It Is Quality of our WORK

PIKA TECH
Which Will Please The GOD
Not Quantity
Mahatma Gandhi

01
 TITLE

“Innovative approach
towards water conservation
PIKA TECH

and containing pollution.

02
PIKA TECH GROUP MEMBERS

S.P.Singh D.S.Dewangan Ramesh Ghate

03
F.R.Verma Santosh Ingale Sandeep Bedpuriya
PIKA TECH WELCOME

PIKA Tech
Heartily greets
you
all

04
 INTRODUCTION

Facilitator
Mr. Sumeet Kumawat
PIKA TECH
Sr.Manager (H&R)

Shop Coodinator
Mr. Atul Goswami
AGM (H&R)

Approved by

Mr. J. Arjun Prasad

GM (CO&CCD)

05
PIKA TECH Steel Authority of India Limited

MAHARATNA COMPANY

TURNOVER OF- RS. 49,350 CRORE STEEL PRODUCTION -13.4MT

06
 BHILAI STEEL PLANT
TURNOVER OF- RS. 15530 CRORE PRODUCTION -5.03MT
PIKA TECH

BSP IS FLAGSHIP INTEGRATED STEEL PLANT OF SAIL

05
ANKUSH QC BSP
7
 BHILAI STEEL PLANT
• ISO-9001: 2008 (QUALITY MANAGEMENT
SYSTEM)
PIKA TECH

• ISO-14001:2004 (ENVIRONMENT
MANAGEMENT SYSTEM)

• SA-8000:2001 (SOCIAL ACCOUNTABILITY

SYSTEM)

• OHSAS:18001:2007 (OCCUPATIONAL
08 HEALTH & SAFETY ASSESSMENT SERIES)
 OUR PRODUCTS

TMT RODS
PIKA TECH

260M LONG RAILS

09
PIKA TECH SPECIAL FEATURES

DMR-249A PLATE FOR AIRCRAFT CARRIER

10 BANDRA-WORLI BRIDGE SAIL TOWER GRADE STEEL

 SOCIAL NEEDS
PIKA TECH

11
 OUR ACHIEVMENTS

PRIME MINISTER’S TROPHY

PIKA TECH

TIME WINNER

12
 OUR ACHIEVMENTS

 Green Tech Silver Safety Award

PIKA TECH
 Indira Gandhi memorial National Award
for Pollution control
 Gold medal in metal sector for outstanding
achievement in Environmental Management
 H.R. excellence Award by CII Chhattisgarh

Many Shram & Vishwakarma awards

13
 GROUP STATUS

Date of formation of Circle - 07- 07- 2012

PIKA TECH
Date of start of present Project - 12- 11- 2016
Date of completion of present
Project - 31- 03- 2017
No. of Project undertaken by
Group so far - 23
No. of Project completed by
the group so far - 20
Frequency of meeting - Every Saturday
Attendance in meeting (%) - 97.8 %
14
 OBJECTIVES OF GROUP

 To have Awareness regarding

PIKA TECH
Safety.
 To Improve Housekeeping.
 To Achieve Production Target.
 To Maintain a healthy work
atmosphere in C.O. Batteries.
15  To Improve Quality.
 POLLUTION IN
AN INTEGRATED STEEL PLANT

Rolling Mills
PIKA TECH

Converter 12%
6%
Blast Furnace 6%
Coke Ovens

Sintering Plant 16%

60%

16
 POLLUTION
PIKA TECH IN COKE OVEN BATTERY

Off-main charging 42% Hatch 4% S.P.CAPS 22%

11
Doors 18% Window 06% Miscellaneous 06%
 NORMS OF CENTRAL POLLUTION CONTROL
BOARD & STATE GOVT. POLLUTION BOARD

Parameters
PIKA TECH

PLD < 10%

PLO < 4%
PLL < 1%
PLD :- PERCENTAGE LEAKAGE DOORS

PLO :- PERCENTAGE LEAKAGE OPENINGS

18 PLL :- PERCENTAGE LEAKAGE LIDS

 S. P. CAP WATER SEALING

Gas Emission from Water sealing

S.P.Cap
PIKA TECH
canal

S.P. cap

19
 WATER AUDIT REPORT BY WATER
MANAGEMENT DEPARTMENT DT. 02.09.2011

 S.P. caps - 195 m3/hr

PIKA TECH
water sealing
 Bed drainage system - 50 m3/hr
 Misc. leakages - 40 m3/hr
 Dewatering of - 15 m3/hr
Communication tunnel

 TOTAL - 300 m3/hr

20
 CONTAMINATED WATER

Water containing highly

PIKA TECH
toxic Phenol, Cyanide,
Ammonia, Tar, Oils, Alkalis,
Acids and Sulphuric acids
etc.
State Pollution Control Board Concept of
“ZERO DISCHARGE

