Pragathi Final QC

PRAGATHI Quality Circle
Welcomes you
28 January 2018 VIJAYANAGAR 1

Presents
Quality Circle
Reduction of Raw Water

Consumption in CDQPP

Steel Limited
VIJAYANAGAR WORKS BELLARY, KARNATAKA
Largest Steel maker in India in single location
JSW Steel is India’s leading steel producer and among the world’s most illustrious
steel makers .

28 January 2018 4
VIJAYANAGAR
STEEL

Team Leader:
Basagouda Patil
Members:
Facilitator: Jitendra Katre
Pradeep Chotia Saravanan
Sharnabasava
Project Theme : Reduction of Raw Water consumption in CDQPP

Q C Project : Implementation and Utilization of RO Water in CDQPP DM Plant
Theme Selected on : 01.01.2016
Project completed on: 30.05.2016
No. of Meeting : 20
Attendance : 92%
Periodicity of meeting: Every Monday

METHODOLOGY
Step 1: Identification of problems.
Step 2: Selection of problem.
Step 3: Defining the problem.
Step 4: Analysis of the problem.

Step 5: Cause and effect analysis.
Step 6: Root cause analysis.
Step 7: Data analysis.
Step 8: Development of solution.
Step 9: Foreseeing probable resistance.
Step 10: Trial implementation and check
performance.
Step 11: Regular implementation.
Step 12: Follow-up and review.
24
STEP 1
SL
DESCRIPTION CATEGORY
NO
1 Auxiliary Power consumption high C
2 Raw Water Consumption high A
3 Pipe line leakages in DM plant A
4 Cooling Tower Effectiveness/Efficiency less A
5 Cooling water Inlet temp High A
6 Lube Oil Temp High A
7 Formation of Algae around CT Basin A
8 Generator winding Temp High A
9 TG Bearing Temp High A
10 Condenser water box differential pressure high A
11 Abnormal Alarms in DCS due to module Problem A
12 TG Inlet Control Valve Hunting/Passing Problem A
13 Turbine RTD Failures A

STEP 1
SL
NO
14 Deterioration of Vaccuum in condenser A
15 Mechanical Seal Failure in CW Pumps A
16 Turbine Islanding Mode Problem C
17 Load hunting Problem B
18 Load throw off Problem C
19 Condenser water Box DP High A
20 DCS Signal/Panel Ear thing Problem A
21 Rotor Earth fault Problem C
22 Generator Transformer Oil leakage B
23 DCS Power Supply failure Problem A
24 ESV Oil Leakage Problem A
25 TG Inlet Steam CV jam Problem C
26 Specific Steam Consumption high B

STEP 1
SL
NO
27 Boiler Water Consumption High B
28 Turbine Inlet Steam abnormal Parameters B
29 SWBP Discharge Pressure high A
30 DAVR Power failure Problem A
31 Failure of Y adaptors in DCS Panels A
32 DM Plant Level gauges Indication Problem A
33 Less Availability of CDQ Boilers B
34 Boiler Tube Puncture Problem B
35 AOP/MOP Pump Discharge Pressure Problem A
36 Chiller Unit Compressor Tripping due to HP/LP A
37 I/H convertor Problem A
38 Trip Oil Pressure Drop Problem A
39 DC JOP Discharge Pressure Problem A

STEP 1
SL
NO
40 Dust accumulation on Generator rotor carbon brushes C
41 Unavailability of 2/3 Logic for Boiler Drum level Transmitters B
Non Availability of bulk tank-1 and 2 to AMT and acid dosing tank connection
42 A
piping
43 Fire Fighting System Unavailable A
44 There is no running amps indication of the drive in DCS A
45 EPB cover unavailability A
46 Compressor Tripping in Boilers B
47 Blower Trip in Boilers B
48 Boiler feed pump freq tripping due to DP Transmitters hardware Configuration B
49 Battery charger failure in DG AMF panel A
50 TSP dosing pump discharge line Problem A
51 Increase in Turbine Vibration A
52 NPIT transfer pump recirculation line frequent leakages A

STEP 1
SL
NO
53 Air washer fill packs arrangement problem B
54 CT fan auxiliary power consumption high C
55 Dewatering Motor manual start stop problem A
56 Chemical handling area floor tiles frequent breakdown B
57 DC EOP Starter penal field Under Voltage alarm signal not showing in DCS A
58 DC charger capacitor banks uncovered A
59 Increase in Boiler steam losses A
60 Drier A&B soft controller unavailable A
61 Automatic lighting ON/OFF provision with timer A
62 Reduction in CT Sump continuous blow down A
63 CDQ-3 Control valves passing problem A
64 Steam Traps Failures Problem A
65 5s implementation in stores A

STEP 2
Total Number of Problems Category A Category B Category C
65 45 13 7
TOTAL NO OF PROBLEMS
50 A - PROBLEMS WHICH CAN BE SOLVED BY OURSELF
B- PROBLEMS WHICH NEEDS HELP FROM OTHER DEPARTMENT

