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					Enhance life of Gas Turbine Air Inlet Filters
              June 2010 to March 2011
              Power Maintenance team
                   History of EMAL
• Established in 2007
• Joint venture between DUBAL and MUBADALA.
• New hi-tech primary aluminium producer in
  Taweelah, Abu Dhabi
• It will be the largest single site aluminium plant
  ever built, and one of the largest industrial
  projects in the UAE outside the oil and gas
  sector.
• Production capacity of 750,000 tonnes of
  aluminium per year after phase I and doubling
  to 1.5 million tonnes annually at the end of
  Phase II.
              The EMAL Vision

• EMAL's people will generate value and create a high
  value-adding, sustainable aluminium smelter that meets
  our stakeholders’ expectations in support of the Abu
  Dhabi 2030 Vision
                                                                                         The Idea
    Business Case / Problem :
•     A Premature failure of Gas Turbine filters experienced by EMAL in less than 6 months of service (i.e.
      @ 3525 running hours), against the expected life of minimum 2 years.
•     Due to high inlet air filter DP, GT # 12 forced shutdown occurred and GT # 21 load restricted to 118
      MW (from 220 MW, for an hour).
•     Loss of generation due to CTG #12 outage is 190 MW for 9 hours = 1710 MWh and the same for CTG
      # 21 is 102 MWh. Then, Total energy deficit of 1812 MWh (imported from Inter tie grid).

Current Condition :
• During high humid and foggy atmospheric conditions, filter differential pressures are shooting up
due to improper functioning of GT Air inlet filtration system.

Target Condition :
•    Enhance the life of the GT filter cartridges from 6 months to 24 months.
                                                 25
                                                        Target Life,
                  Pulse filter life, in months




                                                        24 months
                                                 20


                                                 15


                                                 10
                                                      Current Life,
                                                      6 months
                                                  5


                                                  0
                                                                       1    2
                                                           Filter Replacement interval
                                           The Idea
    Preliminary research using Pareto approach :

           Major factors - Effecting the Life of Pulse filters

                Current Practices           5%
              Moisture ingression           5%
    Suitabiliy of Nano Filter media                                       25%
       Filter house- Under design                                 20%

     Coalescer mats not effective                                 20%

      Pulse cleaning not effective                                        25%

                                      0%   5%    10%    15%    20%      25%     30%
                                                    % of Impact




Tools / Technique used :

•    A3 Concept - a tool that provides a visual and structured Continuous Improvement method for
     developing, communicating, gaining alignment and executing strategic, innovation plans and gap
     analysis based upon a business need.
                                        The Idea
Prioritization of project : (based on Key causes & their impact)

Problem              Root cause analysis - Key Causes                                              Impact
                     • Pulse interval Cycle time set to 30 sec ( OEM recommends 7.5 sec).            25 %
                     • Distance between pulse nozzle & filter is too far ~ 3 ft, (design issue).
Poor performance     • Quality of pulse air is not known (no Dew point measure).
of Pulse Cleaning    • Passing of solenoid valves.
     System          • Pulse air is leaking due to dislodgement of Flex hoses at downstream
                        of solenoid valves.
                     • On-line pulsing is not effective, encourage off-line pulsing.
                     • Mats are heavily clogged by dust, as we missed the PM schedule –              20 %
   Ineffective         mats shall be replaced with in 2 months.
 Coalescer mats      • Even, the new mats are not functioning properly during high humid
                       conditions.
     Design          • Design concerns over the capacity of filter house                             20 %
   deficiencies
   Filter Media      • Filter media may not be suitable to the EMAL site conditions.                 25 %
                     • Several small openings on the walk way gratings between coalescer             5%
 Moisture ingress
                       and pulse filters. Leakage through Auger dust collection ducts.

                     • Avoid removal of mats online, as it would in turn clog the pulse filters.     5%
 Current Practices
                 People Involvement
•   A team of experts formed (on cross-functional level) from Power plant
    Operations & Maintenance, Projects, Engineering, Business systems
    with in the organization (EMAL), as well as EPC contractor (SLWP) &
    OEM ( GE/ Braden).

•   VP Operations, Sponsor of the project, buy-in acquired, by presenting
    the A3, first ever tried in EMAL, with the help of Business systems.
                       How the budget obtained?

