Subcommittee- Technology Management Date:- 25.07.

2013

Project Title- Online Condition Monitoring System for Raw Mill Gearbox

Sr. No Description of Activities Activities details related to Remark

Project
1 Project Identification

a) Reason for project Identification

To carry out online condition
monitoring of critical VRM gearbox
in order to identify abnormalities
timely and avoid Breakdown

b) Is there any change in Technology New technology introduction

c) Reason for Changing old Technology Earlier there was no monitring

system for Gearbox.
d) Any Benefits from it We can get symptoms of possible
abnormalities in very primary stage
and thus suitable action can be
taken proactively to avoid major
failure.
2 Project Planning
a) Is it feasible in the location
proposed. Yes
b) Have you prepared the GA drawing
Provided by supplier
c) Is it Technically approved Yes
d) Have you done the cost Estimation
Yes
e) Minimum Lead time of the Project
06 months
d) What is the schedule of Project Completion before 31.03.2014
3 Administration Planning
a) Is there any additional requirement
of manpower No
b) Any Training needs to be given to
operating and maintenance staff.
By supplier
4 Execution Planning
a) What is the total strength of
Contractual manpower required for No additional manpower required.
Project Can be done by regular manpower.
b) What is the infrastructure available
for their daily livelihood.
N.A.
c) Is the contractual manpower skilled.
N.A.
d) Had they gone under safety training
N.A.
e) Which tools and Crane using for the
project. N.A.
f) Had they gone under any special
training? N.A.
g) Have you prepared the Bar chart for Attached Bar Chart
Execution Yes
5 Legal Compliance
a) Is there any legal permission is No
required
b) Is there any statutory compliance is No
required.
6 Is the technology is new and New technology introduction Criteria for Project Planner
can be patented? to be decided
(If Yes, pl give brief justification)

7 Any Special Comments related

to project
8 Actual Saving achieved against
the Proposed Savings (If
Project is returnable)

9 Review and Feed Back of After 3 Months of project

Project Completion
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
TECHNOLOGICAL PROJECT IDENTIFICATION
Subcommittee- Technology Management Date:- 25.07.13

Reason for Project Cost of Implementation

Sr. No Description of Project Identification Impact Project Schedule

We can get symptoms of

Online Condition Monitoring To carry out online condition possible abnormalities in
1
System for Raw Mill Gearbox monitoring of critical VRM very primary stage and
gearbox in order to identify thus suitable action can
abnormalities timely and avoid be taken proactively to
Breakdown avoid major failure. 56.0 Lacs Before 31.03.2014
2
3
4
5
6
7
8
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
TECHNOLOGY IDENTIFICATION SHEET
Team No.: 203 Team's Name: RAW MILL
Categorization : Technology Implementation / Absorption / Up gradation / Modification
Source* Corporate Technical Research Cell
Project Leader & Team Members : Subhash Baser (Leader), Satish Bakliwal, Amit Ojha, R
Improvement / Project Theme To provide Online Condition Monitoring System for Raw
Reason for To carry out online condition monitoring of critical VRM gearbox in order to identify abn
selection avoid major Breakdown.
Estimated Cost of Implementation (Extra sheet of calculation can be added, if needed) (Rs.)
Returnable / Non returnable : Non returnable

We have installed planetory Gear Box of tyes KMPS656 and KMPS396 in VRM'S -Raw
mills.These are heavy duty gear box and are MOST CRITICAL equipment directly affec
Brief
.Maintenance of theseGear Box is complex and time consuming .These type of Gear B
Justification
Monitoring System to continuous monitor ,trend and evalute vital parameters like tem, F
with tripping and interlocks in order to identify abnormalities timely and avoid Breakdow

Please give the Photograph / Sketch / Diagram of proposed Technology

Impact Assessment
Benefit /
(attach separate Sheet for detailed calculation / Payback etc., if an
Results
Impact on Environment NIL
Any adverse Effect NIL
control measure for adverse
NIL
effect
Minimal lead times for proper
Source for defining
absorption of new technological N.A.
lead time
changes
Scope for Horizontal Replication In Clinker Mills and Coal Mills

Sources * In-house Modification / Magazine, Internet / Supplier / Why-Why / Sister Unit etc.
ment Ltd.
ment Works
FICATION SHEET
Equipment /Area: Raw Mill Gear Box
Date 25.07.13

ader), Satish Bakliwal, Amit Ojha, Ranjeet Kumar

ondition Monitoring System for Raw Mill Gearbox
RM gearbox in order to identify abnormalities timely and

an be added, if needed) (Rs.) 56.0 Lacs

S656 and KMPS396 in VRM'S -Raw mill and Cement

T CRITICAL equipment directly affecting production
e consuming .These type of Gear Box Must have ONLINE
d evalute vital parameters like tem, Flow ,Vibration Torque
rmalities timely and avoid Breakdown.

iagram of proposed Technology

ailed calculation / Payback etc., if any)

NIL
NIL
NIL
 N.A.

n Clinker Mills and Coal Mills

Why / Sister Unit etc.

