SlideShare a Scribd company logo
Visit At J.K. Laxmi Cement ltd,
Sirohi
Purpose Of Visit
To observe their GPP Operation and adopt
good practices in our plant.
To observe their CPP Operation and adopt
good practices in our plant.
To Observe overall performance of their plant
and adopt good practices in our plant.
JK Laxmi Cement An Overview
JK Laxmi Cement is located at Village Jaykaypuram, Dist-
Sirohi, Rajasthan. They have installed three cement units of
capacity 3000, 5000 and 5000 TPD respectively. All three units
are running with double pre-heater and to utilize waste heat of
exhaust gases they have installed waste heat recovery boilers
with all cement units which was supplied and operated by M/s.
Thermax India ltd. A 15MW capacity TG set supplied by M/s
Shin Nippon Machinery ltd has been installed to generate
waste heat power. JKLC also installed 3X18 MW CPP with
3X85 TPH capacity AFBC boilers supplied and operated by
M/s Thermax India Ltd.
WHR Power Plant
They Have installed AQC Boiler at clinker cooler exhaust at
their Cement Unit 1 & 2 while exhaust Gases of unit-3 are
used at fly as dryer. They have also installed PH boiler at all
three pre-heater units. The Basic design Data for their boilers
are as following :
Design Data of Boilers
S.No Description UOM AQC-1 AQC-2 PH-1 PH-2 PH-3
1 Flue Gas Flow Nm3/Hr NA NA NA NA NA
2 Steam generation TPH 4 10 10 22 22
3 Flue Gas inlet Temp Deg C 380 380 265 300 300
4 Flue Gas Outlet Temp Deg C 200 200 190 190 190
5 DP Across boiler mmwc 100 100 100 100 100
Design Data of Turbine
S.No Description UOM TG
1 Power Generation Capacity MW 12
2 Inlet Steam temperature Deg C 325
3 Inlet Steam pressure Kg/cm2 11.5
4 Exhaust Steam Pressure Kg/cm2 0.85
Details And comparison of AQC boilers
S.No Description JKLC AQC
boiler
SCL AQC
Boiler
Remarks
1 Duct Tapping Tapping taken
from Cooler
End (cold End)
in AQC-2 while
From Middle of
cooler in AQC-1
Tapping Taken
From Middle of
cooler
Flue Gas
temperature are
very less at JKLC
compare to our
boilers
2 Deduster
System
They Have
installed De-
duster before
Boiler inlet.
De-Dusting
System Not
Available
De-duster avoids
wear and tear of
tubes but approx 5-
10 deg c temp drops
across De-duster
3 Type Of
Dampers
Butterfly
Dampers Has
been used
Guillotine
Dampers Has
been used
Air ingressment is
very less from
butterfly dampers
but sealing is poor
S.No Description JKLC AQC
boiler
SCL AQC
Boiler
Remarks
4 Expansion
Bellows
Metallic
Expansion
bellows
supplied by
M/s Atulya has
been installed.
We are also
replacing
fabric bellows
by metallic
bellows
Less Air
ingressment from
metallic bellows
compare to fabric
bellows.
5 Dust conveying
system
Drag chain
(Mahindra
make) are
used for clinker
dust
Screw
conveyor used
Less failure of drag
chain compare to
our system.
6 Tube Type Horizontal
arrangement
carbon steel
tubes.
Horizontal
arrangement
carbon steel
tubes except
SSH.
They are facing
Limitation of temp
due to lower
metallurgy.
Details And comparison of AQC boilers
S.No Description JKLC AQC
boiler
SCL AQC
Boiler
Remarks
1 Air ingressment 6% false air
(as per JKLC
WHR team)
10-15% 1.Multilouver
Dampers has been
used instead of
guillotine dampers
at JKLC.
2.Mettelic bellows
are used instead of
fabric bellows at
JKLC.
3. All Headers are
installed inside the
casing at JKLC.
2. Dust
Conveying
system
Mechanical
Dust
conveying.
