Vocational training at ambuja

1. PREPARED BY : APOORVA DHURANDHAR
BRANCH : ELECTRICAL ENGINEERING
COLLEGE : RUNGTA COLLEGE OF ENGG & TECH,BHILAI (C.G.)
REPORT ON ONE MONTH VOCATIONAL TRAINING – 1st July to 31st July 2019
AMBUJA CEMENTS UNIT--BHATAPARA

2. The company's
quintessential
spirit has
ensured a
product that
embodies Giant
Strength.

3. ACKNOLEDGEMENT
 It is my pleasure to be indebted to various people, who
directly or indirectly contributed in the development of
this work and who influenced my thinking, behavior, and
acts during the course of training. I express my sincere
gratitude to Rungta College Of Engg & Tech for
providing me an opportunity to undergo summer training
at Ambuja Cement Bhatapara. I am thankful to Mr.
S.K.Mishra (GM,E&I) and my trainer Mr.Sandeep
Shrivastav(Manager,E&I) for his support, cooperation,
and motivation provided to me during the training for
constant inspiration, presence and blessings. I also
extend my sincere appreciation to Human Resource
Department for their valuable suggestions and precious
time in accomplishing my project . Lastly, I would like to
thank the almighty and my parents for their moral
support and my friends with whom I shared my day-to-
day experience and received lots of suggestions that
improved my quality of work.

4. ABOUT AMBUJA CEMENTS
 Ambuja Cements Ltd, a part of the global
conglomerate LafargeHolcim, is among the leading
cement companies in India. Currently, Ambuja
Cement has a cement capacity of 29.65 million
tonnes with five integrated cement manufacturing
plants and eight cement grinding units across the
country.
 The company has many firsts to its credit – a
captive port with four terminals that has facilitated
timely, cost-effective, cleaner shipments of bulk
cement to its customers.

5. ZERO HARM
For Ambuja Cement, its people are its most
important resource. The company is committed
to ensure the safety of all its employees,
contractors and others connected with its
operations, through its Zero Harm policy.
We Care – an umbrella initiative which covers all
stakeholders – has played a seminal role in
transforming Ambuja Cement's operations as well
as attitudes towards safety.

7. CEMENT PRODUCTION AT
AMBUJA BHATAPARA PLANT..
 FOR CEMENT PRODUCTION AMBUJA
CEMENTS AT BHATAPARA HAS TWO PLANT:
 1 . LINE I – 3800 TPD CLINKER PRODUCTION
CAPACITY.
 2 . LINE II - 9400 TPD CLINKER PRODUCTION
CAPACITY.

8.  TOTAL POWER AVAILABILITY :86 MW
POWER
SOURCES
CSEB DIESEL
GENERATOR
THERMAL
POWER
PLANT
18 MW STG 1
15MW
STG 2
15MW
STG3
33W 5 MW

9. POWER DISTRIBUTION MSS
POWER DISTRIBUTION OF
LINE II

10. CONNECTED LOADS
LINE 1 LINE II
LS CRUSHER 1.2MW
RAW MILL 5.5 MW
COAL MILL 1 MW
KILN COLER &
COAL FIRING
3.8MW
FACTORY
AUXILARY
0.8MW
COLONY 0.3MW
PACKING PLANT &
CLINKER LOADING
1.5MW
CEMENT MILL 1 5 MW
CEMENT MILL II 6.5MW
CEMENT MILL III 5.5MW
TOTAL LOAD 31.1 MW
LS CRUSHER 2.0MW
RAW MILL 12MW
COAL MILL 3.2MW
KILN COOLER
&COAL FIRING
9.5MW
TOTAL LOAD 26.7MW
TOTAL CONNECTED LOAD :57.8 MW

11. CRITICAL MOTORS OF LINE I PLANT:
Bag House Fan Motor[1300MW, Voltage 6.6KV ]
Raw Mill Main Drive[2800KW, Voltage 11KV]
Raw Mill Fan [2800KW,Voltage11KV]
Coal Mill Main Drive [950KW,VOLTAGE11KV]
Kiln Main Drive [700KW,VOLTAGE 690KV]
Cement mill -1(Twin drive)- 2200KW X 2,Voltage 11KV
Cement mill -2(Twin drive)- 2200KW X 2,Voltage 11KV
Cement mill -3(Twin drive) - 2500 KW X 2 ,Voltage 6.6KV

