Proposed Topic of Research:: BITS ID: 201218TS525

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
WORK-INTEGRATED LEARNING PROGRAMMES DIVISION

First Semester 2015-2016
BITS ZC423T : Project Work Outline
1. Proposed Topic of Research:
Cycle time reduction across the manufacturing of Coal burner Body castings for
supercritical Boilers.
2. Broad academic area of work:

Production, Planning and Control.
3. Background of the Proposed Research:

Coal burners : A coal burner fires the pulvarised coal along with the primary air into the
furnace. The secondary air is admitted separately below the burner, around the burner or
elsewhere in the furnace. Ignition takes place by means of radiation and flame propagation
from the fuel already burning in the furnace.
The coal burner consists of a fixed coal burner body that receives the fine pulverized coal
through the coal pipes. The coal burner body is supported at the partition plate by two
supports. A core assembly located between the above two supports and two splitter plates
located at the rear end of the coal burner body streamline the coal flow into the furnace.
The splitter plates in the coal nozzle are also provided with hard facing to reduce nozzle
erosion.
CBB’s diversified design will attain the equal flow at the CBB throat. Addition to that Coal
nozzles are equipped with two splitter plate, this will further diverted and delivered inside
the furnace.
CBB is able to deliver the coal flow dust at the range of 15m/sec to 28 m/sec.
The combustion air for the coal burner is controlled (as per the quantity of coal fired) by
adjusting the damper at the inlet of the windbox. The air control damper in the windbox
provides a continuous flow of air to cool the coal nozzle when the coal burner is not in
service.
BITS ID: 201218TS525 Page 1

Coal Compartment
Fig 1: Coal Compartment
Coal Burner Body Castings
This paper emphases on Study of Cycle time reduction in Manufacturing of Coal Burner
Body for the Supercritical Power plant Boilers. This manufacturing involves Casting and
various Machining Process to attain the finished product. Detailed study on Machining
Process of Coal Burner Body is to understand the Cycle time of each and every process.
Machining process includes 1. Facing 2. Turning 3. Side Face Milling 4. Profile Milling 5.
Drilling and Tapping.
CBB support
tapping (4Nos)
Coal Nozzle
Partition plates
Coal Burner Body
Fig 2 – Burner assembly

Clearance between Nozzle and Partition plates

The component got minute dimensional accuracy as it needs to align with coal nozzle in 3
axis direction. Also the support tapping on CBB and clearance between the Nozzle and
partition plates are essential dimension. Failure on achieving this creates the block in
nozzle tilting process. The jamming of nozzle results with the reduction in cooling air thus
increases the heat radiation. In long run the increased heat radiation reduces the efficiency
of the casting and failure occurs.
The proposed research work shall actually be executed as R&D initiative in our ongoing
660MW MPPGCL project supply, with the initiation of L&T MHPS at our vendor premises M/s
Sanpreet Castings Coimbatore under my supply execution.
4. Scope of Research:
4.1.ACTIITY TIME SCHEDULING / DURATION ESTIMATION:
Duration of an activity is the expected economical transaction time required to

perform an activity according to the specified execution method. The estimation of
this time is based upon the specified practices carried out in an organized manner
under the normal prevailing conditions.
4.1.1. Duration assessment based on Method Study:
The choice of the method of execution of an activity depends upon the past
experience, the market availability of appropriate resources, the resources available
and the cost-benefit analysis of the various methods of execution. In this project,
time estimations were arrived based on Activity database and my past experience in
executing this typical type of jobs. Hence, in depth of study on various execution
methods were not warranted.
4.1.2. Duration assessment based on resources earmarked:
The duration of an activity depends on the volume and nature of resources

earmarked for execution. The resources of men, machinery and materials required
for the execution of each activity.
4.1.3. Duration Estimation based on One-time estimate:
The estimation of duration is based on one or more of the following:
• Planning data
• Past experience on execution of a similar project

4.1.4. PROJECT NETWORKS & DEVELOPMENT PROCEDURE:
Network Diagram shows a group of activities or tasks and their logical relationships
ie, the “Precedence relationships” or “dependencies” among the tasks. These
network techniques generate time-oriented diagram having activities organized in to
a logical order. Their common features are that they make of the network model for
depicting the time plan of the project; apply the critical path concept for
determining project duration and identifying critical activities, and; employ network
analysis techniques for controlling the project-time objectives.
4.2.COMMON METHODS TO REDUCE CYCLE TIME: (Improvement in process)
This study is to compare the above machining process cycle through conventional
machines as manual Side milling machine, Horizontal milling machine, Drilling and
tapping by Bench Drilling machine replaced with CNC vertical machine and Drilling
process with Radial drilling machine.
5. Objectives of the proposed research:

The component got minute dimensional accuracy as it needs to align with coal
nozzle in 3 axis direction. Also the support tapping on CBB and clearance between
the Nozzle and partition plates are essential dimension. Failure on achieving this
creates the block in nozzle tilting process. The jamming of nozzle results with the
reduction in cooling air thus increases the heat radiation. In long run the increased
heat radiation reduces the efficiency of the casting and failure occurs.
Due to the accuracy level and by mean of too many manual processes tend to have
many rejections. This, in turn causes the delay in delivery. Hence, the process shall
be supplemented with CNC process to improve accuracy and to reduce rejection
level to improve the total cycle time.
Also to identify the parallel activities which can be plotted through network diagram
so as to find the effective cycle time for the process.
Added is to find the optimal plant layout for reduced time using sequencing model.

