Sr.No.

Devapur

Description

Units

Savings

Compl. Time Project Cost Pay back in Months (Rs. Lacs) period (Yrs.) (After sanction is available)

kWh/MT clk 1 Energy savings kcal/kg clk kWh/MT cement

1.30 2156.00 36.00 0.77 250.00 555.00 720.00 620.00 988.00 235.00 1325.00 509.00 933.00 8291.00 3.51 18 4 to 18 12 to 18 6 to 18 3 to 12 6 to 12 6 to 8 6 to 12 3 to 12 4.31 6 to 12

2 3 4 5 6 7 8 9

Obsolete items Replacement items Spares items Capex Safety & Environment Quality improvement & Material handling Civil works in Plant- Development & Renovation Civil works in Township area Total

Jalgaon 1 2 3 4 5 Energy savings Reliability Safety & Environment Quality improvement Civil works Total kWh/MT cement 0.75 52.50 153.80 210.50 38.00 392.00 846.80 0.50 8 6 to 12 3 to 6 3 to 8 6 to 12

Project Cost (Rs. Lacs) Devapur Jalgaon P1 3464.00 604.80 P2 4827.00 242.00 Total 8291.00 846.80

Total

4068.80

5069.00

9137.80

Orient Cement : Devapur

Energy Savings Benefits (Reduction in specific energy) Specific Energy Thermal Energy (kwh/MT) (Kcal/kg clk) Kiln-1 Cooler system to be upgraded with new cooler Multi channel burner in place of conventional burner-2 nos. Installation of VFD in Kiln-1 cooler fans (8 nos.) Installation of New high efficiency fan for Kiln-1 PA fan Installation of GRR speed control in Kiln-2 Cooler ESP fan Installation of VFD in last 3 Cooler fans of Kiln-2 Installation of VFD in coal mill-2 CA fan Kiln coal firing blowers replacement Installation of new coal crusher in Line-3 for effective crushing of coal Compl. Time in Months Project Cost Pay Back in Rs. Lacs time (Years) (After sanction is available) Remarks

S.No

Section

Proposal Description

Kiln-1

1.50

26

1800.00

6.00

12

Apart from thermal saving there will be reduction in clinker temp. & hence improved life of belt conveyors (Needs 45 days of Kiln stoppage) Apart from thermal saving, improved clinker quality Power saving & improved process control Power savings & better process control Power savings & process control Power saving & improved process control Power saving Power savings

2 3 4

Kiln-1 Kiln-1 Kiln-1

10 1.00 0.13 Total

200.00 60.00 10.00 2070.00 8.00 28.00 8.00 18.00 Total 62.00 24.00 Total 24.00 250.00

2.20 1.35 1.73

12 12 12

5 6 7 8

Kiln-2 Kiln-2 Kiln-2 Kiln-2

0.50 0.44 0.16 0.18

0.50 1.88 1.48 2.99

9 6 6 12

Kiln-3

0.21

2.22

12

Power savings & reliability of crusher

10

Replacement of FK pump by Cement providing mechanical transport mill-1 system to feed Cement silo no 5

1.67 Total

3.51

18

Direct energy saving.& utilizing the 100% capacity.

2406.00

Priority (P1/P2)

P2

P1 P1 P1

P1 P1 P1 P1

P2

P2

Orient Cement : Devapur

To Maintain Reliability & Plant Health Compl. Time in Months Remarks (After sanction is available)

S.No Section

Proposal Description

Project Cost in Rs. Lacs

Priority (P1/P2)

Obsolete 1 Raw mill-2 2 3 4 5 6 7 8 Inst. Inst. Inst. Inst. Inst. Electrical Electrical

Mill discharge bucket elevator chain Kiln-1 Main Drive upgrade to DCS800 system ESP controller upgrade for Cooler-1 &2 Packer-3& 4 upgrade Kiln-2 PLC I/O upgrade Integration of SCADA,s on one platform with MIS option Replacement of MCC in Packing Plant-2Nos,Kiln1,Additive Crusher & CM-1 (Total-5Nos.) Main PDB Replacement -- Kiln-1 , CM-2 & Colony Total

