Summer Training Report of Shree Cement

Raw Mill Raw Mill Mill Silos Cement Crusher Rotary Kiln 350-370 TPH Air Mixer (Hoppers) Stacker &Cooler Reclaimer Pre heater (300-700 C) Lime stones (CaCO3) from mines o(Shree & RAS) CEMENT Packing Plant 800 TPH 1400-1600oC (High grade + Low grade + Laterite) Avg.9000 TPD FLOW DIAGRAM OF CEMENT MANUFACTURING PROCESS (Unit-1): Transportation 18 Loaders

Though Conveyer belt

Burning to clinkers

Gypsum-4% added

Additives

INPUT-OUTPUT PROCESS STUDY: 1 Raw material (Lime Stone-CaC03) which is the basic constituent of cement is obtained from Mines Shree mine RAS

% OF LIME (CaC03 ) 69-73% (avg. grade) 79-83% (high grade).

MODE OF CONVEYANCE Conveyor belt ( 1.9 Kms ). Trucks / Dumpers.

2.Lime stones from mines are subjected to crusher. Lime stone of size 1M X 1M X 1M are received / accepted at crusher(Maximum size acceptable is 1.2 x 1.2 x 1.2 meters), which are crushed to size of 75mm. The crushing of lime stone is done in four stages where the lime is passed through various stages and its size is reduced at each stage, and the final size of lime stone received at crusher is less that or equal to 75mm. I) 210 mm II) 130 mm III) 110 mm IV) 60 mm It is taken care of that +90 should be nil at the output of crusher. Lime stone of RAS mines is directly taken to stacker by transportation. The specification of crusher at Shree mines MAKE : L&T. MODEL : APPM 1822 MOTOR RATING : 950 KW. CAPACITY : 800 TPH 2

The lime stone is received from various mines at STACKER UNIT, where PILE of lime stone is made by the STACKER (Size of lime stone is below 75 mm.), to maintain uniform quality of lime. There are TWO units of stacker's. Pile is tested at interval of 1 hour to get quality of lime stored in Pile. 3 Reclaimer is used to reclaim the lime stone from the pile. There are TWO units of reclaimer units. Capacity of Reclaimer is 400 & 600 TPH. 5 The material from reclaimer is stored at hoppers. Laterite (Iron Ore) is stored in separate hopper. 6 CCR controls the feeding of High grade lime stone, Average grade lime stone, & Laterite to the RAW MILL. 7 In raw mill grinding of material takes place and then stored in raw mill silos known as C.F. SILOS. 8 From C F Silo’s, powdered lime stone goes to PRE-HEATER( PYRO STRING & KLIN STRING -5-stage Cyclones) where the powder is heated ( The process is known as calcination ) using the hot flue gases of Klin from 65 Deg. Centigrade to 1000 Deg. Centigrade. 9 Now material enters in rotary kiln where it is heated up to 1400-1600 deg. C thus forming clinkers. The hot gases of the kiln passed to Pre – Heater's for heat exchange. 10 Then clinker is passed to cement mill through coolers mid way where in Gypsum and other materials are mixed with the clinkers and crushed collectively resulting Cement (final product). 11 Gypsum is added to increase settling time of cement as per requirment of type of cement

being produced. 12 We manufacture two types of cement i.e. ➢ Ordinary Portland Cement (OPC) – 88% (Lime Stone) + 4% (Gypsum)+ Fillers. ➢ Portland Pozolona Cement (PPC) – 65% (Lime Stone) + 4% (Gypsum) + 25% (Fly ash) + Fillers Finally cement is stored in silos and from there it is sent to packing plant for packing and transportation: COORDINATION WITH OTHER DEPARTMENT: Process department coordinates with all the departments like Mechanical for maintenance purpose, Instrumentation for automation, electrical and Shree power for power supply, mines for raw material, physical & quality control lab for parameter study & control of production quality.