23 CRORES RUPEES PER ANNUM

21
 LEGEND

“Ups and down in life

are very important to
PIKA TECH

keep us going, because

a straight line even in
an E.C.G. means we
are not alive.”
-- Ratan Tata

22
 IDENTIFICATION OF PROBLEMS
1 Failure of reversing winch without alarm.
2 Sludge Box over flow.
3 Jamming of the cap sealing return water line canal.
4 Stand Pipe cap sealing water over flow.
PIKA TECH
5 Flushing of S.P. cap drain line.
6 Cleaning Strainer of H.P.L.A. of Batt# 6.
7 H.M. regulators do not start automatically as power supply resumes.
8 Jamming of the condensate line.
9 Difficulties in cleaning of the goose necks.
10 Difficulties in logging the temperature of pyrometer at night due to poor
visibility at oven top.
11 Frequent breaking of the coupling bolts of the oil pump.
12 No reversing alarm at oven top.
13 Necessity of automatic control of side dampers in Hydraulic main.
14 A.C. of Battery # 4 not working properly.
15 Window latches not sitting properly.
16 Difference in p/s and c/s H.M. pressure.
17 Frequent jamming of the Goosenecks.
18 Jamming of Stand pipes.
19 Leakage of raw gas from charging lids.
20 Leakage of raw gas from Valve Box/Goose Neck joint.
23 21 Open close marking of the stop cocks at upper tunnel vanished.
22 Peep holes not getting closed due to jamming of lids.
 23 Frequent falling of the D.C. lids.
24 Leakage of raw gas from oven windows.
25 Falling of the finger plates in Battery#1.
26 Blackening of S.P. base in Batt#5&6.
PIKA TECH
27 Jamming of the charging Hatches.
28 Difficulties in cleaning T.R.V.spindles.
29 Frequent failure of reversing winch in Battery#4.
30 HPLA valves left open in more than 2 ovens.
31 Locking pins of HPLA valves missing.
32 Breaking and deformation of Tie-rods.
33 No alarm of Hydraulic pump’s failure in control cabin.
34 Over heating of the Waste Heat Boxes.
35 Jamming of coal bunkers during rainy season.
36 Low, end vertical temp in Batt#7.
37 Accumulation of water in front of Batt#4.
38 Falling of coke out side of wharf.
39 Hot spots on quenched coke.
40 Steam valves left open after charging.
41 Coke mass colour dull in middle zone of Batt-3.
24 42 NRV in Booster pump in H.P.L.A. of Batt#5.
43 Removal of oven sole plate.
 TOTAL 55 PROBLEMS LISTED

44. Fluctuation in pre heater temperature.

45 Cracking sound from karnoor plugs.
PIKA TECH
46 Deposition of tar on Goose neck cleaning hole.
47 Falling of Door quenching water in to tunnel.
48 Burning of outer covering wall of Gun-flue zone just
after charging of ovens.
49 Burners of heating flues become crack or out
frequently in Batt.#5.
50 Difficulties of operating suction valves due to manual
operation in Batt.#5&6.
51 Chocking of impulse lines of instruments.
52 Platform for Mixing Station Regulator rotation.
53 Chimney smoking in Batt.#1&7.
54 No alarm of Ammonia liquor failure in control cabin.
25 55 Improper charge level in ovens of Batt.#5&6.
PIKA TECH SELECTION OF PROBLEMS

The problem which can be solved by the circle

members themselves

The problems which need help of other sections for

solution

Problems which require the help of Management for

solution

26
PIKA TECH STRATIFICATION OF PROBLEMS

29
55
P 30
R
O 21
B 20
L
E 05
M
S 10

CATEGORIES
27
 CRITERIA FOR SELECTION

1. PRODUCTION
PIKA TECH

2. SAFETY
3. QUALITY
4. ENVIRONMENT
5. HOUSEKEEPING
28
 PRIORITISATION

Affecting 5 criteria
PIKA TECH
5 Affecting 4 criteria
5
Affecting 3 criteria
3
4 Affecting 2 criteria
5
3 Affecting 1 criteria
7
2
9
1

A B C D E

No. of problems

29
 MAIN PROBLEMS

1.Sludge Box Over flow.

PIKA TECH

2.Blackening of Stand pipe base in Batt # 5&6.

3.Stand Pipes Cap sealing water over flow.

4.Improper charge level in Ovens of Batt # 5 & 6.

5.Gas leakage from Gooseneck / Valve box joint.

30
 PRIORITIZATION
BY NOMINAL GROUP TECHNIQUE

ASSEMBLED THE GROUP

PIKA TECH

PROBLEMS WERE EXPLAINED

MEMBER WERE ASKED TO SHOW

THEIR PRIORITIES WITH REASON

PRIORITIES OF EACH MEMBER ADDED

TOGETHER

THE PROBLEM WHICH COUNTS LEAST

31 WAS SELECTED FOR SOLUTION
 PRIORITIZATION
BY NOMINAL GROUP TECHNIQUE
S Problems MARKS BY GROUP MEMBERS Total Rank
N
o DAKOR VERMA GHATE INGALE SANDIP
PIKA TECH
1. Sludge Box 5 4 5 1 4 19 5
Over flow
2. Blackening
of S.P base
in Batt#5&6 4 3 1 4 5 17 3
3. S.P. cap
sealing
Overflow 1 2 2 2 1 8
4. Improper
charge level
of Batt #5&6 2 1 4 3 3 13 2
5. Gas
Leakage
32 from VB/GN
joint
3 5 3 5 2 18 4
 DATA SHEET

S Months
No Problems
May June July Aug Sept Oct Total Avg.
2016 2016 2016 2016 2016 2016
PIKA TECH
.
1. Sludge Box 82 84 83 81 85 83 498 83
Over flow

2. Blackening of 220 228 222 226 225 223 1344 224

S. P base in
Batt#5&6

3. S.P cap 680 661 652 634 671 666 3964 660
sealing water
Overflow

4. Improper 85 89 90 84 86 89 523 87
charge level of
Batt #5&6

5. Gas Leakage 35 41 38 36 40 38 228 38

33 from VB/GN
joint
 PIE CHART OF THE PROBLEMS

4%
PIKA TECH
10% 9%
Slug box overflow

Water overflow from

25%
AP caps sealing
52% Blackening of AP base
black
Improper charge level

Gas leakage V.B./G.N.

