23 Sun 19/9/10 Turbine Cylinder Cover On
Day 26 Wed 22/9/10 GT / ST Alignment complete
Day 28 Fri 24/9/10 Outage Finish (last N/S finish Sat AM 25/9/10)
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Organisation - Saltend Outage Team
SE Operations Manager
Keith Rigney
SE Leeds Office
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Efficient productivity of our activities is key. Please do not take excessive smoke or tea breaks
and do not tool down before you are advised to do so and please remember that start time
means you are to be on the turbine floor ready for work.
Dayshift start time is 7:00AM, Dayshift finish time is 7:00PM
Nightshift start time is 7:00PM, Nightshift finish time is 7:00AM
Break Times: Morning Tea: 10:00 – 10:15 Lunch: 13:00 – 13:30
Evening Tea: 16:00 – 16:15
We intend to stick to these times, however we may need to request some flexibility on occasions
should workflow necessitate.
Working Time and Break Times
We kindly request your full cooperation on this We kindly request your full cooperation on this
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
• The right balance of skills are present at this outage to carry out all the varying tasks that will be involved.
• Job allocation by Customer Supervisors or Managers and SE Foremen should ensure that tasks are allocated only to competent personnel.
• SE have prepared Trade Cards for each individual that summarise the Trade and Training qualifications held. These cards are issued to each individual before outage starts.
• Do not accept an instruction to carry out a task that you are not trained, qualified and competent to do. If you have concerns immediately raise this with your Foreman, Safety Officer or Manager.
• All lifting operations must be carried out under the control of a qualified Rigger. Riggers are responsible for the correct selection, use and care of the Rigging equipment provided and compliance with applicable lifting plans.
Roles & Responsibilities
No Lift Plan = No Lift No Lift Plan = No Lift
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Typical special tools used during outage
This list will be displayed at the work place for reference.
Where a Standard Tool or Special Tool is not available for the job – DO NOT use any substitute or
other non approved Tool.
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
The following are examples of some of the incidents or other occurrences that we must avoid in
future:
• Delay – Fuel Gas pipework leak, resulting in delay. Caused by a damaged gasket being used or flange misalignment during installation.
•Delay – Bleed Air Orifice Plates, incorrect location on installation. When removing pipework positively attach each orifice plate to the pipe flange.
• Incident & Delay - Poor workmanship, Fuel Nozzle to Top Hat bolts not tightened using correct methodology. The reliable torque procedure is to finish torqueing all bolts as each connection in made, don’t leave to torque up later, risk is that bolts will be missed. Problem discovered after unit restart. Unit had to be shut down to tighten bolts.
• Delay - Installation of bypass spindles, butterfly valves not fully closed. Required rework. Must close valves before fitting spindles by turning butterfly valves in a clockwise direction using special tool (operating tool).
Lessons Learned, incidents to be avoided
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE! LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
• Accident – Employee injured using Hi Torque equipment. He was not trained in equipment use and the equipment was old type. Now specific personnel have been given formal training and only those trained personnel must use such equipment. New equipment is now provided.
• Accident - Employee using a modified tool (unapproved site fabricated) when removing screws on Blade Ring. Special tool for use with air ratchet gun now available (see list of Special Tools manufactured for this outage).
• Accident – Fitter’s Mates accepted request from Customer Supervisor to do work they were not trained to do. Resulted in minor burns and their removal from the job along with Customer Supervisor.
• Employee dismissed – Employee was caught with cigarette lighter and also a powered on mobile phone in an unauthorised area.
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE! LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
Lessons Learned, incidents to be avoided
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
• Delay – Forgot to install Vane Segment wire rope seal in Row 1 Blade Ring. Required rework and caused frustration and dissatisfaction from our customer.
• Incident - No lift plan or procedure in place for turning over turbine blade ring, (new lifting plan now created). A subsequent error (fitting wrong sized swivel eye bolt) resulted in the Blade Ring half being dropped. It was lucky no one was injured. Damaged caused to equipment and reputation.
• Back charge to SE – lost tools during outage. All tools must be signed out of the store and be returned and signed in by the individual who signed them out.
• Incident - Employee disciplined for not following ROS procedure. Take note and understand the plant rules and follow them at all times. If you are requested to carry out a task that is not in accordance with the plant rules then please inform your Foreman/Supervisor (or the Safety Officer or SE Outage Coordinator).
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE! LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
Lessons Learned, incidents to be avoided
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
• Accident – Employee injured when suspended load moved unintentionally due to Crane Driver accidently operating the crane control. Two issues, Load should not have been left suspended and crane control should have been locked off.
• Delay - On reassembly of the equipment, most bolts must have “Molycote” (or similar) applied prior to installation, others must not. Check with Technical Advisor to verify before commencing this process.
• Delay - On reassembly of the equipment, some flange or joint faces should have Triple Boiled Linseed Oil applied prior to installation, others may not. Check with Technical Advisor to verify before commencing this process.
• Incident – Broken sling due to turning rotor incorrectly in preparation for coupling bolt removal. Check procedure for removal and lifting plan before carrying out any lifts – lucky that no one was seriously injured. Ensure that you understand the procedure and only lift with a proper lift plan in place!
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE! LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
Lessons Learned, incidents to be avoided
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Lessons Learned, Caution Points
REMOVAL OF TOP HAT ASSEMBLY (from combustor casing) Top Hat Assembly includes top hat, main nozzle, pilot nozzle and combustor basket
• Before removal of top hat assembly, ensure the following are removed: • Cross flame tubes
• CPFM (Combustion Pressure Fluctuation Monitors) Transducer • Igniters
• Flame eyes
•Take care not to snag springs on combustor baskets during removal and check that springs do not fall into machine.
• Place top hat assembly on plywood sheet on floor before disassembly.
• Combustor baskets MUST be stored in the vertical position. Do NOT place them in horizontal position or pile on top of each other.
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Lessons Learned, Caution Points
REMOVAL OF BYPASS SPINDLES
• Match mark flange to combustor casing using paint marker before removal. • Use overhead crane for removal of bypass spindles. • Check turnbuckle clearance before disassembly as per protocol sheet.
INSTALLATION OF BYPASS SPINDLES – (ONTO TURBINE CASING)
• Ensure bypass spindles are installation in the correct location. • Before installation of bypass spindles, check butterfly valves are fully closed by turning butterfly valves in a clockwise direction using special tool (operating tool). • Use overhead crane for installation of bypass spindles. • Ensure match mark from flange to combustor casing are aligned.
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Lessons Learned, Caution Points
INSTALLATION AND ALIGNMENT OF TRANSITION PIECES
• Check the serial numbers and the location number of each transition piece during installation.
• Start with installation piece numbers 10 and 11.
• Continue installing in a clockwise and anti-clockwise direction with two teams.
• Ensure all bolts are torqued and lock wired.
• Ensure tools and materials are carefully controlled inside the combustor space to prevent any foreign materials being left in side the combustor space.
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Lessons Learned, Caution Points
INSTALLATION OF UPPER HALF BLADE RINGS (ROWS 1-4)
Immediately after installation of Row 2 Blade Ring in position, use the bore-scope or jig to confirm that the thermocouple guide tubes of blade ring, vane and seal housing are aligned.
INSTALLATION AND ALIGNMENT OF FUEL GAS PIPEWORK
• The condition of the RTJ Gasket is critical. If the Gasket is dropped, scratched or damaged in any way, it must not be used. Remove any protective coating from gasket if it has been applied for packaging. Ensure gasket is dust-free before installation.
• If tightening of the flange is carried out on one side more than the other to “Pull in to Parallel”, then the gasket must be replaced before final tightening. IF IN DOUBT, ASK.
•Check tolerances and ensure they meet the criteria.
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
• Don’t be afraid to speak up if you are aware of something wrong.
• If you have a constructive suggestion – let us hear it, we value your contributions.
• As a member of this Outage Team you play an integral part of its success or failure. Every person involved in this project has a part to play in the team and it will take every person to be individually successful for the team to succeed.
Here’s to a Safe, Successful Outage
and let’s enjoy it too!
Final Comments
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
Training & Buddy System
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
The objective of the Buddy System is for our most experienced mechanical technicians and
mechanical foreman to work as part of a pair with a less experienced mechanical fitter to
enhance their experience in working on Mitsubishi Turbine specific tasks.
SE Mechanical Fitter Skills Matrix
Buddy System - Training
NO AT RISK BEHAVIOUR – SAFETY FIRST NO AT RISK BEHAVIOUR – SAFETY FIRST
Task No. Task No. Task No. Task No.
Gas Turbine
5
Mitsubishi
701DA
5
Mitsubishi
701F
5
Transition
Alignment
4
Rotor
Blading
5
Rotor Alignment
4
Bypass Spindle
Overhaul
5
Bearing
Assembly &
Disassembly
5
Heavy Bolt
Removal
5
Blade Ring
Assembly
4
Combuster
Internals (Turbine
Inspection)
5
Skills Matrix Key: 0: No Experience
1: Low Experience 2: Little Experience 3: Moderate Experience
4: Good Experience 5: Very Good Experience
The skills gained during an outage are then assessed using the matrix above and then updated
onto the mechanical fitter’s competency file.
Gas Turbine
Maintenance Training Manual
__________________________________________________________________________________________________________________________________________ The information contained in this document is confidential and must not be reproduced or disclosed to third parties, unless prior written permission has been given by
Shanahan Engineering. © Shanahan Engineering 2010
Contents �Removal of Top Hat Assembly
�Installation of Top Hat Assembly
�Removal of bypass Spindles
�Overhauling of Bypass Spindles
�Installation of Bypass Spindles
�Removal of Transition Pieces
�Installation and Alignment of Transition Pieces
�Removal of Blade Rings
�Overhauling of Blade Rings
�Installation of Blade Rings
�Installation and alignment of Fuel Gas Pipework
� Turbine section blading
Training Manual Task Index
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Shanahan Engineering. © Shanahan Engineering 2010
Final Comments
� SE would like to discuss the opportunity to provide maintenance
services to you in the British Isles
� Capable of offering an enhanced service offering through Wood Group
GTS if this is of interest to you.
� To Continue to improve the quality of our maintenance services to the
power industry.
Thank you for your time