DELTA-FY22_Transmitter.xls

	B	C	D	E	F	G	H	Q	U	W	X
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2	Δ DELTA
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4	Title of Improvement:		Prevention of transmitter failure from heavy rainfall
5	Division	Haldia			Department	Operations
6	Rec No.	HLD/OPN/DELTA/FY22
7	Team Members	Debjit Ghosh			Debankar Das
8	Team Members	Rohit Gupta
9	Linkage to BSC / SDM	Power sale, Gross generation, DSM Gain, Water Management, Availability, PLF, Customer Management			Facilitator	Mr.Sujit Sengupta		Select	Methodology of Improvement	Trigger for Improvement	Improvement Category
10	EPM Process No:	07.04.01 07.04.02 07.04.03 07.17.05		Improvement Category	Productivity	Quality	Delivery (Cycle Time / Response Time)			Select	Select
11	Base level (with UoM)	7.5 MW		Project/Task Start date		11.07.2021			Select	Suggestion	Productivity
12	Target Level (with UoM)	0 MW loss		Project/ Task Finish date		13.07.2021			QC	CAPA	Quality
13	Trigger for Improvement	Suggestion	Brainstorming	Methodology of Improvement		Structured Problem Solving	Brainstorming		Structured Problem Solving	Customer / Stakeholder Feedback	Cost
14	Before (Illustration with sketch)			After (Illustration with sketch)					Structured Process Review	Regulatory	Delivery (Cycle Time / Response Time)
15									LASER	Stretched Targets (SDM)	Safety & Health
16										FMEA	Environment & Sustainability
17											Morale
18											Source of Learning
19										Select	Select
20										Site specific	Within Division
21										Replicable	Across Division
22	Benefits:										Across Tata Group
23	Tangible			Intangible							Across Industry
24	Considering the tripping of ID fan due to fluctuation of flue gas inlet pressure transmitter reading (2/3 logic for both high and low values) or the tripping of ID fan due to fluctuation of steam drum level transmitter reading (2/3 logic for both high and low values) there will be generation loss of 7.5 MW for each boiler due to eventual boiler tripping. Calculation- Loss of generation - Considering power generation from one HRSG boiler as 7.5 MW. For O&M purpose to take the boiler in service assuming the time to be approximately 30 minutes. Total loss= 7.50.5=3.75 MWh. Considering power sale rate to be Rs. 4 /kWh. So, loss in revenue for each occurence will be = Rs. 3.7541000 = Rs 15,000 In addition to this there will be steam loss. Also, considering DM water loss to be approximately 70 MT for each occurence and DM water cost as Rs. 65/ MT , Total loss = 6570= Rs. 4,550 Net loss per occurence= Rs. 19,550 Considering such occurences for 5 times in a year, net revenue loss= Rs. 19,550*5 = Rs. 97,750			Reliability Customer satisfaction Morale Process safety Effective utilization of man-power and saving man-hours							Best in class
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28											Quality Tools
29											Select
30											Flow Diagram
31	Description of Improvement : Trigger for impovement:During heavy rainfall on 1.07.2021, boilers 1-3 & 3-2 flue gas pressure transmitter readings at the inlet duct were fluctuating and which was normalized after the rainfall stopped. Boiler 1-3 PX-10302 value reached up to 100 mmwc and Boiler 3-2 PX-20201 value touched 60 mmwc during the rainfall. Due to water ingress (which is a failure mode for transmitters) or moisture ingress in the transmitters, there's a high chance of pressure transmitter failure. Moisture can quickly corrode the internal electrical connection which can lead to complete failure of transmitters. After Improvement: So, for process improvement and for protection of transmitters from such environmental concerns they're now wrapped with plastic covering for immediate protection.										Ishikawa Diagram
32											Pareto Analysis
33											Run Charts
35											Scatter Diagram
36	Tools Used	Brainstorming	Failure Mode & Effect Analysis (FMEA)	Select	Select	Select	Others (ply specify)				Matrix Diagram
37	Data Source	Past failure data analysis, RCA									Gantt Chart
38	Source of Learning (select an option and share some details)	Within Division		Learning Shared with (select an option and share some details)		Across Division	Across Division				Failure Mode & Effect Analysis (FMEA)
39		RCA after incident on 1.07.2021									Gantt Chart
40	If Replicable, suggest Business Unit / Division / Dept. where it can implemented	Any business location		Figures Audited by Name & Designation:		Mr. Sujit Sengupta (Head - Operation, Chemical)					Stratification
41	Contact person's name & phone number	Debjit Ghosh (Lead Engineer), 7585886805		Sponsor (Div Head) Name & Signature :		Mr. Ashish Bhat (Chief - Haldia Division)					Histogram
42											Brainstorming
43											5 W 1 H & Five Why?????
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