Welcomes for the presentation on

1

Welcomes for the presentation on

“Elimination of EOT CRANE

PENDENT problems”.

एनएलसी इंडिया लललिटेि

2

MINIG CAPACITY

MINE I------------------10.5 MT / Year

MINE I A ------- 3.0 MT / Year

MINE II-----------------15.0 MT / Year

BARSINGSAR MINE - 2.1 MT / Year

Lignite Based 3240 MW

Coal Based 1000 MW

Total 4240MW

Solar power 240

MW

Wind power

34 X 1.5 MW= 51 MW

Thermal power

3ESPs, LIFTs, DG SETs and CRANEs.

Our Division…..DIVISION HEADQC AREA CO ORDINATORUNIT HEAD.

VENKADA SUBAIAH

ED/ THERMAL

P.GANESAN, ACM/E,

FACILITATOR

J. Rathinakumar, DCE/E,

LEADER

P.Anbalagan, Sr.Foreman/E,

Dy.LEADER

R. Senthamizhselvan ,Sr.Foreman/E

MEMBER

4

Alternate week - Friday

Time : 3:30 PM

Venue : Maintenance Room

Overall Attendance : 94%

Project No.:5

MEETING DETALS

S.Savariraj,Sr. Foreman/E

MEMBER

EION QC TEAM STARTED ON:- 01.01.2015

PROBLEM SOLVING METHOD

DR. JURAN’STWELVE STEP METHOD

1

2

3

4

5

67

89

10

11

12Regular

implementation

PLAN

DOCHECK

ACTION

6

SL NO

PROBLEM Category

1 Door limit problem. A

2 Lift Cabin Speed monitor Failed A

3 VIP Lift encoder failed A

4 DG set Emergency switch Problem A

5 Call PB Problem A

6 Level Indication lamp Problem. A

7 Selector tape cut Problem B

8 EOT Crane Pendent not PB damaged A

9 Hopper Heater Power contactor Problem

A

10 EERM motor Problem A

11 Selector tape slip Problem B

12 Car level problem A

13 CERM gear box oil leak problem B

14ADPH crane Hoist operation failed

A

15 Pendent switch problem A

SL NO

PROBLEM catagory

16 Pendent cable problem A

17 Heater earth fault A

18 EHV Interlock switch problem A

19 Final limit contact Limit Switch Problem A

20 Fan Problem in unit-5 Boiler lift A

21 Festooning control cable cut in Stage-1 ADPH crane

A

22 Sill chock problem A

23 Incomer A LT breaker not closing in ESP-2 B

24 6 th Floor Limit switch Problems in Lift-7 A

25 LT Bus E/F due to Rectifier transformer fault.

C

26 DG set not starts from remote. B

27 Lift Door damaged problem A

28 ESP rapping master controller problem A

29 Water entry into the lift pit & Selector tape wheel submerged.

A

30 Lift Door not open problem A

31 Lift Pit light problem A 7

SL NO PROBLEM

catagory

32 MG set rubber coupling failed A

33 Electronic controller failed A

34 EC panel power contactor struck-up

A

35 ESP AC not working B

36 DG out going breaker not closing A

37 Rain water enter in boiler lift -5 problem

B

38 Lift power supply ON/OFF Switch failed

A

39 Boiler lift Selector tap problem B

40 EOT Crane Break problem A

41 AVR first channel problem A

42 Lignite dust fire c

43 EC Panel tripped frequently on U/V problem

A

SL NO PROBLEM

catagory

44 Door motor coil burnt out A

45 Commutator carbon brush worn-out problem.

A

46Rectifier transformer feed back card

failed A

47 Cooling raw water drained B

48 Boiler lift Leveling switch damaged A

49 ACP Control contactor coil fail A

50 Selector tap cut in boiler lift -5 C

51 Man trapped in Boiler Lift – 6 A

52 ADPH EOT crane not working. A

53 Boiler lift-6 door partially open A

54 Car gate switch problem A

55 Boiler lift-4 Door Sill filled with mud A

8

Category Description

A Min. dependence on Other Departments

B With dependence on other department

C Needing Management approval

No

. of

pro

ble

ms

0

10

20

30

40

50

( By Brainstorming)

44

83

9

„U‟ OF IDENTIFIED PROBLEMS( Brain storming done for the A – category Problems )

10

PROBLEM SELECTION MATRIXSl.

