steam consumption

1. 1
Lean Six Sigma Project
To Reduce Specific steam consumption in MUW
Green Belt: Satyendra Kumar Yadav
Define Tollgate Date: 17 Jan 2016
Class C

2. 2
2
Agenda
• Project Charter Review
• Executive Summary
• Value Stream Map
• Operational Definitions
• Data Collection Plan
• MSA
• Baseline Data
• Process Capability
• Measure Tools Summary
• Lessons learned
• Next Steps
• Measure Storyboard
• Measure Signoff

3. 3
3
Reduction of Specific Steam Consumption in MUW Plant
Business Case Opportunity or Problem Statement
•Day by day energy cost is increasing. Energy cost is 60%
of Salt variable cost. Improvement in energy
consumption will help us to maintain our leadership
position in competitive market .
•Contribution Rs.3.25 Crore
•Specific steam consumption in FY 2014-15 was 1.40
Gcal/MT .
•For the H1 2015-16 it has increased to 1.44 Gcal/MT
Goal Statements Project Scope
•Reduce specific steam consumption from 1.40 Gcal/MT
to 1.34 Gcal/MT
•Scope : Steam consumption for MUW 1&2, 3 and 4
•Out of scope : MUW 1&2, 3 and 4 power consumption
Project Plan Team Selection
Green Belt: : Satyendra Kumar Yadav
Project Sponsor : PM Patel
Black belt guide : Jayendra Jadega
Deployment director : Mahesh deshpande
Master black belt : Ashok muthuswamy
Team : Mayur gandhi , Vimal patel ,
Karan patel, Jignesh mandora
Bhargav patel
D M A I C
20-Nov 17-Jan

4. 4
4
Specific Steam Consumption
1.54
1.58 1.58
1.45
1.49
1.51
1.52
1.4
1.3
1.34
1.38
1.42
1.46
1.5
1.54
1.58
1.62
2011-12 2012-13 2013-14 2014-15
With power Without power
TARGET 1.34

5. 5
5
MUW-1/2 Value Stream Mapping
MUW-1/2 Plant Value Stream Mapping
Supplier Process Customer
Solar Salt
Saturated
Brine
Steam &
Power
Chemicals
& Packing
Materials
Power Plant
Store &
Purchase
Brine SSD operation
for Brine
enrichmentin
monsoon only
Settlingof
brine in
Thickenerin
Monsoon
only
Evaporato
rs for
Brine
Evaporati
on
Magma
Handling (10to
15% solid)
Decantation
(solidLiquid
separation)
Outlet 50%
Wetsolid
Settlingof
Liquor overflow
(solidrecovery)
Screeningwith
10 mesh size
De-superheating
Condensation
Centrifugingof
50% solid
Iodisation
(30<=Iodine<50
ppm)
Drying
(WetSalt 2-3%
moisture)
Solar SaltOffice
Quality of Raw Brine:
(1) Density -25 Be
(2) Nacl 260-265 gpl
(3) Ca <0.4 gpl
(4) Mg < 11 gpl
Quality of steam & Power:
(1) 50# steam 50-55 TPH
with 45-50 psi pressure and
150 C
(2) 120 # steam 35 TPH
and 190 C to 200 C
Power plant
Control
Store & Purchase Office
Kyar Brine
Pumpman
MUW-3 Control
room
Circulator
attendant
Pumpman/
condensate
Bad Condensate
GoodCondensate
Dryer/
Centrifuge
Quality : In Dry Salt:
Iodine 30 to 80 PPM,
Ca-0.1% max,Mg - 0.15% max,
Non Caking Agent- 10PPM
Product
Storage/ Silo
Packing
Packing
supervisor
Packing/Weighing/
Restiching/iodisation/
lump rework
Product
Inspectorate
Loading
Bittern
Salt
Solar Salt
Supply Chain
Water Softening
SCM Office
Water Softening
Control room
MST
Tank
Quality :
Draw from body:
Slurry Density: 27 to 28 °Be,
Solid: 10 to 15%
Pre-
heaters
Capacity of Major Equipments
Sr. No. Equipment Capacity Unit Total
1 Evaporator-1 145 TPD
2 Evaporator-2 145 TPD
3 Evaporator-3 145 TPD
4 Evaporator-4 145 TPD
5 Evaporator-5 145 TPD
6 Evaporator-6 145 TPD
7 Centrifuge (2Nos) 30 TPH 60
8 FBD-4 900 TPD
10 Silo 50 T
11 Packing Machines 950 TPD
870

