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checks to be done
checks to be done
AOP PM checks to be done
EOP PM checks to be done
pump (main shaft driven) PM checks to be
done
Auxiliary Hydraulic Oil Pump (AHOP) PM checks to be
done
Hydraulic Oil Pump (main shaft driven) PM checks to be
done
Ratcheting pump PM checks to be done
Booster air compressor PM checks to be done
Main air compressor PM checks to be done.
Naphtha forwarding pump #1 PM checks to be done.
Naphtha forwarding pump #2 PM checks to be done.
Hitech (Lubricity additive) Pump #1 PM checks to be
done
Hitech (Lubricity additive) Pump #2 PM checks to be
done
DM Water circulation pump #1 PM checks to be done.
DM Water circulation pump #2 PM checks to be done.
Cooling Water circulation pump #1 PM checks to be done.
Cooling Water circulation pump #2 PM checks to be done.
Cooling Water circulation pump #3 PM checks to be done.
Hydraulic oil filter # 1 elements inspect/change to be
done
Hydraulic oil filter # 2 elements inspect/change to be
done
Trip oil filter #1 elements inspect/change to be done
Trip oil filter #2 elements inspect/change to be done
Main oil filter #1 elements inspect/change to be done
Main oil filter #2 elements inspect/change to be done
Lube oil cooler c/o valve pad to be fixed.
Lube oil filter c/o valve pad to be fixed.
Warren pump LO fileter to be replaced.
Off base Moog valve last chance filter to be changed
ON base Moog valve last chance filter to be changed
IGV last chance filter to be changed
oil mist demister pad to be checked/replaced
Main fuel shut off valve drain line plunger to be
checked/changed
ON base flow divider o/l fuel line ferrule and line to
be changed
OFF base area to be cleaned
ON base floor area to be cleaned.
Main Lube oil changing ( SERVO PRIME 32 T) to be done
Lube oil tank cleaning to be done
Naptha purge drain tank pump-1 PM to be done
Naptha purge drain tank pump-2 PM to be done
HSD false start drain tank pump-1 PM to be done
HSD false start drain tank pump-2 PM to be done
InstrumentionMaintenceWorklist
a. Switches/ control valve/ SOV to be checked/serviced/calibrated
HYD. Supply pressure low
63 HQ-1
3 way valve Sictch (HSD)
33TDD
L20FTX1
33TUC
ON Base selection
OFF base selection
Warren pump LO Ac
33 VM-1
33 VM-2
88 QA-2
L20FTX1
Motor
L4QAZ2
Warren pump LO DC motor
88QE-2
63 QA-4A, 4B
63 QA-3
63 QD-1
88 DS-1
Hyd.
88 HR-1
L63QAEOP
63QA-4
63QA-3
63DM1
Ratchet Pump motor start
L20CSX
Seam injection darin valve-1
33BS-1
33 BS-2
33 BS-3
33 CJ-1
33 SJ-1
L20BS1X
L20BS2X
L20BS3X
L20SJ1X
steam injection Flow transmitter96 SJ-1
steam injection Flow transmitter96 SJ-2
Main lube oil AOP auto start
63 QA2
63QA-2
Main lube oil EOP auto start
63 QT-2A
63QT-
2A
63QT-2B
63QT-2B
Main lube oil Temp. switches
26 QT1A
26QA-1
26 QT1B
26QT-1A
26 QA1
26QT-1B
warren pump lube oil temp
26 QT-3
L33 CB1O
L33 CB2O
63 TF-2A
63 TF-2B
26QT-3
2A
63 TF-1
63TF-2B
Exhaust High pressure
63 ET-1
63 ET-2
20 TW-1 SOV
20 TW-2
20TW-3 SOV
VA-17-1
63 EA-1
63 ET-1,2
b. TRIPS/alarms to be checked
description
Field Switch no
Flame failure Trip
28FD-7, 28FD-8
Mark v Tag no
L28f DT
33CB1O
33CB2O
63TF-1
63TF-
L86TXT
L63HLL
L26QT
L12H
L63QTX
L63ETH
L39 VT
L4 CT
L63FL2A Z
L63FL2B Z
L63 QAT
L26QT3
63 TF-
125 V DC FCBC2
IMO pump
Aux lube oil pump
Lube oil DC pump
Aux. HYD Oil pump
Warren Lube oil AC Pump
Warren Lube oil DC Pump
Naphtha Pump-1
Naphtha Pump-2
DM pump-1
DM Pump-2
Hi-Tech Pump-1
Hi-Tech Pump-2
Diesel engine staring motor (DC)
Ratchet Motor(DC)
Naptha purge drain tank pump-1
Naptha purge drain tank pump-2
HSD false start drain tank pump-1
HSD false start drain tank pump-2
Aux comp-1
Aux.comp-2
Tur. Comp-1
Tur. Comp-2
Load gear comp.-1
Load gear comp-2
Off base skid-2
Oil mist eliminator-1
Oil mist eliminator-2
Naphtha Scavenging fan
c. Electrical relay checking in Generator , HT and LT switch gear
By Process Value
>Wehaveshutdownofthewholeplant
>whichhasfourGasturbineswith
>compressors...(mechanicaldrive)...
