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Durgapur is situated in the district of Barddhaman in West Bengal state in India. It is located at a distance of 158 kilometer from Kolkata (Calcutta).Its geographical location is defined as 23027 north and 88029 east. It is on the bank of the Damodar River. National Highway 2 (Grand Trunk Road) and the Calcutta Delhi railway line passes through Durgapur
QC RESUME
Name of QC
QCFI Membership No. Organisation Address
ACHIEVERS
081516027 Durgapur Steel Plant Durgapur - 713203
Contact Person
Phone No. No. of employees QC team formed on Registration Number Meets on Problem solved till now 3
MEMBERS QC ACHIEVERS
4
Mr. Rama Shankar Kumar Mr. Devdutta Bhattacharya, Facilitator Mr. Rajesh Prasad
Leader
Mr. Sudip Kumar Khan
CCP
W& AP
WORK AREA
Mechanical Maintenance of the following equipments and systems
CONVERTERS
LANCE SYSTEM
WORK AREA
IDENTIFIED PROBLEMS
Metal spillage on umbrella skirt and Heat shield during oxygen blowing
Delay during tap hole clearing affecting productivity Deflecting shield of Converter getting damaged Huge delay during Converter campaigning Huge delay during old and new hood shifting Dog House door getting frequently deformed and getting jammed blowing Huge quantity of dust and gas emission during oxygen in Converter
CATEGORY A A B A C A C
IDENTIFIED PROBLEMS
Frequent failure of Resilience coupling of Converter Tilting drive
Difficulty in checking oil level through glass indicator in Planetary and Bull Gear Box Oil leakage through oil seal from Bull Gear Box of Tilting Drive of Converter Damage of Converter shell at Tap Hole area Bottom screw of Converter getting frequently damaged Frequent damage of converter sample taking pipe Bottom levers of converter getting dislodged very often.
CATEGORY A A
10
11 12 13 14
B
B A A C
IDENTIFIED PROBLEMS
Frequent failure of coupling pad in convertor tilting drive.
Lack of approach of while lubricating out side wheels of lance trolley.
CATEGORY C C
17
18 19 20 21
B
B C C B
IDENTIFIED PROBLEMS
Failure of pneumatic emergency lifting limit switch of lance
CATEGORY
22
23 24 25 26 27 28
A
B B B A A A
Lack of approach during lance carriage changing Lance trolley locking system failure. Huge accumulation of dust in lance manual valve station. Sample carrier getting stuck up frequently inside pneumatic line Sample carrier outer surface getting deformed Sample carrier deformed. pneumatic line door getting
IDENTIFIED PROBLEMS
SRD Pneumatic system functioning inconsistently.
SRD Need frequent calibration SRD swiveling cylinder pin damage at regular interval Frequent damage of online purging hose in all 3 convertors. OLP hose getting stuck up in OLP drum during changing. BRD getting derailed from track. Difficulty In positioning BRD at zero meter level during campaign repair.
CATEGORY
29
30 31 32 33 34 35
B
B A B A B B
IDENTIFIED PROBLEMS
Leveling and centering of FRD difficult under converter.
Furnace relining device cage out very often FRD roller getting damaged very often. Input coupling bolts of telfer getting frequently loose Gear box failure of telfer Input coupling bolts of telfer getting frequently loose Frequent shearing of tool holder bracket in LBM
IDENTIFIED PROBLEMS
Frequent wear out of drill bit of LBM
Huge accumulation of slag and debris in front of passenger lift creating hazards Frequent jamming of HSBD (hood bottom closer device) movement Large number of refractory bricks of main girders damaged Air getting trapped during pneumatic grease pump lubrication with
CATEGORY
43
44 45 46 47 48 49
B
B C B A A B
Co gas line jamming of burner of ladle filling compound Lack of welding provision at pit side area
IDENTIFIED PROBLEMS
Frequent wear out of drill bit of LBM
Huge accumulation of slag and debris in front of passenger lift creating hazards Frequent jamming of HSBD (hood bottom closer device) movement Large number of refractory bricks of main girders damaged Air getting trapped during pneumatic grease pump lubrication with
CATEGORY
43
44 45 46 47 48 49
B
B C B A A B
Co gas line jamming of burner of ladle filling compound Lack of welding provision at pit side area
IDENTIFIED PROBLEMS
Scrap car positioning problem at 0 meter
Failure of Nitrogen splashing control valve Huge skull and slag accumulation on lance body Lance centering problem Damage of hand railing of online jam cutting platform Huge slag accumulation at dome area of Lance Insufficient stand for keeping ready lance
CATEGORY
50
51 52 53 54 55 56
B
A A B A B C
IDENTIFIED PROBLEMS
Frequent bearing failure of wheel pedestal in steel ladle transfer car and slag pot transfer car
Huge slag accumulation on SPTC and SLTC body Unavailability of gear box component causes difficulty Transfer car body crack. Lack of approach while tightening coupling bolts in transfer cars Uncontrollable rolling of SLTC and SPTC at sample testing zone and tapping zone Difficulty to position at valve station during hose changing
CATEGORY
57
58 59 60 61 62 63
C
B B A A B C
IDENTIFIED PROBLEMS
Difficulty in lance skull disposal at 26 meter level Torquing technique of wheel pedestal is very difficult and laborious
CATEGORY C B
66
67 68 69 70
A
A B A B
IDENTIFIED PROBLEMS
Coupling bolts of SPTC and SLTC getting frequently loose
Slag Pot top stand getting deformed very often Lance calibration platform getting damaged in regular interval Frequent damage of ultra bush in SPTC and SLTC Bearing end cover of transfer cars coming out frequently Collar deformation of wheel of SPTC and SLTC Cable arm frequently damaged in transfer cars.
