1. HINDUSTAN ZINC
HINDUSTAN ZINC
2-Feb-23 1
Safety Contact

2. HINDUSTAN ZINC
HINDUSTAN ZINC
MOM Jun -22
Last MOM for the Month of Jul 22
Sr. No. Date Points Responsibility Target Date Status Remarks
1 2/7/2022
Safety PPE implementation and rain coat implementation in
site.
Sandeep 7/20/2022 Done
2 2/7/2022 Mansoon Preperation and readiness Murugan 7/18/2022 Continue
Manpower and Matreial
Available.
3 2/7/2022 Weekly and daywise trend of IM booking Gourav 7/16/2022 Continue
4 2/7/2022 Environment data as per PFD booking and tracking area wise Gourav 7/16/2022 Continue
5 2/7/2022 Mock drill plan in between 10 to 20 of Month Rajendar 7/15/2022 In Progress
6 2/7/2022 Mock drill Observation point tracking and closing Murugan 7/20/2022 In Progress
7 2/7/2022
Repitative safety violations done driver action to be taken for
blacklist
Yuvaraj 7/5/2022 Continue Informed to concerned
8 2/7/2022 CT fan-1 Gearbox vibration need to track Gourav 7/20/2022 Done Vibration Normal
9 2/7/2022 AHP compressor loading and Undloding hrs benefit study Chittora 7/5/2022 Done
10 2/7/2022 Excess/ less control plan to be frame Murugan 7/6/2022 Done
11 2/7/2022 UBC Loss Breakup plan
Bherulal
Meena
7/5/2022 Done
12 2/7/2022 ID Fan load Study A &B and comparison Muniram 7/7/2022 Done
13 2/7/2022 Before/After shutdown Auxillary comparison Murugan 7/8/2022 Done
14 2/7/2022
Specific oil consumption on higher side in june month to be
controlled
Kilesh 7/5/2022 Continue
15 2/7/2022 HPBP loss Breakup
Rajendar
Meena
7/7/2022 Done

3. HINDUSTAN ZINC
HINDUSTAN ZINC
Safety contact - JULY -22
Hazards :
At coal yard form truck tippler to coal
yard stair case support found
damaged condition.

4. HINDUSTAN ZINC
HINDUSTAN ZINC
Major Safety Improvement
Problem statement :
 The travelling tippler trolley which was operated from control
room was inoperative due to damage of reel power cable.
The local operation of the travelling trolley was done by the
operator from the local electrical panel. Which was inside the
access control and it was a hazard.
.
Kaizen Objective:

Travelling tippler trolley Local operation By Pendant
Team Member:
 Rohitash Sharma, JP Chittora, Bherulal Banzara, Narayan Balai

5. HINDUSTAN ZINC
HINDUSTAN ZINC
 Eliminated hazards & man machine interaction by in-house prepared pendant that is be safe operation of
travelling tippler outside of access control.
9.6.2022 [Presentation name / Author] 38
Travelling tippler
Panel
New Pendent
Result Achieved

6. HINDUSTAN ZINC
HINDUSTAN ZINC
Particulars
ZCPP ZCPP
FTM YTD
Fatal incident 0 0
LTI 0 0
MTI 0 0
Near miss 41 135
Incident(HIPO) 0 0
Accidents(First aid injury) 0 0
Fire incidents 0 0
LTI Free Days 31 days 139 days
Mock drill conducted 1 3
PFDE reporting 24 77
Environment incident reported in system 6 10
SI Compliance 100% 100%
SAFETY PARAMETER - JULY-22

7. HINDUSTAN ZINC
HINDUSTAN ZINC
FY 21-22
(Quarter)
1st
2nd
3rd
4th
IM 104 75 43 78
NM 97 94 91 97
QTR Wise
FY 22-23
(Quarter)
1st
2nd
3rd
4th
IM 53 24
NM 94 41

8. HINDUSTAN ZINC
HINDUSTAN ZINC
Particulars 2020-21 2021-22 2022-23
Fatal incident 0 0 0
LTI 0 1 0
MTI 1 0 0
Near miss 363 379 135
Incident(HIPO) 1 1 0
Accidents(First aid injury) 1 7 0
Fire incidents 5 0 0
PFDE reporting 325 302 77
Environment incident reported in system 92 60 10
LAST 3 YEAR RECORDS

9. HINDUSTAN ZINC
HINDUSTAN ZINC
NM BOOKING – JULY -2022
Boiler & Ash
Handling Plant
Coal Handling
Plant
DM Plant &
Cooling Tower
TG & SWYD
12
10
9
10

10. HINDUSTAN ZINC
HINDUSTAN ZINC
NOS of PFDE Booking JULY - 2022
Boiler & Ash
Handling Plant
Coal Handling
Plant
DM Plant &
Cooling Tower
TG & SWYD
11
3
7
3

11. HINDUSTAN ZINC
HINDUSTAN ZINC
1
2-Feb-23
Mock Drill at CPP
Topic :- Hot Ash Splash On IP During Inspection At bottom
Ash
Observations
1.Siren was not audible loudly.
2. Glass was missing form hood in fire suit
3.Co-worker was without hand gloves.
4. As per Burn injury first aid procedure not Followed
5.Ambulance driver was not aware about exact loction of
incident.
6.Reverse horn was not working of ambulance.
7.Ambulance driver comes out of vehicle while ambulance
was in start condition.
Date :- 23-07-2022

