To Reduce Power Consumption

KPS Customer Order Generation P1: Production Planning & Control KBR KPS KPS P3: PM-1 AKY JSD Raw Material P12: Raw Material (
Planning & Receipt)

KPS P4: PM-2 SR RNS P13: Chipper GKH

KPS P5: PM-3 PKP RNS

KPS P6: PM-4 UT

KPS P7: PM-5 SR

KPS
P8: PM-6 UT

KPS P9: PF Plant

P2: Stock Prep

KBR

Rewinding
DB KPS

Sheeter

Wrapmatic

P14: Pulp Mill GA

P10: Finishing House Ashti Reel Wrapping NS KV KV P11: MSD (Warehouse, Dispatch, Invoice) SM Customer SM P11: MSD Manual Ream / Reel HDPE Packing

ABS Make up Chemical

Manual Ream Finishing

Shrink Bundling

RNS
P15: Chemical Recovery SS SSA SSA P17: ClO2, O2, SO2 CMN

Raw Salt

P16: CSCP CMN

SKJ E1: Mech -PRC RKT

SBS E2: MechM/c AKV

SBS E3: Elect. GN SKJ E15: Safety SB

SBS E4: Civil RKN RKC

SBS E5: Inst. RK

JNP E6: Bilt Power AKK HPS

SSA E7: IT PP

SC E8: R&D BPA SBS

HPS E9: Purchase AKS E18 Mech Workshop

HPS E10: Stores PQ SKJ E19: Water Supply RKT

SSA E11: EC Cell RKJ E20: BTTL

SC E12: QAS BPA HPS

SBS E13: P&D RKJ

RNS
E14: Water Treatment, ET Plant& Filler Preparation GKH SC E22: Environment CSK NSC E23: HR RCY

E16: Costing & Finance TKD

E17: Y & T and Transport RKB

E21: Legal & Claims GW

RSB

Revision 5 Rev. Date 15/09/08

Raw material at chipper belt Macro Std: Length: 25-35 mm Thickness: < 8 mm Chipping of raw material Take corrective action Is chips size ok ? Y Cooking of chips Is k no ok ? N M p steam Is strength ok ? N Feedback W L from Recovery

Y Std: AA 88-90 gpl

Initiate corrective action

Std: k no 14 -16

Y Screening & Washing of unbleached pulp Std: 24-26 kg/ t U/b pulp Is soda loss ok ? Y Bleaching of UB pulp N

Wbl to recovery Bleaching chemicals from chem mfg

Initiate corrective action Purchased chemicals

N
Is strength ok ? Y Feedback to SP

Std: hypo: 24-26 gpl Caustic: 80-82 gpl

Feedback

Is quality ok ?
Y Dewatering Bld pulp to ashti

Initiate corrective action

Internal customer : SP & M/c 1-6 Expectations :

Bld pulp to Stock prepn

Brightness: 87.5 88.5 % ISO

Viscosity: 8-10 CPS

Project Title
Desired Results

: To Reduce power consumption

: To reduce Power consumption from 215 to 211 kwh/ MT Unbld pulp.

Processes to be worked on : Cooking, washing & ODL plant Why this Project is Needed : To generate savings of Rs.5 lac per month over the budget Project Starting Date Estimated Completion Date Meeting Frequency Location & Time Sponser Team Members : 15.07.2011 : 31.12.2011 : Every Thursday, 3.30 pm : P Mill Office : R N Srivastava : Name Function G K Arora* Pulp Mill Harendra Gupta R Waghade Pulp Mill Pankaj Bhende Pulp Mill Elect.. Dinesh Prasad Pulp Mill
4

Pulp Mill

Accepts from Primary Screen Washing on BSW 1 Liquor

Distributing Filtrate (WBL) from Seal tank No1

Defoamer Repulper 1.2 & 3 Pulp Shredding & Repulping Washing Mat pulp By BSW 2 Filtrate Washing on BSW 2 Shredding & Repulping Washing on BSW 3 Shredding & Repulping Washing Mat pulp By BSW 4 Filtrate Washing Mat pulp By BSW 3 Filtrate Hot / Foul Water From B H R Std: H/W 60 650 C F/W : 65 - 700 C Is temp OK ?

