Problem Solver
Sajal Kumar D
Areas Sajal Kumar D is Knowledgeable in:
Problem(Mechanical) solving in the field I am experienced in.Failure analysis and providing solutions.Cost reduction by saving power,By reducing maintenance,Better safety in opearation
Techniques Sajal Kumar D Uses:
Stopping oil leakage in supporting roller-One of the support rollers of kiln had a major oil leakage from the shaft seal due to damaged shaft.Oil was being added to the roller continuously to keep the plant operating resulting in huge lubricant loss and there a possibility of bearing failure.Replacement of the roller needed long stoppage and a new roller was needed which was a major decision to be taken up by the top management.
I got fabricated a spacer gland housing in two halves that shifted the sealing location where the shaft was undamaged.New sealing packing was installed and the unit could be operated without any problem
I got fabricated a spacer gland housing in two halves that shifted the sealing location where the shaft was undamaged.New sealing packing was installed and the unit could be operated without any problem
Sajal Kumar D's Problem Solving Skills:
- I have got specific skills to modify machine design to minimise failures,reduce power consumption,optimise equipment life and s
- I have got specific skills in imparting training to technicians for skill upgradation
- I am having specific skills to analyse mechanical breakdowns and provide solutions
- I have got specific skills in mechanical maintenance of cement plant equipments
- I have got specific skill in solving mechanical problems during commissioning of new cent plants
Sajal Kumar D's Problem Solving Experience:
- Power saving in compressor-A research was conducted by me to reduce power consumption of a reciprocating compressor.A power saving of about 25% was achieved by varying the RPM of the compressor with a VVVF drive and operating the compressor on consumption mode instead of pressure mode where compressor continues to run on operating RPM in unloaded condition.
Now of course,many compressor manufacturers are manufacturing with this technology built in - Bringing down cooling water temperature of machines-Our water reservoir size for machine cooling water had to be reduced due construction activity in the plant.As the volume of water for recirculation was reduced,other operating machines were failing due to high inlet cooling water of the machines.I installed few high pressure water pumps with fine spray nozzles that brought down the cooling water temperature considerably and the equipments could be operated continuously without any problem
- I employed a new development in coating technology in one of my high H.P water pump that reduces friction in the components there by resulting in power saving
- Motor of an open well submersible pump used to get damaged due to dry up of the sump.I changed the design of the suction pipe of the pump in such a way that pump remained submerged in water even when there was not eough pump able water in the sump.The manufacturer,after getting my feed back incorporated this modification in his manufacturing process
- I developed an economizer for pneumatic actuators by reusing waste of the actuator which resulted in power saving to the tune of 47%.This equipment was successfully commissioned in one of the cement plant in India.This research was also published in World Cement journal,October 2010 issue.The research work is being uploaded here.
- One split seal was designed in two halves for F.K.Pump conveying cement.The replacement of original seal used to take more time due to major dis assembly of components resulting in more downtime of the machine.