CATEGORY A/K B A A A B A
IDENTIFIED PROBLEMS
Cabin window too high for operators in pulpit of transfer cars
Transfer car coupler damaged Difficulty in fixing EUBA in BMS top end at 34 meter level Vibro feeder canvas damaged in regular intervals Transfer car ladle online purging hose damaged frequently Frequent leakage from intermediate bunkers Slow discharge from vibro feeders
CATEGORY C A B A B B A
IDENTIFIED PROBLEMS
Inspection door of transfer car getting frequently deformed
Conveyor belt getting damaged frequently Ferro Alloy weigh hopper load cell damaged Damage of gunning mass container gate causes delay Frequent leakage through gunning machine pad. Bearing damage of BMS EUBA drive Frequent failure of BMS pneumatic cylinder
CATEGORY A/K B B A A A A
IDENTIFIED PROBLEMS
Ferro Alloy conveyor belt frequently getting off centered
Damage of gunning discharge hose Spillage and leakages through Fe-Alloy vibro feeder Difficulty in pouring oil in Gear Box of Transfer cars Gunning mass hose crushed under heavy vehicles Ferro Alloy vibro feeder core misalignment. Gunning mass getting solidified in short delivery pipe.
CATEGORY A A B A A A A
IDENTIFIED PROBLEMS
Frequent damage of rollers in ferro alloy conveyor belts. Filter Regulator malfunctioning. Lubricator system of BMS
CATEGORY
99
100 101 102 103 104 105
B
A A B B B A
Frequent leakage through Ferro Alloy additive chute. Failure of Centralized Grease Lubrication system in BMS. Slag deposition at the mouth of ferro alloy additive chute. BMS tray insider liner damage. 10 ton weigh hopper bracket fixing bolts damaged regularly.
IDENTIFIED PROBLEMS
Water valve of gunning machine getting frequently damaged. Gunning mass discharge short pipe damaged frequently.
CATEGORY A A/K A
CATEGORISATION OF PROBLEMS
60 50 40 30 20 10 0 A B C A/K Number of problems in each category
49
41
13
ENVIRONMENT (C)
29
IDENTIFIED PROBLEMS
Metal spillage on umbrella skirt and Heat shield during oxygen blowing Delay during tap hole clearing affecting productivity Huge delay during Converter campaigning
1
2 3 4 5 6 7
Dog House door getting frequently deformed and getting jammed Frequent failure of Resilience coupling Tilting drive of Converter
Difficulty in checking oil level through glass indicator in Planetary and Bull Gear Box Bottom screw of Converter getting frequently damaged
SL. No.
IDENTIFIED PROBLEMS
Frequent damage of converter sample taking pipe
Failure of pneumatic emergency lifting limit switch of lance
8
9 10 11 12 13 14
Sample carrier getting stuck up frequently inside pneumatic line Sample carrier outer surface getting deformed Sample carrier deformed. pneumatic line door getting
SRD swiveling cylinder pin damage at regular interval OLP hose getting stuck up in OLP drum during changing.
SL. No.
