A PAPER ON PumpHouseAutomation For CII (Eastern Region) SUPERVISORY SKILLS COMPETITION.

2012 TEAM PROJECT TITLE

PROJECT THEME

: - Sankalp : - PumpHouseAutomation :- ImprovementatCokeQuenchingPump

House

TEAM MEMBERS

: - Mr.SushilKumarSaini
Mr.ShivNarayanSahu

Mr.SumitKumarGarg

EXISTING SYSTEM

: - ManualcontrolofPumpHouse

PROBLEM

: - Probabilityofwrongoperationdueto
manualoperation,leadingtovariationincoke

moisture.

PROPOSED SYSTEM

: - OperationofPumpHouseinAutoMode

throughDCS

PROJECT COMMENCED : - 01/01/2011 PROJECT COMPLETION : - 30/06/2011

12th NATIONAL SUPERVISORY SKILLS COMPETITION

APAPERONInnovativeExcellenceatWorkplace
FOR CII(EasternRegion)SUPERVISORYSKILLSCOMPETITION2012

SYNOPSIS

TEAM:Smile04/CokeOven/094,JindalSteel&PowerLtd.(C.G.) PROJECTTITLE :ImprovementatCokeQuenchingPumpHouse EXISTINGSYSTEM :ManualcontrolofPumpHouse PROBLEM :Probabilityofwrongoperationdueto manualmodeofpumphouseoperation PURPOSEDSYSTEM :OperationofPumpHouseinAutoMode throughDCS INVESTMENT :8.36Lac PROJECTSTARTED :01/01/2011 PROJECTCOMPLETED :30/06/2011 INTANGIABLEBENEFIT :1.Enhancedsafetyduetoautomation& reducedmanpower. 2.Customersatisfactiononaccountof moisturecontrol. RECURRINGSAVINGS :Rs.10.5Crore IMPACTOFTHEPROJECTIN :Simple&efficientoperation THEAREAOFOPERATION

QUALITY

:Precisecontrolofcokemoisturedueto Automation.

SAFETY

:Enhancedsafetyduetolessmanpower 12th NATIONAL SUPERVISORY SKILLS COMPETITION

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TITLEOFCASESTUDY: ImprovementatCokeQuenchingPumpHouse BRIEFINTRODUCTIONOFTHEORGANISATION:

Jindal Steel & Power Limited (JSPL), part of US $ 15 billion O. P. Jindal group is operating a 3.25 MTPA integrated steel plant and 340 MW captive power plant at Raigarh, Chhattisgarh. The company is running a fully operational 1000 MW Thermal Power Plant through its subsidiary, Jindal Power Limited. JSPL has captive iron ore mines at Tensa (Orissa) and coal minesatRaigarh.Thecompany hasembarkedupona massiveexpansionplanoftheexisting plants and undertaken new projects in power, steel, mining, oil & gas and infrastructure sectors including 2 large green fields integrated steel projects at Angul in Orissa and Patratu in Jharkhand. In Bolivia (South America), JSPL is investing US $ 2.1 billion in development of iron ore mines and setting up an integrated steel plant. The company also has business interestsinAfrica,Asia,AustraliaandSouthAmerica.

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 MAINPRODUCTS:

JSPL PRODUCTS
Plates Coils Steel

Sponge Iron

Beams

Rails

Power

Heavy Machines

Ferro Chrome

COKEOVENPLANTOVERVIEW:

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COKEOVENTYPE ANNUALPRODUCTION POWERGENERATION NUMBEROFBLOCKS NUMBEROFBATTERY ONEBATTERY COALCAKEBULKDENSITY COKINGHOURS EQUIPMENTS: PUSHERCAR QUENCHINGCAR STAMPINGMACHINE

:NONRECOVERY :0.8MillionTon :75MW :2 :16 :11OVENS :1.07to1.1 :66

:2Nos. :2Nos. :2Nos.