34
 THE PROBLEM

Water
PIKA TECH

overflow From
Stand pipe
Caps sealing
in

35 Battery 5&6
 WATER OVER FLOW FROM ASCENSION PIPE CAP SEALING
MILESTONE CHART PLAN

Q.C Name:- PIKA TECH DEPT. CO & CCD Facilitator SUMEET KUMAWAT Member Name

Project; Water over flow from S. P. cap Damage Battery brick work & reduce battery life S P.SINGH
PIKA TECH
sealing D.S.DEWANGAN
F.R.VERMA
Project No.:-20 Date of Beginning 17-12-16 Date of Completion:- 31-03-17
SANDEEP
RAMESH GHATE
Meeting Day :- Saturday No. of Project Completed :-17
SANTOSH INGALE
SL Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
. Activity
No
1. Defining the problem

2. Analyzing the problem

3. Identifying the cause

4. Finding the root cause

5. Data analysis

6. Developing solution

7. Foreseeing problem
resistance

8. Trial implementation &

checking performance

9. Regular
implementation

10 Follow up (review)
PIKA TECH BLAST FURNACE

37
PIKA TECH COKE OVEN BATTERY

38
PIKA TECH HOT COKE

39
40
PIKA TECH

OVEN
41
PIKA TECH
42
PIKA TECH
43
PIKA TECH
44
PIKA TECH
 DEFINE THE PROBLEM
THROUGH FLOW DIAGRAM

ISOLATE I / V OPEN A/P NOTCHING OPEN DOOR

START
PIKA TECH
HANDLE CAPS PREVIOUS OVEN

CLOSED A/P CAPS PUT HPLA ON CLOSED THE DOOR OVEN PUSHED

NO
CHARGE OVEN IF GAS
LEAKAGE CHARGE NEXT OVEN
FROM STOP
CAP
GAS THROUGH
GCM YES WHARF/ C.S.P
OPEN WATER

PRIMARY
COOLERS
AREA BLAST
NO
WHERE IF FURNANCE
EXAUSTER PROBLEM WATER
LIES OVER
FLOW
CCD
YES S/P CAP SEALING
DRAIN LINE

45
RODING
 DIFFICULTIES:- S/P BASE BLACK
PIKA TECH

DAMAGES
OVENS BRICKS

46
 DIFFICULTIES:- GREEN COKE
PIKA TECH

COKE
QUALITY
DETERIORATE

47
 DIFFICULTIES:- SKILLED MANPOWER
PIKA TECH

Extra man days required to

monitor cap sealing water
48
over flow & Roding
PIKA TECH DIFFICULTIES:- S.P.BASE CORROEDED

Frequent damage of Stand pipe

base Bricks due to water
49 ingress in base joint.
PIKA TECH DIFFICULTIES:- HOT WATER

SAFETY
THREATS
DUE TO
HOT
WATER
FALLING.

50
 DIFFICULTIES:- HIGH CONSUMPTION

.
PIKA TECH

HIGH
CONSUMPTION
OF WATER

51
 DIFFICULTIES:-REDUCES BATTERYLIFE
PIKA TECH

52
 SETTING OBJECTIVE

 To Improve consistency in
PIKA TECH

production.
 To Improve Coke quality.
 To maintain the stipulated
environment norms.
 To Optimize man power
requirement.
 To Improve Battery life.
53
 SETTING GOAL

GOAL
PIKA TECH
600
OCCURRENCE IN NOS.

450
659
300 Times/
Month
150
0
0

54 RESTRICT WATER OVERFLOW

 ANALAYSIS OF PROBLEM
4W & IH(EXCEPT WHY)
SL NO CRITERIA DESCRIPTION
WHAT? STAND PIPE CAP SEALING WATER
PIKA TECH
1 IS THE PROBLEM?
OVER FLOW
WHEN? WATER STARTS FALLING OUTSIDE,
2 PROBLEM ARISES?
IN PLACE OF GOING THROUGH
DRAIN LINE
WHERE? BATTERY OVEN TOP
3 PROBLEM COMES?

WHO? OPERATION PERSONS PUSHING

4 WAS EFFECTED?
TARGET, BATTERY LIFE, GAS MAKE,
MANPOWER CONSUMPTION,
AND ATMOSPHERIC POLLUTION

HOW? DUE TO CHOKING, EXCESS WATER

5 THE PROBLEM
55 ARISES?
PRESSURE, ETC.
PIKA TECH WHAT IS THE PROBLEM ?

WATER OVERFLOWING
FROM S/P CAP
SEALING

56
PIKA TECH WHEN THE PROBLEM ARIES?

WATER STARTS
FALLING OUTSIDE, IN
PLACE OF GOING
THROUGH DRAIN LINE

57
PIKA TECH WHERE PROBLEMS COMES ?

IN STAND PIPE
CAPE SEALING
WATER CANAL &
DRAIN LINE IN
OVEN TOP OF
COKE OVEN
BATTERIES.

