KAIZEN REPORT

Quality Month: November 2011 Kaizen No. Page No.:

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Company Name: Emirates Aluminium, Abu Dhabi

Department: Power Operations

Section/Process: Combined Cycle Power Plant

Improvement Title: To conserve DM water

Category: [ ] Quality improvement [ ] Health & Safety [ ] Environment [ * ] Productivity [ ] Office processes [ ] Product design improvement [ ] Service improvement

Before Situation Root Cause Analysis Improvement Measures After Situation • STG20 condenser hot well(HW) make-up rate has

been more since commissioning and HRSG21 & 22 HP FW flow 8 T/h is more in each boiler.

• Due to above, hot well level make-up CV opens 100% constantly, emergency m/up CV opens frequently and HW level maintaining between

-350 and -300 mm with level set point of 0 mm.

HW m/up 16T/h more

H21&22 FW 16T/h more

1. Excessive H21 CBD. 2. Excessive H22 CBD. 3. Condensate passing to

cooling tower-20 sump. 4. FW passing from H21

HP/LP Eco. & Evp. Drains. 5. FW passing from H22

HP/LP Eco. & Evp. Drains. 6. H21 boiler tube leak. 7. H22 boiler tube leak.

1. Throttled H21 CBD (2900C) metering valve from 100 to 25%, by doing this 8 T/h HP FW flow decreased.

2. Throttled H22 CBD (2900C) metering valve from 100 to 25%, by doing this 8 T/h HP FW flow decreased.

3. ST20 HW level increased and became normal level of 0 mm, m/up flow rate decreased by 16 T/h and m/up CV is closed to 50%.

4. Boiler blow down tank spray water flow decreased by 5T/h in each boiler.

1. DM water conserved = 384 T/day = 277.6 $/day 2. Ser. water conserved= 240 T/day = 180 $/day 3. Phosphate conserved= 2.3 kg/day = 2.08 $/day 4. Ammonia conserved = 4.6 kg/day = 3.02 $/day 5. O2 scavenger conserved= 1 kg/day = 4.1 $/day 6. Aux. power conserved=2520 kWh/day= 55.44 $/day 7. Natural gas conserved equivalent to

heat gain in H21 & 22 = 10656 m3/day = 596 $/day. 8. ST20 HW level became to normal level of 0 mm,

m/up CV opening is 50%. ST20 HW level Trend:

Benefits: Participation:

Total cost savings = 1118.24 $/day

Standardization: Horizontal Deployment Opportunities (Replication):

Single Point Lesson:

Remark / Management Comments: Sign

Copy Distribution:

Date of Starting: 15-Sep-2011

Date of Completion: 24-Sep-2011

Control No. (by DQG)

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: ____/____/________