Performance July - 2021

Mining Department
 Explosives Consumption

Mine
2021-22
(up to
Year Unit 2017-18 2018-19 2019-20 2020-21
July-2021 )

Explosives Kgs 23925 29850 45025 48875 28050

Ammonium
Nitrate Kgs 76450 79850 74000 65250 16525

MINES Shock Tube Mtr 19018 27609 28981 25840 8547

(Production +
Development) Detonating
Mtr 9050 13425 11725 12500 6550
Fuse
Short Delay No 250 177 527 170 98

AED No 225 211 214 177 24

Explosives Kgs 1200 1850 0 1275 2675

Ammonium
Kgs 1050 850 0 350 300
Nitrate
Shock Tube Mtr 4417 0 0 0 365
PROJECT
WORK Detonating
Fuse Mtr 0 1275 0 1325 2075

Short Delay No 0 525 0 258 405

AED No 40 0 0 0 02
 Mining (Cost /MT)

UNIT
 
PARTICULARS Mar‘21 APR'21 May’21 JUN'21 JUL'21 YTD FY 2020-21 FY 2019-20

Cost/ Cost/ Rs. Cost/M Rs. Cost/ Cost/ Cost/M Rs. Cost/ Rs. Cost/
  Rs. Lac Mts Rs. Lac Mts Lac ts Lac Mts Rs. Lac Mts Rs. Lac ts Lac Mts Lac Mts
OVER BURDEN
REMOVAL 2.18
2 1.07 1 28.34 42 13.70 16 10.69 9 43.11 9 8.33 1 .94 0
DRILLING
4.36 4 3.91 2 3.26 5 2.14 3 1.69 1 11.02 2 24.21 3 19.70 2
BLASTING
6.59 5 7.37 4 2.99 4 4.55 5 5.42 5 19.53 4 45.80 6 47.86 5
MINES OVERHEADS
3.46 3 5.04 3 8.93 13 1.94 2 2.13 2 16.94 4 35.34 4 36.34 4
AUTO GARAGE
  0   0   0   0   0 .0 0 .0 0 971 0
TOTAL EXPENDITURE 113.6 104.8
A 16.59 14 17.39 9 43.52 65 22.33 26 19.92 17 90.61 19 9 14 5 11
TOTAL PRODUCTION
MT in Lakhs 1.21   2.00   .67   .85   1.20   4.71  
8.15   9.94  
LOADING & TPTN TO 587.5 533.6
CRUSHER 73.30 49 69.57
57 68.96 63 58.31 64 58.67 63 255.05 61 3 59 8 53
ROYALTY CON. 114.7 96.39 106 1055. 1055.
156.78 106 128.59 106 1 106 99.03 106 438.72 106 94 106 90 106
TOTAL EXPENDITURE 183.6 154.6 169.4 1643. 1589.
B 230.08 155 198.16 163 6 169 9 8 157.69 168 693.76 167 48 164 58 159
TOTAL
TRANSPORTED MT .91  
in Lakhs 1.48   1.22   1.09   .94   4.15   10.00   10.00  
G TOTAL EXP. A+B 227.1 177.0   1757. 1694.
246.67   215.55   9   3 177.61   784.37   16   43  
RATE PER TON
  169   171   234   196
  185   186   178   170
 Machinery B/d Particulars
NAME OF THE May-21 July-21 YTD
FY 2020- Apr-21 June-21
SI.No.
EQUIPMENT 21 (Hrs) (Hrs) Reason (Hrs)
( Hrs) ( Hrs)
1. EC480DL Shovel -- -- 0 0 0 NIL 0
PC – 300(1) NIL
2. 66.0 0 0 0 0 0.0
Shovel
PC – 300(2) NIL
3. 11.0 24 0 0 0 24.0
Shovel
Wagon drill of NIL
4. 7.0 0 10 0 0 10.0
ELGi-450
5. Volvo Tipper-1 -- -- 0 0 0 NIL 0
6. Volvo Tipper-1 -- -- 0 0 0 NIL 0
7. Volvo Tipper-1 -- -- 0 0 0 NIL 0
NIL
8 Tipper-1 35.0 2 3 0 0 5.0

9 Tipper-2 36.0 2 30 0 0 NIL 32.0

NIL
10 Tipper-3 22.0 2 2 0 0 4.0
10 Tipper-4 61.0 0 32 2 0 NIL 34.0
NIL
11 Tipper-5 9.0 0 0 2 0 2.0

12 Tipper-6 17.0 2 0 0 0 NIL 2.0

1.Front left side road spring
main plate crack
13 Tipper-7 12.0 4 2 2 2 2.Right side 10.0
road spring main plate crack
Gear box internal sound
14 Tipper-8 11.0 0 0 2 30 32.0
Front drum rotation motor
15 Compactor 62.0 0 16 30 16 bearing &oil seals damage 62.0
 Limestone quality Report for the Month of July-2021

LIMESTONE MINE

Date Source SiO2 Al2O3 Fe2O3 CaO MgO TC LSF

Pile No – 22
01.07.2021 12.98 1.78 1.12 45.79 0.82 81.90 117
North

Pile No - 23
04.07.2021 13.54 1.63 1.06 45.77 0.65 81.60 113
South

Pile No – 24
07.07.2021 13.45 1.68 1.07 45.67 0.73 81.50 113
North

Pile No - 25
12.07.2021 12.33 1.67 1.06 46.36 0.63 82.50 125
South

Pile No – 26
22.07.2021 13.25 1.57 0.97 46.08 0.62 82.00 116
North

Pile No - 27
27.07.2021 13.04 1.64 1.01 46.20 0.61 82.10 118
South
PQC department
Limestone Crusher
CRUSHER PRODUCTION(TPH)

386

360

352
344

343
336
301
201 201 201 201 2019... 2020... 2021-22
(Upto...

CRUSHER PRODUCTION (MT)

415,450
1,037,861

999,945
999,910
872,446
846,809
589,484
FY 16 FY 17 FY 18 FY 19 2019- 20 2020-21 2021-22
Upto July

CR USHER (Uni t s /Ton of M at e r i al )

1.51

1.43

1.31
1.27

1.22

1.22
1.13
2015- 16 2016-17 2017- 18 2018-19 2019- 20 2020-21 2021- 22
( U p t o J u l y)
Raw Mill-1
RAW MILL-1 PRODUCTION(TPH)

119
118

111
110

103

102
102
VRM-
1 2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

Raw Meal Production (MT)

208,899
560,593

537,174
536,478

503,710

502,682
Particulars Details 330,797
FY 16 FY 17 FY 18 FY 19 2019- 20 2020- 21 2021-22
Make Promac-AVM-320
Capacity 90 TPH
Grinding table 3200 mm
f
Roller diameter 2240 mm
No. of rollers 3
Gear box make SEISA Gear Ltd.,-Japan VR M - 1 (Uni t s /Ton of M at e r i al )
Model BPP125V
Ratio 1/29.02
20.35

19.59
Power 1500 KW

19.38
19.30

19.07
18.76

18.44
Input speed 960
Output speed 33.08
Classifier type SNU
2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22
Rotor diameter 2400mm
Motor 55 Kw
Output speed 196 rpm
Raw Mill-2
RAW MILL-2 PRODUCTION(TPH)

116

113
113

111

103

102
VRM-

100
2
2015-16 2016-17 2017-18 2018... 2019-20 2020-21 2021-22

Raw Meal Production (MT)

178,436
563,256

540,912

525,008
423,816
364,498
Particulars Details 274,650
FY 16 FY 17 FY 18 FY 19 2019- 20 2020- 21 2021-22
Make Promac-AVM-320
Capacity 90 TPH
Grinding table f 3200 mm
Roller diameter 2240 mm
No. of rollers 3
Gear box make NGCo.Ltd.,-China VR M - 2 (Uni t s /Ton of M at e r i al )
Type MLX140X-05-00
Ratio 1/29.02

20.37
19.98

Power 1500 KW 19.42

19.38
Input speed 960
18.71

18.60
18.57
Output speed 33.08
Classifier type SNU
2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22
Rotor diameter 2400mm
Motor 55 Kw
Output speed 196 rpm
Pyro System :
Particulars Details
Preheater
Model Six Stage K i l n TP D K i l n S p eci fi c P o wer co n su mp ti o n
suspension(DDF/RS ( k W / t)
P) Pre-heater
Calciner 3470 mm
diameter
TA Duct 2100 mm
diameter

