Professional Documents
Culture Documents
GER-4205
GE Power Systems
Installation and
Outage Management
Processes and
Technologies
Cynthia Breitkreuz
GE Power Systems
Atlanta, GA
Installation and Outage Management Processes and Technologies
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation Planning and Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pre-Installation Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Material Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Arrival and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inventory Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Case Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Material Shortages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Material Shortage Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Direction Role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Change Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Procedural Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Progress Meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
As Built Construction Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Post-Installation Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Post-Outage Review Meeting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Advanced Review Meeting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Managing Outage Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HRSG Post-
Site Pre-Install Units Receive First 2 X GTG
Preparation Meeting Ship Material & STG COD Install
Fire Operational Operational Meeting
Month 0 5 6 9 11 17 18
Assembly /
Installation
by the local GEII office when they are applica- tions, applicable parts lists, and a few detailed
ble to the installation. machine drawings. These prints, which repre-
sent the “as built” condition of the gas turbines,
Installation Schedule
are provided to the technical director to assist
A basic requirement for a successful installation him in his consulting capacity. Any drawings in
plan is the installation schedule. This schedule the sets that are changed during the installation
can take various forms from a bar chart to a period are replaced with the updated drawing.
complex logic network programmed with provi- When the installation is complete, the
sions for resource allocations. The bar chart Technical Director will provide the customer
allows you to list your work activities in sequen- with a set of the construction prints less the
tial order, plan your job duration, determine parts lists (PLs) and machine drawings. This set
your labor and material requirements, and will describe the “as built” condition of the gas
track the job. The logic network, when proper- turbine.
ly programmed, allows all of the above plus crit-
ical-path planning, periodic job tracking with Special Tools
compensation for manpower and material defi- GE will supply a variety of special tools for the
ciencies, and job-cost tracking. The installation gas turbines and generators that are not nor-
schedule that you use on the turbine installa- mally furnished by the installation contractor. A
tion should be designed to meet your needs and list of special tools provided by GE is included
provide the optimum installation cycle. with the construction print list under “Tool
While responsibility for schedule creation, List” or “Installation Device.” The special tools
maintenance, and adherence remain with the shown on these lists are part of the turbine and
installer, it is critical that the installer and GEII generator packages and are turned over and
Technical Direction team review the schedule documented at the completion of the turbine
tasks in concert, to ensure that all work tasks are installation. It is important that these devices be
provided for and to fully leverage the past expe- carefully stored and protected for future main-
riences of both parties. tenance on the machine.
tionally as an activity that takes place at standard Asset Performance requires looking at post-out-
intervals during a scheduled outage. That view age reports and evaluating the plan for the
is changing. While turbine maintenance often equipment at the time of the post-outage meet-
takes place according to established plant ing. Evaluation of equipment performance and
schedules (for example, during a nuclear refu- long-term maintenance planning is therefore a
eling) the approach has evolved to one of man- continual process beginning at the end of one
aging Asset Performance. Equipment owners are outage (refer to Figure 2). Alternatives for
evaluating their overall fleet and analyzing the improving performance, whether in output,
most effective way to maximize the revenue gen- efficiency, emissions, reliability, or availability
erated. This could include extending intervals often require more time to evaluate, procure,
between maintenance cycles, or it could mean and implement than the 6-month to 1-year win-
taking an outage earlier than usual in order to dow allows. Many companies have budgeting
install a performance enhancement package. cycles that make it difficult to support a major
The increasingly macro view of turbine equip- maintenance or capital expenditure not identi-
ment compels a need for even more rigorous fied well in advance. Thus it becomes critical to
planning and analysis. In the past, Owners and view this planning as a continuous process,
Service Providers considered the planning for rather than a discrete event.
maintenance as an activity that began about 6
months to a year in advance of an outage. It Maintenance Planning
would begin with an Advanced Review Meeting A maintenance plan is a continuous process of
and end with a Post-Outage Review Meeting, review, recommendation, and implementation.
where the final inspection report and future Service providers can develop a pro-active plan
recommendations would be reviewed. Some with the customer to support the inspection
actions were taken, but often the report would and repair of the equipment involved. It is crit-
not be filed until the next planning cycle. ical that a plan tailored to the specific outage
Advanced
Advanced Pre-Outage
Pre-Outage
Review
Review Meeting
Meeting
Meeting
Meeting
Efficiency
Efficiency
Reliability/Availability
Reliability/Availability
Emissions
Emissions Improvements
Improvements
Preventative
Preventative Maintenance
Maintenance
Post-Outage
Post-Outage Outage
Outage
Meeting
Meeting Execution
Execution
scope is developed so that participants under- ■ Lube oil system inspection (if
stand their responsibilities and the impact that applicable)
outage planning has on its successful comple- ■ Coupling inspection (if applicable)
tion. This plan must include all work activities,
■ Enclosures (if applicable)
as well as the schedule, parts lists, tooling and
equipment requirements, and repair services ■ Alignment and clearance overview (if
expected. Service providers can assist in devel- applicable)
oping recommendations for parts, and can ■ Start Up comments
track and expedite as needed. Additionally, they
Advanced Review Meeting
can review repair requirements and can assist in
planning the workscope with the selected repair The current condition of the equipment is
facility. It is key to the outage schedule that all reviewed to determine recommendations for
repairs are coordinated. Utilizing a Three operational and outage planning. Parts, materi-
Meeting Concept is an effective process to use for al, technical and procedural issues are
developing maintenance plans. The purpose of addressed to ensure that actions are imple-
each meeting is described below. mented as required to support the scheduled
maintenance program. These meetings are
Post-Outage Review Meeting held 6-to-8 months in advance of all scheduled
This meeting is the end point of one outage outages. The following activities take place at
and the start point for the next. It is held fol- this session.