6. 6
6
MUW-3 Value Stream Mapping
Process
Supplier
MUW-3 Plant Value Stream Mapping
Customer
Solar Salt
Saturated
Brine
Steam &
Power
Chemicals
& Packing
Materials
Power Plant
Store &
Purchase
Brine SSD operation
for Brine
enrichmentin
monsoon only
Settling of
brine in
Thickenerin
Monsoon
only
Evaporato
rs for
Brine
Evaporati
on
Magma
Handling (10to
15% solid)
Decantation
(solid Liquid
separation)
Outlet 50%
Wetsolid
Settling of
Liquor overflow
(solid recovery)
Screening with
10 mesh size
De-superheating
Condensation
Centrifuging of
50% solid
Iodisation
(30<=Iodine<50
ppm)
Drying
(WetSalt 2-3%
moisture)
Solar SaltOffice
Quality of Raw Brine:
(1) Density -25 Be
(2) Nacl 260-265 gpl
(3) Ca <0.4 gpl
(4) Mg < 11 gpl
Quality of steam & Power:
(1) 20# steam 75-80 TPH
with 14-18 psi pressure
(2) 120 # steam 70 TPH
and 190 C to 200 C
Power plant
Control
Store & Purchase Office
Kyar Brine
Pumpman
MUW-3 Control
room
Circulator
attendant
Pumpman/
condensate
Bad Condensate
Good Condensate
Dryer/
Centrifuge
Quality : In Dry Salt:
Iodine 30 to 80 PPM,
Ca-0.1% max,Mg - 0.15% max,
Non Caking Agent- 10PPM
Product
Storage/ Silo
Packing
Packing
supervisor
Packing/Weighing/
Restiching/iodisation/
lump rework
Product
Inspectorate
Loading
Bittern
Salt
Solar Salt
Supply Chain
Water Softening
SCM Office
Water Softening
Control room
MST
Tank
Quality :
Draw from body:
Slurry Density: 27 to 28 °Be,
Solid: 10 to 15%
Pre-
heaters
Capacity of Major Equipments
Sr. No. Equipment CapacityUnit Total
1 Evaporator-1 150 TPD
2 Evaporator-2 150 TPD
3 Evaporator-3 150 TPD
4 Evaporator-4 150 TPD
5 Evaporator-5 175 TPD
6 Evaporator-6 175 TPD
7 Centrifuge (2Nos) 30 TPH 90
8 FBD-6 900 TPD
10 Silo 90 T
11 Packing Machines 1000 TPD
950