  By showing the additional maintenance costs likely to incur, if the problem is
  not solved – A commercial impact

 S.                                                            Replacement interval
                          Item cost details                                                   Variance     Remarks
 No.                                                       6 months        24 months
  1     Pulse filter elements cost                             $748,800          $187,200       $561,600
  2     External Services cost, including Scaffolding,          $18,600            $4,650        $13,950
        Mobilsation & Waste disposal
  3     Internal Labour OT cost @ 10 people in 2 days, 8        $73,280           $18,320        $54,960
        hrs/day @ $114.5 / hour
  4     External Labour cost @50 people in                     $168,000           $42,000       $126,000
        2 days x 24 hrs @$15 / hour
  5     EHS consumables cost                                    $21,600            $5,400        $16,200
  6     Misc. Expenses                                           $3,600                $900       $2,700
Additional Cost impact per unit in 2 years                  $1,030,280           $257,570       $772,710




Additional cost impact for 4 x Units                                      : US $ 3, 090, 840 (every 2 years)
Innovation budget approved:                                               : US $ 3, 000, 000 (one time)
Hence, Break even occurs                                   : with in 2 years
                                                                         Action Plan
S.                                                                                                                                                  Responsible         Expected
      Actionable Item                                                                                                                                                                  Remarks
No.                                                                                                                                                 Person              completion

                                                                                                                                                     Swami / Chris       24-Jun-2010
1.1   Discuss with SLWP site commissioning team, set the new / appropriate pulse timing for all units.                                                                                 Done
                                                                                                                                                       (SLWP)

1.2   Discuss with OEM / GE, implement the new design of pulse nozzles                                                                                   Surya           31-Dec-2010   Reviews in progress

                                                                                                                                                    Dave Meadley /       31-Oct-2010
1.3   Review with SLWP, install new dew point meters at the outlet of all APUs                                                                          Chris


                                                                                                                                                     Surya / Chris       31-Jul-2010   Temp. arrangements
      Provide permanent arrangement for Offline pulsing in all Units. Ensure to perform the pulsing, whenever unit is offline. Identify & rectify
1.4                                                                                                                                                 Longton / Dave                     made. Permanent fix
      the defective solenoids and arrest the pulse air leakages (through flex hose joints)
                                                                                                                                                       Meadley                         i/p.

      Verify the design capacity of APU cooler with GE/ OEM. If it is found to be under designed, replace it with suitable one, to meet the         Ken (GE)/ Surya      30-Dec-2010
1.5
      demand.

      Install Air receiver buffer tank between APU and pulse solenoids, with auto drains and coalescing filter at the outlet. Add dew point          G. Jan ( Eng)       31-Mar-2011   EPR raised, tender
1.6
      meter, in lieu of Point 1.3.                                                                                                                                                     floated

      Add the Coalescer mats replacement interval in to SAP PM Task list, to be performed in every 2 months without fail. Or based on                  Nagaraju          30-Jun-2010
2.1
      condition when dp > 2.5”

      Explore other suitable alternatives to replace the existing coalescers like marine louvers / defoggers. Implement in one of CTG units for          Surya           30-Jun-2012
2.2                                                                                                                                                                                    With Phase # 2
      testing in coordination with GE Environmental services

      Discuss, review and implement the design change for resizing / increasing the capacity of filter house in coordination with GE                Idrees / Ashraf      31-Dec-2010
3.1
      Environmental services and EMAL Engineering.

      Explore other suitable alternatives for Nano filter media, like LP8 (DEWA is using) in conjunction with GE Environmental services OR               Surya           31-Oct-2010   New elements of LP9
4.1   also, through other OEMs like Donaldson & AAF. Implement in one of CTG units for testing purpose in coordination with OEM of Pulse                                               PG procured, Yet to
      filters                                                                                                                                                                          install

                                                                                                                                                     Siva sankar /       15-Jul-2010
5.1   Seal or Cap all unnecessary openings at the gratings to avoid moist air ingression, in consultation with GE / SLWP, for all CTG units.                                           Done
                                                                                                                                                        Swami

5.2   Install dust collection bins at the outlet of Auger (at finished floor level).                                                                     Surya           15-Jul-2010   Completed

      Review the SOP/SMP for online replacement of Coalescers, with revised risk analysis. Encourage off line replacement by scheduling             Nagaraju / Khalil    30-Jun-2010
6.1                                                                                                                                                                                    Done
      the job every time with sufficient advance notification, depending on dust logging of Coalescers / increase in DP.