12. HINDUSTAN ZINC
HINDUSTAN ZINC
Morning TBT Safety Awareness
Training –July’ 22

13. HINDUSTAN ZINC
HINDUSTAN ZINC
Electrical Rescue Hook
Safety Awareness Training

14. HINDUSTAN ZINC
HINDUSTAN ZINC
A.E.D.
Safety Awareness
Training

15. HINDUSTAN ZINC
HINDUSTAN ZINC
Discussion
About Classification
of fire and it’s Hazards

16. HINDUSTAN ZINC
HINDUSTAN ZINC
W@H
Awareness Training

17. HINDUSTAN ZINC
HINDUSTAN ZINC
GESM Safety
Awareness Training

18. HINDUSTAN ZINC
HINDUSTAN ZINC
Reward & Recognition Activity- July’22

19. HINDUSTAN ZINC
HINDUSTAN ZINC

20. HINDUSTAN ZINC
HINDUSTAN ZINC
Plant Performance

21. HINDUSTAN ZINC
HINDUSTAN ZINC
Station Highlights July 22
Department High Lights Benefits
Operation
54.6% Generation Loss(Under Injection) is reduced as
compared to Jun 22
62305 kwhr savings achieved.
Excess(Over Injection) Power Reduced as compared to
Jun 22
42369 Units has been saved
UBC achieved less in Jul 22 - FA -8.0 & BA-9.5 as
compared form April to Jun 22
FA 0.47% reduced, BA 0.6%
reduced.
Highest BA recycle done for the Month Jun22 as compared
form April to Jun 22
551 Tons consumed for the month
Jul 22

22. HINDUSTAN ZINC
HINDUSTAN ZINC
Station Highlights
Department High Lights Benefits
Mech
AHP Compressor-1 overhauling done 395 Kwhr/day Savings
Steam & Mud drum eddy current test carried out For Checking healthiness of bank tube
Steam & mud drum 30 nos tube seal welding done Reduce chance of bank tube leakage
Steam & mud drum 60 nos tube expanding done Reduce chance of bank tube leakage
Boiler expansion restriction removed Rise Boiler Expansion Upto 10mm

23. HINDUSTAN ZINC
HINDUSTAN ZINC
Station Highlights
Department High Lights Benefits
Mech
BFP-B balancing line leakage arresting Reduce 1 gm SCC loss
HDR-13 leakage arresting by online sealing with in house
clamp fabrication.
Reduction in DM Makeup
Department High Lights Benefits
Elec
Travelling tippler trolley Remote pendent & Emergency
Push button installation work .
To Avoid Man-Machine interaction &
Safe operation
MCSA Testing done of 16 HT motor & 12 LT motor by service
engineer
Motor Health assurance
Raw water tank Level Indicator LED power supply
connection provided from New FF MCC
Safety
Air Monitoring system Power supply provided. Safety

24. HINDUSTAN ZINC
HINDUSTAN ZINC
Station Highlights
Department High Lights Benefits
Instrumentation
Boiler fill pump current provided in DCS For Equipment reliability
Alarm provided on annunciator if HPBP opened > 2% For Equipment reliability
New Access control installation for ME room For control of unauthorized entry
Raw water pond LED installation done for level display Automation
DR-1,2 operation provided from DCS Safety Improvement

25. HINDUSTAN ZINC
HINDUSTAN ZINC
Station LowLights
Department Low Lights
Operation
Make up loss Increased for July 22 1.28Gms/Kwhr
Boiler Bank tube leakage faced on 8th
June 22
8.31% Availability
Reduced
Loss due to Pressure was high as compared to Previous Months for
FY 22-23
1.13 Gms/Kwhr
Loss due to Temperature was high as compared to Previous Months for
FY 22-23
0.96 Gms/Kwhr
Loss due to Moisture has increased as compared to Previous Months for
FY 22-23
0.96 Gms/Kwhr
Loss due to Low load has increased as compared to Previous Months for
FY 22-23
15.41 Gms/Kwhr

26. HINDUSTAN ZINC
HINDUSTAN ZINC
Station LowLights
Department Low Lights
Mech
ClO2 dosing pump under breakdown Planned in Aug 22
LP water pump-2 bearing damage Planned in Aug 22
LDO forwarding pump-1 bearing damage Planned - 4th
Aug 22
Alum agitator gearbox damage PR done
Poly agitator gearbox damage PR done
Elec
GT Cooling fan 3, 4. 11 abnormal sound so bearing
replaced.
To improve fan Life
INC GPS Clock faulty card faulty

27. HINDUSTAN ZINC
HINDUSTAN ZINC
DM Plant Highlights & Lowlights
Highlight Lowlight
Coal lab and Chemical lab all rack nomenclature done
Chemical cons. In Regeneration increased
DM plant Area 5S Improved and BAST/BCST tank
Colour done
Defect Elimination not proper
RW by pass in service (save APC loss from RW pump)
DM Plant Efficiency Decreasing
Water loss from clarifier sludge drain (Decanter motor not
available)

