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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
NTPC Ltd.'s overview
Vindhyachal Super Thermal Power Plants Overview
Six Sigma
Why is six sigma needed for Indian Power Sector
Boiler Performance Optimization using Six Sigma
Reduction in Auxilliary Power Consumption using six sigma.
OutlineOutline
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
-
Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
A HUMBLE BEGINING
Foundation Stone Laying12.11.82
The first signboard comes up 5.08.82
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Powering PeoplePowering Peoples Progresss Progress (Generation)
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17820.8
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19707.7
18305
160001650017000175001800018500190001950020000
FY 03-04 FY 04-05 FY 05-06 FY 06-07
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Continuous Improvement in Process & EfficiencyContinuous Improvement in Process & Efficiency (PLF %)
92.46 92.73
82.38
90.01
80
85
90
95
100
FY 03-04 FY 04-05 FY 05-06 FY 06-07
PLF
P
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(
%
)
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
PLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVESPLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVES
Improvement in Performance Parameters
Improvement in business processes (systems)
Cost Optimization
MUDA (Waste) Reduction
Development of World-class spare parts & service providers
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
WHAT IS THIS SIX SIGMA ?WHAT IS THIS SIX SIGMA ?
A Philosophy
A Business Strategy
Disciplined & structured data Disciplined & structured data driven problem solving driven problem solving approach.approach.
All about reducing deviations All about reducing deviations (mistakes) in all that we do.(mistakes) in all that we do.
Good quality reduces costGood quality reduces cost
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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House of
Quality
# 1
Heat Rate
Key Functional Requirements
Key Component Characteristics
Key Generation Processes
Key Process Variables
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House of
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# 2
Boiler/ Turbine
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House of
Quality
# 3
RAH Seals/ Pent House/
ESP
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House of
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# 4
Basket Eff./ Seals
Cost Effective Generation depends broadly on :Cost Effective Generation depends broadly on :--
1) Optimizing Heat Rate
2) Reducing Auxilliary Power Consumption
3) Reducing operation & maintenance (O&M) costs.
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Logic and intuitionLogic and intuitionQuick hits-KaizenBrainstorming etc
Low hanging fruitsLow hanging fruitsSimple QC tools
Bulk of fruitsBulk of fruitsProcess characterizationand optimization including PDCA
Process Process limitationslimitationsSweet fruitsSweet fruits
Six Sigma Methodology
Problem of erosion in radiant super heater placed in water wall soot blower area of stage I, 6 x 210 MW units.
Problem of vibration in the cooling fan NDE bearing of ID fans in stage I.
Problem of damage of rapping motor shaft in ESP of Stage I.
Problem of ingress of dust in the PA fan bearing of stage I.
Platform on safety v/v floor is in unsafe condition in stage I. (5S)
Team Vindhyachal receiving National Quality Award from H.E. President of India for PIP on CW duct painting in stage I units
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
3%Stack
Clean-upEquipment
5%Auxiliary
Power
10%Stack Losses
37%ElectricityProduction
45%Rejected Heat to
Cooling Water/ Cooling
Tower
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
FLUE GAS FLOW DIAGRAMFLUE GAS FLOW DIAGRAM
DDIIVVIISSIIOONNAALL
FFUURRNNAACCEE
RREEHHEEAATTEERR
HHOORRIIZZOONNTTAAL L SSHH
EECCOON.N.11&&22
EECCOONNOOMMIISSEERR
33
PAPH BPAPH B
SAPH BSAPH B
SAPH ASAPH A
PAPH APAPH A
960960
964964
846846
944944
750750
810810
549549
606606
365365
379379
LLHHSS
RRHHSS
PAPHPAPHO/L TEMPO/L TEMP145 145 00CC
SAPH BSAPH BO/L TEMPO/L TEMP160 160 00CC
SAPH ASAPH AO/L TEMPO/L TEMP164 164 00CC
SAPH BSAPH BO/L TEMPO/L TEMP145 145 00CC
PPLLAATTEENN
SSHH
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Problems FacedProblems Faced
More convective flow less retention of heat in 1st pass. Less heat absorption in 1st pass due to Slagging. Less heat absorption in super heater and re heater area
due to dirtiness in the area ,clinkering formation in radiant zone.
Improper secondary damper position. Poor performance of air preheater and its air ingress.