40
C- PROBLEMS WHICH NEEDS HELP FROM MANAGEMENT
30
20
10
0
Category A
Category B
Category C
14
1/28/2018 14
STEP 2 CLASSIFICATION OF ‘A’ CATEGORY PROBLEM
SL Problem Status
1 Raw Water Consumption high TO BE SOLVED
2 Pipe line leakages in DM plant TO BE SOLVED
3 Cooling Tower Effectiveness/Efficiency less SOLVED
4 Cooling water Inlet temp High SOLVED
5 Lube Oil Temp High SOLVED
6 Formation of Algae around CT Basin SOLVED
7 Generator winding Temp High SOLVED
8 TG Bearing Temp High SOLVED
9 Condenser water box differential pressure high SOLVED
10 Abnormal Alarms in DCS due to module Problem SOLVED
11 TG Inlet Control Valve Hunting Problem TO BE SOLVED
12 Turbine RTD Failures SOLVED
13 Deterioration of Vacuum in condenser SOLVED
14 Mechanical Seal Failure in CW Pumps SOLVED
15 Condenser water Box DP High SOLVED
16 DCS Signal/Panel Ear thing Problem SOLVED
SWBP Discharge Pressure high
17 SOLVED
15
SL Problem Status
18 DAVR Power failure Problem SOLVED
19 Failure of Y adaptors in DCS Panels SOLVED
20 DM Plant Level gauges Indication Problem SOLVED
21 AOP/MOP Pump Discharge Pressure Problem SOLVED
22 Freq Chillers Unit Compressor Tripping due to HP/LP SOLVED
23 I/H convertor Problem SOLVED
24 Trip Oil Pressure Drop Problem SOLVED
25 DC JOP Discharge Pressure Problem SOLVED
26 Non Availability of Bulk tank-1 and 2 to AMT and Acid Dosing tank connection piping SOLVED
27 Fire Fighting System Unavailable SOLVED
28 There is no running amps indication of the drive in DCS SOLVED
29 EPB cover unavailability SOLVED
30 Battery charger failure in DG AMF panel SOLVED
31 TSP dosing pump discharge line Problem SOLVED
32 Increase in Turbine Vibration SOLVED
33 NPIT transfer pump recirculation line frequent leakages SOLVED
Dewatering Motor manual start stop problem
34 SOLVED
16
SL Problem Status
35 DC EOP Starter penal field Under Voltage alarm signal not showing in DCS SOLVED
36 DC charger capacitor banks uncovered SOLVED
37 Increase in Boiler steam losses SOLVED
38 Drier A&B soft controller unavailable SOLVED
39 Automatic lighting ON/OFF provision with timer SOLVED
40 Reduction in CT Sump continuous blow down SOLVED
41 CDQ-3 Control valves passing problem SOLVED
42 Steam Traps Failures Problem TO BE SOLVED
43 5s implementation in stores TO BE SOLVED
ESV Oil Leakage Problem
44 SOLVED
45 DCS power supply failure problem SOLVED
Solved A Category Problems Unsolved A Category Problems
40 5
17
STEP 2
DATA GENERATION FOR RANKING MATRIX
1/28/2018
18
STEP 2
RANKING MATRIX FOR SELECTION OF “A”
CATEGORY PROBLEMS
AVERAGE OF ALL RANKING MATRIX(15) FOR HIGHLIGHTING A CRITICAL PROBLEM

SN Problems Cost Quality Environment Safety Total Priority
1 Pipe line leakages in DM plant 4 4 6 6 20 5
2 Steam Traps Failures 5 5 6 7 24 3
3 Raw Water Consumption high 9 9 7 9 34 1
4 5s implementation in stores 6 4 4 5 19 4
TG Inlet Control Valve Hunting Problem

5 7 6 7 5 26 2
RATING TO BE GIVEN OUT OF 10
19 1/28/2018
STEP 2
GANTT CHART FOR SCHEDULED ACTIVITIES
Q.C NAME : PRAGATHI DEPARTMENT : CDQ POWER PLANT MEMBERS
PROJECT NO: 1 FACILITATOR : Mr. PRADEEP CHOTIA TEAM LEADER:BASAGOUDA PATIL

JITENDRA
THEME: REDUCTION IN RAW WATER COMSUMPTION KATRE,SH
ARVANAN,
DATE OF BEGINNING:1 JANUARY 2016
OBJECTIVE: REDUCTION IN CHEMICAL CONSUMPTION : IMPROVEMENT IN RAW WATER CHEMISTRY SHARANB
ASAVA
MEETINGS
STEP ACTIVITIES REMARKS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 Identification of the problem
2 Selection of Problem
SCHEDULED PLAN Start Date
Definition of the Problem and
3 01
Objectives
JANUARY
4 Analysis of the problem 2016
5 Cause- Effect Analysis
6 Root Cause Analysis
7 Data Analysis of the Root Cause
8 Development of Solution
9 Foreseeing Probable Resistance End Date

30
Trial Implementation and Check APRILL
10
Performance 2016
11 Regular Implementations
12 Follow up / Review
20 1/28/2018
STEP 3
OVERVIEW OF CDQPP
1x76 MW CDQ POWER PLANT

CDQ
CHAMBER
PROCESS FLOW CHART
FLUE GAS
O&M SERVICE 980˚C
SPARES & CONS 540˚C , 87 KSC

CDQ POWER
POWER 1,2,3&4
DMWATER BOILERS DRI DM

WATER 1 160˚C MAIN STEAM 530˚C, 84 KSC DRI
TG AUX
TURBINE
TURBINE GENERATOR (98.3 MVA,76MW) CDQ

GLAND STEAM HP/LP EXTRACTION MSDS
12 KSC, 260 oC EXHAUST STEAM BOILER AUX
CONDENSOR O/L
GSC Ejector
CONDENSOR CONDENSOR I/L
atm
DEAERATOR
condensate HW MAKE UP
FEED WATER
Problem DM PLANT
COOLING TOWER
CT MAKEUP
Area
RAW WATER
500

STEP 3
Water
RAW
DM Water

STEP 3
RO PROJECT LAYOUT
RO WATER
TRANSFER BYPRODUCT
PUMP A
RO PLANT PLANT
COOLING
TOWER
RAIN WATER
TRANSFER
PUMP B
RO LINE
VENT
RO LINE
RO VENT TO COOLING
TOWER SUMP
CDQPP DM
RO WATER TANK PLANT
STEP 3
What Is an RAW Water?
Raw water is natural water found in the environment and has not been treated, nor
have any minerals, ions, particles or living organisms removed. Raw water includes
rainwater, ground water, water from infiltration wells, and water from bodies like
lakes and rivers.
Why RAW Water is required in CDQPP ?

Raw Water is required for generation of DM water fed to Boilers for Steam
generation.
At CDQPP ,Raw water is taken from Utility for DM water generation in DM plant.
During DM Generation ,Raw water is being wasted for Backwash and Regeneration
process in terms of water loss
1/28/2018 24
STEP 4
IMPACT OF THE PROBLEM
1. High Utility water consumption
MONTH CONSUMPTION(IN 180000

155728 154744 148059 162382
CUBIC METRE) 160000 144208
JUNE-2015 135926
155728 140000 126259
JULY 120000
135926
AUGUST 100000
154744
80000
SEPTEMBER 144208
60000 CONSUMPTION(IN
OCTOBER 126259 CUBIC METRE)
40000
NOVEMBER 20000
148059
DECEMBER-2015 0
162382
AVERAGE WATER
CONSUMPTION
146758
1/28/2018 25
STEP 4
2. High Chemical Consumption
MONTH CONSUMPTION CONSUMPTION
(NAOH) (H2SO4)
18000
16156
JUNE-2015
16000
13300 6355 13300 14023
14000
JULY 16156 7802 12000
9942
AUGUST 8162 4111 10000 8162
7802 8152
8000 6355 6802
SEPTEMBER 5032 2523
6000 5032 5134
OCTOBER 4111 4393
9942 5134 4000 2523
2000 CONSUMPTION(
NOVEMBER 8152 4393
0 NAOH)
DECEMBER 14023 6802 CONSUMPTION(
H2SO4)
AVRG CHEM
CONSUMPTION
1/28/2018 10681 5302 26