Part3Materialsandtoolsmanagement
Nowthatweknowwhatallworksneedstobedone,itisimportanttocomeupwithainventorylistofmaterials
neededduringshutdown.Thisisthepartwherethreeisalotoftugofwarbetweentheexecutionengineersandthe
plantmanagement.Executionengineersalwaysliketohaveabundantsparesbuttheplantmanagementdoesnotshare
theirenthusiasmwiththis.Ihaveseenmostofthemaintenanceworksgetdelayedduetolackofpropermaterial
management.Ideallyyouhavetobuyeverythingintherightquantitysothatnonegetswastedandalsothereisno
shortsupply,butitrarelyhappens.A
sampleinventorylistforafieldjobwilllooklikethis
Job description
50 mic filter replacement
Materials needed
2
Aconsolidatedlistforallrotary,electrical,fieldandinstrumentationjobsneedscollectedandsentforprocurement
wellinadvance.Materialsshouldarriveatleastaweekbeforetheplannedmaintenancesothatitcanbeproperly
loggedintotheinventory.
Part4Preparationofaworkschedule
Nowthatweknowwhatworkneedstobedoneandalsothematerielforthejobs,timehascometoallocatethejobs
onatimescaleandtoreleaseittotheexecutionengineers.Astherearetwoseparategroupsworkinghere,onefrom
theinhouseplantmaintenanceandotherfromtheexternalturbineoverhaulgroup,itisimportanttosynchronizethe
workscheduleofthetwo.Theturbineoverhaulpersonnelwillhaveafixedtimetabletochoosefrom.Aturbineover
haulcanbedonein15days(roundtheclock24hoursshift)21days(16hoursshift)and30days(812hourshifts).
Itisimportantwhendecidingwhichtimescaletogoonto.Theimportantcriteriais,whentheexternalpersonnel
finishtheiroverhaul,theplantinhousemaintenancemusthavealsofinishedthejobsallocatedtothemsothatthereis
noexcessivedelay.15dayworkschedulecostsalot,sothereisnopointincommittingtheexternalpersonneltoa15
dayworkschedulewhenyourinhousemaintenanceisgoingtotakeyou1920daystocomplete.Inthiscase(20days
fortheinhouseplantmaintenancetocompletetheirworkschedule),itwillbedecidedtogofora21dayturbine
overhaulschedule.
Nowthatweknowthetimespanfortheshutdownmaintenance.itisnowimportanttocomeupwithawork
schedule.workscheduleisaplanofworktobecompletedeachdayduringtheshutdown.Asampleworkschedule
willlooklikethis
Day
Turbine overhaul group
Generator overhaul group
Plant rotary
Plant electrical
Plant field
Plant
inst
1
arrival at site
begin plant electrical
begin plant mechanical begin plant inst
meeting with the maint group
isolation
isolation
isolation
2
Start of dis assembly
begin job list
PM check of motors
thetimewhennewfriendshipsarecementedbetweentheplantmaincrewandtheexternalmaintgroupswhothough
atloggerheadsatmosttimescometogetherforajobwelldone.