IDENTIFIED PROBLEMS
Failure of Nitrogen splashing control valve
Huge skull and slag accumulation on lance body Damage of hand railing of online jam cutting platform Transfer car body crack. Lack of approach while tightening coupling bolts in transfer cars
15
17 17 18 19 20 21
Lance calibration platform getting damaged in regular interval Frequent damage of ultra bush in SPTC and SLTC
SL. No. 22 23 24 25 26 27 28
IDENTIFIED PROBLEMS
Bearing end cover of transfer cars coming out frequently
Cable arm frequently damaged in transfer cars. Transfer car coupler damaged Vibro feeder canvas damaged in regular intervals Slow discharge from vibro feeders
Damage of gunning mass container gate causes delay Frequent leakage through gunning machine pad.
IDENTIFIED PROBLEMS
Bearing damage of BMS EUBA drive Frequent failure of BMS pneumatic cylinder
Ferro Alloy conveyor belt frequently getting off centered Damage of gunning discharge hose Difficulty in pouring oil in Gear Box of Transfer cars Gunning mass hose crushed under heavy vehicles Ferro Alloy vibro feeder core misalignment.
IDENTIFIED PROBLEMS
Gunning mass getting solidified in short delivery pipe. Filter Regulator malfunctioning. Lubricator system of BMS
41
42
IDENTIFIED PROBLEMS
FRD roller getting damaged very often. Input coupling bolts of telfer getting frequently loose
Difficulty in pouring oil in Gear Box of Transfer cars Gunning mass hose crushed under heavy vehicles Ferro Alloy vibro feeder core misalignment.
48
49
Gunning mass getting solidified in short delivery pipe. Huge accumulation of gunning mass in gunning machine parking area.
Huge delay during Converter campaigning SRD swiveling cylinder pin damage at regular interval Failure of Nitrogen splashing control valve
TOTAL
595
PARETO TABLE
Problem Code
A D
PROBLEM
Huge delay during Converter campaign Lance calibration platform getting damaged in regular interval
DELAY
854 248
% OF TOTAL
50.26 14.6
CUM. %
50.26 64.86
235
13.83
78.69
108
6.36
85.05
Vibro feeder canvas damaged in regular intervals SRD swiveling cylinder pin damage at regular interval Bearing damage of BMS EUBA drive Failure of Nitrogen splashing control valve
100
5.89
90.94
95
5.59
96.59
35
2.06
98.59
24
1.41
100
TOTAL
1699
100
100
PARETO CHART
1700 1275 Delay Hours 50 850 Cumulative % 100 75
425
0 PROBLEM CODE A D F H E B G C
25
Sl. No.
1 2 3 4 5 6 7 8 9 10
ACTIVITIES
Definition of Problem Analysis of the Problem Finding out Causes Root Cause Analysis Data Analysis Development of Solution Foreseeing probable resistances Trial Implementation & check performances Regular Implementation Follow up & Review
2 2 1 1 2 2 1 7 3
Continuous
41
BOF CONVERTERS
43
BOF CONVERTER
44
PROBLEM DEFINITION
Now the process of steel making basically involves three steps-first Is charging of hot metal ,scrap, ferro alloy and lime, the second step is blowing oxygen into the converter and lastly taking out the liquid steel from the converter into steel ladle. The converter vessel is symmetrical types with detachable bottom. In the centre section of the vessel the tap hole nozzle is arranged on the tapping side for the liquid steel tapping.
PROBLEM DEFINITION
The
working volume of converter vessel with refractory's is 114 cu. m. The converter vessel is fastened in the trunion by means of tendon. Converter can rotate 360 deg. With the help of spur gear . Inside the converter i.e. furnace vessel refractory lining is basic in nature so it is called basic oxygen furnace as oxygen blow is conducted inside the furnace to make the steel ready with required quality.
PROBLEM DEFINITION
Inside
the converter vessel refractory linings with bricks are basic in nature. This lining needs change after average 4000 heats or according to the condition of converter lining. Converter vessel relining activities and other major activities such as vessel shell repair, lip ring changing, tap hole changing, tendon tensioning etc. commonly known as campaign repair.
REFRACTORY LINING
PROBLEM DEFINITION
FOR THE CAMPAIGN REPAIR ACTIVITY THE PRIME IMPORTANT EQUIPMENT IS THE FURNACE RELINING DEVICE(FRD), THE BOTTOM REPLACEMENT DEVICE(BRD), THE LINING BREAKING MACHINE(LBM)
LBM
PROBLEM DEFINITION
To
perform relining activities the major equipments are bottom replacements device (BRD) and furnace relining device (FRD). With the help of BRD detachable bottom can be removed and with the help of FRD all the relining activities in the converter vessel are done.
