To document an important stage of the outage process, a picture of the rigging to lift and transport the turbine shell was entered into the TOPS system

Total Outage Planning Software (TOPS), which runs on Windows, takes advantage of the mass data storage available with compact-disc technology by archiving the complete outage documentation on CD. Previous outage records can then be indexed, searched, and viewed on a computer with the click of a mouse. Critical-path schedules, parts lists, parts order tracking, work instructions and procedures, custom data sheets, and progress reports can be generated by computer on-site during an outage.

After the initial documented outage, customized data-sheet templates, drawing indexes, work scopes, contractor and vendor listings, schedules, man-hour cost estimations, and previous repair and inspection documentation are available for use during future outages.

TOPS should increase the quality and efficiency of future turbine-generator outage for the same unit or sister units of the same make and similar size. It also provides utilities with more independent control over outages. Furthermore, reliance on original-equipment-manufacturer (OEM) maintenance services, which are sometimes biased and often high-priced, is dramatically reduced.

The software is easy to use, so utility personnel can easily access and view the information stored on CD from anywhere in the plant. This should be particularly attractive to small utilities and cooperatives that do not have access to large network computers, a large staff of computer-trained specialists, or similar programs developed by the Electric Power Research Institute in Palo Alto, Calif., such as Rotating Machinery Workstation.

The TOPS package has two main aspects: general and custom. The general part of TOPS, designed as a guide for the initial computer-aided outage, consists of a work-scope-development template, a series of documentation templates, and repair-or-replace and lifetime-assessment-decision flowcharts. The custom TOPS aspect is developed during the first TOPS-assisted outage. The general TOPS templates are used in conjunction with an experienced technical director (TD) to create a customized computer database for future outages of a specific unit.

The custom aspects are intended to increase the efficiency of future outages. Furthermore, TOPS reduces a utility's dependence on experienced technical-direction personnel. The ultimate goal is to take the results of a successful outage and repeat that outage under the guidance of the TOPS program. High-priced technical directors or outage consultants will be brought in only on an as-needed basis.

TOPS is made up of a series of menus and indexes with hypertext linking. It also allows for search by keyword, title, or drawing number for various indexes.

TOPS contains a general work-scope template for developing custom work scopes for an upcoming outage. The work-scope template has an extensive listing of tasks, covering all types of units, and the user checks off the tasks that are desired. Users can also input additional tasks into the list. Then TOPS compiles the choices and generates the custom work scope for the bid requests.

The program also contains a series of general documentation templates, which can be chosen from a hypertext index or found with a search by keyword option: schedules, part lists, drawing indexes, and data sheets. These templates provide a platform for developing custom documentation during and after the initial TOPS-assisted outage.

In addition, TOPS has a collection of repair-or-replace and lifetime-assessment-decision flowcharts, which provide a sequence of questions to address, plus alternatives that are helpful in deciding whether to repair, replace, modify, or retire a component. The flowcharts can also be used as a guide for performing life assessments on various components. Each component type has a general decision flowchart developed by technical directors and crew foremen. During the custom TOPS development phase, the relevant flowcharts are tailored to the specific unit components for future guidance.

In-service ultrasonic examination of a steam-turbine disk at a nuclear power plant was documented with a digital camera. The image was then fed into the computer

The custom aspects of TOPS are created by an engineer with computer specialization (ECS). Before the outage, the ECS should be on site to begin organizing drawings and past outage information for use in the current outage. The ECS works closely with an experienced TD, who provides the experience and knowledge to structure the schedule, design data sheets, guide the crew foreman and ECS, create parts lists, and draft reports. The ECS produces and updates the critical-path schedule, data sheets, parts lists, and reports on a computer, and he or she orders parts as needed. The TD and ECS work together to photograph the rigging of large, heavy components; document the tools used for each rigging; and record actual setup time and total man-hours required to complete each task. After the outage, the ECS compiles all this information and creates the custom TOPS sections for that unit.

The ECS, assisted by utility personnel and guided by the TD, develops a list of the parts already in stock at the plant and those that need to be ordered before the outage. The parts list is updated continuously on computer. After the outage, the parts list and the parts costs are included in the TOPS program. Along with the text documentation are hypertext links to images (from scanned photographs) of the defective parts replaced and of the new parts as installed for comparison. With this documentation, utility personnel can look for recurring damage and monitor parts that have worn excessively, become fatigued, or failed previously.

As part of the TOPS development, the drawings and blueprints of the unit are gathered and organized before the outage begins. A drawing index is created on the computer with information needed to search for the drawing: the utility drawing-index number, the drawing title, the OEM drawing number, a one-paragraph description of the drawing, and a list of keywords for searches. After the computer index is created, a search can be performed using TOPS to identify the drawings that match the search topic. This drawing index provides fast, effortless access to the drawings during the outage.

Before the outage, the TD and ECS develop a preliminary schedule for the outage based on the work scope provided by the utility. Previous outage notes, schedules, recommendations, and reports can be used as a guide. The TD designs a schedule of outage events, optimized for critical-path flow of events using scheduling software. The projected schedule is updated weekly to make modifications and monitor progress.

Throughout the outage, the actual time and man-hours required for each task are documented. At the completion of the outage, these data are organized and fed into TOPS. Then, when future outages are planned, TOPS can display the past schedule. The schedule is displayed as an overall layout, broken down to just the major tasks, such as low-pressure disassembly, generator inspection, and high-pressure assembly. In addition, the overall schedule tasks can be linked to a detailed schedule for that task.

