SGA - Institute for Industrial · PDF fileAluminium & Power, Jharsuguda 1. IDENTIFICATION OF...

Aluminium & Power, Jharsuguda

SGA REDUCTION OF PA & ID FAN LOADING

• Project: Reduction of PA and ID fan loading

• Baseline: 1. PA Fan 1265 KW

2.ID Fan 1844 KW

• Target: 1. PA Fan 1215 KW

2.ID Fan 1800 KW

Resources - Team Members

Name Role Dept/Function

Manas Tyagi Facilitator Head Operation (CPP)

Aadarsh Leader Maintenance (CPP)

Atish Member O&E (CPP)

Vivek Member O&E (CPP)


1.IDENTIFICATION OF PROBLEM


1. IDENTIFICATION OF PROBLEM

S No LIST OF PROBLEMS IDENTIFIED Area of Work

1 SADC not functioning properly Boiler

2 High PA Header pressure for Mills Boiler

3 High air leakage % in APH Boiler

4 High DP across Fabric filter Boiler

5 Pent house air leakage Boiler

6 Duct air leakage Boiler

7 Damper Problem Boiler

8 Seal trough air ingress Boiler

9 Dog house air ingress Boiler


2.SELECTION OF PROBLEM


2.1 PROBLEM SELECTION


2.2 MILESTONE CHART

SL NO ACTIVITY Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Remarks

1 Definition of problem

2 Analysis of problem

3 Identification of causes

4 Find out the root causes

5 Data analysis

6 Developing solutions

7 Foreseeing possible resistance

8Trial implimentation and

checking performances

9 Regular implimentationHorizontal

deployment

10 Follow up and reviews

PROJECT N0 - 01

MEETING DAY - SATURDAY

TEAM MEMBERS - Aadarsh,

Manas, Prakhar,Vivek,Atish

REGISTATION NO -

DATE OF BEGINNING -01/07/14

MEETING TIME - 16:00hrs

DEPARTMENT- O&E

PROJECT CATEGORY NO - A

DATE OF COMPLETION -

31/03/2015

QUALITY CIRCLE NAME - ELEVATE

PROJECT TITLE - Reduction of Fan Loading


3.DEFINING THE PROBLEM


3.1 DEFINING THE PROBLEM

1. High PA Header pressure for Mills : PA pressure > 8.5

Kpa.

2. High air leakage % in APH > 8 %


3.2 PROCESS FLOW DIAGRAM


3.3 PROBLEM AREA


3.4 PROBLEM AREA

Original APH had flue gas leakage and erosion which caused damage to Hot end

layer.

APH Seals were also damaged due to gas erosion.

Air leakage % of all the units were on Higher sides


4. ANALYSIS OF PROBLEM


1. PA fan loading reduction

2. ID fan loading reduction

Process optimization and improvement in equipment performance

QUESTION

What is the problem

Where is the problem

When the problem occurs

Whom it is concern

How it is affecting 1. Due to higher % of air leakage in APH fan loading increasing.

PROJECT - High loading of PA & ID fan

OBJECTIVE

GOAL

TOOL ANSWER

WHAT Fan loading is high

WHERE In APH and high primary air pressure

WHEN After six month of annual overhaul

WHOM O & M

HOW

4.1 (4-W + 1-H Analysis)


5. IDENTIFICATION OF CAUSES


5.1 CAUSE & EFFECT DIAGRAM


5.2 CAUSE & EFFECT PRIOTRIZATION

S.No Cause Effect level

S.No Cause Effect Level

1 Mill Outlet Temperature Low 10 Improper Soot blowing Low

2 Coal quality Low 11 High Bag filter DP HIGH 3 Damper problem Low 12 Inlet guide vane problem Low

4 Motor & Fan efficiency Low 13 Moisture in flue gas, pulsing air Low

5 Air Ingress in APH HIGH 14 SADC Damper Low

6 Duct leakages Low 15 High excess air Low

7 Seal Air fan damper passing Low 16 Higher PA Pressure HIGH

8 Seal trough passing Low 17 Moist. Variation with climate Low

9 High inlet air ambient air temp. Low


6. ROOT CAUSE ANALYSIS


6.1 HIGH IMPACT ROOT CAUSES

Root cause DEFINITION

Air Ingress in APH Air Ingress in APH is due to increase in clearance between rotating & stationary part as flue gas side operating in negative pressure & PA FD Side operating in positive pressure

High DP of FF High DP in Fabric filter is mainly due to excess flue gas loading due to APH leakages, moisture in flue gas etc.

High PA Pressure High PA air pressure operation wrt design increases fan loading

1


7. DATA ANALYSIS ON ROOT CAUSE


7.1 High Air Ingress in APH

seal plates are provided to avoid leakages of gases or air between the sectors while in rotation. The gap adjusted between the seal and sector plate as per the OEM recommendation as follow

APH seals are getting eroded due to high ash in flue gas and the gap between the seals and sector plate found to be in range as follows :

APH Seals Design Six month after AOH

Hot End Cold End Hot End Cold End

Radial Seal Inboard 5.5 0 10 to 15 0 to 2

Outboard 0 9 3 to 5 9 to 10

Axial Seal 7 3.5 7 to 8 3 to 4

Bypass Seal 3.5 9 4 to 7 9 to 10

The above data reflects that the gap between the seals ( mostly radial) sector plate has increased which resulted into high air leakages.