7. 7
7
MUW-4 Value Stream Mapping
MUW-4 Plant Value Stream Mapping
Supplier Process Customer
Solar Salt
Saturated
Brine
Steam &
Power
Chemicals
& Packing
Materials
Power Plant
Store &
Purchase
Brine SSD operation
for Brine
enrichment in
monsoon only
Settling of
brine in
Thickenerin
Monsoon
only
Evaporato
rs for
Brine
Evaporati
on
Magma
Handling (10to
15% solid)
Decantation
(solid Liquid
separation)
Outlet 50%
Wet solid
Settling of
Liquor overflow
(solid recovery)
Screening with
10 mesh size
De-superheating
Condensation
Centrifuging of
50% solid
Iodisation
(30<=Iodine<50
ppm)
Drying
(Wet Salt 2-3%
moisture)
Solar Salt Office
Quality of Raw Brine:
(1) Density -25 Be
(2) Nacl 260-265 gpl
(3) Ca <0.4 gpl
(4) Mg < 11 gpl
Quality of steam & Power:
(1) 20# steam 75-80 TPH
with 14-18 psi pressure
(2) 120 # steam 55 TPH
and 190 C to 200 C
Power plant
Control
Store & Purchase Office
Kyar Brine
Pumpman
MUW-3 Control
room
Circulator
attendant
Pumpman/
condensate
Bad Condensate
Good Condensate
Dryer/
Centrifuge
Quality : In Dry Salt:
Iodine 30 to 80 PPM,
Ca-0.1% max,Mg - 0.15% max,
Non Caking Agent- 10PPM
Product
Storage/ Silo
Packing
Packing
supervisor
Packing/Weighing/
Restiching/iodisation/
lump rework
Product
Inspectorate
Loading
Bittern
Salt
Solar Salt
Supply Chain
Water Softening
SCM Office
Water Softening
Control room
MST
Tank
Quality :
Draw from body:
Slurry Density: 27 to 28 °Be,
Solid: 10 to 15%
Pre-
heaters
Capacity of Major Equipments
Sr. No. Equipment Capacity Unit Total
1 Evaporator-1 150 TPD
2 Evaporator-2 150 TPD
3 Evaporator-3 150 TPD
4 Evaporator-4 150 TPD
5 Evaporator-5 150 TPD
6 Evaporator-6 150 TPD
7 Centrifuge (2Nos) 30 TPH 90
8 FBD-6 900 TPD
10 Silo 90 T
11 Packing Machines 1000 TPD
900

8. 8
8
Input Process & Output Metrics
8
Finished Product + Waste Salt to SSD in MT Condensate in KL (Good /Bad),Bittern KL
Evaporation- decantation-centrifuging-drying-product packing-cooling , Body & Cal Pre,
Temp, Cooling sea water temp ,Vacuum in Condenser, Total salt in MT, Condensate , Bittern
20# St T/Prod T (Steam Ratio)
Brine Quantity KL/Hr &
Quality – Ca , Mg, NaCl GPL,Ph
Steam 20# -Flow ,Pressure &Temp

9. 9
9
Operational Definitions
Metrics Performance Measure Type Units Operational Definition
Y
20#, 50# Steam Ratio
Continuous MT/MT
20#&50#Steam Ratio is the ratio of 20#&50#Steam consumed
and Total Salt Prouction. Normal Ratio for 20#&50#should beless
than or equal to 1.95&1.5respectively .
X1
Steam Flow
Continuous TPH
Steam is used in MUWplant for evaporation.The flow of steam in
TPHis measured by differential flow transmitter which is displayed
in control room . 20#steam is used in MUW-3&4, while 50#is used
in MUW-1/2.
X2
Brine Concentration
Continuous
Be,%Ca ,Mg,Nacl
content
A laboratory report is generated wrt Ca,Mg,Nacl and pH measured
at central Lab. Ca,Mg,Nacl in GPLand Brine specificgravity in Baume
is called Brine concentration.
X3
Vaccum of Condensor
Continuous In Inch Hg
The differential pressure below atmosphere in main body in Inch of
Hg is known as vacuum.
X4
Body Top Pressure /
Vaccum Continuous
Vacuum in Inch
Hg,Pressure in psi
The differential pressure above atmosphere in body is known as
pressure while the differential pressure below atmosphere is
known as vacuum.This is digitally displayed in DCS.
X5
Body Liqour Temperature
Continuous In Deg C
The absolute temperatue ,at a given pressure,of a liq/vapour which
is measured by thermocouple and displayed digitaly in DCS panel.

