Aluminium & Power, Jharsuguda

SGA
REDUCTION OF PA & ID FAN LOADING

Project:

Reduction of PA and ID fan loading

Baseline:

1. PA Fan 1265 KW
2.ID Fan 1844 KW

Target:

1. PA Fan 1215 KW
2.ID Fan 1800 KW
Resources - Team Members
Name

Role

Dept/Function

Facilitator

Head Operation (CPP)

Leader

Maintenance (CPP)

Atish

Member

O&E (CPP)

Vivek

Member

O&E (CPP)

Manas Tyagi
Aadarsh

Aluminium & Power, Jharsuguda

1.IDENTIFICATION OF PROBLEM

Aluminium & Power, Jharsuguda

1. IDENTIFICATION OF PROBLEM

S No

LIST OF PROBLEMS IDENTIFIED

Area of Work

SADC not functioning properly

Boiler

High PA Header pressure for Mills

Boiler

High air leakage % in APH

Boiler

High DP across Fabric filter

Boiler

Pent house air leakage

Boiler

Duct air leakage

Boiler

Damper Problem

Boiler

Seal trough air ingress

Dog house air ingress

Boiler
Boiler

Aluminium & Power, Jharsuguda

2.SELECTION OF PROBLEM

2.1 PROBLEM SELECTION

Aluminium & Power, Jharsuguda

Aluminium & Power, Jharsuguda

2.2 MILESTONE CHART

QUALITY CIRCLE NAME - ELEVATE

REGISTATION NO -

PROJECT TITLE - Reduction of Fan Loading

MEETING DAY - SATURDAY

Definition of problem

Analysis of problem

Identification of causes

Find out the root causes

Data analysis

Developing solutions

Foreseeing possible resistance

Trial implimentation and

checking performances

Regular implimentation

10

Follow up and reviews

PROJECT CATEGORY NO - A
DATE OF COMPLETION DATE OF BEGINNING -01/07/14
31/03/2015
MEETING TIME - 16:00hrs

PROJECT N0 - 01

SL NO ACTIVITY

DEPARTMENT- O&E

Jul-14

Aug-14

Sep-14

Oct-14

Nov-14

Dec-14

Jan-15

TEAM MEMBERS - Aadarsh,

Manas, Prakhar,Vivek,Atish

Feb-15

Mar-15

Remarks

Horizontal
deployment

Aluminium & Power, Jharsuguda

3.DEFINING THE PROBLEM

Aluminium & Power, Jharsuguda

3.1 DEFINING THE PROBLEM

1.

High PA Header pressure for Mills : PA pressure > 8.5

Kpa.

2.

High air leakage % in APH > 8 %

Aluminium & Power, Jharsuguda

3.2 PROCESS FLOW DIAGRAM

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3.3 PROBLEM AREA

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3.4 PROBLEM AREA

Original APH had flue gas leakage and erosion which caused damage to Hot end
layer.
APH Seals were also damaged due to gas erosion.
Air leakage % of all the units were on Higher sides

Aluminium & Power, Jharsuguda

4. ANALYSIS OF PROBLEM

Aluminium & Power, Jharsuguda

4.1

(4-W + 1-H Analysis)

PROJECT - High loading of PA & ID fan

OBJECTIVE

1. PA fan loading reduction

2. ID fan loading reduction

GOAL

Process optimization and improvement in equipment performance

TOOL

ANSWER
QUESTION
What is the problem Fan loading is high
Where is the problem In APH and high primary air pressure
When the problem occurs After six month of annual overhaul
O&M
Whom it is concern
How it is affecting
1. Due to higher % of air leakage in APH fan loading increasing.

WHAT
WHERE
WHEN
WHOM
HOW

Aluminium & Power, Jharsuguda

5. IDENTIFICATION OF CAUSES

Aluminium & Power, Jharsuguda

5.1 CAUSE & EFFECT DIAGRAM

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5.2 CAUSE & EFFECT PRIOTRIZATION

S.No

Cause

Effect S.No
level

Cause

Effect
Level

Mill Outlet Temperature

Low

10

Improper Soot blowing

Coal quality

Low

11

High Bag filter DP

Damper problem

Low

12

Inlet guide vane problem

Low

Motor & Fan efficiency

Low

13

Moisture in flue gas, pulsing air

Low

Air Ingress in APH

HIGH

14

SADC Damper

Low

Duct leakages

Low

15

High excess air

Low

Seal Air fan damper passing

Low

16

Higher PA Pressure

Seal trough passing

Low

17

Moist. Variation with climate

High inlet air ambient air temp.