Subcommittee- Technology Management Date:- 15.02.14
Project Title:- Online Condition Monitoring System for Raw Mill Gearbox
Sr
Activity Risk Impact Control Measure
No
Installation of sensors inside Proper isolations of electrical and mechanical
1 Injury due to running of machine Hand injury
Gearbox energy sources to be taken
Installation of sensors inside
2 Contact with hot oil Burn injury To empty out the oil before entering into gearbox
Gearbox
Installation of sensors inside Carry out proper ventilation arrangements and
3 Suffocation due to confined space Drowsiness
Gearbox follow the confined spave work procedure.
4

10

11

REVIEWED APPROVED
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
PROPOSAL FOR BLOCK SANCTION
Subcommittee- Technology Management Date

DEPARTMENT/AREA Mechanical-1

LINE NO (I or II) 1

CONCERNED COMMITTEE 3 - Plant infrastructure

(To select from given list)
Jishuhozen
Kaizen
Planned maintenance
Quality maintenance
Safety & environment
MP design
Office TPM
Mines
Education & training

TYPE OF SANCTION Inevitable

(New sanction - Returnable /New Sanction-Essential /Discretionary/Inevitable )

BLOCK CODE NO. 5350234 COST CODE

ITEM Online Condition Monitoring System

DETAILS & JUSTIFICATION
We have installed planetory Gear Box of tyes KMPS656 and KMPS396 in VRM'S
These are heavy duty gear box and are MOST CRITICAL equipment directly affe
Gear Box is complex and time consuming .These type of Gear Box Must have O
monitor ,trend and evalute vital parameters like tem, Flow ,Vibration Torque w
identify abnormalities timely and avoid Breakdown.

Safety and Environment

(Please state the impact of the project NIL
activity on saftey and Enviornment)

Social impact
(Please state if the project has any NA
adverse impact on Community )

Without CDM
ESTIMATED COST (Net Block) Rs/lacs 5600000.00
 GROSS SAVING Rs/lacs 0.00

NET SAVING Rs/lacs 0.00

(gross saving - Int 7.35% on 60% net block)

PAY BACK Period Years

(Net Block/Net saving) #DIV/0!

% RETURN ( 4th year onwards) % 0.00

(Net saving x 100)/ Net block

.. 2..
Breakup of cost estimates

1 MATERIAL COST (Net off modvat) Rs/lacs Rs/lacs

Mechanical 5600000.00
Electrical
Instruments
Civil
Any other (to specify)
Total 1 5600000.00 5600000.00

2 EXECUTION COST
a Consultancy

b Contractor cost
Mechanical
Electrical
Instruments
Civil
Any other (to specify)
Total 'b' 0.00

c Tour & Travel

d Hiring of Resources
Cranes/Transport
Any other

e Contingency

Total 2 (a to e) 0.00 0

3 TOTAL COST ( Sanction required) 1+2 5600000.00

4 Barchart if applicable (Enclosed)

5 Declaration :
i) Included in Purta/Not included in Purta NO
ii) Shutdown Period required for commissioning N.A.
iii)Additional power consumption _____________ Unit/P. A. NIL
iv) This block will comply with new Enviornmental Norms YES
v) This Block will not create any saftey Hazards. YES

SCHEDULE
 a. Sanction
b. Ordering period 25.8.2013
c. Expected date of receipt at site 20.02.2014
d. Civil work N.A.
e. Erection and commissioning 31.03.2014

PERSON RESPONSIBLE SUBHASH BASER

(PREPARED BY) ( HOD-PROJECT) (HOD - CIVIL) (HOD MECH) (HOD ELEC.)

COMMENTS BY UNIT TECH.CELL

(HEAD TECH. CELL)

( FUNC- HEAD -TECHNICAL) (FUNC- HEAD (F&C)) (UNIT HEAD) (CMO (MFG.))