3,024

2,964
2,909
2,747

25.03
23.76

23.08
TA Duct length 64 M

22.18
2,313

20.66
2,266
2,253

19.66
19.11
Preheater Fan
Model KBZ-180-800010-
252(DIDW)
Make REITZ india Ltd.,
Capacity 450000 CUM./Hr. 2015- 2016- 2017- 2018- 2019- 2020- 2021- 2015-
16
2016-
17
2017-
18
2018-
19
2019-
20
2020-
21
2021-
22
16 17 18 19 20 21 22
Inlet temp. 400oc
Motor 1500 Kw
Speed 992
Kiln
Make Promac Kiln Production (MT)
Diameter 3.4 Mtr
Length 53 Mtr
Slope 3.50%
Girth gear type three stage helical

749,900
Gear box

723,889

682,988
ratioParticulars 28:01:00
Details

627,600
608,345
Clinker CoolerHydralic type
Mechanical
Make FLS Cross Bar

404,781
thruster
cooler

283,638
Type CB 10 x 39 with
ABC inlet
Capacity 3000 TPD
Grate area 65.2 Sq m
Cooling fan 132 kW 2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22
-ABC inlet
Chamber 2 x110 Kw
Cooling fans
Kiln
KilnMaximum
Kiln
Maximumproduction
KilnMaximum
production ::3271
Maximumproduction
production ::90257
3271TPD
90257
TPD
Chamber
Cooling fans
Chamber
2 x132 Kw

2 x160 Kw
Kiln Specific Refractory consumption (Kg/ T
MT/Month
MT/Month Cooling fans
Clinker Hydralic roller
of clinker)
Kiln-
Kiln-Maximum
Maximumproduction
production(Day)
(Day)-3271TPD
-3271TPD Breaker breaker
1.210

1.512

Kiln Volumetric Loading;

Kiln Volumetric Loading;
Model MF-310.
Motor 18.5 Kw-for Tr-1
0.929
•• Clinker
ClinkerProduction
0.878

Production
:3271
:3271TPD
TPD   22 Kw-for Cr-1
•• Kiln
Kilneffective
effectivevolume
:384.349M3
volume   22 Kw-for Cr-2

0.482

0.482
:384.349M3

0.444
•• Kiln
Kilnvolumetric
volumetricloading
loading ::
8.50
8.50TPD/M
TPD/M3
3

Cooler
Cooler Volumetric
VolumetricLoading;
Loading;
•• Clinker
ClinkerProduction
Production ::
3271
3271TPD
TPD
•• Cooler
Cooler effectivevolume
effective volume ::
65.20
65.20MM2
2

•• Cooler
Coolervolumetric
volumetricloading
loading ::
50.16
50.16MT/M2
MT/M2
Fuel Handling & Grinding System
C o al C o n su mp ti o n ( MT) Particulars Design Parameters
96,148 89,811
71,648 69,669 73,011 Make Promac
66,454
Type AVM-200
32,216 Capacity TPH 23 TPH
Grinding table f 2000 mm

2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

COAL Roller diameter 1400 mm
No. of rollers 3

S.No Fuel Source 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

MILL Gear box make
Type-size
ELECON
KPAV-80
1 Indonesian   5154.21       Ratio 20.70:1
38606.3 Power 300 KW
2 South African(RB-1)        
6
Input speed 980
42480.3 Output speed 47.26
3 South African(RB-2) 49703.50     102.55
7
Classifier type Dynamic
10168.6 Rotor diameter 2000 mm
4 South African(RB-3) 9 295.39     364.45
Motor 37 KW
5 Australian     4119.70   16448 8631
Output speed 300
6 Pet coke   20969.64 62287.5 68900.92 54437 12273
5
7 US Coal   13688.26 5240.75     10802
C o al Mi l l S P o wer ( Un i ts/ To n o f Mater i al )
8 Mozambican Coal 4892.24         38.70
9 Spent carbon       768.08 1219 510 31.19 33.74 32.05
9 Rice Husk       440 24.88 25.45
22.19
96147.6 89811.00 71648.0 69669.00
11 Total (MT) 73011 32216
6 Particulars
0 Details
12 GCV-ADB 5882 Reciprocating
6418 7781feeder
8099 7438 7011
13 NCV-ARB 5279 5703 7140 7148 6504 6111
Make
Promac 2015- 16 2016- 17 2017- 18 2018- 19 2019- 20 2020- 21 2021-22
Size & Capacity
800mm x3000mm&45
TPH

Hammer crusher
Make & Model
Promac
Capacity
45 TPH
Input feed opening size
250mm

Motor
45 Kw
 Quality Parameters of Clinker &
QUALITY
QUALITYPARAMETERS
PARAMETERS OF
OF CLINKER
CLINKER &
& CEMENT
CEMENT

Cement (Grade wise )

OPC 53 Grade OPC 43 Grade PPC PSC
Clinker
(IS: 269 – 2015) (IS: 269 – 2015) (IS:1489 (P-1) 2015) (IS:455 - 2015)
Sl.No. Particulars UOM
SCRL SCRL SCRL SCRL SCRL
BIS specs BIS specs BIS specs BIS specs BIS specs
results results results results results
0.46
1 Loss On Ignition % 1.5 Max 4.00 Max. 2.52 5.00 Max. 2.96 5.00 Max. 1.38 5.00 Max. 2.53
0.93 1.02
2 MgO % 6.0 Max 6.00 Max. 6.00 Max. 1.02 6.00 Max. 1.02 10.00 Max. 4.90
3 Insoluble Residue (IR)   1.0 Max 0.28 5.00 Max. 1.72 5.00 Max. 1.96 21 to 37.6 31.01 4.00 Max. 1.83
4 SO3 % 2.7 Max 1.74 3.50 Max. 2.47 3.50 Max. 2.44 3.50 Max. 2.14 3.50 Max. 2.54
Lime Saturation Factor
5 % 0.66-1.02 0.91 0.80-1.02 0.88 0.66-1.02 0.87 - - - -
(LSF)
6 Alumina Modules (AM) Ratio 0.66 Min 1.14 0.66 Min. 1.23 0.66 Min. 1.21 - - - -
7 Chlorides Ratio 0.1 Max 0.03 0.10 Max. 0.02 0.10 Max. 0.03 0.10 Max. 0.02 0.10 Max. 0.01
8 Fineness m2/kg 220±25 228 225 Min. 306 225 Min. 293 300 Min. 347 225 Min. 360
Setting Time by Vicat
9                      
method
  a) Initial Minutes 30 Min 220 30 Min. 180 30 Min. 170 30 Min. 180 30 Min. 180
  b) Final Minutes 600 Max 280 600 Max. 240 600 Max. 230 600 Max. 240 600 Max. 240
10 Soundness                      
  a) Le-Chatlier Expansion mm 10 Max Nil 10 Max. Nil 10 Max. Nil 10 Max. Nil 10 Max. Nil
  b) Autoclave Test % 0.80 Max Nil 0.8 Max. Nil 0.8 Max. Nil 0.8 Max Nil 0.8 Max Nil
11 Sulphate Expansion % --- --- --- --- --- --- --- --- --- ---
12 Compressive Strength                      
a) 72 + 1 hour
  MPa 16 Min 38.30 27.0 Min. 31.68 23.0 Min. 30.38 16.0 Min. 20.25 16.0 Min. 25.00
(3 days)
b) 168 + 2 hours
  (7 MPa 22.Min 55.37 37.0 Min. 43.65 33.0 Min. 40.62 22.0 Min. 30.36 22.0 Min. 37.01
days)
c) 672 + 4 hours 43.0 Min.
  ( 28 MPa 33 Min Await 53.0 Min. Await Await 33.0 Min. Await 33.0 Min. Await
days) 58.0 Max.
C3A (Tri calcium
13 by Mass 3 to 12 6.44 --- --- --- --- --- --- --- ---
Aluminate)
14 2C3A + C4AF by Mass --- --- --- --- --- --- --- --- --- ---
15 C3S+C2S by Mass 70 Min 73.95 --- --- --- --- --- --- --- ---
16 C3S by Mass 35 Min 49.34 --- --- --- --- --- --- --- ---
 Quality Parameters of Coal and
QUALITY
QUALITY PARAMETERS
PARAMETERS OF
OF FUEL
FUEL