10. 10
10
Operational Definitions
Metrics Performance Measure Type Units Operational Definition
X6
Body Vapour
Temperature Continuous In Deg C
The absolute temperatue ,at a given pressure,of a liq/vapour which
is measured by thermocouple and displayed digitally in DCS/panel.
X7
Calendria Pressure /
Vaccum
Continuous
Vacuum in Inch
Hg,Pressure in psi
The differential pressure above atmosphere in calendria is known
as pressure while the differential pressure below atmosphere is
known as vacuum.This is digitally displayed in DCS panel.
X8
Desuperheater DA water
flow rate Continuous TPH
Amount of DA water required in desuperheater depends on the I/L
steam temperature , its flow rate and temperature of DA water .
X9
Cooling Tower SW I/L
Temp
Continuous In Deg C
Sea Water is used as a cooling media in across TCL . Cooling water
from condenser goes to cooling tower and gets cooled. The cooling
water from cooling tower is again fed to condenser as a cooling
media.The temperature of sea water entering cooling tower for
cooling is known as sea water I/L temperature.
X10
Cooling Tower SW O/L
Temp
Continuous In Deg C
Sea Water is used as a cooling media in across TCL .Cooling water
from condenser goes to cooling tower and gets cooled. The cooling
water from cooling tower is again fed to condenser as a cooling
media.The temperature of sea water coming out from cooling
tower for cooling is known as sea water O/L temperature.
X11
Cooling Tower Temp.
Range
Continuous In Deg C
The difference of cooling water outlet and inlet temperature is
known as temperature range.

11. 11
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Operational Definitions
Metrics Performance Measure Type Units Operational Definition
X13
Shut-Off Vaccum
Discrete In Inch Hg
When any ejector is started vacuum is observed on vacuum gauge.
Ejector is taken in line by opening sea water valve or cooler and
120# steam valve for ejector vacuum system. The vacuum in line
without taking vapour load on ejector system is known as shutoff
vacuum.Normally Shut off vacuum should be 24'' Hg.
X14
Magma Draw Density and
Solid Content Continuous
Baume, %Solid Magma Draw is Concentrated Brine O/l from body and solid content
is the amount of solid in % present in magma draw. Solid content
should be around 10-15% in magma draw ideal condition.
X15
Salt Production
Continuous MT
V-Salt production is the sum of total salt dispatched from MUW-3
plant to SCMand solar salt MT .It is the sum of waste salt and
finished Product.
X16
Condensate
Continuous KL
The condensate is the water produced in MUW-3 plant due to
cooling of vapour or steam.It is classified as good and bad
condensate depending on its conductivity. If conductivity is less
than 40 µs/Cm2 it is good condensate and sent to MST tank in power
plant and from there finally to water treatment plant via pump.
Rest condensate having conductivity greater than 40 µs/Cm2 is bad
condensate and it is taken in bad condensate tank and from there
sent to water treatment plant via pump.
X17
Bittern
Continuous KL
Bittern is liquid residue in a MUW plant after taking out salt from
brine by evaporation and decantation which is also known as
Mother liquor and it is partly recycled.

12. 12
12
Data Collection Plan
Metric
Performance
Measure
Type Units
Data Source
& Location
How Will Data
Be Collected
Who Will Collect
Data
When Will
Data Be
collected
Sample Size
Stratification
Factors
How Will Data
Be Used
Y
20#, 50# Steam
Ratio
Continuous MT/MT MUW-
1/2,3&4Plant
Total 20#&50#
Steam Consumed/
Total Production
of MUW-1/2,3&4
Shift Engineer Everyday &
Every Shift
End
7Months Data
from April-2015
to October-2015
To Measure
Steam at MUW-
1/2,3&4Plant
To Find 20#&50#
Steam Ratio
X1
Steam Flow Continuous TPH Steam of
MUW-
1/2,3&4Plant
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
To Measure
Production Rate
To Check Impact
of Same on
Production
X2
Brine
Concentration
Continuous Baume,
%Ca,Mg,
NaCl
content
MUW-
1/2,3&4Plant
Brine Inlet
Line/ Brine
Tank
In a sample bottle
afterflushing
sample line .
Sample Boy Daily at 8:00
A.M. except
Holidays
7Months Data
from April-2015
to October-2015
To Measure
Brine Quality
To Check Impact
of Same on
Production
X3
Vaccum of
Condensor
Continuous Inch Hg MUW-
1/2,3&4Main
Condensors
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check Vaccum
Condition in Plant
X4
Body Top
Pressure /
Vaccum
Continuous Pressure in
PSI,
Vaccum in
Inch Hg
At Body Top
in Each Body
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Pressure/ Vaccum
Condition in Plant
X5
Body Liqour
Temperature
Continuous Deg C At Body
Middle in
Each Body
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Temperature
Condition in Body

