Ultratech Cement Ltd Energy Study Date

Technical and Performance Technical Specification & Scope for

21st May 2019
Monitoring Cell Compressed Air System Energy Study

1. Introduction:

M/s Ultratech Cement Limited (UTCL) is largest cement manufacturer in India with 103
million ton per annum cement manufacturing capacity. The company has integrated plants
at 20 locations, split grinding unit at another 26 locations and Bulk Terminals at 6 locations
across the country.

The company has putting continuous efforts to reduce energy consumption since inception
achieving lowest specific energy consumption in the industry segment for its integrated
plants, grinding units. In this process, Ultratech Cement Limited is further exploring energy
saving opportunities to bring down the overall energy consumption by conducting a “In
depth Compressed Air Energy Study” Study in its Integrated Cement Plant including
Captive Power Plants.

2. Requirement of an Agency for Energy Study:

UltraTech intends to appoint an expert agency to provide Energy Studying Services in the
area- “Compressed Air System”

3. Technical Capability and Experience:

The Bidder shall meet the following eligibility criteria for consideration of the bidder’s offer
further and the same shall be supported with valid documentary evidence in support of
meeting the below stipulated eligibility criteria.

3.1 The Bidder shall have at least two process specialists with working experience in
Pneumatic Conveying and Compressed air system for more than ten (10) years
and submit the particulars like name and proof of experience of process
specialists.

3.2 The bidders should have experience of "similar works" as defined below, during
the last 5 years. "Similar Work" is defined as "Carrying out Energy Study in
Integrated Cement Plant, Captive Power Plant, Grinding Unit, Other process and
manufacturing industries like Steel, Aluminium etc.

3.3 The bidders shall submit attested copies of the 'Work Orders' and the relevant
'Work Completion Certificates', clearly indicating the 'type of work', during the
relevant years, in support of the above qualifying criterion, along with their offer

4. Methodology of Energy Study:

The methodology of Energy Study shall consist of the following major activities:

4.1 Scheduling of the visits to the plant for measurement and collection of appropriate
input data regarding compressed air systems necessary for identifying energy
conservation opportunities.

4.2 Historical data of past one year from the start date of Study can also be used for
input operating data validation if available.

4.3 The bidder shall consider existing plant operating conditions including load
factors, plant operating capacity etc.

4.4 The bidder shall determine brief description of processes, technologies and
specific energy consumption parameters for each process in the Study report.

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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

4.5 Bidder shall confirm and compare the present level of operating data in respect of
equipment design data and best efficiency data with reference to available
efficient technologies available in market.

4.6 The bidder shall conduct Study as per plant installed equipment and layout given
by the company.

4.7 Bidder shall establish energy consumption for each operating process/ unit
segregating fixed and variable usage and shall calculate specific energy
consumption (SEC) of each equipment/process.

4.8 Identifying areas of improvement in energy utilization through system study for
energy consuming equipment and processes in the whole plant.

4.9 Bidder may highlights their suggestions or recommendations for improvements

that may yield at various stages of production processes.

4.10 Identifying factors influencing energy use and performance and suggest for
improvements in all the units.

4.11 Identifying high potential areas for incorporating new technologies. The Key
Performance Indicator (KPIs) affecting the performance of the equipment/process
shall be identified. A comprehensive (but not exhaust) list of KPIs shall be
benchmarked and shared with customer.

4.12 The Identified KPIs shall be benchmarked against the best of class values to
identify the areas for improvement in each operational unit. The Best in class
benchmark shall represent the best efficiency of similar process / industry.

4.13 The KPIs for benchmarking shall be finalized after deliberation with the site
personnel of the particular operational unit.

4.14 Identification of implementable Energy conservation opportunities / measures to

enable achievement of the normalized benchmark for each KPI.

