KEY CAPABILITIES
- Engine and compressor extraction, overhaul, installation and commission.
- Structured execution strategy - 1) Collaborative leadership: GRPS and QPME project managers regularly worked in consultation with each other to streamline decisions and maintain accountability 2) Phased execution: Activities were strategically segmented, minimizing operational disruptions and enabling efficient delivery and 3) Integrated tracking: Real-time updates across budget and work orders ensured comprehensive project oversight.
- Experienced budget management - a detailed budget tracker was pivotal in maintaining alignment between financial and operational objectives (eg. all purchase orders issued on time to ensure materials delivered on schedule and linked work orders ensured transparency and integration across all project aspects).
PROJECT OVERVIEW
GR Production Services (GRPS) successfully delivered a comprehensive maintenance and overhaul project for Unit 1 at the QPME-owned Moranbah Gas Processing Facility, setting a benchmark for operational excellence. By integrating advanced planning, collaborative execution and innovative solutions, GRPS addressed critical operational needs while reinforcing its reputation as a trusted partner for large-scale maintenance projects.
SCOPE
The project’s objectives and deliverables were strategically designed to address interdependent workstreams and deliver maximum client value:
- Roof removal and engine extraction
- Objective: Facilitate the safe removal of Unit 1’s CAT G3612 engine by dismantling the roof structure.
- Deliverables: Roof reinstated seamlessly post-engine overhaul.
- Cost: Delivered within budget.
- CAT G3612 engine overhaul
- Objective: Rebuild the engine at an external workshop, encompassing non-destructive testing (NDT), crankshaft machining and compliance with Electrical Equipment in Hazardous Areas (EEHA).
- Deliverables: Reconditioned engine returned to site and successfully reinstalled, ensuring enhanced performance.
- Cost: Delivered on schedule within budget.
- Ariel compressor overhaul
- Objective: Conduct an in-situ overhaul of the Ariel compressor, with a focus on reconditioning and replacing valves, packers and piston assemblies.
- Deliverables: Fully serviced compressor package returned to optimal operational standards.
- Cost: Delivered on schedule within budget.
CHALLENGES & SOLUTIONS
Despite the complexity of the project, GRPS delivered excellence by proactively addressing challenges:
- Time sensitivity: Timely interventions ensured uninterrupted operations and minimized downtime.
- Logistics: GRPS’ advanced planning enabled the safe transport of heavy machinery to off-site facilities.
- Procurement: Agile decision-making resolved delays and ensured all materials were available when needed.
- Work orders and tracking: GRPS implemented a robust tracking system to ensure seamless coordination and visibility across all tasks:
- Total Work Orders: nearly 200 interlinked orders managed under a structured framework.
- Key Activities:
- Replacement of critical components from fan drive couplings through to PLC cards and HMI screens.
- Cooling system cleaning and preparation.
- Procurement and installation of advanced control system items.
- Progress: Material ordering and scheduling were effectively managed, ensuring steady project advancement.
OUTCOMES
- Reliability restored: Unit 1’s operational integrity was fully reinstated, reducing the risk of unplanned outages.
- Prolonged asset life: Targeted interventions extended the lifespan of critical equipment.
- Client satisfaction: GRPS’ transparent communication, adherence to schedules, and unwavering commitment to quality were praised by stakeholders.