BRIEFSUMMERYOFPROJECT:

DEPARTMENT :COKEOVEN TEAMLEADER :SUSHILKUMARSAINIMANAGERE&I, (S7062) TEAMMEMBERS :SUMITGARGJr.MANAGERE&I(S9924) :SHIVNARAYANSAHUAsst.ENGINEER (S3158) PROJECTSTARTEDON :01JANUARY2011 PROJECTCOMPLETEDON :30JUNE2011 NO.OFMEETINGS :24 DURATIONOFMEETING :30MINUTES TIMEOFMEETING :3TO3:30PM ATTTENDANCEINMEETING :95%
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 ACKNOWLEDGEMENT First of all, we thank HR JSPL for launching of SMILE Scheme to achieve the commongoaloftheorganizationandtoprovideplatformtoshareourideas. Further our thanks to Mr. K.K. Mishra HOD Coke oven, Mr. Ashwani Jaiswal Sr.Manager(Mechanical)andMr.P.K.SrivastavSr.Manager(Process)fortheir valuableguidanceandsupportextendedbythemduringthisproject. Last but no the least, we would like to thank all the staff of JSPL, for their cooperationdirectlyorindirectlyextendedtocompetetheproject.
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INTRODUCTIONTOCOKEOVENPLANT: CokeOvenBattery
JSPLoperatestheNonRecoveryCokeOvenPlantatRaigarh. ThisplantisoperatedwithNonRecoveryorHeatRecoverycokemakingtechnologyfromthe Chinese Sino Steel Industry and Trade Group (SSIT). The Raigarh plant has 176 ovens (2 blocksof8batterieseachwith11ovensineachbattery).

PROCESSFLOWATCOKEOVEN:

The coal is received from the ship yard to our coal yard through railway wagons. From the coal yard different variety of coal is feed to the 11 number of coal silos. Here the coal blending is done with the help of weigh feeders and the blended coal is fed to a crusher, which is run by 600 kW HT Motor. The coal after crushing is transferred to the coal tower hoppers.

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CoalSiloStampingMachine

Now the coal cake is formed by the stamping machine and the coal cake is charged in the oven with the help of pusher car. After 65 coking hours the coke is pusher with the help of pusher beam at pusher car and the hot coke is received by the quenching tray at quenching car.

PusherbeampushinghotcokeQuenchingtraywithhotcoke
This quenching car carries the hot coke to the quenching tower for wet quenching. During theprocessofquenchingwaterissprayedonthehotcokeandsuddencoolingofthecokeis done. 12th NATIONAL SUPERVISORY SKILLS COMPETITION
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WetQuenchingProcessCoketiltedinwarf

Afterquenchingofthecokethematerialistiltedinthewarf,fromwhereitgoestothecutter and screening. BF Coke(25 80mm), NutCoke (525mm) &Fines(0 5mm)areobtained afterscreeningandaresuppliedtotherespectiveconsumer.

WETQUENCHINGPROCESS:
In wet quenching process huge amount of water is sprayed from the nozzles and the coke temperature is suddenly reduced from 1000 degree Centigrade to 150 degree Centigrade. Variable quenching cycle is used for the quenching process. Huge amount of steam is generated during the quenching process, which carries ash particles. These ash particles are settlesdownbysprayingwaterfromthequenchingtowertopwiththehelpofRinsingPump. The water is recirculated in the pump house settling tank and is reused for quenching process.

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Improvementarea:Pumphouseatcokeoven

ABOUTPUMPHOUSE:

The pump house consists of two centrifugal pumps driven by 132KW LT (low tension) motor with DOL (Direct online) starter. Onepump remains standby, while the other is in operation. Differentmanualcontrolvalvesareusedfordivertingthewaterflowfromblock1toblock2 andviceversaforquenchingprocess.TheRinsingcentrifugalpumpisdrivenby37KWmotor. On the arrival of quenching car the pump house operator operates the valves manually (butterfly valve & rinsing valve) and starts the quenching pump and monitor the quenching timewithstopwatch/handwatchrespectively.