13. 13
13
Data Collection Plan
Metric
Performance
Measure
Type Units
Data Source
& Location
How Will Data
Be Collected
Who Will Collect
Data
When Will
Data Be
collected
Sample Size
Stratification
Factors
How Will Data
Be Used
X6
Body Vapour
Temperature
Continuous Deg C At Body Top
in Each Body
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Temperature
Condition in Body
X7
Calendria
Pressure /
Vaccum
Continuous Pressure in
PSI,
Vaccum in
Inch Hg
At Each Body
Calendria
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Pressure/ Vaccum
Condition in Body
x8
Desuperheater
DA water flow
rate
Continuous TPH MUW-4Plant From Logsheet MUW-4DCS Operator Every Shift 7Months Data
from April-2015
to October-2015
To know the
proper
Desuperheating
of the steam
To Check Impact
of Same on
Production
X9
Cooling Tower
SW I/L Temp
Continuous Deg C At Main
Condensors
O/L
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Temperature in
Cooling Water
X10
Cooling Tower
SW O/L Temp
Continuous Deg C At Main
Condensors
I/L
From Logsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Temperature
Range in Cooling
Water
X11
Cooling Tower
Temp. Range
Continuous Deg C At Main
Condensors
I/L & O/l
By Difference of
I/L & O/L Temp.
MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check
Temperature in
Cooling Water
X12
Nos. of Dilution Descrete Nos. At MUW-
1/2,3&4
Control Room
From Shift
Engineer Report
Book
Shift Engineer Every Shift 7Months Data
from April-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check Impact
of Same on
Production

14. 14
14
Data Collection Plan
Metric
Performance
Measure
Type Units
Data Source
& Location
How Will Data
Be Collected
Who Will Collect
Data
When Will
Data Be
collected
Sample Size
Stratification
Factors
How Will Data
Be Used
X13
Shut-Off
Vaccum
Descrete Inch Hg AtMUW-
1/2,3&4
Control Room
FromShift
EngineerReport
Book
ShiftEngineer Once in Six
Month
- In MUW-1/2,3&4
Plant
To Check Ejector
Performance and
it's impacton
Vaccum
X14
MagmaDraw
Density and
Solid Content
Continuous Baume,
%Solid
AtMUW-
1/2,3&4
Control Room
FromLogsheet MUW-1/2,3&4DCS
Operator
Every Two
Hours
7Months Data
fromApril-2015
to October-2015
In MUW-1/2,3&4
Plant
To Check Impact
of Same on
Production
X15
SaltProduction Continuous MT MUW-
1/2,3&4Plant
PackingArea
Every Shift Talleyman AfterFillingof
Each Truck/
Tractorand at
the End of
Each Shift
7Months Data
fromApril-2015
to October-2015
MUW-1/2,3&4
Production Shift-
wise
ForPerformance
Measure &
Identify Losses
X16
Condensate Continuous KL MUW-
1/2,3&4Plant
Every Shift MUW-1/2,3&4DCS
Operator
Every Shift 7Months Data
fromApril-2015
to October-2015
MUW-1/2,3&4
Good &Bad
Condensate
To Check the Ratio
of Good to Bad
Condensate
X17
Bittern Continuous KL MUW-
1/2,3&4Plant
Every Shift No Measurement,
DataCollected based
on SaltProduction
Ratio Which is
Normally 3.1KL/Tof
Salt
Every Day 7Months Data
fromApril-2015
to October-2015
To Check the
Quantity
Produced from
MUW-1/2,3&4
Plant
To Check
Efficiency of Plant

