Maintenance Cost Reduction for International Gas Turbine OEM

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Maintenance Cost Reduction for International Gas Turbine OEM

Situation

A major Gas Turbine Manufacturer’s business model for industrial turbine packages has been changed by the move to Service Agreements. This means the OEM now pays for the cost of maintenance.

What We Did

We used RCM principles to review and re-define the work programmes to ensure that each task was sensible, defensible and occurred at the appropriate interval. Appropriate Instrument Maintenance intervals were determined. These were based on the technical characteristics and consequences of failure of each instrument (whereas previously all instruments were checked every year). The analysis also examined possibilities to make design changes to facilitate better maintenance.

Results

  • It was possible to de-tune some overly sensitive instrumentation to provide the end-user with alarms as opposed to trips;
  • Calibration and loop test intervals on many instruments were able to be extended;
  • 56% reduction in maintenance labour costs for annual interventions;
  • Availability improvements of at least 1.5 days per year per gas turbine from planned maintenance alone; and
  • A reduction in Control and Instrumentation Engineer resource requirement of around 60%.