To dig. &Screening Operation Is Twaddle OK? Y Filtering weak B/L Std: 0Tw : 14-15 N Initiate Corrective Action

N Inform Dig. H/s

W B/L in Lignin tnk for Screening/ Recovery

Washing on BSW 4 N Std. 22 24 kg/ MT pulp as Na2SO4 Initiate corrective Action

Is Soda loss OK ? Y

Washed pulp in H D Tower to next Sub process

Digester ready for steaming After chips loading Start circulation pump & Start steaming for i stage Is Temp. & Press. Profile Ok ? Y N

Mp steam from Boiler house Feed back to Boiler h/s for Corrective action N Y * Degassing Regulate Flow Is Pressure Ok ? Std.: Press: 9.8- 10.5 Kg/cm2

Temp.: 1300 c Pressure : 2.3 kg / cm2 N

Cond.Removal From pre heater

Cooking for I stage Retention : 45 minutes

Is Flow within Limit ? Std.: Y Max 30 mt/hr

Steaming for II stage

Is Temperature & Pressure profile Ok ?

Condensate to Dm plant

Temp 1640 c Pressure 6.3 kg / cm 2 Y II stage retention for cooking 30 minutes min. Is K no. & Knots Rate ok ? Y Digester ready for blow

Degassing & strainer Flushing

Adjust retention time N

K no 14 14.5 Knots:4-5 trolley / hr

 To generate savings in power

usage by

Rs Five lac per month

over the budget. Henceforth this project was taken

Sr. No S1 S2 S3 S4 S5 S6

Activity

Expected date of completion 17.07.11 24.07.11 27.07.11 01.08.11 10.08.11

Actual completion date

Are processes defined ? Are critical areas identified ? Are data collected ? Are data analyzed ? Are root causes identified ? Are root causes removed ?

S7

Is customer satisfied ?

Chips at chip bin from Silo Macro Std: Length: 25-35 mm Thickness: < 8 mm N Y Cooking of chips Is k no ok ? M p steam Chips loading in digester Take corrective action Is strength ok ? N Feedback W L from Recovery

Y Std: AA 88-90 gpl

Initiate corrective action

Std: k no 14 -16

Y Screening & Washing of unbleached pulp Std: 24-26 kg/ t U/b pulp Is soda loss ok ? Y Bleaching of UB pulp N

Wbl to recovery Bleaching chemicals from chem mfg

Initiate corrective action Purchased chemicals

N
Is strength ok ? Y Feedback to SP

Std: hypo: 24-26 gpl Caustic: 80-82 gpl

Feedback

Is quality ok ?
Y Dewatering Bld pulp to ashti

Initiate corrective action

Internal customer : SP & M/c 1-6 Expectations :

Bld pulp to Stock prepn

Brightness: 87.5 88.5 % ISO

Viscosity: 8-10 CPS

Accepts from Primary Screen Washing on BSW 1 Liquor

Distributing Filtrate (WBL) from Seal tank No1

Defoamer Repulper 1.2 & 3 Pulp Shredding & Repulping Washing Mat pulp By BSW 2 Filtrate Washing on BSW 2 Shredding & Repulping Washing on BSW 3 Shredding & Repulping Washing Mat pulp By BSW 4 Filtrate Washing Mat pulp By BSW 3 Filtrate Hot / Foul Water From B H R Std: H/W 60 650 C F/W : 65 - 700 C Is temp OK ?

