Name Of QC.:-10th Planet Name of Dept:-O&M(operation) TEAM LEADER:-MR.R.R.NAIK MEMBER:-MR.H.K. UDAN MEMBER:-MR.

JADUMANI SAHOO MEMBER:-MR.N.K.PRADHAN MEMBER:-MR.SANJAY KU. SAHOO FACILITATER:- MR.M.K.JANA DY.FACILITATER:MR.A.K.PASWAN

Formation & Registration of our Quality Circle
Officially formed on 03/06/2003.

Meeting on every alternate evening shift of the rota. Total Nos. of meeting:73 Attendance (%) 85.96

TEP- 1 :

Methodology adopted :-Brain Storming Method
1) Boiler tube leakage. 2) Low condenser vacuum in unit#1. 3) Checking of ESP hopper throat due to dump formation. 4) Poor evacuation of mill,jamming problem. 5) Mill motor bearing temperature going high. 6) Main PA dampers of mill jamming problem. 7) Mill feeder jamming problem. 8) LRSB not retracted. 9) Water logging at cable gallery. 10)Waste coal at feeder floor.

11. Hot line to ERLDC not functional. 12. Power consumption in cable gallery, high (SWGR) lighting. 13. Seal oil filter venting problem. 14.Wastage of condenser sump pit water. 15. Bottom ash drain pump over load. 16. LRSB drain temp. not maintaining high in U # 2. 17) Energy meters in “MS SWGR” not visible. 18) Diesel tank location for DG set is out side DG set building. 19) Air ingress through CEP suction line drain . 20) VC not effective. 21) During LRSB to HRSB C/o water particles trapped inside can cause tube leakages.

22) Solidification of CO, during the H2 purging. 23) Tools for isolation not properly insulated. 24) Draining system of stator CW system not secure. 25) CT sump overflow. 26)Tripping of ash evacuation system. 27)Soot blower flange leakage. 28)Improving Ash slurry series availability. 29)Leakage oil pump (TG)failure. 30)Jamming of material handling valve. 31)Hot air leakage throw PAPH&SAPH. 32)ESP isolation,one key for each field at unit#2. 33) Drain valves of BFPs passing. 34)Oil pit adulterated in FOPH. 35 BADV opening problem. 35 BADV opening problem.

36)Coal accumulation near TP area. 37)tripping of compressor when DMCW pump trip. 38)clinker grinder jamming. 39)air coolers for GT is not temperature operated. 40) water logging at “0”mtr. ESP area. 41) DM water wastage on D/A level high. 42) Ash accumulation near PAPH & SAPH oil tank. 43) Mill#1C classifier temperature low during rainy season. 44)Reducing Aux. Power consumption. 45) Reducing DM makeup water.

46)Ash water leakage from hoppers. 47)flue gas leakage from ID fan inspection manhole. 48)passing of fire hydrant valve. 49)parking of vehicles near service building. 50) noise pollution in mill area. 51)service pump sunction line choking. 52)valve identification problem. 53)vacuums pump choking. 54) Ash dyke overflow. 55) Low line vacuum in fly ash evacuation system. 56)problem in PHE change over. 57)Bearing damage of series pumps. 58)High vibration in FAHP pump.

AFTER BRAINSTORMING THE PROBLEMS ARE CATAGORISED AS UNDER

TYPE -A TYPE-B TYPE-C

08 32 18

TEP- 2 :

WE HAVE SOLVED ALL “A” TYPE PROBLEMS

AFTER BRAIN STORMING OUR TEAM MEMBERS SELECTED THE FOLLOWING PROBLEMS FROM THE ABOVE “B”TYPE PROBLEMS 1.Wastage of condenser sump pit water 2. Bottom ash drain pump over load. 3. LRSB not retracted. 4. Low condenser vacuum in u#1 5. High vibration in FAHP pump. 6. Mill motor brg. Temp. going high. 7. Mill#1C classifier temperature low during rainy season. 8. Soot blower flange leakage. 9. Jamming of material handling valve. 10.Drain valve of BFPs passing. 11. Tripping of ash evacuation system. 12.Ash leakage from hoppers.