58
 WHO WAS AFFECTED ?

THE MOST AFFECTED

ARE MAN WORKING IN
PIKA TECH
OVEN TOP & D.E. PLATE
FORM, DAMAGE SILICA
BRICKS, FALL OF END
VERTICAL
TEMPERATURE,
ENVIRONMENT
POLLUTION DUE TO
CROSS LEAKAGE, EXTRA
MANPOWER FOR
RODING, SEVERAL
REFRACTORY REPAIR
59 JOBS & BATTERY LIFE.
 HOW THE PROBLEM COME ?
DUE TO DRAIN
LINE/CANAL CHOKING,
PIKA TECH
WATER INLET PRESSURE
HIGH, MISALIGNMENT OF
CAP/FUNNEL .

60
 IMPACT OF PROBLEMS

S. Months
No Problems JULY Aug SEPT OCT NOV DEC
Avg
. 2016 2016 2016 2016 2016 2016
PIKA TECH
1. S/P Base lining 602 617 620 603 580 545 596
(nos.)
2. Coke mass temp. 21 30 33 18 15 13 22
End dull

3. Man power 240 232 254 242 240 220 238

consumed for
monitoring

4. Regenerator face 10 15 20 09 08 06 11
wall patching

5. Lintel burning 15 20 19 15 08 07 14

6. Jam brick patching 09 05 06 04 05 07 6

7. Dusting 05 04 06 04 05 07 5
61 8. Ceramic welding 03 03 04 02 01 02 2
 CAUSE ENUMERATION TYPE
POSSIBLE CAUSE ARE SIMPLY LISTED
Main drain jam Abnormal pressure Malfunction of CCD
pump
PIKA TECH
No flushing point Labor negligence Cap are open during
pushing
No air bleeder CCD pump tripped S/P cap tilted
Air lock in main line Alignment out Accumulation in drain
line
Tar settling Poor Pipe quality Feeder broken
Manual valve not Inspection negligence Choking in cap canal
regulated
Unclean water S/P base corroded Improper individual
valve opening
Tar during cap cleaning Water seeping Insufficient inspection
Graphite during pushing Cost control Rod in side drain line

62 Manual valve not Inspection negligence Choking in cap canal

regulated
 FISHBONE DIAGRAM
MAIN DRAIN JAM FUNNEL CHOKING

GRAPHITE FROM SLURRY

NO BLEEDER
CLEANING OPEN CAP
PIKA TECH
AIR LOCK GRAPHITE UNCLEANED
NO FLUSHING POINT TECH. WATER

IN CONSISTENT
TAR DURING SUCTION
CLEANING OF CAPS
TAR SETTLING TAR DURING WATER
CLEANING OF CAPS
OVERFLOWS
FROM STAND
PUMP PIPE CAP
MISALIGNMENT OF MALFUNCTION SEALING
FUNNEL & DRAIN PIPE

STAND PIPE
Method CCD PUMP TRIP
L1 PURCHAGE
TILTED
POOR UNREGULETED
HUMEN VALVES
INSPECTION
POOR QUALITY ERROR
MANUFACTURING
WORKER VALVE JAM
DEFECT
NEGLIGENCY

63 ALIGNMENT OUT ABNORMAL

PRESSURE
 ROOT CAUSE ANALYSIS
IDENTIFICATION BY VALIDATION

Main Cause Sub-Sub Cause Validation of Why

Results
Graphite from open Accepted During
PIKA TECH
FUNNEL cap pushing
CHOKING Unclean tech. water Rejected Filter mounted
Tar during cleaning Rejected Melt
of caps
No flushing point Rejected Available
MAIN DRAIN Accepted After cleaning
JAM Tar settling
caps
Air locking Rejected Vent provided
Unregulated valves Accepted Unskilled
ABNORMAL
Rejected Short
PRESSURE Labour negligency
manpower
Rejected Tripping
CCD pump trip
Misalignment Accepted Water seeping
ALIGNMENT OUT Rejected Inspection
Manufacturing defect
fault
64 Poor quality
Rejected L-1 supply
 ROOT CAUSES

1. Choking due to Graphite/Algae

PIKA TECH
accumulation.
2. Tar & Coke muck deposited in
Main Drain line.
3. Valves not Regulated properly.
4. Misalignment of Funnel and Drain
pipe.
65
 DATA ANALYSIS BY STRATIFICATION

S. Months
N Monthly
o. CAUSES OCT NOV DEC JAN FEB MAR AVG.
PIKA TECH
2018 2018 2018 2019 2019 2019
1. Improper cooling of 2 2 1 1 2 2 1.67
Ingot Mould
Tackles
2. Improper 0 1 0 1 0 1 0.50
Releasing,Stripping
and Handling
3. Loosening of 0 0 1 0 0 0 0.16
Trunnions

4. Stripping Tackles 0 1 0 0 0 0 0.16

Breakdown

66 TOTAL 2 4 2 2 2 3 2.49
 DATA SHEET

S.No.
Causes Frequency
PIKA TECH
1. Choking due to graphite / algae 515
accumulation
2. Tar & Coke muck deposited in 82
main drain line
3. Valve not regulated properly 36

