MAHARASHTRA STATE POWER GENERATION COMPANY LTD

MOT COP MODIFICATION

SHINE KAIZEN TEAM

CHANDRAPUR SUPER THERMAL POWER STATION
 MAHAGENCO AT A GLANCE
Mahagenco is the second highest generation company in INDIA after
NTPC.
Mahagenco is having generation capacity of 13357 MW comprising 9920 MW
thermal, 2585 MW Hydel, 672 MW gas turbine and 180 MW Solar.
Mahagenco is implementing a huge capacity addition programme.
Mahagenco believes in quality management. All major thermal, hydel and
gas turbine power stations have adopted the ISO 9001:2000 certification.
Mahagenco is an eco-friendly power generating company and has received
certification under ISO:14001 and ISO:18001 for its major power stations at
Chandrapur, Koradi, Khaperkheda, Nasik, Parli and at Koyna and Uran power
stations also.
Mahagenco is powered by a dedicated and committed highly skilled work
force of more than 15000.

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CHANDRAPUR SUPER THERMAL POWER
STATION, UNIT 8&9.

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CHANDRAPUR SUPER THERMAL POWER
STATION
ISO 9001, 14001 & OHSAS 18001 UNIT

CSTPS CONTRIBUTION IN
MAHAGENCO
Rest of Mahagenco CSTPS

79%

21%

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CHANDRAPUR SUPER THERMAL POWER
STATION, UNIT 8&9.

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 CSTPS AT A GLANCE

Our Station Head is

Chief Engineer (O&M) – Mr. Jayant Bobde

Our Stage - IV Head is

Dy. Chief Engineer (Unit 8&9) – Mr. Rajesh Rajgadkar

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 CSTPS AT A GLANCE

Our Inspiration is
Superintending Engineer (Electrical-III)
Mr. S. G. Tayde

Our Guide is
Executive Engineer (C&I-III)
Mr. S. S. Chavan

Our Mentor is
Addl. Executive Engineer (C&I-III)
Mr. Rishikesh Kamalakar

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 CSTPS AT A GLANCE

INSTALLED CAPACITY
STAGE I- UNIT 3,4 - 2 X 210 MW
STAGE II - UNIT 5,6,7 - 3 X 500 MW
STAGE III – UNIT 8 & 9 – 2 X 500 MW
SOLAR 5 MW
Total Capacity - 2925 MW
OUR KAIZEN TEAM IS WORKING AT STAGE –IV ,
C&I – III DEPARTMENT

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 SHINE KAIZEN TEAM MEMBERS
GUIDE/ – Mr. RUSHIKESH B. KAMALAKAR
FACILITATOR

LEADER – Mr. NILESH N. BHOLE.

MEMBER – Mr. SACHIN S. BARDE

MEMBER – Ms. TRUPTI G. WATKAR.

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CSTPS HIGHLIGHTS

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 KAIZEN INTRODUCTION

KAI WHICH MEANS CHANGE AND ZEN WHICH MEANS GOOD.

THE POPULAR MEANING FROM TOYOTA IS “CONTINUOUS

IMPROVEMENT.”

KAIZEN IS CREATED IN JAPAN FOLLOWING THE SECOND WORLD

WAR.

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 KAIZAN DEFINITION

“KAIZEN means improvement. Moreover, it

means continuing improvement in personal life,
home life, social life, and working life. When
applied to the workplace, KAIZEN means
continuing improvement involving everyone –
managers and workers alike.“

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 3 OBJECTIVES OF KAIZAN

 kaizen philosophy include quality control , just-in-time

delivery, standardized work, the use of efficient
equipment, and the elimination of waste.
 The basic principle of kaizen is that people who
perform certain tasks and activities are the most
knowledgeable about that task/activity; including them
to effect change is the best strategy for improvement.

Keeping all these principles in mind, we have one

Brain Storming 14
STEP 1

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STEP 1

PROBLEMS DETECTED BY Q.C. MEMBERS SEGGREGATION

1. LLD Supply Failure Issue. A
2. Unnecessary tripping of C/W due to false feedback of Discharge Valve. A
3. All Corner valves limit switches feedback problem A
4. Replacement of Sump Level Switches by Transmitters. C
5. Impulse Line Leakages. A
6. Laboratory Dead Weight tester problem. C
7. Frequent failure of Coal feeder’s Load cell Electronic Module B
8. Operational issues of Sequences in MRHS. A
9. MRHS-Repetitive burning of Rubber Hoses. C
10. Repetitive breakage of manual override switch of Rotex make Solenoids. C
11. AHP Field Instruments malfunctioning due to Ash Dust in JB’s. B
12. PLC software's used to get malfunctioned when power supply fails A
intermittently.
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STEP 1

