SGA Aluminium & Power, Jharsuguda

COMPRESSED AIR OPTIMISATION

• Project: Optimisation of compressed air consumption

• Baseline: No of Compressor running for station load of 850MW is 9.

• Target: Reduction to running of 7 compressors for the same load condition

Resources - Team Members

Name Role Dept/Function

Bimalendu Mohapatra Facilitator Tech Cell (SEL)

Sreeram Pavan Nemani Leader Tech Cell (SEL)

Arnab Srimani Member Maintenance (Steag)

Akshat Paliwal Member Maintenance (Steag)

 Aluminium & Power, Jharsuguda
PROBLEM SELECTION

 Brain storming session was conducted to identify issues of high priority, wherein “Reduction
in compressed Air Consumption” project was selected based on project rating
score. Y1 Y2 Y3
IMPACT ON (Efforts level. If Alignment to
ORGANISATION High - rating 1, if Direct Customer PROJECT-
S.No Issues
(TANGIBLE/ medium - 3, if low - (If High - rating RATING SCORE
INTANGIBLE)) 9) 9, if medium - 3, (Y1*Y2*Y3)
(RATING: 1, 3, 9) if low - 1)
Raw Water
1 Consumption is 5 6 4
120
High
Compressed Air
2 Consumption is 9 3 9
243
High
Belt Utilisation is
3 6 5 6
low
210
HRH Steam
4 Temperature of U3 7 6 4
is low 168
Mill Utilisation is
5 6 6 4 22
low
 CAUSE & EFFECT DIAGRAM Aluminium & Power, Jharsuguda

Man Mother Environment

Improper charging of FF Comp. cooling water failure
Compressed air for cleaning Low rainfall
High emmissions dur start ups
Pipeline damaged
Ash leakages High Air Cons. in mill
Mill B/d Low reservoir level
Inefficient D Pump Opr. Load fluctuations High inlet ambient air temperature/humidity
No common control room Frequent mill changeover Suction DP high
Communication gap Lack of competency
Non avail. Of skill matrix/gap Coal/ash leakages from mills/ESP
Removal of Ash slider clogging
No trainings
Improp. fluidising Dusty envi. Inside compress. house

High Compressed air consumption

No measuring inst. for Unload. Compr.opr Heater/Controller fail
dew point of comp. air FF inline with oil in ser. in both phases Fluid. Sys. fail
FF clogged Sol. Coil burnt High DP across driers
Improper phase opr ADV malfunction.
No avail. Moist flue gas, D Pump ash conv. In timer mode Filter Clogged Alumina Saturated
of ADV puls. air No rig. Checking in S/D
No timely avail. Of Al v/v gate erosion Service water pump failure
Improp. Comp. setpoints Unreliable level probes Conv. v/v passing
Ineff. Step. motor coupl. Damage
No SOP in place Ineffect. PM
Desiccant Drier Comp. in
Puls.air Plunger jam/punc. Transformer failure
Poor quality No moisture seperation ADV faulty mod. mode
Fittings damaged Non perf. Of ESP fields
of Alumina Ineff. drier
No SOP in place Air line leakages
High Rapping motor fail. GD screen damaged
No measuring Low ref. & No SOP for No SOP for ADV opr.
Ash gen. v/v damaged Leakages in pneumatic v/v
inst. for ser. Water pr. Al replac.
Worst coal Inj. Tube misalign.
compr. Air Moist. Varies with climate Solen. v/v Actu. Seal Leakage
feed No insp. dur overhaul
generation Hopper filling diagh.fail
/shutdown
time Optimi. Timer mode swithing Silo pressurised
Dome seal fail
In opr. control
Material Method Machine Vent fan fail. Bag filter clogged
 C&E PRIOTRIZATION Aluminium & Power, Jharsuguda

S.No Cause Y S.No Cause Y

1 Ash Leakages 6 12 No measuring inst. For dew point 4
2 High emission during start up. 3 13 Poor quality of Alumina 4
3 Mill Breakdown 3 14 No availability of ADV 3
4 Load fluctuations 3 15 FF inline with oil in service 4
5 No common control room 4 16 Moisture in flue gas, pulsing air 6
6 Non avail of skill matrix 3 17 No SOP in place for Comp. set point 4
7 Improper fluidising 4 18 ADV faulty 4
8 19 Low refrigerant & Seal water press.
Pipeline Damages 5 3
Of Drier
9 Low rainfall 2 20 Hopper Fill time optimisation 7
10 High inlet air ambient air temp. 4 21 Moist. Variation with climate 5
11 Coal/ash leakages from Mills/ESP 6 22 Unreliable level probes 4
 C&E PRIOTRIZATION Aluminium & Power, Jharsuguda