To dig. &Screening Operation Is Twaddle OK? Y Filtering weak B/L Std: 0Tw : 14-15 N Initiate Corrective Action

N Inform Dig. H/s

W B/L in Lignin tnk for Screening/ Recovery

Washing on BSW 4 N Std. 22 24 kg/ MT pulp as Na2SO4 Initiate corrective Action

Is Soda loss OK ? Y

Washed pulp in H D Tower to next Sub process

Cooked Pulp in Voith & Empacel Blow tanks Is Feed tank level OK? Std: 50 - 60 % Y Feeding pulp to Pressure Knotter CT4 Is Pressure / Cy% OK ? Y Coarse Screening in Primary Knotter

Black Liquor from seal tank N Regulate Stock valves

Consistency : 2.8 3 % Pressure > 1.8 kg/cm2

Initiate Corrective Action

Is Sealing flow OK ?
Y

Is D.P. Regulate stock / N Reject & Dilution Flush with liquor Flow Std.: Ok ? DP < 0.3.bar Reject flow : 20 % feed flow Y Reject Dilution : 75 % reject flow Accepts To Primary Screen Inlet Rejects Knots separation in Vibrating Screens Knots to digester

BL from screen room Liq tank

Pressure Knotter Accept pulp Screening on primary Slotted screen

BL from seal tank no.1

Regulate accept Is N Control valve / D.P Rej & Std : DP < 0.3 Flush with BL Rej dil. Rej flow; 20% of feed OK Y Rej diln :75% of reject flow Reject Accept Secondary stage Accept to screening BSW 1 Is N Regulate accept Std : DP < 0.3 D.P Rej & Control valve / Rej flow; 20% of feed Rej dil. Flush with BL Rej diln :75%of rej. flow OK Y Reject Accept Sand separation Tert stage screening Std : DP < 0.3 Rej flow; 20% of feed Rej diln :75%of rej. flow Accept Accept Is D.P Rej & Rej dil. OK Y N Sand for disposal To dispose Regulate accept Control valve / Flush with BL

Reject

Shives separation on Vibrating screen

Reject

To Digester

Cleaned Unbleached Pulp from P 23.4

Chlorinating Unbleached Pulp ( C/D Stage)

Extracting Pulp with Oxygen Caustic & Hydrogen- Peroxide ( E /Op Stage) Bleaching Caustic Extracted Pulp with Hypo ( Stage 1 ) Bleaching Hypo 1 treated Pulp with hydrogen peroxide Bleaching Pulp with Chlorine - Dioxide ( D Stage ) Washing and Transferring Bleached Pulp to High Density Towers Supply of Bleached Pulp to Stock Preparation For next process Supply Bleached Pulp To Ashti Std.: brightness:87-89 o ISO Viscosity : min. 7 cps

BLD PULP FROM H D TWR

DEWATERING PRESS

IS CY% OK Y

INITIATE CORRECTIVE ACTION

Std.: Consistency; 22-26 %

LOADING THICK PULP IN BAGS

LOADING THICK PULP TRUCKS

TRUCK DISPATCHED TO ASHTI UNIT

Power consumption
Cooking Washing Bleaching

Jan

Feb

Mar

April

May

Jun

Jul

31.8

32.7

33.3

33.7

34.7

34.5

32.2

154.2
145.8

154.4
146.8

156.7
145.9

157.2
149.9

156.4
150.7

158.6
148.5

144.7
139.8

Screening 1. Blow tank stock pump run under capacity due to frequent variation of the stock rate due to intermittent blows. 2. Knotter screen 1 & 2 tank pump is running even though sand trap is not working. 3. For dilution of screen plant presently one additional pump is running , both under capacity. 4. For dilution to screen room liquor tank pump is running, at under capacity. 5. Difficulty in attaining feed consistency decreasing throughput of plant. I 6. Idle running of down stream equipments during tripping of up stream equipments. 7. Shut down and start up during power change over. 8. Decreasing throughput and consequently increasing power consumption due to lot of forign material coming with chips, 9. Idle running of tank s agitators during shut plant. 10. No energy audit of screening sections of pulp mill.

