Improve the turn-around time to load BTAPs

Theme: Asset Optimization & Predictive maintenance

Expected Pilot Duration: 3 Months

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Challenge Summary

To track, monitor & reduce the time to load alumina into a Bogey Tank For Alumina Powder (BTAP).

Challenge Scenario

Alumina is being discharged to 3 hatches of the BTAP using loading spouts under the hopper. Loading process follows the below sequence of events:

  • Placement of BTAP under the alumina discharge spouts
  • Opening of the hatches (3 Nos.)
  • Placement of loading spouts on the hatches
  • Alumina discharge into the Hatches
  • Closing of the hatches (3 Nos.)
  • Housekeeping
  • Placement of Next BTAP under the spout.

Currently the time estimates are taken based on manual visual inspection of the above events, but most of the data point is missed due to other intervention. Therefore based on estimates it takes 25 minutes to load a BTAP and the startup is expected to consider this as a baseline.

The qualified startup is required to track all the time parameters of all the above activities. Startup is expected to identify opportunities for improvement & provide a predictive solution that leads to reducing the overall time taken to load the alumina to the BTAP.

Pilot project will entail the end-to-end monitoring 1 Set Discharge spout of Alumina (3 Discharge Spouts) loading into 1 BTAP.

Profile of the end users

Port team

Responsible for managing and filling the BTAP.

Solution Requirements

Possible alternate application of off-spec polymer or waste polymer can be explored as

Ability to identify the deviation from standard and provide alert and notification

Measurement of various activities in the process needs to be considered as follows:

  • Time to place the wagon under position
  • Time to open the hatch of BTAP
  • Time to set the spouts on position
  • Time to fill the BTAP
  • Time to close the hatch of BTAP
  • Time to clean the Hatch surroundings/ housekeeping

Reduce the overall time taken for loading the BTAP

Processes must be automated with state of the art technology.

Real-time data capturing & predictive analytics for monitoring of alumina filling into BTAP.

Predict daily, monthly & yearly estimates of BTAP filling.

Environmental Constraints: Should be able to perform during the rainy season and dusty environments.

Safety: Simply engineered for easy operation and maintenance.

Installation: Should be installed with minimum downtime, without affecting the working hours.

Expected Outcomes

1. Quantified Metrics & Outcomes:
Operational KPIs/Metrics Current Value Target State (Expected)
Turn-around-time to load 1 BTAP 25 mins Reduce by 10 Mins
Turnaround time to reduce the filling of rake - 30 Mins reduction
2. Qualified Outcomes:
Current State Target State (Expected)
Currently no standard time based on the previous records Standard time and deviation
No notification to the in-charge in case of process deviation Auto alert and notification on mobiles and applications.

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