UNCHAHAR

Udaan
Quality Circle
Welcomes You All

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

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

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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
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INTRODUCTION OF TEAM

Sh. Bhola Nath Sh. A. Banerji Nitin Pal Siddharth Sonker

GM-O&M GM-OPERATION Megha Chaurasiya
FACILITATOR DY. FACILITATOR
CO-ORDINATOR

M. K. Gupta Rajesh Kumar A. K. Singh

Leader Dy. Leader Member
AMIE-MECH DIPLOMA-MECH AMIE-ELEX.

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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

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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

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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

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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

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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
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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

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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

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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

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SELECTION OF PROBLEM

Selected Problem

Frequent tripping
of Vacuum pumps in AshHandling Stage-IV

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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

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DEFINE THE PROBLEM

Flue Gas Path

Problem Area
Problem Area

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DEFINE THE PROBLEM

Flow Diagram

ESP Collecting
Plate Problem area

Hoppers

Hopper ash is evacuated by the vacuum

pumps
Ash collected in Buffer Ash collected in Collector
Hopper tank

Sil Ash Slurry Pump

o House

Truck Ash
Loading Dyke

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DEFINE THE PROBLEM

OFF
TAKE PIT
ASH FAHP
PROBLEM AREA
WATER
TANK
WETTING
UNIT

VACUU
WET- M
PUMP
MODE ESP
DEASHING HOPPER
S
SYSTEM ASHSLURR
Y PIT

ASH
DYK
E
ASH SLURRY
SERIES

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DEFINE THE PROBLEM
Impact of Problem

Impact on working Impact on process:--

person:--

Unsafe working area SPM

increasing

Hopper poking
manually due to Deashingtime
deashing disturbance increasing

Health problem Electrical MCC

of working
disturbance
person

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DEFINE THE PROBLEM

Objectives for Problem Solution

Availability of AHP
System

Healthy Environment

Decrease

Maintenance System

Reliability
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DEFINE THE PROBLEM

Set Goal

Our Aim :- Minimizing the Frequency of Vacuum Pump

tripping by 100% .

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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

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ANALYSIS OF THE PROBLEM
Data Collection – Loss Calculation

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

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

Avg. Man power

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

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

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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

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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 Bearing temperature high
dedication Misalignment
Lack of concentration Lack of process information Under greasing
Bearing jamming High Vibration
Frequent change
No availability
of senior of staff
Over current
Frequent
persons 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
Carryover
Bearing jamming Ash stuck up 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

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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 Yes

Line choking

5 Lack of dedication Not Found No Effect No

6 No availability of senior persons Not Found No Effect No

Frequent change of staff Not Found No Effect No

7
Inadequate seal water pressure Found Air ingress in pump Yes
8

9 Pressure more than design Not Found No Effect No

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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

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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

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DATA ANALYSIS
Pareto Diagram

30 120

Vital Few Useful many 100

25 100
92.4

20 76.92 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

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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.

te d
ec
Rej

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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.

te d
ec
Rej

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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

pted
Ac ce

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DEVELOPING SOLUTION

Selected Solution

Installation of orifice in the seal water line before

vacuum pump.

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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 No. Standby vacuum pumps will be taken
Operation 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.

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 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
collected -
•Plan is to be done for
• Ms flange joints
other vacuum pumps.
• Nuts and bolts.
•Collection of • Orifice of ID – 12 mm
data and performance • Welding rods & machine
• Presentation

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

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TRIAL IMPLEMENTATION & CHECK UNCHAHAR

PERFORMANCE

Installed
Orifice &
Flange
joints

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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

Description
Duration Duration:
: 16 Jan.
26
2018 to 15
Feb. 2019 16 Feb.
2019 to 18
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
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TRIAL IMPLEMENTATION & CHECK PERFORMANCE

90% Goal Achieved

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REGULAR IMPLEMENTATION

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

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

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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

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REGULAR IMPLEMENTATION
Total Loss Before Project

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

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

Avg. Man power

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

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

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REGULAR IMPLEMENTATION
Total Loss After Project

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

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

Avg. Man power

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

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

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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

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

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

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REGULAR IMPLEMENTATION

Intangible Benefits

Increased safety of
working person .

Increased System
continuity & reliability

Reduced MCC
disturbance

Increased self
confidence & moral
of QC members.

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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

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FOLLOW UP & REVIEW
Actual/Comparative Milestone Chart
Utthan Quality Circle 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 Rajesh Kumar - Dy. Leader
Handling Stage-IV A K Singh - Member
Plan
Problem No. 10 Start Date:15/01/2019 & Completion Date:20/03/2019
Description Time in weeks
Actual
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                        

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TOOLS & TECHNIQUES USED

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

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OUR PROJECT

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

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ANY SUGGETION PLEASE

THANKS.

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