GB Six Sigma Project Engineering R01.pptx

GB Six Sigma for project engineering

1. GB Project Project Title: Enhance condensate/ Heat recovery Project Sponsor – Mr. Kushal Kumar rana Project Leader – Mr. Gopal Singla Project Manager– Mr. Ajay Pal Singh Project Manager– Mr. Nikhil Jalan

2. GB Project Methodology Step 4: Finalize Project Y, Performance Standards for Y Step 5: Validate Measurement System for Y Step 6: Measure Current Performance and Gap Step 7: List All Probable X’s Step 8: Identify Critical X’s Step 9: Verify sufficiency of Critical X’s for the project Step 10: Generate and Evaluate Alternative Solutions Step 11: Select and Optimize best solution. Step 12: Pilot, Implement and Validate the solution Step 13: Implement Control System for Critical X’s Step 14: Document Solution and Benefits Step 15: Transfer to Process Owner, Project Closure Step 1: Generate Project Ideas Step 2: Select Project Step 3: Finalize Project Charter and High Level Map D M A I C

3. Why this project was selected? Voice of Business: C ondensate recovery should be optimum as per the process to, improve the energy efficiency, reduce the waste water treatment cost, reduce the fresh water intake, meet environment regulations and to take one step further on the path of sustainability . V oice of Customer: VOC indicates a need for a condensate recovery system that's efficient, reliable, easy to maintain, environmentally friendly, cost-effective, technically viable, user-friendly, and safe. C TQ: The primary CTQ factor would be the percentage condensate recovery of direct/indirect condensate . This includes maximizing the amount of condensate captured and returned for reuse, minimizing losses, and optimizing the overall condensate/ Heat recovery process.

4. Why was this project selected? Data-Driven Decision Making: Six Sigma relies on data and statistical analysis to drive decision-making. Condensate recovery projects involve quantifiable metrics such as recovery rates, energy usage, and resource utilization, making them suitable for rigorous data analysis and improvement. Process Improvement Focus: Six Sigma emphasizes process improvement and optimization. Enhancing condensate recovery involves evaluating and enhancing an existing process, aligning with the DMAIC (Define, Measure, Analyze, Improve, Control) framework used in Six Sigma. Problem Solving and Root Cause Analysis: Condensate recovery projects often involve identifying inefficiencies or issues within the process. Six Sigma's tools, like root cause analysis and process mapping, help pinpoint the root causes of inefficiencies for targeted improvements. Customer-Centric Approach: Six Sigma aims to meet customer requirements and expectations. Improving condensate recovery aligns with sustainability goals, reduces environmental impact, and contributes to resource conservation, which are increasingly important to customers and stakeholders. Performance Metrics and Targets: Six Sigma projects require measurable goals and targets. Condensate recovery projects involve setting specific targets for increased recovery rates, reduced resource consumption, or improved efficiency—elements that align well with Six Sigma's focus on setting measurable objectives. Continuous Improvement Culture: Six Sigma fosters a culture of continuous improvement. Enhancing condensate recovery is an ongoing process that can be refined and optimized continuously, aligning perfectly with the continuous improvement ethos of Six Sigma. Quantifiable Cost Savings and ROI: Improving condensate recovery typically results in cost savings through reduced resource consumption and improved efficiency. Six Sigma projects often require a clear demonstration of potential cost savings and return on investment (ROI), making condensate recovery enhancement an attractive project within this framework.