MIS- STUDY: This covers daily reports of the following areas: 1 2 3 4 4 5 6 7 8

Raw mill log sheet. Kiln log sheet. Coal mill log sheet. Cement mill log sheet. Analyzer log sheet. Shut down check list Daily production report Monthly ISO documents Residue Blaine log sheet

SAFETY MEASURES/ PRACTICES: 1 2 3 4 5

Use of Safety instruments at every point. Bag filter at mill for dust protection. Drinking Water facility at high temp areas like Kiln. Use of hand gloves, dust masks, welding glasses, etc. Use of all PPE at every point.

PACKING PLANT: INPUT/OUTPUT PROCESS: Being final product, the cement is stored in cement silos. There are five silos in our company, three for Unit-I and two for Unit-II. Cement is carried forward to an elevator and is collected in cement bin .Bin is connected to vibrating screen through which cement is passed down to cement tank. There is a valve attached between vibrating screen and cement tank which regulates the flow of cement, level sensor senses the level of hopper attached to cement tank. The gate valve is connected to solenoid valve. The capacity of tank is 45 tons. To measure the temperature of cement, a RTD is connected to cement tank. There is also a direct pathway (optional) from vibrating screen bin to loader if there is no requirement for packing the cement. Dust suppression system has been installed to collect the dust at various locations.Collected dust through dust suppression system is sent back to elevator and and vibrating screen bin. From cement tank, cement is fed to packers. The packer it self has in house tank of capacity of 5 tons. Packer plant consists of two types of packers based on their feature, capacity and working style. Packer are of mechanical as well as automatic type. Nos. TYPE MAKE SPOUT DISCHARGE 04 MECHANICAL L & T 12 SINGLE 03 AUTOMATIC ELECTRONIC 12 DOUBLE ERIWXCO In each packer there are 12 nozzles. The packer rotates on it’s axis. When an office in-charge inserts a bag in nozzle, the latter auto-matically hold the bag until the bag weighs 50 kg. Load cell is mounted and attached with rotors for weighing the quantity of cement in bag . As soon as the load cell sense 50 kg, the nozzle releases the bag and bag moves on the belt conveyor towards to loading point to be loaded in trucks / wagons. Since the packer makes rotation so a person has got to keep inserting bags one by one in each nozzle. After one complete revolution, the nozzle releases the bag. The whole process goes on this way. The average capacity of packing plant is around 9000 tons/day. Finally packed cement is made to reached on loaders through conveyor belts. There is interlocking system also in between. There are 18 loaders, 12 for trucks and 6 for trains (wagons).

CEMENT SILOSMech (5) , 3-Electronic ROTO PACKERS (7 Nos.) CEMENT TANK 4- (18 Nos.) LOADING POINTS (18 Nos.)

FLOW DIAGRAM:

Through bucket elevator

Gate Valve Level Sensor RTD

Load Cell

Through conveyer belt

COORDINATION WITH OTHER DEPARTMENT: Packing plant coordinates mainly with the following departments: 1

Sales and Logistics: These are the departments kept in touch regularly with packing plant. The sales department directs packing plant to load the required quantity and Logistic department specifies the mode of transportation.

2

Instrumentation: For controlling and maintenance of field instruments like load cell, packers and PLC.

3

Electrical

: For power supply

4

Account

: For freight charges to be paid to transporters.

5

P&A

: For manpower planning

6

Cement Mill

: For cement supply

7

Material handling

: For transportation & requirement of loaders.

MIS STUDY: 1 2

Daily report about quantity of cement packed. Daily log sheet of trucks and wagons loaded.

SAFETY MEASURES: 1 The labour should wear hand gloves while loading bags in to trucks / wagons. 2 The use of dust mask must be in practice with in the premises.

MECHANICAL: ORGANISATION STUDY: Mr. S. M. Khira (Sr. VP) (Functional Head - Technical)

Mr. P. K.Tripathi (VP) (Dy. Functional Head - O & M)

Mr. K. N. Lasod (HOD)

Mr. Sanjay Jain

(HOD) (Mechanical) (Mechanical)

