Finishing the unfinished

In any organization set up, there are many different agencies doing different type of activities. The joint effort of these different agencies makes the organization deliver a product or service of desired standards. But every time things are not that simple. Suddenly some unforeseen problem comes up which needs to be given utmost importance and this being a one time or once in a blue moon kind of a problem, it has to be assigned to someone as an additional responsibility. Generally, some people have the reputation of delivering in such situations and such problems fall in their lap. I have been fortunate to encounter many such situations and let me tell you, it is great learning experience.

Today, I shall be sharing one such experience. In BHEL Haridwar unit there was a plan to manufacture fully vacuum impregnated Turbo generator stators of 250-350 MW capacity. To achieve that a new vacuum impregnation plant and curing oven with rotation facility was to be developed. For the curing oven the purchase order was placed on a Kolkatta based reputed party. It was big oven door opening itself was more than four meters and depth about 10 mtrs, height about 5 mtrs . The material was coming from different sources (sub-vendors of the main supplier) and erection work was going on. I was not associated   with this work because I was doing motors, TG exciter and Hydro generators at that time.

Suddenly one fine morning we came to know that the vendor erection team has left without any communication leaving the things as it is. All efforts were made to contact the vendor, but there was no response. There was a lot of hue and cry because the generator could not be manufactured without this oven. Ultimately this task was assigned to me in addition to my current responsibilities.

There were seniors and other people to help, but responsibility was mine. How to go about it?

-        All the available drawings, packing lists, receipt register etc. were taken in possession

-        BHEL Haridwar is a big set up, all stores were checked to find out information about any unidentified packages

-        In the production block, gantry store and nearby locations were searched to locate any supplies that may be in transit

-        Store records were checked to identify receipts against the said purchase order

At the same time a team was sent to Kolkata to visit the vendor works. It was closed but there was a possibility of getting some leads from people around that place. It really helped, as our team was able to contact 4 key people of that closed company. One of them was designer of similar ovens, others were also important persons from oven erection point of view. They were without work and hence formed a team to take up certain activities.  

A works order was prepared and this team was taken on board for taking up erection work.

With the help of packing lists, a list of sub-vendors was prepared. Each of these sub-vendors was contacted to confirm – were there any more items to be delivered. These sub-vendors were very happy to supply those items and in most of the cases offered discount also.

The designer reviewed the design and certain important corrections were suggested and implemented.

Slowly with the help of the 4-member erection team and supplied items the work could start. Many items we could get from our stores (surplus items). Rest of the items were to be procured, but with single mind determination we could complete the oven erection and commissioning in time. The area that looked like a maze of so many erection items, angles, pipes, I- beams, channels, fire bricks etc.-  turned in to an oven with auto control.

The learning here is, if there is problem, it has to have a solution. We should not panic. Patience is a real virtue in such situations. Have faith, it will happen.

These days many stressed power projects (finished/unfinished) are being taken up by developers from NCLT. Such experiences are there at bigger scale as I found out during my recent visit to one such asset.