1) The document describes a delay in loading gas turbines during startup at a power plant due to insufficient fuel gas temperature. 2) The improvement sets the fuel gas temperature setpoint to 165 degrees earlier in the startup sequence, eliminating a 10 minute delay in reaching base load. 3) Benefits of the improvement include environmental gains from reduced emissions, fuel savings from quicker startups, and increased power availability during blackouts.

1. Quality Month: November 2011 Kaizen No. Page No.:
KAIZEN REPORT
Company logo Company Name: Department: Section/Process:
EMIRATES ALUMINIUM POWER OPERATIONS POWER PLANT GAS TURBINES
Improvement Title: DELAY IN LOADING OF GAS TURBINE DURING LOADING SEQUENCE
Category: [ ] Quality improvement [ ] Health & Safety [ ] Environment [ ] Productivity [ ] Office processes [ ] Product design improvement [ ] Service improvement
Before Situation Root Cause Analysis Improvement After Situation
Measures
WHO : 1. Loading delay is
Power operations facing a delay in loading gas turbine during loading
completely avoided.
sequence
WHAT: 2. Time taken to reach base
Loading of gas turbine is restricted at 45MW due to requirement of load is reduced by 10mins.
Fuel Gas temperature of 165degc.
WHEN:
During loading sequence of Gas turbine, Oil bath heater 3- way
temperature control valve set point is not set for 165degc as per the
requirement.
WHERE:
Power Plant – Gas turbines
WHY:
Fuel gas temperature of 165degc is required only at 45MW. So 3-
Axis – X - represent – Time way temperature control valve set-point changes from 45degc to
Axis – X - represent – Time
Axis – Y - represent – Load 165degc only at 45MW. At this stage temperature increment of Axis – Y - represent – Load
45degc to 165degc takes 10mins.
Gas Turbine loading is delayed by 10mins at 45MW HOW: Gas Turbine loading delay of 10mins is completely eliminated
To overcome from this problem & to avoid this 10mins time delay,
Loading of Gas turbine to Base load after synchronising takes suggestion raised to enable the 3-way temperature control valve set-
Loading of Gas turbine to Base load after synchronising takes
21mins point to 165degc right from the start-up sequence. 12mins
Benefits: Participation
1. Environmental: At 45MW exhaust emission NOx gas is more than 25PPM which is not acceptable for the environment. Now it is totally 1. Sugumar Srinivasan – Shift Charge Engineer
eliminated. 2. Seshamani – Shift Supervisor
2. 10mins delay in loading gas turbine from 45MW which is eliminated. Approximately4 startup per month. Each start up a saving of $175 3. Suresh babu – Control Room Operator
is achieved. ($175*4*12 = $8400/year) 4. Natarajan – Power operator
3. During Blackout: Startup of each gas turbine is delayed by 10mins which is eliminated. One blackout per year. Fuel saving at 45MW is
$175/machine. ( $175*6 = $1050/year)
4. During Blackout: Power Import of 250MW is reduced by 30mins. (125MWHR = $ 8500/year )
5. Tripping of CTG: expected 2 per month, Import of 200MW for approx 40mins which is reduced to 30mins = $ 53856 /Year
6. During Blackout: Aluminum production achieved 30mins earlier than before
Standardization: Horizontal Deployment Opportunities (Replication):
Standard Operating Procedure made for starting Gas turbine on Enhanced Fuel Start-up mode. This Suggestion is implemented for all 6 Gas Turbines.
Single Point Lesson: Remark / Management Comments:
Sign
Copy Distribution: Date of Date of Completion: Control No. (by DQG)
Starting:
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices. We confirm that the improvement has been initiated and completed during the Kaizen Blitz week.
Signed by Authorised signatory: _______________________Name:________________________________Designation:_____________________________________ Date: ____/____/________