Location: Port Hedland, Western Australia
Commodity: Natural Gas
Time-frame: March 2022
People & Resources: Jake Konsolis (RS Project Lead), 2x RE Technicians
The Challenge
In early 2022, a valued customer approached Rotation Solutions to plan and conduct a rapid engine change of a Saturn 20 gas turbine.
The challenge set out was to exchange the engine in just five shifts.
The project became a test case for RS’ ability to deliver future engine changeouts with a Formula One pit crew efficiency style.

The Solution
During the planning process, RS director Dane Balle adapted an existing engine change procedure to the Saturn 20, which would be a new undertaking.
The team arranged and supplied all the tooling and consumables for the job, sourcing Solar Turbine parts locally to meet the strict deadline.
Once on-site, Mechanical Engineer Jake Konsolis took over as project lead to work with the client and their in-house maintenance crew.
Risk assessment and planning software, including the Tundra app, was then used to layout a safe and reliable procedure from start to completion of the task.
The RS proprietary RSWI software contains reporting and checklist protocols, such as peer review, which is completed before start-up and which Jake credits for preventing unnecessary problems and delays.
“We found some under tightened fittings and small things in the peer check, but we corrected them before start-up, which is the reason why they’re there,” Jake said.
“That way, you’re not left with egg on your face when you go for a start-up, and you’ve got three fittings leaking.”
Despite a few very-minor issues upon commencement, not related to the engine exchange itself, the team adapted and banded together to get the job done.
“There were a few times there where we had to kind of stop and do a bit of a tidy up and get everything back on track, but in saying that, we got complimented on our housekeeping,” Jake said.
“That’s something we pride ourselves on – excellent housekeeping and being really organised, and our flange management, including all our tapes and labels.”
“I think it all went as smoothly as far as an engine change goes. There’s always something that catches you out, and there are always some challenges along the way, but overall it went very well.”
The Outcome
This engine change has become proof of concept for the RS high-speed engine turnaround service.
With strategic planning and an adaptable, motivated group, the team completed the project within the allocated time frame.
“We achieved it between Monday and Friday, even with a few issues that cost us a bit of time,” said Jake.
“The issues we had weren’t anything to do with our workmanship; they were just random things that tend to pop up.”
The Saturn 20 project has provided RS with invaluable feedback to improve and optimise the process going forward.
“We’ve got a few things in place that’ll aid the speed of the job,” Jake added.
These optimisations include manufacturing a new engine stand that will allow new through-drive and TAI to be installed a week before the engine change, reducing the shutdown period even further.
For more info on our F1 Pit Crew inspired engine change-outs, contact the RS team today!
