1

1 1
The power of togetherness
 ALUMINA REFINERY

DAMANJODI, ODISHA

3
 REG.NO. M&R /TQM/ELECT/QC-39 /2003
UNIT ALUMINA REFINERY

DEPARTMENT ELECTRICAL

SECURITY FILTRATION
HYDRATE FILTRATION
AREA &
PRECIPITATION
3rd & 4th PHASE
MEETING DAY EVERY WEDNESDAY
11 AM

TOTAL NO. OF MEETINGS HELD 32

(calendar year 2016)
PROJECT COMPLETED 29

ATTENDANCE (avg.) 90%

4
 OUR TEAM

J.PASAYAT
FACILITATOR .Mgr (ELEC.)

N.K.RATH M.K.NAYAK Md.HUSSAIN R.K.SENAPATI

LEADER DY.LEADER

K.BHOI D.GOPE P.K.CHETTY M.K.PANDA

5
 IDENTIFICATION OF AREA PROBLEMS
(THROUGH BRAINSTORMING)

SL NO PROBLEMS CATEGORY

1 Frequent tripping of incomer of ASB-494. A

2 Motor LCS problem. A

3 BCH modules of US-05E not inserting properly to service position. A

4 VFD room cooling system is not sufficient. C

5 Continuous running of 3rd phase wash water pump in kelly filter . A

6 Frequent choking of cooling air suction path of seed tank agitator A

7 Interruption in emergency power feeding to critical drives. A

8 Frequent tripping of sumps A

9 Frequent AC failure indication in battery charger of DG set. A

10 Frequent failure of LIC handle of motors. B

6
 IDENTIFICATION OF AREA PROBLEMS
(THROUGH BRAINSTORMING)
SL NO PROBLEMS CATEGORY
11 There is no facility to check sample grease of HT motors A
12 PPT motors exposed to rain environment B

13 No proper cleaning of US 05E transformer rooms. B

14 Difficulty in opening the rolling shutter of transformer rooms. B

15 Stoppage of DG set without any indication A

16 Glass covers of LCS of motor breaking. A

17 Frequent charging of spring charger of I/C-4 in 386 PMCC. A

18 Improper shutdown system in kelly filters. C

19 Difficult to operate pumps 812,813,764A/B during overflow of slurry. C

20 Frequent breakdown of insulator in local isolator unit of seed tank agitators. A

21 Dislocation of cable trolley in hoists. C

7
 IDENTIFICATION OFAREA
IDENTIFICATION OF AREA PROBLEMS
PROBLEMS
(THROUGH BRAINSTORMING)
(THROUGH BRAINSTORMING)

SL NO PROBLEMS CATEGORY
22 Some time motor’s temperature raising high while running. A
23 Pendant problem in PPT hoist. A
24 Difficulties on greasing Sump pump 815 & 816. B
25 T.B. push type connector problem of Disc filter ‘s LCP. A
26 No feeder getting close in test position of H.T. Panels. C
27 Carbon deposition over the power contacts of Vacuum pumps B
28 Frequent brake failure in disc filters. A

29 Failure of indication lamps in LCP of Bokela Disc filter. B

30 The soft ware of Bokela Disc filters is difficult to understand for troubleshooting. C

31 Reversal in direction of isolator of 3rd phase air blower. A

32 Frequent failure of magnetic proximity limit switch in kelly filter. A

8
 IDENTIFICATION OF AREA PROBLEMS
(THROUGH BRAINSTORMING)

SL NO PROBLEMS CATEGORY
33 Frequent failure of VFD (ABB) cooling system leading to drive tripping B

34 Poor D.C. illumination during power failure B

35 Difficulty in knowing the oil level of D G set. B

36 Temperature scanner of DG is not functioning. B

37 No Air line system for DG room. B

38 Frequent burning of Closing coil of PMCC386 & 387. A

39 Problem in rack out of 6.6 KV motor feeder of Siemens panel. B

40 In 3rd phase Disc Filters lubrication system is frequently failure. B

41 Inter stage cooler motors having low current even it is running in full load. A

42 Panel of PPT Hoists exposed to rain environment. A

9
 IDENTIFICATION OF AREA PROBLEMS
(THROUGH BRAINSTORMING)

SL NO PROBLEMS CATEGORY
43 Continuous glowing of light in unmanned sub – station. A
44 Indication lamps are getting fuse in ht panel A
45 HT drive feed back problem at the time of starting the motor A

46 LT motor module limit switch not actuating properly. A

47 Motors greasing nipples getting chocked. A

48 No provision of exhaust fan in transformer rooms. B

49 Isolating & connecting lock of ht panels is not functioning properly A

50 LT breakers manual stop is not functioning properly. A

51 Transformers are in under loaded. B

52 Frequent flash over of lighting JB in Area. A

10
 IDENTIFICATION OF AREA PROBLEMS
(THROUGH BRAINSTORMING)

SL NO PROBLEMS CATEGORY
53 Frequent failure of control fuses of limit switches. B

54 Difficulties to rack out L.T.modules. A

55 Difficulties to shutout problems in Disc filter. B
56 Most of the time cranes were kept out side the flat form. B
57 In stop condition voltage is found in VFD power cable at motor end. A

58 Damaging of segments in disc filters. B

59 In EOT cranes control supply is totally getting ‘OFF’ when its hoisting pendent A
cuts its ‘UP’ limit switch.
60 Ideal running of kelly wash water pump. A
61 FREQUENT PROBLEM IN L&T MAKE LT MODULES OF 4TH PHASE. A

