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. Maintenance Management
Presentation
January 2011

2. 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
__________________________________________________________________________________________________________________________________________
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

3. Maintenance Management Presentation
Index
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
__________________________________________________________________________________________________________________________________________
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. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

4. Recent Examples of
Non MHI Equipment
Maintenance Experience

5. 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
__________________________________________________________________________________________________________________________________________
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. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

6. Scottish Power 1stIntroduction
Company September 2010
Company Introduction
WG GTS Capabilities
• Long term maintenance contracts • Wind Turbine Maintenance & EPC
• Full O & M services and products • Full O & M services and products
• Field service and outage management • Steam Turbine component relifing &
manufacture
• Supply of new, refurbished and APM®
(Advanced Parts Manufacture) parts • On site and off site repairs
• Control systems service, support & trouble • Maintenance & construction contractor
shooting
• Technical field service supply to OEM’s &
• On line monitoring Utilities

7. Maintenance Services Division
including Outage Management
SE Scope of Supply to MPSE

8. SE Scope of Supply to MPSE
Contract Type and Expiration
Plant no. 1 Plant no. 2 Plant no. 3 Plant no. 4
2014
Contract Expiry 2015 2018 2012
Exclusivity of Supply
Yes Yes Yes No
of Manpower
Bulk order
No Yes Yes No
Commitment
__________________________________________________________________________________________________________________________________________
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

9. What’s New In
Shanahan Engineering

10. 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
__________________________________________________________________________________________________________________________________________
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. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

11. Organisation Chart
© Shanahan Engineering
James Greaney Fergal Kelly
Senior Vice President Business Development Manager
Matt Swan
James McManus Keith Rigney Business Development Manager
HSE Manager Operations Manager Maintenance Division
Wood Group GTS
Michael Joyce
Anthony Varey WG HIT (Gas Turbines)
Senior Mechanical
Lead Outage Coordinator WG ST (Steam Turbines)
Engineer
Ronan Norton
Tony Scott Chris Fenwick Outage Coordinator
Mechanical Technical Advisor Mechanical Technician
Paul Mullins
Harry Anderson Ronnie Anderson IR Manager
Mechanical Foreman Mechanical Technician
Emma Wilkins
Paul McGinley Michael Taylor Administration Officer
Mechanical Foreman Mechanical Fitter
Liam Weavers
Robert Cullen Jamie Jenkins Human Resources Officer
Mechanical Foreman Mechanical Fitter
Kara De Souza
Ged Flynn John Dimishky Human Resources Officer
Rigging Appointed Person Inventory Coordinator
MAINTENANCE CREWS

12. Field Staff Training
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
__________________________________________________________________________________________________________________________________________
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. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

13. 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
__________________________________________________________________________________________________________________________________________
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.
NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

14. Health, Safety & Environment
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.
__________________________________________________________________________________________________________________________________________
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

15. Recruitment & Assignment Process
__________________________________________________________________________________________________________________________________________
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

16. 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
__________________________________________________________________________________________________________________________________________
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.
ENSURING BEST IN CLASS SERVICE © Shanahan Engineering 2010

17. Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________
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

18. Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________
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

19. Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________
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

20. Sample Trade Test Completed
__________________________________________________________________________________________________________________________________________
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

21. Trade Test Certificate
SE Trade Test Assessors are qualified to ECITB standard
__________________________________________________________________________________________________________________________________________
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

22. Pre Employment Check List
1. D
__________________________________________________________________________________________________________________________________________
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. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

23. Competency Profile - Form
WORK HISTORY WITH SHANAHAN ENGINEERING (continued)
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
SKILLS MATRIX
Gas Turbine 5 Mitsubishi 701DA 5 Mitsubishi 701F 5 Transition Alignment 4
Bearing Assembly &
Rotor Blading 5 Rotor Alignment 4 Bypass Spindle Overhaul 5 Disassembly 5
Combuster Internals
Heavy Bolt Removal 5 Blade Ring Assembly 4 (based on Turbine 5
Inpection)
Skills Matrix Key:
0: No Experience
__________________________________________________________________________________________________________________________________________
1: Low Experience
The information contained in this document is confidential and must not be reproduced or disclosed toExperience parties, unless prior written permission has been given by
2: Little third
Shanahan Engineering. 3: Moderate Experience
4: Good Experience
© Shanahan Engineering 2010
5: Very Good Experience