Source of Coal
Additives
TM % IM % VM % Ash %
GCV (ADB) GCV (ARB) NCV (ARB) Sulphur %
(K.Cal/kg) (K.Cal/kg) (K.Cal/kg) (ADB)

US Coal 13.00 3.23 36.88 9.73 6740 6061 5846 2.55

Pet coke 9.80 0.80 10.16 2.63 7862 7151 6936 9.57

Spent Carbon 30.61 4.07 22.07 38.63 3432 2482 2267 1.79

QUALITY
QUALITY PARAMETERS
PARAMETERS OF
OF Additives
Additives
Chemical Analysis [ %]
Name of the Material Total
LOI SiO2 Al2O3 Fe2O3 CaO MgO SO3 IR
Moisture

Al- Laterite (Belgaum) 13.70 18.64 14.26 37.42 26.98 0.50 0.32 - -

Iron Ore
(Sai 5.40 5.38 12.14 12.03 68.24 0.28 0.14 - -
Enterprises)

Red Mud 26.11 12.96 14.11 27.58 38.53 1.54 0.20

Slag 17.09 0.66 32.35 22.18 1.65 36.06 5.00 0.30 -

Fly Ash(Nellore) 0.20 0.65 60.20 29.60 4.20 3.70 0.20 0.38 92.84
Fly ash ( CPP) 0.14 6.72 47.20 27.80 4.12 8.40 0.40 3.84 62.40
 Kiln Specific Heat Consumption (Kcal/Kg
Kiln Specific Heat consumption (Kcal / kg Cl.)
Clinker)
700
699
698
697
696
Sp.Heat(kcal/Kg cl.)

695 695
695
694 694
694
693 693
693
692
691
690
21 21 21 21 21 ...
- r- y- n- l- 21
20 p a Ju Ju (
0 A M T D
y 2 Y
F
 Cement Storage &
Packing Plant
Particulars Design Parameters
P ack i n g P l an t ( T.P .H)
Packer I II
Make EEL EEL
Model 6 RSE
6 RSE

59
78

63

67

73

77

76
No of Spouts 6 6
2 0 1 5 -1 6 20 1 6 -1 7 20 1 7 -1 8 2 0 1 8-1 9 2 0 1 9-2 0 2 0 2 0 -2 1 2 0 2 1 -22
Discharge points 1 1
Capacity (Design/ PACKING PLANT (UNITS/TON OF MATERIAL)
90 TPH 90 TPH 1.61 1.60 1.57 1.43 1.34
Rated)
1.28 1.26
Truck Loading
EEL EEL
Machine
Model TLM-1016- TLM-1016-
T-II T-II
6 7 8 9 2
Travel Length 12.3 m 12.3 m 5 -1 6 -1 7 -1 8 -1 - 20 - 21 1 -2
01 01 01 01 19 20 02
Speed of Packer 5.60 rpm 5.60 rpm 2 2 2 2 20 20 2
Installed Power 22 kW 22 kW
Particulars Details No of truck Loader 2 2 Total no of bags
Year Damaged %
Cement Storage Silo # 1 consumption
Dimensions 14 m Φ X 28.25 m 2016 - 17 11471516 0.19
C emen t D i sp atch es ( MT)
height
2017 - 18 12420648 0.18
Storage 5856 MT
2018 - 19 14892701 0.15
Capacity
2019-20 14431774 0.12
Particulars Details
2020-21 10631554 0.09
Cement Storage Silo # 2
2021 -22 1465749 0.08
Dimensions 14 m Φ X 28.25 m
height

868,669
863,867
834,342

Storage 5856 MT B ags B u r stage %

323,246
Capacity
708,939

0.25
662,905

0.19

0.18
441,370

Particulars Details

0.15

0.12
Cement Storage Silo # 3

0.09

0.08
Dimensions 14m Φ X 28.25 m
height
Storage 5432MT 2015- 16 2016- 17 2017- 18 2018- 19 2019- 20 2020- 21 2021
2015 - 2016 - 2017- 2018- 2019- 2020- 2021-
Capacity -22 16 17 18 19 20 21 22
 MIS -
Year Wise Specific power consumption(OPC+PPC+PSC)

S.No Name of the description 2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021=2
2
1 LS Crusher 1.87 1.58 1.53 1.74 1.46 1.29 1.37
Raw mill - 1 26.99 24.98 25.83 25.58 23.77 23.65 22.51
  Raw mill - 2 26.50 24.92 26.00 26.60 22.78 23.84 22.68
2 AVG Raw meal 26.77 24.96 25.91 26.09 23.27 23.84 22.59
3 Coal mill 3.66 3.15 3.29 2.61 3.04 2.96 2.96
4 Kiln 22.05 23.22 21.60 20.66 19.11 19.66 18.02
  UP to Clinker 54.35 52.91 52.34 51.10 46.89 47.66 44.94
5 Cement mill (OPC , PPC & PSC) 31.25 32.20 32.73 31.85 33.26 35.65 32.54
6 Packing Plant 1.61 1.60 1.57 1.43 1.34 1.28 1.26
  Up to cement grinding & Packing 32.86 33.80 34.30 33.27 34.60 36.93 33.80
  Subtotal 87.21 86.71 86.64 84.37 81.49 84.69 78.74
7 Others 1.81 1.44 1.43 1.32 1.27 1.26 1.25
  Total 89.03 88.15 88.06 85.70 82.75 85.95 79.99

89.03
88.15 88.06
85.70 85.95

82.75
79.99

2015- 16 2016- 17 2017- 18 2018-19 2019-20 2020-21 2021-22

KWh/MT
Cement Mill Grinding power OPC,PPC & PSC

80

64.94
61.75
70

60.28
58.80

57.00
55.50
60

50
Kwh/Tec

OPC grinding
34.45

33.80
33.72
32.74

32.37
40 PPC grinding
29.85

28.45
28.34
28.30

27.66
27.42

PSC grinding
26.47

30

20
-21 r-21 -21 -21 l-21 V G
20 p ay un Ju A
A M J D
FY YT
Months
Final Product Mix OPC & PPC

93.04
93.05
93.04
93.03
93.03
100.00
90.00
Consum ption (%)

80.00
70.00
60.00
50.00 Clinker
40.00 Gypsum
30.00
Limestone

5.00
5.00
5.00
5.00
5.00

1.96
1.95
1.96
1.97
1.97
20.00
10.00
0.00
Apr- May- Jun- Jul- YTD
21 21 21 21 Product Mix OPC

100.00
0.0032.22

0.0033.10

0.0033.72
0.0034.48
0.0034.99

90.00
Consumption (%)

80.00
65.81 1.97
64.93 1.97

64.32 1.96
63.56 1.96
63.06 1.95

70.00
60.00
50.00
40.00 Fly Ash
30.00
20.00 Gypsum
10.00
0.00
Mineral Gypsum
Clinker

Product Mix - PPC

Final Product Mix PSC
120.00

42.841.95

43.131.96

40.901.97

41.611.97

42.001.96
100.00

80.00

60.00
Gypsum
40.00
57.13 Slag
56.42

56.04
55.21

54.91

20.00
Clinker
0.00
 VRM KILN Coal Cement Packer Packer
Stoppage Crusher
Analysis VRM-1
Report for
-2the Month of July-Mill
Mill 2021 -1 -2
Total Hours for the Month 744.00 744.00 744.00 744.00 744.00 744.00 744 744
Total Planned stoppage hours 438.40 286.55 317.15 312.00 421.50 177.20    
Total Available Running Hours for
Production 305.20 480.50 426.45 432.00 322.50 566.80    
Total Running Hours for 277.20 401.55 360.45 432.00 322.30 557.50 592.15 581.10
Production
Total Stoppage Hours 28.00 55.10 66.00 0.00 0.20 9.30 151.45 162.50
Total Production 93775.00 43417.00 38650. 54100. 5947.00 87638.22 44137.22 43312.00
00 00
Runfactor (%) 90.83 87.93 84.53 100.00 99.90 98.32 79.60 78.11