62 Natural cooling system of D.G.set is poor. C

11
 IDENTIFICATION OF AREA PROBLEMS
(THROUGH BRAINSTORMING)

SL NO PROBLEMS CATEGORY
63 Siemens VFD trips when there is power failure. A

64 Control transformer readiness not available in bch panel. A

65 PPT agitators are not being started from DCS. A
66 LAN connection to area computer not available. C
67 Bus-coupler 2 breaker of PMCC 386 tripping in dc interruption. A
68 Frequent tripping of disc filter in system fault. B
69 Deposition of dust in sub-station. B
70 Frequent failure of lighting db in ground floor. B
71 Poor approach to 3rd phase ground floor area. C
72 ABB VFD motors started automatically after any fault reset. A

73 Closing healthiness of breaker is not available in dg in-comer. A

74 Un-necessary running of hydro coupling external oil pump motor. A

12
 DETAILS OF PROBLEM

74

45
29

PROBLEMS PROBLEMS PROBLEMS

INDENTIFIED SOLVED UNDER
STUDY

13 FROM MAR 2003

 BENEFITS FROM COMPLETED PROJECTS
SL. NO SOLVED PROBLEM BENEFITS

1 FREQUENT FAILURE OF ELECTRICAL SYSTEM IN KELLY FILTERS Rs.70,590/-

2 VAPOUR ENTERING IN TO LCP OF DISC FILTER. Rs.4,92,OOO/-

3 SPRING CHARGING OF INCOMMER OF PMCC NOT TAKING PLACE AS PER EFFICIENCY INCREASED
PROCEDURE.
4 IMPROPER OPERATION OF PPT MODULES AVAILABILITY ENSURED

5 PPT HOIST ELECTRICAL PROBLEM. Rs.95,800/-

6 FLASHOVER IN 6.6 KV FEEDER. Rs.4,03,100/-

7 ABNORMAL HEATING OF OUTGOING CABLES IN FVNR 400. EFFICIENCY INCREASED

8 HOIST OF 05 AREA IS NOT GOING TO ITS GROUND LANDING POSITION. EFFICIENCY INCREASED

9 UNNECESSARY RUNNING OF KELLY HYDRAULIC PUMP. Rs.3,85,592/-

10 DIFFICULTY IN DIESEL FILLING IN DG FUEL TANK. Rs.12,560/-

11 FREQUENT FAILURE OF SL PUMP MOTORS. Rs.3,67,600/-

12 PROBLEM OF POWER SUPPLY SYSTEM TO EOT CRANE OF DISC FILTER FLOOR Rs.1,73,166/-
AREA.
13 DAMAGE OF TRAILING CABLE INSULATION NEAR CLAMPS OF CABLES IN PPT EFFICIENCY INCREASED
TOP HOIST .

14
 BENEFITS FROM COMPLETED PROJECTS
SL. SOLVED PROBLEMS BENEFITS
NO
14 FAILURE OF INDICATION SYSTEM IN SWITCH BOARD. EFFICIENCY INCREASED
15 DIFFICULT TO REPLACE MOTOR OF GREASE PUMP OF BOKELA DISC FILTER. EFFICIENCY INCREASED
16 CONTINIOUS GLOWING OF LIGHTS IN UNMANNED SUB – STATION. Rs.3,00,982./-
17 FAILURE OF UNLOCK LIMIT SWITCH OF KELLY FILTERS. AVAILABILITY INCREASED
18 IMPROPER SHUT DOWN SYSTEM IN KELLY FILTERS. Rs.44,352/-
(UNNECESSARY RUNNING OF HYDRAULIC OIL PUMP)
19 IDLE RUNNING OF KELLY FILTER WASH WATER PUMP NO 383. Rs.74,244/-.
20 ELEMINATING IDLE RUNNING OF HYDRO-COUPLER MOTOR IN HT PUMP 755 B. Rs.1,46,355/-
21 FREQUENT BREAK DOWN OF DISC FILTER FLOOR CRANE. Rs.28,700/-
22 UNSAFE WORKING CONDITION WHILE CCL CHARGING IN KELLY FILTER. SAFETY ENSURED
23 DIFFICULTIES IN RACK IN/ OUT IN ALSTHOM / BCH MOTOR MODULE. SAFETY ENSURED
24 DIFFICULTIES IN ASSESSING OIL LEVEL IN DAY TANK OF DG SETS. AVAILABILITY INCREASED
25 HARD APPROACH TO SUMP PUMP 815 & 816. SAFETY ENSURED
26 FREQUENT PROBLEM IN L & T MAKE LT MODULES.
Rs. 6,25,200 /-
27 FREQUENT PROBLEM IN 4TH PHASE DISC FILTER LCP AVAILABILITY INCREASED
Rs.
28 PROBLEM IN DIASTER FEED PUMP. 77,25,282/- Rs.10,00,000 /-

29 Problem in 4th phase ppt drives Rs. 9,10,000

Rs.77,25,282/-
TOTAL
15
 CATEGORISATION
(FROM UNSOLVED PROBLEMS)

CLASSIFICATION OF PROBLEM UNDER STUDY

07 NOS

16% A' CATEGORY

09 NOS
20%
64% B' CATEGORY

C' CATEGORY

29 NOS

16
 SELECTION OF PROBLEM (FROM “A”CATEGRY)

SL NO PROBLEM DESCRIPTION
1 FREQUENT TRIPPING OF ASB-494
2 BCH MODULE INSERTING PROBLEM
3 CHOCKING OF COOLING AIR SUCTION PATH IN SEED TK AGTR MOTORS

