OUTAGE MANAGEMENT

OUTAGE APPROACH/PHILOSOPHY A) Time based / machine operating hours based concept related to OEM recommendations - More expensive than condition based approach - Frequent disassembly / assembly, at times, detrimental to the equipment - Loss of generation, cost of overhauling - Risk of damage through human performance error B)Condition based overhaul concept - More logical being mix of OEM recommendation and technical evaluation of operating data - Longer hours of operation / extra generation benefit, better up-keep of machine due to regular online data assessment / evaluation - Need addressing of Insurance/Regulatory issues, if any.

OUTAGE GOALS & OBJECTIVES Will be performed in strict adherence to schedule and in the shortest time as possible without compensating quality of work, personal safety and integrity of equipment and environment. Ensuring proper documentation on daily basis of work completed with necessary disassembly/assembly records, record of deviations, if any, from the planned work, budget expended and deviations from EHS related issues, if any. Final report enumerating the details of work performed, milestones targeted/achieved, total expenditure, lessons learnt including corrective steps for the next outage. Post outage, equipment performance data analysis

OUTAGE SCOPE Scope of Work - Preparation of Detailed scope of work covering OEM recommendations, past inspection recommendations and inputs from Plant Operation section and various other disciplines. - Identification of key activities concerning plant performance Outage Duration - Outage time frame in line with available resources. - Mile stone dates for completion of key activities ( hold/control point to avoid outage over-run with additional augmentation of resources). - Contingency plan to cover over-run. Outage Budget - Budget estimation for the planned activities. - Contingency plan viz. a viz. Financial impact of each day over-run of the outage.

PRE - 0UTAGE READINESS REVIEW CONTROL MECHANISM Detailed work scope prepared and vetted by all concerned sections. Bar chart integrating all vital activities with critical parts identification. Manpower requirement addition to internal resources identified and addressed. Material status. Status of impending contracts. Safety Plan, including confined work space requirements, working at heights and in restricted plant areas. On site support needs – scaffolding, insulation, temporary power, tooling, equipment, labour force break area accommodations etc. Status of pre-outage work. Contingency plans, inspection plans and resources. Lessons learnt from the previous outages and incorporation in the current outage plan.

PRE-OUTAGE PREPARATORY WORK  Review of available spares/spares on order viz.a viz. requirement as per scheduled activities.  Review of available specialized consumables and items on order, especially “Shelf-Life” related items.  Review of specialized equipment specific T&P.  Confirmation of mandatory testing requirement compliance on tools, tackles and lifting devices.  Calibration compliance confirmation on measuring instruments.  Review of on-site support needs – scaffolding, insulation, temporary power, tooling, special equipment, labor force safety and welfare requirements.  Safety plan  Review of pre-outage operating parameters.

PRE-OUTAGE PREPARATORY W0RK.... Cont’d  Review of specific maintenance related issues need to be addressed during unit shutdown.  Review of online machine performance data – vibration, oil temperatures, expansion (absolute / differential)  Review of changed operating parameters needing specific attention

OUTAGE CONTROL – IMPLEMENTATION PHASE Daily progress review. Identification of bottle necks likely to hinder scheduled completion Necessary assistance to the execution team to address concerns – OEM/Consultant related and other issues Ensure strict compliance of EHS related issues – no compromise on working personnel safety Review of inspection/fact finding reports Liaison with OEM in case of serious findings in the inspection report Weekly review of actual outage expenses vs budgeted expenses Commissioning team progress review to ensure timely start up of the unit

POST OUTAGE - MONITORING Compilation of meaningful outage report Performance Analysis Actual vs budgeted outage expenses Identification of Key Players with necessary recognition/rewards Lessons learnt Key issues to be considered/addressed during next outage

KEY ISSUES  Effective / Realistic activities planning schedule  Pre–outage planning schedule  Outage readiness review process  Effective pre-outage activities completion  Critical path tracking process  Realistic amendment of planned scope of work following disassembly inspection and fact finding report.  Milestones progress review process – resources augmentation to achieve targeted schedule  EHS compliance  Post overhaul performance improvement  Budgeted vs actual expenses  Lessons learnt.