CC: MP DECISION SUB COMMITTEE

…03…
COST ESTIMATION SHEET
1 MATERIAL COST
(a) Mechanical
SN Item Description and qty Supplier Basic cost ED
0.00

Total

(b) Electrical
SN Item Description and qty Supplier Basic cost ED
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

(c) Instrumentation
SN Item Description and qty Supplier Basic cost ED
0.00
 (d) Others
SN Item Description and qty Supplier Basic cost ED
0.00
0.00

(e) Civil
SN Item Description Qty Amt (Rs/lacs)

Total 0.00

CALCULATION OF SAVINGS

Gross Saving
Enclosed

Calculation of CO2 abatment

Total
ent Ltd.
nt Works
CK SANCTION
Date:-05.08.2014

ystem

MPS656 and KMPS396 in VRM'S -Raw mill and Cement mills.

RITICAL equipment directly affecting production .Maintenance of these
e type of Gear Box Must have ONLINE Monitoring System to continuous
e tem, Flow ,Vibration Torque with tripping and interlock s in order to
own.

With CDM Funds

Years
OD ELEC.)

D TECH. CELL)

(CMO (MFG.))

Amount Rs/lacs
Sales tax Frt & Ins. Less modvat Net Cost
0.00 0.00 0.00

5600000.00

Amount Rs/lacs
Sales tax Frt & Ins. Less modvat Net Cost
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00

0.00

Amount Rs/lacs
Sales tax Frt & Ins. Less modvat Net Cost
0.00 0.00 0.00
 0.00

Amount Rs/lacs
Sales tax Frt & Ins. Less modvat Net Cost
0.00 0.00 0.00
0.00 0.00 0.00
0.00

(2) CONTRACTOR COST *

Mechanical
Electrical
Instrumentation
Civil

Total 0.00
* Details sheet can be attached.

Rs/lacs

0.00

CO2 in Tons

0.00
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
BAR CHART
Subcommittee- Technology Management
Project Title:-

Sr no Activity 1 2 3 4 5 6 7 8
P
1 Ordering of Material A
P
2 Recipt of material from Supplier A
P
3 Installatiuon and commisssioning A
P
4
A
P
5
A
P
6
A
P
7
A
P
8
A
P
9
A
P
10
A
P
11
A
Cement Ltd.
li Cement Works
CHART
Date:- 15.08.2014

Month
Aug-13
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4 5
 Month
Feb-14
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2
 Month
Mar-14
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
30 31
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
SAVING CALCULATION
Subcommittee- Technology Management Date:-15.08.2014
Project Title:- Online Condition Monitoring System
Description

NOT APPLICABLE
08.2014
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
TRAINING IDENTIFICATION AND IMPLEMENTATION
Subcommittee- Technology Management Da
Project Title:-Online Condition Monitoring System
Training Identified:- Training about DALOG system and its diognasis.
Sr. No Employee name Designation/Grade
1 Satish Bakliwal Sr. Manager
2 Suraj Sharma Sr. Manager
3 Ranjeet Kumar Engineer
4 Lalit Pokharna Sr. Engineer
5 Prashant Sharma Engineer
6 Kulvinder Singh Supervisor
7 Dharmesh Thakur Sr. Manager
8 Ajay Roy Sr. Manager
9
10
11
12
13
14
Tech Cement Ltd.
Kotputli Cement Works
CATION AND IMPLEMENTATION
Date:-19.03.2014

s diognasis.
Training Description Date of Training Remark
Operational training 19.03.2014
Operational training 19.03.2014
Operational training 19.03.2014
Operational training 19.03.2014
Operational training 19.03.2014
Operational training 19.03.2014
Operational training 19.03.2014
Operational training 19.03.2014
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
SAFETY, PROCEDURE
Subcommittee- Technology Management Date:-15.03.2
Title:-Pre-Start-Up Safety Review (PSSR)
Reference Document Number: KCW/SAFETY/SS/ PSSR
Above reference document number should be refer

NOT APPLICABLE AS DESIGN OF MACHINE HAS NOT BEEN CHANGED

ONLY SIGNALS FROM MACHINE ARE TAKEN FOR ANALYSIS PURPOSE
Date:-15.03.2014
 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
MANAGEMENT OF CHANGE CONTROL FORM
Subcommittee- Technology Management Date of requ
Project Title:-Online Condition Monitoring System
Department Mechanical-1

Equipment / Operation Affected : Raw Mil Gearbox

Description of Changes :
No change

Reason for Changes:

Not Applicable
Is the change: Permanent

Results of Risk Assessment :

No hazards identified ?
Yes

Key hazards or risks :

N.A.