For future outage planning, the TOPS program includes the actual man-hours from the previous outage with each task listing on the work-scope-development template. When the new work scope is generated, the man-hours are tabulated and displayed next to each task. The user can input the current cost per man-hour for each labor type, and TOPS then calculates the cost of each task and the total labor cost based on previous outage schedules. Any special equipment, supply use, and costs are also listed for each task.

In addition to the custom work scope, a vendor index includes a listing of qualified bidders that contains vital information: company name, contact person, previous jobs performed, type of work performed, quality of previous work, address, phone number, and e-mail address. The vendor information can be modified and updated throughout the bidding process and the outage. If needed, of vendor listings can be grouped and printed.

Using general data sheets as templates, the TD designs custom data sheets for the specific unit. These can be spreadsheets, charts, graphs, CAD drawings, scanned photographs, or scanned OEM drawings.

At the end of the outage, there is a complete set of custom templates or empty data sheets tailor-made for that unit and ready for the next outage. A data-sheet index is created for TOPS that contains pertinent information for searches: data-sheet title, the CD containing the file, a one-paragraph description of the data sheet, and a list of keywords. TOPS displays the search matches with hypertext links to the data sheets. Then the empty data sheet can be modified and printed immediately.

Also after the outage, the completed data sheets are scanned into the computer and incorporated into TOPS. The information will be archived on CD and available for reference during future outages or during analysis of the unit configurations. A hypertext index for the previous outage data sheets has the same list properties and search capabilities as the empty-data-sheet index. Furthermore, hypertext links can be a guide to relevant data sheets embedded in other sections.

From the beginning of the outage to its end, the TD and ECS photograph the rigging of large, heavy components and document the tools used for each task. After the outage, these photographs are scanned to create digital bitmap images to be incorporated into the custom TOPS. Each major component has a category in the rigging index; each category listing in the index then has a hypertext link to a more detailed listing for that category. The entries in the detailed listings are hypertext links to a series of rigging images that illustrate the rigging tools and methods that worked best at the last outage. In addition, every image is accompanied by text describing the image and providing such details as tool descriptions, utility tool numbers, the location of each tool in the plant at the last outage, and other notes that may be helpful. In addition, listings of custom instructions and procedures for disassembly and assembly of major components for the entire outage is included.

The complete rigging reference file included this photograph of the rigging used for lifting and transport of the turbine rotor

TOPS can be installed on the crew foreman's computer on the turbine deck for quick and easy access to the rigging guide. The images can be shown to the workers at the time of rigging to make the procedure clear and understandable. The rigging guide acts as documentation and reference for future inspections.

The results of previous nondestructive examinations (NDE), electrical tests, leak tests, and other tests are included in the TOPS archives on CD. Hypertext indexes are then sorted by component for the test data and type of inspection report. For example, if "NDE Report" is chosen from the listing, the entire table of contents for the NDE report is shown with hypertext links to each section. During future outages, the past outage information is therefore available to inspectors for comparison and monitoring of trouble areas. Furthermore, previous inspection data are readily available for engineering analysis and life assessment.

All damaged components or areas of steam leakage are photographed and documented. Once repaired, the component is photographed again from the same angle. Following the outage, the before and after photographs are scanned into the computer to be used for the TOPS archives. Each photo has a caption that describes the repair and other circumstances relating to the damage. Correspondingly, a repair index has detailed listings that can be searched by keywords such as the component name or the type of repair performed. Within each listing, hypertext links can call up a series of scanned images from the CD archive. If repairs were documented by NDE inspectors, there will be links to the NDE-report documentation of that component as well. Since all the repairs are documented and readily accessible, the repaired areas can be watched more closely for reoccurring damage or failure.

The TD also keeps a record of the number of man-hours and the amount of time spent repairing each component. Furthermore, the TD documents the bids received, vendors who inquired, and vendors who performed the repairs. The list of vendors will be input into TOPS for future reference. Links to relevant vendor lists will be embedded throughout the repair documentation so information can be retrieved from several routes.

TOPS also supplies a quality-of-repair (QR) report form to be completed by the TD, crew foreman, and outage coordinator (utility employee) when each repair is completed. This form documents the performance and work quality of each vendor used. The QR reports become a part of the TOPS CD documentation. There will be listings by vendor and by component repaired as well as hypertext links to relevant QR reports embedded within the report documentation.

The technical details used to develop the initial TOPS concept and programs were derived from an actual plant outage in 1995. Using documentation generated by the TOPS developers during this outage, that same utility conducted its own outage in 1996 on a sister unit (same make and size). For the 1996 outage, the utility used internal management and technical support as well as locally contracted labor workers. Other technical support, consulting, and assistance from the OEM were used only on an as-needed basis. Even though the documentation was not digitized and stored on CD, large gains and benefits were realized from organizing and documenting the 1995 outage. The 1996 outage went smoothly, cost less, and was completed more quickly than the 1995 outage of the sister unit.

The unique attribute of the TOPS program is that it was developed using technical details from highly experienced technical directors, mechanical engineers, electrical engineers, and outage support personnel, rather than by computer specialists with only a casual knowledge of the technical and management details required to organize and conduct an actual turbine generator outage. The TOPS program could therefore be considered as expert assistance software. Future additions to TOPS could include other major plant components, such as boilers, condensers, heat-transfer tubing, high-energy piping, fuel-processing systems, and waste-filtration systems.

Eugene R. Reinhart is president of Reinhart & Associates Inc., an engineering and inspection firm in Austin, Tex

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