(Formerly Neyveli Lignite Corporation Ltd) (A ‘Navratna

NLC India Ltd(Formerly Neyveli Lignite Corporation Ltd)

(A ‘Navratna’ Govt. of India Enterprise)

Thermal Power Station - II

Welcomes You All

QUALITY CIRCLE

1

CREATING WEALTH FOR WELL BEING

OUR ORGANISATION

2

NLC INDIA LTD

( formerly Neyveli Lignite Corporation Ltd)

Our Vision :To emerge as a leading mining and Power Company, with Social Responsiveness accelerating Nation’s growth.

A NAVARATNA COMPANY UNDER THE MINISTRY OF COAL IN THE 60 TH YAER OF EXISTANCE

MOVED FROM AN ONLY LIGNITE MINING AND POWER GENERATION COMPANY TO BECOME AN ENERGY COMPANY.

PRESENT CAPACITY: MINING :30.6 MTPA

TOTAL POWER GENERATION :4287.5 MW

THERMAL:4531 MW

WIND :51 MW

SOLAR :240 MW

DIVERSIFYING INTO COAL BASED POWER GENERATION AND RENEWABLE ENERGY WITH A

VISION TO ACHIEVE 19831 MW BY 2025 FROM 4287.5 MW

PRESENCE IN TAMIL NADU, RAJASTAN, ORISSA,

UP, WEST BENGAL AND ANDAMAN

3

ABOUT NLC INDIA LTD

CONSISTS 7 UNITS OF 210 MW EACH.

TOTAL CAPACITY 1470 MW

ANNUAL TURNOVER OF MORE THAN RS1000 CRORES, TPS II CATERS TO THE REQUIREMENTS OF THE SOUTHERN STATES

FIRST LIGNITE FIRED STATION WITH 210MW UNITS

MERITORIOUS PRODUCTIVITY REWARD BY CENTRAL ELECTRICITY AUTHORITY CONTINOUSLY FROM 1988 ONWARDS.

STATION WITH ISO 9001& 14001 CERTIFICATIONS

4

THERMAL POWER STATION - II

55

INTRODUCTION

QC NAME: GREEN ENERGYOUR INSPIRATION Mr.M. KASINATHAN /CGM

OUR HOD Mr. G.BAPUJEE/DGM

OUR MOTIVATORS Mr.M. KANAGALINGAM GM/O&MMr. K.S.GOPALAKRISHNAN /GM/MTCE

CO ORDINATOR Mr. B.MATHIVANAN /DGM

FACILITATOR Mr. N.ABDUL JALEEL PH 09486586527

LEADER Mr. S.RAVICHANDRAN PH 09486111070

DY. LEADER Mr. V.ELAVARASAN PH 07598614229

MEMBERS Mr. D.KASINATHAN PH 09443882108Mr. G.NEELAKANDAN PH 09442231635

66

QUALITY CIRCLE PROFILEQCFI NO : 081799100038

QC NAME GREEN ENERGY

UNIT TPS –II, NLC INDIA

DIVISIONTURBINE MAINTENANCE

CIRCLE REGISTERED IN

MARCH - 2013

PROBLEMS IDENTIFIED

57

PROBLEMS SOLVED

7

CASE STUDIES PRESENTED

6

QC MEETING SCHEDULE

FrequencyEvery Second &

Fourth Friday

Duration Two Hour / Month

Total Hours

Spent for this

project 24 Hrs

Attendance90%

No of Meeting

Held for this

Project12

7

WON THE

GOLDEN

AWARD AT

CCQC

2013

HYDERABAD

2016

COIMBATORE

2017

CHENNAI

PAR

EXCELLANCE

AWARD IN

NCQC-2016

HELD AT

RAIPUR

88

CASE STUDY ON

OIL TOPPING UP IN BOILER

FEED PUMP HYDRO COUPLING

9

THIS IS OUR

SEVENTH CASE STUDY PRESENTATION

QC TOOLS INVOLVED

1010

STEP ACTIVITY QC TOOLS SLIDE NO.