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
BOILER RHS LRSB
LRSB ARE DIVIDED INTO
A- S/H Right R/H Left
B- S/H R/H Right And 2nd Pass
C-2nd Pass Only
D- S/H Right And R/H Left
125 127
129
131133
137 135
119
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123
105
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117
115
113
1112nd pass
LRSBs : Long Range Retractable Soot Blowers
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
C14
C
1
5
DCBA
590
580
570
560
550
540
Individual Value Plot of C15 vs C14
C14
C
1
5
DCBA
590
580
570
560
550
540
Boxplot of C15 by C14
Box plot showing the best results for the LRSB A
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
BOILER RHS LRSB
125
127
129
131133
137 135
119
121
123
105
107
109
117
115
113
111 Boiler RHS Red Coloured LRSBs were
selected based on results of Analysis of
Variance (ANOVA)
LRSBs : Long Range Retractable Soot Blowers
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
BOILER LHS LRSB
106
108110
136 138
132 134
130
128 126
120
124
122
112
114
116
118
Red Coloured LRSBS are
in Reheater Area
LRSBs : Long Range Retractable Soot Blowers
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Box and Individual plot
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SAPHA O/L AFTSAPHA O/L BEF
170
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160
155
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145
140
Boxplot of SAPHA O/L BEF, SAPHA O/L AFT
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SAPHA O/L AFTSAPHA O/L BEF
170
165
160
155
150
145
140
Individual Value Plot of SAPHA O/L BEF, SAPHA O/L AFTBox Plot Individual Value Plot
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
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House of
Quality
# 1
Auxilliary Power
Reduction
Key Functional Requirements
Key Component Characteristics
Key Generation Processes
Key Process Variables
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House of
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# 2
Boiler/ Turbine
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House of
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# 3
FD/ PA/ ID Fans/Mills
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House of
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# 4
TIGs/ Hot Air Lkg/ Impeller
Cost Effective Generation depends broadly on :Cost Effective Generation depends broadly on :--
1) Optimizing Heat Rate
2) Reducing Auxilliary Power Consumption
3) Reducing operation & maintenance (O&M) costs.
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Big YBig Y Auxiliary Power Consumption reductionAuxiliary Power Consumption
reduction
Process drill downProcess drill down
BFP power consumptionBFP power consumption
Project Y 2Project Y 2 ID Fan power consumptionID Fan power consumption
Project Y 3Project Y 3 PA Fan power consumptionPA Fan power consumption
Project Y 4Project Y 4 FD Fan power consumptionFD Fan power consumption
Project CTQProject CTQss
Project Y 5Project Y 5 Mill power consumptionMill power consumption
Project Y 1Project Y 1
Project Y 6Project Y 6 CW Pump power consumptionCW Pump power consumption
Project Y 7Project Y 7 CEP power consumptionCEP power consumption
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Key QuestionsWhat is included/excluded in the scope of this project?Includes:
Excludes:
What is the Unit, Opportunity, Defect?
Has this process map been validated by key people?
High level process map done
HT Amp > 1800 amps would be defect.HT Amp > 1800 amps would be defect.
Unit HT SystemUnit HT System
LT System & Offsite LoadLT System & Offsite Load
Process map validated by Champion &Process owners
Process map validated by Champion &Process owners
Supplier
SS IIInput
PPProcess
OOOutput
CCCustomer
High Level Process Map
PA fans
FD fans
Bowl Mills
ID FansESP
CEP BFPHeaters
BoilerSuper heaterTurbineCondenser
Generator GT GRID
Heaters
Steam-water cycle
Stack out
Flue gas path
CW Pump
Cooling water out
Boiler
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Identify Sources of VariationIdentify Sources of VariationA
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EquipmentsCount
36.4 18.4 16.0 10.2 9.7 7.1 2.3Cum % 36.4 54.8
654.3
70.8 81.0 90.6 97.7 100.0
331.6 287.3 183.7 174.3 127.7 40.6Percent
OtherMillFD FanPA FanID FanCWBFP
2000
1500
1000
500
0
100
80
60
40
20
0
Pareto Chart For APC
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Identify Major Sources of VariationIdentify Major Sources of Variation
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Potential Failure Modes Effect Analysis - BFPWhen?Process
Step
What?Potential Failure
Result?Potential Effects
Why?Potential Cause
Existing Controls
Sev Occ Det RPN How Prevent?Mitigants
Who?Responsibility
BFP Passing from 5F1,5F2 & C/V
High amp
Worn out seat & others
To be attd. in O/H
6 10 5 300 1) L/S Adjust. on closing2) Manual Tight., if possible
TMD+Opn*
BFP Reduced Motor Efficiency High amp
Continuous Service
Motor O/H 2 4 5 40 To be attd.in O/H EMD
BFP Passing from R/C V/V& D/V NRV not holding
High amp
Worn out seat & others
To be attd.in O/H
6 10 5 300 1) L/S Adjust. on closing2) Manual Tight., if possible
TMD+Opn*
BFP Passing from 421 V/V (Manual+Motorised)
High amp
Worn out seat & others
To be attd.in O/H
7 8 5 280 1) L/S Adjust. on closing2) Manual Tight., if possible
TMD+Opn*
BFP Passing from 605,607 & C/V V/V
High amp
Worn out seat & others
To be attd.in O/H
4 6 5 120 1) L/S Adjust. on closing2) Manual Tight., if possible
TMD+Opn*
BFP Passing / Opening from 514 A & B V/Vs
High amp
Worn out seat &/or Passing
from 5A1,5A2, 140/6 C/V
To be attd.in O/H
5 10 5 2501) L/S Adjust. on closing
2) Manual Tight., if possibleTMD+Opn*
BFP Passing from 29/14 Spray V/Vs
High amp
Worn out seat & others
To be attd.in O/H 3 6 5 90
1) L/S Adjust. on closing2) Manual Tight., if possible
TMD+Opn*
BFP Passing from 3rd stage V/V (S/B BFP)
High amp
Worn out seat & others of S/B
BFP
To be attd.in O/H 3 6 5 90
1) L/S Adjust. on closing2) Manual Tight., if possible 3) Change the BFP conbin.
