VALUE ENGINEERING ON HR HRSG( SG( He Heat Recove Recover r y Stea Steam Gener Gener ator) tor )
ELECTRIC ELECTRI CA L PA PA NELS [ A CASE STUDY]
PROBLEMS!!!!
Panels from different Sources
Installation & Commissioning Delays
Cost & Delivery Delays
Spares from different makes
Co-ordination efforts
COLLECT INFORMATION
EVALUATE ALTERNATIVES
ANALYSE FUNCTIONS
DEVELOP
FAST DIAGRAM
IMPLEMENT
ALLOCATE COST-WORTH
CHECK PERFORMANCE
CREATIVE BRAIN STROM
RECOMMEND
FIX WEIGHTAGE
COMPARE
TEAM ENGINEERING / DESIGN
COMMERCIAL/PROJECT MANAGEMENT
PURCHASE
ERECTION
COMMISSIONING SERVICES
INFORMA INFORMATION TION PHASE PHASE – ACTIVITIES ACTIVITIES – WORK FLOW FLOW GENERATE ENQUIRY FOR HRSG
EVALUATE EVALUATE OFFERS
MAKE PROPOSAL
PLACE ORDER FOR 3 PANELS
RECEIVE ORDER
GET VENDOR DRAWINGS
COLLECT LOAD DETAILS FOR 3 PANELS
ACCORD APPROVAL
PREPARE SPEC. FOR 3 PANELS
COLLECT FINAL AS FITTED
PREPARE SCHEMES FOR 3 PANELS
INSPECT PANELS
GET CUSTOMER APPROVAL
DESPATCH TO SITE
REVISE AS PER CUSTOMER COMMENTS IF NECESSARY
SORT OUT STORAGE/TRANSIT DAMAGES DAMAGES IF ANY
INDENT FOR 3 PANELS
COMMISSION
FLOAT ENQUIRIES
MODIFICATION MODIFICATION IF ANY TO SORT OUT COMMISSIONING PROBLEMS
COLLECT OFFERS
HANDOVER TO CUSTOMER
BA SI C T Y PES OF LOA LOA D SL.NO DRIVE DESCRIPTION
TYPE
KW
QTY/BLR
RDOL
0.18-6.3
20
1
VALVE ACTUATORS
2
PUMPS
DOL
0.18-3.3
4
3
FANS
DOL
5.5
4
4
DAMPER ACTUATORS
RDOL
5.5
4
5
SOOT BLOWERS
DOL
0.09
20
6
BOILER CONTROL PANEL
S/F
10
1
7
SB CONTROL PANEL
S/F
5
1
8
DRUM GAUGE GLASS
S/F
4
1
9
WELDING
S/F
5
1
10
LIGHTING
S/F
5
1
REMARKS
CON V EN TI ONA L DES DE SI GN ELECTRICAL PANELS
HRSG MCC
DUTY
SB MCC
STANDBY
DUTY
AUTO C/O UNIT L O D R
VALVES DAMPERS
L L O O D D R
DIST PANEL
STANDBY
DUTY
AUTO C/O UNIT L O D
PUMPS FANS
L O D
………
STANDBY
AUTO C/O UNIT L O D
SOOT BLOWERS
F / S
………
F / S
MISCELLANEOUS LOADS
LI ST OF I T EMS ITEM
DESCRIPTION
QUANTITY
REMARKS
HRSG HR SG MC MCC C
SB MC MCC C
DIST DI ST PAN ANEL EL
1
INCOMER
2
2
2
2
INCOMER CABLES
2
2
2
3
AU AUTO C/O UNIT
1
1
1
4
RDOL MODULES FOR VALVES/DAMPERS
24
0
0
5
DOL MODULES FOR PUMPS/FANS
8
0
0
6
DOL MODULES FOR SOOT BLOWERS
0
20
0
7
RDOL SPARE MODULES
5
0
0
8
DOL SPARE MODULES
2
4
0
9
S/F UNIT
0
0
5
10
VACANT MODULES
4
4
2
11
PANEL
1
1
1
12
BU BUS BAR SYSTEM
1
1
1
F U NC NCTI TI ON A NA LYS YSII S SL.NO.
