Steam Line Repairs & Attemperator Replacements
Client: Genuity
Completed: 2024
Critical Planning & Execution Support + Contract Management
Scope
Project involved replacement of three Attemperators, one Hot Reheat Tee and Header Transition Weld Repair for a 450MW Supercritical Boiler.
Challenges
Project sets the outage critical path; underestimation or overestimation leads to significant financial loss or lost generation.
Equipment made from exotic materials (P91, P22 and P11); replacements not widely practiced in Australia.
Prior to TLG engagement, multiple planned attempts with most successful completed 40% over planned duration and resulted in overall increased project costs by a factor of 10.
Long lead times: equipment manufacturing up to 10 months, welding consumables 6 months; limited technical and trades expertise available.
Solutions
Began with a structured “lessons learnt” review of previous failed/over-run works; locked down scope and variation control early; pre-staged new components and work areas, included local lifting systems to remove weather delays and cranage dependencies; increased local power capacities; increased supervision and ensured critical resource spares, imposed tight meetings, cost and progress-tracking rhythms suited to 24/7 work; aligned all parties on project objectives.
Outcomes
- Works were completed one day ahead of the forecast program despite a 60–70% scope increase from previous project attempts.
- Project successfully completed in 30% less time than previous attempts and 1 day before planned duration.
- The station avoided repeat penalty exposure.
- Strict Contract Management returned an estimated ~20% cost saving.
- The client gained confidence to deploy similar replacement methodologies into future boiler campaigns.
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