1 Identification of problem Brain storming 11- 14

2 Selection of problem ABC analysis and 3P analysis 15 – 22

3 Definition of problem Flow diagram 23 – 30

4 Analysis of problem Data collection, 4W 1H 31-32

5 Finding out the causes Brain Storming,Fish bone diagram

33-35

6 Root cause analysis Why-Why analysis 36-37

7 Data analysis Brain Storming, Paretto Diagram 38-42

8 Development of solution Brain storming,ECT Chart 43-45

9 Foreseen probable resistance Brain storming 46

10 Trial implementation PDPC & PDCA Chart 47-52

11 Regular implementation PDCA Chart 53

12 Follow-up and review Data collection, Paretto,AA chart 54- 61

1111

STEP-1: IDENTIFICATION OF PROBLEM

BRAIN STORMING

Sl.No. Problems Identified TYPE

1 HIGHER POWER CONSUMPTION IN BOILER FEED PUMPS C

2 ACCUMULATION OF SILT IN CONDENSER C

3 PASSING IN R/C VALVE OF BFPS A

4 DAMAGE OF CIRCULATING WATER PUMP SUCTION SCREENS A

5 LESS CIRCULATING WATER PRESSURE IN STAGE-I C

6 FREQUENT BEND PUNCTURE IN HPH OPERATING VENTS A

7 CORROSION IN INTERMITTENT COLUMN OF CWPS C

8 PARTING PLANE EROSSION IN BFP BOOSTER PUMP A

9 NRV STRUCK UP IN SEAL DRAIN PUMP A

10 FREQUENT LEAK IN BOILER FEED PUMP SUCTION FILTER B

11 CONDENSER VACUUM LOWER THAN NORMAL IN UNIT-V B

12 HIGH HP TURBINE VIBRATION IN UNIT-VII C

13 HOSE DAMAGE IN HP BYPASS OIL SYSTEM A

14 PROBLEM IN MACHINIG OF VALVE GATES B

15 EXCESS OIL CONSUMPTION IN MAIN OIL TANK DUE TO VAPOUR LOSS A

1212

IDENTIFICATION OF PROBLEM

BRAIN STORMING


16 VIBRATION PROBLEM IN OIL VAPOUR EXTRACTION FANS A

17 PROBLEM IN REMOVING OF CIRCULATING WATER PUMP IMPELLAR SHAFT B

18 BURST OF RUBBER EXPANSION JOINTS IN CIRCULATING WATER LINES C

19 FAILURE OF MAIN STEAM AND HOT REHEAT STRAINER GASKETS A

20 HUNTING OF TURBINE GOVERNING VALVES C

21 PUNCTURE OF T-LINE HOSES IN HP BYPASS SYSTEM A

22 FREQUENT SCALING OF CONDENSER TUBES. C

23 FREQUENT PUNCTURE OF COOLING TOWER UPRAISER PIPES B

24 CHOKE IN AIR CONDITIONING PLANT COOLING TOWER BASIN A

25 LEAKS IN CIRCULATING WATER TUNNEL MANHOLE DOORS. B

26 FREQUENT LEAK IN HRH AND MS STRAINERS A

27 CHOKES IN AIR HANDLING UNIT FILTERS A

28 CW PUMPS SHAFT RUN OUT PROBLEM B

29 CRACKS IN AIRCONDITIONING PLANT COMPRESSOR CRANK SHAFTS C

30 FREQUENT BONNET LEAK IN HP HEATER DRAIN CONDENSATE NRVs A

STEP-1

1313


BRAIN STORMING


31 FREQUENT FLANGE & BONNET FAILURE IN HP HEATER DRAIN CONDENSATE PCVS & ISOLATION VALVES

A

32 HIGH O & M COST OF MAW 10 AND MAW 50 B

33 PUNCTURES IN TURBINE DRAIN PIPES A

34 STEAM LEAK THROUGH TURBINE GLANDS A

35 SAFETY VALVE PASSING A

36 STEM FAILURE IN HP B/P VALVE A

37 FAILURE OF BFP DISCHARGE VALVE A

38 PASSING IN CEP RECIRCULATION VALVE A