No.Problems Identified Theme Nature Prio

rityQ C D S E D CR

1 * H * * - * M 4

2 * M * * * - L 2

3 * M * * * - L 5

4 * H * * - * H 3

5 * M * H * - H

Q=Quality, C=Cost, D=Delivery, S=Safety, E=Easy, D=Delay & CR=Critical

1

L=Low M=Medium H= High * Applicable

Topic selected is

11

“Elimination of EOT CRANE PENDENT

problems”

Definition of Problem

PENDANT is the tools for safe

operation of EOT Cranes.

12

EOT Cranes consist of

1. Control panel

2. Pendent for operation

3. Motors for drive

4. Breaks

5. Protection Limit switches

6. Bus bars for power supply

input.


13

ESP CONTROLS

ASH SLURRY PUMPS

27 NOs

FAN ASSEMBLY

28 NOs

BEETER WHEEL

42 NOs

CW PUMPS 42 NOs

EOT CRANE 1 No.

EOT CRANE 1 No.

EOT CRANE 2 Nos.

MILL MAINT.

ADPH

RAPH& FAN

20 / 5 TONS

20 TONS

6/5 TONS

8 Nos.

CWPH.30 / 5 TONS

EOT CRANES

12 Nos.

EOT CRANEs

Related Daily Jobs.


14

PENDENT PUSH

BUTTONS

NO

NO

YES

YES

Company Logo


14

The problem will be arises and reported only on

the execution job. So the complaint nature will be

“MOST URGENT” always.

EOT CRANE PENDENT is the control device to operate the

Crane from convenient place in the work premises.

1. It is connected through one or

two rubber control cable.

2. Push buttons with actuators to

give commands.

3. It is hanged with metal chain to

hold the Pendent.

4. It‟s weight may be two to 3kg

depending upon the no. of control

operation.

The pendent

problems are

frequently

reported

15

1. Maintenance work stopped..

2. Job hanging on the rope in lifted position.

Safety of the Men & Material is very big question.

3. To attend the problem minimum three persons have to go

up to 15 meter level machine control panel by monkey

ladder. It requires stamina.

4. Delay in job output and loss of revenue.


16

Our Objectives & Goal

Our Objectives are…..1. Frequent failure of Pendent problem should be avoided.

2. To minimize the EOT Crane down time.

3. To avoid Maintenance stoppage.

4. To ensure Safety of the Men & machine.

5. To minimize Maintenance cost & time

Goal setting…..…..

17

Problem Identification

Problem Selection

Root cause Analysis

Problem analysis

Finding Causes

Foreseeing Probable Resistance

Trial Implementation

1

2

3

4

5

6

7

8

9

10

Solution Development

Problem Definition

Data Analysis

11

12

JAN FEB MAR APRIL MAY JUNE JULY

2018

Follow-up & ReviewTrial Follow-up, Review

Regular

Implementa

tion

AUG

18

Understanding the problem by 4W & 1H

WHERE does this problem occurred ?

WHEN does it occur ?

WHO informed this problem ?

HOW much is the severity ?

EOT Crane not working

Mill maintenance work shop

During ID FAN maintenance works.

Dy. Chief Engineer

Men/ Material Safety endangered.EOT Crane under break down. Maintenance work stopped.

WHAT is the problem?

19

21

Sl.

No

YEAR No. Of EOT

Crane

Break

downs

1 2013 47

2 2014 49

3 2015 38

4 2016 51

5 2017 55

PAST 5 YEARS DATAs - EOT CRANE PROBLEMS

REPORTED.

0

10

20

30

40

50

60

2013 2014 2015 2016 2017

47 49

38

5155

48

YEAR

EO

T C

ran

e B

reak d

ow

ns

Average line

22

TOPIC: EOT CRANE BREAK DOWN/FAILURES ANALYSIS

Sl.

No. Problems Failure of parts/ equipment

No. of

times Total

1CONTROL CIRCUIT

PROBLEMS

Push button actuator Problem 3

7Cable problem. 2

Limit switch failed 1

Push button element Problem 1

2POWER CIRCUIT

PROBLEM

Cable leg cut 2 3

0.4kV Bus bar problem 1

3MECHANICAL

PROBLEM

Gear box failed 12

Main Rope & Sheeve problem 1

4 MOTOR PROBLEM Winding open/single Phasing1 1

5 BREAKS PROBLEM Break failed1 1

Total No. of failures 14

DATA COLLECTION SHEET

(Based on Logbook : OCT-2017 to DEC-2017

DATA ARE COLLECTED FROM STAGE-I ADPH PLUS LEVEL EOT CRANE,

RAPH&FANS EOT CRANE AND ADPH STAGE-II MINUS LEVEL EOT CRANE.

As per 80:20 line principle, the Control circuit problem and Power circuit

related problems are dominating in the Pareto chart.

