UNCHAHAR

Utthan
Quality Circle
Welcomes You All

1
 UNCHAHAR

CASE STUDY
FREQUENT TRIPPING OF VACCUM PUMPS
IN ASH HANDLING STAGE-IV

2
 UNCHAHAR
Thermal - 5*210 + 1*500 = 1550 MW
Solar - 10 MW

3
 UNCHAHAR

INTRODUCTION OF QUALITY CIRCLE

Name of QC UTTHAN

Registration No. 45

Department Operation Group-C

Plant NTPC Unchahar

Organization NTPC Ltd.

Formation Date 01/12/2018

Days of Meeting Every Monday of the Month

Time 04:00 PM To 05:00 PM

Place of Meeting Ash Handling stage-III control room

Total Meetings 12 (01 Jan. 2019 to 31 Mar. 2019)

Attendance 90 %

Solved Problems 03 (Till Date)

Numbers of Meetings for this 10

Project
4
 UNCHAHAR
IDENTIFICATION OF PROBLEMS
Through Brain Storming
S.N. PROBLEMS CATG.

1 Drain line choking below settling tank and surge tank in Ash handling Stage-III. A

2 Ash settling problem in ash slurry pump house Stage-III. A

3 No auto running problem of drain sump pump in Stage – III slurry pump house. A

4 Overflow problem of ash water tank in Stage – III. B

5 Frequent gland leakage problem of slurry series pumps in Stage – III. B

6 Low seal water pressure problem in series pump of Stage-III . A

7 Frequent problem of low APH header vacuum and shutoff vacuum in Stage– III. A

8 Choking problem of slurry series pump and line in Stage – III. A

9 Frequent valve limit disturbance problem of suction and discharge of series pump in Stage – III. B

10 Frequent tripping of vacuum pumps in Ash Handling Stage-IV. B

11 Limit disturbance problem of upper and lower dump valve of buffer hopper in Stage-III B

12 Drinking water problem in bottom and APH hopper area Stage-III. A/K

13 Inadequate seal water pressure problem in series pumps of Stage-IV. B

5
 UNCHAHAR
IDENTIFICATION OF PROBLEMS
Through Brain Storming
S.N. PROBLEMS CATG.

14 Seating problem in economiser, duct and bottom area in Stage-III. A/K

15 Unsafe approach to go towards ash slurry pit in Stage-IV. A/K

16 Drain choking problem in minus meter of series pumps in Stage-IV A/K

6
 UNCHAHAR
IDENTIFICATION OF PROBLEMS

Categorization of problems

Type of problem Solved Unsolved Total

problems problems problems

A/K- Type 02 08 10

B- Type 01 00 06

C- Type NIL NIL NIL

Total 03 08 16

7
 UNCHAHAR
SELECTION OF PROBLEM

We have selected the problems on the basis of Preference and Importance.

Each member selected one problem from the category ―A & B‖

P-1 Frequent gland leakage problem of slurry series pumps in Stage – III.

P-2 Frequent tripping of vacuum pumps in Ash Handling Stage-IV.

P-3 Limit disturbance problem of upper and lower dump valve of buffer hopper in Stage-III

8
 UNCHAHAR
SELECTION OF PROBLEM

Criteria for problem selection

We have selected 01 problem out of 05 through following criteria :- (scale 1 to 10 mark)

Urgency

Environment

Frequency

Generation
9
 UNCHAHAR
SELECTION OF PROBLEM

Rating & Ranking Method

Urgency Environment
Members

P1 P2 P3 P1 P2 P3

M. K. Gupta 6 8 4 5 8 7
Rajesh Kumar
5 7 6 6 6 7

A. K. Singh 7 6 6 7 8 6

Total 18 21 16 18 22 20

10
 UNCHAHAR
SELECTION OF PROBLEM

Rating & Ranking Method

Frequency Generation

Members

P1 P2 P3 P1 P2 P3

M. K. Gupta 7 7 6 6 7 6

Rajesh Kumar 6 6 6 7 6 6

A. K. Singh 5 7 7 5 6 7

Total 18 20 19 18 19 19

1512
 UNCHAHAR
SELECTION OF PROBLEM

Rating & Ranking Method

Problems Urgency Environment Frequency Generation Total Rank

P1 18 18 18 18 72 III

P2 21 22 20 19 82 I

P3 16 20 19 19 74 II

1613
 UNCHAHAR
SELECTION OF PROBLEM

Selected Problem

Frequent tripping
of Vacuum pumps in AshHandlingStage-IV

1714
 UNCHAHAR
SELECTION OF PROBLEM
Planning milestone chart
Utthan Quality Circle Dept -Operation (C) Facilitator-Sh. Nitin Pal
Dy. Facilitator – Sh. Siddharth Sonker
Problem: Frequent tripping of Selection Basis – Priority / Plan M K Gupta - Leader
Vacuum pumps in Ash Handling Rating Method Rajesh Kumar - Dy. Leader
Stage-IV
A K Singh - Member