4 DG NOT GETTING PROPERLY COOLED AT THE TIME OF RUNNING.

5 FREQUENT TRIPPING OF SEED PUMPS.

6 STOPPAGE OF DG SET WITHOUT ANY INDICATION

7 INSPECTION WINDOW BREAKING OF LIC

8 LIC FAILURE OF SEED TK AGTRS

9 ABNORMAL TEMP. OF DG SETS.

10 LOCAL PB STATION FAILURE

11 LT MODULE RACKOUT PROBLEM

12 RESIDUAL VOLTAGE FOUND AT VFD O/P IN STOP CONDITION.

13 FREQUENT DAMAGE OF PENDENT IN PPT HOIST.

14 FREQUENT BRAKE FAILURE IN DISC FILTERS.

15 CONNECTOR PROBLEM OF DISC FILTERS LCP.

16 REVERSAL IN DIRECTION OF 3RD PHASE AIR BLOWER.

17
 SELECTION OF PROBLEM
SL NO PROBLEM DESCRIPTION
17 FREQUENT BURNING OF CLOSING COIL OF PMCC 386 & 387.

18 SPURIOUS STOPPING OF INTER STAGE COOLER MOTORS

19 PPT HOIST PANEL EXPOSED TO RAIN ENVIRONMENT

20 FAILURE OF INDICATION LAMPS IN HT PANEL

21 FLASHOVER IN SWITCH BOARD.

22 INTERRUPTION IN EMERGENCY POWER TO CRITICAL DRIVES OF 4 TH PHASE.

23 FREQUENT BREAKAGE OF PANEL KEY IN SIEMENS HT PANELS

24 CLOSING HEALTHINESS OF BREAKER IS NOT AVAILABLE IN DG IN-COMER

25 CONTROL TRANSFORMER READINESS NOT AVAILABLE IN BCH PANEL.

26 PPT AGITATORS ARE NOT BEING STARTED FROM DCS.

27 BUS-COUPLER 2 BREAKER OF PMCC 386 TRIPPING IN DC INTERRUPTION

28 ABB VFD MOTORS STARTED AUTOMATICALLY AFTER ANY FAULT RESET.

29 FAILURE OF EMERGENCY POWER .

18
 SELECTION OF PROBLEM
(MULTIVOTING METHOD)

19
 SELECTION OF PROBLEM
(MULTIVOTING METHOD)

NO OF
SL NO SHORT LISTED PROBLEMS VOTES

1 BUS-COUPLER 2 BREAKER OF PMCC 386 TRIPPING IN DC INTERRUPTION 5

LIC FAILURE OF SEED TK AGTRS

2 6

3 FREQUENT BURNING OF CLOSING COIL OF PMCC 386 & 387. 7

4 INTERRUPTION IN EMERGENCY POWER TO CRITICAL DRIVES OF 4TH PHASE. 8

5 DG NOT GETTING PROPERLY COOLED AT THE TIME OF RUNNING. 5

BCH MODULE INSERTING PROBLEM
6 4
FAILURE OF INDICATION LAMPS IN HT PANEL
7 4
CONNECTOR PROBLEM OF DISC FILTERS LCP.
8 3

20
 SELECTION OF PROBLEM
(CRITERIA RANKING)

SL
NO. HEADS WEIGHTAGE
1 PRODUCTION 0.6
2 SAFETY 0.2
3 INTERNAL CUSTOMER SATISFACTION 0.2

Our management has communicated in various forums

that PRODUCTION is our main concern for meeting the
MOU target while at the same time taking care of
SAFETY & INTERNAL CUSTOMER SATISFACTION.

21
 SELECTION OF PROBLEM
(CRITERIA RANKING)
PRODUCTION HEAD(WEIGHTAGE SCALE:0.1-0.6)
NKR MKN RKS MDH MKP DG KB PKC TOTAL
PROBLEM-1 0.5 0.6 0.5 0.6 0.3 0.5 0.6 0.5 4.1
PROBLEM-2 0.4 0.5 0.4 0.5 0.4 0.4 0.5 0.4 3.5
PROBLEM-3 0.6 0.3 0.6 0.3 0.4 0.6 0.3 0.6 3.7
PROBLEM-4 0.6 0.5 0.6 0.5 0.6 0.6 0.5 0.6 4.5
PROBLEM-5 0.3 0.4 0.3 0.4 0.5 0.3 0.4 0.3 2.9
PROBLEM-6 0.2 0.3 0.2 0.3 0.4 0.2 0.3 0.2 2.1
PROBLEM-7 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 2.4
PROBLEM-8 0.4 0.2 0.3 0.4 0.4 0.4 0.3 0.4 2.8
SAFETY HEAD (WEIGHTAGE SCALE: 0.1-0.2)
NKR MKN RKS MDH MKP DG KB PKC TOTAL
PROBLEM-1 0.2 0.1 0.2 0.2 0.1 0.2 0.2 0.1 1.3
PROBLEM-2 0.1 0.2 0.2 0.1 0.2 0.2 0.1 0.2 1.3
PROBLEM-3 0.1 0.1 0.2 0.1 0.1 0.2 0.1 0.1 1
PROBLEM-4 0.2 0.2 0.1 0.2 0.2 0.1 0.2 0.2 1.4
PROBLEM-5 0.1 0.2 0.2 0.1 0.2 0.2 0.1 0.2 1.3
PROBLEM-6 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.8
PROBLEM-7 0.2 0.1 0.1 0.2 0.1 0.1 0.2 0.1 1.1
PROBLEM-8 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.8

INTERNAL CUSTOMER SATISFACTION HEAD(WEIGHTAGE SCALE: 0.1-0.2)

NKR MKN RKS MDH MKP DG KB PKC TOTAL
PROBLEM-1 0.1 0.2 0.1 0.1 0.2 0.2 0.1 0.2 1.2
PROBLEM-2 0.2 0.1 0.2 0.2 0.1 0.2 0.2 0.1 1.3
PROBLEM-3 0.1 0.1 0.1 0.1 0.1 0.2 0.1 0.1 0.9
PROBLEM-4 0.2 0.2 0.2 0.2 0.2 0.1 0.2 0.2 1.5
PROBLEM-5 0.2 0.1 0.2 0.2 0.1 0.2 0.2 0.1 1.3
PROBLEM-6 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.8
PROBLEM-7 0.1 0.2 0.1 0.1 0.2 0.1 0.1 0.2 1.1
PROBLEM-8 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.8

