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INNOVATION JSW ENERGY BOLT | ISSUE 1

Re-designed Cyclone Vortex With Additional Ribs
RWPL Barmer

How and Why was the problem 80 mm made of 20 mm plates at its last
Development & Use Of Pre-cast Refractory Blocks identified? length a max deforms tendency location
and two ribs at middle and holding
In U-seal Refractory The Vortex finder supplied by M/s DEC locations.
along with BTG supply became de-shaped
and demonstrates short operation life Impact of solution to the business?
How and Why was the many cavities and passages faster application over the
problem identified? are formed, those allowed conventional casting span. To defer further damages and Estimated business impact: 122.26 Lacs/
maintaining originated circular shape
hot gases to move all method in complex location Annum. Post 10 months of operation, no
As reported that Unit # 08 provided bracings. Over the time of
around the metal shell and shapes. deformation was reported in vortex finder.
U-seal refractory fails and operation, it couldn't fulfill its object,
surface. Which resulting
red hot started at various Impact of solution to the became de-shaped further and start
high temperatures as well business?
places mainly in leg joint hindering in operation. Team Members
as weakening the anchor
area. The cause of continue
joints then collapsed Estimated business impact: How was the problem solved? Atul Kumar Yadav
refractory failure and red
refractory structures 328.72 Lacs/ Annum, safe Harit Pratap Singh
hot, the shell plate badly In strive to solution, in-house designed &
working as no hot material Shailesh Kumar
damaged and hot bed What were the challenges leakage and no bed material developed vortex finder made of 12 mm

materials leakages occurred encountered? SS 310 plates. To enhancing strength and Jaychand
spillage thus good Ronald Saldanha
at nearly all it’s joints. To hot campaign life by provides two ribs of
To over such frequent housekeeping.
achieve normality PLF, we
failures subsequent unit
were compel to make seal Post about 10 months of
shutdowns. Redesigned
boxes to abate such operation no bed material Success Story: Reduction in APC
refractory linning pattern by
leakages. The same leakages as well refractory
eliminating calcium silicate
phenomena observed in failure was reported. Post completion of COD of all Units in
boards with insulite
Unit # 02 as well. March 2013, and subsequent process
refractory and optimization, Auxiliary power was being
How was the problem Pre-cast refractory monitored on YoY basis as: FY 2014-15:
solved? blocks,
10.83 %, FY 2015-16: 11.30 %, FY 2016-17:
U-seal refractory application indigenously 12.02 %.
designed, develop
was done in order of 01X78 It was observed that Aux. Power was
in refractory
MM Calcium Silicate increasing gradually over a period & when
workshop. Made of
Board,01X170 mm Insulation it crossed the normative value of 11.5 % it
high abrasion
castable (Insulite - 11 li) started effecting the revenue of the
resistance 10 % SiC
subsequently 01X150mm company. In order to reduce Auxiliary
based refractory. It
Dense castable (HF-90). The Power Consumption each and every area
also helps us in
cause of shrinkage, gaps in of the plant were analysed. Brainstorming
significant slash in
wearable refractory & fusion sessions were conducted and potential
down time span by
of calcium silicate board, areas were explored for reduction in the

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