Operation group B

POWER SEEKERS
Quality Circle

1
 SSTPS

CASE STUDY
ASH SLURRY PUMP-8 FREQUENT SUCTION CHOKING
AND LOAD THROW OFF
Installed Capacity(Thermal+Solar)=
(5*200+2*500+1*15=2015) Power seekers

NTPC SSTPS

 First Thermal power station of NTPC

 Unit-1 synchronized on 13 Feb 1982

3
 Team Details Power seekers

Alok Gupta, Co-ordinator Pratap Bhanu, Facilitator Md Z. Alam, Dy Facilitator SNS Yadav ,Team Leader

RS Vishwakarma, Dy Leader Anurag Rai, Member Jitendra Kumar , Member

 Introduction of QC Team Power seekers

Team Name Power Seekers

Department Operation(O&M)
Formation 21-June-2019
Day Of Meeting First Evening Shift
Time 1 Hour
Place Stage 1 Unit 1 Control Room
Total Numbers Of Meetings 8
Percentage Of Attendance 98%

Solved Problem 1

No. Of Meeting For This Project 8

 Power seekers
STEP
TOOL USED: BRAIN STORMING
1
CATG.
SL. NO PROBLEMS
A/B/C
1 NO LADDER APPROACH TO CEP-6 A

2 COAL FEEDER CHOKING IN STAGE-1 IN REGULAR WAY A

3 NO TOILET IN ESP AREA A

4 LEAKAGE OF FIRE HYDRANT VALVE C

5 MODIFICATION OF CBD DRAIN IN AUTO B

6 SAVING OF OIL IN CENTRIFUGE SYSTEM B

7 SUCTION CHOKING OF ASH SLURRY SERIES P/P NO -08 & FREQ LOAD THROW OFF A

8 NO EMERGENCY WATER SUPPLY FOR SERVICE WATER PUMP PIT A

9 CMR - PUMP -C IS NOT AVAILABLE A

10 D.M.C.W. HEADER DRAIN V/V SPINDLE AT MINUS METER B

 Power seekers
STEP
1 CATG.
SL. NO PROBLEMS
A/B/C
11 NO LADDER APPROACH TO MDBFP-C LOP FILTER A

12 FREQUENT OIL LEAKAGE IN GT BUSHING B

13 PROPER NOMENCLATURE OF DRAIN AND VENTS AT LOCATIONS B

14 COND. HOTWELL DRAIN PIPE TO BE EXTENDED FURTHER DOWNWARD B

15 AIR INGRESS FROM COMPRESSOR INTO DMCW SYSTEM A

16 LACK OF PRESSURE GUAGE AT PUPPET V/V OUTLET OF WALL BLOWER A

17 FEEDER GLASS NOT REMAIN ALWAYS CLEAN A

18 ABSENCE OF PROPER PLATFORM FOR R.H. SPRAY V/V OF TDBFP-6B A

19 STEAM LKG FROM IP- LP CROSSOVER IN TDBFP #6B A

20 NO APPROACH FOR P.APH & S.APH - SB OIL LEVEL A

 Power seekers
STEP
1
CATG.
SL. NO PROBLEMS
A/B/C
21 BOILER TUBE LKG PROBLEM B

22 POOR LIGHTING IN BOILER AREA A

23 DISPLAY OF O2 INGREASES IN H2 PLANT A

24 LACK OF SAFETY POSTER IN WORKING AREA A

25 LKG OF RH SPRAY LINE OF TDBFP-7A A

26 AIR LKG IN AIR COMPRESSOR SYSTEM A

27 POWER OF 1 CW PUMP CAN BE SAVED AFTER CW DUCT LKG ATTENDED A

28 VIEW GLASS IN FEEDER DOES NOT CLEAR ALWAYS A

29 POOR LIGHTING IN TG 00 METER AREA A

30 LKG FROM TOP COVER OF SOP COOLER (H2 SIDE ) B

 Power seekers
STEP
1 CATG.
SL.NO PROBLEMS A/B/C
31 IMPLEMENTATION OF 5 S IN OPERATION DPT. A

32 BOILER TUBE LKG PROBLEM B

33 DRAINAGE PROBLEM IN TG AREA B

34 FALLING OF FLY ASH FROM CHIMNEY B

35 ROAD SAFETY PROBLEM NEAR ASH SLURRY PHASE II C

36 POOR LIGHTING ON ROAD NEAR FIRE STATION B