STEP 4
3. More Regeneration Cycles in SAC/SBA and MB
MONTH No of SBA/SAC No of MB
REGENERATION/MONTH REGENERATION/MONTH
20 18
JUNE-2015 15 4 18 17
16
16 15 15 15 15
JULY 16 4
14
AUGUST 15 5
12 No of SBA/SAC
10 REGENERATION/
SEPTEMBER 18 4 8 6 MONTH
6 5 5 No of MB
4 4 4 4
OCTOBER 17 4 4 REGENERATION/
2 MONTH
NOVEMBER 15 6
0
DECEMBER 15 5
AVERAGE
15 4
VIJAYANAGAR 27
STEP 4
3. Water Loss in Regeneration and Backwash

MONTH Water Loss in Water Loss in
Backwash (in M3) Regeneration (in M3)
1200 1070 1080
JUNE-2015 1100 600
1100 1050 1050 1044
1020
1000
JULY 1050 560
AUGUST 1020 550

800
Water Loss in
600 560 600
SEPTEMBER 1050 576 600 550 576 570 580 Backwash (in M3)
OCTOBER 1044 570
400 Water Loss in
NOVEMBER 1070 580 Regeneration (in
200 M3)
DECEMBER 1080 600
0
AVERAGE
VIJAYANAGAR 28
STEP 4
Objectives of Problem
 Reduction of Raw Water Consumption
 Increase in OBR(Output between Regeneration)
 Reduction of Chemical Consumption
 Improvement in DM Plant Inlet Water Parameters
 Reduction in Power Consumption
 To Minimize Water Loss in DM plant Process
 Increase in Resin Life
 Reduction in DM Water generation time

STEP 4
GOALS
 Reduction of Raw Water Consumption from 149805 cubic mtr to
135487 cubic mtr/month
 Increase in OBR(Output between Regeneration) for SAC/SBA from 150
hrs to 257 hrs
 Increase in OBR(Output between Regeneration) for MB from 200 hrs to
447 hrs
 Reduction of Chemical Consumption (H2SO4) from 4922 kg to 1595 kg
 Reduction of Chemical Consumption (NAOH) from 10540 kg to 2915 kg
 Improvement in DM Plant Inlet Water Total Hardness from 141PPM to
27PPM
 Reduction in Power Consumption of DM plant Auxiliaries from 3855kw
to 771kw
 Reduction in DM Water Loss from 24% to 4%

STEP 4
4W 1H ANALYSIS OF THE PROBLEM
What is the Where is the When does How much it is

problem? problem? the problem Who are affecting?
occurs? affected?
9% of
• Increase in • CDQ Power Plant Overall Raw
RAW Water • DM Plant • During DM and Boiler
Consumption Plant Water
Operation Consumption
31 VIJAYANAGAR
1/28/2018
STEP 4
PROJECT SOLUTION
CAUSE ANALYSIS IMPLEMENTATION
SELECTION DEVELOPMENT
Identification of causes
Validation of causes
1/28/2018 32
Root cause analysis
STEP 8 4
STEP BRAINSTORMING
Alex F. Osborn
1888 – 1966
33
1/28/2018
STEP 5 Cause Identification
Identification of Causes for Identification of Causes for
S l no Increase in RAW Water Remarks S l no Increase in RAW Water Remarks
Consumption Consumption
1 UNTRAINED OPERATOR ACCEPTABLE
10 RAIN WATER INSIDE SENSOR ACCEPTABLE
2 MANUAL OPERATION ACCEPTABLE
POOR MAINTENANCE PLAN
3 ACCEPTABLE 11 LACK OF COMMUNICATION ACCEPTABLE
PIPELINE LEAKAGES 12 IMPROPER SOP ACCEPTABLE
4 ACCEPTABLE
13 LACK OF KNOWLEDGE ACCEPTABLE
EQUIPMENT MALFUNCTION
5 AND FAILURE ACCEPTABLE 14 POOR TRAINING ACCEPTABLE
6 POOR RESIN QUALITY ACCEPTABLE 15 POOR CHEMICAL QUALITY ACCEPTABLE

16 AMB TEMP ACCEPTABLE
7 POOR RAW WATER QUALITY ACCEPTABLE
17 HIGH TURBIDITY ACCEPTABLE
8 HIGH CONDUCTIVITY ACCEPTABLE
9 HIGH HARDNESS ACCEPTABLE 18 HIGH CHLORIDES ACCEPTABLE
1/28/2018
34
STEP 5 Cause Identification
Identification of Causes for

S l no Remarks
Increase in RAW Water Consumption
NOT ACCEPTABLE
1 Flow Transmitter Wrong Reading Indication
2 Power Supply to Transmitter Problem NOT ACCEPTABLE
3 Leakages in Raw Water Line NOT ACCEPTABLE
4 Actuator Malfunctioning NOT ACCEPTABLE
5 Manual Isolation valve Passing NOT ACCEPTABLE
6 Flange Leakages NOT ACCEPTABLE

7 Tanks Overflow NOT ACCEPTABLE
8 Negligence of Operator NOT ACCEPTABLE
NOT ACCEPTABLE
9 Pressure Vessels crack
1/28/2018
35
STEP 5
CAUSE AND EFFECT ANALYSIS
METHOD
MAN
LACK OF FAILURE OF AUTO
IMPROPER
KNOWLEDGE OPERATION
SOP
POOR SOP/SMP POOR MAINTENANCE

AND NOT PLAN
UNTRAINED FOLLOWING SOP
OPERATOR POOR TRAINING
MANUAL
MORE REGENRATION CYCLES
OPERATION
LACK OF IN MB
LESS OBR
COMMUNICATION
MORE REGENRATION LESS OBR

MORE
CYCLES IN SBA/SAC
INSTRUCTIONS TO
OPERATOR
Increase in Raw
water
POOR QUALITY MALFUNCTION
MEDIA IN VESSELS POOR RESIN OF SENSORS
HIGHCHLORIDES QUALITY
PLC FAILURE
HIGH TURBIDITY RAIN WATER
EQUIPMENT AMB TEMP
HIGH MALFUNCTION AND
CONDUCTIVITY POOR CHEMICAL FAILURE
QUALITY
PIPELINE
LEAKAGES
HIGH HARDNESS
MACHINE
MATERIAL
48
STEP 6
VALIDATING MAN RELATED CAUSES

