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resolved?
In-House Generator Stator Chemical
Cleaning by introducing Nitrogen (N2)
The entire team had felt extremely happy
bubbling arrangement in SCW tank to
as the problem was solved in-house
without disturbed the stator coil system.
reduce Dissolved Oxygen in stator water.
Management had given positive response
This Chemical cleaning was process was
including selection of cleaning chemical,
& supported in all aspects to achieve the
circulation pump, corrosion inhibitors,
results.
online monitoring of chemical & process
Any specific aspects which you may like
parameters, balancing of N2 pressure &
to mention?
DO in stator water system. In this process
injection of chemical solution was
Management supported well and they
believed in our team to carry out such a
continuously done for nearly 72 hrs. at
critical activity without. After seeing the
inlet of stator coil, in parallel with removal
of contaminants (copper oxides) at outlet
results, the same activity was repeated in
by using Mixed Bed (MB) in SCW system.
Jaigarh plant also.
High pure Nitrogen (N2) was used for
blanketing to reduce the DO in stator
water system. The overall activity was
carried out in coordination with
Chemistry, Operation and Maintenance
dept. Total Cost incurred for the said
activity was Rs. 5000/-.
Impact of solution to the
business?
This had saved cost of generator
identified?
stator coils and cost of cleaning
Increasing trend in 300 MW Generator
by OEM is around Rupees 120
stator coil differential pressure indicating
Lacs/Unit. And Generator
the flow restrictions within the stator
performance was improvement a
cooling water channels. Observed there
lot. Generator stator DP reduced
was continuous increasing trend in Stator
from 0.23 to 0.15 Mpa, stator
coil dP from 0.15 to 0.23 Mpa and
water flow improved from 46 to 55
reduction in stator water flow from
TPH.
55 to 46 TPH.
INNOVATION How and Why was the problem How was the problem solved? How the team felt on the problem being
JSW ENERGY BOLT | ISSUE 1
Installation Of VFD In CEP, ID Fan; Auto Mode Of Coal Mill
JSWEL, Ratnagiri Sealing Air System; Header Pressure Reduction in PA Fan;
Operational Improvement in Sea Water System, ACW System,
Replacement Of APH Basket Milling System, LDO Transfer System
How and Why was the By reducing the auxiliary power in ESP How and Why was the Recognition of the team by the top
problem identified? System, Cost saving of 4 Crore per problem identified? management (at plant level and at
year achieved.
QIP team name reduction of defects in Problem - Lower PLF and no schedule corporate level) felt the team motivated
ESP system, as a part of QIP team we How the team felt on the problem from MSEDCL /DAM/TAM resulting the and enthusiastic.
have started identifying the defects and being resolved? Auxiliary Power Consumption (APC) % Any specific aspects which you may like
root cause analysis carried out for the Team are feeling very happy and defects on higher side. to mention?
defects. Most of the defects are arises are reduced drastically due to running
due to running hours of equipment's so hours optimization. How was the problem solved? The journey continued to improve the
we have started optimize the ESP Installation of VFD in CEP and reducing plant performance and make our plant the
parameters after studying the ESP Any specific aspects which you may like the pressure set point of the CEP from best in all aspect so that our plant will be
documents and gathering the knowledge to mention? 2.7 MPa to 1.9 MPa. the benchmark to others. Rather than
from ESP training given by BHEL Received an award for this innovative idea individual, team work always give the
representative. We have conducted implemented in ESP System. Installation of VFD in ID fan and best result.
testing after changing the ESP replacement of hydraulic coupling
parameters and ensured Team Members with spacer shaft. Team Members
system improvements. IFC installation and reduction in service Mr. Vijay Likhitkar
Mr. Ganesh Kumar R
How was the problem solved? air set point from 6.5 KSC to 5.5 KSC. Mr. Chinmay Thakur
Mr. Anand Vaidya Mr. Vikas Jagdale
By changing ESP Fields charging ratio and Mr. Ajay Patil Replacement of APH basket and reduction Mr. Samir Talekar
running time optimization of ERM CRM Mr. Rajesh Padhy of DP across APH from 2.13 KPa to Mr. Avadhut Kelkar
motors and hopper heaters. 0.85 KPa.
What were the challenges What were the challenges
encountered? encountered?
After changing the ESP Equipment stability with variation of
parameters found difficulties in load is one of the challenges.
taking samples from chimney Impact of solution to the business?
during testing.
Reduction in APC from 9.07 % to 8.9%.
Impact of solution to the

business? How the team felt on the problem
being resolved?

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