39 FREQUENT BONNET LEAK IN DR34 BEFORE GATE VALVE A

40 FREQUENT BONNET LEAK IN THE PCV DR11 B

41 FREQUENT FLANGE LEAKS IN AST TO SEALS LINE A

42 OIL CONTAMINATION IN BOILER FEED PUMPS C

43 FREQUENT FAILURE OF DIAPHRAGM IN HOTWEL MAKE UP VALVES C

44 OIL CONTAMINATION IN TURBINE BRG. & MOT C

STEP-1

14

Sl.No. Problems Identified

45 HIGH AUXIALIARY STEAM TEMPERATURE C

46 BEARING FAILURES IN MAL VALVES A

47 BEARING FAILURES IN BALL CLEANING SYSTEM PUMPS A

48 FREQUENT BONNET FAILURE IN BFP DISCHARGE NRV A

49 METALLIC BELLOW PUNCTURES C

50 MAL VALVE GLAAND LEAK A

51 SAFETY VALVE FLANGE FAILURE A

52 HP HEATER SOV PASSING A

53 MOTOR OPERAED VALVE STEM THREAD FAILURE A

54 OPERATING VENT BEND FAILURE A

55 BFP BALANCING LEAK OFF FLANGE FAILURES A

56 CWP THRUST BEARING TEMP HIGH A

57 DELAY IN OIL TOPPING UP IN BFP HYDRO-COUPLING A


BRAIN STORMINGSTEP-1

STEP-2: SELECTION OF PROBLEM

1515

In day to day operation, we have identified 57 Problems in our work

area.

✓ All the problems have been studied in detail and are listed as Type

A,B,C.

✓ We have decided to study Type – A problem as this can be solved by

QC team itself.

✓ A Type : 34 problems (Problem in the capacity of the QC team itself)

✓ B type : 9problems (Problems which can be solved with the help of

other division)

✓ C type :14 problems (Problems which can be solved with the help of

top management )

34

16

Problem Categorization

Total Problems

57

TO BE SOLVED BYTHE CIRCLEMEMBERS

OTHER DEPT. HELP REQUIRED

MANAGEMENTAPPROVAL REQD.

9 14

BA C

17


3P – Analysis

Proprietary, priority, Preference

PROPRIETARY - I STAGE (GROUPING – P1)

PRIORITY - II STAGE (SELECT A FEW IMPORTANT FROM THE ABOVE - P2)

PREFERENCE - III STAGE (FINAL SELECTION OF ONE/TWO PROBLEM - P3)

17

We have decided to undertake 3P analysis for A type

problems i.e to decide Proprietary, Priority and final

selection with preference to the problem


PROPRIETARY GROUPING: UNDER PROPRIETARY GROUPING WAS DONE

1818

While visualizing the proprietary classification, we had conceptual base

of our divisions, objective & goals in the following categories and the

34 problems under category A were segregated according to

proprietary (4 aspects)

S.No PROPRIETARY GROUP PROBLEM No TOTAL

1 Cost related 16,31,33,37,38,41,46,51 8

2 Safety related 19,26,27,30,,36,47,50,55 8

3 Environment related 8,13,15,21,24,48,54 7

4 Process related 3,4,6,9,34,35,39,52,53,56,57 11


1919

Priority by QC members – P2

After analyzing the problems one by one in QC meeting, members

decided to take process related problems as these problems if left not

attended may result in loss of generation.