ITEM
VERB
NOUN
KIND
1
CABLE
CONDUCT
CURRENT
B
2
INCOMER
RECEIVE
POWER
B
PROTECT
EQUIPMENT
B
SENSE
FAILURE
B
CHANGE
FEEDER
B
CLOSE
CIRCUIT
B
ENABLE
REVERSAL
B
SENSE
OVERLOAD
B
TRIP
CIRCUIT
B
CLOSE
CIRCUIT
B
SENSE
OVERLOAD
B
TRIP
CIRCUIT
B
CLOSE
CIRCUIT
B
PROTECT
EQUIPMENT
B
3 4
5
6
AUTO C/O UNIT RDOL MODULE
DOL MODULE
S/F UNIT
7
RDOOL SPARE
BRIGE
GAP
S
8
DOL SPARE
BRIGE
GAP
S
9
VACANT MODULE
KEEP
SPACE
S
FACILITATE
EXPANISION
S
CONDUCT
CURRENT
B
FACILITATE
DISTRIBUTION
B
HOUSE
MODULE
B
PROTECT
MODULE
B
10 11
BUS BAR PANEL
FA ST DI A GRA M MEET SPEC.
BRIDGE GAP
IMPROVE APPEA.
PREVENT RUSTING
WHY
HOW ENABLE REVERSAL
PROTECT COMPT.
CONDUCT CURRENT
CLOSE CIRCUIT
FACILITATE OPERATION
DISTRIBUTE POWER
RECEIVE POWER
ACCOM COMPT
FORM VOL
FACILITATE CONNECTION
LOCATE MODULES
ALLOT SPACE
DECIDE SPACE
FACILITATE C/O
PROTECT MODULES
ENSURE SAFETY
FACILITATE EXPANSION
SENSE FAILURE
COMPLY STATUTE
SCOPE
EXAMINE CAPACITY
RECEIVE ORDER
FU N T I ON -COSTT-WO WOR RT H A NA LY SI S SL.NO ITEM
VERB
NOUN
KIND
PRESENT QTY.
REQD.QTY . UNIT COST TOTAL COST WORTH VALUE GAP
VALUE INDEX
1
CA C ABLE
CONDUCT
CURRENT
B
6
1
0.5
3
0 .5
2 .5
6
2
IN INCOMER
RECEIVE
POWER
B
6
1
8
48
7 .5
40
6
PROTECT
EQUIPMENT
B
SENSE
FAILURE
B
3
1
9.5
28.5
9 .5
19
3
CHANGE
FEEDER
B
CLOSE
CIRCUIT
B
24
24
14.4
345.6
293.76
51.84
1 .18
ENABLE
REVERSAL
B
SENSE
OVERLOAD
B
T R IP
CIRCUIT
B
CLOSE
CIRCUIT
B
28
28
9.5
266
2 2 6 .1
39 .9
1.176
SENSE
OVERLOAD
B
T R IP
CIRCUIT
B
CLOSE
CIRCUIT
B
5
5
5
25
21 .25
3 .7 5
1.173
PROTECT
EQUIPMENT
B
3
4
5
6
AUTO C/O UNIT
RDOL MODULE
DOL MODULE
S/F UNIT
7
RDOL SPARE
BRIGE
GAP
S
5
5
14.4
72
61.2
10 .8
1.176
8
DOL SPARE
BRIGE
GA G AP
S
6
6
95
57
45.6
11 .4
1 .25
9
VA V ACANT MODULE KEEP
SPACE
S
10
5
5
50
25
25
2
3
1
75
225
2 00
25
1.125
3
1
200
525
75
1.142
10
11
BU B US BAR
PANEL
FACILITATE EXPANISION
S
CONDUCT
B
CU CURRENT
FACILITATE DISTRIBUTION
B
HOUSE
MODULE
B
PROTECT
MODULE
B
CR EA EA T I V E I D EA EA S EXISTING
HRSG MCC
DIST PANEL
SB MCC
DECENTRALISE ALTERNATIVE I
-DELETE PANELS -MOVE HARDWARES TO