Mr. Atul Sharma

Kiln

Mr.R.S.Gehlot

Raw Mill

Crusher Stacker &

Compressor Pollution

Reclaimer

House

Cement Mill

Lubrication Maintenance Control

Cell

Packing Plant

SPECIFICATIONS: KILN I : MAKE SIZE CAPACITY INCLN KILN RPM MOTOR

-

L&T 3.98 X 56 M2 3000 TPD 4% 82’ 28” 3.8 DC 226 KW, 1000 rpm

PRE HEATER I MAKE CAPACITY TWIN CY. I II III IV CALCINER

-

L&T/FLS 3000 TPD 5.6 X 8.9 M2 6.9 X 6 M2 6.9 X 6 M2 6.9 X 6 M2

-

Pfiffer (Germany) Vertical, hydraulic operated rollers 2600 KW, 1000 rpm 350 TPH

6.3 X 17.9 M2

RAW MILL II MAKE TYPE MOTOR CAPACITY

RAW MILL FAN I MAKE TYPE PR. TEMP CAPACITY MOTOR IMPELLOR

-

L&T/FLS 280/ 307 100 MMWG 350 degC MAX 6000 m3 1600 KW, 991 rpm 3070 mm

RAW MILL FAN II PR. TEMP CAPASITY MOTOR

-

1122 MMWG 350 degC MAX 600000 m3/ hr 2710 KW, 991 rpm

COORDINATION WITH OTHER DEPARTMENT: Mechanical department is directly related to Process Department. All the mechanical problems of process are attended by mechanical department. It is divided into areas like:1 Mines 2 Stacker, reclaimer & Raw mill 3 Pre heater & Kiln 4 Cement mill & Ash handling 5 Packing plant Each section looks after its particular area. For routine & general purpose spare & tools maintained by the department itself but major parts & machines are maintain by Central Store only, so department needs to coordinate with Central Store. To get hired suitable man power department coordinates with P & A Department. For any maintenance work there is a format of SAFETY PERMIT. In that safety officer review the situation and write the safety instruction on permit. Those instructions should be followed by responsible engineers and workers. MIS- STUDY: 1. 2. 3. 4.

Daily check list form various department Monthly area wise report. Shut down maintenance work report. Last sixth month trend of leakage, replacement, grease & oil consumption etc.

SAFETY MEASURES/ PRACTICES: 1. 2. 3. 4.

Use of Protection Equipments at every point. Permit from Safety officer. Shut down, electrical isolation or rack out of equipment. For online maintenance permit from process.

MAINTENANCE PRACTICES: 1. Preventive maintenance 2. Shut down maintenance (1 Major -20 days , 2 Minor-10 days) 3. Routine check list for equipments Responsible maintenance person takes round of their areas and make observation according to their check list Preventive maintenance schedule is followed up and any abnormality found in between is rectified in coordination with process department.

ELECTRICAL: INPUT-OUTPUT PROCESS STUDY: SHREE POWER generates power of 11 KV which is further stepped down to 6.6 KV. All HT motors, fans, coolers are connected to 6.6 KV. Again it is stepped down to 415 V for LT small field drives. SCL is having 45 MW TG Power (2x18 MW, 1x6MW, 1x3 MW) capacity and DG sets which is used in case of power failure or as an auxiliary supply to power plant. The power distribution is done as below: S.N AREA . 1 MINES

UNIT I (KW)

UNIT 2 (KW)

UNIT 3 (KW)

420

800

900

2

RAW MILL

3510

5000

3200

3

KILN

4200

5250

3200

4

COAL MILL

1000

1150

900

5

CEMENT MILL

4200

5850

6500

6

PACKING PLANT

240

340

300

7

HIGH GRADE CRUSHER SUBTOTAL

95

300

400

13665

18690

15400

MISC. LOAD

840

500

500

TOTAL

14505

19190

15900

14.5 MW

19.19 MW

15.90 MW

GRAND TOTAL

52.90 MW

COORDINATION WITH OTHER DEPARTMENT: Electrical department coordinates with all the departments like Process, Mechanical, Instrumentation, Shree Power, Store, Purchase, IT and Rajasthan Electricity Board (Power Grid) to get power for RAS etc. MIS- STUDY: 1. Man power distributions 2. Daily check list from various department 3. Monthly area wise report.

4. 5. 6. 7.

Monthly Power distribution target Shut down maintenance work report. Monthly target report. Annual target report.