      Review and refine the existing method statements / SOPs, suggest and implement new improvements and better techniques for safe                 Siva sankar /       31-Jul-2010
6.2                                                                                                                                                                                    Done
      replacement Pulse filter elements.                                                                                                               Nagaraju

      Monitor daily the DP across the pulse filters for all units and measure the effectiveness of above corrective actions in improving the life   Chris longton /      30-Jun-2013
6.3   of the pulse filters, over a period of 2 years in one CTG unit under testing, then implement the most feasible solutions in rest of the           Surya
      units (for 4 x combined cycle CTG units)
                                                            Results
                                                   (Planned Vs Actual)
Measures :
Action Item        Jun-10         Jul-10         Aug-10     Sep-10    Oct-10        Nov-10            Dec-10         Jan-11     Feb-11    Mar-11
         1.1

         1.2

         1.3

         1.4

         1.5

         1.6

         2.1

         2.2

         3.1

         4.1

         5.1

         5.2

         6.1

         6.2

         6.3



Check and Adjust :
                                                                              Action Items
   Review Timing
                         Item 1                    Item 2            Item 3                  Item 4                    Item 5             Item 6

Weekly             1.1      1.3     1.5    2.1                                       4.1                       5.1     5.2          6.1   6.2      6.3

Monthly            1.2      1.4     1.6    2.2

Quarterly                                                      3.1
                            Benefits
Tangible:

•   Reduction in unit downtime ( i.e. high unit availability)
•   Increase in unit reliability ( i.e. avoiding forced outages)
•   Cost savings > US $1.5 millions /year (after break even)
•   Less impact on environment ( reduction in waste disposal)

Intangible:

•   with reduction of hectic work load
    – Improves employee morale
    – Maintenance staff can concentrate on other important activities,
      thereby reduction of other equipment breakdowns.
•   Incredible response & positive feedback from all stockholders
                      Learning
• Other Companies using same technology in the region
  could take benefit of this innovation.

• It became an Innovation standard tool for all other
  business cases in EMAL – considered as model tool.

• It sets as an example and presented to various levels
  with in the organization.

• Use SAP (Computerized Management Systems) for
  better monitoring and execution of the innovation project.
                 7. Way Forward
• Measure the progress of Innovation project deliverables,
  as per plan.

• Monitor the performance of Gas turbine Air inlet filtration
  system and ensure the target is achieved.

• A3 template is being standardized with minor
  improvements.
Q&A
Thank You
                                                                                                                                                                                                                                                                                                      EMAL A3                                                                                                                                                                SPA
                                                                                                                                                                                                                                                                                                                                                                                                                                                                             DATE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        : Surya N. Murthy
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        : 15-June-2010
                                                                                                                                                                                                                                                                                                                                                                                                                                                                             DOC. Ref                   :PWM/A3/01/MMD/01
                                                                                                                                                                                                                                                                 For enhancing the life of GT Pulse filter elements
                                                                                                                                                                      Business Metrics                                                                                               3.       Target Condition:
1. Business Case:
                                                                                                                                                                                                                                                                                     Factors           Item        Target Conditions                                                             Hypotheses
                         1.                               Strategic Task(s):
                                                                                                                                                                                                            25
                                                                                                                                                                                                                                              Target Life,