S.No Cause Y S.No Cause Y

23 Improper phase operation 7 35 Service water pump failure. 4
24 Heater or controller failure 3 36 Stepping motor coupling failure 2
25 37 ESP field transformer
ADV solenoid coil burnt 3 3
failure/availability
26 38 ESP field rapping motor
Valve gate erosion 4 7
failure/availability
27 Ineffective PM 3 39 ESP field GD screen failure 4
28 Pneumatic fitting damaged. 6 40 Solenoid valve diaphragm failure. 4
29 Pneumatic v/v damaged. 3 41 Actuator seal leakage. 4
30 No inspection of FF injection tubes. 2 42 Vent fan failure 3
31 Dome seal failure. 3 43 Silo bag filter clogged. 4
32 Drier filter clogged. 4 44 Worst coal feed 8
33 Alumina saturated. 4 45 Service water pump failure. 4
34 High DP of FF 7 46 Unloaded Compressors 7
 Aluminium & Power, Jharsuguda
HIGH IMPACT ROOT CAUSES

Root cause DEFINITION

Leakages Some of the compressed air is being wasted on account of leakages from the fittings,
gaskets, punctured or damaged pipelines etc.
High DP of FF If the differential pressure across the fabric filter is more than 1200 Pa, the pulsing
frequency increases and pulsing continues till the DP falls down to 1200 Pa.
ESP Field If the fields of the electrostatic precipitators are running at lowered efficiency /
Availability unavailable, the consumption of air will increase due to high pulsing frequency in FF.

Unloaded Unloaded operation refers to the state of compressors where in the compressors are
Compressors electrically live and rotating but generating pressure required for circulation of coolant
only. It does not generate pressure required for actual process operation.
Coal flow Coal Flow measured in tonnes per hour has a direct impact on air consumption. Higher
the coal flow, more is the ash generated and more is the air consumed for conveying of
the ash, thereby requiring more compressors to run.
Dew Point Atmospheric Dew Point of service air between -4°C to -10°C. ADP for instrument air
between -20°C to -40°C

Probe mode In order to improve the material loading of the evacuation system, probe mode
Operation operation to be done.

1
 IMMEDIATE ACTIONABLES Aluminium & Power, Jharsuguda

S.No Cause Action Proposed Responsi Target Status

bility date
1 More no. of unloaded Interconnection of instrument air Sreeram 15-1-14 Completed
compressors header of Ph#1 & Ph#2

2 Low material loading factor Operation shifted from timer Arnab 20-2-14 Completed
of ash evacuation system mode to probe mode.

3 Frequent Leakages in ash Forming Special task force for S.Sahoo 10-1-14 Completed
conveying system. arresting air leakages and v/v
passing in AHP.

4 Sealing of compressor house Seal compressor house. To ensure Akshad 15-1-14 Completed
proper ventilation, install
industrial exhaust fan

7
 Aluminium & Power, Jharsuguda
GRAPHICAL ANALYSIS

Hypothetical Statement-There is a relation between FF DP & Hypothetical Statement- There is a relation between Coal cons.&
Compressor Pow. Cons.. Compressor Pow. Cons..

Result-The Plot shows no significant relation between FF DP & Result- The Plot shows a significant relation between between Coal
Compressor Pow. Cons. cons.& Compressor Pow. Cons.

8
 Aluminium & Power, Jharsuguda

IDEAS/CREATIVE SOLUTIONS

S No Idea Area of Work

Driers and auto drain
1 Dew point of service air to be maintained < 15 degree Celsius.
valve.

2 System air Leak test will be carried out in Ph-1 & Ph-2. Conveying system

Air Leakage from instruments are to be identified and arrested. Monthly

3 Entire plant
audits of instruments to be carried out .

Removal of one filter (inlet/outlet) from dryer and differential Pressure to be

4 monitored across the dryer. If DP is reduced & performance is not affected, air Compressor house
filters to be removed from other dryers also.