FLOW DIAGRAM:

Power Distribution UNIT-1&2 From Power Plant

6.6 KV SUB STATION 3PH, 6.6KV COPPER DOUBLE BUS 450MVA

Unit-2 Packing Plant LC-1

LC-1A

LC-2

LC-3

LC-4

UNIT-2 : LC (Load Center)-1 1. 2. 3. 4. 5. 6.

Mines High Grade Feeder Crusher Truck Unloader Conveyer Belts Stacker

LC-2 1. 2. 3. 4. 5. 6.

Reclaimer Raw Mill Fan Spare RM Feed and Grinding RM Transport Raw Mill Hopper

Unit-1

LC-3 1. 2. 3. 4. 5. 6. 7.

Spare PCC Kiln & Cooler ESP Fan Coal Mill Fan PH Fan Cooler Vent MCC-9

1. 2. 3. 4.

Cement Mill Roller Press PCC Cement Mill SEPAX

LC-4

UNIT-1 1. Crusher-1 (500 KW Motor) 2. ESP Fan (300 KW Motor) 3. SG Fan (1600 KW Motor) 4. Kiln Cooler MCC 5. Raw Mill (1600 KW Motor) 6. Booster Fan (660 KW Motor) 7. Coal Mill (300 KW Motor) 8. R/M Fan (1600 KW Motor) 9. Cement Mill (3930 KW Motor) 10. PESP Fan (365 KW Motor) 11. SEPEX Fan Motor (510 KW Motor) 12. KALUGA Turbine (2.5 MW) 13. PCC: 1,3,4,5 SAFETY MEASURES/ PRACTICES: 1. Use of PPE at every point. 2. Permit from Safety officer. 3. Shut down, electrical isolation or rack out of equipment.

INSTRUMENT: INPUT-OUT PUT PROCESS STUDY: Instrumentation department plays a vital role in any process industry. The whole plant is run and controlled by field instruments and Programmable electronic controllers. I/P (24 V DC) DI

On-Off (Switch)

Commn. Bus

(24 V DC) DO

24VDC

(4-20 ma) AO

4-20 ma

O/P

CPU (Microprocessor) Variable (Flow,Pr Temp, % etc.)

(4-20 ma) AI

Memory (EEPROM)

COORDINATION WITH OTHER DEPARTMENT: Instrumentation department coordinates with all the departments like Process, mechanical, electrical, shree power, store, purchase, IT etc. MIS- STUDY: 1. 2. 3. 4.

Man power description Daily check list form various department Monthly area wise report. Shut down maintenance work report.

SAFETY MEASURES/ PRACTICES: 1. Safety from electrical hazards. 2. Interlocking for Process safety. 3. Use of PPE at every point.

INSTRUMENTATION USED IN THAT SECTION: PLC Location 1. Mines & crusher 2. RM-1 3. RM-2 4. KILN & PH-2 5. Cooler & Coal mill 6. Cement mill-2 7. Kiln-1 8. Cement mill-1 9. Packing Plant 10. Stacker 11. Reclaimer

Processor MODICON 984-480E MODICON 984-785E MODICON 984-785E MODICON 984-785E MODICON 984-785E MODICON 984-785E SCNEDZER CPU 43412A SCNEDZER CPU 43412A MODICON 984-785E ALLEN BREDLY SLC 5/03 ALLEN BREDLY SLC 5/03

DRIVES 1. Kiln main drive 2. Cooler grates 1,2,3 3. Raw mill 4. Reclaimer 1 5. Reclaimer 2 6. Cooler fans-7, 8, 9, 10 7. Mills classifiers 8. Coal feeding screw 9. Luffing Drive (Reclaimer) 10. Slew drive (Reclaimer) BELT WEIGHERS ESP CONTROLLER CELL Scanner Burning Zone temp. Temp. Transmitters (0-1200) Gas Analyzer Flow meters (200 TPH) Telemetry system -

D.C. drive D.C. drive (LHTOR make) D.C. drive (SIEMENS) A.C. drive D.C. drive V.F.D. V.F.D. V.F.D. A.C. drive A.C. drive

J & N Make BHA Make ROTAC Make Pyrometer (Toshniwal make) H & D make Rosemount Make J & N Make Data Linc group

ORGANISATION STUDY (P & A) :