                                                                                                                                                                             Pulse filter life, in months
                                                                                                                                                                                                                                              24 months                                                  1.1       Pulse filters working at 7.5 sec cycle time, in all CTG units.                If we are able to set pulse timer at 7.5 sec, without damaging other parts, while meeting the demand of pulse air supply, we are able to
                                                                                                                                                                                                            20
                                                                                                                                                                                                                                                                                                                                                                                                 improve the effectiveness of pulsing. Ensure APU cooler capacity is sufficient to handle the desired flow rate, if not, replace with higher
                                                          Improper functioning of GT Air inlet filtration system. Premature failure of Pulse filters in less than                                                                                                                                                                                                                                capacity cooler.
                                                          6 months @ 3525 running hours, against the expected life of minimum 2 years, as per GE                                                            15                                                                         Pulse             1.2       Modify Pulse nozzle at 1 ft distance                                          If we are able to perform this design change, improves the performance of pulse system.
                                                          contractual terms.
                                                          Due to high inlet air filter DP, GT # 12 forced shutdown occurred and GT # 21 load restricted to
                                                                                                                                                                                                            10
                                                                                                                                                                                                                                            Current Life,
                                                                                                                                                                                                                                                                                      Cleaning
                                                                                                                                                                                                                                                                                      System             1.3     For
                                                                                                                                                                                                                                                                                                                   Install dew point meter at APU outlet.                                        If we maintain Pulse air dew point below 40 oF, improves the effectiveness of pulsing.
                                                          118 MW (from 220 MW, for an hour) on 10th June’ 2010, Thursday at 06:07 hrs.                                                                       5
                                                                                                                                                                                                                                            6 months
                                                                                                                                                                                                                                                                                                         1.4       Ensure availability of pulse system at all times by plugging the              If we are able maintain the pulsing at all times, improves the DP across pulse filters. Offline pulsing is proven to be much effective. Also,
                                                          Loss of generation due to CTG #12 outage is 190 MW for 9 hours = 1710 MWh and the same for                                                                                                                                                               leakages. Perform offline pulsing, whenever possible.                         introduce Air receiver (buffer storage) tank between APU and pulse solenoids, to ensure un-interrupted supply of air at desired pressure.
                                                          CTG # 21 is 102 MWh. Then, Total energy deficit of 1812 MWh (imported from Inter tie).                                                             0
                                                                                                                                                                                                                                                             1       2                                   2.1       Coalescer mats replacement interval is derived as maximum 2                   If we are able to adhere to fixed replacement interval in 2 months, we could avoid reoccurrence of forced shutdown. Also, ensure that DP
                         2.                                                                                                                                                                                                                                                                                                                                                                      across the mats is below 2.5 “ Wc. during the foggy season. Otherwise replace with new mats.
                                                                                                                                                                                                                                                 Filter Replacement interval                                       months and the same must be added to SAP PM task list.
                                                          Constraints:                                                                                                                                                                                                               Colaescer
                                                                                                                                                                                                                                                                                                         2.2       Replace the existing type of coalescer mats with other suitable               If we are able to explore other suitable alternatives superior than the existing coalescers like marine louvers / defoggers, we can improve the

                                                                                                                                                                                                                                                                                                                 For
                                                          Man Power & resources deployment within short notice.                                                                                                                                                                        mats
                                                                                                                                                                                                                                                                                                                   alternatives.                                                                 performance of mats in high humid & foggy conditions.
                                                          Scheduled Outages are not allowed on CTG units due to gas fuel & Intertie support restrictions in                                                 25
                                                                                                                                                                                                                                              Target Life,
                                                                                                                                                                                                                                                                                                         2.3       Replace or modify weather hoods for more moisture separation.                 If we are able to modify / replace the weather hoods with better design, to improve the moisture separation & to reduce the impact on mats.




