I am seeking feedback on the optimal duration in days for conducting Annual Insp CI HGPI Major overhauls on GE Frame 5 gas turbines. Are there any specific tactics or improvements that have been implemented to minimize outage durations? I recently visited a company that was taking 56 days for a Major overhaul due to only working day shifts, whereas the industry norm is around 30 days. Any insights or suggestions are greatly appreciated. Thank you for your input.
How long does the OEM recommend for the duration of operation? It is suggested to work around the clock to reduce the turnaround time. Are major overhauls priced as lump sum contracts or based on daily manpower rates? How do they manage a 56-day outage? Do they have a standby unit available? What exactly is a GE Frame 5 and is it a gas turbine-powered generator? What is its capacity or rating?
When dealing with precision high-speed equipment like GTs, it is important to exercise caution. While certain tasks can be completed around the clock, others should be carried out by specialized technicians without any shift changes. In situations like these, prioritizing quality is essential, with speed being secondary only if quality remains uncompromised. Remember, when it comes to precision equipment, expertise and attention to detail are key.
I concur with the concern that a specialist working a 56-day shift may experience a loss of concentration. It would be beneficial if the machine undergoing maintenance had standby units in operation. In a specific plant I visited, I observed overhaul teams working on key rotating equipment during daylight hours only, completing around 14 days of active work within a 30-day shutdown period. They would then be on standby until startup, except when encountering challenges such as opening steam turbine casing bolts that had not been accessed in seven years.
Is it possible to have work completed during each shift signed off to document the tasks completed by a specific specialist and to monitor any issues with shift transitions? For welding projects, a designated table can be used to log details such as the specific joint worked on, the welder involved, and other pertinent information to help identify and address any welding defects that may arise.
The duration of a project is influenced by both active working time and various delays that can occur, such as waiting for materials, secondary craft availability, equipment issues, specialist availability, supervision, inefficient timing of rest breaks, and permit delays. These delays can account for 50-60 percent of the overall project duration, even in well-executed shutdowns. By prioritizing Planning, Scheduling, and Work Preparation, these delays can be reduced to around 20-30 percent. In my opinion, this approach is more effective than simply working around the clock on critical machinery to complete the project in 56 days.
It sounds like you're really diving into optimizing those overhaul durations! From my experience, shifting to a 24/7 work schedule can significantly reduce downtime, especially if you can manage the logistics effectively. Additionally, implementing a detailed pre-planning phase to identify potential bottlenecks and having parts on standby can help streamline the process. Companies that have adopted a modular approach—pre-assembling components off-site—have also seen reductions in outage times by allowing for quicker installations on-site. Sharing best practices between teams can also foster innovation—maybe setting up a debrief after each overhaul to capture lessons learned could help your team get closer to that 30-day target.
It sounds like you’re tackling a significant challenge with those overhaul times! One key improvement I've seen is implementing a round-the-clock shift pattern during major overhauls, which can drastically reduce downtime—especially when paired with pre-outage planning and a detailed task breakdown. Additionally, leveraging a modular approach to repair and having critical components pre-inspected or refurbished in advance can help streamline the process. Collaborating closely with suppliers to ensure faster access to parts can also reduce delays. Have you considered adopting best practices learned from lean manufacturing principles? They can help optimize workflows and identify waste in your current processes!
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Answer: - The industry norm for the optimal duration of Major overhauls on GE Frame 5 gas turbines is around 30 days.
Answer: - Yes, implementing tactics such as working day and night shifts, efficient planning, utilizing advanced technologies for faster diagnostics, and having a well-trained maintenance team can help minimize outage durations.
Answer: - Companies can consider implementing strategies like optimizing maintenance schedules, improving workflow efficiency, investing in training for the maintenance team, and possibly exploring outsourcing options to streamline the overhaul process and reduce downtime.
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