28. HINDUSTAN ZINC
HINDUSTAN ZINC
Unit monthly performance
Description Units Apr-22 May-22 Jun-22 Jul-22
Q-1 Q-2 YTD
FY(22-23) FY(22-23) FY(22-23)
Availability % 89.67% 60.00% 97.71% 91.69% 82.46% 91.69% 84.62%
Generation MU 46.77 33.62 52.01 47.53 132.40 47.53 2477.68
Running Hrs Hrs 645.60 446.42 703.50 682.17 1795.52 682.17 8644.29
PLF % 70.99% 49.39% 78.95% 69.81% 78.95% 69.81% 67.16%
Unit heat rate Kcal/kwh 2564.83 2606.72 2596.78 2577.82 2589.44 2577.82 2585.32
Aux. Consumption % 8.40% 8.36% 8.41% 8.48% 8.39% 8.48% 8.42%
Sp. Coal Consumption Gms/Kwh 427.47 434.45 432.79 429.64 431.57 429.64 430.89
Sp. Oil Consumption ml/Kwh 0.20 0.35 0.47 0.19 0.33 0.19 0.30
Planned Stoppage No 0.00 1.00 0.00 0.00 1.00 0.00 1.00
Forced Stoppage No 2.00 0.00 0.00 1.00 3.00 1.00 3.00
Tripping No 0.00 1.00 1.00 0.00 2.00 0.00 2.00
Blackout No 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Specific Water
Consumption
Cu mtr/mwh 2.53 2.60 2.53 2.38 2.55 2.38 2.50

29. HINDUSTAN ZINC
HINDUSTAN ZINC
Month KPI details
Description
Units FTM FTY
BP Act BP Act
Generation mu 67.40 47.53 243.49 179.93
PLF % 100% 69.81% 90.89% 67.16%
Availability % 100.00% 91.69% 90.89% 84.62%
Sp. Steam Consumption kg/kwh 3.66 3.71 3.66 3.72
Sp. Coal Consumption gm/kwh 410.00 429.64 410.00 430.89
Heat Rate kcal/kwh 2460.00 2577.82 2460.00 2585.32
Tripping No. 0.00 0.00 0.00 2.00
Planned Stoppage No. 0.00 0.00 0.00 1.00
Unplanned stoppage No. 0.00 1.00 0.00 3.00
Specific Water Consumption Cu mtr/mwh 2.24 2.38 2.24 2.50
Coal Consumption (@6000 GCV) mt 27632.05 20419.32 99831.92 77527.31

30. HINDUSTAN ZINC
HINDUSTAN ZINC
Unit Yearly Performance
KPIs Apr/22 May/22 Jun/22 Jul/22
Generation 46.77 33.62 52.01 47.53
Running Hrs 645.60 446.42 703.50 682.17
Boiler efficiency 87.54 84.19 86.79 87.58
PLF 70.99 49.39 78.95 69.81
SOC 0.20 0.35 0.47 0.19
SCC 427.47 434.45 432.80 429.64
SSC 3.72 3.73 3.70 3.71
APC 8.40 8.36 8.41 8.48
Heat Rate 2564.83 2606.72 2596.78 2577.82
TG heat rate 2254.02 2271.78 2275.56 2269.92

31. HINDUSTAN ZINC
HINDUSTAN ZINC
SCC Analysis Last Four month
Actual Losses Comparison From Previous Month
Description Apr-22 May-22 Jun-22 Jul-22 30-Apr-22 31-May-22 30-Jun-22 31-Jul-22
COAL Lost in terms of sensible heat in fly ash 0.26 0.66 0.26 0.25 0.03 0.39 -0.39 -0.01
COAL Lost in terms of sensible heat in bottom ash 0.53 0.59 0.53 0.49 0.05 0.06 -0.06 -0.04
COAL Lost due to Moisture in air 0.58 0.60 0.58 0.57 0.04 0.03 -0.02 -0.01
Loss due to Moisture Loss -0.41 -0.84 0.75 1.32 -0.75 -0.43 1.59 0.57
Loss due to Hydrogen loss 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Low load loss 13.36 12.21 12.25 15.41 13.33 -1.15 0.04 3.16
Loss due to excess make up for power gen 1.26 2.99 1.07 1.28 -1.14 1.73 -1.91 0.21
Loss due to Pressure 0.58 0.25 0.66 1.13 0.58 -0.34 0.41 0.47
Loss due to Temperature 0.36 0.79 0.58 0.96 0.36 0.44 -0.22 0.38
COAL Lost due to Low vacuum 0.51 1.58 1.82 0.79 0.48 1.08 0.24 -1.03
Loss Due to UNBURNT 10.43 18.85 11.83 9.16 -3.63 8.42 -7.03 -2.67
Loss Due to HPBP 0.00 0.00 7.27 1.08 0.00 0.00 7.27 -6.19
Loss due toExit Flue Gas Temperature 1.93 2.26 1.99 1.33 1.08 0.33 -0.27 -0.66
Loss Due to CBD 0.13 0.41 0.04 0.13 0.13 0.28 -0.37 0.09
Loss Due to Soot Blowing 0.98 0.83 0.92 0.86 -0.01 -0.15 0.09 -0.06
COAL loss due to mill rejection 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Unaccounted Losses 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Net loss 30.50 41.18 40.55 34.75 10.55 10.69 -0.63 -5.80
Total loss including unaccounted loss 30.50 41.18 40.55 34.75 10.55 10.69 -0.63 -5.80
SCC for the month 427.47 434.45 432.80 429.64 11.79 6.98 -1.65 -3.16