Problem No. 10 Start Date:12/01/2019

Description Time in weeks
1 2 3 4 5 6 7 8 9 10 11 12

Define the problem

Analyse the problem

Identification of causes

Finding out the root causes

Data analysis

Developing Solution

Foreseeing probable resistance

Trial implement/Check
performance
Regular implementation

Follow up/Review

14
 UNCHAHAR
DEFINE THE PROBLEM

Flue Gas Path

Problem Area
Problem Area

15
 UNCHAHAR
DEFINE THE PROBLEM

Flow Diagram

ESPCollecting Plate
Problem area

Hoppers

Hopper ash is evacuated by the vacuum pumps

Ash collected in Buffer Hopper Ash collected in Collectortank

Silo Ash Slurry PumpHouse

Truck Loading Ash Dyke

16
 UNCHAHAR
DEFINE THE PROBLEM

OFF
TAKE PIT PROBLEM AREA
ASH FAHP
WATER
TANK
WETTING
UNIT

VACUUM
WET-MODE PUMP

DEASHING ESP
SYSTEM HOPPERS

ASHSLURRY
PIT

ASH
DYKE

ASH SLURRY SERIES

17
 UNCHAHAR
DEFINE THE PROBLEM
Impact of Problem

Impact on working person:-- Impact on process:--

Unsafe working area SPM increasing

Hopper poking
manually due to Deashingtimeincreasing
deashing disturbance

Health problem of Electrical MCC

working person
disturbance

18
 UNCHAHAR
DEFINE THE PROBLEM

Objectives for Problem Solution

Availability of AHP System

Healthy Environment

Decrease Maintenance

System Reliability

19
 UNCHAHAR
DEFINE THE PROBLEM

Set Goal

Our Aim :- Minimizing the Frequency of Vacuum Pump

tripping by 100% .

20
 UNCHAHAR
ANALYSIS OF THE PROBLEM
Data Collection
Vacuum Pump tripping frequency in ESP :---

Source: Permit book , Shift O&M log Time Duration: 16 Nov 2018 To 15 Feb 2019
book.

Stage Pass-A Pass-B Pass-C Pass-D Total

IV 15 17 18 17 67

Data collected by : Sh. M K Gupta

21
 UNCHAHAR
ANALYSIS OF THE PROBLEM
Data Collection – Loss Calculation

Time Duration: 16 Nov. 2018 To 15 Feb. 2019

Total
No. Of Amount
Description Quantity/day Rate Calculation
days
(Rs.)

Avg. Man power

10X3 359 92 30X359X92 990840.00
for ash removal &
poking

Total Loss in ash removal by poking = (Rs.) 990840.00

22
 UNCHAHAR
IDENTIFICATION OF CAUSES
Through Brain Storming

 Over current
 Bearing temperature high
 High Vibration
 Inadequate seal water pressure
 Carryover
 Open to air
 Pump belt is loose
 Under greasing
 Poor maintenance
 Over running
 Vacuum line choking
 Vacuum line gasket damage
 Pump developing inadequate vacuum
 Foreign material stuck-up
 High header vacuum
 Manual mistake in selection
 Valve limit malfunction
 MCC disturbance

23
 UNCHAHAR
IDENTIFICATION OF CAUSES
Fishbone Diagram

MAN MACHINE
Foreign mat. stuck up
No proper training Manpower shortage Pressure more than
Excess workload Carryover design Seal water line damage
Lack of knowledge Tiredness
Inadequate seal water pressure Seal water pressure dropped
Lack of experience
Lack awareness Over greasing Pressure from source dropped
Lack of dedication Bearing temperature high
Misalignment
Lack of concentration Lack of process information Under greasing
Bearing jamming High Vibration
Frequent change of
No availability of
senior persons staff Frequent
Over current Bearing clearance

Bearing jamming Bearing damage

increased tripping
of
Shed not provided over the vacuum pumps
Bearing damage
Open to air
Wrong procedure followed
vacuum
Bearing jamming Ash stuck up Carryover
pump
Insufficient FAHP wtr
Suction valve limit malfunction discharge
Negligence of maintenance group Stand by not available

