![Page 1: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/1.jpg)
IMTMA-ACE MICROMATIC
Productivity championship
awards 2019
20th and 21th August 2019
Bengaluru
Bharat Heavy Electricals Ltd
![Page 2: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/2.jpg)
2
2015-16 Turn over Rs. 800 Crores
Over 30,000 of Valves were manufactured and
supplied during the year.
![Page 3: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/3.jpg)
• High Rework Rate due to Back Seat
• Leak High Rejection Rate due to Seat Crack & Stem Collar Breakage
• High Process cost and Production Cycle Time due to Body-Yoke Welding.
![Page 4: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/4.jpg)
Hand & Motor
Operated
Carbon Steel &
Alloy Steel
2015-16 (~26K)
![Page 5: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/5.jpg)
Bypass Valve
Pressure Relieving Valve
Main Valve
![Page 6: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/6.jpg)
![Page 7: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/7.jpg)
Start
Raw material
Machining-
Valve body
Pre-Heating
Seat Welding
Post Heating
Final
Machining-
valve body
Inspection
Pre-heating
Root welding
Arc Welding
Stress
Relieving
Penetration
Removing
OK
No
t O
K
Radiographic
Inspection
LP Inspection
Shot Blasting Phosphating
Spot facing
Assembling
Hydrotesting
Final
Inspection
Handover to
User
End
Re-
Wo
rk
No
t O
K
Re-
Wo
rk
OK
22
Activities
Re-
Wo
rkMachining-
yokeM
achin
ing
Lapping
Parting
Re-Work
![Page 8: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/8.jpg)
Shell TestSeat Test Backseat Test
Valves is in fully
closed condition
5% of the Valves
Tested Annually
fails this Test
As per the
Manufacturer Test
Procedure.
Valves is in partial
open Condition
There should be no
leak from the
Body-Yoke
Assembly or the
Packings
Valve is in fully
opened condition,
and seated against
the backseat.
No leak should be
there from the
Packing region
30% of the Valves
Tested Annually
fails this Test
![Page 9: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/9.jpg)
Body Seat
Rejection
Body Yoke
Welding Rejection
Due to repeated heat treatment, during
Body – Yoke welding. The seat cracks.
This seat crack, calls for rejecting Body or
Yoke
After the Seat Leak, LPI is done
again, which shows Seat Crack in
some of the Cases
Since Conventional Welding is involved,
defects in welding are unavoidable
13% of Valves manufactured annually get
rejected due to this
![Page 10: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/10.jpg)
![Page 11: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/11.jpg)
![Page 12: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/12.jpg)
![Page 13: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/13.jpg)
1.Cycle Time
2.Material Handling
3.Rework Rate
4.Cost of Valve
5.Operator Fatigue
1.Productivity
2.Safety
3.Customer Satisfaction
Wastage of
Manpower and
Resources
![Page 14: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/14.jpg)
Sl.No Problem No of Valves
1 Backseat Leak 2129
2 Seat Leak 350
3 Center Out Problem 253
4 Improper Machining 127
5 Yoke Thread Problem 59
Total 2918
RT & UT FAILURE DATA - 2015-16
MONTH Size-1/2" Size-1"Size-1
1/2"Size-2"
TOTAL
(Nos)
JUNE 5 10 0 1 16
JULY 1 0 1 3 5
AUGUST 0 0 0 0 0
SEPTEMBER 3 0 15 16 34
OCTOBER 9 19 1 0 29
NOVEMBER 2 1 0 0 3
DECEMBER 7 38 2 0 47
JANUARY 8 18 0 2 28
FEBRUARY 0 59 2 24 85
9 MONTH 247
1 MONTH 25
PER ANNUM 330
PRODUCTION 26613
Percentage of
Rejection =13%
Percentage of
Rework =11%
![Page 15: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/15.jpg)
1. Disc – Disc Retainer – Inside of Packing Ring
2. Disc Retainer – Packing Bush – Inside of Packing Ring
3. Body – Outside of Packing Bush – Outside of Packing Ring
Disc
Disc Retainer
Packing Bush
Retainer
Packing
Ring
Return to New
![Page 16: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/16.jpg)
Order Cost of Process Rate Cum Rate % Cum %
A Welding and Inspection 588 588 28.52 28.52
B Yoke 295 883 14.31 42.82
C Body Machining 290 1173 14.06 56.89
D Body 251 1424 12.17 69.06
E Stem 200 1624 9.7 78.76
F Yoke Machining 135 1759 6.55 85.31
G Packing Bush, Retainer, Support 120 1879 5.82 91.13
H Dies & Retainer 100 1979 4.85 95.97
I Stud 58 2037 2.81 98.79
J Nut 25 2062 1.21 100
28.52
42.82
56.89
69.06
78.76
85.31
91.1395.97
98.79 100
0
10
20
30
40
50
60
70
80
90
100
0
500
1000
1500
2000
A B C D E F G H I J
CU
M %
VA
LV
E C
OM
PO
NE
NT
RA
TE
Cost of valve-1/2” carbon steel valve
Total : ₹ 2,022
![Page 17: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/17.jpg)
RT Failure
Penetration
Re-work
Seat Crack Rejection
Cost of Valve
![Page 18: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/18.jpg)
• Welded Joint between Yoke and Body replaced by a screwed joint
• Stem integrated Tapered Backseat introduced.