TPH 338.14 108.03 107.14 125.23 18.48 157.29 74.52 74.53

Stoppages Department Total Stoppage Hours

Wise
Mechanical 8.25 10.45 0.00 0.00 0.00 0.30 0.50 1.40
Electrical 7.05 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Instrumentation 0.00 0.15 1.00 0.00 0.00 0.00 0.00 0.00
Power plant 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Process 0.00 0.00 0.00 0.00 0.00 0.00 14.50 15.40
General 12.30 44.10 65.00 0.00 0.20 9.00 136.05 145.30
Total 28.00 55.10 66.00 0.00 0.20 9.30 151.45 162.50
Mechanical Department
UIPEMENT CIRCUIT AVAILABILITY DURING THE MONTH OF JULY-2021

LS CRUSHER VRM 1 VRM2 COAL MILL

277.20 329.20
401.55 360.45 321.5
461.50 383.55
422.5

5.30
13.25

KILN CEMENT MILL PACKER-1 PACKER-2

151.55 161.50
312.00 186.60 0.30 1.40
432.00
0.30 581.10
557.10 592.15

Running Mech. Stoppage Planned Stoppage Others stoppage

Hours Hours Hours
SCRL-GUDIPADU UNIT Hours
EQUIPEMENT CIRCUIT AVAILABILITY DURING THE MONTH OF JULY2021
MECHANICAL SECTION WISE MACHINERY PLANNED STOPPAGE HOURS & REASONS
FOR MONTH OF JULY-2021.
S.NO DATE EQUIPMENT STOPPAGE REASON STOPPAGE TIME REMARKS
1 01-07-21 LS Crusher Surge hopper discharge belt conveyor scrut 2.25 Planned
rubber damage
2 02-07-21 LS Crusher 115 BC03 belt conveyor joint open 0.35 Planned
3 05-07-21 LS Crusher Travel drive breaks full tight 0.20 Planned
4 12-07-21 LS Crusher Stacker long belt belt sway 2.00 Planned
5 24-07-21 LS Crusher Stacker long belt scrutt rubber damaged 0.30 Planned
6 25-07-21 Packer-2 Bucket elevator sway observed abnormal sound 1.10 Planned

MECHANICAL SECTION WISE MACHINERY BREAKDOWN STOPPAGE HOURS &

REASONS FOR MONTH OF JULY-2021.
S.NO DATE EQUIPMENT STOPPAGE REASON STOPPAGE TIME REMARKS
1 01-07-21 VRM 1 Reject bucket elevator geared coupling damage 2.40 Break down
2 03-07-21 VRM-1 Mill feed chute liner plate fall down 7.20 Break down
3 04-07-21 VRM-1 Mill feed chute liner plate fall down 3.25 Break down
4 07-07-21 Packer-2 Long belt damaged 0.30 Break down
5 08-07-21 Cement mill Gearbox lubrication oil pressure low 0.30 Break down
6 09-07-21 Packer-1 4th Spout chair problem 0.30 Break down

SCRL-GUDIPADU UNIT
UIPEMENT CIRCUIT AVAILABILITY DURING THE MONTH OF JULY-2021

6.00
SECTION WISE PLANNED STOPAGE HOURS
5.00

4.00

3.00
5.30
2.00

1.00
1.10
0.00 0.00 0.00 0.00 0.00 0.00
0.00
LS CRUSHER VRM1 VRM2 COALMILL KILN CEMENTMILL PACKER1 PACKER2
14.00
12.00
SECTION WISE BREAKDOWN STOPAGE HOURS
10.00
8.00
13.25
6.00
4.00
2.00
0.00 0.00 0.00 0.00
0.00 0.30 0.30 0.30
LS CRU... VRM1 VRM2 COALMILL KILN CEMENT... PACKER1 PACKER2

SCRL-GUDIPADU UNIT
RFORMANCE (STORES INVENTORY CONSUMPTION)

120
STORES INVENTORY CONSUMPTION Rs./MT OF CEMENT DISPATCH
111.90
100
94.90
80

60
56.37
40
49.99

20

SCRL-GUDIPADU UNIT
PERFORMANCE (STORES INVENTORY CONSUMPTION)

REVENUE COSUMPTION
( Rs./MT OF CEMENT DISPATCH )

120
100 111.9
94.9
80
60 65.28 68.52
56.37
40 44.37 49.28 49.99
20
0
2017-18 2018-19 2019-20 2020-21 2021-22 2021- 2021- 2021-
A... 22... 22... 22 ...

SCRL-GUDIPADU UNIT
RFORMANCE (STORES INVENTORY CONSUMPTION)

CONSUMPTION OF LUB. OILS ML/MT OF CEMENT DISPATCH

40
35
30 Oil consumption increased in July month due to VRM-1
25 Elecon gearbox flush out & commissioning done.
20
33.51
15
10 16.16
5 6.79
2.99 4.88 2.91
0 1.19
2018-19 FY 2019-20 FY 2020-21 FY 2021-22 2021-22 2021-22 2021-22
APRIL MAY JUN JULY
CONSUMPTION OF GREASE Grm. /MT OF CEMENT DISPATCH
10
8
6
4 8.52
5.07 4.56 4.67 3.61
2
1.51 0.71
0

SCRL-GUDIPADU UNIT
AW MILL – 1 ELECON GEARBOX COMMISSIONING

VRM-1 Elecon gear box

commissioning:

. VRM 1 M/s. Elecon gearbox oil flush out was done

with fresh oil.

 VRM 1 M/s. Elecon gearbox commissioning done

under the observation of M/s. Elecon engineers

 Under the no load & load condition the gear box

vibration and temperature readings recorded by the
M/s. AP Vibration and engineering analysis.

ELECON GEARBOX

SEISA GEARBOX
 MECHANICAL SECTION WISE MAINTENANCE ACTIVITIES

MAINTAINANCE ACTIVITIES
SR
SECTION WORK DESCRIPTION REMARKS
NO
1 115BC04 STACKER LONG BELT TAIL DRUM LAGGING DONE  
LS CRUSHER
2 115BC03 CROSS COUNTRY CONVYOR BEND PULLEY LAGGING DONE  
1 RAW MILL-1 FEED PIPE WELDING  
2 212BC02 CONVEYOR BELT DISCHARE CHUTE CHANGING  
3 RAW MILL-1 VRM MAIN GEAR BOX CHANGING  
4 RAW MILL-2 CA FAN IMPELLER BLADES HARD FACING  
5 214BC03 CONVEYOR BELT CHANGING  
6 RAW MILL-1 FEED PIPE EXTENDED INSIDE THE GRIT CONE  
7 214BC02 CONVEYOR BELT TAIL DRUM LAGGING WOR DONE  
8 RAW MILL-1 REJECT ELEVATOR-1 GEAR COUPLING CHANGED  
9 212BC03 CONVEYOR BELT GEAR BOX CHANGED  
10 RAW MILL-1 GRIT CONE REJECT FEED PIPE FLANGE SYATEM PROVIDED  
11 RAWMILL-2 FEED RAL DISCHARGE CHUTE REPAIRED  
12 BLENDING SILO BUCKET ELEVATOR INSPECTED  
13 RAW MILL IRON ORE WEIGH FEEDER BELT CHANGED  
14 LIME STONE WEIGH FEEDER TAIL & HEAD DRUM LAGGING WORK DONE  
15 RAW MILL-2 FEED PIPE WELDING CHECKING AND RE WELDING DONE  
16 212BC01 CONVEYOR BELT JOINT DONE AND 10 MTR BELT ADDED  
17 212BC02 CONVEYOR BELT DISCHARGE CHUTE DIVERTING GATE TOP CHUTE REPAIRED  
212BC04 CONVEUOR BELT HEAD/TAIL PULLEY BEARINGS CHECKING,CLEARENCE ADJUSTING AND
18  
GREASING DONE
214BC02 CONVEUOR BELT HEAD/TAIL PULLEY BEARINGS CHECKING,CLEARENCE ADJUSTING AND
19 GREASING DONE
 

20 214BC02 CONVEUOR BELT HEAD/TAIL/SNUB PULLEY BEARINGS CHECKING,CLEARENCE ADJUSTING  

AND GREASING DONE
214BC03 CONVEUOR BELT HEAD/TAIL/SNUB PULLEY BEARINGS CHECKING,CLEARENCE ADJUSTING
21  
AND GREASING DONE