200 25 25 50 30 90 60 75 555

18 6 6 6 6 8 6 4

Obsolete Design , spares not available System is obsolete and spares of DCS 500 are not available . Obsolete and efficiency of ESP will be improved Obsolete and accuracy not up to mark. Obsolete and spares not available Obsolete and MIS Report option is not available. Modification & upgrade cumbersome. Fault finding is not easy. Obsolete & Spares are not available Obsolete & Spares are not available

P1 P2 P1 P1 P1 P2 P2 P2

Replacement Items Cooler hammer mill upgradation (If total cooler modification is done this is not required) To avoid kiln stoppage due to hammer mill mouth jamming with clinker lumps, due to hammer mill inadequate capacity (Kiln running hrs. lost -Approx. 36 hrs annually) At present running above capacity, No margin available May be defered for 2 years (under observation) Present system is undersize creating repeated spillage To replace present Duoflex burner for better reliability

Kiln-1

100

12

P2

10 11 12 13

Kiln-1 Kiln-1 Kiln-2 Kiln-3

PC pre-heater bucket elevator capacity upgradation KILN-1 outlet cowl shell replacement. Kiln-1 1st tyre shell with floated chair pads replacement. Kiln-2 dust transport FK pump & screw conveyor capacity upgradation Burner pipe (Pyro jet) Total

200 175.00 45 200 720 125 30

18 12 12 12

P2 P2 P1 P1

Spares 14 15 Raw mill-1 Raw mill-1 Spare gear box for roller press (1 nos.) Polycom roller sleeve (2 nos.) 18 12 Common for Devapur & Jalgaon Increase in production by 5 MT P2 P2

Orient Cement : Devapur

To Maintain Reliability & Plant Health Compl. Time in Months Remarks (After sanction is available) 8 6 12 9 12 6 6 8 Spare required Spare required Spare required For all three lines stand by required For all three Kilns-impeller System installed is first time in such system, hence not reliable Spare required Breakdown on this account takes long plant stoppages These items are required to meet emergency requirement for improving the availbility of plant incase of any failures. These items are required to meet emergency requirement for improving the availability of plant incase of any failures. This item is required to meet emergency requirement for improving the availbility of plant incase of any failures. Clinker feeding mcc &power transformer commissioning work These items are required to meet emergency requirement for improving the availability of plant incase of any failures.

S.No Section

Proposal Description

Project Cost in Rs. Lacs

Priority (P1/P2)

16 17 18 19 20 21 22 23

Raw mill-3 Raw mill-3 Kiln-3 Kiln-3 Kiln-3 Kiln-3 Cement mill1&2 Inst.

SKS fan impeller RP fluid coupling unit (1 No.) VRM coal mill roller complete assembly with yoke Primary air fan complete assembly as a stand by equipment (for all 3 kilns) Pre-heater fan impeller with shaft assembly Standby panel for kiln-3 main drive RP fluid coupling unit (1 No.) Common standby panel for kiln-3 PH Fan & Bag house fan with bypass & switching arrangement HT Spare Motor-- L-1-PC Fan,CM-2-SKS Fan,LSC , RM-2 Vent Fan ----1000KW,1000RPM

15 25 80 25 40 30 25 90

P2 P1 P1 P1 P2 P1 P1 P1

24

Electrical

25

P2

25

Electrical

MV Spare Motor -- L-3 Bag House Fan & PH Fan-1650KW,1000RPM

35

P1

26

Electrical

Spare Transformer for L-3 Kiln Main Drive VFD Applicaton Power Cable for Packing Plant - Trx & CM-2 Clinker feeding MCC HT Spare Motor -- RM-3 SKS Fan, Total

15

P2

27

Electrical

20

P2

28

Electrical

40 620 50 25

P1

Capex 29 30 Raw mill-1 Raw mill-3 ESP dust transportation to CM Automatic welding machine 12 3 Product cost reduction proposal To reduce build up time insitu P1 P1