32. HINDUSTAN ZINC
HINDUSTAN ZINC
SCC action plan for Aug-2022
SCC Reduction Plan for the Month of Aug 22
Loss description Activity to be done Responsibility Target date Remarks
Loss due to Vacuum
CT fan Blade angle changing based
on prior air flow result.
Gourav/Murugan 15/8/2022
Expected Vacuum improvement -
0.005 kg/cm2 and expected SCC
savings 0.5 Gms/Kwhr
a. CT fan-1 Gourav/Murugan 6/8/2022
b. CT fan-4 Gourav/Murugan 8/8/2022
c. CT fan-5 Gourav/Murugan 10/8/2022
Loss Due to Sootblowing
APH header drain line leakage Gourav/Murugan 10/8/2022
SB-13 drain valve Passing & bypass
orifice inspection
Gourav/Murugan 7/8/2022
A. Orifice Checked found OK.
Orifice dia:1.5mm
B. ON/OFF Valve checking
pending

33. HINDUSTAN ZINC
HINDUSTAN ZINC
SCC action plan for Aug-2022
SCC Reduction Plan for the Month of Aug 22
Loss description Activity to be done Responsibility Target date Remarks
Loss due to Excess Makeup
LP 02 Safety valve Passing Gourav Next Opportunity
MS line Manual Isolation & ERV
Valve Passing. Gourav
Next Opportunity
HP 04 Safety valve Passing Gourav
Next Opportunity
Spare received
Loss due to Exit Flue gas
Temperature
Air ingress Point Arresting
Gourav/Muruga
n
14.08.2022
0.5% boiler efficiency is
Loss
APH outlet temperature to be
minimised and Mill C Cold air gate
passing to be rectified.
Gourav/Muruga
n
08.08.2022
Economiser, APH, Super heater
area temperarature mapping
against design.
Rajendra Meena 06.08.2022
Loss Due to Temperature
Attemperator Control Valve fine
tuning to be done
Muniram/Bheru
singh
06.08.2022
Loss Due to Pressure
Pressure maintianing Training to
be done for DCS Engineer
Bheru lal Meena 13.08.2022

34. HINDUSTAN ZINC
HINDUSTAN ZINC
SCC Targets for Aug-2022
July 22 Month SCC 429.63 Gms/Kwhr
Aug Month SCC target at 70% PLF 425.00 Gms/Kwhr
Targeted Savings Break Up for Aug 22
Savings due to Startup Losses 1 Gms/Kwhr
Savings in HPBP 1 Gms/Kwhr
Savings in Vacuum loss area 0.5 Gms/Kwhr
Unburnt Carbon losses 1 Gms/Kwhr
Pressure and Temperature control 1 Gms/Kwhr
Total 4.5 Gms/Kwhr

35. HINDUSTAN ZINC
HINDUSTAN ZINC
UBC Analysis July 22
Fineness vs UBC O2% vs UBC vs net loss in Gms/kwh
1st 2nd 3rd 4th
FINENESS AVERAGE 69.5 70.4 71.7 74.4
FA 8.93 9.56 8.44 7.66
BA 10.13 10.92 10.19 9.83
10.13 10.92 10.19 9.83
8.93 9.56
8.44 7.66
69.5
70.4 71.7 74.4
0
10
20
30
40
50
60
70
80
90
100
1st 2nd 3rd 4th
FA 8.93 9.56 8.44 7.66
BA 10.13 10.92 10.19 9.83
O2 % 2.58 2.68 2.36 2.20
2.58 2.68 2.36 2.20
10.13
10.92
10.19
9.83
8.93
9.56
8.44
7.66
0.00
5.00
10.00
15.00
20.00
25.00

36. HINDUSTAN ZINC
HINDUSTAN ZINC
UBC Data June Month
1st 2nd 3rd 4th
FC/VM 1.31 1.26 1.45 1.58
FA 8.93 9.56 8.44 7.66
BA 10.13 10.92 10.19 9.83
10.13 10.92 10.19 9.83
8.93
9.56
8.44
7.66
1.31
1.26
1.45
1.58
0
5
10
15
20
25
Week
Average
Load
O2 % BA FA FC/VM
Average
Finess
1st 71.33 2.58 10.13 8.93 1.31 69.47
2nd 68.91 2.68 10.92 9.56 1.26 70.38
3rd 71.12 2.36 10.19 8.44 1.45 71.72
4th 62.54 2.20 9.83 7.66 1.58 74.41
Week Action taken for UBC
W1
Maintained mill outlet temp 80 Deg Celsius and O2 maintain 2.3 to 2.5%.
Maintain Mill air flow ratio 1.6 to 1.8 range.
W2
Mill output fineness study has been done and changed the classifier
position.
SADC position change from 30 to 25 and O2 maintained around 2.2 to
2.5%.
Coal pipe Temperature mapping done.
W3
O2 range in boiler has been set at 2.0% from 2.3%
Dirty pitot tube recommendations points inspected during Mill PM.
W4
Changed the Classifier setting from 7 to 6 for improving fineness.
Mill coal pipe clean air flushing done.