Priority given by QC members are tabulated here

PROBLEM SELECTED BY MEMEBERSPROBLEM

NO PROBLEM PRIORITY GIVEN BY

57 DELAY IN OIL TOPPING UP IN BFP

HYDRO-COUPLING

V.ELAVARASAN

3 PASSING IN R/C VALVE OF BFPS D.KASINATHAN

26FREQUENT LEAK IN HRH AND MS

STRAINERS

G.NEELAKANTAN

STEP-2:SELECTION OF PROBLEM

2020

Preference- To decide the preference, weightage

method used. Marks given by each member is

recorded below

PROBLEM

NO

PROBLEM

PRIORITY GIVEN

BY MEMBERS 1 TO

10

TOTAL

SCORE

E K N

57

DELAY IN OIL TOPPING UP IN BFP HYDRO-

COUPLING 9 8 7 24

3PASSING IN R/C VALVE OF BFPS

6 9 6 21

47FREQUENT LEAK IN HRH AND MS

STRAINERS7 6 9 22

STEP-2: SELECTION OF

PROBLEM

By using all the above tools and techniques, datacollection and data analysis, our team has arrived at adecision that the problem No. 56 has maximum impacton the process, which was given top preference.

Problem No. 57 scored maximum, so our problem now is

2121

DELAY IN OIL TOPPING UP IN

BFP HYDRO-COUPLING

MILE STONE CHART FOR

ACTION PLAN

2222

STEP ACTIVITY MONTH

OC

T

2017

NO

V

2017

DE

C

2017

JA

N

2018

JF

EB

2018

MA

R

2018

AP

R

2018

MA

Y

2018

JU

N

2018

JU

L

2018

AU

G

2018

SE

P

2017

1 Definition of problem

2 Analysis of problem

3 Cause and effect diagram

4 Root cause analysis

5 Data analysis

6 Development of solution

7 Foreseen probable resistance

8 Trial implementation

9 Completion in all Pumps

Starting Date: 01.10.2017 Ending date: 31.08.2018

Note : Follow-up and review is a continuous process

STEP – 3 DEFINING THE PROBLEM

24

BFP 5000 RPM

HYDROCOUPLING

5200 RPM

MOTOR 1400 RPM

3500 KW

DRIVE FOR BOILER FEED PUMP

320 T/Hr flow

180 Ksc pressure

170 deg Temp


• There are 3 no BFPs for each unit , 2 no will be kept in service and the third one is kept as auto reserve.

• Boiler feed Pump supplies Feed water to Boiler at 180 Kscpressure and 170 degree centigrade temp.

• Each BFP pumps approximately 320 T/Hr of feed Water to Boiler.

• If any of the running pump trips, reserve pump will start automatically and if reserve pump is not available, unit load has to be reduced by 50% i.e. From 210 MW to 105 MW.

BOILER FEED PUMP


• Each BFP is driven by a Hydro Coupling which in turn gets the drive from a 3.5 MW motor.

• The Hydro Coupling Oil Tank not only supplies working fluid to hydro Coupling but also supplies Lub oil to Pump & Motor.

BOILER FEED PUMP

27

➢Capacity of the Hydro Coupling oil tank is 700 lit

Oil Tank level can be seen through a level view glass

marked LOW, NORMAL, HIGH

➢It is customary to top up oil when the oil level

drops below Normal.

➢Oil level drops due to evaporation & leakage losses

STEP-3: DEFINING THE PROBLEM

Hydro Coupling oil tank

28

HI LEVEL

NORMAL LEVEL

LOW LEVEL


29


Oil Topping Up

➢ Oil is Topped up by a hand

pump after opening the lid

at the top of the oil tank

➢ In a running pump

Oil temp is around 110 degree

centigrade.

Speed of the Hydro Coupling

will be around 5000 rpm.

If the lid is opened in a

running pump oil will be

splashing out of the tank at

high speed and will lead to

injuries to the workmen.

Hence it is advisable to stop

the running pump and then top

up oil.

❖Before stopping the pump, reserve pump has to be started and loaded slowly and paralleled with the running pumps.

❖The pump for which oil is to be topped has to be unloaded slowly and then stopped.

❖The entire process of pump change over takes approximately 30 minutes during which all the 3 BFPs will be in service.

❖Due to the change over process not only the oil topping gets delayed, but also there is considerable increase in power consumption.

❖During oil top the pump will not be available for service. Hence LINE CLEAR has to be obtained.

