Power Generation · 🇮🇶 Iraq · 2024
Spare-parts and obsolescence programme — gas turbine station, Basra
A two-year spare-parts and obsolescence programme for an operating gas turbine power station in Basra, supporting 1,200 MW of installed capacity across multiple units.
Our role
Lead supplier — critical and operational spares; obsolescence management on legacy DCS modules.
The challenge
What we walked into.
The site operates a mixed fleet of gas turbine units with original commissioning between 2008 and 2014. Several controller and protection cards in the legacy DCS were declared obsolete by the OEM in 2022, threatening forced derate during scheduled outages.
Approach
How we delivered.
- 01Walked the site with the operations and maintenance team to build a 380-line critical spares list, indexed against the manufacturer's recommended-spares manuals.
- 02Pre-positioned a vendor-managed inventory pool at site for the top 80 SKUs, with replenishment triggers tied to consumption.
- 03For the 14 obsolete DCS cards, ran a parallel programme of repair-and-return with two specialised service partners, certified to manufacturer specification.
- 04Provided commissioning support for 4 controller swap-outs during planned outages.
Outcome
What changed.
100% spares availability across the two-year period.
Zero forced derate caused by spare-part unavailability.
Average spares lead time reduced from 9 weeks to 3 weeks.
Avoided $14M+ in deferred-production cost on three outages.
Technologies & equipment
Gas turbine controller cards, protection relays, AVR modules
Distributed control system (DCS) I/O cards and processors
Hazardous-area motors and frequency-controlled drives
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