PROBLEM DEFINITION
After
LBM
completion of bottom removal de bricking inside the converter is done by LBM machine .After de bricking the converter shell is inspected by operation personnel and required rectification is done by mechanical. After rectification of shell plate new tap hole fixing job is done by the help of BRD machine. After tap hole fixing , FRD machine is taken from parking area to the bottom of converter for remaining task of campaign repair.FRD is prime important machine of campaign repair as almost more than half of the repair job is performed by the FRD itself.
START Take Shutdown of Converter Cooling of Converter shell Converter Bottom removal
YES
POSITION O.K.
NO
Relining work by using FRD Removal of F.R.D Bottom fixing with B.R.D. Handed over to Operation
END
operation and refractory log book, we have found that cumulative delay in the 3 years from 2009- 2011 has been 854 hours.
Not
only the production delay there has been 9 accidents including 11 11 fatal case .
SETTING OBJECTIVES
54
Objective Policy
What?
How?
Methodology Policy
Our objective is to reduce the delay time at the most, reduction of consumption of cage telescopic pipe, rollers , hoist rope and accident at the lowest limit .
Our goal is to reduce the delay time by at least 70% and reduction of consumption of cage telescopic pipe, rollers and hoist rope at least 70% and zero accident within 15 November 2012.
WHO ?
During Relining
WHERE ?
WHO ?
WHEN ?
WHERE ?
WHAT ?
WHO ?
WHO ?
Spillage of metal
Bottom stuck up
Due to non nitrogen splashing before starting the furnace
Due to centering problem of locking eye bolt
Welding problem
Insufficient machine Non availability of overhead crane
Welding failure
Lack of skill of welder
62
CAUSES
DELAY IN CONVERTER RELINING DELAY IN BOTTOM REMOVAL/ FIXING DELAY IN SHELL PLATE REPAIR DELAY IN TAP HOLE PLATE FIXING DELAY IN FINAL SYSTEM CHECKING
2009
165 hrs 20 hrs 16 hrs 4 hrs 6hrs
2010
126 hrs 09 hrs 12hrs 6 hrs 7hrs
2011
170 hrs 12 hrs 36 hrs 5 hrs 6 hrs
Brick packing material getting inserted into the rope drum Why
Mismatch of track of trolley and working platform Why Uneven tension in ropes of FRD cage Why Packing material getting inserted between ropes of FRD rope drum Why
OF
Mismatch of track of trolley and working platform Why Uneven tension in ropes of FRD cage Why Shearing of cage holding guide roller Why
Why Why
FRD DERAILMENT
Deformation of track line and having single collar in FRD wheel Why Presence of skull and slug on FRD track Why
Why
ROOT CAUSES
FRD ROPE JUMBLE AND DEFOMATION OF FRD GUIDE ROLLER
DERAILMENT OF FRD
72
DATA ANALYSIS
74
2009
3.8 hrs
2010
2.7 hrs
2011
2.9 hrs 66.8 hrs 42.8 hrs 3.6 hrs 19.2 hrs
TOTAL
(HOURS)
83.2 hrs 77.5 hrs 52.1 hrs 43.9 hrs 3.3 hrs 2.7 hrs 16.1 hrs 29.6 hrs
F. Delay due to power failure G. Delay due to FRD fork lift platform dis balancing
H. Final system checking I .Delay during lowering the FRD platform J. Delay due to FRD balancing problem
11.6 21.2
9 23.7 11.2
TOTAL
178.8 175.3
156.6 526.9
G E B F J D A
C H
I TOTAL
138.8 9
23.7 526.9
26.34 1.7
4.49
CODE B C E I
G F
J D A H
21.2 11.6
11.2 9.6 9.4 9
4 2.2
2.1 1.8 1.7 1.7
90.31 92.51
94.61 96.41 98.13 100
PARETO DIAGRAM
500
100 75 50 25 0
400
300 200 100 0 CAUSES B C E I G F J D A H
ROOT CAUSE
FRD ROPE JUMBLE & GUIDE ROLLER DEFORMATION OF FRD CAGE
79
DEVELOPING SOLUTIONS
80
BRAINSTORMING
DEVELOPING SOLUTION
While developing solution first proposal to check the cage alignment every hour
Evaluation
81
DEVELOPING SOLUTION
The second proposal was that proper track level should be maintained & cage guide channel & telescopic pipe to be chamfered .