❖Since non availability of one pump may have consequence of 50% load reduction if another pump trips, permission has to be obtained from CHIEF GENERAL MANAGER 30

STEP-3: DEFINING THE PROBLEMPump Change Over

31

STEP-4 ANALYSIS OF PROBLEM

4 W 1H

WHAT IS THE PROBLEM ? DELAY IN OIL TOPPING UP IN BFP HYDRO COUPLING

WHEN IT IS NOTICED? WHEN OIL LEVEL IS LOW IN BFP HC

WHERE IT OCCURRED? IN RUNNING BFPS

WHICH WAS AFFECTED? OIL TOPPING UP

HOW IT HAPPENED? DUE TO PUMP CHANGE OVER

ANALYSIS OF PROBLEM

USING 4W 1H

32

Copy of log sheet

on 01/10/2017

when pump was

changed over for

oil top up in

Boiler Feed Pump

2A

33

STEP-5: IDENTIFICATION OF CAUSES

Oil Topping is split into the following Activities

1. Applying Line Clear 5min

2. Getting approval from CGM 15min

3. Pump changeover 30min

4. Issuing Line Clear 5min

5. Opening the top up lid 5min

6. Topping up Oil 20min

7. Closing the Lid 5min

8. Returning Line Clear 5min

TOTAL TIME TAKEN FOR OIL TOPPING

UP IS 90 MIN.

34

STEP-5: IDENTIFICATION OF CAUSES

TOTAL TIME TAKEN

FOR OIL TOPPING UP 90 MIN.

PROCEDURAL DEALY 60min

PROCESS DELAY 10min

PROCESS 20min

PEOPLE3535

STEP-5: CAUSE & EFFECT ANALYSIS

EFFECT

DELAY IN OIL

TOPPING UPCAUSES

APPLY LINE CLEAR

MANUAL TOP UP

HIGH SPEED MACHINE

OPEN LID MANUALLY

CLOSE LID MANUALLY

4 P Analysis

INTIMATION TO CGM THROUGH PROPER CHANNEL

PUMP CHANGE OVER

PLANT

POLICIES PROCEDURES

SAFETY PROCEDURES

CLOSE LINE CLEAR

36

STEP-6: FINDING OUT THE ROOT CAUSE

WHY

WHY

WHY THERE IS DELAY IN OIL TOP UP IN BFP

LINE CLEAR TO BE OBTAINED

WHY LINE CLEAR TO BE OBTAINED

THE PUMP WILL NOT BE AVAILABLE FOR SERVICE WHILE

TOPPING UP OIL

37

STEP-6: FINDING OUT THE ROOT CAUSE

WHY

WHY

PUMP SHOULD NOT BE STARTED DURING OIL TOP UP

THERE IS NO PROVISION FOR OIL TOP IN A RUNNING PUMP.

WHY THE PUMP WILL NOT BE AVAILABLE

WHY THE PUMP SHOULD NOT BE STARTED

38

STEP-7: DATA ANALYSIS

38

Delay due to

Administrative Procedures 15min

Line clear 15min

Pump Changeover 30min

Maintenance Procedure 10min

PARETO DIAGRAM

80/20 LINE

100

90

80

70

60

50

40

30

20

10

0

PE

RC

EN

TA

GE

X

CAUSE

PUMP C/O ADMIN LINE

CLEAR

22

42

BEFORE MODIFICATION

Y

1

22 14

MTCE

40


40

During Pump Change Over

For 30 min all the three BFPs will be in

service resulting in higher auxiliary power

consumption

41


Power consumption for 30 min

Considering an average Amps as 190A during

the pump change over, the power consumed

for 30 min is

190 A*30/60 Hr*6.6KV*1.732*0.85

=1085 Kw Hr

42


Power consumption for 30 min

On an average there is one oil top up in every

two months in each pump.

There are 21 BFPs

Power consumption for 21 pumps/Year

1085 *6*21=1,36,710 Kw Hr

REGULAR TOP UP OILIN RESERVE PUMP

PERMISSION FROM

CGM OBTAINED.LC

NEED NOT BE APPLIED.

OBTAINING

PERMISSION FROM

CGM IS REDUNTENT

FABRICATE A METHOD

FOR ONLINE TOP UP

OF OIL.