Pump belt is loose

Over running
Poor quality of belt

Scheduled changeover not followed

MATERIAL METHOD

24
 UNCHAHAR
FINDING OUT THE ROOT CAUSES

Identification by Validation

S. N. Root Causes Inspection Effect Validity

1 No Proper Training Not Found No Effect No

2 Poor Maintenance Found Frequent Wear & Tear Yes

System Operation Held

3 Lack Of Experience Found Yes
Up

4 Foreign material stuck up found Line choking Yes

5 Lack of dedication Not Found No Effect No

6 No availability of senior persons Not Found No Effect No

Not Found No Effect No

Frequent change of staff
7
Inadequate seal water pressure Found Air ingress in pump Yes
8

9 Pressure more than design Not Found No Effect No

25
 UNCHAHAR
FINDING OUT THE ROOT CAUSES
Identification by Validation

S. N. Root Causes Inspection Effect Validity

10 Pressure from source dropped Not Found No Effect No

11 Under greasing Found Frequent Wear & Tear No

12 Pressure more than design Not Found No Effect No

13 Current and temp.

Bearing damage Found increasing No

14 Ash stuck up Not Found No Effect No

15 Scheduled changeover not followed Found Wear & Tear In pump Rare

16 Stand by not available Not Found No Effect No

Insufficient FAHP wtr discharge Found Carryover

17 No

18 Wrong procedure followed Not Found No Effect No

Pump tripping & line

Poor quality of belt choking
19 Found Yes

26
 UNCHAHAR
DATA ANALYSIS
Duration:- 16 January 2019 To 15 Feb 2019

Various Root
S.N. Causes Frequency Cumulative No. Total % Cumulative %

Inadequate seal water

1. 57.69 57.69
pressure 15 15

Foreign mat. Stuck up

2. 5 20 19.23 76.92

Poor Maintenance
3. 04 24 15.38 92.4

4. Poor quality of belt 02 26 7.6 100.00

27
 UNCHAHAR
DATA ANALYSIS
Pareto Diagram

30 120

Vital Few Useful many 100

25 92.4 100

76.92
20 80
Frequency

Cumulative %
57.69
15 60

10 40

5 20

0 0
Inadequate seal Foreign mat. Poor Poor quality of
water pressure Stuck up Maintenance belt
Root Causes

28
 UNCHAHAR
DEVELOPING SOLUTION
Suggestion No. 1 : Replace the service water pump with high discharge.
pump.
Reason :This suggestion was rejected by the group because this
pump was already as per design pressure.

29
 UNCHAHAR
DEVELOPING SOLUTION
Suggestion No.2 : Reduce the diameter of seal water pipe for increasing
pressure.
Reason : This suggestion was rejected by the group because it is
too costly & time taking.

30
 UNCHAHAR
DEVELOPING SOLUTION
Suggestion no.3 : Installation of orifice in seal water line before vacuum pump.
Reason : This suggestion was accepted by the group as It was easy
to install in the seal water line & not too costly.

40 NB

31
 UNCHAHAR
DEVELOPING SOLUTION

Selected Solution

Installation of orifice in the seal water line before

vacuum pump.

32
 UNCHAHAR
FORESEEING PROBABLE
RESISTANCE

S. N. Probable Resistance Solution

1 Whether new changes would be permitted or not ? We will convince the Head of the Department
of Maintenance with the help of site
engineer.

2 How could we make it ? We will take the help of our Ash Handling
Maintenance group.

3 Could it be done in running of the vacuum pump ? No. It could be done only when the vacuum
pump will be off and under PTW.

4 Would there be any resistance from our Operation No. Standby vacuum pumps will be taken
group? in service.

We will take the help of Maintenance Engineer

5 How would we arranged the material & spares? to arrange the spares from stores and scrap
yard.

33
 TRIAL IMPLEMENTATION & CHECK UNCHAHAR
PERFORMANCE

ACT
PLAN
• Taken permit for
Planned to install the orifice first
regular in vacuum pump – A1
Implementation. After permission following things
•Plan is to be done for collected -
• Ms flange joints
other vacuum pumps.
• Nuts and bolts.
• Collection of data
• Orifice of ID – 12 mm
and performance • Welding rods & machine
• Presentation

CHECK DO
• Cut the pipe into 2 parts
• Checked the leakages in seal water
line. • Welding of flange joints at
both ends.
• Checked the seal water pressure
in pressure gauge. • Place the orifice between
flange.
• Checked the seal water permissive
in OWS. • Fastening of nuts & bolts in
flange joints.