37. HINDUSTAN ZINC
HINDUSTAN ZINC
UBC action plan for july-2022
UBC Action plan -Aug-22
Sr. No Action for improvement Status Target Date Responsibility
1 Mill classifier position Changing (Under study) Continous Continous Shift incharge
2 Coal pipe purging periodically Weekly Weekly Shift incharge
3 Maintain wind box DP as per coal properties SADC fuel air damper change. Continuous DCS engineer
4 Maintain secondary air by observing oxygen at APH I/L
Continous process. O2 maintain by 2.0 to
2.3%
Continous DCS engineer
5
Mill fineness maintain 75% in 200 mesh for all corner in
all mills
70 -75% As per PM plan Shift incharge
6 Maintain PA header pressure
Continous process. Maintain by 750 to
765
Continuous DCS engineer
7 O2 cross check with portable analyser daily checked Continuous Boiler Operator
8 Sample collection line to be flushed daily checked Continuous Chemist
9 Maintain Air fuel ratio 1. 5 to 1.8 in all mills Maintain Continuous DCS engineer
10 Coal pipe temp mapping Weekly Continuous Shift incharge
11 Clean air velocity test
Quotation Received Order placing in
Progress
17.08.22 Murugan
12 Dirty pitot tube test recommendation Implementation Under progress pending Murugan/Karthikeyan
13
Mill roller setting to be compared with other Location
units
Under progress 10.08.22 Murugan/gourav

38. HINDUSTAN ZINC
HINDUSTAN ZINC
Generation Loss for July-2022
Budget For Jul-2022 Actual Generation For Jul-2022
67395240 47527000
Reasons Generation loss (KWh) Generation loss
Auto Operation
18237.01 0.03%
Export Schedule Change
6018.42 0.01%
Gen91.5MW & Mines Variation in Load
537.55 0.00%
Mill Hinge Gate Problem/tripping
119.45 0.00%
Coal Feeder Chocking
22120.24 0.03%
Operation Parameters
4770.65 0.01%
Total Loss (KWh) 51803.31
Cost for Loss (Rs.) 223790.30

39. HINDUSTAN ZINC
HINDUSTAN ZINC
Monthly Less & Excess for Jul-22
35%
12%
1%
0%
43%
9%
Total Less Power
Auto Operation
Export Schedule Change
Gen91.5MW & Mines Variation in
Load
Mill Hinge Gate Problem/tripping
Coal Feeder Chocking
Operation Parameters
85%
9%
3%
1%
0%
2%
Total Excess Power
Auto Operation
Export Schedule Change
Mill Hinge Gate Problem/tripping
Coal Feeder Chocking
Tripping of Mines Feeder/load
various
Operation Parameters
Month
Less Power Excess Power
Description Amount in Kwh Total in % Description Amount in Kwh Total in %
Jul-22
Auto Operation 18237.01
51803.31
35% Auto Operation 40506.90
47524.87
85%
Export Schedule Change 6018.42 12% Export Schedule Change 3965.92 8%
Gen91.5MW & Mines Variation in Load 537.55 1% Mill Hinge Gate Problem/tripping 1509.93 3%
Mill Hinge Gate Problem/tripping 119.45 0.2% Coal Feeder Chocking 524.50 1%
Coal Feeder Chocking 22120.24 43% Tripping of Mines Feeder/load various 106.40 0%
Operation Parameters 4770.65 9% Operation Parameters 911.23 2%

40. HINDUSTAN ZINC
HINDUSTAN ZINC
Excess/Less action plan Status
Action Plan for Less & Excess control for Aug 22
S.No. Description Action to be taken
Responsibility
Target
Date
Status
Remarks
1 Coal Mill - feeder Chocking to be avoided
Training for Proper blending of
coal & biomass to be ensured
Kailash Kalal 05.07.2022Done
Coal flow additive to be used at
BCN-1
Kailash Kalal 15.07.2022Done
As per rain
Additional manpower to be
ensured for coal choke removal
at coal feeder in each shift.
Kailash Kalal 15.07.2022Done
Wet coal feeding to be avoided Kailash Kalal 15.07.2022Done
Dry coal storage as
Maximum qty
2
Coal Mill - feeder hinge gate strucking to be
avoided
Coal Mill Feeder hinge gate
greasing frequency to be
increased from monthly to
weekly basis.
Gourav 05.07.2022
3
Coal Mill tripping to be avoided (Coal Mill -
C Tripped on 28.06.2022)
Training of new DCS engineers
to be done for special logics
Murugan 05.07.2022Done
FD fan maintenance
mode training to be
given
Overstay of DCS engineers and
Shift Incharges to be avoided,
vacancies to be filled ASAP.
SKM 30.07.2022
Under
Progress
4
Mis Communication & Wrong entry to be
avoided.
Training of new DCS engineers
to be done for schedule change
Murugan 04.07.2022Done

41. HINDUSTAN ZINC
HINDUSTAN ZINC
Excess/Less action plan Status
Action Plan for Less & Excess control for Aug 22
S.No. Description Action to be taken
Responsibilit
y
Target Date Status
Remarks
5 Unit Tripping to be avoided Counselling and awareness training to be given for
maintaining proper plant parameters in desired
range to all DCS Engineers (Old & New)
Murugan 04.07.2022 Done
6 To minimize Correction factor
Auto Loop - Correction factor to be provided as per
the decided factor values & Loss file download
every 4 hrs interval & optimize.
Rajendra
Meena
Immediate Continous
Load 90 MW and above =(-50KW)
Load 80 Mw to 90 MW=(-150KW)
Load Below - 80 MW =(-250KW)
7 Best Shift persons Performance Best Shift persons Performance to be analysed and
R&R to be done
Chittora / Vijay 07.08.2022
8 Analysis of Less & Excess file to be
done in every 4 Hours by DCS
Engineer
Training to be given to DCS engineers for
downloading of Less Excess file from M- Cube
Bheru Banzara05.07.2022
Under
Progress