24. Competency Profile - Certificates
__________________________________________________________________________________________________________________________________________
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

25. Competency Profile - Certificates
__________________________________________________________________________________________________________________________________________
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

26. Competency Profile - Certificates
__________________________________________________________________________________________________________________________________________
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

27. Outage Skills Matrix
__________________________________________________________________________________________________________________________________________
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

28. Pre-Outage Familiarisation Presenta
Saltend GT2 Outage – August 2

29. Pre-Outage Familiarisation Presentation
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
NO AT RISK BEHAVIOUR – SAFETY FIRST
__________________________________________________________________________________________________________________________________________
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

30. 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
__________________________________________________________________________________________________________________________________________
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

31. Health, Safety & Environment
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.
__________________________________________________________________________________________________________________________________________
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

32. Pre-Outage Familiarisation Presentation
Saltend Unit 2 Outage Work Scope:
• GT Turbine Inspection
• GT Rotor Replacement
• Steam Valve Inspection
• GT Expansion Joint Repair
__________________________________________________________________________________________________________________________________________
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

33. Pre-Outage Familiarisation Presentation
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)
__________________________________________________________________________________________________________________________________________
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

34. Organisation - Saltend Outage Team
SE
Operations Manager
Keith Rigney
SE Leeds Office
__________________________________________________________________________________________________________________________________________
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

35. Working Time and Break Times
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.
We kindly request your full cooperation on this
__________________________________________________________________________________________________________________________________________
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

36. Roles & Responsibilities
• 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.
No Lift Plan = No Lift
__________________________________________________________________________________________________________________________________________
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

37. 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 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

38. Lessons Learned, incidents to be avoided
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).
__________________________________________________________________________________________________________________________________________
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
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
Shanahan Engineering.
© Shanahan Engineering 2010

39. Lessons Learned, incidents to be avoided
• 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.
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
__________________________________________________________________________________________________________________________________________
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

40. Lessons Learned, incidents to be avoided
• 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).
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
__________________________________________________________________________________________________________________________________________
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

41. Lessons Learned, incidents to be avoided
• 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!
__________________________________________________________________________________________________________________________________________
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
LETS DO IT RIGHT THE FIRST TIME – ASK IF YOU ARE NOT SURE!
Shanahan Engineering.
© Shanahan Engineering 2010

42. 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.
__________________________________________________________________________________________________________________________________________
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

43. Lessons Learned, Caution Points
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.
__________________________________________________________________________________________________________________________________________
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

44. Lessons Learned, Caution Points
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.
__________________________________________________________________________________________________________________________________________
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

45. Lessons Learned, Caution Points
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.
__________________________________________________________________________________________________________________________________________
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

46. Final Comments
• 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!
NO AT RISK BEHAVIOUR – SAFETY FIRST
__________________________________________________________________________________________________________________________________________
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

47. Training & Buddy System

48. Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________
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

49. Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________
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

50. Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________
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

51. Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________
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

52. Fuel Gas Pipework Installation & Alignment
__________________________________________________________________________________________________________________________________________
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

53. Buddy System - Training
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
No. Task No. Task No. Task No.
Task
Gas Turbine 5 Mitsubishi 5 Mitsubishi 5 Transition 4
701DA 701F Alignment Skills Matrix Key:
Bearing 0: No Experience
Rotor Bypass Spindle
Rotor 5 4 5 Assembly & 5 1: Low Experience
Alignment Overhaul
Blading Disassembly 2: Little Experience
Combuster 3: Moderate Experience
Heavy Bolt 5 Blade Ring 4 Internals (Turbine 5 4: Good Experience
Removal Assembly Inspection) 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.
__________________________________________________________________________________________________________________________________________
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. NO AT RISK BEHAVIOUR – SAFETY FIRST © Shanahan Engineering 2010

54. Gas Turbin
Maintenance Training Manu

55. Training Manual Task Index
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
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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

56. 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
__________________________________________________________________________________________________________________________________________
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