20th July 2016 31st March 2017
Project Duration
![Page 19: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/19.jpg)
Existing New
![Page 20: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/20.jpg)
Return to Existing
1. Disc – Disc Retainer – Backseat - Inside of Packing Ring
2. Disc – Backseat Inside of Packing Ring
3. Body - Bonnet
Bonnet
![Page 21: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/21.jpg)
AFTERBEFOREInternal
Treading
Leg provides extra strength
![Page 22: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/22.jpg)
Bonnet Yoke
Internal
Treading
External
Treading
![Page 23: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/23.jpg)
Threaded Body
Connecting Bonnet
Threaded Yoke
![Page 24: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/24.jpg)
Retainer ring Stopper RingPacking bush
![Page 25: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/25.jpg)
Copper Washer provided in
the Matching AreaFlexibility caused the
problem
![Page 26: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/26.jpg)
Lapping and
Leakage
elimination
![Page 27: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/27.jpg)
![Page 28: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/28.jpg)
![Page 29: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/29.jpg)
Screwed yoke:•No Welding•Interchangeability•Low cost•Less production time •No rework/rejection•Easy serviceable
Screwed bonnet:•No Power guns•Faster assembly•No defect•Easy serviceable
Forging body:•No welding•Different material•More strength
Spiral wound gasket:•No shell leakage•Easy replacement•Withstands<550 ®C•Easy serviceable at site
Taper feature in stem:•No collar cut at site•No load for disc•No customer complaint•Excess strength•No lapping/grinding
Threading:•All threads are metric•More Strength•No thread damage
![Page 30: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/30.jpg)
Before
YOKE ACTS AS A PRESSURE PART
Carbon
Steel
Yoke
and
Body
Alloy
Steel
Yoke
and
Body
BONNET ACTS AS A PRESSURE PART
After
Carbon
Steel
Yoke for
Alloy
Steel
Body
![Page 31: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/31.jpg)
₹ 251
₹ 295
₹ 588
₹ 36
₹ 37
₹ 290
₹ 135
₹ 7
₹ 58
₹ 25
₹ 200
₹ 100
Body
Yoke
Welding & Inspection
Retainer
Packing Bush
Body Machining
Yoke Machining
Stopper Ring
Stud
Nut
Stem
Disc & retainer
Total : ₹ 1,434
Bonnet Rs.80
![Page 32: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/32.jpg)
28.52
42.82
56.89
69.06
78.76
85.31
91.1395.97
98.79 100
0
10
20
30
40
50
60
70
80
90
100
0
500
1000
1500
2000
A B C D E F G H I JC
UM
%
VA
LV
E C
OM
PO
NE
NT
RA
TE
Cost of valve
14.31
28.37
40.54
50.24
56.79
62.6
67.4670.27 71.49
0
10
20
30
40
50
60
70
80
90
100
0
200
400
600
800
1000
1200
1400
1600
1800
2000
B C D E F G H I J
Revised Cost of Valve
Cost of valve reduced
upto 29%
![Page 33: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/33.jpg)
Start
Raw material
Machining-
Valve body
Pre-Heating
Seat Welding
Post Heating
Final
Machining-
valve body
Inspection
Pre-heating
Root welding
Arc Welding
Stress
Relieving
Penetration
Removing
OK
No
t O
K
Radiographi
c Inspection
LP Inspection
Shot Blasting Phosphating
Spot facing
Assembling
Hydrotesting
Final
Inspection
Handover to
User
End
Re-
Wo
rk
No
t O
K
Re-
Wo
rk
OK
14
Activities
Re-
Wo
rkMachining-
yokeM
achin
ing
Lapping
Parting
Re-Work
8 Activities
are
eliminated
![Page 34: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/34.jpg)
Financial gain due to manufacturing of screwed type
valve manufacturing/annum
Sl.No Description of costing involved Amount (Rs.)
1 REJECTION COST (PDO) Rs.11,94,630
2 COST SAVING BY MATERIAL REDUCTION Rs.1,79,13,034
3 COST SAVING BY MATERIAL SUBSTITUTION Rs.49,73,464
4 ELETRODE COST FOR REWORK DUE TO RT FAILURE Rs.6,13,665
5 FURNACE COST Rs.11,80,940
6 REWORK COST Rs.35, 87,079
Total loss/annum Rs.6,32,05,514
![Page 35: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/35.jpg)
Electrical energy savings:
25035 kWh/ year
Man hour savings:
89005 hrs/ year
![Page 36: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/36.jpg)
Machining of the
New Body Internals
![Page 37: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/37.jpg)
The approximate concentration of gases during
welding by stick electrode:
Gas SO2 CO CO2
Quantity
(mg/m3)2.62 17.2 5760
The concentration of elements in welding fume
Elements Mn P Al Ni
Quantity
(mg/m3)2.5 2.3 8.5 0.07
7 Million worldwide died in 2012
Fumes and Gases are produced as Air Pollutants
Welding fume is classified as
potentially carcinogenic to
humans
Gases produced : Ozone, Nitrous Gases, Carbon Monoxide, Phosphine,
Phosgene etc.
![Page 38: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/38.jpg)
Irritation of the eyes,
nose, and chest
Coughing Shortness of breath Bronchitis Nausea / Vomiting
Loss of appetite
Cramps
Fluid in the lungs (Edema)
Inflammation of the
lungs
(Pneumonitis)
![Page 39: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/39.jpg)
Chronic lung problems
Bronchitis, Pneumonia,
Asthma, Emphysema,
Silicosis, Siderosis,
Lung Cancer Cancer of Larynx Cancer of Urinary tract
Parkinson’s Disease Skin Disease Kidney Damage Heart Disease
![Page 40: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/40.jpg)
![Page 41: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/41.jpg)
PATENT NO:
201731010196
![Page 42: Bharat Heavy Electricals Ltd - IMTMA · 2019-08-26 · PowerPoint Presentation Author: Deepakraj Solanki Created Date: 8/22/2019 2:27:35 PM](https://reader035.vdocuments.us/reader035/viewer/2022080506/5f78349c44a8de775741ed35/html5/thumbnails/42.jpg)