2nd Proposal
82
Evaluation
DEVELOPING SOLUTION
Providing a air blower in front of the cage drum to drive out the packing material
Evaluation There is no scope of providing a blower due to scarcity of space on FRD platform.
85
DEVELOPING SOLUTION
Evaluation Providing cover fabrication on rope drum. 4th Proposal This will prevent the packing material from getting entangle with the rope drum. Remarks
86
DEVELOPING SOLUTION
Evaluation
Replacement of hard roller with soft roller.
5th Proposal
Remarks
89
DEVELOPING SOLUTION
Providing guide collar at all the four corners beside FRD wheel .
6thProposal
Evaluation
Remarks
92
TASK
Approval to obtain for implementing solution Measurement & Drawing Discussion & check for material availability Approval for procurement Procurement of required materials Fabrication of guide rollers Arrangements to be made before erection Machining of Telescopic pipe Erection of Guard net on rope drum Fitting of new guide rollers Checking Corrective Action to be taken
Responsibility
SSR KKG SK RP RSK
Time Frame
Actual time taken Same Same Same Same Same Same Same Same Same Same Same Same
03.09.12 04.9.12 05.05.12 06.05.12 07.5.12 8.9.12 11.9.12 13.09.12 14.09.12 15.09.12 16.0912 17.9.12 23.9.12 24.9.12 26.9.12
13
14
Checking
Data Collection to sustain the process
27.9.12 30.9.12
01.10.12 cont.
Same
Same
SSR: Subhasish Singha Roy KKG: Kallol Kumar ghosh SK: Sudip Kumar Khan RP: Rajesh Prasad RSK: Rama Shankar Kumar
Primary Responsibility Secondary Responsibility
In case of Emergency
95
QC Achievers
Step 8
Brainstorming
Resistance # 2
To reduce the vibration while moving the cage up& down only chamfering of cylinder was not sufficient Management had concern about longevity of the hard rollers
Chamfering of cage guide channel also done and stud length increased to make it full proof
Resistance # 3
Periodic changing of rollers one by one proved that our decision was correct It was a counseling factor to explain them that it will not harm any established design
Resistance # 4
Operation had objection of welding any jack pad to eradicate the leveling problem
Resistance # 5
Resistance # 6
97 QC Achievers
Step 9
TRIAL IMPLEMENTATION
Incorporating the chamfering job on the telescopic tubes and cage guide channel within 19 Sep 12 Replace all the hard rollers with the soft rollers within19 Sep 12 Installing a covering net over the rope drum within 19 Sep12
100
CHECKING PERFORMANCES
No of cage out before & after modification
6 5 4 3 2 1 0
101
CHECKING PERFORMANCES
T i m e i n m i n s
400 350
300
250
200
330 360 270 180 210 360
100
210
240
0 Campaign time Top Cone Changing Bottom Cone Changing Barrel changing Hood Changing Average time taken for maintenance activities - before and after modification Time taken after modification (in minutes)
102
REGULAR IMPLEMENTATION
103
COMPARATIVE GRAPHS
6
Before QC
5
After QC
Period of implementation
4
0 0 0 0 0 0 0 0 SEP 2011 OCT NOV 2011 DEC 2011JAN 2011 2012 FEB MAR 2012APR 2012 MAY 2012JUN 2012JUL 2012AUG 2012 SEP 20122012 OCT NOV 2012DEC 2012JAN 20122013 FEB MAR 2013 2013
104
(000 T)
2034 1914
1966
1888
1961
2008-09
2009-10
2010-11
2011-12
2012-13
TANGIBLE BENEFIT
Increase in number of Heats because of this modification: 30 Heats Average Heat Size: 118 ton liquid steel 30 Heats equivalent to (30 X 118) = 3540 ton of liquid steel Quantity of saleable steel produced @ 90% yield = 3186 ton
year
106
Safe working atmosphere Maintenance work simplified Fatigue reduced Better housekeeping Self Satisfaction
STANDARDIZATION
110
converter
NO. #1 #2 #3
May 12
Sl. No. 1 2 3 4 5 6 7 8 9 10 ACTIVITIES Definition of Problem Analysis of the Problem Finding out Causes Root Cause Analysis Data Analysis Development of Solution Foreseeing probable resistances Trial Implementation & check performances Regular Implementation Follow up & Review
Jun 12
Jul 12
Aug 12
Sep 12
Oct 12
Nov 12
Dec 12
Jan 13
Number of Meetings
2 2 1 1 2 2 1 7 3
Continuous
Planned
Actual
112
114