Questionnaire for plant energy assessment and target setting

(Applicable to Cement plants covered under PAT –II)

Name and address of Plant

Plant elevation (from MSL), in meter

Plant annual capacity & establishment year

Main products (all types of cement)

Section wise data of plant :

1. L S Crusher
Performance Guarantee Data
Whether covered
Operating capacity Make & Type of SPC (kWh/ MT
Particulars I/P and O/P size (mm) under GTG
(TPH) crusher material) TPH SPC @ O/P size of (Y/N)

Crusher-1
Crusher-2
Crusher-3

2. Raw Mill
Limestone Bond Index _______________kWh/ T (all test results of BI tested during 2016 - 19 preferably in an independent NABL accredited laboratory)

Performance Guarantee Data

Moisture content in
Operating capacity Make & Type SPC (kWh/ MT Raw meal residue over 90
Particulars Feed Lime Stone (in
(TPH) (Provide in detail) material) mic/ 212 mic
%) SPC @ residue
TPH
-----and sieve --

Mill-1
Mill-2
Mill-3

3. Coal Mill*
Coal Hard Grove Index _______________kWh/ T ( Separate for each type of coal/ Fuel used)
Moisture content in Performance Guarantee Data
Operating capacity Make & Type SPC (kWh/ MT Fine coal/ Fuel residue over
Particulars Feed Fuel SPC @ residue
(TPH) (Provide in Detail) material) 90 mic/ 212 mic TPH
(in %) -----and sieve --
Mill-1
Mill-2
Mill-3
Mill-4
* separate data for each type of fuel
4. Pyro section
Particulars Operating Capacity Technology SPC (kWh/ MT clinker) STEC (kCal/kg STEC (kCal/kg clinker)- On TSR (%) Clinker litre Performan
(TPD) supplier clinker)- On fuel NCV fuel NCV basis weight/ Free lime
basis & without AF (with AF)

TPD
Kiln-1
Kiln-2
Kiln-3

Pyro section equipment supplier details & Important operating KPIs

Particulars Kiln supplier and Cooler supplier, Main burner (supplier, Preheater type, no of WHRS (Y/N)
dimension grate area and Type and capacity) stages if Y then capacity (in MW) and Establishment year Kiln inlet O2 (%) Kiln Inlet temp (oC)
type of cooler tapping point

Kiln-1
Kiln-2
Kiln-3

5. Cement Mill*
Clinker bond Index _______________kWh/ T (all test results of BI tested during 2016 - 19 preferably in an independent NABL accredited laboratory)
Performance Guarantee Data
Operating Capacity With pregrinder (Y/N), SPC (kWh/ MT Cement residue over 45 mic/ Cement blaine
Particulars Make & Type SPC @ residue
(TPH) if yes then pl specify cement) 212 mic (m2/kg) TPH
-----and sieve --

Mill-1

Mill-2

Mill-3

* separate data for each type of cement produced

5A. Major Equivalent Product Produced

Financial Year Major Equivalent
Product Produced

2016-17
2017-18
2018-19

6. Packing Plant
 Performance Guarantee Data
Operating Capacity SPC (kWh/ MT Whether covered
Particulars Make & Type
(TPH) cement) TPH SPC under GtG (Y/N)

Packer-1

Packer-2

Packer-3

Packer-4

7. Utility (Details of compressors > 90 kW motor) - only for plant

Compressor capacity Pressure setting Motor with VFD
Particulars Motor capacity Make & Type End use
cfm/bar Load (bar) Unload (bar) (Y/N)
Compressor-1
Compressor-2
Compressor-3
Compressor-4
8. CPP
Particulars Operating Capacity Boiler Type and PLF Heat Rate Aux power consumption (%) Type of condensasor Type of power Performance Guaran
(MW) capacity cooling system generation cycle
(Air/Water) Heat rate

CPP-1
CPP-2
CPP-3

7. Utility (Details of compressors > 90 kW motor) - only for CPP

Compressor capacity Pressure setting Motor with VFD
Particulars Motor capacity Make & Type End use
cfm/bar Load (bar) Unload (bar) (Y/N)
Compressor-1
Compressor-2
Compressor-3

9. Plant other KPI

(i) SPC (upto clinkerization) ________________________kWh/MT clinker
(ii) SPC (Cement Grinding - all type of Cement) ________________________kWh/ MT cement
(iii) SPC (overall) ________________________kWh/ MT cement
(iv) Clinker to cement ratio (separate for each type of product) OPC- PPC-
(v) Kiln feed to Clinker ratio
(vi) Fuel to clinker ratio
(vii) Kiln Heat balance (carried out during 2016 to 2019 - Preferably by third party)