PROBLEMS DETECTED BY Q.C. MEMBERS SEGGREGATION

13. Slurry HP Seal pump used to get tripped whenever LP Seal pump get A
isolated due to logic issue.
14. C/W Pump winding temperature connectivity loss due to vibration of B
pump as JB is mounted on motor.
15. Unnecessary tripping of C/W Pump due to entangling of Level Switch A
probes.
16. Repetitive breakage of Actuator Gear train of Switch Valve at AHP C
Conveying System.
17. Repetitive tripping of Conveying Air Compressor due to increase in DP B
across Suction Air Filter.
18. False Tripping Slurry Series Pumps due to sudden blanking of level A
transmitter of Sump tank.
19. False Indication of Silo level transmitter due to which sequential
A
operation hampers.
20. MRHS, Slurry & BA- Loss of Software logic due to lack of permanent
B
License. 17
STEP 1

PROBLEMS DETECTED BY Q.C. MEMBERS SEGGREGATION

21. Transmitter impulse line choke up. A
22. Coal Mill Tripping due to RTD malfunctioning. B
23. BFP thrust pad RTD failure. A
24. Oxygen percentage not shown properly. A
25. CEP Recirculation Valve calibration disturbed. A
26. BFP Recirculation Valve Open / Close limit switch setting disturbed. A
27. Inoperativeness of Hot Air Gate. A
28. Inoperativeness of Hot Air Damper. A
29. Inoperativeness of Cold Air Damper. A
30. Sluggish Operation of PA Vane. B
31. Superheat & Reheat spray control valve passing. B
32. Improper signal of primary instrument for Heat rate calibration. B
33. TDBFP control valve position feedback disturbed. A
34. Failure of Coal feeder Tacho speed sensor. A 18
STEP 1

PROBLEMS DETECTED BY Q.C. MEMBERS SEGGREGATION

35. Failure of MDBFP working oil Temp measurement system. B
36. Disturbance of Control valve position feedback . A
37. Control valve EP converter failure. A
38. ID,FD,PA Fan bearing temperature RTD temp mismatch with local gauges. A
39. Water ingress in Auxiliary Instrument in rainy season. B
40. HPT/IPT-Top/Bottom cable of thermocouple loosening. A
41. SADC system Instrumentation failure. C
42. Platforms not available in Boiler Elevation while working. C
43. TDBFP suction / discharge temperature (Δ T) malfunctioning. B
44. Tripping of Igniter/Scanner Fan. B
45. BCW ON permissive not available frequently due to inadequate water flow. B
46. Failure of DPU electronics cards. A
47. Failure of Scanner during rainy season. B
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STEP 1

PROBLEMS DETECTED BY KAIZEN MEMBERS SEGGREGATION

48. Coal feeder local panel reverse /forward switch problem. B
49. Failure od DCS network due to cable damaged by rat. C
50. No response for spares by Instrument supplier/manufacturer . C
51. Procurement Processing difficulties due to delayed response of vendors C
and delay in file processing by management.
52. Inoperativeness of HOTV during Boiler Light up. A

After categorization, all these problems have been segregated by

ABC Analysis 20
STEP 2

Category Scope Problems No. Total

Problems within our 1,2,3,5,8,12,13,15,18,19,21,23,24,25,2

A 6, 27,28,29,33,34,36,37,38,40,46, 52 26
Control & Capacity.

Problems which can be

7,11,14,17,20,22,30,31,32,35,39,43,44
B solved with the help and ,45,47,48 16
resources of other sections.

Problems within
C Management Control & 4,6,9,10,16,41,42,49,50,51
Capacity.
10

Total Problems 52
In order to know the percentage of A,B,C problems, we have drawn
Pie Chart 21
STEP 2

2.2 ABC Analysis Pie Chart

19.23%

50%

30.76%

A-26 B-16 C-10

Since ‘A’ type problems can be solved by us,
So considering them we have done
‘3P’ Analysis
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STEP 2

• PROPRIETARY
• Grouping as per our Company’s specific objectives and
1st P Organizational strategic plans.

• PRIORITY
• To fix priority to important from above according to extent of
2nd P Generation Loss.

• PREFERENCE
• Final Selection of Problems having impacts and concerns on our
3rd P department.