22
 SELECTION OF PROBLEM (CRITERIA RANKING)

HEADS

PROBLEMS PRODUCTION SAFETY INT. CUSTOMER TOTAL

PROBLEM-1 4.1 1.3 1.2 6.6
PROBLEM-2 3.5 1.3 1.3 6.1
PROBLEM-3 3.7 1 0.9 5.6
PROBLEM-4 4.5 1.4 1.5 7.4
PROBLEM-5 2.9 1.3 1.3 5.5
PROBLEM-6 2.1 0.8 0.8 3.7
PROBLEM-7 2.4 1.1 1.1 4.6
PROBLEM-8 2.8 0.8 0.8 4.4

Problem No. 4 – INTERRUPTION IN EMERGENCY POWER TO CRITICAL

DRIVES OF 4TH PHASE.

23
 SELECTED PROBLEM

24
 MILE STONE CHART (PLAN)
NAME OF QC AREA INCHARGE FACILITATOR TEAM:
SYNERGY MR.R.N SWAIN. AGM(ELCT.) MR J. PASAYAT. MGR.(ELCT.) Md. HUSSAIN
PROJECT- INTERRUPTION IN REASON FOR SELECTION N.K.RATH
EMERGENCY POWER TO INCREASE AVAILABILITY OF EMERGENCY POWER. D.GOPE.
CRITICAL DRIVES OF 4TH MK NAYAK
PHASE. MK PANDA
PROJECT NO-30 DATE OF STARTING PLANNED DATE OF COMPLETION K BHOI
10.06.15 31.12.15 PK CHETTY
RK SENAPATI
SL
ACTIVITIES / WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
NO
1 IDENTIFICATION OF PROBLEM

2 SELECTION OF PROBLEM

3 DEFINING THE PROBLEM

4 ANALYSING THE PROBLEM

5 IDENTIFYING THE CAUSES

6 FINDING ROOT CAUSES

7 ANALYSIS OF ROOT CAUSES

8 DEVELOPING THE SOLUTION

9 PROBABLE RESISTANCE

10 TRIAL IMPLEMENTATION

11 REGULAR IMPLEMENTATION

12 FOLLOW UP/REVIEW

25
 MINES
DEFINITION OF THE PROBLEM
HIGH LEVEL FLOW DIAGRAM

RECLAIMER CRUSHER BALLMILL PRE-

STACKER DESILICATION

SAND POST SECURITY

DIGESTION SEPARATION SETTLERS
DESILICATION FILTRATION

RED MUD POND TTD WASHERS

PHE PRECIPITATION CALICINATION ALUMINA

26
EVAPORATION
 DEFINITION OF THE PROBLEM (ABOUT PRECIPITATION AREA)

PHE,HYDRATE FILTRATION,PRECIPITATION AND CLASSIFICATION UNIT

ALUMINATE LIQUOR FROM KELLY

FILTER SEED SLURRY TO PPT TANKS

CLASSIFYING
16
CYCLONE
T 16
INLET AT 100 0C H T 16
H T 16
H T 16
H T 16
PLATE HEAT EXCHANGER H T 16
H T 16 PRODUCT FILTER
H T 16
H T 16

SEED SLURRY TO PPT TANKS

H T 16
H T 16
H T 16
H T 16
0 20
OUTLET AT 60 C H T 16
th
HT TO CALCINATION
HT
K

SPENT LIQUOR TO EVAPORATION

ALUMINATE LIQUOR TO SEED SEED PUMP

TANK
 DEFINITION OF THE PROBLEM
(POWER FEEDING SYSTEM)

EMERGENCY
POWER

PPT AGITATOR
UNIT
SUBSTATION
06 - EX

LOOP
SUB
STATION

SEED TANK PRECIPITATION TANK

CDS SPP AGITATOR

GRID SUPPLY
 DEFINITION OF THE PROBLEM
(ELECTRICAL DISTRIBUTION SYSTEM TO CRITICAL DRIVES)

US-06EX
TRF 3311 & 3312 SWBD-
407

PPT /
CDS LS-02 SEED
TANK
AGTR.

US-06EX
TRF-3309 & 3310 SWBD-
406

29
 DEFINITION OF THE PROBLEM
(EMERGENCY DG POWER)

BOARD-407
DG POWER -1250 KVA DG SWITCH BOARD-409 +

PPT
TANK

ALL CRITICAL DRIVES

BOARD-406

30
 DEFINITION OF THE PROBLEM
(WHEN EMERGENCY POWER FAILS)

PPT TANK AGITATOR

EMERGENCY 06E
POWER ELECTRICAL
PANEL
PPT SWITCH BOARD-406
&407

31
 DEFINITION OF THE PROBLEM
(IMPACT)
( DUE TO POWER INTERRUPTION)
1. Settling of precipitation & seed tanks.
2. Huge tank revival cost.
3. Deterioration of production quality.
4. Stoppage of process for long periods.
5. Huge production loss.
6. Fearness among area people.
7. Bad impression on area as well as on department.
8. Chances of accident / flashover.
9. Safety hampered.
10. Internal customer dis-satisfaction.

32
 DEFINITION OF THE PROBLEM

 PPT SLURRY = ALUMINA HYDRATE + SPENT LIQUOR.