37 STEAM PIPE INSULATION NEAR LP DRAIN PIPE B

38 AUX PRDS HDR PR. CONTROLLING PROBLEM DURING STARTUP LINE B

39 SH/RH SPRAY CONTROL V/V PASSING C

40 FLY ASH HOPEER CHOCKING B

 Power seekers
STEP
1 CATG.
SL. NO PROBLEMS
A/B/C
41 EXCESS STEAM CONSUMPTION DURING SOOT BLOWING OPERATION A

42 FREQUENT HEAVY HYDROGEN CONSUMPTION IN GENERATOR A

43 ASH SLUURY SUMP LEVEL MAINTAINING PROBLEM B

44 PAPERLESS OFFICE A

45 FLUE GAS EXIT TEMP HIGH B

46 NO COAL FLOW IN MILL FEEDER B

47 CENTRIFUGE HEATER CUT IN / CUT OUT PROBLEM A

48 TURBINE BEARING TEMP HIGH B

49 TURBINE OIL LOSS THROUGH VAPOUR EXTRACTION FAN A

50 SILICA LEVEL HIGH IN CONDENSATE AND CBD A

51 MAIN OIL PUMP SUCTION PRESSURE NOT DEVELOPING A

52 SOOT BLOWING JAMMING PROBLEM B

53 CW FLOW TO THE CONDENSER IS NOT ADEQUATE A

 Power seekers
STEP
1
Problem Type Explanation

A Can be executed by QC team only.

B Needs the help from other departments for implementation.

C Needs sanction of expenditure from management.

CATEGORIZATION Problem
Problem A type B type C type
Type No of Problems

A 30 6%
B 20 38%
C 03 57%
Total 53
 SELECTION OF PROBLEM
Power seekers
STEP 2

System
Energy
Safety Saving
Ease To Work Developmen
t

CRITERIA FOR PROBLEM SELECTION

 Problems Short-listed Power seekers
STEP 2

Problem:-1(P1)
Coal feeder choking in Stage-1

Problem:-2(P2)

• Air Ingress from Compressor into DMCW System

Problem:-3(P3)

• Suction Choking of Ash slurry pump series-8 & Frequent Load throw off

Problem:-4(P4)

• Soot Blower Mechanical jamming problem

 Selection of Problem Power seekers

STEP (SCORE METHOD RANKING BASED)

2
Member-1 : R S Vishwakarma

Problem
Criteria
P-1 P-2 P-3 P-4
Safety
8 8 7 6
Energy conservation
6 6 8 9
Ease to work
5 7 6 7
System Development
7 6 7 8

Total 26 27 28 30

Priority 4 3 2 1
 Selection of Problem Power seekers

STEP (SCORE METHOD RANKING BASED)

2
Member-2 : Anurag Kumar Rai

Problem
Criteria
P-1 P-2 P-3 P-4
Safety
5 9 8 7
Energy conservation
6 6 8 6
Easy to work
7 7 7 8
System Development
8 5 6 7
Total
26 27 29 28
Priority
4 3 1 2
 Selection of Problem Power seekers

STEP (SCORE METHOD RANKING BASED)

2
Member-3 : Jitendra Kumar

Problems
Criteria
P-1 P-2 P-3 P-4
Safety
8 7 8 7
Energy conservation
6 7 8 8
Easy to work
5 8 9 7
System Development
6 6 7 8
Total
25 28 32 30
Priority
4 3 1 2
 Selection of Problem Power seekers

STEP
(SCORE METHOD RANKING BASED)
2
Priority
Member/Priorities
P-1 P-2 P-3 P-4
R S Vishwakarma
4 3 1 2
Anurag Kumar Rai
4 3 2 1
Jitendra Kumar
4 3 1 2

Total 12 9 4 5

Priority 4 3 2
1

P-3 Problem is selected

P-3 Choking problem of Ash slurry series pump-8 & Freq Load throw Off
 Selection of Problem Power seekers
STEP 2

