kym_mmsd present 13.09.13

8/13/2019 Kym_mmsd Present 13.09.13

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KAYAMKULAM


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MOU vs. ACTUAL

Parameters UNITS 2013-14 Actual up

to Aug 2013

Achieved

(2012-13)

Generation MU 1200 325.95 1548.63

PLF % 38.1 24.65 49.17

DC % 91 89.97 90.97

CC Heatrate Kcal/Kwh 1985 1943 1960

APC % 2.8 3.08 2.6

PO % 4.34 2.75 0.67

FO % 0.5 0.0 0.952


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O&M REVIEW MEETING ON EVERY WEDNESDAY AS PER

THE MEETING CALENDAR

BUDGET FOLLOW-UP BASED ON ABB IN SAP

REAP ANALYSIS AREA WISE

PLANT MODIFICATION REGISTER STATUS ONLINE

ONLINE MONITORING OF STATUTORY DOCUMENTS

NMI ACTION PLAN BEFORE GETTING TAGGED AS NMI

EQUIPMENT CONDITION MONITORING

SEPARATE WEBSITE FOR MTP & SD ON INTRANET

BEST PRACTICES OF MTP


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PM MODULE


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NO AREA / ISSUE STATUS

1PTW ISSUANCE THROUGH SAP SYSTEM FOR ALL

STATION EQUIPMENTSIN PRACTICE

2 ISSUANCE OF ISOLATION & NORMALISATION SLIPS IN PRACTICE

3 ISSUING KEY SAFE NUMBERS TO PERMITS IN PRACTICE

4CLOSING OF PERMITS IN HARD COPY AS WELL AS IN

SAPIN PRACTICE

PTW / SAFETY SYSTEM


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PTW / SAFETY SYSTEM ISSUES

Direct closing provision from PTW register to be given to

maintenance.

Permit validity appears as 01 year by default. Default option may

be changed to 01 day

Currently, there is no validity period mentioned for permits with

Hot-work, Height workand work inConfined spaces.

Validity of such long duration permits shall be mentioned. Being

issued on daily basis these add to procedural delays. In addition,

not able to generate a distinct permit number in SAP each time it is

re-issued. Orphans are created by Cutting-off these permits from

the main permit


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In Kayamkulam, confined space permit is being issued in-line with

Kerala Factories and Boilers check list which is mandatory and

auditable during their statutory inspections. Accordingly, Head of

Chemistry is the designated authorized person to inspect the area

before start of work and issue the signed checklist.

Process is outside SAP and no records available in SAP for

scrutiny. Alternatively, there is another checklist in SAP which is

supposed to be signed by CFT personnel which if followed creates

duplicity. In order to overcome this, incorporation of Kerala State's

checklist in SAP with a provision to operate either of the checklists

and giving authorization to Head of Chemistry ( E.No.004780)

PTW / SAFETY SYSTEM ISSUES contd


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Points should be complied before start of Work

in a Confined SpaceSl. No.

POINT TO BE CHECKED STATUS

1 Availability of Permit for Work Yes No

2 Availability of competent person for supervising the work Available Not available

3 Check for explosive atmosphere and the area should be free from explosive mixture Yes No

4 Proper means of exit provided (existing Man doors / escape doors are in open

condition) Provided Not provided

5 Availability of fire water system & portable extinguisher Available Not available

6 Proper ventilation with forced air circulation Provided Not provided

7 Check for O2contentsufficient for working- by Safety & Chemistry:

To be checked once in 05 days for work duration>05 days)

[Acceptable Range : 20.0 % to 24.0%]

Checked /

% of O2= Not checked

8 Standby personnel provided for vessel entry Available Not available

9 Hot Work Permit is ensured (Standby personnel provided for fire watch from

executing dept / contractor / CISF).

Available Not available

10 Oxygen and Acetylene cylinders kept out side the vessel / tank Yes No

11 24 V supply for hand lamps Provided Not provided

12 Ensure the availability of a lifeline tied to the hip of working personnel keeping the

other end outside the confined area. Also, ensure the availability of standby

personnel just outside the confined space holding the lifeline.

Checked &

Ensured

Not ensured

13 Personal Protective Equipment required are available Yes No

14 Safety Helmets / Shoes / Gloves / Goggles / welding suit / Face shield / Fresh AirMask / Apron / life line / Safety Belt Available Not available


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OUTAGE DETAILS

UNIT TYPE OF OUTAGE PLANNED ACTUAL

GT-1 CI-9 16-Apr-2013

to 23-Apr-2013

(08 days)

30-June-2013 to

05-July-2013

(*06 days)

HRSG-1 HRSG#1 License

renewal

Filter Clean/Change/

Compressor Water

Wash

19-July-2013

to 22-July-2013

Completed with GT-1 CI

STG Governing system

OH

19-July-2013

to 30-July-2013

(12 days)

17-Aug-2013 to

26-Aug-2013

(*10 Days)

*2 days gain was there in CI and STG governing system as no cooling time required

due to non running

ACTUAL OUTAGE FOR 2013-14 (TILL NOW)


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GT1 START DATE DAYS REMARKS

CI-10 / Gas Skid commissioning 01-Sept-2014 14

CI is for 8 days only. Skid

commissioning for 14 days in

parallel.

