PANTOGRAPH ISOLATOR hot

spot elimination
 QC TEAM VIDYUT VAHINI

SURESH

Leader

JEGATHESWARAN

Dy. leader

JEMINI MANORANJAN SATYA SOUMYA MAHESWAR

Member Member Member Member Member

 QC STEPS FOR PROBLEM SOLVING

STEP 1 - IDENTIFICATION OF PROBLEMS

STEP 2 - SELECTION OF PROBLEM
STEP 3 - DEFINE THE PROBLEM
STEP 4 - ANALYZE THE PROBLEM
STEP 5 - IDENTIFY THE CAUSES
STEP 6 - FIND OUT THE ROOT CAUSE
STEP 7 - DATA ANALYSIS ON ROOT CAUSE
STEP 8 - DEVELOPMENT OF SOLUTION
STEP 9 - FORESEEING PROBABLE RESISTANCE
STEP 10 - TRIAL IMPLEMENTATION
STEP 11 - REGULAR IMPLEMENTATION
STEP 12 - FOLLOW UP / REVIEW
STEP:1

IDENTIFICATION
OF PROBLEM
 1.IDENTIFICATION OF PROBLEMS

S.NO PROBLEM CATEGORY

1 Canopy provision for PRV A
2 EMS communication JB modification A
3 RPH-1 raw water pressure indication B
4 Pathway for man lifter movement A
5 DC parameters integration in SCADA A
6 Neutral Bushing modification in ICT B
7 New office for AC maintenance team A
8 EMS system upgradation B
9 SEZ Costume office DB Renovation A
10 ICT Cooling fan structure modification A
12 Access control system in Switchyard A
13 Capacitor bank fencing provision C

14 LEM watt-hour meter calibration, repair & communication with EMS B

15 RPH HT cable support provision A

16 WTP power reliability B
17 LEP light installation C
18 Regulating Trafo OLTC overhauling C
19 PFIC Conductor insulation coating A
20 DC isolator mechanical interlock A
21 Switchyard hot spot C
STEP: 2

SELECTION
OF
PROBLEM
 STEP 2: SELECTION OF PROBLEMS

A-type -> Can be solved within the team/department

B-type -> Need other department support

C-type -> Need help of top management

For this selection only A type of the problem only considered to solve at earliest
 STEP 2: SELECTION OF PROBLEMS
SL. No. PROJECT SURESH JAGATHESWARAN MANOJ N MAJI MANORAMJAN TOTAL

1 EMS communication JB modification 8 7 6 8 9 38

2 Canopy provision for PRV 9 6 8 7 8 38

3 DC parameters integration in SCADA 7 7 6 8 7 35

4 Automation of air and water data in EMS 9 8 7 7 6 37

5 Pathway for man lifter movement 7 7 6 9 6 35

6 ICT Cooling fan structure modification 8 8 6 9 7 38

7 Switchyard Hot spot 9 9 9 8 8 43

LEM watt-hour meter calibration, repair & communication with

8 7 9 7 6 9 38
EMS

9 PFIC operation from URCP 9 8 9 7 8 41

10 Pathway for marshalling box 9 8 8 8 7 40

11 Switching parameter. 9 6 7 6 9 37

12 DC isolator mechanical interlock 8 9 9 9 6 41

13 Diode cubical door lock problem 8 8 7 9 9 41

By ranking method, Switchyard Hot spot

got highest mark
 STEP 2: SELECTION OF PROBLEMS

S.NO Project 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 28 29 30

1 DEFINE THE PROBLEM

2 ANALYZE THE PROBLEM

3 IDENTIFY THE CAUSES

4 FIND OUT THE ROOT CAUSE

5 DATA ANALYSIS ON ROOT CAUSE

6 DEVELOPMENT OF SOLUTION

7 FORESEEING PROBABLE RESISTANCE

8 TRIAL IMPLEMENTATION

9 REGULAR IMPLEMENTATION
STEP:3

DEFININING
THE
PROBLEM
DEFINE THE PROBLEM

Hot spot
observed in
L plate
between
isolator gear
box and
flexible
jumper.
 DEFINE THE PROBLEM

hotspots were observed frequently on 400KV pantograph

isolator fixed clamp dropper connecting L –clamp
STEP: 4

ANALYSIS
OF THE
PROBLEM
 4W -1H ANALYSIS

WHAT Hot spot in 400/220 KV switchyard

WHERE Pantograph,220 KV bay isolators

WHEN Potline load increases

WHO Potline and all auxiliary power users

We have to reduce potline current in order to

HOW
keep temp. of hot spot with in permissible range
STEP: 5

IDENTIFICATION
OF CAUSE
 Ageing Poor quality
Poor Planning
Machine
Unavailability
Man
Poor awareness & communication
Worn out of Nuts &
Poor skill Insufficient support to Bus bar Quality checklistbolts
absent
No specific flatness
Poor workmanship
measurement system
Wrong tightening equipment
Worn out of m/c parts
Incompetent person
assigned to JOB High dust
New joinee/Job Dust ingression in Due to Environment condition
bushing Wrong installation during Project
misalignment of clamps
Improper surface contact
HOTSPOT IN
No Quality cross check/Validation of incoming material JOINTS
Wrong installation
Poor nut/bolt material
No standard guideline/manual on
Hot-spot
Material degradation due to improper Poor clamp material System constrained
Handling/storage to follow right
procedure
Wrong material selection Wrong tightening equipment
Wrong Conductor
material Poor flat surface of clamp Unavailability of tool
Design issue
No proper standard available
Material Method No proper awareness
wo
 IDENTIFICATION OF CAUSE

The probable causes are listed here,

 Dust accumulation in joints & gaps.
 Due to looseness at assembly points.
 Due to crack in clamps/plates.
 Deterioration of quality of clamp, plates & fasteners due to ageing.
 Improper surface contact between clamps and pads .
 Poor execution during installation.
 Mechanical Load on isolator parts due to insufficient supporting insulators.
 Misalignment of Bus bar & isolator clamps.
STEP: 6

FIND OUT
THE ROOT
CAUSE
WHY-WHY ANALYSIS for pantograph isolator Fixed Clamp

Frequent hot spot in switchyard 400KV

pantograph isolator Fixed clamp

Looseness observed at PG fixed clamp Dropper

L plate jointing part.