(DENSITY: 850 GRAM SOLID IN ONE LITRE OF LOQUOR.)
 CONTINUOUS AGITATION IS REQUIRED TO MAINTAIN SOLID IN SUSPENDED FORM.
OTHERWISE HYDRATE WILL SEPARATE FROM SL & SETTLES DOWN DUE TO GRAVITY &
BECOMES HARD ROCK.
TANK CAN NOT BE USED FOR PROCESS.
BECAUSE OF HIGH DENSITY OF SLURRY
SETTLING OF TANK OCCURS WITHIN 15 MINUTES.
33
 OBJECTIVE

34
 GOAL

35
 ANALYSIS OF PROBLEM

WHAT Interruption in power supply

to critical drives.
WHEN From dt.01.07.14 to dt.31.06.15

WHO Mk Nayak & Mk Panda

WHERE From Shift log book.

HOW By studying.

36
 ANALYSIS OF PROBLEM
(DATA ON NORMAL POWER FAILURE & INTERRUPTION OF EMERGENCY POWER) JULY”14 TO JUNE”15

SL NO. DATE OF NORMAL POWER FAILURE INTERRUPTION OF EMERGENCY POWER

1 28-07-14 No

2 31-07-14 No

3 03-08-14 Yes

4 19-08-14 No

5 10-10-14 No

6 11-11-14 Yes

7 10-03-15 No

8 17-04-15 No

9 18-06-15 Yes

37
 ANALYSIS OF PROBLEM
(LOSSES)

1.
LOSSES
SL EFFECTS NUMBERS
(In Rupees )

Settling of
1 01 6,00,000.00
precipitation tanks.

2. Man hour loss.

3. Process hampered.

4. If two adjacent tanks settle then total phase will hampered for longer period.

38
 ANALYSIS OF PROBLEM
(DATA ON LOSSES)

DETAIL COST CALCULATION FOR EACH TANK REVIVAL

Cost of Steam charging Duration of steam Total steam Cost of steam

steam per rate charging consumption (cost per ton x
ton steam
( coal cost consumption)
only)
Rs.500 25 ton per hour 2days=48hrs. 1200 tons 6,00,000.00

39
 IDENTIFYING THE CAUSES
(THROUGH BRAINSTORMING)

1. No fuel.
2. Outgoing Breaker problem.
3. Relay malfunctioning.
4. DG AMF panel breaker problem.
5. Battery problem.
6. DG in over load.

7. Breaker coil burnt

8. Interlock not satisfied.

9. DG engine got air lock.

10. coolant or radiator problem.

11. No alternative source at DG board.

12. Poor illumination in SWGR room.

13. DG alternator fails.

14. DG has low capacity.

40
 C & E ANALYSIS

FUEL WINDING TEMP.HIGH

PROBLEM

FUEL SOLENOID ALTERNATOR

PROBLEM PROBLEM
NO FUEL
DG NOT OVER LOAD NO GREASING
STARTING CONNECTING LEAD
BEARING TEMP HIGH
PROBLEM NO FUEL
CHARGER LATE DETECTION
LOW PROBLEM DG STOPS
ELECTROLYTE DURING RUNNING
OLD TRIP
PERSISTING BATTERY RADIATOR JAMMING
PROBLEM
COOLANT TEMPERATURE HIGH
DG

41
 C & E ANALYSIS

SWBD 409
SWBD- 409

I/C
BREAKER PROBLEM OUT GOING
BREAKER PROBLEM
NO STANDBY
I/C,DG
TWO DG SETS
RUNNING REQUIRED

POOR ILLUMINATION AT NIGHT

DURING POWER FAILURE

TOTAL SS LIGHTS FROM

ONE DG

LTG. TRF. PROBLEM

NO S/B ALL AC LIGHTS

DG I/C NOT GLOWING
BREAKER SWBD- 406
PROBLEM

42
 C & E ANALYSIS

407- SWBD

NO. OF PPT MORE (DESIGN)

TRIPPING OF
BREAKER

RELAY
MALFUNCTION TWO DG RUNNING REQUIRED
OVER LOADING
SPURIOUS RATING OF AGTR. MOTOR
TRIPPING IS HIGH (DESIGN)
I/C BRKR
PROBLEM
CLOSING COIL BURNT EACH PPT DRAWS MORE CURRENT

INTERLOCK NOT SATISFIED ONE DG CAPACITY

MECHANISM PROBLEM INSUFFICIENT IF
OTHER DG TRIPS
NO MAINTENANCE CLOSING
PROBLEM
AMBIENT FULL OF DUST
JAMMING

43
 IDENTIFIED ROOTCAUSES

1. Fuel solenoid problem.

2. Radiator jamming.
3. Breaker closing coil burnt.
4. Relay malfunctioning.
5. Spurious tripping of breaker.
6. Late detection of DG overload.
7. Insufficient DG capacity in 407-SWBD(in case of one DG trip).
8. No stand by DG incomer in 406-SWBD.
9. Total substation light is from one DG.
10. Charger problem.
11. Battery electrolyte low.
12. Connecting lead problem.
13. No fuel.

44
 VALIDATION OF ROOT CAUSE
1. Fuel solenoid problem.

Fuel solenoid problem may be there but it is

looked after by mech. Dept. so valid but not actionable.

2. Radiator jamming.
Radiator problem may be there but it is
looked after by mech. Dept. so valid but not actionable.

3. Breaker closing coil burnt.

Coil failures occurring as observed from log-book- valid
But breaker can be closed manually - Not actionable.

45
 4. Relay malfunctioning.

Sl No Date DG No Remarks
Looked after by (Not valid)
testing group

5. Spurious tripping of breaker.

(Not valid)

46
Root cause -6
Late detection of DG overload.

SUB STATION US 06EX

WAY TO DG ROOM

SUB STATION US 06E US 06E

DG ROOM-2 DG ROOM-1
MAINT.
OFFICE
VALIDATION:-
1.
2.
AT THE TIME OF POWER FAILURE 3 PERSONS ARE AVAILABLE.
REMOTE LOCATION OF DG SHED.
VALID
3.
4.
TWO DIFFERENT SUBSTATION.
FLOOR IS DIFFERENT.
&
5. QUICK MONITORING IS NOT POSSIBLE. ACTIONABLE
47
Root cause -7 Insufficient DG capacity in 407-SWBD(in case of one DG trip).

