QC CASE STUDY: PREVENT OR REDUCE CHOCKING OF RC FEEDER#G AND MILL#G CENTRE PIPE
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IN RAINY SEASON RC FEEDERS GET CHOKED DUE TO HIGHLY VISCOUS COAL, CHOKING IS MORE IN FEEDER#G.
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QC CASE STUDY: PREVENT OR REDUCE CHOCKING OF RC FEEDER#G AND MILL#G CENTRE PIPE
- 2. PROJECT PROFILE Project Name NTPC Tanda Location Ambedkar Nagar Establishment Year 1979 Taken Over By NTPC 2001 Installed Capacity 110x4 MW Under Commissioning 660x2 MW PLF >90% Main Raw Materials Coal, Water, Air SARYU SYNERGY Better Together
- 3. ABOUT TEAM • NAME : SARYU SYNERGY • DEPARTMENT : OPERATION & BMD • FORMATION : MAY 2018 • DAY OF MEETING : WEDNESDAY • TIME : 5:30-6:30 PM • PERIOD : IN 15 DAYS • NO. OF MEETINGS : 20 • % OF ATTENDANCE : 92% • SOLVED PROBLEM : 09 ( TILL DATE) SARYU SYNERGY Better Together
- 4. ABOUT TEAM MEMBERS COORDINATOR : SRAWAN KUMAR(OPN) FACILITATOR : RAVI PAL SINGH(OPN) TEAM LEADER : PANKAJ YADAV(BMD) TEAM DY LEADER : ANIL KUMAR(BMD) Team Members :DINESH KR YADAV(OPN) RAMESH THAKUR(OPN) SARYU SYNERGY Better Together SARYU SYNERGY Better Together
- 6. STEP-1: IDENTIFICATION OF PROBLEMS S NO. NAME OF PROBLEM CATEGORY 1. Atomizing Valve Oil Gun Gland Leakage A 2. Oil Gun Flange leakage A 3. Frequently damage of soot blower line flange gasket A 4. Soot blower line pressure gauge line leakage B 5. M.S. stop valve gland Leakage A 6. Safety Valve passing B 7. Oil gun choking problem A 8 Soot blower mechanical jamming. B SARYU SYNERGY Better Together
- 7. S NO. NAME OF PROBLEM CATEGORY 9. Phosphate dosing pump gudgeon pin circlip occasionally damage. A 10. Economizer lower most bend erosion problem. C 11. H2 leakage from gen-1 casing C 12. Turbine bearing vibration in unit#2 6h and 7h C 13. In unit #1 ID Fan A current hunting approximate 20A. B 14. Frequency of vertical shaft shearing of mill 1A C 15. Mill 4G continuous poor fineness B 16. Erosion of roller journal housing. A STEP-1: IDENTIFICATION OF PROBLEMS SARYU SYNERGY Better Together
- 8. S NO. NAME OF PROBLEM CATEGORY 17. Mill 2A less air flow. A 18. Hinge gate lever spring detachment. A 19. MRHS gate limit switch rod frequently broken. A 20. Mill 1A high vibration below 17A load. B 21. Feeder gear box lube oil leakage from oil seal. A 22. Lube oil leakage from shaft seal(DE) side in mill 2G C 23. View glass of return oil in mill 2 B not visible. A 24. CRH line LHS drain leakage in unit 1 near the condenser pass A. A STEP-1: IDENTIFICATION OF PROBLEMS SARYU SYNERGY Better Together
- 9. S NO. NAME OF PROBLEM CATEGORY 25. Steam leakage from Ext 7M valve flange in Unit#2. A 26. Frequent PF coal pipe leakages in all units. A 27. Steam leakage from steam ejector near the evacuation line . A 28. MRHS line mill G frequently chocking. B 29. U#2 MOT cooler I/L valve A-1 inoperative. B 30. RC feeder#2A I/L gate jamming and drum locking. A 31 U#1 TG Governing filter chocked but there was no alarm persisted in Skoda system. C 32. U#1 PA Fan #B jerky operation. C STEP-1: IDENTIFICATION OF PROBLEMS SARYU SYNERGY Better Together