                                                                                                                                                                             Pulse filter life, in months
                                                          summer peak periods.                                                                                                                                                                24 months
                                                                                                                                                                                                                                                                                                         3.1       Modify the sizing / increase the capacity of filter house at least by         If we could able to succeed in resizing the filter house ( by adding the 10% more number of elements), life of the pulse filters can obviously
                                                                                                                                                                                                            20                                                                        Design
                                                          Access constraints to reach the 12 m height filter module. No proper stair case, except cage                                                                                                                                aspects                      10%                                                                           improves. When we compared the number of elements and mass flow rates of 9E Vs 9FA (by ratio analysis), the difference is found to be 9%.
                                                          ladder.                                                                                                                                           15
                                                                                                                                                                                                                                                                                                         4.1       Replace the existing pulse filter media with other suitable                   When we are networking with other 9FA users in UAE, the suitability of the LP9 Nano pulse filter media with respect to local weather
                         3.                               Strategic Pathway:                                                                                                                                10                                                                         Filter                      alternatives.                                                                 conditions is still under testing, as if it is new and recently introduced to the UAE. GE is conducting RCFA for similar failure (within 4 months)
                                                                                                                                                                                                                                            Current Life,
                                                                                                                                                                                                                                                                                       Media                                                                                                     at Um Al Nar. If we able to try with other suitable alternative media, like LP8 (DEWA is using) and Donaldson Spider web elements, we could
                                                                                                                                                                                                                                            6 months
                                                          Discuss & involve the Supplier GE / SLWP.                                                                                                          5                                                                                                                                                                                   succeed in establishing the suitable options with improved life time.
                                                          Design reviews and implementing the action plan.                                                                                                                                                                                               5.1       Seal / cover the openings at the gratings.                                    If we are able to seal the unnecessary openings, we can avoid moist air ingression.
                                                                                                                                                                                                             0                                                                        Moisture
2.                                                       Current Condition:
                                                                                                                                                                                                                                                             1       2
                                                                                                                                                                                                                                                 Filter Replacement interval          ingress            5.2       Install dust collection bins at the outlet of Auger (at finished floor        Our efforts to resist moisture ingestion to pulse filters.
                                                                                                                                                                                                                                                                                                                   level).
                                                                                                                                                                                                                                                                                                         6.1       Always avoid online replacement of clogged coalescer mats                     Based on the lessons learned, we must always try to avoid online replacement of coalescers, as it is not only affecting the life of pulse filters
                                                         During high humid atmospheric conditions, Air filter DP is shooting up to the alarm levels ( i.e. greater than 152 mm WC) and rest of the periods within
                                                                                                                                                                                                                                                                                                                                                                                                 and also, posing difficulties to work under such harsh and high air draft conditions, in EHS point of view, unless there is an emergency.
                                                         the limits, since the coalescer mats are not functioning properly
                                                                                                                                                                                                                                                                                      Current
                                                                                                                                                                                                                                            25                                       Practices           6.2       Explore and implement the best practices in replacing the                     Review and refine the existing method statements, suggest and implement new improvements and easier techniques in replacing these
                                                              Problem, Statement                                Key Causes                                                                                                                            Target Life,
                                                                                                                                                                                                                                                                          Impacts                                  elements.                                                                     elements.
                                                                                                                                                                                                             Pulse filter life, in months




                                                                                                                                                                                                                                                      24 months
                                                                                                                                                                                                                                            20
                                                     1        Pulse cleaning is not effective as there is       Pulse interval Cycle time set to 30 sec where as OEM recommends 7.5 sec.                                                                                  25 %
                                                              no signs of dust accumulation at bottom of        Distance between pulse nozzle and the filter is too far about 3 ft,15 where as other
                                                              the Auger floor.                                  OEM maintains the same nearly at 1 ft (design issue)
                                                                                                                Quality (Dew point) of pulse air is not known (no instrument to measure).
                                                                                                                                                                                     10                                                                                             4. Action Plan
                                                                                                                                                                                          Current Life,
                                                                                                                Non-availability of pulse cleaning system for longer periods of time (not available for
                                                                                                                                                                                          6 months
                                                                                                                CTG # 22).                                                            5                                                                                                S.                                                                                                                                                                                      Responsible          Expected
                                                                                                                                                                                                                                                                                                   Actionable Item                                                                                                                                                             Person               completion            Remarks
                                                                                                                Several solenoid valves are passing in all units. There are no individual module                                                                                       No.
High Differential Pressure across Pulse filters