42. HINDUSTAN ZINC
HINDUSTAN ZINC
Water fall diagram for APC for JUL-2022
Month
D
e
c
.
-
2
1
Apr-22 May-22 Jun-22 Jul-22 Deviation
PLF 70.99% 49.39% 78.95% 69.81% -9.14%
MILL 0.61% 0.54% 0.65% 0.58% -0.07%
FD 0.45% 0.44% 0.50% 0.44% -0.05%
ID 0.78% 0.81% 0.89% 0.81% -0.08%
PA 0.87% 0.83% 0.76% 0.78% 0.02%
ESP 0.13% 0.11% 0.15% 0.16% 0.02%
UST 0.19% 0.19% 0.20% 0.22% 0.02%
BFP 2.36% 2.28% 2.46% 2.55% 0.09%
CEP 0.26% 0.25% 0.27% 0.28% 0.02%
CWP 1.10% 1.10% 1.21% 1.30% 0.09%
CTT 0.49% 0.52% 0.56% 0.59% 0.03%
WST 0.07% 0.07% 0.07% 0.07% 0.00%
CHT 0.12% 0.12% 0.10% 0.09% -0.01%
SST 0.61% 0.64% 0.66% 0.72% 0.07%
69.81%
0.58%
0.44%
0.81%
0.78%
0.16%
0.22%
2.55%
0.28%
1.30%
0.59%
0.07% 0.09%
0.72%
64.00%
66.00%
68.00%
70.00%
72.00%
74.00%
76.00%
78.00%
80.00%
1
PLF MILL FD ID PA ESP UST BFP CEP CWP CTT WST CHT SST

43. HINDUSTAN ZINC
HINDUSTAN ZINC
APC action plan for August-2022
S.No. Auxiliary Action To be taken Responsibility
Target
Date
Potential
Savings Remarks
(kwh/day )
1 BFP-B
Refurbishment & replacement
of BFP cartridge
Gourav
8/20/202
2
500
Spares manufacturing in
progress at workshop
2 BFP-A Pump availability for Operation Gourav
8.08.202
2
500
3 Common
Replacement Maingate
highmast light of 400 W with
300 W LED's.
JP Chittora
8/15/202
2
36 Material Received
4 Common
Replacement of existing motors
with IE3 motors
Rohitash Sharma
12/30/20
22
Payback data to be finalised
from EESL
5 Compressor
AHP compressor partial loading
rectification work
Gourav 8/8/2022 50
6 ESP ESP 5&7 to be kept off JP Chittora
Continou
s
100
7 ESP
ESP field-1 heater to be made
off
JP Chittora
Continou
s
200 Under Discussion
8 Zawar
Identifying and running of
energy efficient equipment.
Murugan
Continou
s
9 Boiler
Boiler Air leakages in duct to be
attended
Gourav
20.08.20
22
1000
10 Compressor
Instrument Air leakage to be
aressted in silo bagfilter
Gourav 2/8/2022 50 Work Completed

44. HINDUSTAN ZINC
HINDUSTAN ZINC
APC Targets for August-2022
% Kwhr/Month
Jul 22 Month APC at 70% PLF 8.49
Aug 22 Month APC target at 70% PLF 8.24
Targeted APC Savings Break Up for Aug 22
Start Up losses 0.1
Expected savings in Aug 22 0.15 2000

45. HINDUSTAN ZINC
HINDUSTAN ZINC
SPM details for July-22
Date 15th Min.Average SPM Remarks
7/1/2022 0
7/2/2022 0
7/3/2022 0
7/4/2022 0
7/5/2022 0
7/6/2022 0
7/7/2022 0
7/8/2022 0
7/9/2022 0
7/10/2022 0
7/11/2022 0
7/12/2022 0
7/13/2022 0
7/14/2022 0
7/15/2022 0
7/16/2022 0
7/17/2022 0
7/18/2022 0
7/19/2022 0
7/20/2022 1 Spike
7/21/2022 0
7/22/2022 0
7/23/2022 0
7/24/2022 0
7/25/2022 0
7/26/2022 0
7/27/2022 0
7/28/2022 0
7/29/2022 0
7/30/2022 0
7/31/2022
Total 1

46. HINDUSTAN ZINC
HINDUSTAN ZINC
FTY COAL CONSUMPTION 2022-23
Coal Consumption
Importate 21961.453
BOTTOM ASH 551.763
LINKAGE 44.89
BIOMASS 101.1
Importate
97%
BOTTOM ASH
2%
LINKAGE
0%
BIOMASS
1%
FTY -22-23 COAL CONSUMPTION
Importate BOTTOM ASH LINKAGE BIOMASS

47. HINDUSTAN ZINC
HINDUSTAN ZINC
Coal Consumption Pattern for last four month
SEA PEGASUS,
11%, 11%
STAR FIGHTER,
13%, 13%
ZAFIRAKIS, 59%,
59%
MANASOTA, 4%,
4%
OCEAN , 2%, 2%
CARBONSHALE,
3%, 4%
BIOMASS, 7%,
7%
Consumption pattern for April -22
SEA PEGASUS
STAR FIGHTER
ZAFIRAKIS
MANASOTA
OCEAN
CARBONSHALE
BIOMASS
STAR FIGHTER, 0%,
1%
MANASOTA, 58%,
58%
OCEAN , 32%, 32%
CARBON, 1%, 1%
BIOMASS, 8%, 8%
, 0%, 0%
, 0%, 0%
Consumption pattern for May -22
STAR FIGHTER
MANASOTA
OCEAN
CARBON
BIOMASS
MANASOTA,
24%, 24%
OCEAN , 38%,
38%
TAI
KNOWLEDGE,
7%, 7%
ALPHA, 18%,
18%
CARBON, 5%, 5%
BIOMASS, 8%,
8%
, 0%, 0%
Consumption pattern for June -22
MANASOTA
OCEAN
TAI KNOWLEDGE
ALPHA
CARBON
BIOMASS
MANASOTA
2%
TAI KNOWLEDGE
37%
ALPHA GALLANT
56%
MV G.P. ZAFIRAKIS
0%
BOTTOM ASH
2%
LINKAGE
0%
LINKAGE BIOMASS
1%
FUEL CACEOUS SHALE
2%
Consumption pattern for JULY-22
MANASOTA
TAI KNOWLEDGE
ALPHA GALLANT
MV G.P. ZAFIRAKIS
BOTTOM ASH
LINKAGE
LINKAGE BIOMASS
FUEL CACEOUS SHALE