5 Isolating supply of service air to Boiler & TG area. BTG

6 Compressor operator to coordinate with AHP control room. AHP

Installation of dew point monitors for online monitoring of compressed air
Compressor house
7 dew point

Compressor house
8 Installation of high dust seperation system
 Aluminium & Power, Jharsuguda
IDEAS/CREATIVE SOLUTIONS

S No Idea Area of Work

Compressor house
9 Feasibility study to be done for taking 2 no. Receivers before the drier.

Compressor house
10 System air Leak test will be carried out in Ph-1 & Ph-2.

Feasibility study to be done for modifying Suction line for compressors from Compressor house
11
inside the chamber to outside.

Compressor house
12 Online Free Air Delivery meter to be procured.

Installing isolation v/v in AHP headers (wherever required) for online arresting
13 Conveying system
of air leakages.
Compressor house
14 Feasibility checking to be done for bypassing dryer for service air.

15 Optimizing loading and unloading pressure set points for all compressors. operation

16 Replacement of normal bends with cast basalt/ceramic lined bends. Conveying system

Auto drain valves to be installed in Receiver tanks. Compressor house

17

Proper sealing of compressor house and installation of exhaust fan. Compressor house
18
 Aluminium & Power, Jharsuguda
LIST OF SELECTED SOLUTIONS

SL SOLUTIONS

1 Header Drain valve size increased from 0.5" to 1"

2 Auto drain valves to be installed in Receiver tanks.

3 Installation of dew point monitors for online monitoring of compressed air

dew point

4
Installation of high dust separation system.

5
Installation of isolation valve in purging header

6 Optimizing loading and unloading pressure set points for all compressors.
 Aluminium & Power, Jharsuguda
TRIAL IMPLEMENTATION PLAN

SGANAME: Reduction in
DEPARTMENT: Ash Handling Plant/BOP/C&I
compressed Air Consumption
Responsible
Control Target/ Actual Current
Individual/ Issues/Barri Risk
SL Solution Action Improvement Action Complete Status/
Solution ers Mitigation
Number Date Comments
Owner
Installation of high dust Modification
Compressor inlet vacuum will
seperation system in required in
1 1 improve and better capacity Akshat 15th feb'14 Completed
compressor number 7 of compressor
utilization will take place
phase 1 package
Other fittings
Improve dew point of air and High lead time required for
Installation of auto drain
2 2 less carryover of moisture to Sameer of the drain installation to 25th dec'13 Completed
valves
fabric filter valves be made ready
beforehand
Unit
Installation of the online Continuous monitoring of the air
3 3 Sameer shutdown … 10th jan'14 Completed
dew point meter dew point
required
All erection to
be completed
beforehand.
Proper draining of moisture from Unit
Header Drain valve size Deepak Only single
4 4 headers, evaporators and shutdown 20th dec'13 Completed
increased from 0.5" to 1" Parasar welding joint to
moisture separators required
be left for
opportunity
work
Monitoring the cooling effect at
Installation of isolation
5 5 different flow setting and Setting Sameer No Barriers … 13th Jan'14 Completed
valve in purging header
flow accordingly

Optimization of loading
To minimise the unloading hours
6 and unloading set point of 6 Sreeram No Barriers 15th Nov'13 Completed
of the compressors
compressors
 Aluminium & Power, Jharsuguda
IMPROVED PROCESS CAPABILITY

Sigma level 4.19 Sigma level 5.28

 CONTROL PLAN Aluminium & Power, Jharsuguda

Specificati
on Current
Process Input (LSL,USL, Control Sample Sample
Step parameter Process Output Target) MSA Method size Frequency Reaction Plan
Suction of
Atmospheric USL: 3 Inlet Vacuum < 0.05
√ NA Inlet Filter Continuous Continuous
air through Microns Kg/cm^2
filter
Compression LSL: 4 Kg Cal. Sheet
√ Pressure Tx. Continuous Continuous Safety v/v pop up.
of air & oil USL: 8 Kg Attached
LSL: 85
Cooling of air Degrees C ; tripping on 110
√ NA RTD Continuous Continuous
& oil. USL 109 degrees C
Degrees C
If the dew point
LSL: 4
Drying of increases beyond
Degrees C & Calib. Sheet Dew Pont
compressed Dew Point √ Continuous Continuous 10 degrees C, The
USL: 10 attached. Meter
air auto drain valves
degrees C
are checked.