PROBLEM SELECTED

Suction Choking of Ash Slurry Pump-8

&
frequent load throw off

27
 Work plan & Milestone Chart
Power seekers

SELECTION OF
PROBLEM
Planning milestone chart
QUALITY CIRCLE: Power Seekers DEPT –OPERATION (O&M) Facilitator PRATAP BHANU
Dy Facilitator M Z ALAM
PROBLEM – Suction Choking of ASP-8 & load Throw RANKING BASE SELECTION
off Leader SNS YADAV
Dy Leader RS VISHWAKARMA
PROJECTS No.- 01 Date of start-21 June 2019
Member JITNEDRA KUMAR
EVENING SHIFT -6 To 7 PM Member ANURAG RAI
Description Time in weeks

1 2 3 4 5 6 7 8

Define the problem

Analyse the problem

Identification of causes

Finding out the root causes

Data analysis

Developing Solution

Foreseeing probable resistance

Trial implementation & Check

performance

Regular implementation

Follow up/Review
 DEFINING THE PROBLEM Power seekers

STEP-
3

Suction Choking of Ash Slurry Pump-8

&
frequent load throw off

29
 DEFINING THE PROBLEM Power seekers

STEP-
3 PRESENT SYSTEM OF ASH EVACUATION

ADL-8
ADL-7
ADL-6
ADL-1
ADL-2
ADL-4
ADL-5
ADL-3

DW-PH
ADL-9

4D

1D 2D 4D 5D
8D 7D 6D
B4 C4 D4 E4 F4
8C 7C 6C 1C 2C 4C 5C
B3 C3 D3 E3 F3
8B 7B 6B 1B 2B 4B 5B
B2 C2 D2 E2 F2
8A 7A 6A 1A 2A 4A 5A
9 8 7 1 2 3 4 5 B1 C1 D1 E1 F1
6
ASPH PH-2 ASPH PH-1 A B C D E F
ASPH ST-II
Unit-6,7 ADL-9
Unit-4,5 Unit-1,2,3 PHASE-1 STAGE-2 ADL-3
PHASE-2
ASH DISPOSAL SYSTEM OF AHP ST- I & II
 DEFINING THE PROBLEM Power seekers

STEP-
3 SSTPS ASH EVACUATION THROUGH
SINGLE LINE DAIGRAM

STAGE1 STAGE2

Unit-1,2,3 Unit-4,5 Unit-6,7

PHASE-1 PHASE-2

ASP-1,2,3,4,5 ASP-6,7,8,9 ASP-A,B,C,D,E,F

ASH DYKE
 DEFINING THE PROBLEM Power seekers
STEP Our observations
3 With the existing Ash slurry series pump-8

• ASH SLURRY LINE -8 SUCTION

• CHOKING
ASH SLURRY LINE LOAD
THROUGH OFF
 DEFINING THE PROBLEM
Power seekers

STEP
3 Start

ASP-8 Pumps started

Check Current and discharge pressure YES Yes

Pump is OK
If Normal END

NO
Start Suction Flushing

Again check Current and discharge pressure

YES
If Normal
YES
NO
Again check Current and discharge pressure NO Raise Notification
Start Jetting ash slurry Pit at suction If Normal for maintenance

11/24/21 31
 DEFINING THE PROBLEM
Power seekers

STEP
3 Start

ASH PIT LEVEL LOW

Check Current and discharge pressure YES Yes

Pump is OK
If Normal END

NO
GIVE EXTRA MAKE UP WATER

Again check Current and discharge pressure

YES
If Normal
YES
NO
Again check Current and discharge pressure Raise Notification
OPEN ASH SLURRY PUMP DISCHARGE VENT If Normal for maintenance

11/24/21 31
 DEFINING THE PROBLEM
Power seekers

STEP
3

Reduce Reduce Work Provide safe

Increase Maintenance load on atmosphere
Availability of Cost and operation &
Series Possible people Healthy
generation loss increased Environment

11/24/21 31
 DEFINING THE PROBLEM
Power seekers

STEP
3 SET GOAL

AIM:-ASP-8 SUCTION CHOKING TO BE REDUCE BY

100%,MINIMIZE LOAD THROW OFF CONDITION OF ASP-8 BY
100%
11/24/21 31
 ANALYSIS OF THE PROBLEM Power seekers

STEP
4

33
 Analysis Of The
STEP Power seekers

4 AnalyzingProblem
by 4W &1H
WHAT  Frequent chocking of Ash slurry pump series-8 & Freq Load throw Off
is the problem?
WHERE  Ash slurry pump house phase-2 Ash slurry pump-8
is the problem?
WHEN  Mostly during Pit level Low and After maintenance activity on ASP-8 Or long
duration of stoppage of ASP-8
It is happening?
WHO  Operation
 Maintenance
is affected?  Environment
 Organization

HOW  Poor Availability of Series

it is affecting?  Increase Maintenance Cost loading & Generation Loss.