Orient Cement : Devapur

To Maintain Reliability & Plant Health Compl. Time in Months Remarks (After sanction is available) 18 2 8 6 12 6 3 6 12 For easy reach for transportation & maintenance. In house Maintenance of Transformers For enhancing of the pile capacity about 10000 MT. From easy & full proof operation from CCR. & to avoid manual changeover of the gates. Utilizing 100 % feeding to the Cement Silo. Monitoring of kiln condition will be easier. Corrective action can be taken in advance Calibration time will be reduced. Accuracy will be better. Easy fault finding, control & operation from one place . Improper communication resulting in data hang up because Control logix CPU is faster and SLC IOs are slower. Accuracy and reliability is not good. Packing Plant Power supply is feding from various places and to Isolate the P/Plant Load it is necessary to install one Transformer only for Packing Plant. Kiln Max.RPM not getting due to RPM Restriction of Motor(1000RPM).Needs higher RPM Motor to get Max.RPM of Kiln. To reduce the loading time of Clinker & Cement racks.

S.No Section

Proposal Description

Project Cost in Rs. Lacs

Priority (P1/P2)

31 32 33 34 35 36 37 38 39 40 41 42 43 44

Cement mill1&2 Electrical PBSR Cement mill1&2 Cement mill-1 Inst. Inst. Inst. Inst. Inst. Inst. Inst. Inst. Inst.

Lift arrangement in Cement mill for RP-I & RP-II Transformer Oil Filter M/C Extension of reclaimer travel rail length about 30 mtrs.towards west side. Automation of Cement silo change over valves. CM-I, silo elevator capacity to be increased to 200 TPH CCTV cameras in Kiln-1&2 Online bag weight adjustment system for Packer1,2,3,4,5&6 Automation for bulk loading system with connectivity to main server PLC control system for packer-1,2,3,4&5 SLC Input/Output module upgrade to control logix C) Cement Mill-1 A) Raw Mill-1 B) Kiln-1 Kiln-2 (kiln feed) & Kiln-3 (coal and kiln feed) SFF upgradation Transformer--2MVA--- Packing Plant Power Distribution

80 8 70 20 125 30 10 15 40 20 40 50 75

P2 P2 P1 P1 P1 P1 P1 P2 P2 P2 P2 P2 P2

45

Electrical

20

P1

46

Electrical

Kiln-3 Main Motor - 705KW,1500RPM

25

P1

47

Packing plant Locomotive (1 no.)

250.00

12

P1

Orient Cement : Devapur

To Maintain Reliability & Plant Health Compl. Time in Months Remarks (After sanction is available) 12 12 Inhouse emergency requirement Inhouse emergency requirement

S.No Section

Proposal Description

Project Cost in Rs. Lacs

Priority (P1/P2)

48 49

Workshop Workshop

Drilling machine (1 no.) Lathe machine (1 no.) Total Total

15 20 988

P2 P2

2883

Orient Cement : Devapur

Safety & Environment Compl. Time in Months S.No Section Proposal Description Project Cost in Rs. Lacs (After sanction is available) 12 Remarks

Kiln-1

Separate CO2 purging Automatic control system for fire extingushing in Dust collectors of VRM Coal Mill-1 Present CO2 purging Automatic control system for fire extingushing in Dust collectors of Coal Mill-1 CSP top dust collector

20.00

No system available as on date

Kiln-1

20.00

12

No system available as on date

Kiln-1

25.00

12

Undersize, creating environment issue To avoid pressurization problem & dusty atmosphere Existing one is project time lift and not suitable for plant running. Environment Friendly.

