8

REPRISM 2021

CASE STUDY SUBMISSION

Instructions for filling out the application form

1. Provide complete and accurate details in part A. These details are subject to independent
validation. Any discrepancies can lead to disqualification of your entry.
2. Fill all details in Part B. All details are critical for the holistic evaluation of your
nomination/application.
3. Projects initiated between 1st April, 2019 to 1st September, 2021 are eligible for participation.
The project implementation should have been completed before 1 st September, 2021. In
case of major projects awaiting final completion please ensure that the entries cover details
of milestones completed before 1st September, 2021.
4. The participants can be from the Total Quality Management, Technical Services,
Production, Operations, Engineering, Maintenance, Projects, Power, Quality Control, R&D
or mining.
5. The teams need to mandatorily include 1 young engineer (less than 5 years experience)
and/or 1 woman engineer from the manufacturing functions.
6. You can use this format to share entries with your Unit head / Unit HR head for the internal
screening process. The number of nominations per unit are limited (Large – 5 Mid – 3 and
small – 1. ABSTC as an independent unit can submit 2 entries). Please take an on-mail
approval from your unit head and/or unit HR head before you submit your case study online
for the committee evaluation process.
7. The submission link for the committee evaluation process will be shared on 6 th October,
2021 The submission window will be open from 7 th October, 2021 to 9th October, 2021
23:59 hours IST. Kindly note that no entries will be accepted post the completion of the
registration window.
 8

Part A
Application category
S. Select relevant
Category check box
No.
1 Maintenance and Productivity ☐
Agility and
2 Process and Workflow 
excellence in
3 Clean green initiatives 

Team details
SPOC details (all communication / clarification regarding the application will be shared with the SPOC)
Name
Poornata ID
Job Band
Department
E-Mail ID
Mobile No.
Location
Unit &
Business

Other Team Members

Young engineer /
Woman
Poornata Job Employee (Y/N) Business –
Name Department (For Young Engineers
ID Band Unit
also indicate year of
passing and total
years of experience)
  Sanjay Kumar Cpp Opr 8 MAHAN
Neeraj Sharma Cpp Opr 9 MAHAN
Ravi Singh Cpp Opr 10 MAHAN
 8

Part B
Project / Initiative Title

REDUCTION IN UNIT COLD STARTUP TIME & OIL COST OPTIMIZATION

Project/Initiative Start Date Project/Initiative Completion Date

01/04/2019 31/07/21

Executive Summary
Briefly describe the achievement in terms of the situation or the challenge, action taken and impact
maximum 300 words

• Unit Light up is a complex process comprising of several steps which need to be well coordinated in
order to achieve both process and cost effectiveness. Time becomes an important factor during unit
light up, synchronization and load rising. Cold light up is the most time and cost consuming activity of
unit operation. Analytically we found that there was a huge deviation in time required for unit cold start
up proposed by OEM as compared to actual. Specific oil consumption was very high and not in line with
our P&B target besides oil prices were increasing day by day due to inflation. Our method of Boiler hot
flushing and condensate dumping reduced the after AOH cold start up time by 50 % along with saving
of 27 KL of fuel oil per light up after AOH and 10 KL in normal cold light up.

Synopsis (Details of Project/Initiative/Achievement in not more than 6 pages)

 8

PREVIOUS HISTORICAL DATA

DESIGN TIME FROM ACTUAL TIME FROM

DATE OF LIT OIL
UNIT LIGHT UP TO LIT UP TO
UP CONSUMPTION
SYNCRONIZATION SYNCRONIZATION
4 15.01.2019 180 MIN 17.5 HRS 62.69 KL
2 2.12.2017 180 MIN 14.5 68.5 KL
1 1.09.2017 180 MIN 14.5 HRS 75.38 KL
3 4.05.2017 180 MIN 15 HRS 74.83 KL

COLD START UP CURVE – (180 MIN for synchronization “predicted”)

Activity Time consumption ( min) Oil consumption @ 6kg & 4 oil guns
Bringing Drum Metal temperature to 100 DegC 40 4
Steam Dumping 90 7.2
Rolling @ 600 RPM 30 2.7
Rolling @ 3000 RPM 20 1.8
Synchronization and load raising 80 MW with heater charging 90 8.1
 8

Delay activity factors Frequency Cumulative Cumulative %

Steam parameter not stabilizing 35 35 43.75%
Sample line chocking 18 53 66.25%
Equipment line up 12 65 81.25%
Unplanned equipment breakdown outage 8 73 91.25%
Process requirement step delay 5 78 97.50%
Fuel interruption 2 80 100.00%

40 120.00%

35
35 100.00%
97.50%
100.00%
91.25%
30
81.25%
80.00%
25
66.25%

20 18 60.00%

43.75% Frequency
15 Cumilative %
12 40.00%
10 8
5 20.00%
5
2
0 0.00%
Steam Sample line Equipment Unplanned Process Fuel
parameter not chocking line up equipment requirement interruption
stablising breakdown step delay
outage

DATA ANALYSIS RESULT USING PARETO ANALYSIS

 8

Key Initiatives taken for reducing oil consumption & Startup time are:
 