Low

Low

HIGH

HIGH
Low

Aluminium & Power, Jharsuguda

6. ROOT CAUSE ANALYSIS

Aluminium & Power, Jharsuguda

6.1 HIGH IMPACT ROOT CAUSES

Root cause

DEFINITION

Air Ingress in APH

Air Ingress in APH is due to increase in clearance between rotating & stationary part as flue gas
side operating in negative pressure & PA FD Side operating in positive pressure

High DP of FF

High DP in Fabric filter is mainly due to excess flue gas loading due to APH leakages, moisture in
flue gas etc.

High PA Pressure

High PA air pressure operation wrt design increases fan loading

Aluminium & Power, Jharsuguda

7. DATA ANALYSIS ON ROOT CAUSE

Aluminium & Power, Jharsuguda

7.1 High Air Ingress in APH

seal plates are provided to avoid leakages of gases or air between the sectors while in
rotation.
The gap adjusted between the seal and sector plate as per the OEM recommendation as
follow
APH Seals

Design

Six month after AOH

Hot End

Cold End

Hot End

Cold End

5.5

10 to 15

0 to 2

3 to 5

9 to 10

Axial Seal

3.5

7 to 8

3 to 4

Bypass Seal

3.5

4 to 7

9 to 10

Radial Seal

Inboard
Outboard

APH seals are getting eroded due to high ash in flue gas and the gap between the seals
and sector plate found to be in range as follows :
The above data reflects that the gap between the seals ( mostly radial) sector plate
has increased which resulted into high air leakages.

Aluminium & Power, Jharsuguda

Following graph shows the month wise increase of APH air leakage in unit # 7
APH Air Leakage % Vs Fan Loading
1900

14.0

1800

12.3

11.7
1700

11.0

10.5

10.0

9.9
9.4

9.0

1500

8.0

7.7

KW

1600

12.0

1400

6.0

1300

4.0
1200
2.0

1100
1000

0.0
1

PA

ID

Leakage %

Aluminium & Power, Jharsuguda

7.2 Higher Primary Air Pressure

OEM recommended Primary air pressure =8.5 Kpa

Tripping value 5.4 KPA
In order to avoid tripping of unit on MFT logic operators use to maintain the primary air
pressure more than 8.5 Kpa which is contributing higher loading of PA fan

Aluminium & Power, Jharsuguda

8. DEVELOPMENT OF SOLUTION

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8.1 IMMEDIATE ACTIONABLES

S.No

Cause

Action Proposed

Responsibility

Target date

Status

Air Ingress in
APH

Rectification of
damaged seals.

Aadarsh/Indrajeet
/ Arohi

As per AOH

Installed

High DP of FF

Leakage arrest in
penthouse & seal
trough

Aadarsh/Indrajeet
/ Arohi

As per AOH

Done

High PA Air
Header Pressure

Operational Control

Vivek/ Atish

Continuous

Daily
Monitoring

Dampers & IGVs

Problem

Checking &
calibration of links

Chandrakant
Panda

Continuous

Done

24

Aluminium & Power, Jharsuguda

8.2 IDEAS/CREATIVE SOLUTIONS

S No
1
2

Idea
CFD analysis of flue gas duct (uniform distribution of flue gas flow)
Combustion optimization to optimize primary air pressure

Area of Work
Boiler
Boiler

Improvement of APH seal ( Online sector plate lifting arrangement N.A so we can
put soft touch seal)
Installation of magna drives