- 10. S NO. NAME OF PROBLEM CATEGORY 33. APH #2B duct punctured ,flue gas is on dangerous mode. A 34. U#1 barring gear motor cooling fan not available. C 35. U#1 Opacity#A getting out frequently. B 36. U#2 Oil splashing from Tg Bearing 7 lube oil return line . B 37. Station T/F incomer circuit breaker(6.6 KV) not closing in remote. C 38. BFP#2B discharge NRV passing. B 39. Mill G Seal air Line leakage A 40 Feeder & Centre pipe choking frequency of Mill G is more A 41 APH gearbox Failure C STEP-1: IDENTIFICATION OF PROBLEMS SARYU SYNERGY Better Together
- 12. STEP-2: SELECTION OF PROBLEMS Problem Categorization 0 5 10 15 20 25 A B C TOTAL NO OF PROBLEMS UNSOLVED PROBLEMS SOLVED PROVLEMS A B C TOTAL NO OF PROBLEMS 20 11 10 UNSOLVED PROBLEMS 14 10 8 SOLVED PROVLEMS 6 1 2 SARYU SYNERGY Better Together
- 13. STEP-2: SELECTION OF PROBLEMS Out of 41 identified problems 09 problems have been already solved & implemented. From the remaining 32 problems we have selected 4 problems(one by each member). S.No. Symbol Problem Selected By 2 P1 Oil Gun Flange leakage Anil Kumar 17 P2 Mill 2A less air flow. Dinesh Kumar Yadav 40 P3 Frequent choking of Mill G Feeder & Centre pipe Pankaj Yadav 33 P4 APH #2B duct punctured, flue gas is on dangerous mode. Ramesh Thakur SARYU SYNERGY Better Together
- 14. Points Assigned By Every Members To Each Problem (Scale 1 to 10) Pankaj Yadav Anil Kumar Criteria Safety Environ ment Urgency Easy To Work Time Saving Total Criteria Safety Environ ment Urgency Easy To Work Time Saving Total Problem Problem P1 6 4 2 3 3 18 P1 2 3 6 2 6 19 P2 4 4 6 5 5 24 P2 1 3 8 9 3 24 P3 6 7 7 8 9 37 P3 6 8 8 9 4 35 P4 6 5 4 4 5 24 P4 2 4 3 7 5 21 Dinesh Kumar Yadav Ramesh Thakur Criteria Safety Environ ment Urgency Easy To Work Time Saving Total Criteria Safety Environ ment Urgency Easy To Work Time Saving Total Problem Problem P1 7 4 3 4 3 21 P1 3 3 6 4 3 19 P2 5 5 7 6 6 29 P2 5 2 4 3 1 15 P3 6 6 6 8 9 35 P3 3 8 6 5 7 29 P4 5 6 5 5 5 26 P4 6 7 2 6 1 22 STEP-2: SELECTION OF PROBLEMS SARYU SYNERGY Better Together
- 15. Problems P1 P2 P3 P4 Members Pankaj Yadav 18 24 37 24 Anil Kumar 19 24 35 21 Dinesh Kumar Yadav 21 29 35 26 Ramesh Thakur 19 15 24 22 Grand Total 77 92 131 93 Rank 4 3 1 2 STEP-2: SELECTION OF PROBLEMS Weightage Matrix SARYU SYNERGY Better Together
