Combined-Cycle Plant Upgrade
Turbine, piping and controls upgrades on a 620 MW plant, finished inside one planned outage with the unit back online early.
- Owner
- Confidential
- Location
- U.S.
- Market
- Energy Infrastructure
- Delivery
- EPC
- Scale
- 620 MW
- Completed
- 2023
Turbine, piping and controls upgrades delivered inside one planned outage window, with the unit back online early.
Every day offline cost the plant generating revenue, and the outage window was fixed long before engineering was done. Turbine work, piping replacement and a controls migration all competed for the same space, cranes and crews. Hidden conditions inside equipment could not be seen until the unit was opened.
The approach.
- 01
Outage schedule by the hour
Thousands of outage activities were planned at hourly detail, with shift-by-shift updates to the critical path.
- 02
Pre-outage work done early
Piping spools, supports and control cabinets were fabricated and staged before shutdown, shrinking work inside the window.
- 03
Contingencies priced ahead
Likely findings inside the turbine were planned with parts and crews on standby, so discovery did not become delay.
- 04
Controls proven on a simulator
The new control logic was tested against a plant simulator before startup, cutting time spent tuning live equipment.
The outcome.
“In an outage, the schedule is the product. Every hour we gave back was power the plant could sell.”
Outage manager, GilbertLanham
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