7

3

2

1

50.0%

21.3%

14.3%

7.1% 7.1%

71.4%

85.7%

14 Nos.92.2%

100%

80:20 line

DATA COLLECTION OCT-2017 to DEC-2017

23

24

Sl.

No.Possible causes

Sl.

No

.

Possible causes

1 Cable insulation damaged 12 Break shoe problem

2 Push Button failed. 12 Main Hoist Limit switch problem

3 Motor Rotor resistance failed 13 Power cable Charred /Cut

4 Long Travel limit SW failed 14 Gear box failed

5Dust accumulation on Bus Bar

Rail15 Over load

6 Control supply failed 16 Pendent hit on Job during work.

7 Pendent Actuator missing 17 Contactor failed

8 Cable Open 18 Pendent chain cut

9 Contactor Mech. interlock 19 Cable gland failed

10 Loose connection in Control cable 20 Dove droppings

MACHINE

(PENDENT)

MATERIAL

PROCESS

MAN

EOT CRANE PROBLEM

(By Brain storming )

Motor Rotor resistance failed

Over load

Control supply failed

Cable gland failed

Cable insulation damaged

Cable OpenLong Travel limit SW failed

Main Hoist Limit switch

problem

Contactor Mech. interlock Push button fail

Gear box failed

Push Button failed.

Loose connection in

Control cable

Break shoe problem

Dove droppings Pendent Actuator missing

Dust accumulation on Bus

Bar Rail

25

Pendent hit on Job during work.

Pendent chain cut

Electric shock


MACHINE

(PENDENT)

EOT CRANE PROBLEM

Control supply failed


Cable OpenPush Button failed.

Pendent chain cut

Electric shock

Causes Occurr

ence

Severi

ty

Score Is analysis

require

Push Button failed 2 2 4 No

Control supply failed 2 4 8 YES

Electric shock 1 10 10 YES

Cable Open 1 2 2 No

*Occurrence Data period:

01.06.2017 to 31.06.2017

1. RISK/ SAFETY – 10 Points (Highest)

2. Work Stopped/Safety- 5(Moderate)

3. Complaint – 2 Points (Less) 26

PROCESS


Long Travel limit SW failed


problem

Gear box failed

Loose connection in

Control cable

27

Causes Occur

rence

Seve

rity

Score Is analysis

require


problem

1 4 4 NO

Long Travel limit SW failed 2 2 4 NO

Loose connection in Control

cable

1 2 2 NO

Gear box failed 1 2 2 NO


01.06.2017 to 31.06.2017



3. Complaint – 2 Points (Less)

EOT CRANE PROBLEM

MAN

EOT CRANE PROBLEM


Over load

Push button fail

Pendent Actuator missing

Pendent hit on Job during work.

Causes Occur

rence

Seve

rity

Score Is analysis

require

Pendent Actuator missing 4 2 8 YES

Pendent hit on Job during work. 1 2 2 No

Push button fail 1 2 2 No

Over load 1 2 2 NO


01.06.2017 to 31.06.2017



3. Complaint – 2 Points (Less) 28

MATERIAL

EOT CRANE PROBLEM


Motor Rotor resistance failed

Cable gland failed

Contactor Mech. interlock

Break shoe problem

Dove droppings

Dust accumulation on Bus

Bar Rail

29

Causes Occurr

ence

Sever

ity

Score Is analysis require

Dove droppings 1 2 2 No

Motor Rotor resistance failed 1 2 2 No

Contactor Mech. interlock 1 2 2 No

Dust accumulation on Bus Bar Rail 2 2 4 Regular Preventive maintce.

taken. So , No need.


01.06.2017 to 31.06.2017



3. Complaint – 2 Points (Less)

MACHINE

(PENDENT)

MATERIAL

PROCESS

MAN

EOT CRANE PROBLEM


Cable Open

Pendent Actuator missing

30

Electric shock



POINT TO ANALYZEVALIDATION

METHODOLOGY

FINDINGS /RESULT REMARKS

Control supply failedCheck by visit, Data

collection and

Measurement of

parameter

68V AC respect to

Neutral and fuse

blown out.

RISK LEVEL HIGHElectric shock

POINT TO ANALYZEVALIDATION

METHODOLOGYFINDINGS /RESULT REMARKS

Pendent Actuator

missing

Data collection/

Frequency high

Check nuts Missing.

Accessible to every

one and not able to

identify the culprit.

Possibility of

short with

pendent

body &

Significant

31

Identify Root Cause

(By Brain storming )Root Cause Analysis

Why Why Analysis

It is un avoidable..

