This document proposes several ideas to improve plant sustainability and reliability at a manufacturing facility. It suggests reducing the closure time for slurry injection nozzles from 72 to 5 seconds to prevent blockages during power issues. It also recommends repairing drainage channels and applying a waterproof coating around a CP lift pit to stop water seepage and ensure lift integrity. Replacing the chipper die plate after each operation is proposed to reduce waste generation and maintain smooth plant operations. Installing a larger condenser for a dow vent collection tank is suggested to properly condense vapors and reduce dow wastage. Additionally, stopping a blended glycol pump and casting water tube well except during required periods as well as stopping an esterifier agitator before

1. IDEA SUBMISSION
Topic: Plant Sustainability & Reliability

2. Plant Sustainability and Reliability:
 In this presentation, We have covered a number of ideas which are related to plant sustainability and
reliability. Sustainable manufacturing can be very cost-effective. By improving the efficiency of your
equipment and processes, you can lower energy consumption, decrease manufacturing time, reduce waste,
and use less material — all of which can provide significant cost savings for you.
Factors for Achieving Sustainable Manufacturing
1. Optimize your current resources.
2. Reduce / Eliminate waste.
3. Avoid Delays in Production.
4. Recycle.
5. Ensuring Standby Equipment's Health (RSO Plan etc.)
6. Save Time
The different ideas are discussed in parts, Please continue on next slide

3. Plant Sustainability and Relaibility-Part-1:
Slurry Injection Nozzle Closure Time Reduction
 Part-1:
In recent power dips / Failure, It has been seen that Slurry injection nozzles had issue when one of the nozzle
gets blocked due to power dip or power failure. The other nozzle also took time against miscellaneous issue
(SOV's etc.) against which plan startup was delayed, Delay in plant startup causes further quality issues.
The Idea:
 Against low flow interlock, Slurry Nozzle has some default time setting before which it fully closes. Slurry
nozzle closes in 72 seconds. Time required for diverting slurry is 5 seconds, then EG flushing for 67 seconds.
 It is suggested to reduce slurry nozzle closure time from 72 second to 5 second so that nozzle is closed as
soon as the interlock is operated. In this way, slurry nozzle blockage can be avoided and nozzle will be readily
available for injection preventing any production loss or quality issues.
Note:
Slurry nozzle always gets block whenever there is power dip / power failure or ay issue with Slurry feed Pumps.

4. We will have the following benefits
1. Slurry injection nozzle will be readily available avoiding any maintenance activities for its de-
blocking.
2. During Power Failure or Power Dips, We have seen delays in slurry injection due to nozzle
blockage and miscellaneous issues with standby nozzle. So the production loss will be avoided.
3. During delay in slurry injection, Product degrading will be avoided and Quality will be restored
soon.
4. Delay in slurry injection triggers further process and quality issues.
5. Delay in slurry injection also caused high waste and product downgrade.
6. In normal plant operation, Its operational nozzles gets blocked due to any reason (Interlock, Pump
etc.) and standby nozzle doesn’t work. Plant can be put on idling. If Slurry is injected immediately,
We can restore plant immediately.
Savings Calculations:
Calculations will be done after further discussion and assessment.
Improvements and Savings

5. We will have the following benefits
1. Oligomer line pressure will remain healthy hence avoiding any process issue.
2. No plant throughput reduction due to poor performance of oligomer pump.
3. No UFPP level dip hence no issue with product quality.
Savings Calculations:
Calculations will be done after further discussion and assessment.
Improvements and Savings

6. Plant Sustainability and Relaibility-Part-3:
CP Lift Integrity (Water Seepage into CP Lift pit)
 Part-3:
Water ingression in CP lift has compromised lift integrity as well as CP building. Due to frequent dewatering on
weekly basis, Its has also increased HSE issue / hazards (Vessel entry & Scaffolding into pit every week), Water
ingression in CP lift has caused CP lift maintenance issues (Rope replacement, Bottom Pulley damage etc.). It is
suggested to repair all drain channels around CP lift and apply water proofing coating in CP Lift pit so that water
ingression can be stopped and Lift integrity could be ensured. This will also eliminate HSE concern due to
frequent dewatering.
The Idea:
 Repairing of all drain channels around CP lift.
 Water proofing coating around CP Lift pit’s wall.
Savings:
1. Reduced maintenance and manpower cost.
2. CP Lift is an important equipment, Its health and integrity will be ensured.
3. No more HSE Hazards due to frequent pit cleaning / dewatering.

7. Plant Sustainability and Relaibility-Part-4:
Chipper Die Plate Replacement after each stoppage
 Part-4:
As we are aware that increase in chipper waste or any issue with the chippers operation effects our efficiencies,
Production and quality. If chipper is stopped after taking in operation and its die plate is not replaced, It will
cause slow holes or laces accumulation when it will be operated next time. These issues will cause delay in
chipper operation which will cause quality issues and plant production loss. When it comes online, It will be
going on waste against slow holes and laces accumulation which will cause high waste generation.
The Idea:
 Chipper die plate to be replaced after each operation.
 Keep chipper system healthy (RSO) when chipper is offline.
Benefits and Savings:
1. Waste reduction of Rs 0.78 M/Year.
2. Smooth plant operation
3. Consistent quality

8. Plant Sustainability and Relaibility-Part-5:
Replace Dow vent collection tank cooling water condenser
 Part-5:
As we are aware that after installation of EG ejector, polymer filter and HTM project Dow venting load increase at Dow
vent collection tank , uncondensed dow waste through single stage ejector and not recoverable(dow is hi cost fluid use as
heating media).Present condenser is undersize and not properly condense dow vapors we face difficulty when vent
collection is overload during excessive venting especially at plant shut down or start up even during normal plant operation
when vent collection system disturbed plant heating variation start and increase banks break rate which is the loss of
production and quality . Large size condenser will condense all vapor and reduce load at single stage jet we can also reduce
steam pressure after installation of large condenser .
The Idea:
 It is suggested to replace vent collection tank cooling water condenser 1812H01C with large size condenser
for proper condense of dow vapors
 Increase dow condensate line die for ease dow transfer in vent collection tank .
Benefits and Savings:
1. Reduce dow wastage which is waste from single stage jet one liter dow cost is almost 1000 PRs.
2. Smooth plant operation and control smooth heating at Polymer and spinning reduce break rate .
3. Reduce steam pressure reduce dow pulling towards jet side .

9. Plant Sustainability and Relaibility-Part-6:
Stoppage of Blended glycol pump and casting water tube well
 Part-6:
Batch polymer plant running cost is hi which is try to reduce by taking some routine actions on energy for plant
sustainability and improvement after each batch some motors running with out any requirement just like
blended glycol pump is only use for glycol measure vessel filling only for 20 mint other wise no need to run this
pump , casting tube well only requirement during batch casting for 30mint .During 40% pet flex charging in
Esterifier its agitator trip on over load to avoid tripping of motor stop it before overload setting avoid
equipment damage and delay time for resetting un availability of elect ration
The Idea:
 It is suggested to stop casting tube well after cast batch and log its status part of casting procedure again
start tube well 10 mint before casting .
 Stop blended glycol pump after filling measure vessel we use fresh glycol in blended .
 Esterifier Agitator stop before overload avoid equipment damage and reduce delay time .
 Benefits and Savings:
1. Reduce energy cost at batch polymer after implement of both above practice .
2. We can save 1.1 million from tube well energy 35 kW motor and .46 million from blended glycol pump
10kw motor Total saving almost 1.5 million with out any modifications
3. Reduce ETC by stop agitator before overload and reduce ETC