                                                                                                                isolation valves posing difficulties in identifying the defective solenoids.
                                                                                                                                                                                      0                                                                                                                                                                                                                                                                                         Swami / Chris        24-Jun-2010
                                                                                                                                                                                                                                                                                        1.1        Discuss with SLWP site commissioning team, set the new / appropriate pulse timing for all units.                                                                                                                       Done
                                                                                                                Flex hoses at the downstream of solenoid valves are getting dislodged at several        1      2                                                                                                                                                                                                                                                                  (SLWP)
                                                                                                                                                                                               Filter Replacement interval                                                                                                                                                                                                                                                         Surya              31-Dec-2010
                                                                                                                places, there by pulse air is leaking – not reaching to the elements.                                                                                                   1.2        Discuss with OEM / GE, implement the new design of pulse nozzles                                                                                                                                                       Reviews in progress
                                                                                                                Since, on-line pulsing is not effective, encourage off-line pulsing.                                                                                                                                                                                                                                                                                            Dave Meadley /        31-Oct-2010
                                                                                                                                                                                                                                                                                        1.3        Review with SLWP, install new dew point meters at the outlet of all APUs
                                                                                                                Auger dust collection system not yet commissioned.                                                                                                                                                                                                                                                                                                                   Chris
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                 Surya / Chris         31-Jul-2010
                                                                                                                                                                                                                                                                                                   Provide permanent arrangement for Offline pulsing in all Units. Ensure to perform the pulsing, whenever unit is offline. Identify & rectify the defective                                                              Temp. arrangements
                                                     2        Coalescer mats not effective                      Mats are heavily clogged by dust, as we could not get the opportunity (planned                                                                            20%           1.4                                                                                                                                                                                     Longton / Dave
                                                                                                                                                                                                                                                                                                   solenoids and arrest the pulse air leakages (through flex hose joints)                                                                                                                                                 made. Permanent fix i/p.
                                                                                                                outage) to replace the coalescers with in 2 to 3 months.                                                                                                                                                                                                                                                                                                           Meadley
                                                                                                                Even, the new mats are not functioning properly during high humid conditions.                                                                                                                                                                                                                                                                                     Ken (GE)/           30-Dec-2010
                                                                                                                                                                                                                                                                                        1.5        Verify the design capacity of APU cooler with GE/ OEM. If it is found to be under designed, replace it with suitable one, to meet the demand.
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     Surya
                                                     3        Design deficiency of Filter house                 Under sizing and capacity of filter house                                                                                                                 20%                                                                                                                                                                                                    G. Jan ( Eng)        31-Mar-2011         EPR raised, tender
                                                                                                                                                                                                                                                                                        1.6        Install Air receiver buffer tank between APU and pulse solenoids, with auto drains and coalescing filter at the outlet. Add dew point meter, in lieu of Point 1.3.
                                                     4                                                          Filter media may not be suitable to the EMAL site conditions.                                                                                             25%                                                                                                                                                                                                                                             floated
                                                              Concerns over the Filter media not
                                                              withstanding to high humidity & fog                                                                                                                                                                                       2.1        Add the Coalescer mats replacement interval in to SAP PM Task list, to be performed in every 2 months without fail. Or based on condition when dp > 2.5”                        Nagaraju           30-Jun-2010
                                                                                                                                                                                                                                                                                                   Explore other suitable alternatives to replace the existing coalescers like marine louvers / defoggers. Implement in one of CTG units for testing in coordination                 Surya            30-Jun-2012
                                                     5        Moisture ingression                               There are several small openings on the walk way gratings between coalescers and                                                                          5%            2.2                                                                                                                                                                                                                               With Phase # 2
                                                                                                                                                                                                                                                                                                   with GE Environmental services
                                                                                                                pulse filters. Leakage through Auger dust collection ducting and hose.
                                                                                                                                                                                                                                                                                                   Discuss, review and implement the design change for resizing / increasing the capacity of filter house in coordination with GE Environmental services and                    Idrees / Ashraf       31-Dec-2010
                                                                                                                                                                                                                                                                                        3.1
                                                     6        Current Practices: Online replacement of          It was inevitable & forced to remove the mats online, to reduce the coalescer DP,                                                                         5%                       EMAL Engineering.
                                                              clogged coalescer mats                            but which in turn clogged the pulse filters further.                                                                                                                               Explore other suitable alternatives for Nano filter media, like LP8 (DEWA is using) in conjunction with GE Environmental services OR also, through other                          Surya            31-Oct-2010         New elements of LP9 PG
                                                                                                                                                                                                                                                                                        4.1
                                                                                                                                                                                                                                                                                                   OEMs like Donaldson & AAF. Implement in one of CTG units for testing purpose in coordination with OEM of Pulse filters                                                                                                 procured, Yet to install
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                 Siva sankar /         15-Jul-2010
                                                                                                                                                                                                                                                                                        5.1        Seal or Cap all unnecessary openings at the gratings to avoid moist air ingression, in consultation with GE / SLWP, for all CTG units.                                                                                 Done
2.1 Parato Approach:                                                                                                                                                                                                                                                                                                                                                                                                                                                                Swami
                                                                                                                                                                                                                                                                                        5.2        Install dust collection bins at the outlet of Auger (at finished floor level).                                                                                                   Surya              15-Jul-2010        Completed
                                                            Major factors - Effecting the Life of Pulse filters                                                                                                                                                                                    Review the SOP/SMP for online replacement of Coalescers, with revised risk analysis. Encourage off line replacement by scheduling the job every time with                     Nagaraju /           30-Jun-2010
                                                                                                                                                                                                                                                                                        6.1                                                                                                                                                                                                                               Done
                                                                                                                                                                                                                                                                                                   sufficient advance notification, depending on dust logging of Coalescers / increase in DP.                                                                                       Khalil
                                                                   Current Practices                     5%                                                                                                                                                                                        Review and refine the existing method statements / SOPs, suggest and implement new improvements and better techniques for safe replacement Pulse filter                      Siva sankar /          31-Jul-2010
                                                                                                                                                                                                                                                                                        6.2                                                                                                                                                                                                                               Done
                                                                                                                                                                                                                                                                                                   elements.                                                                                                                                                                      Nagaraju
                                                                Moisture ingression                      5%                                                                                                                                                                                        Monitor daily the DP across the pulse filters for all units and measure the effectiveness of above corrective actions in improving the life of the pulse filters,            Chris longton /       30-Jun-2013
                                                                                                                                                                                                                                                                                        6.3
                                                  Suitabiliy of Nano Filter media                                                                   25%                                                                                                                                            over a period of 2 years in one CTG unit under testing, then implement the most feasible solutions in rest of the units (for 4 x combined cycle CTG units)                       Surya
                                                     Filter house- Under design                                                          20%