5. Scope Justification Resource Optimization: Enhancement in condensate recovery will optimize the use of the valuable water resources. This will also resource utilization, reduce wastage, and improve overall efficiency of the system. Cost Reduction and Savings: condensate recovery enhancement directly impacts the bottom line by reducing water and energy consumption, minimizing maintenance costs, enhancing operational efficiency, and ensuring compliance. This leads to substantial cost reductions and savings for the business in the long run. Environmental Sustainability: Emphasize the project's alignment with sustainability goals. Justify the scope by showing how better condensate recovery reduces water usage, energy consumption, and environmental impact, aligning with regulatory requirements and corporate sustainability objectives. Operational Efficiency and Reliability: Discuss how enhancing condensate recovery improves overall plant operations. Justify the scope by highlighting increased reliability, reduced downtime, and improved equipment efficiency. Compliance and Risk Mitigation: As on today " Zero discharge" of waste water is a stringent environmental goal and regulatory requirement. This project shall ensure the optimum utilization of the condensate, which will lead to reduction in waste water generation. Customer Satisfaction and Quality Improvement: Improving condensate recovery directly addresses water and energy conservation, waste reduction, and environmental stewardship, making it a fundamental aspect of sustainable industrial practices. It aligns with broader sustainability goals by reducing environmental impact, conserving resources, and operating more efficiently. Strategic Alignment: This project will contribute in the direction to achieve the company’s strategic goal reducing operational cost, improving efficiency, or achieving a competitive advantage.

6. Project Charter Business Case Opportunity Statement Steam condensate is getting wasted directly or its heat is getting wasted due to various reasons. This lost heat and condensate quantity can be recovered and utilized, which will results in approximate monetary savings of 1 Cr. per annum . Condensate recovery enhancement will reduce the fresh water consumption. Also at same time, the waste water will reduce, this will lead to reduce the load on ETP, cooling towers and will lead to fuel savings in boiler. Goal Statement Project Scope To enhance the condensate recovery from the 73% (existing level) to 80% (Target level). Currently level – 71.8% T arget Level – 78% Condensate (Pure + Mix) generating from the all Plants & Steam main header is under this project scope. Project Team Project Timeline Mr. Kushal Kumar Rana – Project Sponsor Mr. Gopal Singla – Project Lead Mr. Ajay Pal Singh – Project Manager Mr. Nikhil Jalan – Project Manager Shiv Kumar, Suresh Singh, Gursharan Singh, Mandeep Kamboj – Team Member M D A I C Problem Date: 25/02/24 Date: 17/03/24 Date: 19/05/24 Date: 20/06/24 Date: 21/01/24

7. Supplier INPUTS Process Output Customer Fuel Suppliers HRM Husk Coal Vapsi Manpower Receiving and Storage of Fuel Storage Yield Receiving Yield % Boilers Fuel Vendors DM Plant Process Owner/ Plants PSPCL/ Turbine Generation Equipment Manufactures Natural Resources FUEL DM Water Condensate Auxiliary Power Equipment Efficiency Metering System SOP Steam Generation Quality/Quantity of Steam Power Fly Ash Boiler operations team Turbines Boiler OEM Insulation vendors/ Contractors Pipeline suppliers Pipe network designer Steam Insulation Pipeline design Pipe Rack Steam line accessories Steam distribution Quality of Steam at user end Quantity of Steam at user end Condensate of main steam headers Heat loss through insulation Process users DM Plant Environment SIPOC

8. SIPOC Supplier INPUTS Process Output Customer Equipment OEM Boiler Process media Heat Transfer Equipments Quality/Quantity of Steam at user end Process where heat is required Heat transfer/ condensate generation Quality of Condensate Quantity of Condensate Heated process media Flash steam DM Plant ETP Utility (CT) Environment Process Plants Equipment OEM Pipeline/ structure suppliers Quality of Condensate Quantity of Condensate Condensate collection network Condensate transfer from generation sources to DM Plant Heat Exchanger Condensate collection Quantity of Direct/ Indirect Condensate Heat Recovery from indirect condensate Reuse of direct condensate in boiler Reuse of indirect condensate after heat recovery in DM Plant as RO water DM Plant Boiler Process Plants DM Plant OEM DM Chemicals Suppliers Indirect condensate DM Plant DM Regeneration Chemicals Condensate treatment Quantity/ Quality DM water Effluent generation Boiler ETP

9. As-Is Process Map

10. To Be Process Map

11. CTQ Characteristics CTQ Performance Standards CTQ Measure Data Type Operational Definition CTQ Characteristics Target USL LSL Steam Condensate recovery % Continuous Steam is generated at different pressures of 87/64/10 kg/cm2 and temperature range of 500 deg c to 180 deg c. 87 & 64 kg/cm2 steam is used to drive the turbines and exhaust steam is being used for the various process heating purposes at a pressure of mainly 4.5 kg/cm2 and temp of 180 deg c. In the process of steam utilization, two types of condensate is generated i.e., Pure Condensate & Mix Condensate. Pure condensate is sent back to boiler for reuse and indirect condensate is either used as RO water after heat recovery or is sent to cooling towers/ etp as per its contamination level. 78% 87% 71.8%

