Se Maintenance Presentation Jan 2011
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Se Maintenance Presentation Jan 2011

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The purpose of this presentation is: ...

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

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  • 1. Maintenance Management Presentation January 2011
  • 2. IntroductionThe 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 SEPresentation 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
  • 3. Maintenance Management Presentation Index 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__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 4. Recent Examples of Non MHI EquipmentMaintenance Experience
  • 5. Recent Examples of Non MHI Experience 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__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 6. Scottish Power 1stIntroduction Company September 2010 Company Introduction WG GTS Capabilities • Long term maintenance contracts • Wind Turbine Maintenance & EPC • Full O & M services and products • Full O & M services and products• Field service and outage management • Steam Turbine component relifing & manufacture• Supply of new, refurbished and APM® (Advanced Parts Manufacture) parts • On site and off site repairs• Control systems service, support & trouble • Maintenance & construction contractor shooting • Technical field service supply to OEM’s &• On line monitoring Utilities
  • 7. Maintenance Services Divisionincluding Outage Management SE Scope of Supply to MPSE
  • 8. SE Scope of Supply to MPSE Contract Type and Expiration Plant no. 1 Plant no. 2 Plant no. 3 Plant no. 4 2014 Contract Expiry 2015 2018 2012Exclusivity of Supply Yes Yes Yes No of Manpower Bulk order No Yes Yes No Commitment __________________________________________________________________________________________________________________________________________ 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
  • 9. What’s New InShanahan Engineering
  • 10. What’s New In Shanahan Engineering 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__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 11. Organisation Chart© Shanahan Engineering James Greaney Fergal Kelly Senior Vice President Business Development Manager Matt Swan James McManus Keith Rigney Business Development Manager HSE Manager Operations Manager Maintenance Division Wood Group GTS Michael Joyce Anthony Varey WG HIT (Gas Turbines) Senior Mechanical Lead Outage Coordinator WG ST (Steam Turbines) Engineer Ronan Norton Tony Scott Chris Fenwick Outage Coordinator Mechanical Technical Advisor Mechanical Technician Paul Mullins Harry Anderson Ronnie Anderson IR Manager Mechanical Foreman Mechanical Technician Emma Wilkins Paul McGinley Michael Taylor Administration Officer Mechanical Foreman Mechanical Fitter Liam Weavers Robert Cullen Jamie Jenkins Human Resources Officer Mechanical Foreman Mechanical Fitter Kara De Souza Ged Flynn John Dimishky Human Resources Officer Rigging Appointed Person Inventory Coordinator MAINTENANCE CREWS
  • 12. Field Staff TrainingMechanical 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__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 13. Field Staff TrainingRigging 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 PersonOffice Staff Training Occupational Awareness First Aid Defibrillator Manual Handling__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 14. Health, Safety & EnvironmentFresh 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 handhazards and reducing the potential risks. Includes implementation of standardisedgloves and criteria for use of each type.Care & Custody – Implemented by outage coordinators and foremen, includes rolecall before and after each shift and implementation Fresh Eyes Policy from amanagement perspective.Safe Work Policy, encouraging employees not to put themselves or fellow workers atrisk by adopting un-safe work practices. Encouraging Reporting of all accidents, incidents and near misses to CompanyForeman and the Outage Safety Officer. Tool box talks given at the start of each shift focusing on the potential risks ofspecific tasks to be carried out during that shift.__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. © Shanahan Engineering 2010
  • 15. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 16. Recruitment & Assignment Process1. Industry wide advertisement (British Isles)2. Completion of application forms3. Review & shortlist of most suitable applications4. Trade Test of short listed applicants5. Reference check of applicants6. HR & IR check of applicants7. Qualification check and validation of applicants8. Personal health screening check9. Identify shortfall in training10. Enter into company database (using Bond Adapt Software)11. Prepare Competency Form including skills matrix12. Prepare Shanahan Trade ID card13. Assignment to outage based on qualification, skills matrix and outage scope14. Pre outage induction and familiarisation15. Buddy System Training16. Post outage assessment with SE and MPSE17. Repeat steps 11 to 17 based on post outage assessment__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. ENSURING BEST IN CLASS SERVICE © Shanahan Engineering 2010