 Work load on operation people increased.
 Safety issue
 IDENTIFICATION OF THE CAUSES
STEP FISHBONE DAIGRAM
Power seekers

5 MATERIAL
MACHINE Ash deposit

Foreign material stuck

Flushing line choked
Suction ineffective
suction Bend
Flushing valve Air ingress dislocated,
Uncovered channel faulty False reading Hole
Shortage of Ash deposit
water Heavy Ash particle Pump faulty Gauge Defective

Discharge line
Shortage of Impeller faulty choking
service water C/G faulty
Pump choking Frequent
Choking of
ASP-8 & load
Water shortage Unskilled throw off
Line
Rotation No training
Poor ash water ratio On leave

Poor maintenance Man power shortage

Ash hip
Pit level high No responsibility
Pump-3 discharge

Pit level high in ph-1 Flushing valve

Operator negligence
open
& stage2 MAN
METHOD Unskilled 38
 IDENTIFICATION OF CAUSES Power seekers

STEP
5
LIST OF PROBABLE CAUSES
Suction Valve Discharge Line
not fully open choke
Suction line
Ash slurry choke
pump impeller ASP-8 is not in use
inefficient for long time after
Suction choke at maintenance
Mouth due to Ash
Series Flushing
Suction pipe accumulation
line Passing
Size not
sufficient
Air ingress at
Pump Motor low
suction line
Speed or Motor
jamming 37
 ROOT CAUSE ANALYSIS Power seekers

STE FIND OUT ROOT CAUSES

PSL NO PROBABLE ROOT CAUSE INSPECTION EFFECT VALIDIT
Y
1 Suction v/v not fully open Not Found No effect NO
2 Suction line choke Yes Line choking and ash hip Yes
accumulation
3 Insufficient impeller Not found No effect No

4 ASP-3 discharge location Yes suction bend hole Yes

5 Insufficient size of suction pipe Not found No effect No

and bends
6 Discharge line frequent choking Not found No effect No
7 Flushing valve passing Not found No effect No
8 ASP -8 not in use for long time Not found No effect No
9 Pump Motor Jamming Not found No effect Yes
10 Suction Pipe Puncture Found Air ingress and load throw off Yes

39
STEP
DATA ANALYSIS Power seekers

7 ASP-8 Suction line DATA COLLECTED FROM LOG BOOK & PERMIT BOOK
choking and Freq load
Duration:-15/04/2019 to 15/08/2019
throw Off
DATA ANALYSIS ON THE ROOT CAUSE

SL. Cause of Choking Frequency Cumulative Total % Cumulative %

NO

1 Ash hip 10 10 29.41 29.41

accumulation

2 Air ingress in 20 30 58.65 88.23

suction

3 ASP pump 1 31 2.94 91.17

choking

4 Discharge line 3 34 8.84 100

choking

44
 DATA ANALYSIS ON THE ROOT CAUSE
Power seekers

STEP 7

Vital few
Lorentz curve of concentration

Useful many

Cumulative
Frequenc

%
y
 DEVELOPMENT OF SOLUTION Power seekers
STEP
8 WHY- WHY ANALYSIS

ASP-8 taking Low current and Low discharge Pressure

WHY ASP-8 suction flow is less

WHY First pump of ASP-8 not giving sufficient suction flow

WHY Suction line is choke or Valve is not fully open

WHY Ash HIP Accumulated at Suction mouth

WHY Suction line dislocated inside pit and Air Ingress

47
 DEVELOPING SOLUTION Power seekers
STEP
8
Suggestion 1:-Replacement of suction pipe diameter OR Increase size

Reason:-Rejected By Group as Pipe size is similar with other and as per design

Suction pipe Of ASP-8

46
 DEVELOPING SOLUTION Power seekers
STEP
8 Suggestion 2:-Flushing line Passing.

Reason:-Accepted ,Checked with members No passing observed

46
 DEVELOPING SOLUTION Power seekers
STEP
 Suggestion 3:-ASH Pit level to be reduced and Pit inspection to be done
8
 Reason:-Accepted By group.