- 18. Q. C. Name Department Facilitator Members SARYU SYNERGY O&M(OPERATION&BMD) Mr. RAVI PAL SINGH 1. PANKAJ YADAV (Leader) Project Reason for selection 2. ANIL KUMAR Prevent chocking of RC Feeder & Centre pipe of Mill G due to wet coal TO improve Mill G Availability 3. DINESH YADAV Date of start 01.05.2018 Date of completion 30.10.2018 4. RAMESH THAKUR S. N. Steps Weeks 1 2 3 4 5 6 7 8 9 10 11 12 Target Actual 1 Defining the problem 1 2 Analysis of the problem 2 3 Identification of causes 2 4 Root cause analysis 1 5 Data analysis of root causes 1 6 Developing of solution 2 7 Foreseeing probable resistances 1 8 Trial implementation and check performance 1 9 Regular implementation 1 10 Follow up and review Planning mile stone chart (Project activity planning) SARYU SYNERGY Better Together
- 20. Rc Feeder Manual Cleaning
- 21. Manually cleaned out wet coal
- 23. Accumulated wet coal in centre pipe which could not be cleaned out
- 25. PIN TYPE GATE WHEEL TO OPERATE PLATE TYPE GATE (PLATE THICKNESS 40 MM) SARYU SYNERGY Better Together
- 26. 300 MT
- 28. FEEDER CHOKE
- 31. STEP-4: ANALYZE THE PROBLEM SARYU SYNERGY Better Together FEEDER Frequency 1A 1 1B 1 1C 4 1D 4 1E 1 1F 1 1G 8 2A 1 2B 0 2C 1 2D 0 2E 0 2F 1 2G 15 FREQUENCY OF CHOKING IN YEAR 2017 FEEDER Frequency 3A 0 3B 2 3C 2 3D 0 3E 2 3F 0 3G 2 4A 3 4B 1 4C 0 4D 1 4E 0 4F 1 4G 4
- 32. 0 2 4 6 8 10 12 14 1A 1B 1C 1D 1E 1F 1G 2A 2B 2C 2D 2E 2F 2G 3A 3B 3C 3D 3E 3F 3G 4A 4B 4C 4D 4E 4F 4G Bar Chart-Frequency of choking between 01.05.2017 to 30.10.2017 RC Feeder#G has more choking STEP-4: ANALYZE THE PROBLEM SARYU SYNERGY Better Together
- 36. STEP-4: ANALYZE THE PROBLEM HEAD OF LOSS QUANTIFIED VALUE OF LOSS LDO FOR POOR FLAME Rs. 95,70,000.00 PER YEAR IF UNIT TRIP DUE TO FLAME LOSS RVENUE LOST Rs 12,54,000.00 PER TRIP MILL#G UNAVAILABILITY DUE TO PTW 66 HOURS PER YEAR MILL#G UNAVAILABILITY FOR CLEANING 43.5 HOURS PER YEAR SARYU SYNERGY Better Together ESTIMATION OF LOSSES
- 38. STEP-5: FIND OUT CAUSES SARYU SYNERGY Better Together 12 probable causes have been found through brain storming method and the list has been classified into 04 categories by stratification method MAN Laziness in cleaning Improper coal cleaning Wrong pin closing method MACHINE Complicated system Extra pin type gate Extra feeder outlet gate METHOD • More time taking • Wet Coal sticking on feeder body • Wet coal sticking on center pipe MATERIAL • Penetration of gate plate is difficult • Coal accumulation • MS PIN IN WET COAL CAUSE
- 41. STEP-6: FIND OUT ROOT CAUSE SARYU SYNERGY Better Together MAIN CAUSE SUB CAUSE VALIDITY RANK OUT OF 10 MAN UNTRAINED MANPOWER USED NO 0 LACK OF MANPOWER NO 0 FATIGUE YES 1 MACHINE WRONG POSITION OF MANHOLE YES 1 GATE PLATE RAKE THICKNESS MORE YES 10 HEAVY COAL LOAD YES 1 METHOD DIFFICULT PIN & PLATE CLOSING YES 1 IMPROPER FEEDER BODY CLEANING YES 1 IMPROPER CENTER PIPE CLEANING YES 1 MATERIAL JAMMING OF MS PIN YES 10 WET COAL YES 3 BLIND HOLE RAKE YES 2 VALIDATION METHOD
- 43. STEP-7: DATA ANALYSIS PARETO TABLE SARYU SYNERGY Better Together PROBABLE ROOT CAUSES MARKS CUMULATIVE MARKS PERCENTAGE CUMMULATIVE % GATE PLATE RAKE THICKNESS MORE 10 10 32.3 32.3 JAMMING OF MS PIN 10 20 32.3 64.5 WET COAL 3 23 9.7 74.2 BLIND HOLE RAKE 2 25 6.5 80.6 DIFFICULT PIN & PLATE CLOSING 1 26 3.2 83.9 WRONG POSITION OF MANHOLE 1 27 3.2 87.1 HEAVY COAL LOAD 1 28 3.2 90.3 IMPROPER FEEDER BODY CLEANING 1 29 3.2 93.5 IMPROPER CENTER PIPE CLEANING 1 30 3.2 96.8 FATIGUE 1 31 3.2 100.0
