VIZAG GRINDING UNITqcfihyderabad.com/cementconclave2018/wp-content/... · • To provide reliable...
Transcript of VIZAG GRINDING UNITqcfihyderabad.com/cementconclave2018/wp-content/... · • To provide reliable...
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.