Client Background:

Our client, a major UK energy company, relied on a fleet of legacy gas turbines for power generation. One of their units, a legacy model that had been in operation for over two decades, experienced a critical combustor failure. The manufacturer had long ceased production of this particular turbine model, sourcing a new combustor would leave the unit non-operational for 48 weeks, leaving the client in a predicament for the upcoming winter period where production was critical.

Consultant Engagement:

The client engaged the services of SS&A Power Consultancy, a group of seasoned industrial consultants with expertise in turbine technology and a strong network within the energy sector. The consultant’s primary objective was to identify and facilitate procurement and assessment of the obsolete parts necessary to bring the malfunctioning turbine back online.

Challenges:

  1. Obsolete Parts Location: The first challenge involved locating the specific parts required, SS&A was aware that three other power plants operated units of this kind and one was undergoing an upgrade and combustor parts would be available for sale. Through its service network, SS&A was able to facilitate a commercial transaction between the client and the power plant with identical parts available for sale.
  2. Quality Assurance: Given the age of the combustor parts being procured, ensuring the quality and reliability of the sourced parts was paramount. The consultant mobilized a team to site and carried out visual and NDT assessments so as to ensure that the parts were fit to operate for another major operational cycle.
  3. Budget Constraints: The client had budget constraints, necessitating a delicate balance between cost-effectiveness and the urgency of getting the turbine operational.

Approach:

  1. Technical Expertise: SS&A leveraged their deep understanding of this particular gas turbine technology to dissuade the client from its original intent, with was to reverse engineer the parts.
  2. Global Network: Utilizing their extensive industry network, SS&A was able to identify a power plant with similar units with parts available to trade.
  3. Quality Control Measures: SS&A mobilized a team to the power plant and conducted a visual assessment, reviewed past inspection reports and carried out NDT assessments to ascertain fitness for purpose.

Results:

After weeks of tireless effort, the SS&A aided the client in successfully sourcing the required combustor parts. The comprehensive quality control measures implemented ensured the reliability of the components. The turbine was successfully restored to operational status prior to the critical winter period, preventing significant downtime and potential financial losses for the client.

Conclusion:

This case study highlights the critical role of consultants in navigating complex challenges within the industrial sector. The successful sourcing of obsolete gas turbine parts underscores the importance of technical expertise, a robust industry network, and effective facilitation skills in resolving unique and urgent problems faced by clients in the energy sector.