SCRL-GUDIPADU UNIT
 MECHANICAL SECTION WISE MAINTENANCE ACTIVITIES
SR NO SECTION WORK DESCRIPTION REMARKS
22 RAW MILL-1 FEED PIPE LOCKING DONE INDISE GRIT CONE IN 120 DEG  
RAWMILL-1 ROLLER -1 FALSE AIR EXP JOINT CLOTH REMOVED AND RUBBER LAYER PROVIDED
23  
AROUND THE ROCKER ARM
24 RAW MILL-1 REJECT BUCKET ELEVATOR GEAR BOX INPUT PINION BEARING NU 2312 CHANGED  
25 RAW MILL-1 REJECT BUCKET ELEVATOR GEAR BOX OIL CHANGED  
26 RAW MILL-2 ROLLER-2 & 3 SEAL AIR FLOW GAP REDUCED 35 MM TO 8 MM  
27 RAW MILL-2 FEED RAL DIASCHRGE CHUTE BOTTOM EXPANSION JOINT CHUTE CHANGED  

28 RAWMILL-2 SEAL FAN 8" DUCT REMOVED AND 16" DUCT POSITIONED AND FLANGES WELDED  
THEN 8" DUCT REFIXED
29 BLENDING SILO BUCKET ELEVATOR GEAR BOX HOLD BACK CHANGED  
30 BLENDING SILO BUCKET ELEVATOR INTREMIDEATE GEAR FLAOT ADJUSTED 1.1 TO 0.03 MM  

31 BLENDING SILO BUCKET ELEVATOR GEAR BOX OIL CHANGED AND GEAR BOX INTERNALS CLEANED  
RAW MILL WITH CORA CLOTH
114AF01 APRON FEEDER GEAR BOX INSPECTION COVER OPENED AND INTERNALS INSPECTION
32  
DONE
33 115BC01 & 03 BELT GEAR BOX INSPECTION DONE BY ELECON ENGINEER  
34 RECLAIMER TRAVEL DIVES BOTH GEAR BOXES INSPECTION DONE BY ELECON ENGINEERS  
212QR01 & QR01A SCRAPER CHAIN AND HARROW GEAR BOX INTERNALS INSPECTION DONE BY
35  
ELECON ENGINEER
RAW MILL REJECT / BLENDING SILO ELEVATORS GEAR BOX INSPECTION DONE BY ELECON
36 ENGINEERS  

37 RAW MILL SURGE BIN INSIDE CONES REMOVED FOR BOTH MILLS  
38 HOT AIR TAPPINGS PROVIDED AT MILL INLET AND W/F FLOOR AREAS  
39 BUFFLE PLATE PROVIDED IN 214BC02 DISCHARGE CHUTE  
40 BLENDING SILO TOP DISTRIBUTION BOX FABRICATED FOR EQUAL FLOW OF MATERIAL  

SCRL-GUDIPADU UNIT
 MECHANICAL SECTION WISE MAINTENANCE ACTIVITIES

S.NO SECTION WORK DESCRIPTION REMERKS

1 Raw coal belt conveyor rejoint work and all pulley bearings inspection
done.  

2 Coal crusher magnetic separator carrying roller shaft repair work done
nd head drum lagging done..  
Coal mill bag filter bottom screw conveyor geared couplings inspection  
3 done.
4 Coal mill general inspection carried.  
5 PC & KC SFM venting bag filter bags to be clean.  
COAL MILL Coal mill outlet duct expansion joint area hitting portion additional plate
6
provided.  
7 Coal mill feed pipe welding done.  
8 Coal mill discharge bag filter RAL rotor gaps adjusted.  
9 Coal mill discharge bag filter RAL 2 both bearings replaced.  
10 Coal mill booster fan inlet expansion joint cloth replaced.  
11 Coal crusher NDE side bearing & sleeve replaced.  
12 Coal crusher drive v belts replaced.  
1 Kiln feed B/E Belt & joint inspection and bucket bolts checked.  
2 Blending silo extraction gate B&E airslide cloth changed.  
3 Kiln girth gear to pinion readings are recorded  
4 Kiln 3rd tyre chair pad block welding done  
KILN
5 Kiln main gearbox in put oil seal replaced  
6 Kiln auxialary clutch coupling replaced  
7 Kiln outlet seal plates replaced.  
8 Cooler general inspection.  
 MECHANICAL SECTION WISE MAINTENANCE ACTIVITIES

S.NO SECTION WORK DESCRIPTION REMERKS

9 Cooler fan 7 bearings replaced  
10 DBC 1&2 worn-out rollers replaced  
11 ESP General inspection done  
12 DBC 1 discharge chute inside liner plate provided.  
13 Preheater pc outlet duct corner portion additional ribs provided .  
14 P/H 2nd floor rice husk system nozzles provided.  

15 Kiln feed bucket elevator drive fluid coupling and gearbox hold back
KILN replaced.  
16 ESP outlet exp joint cloth replaced.  
17 Kiln 3rd tire area shell crack welded.  
18 Additional ribs provided for kiln drive torsion shaft.  
19 Cooler inlet spillage chute air blaster orientation changed.  
20 Cooler ccr side air blaster maintenance purpose platform provided.  
21 Kiln outlet area dust ring extended.  
22 Kiln outlet tad entry area platform provided.(for door opening)  
1 CEMENT MILL SEPERATOR RETURN AIRSLIDE CLOTH 9 MTRS. REPLACED  
CLINKER TUNNEL BELTS DAMAGED IMPACT IDLERS, GUIDE ROLLES AND
2 CARRYING IDLERS REPLACED  
3 CEMENT MILL SEPERATOR FEEDING AIRSLIDE CLOTH 5MTRS. REPLACED  
4 CEMENT MILL & CEMENT MILL INLET HAG FRESH AIR DAMPER REPLACED WITH NEW ONE  
5 PACKING PLANT GYPSUM WEIGH FEEDER ENDLESS BELT CHANGED WITH NEW BELT  
6 CEMENT MILL RECIRCULATION BUCKET ELEVATOR FEEDING CHUTE REPLACED  
7 BULK LOADING BUCKET ELEVATOR STEEL CORD BELT REPLACED  
8 PACKER -2 NO-3 SPOUT BAG DISCHARGE CYLINDER REPLACED  
 MODIFICATION JOBS

Raw mills individual roller lubrication system provided,

instead of common lubrication system - To
enhancement of equipment life
VRM – 2 , Seal air fan out let duct modification – For
increase the seal air pressure and energy saving
Coal crusher discharge bypass Chute arrangement work
done – For Bypass the coal crusher due to crushed coal
and pet coke ( minus 40mm) availability and energy
saving
Raw mills ,In surge hopper cones removed and 214 BC02
discharge buffer plate provided – avoid the Jam in surge
hopper ,coatings and uniform distribution of material
TAD takeoff area platform arranged for easy approach of
inspection door – Safety
Performance JULY -2021

Electrical Department
 APSPDCL DG Sets CPP
Sourcing
UNITS
of Power
%
month wise(%)%& FY 2021-22
UNITS UNITS
In lakh
%
units TOTAL

Apr-21 134300 1.73 0 0 7641200 98.27 7775500

May-21 131300 1.81 0 0 7123050 98.19 7254350
JUNE-21 914388 14.58 0 0 5353462 85.42 6267850
JULY-21 1166743 18.38 0 0 5182257 81.62 6349000
AUG
SEP
OCT
NOV
DEC
JAN
FEB
MAR
YTD 2346731 8.49 0 0 25299969 91.51 27646700
Sourcing of Power month wise(%)
 Electrical Stores Consumption in Lakhs
Project and Total
Sl. No. Month Capital
Development
General Stores Consumption / Ton of
Cement
1 Apr-21 22655.88 122773.83 95049.35 240479.06
Cement Production (MT) 87449
2 May-21 104176 67752 28216 200144

June- Cost
3 209566 80538 418547 499462 Consumption Rs.(Lakhs)
21 (Rs.)/ton
4 July-21 1547009 65379 92929 1705318