                                                   Coalescer mats not effective                                                          20%
                                                                                                                                                                                                                                                                                    5. Measures
                                                    Pulse cleaning not effective                                                                    25%
                                                                                                                                                                                                                                                                                     Action Item        Jun-10    Jul-10     Aug-10       Sep-10     Oct-10      Nov-10      Dec-10     Jan-11         Feb-11   Mar-11
                                                                                           0%         5%        10%       15%         20%       25%       30%                                                                                                                             1.1
                                                                                                                    % of Impact                                                                                                                                                           1.2
                                                                                                                                                                                                                                                                                          1.3
                                                                                                                                                                                                                                                                                          1.4
                                                                                                                                                                                                                                                                                          1.5

2.2 Additional maintenance Costs: (due to reduced filter life)                                                                                                                                                                                                                            1.6
                                                                                                                                                                                                                                                                                          2.1
                                                                                                                                                                                                                                                                                          2.2
                                                                                                            Replacement interval                                                                                                                                                          3.1
              S.                                                                                                                                                                                                                                                                          4.1
                                                                    Item cost details                                 24                 Variance        Remarks
              No.                                                                                       6 months                                                                                                                                                                          5.1
                                                                                                                      months
                                                                                                                                                                                                                                                                                          5.2
                                        1                                                                                                                                                                                                                                                 6.1
                                                      Pulse filter elements cost                            $748,800      $187,200        $561,600
                                        2                                                                    $18,600        $4,650         $13,950                                                                                                                                        6.2
                                                      External Services cost, including                                                                                                                                                                                                   6.3
                                                      Scaffolding, Mobilsation & Waste disposal
                                        3
                                                      Internal Labour OT cost @ 10 people in 2
                                                                                                             $73,280        $18,320         $54,960
                                                                                                                                                                                                                                                                                    6. Check and adjust
                                                      days, 8 hrs/day @ $114.5 / hour
                                        4                                                                   $168,000        $42,000       $126,000
                                                      External Labour cost @50 people in                                                                                                                                                                                                                                                                                              Action Items
                                                                                                                                                                                                                                                                                      Review Timing                                                                                                                                                                                                                In progress
                                                      2 days x 24 hrs @$15 / hour                                                                                                                                                                                                                                      Item 1                      Item 2                   Item 3                        Item 4                   Item 5                     Item 6
                                        5             EHS consumables cost                                   $21,600         $5,400         $16,200                                                                                                                                  Weekly                      1.1     1.3     1.5      2.1                                                    4.1                        5.1      5.2              6.1       6.2    6.3
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   Completed
                                        6             Misc. Expenses                                          $3,600           $900          $2,700                                                                                                                                  Monthly                     1.2     1.4     1.6      2.2
              Additional Cost impact per unit in 2 years                                                $1,030,280        $257,570        $772,710                                                                                                                                   Quarterly                                                                       3.1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   Delayed
Additional Maintenance Costs for 4 x CTG units in 2 years                                                                                   $3,090,840

				
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