4. Misalignments of Funnel and 26

Drain line

Total 659
67
 PARETO TABLE

S.No.
Causes Freq. % Cum
%
PIKA TECH
1. Choking due to graphite 515 81 81
/algae accumulation.
2. Tar & Coke muck deposited 82 10 91
in main drain line.
3. Valve not regulated 36 6 97
properly.
4. Misalignments of funnel 26 3 100
and drain line.
Total 659 100

68
 16
PARETO GRAPH
VITAL USEFUL MANY
FEW
O 97% 100% C
100%

C 14
12
91% U
515
M
PIKA TECH
C 90%
10 81%
80%
U
U L
R 70%
60%
A
E 6 T
50%
N 40% I
82
C 4 V
36 30%

E 26
20%
E
2
10% %
0%
0
TAR / GRAPHITE UN REGULATED MISALIGNMENT

69 Insuffi DEPOSITATION VALVE OF

FUNNEL/DRAIN
cient CAUSES
 MAIN CAUSE

Insufficient time for cooling of core barrel Tackles

PIKA TECH

70
 WATER OVERFLOWS FROM STAND PIPE CAP
SEALING
MAIN
CAUSE

CHOKING DUE TO GRAPHITE

ACCUMULATION
PIKA TECH
GOAL

TO ELIMINATE THE CAUSE

AS SOON AS POSSIBLE
HOW

BRAIN STORMING

71
 DEVELOPMENT OF SOLUTION

SUGGESTIONS
PIKA TECH
Cover the drain line

Not to use air de-graphitisation

Provide pneumatic cap sealing

Open single cap

72
PIKA TECH OBSERVATIONS

Technical Water inlet

valve closed

Technical Water inlet

valve opened after
10 minutes

73
 10:00 MIN
ON/ OFF

TIMER

OFF
ON

INLET WATER LINE

To incorporate intermittent
OPEN DRAIN
74
flow of water 74
 DEVELOPMENT OF SOLUTION

FEASIBLE SUGGESTION
PIKA TECH

To Incorporate
intermittent
flow of water
with the help of
Solenoid Valve
75 AND TIMER.
 DEVELOPMENT OF SOLUTION

SMART ANALYSIS
It is specific as only graphite & algae was
Specific
PIKA TECH
responsible for problem .
Measurable We can find effectiveness of the accepted
solution by measuring Water overflows.
Achievable The solution can be easily implemented .

Realistic We have carried out an initial trial of solution

& found that it is implementable .
with
reasoning
Time bound It can be completed within 1 month.

76 By smart analysis we found solution is authentic .

 DEVELOPMENT OF SOLUTION

TIME BOUND & RESPONSIBILITY

SHARED ACTION PLAN
PIKA TECH
ROOT ACCEPTED ACTION PLAN RESPONSI- TARGET FOR RESULTS
CAUSE SOLUTION BILITY COMPLETION
1. Design and drawing RG/SPS 01days 01 days
Choking To
due to incorporate 2. Listing of required SI/SANDIP 01days 01 days
graphite / intermittent material
algae flow of water 3. Issue of material from DAKOR/FR 01days 01days
accumulati with the help stores
on. of Solenoid RG/DAKOR
4. Installation &Wiring 03 day 03day
valve and
timer
5. Fabricating SINGH/FR 01 days 01days

6 .Testing SANDIP 01 days 01 days

77
69
 FORESEEING PROBABLE
RESISTANCE

1. Non-Quality Circle members

may oppose due to extra load.
PIKA TECH
2. Doubt may be raised regarding
safety.
3. Uncertainty of results.
4. Convincing the working Gas
Group.
5. Resistance by In-charges
and H.O.D.

78
 PRESENTATION IN FRONT OF H.O.D.

The suggestion was

discussed
PIKA TECH

with
HOD, Facilitator
and
others Concerned
thereafter
decided to
implement it on trial
79 basis.
PIKA TECH P.D.C.A. CYCLE

ACTION PLAN

CHECK DO

80
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE

PDCA PLAN
PIKA TECH
OBJECTIVES:
1. To strictly follow all the safety norms.
2. To Install Solenoid actuated diaphragm type
valve in cap sealing inlet main header line as
per design.
3. To provide Electrical fitting as per
requirement.

81
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
COUNTER MEASURE MATRIX PLAN
S.No JOB TO BE DONE DURATION RESPONSIBILITY
PIKA TECH
1 Material procurement. Two days Mr. Dewangan
i. 80mm MS pipe Mr. F.R.Verma
ii. 50mm 6 flange Mr. Sandeep
iii. Solenoid,Timer,Retifier,
Cable & Box.
2 Fabrication & Erection Two days Mr. S.P.Singh
i. As per design. Mr. Ramesh Ghate
ii. Material shifting.
3 Implimentation. Two days Mr. Santosh Ingale
i. Technical water shut Mr.Dewangan
down.
ii. Commissioning.
4 New procedure with all safety One days Mr. S.P.Singh
aspect . Mr. Sandeep
82 i. Explaining modified valve
i. Safe working condition
 TRIAL IMPLEMENTATION & DO
PIKA TECH CHECKING PERFORMANCE