5
Capital 1547009 17.69

6 Project and
Development 65379 0.75
7
General
8
maintenance 92929 1.06
9
Total 1705318 19.50
10

11

12
 ELECTRICAL DEPARTMENT PERFORMANCE REPORT 2021- 22

YTD 2016- YTD YTD YTD YTD April May- June- YTD
Sl.No DESCRIPTION 17 2017- 2018- 2020-21 2021 July-2021
19 2019-20
-2021 2021 2021-22
18
1 CRUSHER 1.70 1.63 1.74 1.46 1.29 1.37 1.41 1.33 1.38 1.37
2 VRM - 1 27.30 27.82 25.58 23.77 23.65 21.86 20.99 23.49 24.19 22.46
3 VRM - 2 27.21 25.92 26.60 22.78 24.02 22.00 21.55 23.97 24.25 22.66
5 Total Raw meal 27.12 27.79 26.09 23.27 23.84 21.94 21.27 23.72 24.22 22.56
6 COAL MILL 3.45 3.61 2.61 3.04 2.96 3.29 2.91 2.72 2.75 2.96
7 KILN 25.50 23.16 20.66 19.11 19.66 17.71 17.38 18.80 18.57 18.00
8 Upto Clinker 57.78 56.18 51.10 46.89 47.76 44.31 42.97 46.57 46.92 44.89
9 CEMENT MILL 32.26 32.85 31.85 33.26 35.65 30.17 32.43 35.08 32.96 32.54
10 PACKING PLANT 1.62 1.59 1.43 1.34
1.28 1.18 1.31 1.29 1.26 1.26
Grinding &
11 33.88 34.44 33.27 34.60
Packing 36.93 31.36 33.74 36.37 34.22 33.79
12 Upto packing 91.66 90.63 84.37 81.49 84.69 75.67 76.71 82.95 81.14 78.69
13 Plant Lighting 0.32 0.29 0.22 0.19 0.18 0.15 0.18 0.19 0.18 0.17
14 Colony Lighting
0.23 0.26 0.23 0.22
0.23 0.19 0.24 0.24 0.25 0.23
Utilities &
15 0.48 0.55 0.53 0.49
Water works 0.46 0.36 0.48 0.55 0.48 0.46
Tr &
16 Distribution 0.48 0.38 0.34 1.27
losses 0.39 0.38 0.40 0.39 0.40 0.39
17 TOTAL 93.17 92.10 85.70 82.75 85.95 76.74 78.00 84.32 82.45 79.94
18 POWER PLANT 0.24 0.28 0.14 0.26
0.33 0.03 0.03 0.39 0.26 0.16
4879336 517855 613730 735665 6105338 777550 7254350 626785 6349000 7099233
19 KWH 0 2 15 0 0

20 KVAH 5060926 538436 642702 763837 6333156 809947 7556615 646170 6545361 7245303
6 5 99 9 1
KWH-KVAH
21 181590 205817 289723 281728
4
227817 323979 302265 188036 196361 252660
Difference
22 Average PF 0.964 0.96 0.96 0.96 0.97 0.96 0.96 0.97 0.97 0.97
23 Recorded MD 13346 13303 13722.
33 14800 13502 14190 14320 14290 14270 14268
APSPDCL
Recorded 1763.4 6357.7 5544
22 5600    
0
2503.6 2223 6061.5 5935.9 4181
Maximum MD
Electrical Units Consumption In lakh units
Power Factor -Month wise
 LIST OF ACTIVITIES : ELECTRICAL : Crusher and Raw Mill Section
STACKER PANEL CONTROL WIRING MODIFICATION WORKS DONE.
STACKER/RECLAMIER LT MOTORS MAINTENANCE DONE.
RAW MILL 1& 2 HT MOTORS MAINTENACE DONE.
RAW MILL 1&2 CA FAN MOTORS MAINTENANCE DONE.
RABH FAN HT MOTOR MAINTENANCE DONE.
RABH LT MOTORS MAINTENANCE DONE.
RAW MILL 1&2 LT MOTORS MAINTENANCE DONE.
216BE01MT01 RAW MILL-1 BUCKET ELEVATOR MOTOR BOTH ENDS BEARING REPLACED.
216FA01MT01 RAW MILL -1 SEAL AIR FAN MOTOR BOTH ENDS BEARING REPLACED.
RAW MILL -2 LRS PAINTING AND MAINTENANCE DONE.
RAW MILL-1 LRS SHED WORK COMPLETED.
IN LC-3 MCC-5 ALL FEEDERS TERMINAL CHECKING, TIGHTNESS AND BLOWERING DONE.
IN LC-2 MCC-2 ALL FEEDERS TERMINAL CHECKING, TIGHTNESS AND BLOWERING DONE.
RAW MILL -1 FEEDING RAL FEEDER SIDE MNX 32 POWER CONTACTOR CHANGED.
KILN /COAL MILLSECTION SHUTDOWN ACTIVITIES:
LIST OF ACTIVITIES : ELECTRICAL : Pyro Section
COAL CRUSHER FEEDING GROUP LT MOTORS MAINTENANCE DONE

613DB03MT03 (DAMPER) MOTOR POWER CABLE & CONTROL NEW CABLE LAYING DONE.
COAL MILL GOUP LT & HT MOTORS MAINTENANCE DONE
COAL FIRING GROUP LT MOTORS MAINTENANCE DONE.
SILO LT MOTORS MAINTENANCE DONE.
PRE-HEATER & KILN LT & HT MOTORS MAINTENANCE DONE.
316FA17MT17 NOSE RING FAN FEEDER SIDE MCCB 100A & MNX 95 CONTACTOR REPLACED WITH NEW ONE
COOLER FANS LT MOTORS MAINTENANCE DONE.
317FA01VS01 COOLER FAN-1 POWER CABLE INCOMING & OUTGOING NEW CABLE 3C X 240 SQ.MM ALL. ARMOURED CABLE LAYING
AND LUGGING, CONNECTION, TRAIL DONE
DBC LT MOTORS MAINTENANCE DONE.
DBC -1 & 2 PULL CORD ROPE PURPOSE HOOKS WELDING DONE.
ESP LT MOTORS MAINTENANCE DONE.
LC-4, LC-5, KILN, COAL MILL & ESP TRANSFORMERS MAINTENANCE AND SILICA GEL CHANGING DONE
MCC-6, PMCC-7 & PMCC-8 ALL LT FEEDERS MAINTENANCE DONE
COMPRESSOR ACB BREAKER CHECKING AND COMPRESSOR MCC BUS BAR TIGHTNESS DONE
COMPRESSOR MOTORS MAINTENANCE DONE
Cement mill Main drives and CA fan motors slip rings cleaned and carbon brushes checked and 2no’s carbon brushes replaced
LIST OF ACTIVITIES : ELECTRICAL : Cement and Packing Plant Section
new brushes'.
 In cement mill motors external cooling fan motors on and off control purpose MCB provided.
 Cement mill LRS maintenance done.
 In cement 416-LU01-PU05-MT05 Motor, 416-LU05-PU05-MT05 motors replaced with spare motor.
 MCC-9,MCC-10,MCC-12,LTDB are maintenance done.
 0.37 KW,4KW,1.1KW spare motors over hauling done.
 Cement mill section all Greased motors greasing done.
 416-BC01-MT01 Motor bearings replaced with new bearings.
Packing plant
In packer-1 spout motors all power contactors maintenance and tips cleaned.
Truck loaders 4 no's maintenance done.
 Both packers slip ring units maintenance done.
 Packer 1 & 2 Section feeders maintenance was done.
 Truck Loader-2 Travel drive Motor break Unit replaced with new break.
In packing plant section 2 no’s motor replaced with spare motor(523-BA01-EXT01-MT01, 513-BA01-EXT01-MT01).
 Packing plant section greased all motors greasing done
 Circuit
ELECTRICAL Availability
SECTION WISEand Section Wise
MACHINERY Electrical STOPPAGE
BREAKDOWN departmentHOURS
Stoppages PlannedFOR
& REASONS & Breakdowns
MONTH OF July-2021.

