OH matrix

Sl.no. Description Weightag Marks e Obtained(B) (A) Criteria

1 Outage from last overhaul

5.00

5.00 No outage-5,01 outage -4,02 outage-3, 03 outage -2,4outage then 01 other wise 0. 5.00 100% before three months then 5, 98% then-4, 95%then 3, 90% then 2, below 90 % then 1 5.00 R-0, R-1 & R-2 availale then 5, if R-1&R-2 are avaialable then 4,if only R-2 is available then-3. if not then 0 , these include availability of SoW as mentionEngineering declaration in sheet-3 2.00 If covered in Engineering declaration then 02 otherwise 0. 2.00 If list is available in Engineering declaration then 2 otherwise 0.

2 OPI score (3 month before schedule start of OH)

5.00

Pre OH

3 Engineering declaration (competeness & its quality)

5.00

4 Liabilities 5 Availability of Special T&P & its use

2.00 1.00

OH matrix
6 Adherence to OH scheduled 4.00 4.00 As per finali scheledue then 04,deviation from original scheledue by one week then 032, by 10 days then 02, up to 15 days then 01 otherwise 0. 7 Actual OH duration vis a vis planned duration 6.00 5.00 Within 24 hours full marks,up to 72 hours 60 %, up to 5 days 20 %, beyond 05 days, no marks. 2.00 All available 100 %, up to 50% available prorata, less than 50 % no marks 5.00 MitigatEngineering declaration within OH duration then full marks, other wise 0 (certified by OS) 5.00 Mitigation within OH duration then full marks other wise 0 (certified by OS) 4.00 Compliance then full marks other wise 0. 5.00 Zero accident then 5, 0ne fatal :-(-5),More than 0ne fatal:-(-10) 5.00 05 reporting during OH:Full Marks, 03 Reporting :50 %,No Reporting then : ZERO 5.00 If 100 % then full other wise 0. 2.00 Up to 02 % full marks, 02 to 05% then 1 other wise 0. 10.00 As per guide lines then 100 % other wise 0.condition mentioned in Sheet -3

8 Maintenance Protocols

5.00

9 Mitigation of Surprises during OH

2.00

During OH

10 Mitigation of liabilities

2.00

11 Compliances of all recommendation 12 Safety during OH (no accident)

2.00 3.00

13 Reporting of Near Miss accident through SAP

2.00

14 % of radiography of welded new joints 15 Joints failed during first RT 16 Recommissioning activities

2.00 2.00 2.00

18

OH cost based on ABB data

OH matrix
3.00 4.00

5.00 Highest OH cost of units among the similar type of units then 0 other wise on prorata basis.Comparision between last three years (1,2 &3) and again (2,3,4) based on ABB Budget. 7.00 500 MW UNITS If improvement is =>18% of pre OH draft power--- full marks, If <= 5 %, NIL marks. In between improvement - Marks on proportionate basis 200 MW UNITS If improvement is =>10% of pre OH draft power--- full marks, If <= 5 %, NIL marks. In between improvement - Marks on proportionate basis 6.00 If 50% of the gains achived during OH is sustainesd than full marks, If gain sustained is less than 20% than NIL marks, Between 60-20%, marks on proportionate basis 5.00 Within 01 month-0, 02 months then 01, 03 months then 03, 06 months then 4.abobe six months then full marks. 6.00 Reduction of Average Break down work Orders (Compare 6 months before OH and 6 months after OH);70 % reduction then full marks,50 % reduction then 50 % marks, Less than 50 % then zero. 5.00 Non-repeatability of same problem (Compare 6 months before OH and 6 months after OH) If same problem is persisting then zero other wise full marks 5.00 Post OH new Break Down work orders related to work done in the OH. If maintenance induced defect arises then zero marks otherwise full. 5.00 Reduction / Non- repetition of PdM Exceptions based on Pre and Post OH PdM Survey.If PdM exception is repeated then zero otherwise full marks. 6.00 For each OH of a unit depending on its nature, recoverable heat rate deviation is to be worked out. Post OH, respective HR improvement achieved would be compared wrt the recoverable HR deviation. We propose the following marks: 90% and more: 5 marks (full marks) ,80-90%: 4 marks ,70-80%: 3 marks ,60-70: 2 marks,50-60%: 1 marks,Less than 50%: 0 marks 5.00 HR deterioration less than 15 kcal/kWh: 5 marks; 15-20 kcal/kwh: 4 marks; 20-25 kcal/kwh: 3 marks; 25-30 kcal/kwh: 2 marks; 30-35 kcal/kwh: 1 marks, more than 35 kcal/kwh: 0 marks 6.00 Within 03 Months of OH then Full marks, 04 Months then 04 marks, 06 Months then 02 marks otherwise ZERO

19

Improvement in Draft Power after OH (%)

20

Sustainabilty of improvement in Draft Power (in six months) (%) Unit Outage after OH a.Equipment outage after OH (CM Notification)

3.00

21

5.00

Post OH

22

5.00

b.Problem repeatation

5.00

c.Maintenance induced defect. d.PdM exceptions

5.00

5.00

23

Heat Rate reduction. Improvement by OH

5.00

24

Heat Rate sustenance after six month of OH Unit OH report

5.00

25

5.00