P & A (PERSONAL AND ADMINISTRATION): OVERVIEW: P & A department plays a major role in an organization. It deals in manpower planning and recruitment, security, training, system management and rectification. It coordinates with every department in a company in order to facilitate by giving them manpower, transport, cultural events and maintaining the record of attendance, leaves of their employees. It also takes care of the human welfare activities like arranging cultural events, national festivals and excursion. P&A department also manage the staff colony and to provide them the basic amenities like healthy air, potable water, security and clean environment. COORDINATION WITH OTHER DEPARTMENTS: 1. This department coordinates with every department in the company for providing and meet the plant requirement for smooth functioning of organization. 2. Besides it has also got stint to make relations with other departments out side to the company.

SAFETY MEASURES/ PRACTICES: P & A department ensures safety practices in all other departments. like: 1. 2. 3. 4.

Mines safety : Blasts should be done properly , use of dust masks ,etc. Electrical safety : Checking competency certificates , earting of equipments , etc . General safety : Road safety , lighting & air ventilation arrangements , etc Shutdown & Safety permits : Height permits, silo cleaning permits, electrical shutdown, etc. 5. Fire safety : To look after fire extinguishers , hydrant pumps ,etc

RMH - RAW MATERIAL HANDLING: INPUT/OUTPUT PROCESS: Raw material is that material which gets processed upon and gives final (desired) product. It is considered as an input to any industry to get some planned output such as product and energy. There fore every industry is dependent upon the supply of raw material. In Shree Cement and Shree Power, we have a separate department which takes care of all types of raw material, required for the plants to produce the desired output. It has different application depending their contents, calorific values and cost. In our industry we use lime stone and petroleum coke. There is only one RMH section which caters to both Shree cement and Shree Power. Lime Stone, Pet coke, Gypsum, Laterite, Mill scale, Fly ash, Bituminous, Coal are the types of raw materials used in our company. For Shree Cement: 1. The raw material is lime stone (CaCo3) which is obtained from Shree and RAS mines. 2. Shree mines has low lime content (65-78 %) called average grade while RAS mines has high lime content (75-83 %) considered as high grade raw material. 3. Gypsum is imported from Jaisalmer and Bikaner . 4. Fly ash is attained from industries at free of cost but transportation charges have to be paid. It comes from Surat Garh, Kota and Delhi 5. Fly ash is mixed with clinkers as filler. 6. Gypsum (4-7 %) is added with clinkers to increase settling time of cement. Fly ash, the wastages of Shree Power is also used here. For Shree Power: 1. Required raw materials are Pet coke, Lime stone and bituminous. 2. Pet coke is procured from Reliance Industry, termed as India coke. Its calorific value is around 7600. 3. Bituminous coal is obtained from Gujarat (Cola Mines). Its calorific value is around 4000.

LOGISTICS/ SALES:

1. PROCESS FLOW:

Buyers Order/ demand Sales & Marketing department Acknowledgement Logistics

Contact to Transporters/ Rail Information/ Direction

Packing Plant

Transportation ( Rail or Road)

LOGISTICS: Logistics department deals with the dispatches of cement to their prospective buyers. All the dispatches are carried out by means of rail and roads. The job of this department is to dispatch against the order from buyers at mutually agreed contract such as time, mode of transportation and freight rates. The prime focus of this department is to make a dispatch on time at the lowest fares and smallest route. It also takes care of convenience of transportations. INPUT/OUTPUT PROCESS: As marketing department get an order from a buyer, they inform our logistics deptt and make sure that dispatch along with required quantity has to be carried out in the stipulated time. The marketing dept. gives all the relevant details to the logistics. as soon as payment against order is received the logistics deptt. Studies the suitable and shortest route, then decides the mode of transportation keeping various constraint such as time, money and convenience in their mind. the delivery is made to buyer all the taxes and freight already paid.. In addition to it we have to pay excise duty on cement @400/ton and education cess @ 2%. Generally around 150 trucks/ trailers are transported daily. MIS REPORT: Logistics deptt. has to make a MIS report against each dispatch and it has to specify in detail how and why a certain dispatch has been carried out. It has to furnish all the details about the dispatch such as freight rate, mode of transportation, route along with the causes for selection of such parameters.