Following graph shows the month wise increase of APH air leakage in unit # 7

7.7

9.0 9.4

9.9 10.5

11.0

11.7

12.3

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

1 2 3 4 5 6 7 8

%

KW

APH Air Leakage % Vs Fan Loading

PA ID Leakage %


7.2 Higher Primary Air Pressure

OEM recommended Primary air pressure =8.5 Kpa Tripping value 5.4 KPA In order to avoid tripping of unit on MFT logic operators use to maintain the primary air pressure more than 8.5 Kpa which is contributing higher loading of PA fan


8. DEVELOPMENT OF SOLUTION


8.1 IMMEDIATE ACTIONABLES

24

S.No Cause Action Proposed Responsibility Target date Status

1 Air Ingress in

APH

Rectification of

damaged seals.

Aadarsh/Indrajeet

/ Arohi

As per AOH Installed

2 High DP of FF Leakage arrest in

penthouse & seal

trough

Aadarsh/Indrajeet

/ Arohi

As per AOH

Done

3 High PA Air

Header Pressure

Operational Control Vivek/ Atish Continuous Daily

Monitoring

4 Dampers & IGV’s

Problem

Checking &

calibration of links

Chandrakant

Panda

Continuous

Done


8.2 IDEAS/CREATIVE SOLUTIONS

S No Idea Area of Work

1 CFD analysis of flue gas duct (uniform distribution of flue gas flow) Boiler

2 Combustion optimization to optimize primary air pressure Boiler

3 Improvement of APH seal ( Online sector plate lifting arrangement N.A so we can put soft touch seal)

Boiler

4 Installation of magna drives Boiler

5 SADC correctness Boiler

6 online performance monitoring system Boiler


8.3 LIST OF SELECTED SOLUTIONS

SL SOLUTIONS

1 Soft touch seal installation

2 PA pressure optimization


9. FORSEEING POSSIBLE RESISTANCE


FORESEEING PROBABLE RESISTANCE

Sl no Probable resistance Resistance possible by

whom Solution Responsibility

1 Arrangement of Spares Procurement Approval

Evaluation of cost benefit of

implementation of APH soft

seal

Aadarsh/vivek

2 Optimization of pa pressure

by operators Operator

Data trends to be available

for 6 months Atish

3 SOP modification Operator/ Team Leaders SOP was verified and

approved by HOD Prakhar


10. TRIAL & IMPLEMENTATION


11. TRIAL & IMPLEMENTATION

Soft Touch Radial Seals shows better overlap with the sector plates and hence

ensure proper sealing and reduction in flue gas leakages.


2. PA loading reduced after primary air pressure optimization

6

6.5

7

7.5

8

8.5

9

9.5

10

10.5

1230

1240

1250

1260

1270

1 2 3 4 5 6 7 8 9 10

KW

Weeks

PA pressure Vs Loading

PA Series1


11. REGULAR IMPLEMENTATION


Regular implementation

• Installation of seals in all units based on overhauling schedule.

• Continuous monitoring of PA pressure by the operator on shift basis.


INTANGIBLE BENEFITS

SELF DEVELOPME

NT

KNOWLEDGE SHARING

LEADERSHIP

COMMUNICATION SKILL

SELF MOTIVATION

TEAM SPIRIT

INTANGIBLE BENEFITS

Aluminium & Power, Jharsuguda TANGIBLE BENEFITS BEFORE & AFTER

35

Aluminium & Power, Jharsuguda TANGIBLE BENEFITS BEFORE & AFTER


TANGIBLE BENEFITS

Investment Details :

For APH

Investment on cost of seal per Unit : INR 2.00 Lakhs

Overall Reduction in Fan loading per unit : 292 KW

Payback Month : 1 months

Savings Calculations:

Envisaged net saving for all 9 Units (Rs/ Lakhs) : INR 38 lakhs


12. FOLLOW UP & REVIEW

Aluminium & Power, Jharsuguda 12. FOLLOW UP & REVIEW

1. Daily monitoring and controlling of operating parameter by the operator. 2. Daily monitoring of performance parameter by the O & E team. 3. Weekly operational review by the operation head. 4. Operational review by the team leader and plant head on monthly basis

Parameters UoM Std Value U 1 U 2 U 4 U 5 U 6 U7 U 8 U 91 Load MW MW 135 138 138 138 138 139 139 138 138

2 MS Pressure Mpa 13.63 13.71 13.71 13.67 13.71 13.72 13.74 13.75 13.70

3 MS Temperature (Turbine inlet) °C 537 541.1 539.4 541.9 538.8 538.3 537.9 538.4 537.9

4 HRH temperature(Turbine inlet) °C 537 536.5 536.0 539.2 539.9 537.8 539.3 537.0 539.6

5 RH Spray TPH 0 0.0 0.0 0.0 0.0 0.2 0.0 0.0 0.0

6 Super Heater Spray TPH 11 20.4 22.3 17.2 28.3 21.4 23.5 26.1 27.2

7 Vacuum Kpa -89.82 -86.42 -86.05 -86.53 -87.10 -87.00 -86.75 -86.07 -85.27

8 Spray as % of MS flow % 2.70% 4.59% 5.02% 3.86% 6.34% 4.69% 5.13% 5.61% 6.14%

9 O2 % % 2.2-2.5 2.1 2.4 2.4 2.9 2.8 2.8 2.5 2.6

10 PA header press Kpa 6.5 6.5 6.8 6.9 6.7 6.4 6.3 6.2 6.4

11 Exist Flue Gas Temperature °C 138.0 139.0 136.1 137.5 138.8 137.0 139.9 137.5 139.7

12 Make-up water Flow 7.01 4 5.32 5.77 11.18 2.46 2.59 6.26

A shiftFLASH REPORT 22.04.2015


Thank You Queries Please..

Date post:	30-Mar-2018
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