  • 17. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 18. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 19. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 20. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 21. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 22. Pre Employment Check List1. D__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 23. Competency Profile - Form WORK HISTORY WITH SHANAHAN ENGINEERING (continued) 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 SKILLS MATRIX Gas Turbine 5 Mitsubishi 701DA 5 Mitsubishi 701F 5 Transition Alignment 4 Bearing Assembly & Rotor Blading 5 Rotor Alignment 4 Bypass Spindle Overhaul 5 Disassembly 5 Combuster Internals Heavy Bolt Removal 5 Blade Ring Assembly 4 (based on Turbine 5 Inpection) Skills Matrix Key: 0: No Experience__________________________________________________________________________________________________________________________________________ 1: Low ExperienceThe information contained in this document is confidential and must not be reproduced or disclosed toExperience parties, unless prior written permission has been given by 2: Little thirdShanahan Engineering. 3: Moderate Experience 4: Good Experience © Shanahan Engineering 2010 5: Very Good Experience
  • 24. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 25. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 26. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 27. Outage Skills Matrix__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. © Shanahan Engineering 2010
  • 28. Pre-Outage Familiarisation Presenta Saltend GT2 Outage – August 2
  • 29. Pre-Outage Familiarisation PresentationPresentation 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 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 30. 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
  • 31. Health, Safety & Environment Consider safety first at all times. Please do not put yourself or your fellow worker atrisk by adopting un-safe work practices.Report all accidents, incidents and near misses to your Company Foreman and theOutage Safety Officer.Take immediate action to correct any workplace health risk and report it to yourCompany Foreman and the Outage Safety Officer.Understand the Risks in your workplace. Assess the Risks and eliminate or reducewherever 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.__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. © Shanahan Engineering 2010
  • 32. Pre-Outage Familiarisation PresentationSaltend Unit 2 Outage Work Scope:• GT Turbine Inspection• GT Rotor Replacement• Steam Valve Inspection• GT Expansion Joint Repair__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. © Shanahan Engineering 2010
  • 33. Pre-Outage Familiarisation PresentationSchedule Overview:Day 1 Sat 28/8/10 Outage StartDay 5 Wed 1/9/10 Turbine Cylinder Cover OffDay 7 Fri 3/9/10 Compressor Casing OffDay 10 Mon 6/9/10 GT Rotor OutDay 11 Tue 7/9/10 GT Rotor In (new rotor)Day 16 Sun 12/9/10 Compressor Casing OnDay 23 Sun 19/9/10 Turbine Cylinder Cover OnDay 26 Wed 22/9/10 GT / ST Alignment completeDay 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 34. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 35. Working Time and Break TimesEfficient productivity of our activities is key. Please do not take excessive smoke or tea breaksand do not tool down before you are advised to do so and please remember that start timemeans you are to be on the turbine floor ready for work.Dayshift start time is 7:00AM, Dayshift finish time is 7:00PMNightshift start time is 7:00PM, Nightshift finish time is 7:00AMBreak Times:Morning Tea: 10:00 – 10:15Lunch: 13:00 – 13:30Evening Tea: 16:00 – 16:15We intend to stick to these times, however we may need to request some flexibility on occasionsshould workflow necessitate. 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
  • 36. Roles & Responsibilities• The right balance of skills are present at this outage to carry out all the varying tasksthat will be involved.• Job allocation by Customer Supervisors or Managers and SE Foremen should ensurethat tasks are allocated only to competent personnel.• SE have prepared Trade Cards for each individual that summarise the Trade andTraining qualifications held. These cards are issued to each individual before outagestarts.• Do not accept an instruction to carry out a task that you are not trained, qualifiedand 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 equipmentprovided and compliance with applicable lifting plans. 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
  • 37. Typical special tools used during outageThis 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 orother 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
  • 38. Lessons Learned, incidents to be avoidedThe following are examples of some of the incidents or other occurrences that we must avoid infuture:• Delay – Fuel Gas pipework leak, resulting in delay. Caused by a damaged gasketbeing used or flange misalignment during installation.•Delay – Bleed Air Orifice Plates, incorrect location on installation. When removingpipework positively attach each orifice plate to the pipe flange.• Incident & Delay - Poor workmanship, Fuel Nozzle to Top Hat bolts not tightenedusing correct methodology. The reliable torque procedure is to finish torqueing all boltsas each connection in made, don’t leave to torque up later, risk is that bolts will bemissed. Problem discovered after unit restart. Unit had to be shut down to tightenbolts.• Delay - Installation of bypass spindles, butterfly valves not fully closed. Requiredrework. Must close valves before fitting spindles by turning butterfly valves in aclockwise direction using special tool (operating 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 LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE! Shanahan Engineering. © Shanahan Engineering 2010