4.15 Energy conservation opportunities / measures thus identified to compress the gap
between the current value of KPIs and benchmark shall be identified and
categorized in the following classes:

4.15.1 Operational improvements and controls,

4.15.2 De-bottlenecking options and improving yields.

4.15.3 Improvement in maintenance practices

4.15.4 Existing System modification

4.15.5 Brownfield technology upgrade

4.15.6 New Innovative Technology

4.16 All the above identified opportunities shall be filtered into opportunities that can
be implemented after due consideration to the following:

4.16.1. Technically compatible with the upstream & downstream processes.

4.16.2. Require large scale replacement of early / midlife equipment.

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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

4.16.3. Predicting the impact of Energy improvements projects on overall energy

Performance.

4.17 Estimation of investment required and Return on Investment (ROI) of energy

saving opportunities based on detailed techno-economics analysis and operating
scheme.

4.18 Preparation of Study reports and deliverables:

4.18.1. The report shall summarize the review of the existing system and the
findings of the energy Study, the recommendations on short term,
medium term and long term energy conservation opportunities /
measures and associated reduction in energy savings as below:

4.18.1.1. ROI within 01 year period

4.18.1.2. ROI between 01 to 03 years

4.18.1.3. ROI between 03 to 05 years

4.18.2. The tables or spreadsheets used to calculate energy saving calculation

shall be included in the energy Study report preferably as appendix along
with the key assumptions made. Units of measurement for reporting the
observations / findings / calculations shall be the units as followed by
UTCL.

4.18.4. The report submitted by the bidder shall indicate equipment/process wise
/ system wise observations / calculations, layout/scheme,
recommendations etc. and investments required, if any

5. Scope of Services:

5.1 The scope of work shall include conducting the overall system compressed air
energy Study of Ultratech Cement and Thermal Power Plant. The Study shall
cover all activities mentioned in the scope of work as per Annexure-1A/1B.
However, it is not possible to list out all the minor activity in detail. So, all such
minor / any other left out activity essential for compressed air energy Study shall
deemed to be included in the scope of work.

5.2 All the measuring instruments, fittings & other ancillaries shall be arranged by the
bidder. The bidder should ensure that the instruments possess the desired
accuracy as stipulated under ISO11011 for process parameter measurement and
are calibrated by NABL approved lab with valid certificates. UTCL will provide the
required location/points for the placement of instruments & connection of power
cables.

5.3 The Compressed air energy Study of different processes /sections/applications of

Cement/Captive Power Plant shall be carried out at equipment level majorly as
follow:

Process View Point

 Lime Stone Crusher,

 Material Handling System including Conveying,
 Raw Mill,
 Coal Mill,
 Rotary Kiln,
 Pre-Heater,
 Cooler,
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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

 Cement Grinding,
 Flyash Handling System,
 Packing Plant,
 Wagon Loading/Unloading
 Captive Power Plant (complete system)

Application view point

 Raw mill/Coal mill/Cement Mill Girth Gear

 Blending
 Bag House and Bag filter purging
 Air Blasters
 Coal bin purging
 Instrument air (solenoid valves)
 Fly ash unloading and conveying
 Packing Plant
 Pyrometer cooling
 TAD duct cooling
 Silo/bin aerations
 Coal firing
 RM/KM Airlift

Compressed air system view point

 Supply
 Transmission and Distribution
 Demand

5.6 Process parameter shall be measured without causing major disturbance to the
actual process stream. Some operational arrangements/ corrections/
adjustments, if desired so for process measurement, an intimation shall be raised
to the company at least one day in advance. However final decision pertaining to
the availability of the equipment for test, operational adjustments, time line etc.
will rest solely with company.

5.7 UTCL as far as possible will provide all the available design data, P&ID’s, GA
drawing, layout and other technical specifications to the bidder for calculation of
test result. However, in case, required data is missing or not available, then bidder
can use standard guidelines & curves for the sake of calculation of test result with
a-priori permission from UTCL.

