PRODUCTIVITY EXCELLENCE

VIZAG GRINDING UNIT

CAPACITY UTILIZATION

Production Capacity

UoM Capacity Atual %

Total Cement MT 9,50,000 10,22,539 108

PPC TPH 160 169 106

PSC TPH 80 77 96

Conservation of Raw Materials

Raw materials used in Cement %

Fly ash used in PPC 32.37

Raw Slag used in PSC 68.16

Approach to the Implementation of Best Practices

1.Inter Grinding has adopted while PSC grinding.

2. Recirculation Bin discharge Air slide replaced

with belt conveyor.

3. Frequent Smart MCC tripping's due to

communication interruption avoided by reducing

the induction.

4.Optimaization of Cement Mill.

5.Installtion of XRF

% of Fly ash used in cement &

% of slag used in cement

Production Capacity UoM Actual %

Fly ash used in PPCMT 2,92,440 32.37

Raw Slag used in PSC MT 81,238 68.16

Spares Consumption

Spares Consumption

Rs/T of Product 30.36

Spares Consumption

Spares Consumption

Rs/T of Product 30.36

Man Power Utilization (Permanent & Contract)

UoM

Man Power Utilization

(Permanent & Contract)

T of Product/Man

Power

Rs.46.64/MT

Compliances with Environmental Norms

(Dust, SOx & NOx Emission)

Compliances with UoM SPM

Environmental Norms mg/Nm3 30

Cement Mill Vent Stack mg/Nm3 17.6

Cement Mill Separator Stack mg/Nm3 14.9

Industrial Relations Issues

Harmonious relations with all .

Management System Implementation

Environmental Management System ISO 2015:14001

Quality Management System ISO 9001:2015

Occupational Health & Safety Management System OHSAS 18001:2007

Maintenance Practice

(Preventive/Proactive/Condition Monitoring)

We have been following ERP based Ramco Virtual works Maintenance management system along with Real time integration to ensure Systematic Maintenance Approach

1. Replacing reject bin air slide with belt conveyor to reduce mill stoppages due to air slide jam.

Before: After:Before: After:

2. Eliminated frequent Smart MCC tripping due to communication interruption

• Old single strand Profibus cable changed with New Multistrand cable and cable laid in separate route inside PVC Pipe to eliminate electromagnetic interference from power bus

3. Forced Cooling arrangement for Cement Mill Main Motor Slip ring chamber

• Forced cooling arrangement provided in slip ring chamber to reduce the temperature inside. This is done to avoid unplanned breakdown due to flash over of slip ring due to temperature rise.

4. Provided RTD for Measurement of Classifier bottom bearing

• To monitor Classifier bottom bearing temperature and to avoid mill stoppage an additional RTD has been provided

5. Removal of suction damper for cement mill vent bag house ID fan

• To provide reliable and smooth operation of the equipment, we have removed suction damper and we have replaced the shaft of the impeller and replaced with the new one

6. Installation of XRF

• Continuous Monitoring of Quality of Cement and raw material. Initially we used to carryout the manual analysis at laboratory, for continuous monitoring in the chemical analysis we have installed the XRF unit, which will monitor the cement sample analysis on hourly basis

7. Erection of new pipeline arrangement for unloading of fly ash

• Erection of new pipeline for the fly ash unloading work has been completed and installation of cast basalt bend and target box erection also completed

8. Grinding media regradation in 2nd Chamber

950000 950000 950000 950000

1198

299684

658247

1021539

0

200000

400000

600000

800000

1000000

1200000

2014-15 2015-16 2016-17 2017-18

Capacity VS Production in MT

Capacity MT Production(MT)

2014-15 2015-16 2016-17 2017-18

Capacity utilization % 12.6 31.5 69.3 107.5

0.0

20.0

40.0

60.0

80.0

100.0

120.0

Capacity utilization %

60%

80%

90%94%

0%

20%

40%

60%

80%

100%

2014-15 2015-16 2016-17 2017-18

Grinding Media loading Percentage

Loading Percentage

Initiatives implemented during 2017-18.• To control the dust emission at wagon tippler, two nos of additional extraction ducts

are fabricated and installed to increase the coverage of suction

• There were frequent problems of overloading on the conveyor during the unloading of

wagons. To avoid this one number of belt weigher to be installed at wagon tippler-

discharge belt conveyor. Capacity of the belt weigher is 2000 TPH. After

commissioning, belt is not over loading due to monitering of feed rate in control room.