ROOT CAUSE.

Pendent, pendent cable and Unauthorized person

access are the root causes.

Electric shock & Supply fail?Cable insulation failed / cable earthed.

Pendent weight… and aging of cable

It is un avoidable.

Unknown persons doing purposely. Accessible to all at site.No lock/ fool proof method not available.

WHY

WHY

WHY

32

Pendent Actuator missing ?


ROOT CAUSE.

Pendent &cable and Unauthorized person access

are the root causes.

1. Small handy pendent may be

fitted.

2. Periodically cable to be

changed.

3. Alternate method may be

adopted.

4. Unauthorized person access

to be prevented

33

Data Analysis


Suggestions of Our team

1 Replace the missing Push Buttons and replacement of cableperiodically.. REJECTED.

2 Provide Lock to prevent unauthorized person access and Handy pendent . REJECTED.

3 Lockable fixed control station for Pendent. NOT POSSIBLE

4 RF Wireless remote pendent can be introduced. Accepted.

34

DATA ANALYSIS FOR IMPLEMENTATION

Available

resource /

Materials

Field

Requirement

One to one

replacement / Status.

Road Block if any Remark

RF WIRELESS

REMOTE

PENDENT

Needs 16 Control

lines

Yes. It shall be one to

one Replacement.

Control lines are

grouped.

Alternative models

not available.

Modification

is needed.

OPERATION

DISTANCE

75 meter (Min) Yes -- --

LOCKABLE Controllable Yes -- --

WEIGHT About 260gms Yes -- --

OPERATING

VOLTAGE

Pendent: 3 V

Receiver: 230 V

Yes -- --

Cost

Lower than

existing

Yes. RF wireless remote

Pendent cost is less than

conventional pendent with

cable.

-- --

35

RF wireless remote Pendent Data collection

DATA ANALYSIS FOR IMPLEMENTATION

36

Data collection Wire less RF remote pendent and receiver

Details Transmitter Receiver

Dimension239*68*65

mm

331*160*140

mm

Weight 255g 1200g

Material Glass-fiber

Protection

levelIP65

Power supplyDC 3V (2 AA

batteries)220V/110V AC

SPECIFICATIONS

Control distance up to 100 meters

Control motions 4/8/10/16/18/20

Structure Glass-fiber

Operation

Frequency310-330Mhz & 433Mhz

Certification CE, FCC

Unique codeOver 4.3 billon unique ID

codes

Working

temperature-35°C to +80°C

Output capacityFull sealed relay output

with 5 amperes

Market available models/specification

Developing the solution.

37

RF

waves

38

DEVELOPPING SOLUTION


Introduction of

8 Channel relay

39

40


RE

LA

Y C

HA

NN

EL

Sl.No.

ACTIVITYPROBABLE

RESISTANCEACTION TAKEN TO

OVERCOME RESISTANCE

1 Provide new RF PendentWill it work properly up to safe range.

Yes, it is covers 100M distance.

2 Provide new RF PendentWill it work properly and safe.

Physically verified for relay output and found no hindrance

3 Inclusion of 8 Ch RelayWill it affect air Operation of the Crane.

Ensured , no issue.

4Incorporating above new

provisions

Will it affect safety of the Crane and users.

Ensured. Safety point of view, it is more safety.

5Incorporating above new

provisions

Will it affect IR relation of Lift user and operator.

No. It will encourage to all.

FORESEEING RESISTANCE.

(BRAIN STORMING)

41

TRIAL IMPLEMENTATION

MODIFICATION EXECUTION (March- 2018)

42


MODIFICATION EXECUTION (March- 2018)

43

44

Performance report from Customer division

Topic: EOT CRANE Failures analysis

Sl.


No. of

occurrence

1PENDENT related

problems

Cable, Push Button and PB

Actuator. 0

2Unauthorized use of EOT

crane

Pendent Actuator missing 0

3Handling / Operational

defectsJob/ Pendants

0

4 Electric shockWorking Voltage is 3V only.

Eradicated. 0

5 Pendant Cable 10M Removed --

6 Safety 100 % ensured.--

* DATA ARE COLLECTED FROM STAGE-I ADPH PLUS LEVEL EOT CRANE ,


PERIOD: - From APR-2018 to JUN-2018


45

TRIAL IMPLIMENTATION DATA BEFORE AFTER

Sl.


OCT-2017 to

DEC-2017

APR-2018 to

JUN-2018

No. of

times Nos.No. of

times Nos.