10. Additional details

1. Month wise detailed and section wise STEC & power report for last 03 years
2. Details of AF used, if any
3. To attach the soft copy of MEA carried out during PAT Cycle II for BEE
Abbreviation used
AF Alternative Fuels
CFM Cubic Feet per Minute
CPP Captive Power Plant
GtG Gate to Gate
KPI Key performance Indicators
PLF Plant Load Factor
SPC Specific Power Consumption
STEC Specific Thermal Energy Consumption
TPD Tonnes Per Day
TPH Tonnes Per Hour
TSR Thermal Substitution rate
VFD Variable Frequency Drive
Performance Guarantee Data

SPC STEC

Pyro Operational data

Kiln inlet draft (in Calciner outlet O2 Calciner outlet Preheater Preheater Preheater fan False air Tertiary Cooler Clinker Cooler Burner Raw meal Kiln %
mbar) (%) temerature (oC) pressure drop outlet gas inlet pressure in air exhaust temperau specific flame temperatu fuel firing
(in mbar) temperature (in mbar) preheater temperatu air re (after air momentu re (in oC)
(oC) (%) re temperatu cooler , in (nm3/kg m (%
(preheate re (in oC) o
C) clinker) m/sec)
r side and
in oC)
ance Guarantee data

PLF
 Questionnaire for plant energy assessment and target setting
(Applicable to Cement plants covered under PAT –II)

Name and address of Plant

Plant elevation (from MSL), in meter

Plant annual capacity & establishment year

Main products (all types of cement)

Section wise data of plant :

1. L S Crusher
Performance Guarantee Data
Whether covered
Operating capacity Make & Type of SPC (kWh/ MT
Particulars I/P and O/P size (mm) under GTG
(TPH) crusher material) TPH SPC @ O/P size of (Y/N)

Crusher-1
Crusher-2
Crusher-3

2. Raw Mill
Limestone Bond Index _______________kWh/ T (all test results of BI tested during 2016 - 19 preferably in an independent NABL accredited laboratory)

Performance Guarantee Data

Moisture content in
Operating capacity Make & Type SPC (kWh/ MT Raw meal residue over 90
Particulars Feed Lime Stone (in
(TPH) (Provide in detail) material) mic/ 212 mic
%) SPC @ residue
TPH
-----and sieve --

Mill-1
Mill-2
Mill-3

3. Coal Mill*
Coal Hard Grove Index _______________kWh/ T ( Separate for each type of coal/ Fuel used)
Moisture content in Performance Guarantee Data
Operating capacity Make & Type SPC (kWh/ MT Fine coal/ Fuel residue over
Particulars Feed Fuel SPC @ residue
(TPH) (Provide in Detail) material) 90 mic/ 212 mic TPH
(in %) -----and sieve --
Mill-1
Mill-2
Mill-3
Mill-4
* separate data for each type of fuel
4. Pyro section
Particulars Operating Capacity Technology SPC (kWh/ MT clinker) STEC (kCal/kg STEC (kCal/kg clinker)- On TSR (%) Clinker litre Performan
(TPD) supplier clinker)- On fuel NCV fuel NCV basis weight/ Free lime
basis & without AF (with AF)

TPD
Kiln-1
Kiln-2
Kiln-3

Pyro section equipment supplier details & Important operating KPIs

Particulars Kiln supplier and Cooler supplier, Main burner (supplier, Preheater type, no of WHRS (Y/N)
dimension grate area and Type and capacity) stages if Y then capacity (in MW) and Establishment year Kiln inlet O2 (%) Kiln Inlet temp (oC)
type of cooler tapping point

Kiln-1
Kiln-2
Kiln-3

5. Cement Mill*
Clinker bond Index _______________kWh/ T (all test results of BI tested during 2016 - 19 preferably in an independent NABL accredited laboratory)
Performance Guarantee Data
Operating Capacity With pregrinder (Y/N), SPC (kWh/ MT Cement residue over 45 mic/ Cement blaine
Particulars Make & Type SPC @ residue
(TPH) if yes then pl specify cement) 212 mic (m2/kg) TPH
-----and sieve --

