Modification done & proposed 13.07.17 FAD.ppt

presentation on modification

1. MAJOR MODIFICATION DONE
IN QTR -1 & MODIFICATION
PROPOSED IN FY 17-18
FAD – Maint (CMO)

2. Automation of GCP-ABAutomation of GCP-ABAutomation of GCP-ABAutomation of GCP-AB
Better control & monitoring of GCP system as well as easy analysis
of fault finding through trend graph & alarm system in SCADA .

3. Installed VVVFD in GCP-C ID fan Installed VVVFD in GCP-C ID fan
Previously Gcp-C I.D fan is running at
full speed with 50% inlet damper
throttle leading to impact pressure on
impeller .
After installation of VVVFD I.D fan
flue gas suction is control through
speed variation of motor through
VVVFD causing huge energy(Kwh)
saving of about 43 MWh/month as
well as no puffing in furnace floor.

4. MonMonorail fitted for Divertor Switch replacement orail fitted for Divertor Switch replacement
of Furnace Transformer. of Furnace Transformer.
Previously Divertor switch
replacement of Furnace Transformer
during maintenance was done through
chain block hanging in wire rope fitted
over the transformer.Chain block has
to be moved across the wire rope by
helpers climbing through ladder for
shifting of divertor switch .It was
unsafe act which can leads to damage
of equipment & causes human injury.
Presently shifting of Divertor switch
through monorail fitted above the
transformer.Eliminate Unsafe Act,
Damage of Equipment,Reduces
replacement time & manpower.
Divertor
Switch
Monorail

5. Level switch installation for low oil level detection in Level switch installation for low oil level detection in
Hydraulic power packs of all furnacesHydraulic power packs of all furnaces
To detect low oil level in HPP tank due to any leakages in HPP
system & provide alarm & tripping of HPP pump to prevent oil loss.
Modification initiated against problem that occurred in HPP-E
where there was a loss of about 50 ltrs oil due to hose pipe damage.

6. Change Over of Vertical pump-1&2 through Change Over of Vertical pump-1&2 through
AutomationAutomation
Previosly changeover of Vertical Previosly changeover of Vertical
pump-1&2 due to tripping or low pump-1&2 due to tripping or low
water pressure is done water pressure is done
manually .It takes about 10 manually .It takes about 10
minutes to develop the water minutes to develop the water
pressure leading to switching off pressure leading to switching off
of Furnaces.of Furnaces.
Presently automatic change over Presently automatic change over
of vertical pump within 20sec of vertical pump within 20sec
through PLC (inhouse through PLC (inhouse
development of logic)due to development of logic)due to
tripping of other in service tripping of other in service
eliminates switching off of eliminates switching off of
Furnaces.Furnaces.

7. Level transmitter installation in all furnaces for Level transmitter installation in all furnaces for
measuring Electrode holder positionmeasuring Electrode holder position
Previous measurement system
(Encometer ) shows erratic value and
has high maintenance( string wear &
tear ).Tampering of reading was
possible.
Replacement of previous measurement
system with Level transmitter enables
hassle free reading and involves low
maintenance (Laser rays).Thus
providing smooth operation &
maintenance .
Tampering of reading is not possible.
Level Transmitter

8. Vibration/Temperature sensor installed in ID fan Vibration/Temperature sensor installed in ID fan
plumber block to monitor vibration & temperatureplumber block to monitor vibration & temperature
Online monitoring of &temperature vibration in all GCP ID fans
DE/NDE plumber blocks as well as providing alarms in centralized
control room .
DE NDE

9. New UPS room for Existing UPS System with New UPS room for Existing UPS System with
automatic change over facilityautomatic change over facility
Previously UPS was kept at Previously UPS was kept at
GCP-AB MCC room. GCP-AB MCC room.
Malfunctioning of equipment Malfunctioning of equipment
occur due to heat.occur due to heat.
Presently it is kept in closed Presently it is kept in closed
dedicated room with automatic dedicated room with automatic
changeover of UPS reduces changeover of UPS reduces
equipment breakdown .equipment breakdown .

10. Optimisation of Existing Shift EngineersOptimisation of Existing Shift Engineers
Providing Responsibility Electrical Shift Responsibility to Providing Responsibility Electrical Shift Responsibility to
shift Electrician .shift Electrician .
1.Optimisation of Existing Shift Engineers.1.Optimisation of Existing Shift Engineers.
2.Improves Confidence & Resposibility in Shift Electician.2.Improves Confidence & Resposibility in Shift Electician.

11. Modification proposed in FY 17-18Modification proposed in FY 17-18
1) Installation of On line oil filtration in F/C- D transformer
OLTC.
Benefits:-
1.Increase Tap Changer Life Consistent High Dilectric Strength of oil.
2.Extend the oil life Contact wear become reduced.
3.Maintenance & Inspection become reduced.
4.Cost Saving due to reduced & maintenance extended oil life.
2) Each Tap over current protection to be installed for F/C-E .
Benefits :-
1.Protect Transformer Tap winding from over current.
2.Measures accurate secondary current.

12. Modification proposed in FY17-18Modification proposed in FY17-18
3) Centralized control room with full automated operation of all
furnaces & GCP .
Benefits:-
1.Centralized control.
2.Optimised Manpower.
3.Trouble Shooting is faster.
4.Easy Problem Analysis.
4) Copper flexible cable to be fitted in all ID Fans and Vertical pumps .
Benefits:-
1.Save maintenance time during motor/pump replacement or during
alignment.
2.Reduces damage of motor terminals due to stress by armoured cable.

13. Modification proposed in FY17-18Modification proposed in FY17-18
5)Installation of water level sensor in granulation tank & automatic
switching of valve to maintain water level.
Benefits:-
1.Elimintes manpower dependency.
2.Maintain required water level for proper granulation also reduces wastage
of water due to overflow.
6) Online Electrode slipping measurement of F/C-B.
Benefits:-
1.Correct measurement.
2.Online measurement display from control room.
3. Data can be recorded in PLC, which help in analysis.

14. Modification proposed in FY17-18Modification proposed in FY17-18
7) Replacement of Existing DSL system with Energy chain
System in LT of Production Cranes.
Benefits:-
1.Minimizing Breakdowns.
2.Overcoming unsafe operating condition.
3.Ease of maintenance.
4.Easy fault finding.
8)Installation of VVVFD in new 10MT EOT grab crane at RMHS .
Benefits:-
1.Better control & Smooth operation.
2.Energy saving.
3.Low maintenance cost.

15. Modification proposed in FY17-18Modification proposed in FY17-18
9) PCD and Electrode Column Assembly Modification.
Benefits:-
1.Consistent furnace operation.
2.Reduction in specific energy.
10) Replacement of cast aluminum blade with FRP blade of axial
fan (07 nos ) of FD Cooler, GCP-AB & C
Benefits:-
1.Energy Saving. Proposed energy saving is 5.9MWh/Month/axial fan.

16.  Thank You