Finding 1 Huge accumulation observed Near suction of ASP-8

Finding -2 Suction bend is dislocated and Hole observed

Major Finding and Gives

Idea for Solution

46
 DEVELOPING SOLUTION
Power seekers
STEP
8
 DEVELOPING SOLUTION Power seekers
STEP
8
Finding 1 Huge ash accumulation observed Near suction of ASP-8

Finding -2 Hole is observed Near Suction bend causing Unloading

Ash Series-3 line discharge ash is Coming near

OBSERVATION ASP-8 Suction, This ash is getting accumulated
at ASP-8 Suction mouth, This causing
Suction choking and Suction Bend dislocation
and Hole at bend.

SELECTED
SOLUTION

Relocation of ASP-3 Discharge pipe & ASP-8 Suction Bend replacement

46
 Foreseeing Probable Resistance
STEP 9
Resistance
Convincing Maintenance
Convincing Senior management for Complete Plan
and New Location of ASP-3 discharge
Keeping Ash Pit Level in Phase-2 Low for 24 Hrs
JOB safety
ASP-8 outage for long duration
New Location of ASP-3 discharge
Power seekers
Solution
Analysing and showing defect at site
Detail relocation and bend
replacement Plan is Given with
senior & discussed in DPM
Ensure Availability of ASP-6,7.9
Ensured Presence of NTPC executive
from Both Maintenance and
Operation department
Other Series even in stage-2
Maintenance managed.
New Location is Just Near to ASP-A
(Stage-2 Series pump) discharge, So
it will not create Problem
58
 TRIAL IMPLEMENTATION & PERFOMANCE CHECK
STEP 10
PLAN TO RELOCATE ASP-3
DISCHARGE FROM ASP-8 TO JUST
SIDE OF PIT & REPLACEMENT OF
ASP-8 SUCTION BEND PIPE INSIDE
PIT.
Permission Taken, Other Series
availability is ensured. Fire Water
and alternate sources arranged in
other units. and PTW issued.
*New Location is Selected on Basis
Of Past Performance of ASP-A
Stage-2 discharge, Side of ASH Pit.
All Processes and Result are
Widely discussed .
Performance is checked for 15 days
Power seekers
PTW issued to Maintenance on
22/08/2019.
*Ash Pit level Reduced below to
P D suction bend of ASP-8
*ASP-3 Discharge line removed by
PLAN DO Cutting.
*Relocated and Welding done
To New Suggested location.
*ASP-8 Suction Bend pipe cutting
done
*ASP-8 New Suction bend pipe
Fixed.
ACT CHECK After Permit Cancellation
A C *ASP-8 Taken In service, Since it
was in stop condition for more
than 24 hours. No Flushing
required and immediately it has
taken Load.
*Load through off situation is
checked on basis of Shift
Feedback
For nearly two week. Series has
Running Normal and No 58 choking
observed.
TRIAL IMPLEMENTATION & PERFOMANCE CHECK
Power seekers
TRIAL IMPLEMENTATION & PERFOMANCE CHECK Power seekers

OLD Removed New Relocated

Line ASP-3 Discharge

ASP-A from
Stage-2
Discharge line

ASP House Stage-1 Phase-2 top of Ash Pit

TRIAL IMPLEMENTATION & PERFOMANCE CHECK Power seekers

Power Seeker Newly Relocated

Team Leader and ASP-3 Discharge
Member at Site Line

ASP House Stage-1 Phase-2 top of Ash Pit

 TRIAL IMPLEMENTATION & PERFOMANCE CHECK Power seekers

Data Comparison Duration:- 22 Aug to 18 Sep

Data Source:-Shift Offsite Engineer Log Book, Permit Book, Notification

Data Source:-Phase 2 Daily Activity Register, Follow Up check List

Description Before(15.04.19 to 15.08.19) After(22 Aug to 18 Sep )

ASP-8 Suction choking 10 0
ASP-8Load Throw off 20 0
ASP-8 Discharge Line Choking 3 0
Suction Bend Damage 01 0