Pneumatic
Dust
Conveying.
Lower operating
cost of mechanical
conveying compare
to pneumatic.
Details And comparison of PH boilers
S.No Description JKLC AQC
boiler
SCL AQC
Boiler
Remarks
3 Tube
arrangement
Vertical tube
arrangement
and Horizontal
flow of Flue
gas.
Vertical tube
arrangement
and Horizontal
flow of Flue
gas.
4 Boiler
circulation
Forced
circulation
Natural
Circulation
JKLC has installed
circulation pumps
for circulation in
boilers because of
less height of boiler
drum
5 Boiler Design Designed for
only HP steam
generation
Designed for
HP&LP steam
generation
Details And comparison of PH boilers
Details Of 3X18 MW CPP
M/s Thermax India Ltd has supplied and operates 3X85
TPH AFBC boilers at JKLC. Plant was in shutdown
condition due to less power requirement. JKLC had a
contract with state govt to purchase 20MW @2.8Rs per unit
so they are only run CPP whenever load demand raised
above 33MW (They could not run less then 13MW on their
TG’s). However they have preserved their boilers with
conventional wet preservation method.
Some Good practices of JKLC
All valves are lubricated and cleaned every after 15 days as per
preventive schedule.
They have covered all instruments, actuators and control vales by
polythene to avoid dust deposition.
They have provided SOP of TG and boiler start-up in their CCR.
Proper Tagging has been done on every instrument panel.
They strictly follows 5’s in shutdown activities also.
 They did not weld directly on casing cracks, they used to weld a
‘V’ Piece filled by glass wool on cracks.
Photographs Of JKLC
5’S’ at
Shutdown
work
Photographs Of JKLC
Fins cleaning Arrangement
Photographs Of JKLC
Metallic bellow instead of fabric bellow at inlet duct
Photographs Of JKLC
Hammering station of PH Boiler
Photographs Of JKLC
Tagging At instruments
Photographs Of JKLC
Proper maintenance of valves
Photographs Of JKLC
SOP in CCR
Photographs Of JKLC
‘V’ piece welding at casing cracks
Photographs Of JKLC
Multi louver dampers

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Cement Plant visit report with photographs

  • 1. Visit At J.K. Laxmi Cement ltd, Sirohi
  • 2. Purpose Of Visit To observe their GPP Operation and adopt good practices in our plant. To observe their CPP Operation and adopt good practices in our plant. To Observe overall performance of their plant and adopt good practices in our plant.
  • 3. JK Laxmi Cement An Overview JK Laxmi Cement is located at Village Jaykaypuram, Dist- Sirohi, Rajasthan. They have installed three cement units of capacity 3000, 5000 and 5000 TPD respectively. All three units are running with double pre-heater and to utilize waste heat of exhaust gases they have installed waste heat recovery boilers with all cement units which was supplied and operated by M/s. Thermax India ltd. A 15MW capacity TG set supplied by M/s Shin Nippon Machinery ltd has been installed to generate waste heat power. JKLC also installed 3X18 MW CPP with 3X85 TPH capacity AFBC boilers supplied and operated by M/s Thermax India Ltd.