THE “B”CATAGORISED PROBLEMS ARE PRIORITISED BY NOMINAL GROUP TECHNIQUE. (NGT) SCALE : 1 - 10 WEIGHTAGE BASIS: 1. SAFETY 2. PRODUCTIVITY 3. HOUSE KEEPING 4. QUALITY 5. ENVIORNMENT
PROBLEM NO.

1
MEMBERS

2 8 7 9 8 7 39 4

3 9 8 8 7 6 38 5

4 8 7 8 7 6 36 7

5 5 9 10 9 7 40 3

6 6 9 6 4 5 30 11

7

8 6 5 7 5 6 29 12

9 8 6 8 7 8 37 6

10 6 5 7 8 6 32 9

11 7 7 6 9 6 35 8

12 6 5 7 6 7 31 10

R.R. NAIK J. SAHOO N.K. PRADHAN H.K. UDAN S.K. SAHOO TOTAL
 

8 9 8 9 8 42 2

9 10 9 8 9 45 1

RANKS

NO.

ACTIVITY

1 Defining problem 2 Analysing the problem 3 Identifying the cause 4 Finding out root cause 5 Data analysis 6 Developing solutions Foreseeing probable 7 resistance Trial implementation and 8 Checking performance 9 Regular implementation 10Follow-up / Review

123 12 13

45

TIME in weeks

67

8

9 10 11

TARGET (12 WEEKS )

Glass Window Conveyor Belt Bunker

Feeder Drain line

Mill # 1 C
DESIGN BY MR R.R.NAYAK

COAL BUNKER

Storage of coal . No need of continuous through conveyers .
Total capacity is 1600Tone.

feeding

FEEDER

• To supply coal to the mill for •

pulverization . To regulate coal supply to mill .y much sought internationally.

MILL

Pulverizing the coal to desired fineness . Supply pulverized coal to boiler .

BUNKER FLOOR

Unload the coal from conveyor . Bunker feeding .

By using Flow Diagram
START
IT IS RAINING
YES
VERY MUCH WET COAL COMING IS HOT AIR DAMPER YES FULLY OPEN

NO

MILL # 1C CLASSIFIER TEMP LOW

WET COAL COMING FROM CHP

ARRANGE PROPER DRAINAGE

NO
C&I PROBLE M

END

FLOW CHART FOR MILL#1C CLASSIFIER TEMPERATURE LOW

STEP- 4 :

DATA SHEET BASED ON OPERATION LOG SHEET
MONTH JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPT EMBER OCT OBER NOVEMBER DECEMBER TOTAL MILL#1C classifier temp lo. 0 0 3 4 6 10 7 3 4 1 0 0 38

DATA COLECTED BY MR.H.K.UDAN & MR.S.K.SAHOO

STEP- 5 :
MACHINE
PA HEADER TEMPERATU RE LOW HOT PA DAMPER NOT OPENING BYPASS PA FLOW LO

MAN
MIXED AIR GATE OPENING PROBLEM MALFUNCTIONING OF C&I EQUIPMENT

FACILITY NOT PROVIDED MISTAKE BY OPERATOR INSUFFICIENT TRAINING INADQUATE KNOWLEDGE

COLD AIR GATE ERRODED

MILL 1C CLASSIFIER TEMP LOW
NO PROPER HEATING AT MIXING BOX NO GLASS AT THE WALL WINDOWS RAIN WATER INGRESS AT BUNKER FLOOR

DAMPER TO ACTUATOR DELINKED

VERY WET COAL

MATERIAL

PROCEDURE

NO BARRIER SURROUNDING BUNKER TOP OPENING

(CAUSE & EFFECT DIAGRAM)

STEP- 6 : VALIDATION OF ROOT CAUSES THROUGH COLLECTING DATA FROM OPERATION LOG SHEET 
SL.NO TYPES OF CAUSE
VERY MUCH WET COAL.