CENTRAL STORE: INPUT/ OUTPUT PROCESS: The central store is the place where all the need full items relating to technical, consumer electronics and general things are kept and managed to their respective locations, all the location are addressed according to their specifications . There is a fix pattern to manage and access the various things. Spare parts, stationary, fuel ( petrol, diesel, oil) , general items ( rain coat, safety helmet e.t.c)., vehicle, consumables , electronic items are kept and managed. In our stores all the items are placed systematically and managed by in-house s/w Sumridhi.Items could be located by their item code. Any requirement of material is processed through stores. Department prepares indent through ERP with proper specification and code and is then is then forwarded to stores. Stores verifies the availability of materials and when it is not in stock then forwards to purchase department for further process of purchasing. One should have a primary know how process through ERP to make an indent. The Purchase department will search the various vendors dealing in that item taking care of quality and cost. Once it get thru, will ask for quotations from various vendors. After receiving the quotations, it will study and find the one with good quality and less cost or as per the requirement and generate the order only after the approval of Executive Director who heads this purchase department. After the delivery the required items are first kept in store, the store person will then inform to it’s indentor to approve the item on MRN (Material receipt note). Once the indenter approve, the store then permits him to get issued otherwise the store will again inform to purchase department about the incorrect delivery of material . The purchase department will then inform to his vendor and arrange to supply the required one. Once the vendor supplies the required item and at the same time the user approves, the purchase deptt issues a bill and forwards the same to account department. After verified for it’s correctness the payment is made to vendor.Inventory items are identified , listed and minimum inventory is maintained. Inventory management is carried out in store regularly to make sure the things are placed at the right locations.

FLOW DIAGRAM: CRUSHER

Indent ERP(SumRiddhi)

Requisition

Yes

STORE

No Supply

Indent PURCHASE

Order VENDOR

IT (INFORMATION TECHNOLOGY): INPUT/OUTPUT PROCESS: The section deals with all the departments, connecting al-together to data transfer and communication. It takes care of maintenance work for all the systems, kept on desks. It maintains all the data base of each employee up to date. IT section has designed our web site names www.shreecementltd.com. Every employee has got the facility of having his own email account where by he can send and receive mails. One of the major tasks of this section to have implemented an in house ERP called SUMriddhi. A robust IT platform with SUMriddhi, Shree ERP enables a seamless integration of management practices with business process at Shree resulting in the achievement of optimum speed , efficiency, transparency, internal controls and overall profitability. Through this system every department has now become transparent to each other. We can have details of store contents instantly by logging in ERP. COORDINATION WITH OTHER DEPARTMENT: 1

It coordinates with every department in the company like Technical, P & A, Account, Purchase, Logistics and Stores

2. Electrical department to get power supply for their equipments. 3. Instrumentation department to get regular maintenance for their UPS. MIS STUDY: IT department furnishes and submits daily reports to higher management covering the various points as below. 4. Descriptions of all the calls received from various departments. 5. Daily routine work of server, networking and power supply. SAFETY MEASURE/ PRACTICE: To overcome the data loss we take routine back up in CD’s of the same. In order to stop illegal mailing, the accounts of users are password protected. To block the access external devices, every system is protected by anti virus.

PURCHASE PROCESS: As per requirement / order of individual department, purchase department carries out the activity for purchasing the indented material Indented material is checked against the existing stock at stores, if material is not found at stores then indent process is initiated by raising an indent for the same following the consent of Executive Director. Quotations from some concerned leading vendors are invited. After consulting the vender for negotiating of price and genuine material. After the delivery of required material, the indentor is called to check and approve the material received. MIS STUDY: 1. Daily indent report sent to the head. 2. Bill of delivered materials to be sent to accounts. COORDINATION WITH OTHER DEPARTMENTS: 1. Store 2. Account