S.NO DATE EQUIPMENT STOPPAGE REASON STOPPAGE TIME REMARKS

Power cable
01.07.21 Stacker CRD Cable problem 5.00 damaged
1 L.S.Crusher
05.07.21 Stacker Travel drive thruster motor replacement 2.05 Motor burnt

8
7.05
7
6
5
4
3 Planned Stoppage Hours
2 Breakdown Hours
1 Other Stoppages
0 0 000 000 000 000 000 000 000
0
Performance –July’2021

Instrumentation Department
 Availability Section wise for FY 2021-22

Availability
100.10

100.00 100.00
99.99 100.00 100.00
100.00 100.00
100.00
100.00 99.98 99.98
99.97
99.94 99.94
99.91
99.90 99.88
99.84

99.80

99.70
%

99.60

99.50

Availability
99.40

99.30

99.20
Crusher VRM-1 VRM-2 Kiln Coal Mill Cement Mill Packer-1 Packer-2

Actual 2020-21 Actual Target 2021-22

2021-22
 MTBF Section wise for FY 2021-22

MTBF
7000.00

6031.42
6000.00 5773.51
5451.77

5000.00
4640.58

4000.00
Hours

3000.00

2082.45 2165.15 2107.85

2000.00 1877.87 1790.30

1211.95 1148.00
968.00
1000.00 854.11
710.51 624.80
614.90

0.00
Crusher VRM-1 VRM-2 Kiln Coal Mill Cement Mill Packer-1 Packer-2

Actual 2020-21 Actual 2021-22 Target 2021-22

MTTR -Section wise for FY 2021-22

MTTR
1.20

1.00 0.99
1.00

0.80

0.70
0.67
0.65
0.60
Hours

0.60

0.40
0.40

0.30
0.25

0.20
0.12

0.00 0.00 0.00 0.00 0.00 0.00

0.00
Crusher VRM-1 VRM-2 Kiln Coal Mill Cement Mill Packer-1 Packer-2

Actual 2020-21 Actual 2021-22 Target

2021-22
 Spares Consumption in 2021-22 ( Rs. Lakhs)

54.06
60.00

50.00

40.00

26.60
30.00
17.97

20.00
7.05

4.69

10.00
3.52

2.71

0.00
0.00

0.00

0.00
0.00 0.00 0.00 0.00
0.00
 Instrumentation DEPARTMENT : List of Activities in JULY -2021 – Raw mill Section and KILN Section

Section
List of Activities Remarks
Raw Mill 1. Elecon new gearbox commissioning work and loop testing
done.
2. RM-2 new roller Lubrication system commissioning work done
and troughed all signals to CCR
3. Stacker Travel drive VFD drawing modified and rewiring done
according to drawing and trail run taken.
4. Additive weigh feeders maintenance, tare calibration done
and checked with test weights.
5. RABH MV drive VFD maintenance, connections tightness,
filters cleaning and inspection of cooling fans.
6. RM-1 & 2 CA Fans VFD maintenance done and inverter
module cooling fan changed.
7. Reclaimer I/O panel ferrule updation work and cable dressing
work done.
KILN 1. Kiln main drive vfd panel maintenance done.
2. Pre heater fan vfd panel maintenance done.
3. Cooler Hydraulic HRB vfd panels maintenance done.
4. Kiln PA fan and kiln coal jet air blowers maintenance done.
5. All gas analysers maintenance done.
6. Acrylic sheet fixed for cooler water spray pump-1 vfd panel.
7. 20kva and 10kva Ups panels blowering and maintenance
done.
8. Fpi sox nox analyser calibration done.
 Instrumentation DEPARTMENT : List of Activities in JULY -2021- Cement mill section

List of Activities Remarks

1. In MCC-11A AI and AO module wiring completed.

2. 414DC01FA01 silo top bag filter wiring changed and taken to ccr
control.
3. Fly ash unloading compressor run feed back taken to ccr.
4. 513DV03MT03 dosing valve close limit new one changed due to old
limit not working.
5. Cement mill main motor-2 winding temperature scanner power card
changed.
6. Commercial office 3kva ups new batteries installed.
7. AAQMS-1 and AAQMS-2 stations sox, nox analysers servicing and
calibration done along with service engineer.
8. New weigh bridge (near store) set up and installation completed.
9. Packing plant compressor air dryer new compressor changed.
10. Control print all three print heads servicing done and for spare head
pcb ribbon strip changed.
INSTRUMENTATION SECTION WISE MACHINERY BREAKDOWN STOPPAGE HOURS & REASONS FOR MONTH OF JULY-2021.

S.NO DATE EQUIPMENT STOPPAGE REASON STOPPAGE TIME REMARKS

1 CRUSHER NILL

2 1/7/2021 VRM-1 Cyclone RAL-2 motion detector fault 0.15

3 5/7/2021 VRM-2 Separator Local Stop Activated due to cable Problem 1.0

4 COALMILL NILL

5 KILN NILL

6 CEMENTMILL NILL

7 PACKER-1 NILL

8 PACKER-2 NILL

1.20

1.00

0.80

0.60
1.00
0.40

0.20
0.00 0.15 0.00 0.00 0.00 0.00 0.00
0.00
LS CRUSHER VRM1 VRM2 COALMILL KILN CEMENTMILL PACKER1 PACKER2

SCRL-GUDIPADU UNIT
CIVIL
 Civil Development works in Cement, Power plant, Mines and Colony

List of Activities Remarks

1. Laying of CC Road from Colony Entrance to Load center 1B. - (Quantity – 1150 CUM).

2. Construction of Gypsum shed in plant.

3. Construction of ARF shed in plant

4. Robotic lab works in CCR.

5. Construction of Two wheeler shed near power plant.

6. Construction of Four wheeler shed near bachelor hostel & B Block in colony.

7. Construction of Electrical workshop, Cable trench works near Load center - 6.

8. Flooring works in Workshop & Tiles laying in colony.

9. Brick pedestals for fire fighting water line near coal yard in cement plant.
Laying of CC Road from Colony
Entrance to Load center 1B.
Construction of Gypsum shed in
plant.
Construction of AFR shed in plant
Robotic lab works in CCR.
Commercial & Packing
Plant
 PACKER -1 PERFORMANCE

100 90 90 90 90 90
90
80
70 65 68 65 66 67
60
50
40
30
20
10
0
202 Ap Ma Ju Jul-21 Au Se Oc No De Ja Fe Ma

Description 2020- April’ May- June- July- Aug- Sep- Oct- Nov- Dec-21 Jan- Feb- Mar-
21 21 21 21 21 21 21 21 21 22 22 22

Cement Desp 37632 39686

Qty MT 9 39076 32042 33546 .3
Running Hrs 5772. 573.3 494.5 592.1
87 5 5 505.16 5
Power
Consumption – 0.63 0.58 0.63 0.61 0.51
Units per ton
 PACKER - 2
PERFORMANCE
Target - TPH Achieved-TPH

100 90 90 90 90 90
90
80
70 63 60 61 63
60 57

50
40
30
20
10
0
202 Ap Ma Ju Ju Au Se Oc No De Ja Fe Ma

2020- May- Dec- Jan- Feb- Mar-

Description 21 April’21 21 June-21 July-21 Aug-21 Sep-21 Oct-21 Nov-21
21 22 22 22
Cement Desp 27511.
Qty MT 309804 33899 32081.5 36536.5
5

Running Hrs 5451.1

538.5 457.6 530.26 581.1
3
Power
Consumption
–Units per 0.65 0.6 0.67 0.69 0.50
ton
 DAMAGED BAGS Target V/s Achieved

0.1 0.09 0.09

0.08 0.08 0.08
0.08 0.07
0.06
0.04
0.02 Achieved %
0 Target %

Description 2020-21 April’21 May-21 June-21 July-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22

No of bags 1376519 146477 117011 131536 152210

Dispatched 6 6 0 6 8

No of bags 12198 973 930 1160 1220

Damages
Total no of
bags 1377739 146574 117104 131652 152332
consumptio 4 9 0 6 8
n
 CEMENT TRUCKS AVERAGE IN AND OUT TIME

4.5
4 4.1
4
3.5
3.5 3.33 3.31 3.37
3
2.5
2
Achieved
1.5
Target
1
0.5
0
-21 l-21 -21 -21 -21 t-21 r-21 r-21 r-21 r-21 -22 -22 -22 -22
020 pri ay une July us be be be be ary ary rch 021
2 A M J u g m to m m nu ru a 2
A t O e c e
v ec e Ja Fe b M
p o
Se N D
Performance July- 2021

Safety Department
 SAFETY Department : List of Incidents
Safety Report for the Month of July
& Man
S
No.
Power Statistics
Description
in July-2021July -2021 Year to Date

Number of Near miss 1

1 08

1
2 No. of Accidents – Employees (First Aid Cases) 2

3 No. of Accidents – Contractors (First Aid Cases) 0 2

Man Hours worked:

Employees 6641
4 159133.2
11514
Contractor 271433.2

5 Accident frequency ratio 0 0

6 Accident severity ratio 0 0

7 Training Man hours 142 1183
 Safety : List of Training Activities in
Sl.
No
JULY -2021
Name of the Training Internal /
External
Attended employees Trainer/
Organized by
Date of the
Training

Sri.S.Yadyya
1 Tool Box Talk Internal 105 Reddy /AM Safety dates
Different

Safety induction training

Safety
2 Internal 45 Different dates
Department
(persons)
S.No. Safety department
Activities Activities
Date the
Remark
1
month of JULY -2021
Safety committee meeting was conducted in newly constructed 07/07/21
training hall.
2 19/07/21 to
Both Cement plant and power plant shut down works are attended. 27/07/21
3 24.07.2021
Emergency Eyewash Shower Checking done

4 14.07.2021
Air blasters identification numbers (Tag numbers) are written.
5 Fire Extinguishers Inspection was done. 26.07.2021

6 Smoke Detectors Check List Verification done 04.07.2021

7 Road mirrors mounting was done at several road crossing/junction 16/07/2021

points.