FREQUENCY

1 2 3 4

5 7 4 1
DATA COLECTED BY MR.N.K.PRADHAN & MR.JADUMANI SAHOO

WATER INGRESS AT BUNKER FLOOR. MALFUNCTION OF C&I EQUIPEMENT. HOT PA DAMPER NOT OPENING.

PARETO TABLE
CAUSE  NO

TYPE OF CAUSE

NO OF  OCCURENCE

CUMMULATIV E

% TO TOTAL

COMULATIVE          %

1

WATER INGRESS AT BUNKER FLOOR.

07

07

41 . 2

41 . 2

2 3 4

VERY MUCH WET COAL. MALFUNCTION OF C&I EQUIPEMENT. HOT PA DAMPER NOT OPENING. TOTAL

05 04

12 16

29 . 4 23 . 6

70 . 6 94 . 2

01 17

17

5.8 100

100

CONTRIBUTION OF CAUSES TO THE PROBLEM ( SHOWN IN %)

23. 6 % 29. 4 %

5. 8 %

41. 2 %

CAUSE NO-1 CAUSE NO-2 CAUSE NO-3 CAUSE NO-4

STEP-8 : DEVELOPING SOLUTIONS PARETO ANALYSIS
17 14.825

94.2 70.6

100 % 87.5%
75%

FREQUENCY

12.75 10.625

8.5 6.325
4.25

41.2

50 %
37.5% 25% 12.5%

2.125

1

2

3

4

CAUSE NO

CUMILATIVE %

62.5%

OF CAUSE NO.1
( TOOLS USED BRAIN STORMING )

TOOLS USED BRAIN STORMING

OF CAUSE NO.1

OF CAUSE NO.2 TOOLS USED BRAIN STORMING

OF CAUSE NO.3
TOOLS USED BRAIN STORMING

OF CAUSE NO.4
TOOLS USED BRAIN STORMING

STEP-9 :

FORSEEING THE PROBABLE RESISTANCE

Discussed about the problem, its  causes and analysis with our     HOD (O&C) The proposed solution was  conveyed to him, got verbal  approval to go ahead for trial  implementation.

NO.

ACTIVITY

COMPARATIVE MILESTONE TIME CHART in weeks

1 Defining problem 2 Analysing the problem 3 Identifying the cause 4 Finding out root cause 5 Data analysis 6 Developing solutions Foreseeing probable 7 resistance Trial implementation and 8 Checking performance 9 Regular implementation 10Follow-up / Review

1 2 3 4 5 6 7 8 9 10 11 12 13 14
TARGET ( 12 WEEKS ) ACTUAL ( 13 WEEKS )

INTANGIBLE BENEFITS
BY THE END, WE HAVE ASSESED THE BENEFITS TO THE MEMBERS SUCH AS:
→ → → → → → → → IMPROVEMENT OF SELF CONFIDENCE. KNOWLEDGE REGARDING QC TOOLS/TECHNIQUES SPEAKING UP AT MEETING INCREASED. CREATIVITY HAS INCREASED. IMPROVEMENT IN ABILITY, TEAM WORK AND INTERACTION WITH OTHERS. USING COMPUTERS . STAGE FEAR REMOVED. TIME MANAGEMENT IMPOVED.

ABOVE ALL OUR CIRCLE HAS INSPIRED THE NON MEMBERS AND NEW CIRCLES ARE FORMED IN OUR DEPARTMENT.

Mill#1C classifier temperature during rainy Season can be adequately maintained & Feeder floor will not be dirty.

FLOW DIAGRAM BRAINSTORMING DATA COLLECTION CHARTS & GRAPHS CAUSE AND EFFECT DIAGRAM PARETO ANALYSIS

CREATED BY JADUMANI SAHOO