Date of risk assessment performed :

15.03.2014

Risk controls identified :

Other requirements :
a. Special training required?
No

b. Changes to existing procedures?

No
c. New procedures? No
d. Any others? No

Authorization to proceed :

Sign.

Concern HOD HOD (Tech. Services)

CC to : Management Representative / System Co-Ordinator

Tech Cement Ltd.
Kotputli Cement Works
OF CHANGE CONTROL FORM
Date of request:-15.03.2014

Raw Mil Gearbox

No change

Not Applicable
Temporary For how long?

Yes

N.A.

15.03.2014

No

No

No

No

Yes

HOD (Safety) Concern FH

 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
HANDOVER TAKENOVER CERTIFICATE
Subcommittee- Technology Management Da
Title:-Online Condition Monitoring System
Department:- Mechanical-1

Technical Data : Drawings and Operation manuals

Mechanical
Yes

Electrical:
Not Required

Instrumentation: Yes

Safety
Not required

(HANDED OVER BY)

Tech Cement Ltd.
Kotputli Cement Works
AKENOVER CERTIFICATE
Date:-19.03.2014

Drawings and Operation manuals

Yes

Not Required

Yes

Not required

(TAKEN OVER BY)

 UltraTech Cement Ltd.
Unit : Kotputli Cement Works
Installation / Commissioning Report
Subcommittee- Technology Management Date:-19.03.2
Appendix to Capital Expenditure Manual Version 3
Appendix Name : Installation Report Format
Location Code : Raw Mill
Cost Centre: GK0RM0110
Capex Proposal number & Date ( Appropriation Request Number) 5350234.00
Main Work Breakdown Structure
Purchase Order & Date (Main Supplier / Contrctor ) 7210500242 dated 25.08.13
Supplier (Name & Code ) Dalog Systems GMBH
Date of receipt of machinery /Asset (Main Equipment ) 09.02.2014
Date of Goods Received Note (GRN) No.(MianEquipment) 09.02.2014
Brief description of asset Sensors and instrument panel
condition monitoring system

Brief description of structure /Electrical/Civil /System/Other done for installation

Is it an addition to the existing asset ? (Y/N) Yes

If yes, Original Asset Code :

14.03.2014
Date of installation of machinery / asset
Work completion /Installation report no./ Commissioning date 14.03.2014
(Issued by supplier)

Certificate of Installation
We do hereby certify that all the facts mentioned above are true & we have completed the installation of th
machinery successfully.
Prepared by Approved by
Designation Project in Charge Department Head

Signature
Date

Encl: Copy of Work Completion /Installation Report issued by supplier

FOR USE OF ACCOUNT :

Asset Under Construction No (AUC):
Main Asset No in the Fixed Asset Register :
Asset Class :
First Depreciation Computed in the Month of : Entered ON
AMOUNT IN RS :

Signature of SH
port
Date:-19.03.2014

Appendix No : 6
w Mill
0RM0110
0234.00

0500242 dated 25.08.13

og Systems GMBH
02.2014
02.2014
sors and instrument panels for DALOG
dition monitoring system

14.03.2014

14.03.2014
pleted the installation of the said

Approved by Approved by
Department Head FH/Unit Head

ssued by supplier

Entered ON :

Signature of SH Accounts
 MODEL EQUIPMENT DEVELOPMENT CRITERIA
Sr. Adv Model
Attribute Model
No. Eqpt
BASIC CONDITION ELEMENTS
1 Availability of Safety equipment such as Fire extinguisher, Alarms, N.A.
Sand buckets etc., if necessary.
2 Employees are trained on safety aspects and they are using YES
appropriate PPEs
3 Abnormality free area / Equipment. 75% 100%
4 Machine guarding is properly done YES
5 Cleanliness is maintained on equipments & surrounding YES
6 There is a place defined for everything and everything is in its YES
designated place
7 SOPs, Trouble shooting, Cleaning/ Inspection Standards, are YES
displayed and being used
8 Visuals such as Area Owner, Activity Schedule, Flow directions, YES
Match Marks, Level Indicators,PPE's, Walkways, Inspection Route
etc. are developed, displayed and used.
9 Display of Equipment Specification (Know your equipment) YES
10 Display of Process / Layout etc. YES
SYSTEMS & PROCESSES
1 Capturing of abnormaility & recording in register YES