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STEP 2

GROUP PROPRIETARY PROBLEM Sr. Nos. TOTAL

No GROUP
Loss of Generation Related
1 Problems
1,52 2

2,3,5,12,13,15,18,19,21,23,25,26,27,28,
2 System Related Problems
29 33,36,37,38,46
20

3 Heat Rate Related 24 1

40
4 Safety Related Problems 1

Environment Related
5 Problems
8,34 2

Total 26 24
STEP 2

ECT TECHNIQUE
E - EFFECT ON POWER GENERATION
C - RISE IN GENERATION COST
T - TIME CONSUMPTION

KAIZAN Members decided to give weightage on the scale

of 10 to above 3 aspects on the basis of problem impact.

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STEP 2

GR RM PD SS VP PN AR TOT
NO AL
E C T E C T E C T E C T E C T E C T
Generation
1 Loss 10 8 9 10 7 8 10 9 9 10 8 8 9 7 10 9 8 8 157
Related
2 System 9 7 8 9 6 7 9 8 8 9 7 7 8 6 9 5 7 9 138
Related

3 Heat Rate 7 8 6 6 9 8 7 8 7 9 8 5 6 7 7 8 5 7 128

Related

4 Safety 7 8 5 122
Related 8 6 7 8 5 6 8 7 7 8 6 6 7 5 8

5 Environme 6 7 5 7 7 7 6 7 6 8 7 4 7 6 8 5 4 3 109
nt Related

Based on Priority given by KAIZAN members

Bar Graph has been drawn. 26
STEP 2

Weightage By KAIZEN Members

180
160
140 157
138
120
Total Marks

128 122
100 109
80
60
40
20
0
GENR SR HRR SFR ER
A Group Problems
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STEP 2

Pr. Problem No. of Events Man Total Loss Hours

No Since Commissioned Hours/Event (C=A*B)
(A) (B)
1 LLD Supply Failure. 1 6 6

52 Inoperativeness of HOTV during Boiler 4 1 4

Light up.
Total No. of Loss Hours 10

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STEP 2

Pr. No Problem Total Loss Cumulative % Hour Loss

(Hours) (Hours)
1 LLD Supply Failure. 6 6 60.00 %

52 Inoperativeness of HOTV during 4 4 40.00 %

Boiler Light up.
Total No. of Events 10 100.00%

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STEP 2

Pr. No LLD Supply Inoperativeness Total Loss

Failure Issue. of HOTV during
Boiler Light up.
No. of Events (A) 1 4

Man Hours/Event (B) 6 1

Gen Loss Hours (C) 6 4

= A* B
Gen Loss (D) 3 MU’s 2 MU’s
=500*C
Misc Consumption (E) 0.06 MU’s 0.00 MU’s
= 2% of ( D)
Net Gen Loss (D + E) (F) 3.06 MU’s 2.00 MU’s

Monetary Loss (G) 0.535 Cr 0.350 Cr 0.885 Cr

=(Rs 1.75/ Unit)*F
Burden of extra Oil Consumption (H) 0.315 Cr 0 Cr 0.315 Cr
= 35 (Rs/L) * 2500(Ltrs) * 6 Guns
* 6 Hrs(Hrs of usage of Oil) * A
Total Loss = G + H Rs.0.850 Cr Rs.0.350 Cr Rs. 1.20 Cr 30
STEP 2

Problem Problem Description Gen Loss INR Cumulative % Gen Loss Cumulative %
No. (Cr) Gen. Loss INR
(Cr)

1 LLD Supply Failure. 0.850 0.850 70.83% 70.83%

52 Inoperativeness of 0.350 1.200 29.17% 100.00%

HOTV during Boiler
Light up.

100.00%

Based on Cumulative Generation Loss

Bar Graph has been drawn. 31
STEP 2

Preference of Problems
80.00%
70.83%
70.00%
60.00%
Percentage % 50.00%
40.00%
29.17%
30.00%
20.00%
10.00%
0.00%
LLD Supply Failure Inoperativeness of HOTV
during Boiler Light up.
Problems

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STEP 2

33 Hence it has been decided to take up this issue on priority

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STEP 11

SR.NO TOOLS SR.NO TOOLS

1 Brain Storming 7 Cause & Effect Diagram

2 ABC Analysis 8 4 W 1H Analysis

3 3P Analysis 9 Pareto Diagram &

Lawrenz Curve
4 Weightage Method 10 P.D.C.A cycle

5 WHY WHY 11 Reverse Engineering

6 BAR Graph, Pie 12 Gantt Chart

CHART 34
 ANY
QUESTIONS ?

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