L plate assembly unable to withstand the

intermittent impact during isolator operation
and increase in smelter load

Less surface contact area and improper

Gripping provision at L clamp area
WHY-WHY ANALYSIS for Pantograph isolator L plates

Frequent hotspot in L plate between pantograph

isolator to BAY BUS.

Due to less surface contact area

As there is a misalignment between flexible clamp and

L-plate
STEP: 7

DATA
ANALYSIS ON
ROOT CAUSE
Data Analysis :
Equipment Date Temperature
BAY-4, PENTO ISOLATOR 89 B (B ) 09.01.2017 102.7
BAY-11,PENTO ISOLATOR 89 B ( Y) 09.01.2017 98.8
BAY-11,PENTO ISOLATOR 89 B ( B ) 09.01.2017 163.8
BAY-13,PENTO ISOLATOR 89 B ( R ) 09.01.2017 143.8
BAY-11,PENTO ISOLATOR 89 B ( Y) 12.01.2017 124 Temperature
BAY-11,PENTO ISOLATOR 89 B ( B ) 12.01.2017 174.5 recorded as per
BAY-13,PENTO ISOLATOR 89 B ( B ) 12.01.2017 166.1 CBM report
BAY-11,PENTO ISOLATOR 89 B ( B ) 01.02.2017 104
BAY-4, PENTO ISOLATOR 89 B (R ) 20.02.2017 107.7
BAY-13, PENTO ISOLATOR 89-B PHASE-B 30.05.2017 143.8
BAY-1, PENTO ISOLATOR 89B, B phase 30.05.2017 94.7
BAY-1, PENTO ISOLATOR 89B, R Phase 16.07.2017 100.4
BAY-4, PANTOGRAPH ISOLATOR-2, B Phase 02.08.2017 103.7
BAY-4, PENTO ISOLATOR 89A, B phase 16.09.2017 99.7
BAY-11,PANTO ISOLATOR-2,PHASE-B 07.10.2017 105.4
ROOT CAUSE ANALYSIS for pantograph isolator Fixed Clamp

 For Pantograph Isolator Fixed Clamp:

Less surface contact area and
improper Gripping provision at L-
clamp area
ROOT CAUSE ANALYSIS for Pantograph isolator L plates

Less surface contact to Flexible

Misalignment Clamp

Pantograph
Gear Box

L-Plate

400 KV Bay Bus

STEP: 8

DEVELOPMENT
OF SOLUTION
 PROBABLE SOLUTIONS for pantograph isolator Fixed Clamp

Serial Points discussed during brainstorming Possibility Validation

no

1 Remove connecting pad & weld dropper & fixed Welding joint may fail while rejected
contact isolator operation

2 New set of pantograph isolator from other vendor High cost rejected

3 Fixed clamp design need to be changed More mechanical strength &

more contact surface area
 PROBABLE SOLUTIONS for pantograph L-clamp
Serial Points discussed during brainstorming Possibility Validation
no

1 Civil work to be done again for adjustment of level Not possible in operational rejected
switchyard

2 Increase the thickness of L-plate Not sufficient to cover the rejected

gap

3 L-Plate reversal to be done More mechanical strength &

more contact surface area
 SOLUTION IDENTIFIED

A brainstorming session has been done by all QC team

members, department head & OEM .After analysis of all
possibilities it has been decided to change the fixed clamp
with new design having more strength & more surface
contact area which leads to provide current flow path.
 For L-plate the required gap can be adjusted and surface
contact area has been increased by reversing the plate by 180
deg.

Tool used for finding solution: brain storming

STEP: 9

FORESEING
THE PROBABLE
RESISTANCE
 FORESEING THE PROBABLE RESISTANCES

S. No Probable Resistances

1 400 KV Bus Shutdown.

2 High induction voltage men working at Height

3 Local earthing of 400 KV Bus

STEP:10

TRIAL
IMPLEMENTATION
 RESPONSIBLE MATRIX

S. NO ACTION PLANS RESPONSIBILITY

1 BOQ preparation and material procurement Suresh

2 MOC preparation and approval Suresh

3 Implementation and checking Jagdishwaran

5 Training Jagadiswaran
STEP:11

REGULAR
IMPLEMENTATION
 IMPLEMENTATION for Fixed Clamp

Hot spot BEFORE AFTER

point

After installation of modified fixed clamps Hotspots are eliminated & the system is
running smoothly
 IMPLEMENTATION for L-Clamp

Hot spot
point

BEFORE AFTER

After reversing of L-clamp to 180 deg. Hotspots are eliminated & the system is
running smoothly
 BENEFITS

OPERATION
• 400 KV Bay shutdowns deuced

• Man hour reduction

COST

SAFET • Work at height risk eliminated to attend hotspot

Y

RELIABI • System became more reliable.

LITY

• Team motivation improved as we have solved a

RELIABILITY problem which was hanging last more than 2 years.
Intangible
Gains
STEP: 12

FOLLOW
UP &
REVIEW
 CONTROL MEASURES

CBM Report before & after.

 Shutdown time in SAP before & after.

THANK YOU!