- 44. STEP-7: DATA ANALYSIS PARETO DIAGRAM SARYU SYNERGY Better Together VITAL FEW USEFUL MANY 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 0 5 10 15 20 25 30 GATE PLATE RAKE THICKNESS MORE JAMMING OF MS PIN WET COAL BLIND HOLE RAKE DIFFICULT PIN & PLATE CLOSING WRONG POSITION OF MANHOLE HEAVY COAL LOAD IMPROPER FEEDER BODY CLEANING IMPROPER CENTER PIPE CLEANING FATIGUE MARKS CUMMULATIVE % BREAK EVEN POINT
- 46. STEP-8: DEVELOPMENT OF SOLUTION SN. SOLUTION ACCEPT/REJECT REASON 1 USE SERVICE AIR IN CENTER PIPE BETWEEN BUNKER AND FEEDER REJECT •REQUIRE NEW COMPRESSOR •HAVE HIGH COST 2 BY CHANGE WITH NEW FEEDER REJECT •HIGH COST •SAME PROBLEM 3 POKING IN CENTER PIPE MAN HOLE WITH USING A LONG BAR REJECT •MORE MANPOWER FOR POKING •HAZARDOUS 4 CHANGE THE DESIGN OF FEEDER REJECT •HIGH COST OF DEVELOPMENT 5 HAMMERING ON CENTER PIPE REJECT •REQUIRE EXTRA MANPOWER •COSTLY 6 PROVIDE A POKING HOLE IN CENTER PIPE REJECT •ONLY PARTIAL CHOKING CLEAR 7 USE SKILLED LABOUR FOR HAMEERING OF FEEDER REJECT •HIGH COST 8 REPALCE FEEDER INLET GATE FROM PIN TYPE TO PLATE TYPE PROVIDED BY OEM REJECT •PROVEN IN OTHER FEEDERS •COSTLY AND TIME TAKING 9 REPALCE FEEDER INLET GATE FROM PIN TYPE TO PLATE TYPE FABRICATED INHOUSE. ACCEPT •PROVEN IN OTHER FEEDERS •CHEAPEST AND QUICKEST SARYU SYNERGY Better Together
- 49. STEP-9: FORESEEING PROBABLE RESISTANCE SARYU SYNERGY Better Together By Brain storming our team have identified the following probable constraints and found the ways to overcome them.. Sl No RESISTANCE ELIMINATION 1 BUNKER EMPTY BUNKER EMPTY ONLY DURING OVERHAULING 2 MATERIAL AND FABRICATION MATERIAL ARRANGED FROM BMD STORE COMPONENT PRE FABRICATED IN CENTRAL WORKSHOP 3 PERMISSION FOR IMPLEMENTATION OF SOLUTION DEPARTMENTAL NOTE FOR APPROVAL 4 15 DAYS FOR IMPLEMENTATION OF SOLUTION SOLUTION IMPLEMENTED DURING OVERHAULING
- 55. 0 2 4 6 8 10 12 14 16 1A 1B 1C 1D 1E 1F 1G 2A 2B 2C 2D 2E 2F 2G 3A 3B 3C 3D 3E 3F 3G 4A 4B 4C 4D 4E 4F 4G Frequency of choking between 01.05.2018 to 30.10.2018 Frequency of choking between 01.05.2017 to 30.10.2017 STEP-10: TRIAL IMPLEMENTATION AND CHECK PERFORMANCE Unit#3,4 gates replaced and frequency of choking reducedUnit#1,2 frequency of choking is nearly same SARYU SYNERGY Better Together