34
TRIAL IMPLEMENTATION & CHECK UNCHAHAR

PERFORMANCE

Installed
Orifice &
Flange
joints

35
 UNCHAHAR
TRIAL IMPLEMENTATION & CHECK PERFORMANCE
Data Comparison
Data Source : Log Book and PTW Register
Data Collected By — Sri M. K. Gupta

Trial implementation done in Vacuum Pump – 6A1

BEFORE AFTER
Duration Duration:
: 16 Jan. 16 Feb.
26
Description
2018 to 15 2019 to 18
Feb. 2019 Mar. 2019

1. Inadequate seal water pressure 15 0

2. Foreign mat. Stuck up 05 01

3. Poor Maintenance 04 01

4. Poor quality of belt 02 01

03
Total 26 03 BEFORE AFTER
36
 UNCHAHAR
TRIAL IMPLEMENTATION & CHECK PERFORMANCE

90% Goal Achieved

37
 UNCHAHAR
REGULAR IMPLEMENTATION

After successful trial and implementation in Vacuum pump-6A1. The

team decided to implement it regularly in all other vacuum pumps.

38
 UNCHAHAR
REGULAR IMPLEMENTATION

Project Cost

Description Quantity Rate (Rs.) Total Amount

MS flange joints & orifice

03 scrap 0.00

Welding rod 06 15*6 90.00

Nut bolt 08 15*8 120.00

skilled (fitter &

Man Power 2*506 1012.00
welder)
Helper 2*359 718.00

Total Project Cost (Rs.) 1940.00

39
 UNCHAHAR
REGULAR IMPLEMENTATION
Total Loss Before Project

Time Duration: 16 Jan. 2019 To 15 Feb. 2019

Total
No. Of Amount
Description Quantity/day Rate Calculation
days
(Rs.)

Avg. Man power

06X3 359 31 06X359X31 200322.00
for ash removal &
poking

Total Loss in ash removal by poking = (Rs.) 200322.00

40
 UNCHAHAR
REGULAR IMPLEMENTATION
Total Loss After Project

Time Duration: 16 Feb. 2019 To 18 Mar. 2019

Total
No. Of Amount
Description Quantity/day Rate Calculation
days
(Rs.)

Avg. Man power

02X3 359 31 30X359X31 66774.00
for ash removal &
poking

Total Loss in ash removal by poking = (Rs.) 66774.00

41
 UNCHAHAR
REGULAR IMPLEMENTATION

Tangible Benefits

(A) Total Loss Before Project

Rs. 200322.00

(B) Project Cost (One Time) Rs. 1940.00

(C) Total Loss After Project Rs. 66774.00

Rs. 131608.00
(A-B-C) Saving ( In 31 Days)

Projected Yearly Saving - 131608/31*365 = Rs. 1549578.00

42
 UNCHAHAR
REGULAR IMPLEMENTATION

Intangible Benefits

Increased safety of
working person .

Increased System
continuity & reliability

Reduced MCC
disturbance

Increased self
confidence & moral of
QC members.

43
 UNCHAHAR
FOLLOW UP & REVIEW

Checklist : Weekly Activities

Start date:------------------- End date:---------------

S. N. Activity Status Remarks

Checking of seal water pressure in

1 OK/Not OK
gauge & in OWS.

Checking of Seal water line

2 OK/Not OK
leakages.

Checking of flange joints & orifice

3 OK/Not OK
condition.

Regular Checking on weekly basis

44

Utthan Quality Circle
UNCHAHAR
FOLLOW UP & REVIEW
Actual/Comparative Milestone Chart
Dept -Operation (C) Facilitator- Sh. Nitin Pal
Dy. Facilitator – Sh. Siddharth Sonker

Problem: Frequent tripping of Selection Basis – Priority / Rating M K Gupta - Leader

Vacuum pumps in Ash Method Plan
Handling Stage-IV
Actual Rajesh Kumar - Dy. Leader
A K Singh - Member
Problem No. 10 Start Date:15/01/2019 & Completion Date:20/03/2019
Description Time in weeks
1 2 3 4 5 6 7 8 9 10 11 12
Define the problem

Analyse the problem

Identification of causes

Finding out the root causes

Data analysis

Developing Solution

Foreseeing probable
resistance
Trial implement/Check
performance
Regular implementation

Follow up/Review

45
 UNCHAHAR
TOOLS & TECHNIQUES USED

• Flow Diagram
• Brain Storming
• PDCA Cycle
• Data Collection &
Stratification
• Pareto Diagram
• Fishbone Diagram
• Milestone Chart

46
 UNCHAHAR

OUR PROJECT

Drain line choking below settling tank and surge tank in Ash handling Stage-III

47
 UNCHAHAR
ANY SUGGETION PLEASE

THANKS.

48