DG DG

409 DG SWBD

407 SWBD

20 NOS
PPT MOTOR M M
64KW

48
Root cause -7
Insufficient capacity in 407-SWBD(in case of one DG trip).
Load calculation of DG
DG-1001(section-A) DG-1002(section-B)
SL. DRIVES CURRENT SL. DRIVES CURRENT
NO. NO. In Amps NO. NO. In Amps
1 PPT-1111 100 1 PPT-1110 92
2 PPT-1113 103 2 PPT-1112 94
3 PPT-1116 90 3 PPT-1115 106
4 PPT-1117 91 4 PPT-1119 96
5 PPT-1118 90 5 PPT-1120 98
6 PPT-1123 95 6 PPT-1121 90
7 PPT-1124 90 7 PPT-1125 102
8 PPT-1126 90 8 PPT-1127 96
9 PPT-1128 92 9 PPT-1129 80
Total 9 no.s 841 TOTAL=1695A Total 9 no.s 854

49
Root cause -7 Insufficient DG capacity in 407-SWBD
(in case of one DG trip).

OBSERVATION:

DG CAPACITY=1740Amps

DG should be loaded to 80% as per manufactures standard.

So capacity = 1740Amps x 0.8=1392Amps
If one DG trips Total load become
Section(A)+Section(B)=1695Amps+seed tk& ltg. VALID
But total capacity is 1392Amps &
ACTIONABLE
50
Root cause -8 No stand by DG incomer in 406-SWBD.
DG DG

DG DISTRIBUTION SWBD 409

SWBD-406

LOAD LTG

1. If one DG fail then other DG can not give VALID

power due to over loading.
2. If feeder breaker/cable/relay problem
&
then there is no alternative source ACTIONABLE
51
Root cause -9 Total substation lighting is from one DG. TUBE LIGHT

409 408

406 LTG
BOARD

407 ENTRANCE

US 06EX

52
 Total substation light is from one DG.
Root cause -9

DG DG

DG DISTRIBUTION SWBD 409

SWBD-406

LOAD LTG

1. If DG-1002 did not start in the night so substation will VALID

be dark. &
2. At the time emergency power normalisation will take
long time.
ACTIONABLE

53
 VALIDATION OF ROOT CAUSE

Sl.no. Root causes observation Remarks

10. Charger problem.

N
No data Charger, battery are being checked regularly and
O
11. Battery
electrolyte low. found preventive maintenance is being done every month . T

12. Connecting lead

problem. V
A
L
No data Fuel status is being checked every day & being I
13. No fuel found recorded in log book D

54
 DEVELOPMENT OF SOLUTION
(ROOT CAUSE-1)

ROOT CAUSE .1 PROPOSED SOLUTION JUSTIFICATION ACCEPTANCE

Loading of all DG set to be Quick monitoring will

monitored at one place and be possible & can be
Accepted
preferably in shift room. implemented easily.

Late detection of
DG overload. Deputation of shift person to DG
room for monitoring load.

Due to insufficient
There is two DG rooms (4No.s DG sets)
manpower, it is not
Not Accepted
possible.

One person Sitting in every

switchgear room in every shift.
(There is two switchgear rooms &
4No.s Of swbds to feed DG power)

55
 DEVELOPMENT OF SOLUTION
(ROOT CAUSE-2)

ROOT CAUSE. 2 PROPOSED SOLUTION JUSTIFICATION ACCEPTANCE

It takes more cost
Addition of a new section. (2500A L&T breaker +new panal NOT ACCEPTED
+cable 300sq mm x 4 +cable trench)

1. No stand by
Addition of new Standby It takes more cost
DG incomer NOT ACCEPTED
modules for critical drives (2 in1 isolator 400A +module400A
in 406- in switch board 407.
+cable300sq mm 25mtrs)

SWBD.

Use of spare out going It can be done as there is a

breaker as incomer in 406 spare breaker available in ACCEPTED
SWBD . this swbd 406.

56
 DEVELOPMENT OF SOLUTION
(ROOT CAUSE-3)

ROOT CAUSE .3 PROPOSED JUSTIFICATION ACCEPTANCE

SOLUTION
1.)We have two DG sets in third
phase. Out of which one DG set is
Addition of other DG less loaded and has margin.
source at DG 2)Two extra breakers are available Accepted
Distribution but present in one section. Feeder
board:409 rearrangement can be done & one
breaker in each section can be made
available.
1. Insufficient DG
capacity in 407- Addition of other DG
There is no spare outgoing breaker.
SWBD(in case of
one DG trip).
source
Distribution
at DG
Two additional sections are to be Not
board:407
added. Higher cost involved. accepted

Stoppage of tank
There is a load requirement of Not
around 2000A after stoppage of
agitator which are
offline tanks against capacity of accepted
not in line or CCL.
1600A.

57
 DEVELOPMENT OF SOLUTION
(ROOT CAUSE-4)

ROOT CAUSE .4 PROPOSED JUSTIFICATION ACCEPTANCE

SOLUTION

Lighting to be
segregated. Part of the Light will still be there in case Accepted
lights to be supplied one DG has any problem.
from other DG set.

Total substation Complete lights to be In case of other DG source fail

NOT
changed to other DG then the switchgear room will be
light is from one ACCEPTED
source. dark
DG.
DC lights were provided, but
lighting is insufficient. So, High
NOT
DC lights to be capacity battery & battery ACCEPTED
provided charger should be provided for
high wattage lamps which
demands more cost.

58
 ACCEPTED SOLUTIONS

SL.NO ROOT CAUSE SOLUTION REMARK

Late detection of DG Loading of all DG set to be monitored at
overload. one place and preferably in shift room. ACCEPTED
1.