  • 4. WHR Power Plant They Have installed AQC Boiler at clinker cooler exhaust at their Cement Unit 1 & 2 while exhaust Gases of unit-3 are used at fly as dryer. They have also installed PH boiler at all three pre-heater units. The Basic design Data for their boilers are as following :
  • 5. Design Data of Boilers S.No Description UOM AQC-1 AQC-2 PH-1 PH-2 PH-3 1 Flue Gas Flow Nm3/Hr NA NA NA NA NA 2 Steam generation TPH 4 10 10 22 22 3 Flue Gas inlet Temp Deg C 380 380 265 300 300 4 Flue Gas Outlet Temp Deg C 200 200 190 190 190 5 DP Across boiler mmwc 100 100 100 100 100
  • 6. Design Data of Turbine S.No Description UOM TG 1 Power Generation Capacity MW 12 2 Inlet Steam temperature Deg C 325 3 Inlet Steam pressure Kg/cm2 11.5 4 Exhaust Steam Pressure Kg/cm2 0.85
  • 7. Details And comparison of AQC boilers S.No Description JKLC AQC boiler SCL AQC Boiler Remarks 1 Duct Tapping Tapping taken from Cooler End (cold End) in AQC-2 while From Middle of cooler in AQC-1 Tapping Taken From Middle of cooler Flue Gas temperature are very less at JKLC compare to our boilers 2 Deduster System They Have installed De- duster before Boiler inlet. De-Dusting System Not Available De-duster avoids wear and tear of tubes but approx 5- 10 deg c temp drops across De-duster 3 Type Of Dampers Butterfly Dampers Has been used Guillotine Dampers Has been used Air ingressment is very less from butterfly dampers but sealing is poor
  • 8. S.No Description JKLC AQC boiler SCL AQC Boiler Remarks 4 Expansion Bellows Metallic Expansion bellows supplied by M/s Atulya has been installed. We are also replacing fabric bellows by metallic bellows Less Air ingressment from metallic bellows compare to fabric bellows. 5 Dust conveying system Drag chain (Mahindra make) are used for clinker dust Screw conveyor used Less failure of drag chain compare to our system. 6 Tube Type Horizontal arrangement carbon steel tubes. Horizontal arrangement carbon steel tubes except SSH. They are facing Limitation of temp due to lower metallurgy. Details And comparison of AQC boilers
  • 9. S.No Description JKLC AQC boiler SCL AQC Boiler Remarks 1 Air ingressment 6% false air (as per JKLC WHR team) 10-15% 1.Multilouver Dampers has been used instead of guillotine dampers at JKLC. 2.Mettelic bellows are used instead of fabric bellows at JKLC. 3. All Headers are installed inside the casing at JKLC. 2. Dust Conveying system Mechanical Dust conveying. Pneumatic Dust Conveying. Lower operating cost of mechanical conveying compare to pneumatic. Details And comparison of PH boilers
  • 10. S.No Description JKLC AQC boiler SCL AQC Boiler Remarks 3 Tube arrangement Vertical tube arrangement and Horizontal flow of Flue gas. Vertical tube arrangement and Horizontal flow of Flue gas. 4 Boiler circulation Forced circulation Natural Circulation JKLC has installed circulation pumps for circulation in boilers because of less height of boiler drum 5 Boiler Design Designed for only HP steam generation Designed for HP&LP steam generation Details And comparison of PH boilers
  • 11. Details Of 3X18 MW CPP M/s Thermax India Ltd has supplied and operates 3X85 TPH AFBC boilers at JKLC. Plant was in shutdown condition due to less power requirement. JKLC had a contract with state govt to purchase 20MW @2.8Rs per unit so they are only run CPP whenever load demand raised above 33MW (They could not run less then 13MW on their TG’s). However they have preserved their boilers with conventional wet preservation method.
  • 12. Some Good practices of JKLC All valves are lubricated and cleaned every after 15 days as per preventive schedule. They have covered all instruments, actuators and control vales by polythene to avoid dust deposition. They have provided SOP of TG and boiler start-up in their CCR. Proper Tagging has been done on every instrument panel. They strictly follows 5’s in shutdown activities also.  They did not weld directly on casing cracks, they used to weld a ‘V’ Piece filled by glass wool on cracks.
  • 13. Photographs Of JKLC 5’S’ at Shutdown work
  • 14. Photographs Of JKLC Fins cleaning Arrangement
  • 15. Photographs Of JKLC Metallic bellow instead of fabric bellow at inlet duct
  • 16. Photographs Of JKLC Hammering station of PH Boiler
  • 17. Photographs Of JKLC Tagging At instruments
  • 18. Photographs Of JKLC Proper maintenance of valves
  • 20. Photographs Of JKLC ‘V’ piece welding at casing cracks
  • 21. Photographs Of JKLC Multi louver dampers