Gas Turbine – Off-Shore Construction Set-Up Reduction
The Opportunity
Our client had a major offshore campaign planned for a North Sea Asset, which included completing the installation and commissioning of a Gas Turbine(GT). The installation included non-standard activity due to the condition of the GT which had been positioned on the asset but not commissioned or operated in any way.
There were additional challenges with parts from the GT which had been used to service other turbines resulting in non-standard items requiring replacement e.g. Drive-shaft and stored materials both on and offshore required checking and in some instances re-working and replacing.
The original schedule for the GT Installation spanned the full term of the campaign from Flotel arrival to departure with no allowance for scope growth or slippage, the lack of float in the schedule was considered to be very high risk.
Approach Taken
PBI facilitated a Value Stream Mapping session with a team of engineers, offshore personnel & vendors who would be undertaking the campaign, the VSM identified 150 issues to be addressed.
The same team then worked on the issues in a 4 day Kaizen Event where they:
Refined the installation, set-up reduction methodology used to refine the plan with a focus on optimisation of parallel working. Complete process / all trades mapped-out and worked the detail of the Work pack
Accelerated the readiness for installation, critical Vendor interfaces defined and assessed in detail, mitigating any risks
Checked & Streamlined materials and logistics arrangements for all stages of installation process including vendor supplied parts and equipment
Benefits Realised
The installation schedule was reduced by 6 weeks and 3 days to a total duration of 14 weeks and 6 days, which was a reduction of 104 days equating to a 30% in the scheduled time, a reduction of 2,160 offshore hours.
45 days of off-shore personnel, across all trades, was freed up to do other work during the campaign.