se maintenance presentation jan 2011

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



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



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

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



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



� 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


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



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




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




�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



Recruitment & Assignment Process



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



Sample Trade Test Completed



Trade Test Certificate

SE Trade Test Assessors are qualified to ECITB standard



1. D

Pre Employment Check List




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



Competency Profile - Certificates



Outage Skills Matrix

Pre-Outage Familiarisation Presentation

Saltend GT2 Outage – August 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





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



� 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



Saltend Unit 2 Outage Work Scope:

• GT Turbine Inspection

• GT Rotor Replacement

• Steam Valve Inspection

• GT Expansion Joint Repair




Schedule Overview:


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)



Organisation - Saltend Outage Team

SE Operations Manager

Keith Rigney

SE Leeds Office



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 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



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 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!



• 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.





• 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).





• 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!





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.




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.




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.




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.



• 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


Training & Buddy System



Fuel Gas Pipework Installation & Alignment



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


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



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



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

se maintenance presentation jan 2011

Business

ebussi power station

prior written permission

new office facility

scottish power

outage executionto

exclusivity of supply

hse manager new recruitment

risk behaviour safety