15. 15
15
Measurement System Validation
Purpose:
To validate that the base line calculated does not have measurement
system error .
Process Steps:
Identified key process parameters for the measurement system
1.Done calibration for 50# steam flow at MUW 4
2.50# & 20 # Steam flow Zero checked for MUW-1/2,3 & 4

16. 16
16
MUW-1/2 STEAM RATIO
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
1-Apr-15 1-May-15 1-Jun-15 1-Jul-15 1-Aug-15 1-Sep-15
Steam ratio : muw-1/2
Steam
ratio
Target : 1.45

17. 17
17
Process Capability : MUW-1/2 Steam Ratio: - 0.22

18. 18
18
MUW 3 STEAM RATIO
0
1
2
3
4
5
6
1-Apr-15 1-May-15 1-Jun-15 1-Jul-15 1-Aug-15 1-Sep-15
Steam ratio : MUW-3
Steam
ratio
Target : 1.97

19. 19
19
Process Capability : MUW-3 Steam Ratio: - 0.17

20. 20
20
MUW-4 STEAM RATIO
0
0.5
1
1.5
2
2.5
3
3.5
1-Apr-15 1-May-15 1-Jun-15 1-Jul-15 1-Aug-15 1-Sep-15
Steam ratio
Steam
ratio
Target : 1.94

21. 21
21
Process Capability :MUW-4 Steam Ratio: - 0.43

22. 22
22
Measurement System Validation
Purpose:
To validate that the base line calculated for repeats does not have measurement system error
Process Steps:
Identified key process parameters for the measurement system
1. Zero checked for 20# steam flow at MUW-3 plant.
Performed reproducibility study for measurement system validation

23. 23
23
Gage Study – % Solid in Magma Draw

24. 24
24
Gage Study –Magma Draw Baume

25. 25
25
Measurement System Validation
Purpose:
To validate that the base line calculated for repeats does not have measurement system error
Process Steps:
Identified key process parameters for the measurement system
1. Zero checked for 20# steam flow at MUW-3 plant.
Performed reproducibility study for measurement system validation

26. 26
26

27. 27
27

28. 28
28
Measure Phase Executive Summary
• Calibration for 50# steam flow and Desuperheater DA water
flow in MUW-4 is done and found OK.
• Zero checked for 50# steam flow measurement for MUW -1/2
unit 1 & 2 and found ok.
• Zero checked for 20# steam flow measurement for MUW 3&4
unit 1, 2 & 3 and found ok.
• Calibration for 50# steam flow will be done whenever stoppage
is available.
• Process capability test done for MUW-1/2 , 3 & 4 Concetti
stitching machine and found OK .

29. 29
29
Next Steps
• Activities for Analyze Phase
– Identify Critical X’s
– Identify Potential Root Causes Affecting Critical X’s
– Reducing the List of Potential Root Causes
– Root Cause Analysis
– Impact of Root Causes on Key Outputs (Y)
– Prioritized Root Causes
– Analyze Summary
• Planned Lean Six Sigma Tool use
– Basic statistical analysis
– Basic graphing tools

30. 30
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Measure Storyboard
Measure Toll Gate

31. 31
31
Define Signoff
• I concur that the Define Phase was successfully completed on 17/01/2015
• I concur the project is ready to proceed to next phase: Analyse
Jayendra Jadeja
Black belt guide
Mahesh Deshpande
Deployment Director
Satyendra Kumar Yadav
Green Belt
Ashok Muthuswamy
MBB/Consultant
P M Patel
Project Sponsor

32. 32
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32
Thank You