ACCOUNT: INPUT-OUT PUT PROCESS STUDY: 1. Inputs are payment, billing, quantity data, sales figure, salary details and any kind of accounts related documents come from all other departments. 2. Outputs are: Day to day payment of contractors, transport, store, purchase Salary & wages- TA, DA (SBI) Banking cheque (SBBJ, SBI, UTI) Inter department payments COORDINATION WITH OTHER DEPARTMENT: Accounts dptt coordinates to all the departments of SCL, RAS, DEPOTS and other branches. Some of them are: LAB: daily report of production & dispatch (excise purchase) comes from lab. PACKING: sales quantity report MINES: limestone production quantity CIVIL: Contractor’s bills RMH: quantity data SHREE POWER: Unit cost collected by cost department & then it comes here. P & A: salary or package related data, leave record of individuals. SALES A/C: sales figures, realization LOGISTIC: Transport (rail, road) information, dispatch info. IT: Here Mr. K.K.Soni from IT department is permanently sitting at A/C office. MARKETING: TA, DA, DEPOTS bills STORE: Here separate section for store accounting located at stores itself. MIS- STUDY: Account department submits the report, monthly balance sheet to higher management. Covering following points: Profit & loss Expenses (Head wise) Donation details Lime stone cost etc. Monthly Transaction

SHREE POWER INPUT/OUTPUT & PROCESS STUDY: Power Plant Operation can be broadly divided into four major parts. 1. DM Plant 2. Boiler 3. Turbine 4. Coal Handling Plant DM plant: It consists of following sub-divisions Raw water reservoir Pump House RO plant DM plant Effluent Water Treatment Plant Raw water is stored in raw water reservoir from different sources and then it comes to RO Plant through pump house where RO water is generated and is stored in a tank from where it is used in Cooling Tower and DM Plant for generation of DM water. DM water stream is having a capacity of 5.0 M3/Hr. This DM water is used in Boiler for Steam generation. The reject of RO plant and DM plant is fed to Effluent water treatment plant which generates RO water which is used in cooling tower as make up. The reject water of Effluent water treatment plant is sent to Mines directly for road spray purpose and thus no water is disposed off which creates any pollution. Boiler : Shree power is having 2 Nos. coal fired AFBC boiler Make TBW Capacity 2x80 TPH Pressure at SH Outlet 64 Kg/Cm2 Steam Temp. 485 Deg C It consists of Boiler Auxiliaries including ID fan, FD fan, PA fan, Burner assembly, Rotary feeders, screw feeders and Drag chain feeder’s etc. WESMAN Make Burners are used during boiler start up. Feed water is supplied to boilers through feed pumps. Specification of feed pump is as follows Make KSB Model HAD 100/9 Total head 925 m Pump speed 2985 RPM Motor rating 370 kW Motor speed 2985 RPM The Bed temperature is maintained around 9300C from where the fuel (normally Pet coke) takes heat to get burnt and after burning liberates heat energy. The air required for fuel combustion is supplied at certain pressure to the Boiler through the

FD fan. The PA fan is used to transport the fuel into boiler from the feeders The specification of FD fan and PA fan is as follows

Specification of FD fan

Specification of PA fan

Make Type Capacity Speed Outlet pressure Outlet total pr. Air/Gas density Motor rating Motor Speed

Make Type Capacity I/L St Pr. O/L St.Pr. Air/Gas density Speed Motor Rating Motor Speed

ABB Centrifugal 31.63 Kg/sec 1475 RPM 975 mmwc 1010 mmwc 1.021 Kg/m3 400 kW 1478 RPM

ABB Centrifugal 4.74 Kg/sec 730 mmWC 1580 mmWC .817 Kg/m3 1480 RPM 75 kW 1480 RPM

The ID fan is required to escape the flue gases out from the Boiler and maintain the desired pressure in furnace and flue gas path. The specification of ID fan is given below Specification of ID fan Make Type Capacity I/L St. pr. Fan speed Air/Gas Density Motor Rating Motor speed

ABB Centrifugal 38.17 Kg/sec 200 mmWC 890 RPM 0.748 kg/m3 180 kW 890 RPM

Coal is crushed to desired size in coal crusher. Coal crushers have been supplied by McNally Bharat Engineering Co. Lime stone crushers have been installed for crushing the limestone. Crushed coal and limestone are fed in their respective bunkers through belt conveyors.