Newly erected fire hydrant line flush out work was done. 29.07.2021
8
9 In several dates
Tool box talk was conducted.

10 safety induction training was conducted. In several dates

11 Quotation boards are arranged in staff colony, in various locations. 04/07/21

Performance July’2021

Human Resource Department

 Regular
Department Eexecuti Workm Savya
Staff Employ G.Total
ves en sachi & Exit,Internal
ees Employee JoiningDATE External
/
Training & TOPIC
Development FACULTY NO
DURATIO
N Hours

PIO Office 1   0 1 0 1
Accounts 4   0 4 1 5 HAG operation
Civil 3 1 0 4 4 8 26.07.21 Internal and importance of Mr.T.Rajaiah, AGM- 9 2 HOURS
Commercia
QC
3 2 0 5 4 9 blended cement
l
Packing
0 1 0 1 3 4
Plant
EDP 2   0 2 0 2 Mr.P.V.Kiran
Electrical 9 12 0 21 2 23
30.07.21 External Cost optimization Ananth and Mr K 35 3 Hours
study
MuraliKrishnan
Security 1   0 1 0 1
HR-
6 1 0 7 7 14
ADMIN
Instrumenta
9 2 0 11 8 19
tion
Mechanical 16 11 0 27 13 40
Auto 1   0 1 0 1
Mines 6 7 0 13 7 20
P&QC 24 4 0 28 45 73
Safety 2 1 0 3 0 3
Stores 2 2 0 4 3 7
Power
27 9 0 36 24 60
Plant Training Man Days & Hours of this month 15.375 Man days & 12 3Hrs
TOTAL 116 53 0 169 121 290

Joinings: :
1.Mr.B.Lokeswarareddy, Joined as Electrical Engineer (Power
Plant ) joined on 19.07.2021
Resignation / Retirement:
POWER PLANT
 POWER PLANT PERFORMANCE
Year
Description Unit April-21 May-21 JUN-21 JUL-21 21-22

Total Thousand
Generation MWH 8799.84 8260.32 6119.04 5912.88

Plant PLF % 44.41 33.99 31.79

48.89
Thousand
Aux Cons 1125.62 1100.52 743.988 701.023
MWH

Aux Cons % 12.79 13.32 12.16 11.86

Thousand
Export to Grid 22.5 26.9 15.7 23.7
MWH

Cement Plant Thousand

Cons MWH 7641.20 7123.05 5353.462 5182.257

Sp. Heat Cons K Cal / KWH 3267 3346 3326 3323

0.612 0.623 0.619 0.633

Sp. Coal Cons Kg / KWH

4.31 4.36 4.32 4.32

Sp. Steam Cons Kg / KWH

4.31 5.08 5.41 5.80

Sp. Fuel Cost Rs / KWH

0.140 0.141 0.141 0.144

Sp Fuel / Steam Kg/ Kg

5384 5147 3786.8 3743

Total Coal Cons MT 4

1160 981 757 774

Total Fly Ash MT

210 160 78 61
Total Bed Ash MT

3163.16 6232.79 1098.7 4994.94

Total Coal Recd MT 4

2806.8 3892.59 1204.4 2456.43

Cl. stock of Coal MT 9

Cl. stock of Fly

MT 2 68 2 72
Ash

Cl. stock of Bed

MT 420 580 78 719
Ash
Coal receipts – Consumption – Stock and Lab Test Results – Month Average

Coal receipts – Consumption – Stock

Opening Stock Month Consumption Closing Ph.cal Stock Yr to date Yr to date
Receipts stock Dimensions consumption receipts
Description
Thousand MT Thousand Thousand Thousan MtrXMtrXMtr Thousand MT Thousand
MT MT d MT MT
South Africa –
RB3
South Africa – RB
AUS.COAL 1204.49 4994.94 3743 2456.43 17458 14886.79
US COAL 0 0 0 0 602.84 602.84
Total 1204.49 4994.94 3743 2456.43 18060.84 15489.63

Lab Test Results – Month Average

HHV LH Moistu Ash VM Carb Hydrog Oxyge Nitrog Sulfu Pric Price /
V re on en n en r e K.Cal

Australian coal 5720 525 10.33 22.3 29.39

0 2
US COAL
 Plant Operation – Performance
Turbine Station Boiler Oil Run Shut Dn Brk Dn Spares Consuma
Month Heat Rate Heat Rate Eff Consum Hrs Hrs Hrs bles
APRIL-21 2689 3267 83 720 0 0
MAY-21 2736 3346 82 744 0 0

JUN-21 2691 3326 81 476.4 243.2 0

JUL-21 2687 3323 82 461.41 282.19 0

Average 2700 3315 82 2402.21 525.39 0

Year 20-21 2739 3499 78 5884.10 2845.7 30.43

Year 19-20 2708 3379 80 6848.46 1917.18 17.56

Year 18-19
2565 3217 80 8405.18 204 150.42
 R.O PLANT PERFORMANCE & CHEMICALS COST REPORT 2021-2022.

MONTH RUNNING HRS PROD REJECT T.R/W RCRY CHEM.COST PRD.COST

WISE (MT) (MT) (MT) (%) (RS/-) 1.0 MTW/ (RS/-)

APR-21 101 965 457 1422 68 1734 2.15

MAY-21 98 1025 480 1517 68 1914 2.23

JUN-21 88 850 405 1300 68 1850 1.83

JULY-21 92 850 409 1250 68 1206 1.42

AUG-21

SEP-21

OCT-21

NOV-21

DEC-21

JAN-22

FEB-22

MAR-22

TOTAL 68
379 3690 1751 5489 6704 7.61
TOTAL CHEMICALS CONSUMPTIONS COST REPORT 2021-2022

MONTH WISE R.O.P.Chem D.M.P.Chem BLR.Chem C.T.Chem Cons TOTAL. Chem.

Cons Cost Cons Cost Cons Cost Cost Cost
(RS)/Month (RS)/Month (RS)/Month (RS)/Month (Rs/-)/Month

APR-21 1734 9324 14210 20418 45686

MAY-21 1914 9144 16506 20282 47845

JUN-21 1850 6720 13360 14981 36614

JULY-21 1206 6705 11330 17145 36386

AUG-21

SEP-21

OCT-21

NOV-21

DEC-21

JAN-22

FEB-22

MAR-22

TOTAL 6704 31893 55406 72826 166531

D.M PLANT PERFORMANCE & CHEMICALS COST REPORT 2021-2022.

MONTHWISE RUNNING HRS WATER.PROD CHEM. COST PRD.COST

(MT) ( RS/-)/MONTH 1.0 MTW/ (RS/-)
APR-21 93 807 9324 9.66

MAY-21 101 860 9144 8.92

JUN-21 88 748 6720 8.98

JULY-21 92 775 6705 8.89

AUG-21

SEP-21

OCT-21

NOV-21

DEC-21

JAN-22

FEB-22

MAR-22

TOTAL 374 3190 31893 9.11

FLY ASH & BED ASH (LOI %) REPORT 2021-2022

MONTHWISE FLY ASH LOI % BED ASH LOI % USAGE OF RAW

(AVG /MONTH) ( AVG /MONTH) MATERIALS

APR-21 5.52 1.01 AUSTRALIAN

MAY-21 6.66 1.02 AUS+US

JUN-21 5.65 1.00 "

JULY-21 5.76 1.00 AUSTRALIAN

AUG-21

SEP-21

OCT-21

NOV-21

DEC-21

JAN-22

FEB-22

MAR-22

TOTAL 5.90 1.01 AUSTRALIAN+US