Resolving Chronic Creeping Issues in a Cement Plant Through Effective Troubleshooting

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Resolving Chronic Creeping Issues in a Cement Plant Through Effective Troubleshooting

In this case study, we delve into a chronic problem of creeping that plagued one of the cement plants operated by a multinational company. The issue caused extensive damage to various areas, including the rotating kiln, cyclones, and disrupted cement supply, ultimately leading to a loss of customer confidence. The management enlisted the expertise of BiC, a promoter who possessed extensive experience in instrumentation. This article explores the identification, analysis, and resolution of the creeping problem, highlighting the importance of out-of-box thinking and collaborative problem-solving.

Investigation

BiC's promoter was appointed as the in-charge of instrumentation in the cement plant to address the recurring issue of creeping. Recognizing the severity of the problem, the following root cause analysis was conducted:

Isolation: Cement plants are intricately connected with electrical systems. It was essential to differentiate between electrical and instrumentation components to pinpoint the origin of the issue.

Instrumentation Focus: Through meticulous examination, it was determined that the problem originated from the instrumentation side.

Sensor Evaluation: The initial suspicion was that the problem might be related to sensors or the control system (DCS). However, thorough investigation revealed that the issue was not sensor-related.

Historical Data Analysis: Collected historical data was meticulously scrutinized, employing a root cause analysis approach. BiC collaborated with the Original Equipment Manufacturer (OEM) to further analyze the problem.

Approach

Grounding Evaluation: As a potential cause, inadequate grounding was considered. To rectify this, additional earth pits were promptly installed. However, this did not yield any significant changes in the creeping issue.

PLC Controller Examination: The focus then shifted toward the logic/PLC controller. Suspicions were raised regarding the controller's common plan, Backplane. As a result, the backplane was replaced.

Actions

  1. Grounding Evaluation: As a potential cause, inadequate grounding was considered. To rectify this, additional earth pits were promptly installed. However, this did not yield any significant changes in the creeping issue.

  2. PLC Controller Examination: The focus then shifted toward the logic/PLC controller. Suspicions were raised regarding the controller's common plan, Backplane. As a result, the backplane was replaced.

Results

Following the replacement of the backplane, the chronic creeping issue was successfully resolved. The cement plant could resume its operations without further disruption or damage. The expertise and problem-solving abilities of BiC's promoter played a crucial role in identifying and rectifying the problem. keep pushing for a solution, and consistent focus till the result is achieved.

Conclusion

This case study highlights several key takeaways from resolving the creeping issue in the cement plant:

  1. Out-of-Box Thinking: The ability to think beyond conventional solutions and explore various possibilities is vital in troubleshooting complex problems.

  2. Collaboration and Contribution: Encouraging every individual, irrespective of their relevance to the issue at hand, to contribute their insights can lead to innovative problem-solving.

  3. Broad Expertise: BiC's promoter brought extensive experience in troubleshooting areas such as cement plants, soda ash and caustic plants, fertilizer power plants, and various technologies encompassing mechanical, instrumentation, electrical, and oil and gas. This multidisciplinary expertise proved invaluable in addressing the issue effectively.

  4. Seek Help: Recognizing the need for external expertise and seeking assistance when necessary is crucial for successful troubleshooting.

The promoter's comprehensive experience in managing projects of varying scales, coupled with a troubleshooting mindset, demonstrated that problem-solving is an art that transcends technology.

By leveraging BiC's expertise and the lessons learned from this case study, companies can overcome complex challenges in their operations, enhance efficiency, and ensure the reliability of their processes

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1978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
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21978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
Next
31978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
Next
41978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
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