48. HINDUSTAN ZINC
HINDUSTAN ZINC
Chemical analysis of coal
Financial year
Month TM ASH VM FC GCV FC/VM UBC in FA UBC in BA
Design 10 12 23 55 6000 2.39
FY22-23
Apr-22 9.14 20.5 29.65 48.17 6086.48 1.62 8.47 10.3
May-22 8.91 12.11 27.8 48.33 5864.7 1.74 13.31 14.15
Jun-22 11.36 18.1 33.19 44.75 5800.82 1.35 10.24 11.54
Jul-22 12.37 16.37 32 45 5876.94 1.406 8.00 9.57

49. HINDUSTAN ZINC
HINDUSTAN ZINC
Coal Handling Plant

50. HINDUSTAN ZINC
HINDUSTAN ZINC
TAT for JULY-2022
25 21 17 15 25 28 10 14 24 26 26 29 21 19 11 12 18 6 11 19 16 23 19 18 11 44 34 36 10 8 28
1/Jul/22, 3:41:59
2/Jul/22, 3:28:28
3/Jul/22, 4:04:01
4/Jul/22, 2:34:52
5/Jul/22, 3:39:54
6/Jul/22, 2:07:36
7/Jul/22, 2:24:01
8/Jul/22, 2:15:05
9/Jul/22, 2:47:05
10/Jul/22, 3:59:09
11/Jul/22, 3:12:10
12/Jul/22, 2:55:08
13/Jul/22, 3:19:05
14/Jul/22, 8:41:34
15/Jul/22, 6:34:04
16/Jul/22, 3:49:06
17/Jul/22, 3:54:38
18/Jul/22, 3:12:16
19/Jul/22, 2:42:33
20/Jul/22, 3:23:54
21/Jul/22, 3:15:41
22/Jul/22, 2:51:14
23/Jul/22, 3:38:40
24/Jul/22, 2:05:39
25/Jul/22, 3:03:57
0:00:00
1:12:00
2:24:00
3:36:00
4:48:00
6:00:00
7:12:00
8:24:00
9:36:00
0
5
10
15
20
25
30
35
40
45
50
NO
OF
TRUCKS/DAY
DAY OF THE MONTH
Apr-22
May-22
Jun-22
Jul-22
2:51:37
2:55:28
3:25:49
3:20:21

51. HINDUSTAN ZINC
HINDUSTAN ZINC
DM WTP OPERATION REVIEW FOR
MONTH OF JULY-2022

52. HINDUSTAN ZINC
HINDUSTAN ZINC
IONIC LOAD & OBR (SAC & SBA ) MONTH WISE 2022-23
3990
3800
3900
3796 3780
3620
3924
4152 4052
3920
3950
3990
3923
320 326
310 312 312
292
328
275
312 315
336
318 310
0
50
100
150
200
250
300
350
400
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
Cation
Load
SAC
OBR
307
335 328 330
290 280 290
251
270
308
320 311
286
0
50
100
150
200
250
300
350
400
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
anaion
load
SBA
OBR

53. HINDUSTAN ZINC
HINDUSTAN ZINC
CHEMICAL CONSUMPTION IN REGENRATION
(SAC,SBA,MB ) MONTH LY COMPERISON FTY 2022 -23
4878.0
5610.0 5389.0
8295
10606
8952
5854 5789 6005
7175
6371 6543
8424
330.0 403.0 413.0 434
1084 1084
441 509 439 514 354 359 646
0.0
2000.0
4000.0
6000.0
8000.0
10000.0
12000.0
Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
HCl
NaOH
limit
Limit

54. HINDUSTAN ZINC
HINDUSTAN ZINC
DM WATER CONSUMPTION BREAK UP Month wise (M3) 2022-23
1696
1922
2370
3201
1962 1908
1655
1900
2269
2059
1949
2213
360 389
469 409 427 459
285
460
331 351 339 291
1336
1515
1901
2710
1515
1429
1270
1440
1938
1708
1532
1922
0
18
0
82
20.0 20.0
0.0 0.0 0.0 0
78
50.0
0
10
20
30
40
50
60
70
80
90
0
500
1000
1500
2000
2500
3000
3500
Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 July
TOTAL DM CONS.IN m3
Soot Blowing CONS. IN
m3
DM Uncounted loss IN
m3
WATER LOSS FROM CBD
IN m3

55. HINDUSTAN ZINC
HINDUSTAN ZINC
DM FEED (regeneration) consumption BREAK UP MONTHLY-2022-23
54
72
105
125
160
175
180
196
160
140
170
180
160
180
40
50
70
90 90
110
100
90
70
60
80
90
60
70
10
0
10 10 10 10 10
0
35
0 0 0
10 10
0
50
100
150
200
250
Jun-21 Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
SAC Regeneration
SBA Regeneration
MB Regeneration