1CONTROL CIRCUIT

PROBLEMS

Push button actuator Problem 3

7

0

1

Cable problem. 2 0

Limit switch failed 1 1

Push button element Problem 1 0

2POWER CIRCUIT

PROBLEM

Cable leg cut 2

3

0

10.4kV Bus bar problem 1 1

3MECHANICAL

PROBLEM

Gear box failed 1

2

0

0Main Rope & Sheeve problem 1 0

4 MOTOR PROBLEMSlip ring Brush & Holder

problem 1 1 0 0

5 BREAKS PROBLEM1 1 1 1

Total No. of failures 14 3

* DATA ARE COLLECTED FROM STAGE-I ADPH PLUS LEVEL EOT CRANE ,


DATA COLLECTION SHEET Topic: EOT CRANE BREAK DOWN ANALYSIS

46

78% Problems

solved

PROBLEMs PROBLEMs

SL NO

WHAT WHY WHO WHERE WHENHOW

1Commissioning To fix

Receiver and relay

R.Senthamizhselvan

P.AnbalaganEOT Crane Control Panel

MARCH -01 TO 21

Drilling, fixing , wiring

2Testing & Trial Checking

To Check funtions

J.RATHINAKUMAR

R.SenthamizhselvanEOT Crane

MARCH 08 TO 21

checking

3Fore seeing probable resistance

To forecast road blocks.

J.RATHINAKUMAR

P.Anbalagan

In EOT Crane and its Work premises

FEB-

22

Brain storming, Data collection meeting with experts and modifying datasheets and procedures

4Meeting organizing and Communication

Over all

Co-ordination

P.AnbalaganAt our office.

Throughout the Project

Over Phone and in person

5Model fabrication

For effective Presentation

R.Senthamizhselvan

S Savariraj

P. Anbalagan

At LabAug-2018

Assembling / Testing

47

1. Approved Circuit Diagram was included in

Drawing.

2. Modification details were informed to User

divisions In-charge.

3. Training was given to user division and our

division members.

REGULAR IMPLEMENTATION

Follow-up reviews were carried out.

48

No complaint with this new arrangements till date.

Pendent and Receiver

Working person Statement

User division In

charge

Pendant Fail report

Working well Working very well

Very effective. 0

Data source : Log book

49

Data collection July to Aug-2018No. of Inspection made: 9

Regular implementation

Follow-up reviews

50

Job carried out by single workman.

Sl.

No.

AIM ACHIEVED

1 Frequent failure of EOT Pendent

problem should be eliminated.

Eliminated

2 To minimize the EOT Crane down

time.

Minimized

3 To avoid Maintenance stoppage. Minimized

4 Safety of the Men & machine

increased

Yes. Achieved

5 Maintenance cost & time is come

down

Minimized.

AA CHART

51

Cost Benefit Analysis

• 15 Meters 12 core control cable removed.

•5 Kg weight pendant removed

Maintenance Qty in preventive schedule reduced

(3X 40X Rs. 8.75)………………………………… ..……..= Rs 1,020/-

Each EOT Crane operating worker reduced = 1 No.

3 EOT crane (3X Rs.550) X25 days = Rs 4,1250/-

Push Button saved (4X 265) = Rs 1,060/-

Rs 43,330.00

52

Modification costRemote pendant set = Rs. 26750.00

Power pack = Rs. 450.00

Relay Channel = Rs. 350.00

Total………… …..= Rs. 27550.00

For three EOT Cranes Rs. 82650.00

PAY BACK PERIOD

IS SIX MONTHS

For 3 Cranes the cost saved for three months is

Rs.43,300.00 . For one year = Rs. 1,73,200.00

Now modification in progress for 9 more EOT Cranes.

Cost saved per Year will be : Rs 6,92,800.00

Benefit Analysis

System Availability Increased .

Breakdowns of EOT Crane is reduced.

Working Environment Improved.

Working time for every job is reduced.

Operation Department Satisfaction

increased.

Men and Material SAFETY ensured..53

0

2

4

6

8

10

Problem Solving Skill

Self Development

Team WorkPresentation Skill

Knowledge on QC Tools

Before QC After QC

54

1.ABC ANALYSIS

2.PRIORITY / RATING

3.GANTT CHART

4.FLOW DIAGRAM

5.PARETO DIAGRAM

6.BRAIN STORMING

7.CAUSE & EFFECT DIAGRAM

8.VALIDATION OF CAUSES

9.WHY-WHY ANALYSIS

10.ACTION PLAN( 5W +1 H)

11. AA CHART55

56

Request your Queries &

Improvement Suggestions Please……..

Welcomes for the presentation on

Documents

Transcript of Welcomes for the presentation on