WASH PLANT & ODL 1. 2. 3. Running wash plant at under capacity during low blow tank levels. Container tank pump running hours is more due to washer gland leakages . No interlocking for stopping idle running of equipments in case of any plant

shut down(for equipments which are out of inter locks).

4. Idle running of down stream equipments during tripping of up stream equipments. 5. 6. Two or three source of Power supply. Pump used for supplying black liquor to recovery is running under capacity.

BLEACHING & PULP TRANSFER

Running the bleach plant at less rate . Idle running of down stream equipments during tripping of up stream equipments. Scaling in the lines. More dilution at conveyors. Hypo tower ring dilution pump is running under capacity.

Caustic dosing pump running under capacity.

Two pumps running for pulp supply to paper machines. Box pump running even though no leakages from the B/P floors. No interlocking for new equipments running from field. Running of HD 2 pump & its agitator only for screw press, Running hours of all tower agitators when there supply pumps are shut. Installation of oversized motor/pump due to non availability of required sizes.

 Optimization of bleaching chemicals in proper manner.

 Non availability of bleaching chemicals.

Man
Optimization of bleaching chemicals in proper manner Higher deviation in lab test results
LC 4 LC 6

Method
LC 1

Eop stage bypassing for BPW-1 maintenance Large variation in bleach plant feed consistency Bleach plant stock rate variation Frequent bypassing of washers

Delay in lab test results reporting Less awareness in operators

LC 2

Casual approach in shade inspection Non uniform chemical dosing at ODL with respect to feed rate Chemicals strength variation Variation in raw material components Non uniform unbld. pulp K. No

More consumption of Beaching chemicals

Less washing at POW-2 mat

LC 5

LC 3

Poor performance ODL & B/Plant washers Malfunctioning of instruments Frequent gland leakage problems of washers

Variation in POST ODL K.No

Material

Machine

LC1 LC2 LC3 LC4 LC5 LC6

: Eop stage bypassing for BPW-1 maintenance (Frequent bypassing of BPW-1 due to poor performance) : Bleach plant stock rate variation (< 360M3/Hr) : Frequent gland leakage problems of washers (Variation in washer vacuum) : Delay in lab test results reporting (>1.0 Hr) : Variation in POST ODL K.No (> 10.5) : Casual approach in shade inspection (Could not tally lab results)

Likely Causes

LC 1 LC 2 LC 3 LC 4 LC 5 LC6

Eop stage bypassing for BPW -1maintenance (Frequent bypassing of BPW-1 due to poor performance) Bleach plant stock rate variation (< 360M3/Hr)
Frequent gland leakage problems of washers (Variation in washer vacuum) Delay in lab test results reporting (>1.0 Hr) Variation in POST ODL K.No (> 10.5)

15 11 8 7 2

LC6 : Casual approach in shade inspection (Could not tally lab results)

Based on data following likely causes are confirmed as root causes

RC 1.
RC 2. RC 3.

Eop stage bypassing for BPW -1maintenance

Bleach plant stock rate variation Variation in POST ODL K.No

Root cause RC1 Eop stage bypassing for BPW -1 maintenance Bleach plant stock rate variation

Action taken

Date of completion

Responsib ility Shift I/C, Shift Operator Shift I/C, Shift Operator

RC2

RC3

Variation in POSTODL K.No

Month
Cl2 (Kg/Mt of Bld. Pulp)
Hypo (Kg/Mt of Bld. Pulp) ClO2 (Kg/Mt of Bld. Pulp) H2O2 (Kg/Mt of Bld. Pulp) Caustic (Kg/Mt of Bld. Pulp)

21st Jul

22nd Jul 23rd Jul 24th Jul

25th Jul

26th Jul

28th Jul 29th Jul 30 Jul 31st Jul

Before

After

Jan- Jun 2011

Aug-2011

4.98 Lac 3.18 Lac

Before

After

Total Saving (Rs. In Lac) =

 Sense of satisfaction and pride on achievement of results. Team work can solve complex problems with simple solutions.

Results come through team work and involvement of all the process owners.