12. Past Performance Trends

13. Past Performance Trends

14. Past Performance Trends

15. Past Performance Trends Test Results for I Chart of Steam Gen. (MT) TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 8, 23, 27, 39, 40, 41, 84, 85, 87, 88, 89, 97, 116, 128, 133, 134, 135, 136, 137, 138, 139, 140, 142, 156, 158, 160, 162, 168, 169, 170, 171, 178, 179, 180, 181, 183, 184, 185, 186, 187, 203, 204, 205, 206, 207, 208, 209, 213, 214, 215, 216, 217, 218, 235, 236, 237, 242, 245, 246, 247, 248, 249, 250, 253, 254, 255, 256, 257, 258, 259, 260, 264, 269, 270, 273, 274, 275 Test Results for MR Chart of Steam Gen. (MT) TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 23, 24, 27, 87, 89, 90, 97, 98, 116, 117, 124, 242 Test Results for I Chart of % Total Cond. TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 23, 27, 39, 40, 41, 42, 87, 88, 89, 92, 94, 95, 98, 116, 117, 141, 159, 198, 205, 206, 214, 234, 255, 256, 257, 258, 259, 260, 261, 263, 264, 265, 266 Test Results for MR Chart of % Total Cond. TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 23, 27, 28, 39, 87, 89, 90, 96, 98, 99, 100, 101, 116, 141

16. Past Performance Trends Test Results for I Chart of % Direct Cond. TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 8, 23, 24, 27, 28, 39, 87, 88, 89, 97, 116, 117, 165, 182, 183, 187, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 209, 210, 211, 212, 214, 215, 216, 217, 242, 256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268 Test Results for MR Chart of % Direct Cond. TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 23, 24, 39, 86, 87, 90, 97, 98, 116, 117, 176, 242, 243 Test Results for I Chart of % Indirect Cond. TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 23, 28, 41, 42, 87, 89, 94, 95, 97, 98, 100, 116, 141, 172, 239, 242, 247, 250, 252 Test Results for MR Chart of % Indirect Cond. TEST 1. One point more than 3.00 standard deviations from center line. Test Failed at points: 27, 28, 29, 87, 88, 96, 97, 99, 100, 101, 116, 117, 142

17. Checklist for Condensate & Heat Recovery

18. Baseline Performance Flow Meter for Condensate Measurement Area Status Logical Validation IBB Direct Condensate Line Installed Pending Acetic Anhydride direct Condensate Line Installed Pending Main Block direct condensate line Installed Pending Indirect condensate line Installed Pending

19. Improvement Areas Identified: Sr. No. Condensate loss points Plant Issue 1 IBB Recovery condensate IBB Recovery Direct condensate is not recovered 2 Main Steam Line condensate All main Steam headers Main steam header condensate directly drained locally into the ground 3 Hot Water Tank ALL Plants Direct steam is used to hot the water 4 Reboiler condensate of all plants ALL Direct Condensate is mixing with indirect condensate 5 FBD, Reboiler condensate of Unit-07 Unit-07 Direct condensate is going into indirect condensate 6 FBD condensate IBU-01 & IBU-02, Unit-04, Unit-05 Pure condensate is going into mix condensate, which is further going to the cooling tower instead of recovery 7 MCA/IPCA jacket lines condensate MCA/IPCA Pure condensate is not recovered 8 IP-03 utility (VAM 120 TR Chilling) condensate IP-03 Utility Pure condensate is not recovered 9 IBU-01, IBU-02, IP-01 direct condensate IBU-01, IBU-02, IP-01 Pure condensate is going to indirect condensate 10 Hot DM is sent to the direct consumer's of DM Ethyl, IBU-02, Unit-05, 06, ARD, Hot DM water is sent to the process plant for direct consumption instead of Cold DM water.

20. Thank You