Filter Clean/Change/ Compressor Water

Wash10-Apr-2014

2


Wash 07-Jan-2015 2Total 18

GT2 START DATE DAYS REMARKS

CI-10 / HRSG Inspection for license renewal 01-Apr-2014 8

Gas skid commissioning / Filter

Clean/Change/ Compressor Water Wash16-Sept-2014 14

Skid commissioning for 14 days.

Though license renewal is due on

03-11-2014, this will be advanced

to club with CI to utilize the

opportunity


Wash08-Dec-2014 2

Total 24

PLANNED OUTAGE FOR 2014-15

OUTAGE DETAILS


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O/H MODULE


1 IMPLEMENTATION OF OVERHAUL MODULE IMPLEMENTED IN FEB 2011

2 OVERHAUL ACTIVITIES UPTO MICRO LEVEL IN PRACTICE

3UPLOADING OF ENGG DECL IN SAP THROUGH THE

DMS SYSTEMIN PRACTICE

4O/H DAILY EXCEPTION REPORT THROUGH SAP O/H

MODULE

IN PRACTICE SINCE GT-2 CI

(Nov 2012)

5DISCONTINUATION OF O/H DAILY EXCEPTION REPORT

THROUGH FAX

IN PRACTICE SINCE GT-2 CI

(Nov 2012)


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OVERHAULING PREPAREDNESS INDEX


1IMPLEMENTING ERP BASED OPI MONITORING

SYSTEM

IMPLEMENTED (SINCE

OVERHAUL 2010-11)

2 OPI REVIEW MEETINGS AS PER GUIDELINES IN PRACTICE

3 OPI SCORES FOR OVERHAULS 15-16 AVAILABLE IN SAP


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OPI 2015-16


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OPI ISSUESGT-1 MI (2015-16) :

PR details for Critical materials are not appearing(100084938,100087956) at identification, indents & enquiry links.

Order link is leading to wrong PO.

Service PRs are linked correctly from Identification,

Indents , Enquiry & Offer links, but Order is linked to wrong PO.

HGPI (2015-16)

PRs for Critical materials at received link is showing double entry

Service PRs not linked at Offer

Screen shots attached for OPI data matrix entry and ZOPISCORE

for GT-2 HGPI 2015-16 .


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OPI ISSUES Contd

For Gas Stations, Rolling Plan must be shortened to 05 Year in

view of high uncertainty and same to be implemented in SAP

For GT-1 CI carried out in May 2013, flash report was not

getting generated in OH module

PR release problem for Capital Spares for next overhaul due

to NMI tags.

Provision for adding checklist in OPI in order to ensure the

Material/service indents in time.

SRM / e procurement casesstatus non-availability in SAP


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ACTIVITY BASED BUDGETING

C S G


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ACTIVITY BASED BUDGETNO AREA / ISSUE STATUS

1

REVIEW AND UPDATE ALL THE TASK LISTS BY REPLACING OLD

MATERIAL & SERVICE CODES WITH NEW ONES IMPLEMENTED FOR ABB 2013-14

2 ABB FOR O&M AREAS WERE COMPLETED.IMPLEMENTED

(ABB 2011-12 ONWARDS)

3CAPITAL SPARES CONSUMPTION/ PROCUREMENT PROJECTION

THROUGH ABB DONE FOR 2012-13 , 2013-14 & 2014-15

IMPLEMENTED (2012-13

ONWARDS)

4COST BOOKING FOR SPARES THROUGH MAINTENANCE

ORDERS.IN PRACTICE

5COST BOOKING FOR CONTRACTS THROUGH MAINTENANCE

ORDERS.IN PRACTICE


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ISSUES - ABB

For effective contracts/spares procurement and follow up, ABB

should be included for MBOA also.

Automatic PR generation yet to start.

Actual cost booking against the budgeted cost for reliability,

Building, Township and other assets is not being done due to cost

element issues, though budget was projected in 2013-14 ABB.

BD planned cost should be accounted on pro-rota basis spread

over 12 months period. At present all cost appears on 1st April.This will help in streamlining the ratios.

Service & Materials booking through maintenance orders for

non-O&M sections (for example: O&M stores etc)


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NMI

Full NMI tagging is not happening (ZMMCONS)

Provision for online tagging in SAP for NMI(ex:

Emergency spares)


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MATERIAL CODIFICATION


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CODIFICATIONN

O AREA / ISSUE STATUS

1 SERVICE CODIFICATION IN PRACTICE

2 MATERIAL CODIFICATION IN PRACTICE

Service codes for motor rewinding not issued. PR raised

without service code. Why service code at all ??

For act asgn K post Po, not able to create SES with

service code(msg no.9000267977)

Provision may be given to view other proj PO below E-5


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ERP ISSUES


1 ERP Directory (category wise) TO BE PROVIDED

2

ACTUAL CASH FLOW FOR CAPITAL SPARES

AT A GLANCE AS PER the FORMAT OFBUDGET GROUP

TO BE PROVIDED

3 RISK PLOT PROCEDURESTO BE PROVIDED

4T-CODE ZSM067 FOR SRM BID VIEWING

FOR BETTER MONITORING

AUTHORIZATION TO

BE PROVIDED

FOR MTP


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THANK YOU

kym_mmsd present 13.09.13

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