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An outage is a hundred jobs that must not collide.
Most of a generating station's maintenance is compressed into planned outages. The risk is not any one job. It is two crews working on connected equipment without knowing about each other.
Start a pilotA boiler feed pump seal starts to leak inside the outage window.
An illustrative night on this kind of floor, and what Plant Cortex does at each point.
The finding
During the outage walk-down, an operator finds the seal weeping. The window is fixed and the pump is on the critical path.
The question
The planner asks what the seal replacement involves. The answer cites the pump manual, lists the isolation points, and shows the seal kit on the shelf.
The work
The permit check shows another crew already has an active permit on the same pump discharge line, before either crew starts. A work order carries the parts reserved for this job.
What stays
Hours and parts are logged on the work order. The planned-versus-reactive picture updates, and the preventive plan for that pump now has a seal inspection step.
Where this floor gets hurt.
Simultaneous work on one system
Two permits on connected equipment is the classic outage hazard. A new permit is checked against open ones on the same equipment.
Parts that must be there on day one
Reserving stock against a work order means two jobs cannot count on the same last spare.
Preventive maintenance that drifts
Plans by calendar or by meter reading, with a working calendar that skips weekends and holidays.
Evidence for the audit
Who approved what, under which authority, with what signature, is held as a record, not rebuilt afterwards.
- Boilers and burners
- Steam and gas turbines
- Feed and condensate pumps
- Cooling towers
- Generators and switchgear
- Fuel handling
The questions this floor asks, and what comes back.
Examples of shape only. The real content comes from your own manuals and drawings.
What are the isolation points for the feed pump?
Comes back withIsolation steps from the pump manual with the page, ready to drop into a permit.
Which spares do we hold for the cooling tower fan gearbox?
Comes back withMatching stock lines, where-used links, and approved alternatives if you have recorded any.
The modules that matter most here.
Work orders
Hours, parts and checklists on one job, with reservations so parts are not double-booked.
PM plans
Calendar or meter based, with a working calendar and a compliance view.
Permits
Overlap check on the same equipment, approval by department or limit.
Maintenance KPIs
Backlog, planned versus reactive, schedule compliance, spend per machine.
Other floors.
Cement & Minerals
Long chains of heavy machines, from many suppliers, where one trip travels downstream.
See this floor
Steel & Metals
Heat, cranes and hydraulics, where the margin for a wrong step is thin.
See this floor
Chemicals & Process
Hazardous service, where the paperwork is part of the safety system.
See this floor
Pulp & Paper
One long machine that is expensive to stop and hard to restart.
See this floorBring the manuals for one power generation unit.
A few real documents, a few weeks, and success criteria agreed up front.