SHOWING STAND PIPE CAP SEALING SYSTEM LAYOUT WITH INTRODUCTION PHYSICAL ARRANGEMENT OF
OF SOLENOID VALVES SOLENOID VALVE

SHOWING SIMPLISTIC CIRCUIT DIAGRAM LOGIC FOR

ACTUATION OF SOLENOID VALVE

83 CONTROL PANEL MOUNTED

FOR ACTUATION OF
SOLENOID VALVE
 TRIAL IMPLEMENTATION &
CHECK
PIKA TECH CHECKING PERFORMANCE

STILL THE
PROBLEM OF
OVERFLOW
WAS NOT
SATISFACTORY

84
 TRIAL IMPLEMENTATION & CHECK
CHECKING PERFORMANCE

NOS. OF OCCURRENCE OF WATER

OVERFLOWS
PIKA TECH
FROM PERIOD 25.2.17 TO 03.3.17

PROBLEMS WATER NOS. OF

OVERFLOW OCCURANCE
Before After
Choking due to graphite/
Algae accumulation 20 09

Choking in main drain Nil Nil

line
Misalignment of funnel Nil Nil
85
 TRIAL IMPLEMENTATION &
CHECK
PIKA TECH CHECKING PERFORMANCE

Solenoid Valve
Failed 18 Times
during one
week

86
 TRIAL IMPLEMENTATION &
ACTION
CHECKING PERFORMANCE

BRAIN STORMING
PIKA TECH

87
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE

DATA SHEET
S.No.
Causes For solenoid Frequency
PIKA TECH

Failure
1. Due to Conch/ Snail 10

2. Due to Electric Tripping 6

3. Electric Coil Damage due to 1
water from Wheel Valve
4. Solenoid Valve nut-bolt & 1
Diaphragm damages during
cleaning
88 Total 18
 TRIAL IMPLEMENTATION &
PIKA TECH CHECKING PERFORMANCE

WHEEL VALVE

SOLENOID VALVE

COIL

89 CONCH/ SNAIL
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE

CONCH / SNAIL
PIKA TECH

MAIN CAUSE
90
 TRIAL IMPLEMENTATION &
ACTION
CHECKING PERFORMANCE

Suggestion- Change position of Solenoid Valve /

wheel Valve.
PIKA TECH

Present Suggested

91
 TRIAL IMPLEMENTATION &
ACTION
CHECKING PERFORMANCE

Suggestion-To use A.C Solenoid valve in place of D.C.

PIKA TECH
70mm D.C 40mm A.C
Solenoid Solenoid
Valve Valve

92
 TRIAL IMPLEMENTATION &
PLAN
CHECKING PERFORMANCE

Suggestion-Drain point before inlet-valve.

PIKA TECH

DRAIN POINT
93
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
ACTION
PDCA-1
PIKA TECH

94
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE

PDCA-1 PLAN

1.To use 230 A.C. Soleniod valve.

PIKA TECH
2. To relocate the position of
Wheel valve & soleniod valve.
3. To provide a drain point with
Stop cock valve before wheel valve.
S.N JOB TO BE DURATION RESPONSIBILITY
o. DONE
1 Material One day Mr. Dewangan
procurement Mr. Sandeep
2 Fabrication & One day Mr. S.P.Singh
Erection Mr. F.R.Verma

95 3 Commissioning One day Mr.Santosh Ingale

 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
DO
PIKA TECH

96
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
DO
PIKA TECH

97 CONCH DRAINED OUT

 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
DO

PDCA-1
PIKA TECH

98 Before Modification After Modification

 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
CHECK
PDCA-1
PIKA TECH

S.No. Causes For solenoid Failure Frequency

1. Due to Conch/ Foreign material NIL

2. Due to Electric Tripping 1
3. Electric Coil Damage due to NIL
water from Wheel Valve
4. Solenoid Valve nut-bolt & NIL
Diaphragm damages during
cleaning
99 Total 1
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
Comparative study Before & After CHECK

S.NO. PROBLEMS BEFORE AFTER REMARK

PIKA TECH
Water over Due to modified automatic
1 flow 20 nil actuated solenoid valve.

Water By closing the main inlet

2 consumption 15m3/hr 7.5 m3/hr valve for some pre-
determined time(10min).
3 Man power 6 3 Roding was not required
to clean drain line.
Stand pipe Water falling in S.P. base
4 base lining 28 3 was elaborated.

Top linter Water seeping inside

5 burning 8 nil bricks lining was stopped.
100
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
Comparative Graphs/ Charts for CHECK

Result Obtained
PIKA TECH
WATER OVER FLOW S.P.CAP SEALING
20
FREQUENCY

15

20
OVERFLOWS

10

05

0
0
BEFORE AFTER
101
 TRIAL IMPLEMENTATION &
CHECKING PERFORMANCE
CHECK

WATER CONSUMPTION 50% LESS

PIKA TECH
WATER CONSUMPTION IN M3/HR.

20

15

10

15M3/HR

05
7.5M3/HR.

0
WATER CONSUMPTION WATER CONSUMPTION

102
BEFORE MODIFICATION AFTER MODIFICATION
 OUR PRIME MINISTER

Hard work never brings fatigue,

PIKA TECH
It brings satisfaction.
-- Shri Narendra Modi

103
 REGULAR IMPLEMENTATION
PIKA TECH
After the encouraging results :

The suggestion
was approved
and
gradually implemented
in
Battery 5 C/S & Battery 6 B/S.