TMD+Opn*
BFP Low PumpEfficiency
High amp
Worn out cartridge
Pump O/H 5 10 5 250 1) Combination Change (AC / BC)
2) To be attd.in O/H
TMD
BFP Higher DP across FRS High amp
Slightly higher flow require.
Regularly 5 10 5 250 Experiment regularly to optimize DP
Operation +
C&I*+TMD
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Decide Focus Area ?Decide Focus Area ?Priority / Focus
Ease of implementationDifficult Easy
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Low
High
BFP
ID Fan
FD FanMill
PA Fan
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Informed to operational staff.Communicate project results with operating staff and process owner.Communicate results to HOD
Control/Response Plan HighlightsControl/Response Plan Highlights Benefits of Project Benefits of Project
Communication & TranslationCommunication & Translation
Control SummaryControl Summary
When HT equip. amp goes up steeply,all associated V/Vs being checked.
PA Fans being regularly checked for hot air leakage.
Boiler & ESP man/peep holes being checked regularly for any passing.
Future control plan prepared for arresting APC further.
Direct Saving.Conservation of Coal.Lesser Environmental Pollution.Better CSR Practices & other intangible benefits.
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
Control Charts of APC Before & After ProjectControl Charts of APC Before & After Project
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
FMEA Analysis for Current Window of Opportunity FMEA Analysis for Current Window of Opportunity When?Process
Step
What?Potential Failure
Result?Potential Effects
Why?Potential Cause
Existing Controls
Sev Occ Det RPN How Prevent?Mitigants
Who?Responsibility
Sev Occ Det New RPN
BFP Passing from 5F1,5F2 & C/VHigh amp
Worn out seat & others
To be attd.in O/H
6 10 5 300 1) Change V/Vs2) L/S Adjust. on
closing
TMD+Opn*
6 10 5 300
BFP Passing from 607 &C/V
High amp
Worn out seat & others
To be attd.in O/H
4 6 5 120 1) L/S Adjust. on closing2) Manual Tightening
TMD+Opn*
3 6 5 90
BFP D/V NRV +3rdstage spray
v/vs not holding
High amp
Worn out seat & others
To be attd.in O/H
6 10 5 300 1) L/S Adjust. on closing
2) Manual Tightening
TMD+Opn*
6 10 5 300
BFP Higher DP across FRS
High amp
Slightly higher flow
require.
Regularly 5 10 5 250 Experiment regularly to optimize DP
Opn,C&I TMD
5 10 5 250
PA Fan
TIGs in Open/ Struck up Condition
High Curre
nt
Improper Practices by Mill area lab.
As and when
needed3 10 5 150
Mill labours to be discouraged from keeping it in open condi. & Struck up condition to be att
on pri & Mois. draining
Opn.2 10 5 100
PA Fan
Hot Air Leakage
High Curre
nt
Aging/ Imp. Maint./
Expansions
During Opportunity 4 10 5 200
To be attended at first opportunity.
BMD R/P 3 10 5 150
Mill Improper Rollers Setting
Higher Amps
Maintenance Fault/Foreign
Material
Roller Setting 3 9 5 135
1) By effectively screening foreign material
2) During Opportunity
BMD Mill CHP 3 9 5 135
ID Fan
Various Leakages
Higher Amps
Mech Damage/Expansio
n/ Maintenance Prac
During Opportunity
or in O/H5 10 5 250
1) Regular Checking 2) To be attd.in O/H
3) During Opportunity
BMD R/P+P/P 3 10 5 150
ID Fan
Peepholes/ Manholes Passing
Higher Amps
Mech Damage/Expa
nsion
Regular Checking/
Opportunity or in O/H
4 10 5 2001) Regular Checking 2) To be attd.in O/H
3) During Opportunity
BMD+ Opn. 3 10 5 150
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth
BottomBottom--line isline is....
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Thermal Power Plant Performance Improvement using Quality Initiatives
NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth