African Utility Week 2008, Cape Town, South Africa

Title of presentationGerhard Holtshauzen, Group Leader – Field Engineering Services, Mpumalanga,

South Africa

African Utility Week 2008, Cape Town, South Africa

• Refurbishment of old plant

• Definition of “old”

• Timing of refurbishment

• How do we get to the final SOW

• Execution of the anticipated SOW

• Commissioning of plant

Introduction

African Utility Week 2008, Cape Town, South Africa

Agenda (i)

• Contracting

• Site establishment

• Challenges to establish the correct technical team

• Final SOW vs. Client URS

• Approved SOW & accuracy of details / information

• Execution

African Utility Week 2008, Cape Town, South Africa

Agenda (ii)

• Inspection/s

• Planning & scheduling

• QA & QC

• History capturing / reporting

• Quality of documentation

• Next maintenance intervention

• Contract strategy for commissioning

• Case study

African Utility Week 2008, Cape Town, South Africa

Contracting

•••• Before any decisions consider

• Size of project

• OEM availability

• Impact of Licensing

• Copy rights on drawings / designs

• Availability of approved contractors

• The bigger picture for identified

contractor

African Utility Week 2008, Cape Town, South Africa

Contract strategies

• Various strategies to follow

• Fixed price

• Cost reimbursement

• Target pricing

• Biggest decision:

“How do I choose the applicable and

most appropriate strategy?”

African Utility Week 2008, Cape Town, South Africa

Site establishment

• Basic example

• Site Startup Checklist example.doc

African Utility Week 2008, Cape Town, South Africa

Challenges to establish a technical team

•••• Geographic location

• Points to ponder:

• Can I afford to move permanent personnel around?

• Do I have a floating crew?

• Importation of specialist / s?

• OEM support / assistance

• “wearing both caps”

African Utility Week 2008, Cape Town, South Africa

Attraction of skills

• Internal / external approach

• Experience vs. inexperienced mix

• Remuneration incentives

• Training opportunities

• Hrs at work

African Utility Week 2008, Cape Town, South Africa

• Immediately

• review available documentation

• study client URS thoroughly

• clarify URS where applicable

• inspections

• testing

• DRAWINGS!!!• Note: quality of reports

Now we are on site

African Utility Week 2008, Cape Town, South Africa

• Parking lot for challenges:

• What difficulties have you experienced in your company: Contractor & client – technical scope clarifications• 10 Minutes

Technical inter phase challenges

African Utility Week 2008, Cape Town, South Africa

• Technical team: client vs. contractor

• Modus operandi

• When do we meet?

• Who does what (responsibilities)?

• Response time allocated

• How do deal with exemptions?

• Third Party involvement

THE team

African Utility Week 2008, Cape Town, South Africa

• Known age of plant

• Historic operating data vs. proposed operating philosophy

• Accessibility for inspections

• Impact of proposed modifications in terms of design code

• New legislation – OHS (Act) requirements

• New environmental legislative implications

• When is the next maintenance intervention?

Challenges for the final SOW

African Utility Week 2008, Cape Town, South Africa

• Timely

• Bigger team in first few weeks to get a head start

• Do not move the “experience around

• Accurate

• Referenced to database or applicable drawings

• Only report on findings

• Client / AIA recommendations

Inspections

African Utility Week 2008, Cape Town, South Africa

• Project management

• Planning & scheduling

• Reporting lines

• Client involvement

• Realistic progress reporting -different contract strategies

Execution

African Utility Week 2008, Cape Town, South Africa

• Inspection methodology

• Approved and tried data packs

• CMMS inputs

• Applicable format

• Client / AIA interventions

• Ownership & control

Quality assurance (QA)

African Utility Week 2008, Cape Town, South Africa

• Maintenance function

• Discipline

• Reporting of exemptions

• Corrective actions to be taken

Quality assurance (QC)

African Utility Week 2008, Cape Town, South Africa

• The economizer of the refurbished

plant (3rd unit) is 60% worse than

the base data indicated

• Possible solutions (10 minutes)

• XX

• XX

Scenario

African Utility Week 2008, Cape Town, South Africa

• Make sure the applicable approach

is chosen

• Involve the team in the

refurbishment / upgrade activities

• Opportunities for trainees

Commissioning

African Utility Week 2008, Cape Town, South Africa

• Consider a typical boiler

environment: Boiler, mills, fans,

fuel oil plant, draught groups,

precips / FFP, etc (10 minutes).

• Pro’s Fragmented

• Con’s Fragmented

• Pro’s Umbrella

• Con’s Umbrella

Case study - What approach so we take?

African Utility Week 2008, Cape Town, South Africa

• Reporting lines

• Responsibilities

• Clarifications

• Placement of orders

• Logistics' (Materials, availability of

information)

• Contract strategy

• Lead times on critical spares

Lessons learnt with the RTS of an electricity generating utility

African Utility Week 2008, Cape Town, South Africa

• Realistic expectations

• “Paper planning”

• Technical expertise

• Extent of design packages

• Environmental laws

Lessons learnt with the RTS of an electricity generating utility

African Utility Week 2008, Cape Town, South Africa

• Fuel oil plant

• Design OEM

• Team on site from day 1

• P&ID’s

• As is

• As required

• As build

Commissioning success story

African Utility Week 2008, Cape Town, South Africa

• Correct “mix” of Technical skills

• FIRE!!!

Commissioning success story