104
 REGULAR IMPLEMENTATION

Sl. JOBS DAYS

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14
O
PIKA TECH
1 Preparing
operational
procedures
2 Training
people
3 Giving
Instructions
4 Follow up after
implementation

MILESTONE CHART FOR FULLIMPLEMENTATION

105
 REGULAR IMPLEMENTATION

TRAINING SCHEDULE
PIKA TECH

DATE ACTIVITY SHIFT I/C C/M SR, TRAINER

OPR/OPR
C.S.Verma
25.03.2017 Cap sealing Mr.Pradeep K.S.Sonwani Namdas S.P.SINGH
process S.K.Dubey
D.K.Dhruv
Bharatlal
26.03.2017 Safety Mr. Nandi J.R.Sonwani Agagalle F R VERMA
Anuram
Narayan
Kedar
27.03.2017 Benefits of Mr.Anurag H.D.Saytode Ashok sahu INGALE
modification Raj Kishore SANDEEP

28.03.2017 Feed back Excellent Very good Very nice Satisfied

106
 DATA BASED RESULT

Data Based Result

PIKA TECH
659
800 515
600
400
200 05 05

0
Before After
Implementation Implemantation

107 Due to all Causes Due to Graphite accmalation

 DATA BASED RESULT-1

OVERFLOW IS < 0.75%

PIKA TECH
4000
FREQUENCY OF OCCURENCE

3000

2000 659
TIMES
1000 TIMES
05

BEFORE AFTER
108
 DATA BASED RESULT-2

Manpower saving
PIKA TECH
in cleaning the
M 350
drain by rodding
A 300
N 250

D 200

A 150 220 MANDAYS/MONTH

Y 100 BEFORE

S 50
AFTER 90 MANDAYS/MONTH

109
 DATA BASED RESULT-3

WATER CONSERVED BY 50%

40
PIKA TECH

30
FREQUENCY

20
30
m 3
OVENS

10
/hr 15
m3/hr
0
BEFORE AFTER
110
 COMPARATIVE STUDY PARETO
PARETO BEFORE PARETO AFTER
IMPLEMENTATION IMPLEMENTATION
PIKA TECH
97%
100%
515
91%
700 700
81%

82
36
26 05 100
7 100%
4 %
0
0
A B C D
A B C D

111
 BENEFITS

1. This effort totally negated the reasons

leading to the brickwork damage.
PIKA TECH

2. Improved availability of ovens for

production.

3. 50% reduction in consumption of cap

sealing water.

4. Increasing life of Acension pipes.

5. End vertical damages prevented.

112
 TANGIBLE BENIFITS

Net profit
PIKA TECH
Rs. 1.27 Crores/annum

113
 INTANGIBLE BENEFITS
 Better & Safe working Environment.
 High morale.
PIKA TECH
 Ever increasing confidence level of
the Group.
 Employee’s creativity highlighted.
 Superb team spirit & cohesion.

114
 RADAR GRAPH

A
30 AFTER
A. JOB SATISFACTION BEFORE
B. SELF CONFIDENCE G 20 B

C. TECH. KNOWLEDGE 10

D. AWARENESS ABOUT 0

SUGGESTIONS F C

E. MORALE & WORK SKILL

F. COOPERATION BETWEEN E D
WORK GROUP

G. LEADERSHIP QUALITY

115
 WHAT IS HEART OF TRANSFORMATION
PIKA TECH

It is the release of
intrinsic motivation
by creating joy, pride & happiness
in work and learning.

Dr.W.E.Deming "Need for Change"

116
 CHECK LIST

Sl. Parameter/Equipment Frequency Responsibility

PIKA TECH
No. To Be Inspected

MONITER SOLENOID VALVE DAILY S.P.SINGH

1.
FUNCTION & TIMER. SANDEEP

MAINTAIN STAND PIPE CAP DAILY DEWANGAN

2.
CANAL CLEANED. GHATE

MAINTAIN AND REGULATE WEEKLY SANTOSH

3.
ALL INDIVIDUAL AND MAIN F.R.VERMA
VALVES.

TO DRAIN CONDENSATE IN ALL SHIFTS SHIFT I/C

4.
EACH SHIFT
117
 FREQUENCY OF REVIEW & RESULT
OBTAIN
DATA COLLECTED OF WATER OVERFLOW

MONTHS APR MAY JUN JUL AUG TOTAL AVG.

2017 2017 2017 2017 2017 overflows
PIKA TECH
A SHIFT NIL 3 NIL 3 3 9
B SHIFT NIL NIL 2 3 NIL 5 5
C SHIFT 2 2 3 2 3 12 Times
TOTAL 2 5 5 8 6 26
8
O
C
7

6
C WATER
5 OVERFLOW
U 4
R 3
E 2
N 1
C 0

118 E APR MAY JUN JULY AUG

MONTHS
PIKA TECH STANDARDISATION

After successful
implementation, we have
amended our standard
operational practice.