2. No stand by DG Use of spare out going breaker as

incomer in 406- incomer . ACCEPTED
SWBD.

Insufficient capacity Addition of other DG source at DG

3. Distribution board:409
in 407-SWBD(in case ACCEPTED
of one DG trip).

Total substation light Lighting to be segregated. Part of the ACECPTED

4. lights to be supplied from other DG set.
is from one DG.

59
 DEVELOPMENT OF SOLUTION
(ACTION PLAN)

SL TARGET DATE
ACTION PLAN RESPONSIBILITY RESULT
NO. (PLANNED)

Loading of all DG set to be

monitored at one place and MD. HUSSAIN ARRANGEMENT
1 K.BHOI
17.12.15 DONE
preferably in shift room.
Use of spare out going
N.K RATH ARRANGEMENT
2 breaker as incomer by laying R.K SENAPATI 22.12.15 DONE
cable.

Addition of other DG source

at DG Distribution board:409 D.GOPE ARRANGEMENT
3 M.K.NAYAK
22.12.15 DONE

Lighting to be segregated. Part

of the lights to be supplied P.K CHETTY ARRANGEMENT
4 M.K.PANDA
29.12.15 DONE
from other DG set.

60
 FORESEEING PROBABLE RESISTANCE

SL.NO SOLUTION RESISTANCE REMEDIAL ACTION TAKEN RESULT

ANTICIPATED

Loading of all DG set to be monitored at

1.
one place and preferably in shift room.
No resistance. NIL C
Similar spares are available in O
SWBD-408, which will be
2. Use of spare out going breaker as Spare will be exhausted. used in case of scarcity if N
incomer in 406 SWBD . SWBD-406
V
3 Interlocks will be developed
Addition of other DG source at DG Paralleling of DG source for breaker closing & I
instruction will be displayed
Distribution board:409 may occur
on the breaker panel door N
C
E
4 Lighting to be segregated. Part of the NIL
lights to be supplied from other DG set.
No resistance
D

61
61
 TRIAL IMPLEMENTATION OF SOLUTION

ROOT CAUSE NO- 1 LOCATION SOLUTION IMPLEMENTE

DATE

Loading of all DG set to be monitored 17.12.2015

Shift maintenance at one place and preferably in shift
Late detection of DG room of US-06E room.
overload.

SOCO METER DIGITAL VOLT METER

62
 TRIAL IMPLEMENTATION OF SOLUTION

ROOT CAUSE NO- 2 LOCATION SOLUTION IMPLEMENTED

DATE

No stand by DG incomer SWBD - 406 Use of spare out going breaker as 22.12.2015
in 406-SWBD. incomer .

B/C-1 B/C-2 SWBD-406

X X
X X X X

I/C – 1 I/C from I/C – 2

1002 DG SPARE
TRF. 3309 TRF. 3310

63
 TRIAL IMPLEMENTATION OF SOLUTION

ROOT CAUSE NO- 3 LOCATION SOLUTION IMPLEMENTED

DATE

Insufficient DG capacity in SWBD - 407 Addition of other DG source at DG 27.12.2015

407-SWBD(in case of one Distribution board:409
DG trip).

SWBD-407
B/C-1 B/C-2 B/C-3

X X X
X X X X

I/C from I/C – 1 I/C from

1002 DG I/C – 2
TRF. 3311 1001 DG TRF. 3312

64
 DG DG

DG

409 DG SWBD

2 spares CALCINATION
TWO
We need one breaker in each section of the switchboard. But we there was two spare breakers
in section 1 & no spare breaker in section2.
So brain storming was carried out & decided to shift calcination feeder breaker to section-1. This
will make one breaker free in each section of the Switch board.

65
 TRIAL IMPLEMENTATION OF SOLUTION
ROOT CAUSE NO- 4 LOCATION SOLUTION IMPLEMENTED
DATE
Total substation light is Lighting to be segregated. Part of
from one DG. AT US-06EX the lights to be supplied from other 29.12.2015
DG set.

409 408

406 LTG
BOARD

US
06EX
407 ENTRANCE

TUBE LIGHT

66
 US 06EX TUBE LIGHT

409 408

406 LTG
BOARD

ENTRANCE

407 ENTRANCE

67
 COST OF IMPLEMENTATION
SL.NO ITEMS QUANTITY COST
In Rs.
1. Power cable with glanding & 110 x 4 3,52,000
termination runs=440mtr
3.5x300sqmm Al.
2 Control cables 210mtr 16,800

3 Volt meter 4 nos 2,000

4 Socometer 4 nos 20,000

5 Helper support 15 mandays 5,250

Total 3,96,050
All materials listed above were taken from balance of expansion project.

68
 CHECKING PERFORMANCE
TRIAL
WORK DONE LOCATION IMPLEMENTATION NO OF OBSERVATION RESULT
DATE INSTANCES
Monitoring of
loading of all DG set
in shift room. US-06E 17.12.2015 03 Monitored satisfactory

Provision of second
incomer in SWBD SWBD-406
406. 22.12.2015 03 Second Incomer satisfactory
could take the
load.

Provision of
additional DG SWBD-409
source at DG 27.12.2015 03 Load was given satisfactory
Distribution without voltage
board:409 drop.
Provision of partial
lighting from 3RD US-06EX 29.12.2015 03 Illumination was satisfactory
phase DG set. sufficient .

After success of trail implementation the solutions were kept in line permanently & declared as
regular implementation.

69
 CHECKING PERFORMANCE
Resumption of Power
after implementation
Solution implemented GOAL
within 15 minutes
(Yes/No)

Monitoring of loading of all DG set in

shift room. YES ACHIEVED

Provision of second incomer in SWBD YES ACHIEVED

406.