⮚ Initial heating and Hot water flushing: With this method drum metal temperature was achieved 100 degC,
without oil support, giving substantial saving in oil consumption. Further, hot water flushing before oil
firing ensured achieving quality steam parameters early reducing overall start-up time.
⮚ Condensate dumping line: Additional Condensate dumping line was made operational in opportunity
shutdowns by a modification done in condensate line.
⮚ Sample line chocking: Sample lines got chocked due to foreign impurities in boiler which increased sample analysis
time therefore causing delay in process. Additional connection to sample line from Main steam drain line eliminated
this problem
⮚ Furnace temperature probe commissioned: Making FTP operational ensured standardization of coal mill
cut in time as per OEM startup curve.
⮚ Further deployment of dedicated person for steam quality analysis, pre startup checks and equipment trials
before start-up ensured reduction in unplanned delays.
 8

TANGIBLE AND INTANGIBLE GAINS-

Direct reduction in AOH light up oil consumption

⮚ Initial heating : 4 KL
⮚ Boiler hot flushing : 16 KL
⮚ Condensate dumping line: 7 KL

Total – 27 KL

Direct reduction in Normal cold light up oil

consumption
⮚ Initial heating : 4 KL
⮚ Hot water flushing: 3KL
⮚ Condensate dumping line :3 KL

Total – 10 KL
 8

IMPACT ON SPECIFIC OIL CONSUMPTION

Lowest specific oil consumptiobn benchmark figures in similar capacity units.

AFTER IMPLEMENTATION DATA

DATE OF UNIT TIME OIL Oil saved Equivalent
AOH LIGHT ( HOURS ) CONSUMPTION (previous cost saving
UP ( KL ) avg. 65 KL) @52000/KL
2 APRIL 2019 6 9.1 41 24 12.48 Lakhs
7 JUNE 2020 3 8.4 35 30 15.60 Lakhs
28 SEP 2020 3 8.1 33 32 16.64 Lakhs
28 DEC 2020 1 6.8 23 42 21.84 Lakhs

DESCRIPTION PROJECTED SAVING

COLD LIGHT UP AFTER AOH X 3 NOS PROJECTED @15 Lakhs /light up 45 lakhs

NORMAL COLD LIGHT UP X 6 NOS PROJECTED @ 10 KL/light up 31.2 lakhs

TOTAL SAVINGS PROJECTED 76.2 lakhs

* As number of light ups and AOH are uncertain an approximate value has been considered for
calculation purpose.
 8

Q&A – Project Highlights

This was a team project which started from Unit #6 of MAHAN as part of
improvement initiative.
To understand the scope, benefits and results a six month time window was
considered.
Opportunities were limited as AOH were planned for only 3 units per year.
Later the process modification has now been carried in every AOH for a period
of one and a half years and the results have been sustainable.
At the beginning phase this project was one of its kind, later on seeing the
benefits same was implemented at ADITYA.
The biggest advantage of this project that it does not involve any investment
and has been done completely in-house.
Last but not the least it is completely safe and causes no harm to man or
machine, in fact it reduces the ESP charging time to reduce environment
pollution.
 8

Please answer the following questions:

1. What were the challenges faced by the Unit/Business/team/individual OR the reasons for the
introduction of this initiative?
2. What are the details of the initiative? These could include
a. Design Elements (including who was involved. whether any consultants were used),
b. Planning & Execution –
i. Benchmarking study, if any
ii. Research Completed
iii. Key action steps
iv. Timelines
3. What were the results achieved? Elaborate on achievements against targets set as well as
impact on business. Please quantify in value terms wherever feasible.
4. Were there any surprises / unexpected challenges faced while executing the initiative? If so,
how were they handled?
5. What were the key learnings during the journey? What could the team/individual do differently
if they had to undertake the same initiative all over again?
6. How long has the initiative been in place and what processes and systems have been built
around the same to sustain the initiative?
7. What is unique about the project / initiative?
8. Share Evidence of Success - What has the Return on Investment been and how has the
initiative strengthened the organization?

Results Achieved (the list is indicative – you could include other relevant parameters)
 8

Parameter Result
Finance (report both in Cr INR and Mn USD)
CAPEX employed NIL
Overall Rupee/Dollar Value Saved
Increase in Revenue / EBITDA  
Saving in OPEX
Operational Efficiency

Increase in Production  
Reduction in energy consumption (in kWh)
Reduction in Manpower (hours saved)
Better management of inventory
Reduction in unplanned downtime 50 %
Customer
Reduction in Customer Complaints  
Value delivered for customer  
27 Kl of oil per AOH light up & 10 Kl
Quality cost reduction
normal light up.
Have you productized the innovation? No
Environment
Energy consumption reduction (in kWh)
Waste Reduction
Water Consumption Reduction (in kilolitres)
Recognition from Environmental Bodies Early charging of ESP
Learning / Growth
Is the project replicable and scalable across
different units / businesses? Please provide Yes, Aditya
details of cross unit
Have you shared the knowledge acquired
with any other units / presented across
Yes , Aditya
business specific forums? Have the learnings
been implemented across business units?
Any recognition received (Internal or External)
Unit head at MPR
for this Projects – Please specify
 8

Have you filed a patent / initiated any IPR

related proceedings in any geography? No
(Please provide details)
*Others Specific oil consumption.
* Represents any measurable parameter which has been impacted by the submitted entry

Any other specific remarks

This is a project where we have brought an improvement in unit

synchronization time without compromising any criteria in terms of steam
quality and at same time creating a meaningful impact on power plant
quality & CAPEX parameter “specific oil consumption”.

*******************