SL
PROBLEM OBSERVATION REMARKS
NO
UNSKILLED All operators are Experienced and well

1
OPERATOR trained. Checked training records. Had
discussion with operators.
This is not a cause
Communication to the operator is through
LACK OF single window thus avoiding confusion.
2
COMMUNICATION
DM plant operation is running in Auto

MANUAL OPERATION
3 mode without any problem This is not a cause

STEP 6

STEP 6
VALIDATING MACHINE RELATED CAUSES

SL NO PROBLEM OBSERVATION REMARKS
EQUIPMENT
MALFUNCTION AND All pumps PM Schedule is up to date and
1 FAILURE no malfunctioning observed This is not a cause
Found water leakages in pipe lines, PM

PIPELINE LEAKAGES schedule made and healthiness of pipe
2 This is not a cause
lines ensured
PLC FAILURE Hardware Components and Software

This is not a cause
3 Logic Checking on a Monthly basis States
that PLC is not a Cause
RAW Water Flow Transmitter is Equipped

MALFUNCTION OF
4 with Water Proof Enclosure and Periodic This is not a cause
SENSORS
calibration States that Sensor is ok
28 January 2018 39
VIJAYANAGAR
STEP 6

STEP 6
VALIDATING MATERIAL RELATED CAUSES
SL NO PROBLEM OBSERVATION REMARKS
Diff Pressure across the Inlet and Outlet of DMF

POOR QUALITY MEDIA IN This is not a cause
1 and ACF Vessels found Normal shows that quality
VESSELS
of media is good
Raw Water Turbidity is above the Predefined
2 HIGH TURBIDITY This is a cause
value
Concentration of H2SO4 and NAOH are accurate
3 POOR CHEMICAL QUALITY as per Material Safety Data Sheet(MSDS) This is not a cause
Provided by Vendor
Output between regeneration quantity is ok states
4 POOR RESIN QUALITY This is not a cause
that resin quality is ok
Raw Water Hardness is above the Predefined
5 HIGH HARDNESS This is a cause
value
Raw Water Chlorides is above the Predefined
6 HIGH CHLORIDES This is a cause
value
HIGH CONDUCTIVITY Raw Water Conductivity is above the Predefined
7 This is a cause
value

STEP 6

STEP 6
VALIDATING METHOD RELATED CAUSES

SL
PROBLEM OBSERVATION REMARKS
NO
SOP was displayed at the MCR and training of all the
POOR SOP/SMP AND NOT
1
FOLLOWING SOP
operators was evidenced This is not a cause
MORE REGENERATION This is a cause

2 LESS OBR IN SBA/SAC REGENERATION
CYCLE IN SBA/SAC
MORE REGENERATION
3 LESS OBR IN MB REGENERATION This is a cause
CYCLE IN MB
Audited electrical and mechanical
maintenance records, checklist and SMP.
4 POOR MAINTENANCE PLAN This is not a cause
Discussed with technicians.
As per Daily Inspection Report DM plant

FAILURE OF AUTO operation is running in Auto mode without
5
OPERATION This is not a cause
any problem

STEP 6

STEP 7
OCCURENCES CHART
The causes which did not satisfy the standards were put in to a occurrence chart to find out
the root cause.
NO OF
SL CUMULATIVE CUMULATIVE
CAUSES July-15 Aug-15 Sept-15 Oct-15 Nov-15 Dec-15 OCCURENCES
NO FREQUENCY %
IN SIX MONTH
TURBIDITY
1 14 12 10 10 13 14 73 73 24.74
2 HIGH HARDNESS(60 to 110PPM) 21 18 20 21 19 22 121 194 65.76
3 HIGH CHLORIDES(20-40PPM) 10 8 11 8 10 9 56 250 84.74
4 CONDUCTIVITY 6 6 8 4 4 5 33 283 94.93
MORE REGENERATION CYCLE IN

5 3 1 2 0 1 2 9 292 98.98
SAC/SBA
6 MORE REGENERATION CYCLE IN MB 0 1 0 0 1 1 3 295 100
TOTAL 295
STEP 7

STEP 7
PARETO ANALYSIS
295 100
90
245
80
Vital Few 70
195
60
145 50 FREQUENCY
121
Useful Many 40
CUMULATIVE
PERCENTAGE
95
73 30
56
20
45 33
10
9
3
-5 0
HIGH HARDNESS TURBIDITY CHLORIDES No OF SAC/SBA REG
CONDUCTIVITY No OF MB REG CYCLES
(60 TO 110PPM) (20-40PPM) CYCLES

STEP 7
SL NO CAUSES Nov-15 Dec-15 Jan-16 Feb-16 Mar-16 Apr-16 TOTAL
1 HIGH TURBIDITY 14 12 10 10 13 14 73
2 HIGH HARDNESS 21 18 20 21 19 22 121
3 HIGH CHLORIDES 10 8 11 8 10 9 56
4 HIGH CONDUCTIVITY 6 6 8 4 4 5 33
N REGENERATION
5 3 1 2 0 1 2 9
CYCLE IN SAC/SBA
MORE REGENERATION
6 0 1 0 0 1 1 3
CYCLE IN MB
25
20
15
HIGH HARDNESS
10
HIGH TURBIDITY
5
HIGH CHLORIDES 0
HIGH CONDUCTIVITY 1
2
3
MORE REGENERATION CYCLE IN 4
SAC/SBA 5
MORE REGENERATION CYCLE IN MB 6

STEP 7
Sr no CAUSES OCCURANCES FOR 6 MONTHS

1 HIGH HARDNESS 121
2 HIGH TURBIDITY 73
3 HIGH CHLORIDES 56
4 HIGH CONDUCTIVITY 33
5 MORE REGENERATION CYCLE IN SAC/SBA 9
6 MORE REGENERATION CYCLE IN MB 3
OCCURANCES FOR 6 MONTHS

3
33 9
121 HIGH HARDNESS
56 HIGH TURBIDITY
HIGH CHLORIDES
HIGH CONDUCTIVITY
MORE REGENERATION CYCLE IN SAC/SBA
73
MORE REGENERATION CYCLE IN MB

STEP 8
BRAIN STORMING
1/28/2018 50
Improving availability of CDQ loco by reducing
downtime.
STEP 8
Reduction of Raw Water Consumption in