Provision of additional DG source at YES

ACHIEVED
DG Distribution board:409

Provision of partial lighting from 3RD YES ACHIEVED

phase DG set.

70
 FOLLOW UP/ REVIEW &
RECURRENCE PREVENTION
CHECK LIST

SL NO. HEADS FREQUENCY

1. Soco meter 06 months

06 months
2. Spare breaker

06 months
3. Cable tightness

06 months
4. Lighting circuit

71
CHECKED BY
 FOLLOW UP/ REVIEW &
RECURRENCE PREVENTION

STANDARDIZATION

1. Power circuit & lighting circuit drawing incorporated in main

drawing.
2. Interlock to prevent DG paralleling was incorporated in main
drawing.

72
 TANGIBLE BENEFITS
OPPORTUNITY BENEFIT
RISK due to non
SWBD NO. availability of COST Tentative cost Remarks
emergency power saving in Rs.
Tank cleaning Per hour
cost & phase production:1500/24
Settling of seed tank stoppage of =62.5 ton.
406 agitator, SL tank one phase for 25,00,000 4 hr production
agitator at least 4 hours loss: 62.5x4=250
ton. Price of
Alumina per kg is
Rs.10.

Settling of precipitation Tank revival

407 tank agitator at least cost @600000 24,00,000 On account of
four. per tank steam loss.

TOTAL Rs.49,00,000 /-

73
 INTANGIBLE BENEFITS

1. Easy & fast communication of DG monitoring.

2. Plant availability increased.

3. Self confidence improved.

4. Internal customer satisfied.

74
 MILE STONE CHART (PLAN v/s ACTIVITY)

NAME OF QC AREA INCHARGE FACILITATOR TEAM:

SYNERGY MR.R.N SWAIN. AGM(ELCT.) MR J. PASAYAT. MGR.(ELCT.) Md. HUSSAIN
N.K.RATH
PROJECT- INTERRUPTION IN REASON FOR SELECTION D.GOPE.
EMERGENCY POWER TO INCREASE AVAILABILITY OF EMERGENCY POWER. MK NAYAK
CRITICAL DRIVES OF 4TH
MK PANDA
PHASE.
K BHOI
PK CHETTY
PROJECT NO-29 DATE OF STARTING PLANNED DATE OF COMPLETION RK SENAPATI
10.06.15 06.01.16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
ID EN T IF IC A T ION OF PR OB LEM

S E LE C T IO N O F P R O B LE M

D E F IN IN G T H E P R O B LE M

A N A LY S IN G T H E P R O B LE M

ID E N T IF Y IN G T H E C A US E S

F IN D IN G R O O T C A US E S

A N A LY S IS O F R O O T C A US E S

D E V E LO P IN G T H E S O LUT IO N

P R O B A B LE R E S IS T A N C E

T R IA L IM P LE M E N T A T IO N

R E G ULA R IM P LE M E N T A T IO N

F O LLO W UP / R E V IE W

75 PLANNED ACTUAL
 QC TOOLS & TECHNIQUES USED

 FLOW DIAGRM
 CAUSE & EFFECT DIAGRAM
 BRAINSTORMING
 DATA COLLECTION
 MILESTONE CHART

76
 WE ARE THANKFUL TO:

77
 OUR NEXT PROJECT

78
Thank You

SYNERGY TEAM
80
Root cause -9 Total substation lighting is from one DG.

409 408

406 LTG
BOARD

407 ENTRANCE

81
 ANALYSIS OF PROBLEM
(Interruption of power to critical drives)
SL NO. DATE DG NO. NATURE OF FAILURE IMPACT

1 28-11-14 1001 BREAKER NOT GETTING ON BREAKER

2 31-03-15 1001 TRIPPED AT THE TIME OF LOAD DG
3 03-04-15 1001 BREAKER NOT CLOSE BREAKER
4 19-04-15 1002 TRIPPED AT THE TIME OF LOAD DG
5 10-06-15 12 NOT GETTING START RELAY
6 10-06-15 1001 NOT GETTING STOP RELAY
7 10-06-15 1002 NOT GETTING STOP RELAY
8 17-07-15 12 NOT GETTING START AT THE TIME OF DG
FAILURE
9 18-07-16 12 NOT GETTING START DG
10 29-07-15 1001 NOT START IN AUTO DG
11 17-10-15 11 NOT STARTED BREAKER
12 01-12-15 1002 FAILS AT THE TIME OF LOAD DG
13 02-12-15 1002 NOT START RELAY

82
83
 06E DG Distribution board 384 (3rd phase) 06Ex DG Distribution board 409. 4th phase)

84
 VALIDATION OF ROOT CAUSE
1. Late detection of DG overload.
Charger problem.
Battery electrolyte low.
Connecting lead problem.
STEAM CCL
No fuel.

85
 APPROVED FINANCIAL VETTING

86
 Ppt agtr ,motor,switch board,dg,trf
 PHOTO

87
 NORMAL POWER FAIL / INTERRUPTION

88
 DEFINITION OF THE PROBLEM
(AN OVERVIEW OF PRECIPITATION TANKS)

Total tanks-20 numbers

30 mtr height
PPT AGITATOR
45000 mtr cube precipitation
WITH MOTOR
slurry(hydrate+spent liq.)

89
 747
US-6EX

P
ELECTRICAL SWITCH BOARD

O
PPT AGTR PPT AGTR
MODULE
TRF MODULE TRF 1029
DG
3311
POWER
3312 W
PPT AGTR PPT AGTR
MODULE MODULE

1250KV R
DG 1001
&1002

90
 DEFINITION OF THE PROBLEM

GRID POWER
(NORMAL POWER
FROM CDS)
PPT SWBD No-407 (CRITICAL DRIVES)

EMERGENCY DG POWER DG SWITCH BOARD

91 (WHEN GRID POWER FAILS) No- 409