12. • General Diagram
Maintenance of VFD includes:
1. Cooling fan checking
2. Electrolytic capacitor checking
3. Parameters checkup
4. Diode and IGBT testing
5. Capacitor reforming
LV-VFD
• ACS800, Standalone module, DSU
, INU modules
MV-VFD
• ACS5000 (COAL MILL AND RAW
MILL), YASKAWA (PH & BH FAN),
ACS2000
Purpose of using VFD:
1. SPEED CONTROL POSSIBLE
ACCORDING TO PROCESS.
2. POWER SAVING (As
compared to DOL + Damper
combination)
3. Provides Soft start
VFD’s (VARIABLE FREQUENCY DRIVE)

13. HT
MOTOR
Cleaning carbon filter,
checking carbon brush
length, checking of slip ring
assembly.
Checking of all motor
termination and insulation
checking.
Checking of IR value and
winding resistance.
LT
MOTOR
Running hours based motor
O/H.
1500 RPM or below – 3 Yrs.
2900 RPM range– 6-12
Months
Checking of terminal and
junction box.
Checking of IR value and
winding resistance. Trial of
motor is done and current in
each phase is measured.
Check for abnormal
noise/vibrations/Excessi
ve heat/Burning
smell/Chemical smell.
Check for proper
earthing connection
and any loose bolts.
Check for cooling of
motor effectiveness
Check for the dirt,
dust and oil on the
motor which could
results into failure
WBI
MOTOR MAINTENANCE

14. Total cement packers – 7 Nos. installed in ACL Bhatapara
Packers 1 to 4, capacity – 120 TPH – 8 Spout
Packers 5 to 6, capacity – 180 TPH – 12 Spout
Packers 7 - capacity – 240 TPH – 16 Spout
Total – 16 Nos. close type wagon loaders.
Total – 8 Nos. open type wagon loaders.
Total – 5 nos. Truck loaders.

15.  Arc flash is a dangerous condition associated with the release of energy caused by
an electric arc. An electric arc is the passage of substantial electrical current
through ionized air. It produces extremely high temperature and is explosive in
nature
 ARC FLASH INJURIES:
1. Electric shock
2. Severe Burns
3. Blindness
4. Hearing damage
 Causes of arc flash:
ARC FLASH AND RELATED HAZARDS
Spark discharge from: Accidental touching and Dropping tools
Failure of insulating materials
Dust, impurities, corrosion, condensation.

16.  ARC FLASH BOUNDARY:
•Limited Approach Boundary.
•Restricted Approach Boundary
•Prohibited Approach Boundary
LT 25.4 mm 304.8 mm 1070
mm
HT 177.8 mm 660.4 mm 1530
mm
 Wear arc rated PPE,arc flash suite
within arc flash danger zone
 Perform regular preventive
maintenance.
 Job safety analysis and job related
sops
De-energize equipment before working
Proper labelling on all the equipments
ACL, BHATAPARA
16
KEY FACTORS TO MAINTAIN ARC FLASH SAFETY

17. Electrostatic precipitators
 Electrostatic precipitators (ESP) are
used for gas cleaning in almost every
section of cement manufacture. The
characterisation of dust emissions
has been done for different units,
such as rotary kiln and raw mill, alkali
by-pass, clinker cooler, cement and
coal mill, in terms of exit gas quantity,
temperature, dew point, dust content
and particle size. It is seen that all
these characteristics have a wide
range of variance. The ESP system
must effectively deal with these
variations.
The basic principle of electrostatic precipitator is that gas borne
particles( mainly ash) are ionised by the high voltage discharge
electrode by the CORONA EFFECT.The ash particles ionise to
negative charge and are attracted to the positively charged collector
plates.

18. ALTERNATIVE FUEL RESOURSE
AFR is an alternative
way of reducing the
consumption of coal
which is a serious matter
of concern .
Keeping this in mind
Ambuja Cement unit
Bhatapara has set up
AFR ptant as substitute of
coal.
It is successful in saving
22 crore rupees in a
single year.

19. “In learning you will teach, and
in teaching you will learn.”
THANK YOU