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 SelectionofProblem:
Ourteammemberdecidedtodoimprovementatpumphouseareaandlistedoutvarious problemsrelatedtopumphouse,whichareasfollows: LISTOFPROBLEMSATPUMPHOUSE 1ManualoperationofvalvesforBLK1&2aftereachquenching 2Variationincokemoisture. 3.NofeedbacktotheDCSoperatorforquenchingatpumphouse. 4Manualstart/stopofpumpbyoperator. 5.Quenchingtowernozzlechoking 6.Voltagedripduringstattimeofquenchingpump. Teamdecidedtoseealltheproblemonthebasisoffollowingfactor: Maintenancepractices Equipmentavailability Safety Customersatisfaction Housekeeping
Table showing Problems related to pump house
Problem no Description Manualoperationof valvesforBLK1&2 aftereachquenching Variationincoke moisture Nofeedbacktothe DCSoperatorfor quenchingatpump house Manualstart/stop ofpumpbyoperator Quenchingtower nozzlechoking Voltagedripduring stattimeof quenchingpump Maint. Practices Equip. Avail. Safety Customer satisfaction House keeping

1 2

4 5 6

On the basis of above mention factor team selected four most top problems which are affectingallthefactorsandtheseproblemsare: A.ManualoperationofvalvesforBLK1&2aftereachquenching B.Manualstart/stopofpumpbyoperator. C.Variationincokemoisture D.Quenchingtowernozzlechoking. 12th NATIONAL SUPERVISORY SKILLS COMPETITION
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 Now,teamusedrankingmethodtoselectmostprobableproblem,whichsolvefirst.

RANKINGMETHOD.
Sumit Garg 4 8 Shiv Sahu 3 6

Problem/Name

SK Saini 4 7

Kartik Bhagat 3 5

Total 14 26

Manual operationof Manualstart/ stopofpump byoperator

Variationincoke moisture

9 8

10 8

9 7

8 6

36 29

Quenching towernozzle choking

Variationincokemoisture

Rating points36

By using, rating method technique team member given the rating to selected problems and foundthehighestratingofproblemno.Cwhichgot36pointsandthatproblemisVariation incokemoistureso,ourteamdecidedtosolvethisproblemfirst. This problem may be due to the machine, man, method or material. We target our problem and try to find out the causes and subcauses of our problem with the help of fish bone diagram. In machine there is no automation in pump house, Man can do the mistake during openingand closing themanual control valve, it maybe due tothemethodthat themethod which we use not user friendly or it may take lot of much time during opening and closing the valve. Material can also may be the one major causes of our problem that may be cake size not proper or may be breaking of coke during pushing and charging operation. In miscellaneous, rainy season may be the cause of variation in coke moisture. In this way, we triedtoidentifythecausesofourproblembyusingFishBoneAnalysis. 12th NATIONAL SUPERVISORY SKILLS COMPETITION
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FISHBONEDIAGRAM
MACHINE
MAN MAN

Mistake in operation in valve opening Mistake in reading time Pump House Lack Of Skill No Automation Lack Of Training

Break Time taken Cake Valve Open / Close Size Rain Season

Coke Moisture Variation

Not user friendly

Not Safe

METHOD

MATERIAL

MISCELLANEOUS

Copyright 2010JindalSteel&PowerLtd.

Now, our team decided to use ranking method for causes and subcauses identified from fishbone diagram and found, No automation at pump house have max. Marks that is 31, so ourteamdecidedtodoautomationinpumphousearea. RANKING METHOD.. Causes/subcauses SK ShivSahu Total Sumit Kartik Saini Garg Bhagat
Mistakeinvalve operationBlk1,2 Valveopeningand closingnotproper Cakeheight 4 8 7 9 4 3 8 5 8 3 4 7 6 7 3 8 6 5 7 4 19 29 23 31 14