Mill-1

Mill-2

Mill-3

* separate data for each type of cement produced

5A. Major Equivalent Product Produced

Financial Year Major Equivalent
Product Produced

2016-17
2017-18
2018-19
6. Packing Plant
Performance Guarantee Data
Operating Capacity SPC (kWh/ MT Whether covered
Particulars Make & Type
(TPH) cement) TPH SPC under GtG (Y/N)

Packer-1

Packer-2

Packer-3

Packer-4

7. Utility (Details of compressors > 90 kW motor) - only for plant

Compressor capacity Pressure setting Motor with VFD
Particulars Motor capacity Make & Type End use
cfm/bar Load (bar) Unload (bar) (Y/N)
Compressor-1
Compressor-2
Compressor-3
Compressor-4

8. CPP
Particulars Operating Capacity Boiler Type and PLF Heat Rate Aux power consumption (%) Type of condensasor Type of power Performance Guaran
(MW) capacity cooling system generation cycle
(Air/Water) Heat rate

CPP-1
CPP-2
CPP-3

7. Utility (Details of compressors > 90 kW motor) - only for CPP

Compressor capacity Pressure setting Motor with VFD
Particulars Motor capacity Make & Type End use
cfm/bar Load (bar) Unload (bar) (Y/N)
Compressor-1
Compressor-2
Compressor-3

9. Plant other KPI

(i) SPC (upto clinkerization) ________________________kWh/MT clinker
(ii) SPC (Cement Grinding - all type of Cement) ________________________kWh/ MT cement
(iii) SPC (overall) ________________________kWh/ MT cement
(iv) Clinker to cement ratio (separate for each type of product) OPC- PPC-
(v) Kiln feed to Clinker ratio
(vi) Fuel to clinker ratio
(vii) Kiln Heat balance (carried out during 2016 to 2019 - Preferably by third party)
10. Additional details
1. Month wise detailed and section wise STEC & power report for last 03 years
2. Details of AF used, if any
3. To attach the soft copy of MEA carried out during PAT Cycle II for BEE
Abbreviation used
AF Alternative Fuels
CFM Cubic Feet per Minute
CPP Captive Power Plant
GtG Gate to Gate
KPI Key performance Indicators
PLF Plant Load Factor
SPC Specific Power Consumption
STEC Specific Thermal Energy Consumption
TPD Tonnes Per Day
TPH Tonnes Per Hour
TSR Thermal Substitution rate
VFD Variable Frequency Drive
Performance Guarantee Data

SPC STEC

Pyro Operational data

Kiln inlet draft (in Calciner outlet O2 Calciner outlet Preheater Preheater Preheater fan False air Tertiary Cooler Clinker Cooler Burner Raw meal Kiln %
mbar) (%) temerature (oC) pressure drop outlet gas inlet pressure in air exhaust temperau specific flame temperatu fuel firing
(in mbar) temperature (in mbar) preheater temperatu air re (after air momentu re (in oC)
(oC) (%) re temperatu cooler , in (nm3/kg m (%
(preheate re (in oC) o
C) clinker) m/sec)
r side and
in oC)
ance Guarantee data

PLF
 Questionnaire for plant energy assessment and target setting
(Applicable to Cement plants covered under PAT –II)

Name and address of Plant

Plant elevation (from MSL), in meter

Plant annual capacity & establishment year

Main products (all types of cement)

Section wise data of plant :

1. L S Crusher
Performance Guarantee Data
Whether covered
Operating capacity Make & Type of SPC (kWh/ MT
Particulars I/P and O/P size (mm) under GTG
(TPH) crusher material) TPH SPC @ O/P size of (Y/N)

Crusher-1
Crusher-2
Crusher-3

2. Raw Mill
Limestone Bond Index _______________kWh/ T (all test results of BI tested during 2016 - 19 preferably in an independent NABL accredited laboratory)

Performance Guarantee Data

Moisture content in
Operating capacity Make & Type SPC (kWh/ MT Raw meal residue over 90
Particulars Feed Lime Stone (in
(TPH) (Provide in detail) material) mic/ 212 mic
%) SPC @ residue
TPH
-----and sieve --

Mill-1
Mill-2
Mill-3

3. Coal Mill*
Coal Hard Grove Index _______________kWh/ T ( Separate for each type of coal/ Fuel used)
Moisture content in Performance Guarantee Data
Operating capacity Make & Type SPC (kWh/ MT Fine coal/ Fuel residue over
Particulars Feed Fuel SPC @ residue
(TPH) (Provide in Detail) material) 90 mic/ 212 mic TPH
(in %) -----and sieve --
Mill-1
Mill-2
Mill-3
Mill-4
* separate data for each type of fuel
4. Pyro section
Particulars Operating Capacity Technology SPC (kWh/ MT clinker) STEC (kCal/kg STEC (kCal/kg clinker)- On TSR (%) Clinker litre Performance Guarantee Data
(TPD) supplier clinker)- On fuel NCV fuel NCV basis weight/ Free lime
basis & without AF (with AF)