SADC correctness

Boiler

online performance monitoring system

Boiler

Boiler
Boiler

8.3 LIST OF SELECTED SOLUTIONS

SL

SOLUTIONS

Soft touch seal installation

PA pressure optimization

Aluminium & Power, Jharsuguda

Aluminium & Power, Jharsuguda

9. FORSEEING POSSIBLE RESISTANCE

Aluminium & Power, Jharsuguda

FORESEEING PROBABLE RESISTANCE

Sl no

Probable resistance

Resistance possible by
whom

Procurement Approval

Solution

Responsibility

Evaluation of cost benefit of

implementation of APH soft
seal

Aadarsh/vivek

Atish

Arrangement of Spares

Optimization of pa pressure
Operator
by operators

Data trends to be available

for 6 months

SOP modification

SOP was verified and

approved by HOD

Operator/ Team Leaders

Prakhar

Aluminium & Power, Jharsuguda

10. TRIAL & IMPLEMENTATION

Aluminium & Power, Jharsuguda

11. TRIAL & IMPLEMENTATION

Soft Touch Radial Seals shows better overlap with the sector plates and hence
ensure proper sealing and reduction in flue gas leakages.

Aluminium & Power, Jharsuguda

2. PA loading reduced after primary air pressure optimization

PA pressure Vs Loading
1270

10.5
10

9.5

1260

KW

9
8.5
1250
8
7.5
1240

7
6.5

1230

6
1

Weeks
PA

Series1

10

Aluminium & Power, Jharsuguda

11. REGULAR IMPLEMENTATION

Aluminium & Power, Jharsuguda

Regular implementation
Installation of seals in all units based on
overhauling schedule.
Continuous monitoring of PA pressure by the
operator on shift basis.

Aluminium & Power, Jharsuguda

INTANGIBLE BENEFITS
SELF
DEVELOPME
NT

KNOWLEDGE
SHARING

TEAM SPIRIT

INTANGIBLE
BENEFITS

SELF
MOTIVATION

LEADERSHIP

COMMUNICATI
ON SKILL

TANGIBLE BENEFITS
BEFORE & AFTER

Aluminium & Power, Jharsuguda

35

TANGIBLE BENEFITS
BEFORE & AFTER

Aluminium & Power, Jharsuguda

Aluminium & Power, Jharsuguda

TANGIBLE BENEFITS
Investment Details :
For APH

Investment on cost of seal per Unit

Overall Reduction in Fan loading per unit
Payback Month

: INR 2.00 Lakhs

: 292 KW
: 1 months

Savings Calculations:

Envisaged net saving for all 9 Units (Rs/ Lakhs)

: INR 38 lakhs

Aluminium & Power, Jharsuguda

12. FOLLOW UP & REVIEW

Aluminium & Power, Jharsuguda

12. FOLLOW UP & REVIEW

1.
2.
3.
4.

Daily monitoring and controlling of operating parameter by the operator.

Daily monitoring of performance parameter by the O & E team.
Weekly operational review by the operation head.
Operational review by the team leader and plant head on monthly basis

FLASH REPORT 22.04.2015

A shift
1
2
3
4
5
6
7
8
9
10
11
12

Parameters

UoM Std Value

U1

U2

U4

U5

U6

U7

U8

U9

Load MW
MS Pressure
MS Temperature (Turbine inlet)
HRH temperature(Turbine inlet)
RH Spray
Super Heater Spray
Vacuum
Spray as % of MS flow
O2 %
PA header press
Exist Flue Gas Temperature
Make-up water Flow

MW
Mpa
C
C
TPH
TPH
Kpa
%
%
Kpa
C

138

138

138

138

139

139

138

138

13.71

13.71

13.67

13.71

13.72

13.74

13.75

13.70

541.1

539.4

541.9

538.8

538.3

537.9

538.4

537.9

536.5

536.0

539.2

539.9

537.8

539.3

537.0

539.6

0.0

0.0

0.0

0.0

0.2

0.0

0.0

0.0

20.4

22.3

17.2

28.3

21.4

23.5

26.1

27.2

-86.42

-86.05

-86.53

-87.10

-87.00

-86.75

-86.07

-85.27

4.59%

5.02%

3.86%

6.34%

4.69%

5.13%

5.61%

6.14%

2.1

2.4

2.4

2.9

2.8

2.8

2.5

2.6

6.5

6.8

6.9

6.7

6.4

6.3

6.2

6.4

139.0

136.1

137.5

138.8

137.0

139.9

137.5

139.7

7.01

5.32

5.77

11.18

2.46

2.59

6.26

135
13.63
537
537
0
11
-89.82
2.70%
2.2-2.5
6.5
138.0

Aluminium & Power, Jharsuguda

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