FIELD
DIST PANEL
ALTERNATIVE ALTERNATIVE II HRSG MCC
ALTERNATIVE III
HRSG MCC
SB MCC
DIST PANEL
SB MCC
B
BUS TRUNKING
DUTY
ALTERNATIVE ALTERNATIVE IV
STANDBY
COMMONBUS HRSG MCC
SB MCC
DIST PANEL
INTEGRATION
CRI TE TERIA RIA A ND W EI GHT HTA A GE FIXATION WEIGHTAGE ANALYSIS
MAJOR DIFFERENCE MEDIUM DIFFERENCE SMALL DIFFERENCE EQUAL
POINTS
3 2 1 0
B A-3
A
B
C C-2 B-2 C
D A-1 B-1 D-1 D
SYMBOL CRITERIA
RAW SCORE
FINET WEIGHTAGE DECIDED
A
CUSTOMER'S ACCEPTANCE
3
9
B
ECONOMIC BUYING
4
8
C
ERECTION CONVENIENCE
3
7
D
LOGISTICS
0
6
TOTAL A-4 B-3 C-2 D-1
EV A LU LUA A TI ON MATRI X
ALTERNATIVE
SL NO.
1
CRITERIA
CUSTOMERS ACCEPTANCE
WEIGHTAGE
DECENTRALISATION DE
CABLING
2
1 9
9
18 4
2
ECONOMIC BUYING
3
ERECTION CONVENIENCE
8
32
28
LO LOGISTICS
6
6
RATING: 1- GO GOOD OD 2-BETTER 3-BEST 4-EXCELLENCE
3 24
2 14
2 12
36
8
7
4
2
1
1 4
27
16
INTERATIO NO.
3
1
4 7
BUS TRUNKING
3 21
3 18
4 24
DEV E LO LOP PED I N TEG TEGRA RA TED H RS RSG G E LEC LECTRI TRI CA L PA N E L
DUTY
STAND BY AUTO C/O UNIT
L O D R
L L O L O D O D R D
F / S
-VALVES -DAMPERS -FANS -PUMPS -SOOT BLOWERS -MISCELLANEOUS LOADS
COST COM PA R I SON SL.NO.
ITEM
BEFORE
AFTER
QTY.
C OS T
QTY.
C OS T
1
INCOMER
6
48
2
16
2
INCOMER CABLES
6
3
2
1
3
AUTO C/O UNIT
3
28.5
1
9.5
4
RDOL MODULES FOR VALVES/DAMPERS
24
345.6
24
345.6
5
DOL MODULES FOR PUMPS/FANS
28
266
28
266
6
DOL MODULES FOR SOOT BLOWERS
5
25
5
25
7
RDOL SPARE MODULES
5
72
4
57.6
8
DOL SPARE MODULES
6
57
3
28.5
9
S/F UNIT
10
50
3
15
10
VACANT MODULES
3
225
1
200
11
PANEL
3
600
1
525
COMP MPA A RI SON BEFORE
HRSG MCC
SB MCC
DIST PANEL
AFTER
3
PANELS (QTY)
1
100
SIZE (%)
80
100
WEIGHT (%)
85
100
COST (%)
86.5
100
ERECTION TIME (%)
65
100
LOGISTICS (%)
50
NO.OF BOILERS WITH NEW DESIGN =8 COST SAVING PER BOILERS =Rs.2,30,900/-
INTEG MCC
Submitted to INDIAN VALUE VALUE ENGINEERING SOCIETY – VIII NATIONAL NATIONAL CONFERENCE – MUMB MUMBAI AI – 30 TH NO NOVEMBER VEMBER 1991 1991 BY S.SANTHIRAJ & selected as the best be st case study For more details, contact
[email protected] [email protected]