6. Plan of work:
Chapter I Introduction
I.1. Value of Cycle Time Reduction
I.2. Industry Background
I.3. Thesis Overview
Chapter II. Developing product layout

II.1 Steps in Assembly line balancing
II.2. Methodology
II.3. Data Collection from old projects
II.4. Results
lI.5. Improvement
Chapter III. Single Product Analysis

III. 1. Capacity planning
III.2. Measuring capacity
III.3. Results
III.4. Implementation
Chapter IV. Operations Scheduling

IV. 1. Scheduling Techniques
IV. 2. Methodology
IV. 3. Results
IV.4. Implementation
Chapter V. Components of productivity

V.1 Factors affecting productivity
V.2. Measuring productivity
V.3. Data Collection
V.4. Statistical Quality control
V.5. Results
Chapter VI. Conclusions

VI.1. Summary
VI.2. Recommendation
Chapter VII. Bibliography

Chapter VII
Chapter VI
Chapter V
Chapter IV
Chapter III
Chapter II
Chapter I
10th Sep
30th Sep
31st Aug
10th Oct
5TH Aug
31st Oct
Fig 3 Ganntt Chart for the proposed research.
7. Literature references:
1. Thermal Engineering 9th Edition by Er. R. K. Rajput
2. Rusell, R.S. & Taylor, B.W., “Operations Management Along the Supply Chain, Wiley
Student Edition, 6th Ed., 2009.
3. Projects: Planning, analysis, selection, Financing, Implementation and Review 7th

edition by Dr. Prasanna Chandra
4. Operation Research Second edition by Dr. Richard Bronson & Govindasamy

Naadimuthu
5. Taha, Hamdy A, Operations Research: An Introduction, Pearson Education, 9th,

Edition, 2012
6. Operation Research by A. M. Natarajan, P. Balasubramanian & A. Tamilarasi
7. Operations Management – Supplement to Text book, ICFAI Center for Management

research, March 2007.
8. Fundamentals of Quality Control and Improvement, by Amitava Mitra, Prentice Hall

of India, 3rd Ed., 2008
9. Article on Fuel Firing System: Coal piping, Wind box & Burners by Mr. Prashanjit
Chattopadhyaya – 2013
10. L & T MHPS production drawing for Coal Burner Body.

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BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK-INTEGRATED LEARNING PROGRAMMES DIVISION

BITS ZC423T : Project Work Outline

1. Proposed Topic of Research:

2. Broad academic area of work:

3. Background of the Proposed Research:

BITS ID: 201218TS525 Page 1

Fig 1: Coal Compartment

Coal Burner Body Castings

Coal Burner Body

Fig 2 – Burner assembly

BITS ID: 201218TS525 Page 2

Duration of an activity is the expected economical transaction time required to

4.1.1. Duration assessment based on Method Study:

4.1.2. Duration assessment based on resources earmarked:

The duration of an activity depends on the volume and nature of resources

4.1.3. Duration Estimation based on One-time estimate:

The estimation of duration is based on one or more of the following:

• Past experience on execution of a similar project

BITS ID: 201218TS525 Page 3

4.2.COMMON METHODS TO REDUCE CYCLE TIME: (Improvement in process)

5. Objectives of the proposed research:

BITS ID: 201218TS525 Page 4

Chapter II. Developing product layout

Chapter III. Single Product Analysis

Chapter IV. Operations Scheduling

Chapter V. Components of productivity

Chapter VI. Conclusions

Chapter VII. Bibliography

BITS ID: 201218TS525 Page 5

3. Projects: Planning, analysis, selection, Financing, Implementation and Review 7th

4. Operation Research Second edition by Dr. Richard Bronson & Govindasamy

5. Taha, Hamdy A, Operations Research: An Introduction, Pearson Education, 9th,

6. Operation Research by A. M. Natarajan, P. Balasubramanian & A. Tamilarasi

7. Operations Management – Supplement to Text book, ICFAI Center for Management

8. Fundamentals of Quality Control and Improvement, by Amitava Mitra, Prentice Hall

10. L & T MHPS production drawing for Coal Burner Body.

BITS ID: 201218TS525 Page 6

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