Kiln-2

Replacement of Kiln-2 ESP fan with New high capacity fan

50.00

12

Kiln-3 Cement mill

Additional lift for pyro-system of line-3 Installation of higher capacity of dust collector on Jalgaon Clinker Silo top Total

100.00

18

20.00 235.00

Priority (P1/P2)

P1

P1

P1

P1

P2

P1

Orient Cement : Devapur

Quality Improvement and Material Handling Benefits S.No Section Proposal Description Prod. Quality Impr. P Reliability/ Other P Project Cost in Rs. Lacs Compl. Time in Months (After sanction is available) Remarks Priority (P1/P2)

Kiln-2

Kiln rpm to be increased, as present kiln degree of filling is high Particle size Disrtibution Analyzer

To improve clinker quality higher RPM is required (up to 5 RPM as against present 3.8 RPM) 30 8 For Mills Optimisation.Increase in productivity,optimum usage of Fly ash and consistent quality product. Present Storage capacity is sufficient for 40days consumption.To increase storage capacity (approx. 8000 MT, 8 Days ) and avoid Hopper/Crusher jamming ,inconsistent product quality,mill stoppages and Additive Push Feeder breakdowns during mansoon. During monsoon movement of trucks , unloading and dozing/stacking of Gypsum is very difficult due to wet material and jamming of trucks in front of Sheds.To avoid these problems and to increase storage capacity (approx.6000MT) , Sheds extension is required. Present Storage capacity is sufficient for 21 days consumption.To increase storage capacity (approx.16000MT, 9 Days)and avoid crusher jamming/Process problems ,Quality and production loss during mansoon

P2

Quality control

P1

Material handling

Line - I & II Additive Sheds Extension

25

P2

Material handling

Gypsum Sheds Extension

30.00

P2

Material handling

Coal Sheds Extension

40.00

P2

Material handling

Clinker Storage Silo/ shed (50,000 MT)

P Total

1200.00 1325.00

Reduction of Clinker handling charges, clinker quality loss. Further to be evaluated.

P2

Orient Cement : Devapur Infrastructure Development in Plant Area Amount Rs. in Lacs Compl. Time in Months (After sanction is available)
6 6 12 12 12 6 Priority (P1/P2)

S.No.

Job Description

Development Works 1 2 3 4 5 6 Development work in mines office, mines roads & Missamma sagar area Development of garden in plant & beautification Renovation of plant main gates-1&2 Renovation of CCR building (Front elevation,staircase,and wall panelling) Construction of first floor at Administration office building Construction of Refractory brick godown at line -3 Total 10 13 14 Making of RCC approach road from main road to laterite shed Extension of track to accommodate full rake with MU power and 8 wheeler brake van (100 mtrs). Laying of addition line (no.2) for fresh empty clinker rake placement Total TOTAL : 6.00 20.00 50.00 40.00 25.00 8.00 149.00 15.00 140.00 205.00 360.00 509.00 3 12 12 P1 P1 P1 P1 P1 P1 P1 P1 P1

Orient Cement : Devapur Infrastructure Development in Town ship area Amount in Rs. Lacs
6.00 10.00 12.00 12.00 16.00 22.00 25.00 25.00 30.00 50.00 50.00 60.00 125.00 75.00 100.00 150.00 165.00 TOTAL : 933.00

Compl. Time in Months (After sanction is available)

6 3 3 3 6 7 12 12 6 6 12 12 12 12 9 12 12

S.No.

Job Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Providing and fixing of granite slabs, tiles and wooden cupboards in "C" type quarter kitchen area -24 nos Drain repair work Height increase of boundary wall at Maddimada village side Making RCC Road community hall to old library Providing and fixing of granite slabs, tiles and wooden cupboards in "D" type quarter kitchen area -50 nos Making RCC Road in "F" type quarters Area 500 RMT Development of gardens and beautification work, green house, nursery, STP pump house Water pond development near J type quarter Renovation of Guest House Widening of roads in colony - B type quarter to main gate, C type quarter to D type quarter, Main gate to Temple 5.0 Km Replacement of all PDB's and tower lights Construction of contractor workmen quarters near " J " type quarter - 40 nos Renovation of community hall and Construction of club building, Gym and Library Construction of Shopping complex in Town ship Making stadium view in football ground with seating arrangement with portal crip shed, sports arena Construction of school building E/M and T/M Extention of one bed room & one toilet in " E " type quarters - 110 nos

Priority (P1/P2)

P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1