CDQPP
To Set Up a New RO Plant in CDQ

Power Plant
Not implementable
Cost of Project will be very high

STEP 8
Reduction of Raw Water Consumption in CDQPP
Installation of Clarifier in DM Plant for Removal of High

TDS and Turbidity
Not implementable
Installation Cost is very High and it require more

STEP 8
Reduction of Raw Water Consumption in

CDQPP
 Utilization of RO Water from Near by RO Unit
 Implementable
 Nearby RO Plant is Converting By-product Effluent Water into Usable
RO Water which is available in Excess Quantity
 Analysis of RO Water Parameters of Neighbouring RO Plant to be done

 Implementable
 Based on RO Water Report it has been decided to use ROWater to our
DM Plant

STEP 8
Sl. No. ACTIVITY RESPONSIBILITY TARGET DATE
RO Water Project Layout, Pipe Line

1 Jitendra Katre,Sharanbasava 28 February 2016
and Tank Erection Fabrication Work
Pneumatic Actuators,Pressure and

2 Level transmitters,Pressure and Pradeep Chotia,Basagouda Patil 15 March 2016
Level gauges Installation Work
Cable laying and Commissioning of

3 Sharanbasava,sharvanan 30 March 2016
Field Instruments in DCS
Hydraulic Testing and Trial of RO Jitendra katre,Pradeep

4 22 Aprill to 31 Aprill
Plant Chotia,Basagouda Patil
1/28/2018 54
Improving availability of CDQ loco by reducing
downtime.
STEP 9
FORESEEING PROBABLE RESISTANCE-1
• Resistance – Layout of RO pipeline

• Reason – Ambiguity in deciding the layout of RO
pipeline because of road crossing
• Solution – Decided to utilize the existing cable rack for
erection of RO pipeline

STEP 9
Resistance –Civil excavation work clearance

for laying of RO pipeline.
Reason – Because of busy traffic road & raw

material carrying lorries, trucks
Solution –Utilization of existing cable rack for

erection of pipeline
STEP 9
Resistance – Procurement of Resources
Reason –Unavailability of resources/material
Solution –Taken approval from the higher

management for the project budget

STEP 9
Resistance – Manpower Services for RO project

Reason – Unskilled & limited manpower for the
dedicated project
Solution –Taken service budget and contract
given to third party for erection and
commissioning of pipe line

STEP 9
Resistance –Communication with RO plant officials for

laying of pipe line
Reason – Due to possibility of RO water generation

stoppage
Solution –Decided to connect the RO water pipe line

mutually in planned shutdown

STEP 9
Resistance–Communication with Utility department for

isolation of complete raw water line of CDQ PP
Reason – For installation of manual butterfly valve in

RO water line to DM plant
Solution –Maintained CT basin & DM tank optimum

level in co-operation with utility department and
operation department

STEP 10
TRIAL IMPLEMENTATION 1
PLAN:RO Pipeline Leakages Arresting Work.
DO: Replacement and Use of more Quantity of

Adhesive from UPVC-717 to CPVC-724
CHECK: Hydro Test Performed and Checked Joints

for any leakages
ACT: Trial was Successful

STEP 10
PLAN: Installation of pressure transmitter in RO line
DO: RO Line Pressure Control Logic Implementation in DCS
CHECK: RO line Pressure Trend Analysis done

STEP 10
PLAN:Installation of RO Tank Level Transmitter and

Actutator in RO Line
DO: Instrument Fixing and Auto Level Control Logic

for RO Storage Tank given in DCS
CHECK: RO Tank High Level Interlock Check

STEP 10
PLAN:Installation of RO Line Vent Valve
DO:1’’ PVC Ball Valve Installed in RO Line for

Venting of Air
CHECK: After Charging of RO Water Line , Air

Venting checked

STEP 10
PLAN:Installation of Extra valve in RO Water Line to

BY Product plant
DO:8’’ Butterfly Valve Installed in Byproduct RO

water Line
CHECK:Line Pressure Checked by Throttling the
valve so that water will come in DM tank during Low
Pressure.

STEP 10
PLAN:Proper Support for UPVC Pipe Size Fittings
DO:Support Arrangement and clamps Installed for

UPVC Pipeline
CHECK:Inspection of Any Bending of Line and
Vibration in RO Line

STEP 10

STEP 10
RAW WATER CONSUMPTION (BEFORE & AFTER)
180000
MONTH CONSUMPTIO CONSUMPTION(IN CUBIC
N(IN CUBIC METRE)AFTER 160000
METRE)BEFO
RE
140000
JUNE 155728 134838
JULY 135926 114584 120000
AUGUST 154744 127552
100000 CONSUMPTION(IN
SEPTEMBER 144208
132274 CUBIC
80000
OCTOBER 126259 140284 METRE)BEFORE
NOVEMBER
148059 103632 60000 CONSUMPTION(IN
DECEMBER CUBIC
162382 133390 40000
JANUARY 130311 145245
METRE)AFTER
FEBRUARY 20000
151914 135060
MARCH 167147 156210 0
APRIL 163083 152469
MAY 157899 150307
AVERAGE WATER
CONSUMPTION
149805 135487

STEP 10
CHEMICAL CONSUMPTION(H2SO4)(BEFORE & AFTER)
MONTH H2SO4 H2SO4 CONSUMP(KG)

CONSUMP(KG AFTER
) BEFORE 9000
JUNE 6355 1447 8000
JULY 7802 1652 7000
AUGUST 4111 1499
SEPTEMBER 2523
6000
1683 H2SO4
OCTOBER 5134 1241
5000
CONSUMP(KG)
NOVEMBER 4393
2040
4000 BEFORE
DECEMBER 6802
1632
3000 H2SO4
JANUARY 3277 2142 2000 CONSUMP(KG)
FEBRUARY 4750 AFTER
1530 1000
MARCH 5136 1632
5423
0
APRIL 1020
MAY 3366 1631
AVERAGE WATER
CONSUMPTION
4922 1595

