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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