Average =.28 issues/day Average =Nil issue/day

100% Target is achieved

 REGULAR IMPLEMENTATION Power seekers

After Relocation of ASP-3 discharge No Further Choking observed and Series

Air Ingress from Suction is also not observed. Series not getting unloaded.
 REGULAR IMPLEMENTATION Power seekers

PROJECT COST

1:-One Time cost of suction bend replacement SL no Element Cost(Rupee)

1 Welding electrode 4000

2 Pipe Bend 7000

3 Manpower cost 4000

4 Miscellaneous(Nut,bolt etc) 2000

TOTAL 17000/

2:-One Time cost of ASP-3 Discharge Relocation SL no Element Cost(Rupee)

1 Welding electrode 3500

2 Pipe Bend 7000

3 Manpower cost 4000

TOTAL 14500/

Total= 1+2=17000+14500=31500/ Project Cost=31500

*Data source:-All data is taken from AHM

 REGULAR IMPLEMENTATION Power seekers

Duration:-15/04/2019 to 15/08/2019v
Tangible Benefit
Loss Calculation
Cost due to clearing Choking
Department AVG Manpower involve Cost for 4 hrs * Total cost Freq Total cost
Maintenance 4 250 1000 10 =10000
&Operation
*Average time in clearing suction
Generation Loss Due to Reduction(ASP-8 Not available due to Suction bend leakage)
Department DC loss Mill Unit Incentive /unit Total cost
DC Loss due Series problem 0.73mu 0.50Rupee 3.65L
*Generation loss on 20 Aug 2019(In stage-2)

Total Loss =3.75 L

Duration:-22/08/2019 to 18/09/2019
After Project implementation No choking and Generation loss observed on head on Ash series problem.

Total Benefit =3.75 L

*ALL Data from Partial loss booking,AHM
 REGULAR IMPLEMENTATION Power seekers

Intangible Benefit

Work Load
on
Possible Series
Increased Better Energy Maintenanc
Generation Availability
Safety Environment Saving e and
Loss reduced Increased
Operation
reduced
 Follow UP & Review Power seekers

CHECKLIST: -ROSTER ACTIVITIES (IN EVERY ROSTER), SECOND MORNING SHIFT

Date:- Time:-
SL NO ACTIVITY STATUS REMARKS
1 ASH LEVEL REDUCED ASH ACCUMULATION YES/NO  

2 ASH LEVEL REDUCED/SUCTION PIPE CHECKED YES/NO  

3 DAILY LOCAL PHASE REGISTER ABNORMALTY MENTION

FOUND/NORMAL DATE/TIME
REPORT REGARDING ASP-8
4 PERMIT REGISTER REPORT ANY PTW/NIL DETAIL: -
REGARDING ASP-8
 Follow UP & Review Power seekers

CHECKLIST: -SHIFT WISE CURRENT AND DISCHARGE PRESSURE

Date/Shift ASP -8 (A/B/C/D) CURRENT DISCHARGE PRESSURE REMARKS
       

       

       

       

       

       
 Follow UP & Review Power seekers

Actual &Comparative milestone chart Target

Actual
Description Time in weeks
1 2 3 4 5 6 7 8
Define the problem

Analyse the problem

Identification of causes

Finding out the root causes

Data analysis

Developing Solution

Foreseeing probable resistance

Trial implementation & Check

performance

Regular implementation

Follow up/Review
 Tools & Technique Used Power seekers

Flow Diagram
Brain storming
Tools & PDCA
Technique Data Collection
Used Pareto Diagram
Fish Bone Diagram
Milestone Chart
 Future Plan Power seekers

Soot Blower Mechanical Jamming Ratio to be minimized

and
Increase Soot blower Availability in stage-1,2 Units
 Gratitude Power seekers

GM (Operation)-Mr SC Naik sir

Team Operation AGM(operation)-Mr A Vishwas sir

Group B AGM(Operation)-Mr AS Gupta Sir

CSCE(Operation, Group-B)-Mr Awadhesh Sir
ASCE(Operation-Group B)-Mr KK Pandey sir
ASCE(operation-Group B)-Mr Gautam Sir
DGM(AHM)-Mr AR Kauhambi Sir

Guidanc
Help Support
e
ANY REGULAR
SUGGESSTION
IMPLEMENTATION Power seekers