4343

STEP-8: DEVELOPMENT OF SOLUTION

44


44

ALTERNATIVESOLUTION REMARKS RESULT

ALT 1. REGULAR TOP UP OIL IN RESERVE PUMP

IN STOPPED CONDITION OIL LEVEL WILL BE HIGH

NOT ACCEPTED

ALT 2.PERMISSION FROM CGM OBTAINED.LC NEED NOT BE APPLIED

SAFETY PROCEDURE CANNOT BE BY-PASSED

NOT ACCEPTED

ALT 3.OBTAINING PERMISSION FROM CGM IS REDUNTENT

ADMINISTRATIVE PROCEDURE. CANNOT BE BYPASSED.

NOT ACCEPTED

ALT 4.

DESIGN A METHOD FOR ONLINE TOP UP OF OIL. FEASIBLE

ACCEPTEDAccepted

4545

ECT CHART

S.No OPTIONS EFFECT COST TIME PRIORITY

1 REGULAR TOP UP OIL INRESERVE PUMP

NOT GOOD

VERY HIGH MORE 2

2 PERMISSION FROM CGM OBTAINED.LC NEED NOT BE APPLIED

NOT GOOD

NIL MORE -

3 OBTAINING PERMISSION

FROM CGM IS REDUNTENT

NOTGOOD

NIL MORE -

4 DESIGN A METHOD FOR

ONLINE TOP UP OF OIL.

VERY GOOD

LESS LESS 1


46

STEP-9: FORESEEN PROBABLE RESISTANCE

46

S.No.

FORESEEING PROBLEM

ACTION

1 Approval by HOD QC members explained the reason behind the

modification and the benefits Obtained a positive reply

from HOD.

2 Procurement of

required Materials.

The required 1 inch pipe and bend is readily available.

3 Process affected Operation division was briefed about the advantages and

they immediately agreed for the modification. The

modification can be carried out during shut down of the

unit.

4 Approval by HOD Operation Division

Turbine Operation HOD was briefed and he readily agreed

5 Approval of top

management

The whole data were presented and explained to top

management and the advantages were briefed. After going

thro the ground work done by the team the top

management got convinced that this will work and readily

agreed.

4747

DECIDED TO ERECT AN AIRVENT OVER THE TOP UP LID

AGREED

MOBILIZATION OF MATERIALS TO SITE

ERECTION DURING SHUT DOWN

BEARING TEMP NORMAL AND

NO OIL LEAKCHECK FOR ANY

LEAK WHILE TOP UPIMPLEMENT

MODIFY THE LINES

TO DISCUSS WITH DIVISION HEAD

STOP

NOT AGREED

CHECK

STEP-10: TRIAL IMPLEMENTATION PDPC CHART

48

STEP-10: TRIAL IMPLEMENTATION P-D-C-A CYCLE

PLAN

Proposed to erect an air vent on the top up lid.

Required materials were collected

RESPONSIBILITY :- MR. Sameer & MR. Pavadai

TIME SCHEDULE :- START DATE : 10.04.18;

COMPLETION DATE: 01.05.18

DO

Modification carried out in BFP 2A.

RESPONSIBILITY :- MR. Sameer & MR. Pavadai

TIME SCHEDULE :- DATE; 02.05.2018 ;

ACTIONThe performance was found good. Hence the modification was .

Carried out in BFP2B & BFP2C.Continuous feedback is

being collected through operation division. It was decided to

study the performance & implement in other BFPs

RESPONSIBILITY : MR. Narayanan & Sameer

TIME SCHEDULE : START DATE: 01.06.18 ;

PROPOSED COMPLETION DATE: 31.08.18

4949

CHECK

Oil top up done by connecting the delivery hose of the hand pump

to the air vent. No leak observed while topping up when the pump

is in service.

RESPONSIBILITY : MR. Narayanan & Sameer

TIME SCHEDULE :- DATE : 31.05.2018 ;

STEP-10: TRIAL IMPLEMENTATION P-D-C-A CYCLE

5050

A P

DC

Modification carried

out in BFP 2A.

