Subject: Felicitation of Quality Circle Teams for Outstanding Performance
Quality Circle (QC) teams from the Mechanical Maintenance Department were constituted in the
year 2024. Two of these teams undertook two interlinked projects with challenging objectives
and achieved excellent results:
1. Team 1: Reduction of flaming and consequent furnace breakdowns at E2 of SAF-II.
o Solution: In-house fabrication and installation of a false mica ring below the
electrode seal rope.
o Result: Substantial reduction in flaming and associated breakdowns.
2. Team 2: Reduction of furnace downtime due to hose leakages at SAF-II.
o Solution: Replacement of carbon-free rubber hoses with stainless steel (SS)
corrugated flexible hoses.
o Result: Significant decrease in hose failures and breakdowns, with downtime
reduced by 80%.
Both teams demonstrated exceptional teamwork, innovation, and commitment in resolving
persistent issues and contributing to the improvement in equipment availability.
It is proposed that the contribution of these teams may be recognised at appropriate forum and
they may be felicitated for their outstanding contributions. Their achievements may also be
shared on CFP intranet to motivate and inspire others. Recognizing and rewarding the efforts of
these QC teams will not only honor their contributions but also foster a spirit of innovation and
teamwork across CFP. It will serve as a motivation for other teams to actively participate in
problem-solving initiatives, contributing to the overall growth and success of the organization.
Submitted for kind consideration please.
N. L. Yenarkar
G M (Mech. Maint.)
CGM (Works)
CGM (HR)
Quality Circle Report - 1
Project Title: Reduction of Flaming and Consequent Furnace Breakdowns at E2 of SAF-II
Team Members (Mechanical Maintenance Department)
1. Shri. K. L. Mundele
2. Shri. Dinesh Borkar
3. Shri. H.P. Nimje
4. Shri. A.B. Sakharkar
Leader : Shri. Akash Deep Verma
Facilitator: Shri. N. L. Yenarkar
Background
The Electrode no. 2 at SAF-II has seen frequent breakdowns of hose leakages caused by flaming.
The flaming occurs when there is increased gap between electrode seal rope and the electrode
holder outer surface resulting in operational disruptions and inefficiencies. The gap is created
over a period of time due to continuous operation and settling / warpage of mechanical parts.
Due to the increased gap, the electrode seal rope does not get sufficient support on its bottom
surface and thus it is unable to cover the gap area upto electrode outer surface. This in turn leads
to disturbance in the electrode seal causing heavy flaming. Addressing this issue became a
priority to ensure smoother operations and reduce downtime.
Problem Statement
Frequent flaming incidents at the E2 furnace of SAF-II caused:
Increased furnace downtime.
Additional maintenance costs and labor hours.
Loss of production output due to breakdowns.
Objective
To reduce incidents of flaming and subsequent furnace breakdowns at E2 of SAF-II by
improving electrode seal system.
Solution
After analyzing the problem, the team proposed an in-house solution:
1. Design and Fabrication:
o A false mica ring was designed to provide additional support to the electrode seal
rope.
o This ring was positioned below the electrode seal rope to provide additional
support during operations.
o The design and fabrication of the mica ring were completed with assistance from
the drawing office and by utilizing in-house resources.
2. Installation:
o The false mica ring was fabricated and installed on the furnace in January 2025.
Implementation
The design of the false mica ring was finalized through brainstorming.
Materials were sourced internally, ensuring cost-effectiveness.
Fabrication of the ring was carried out using the available in-house resources and
expertise of the team.
The installation process was executed in least possible time.
Implementation Date: January 2025
Results
The implementation of the false mica ring resulted in significant improvements:
1. Reduction in Flaming:
o The flaming incidents have substantially reduced, leading to safer and more
efficient furnace operations.
2. Minimized Breakdowns:
o The breakdowns caused by flaming have shown tendency of reduction, as a result
of reduced occurrence of flames.
3. Cost Savings:
o Reduced downtime and maintenance interventions led to a decrease in overall
operational costs.
4. Enhanced Productivity:
o Consistent furnace performance improved production rates and operational
efficiency.
Conclusion
The Quality Circle initiative effectively addressed the problem of frequent flaming and furnace
breakdowns at E2 of SAF-II. Through teamwork, innovation, and resource optimization, the
team successfully implemented a sustainable solution that improved operational reliability and
reduced maintenance efforts.
Acknowledgments
The team acknowledges the support of:
The Drawing Office for their assistance in design.
The management of CFP Chandrapur for providing resources and guidance.
All team members and the facilitator, Shri. N. L. Yenarkar, for their dedication and
collaboration in making this project a success.
Future Recommendations
1. Regular monitoring of the electrode seal rope and mica ring to ensure sustained
performance.
2. Replication of this solution in other furnaces experiencing similar issues.
3. Periodic review based on operational feedback.
Quality Circle Report - 2
Date: 20/01/2025
Project Title: Reduction of Furnace Downtime Due to Hose Leakages at SAF-II
Team Members (Mechanical Maintenance Department)
1. Shri. D. B. Talwekar
2. Shri. Prashant Gedam
3. Shri. Mukesh Sahu
4. Shri. A.B. Sakharkar
Leader : Shri. P. P. Pajai
Facilitator : Shri. V. D. Mahajan
Background
The SAF-II furnace at CFP frequently experienced downtime due to water leakage from the
interconnecting water cooling hoses installed at the cooling shields. These leakages were
primarily caused by flaming at the electrodes, which burned the rubber hoses. Frequent failures
resulted in increased maintenance costs, production losses, and safety hazards.
Problem Statement
Frequent hose failures in SAF-II led to:
Furnace downtime.
Increased maintenance interventions and costs.
Production disruptions.
Objective
To reduce furnace downtime caused by hose leakages by improving the durability and
performance of the water cooling hoses at SAF-II.
Solution
The team proposed the following solution:
1. Observation and Analysis:
o Identified that flaming at the electrodes caused the rubber hoses to burn and fail
approximately within a week of installation, particularly at E2 of SAF-II where
flaming was more intense.
2. Proposed Change:
o Replaced the existing carbon-free rubber hoses with stainless steel (SS)
corrugated flexible hoses.
o The SS hoses were designed and fabricated as per CFP Drawing No. FM-04-
1029.
Implementation
The SS corrugated hoses were procured from local supplier as per the drawing prepared
to suit site conditions.
Installation was carried out during a planned shutdown to minimize furnace downtime.
Implementation Date: 20/12/2024
Results
The replacement of rubber hoses with SS flexible hoses has yielded significant results:
1. Improved Durability:
o The earlier rubber hoses, which used to fail within a short duration, were replaced
by SS hoses that have not leaked to date.
2. Reduced Downtime:
o Incidences of leakage of the metallic hoses installed on line 205 have been NIL
since installation i.e. a reduction of 100%.
3. Cost Savings:
o Reduction in maintenance frequency, spare consumption and associated labor
costs.
4. Enhanced Productivity:
o Decreased downtime leads to more consistent production rates.
Conclusion
The Quality Circle team successfully implemented a durable solution to address hose leakages at
SAF-II. By replacing rubber hoses with SS corrugated flexible hoses, the team achieved a
substantial reduction in furnace downtime, maintenance efforts, and production losses. This
initiative highlights the effectiveness of teamwork, problem-solving, and innovative thinking.
Future Recommendations
1. Regular inspection and maintenance of SS hoses to ensure sustained performance.
2. Consider implementing similar solutions for other electrodes of SAF-II & also for SAF-I.
3. Explore additional measures to mitigate electrode flaming and enhance furnace
reliability.