56. HINDUSTAN ZINC
HINDUSTAN ZINC
LSI FTM JULY-2022
Average LSI:-0.55
0.64
0.54
0.63
0.58
0.64 0.63
0.58
0.25
0.53 0.55 0.53
0.67
0.50
0.53
0.62
0.57
0.60
0.47 0.46 0.44
0.55 0.55
0.51
0.59
0.48
0.55
0.73
0.53 0.55
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
LSI
LSI

57. HINDUSTAN ZINC
HINDUSTAN ZINC
CT HOT BLOW DOWN AGAINST CT CONDUCTIVITY & COC
14207
12385
9085
8064
4874
6200 6382
5899
11005 9058
6582
8518
9106
475 450 441 434 412 423 432 519 456 448 472 470 465
4241 4110 4099 4068 3941 4002 3792 4040
4560 4663 4941
4070
4471
9.44
9.87 9.88 9.84 9.98 9.93 9.73
9.17
10.92
11.53 11.79
9.90
10.90
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
0
2000
4000
6000
8000
10000
12000
14000
16000
Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
CT BLOW DOWN
MAKE UP
CONDUCTIVITY
CT
CONDUCTIVITY
CT COC

58. HINDUSTAN ZINC
HINDUSTAN ZINC
RW Pond consumption BREAK UP
R/W POND BREAK UP
Source
Nov-
20
Dec-
20
Jan-21 Feb-21 May-21 June-21 July-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22
March-
22
April-22 May-22 June-22 July-22
in m3
in m3
in m3 in m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3
Total Raw water
Received
64815 52055 81182 116050 4136804 172852 184014 193372 191551 196189 166862 138719
150429
152310 182025 136137 117400 160283 135550
RW received
from Intake
totalizer
65622 73649 65680 35040 25714
18959
51977 55061 87448 105244 65660 27953
Water cons
according to RW
by pass
127750 117902 130509 131822 113005
131470
100333 126964 48689 12156 94633 107597
Water cons
according to RW
Pump discharge
61766 14516 57252 81226 22204 8504 78343 13643 13934 635 127 0 0 26406 29527 688700 84371 37591 5058
Water cons.
according to Fire
fighting pump
discharge
249 364 559 505 1343 334 506 666 459 738 1071 683 790 825 778 881 2354 1401 596
Water cons
according to RW
tank level diff.
1920 36215 32191 28799 20861 32655 43691 52441 28560 42560 36620 22654 21589 20636 21000 24000 24000 27000 27300
Dewatering
pump water
0 0 0 0 0 0 0 0 0 0 0 0 18600 18000 18000 18000 8400 3600 2400

59. HINDUSTAN ZINC
HINDUSTAN ZINC
Fire water consumption breakup for FTM 2022-23
683
790 825 778
881
2354
1401
596
0
500
1000
1500
2000
2500
In m3 In m3 In m3 In m3 In m3 In m3 In m3 In m3
Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
Series1

60. HINDUSTAN ZINC
HINDUSTAN ZINC
CBD LAB PH V/S SWAS PH Comparison
pH (Limit) – 9.2 - 9.8
9.05
6.23 6.44
8.86 8.80
9.52 9.52 9.58 9.47 9.42 9.40 9.28 9.17 9.37 9.43 9.41 9.41 9.45 9.38 9.42 9.32
9.62 9.59 9.58 9.56 9.58 9.58 9.49 9.58 9.52 9.58 9.60 9.58 9.58
0.00
2.00
4.00
6.00
8.00
10.00
12.00
Swas
Lab

61. HINDUSTAN ZINC
HINDUSTAN ZINC
BFP SUCTION LAB PH V/S SWAS PH Comparison
pH (Limit) – 8.80 – 9.2
9.00 8.96 9.01 9.02 9.01 9.00 8.95 8.79
9.08 9.01 9.00 9.02 9.00 9.04 8.89 9.02 8.97 9.01 8.97 9.02 8.98 9.01 8.97 9.01 9.01 9.04 9.05 9.06 9.02
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
Swas
Lab

62. HINDUSTAN ZINC
HINDUSTAN ZINC
CEP LAB PH V/S SWAS PH Comparison
pH (Limit) – 8.80 – 9.2
9.14 9.18 9.14 9.17 9.17 9.20 9.14 9.16 9.11 9.04 9.12 8.99 8.97 9.02 9.02 8.97 8.96 8.98 9.05 9.10 9.15
0.00 0.00 0.00
9.01 9.01 8.94
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
Swas
Lab

63. HINDUSTAN ZINC
HINDUSTAN ZINC
DEA I/L ,MS AND CEP CATAION CONDUCTIVITY
TREND
Cation Conductivity (Limit) – <1 ppm
0.50 0.52 0.53 0.52 0.53 0.51
0.13
0.42
0.67
0.74 0.75
0.49
0.73 0.71 0.73
0.64 0.61 0.58 0.56 0.60
0.42
0.64 0.63 0.64 0.64 0.67 0.67
0.43
0.61
1.15
1.54
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
1.80
CEP
MS
Dea

64. HINDUSTAN ZINC
HINDUSTAN ZINC
SWAS DEFECT
CBD AND MS SILICA ANALYSER NOT WORKING
BFP AND ECO pH meter card damage

65. HINDUSTAN ZINC
HINDUSTAN ZINC
THANK’S YOU