- 59. STEP-12: FOLLOW-UP AND REVIEW SARYU SYNERGY Better Together Comparative mile stone chart for checking performance S. N. Steps Weeks 1 2 3 4 5 6 7 8 9 10 11 12 Target Actual 1 Defining the problem 1 1 2 Analysis of the problem 2 2 3 Identification of causes 2 2 4 Root cause analysis 1 1 5 Data analysis of root 1 1 6 Developing of solution 2 2 7 Foreseeing probable 1 1 8 Trial implementation and 1 2 9 Regular implementation 1 1 10 Follow up and review Q. C. Name Department Facilitator Members SARYU SYNERGY O&M(OPERATION&BMD) Mr. RAVI PAL SINGH 1. PANKAJ YADAV (Leader) Project Reason for selection 2. ANIL KUMAR Prevent chocking of RC Feeder & Centre pipe of Mill G due to wet coal TO improve Mill G Availability 3. DINESH YADAV Date of start 01.05.2018 Date of completion 30.10.2018 4. RAMESH THAKUR
- 60. COST OF FEEDER GATE TOTAL COST OF MATERIALS – COST OF 10 MM SHEETS – 1.5 M X 1M (2 PIECE) TOTAL AREA OF 10 MM SHEET- 6.86 m2 1MX0.8M (2 PIECE) DENSITY OF SHEETS-78.5 KG/ m2 1M X1 M(1 PIECE) RATE OF SHEET MATERIALS-60.6/ KG 0.4M X0.2M (1 PIECE) TOTAL COST OF 10 MM SHEETS-32633.70 RUPEES 1MX.7M ( 1 PIECE) COST OF 8 MM SHEETS – 0.4 MX 0.7M (1 PIECE) TOTAL AREA OF 8 MM SHEETS -.28 m2 DENSITY OF SHEETS- 78.5 KG/ m2 RATE OF SHEET MATERIALS -60.6/ KG TOTAL COST OF 08 MM SHEETS -902.93 RUPEES COST OF 8 MM LINER ( SS)- 0.6M X 0.7M ( 3 PIECE) TOTAL AREA OF 8 MM LINER - 0.28 m2 0.2M X 0.7( 1 PIECE ) DENSITY OF SHEETS – 80 KG/ m2 RATE OF SHEET MATERIALS - 182.50/ KG TOTAL COST OF 08 MM LINER - 20440 RUPEES
- 61. COST OF FEEDER GATE COST OF BEARING- CAM FOLLOWER - RATE OF BEARING-CAM FOLLOWER -700RUPEES/ PIECE NO OF BEARING (CAM FOLLOWER) – 10 PIECE TOTAL COST OF( BEARING- CAM FOLLOWER ) - 7000 RUPEES COST OF 6306 BEARING - RATE OF 6306 - 400 RUPEES/ PIECE NO OF 6306 BEARING – 02 PIECE TOTAL COST OF 6306 BEARING - 800 RUPEES TOTAL COST OF MS SPUR GEAR (200MM) FROM WORKSHOP -4000 RUPEES TOTAL FABRICATION COST FROM WORKSHOP – 20,000 RUPEES TOTAL IMPLIMENTATION COST = TOTAL COST OF 10 MM SHEETS +TOTAL COST OF 8 MM SHEETS +TOTAL COST OF 8 MM LINER ( SS) + TOTAL COST OF (BEARING- CAM FOLLOWER ) + COST OF 6306 BEARING + TOTAL COST OF MS SPUR GEAR (200MM) FROM WORKSHOP+ TOTAL FABRICATION COST FROM WORKSHOP = (32,633.70 + 902.93 +20,440 + 7,000 +800 +4,000+20,000) RUPEES = 85776.33 RUPEES
- 62. COST BENEFIT ANALYSIS FOR 04 FEEDERS AND IN 01 YEAR STEP-12: FOLLOW-UP AND REVIEW COST OF FEEDER GATE MATERIAL, COST : RS 65,776.00 FABRICATION COST : RS 20,000.00 TOTAL FOR 01 FEEDER : RS 85,776.00 TOTAL FOR 04 FEEDERS : RS 3,43,104.00 ~Rs. 3,50,000.00 BENEFIT PER ANNUM SAVING OF LDO PER YEAR : RS 95,70,000.00 SAVING DUE TO UNIT AVAILABILIT: RS 12,54,000.00 TOTAL : RS 1,08,24,000.00 ~Rs. 1,10,00,000.00 SARYU SYNERGY Better Together
- 63. ADVANTAGES STEP-12: FOLLOW-UP AND REVIEW SARYU SYNERGY Better Together TANGIBLE ADVANTAGES INTANGIBLE ADVANTAGES • Exposure of cross functional area. • Exposure to QC tools and techniques. • Motivation and better team spirit. • Feeling of achievement among team members. • Reduce operational stress. • Rs 95,70,000.00 saved in LDO per annum. • Rs 12,54,000.00 saved by preventing even one tripping of Unit on flame loss. • Availability of bottom Mill#G and RC Feeder#G is improved. • Stability of Unit by availability of Mill#G.