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Raw Mill

Raw Mill Mill


Cement
CrusherSilos
Pre Rotary
Air
350-370
Mixer
Stacker
heater
Lime stones (CaCO3) Kiln
&Cooler
TPH
(Hoppers)
Reclaimer
(300-700
from C)
mines o(Shree & RAS)
CEMENT
Packing
800 Plant
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 % OF LIME (CaC03 ) MODE OF CONVEYANCE


Shree mine 69-73% (avg. grade) Conveyor belt ( 1.9 Kms ).
RAS 79-83% (high grade). 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 Raw mill log sheet.


2 Kiln log sheet.
3 Coal mill log sheet.
4 Cement mill log sheet.
4 Analyzer log sheet.
5 Shut down check list
6 Daily production report
7 Monthly ISO documents
8 Residue Blaine log sheet

SAFETY MEASURES/ PRACTICES:

1 Use of Safety instruments at every point.


2 Bag filter at mill for dust protection.
3 Drinking Water facility at high temp areas like Kiln.
4 Use of hand gloves, dust masks, welding glasses, etc.
5 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).
ROTO PACKERS CEMENT
(7 Nos.) SILOSMech
(5) , 3-Electronic
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 Daily report about quantity of cement packed.


2 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 Mr.R.S.Gehlot

Kiln Raw Mill

Crusher Stacker & Compressor Pollution Lubrication Maintenance


Reclaimer House Control Cell

Cement Mill Packing Plant


SPECIFICATIONS:

KILN I :

MAKE - L&T
SIZE - 3.98 X 56 M2
CAPACITY - 3000 TPD
INCLN - 4% 82’ 28”
KILN RPM - 3.8
MOTOR - DC 226 KW, 1000 rpm

PRE HEATER I

MAKE - L&T/FLS
CAPACITY - 3000 TPD
TWIN CY. I - 5.6 X 8.9 M2
II - 6.9 X 6 M2
III - 6.9 X 6 M2
IV - 6.9 X 6 M2
CALCINER - 6.3 X 17.9 M2

RAW MILL II

MAKE - Pfiffer (Germany)


TYPE - Vertical, hydraulic operated rollers
MOTOR - 2600 KW, 1000 rpm
CAPACITY - 350 TPH

RAW MILL FAN I

MAKE - L&T/FLS
TYPE - 280/ 307
PR. - 100 MMWG
TEMP - 350 degC MAX
CAPACITY - 6000 m3
MOTOR - 1600 KW, 991 rpm
IMPELLOR - 3070 mm

RAW MILL FAN II

PR. - 1122 MMWG


TEMP - 350 degC MAX
CAPASITY - 600000 m3/ hr
MOTOR - 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. Daily check list form various department


2. Monthly area wise report.
3. Shut down maintenance work report.
4. Last sixth month trend of leakage, replacement, grease & oil consumption etc.

SAFETY MEASURES/ PRACTICES:

1. Use of Protection Equipments at every point.


2. Permit from Safety officer.
3. Shut down, electrical isolation or rack out of equipment.
4. 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 UNIT I (KW) UNIT 2 (KW) UNIT 3 (KW)


.
1 MINES 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 95 300 400


CRUSHER
SUBTOTAL 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. Monthly Power distribution target
5. Shut down maintenance work report.
6. Monthly target report.
7. 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 Unit-1

LC-1 LC-1A LC-2 LC-3 LC-4

UNIT-2 :

LC (Load Center)-1
1. Mines
2. High Grade Feeder
3. Crusher
4. Truck Unloader
5. Conveyer Belts
6. Stacker

LC-2
1. Reclaimer
2. Raw Mill Fan
3. Spare
4. RM Feed and Grinding
5. RM Transport
6. Raw Mill Hopper
LC-3
1. Spare
2. PCC Kiln & Cooler
3. ESP Fan
4. Coal Mill Fan
5. PH Fan
6. Cooler Vent
7. MCC-9

LC-4
1. Cement Mill
2. Roller Press
3. PCC Cement Mill
4. SEPAX

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 (24 V
DC) Commn. Bus DC) O/P
On-Off DI DO 24VDC
(Switch)
CPU
(Microprocessor)
(4-20 (4-20
Variable ma) ma)
(Flow,Pr AI Memory (EEPROM) AO 4-20 ma
Temp, % etc.)

COORDINATION WITH OTHER DEPARTMENT:

Instrumentation department coordinates with all the departments like Process, mechanical,
electrical, shree power, store, purchase, IT etc.

MIS- STUDY:

1. Man power description


2. Daily check list form various department
3. Monthly area wise report.
4. 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 Processor
1. Mines & crusher - MODICON 984-480E
2. RM-1 - MODICON 984-785E
3. RM-2 - MODICON 984-785E
4. KILN & PH-2 - MODICON 984-785E
5. Cooler & Coal mill - MODICON 984-785E
6. Cement mill-2 - MODICON 984-785E
7. Kiln-1 - SCNEDZER CPU 43412A
8. Cement mill-1 - SCNEDZER CPU 43412A
9. Packing Plant - MODICON 984-785E
10. Stacker - ALLEN BREDLY SLC 5/03
11. Reclaimer - ALLEN BREDLY SLC 5/03

DRIVES
1. Kiln main drive - D.C. drive
2. Cooler grates 1,2,3 - D.C. drive (LHTOR make)
3. Raw mill - D.C. drive (SIEMENS)
4. Reclaimer 1 - A.C. drive
5. Reclaimer 2 - D.C. drive
6. Cooler fans-7, 8, 9, 10 - V.F.D.
7. Mills classifiers - V.F.D.
8. Coal feeding screw - V.F.D.
9. Luffing Drive (Reclaimer) - A.C. drive
10. Slew drive (Reclaimer) - A.C. drive

BELT WEIGHERS - J & N Make


ESP CONTROLLER - BHA Make
CELL Scanner - ROTAC Make
Burning Zone temp. - Pyrometer (Toshniwal make)
Temp. Transmitters (0-1200) - H & D make
Gas Analyzer - Rosemount Make
Flow meters (200 TPH) - J & N Make
Telemetry system - 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. Mines safety : Blasts should be done properly , use of dust masks ,etc.
2. Electrical safety : Checking competency certificates , earting of equipments , etc .
3. General safety : Road safety , lighting & air ventilation arrangements , etc
4. 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 e-
mail 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 ABB Make ABB


Type Centrifugal Type Centrifugal
Capacity 31.63 Kg/sec Capacity 4.74 Kg/sec
Speed 1475 RPM I/L St Pr. 730 mmWC
Outlet pressure 975 mmwc O/L St.Pr. 1580 mmWC
Outlet total pr. 1010 mmwc Air/Gas density .817 Kg/m3
Air/Gas density 1.021 Kg/m3 Speed 1480 RPM
Motor rating 400 kW Motor Rating 75 kW
Motor Speed 1478 RPM Motor Speed 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 ABB
Type Centrifugal
Capacity 38.17 Kg/sec
I/L St. pr. 200 mmWC
Fan speed 890 RPM
Air/Gas Density 0.748 kg/m3
Motor Rating 180 kW
Motor speed 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 SHIN NIPPON


Type Horizontal , impulse , multistage, multivalve
Axial flow , condensing & geared
Output 18 MW
Turbine speed 6200 RPM
Generator speed 1500 RPM
Inlet steam pressure 62 kg/cm2
Inlet steam temp. 485 degC
Extraction Pressure
IIst Extraction Pr. 15.5 kg/cm2
IInd Extraction Pressure 5.10 kg/cm2
IIIrd Extraction pressure 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.

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