  • 39. Lessons Learned, incidents to be avoided• Accident – Employee injured using Hi Torque equipment. He was not trained inequipment use and the equipment was old type. Now specific personnel have been givenformal training and only those trained personnel must use such equipment. New equipmentis now provided.• Accident - Employee using a modified tool (unapproved site fabricated) when removingscrews on Blade Ring. Special tool for use with air ratchet gun now available (see list ofSpecial Tools manufactured for this outage).• Accident – Fitter’s Mates accepted request from Customer Supervisor to do work theywere not trained to do. Resulted in minor burns and their removal from the job along withCustomer Supervisor.• Employee dismissed – Employee was caught with cigarette lighter and also a powered onmobile phone in an unauthorised area. 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
  • 40. Lessons Learned, incidents to be avoided• Delay – Forgot to install Vane Segment wire rope seal in Row 1 Blade Ring. Requiredrework and caused frustration and dissatisfaction from our customer.• Incident - No lift plan or procedure in place for turning over turbine blade ring, (newlifting plan now created). A subsequent error (fitting wrong sized swivel eye bolt) resultedin the Blade Ring half being dropped. It was lucky no one was injured. Damaged causedto equipment and reputation.• Back charge to SE – lost tools during outage. All tools must be signed out of the storeand be returned and signed in by the individual who signed them out.• Incident - Employee disciplined for not following ROS procedure. Take note andunderstand the plant rules and follow them at all times. If you are requested to carry out atask that is not in accordance with the plant rules then please inform yourForeman/Supervisor (or the Safety Officer or SE Outage Coordinator). 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
  • 41. Lessons Learned, incidents to be avoided• Accident – Employee injured when suspended load moved unintentionally due to CraneDriver accidently operating the crane control. Two issues, Load should not have been leftsuspended 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 beforecommencing this process.• Delay - On reassembly of the equipment, some flange or joint faces should have TripleBoiled Linseed Oil applied prior to installation, others may not. Check with TechnicalAdvisor to verify before commencing this process.• Incident – Broken sling due to turning rotor incorrectly in preparation for coupling boltremoval. Check procedure for removal and lifting plan before carrying out any lifts – luckythat no one was seriously injured. Ensure that you understand the procedure and only liftwith a proper lift plan in place! __________________________________________________________________________________________________________________________________________ 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 LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE! Shanahan Engineering. © Shanahan Engineering 2010
  • 42. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 43. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 44. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 45. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 46. Final Comments• 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 takeevery person to be individually successful for the team to succeed. Here’s to a Safe, Successful Outage and let’s enjoy it too! 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
  • 47. Training & Buddy System
  • 48. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 49. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 50. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 51. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 52. 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 byShanahan Engineering. © Shanahan Engineering 2010
  • 53. Buddy System - TrainingThe objective of the Buddy System is for our most experienced mechanical technicians andmechanical foreman to work as part of a pair with a less experienced mechanical fitter toenhance their experience in working on Mitsubishi Turbine specific tasks.SE Mechanical Fitter Skills Matrix No. Task No. Task No. Task No. Task Gas Turbine 5 Mitsubishi 5 Mitsubishi 5 Transition 4 701DA 701F Alignment Skills Matrix Key: Bearing 0: No Experience Rotor Bypass Spindle Rotor 5 4 5 Assembly & 5 1: Low Experience Alignment Overhaul Blading Disassembly 2: Little Experience Combuster 3: Moderate Experience Heavy Bolt 5 Blade Ring 4 Internals (Turbine 5 4: Good Experience Removal Assembly Inspection) 5: Very Good ExperienceThe skills gained during an outage are then assessed using the matrix above and then updatedonto the mechanical fitter’s competency file.__________________________________________________________________________________________________________________________________________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 byShanahan Engineering. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010
  • 54. Gas TurbinMaintenance Training Manu
  • 55. Training Manual Task IndexContents 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 __________________________________________________________________________________________________________________________________________ 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
  • 56. Final Comments SE would like to discuss the opportunity to provide maintenanceservices to you in the British Isles Capable of offering an enhanced service offering through Wood GroupGTS if this is of interest to you. To Continue to improve the quality of our maintenance services to thepower industry. Thank you for your time __________________________________________________________________________________________________________________________________________ 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