STEP 10 CHEMICAL CONSUMPTION(NAOH) BEFORE & AFTER
MONTH NAOH CONSUMP(KG) NAOH 18000

BEFORE CONSUMP(KG)
AFTER 16000
JUNE 13300 2303 14000

JULY 16156 2625 12000
AUGUST 8162 2859
SEPTEMBER 5032 10000 NAOH
1419
OCTOBER 9942 2501
CONSUMP(KG)
8000
NOVEMBER 8152
BEFORE
3744
DECEMBER 14023 6000 NAOH
2478
CONSUMP(KG)
JANUARY 12754 3370 4000 AFTER
FEBRUARY 8728 3009
2000
MARCH 13234 3363
APRIL 12052 0
3213
MAY
4956 4098
AVERAGE
(NAOH
)CONSUMPTI
ON 10540 2915 70
VIJAYANAGAR
STEP 10 TURBIDITY(DM PLANT I/L WATER) BEFORE
MONTH TURBIDITY (NTU) TURBIDITY (NTU)
BEFORE AFTER
6
JUNE-2015 4.5 0.5
JULY 3.2 0.8

5
AUGUST 5.3 0.3 4

SEPTEMBER 5.2 0.6
3
OCTOBER 5.5 0.2
TURBIDITY (NTU)
NOVEMBER 5.6 0.4 2 BEFORE
DECEMBER 4.7 0.8 TURBIDITY (NTU)
1 AFTER
JANUARY 4.8 0.5
0
FEBRUARY 5.2 0.7
NOVEMBER
JUNE
JULY
AUGUST
SEPTEMBER
APRIL
FEBRUARY
MAY
DECEMBER
JANUARY
MARCH
OCTOBER
MARCH 4.6 0.7
APRIL 5.7 0.8
MAY-2016 5.3 0.4
AVERAGE 4.9 0.5

VIJAYANAGAR 71
STEP 10
CONDUCTIVITY(DM PLANT) BEFORE & AFTER
MONTH CONDUCTIVITY CONDUCTIVITY
BEFORE BEFORE
JUNE 335 186 450

JULY 320 233 400
AUGUST 357 156 350
SEPTEMBE 319 164
300
R 250
OCTOBER 386 143 200
150
NOVEMBER 330 182
100
CONDUCTIVITY(BEFORE)
DECEMBER 345 158 50
0 CONDUCTIVITY(AFTER)
JANUARY 376 220
FEBRUARY 365 179
MARCH 334 136

APRIL 342 220
MAY 310 134
AVERAGE 343 176
VIJAYANAGAR 72
STEP 10
TOTAL HARDNESS(DM PLANT) BEFORE
MONTH TURBIDITY TURBIDITY
PPM BEFORE PPM AFTER
JUNE-15 119 20 180
JULY 134 26 160

140
AUGUST 136 28
120
SEPTEMBER 126 32
100
OCTOBER 156 24 TURBIDITY
80
NOVEMBER 165 29 PPM BEFORE
60
DECEMBER 123 30 TURBIDITY
40
JANUARY 144 22
PPM AFTER
20
FEBRUARY 151 27 0
MARCH 147 32
APRIL 165 21
MAY-16 128 29
AVERAGE 141 27
VIJAYANAGAR 73
STEP 10 CHLORIDES DM PLANT (BEFORE & AFTER)
MONTH CHLORIDES CHLORIDES

PPM BEFORE PPM AFTER
JUNE 38 19 80
JULY 43 26 70
AUGUST 51 22 60
SEPTEMBER 48 24 50
OCTOBER 52 21 40 CHLORIDES PPM

NOVEMBER 67 28 30 BEFORE
DECEMBER 45 24 20
CHLORIDES PPM
AFTER
JANUARY 53 27 10
FEBRUARY 62 25
0
MARCH 71 26
APRIL 55 23
MAY 48 21
AVERAGE 53 24
VIJAYANAGAR 74
STEP 10
NO OF SBA/SAC REGENERATION CYCLES IN DM PLANT (BEFORE)
MONTH No of SBA/SAC No of
REGENERATION SBA/SAC 20
BEFORE REGENERATIO
N/MONTH 18
AFTER
16
JUNE 15 4
14
JULY 16 4
12
AUGUST 15 4
10 No of SBA/SAC
SEPTEMBER 18 5
8 REGENERATION
OCTOBER 17 4 6 BEFORE
NOVEMBER 15 5 4 No of SBA/SAC
REGENERATION/MO
DECEMBER 15 4 2
NTH AFTER
JANUARY 16 4 0
FEBRUARY 17 5
MARCH 16 5
APRIL 16 4
MAY 15 5
AVERAGE 15 5
VIJAYANAGAR 75
STEP 10
NO OF MB REGERATION CYCLES IN DM PLANT (BEFORE & AFTER)
MONTH No of MB No of MB
REGENERATION REGENERATION
BEFORE AFTER
7
JUNE 4 1 6
JULY 4 1
5
AUGUST 5 1
SEPTEMBER 4 1
4
No of MB
3
OCTOBER 4 1 REGENERATIO
NOVEMBER 6 1
2 N BEFORE
1 No of MB
DECEMBER 5 1
REGENERATIO
JANUARY 6 1 0 NS AFTER
NOVEMBER
SEPTEMBER
JUNE
JULY
AUGUST
APRIL
FEBRUARY
MAY
DECEMBER
JANUARY
MARCH
OCTOBER
FEBRUARY 6 1
MARCH 4 1
APRIL 4 1
MAY 5 1
AVERAGE 1
4.
VIJAYANAGAR 76
STEP 10
PROJECT COST EVALUATION
MATERIAL TOTAL COST

PVC Pipe and Manpower Cost Rs.9,64000
Structure and Pipe Erection Cost Rs.2,50000
Tank Material Cost Rs.176400
Tank Erection Cost Rs.471000
I & C Material Rs.304000
TOTAL (RO Project Cost) Rs 21,65400

STEP 11 Improving availability of CDQ Gas analyzer by reducing downtime. ECCHHA
CCQC 2016
TANGIBLE BENEFITS
1. Raw Water consumption for CDQPP is reduced from 149805 cubic metre to 135487cubic
metre
Raw Water Consumption
149805
150000
145000
140000 135487
135000
130000
125000
Before QC After QC
73
CCQC 2016
TANGIBLE BENEFITS
2. Reduce in Chemical Consumption in DM Plant.
CHEMICAL CONSUMPTION
10540
12000
10000
8000
CHEM NAME BEFORE AFTER 4922
6000
2915
4000
2000 1595
NAOH 10540 2915 0
NAOH
H2SO4
BEFORE AFTER
H2SO4 4922 1595
74
STEP 11
COST OF CHEMICALS CONSUMPTION /MONTH (BEFORE)
SR PROCESS H2SO4 NAOH COST OF COST OF COST

