Improve Boiler System Operations- Application of Statistical Process Control

Abstract

The Utilities Department provides utility services to Monsanto and Cain Chemical Company production units at Chocolate Bayou. Over two years ago the department recognized that a significant reduction in waste and rework could be achieved by improving steam boiler and boiler feedwater system operations. The processes were experiencing high maintenance cost due to metering pump and analyzer failures, equipment failures and fouling due to poor control of chemical treatment, and steam vent losses due to unproven system reliability. The team used statistical process control to prevent overadjustment of the process, identified special causes, interviewed customers and applied the ten steps to quality improvement. Results include a six-fold reduction in process variability, $2.3 million/year cost reduction, and improved reliability and customer relations.