2 Record of daily meetings sheduled, conducted (attendance YES

register)& recorded for Model & team area improvement
3 QC Tools are used to overcome recurring problems YES
4 System of capturing Kaizen, OPL's. documentation of Kaizens YES
5 Training sessions are conducted for crew YES
6 Miantain updated Team Activity Board YES
7 QCDIP Performance indicators are developed, analysed and YES
tracked
8 Capturing and Sharing Best Practices YES

RESULT INDICATORS
1 Reduction in Model equipment downtime N.A.

2 Reduction in process defects & procduction defects YES

3 Reduction in incidents (safety performance) YES

Page 35 of 42
 MODEL EQUIPMENT DEVELOPMENT CRITERIA
Sr. Adv Model
Attribute Model
No. Eqpt
4 Improvement in pollution control N.A.

5 Increase in OEE (MTTR & MBF trends) YES

6 Rationalization of lubrication system N.A.

7 Reduction in cleaning / inspection time N.A.

8 % of Hairzontal replaication of Model equipment N.A.

BEHAVIORAL ASPECTS
1 Awareness of concept within team members YES

2 Clarity on action plans & future activities YES

3 Team spirit YES

4 Skill enhancement/ no. of jobs transferred to operations YES

Page 36 of 42
 PROPOSED SAVINGS

Compressor Controller
Total Daily Energy Consumption KWH/ Day
Projected Guaranteed Electric Energy Savings (8%) KWH/ Day
Power cost Rs/KWH
Daily Energy Cost Savings (@ Rs. 4.44/unit) Rs/ Day
Running Days Days
Annual Energy Cost Savings (@ 330 days) Rs
Proposed savings in Rs lacs
 22611
1808
4.44
8031
330
2650230
26.50
 ACTUAL SAVINGS

Gearbox Online condition Monitoring System

Average Power before modification
Average Power after modification
Actual power saving after installation
Power saving @ 90 day
Power cost
Energy cost saving @ 3.95 Rs/ KWh
Annualised Savings in Lacs
GS

onitoring System
kwh /day N.A.
kwh /day N.A.
kwh /day N.A.
Kwh N.A.
Rs/KWH N.A.
Rs N.A.
N.A.
 Project Review and Feed Back
1 Project Background Overview / Project definition
1.1 Project Overview
(Give a very brief summary of the project outlining the planned
objectives)
1.2 Project dates
(Dates from project initiation to completion; enter major
milestone dates such as design completion, product release
etc.)
1.3 Project Organization
List all project participants including Project team members
and sponsors (and their roles within the project).

2 Project Performance and Outcome

2.1 Was the project successful?
2.2 Compare the final project outcome with the planned project
goal and objectives.
(Describe the success of the project in terms of achieving its
intended objective and outputs. Were deliverables delivered
on time and with customer acceptance?)

2.3 List any project deviations (in terms of scope, time resources,
cost, delays) and reasons for deviations.
2.4 Were the quality objectives met (if applicable)?
2.5 List project models, methods, tools or processes used.
2.6 Minimal lead times for proper absorption of new technological
changes
3 Project Experiences / Observations
3.1 Were there any unexpected impacts (positive or negative)?

3.2 Describe experience with the project management methods

and tools
4 Unrealized / Outstanding Outputs
4.1 List Outstanding items
Identify any remaining/outstanding items impacting project
completion/closure (e.g. training)
4.2 Actions points required (on the outstanding items)
4.3 Were any outputs unrealized?
List items that will not be implemented within the project,
4.4 If so, how has this affected the overall impact of the project?

5 Improvement Recommendations and Comments

5.1 Suggestions for Improvements
6 Other Comments
6.1 Closing remarks
ew and Feed Back
definition
To carry out online condition monitoring of critical VRM
gearbox in order to identify abnormalities timely and
avoid Breakdown
Ordering of material- Aug'14

Subhash Baser (Leader)

Members: Satish Bakliwal
Amit Ojha
Ranjeet Kumar

Yes

We can get symptoms of possible abnormalities in very

primary stage and thus suitable action can be taken
proactively to avoid major failure.
N.A.

N.A.
N.A.
N.A.

N.A.

N.A.

N.A.

N.A.
N.A.

N.A.

Comments
N.A.

N.A.