NO VESSEL CONSUMP(KG CONSUMP(K H2SO4(RS/KG) NAOH(RS/KG) /MONTH
) G)
1 SAC 3740 - 9.5 - 35530
2 SBA NIL 7080 - 19.9 140892
3 MB 460 1820 9.5 19.9 40588
TOTAL CHEMICAL COST/MONTH RS/-217010

STEP 11
COST OF CHEMICALS CONSUMPTION /MONTH (AFTER)
SR PROCESS H2SO4 NAOH COST OF COST OF COST

NO VESSEL CONSUMP(KG) CONSUMP(KG) H2SO4(R NAOH(RS/KG) /MONTH
S/KG)
1 SAC 1870 - 9.5 - 17765
2 SBA - 7080 - 19.9 70446
3 MB 230 1820 9.6 19.9 20294
TOTAL CHEMICAL COST/MONTH RS/-108505

STEP 11
CHEMICAL COST BEFORE &AFTER
CHEMICAL COST/MONTH
250000
200000
150000
100000
50000
0
BEFORE AFTER

STEP 11
TANGIBLE BENEFITS
SAVINGS PER ANNUM
Cost of Chemical Saving Using RO Water for CDQPP DM Plant RS108505
Cost of Water Saving in terms of Regenerating Water Rs13725
Total Cost Saving per month RS122230
Total cost saving per year(122230x12) RS1466760

STEP 11
TANGIBLE BENEFITS
Total ROI Calculation
Cost of Chemical Saving Using RO Water for CDQPP RS108505

DM Plant
Cost of Water Saving in terms of Regenerating Water Rs13725
Total Cost Saving per month RS122230
Total cost saving per year(122230x12) RS 1466760
Estimated cost of RO Water Supply Project to CDQPP RS2165000
Expected PAYBACK PERIOD=2165000/122230 17 Months(February 2018)

STEP 11
1) WATER CONSUMPTION BEFORE(5405M3)
SR NO PROCESS QUANTITY WATER TOTAL

CONSUMPTION/REG WATER CONSUMPTION
1 SAC REGENERATION 20 30 600
2 SBA REGENERATION 20 20 400
3 MB REGENERATION 5 20 100
4 DMF BACKWASH 20 26 520
5 ACF BACKWASH 20 4 80
TOTAL WATER LOSS FOR BACKWASH AND REGENERATION 1700M3/MONTH
TOTAL WATER LOSS IN DM PLANT 7105 M3/MONTH

TOTAL WATER LOSS IN PERCENTAGE 24%
IF RAW WATER IS CONVERTED INTO DM WATER THERE WILL BE LOSS OF 24% OF RAW WATER
28 January 2018 85
STEP 11
1) WATER CONSUMPTION AFTER (5405 M3)
SR NO PROCESS QUANTITY WATER TOTAL

CONSUMPTION/REG WATER CONSUMPTION
1 SAC REGENERATION 4 30 120
2 SBA REGENERATION 4 20 80
3 MB REGENERATION 1 20 20
4 DMF BACKWASH 1 26 26
5 ACF BACKWASH 1 4 4
TOTAL WATER LOSS FOR BACKWASH AND REGENERATION 250M3/MONTH
TOTAL WATER LOSS IN DM PLANT 5655 M3/MONTH

TOTAL WATER LOSS IN PERCENTAGE 4%
IF RAW WATER IS CONVERTED INTO DM WATER THERE WILL BE LOSS OF 24% OF WATER
28 January 2018 86
STEP 11
2) CHEMICAL CONSUMPTION BEFORE
SR PROCESS QUANTIT NO OF TOTAL QUANTITY PRICE /KG TOTAL CHEMICAL

NO Y(KG) REGENERATIONS PRICE
1 SAC REG(H2SO4) 204 20 4080 7.5 30600
2 SBA REG(NAOH) 354 20 7080 28.5 201780
3 MB REG(H2SO4) 102 5 510 7.5 3825
4 MB REG(NAOH) 177 5 885 28.5 25222.5
TOTAL CHEMICALCOST RS261427.5
28 January 2018 87
STEP 11
2) CHEMICAL CONSUMPTION AFTER
SR PROCESS QUANTIT NO OF TOTAL QUANTITY PRICE /KG TOTAL CHEMICAL

NO Y(KG) REGENERATIONS PRICE
1 SAC REG(H2SO4) 204 4 816 7.5 6120
2 SBA REG(NAOH) 354 4 1416 28.5 40356
3 MB REG(H2SO4) 102 1 102 7.5 765
4 MB REG(NAOH) 177 1 177 28.5 5044.5
TOTAL CHEMICALCOST RS 52285.5
28 January 2018 88
STEP 11
2) POWER CONSUMPTION BEFORE
SR POWER KWH DURATION OF NO OF REGN TOTAL POWER TOTAL COST

NO CONSUMPTION(KWH) OPERATION CONSUMPTION
1 DM REG PUMP FOR 7.5 1.5 20 225 990

SAC REGN
2 DM REG PUMP FOR 7.5 1.5 20 225 990
SBA REGN
3 DM REGN PUMP 7.5 1.5 5 56.25 247.5
FOR MB REGN
4 DMF BACKWASH 18.5 0.5 20 185 814
PUMP FOR DMF
BACKWASH
5 DMF BACKWASH 18.5 0.5 20 185 814
PUMP FOR ACF
BACKWASH
TOTAL POWER CONSUMPTION RS 3855.5

28 January 2018 89
STEP 11
2) POWER CONSUMPTION AFTER
SR POWER KWH DURATION OF NO OF REGN TOTAL POWER TOTAL COST

NO CONSUMPTION(KWH) OPERATION CONSUMPTION
1 DM REG PUMP FOR 7.5 1.5 4 45 198

SAC REGN
2 DM REG PUMP FOR 7.5 1.5 4 45 198
SBA REGN
3 DM REGN PUMP 7.5 1.5 1 11.25 49.5
FOR MB REGN
4 DMF BACKWASH 18.5 0.5 4 37 162.8
PUMP FOR DMF
BACKWASH
5 DMF BACKWASH 18.5 0.5 4 37 162.8
PUMP FOR ACF
BACKWASH
TOTAL POWER CONSUMPTION RS 771.5

28 January 2018 90
STEP 11 ECCHHA
CCQC 2016
INTANGIBLE BENEFITS
• We learned, analyzing and problem solving

tools.
QC Members • Our confidence level and presentation skill
has improved.
• We learned putting thoughts to actions.
• By reducing chemical and waste water