On 02.05.2018

Oil top up done by

connecting the delivery

hose of the hand pump

to the air vent when the

pump is in service

on 31.05.2018. No

leak observed

while topping

up.

DOCHECK

STEP-10: TRIAL IMPLEMENTATION

Proposed to erect

an air vent on the

lid. Required

materials were

collected by

01.05.2018

The performance

was found

good. Hence the

modification was

Carried out in

BFP2B & BFP 2C.

It was decided to

implement in

other BFPs

.

51

STEP-10: TRIAL IMPLEMENTATION

Modification wascarried out inBFP 2A. Oil topup done byconnecting thedelivery hose ofthe hand pump tothe air vent.

Modificationwas completedon 02.05.2018

No leakobserved whiletopping up oil.

51

ONLINE OIL TOPPING UP

52

• The performance was found good. Hence the

modification was Carried out in BFP2B & BFP2C.

• Continuous feedback is being collected through

operation division.

• The modification was carried out in other BFPs also.

5353

STEP-11: REGULAR IMPLEMENTATION

Oil was topped up in the BFPs where modification was carried out keeping

the pump in service. There was no problem in oil top up.

5454

L

QC members with their excellent dedication & team work is continuously

monitoring the oil levels in boiler feed pumps and implementing the new

modified methoed of oil topping up whenever necessary

STEP-12: FOLLOW UP & REVIEW

55


MILE STONE CHART FOR

ACTION PLAN

5656

STEP ACTIVITY MONTH

OC

T

2017

NO

V

2017

DE

C

2017

JA

N

2018

JF

EB

2018

MA

R

2018

AP

R

2018

MA

Y

2018

JU

N

2018

JU

L

2018

AU

G

2018

SE

P

2017

1 Definition of problem

2 Analysis of problem

3 Cause and effect diagram

4 Root cause analysis

5 Data analysis

6 Development of solution

7 Foreseen probable resistance

8 Trial implementation

9 Completion in all Pumps

Starting Date: 01.10.2017 Ending date: 31.08.2018

Note : Follow-up and review is a continuous process

☺ No Pump change over required. Oil can be topped up even if the

pump is running.

☺ There is a power saving of 1085 units Per oil top up

☺ Selling cost / unit is Rs3.375

☺ Cost saving per oil top up is approximately equal to Rs 3660 /-

☺ Cost saving per annum Rs 4,61,400

5757


☺ Pump change over is not required.

☺ Safe oil top up

☺ No delay in oil top up. Oil can be topped up evenif the pump is in service.

☺ Line Clear not required. Work permit is enough.

☺ Reliable operation is ensured

☺ Avoids frustration to operating Engineers

☺ Improved self confidence

☺ Pride over own modification work

58


59

STEP-12: FOLLOW UP & REVIEWPAY BACK PERIOD

1/2 meter pipe (used) = 500.00

Labor cost for modification = 1,000.00

Labour cost for testing = 1,000.00

TOTAL COST OF MODIFICATION = 2,500.00

PAY BACK PERIOD = IMMEDIATE

59

COST OF MODIFICATION

6060

AA CHART

ACHIEVEMENT

BY PROVIDING AN AIR VENT OIL CAN BE

TOPPED UP IN A RUNNING PUMP.THE AIM

IS ACHIEVED.

AIM

TO TOP OIL WITHOUT

DELAY AND WITHOUT

STOPPING THE PUMP.

QC TEAM TARGET ACHIEVED

61

STEP-12: FOLLOW UP & REVIEWRECURRENCE PREVENTION

61

After modification, Regular feed back is beingcollected from operating engineers.

CONCLUSION

BY SUCCESSFULLY INTRODUCING AN AIR VENT

SAFE OIL TOP UP IS ACHIEVED. THE PROBLEM OF

PUMP CHANGE OVER IS ELIMINATED. THE QC

TEAM’S TARGET WAS ACHIEVED.

626262

Our sincere Thanks to

Turbine operation & services division

63

6464

65

Documents

(Formerly Neyveli Lignite Corporation Ltd) (A ‘Navratna