TPD SPC STEC

Kiln-1
Kiln-2
Kiln-3

Pyro section equipment supplier details & Important operating KPIs

Particulars Kiln supplier and Cooler supplier, Main burner (supplier, Preheater type, no of WHRS (Y/N) Pyro Operational data
dimension grate area and Type and capacity) stages if Y then capacity (in MW) and Establishment year Kiln inlet O2 (%) Kiln Inlet temp (oC) Kiln inlet draft (in Calciner outlet O2 Calciner outlet Preheater Preheater Preheater fan False air Tertiary Cooler Clinker Cooler
type of cooler tapping point mbar) temerature (oC) pressure drop outlet gas inlet pressure in air exhaust temperau specific
(%)
(in mbar) temperature (in mbar) preheater temperatu air re (after air
(oC) (%) re temperatu cooler , in (nm3/kg
(preheate re (in oC) o
C) clinker)
r side and
in oC)

Kiln-1
Kiln-2
Kiln-3

5. Cement Mill*
Clinker bond Index _______________kWh/ T (all test results of BI tested during 2016 - 19 preferably in an independent NABL accredited laboratory)
Performance Guarantee Data
Operating Capacity With pregrinder (Y/N), SPC (kWh/ MT Cement residue over 45 mic/ Cement blaine
Particulars Make & Type SPC @ residue
(TPH) if yes then pl specify cement) 212 mic (m2/kg) TPH
-----and sieve --

Mill-1

Mill-2

Mill-3

* separate data for each type of cement produced

5A. Major Equivalent Product Produced

Financial Year Major Equivalent
Product Produced

2016-17
2017-18
2018-19

6. Packing Plant
Performance Guarantee Data
Operating Capacity SPC (kWh/ MT Whether covered
Particulars Make & Type
(TPH) cement) TPH SPC under GtG (Y/N)

Packer-1

Packer-2

Packer-3

Packer-4

7. Utility (Details of compressors > 90 kW motor) - only for plant

Compressor capacity Pressure setting Motor with VFD
Particulars Motor capacity Make & Type End use
cfm/bar Load (bar) Unload (bar) (Y/N)
Compressor-1
Compressor-2
Compressor-3
Compressor-4

8. CPP
Particulars Operating Capacity Boiler Type and PLF Heat Rate Aux power consumption (%) Type of condensasor Type of power Performance Guarantee data
(MW) capacity cooling system generation cycle
(Air/Water) Heat rate PLF

CPP-1
CPP-2
CPP-3

7. Utility (Details of compressors > 90 kW motor) - only for CPP

Compressor capacity Pressure setting Motor with VFD
Particulars Motor capacity Make & Type End use
cfm/bar Load (bar) Unload (bar) (Y/N)
Compressor-1
Compressor-2
Compressor-3

9. Plant other KPI

(i) SPC (upto clinkerization) ________________________kWh/MT clinker
(ii) SPC (Cement Grinding - all type of Cement) ________________________kWh/ MT cement
(iii) SPC (overall) ________________________kWh/ MT cement
(iv) Clinker to cement ratio (separate for each type of product) OPC- PPC-
(v) Kiln feed to Clinker ratio
(vi) Fuel to clinker ratio
(vii) Kiln Heat balance (carried out during 2016 to 2019 - Preferably by third party)

10. Additional details

1. Month wise detailed and section wise STEC & power report for last 03 years
2. Details of AF used, if any
3. To attach the soft copy of MEA carried out during PAT Cycle II for BEE
Abbreviation used
AF Alternative Fuels
CFM Cubic Feet per Minute
CPP Captive Power Plant
GtG Gate to Gate
KPI Key performance Indicators
PLF Plant Load Factor
SPC Specific Power Consumption
STEC Specific Thermal Energy Consumption
TPD Tonnes Per Day
TPH Tonnes Per Hour
TSR Thermal Substitution rate
VFD Variable Frequency Drive
 Burner Raw meal Kiln %
flame temperatu fuel firing
momentu re (in oC)
m (%
m/sec)