TG SET : It consists of Turbine assembly, Reduction gear box, Generator and Auxiliaries including Oil reservoir, Lube oil system, control oil system, HP heater, LP heater, Cooling Tower, Condenser etc. The superheated steam from Boiler at 62 Kg/cm2 pressure and 485 deg.C temperature is supplied to Turbine which rotates it’s rotor at rated speed of 6200 rpm which in turn rotates the generator rotor at rated rpm of 1500 through a reduction

gear box. The steam at considerably reduced pressure and temperature is converted into water in condenser where cooling water takes away the heat from steam and is dissipated in cooling tower and cooling water is again circulated into condenser. The condensate is recirculated into boiler through Boiler Feed Pump. Specification of 2x18 MW Turbine Make Type Output Turbine speed Generator speed Inlet steam pressure Inlet steam temp. Extraction Pressure IIst Extraction Pr. IInd Extraction Pressure IIIrd Extraction pressure

SHIN NIPPON Horizontal , impulse , multistage, multivalve Axial flow , condensing & geared 18 MW 6200 RPM 1500 RPM 62 kg/cm2 485 degC 15.5 kg/cm2 5.10 kg/cm2 1.19 kg/cm2

Max. steam flow to turbine 74.9 TPH Max. Exhaust flow 60.85 TPH Gear box ratio ¼.129

Rest of the Plant : It includes low CV fuel Handling System, Bed ash Handling System and Coal Handling/Lime handling system Low CV Fuel Handling System The flue gases coming out from the Boiler contains a huge quantity of Fuel and therefore it is called as low CV fuel. The heaviest particles in the flue gases are collected in a hopper called as Air Pre Heater/Boiler Bank hopper due to gravity. Ahead, the low CV fuel is collected in three Electro static Precipitator hoppers by charging them with the help of high voltage. By Dense phase system, this low CV fuel from all hoppers is collected in a silo from where it is dumped into Tractor Trolleys or Trucks and is transported to Cement Plant where it is again used in firing within the Kiln. Bed ash handling system Fuel contains some ash within it and limestone, which is used as a sorbent in the boiler also, contains ash. These two increase thickness of the bed (heat reservoir) of the boiler and therefore it is needed to reduce by draining it. This drained ash is called as bed ash. Again this is collected in a silo through dense phase system and is dumped into

trolleys and is transported to Cement Plant. Coal Handling/Lime Handling System The Fuel either coal or pet coke is initially collected into a hopper from where it comes to Bunker within a definite size span through various belt conveyors, screens and crusher. This fuel is fed to the boiler through Drag chain or rotary feeders. Similarly the Bed material or Limestone is fed up to respective bunkers through belt conveyors, screens and crusher within a definite size span. The bed material is fed to the boiler directly but Lime stone is fed through the screw feeder and drag chain feeders. Electrical Supply Distribution For plant Auxiliaries

The 2x18 MW TG sets generate electricity at 11 KV level. The auxiliary supply utilization is at 6.6 KV and at 415 Volts. So the 11 KV supply is first stepped down by using a 6 MVA, 11/6.6 KV transformer located at Shree Power. The 6.6 KV supply is being utilized for supplying power to HT motors viz. BFP (3Nos.), FD fans (2 Nos.) and CWPs (3 Nos.). This 6.6 KV supply is further stepped down to 415 Volts by using two nos. 2.5 MVA 6.6/0.415 KV auxiliaries transformer. This 415 Volt supply is further utilized for supplying power to various MCCs which in turn is used for supplying power to various 415 Volts motors and other accessories like lighting , air conditioners etc. For Cement Plant : The 11 KV supply generated by 2 x 18 MW TG sets is evacuated to cement plant by using two 31.5 MVA, 11/6.6 KV power transformers. The two transformers GT-1 and GT-2 supply power to unit-1 and unit-2 of Cement Plant at 6.6 KV. The two 31.5 MVA transformers are located at 132 KV switchyard and the supply from these two transformers is being received at 6.6 KV substation of cement plant which is further distributed to various sections of cement plant. These two transformers are bi-directional transformer so in case of non running of TG sets , the same transformers can be used for drawing power to run the Shree Power Auxiliaries which may be supplied by either 3.0 MW TG set, DG sets or RVPN.