Noautomationin pumphouse Moisturevariation duringrainy

Noautomationinpumphouse

Ratingpoints31 13

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 PUMPHOUSEOVERVIEW
MANUALMODE Description: All the valves were operated by the pump house operator manually on the arrival of quenching car and the quenching pump was been started and stopped by the operator manually. The Pump ON time was monitored by stop watch / hand watch, as showninpicture. (4Valves,Approx.64times/day)

SCHEMATICDIAGRAMOFPUMPHOUSE
Butterfly Valve-1

Block-1
NRV

Quenching Pump-1 Butterfly Valve-2 Water Settling Tank

Block-2
NRV

Quenching Pump-2

Block-1
Rinsing Valve-1

Rinsing Pump Rinsing Valve-2

Block-2

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The hot coke after pushing is received in quenching car. Then the hot coke is quenched with water spray at the pump house. Operator use quenching cycle to complete the quenching process.

QUENCHINGCYCLE: CYCLE1PUMPONTIME =105sec CYCLE2PUMPOFFTIME=180sec CYCLE3PUMPONTIME=90sec TotalCYCLETime=375Sec

During quenching in cycle1,pump is ON for 105 sec and is OFF for 180 sec in cycle2,it is again started for 90 sec in cycle3, so in this way total quenching cycle is completed in 375 sec. Thequenchingcycletimeismonitoredbytheoperatorusinghandwatch/stopwatch;there are chances of human error during this operation. There was probability of making mistake especially in night shift by the operator to see the quenching time and this will lead to variationincokemoisture. Astherewasnovalvepositionindicator,sotherewerechancesofvariationofvalveopening by the operator leading to variation in water flow and finally leading to variation in coke moisture. Study of coke moisture data from April 2009 to Dec 2010 was carried out. Following trend showsthesame:

Month Itcanbeseenfromtheabovetrend,thatthemoistureishavingavariationof+/1%. 12th NATIONAL SUPERVISORY SKILLS COMPETITION

A pr il '0 9 Ju ne A '0 ug 9 us t' O 09 ct ob D er e ' ce m 09 be r' Fe 09 br ua ry '1 0 A pr il '1 0 Ju ne A '1 ug 0 us t O '1 ct 0 ob D er e ' ce m 10 be r' 10

COKEMOISTURETREND Coke Moisture 7.00 6.50 6.00 5.50 5.00 4.50 4.00
%M o is tu re

Series1

15

INNOVATIVESOLUTION A fterbrainstorming,itwasconcluded to go for "Automation of pumphouse'to resolvetheproblemofvariationincokemoisture. Trial,ImplementationandCheckperformance:

After developing a vital solution, it was a time to implement our solution, so we have just followed PDCA cycle for it. In it the first step is to plan our work, and then it requires its working. After working we check the system, whatever we have done. Finally we provided the training to the pump house operators & DCS operators under Act part of the PDCA cycle. Figure showing PDCA cycle of any particular implementation. This Cycle is also called as DemingWheelasinventedbyScientistDeming.

PDCACYCLE

PLAN:
Firstweplantheobjectiveofourproject OperationofPumpHouseinAutoModethroughDCS

QuenchingPump1&2 RinsingPump ButterflyValve1&2 RinsingValve1&2 12th NATIONAL SUPERVISORY SKILLS COMPETITION

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 DO:
Followingactivitieswerecarriedout: 1. Allmanualcontrolvalvesreplacedbymotorizedvalves. 2. Power&controlJBwerefixed. 3. Powerfeedersweremadeready. 4. Power,control&signalcableswerelaid. 5. Signallightmountedforblock1&2respectively. 6. SoftwaredevelopmentdoneinDCSfor Automaticstart/stopofquenchingpump1&2. Automaticvalvechangeoverafterquenching. TwotimersOperatorSelectablegiveninDCSforquenchingpumpcycletimefor differentcakeheight.Asshowninbelowpicture

Picture:Showingtheworkimplementationforthesolution

Power&controlJB

MotorizedButterflyvalve

MotorizedRinsingValve

DCSSoftwaredevelopment

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DCS

ReadySignallight

CHECK:
Afterimplementingthesolution,wecheckthefollowingsteps: 1.CheckedpowerandcontrolwiringbothfieldandDCSside. 2.WorkingofallmotorizedvalvethroughDCS. 3.Trialrunofsoftwaredeveloped. 4.CheckedQuenchingcycletimeinautomode. 5.Checkedtheoperationoflimitswitchesinthevalveactuators.

