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[Audio] Good Morning EVERYONE MYSELF Subramaniam Velmani kaizen today I will be presenting on the Kaizen topic : INCREASE AVAILABILTY OF SLURRY PIPELINE FOR BP.3171.11/12 BP.3181.11/12 BP.3171.45/46.
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[Audio] MY team members are : Murtadha Lawati , SUJIT PATIL, Mamun Ahmed, Ahmed Balushi and Rajkumar Gupta.
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[Audio] Our kaizen aligns with our values make it happen key behaviours of obsession with safety and risk management, Levers in innovation and the Ambition best in class reliable operator.
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[Audio] Problem Identification: Frequent complain of slurry water leakage from slurry pipelines. Environment concerns - Slurry accumulation in site on ground. Area unsafe for workmen working in surroundings. Monthly average 2 complains from operation department. Pipeline availability reduced and maintenance cost increased. Increase in Cleaning cost..
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[Audio] Planning Stage – Problem Analysis - Scenario Before Kaizen you can see slot formation in slurry pipeline due to corrosion.
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[Audio] The CONSEQUENCES of the problem are Frequent cleaning activity and Diesel pump fixing for Dewatering.
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[Audio] Other consequences are you can see the leakage.
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[Audio] Root cause analysis done for the problem Slurry Pipeline Break down using why-why analysis techniques starting with 1st why Leakage in various locations Why because Frequent failure of Pipeline why because Slot formation / Pipe wall thickness reduction why because Corrosion & Erosion why because Corrosion & Erosion why because Pipeline material not suitable hence this is the root cause.
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[Audio] BRAINSTORMING DONE WITH TEAM MEMBERS. RESULT WAS TO CHANGE PIPELINE MATERIAL FROM CS TO HDPE This is because HDPE has excellent corrosion resistance, lightweight nature, and longer lifespan. Easy to Install. Time saving.
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[Audio] Scenario After Kaizen : FOR THE TESTING AT THE LOCATION BETONITE BAG KEEPING AREA HDPE PIPELINE LAYING WAS DONE FOR 20 METERS. PIPELINE DID NOT GET DAMAGED EVEN AFTER 2 YEARS LATER DECIDED TO CHANGE BP.3171.11/12 BP.3181.11/12 BP.3171.45/46 NOTE BEFORE KAIZEN: CS PIPE LINE LIFE WAS 8 TO 12 MONTHS AFTER THAT PIPE LINE STARTS LEAKING DUE TO EROSION. LEADING TO PIPELINE REPLACEMENT WITHIN A YEAR.
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[Audio] Act Stage – Kaizen Implementation these are the HDPE pipeline joint and elbow.
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[Audio] You can see HDPE welding machine and the welded joints.
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[Audio] Scenario After Kaizen CS Pipeline Replaced by HDPE Pipeline For BP.3171.11/12 BP.3181.11/12 BP.3171.45/46 TOTAL 350 M into 3 Pipeline which is equal to 1050 M.
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[Audio] GAIN CALCULATION: Using manlift for attending one breakdown its costing 180 OMR approximately and its estimated to have 12 times breakdown in a year costing 2160 OMR . Cost of attending 1 time breakdown by scaffolding is 192 OMR estimated 12 times breakdown in a year costing 2304 OMR..
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[Audio] Before Kaizen: 350-meter X 3= 1050 meters pipeline was Replaced every 2 years for the equipments BP.3171.11/12 BP.3181.11/12 BP.3171.45/46 The Cost of pipeline replacement including Scaffolding Cost Manpower Cost Crane cost CS Pipe 1050 meter Welding Rod 200kg was 30,520 OMR This is much cost saving done by changing the pipeline material to HDPE.
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[Audio] These Are the Safety and environmental gains.
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[Audio] THANK YOU. C- Check Indicators. P C A D. THAN IZ YOU.