• As per IMP02 discharge chute modified to avoid the fall of material from a height of 7

mts. Even though there is no that much improvement (significant value come down to

256 to 224). Then we propose to replace the existing 6000M3/Hr bag filter with

12000M3/Hr bag filter, after installation and commissioning of this higher capacity bag

filter it is observed that there is no visible emmission of dust.

• For regular inspection of cement mill internals like liners, diaphragm etc., no approach

was provided initially, by modification of cement mill inlet duct connecting through

HAG approach has been provided hence making it compatible for liners shifting and

inspection.

• To provide reliable and smooth operation of the equipment, we have replaced the

shaft of the impellar and replaced with the new one.

• We need regular inspection of silo internals, paddle mixer and other silo equipments

and by providing connecting platform from cement mill lift to fly ash silo which would

reduce efforts of manpower

• Initially we use to carryout the manual analysis at laboratory, for continuous

monetering in the chemical analysis we have installed the XRF unit, which will moniter

the cement sample analysis on hourly basis

• The existing coveying system is frequently failing and effecting the dispatch also some

of the spares needed to be imported which requires higher lead time, a new conveyor

system is proposed to avoid the stoppages

Initiatives implemented during 2017-18.• The existing breather arrangement for the gear boxes were removed and new silica

gel hygroscopic breathers were fixed with the matching socket for removing purpose

• The fifthwheel for the truck loading machine used to get jammed frequently in

operation also. So to avoid that situation we have provided a lubrication point by

providing grease nipple with rubber hose for regular maintenance.

• The existing hood and top clamp of the wagon tippler is set for box N type purpose

and to accomodate the BOST type wagon we have modified the wagon tippler top

clamping arrangement and its hood also

• For the additional safety of the equipment and as well as wagon while unloading, we

have installed an additional channell for the rail table of the wagon tippler so that the

wagon can take load on this channel piece to avoid slippage.

• The existing wagon loading machines were suitable for railway wagons and containers

which are having side doors/openings to load cement bags, so as to avoid the time

delay in the loading of the cement bags from the front doors of the container type

rakes we have modifed the wagonloading machies to suit the site conditions

Initiatives implemented during 2017-18.• Wheel stoppers fabrication work done and installed at truck loading machine area at

bottom of the truck wheels

• Before installation of the knife edge gate at bucket elevator boot inlet chute, whenever

power fails bucket elevator gets tripped and cement get rushed towards the boot of

the bucket elevator and to clear that material so much of man power to be engaged,

after installation of this gate whenever power fails this gate will automatically closes to

avoid heavy rush of cement

• We have provided an inspection door for existing airslide distribution box and also an

lip plate has been fitted at the material falling area to avoid wear of cloth for easy

maintenance and reliability of the equipment

• The existing drain pipeline has been modified by installing the autodrain valve and

observation done to remove the moisture content in the air reciever tank itself

• The clinker bucket elevator 145BE01 bucket elevator having a single side inspection

door at boot so we have provided an additional door at boot of elevator on opposite

side to avoid unwanted stoppages and for regular inspection purpose

• The existing refrigerant type air drier for the flyash unloading air compressor is

malfunctioning due to this some times there may be a chance of entering of moisture

into the flyash tankers and leads to blockage of pipeline of the unloading

arrangement. Some times it may leed to back pressurse the rubber hose and burst

leads to heavy leakage of flyash(AIA & HIRA). To avoid this we have installed a higher

capacity refrigerant type air drier in place of existing drier, with this we have achieved

zero percent of moisture in the input airline of the flyash unloading.