119
 APPLICABILITY

In all other
PIKA TECH

COKE OVEN
BATTERIES
with
120
Water Seal
 PLAN MILESTONE CHART ACTUAL

Q.C Name:- PIKA TECH DEPT. CO & CCD Facilitator SUMEET KUMAWAT Member Name

Project; Water over flow from S/P cap Damage Battery brick work & reduce battery life S.P.SINGH
PIKA TECH
sealing D.S.DEWANGAN
F.R.VERMA
Project No.:-20 Date of Beginning17-12-16 Date of Completion:- 31-03-17
SANDEEP
RAMESH GHATE
Meeting Day :- Saturday No. of Project Completed :-17 Actual completion:-15-04-17
SANTOSH INGALE
SL Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
. Activity
No
1. Defining the problem

2. Analyzing the problem

3. Identifying the cause

4. Finding the root cause

5. Data analysis

6. Developing solution

7. Foreseeing problem
resistance

8. Trial implementation &

checking performance

9. Regular
implementation

10 Follow up (review)
 ACHIEVEMENTS
PIKA TECH ARRANGED A TRIP TO PURI FOR PRW WORKER(WITH FAMILY)

122
 ACHIEVEMENTS
PIKA TECH APPRECIATION LETTER BY GM CO &CCD

123
 ACKNOWLEDGEMENT
PIKA TECH
GM (CO & CCD)
CRG GAS GROUP
ELECTRICAL
HEATING & REGULATION
BUSINESS EXCELLENCE DEPTT.
124
 FUTURE PLAN
PIKA TECH

1. Improper Coal 2. Blackening of

Charge Level in Stand pipe base in
Batt # 5&6. Batt#5&6.

125
 LEGEND
PIKA TECH

is not what you2.see

1. Improper
Dream RawinGas
Coal
sleep.Charge leakage
Dream is something from
which
Level in Batt # Gooseneck &
does5&6.
not let you sleep.
Valve Box joint.
126 --DR --Dr.A.P.J.
A.P.J. ABDUL KALAM
ABDUL
 THANKS……..
PIKA TECH

127
 PIKA Tech
expresses its special
PIKA TECH

gratitude to august
audience for their
Graceful listening and
N.C.Q.C. Mysuru Chapter
for
providing stage for Presentation.

128
PIKA TECH FINANCIAL BENEFITS

Cost saving on account of saving of technical water by incorporating solenoid

operated valves.
Consumption of technical water for cap sealing system per battery = 30 m3/hr
Volume of technical water required per annum for cap sealing = 30x24x365
per battery = 262800 m3
Saving of water by 50% reduction of consumption = 15 m3/hr
Volume of water saved with implementation of suggestion = 50% of 262800
131400m3
Cost of technical water at BSP = 45Rs/m3
Cost of water saved per annum per battery 131400x 45
= 59,13,000Rs
Cost saving per battery per annum
with the implementation of suggestion =Rs 59.13lacs
Number of batteries running
with water sealed caps (Batt. 5&6) =2
Envisaged saving with implementation of this
suggestion to other batteries = 2 x 59.13
= Rs1. 18crores

129
 •Financial gain on account of reduction in manpower for following jobs
in two Batteries i.e. Batt # 5&6:-
PIKA TECH
Manpower required for Roding & Monitoring (avg.) = 104/month
Manpower required for Stand pipe base patching = 90/month
Manpower required for regenerator patching = 25/month
Manpower required linter repair = 15/month
Total saving in manpower after modification = (104+90+25+15)
= 234/month
Annual cost of labor (SSW) saved = RS 333/- x 234 x 12
= Rs 09, 35,064
Total saving for one Battery = Rs 04, 67,532
Hence total recurring annual saving in two Batteries =Rs 467532 x 2
= Rs 935064

TOTAL (A+B) = (1.18 + 0.09) = RS 1.27 CRORES PER ANNUM

NET SAVING PER YEAR = Rs 1.27 Crores

123
 FIGURE –SHOWING STAND PIPE CAP ASSEMBLY CANAL AND
PIKA TECH WATER SEAL WITH CAP SEATED

STAND
CAP ASSEMBLY PIPE CAP
CANAL

HEIGHT OF WATER
SEAL INSIDE CAP
ASSEMBLY

HOT RAW GASES INSIDE

STAND PIPE

131
 LATE KU.PIKA BHATTACHARJEE
DOB:-16.06.1993 DOD:-13.08.2004

PIKA HERITAGE
PIKA TECH

PIKA HOSTEL PIKA HOUSE

132
 INTANGIBLE BENEFIT
(INDIVIDUAL)

SL. BENEFITS BEFORE AFTER

NO. AVERAGE INCREASE
TOTAL AVERAGE TOTAL AVERAGE INCREASE IN %

A JOB SATISFACTION 18 3 28 4.67 1.67 55.56

B SELF CONFIDENCE 18 3 29 4.83 1.83 61.11

C TECH. 15 2.5 26 4.33 1.83 73.33

KNOWLEDGE
D AWARENESS ABOUT 16 2.66 27 4.50 1.84 69.17
SUGGESTIONS
E MORALE 21 3.5 29 4.83 1.33 38.10

F COOPERATION 17 2.83 30 5.00 2.17 76.68

BETWEEN WORK
GROUP
G LEADERSHIP 16 2.66 26 4.33 1.67 62.91
QUALITY1

126
SCALE Min=1 Avg=2 Good=3 Better=4 Best=5

TEAM MEMBER=6
134
PIKA TECH