Storage & Auto set Unloaded

distribution of LSL: 4.5 Bar, Calib. Sheet points, compress. Take
Pressure √ Continuous Continuous
compressed USL: 5.5 Bar attached pressure load when the
air transmitter. press. Decreases
and vice versa.
REVISED PROCESS MAP
Aluminium & Power, Jharsuguda

15
 Aluminium & Power, Jharsuguda

LINE LEAKAGE VALIDATION

100 250
93
90

80 77 200
73
70
63
60
60 55 150
53
50 46
43
39 40
40 37 38 100

30
24

20 17 50
14 15
9 9 9 9 10 10
10 8
2 2 1 1
0 0
Sept'13 Oct'13 Nov'13 Dec'13 Jan'14 Feb'14 Mar'14

TF-TT ESP ECO+APH FF Total Leakages

 Aluminium & Power, Jharsuguda
FMEA VALIDATION
FAILURE MODE EFFECT ANALYSIS FOR HIGH COMPRESSED AIR CONSUMPTION & HIGH POWER CONSUMPTION
Proce S O D R S O D R
ss Potential Potential Failure Potential Current Actions Target Stat
Process E C E P Resp.
Requir Failure Mode Effects Causes Controls Recommended Date us E C E P
nment V C T N V C T N
What are the

How well can you detect

cause or FM?
Risk Priority Number
How often does cause or FM
What are the

Whose Responsible for the

How Severe is the effect?
actions for

recommended action?
existing controls
reducing the
and procedures
occurrance of the
In what ways (inspection and
What is the impact What causes the Cause, or

occur?
does the test) that prevent
on the Key Output Key Input to go improving 2/8/2013
Equipment/Proc either the cause
Variables? wrong? detection?
ess go wrong? or the Failure
Should have
Mode? Should
actions only on
include an SOP
high RPN's or
number.
easy fixes.
COMPRE Reduced flow, High
SSED Compr Chocking/Partial heat generation, Dusty Cleaning/Replace
7 9 1 63 arnav 1/8/2013 C 7 4 1 28
AIR essor blockage More power Atmosphere ment of the filters
SYSTEM consumption
Installation of high
Inlet vaccuum dust seperation deepak 17-5-2013
shall be filters
<0.1kg/cm² Sealing the
compressor room
rajesh 17-5-2013
so as to prevent
dust & ash ingress
high moisture % Cleaning/Repalce
7 4 2 56 sreeram 1/8/2013 C 7 2 2 28
in air ment
entry of Continuous Cleaning of filters
damage/punctu dust,moisture and operation with Filter cleaning as soon as
7 6 1 42 arnav 1/8/2013 C 7 4 1 28
re high operating higher differential every PM or as DP>0.1kg/cm² OR
temperatures pressure required every PM
Replacement of
Untimely
change of filter filter if DP do not
7 replacement of 7 1 49 deepak 1/8/2013 C 7 4 1 28
(<4000 hrs) decrease even
filters
after cleaning
OEM
Poor quality of Procurement of
7 4 reccommended 1 28 Sameer 1/8/2013 C 7 3 1 21
filters filters from OEM
filters
screw element Cleaning/Repalce
10 1 8 80 sreeram C 10 1 6 60
damage ingress of foreign change of filter ment
Increased coolant material (<4000 hrs) Cleaning &
10 4 3 120 arnav 1/11/2013 C 10 2 3 60
contamination replacement
 Aluminium & Power, Jharsuguda
SUSTENANCE

No. Compressors running

13
12
12
11 11
11
10
10
9
9
8
8
7 7 7 7 7 7 7 7
7
6
6
5
4
3
2
1
0
Oct'13 Nov'13 Dec'13 Jan'14 Feb'14 Mar'14 Apr'14 May'14 June'14 July'14 Aug'14 Sept'14 Oct'14 Nov'14 Dec'14
 Aluminium & Power, Jharsuguda
ACTUAL BENEFIT CALCULATION

No. of Compressors Running No. of Compressors Running

for average load of 850MW for average load of 850MW
(before improvement) (After improvement)

9 7

Particular UOM Quantity

Power consumption / Compressor KW 350

Annual Saving of Power MU 6.14
Annual Saving Crores Rs. 1.22
 Aluminium & Power, Jharsuguda

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