lowing the completion of an outage. Its purpose ■ Review previous inspection report
is to review the outage report, performance,
■ Review unit history since last
and findings, as well as to identify problems,
inspection and identify additional
determine best practices, and discuss recom-
work scope
mendations. A performance review, for which
criteria should be established at the pre-outage - This includes operational trending
meeting, should take place. In addition, parts data
recommendations can be made and a prelimi- - Forced outage occurrences
nary plan for the next scheduled outage can be - Operational issues, which require
outlined. The final outage report should maintenance activity at a scheduled
include: inspection (such as lube oil leaks,
■ Job summary faulty instrumentation, etc.)
■ Inspection summary - Specific fleet issues, which may
affect reliability of the unit
■ Recommendations
■ Review parts inventory for unit
■ Parts used and recommended
■ Review all parts orders and associated
■ TIL/ECN activity
delivery dates
■ Combustion section data
■ Review TIL list for unit for additional
■ Compressor section data (if workscope and parts requirements
applicable) ■ Review status of parts being
■ Turbine section data (if applicable) refurbished
■ Review completion / ship dates Critical Path Management - Any given outage is
■ Review inspection reports / findings likely to have unexpected work that can impact
the schedule. Data shows that 39% of outage
■ Review changes in safety regulations,
delays are due to emergent or unplanned work.
which require implementation during
GEII approaches Critical Path Management
the next inspection
with standard processes developed through
Managing Outage Duration years of project experience, coupled with the
Many factors affect the length of an outage. use of custom-designed software developed
Two of them are a well-defined workscope and specifically for this application. The software
the appropriate combination of skilled people. enables the incorporation of emergent work
Workscope and responsibilities of all parties are into the schedule. Resource loading can be eval-
discussed during the pre-outage meeting. uated and shifted as required. Incoming parts,
Access to skilled engineers and technicians repairs, and other work, which can affect the
should be considered when scheduling the timeliness of task completion, are tracked with
work. As the U.S. industry moves from per- alternatives developed in advance to the fur-
forming maintenance in spring or fall to having thest extent possible. The project baseline
outages primarily in the spring (refer to Figure schedule is developed utilizing task level data,
3), one must consider the impact on the avail- best practices, and lessons learned from past
ability of trained craft labor, technicians, and and current outages.
specialists. With more operations moving Once the schedule is finalized, the work on crit-
toward outsourcing versus in-house mainte- ical path is identified. GEII personnel then use
nance crews, this concern is magnified. a Failure Modes and Effects Analysis (FMEA) to
To effectively manage the outage and minimize identify the areas of greatest risk and develop
the impact of the unexpected, it is important to contingency plans to mitigate that risk (refer to
consider several elements. Figure 4). The FMEA is a systematic approach
occurrence, and the ability to detect the cause items and communication of the status of off-
or failure mode, a risk priority number (RPN) site work, such as repairs. GEII is also develop-
can be calculated. This assists the Project ing on-line collaboration tools that will allow
Manager to determine which area needs risk faster exchange of information among outage
mitigation efforts first. Another tool utilized is participants. All of this can make communica-
the Cause and Effect Diagram (also referred to tion more efficient, but it can happen only if
as a Fishbone Diagram). Traditionally used by the infrastructure to enable it exists.
engineers in Root Cause Analysis, this tool has
been leveraged for pro-active applications in Summary
contingency planning (refer to Figure 5). The Experience shows that the quantity and quality
Cause and Effect Diagram provides an organ- of advanced preparation heavily influence the
ized visual method of displaying all possible successful execution of an installation or
causes of a problem and is helpful in consider- maintenance outage. GEII will continue to
ing all reasons for occurrence. develop better and faster ways to plan and
Information Management – With information implement equipment service. Through
technology playing an increasingly larger role development of new tools, communication and
in daily activity, it is necessary to consider the planning will become faster and more flexible.
3 2
No Electrical Hook-Ups Not enough Extension Cords
Failure to
complete
3 Bolting
2 Inconsistent Extensiometer Shell ‘On-
Incorrect Layoff Calculated Measurements
Time’
3 2 Incorrect Replacement
Not enough Bolt Heaters Layoff Marked Incorrectly Nuts Shipped 4
2
Nuts Stick during Installation Impact
High Low
Easy 1 2
Project Management Craft Labor Issues Supplier issues Implement
3 4
Hard
Ongoing programs in technology will enhance work on site. These advances, coupled with the
the capability of GEII service personnel to unique skills of Customer/GEII teams, will help
communicate with experts globally, improving set new standards of service well into the
both responsiveness time and the quality of future.
List of Figures
Figure 1. Installation project timeline
Figure 2. Outage management cycle
Figure 3. U.S. maintenance shift
Figure 4. Contingency planning – risk analysis
Figure 5. Contingency planning – cause and effect