ACTION:
During checking of implemented solution, we found everything normal. Following activities werecarriedoutforsmoothfunctioningoftheimplementedsystem: 1.TraininggiventoDCSOperators. 2.TraininggiventopumphouseOperators. 3.Traininggiventoquenchingcaroperators. 4.Quenchingreadysignalprovidedinblockforquenchingcaroperator.

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RESULT:
After implementation of project, we study coke moisture trend and found stability in variationofcokemoisturewhichislessthan0.5%asshowninbelowcokemoisturetrend

Coke Moisture
BEFORE

AFTER <5 %

7.00 6.50 6.00 5.50 5.00 4.50 4.00 August ' February ' August ' February ' June ' 09 June ' 10 June ' 11 December December August' 11 April ' 09 October ' April ' 10 October ' April '11

% Moisture

Series1

Month

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BENIFITS INTANGABLEBENIFITS:
FullyautomaticquenchingpumpandcontrolvalveoperationforBlock1&2. Variablequenchingcycletimefordifferentcoalcakeheight. Enhancedsafetyduetoautomationandreducedmanpower. Customersatisfactiononaccountofmoisturecontrol. FullcontrolofDCSoperatoroverthequenchingpumpandquenchingcycle.

TANGABLEBENIFITS:
Reductionandstabilityincokemoistureapprox.0.50% 4Manpowersavingatpumphouse. RerecuringsavingofRs.10.5Crores.

BENEFITOFREDUCTIONINCOKEMOISTURE:
AveragecokemoistureinFY0910was5.58% AveragecokemoistureinFY1011is5.08% Sototalreductioninmoistureis=0.50% 6kgcokewillbelessconsumedinBlastFurnacewithreductionof1%in cokemoisture Hencewesaved(50x6)/100=3kgcokewithpertonofhotmetal production TotalhotmetalproductioninFY1011was1672053MT Totalcokesaved=(3x1672053)/1000=5000mtapprox Rateofcokepertonis=21000Rs

Totalsaving=21000x5000=10.5Crore

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PROJECTCOST:

SNO ITEM QTY PRICE(Lacs) MotorizedButterflyValve 3 1 1 Actuator MotorizedRinsingValve 4 0.7 2 Actuator 3 LCS 5 0.07 4 19C,2.5SQMM,ARMCUCable 500Mtrs. 80/mtr. 5 12C1SQMM,ARMSCRENCable 500Mtrs. 60/mtr. 1000 25/mtr. 6 4C2.5SQMM,ARMCUCable Mtrs. 1000 40/mtr. 7 7C2.5SQMM,ARMCUCable Mtrs. 8 SignalLight 2Set 5000 9 Miscellaneous ServiceChargesforcablelaying 10 andothermiscellaneousjobs TOTALRs.

TOTALAMOUNT(Lacs) 3 2.8 0.35 0.4 0.3 0.25 0.4 0.01 0.1 0.75 8.36

ACHIVEMENTS&LEARNINGS:
InhousedevelopmentofABBDCSsoftwareforthepumphouseautomationleadingto confidenceandeliminatingthedependencyonABBforsoftwaredevelopment. Cantakenewchallengesbythelearning'softhisproject

PROJECTUNDERPROGRESS2012: Flushing system for Quenching Pipe

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SMILINGONFACESOFPUMPHOUSEOPERATORS

SPECIALTHANKSTO:
Mr.K.K.Mishra(HODCokeOven) Mr.AshwaniJaiswal(Sr.ManagerMech) Mr.PradeepSrivastav(Sr.ManagerProcess) Fortheirvaluableguidanceandsupportextendedforthisproject.

THANKS.......................

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