Environment
treatment
House keeping • By applying 5S concept in Project
Safety • By categorization of hazardous chemicals

and putting MSDS board in site
76
STEP 12 ECCHHA
CCQC 2016
FOLLOWUP AND REVIEW

1. Training has been conducted for operators and technicians.
2. Check list was followed.
3. There was no deviations in DM Plant Inlet Water Parameter
4. Water and chemical consumption reduced to a great extent
78
STEP 12 ECCHHA
CCQC 2016
GANTT CHART OF SCHEDULE &

QC NAME : ECCHHA
PROJECT NO: 2
ACTUAL Co-ordinator : Hariprasad D
THEME: Improving availability of CDQ gas analyzer by reducing down time
OBJECTIVE: Probe modification to reduce probe choking
DEPARTMENT: CDQ
Facilitator Suresh K Leader : Sidlingappa H
START DATE:06.JAN.2016
END DATE :30.MAR.2016
Members :
Saichand G
Naveen H J
Anup M
MEETINGS
Step ACTIVITYS REMARKS
1 2 3 4 5 6 7 8 9 10 11 12
1 Identification of the problem
2 Selection of Problem
Definition of the Problem and SCHEDULED PLAN

3
Objectives ACTUAL STARTDATE
06.JAN.2016
4 Analysis of the problem
5 Cause- Effect Analysis
6 Root Cause Analysis
7 Data Analysis of the Root Cause
8 Development of Solution
9 Foreseeing Probable Resistance

END DATE
Trial implementation and Check 30.MAR.2016
10
Performance
11 Regular Implementations
12 Follow up / Review
81
CCQC 2016
QC TOOLS AND TECHNIQUES

USED Q.C. Tools & Techniques Used
PROBLEM SOLVING TECHNIQUES

STEP NO PROBLEM SOLVING STEPS PROBLEM SOLVING TOOLS USED.
USED.
1 IDENTIFICATION OF PROBLEM BRAINSTORMING

2 SELECTION OF THE PROBLEM GRAPH RANKING MATRIX,
3 DEFINING THE PROBLEM FLOW DIAGRAM
4 ANALYSIS OF THE PROBLEM 4W1H
5 IDENTIFICATION OF CAUSES CAUSE AND EFFECT DIAGRAM BRAINSTORMING,
6 FINDING OUT THE ROOT CAUSE PDCA,
7 DATA ANALYSIS PARETO DIAGRAM,GRAPH,CHECK SHEET,

8 DEVELOPING SOLUTIONS. BRAINSTORMING,
9 FORESEEING PROBABLE RESISTANCE. BRAINSTORMING,
TRAIL IMPLEMENTATION & CHECKING

10 GRAPHS,DATA COLLECTION, PDCA,
PERFORMANCE.
11 REGULAR IMPLEMANTATION. PDCA,
12 FOLLOW UP AND REVIEW.
82
ECCHHA
CCQC 2016
INTRODUCTION
QUALITY CIRCLE PROJECT
WAY FORWARD
83
STEP 12 ECCHHA
CCQC 2016
FUTURE PLANS
1. Optimization of Aux power consumption.
2. CT fans Blade Replacement from GRP to FRP for better

air flow and Power consumption
3. Installation of VFD drives for HT Pumps closed loop

control
4. Steam Trap failure detection system installation
5. LRSB and RSB Installation for Boiler.
84
STEP 12
85
STEP 12
THANK YOU

Pragathi Final QC

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PRAGATHI Quality Circle

28 January 2018 VIJAYANAGAR 1

Reduction of Raw Water

28 January 2018 VIJAYANAGAR 2

28 January 2018 VIJAYANAGAR 3

28 January 2018 VIJAYANAGAR 5

Project Theme : Reduction of Raw Water consumption in CDQPP

28 January 2018 VIJAYANAGAR 7

Step 4: Analysis of the problem.

2 Raw Water Consumption high A

3 Pipe line leakages in DM plant A

4 Cooling Tower Effectiveness/Efficiency less A

5 Cooling water Inlet temp High A

6 Lube Oil Temp High A

7 Formation of Algae around CT Basin A

8 Generator winding Temp High A

9 TG Bearing Temp High A

10 Condenser water box differential pressure high A

11 Abnormal Alarms in DCS due to module Problem A

12 TG Inlet Control Valve Hunting/Passing Problem A

13 Turbine RTD Failures A

28 January 2018 VIJAYANAGAR 9

28 January 2018 VIJAYANAGAR 10

28 January 2018 VIJAYANAGAR 11

28 January 2018 VIJAYANAGAR 12

28 January 2018 VIJAYANAGAR 13

Total Number of Problems Category A Category B Category C

50 A - PROBLEMS WHICH CAN BE SOLVED BY OURSELF

B- PROBLEMS WHICH NEEDS HELP FROM OTHER DEPARTMENT

45 DCS power supply failure problem SOLVED

Solved A Category Problems Unsolved A Category Problems

AVERAGE OF ALL RANKING MATRIX(15) FOR HIGHLIGHTING A CRITICAL PROBLEM

1 Pipe line leakages in DM plant 4 4 6 6 20 5

2 Steam Traps Failures 5 5 6 7 24 3

3 Raw Water Consumption high 9 9 7 9 34 1

TG Inlet Control Valve Hunting Problem

RATING TO BE GIVEN OUT OF 10

Q.C NAME : PRAGATHI DEPARTMENT : CDQ POWER PLANT MEMBERS

PROJECT NO: 1 FACILITATOR : Mr. PRADEEP CHOTIA TEAM LEADER:BASAGOUDA PATIL

1 Identification of the problem

5 Cause- Effect Analysis

6 Root Cause Analysis

7 Data Analysis of the Root Cause

9 Foreseeing Probable Resistance End Date

1x76 MW CDQ POWER PLANT

O&M SERVICE 980˚C

SPARES & CONS 540˚C , 87 KSC

DMWATER BOILERS DRI DM

TURBINE GENERATOR (98.3 MVA,76MW) CDQ

12 KSC, 260 oC EXHAUST STEAM BOILER AUX

28 January 2018 VIJAYANAGAR 21

28 January 2018 VIJAYANAGAR 22

What Is an RAW Water?

Why RAW Water is required in CDQPP ?

MONTH CONSUMPTION(IN 180000

1/28/2018 10681 5302 26

3. Water Loss in Regeneration and Backwash

AUGUST 1020 550

 Reduction of Raw Water Consumption

 Increase in OBR(Output between Regeneration)

 Reduction of Chemical Consumption

 Improvement in DM Plant Inlet Water Parameters

 Reduction in Power Consumption