5.9 The prospective bidder should submit following document along with the proposal
for review & approval of UTCL.

5.9.1 Proposed Study plan with timelines

5.9.2 Reference List of Cement plant and Thermal Power Plant where
comprehensive Study has been carried out.

5.9.3 List of test instrument with their accuracy class, calibration date &
certifying agency (Instrument accuracy should be as per relevant
ASME guidelines)

5.9.4 Copy of Report of Energy Study carried out at similar units as per ISO
standards with test schemes.

5.9.5 Studyor’s profile & work experience.

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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

6. Energy Study Report format:

The comprehensive Study report should contain all energy saving measures, which are
identified and quantified.

The following outlines a final report of an energy Study:

6.1 A table of contents

6.2 Executive Summary

6.3 Present level of energy efficiency of Process wise or Equipment wise and its design
data

6.4 Existing Installation/Arrangement/Scheme and operating procedure

6.5 Proposed solution of energy efficiency improvement for process wise and
equipment wise

6.6 Proposed Schematic arrangement with operating procedure and impact on the
system

6.7 Energy consumption after implementation of proposal process wise and equipment
wise

6.8 Cost investment of proposals (process wise and equipment wise)

6.9 Assumptions of Input data

6.10 Expected savings and payback with basis (process wise and equipment wise)

6.11 Bill of material of proposed investment

6.11 List of instruments and devices used during Study with accuracy level and
traceability of calibration status.

7. General Conditions:

7.1 The Energy Study executive agency may visit the site before submission of bid at
their own cost. No extra payment will be given for visits made by the representative
of the bidders to UTCL in connection with the proposed study.

7.2 The tentative period of shut down required for fixing of specialized instruments for
Study purpose if any to be indicated by the bidder in the tender.

7.3 Any repair and maintenance required after preliminary study to conduct final Study
study has to be clearly identified by the bidder and the same will be carried out by
UTCL.

7.4 Power, water and compressed air will be made available by UTCL free of charge
to carry out the proposed Study.

7.5 The list of instruments to be used by the bidder is to be submitted with proper
calibration certificate before commencement of measurement.

7.6 The Study report shall include references taken for technical inputs as papers,
journals, handbooks, publications etc.

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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

7.7 Soft copy (Each Unit) of draft Energy Study report to be delivered within 1 week of
field measurement study.

7.8 The energy Study executive agency shall be called to visit the plant for discussion
on implementation of recommendations. Charges regarding the same shall be
included in commercial proposal.

7.9 Three (3) copies (Each Unit) of the final Study report to be delivered in hard bound
duly signed by the Bidder in original.

7.10 Soft copy (Each Unit) of Final Energy Study report along with all soft
calculations/formula to be delivered.

8. General Conditions:

Bidder shall deploy all the required instruments required for doing comprehensive
compressed air system study. The instruments shall be calibrated and accuracy shall be as
per ISO 11011 standards

9. Training:

At the end of study, half day training shall be imparted to UTCL on Compressed air
system, its performance improvement, and latest trends in technology, best operational
practices, and comparison with benchmark figures.

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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

ANNEXURE-1A

Scope of Work for Compressed Air Energy Study

Sn Scope of Work for Energy Study- Cement + CPP

Remarks
1 Input Data Collection and Validation
 Collecting available inputs regarding compressed air systems from the
plant
 Assessment of complete plant compressed air distribution network
including the following:
a. Existing compressors, receivers, driers and its piping
arrangement to various sections and applications
b. Review the existing piping scheme with actual pipe routings or
making new schematic diagram as per existing arrangement
2 Measurement
 External and Internal leakage test with ultrasonic leak detectors for
complete compressed air network. Air leak Study will consist of following
scope of work:
a. Identification of location and size of leaks with Ultrasonic Meter
b. Picture and tagging of each leak for easy identification and
rectification
c. Quantifying the leaks in terms of leak rate (CFM) and energy cost
d. Submitting the report along with photographs of each leak
 Compressor efficiency study including
a. FAD and Volumetric Efficiency test
b. Specific Power Consumption study
c. Loading Unloading pattern
 Measuring flow, pressure and data logging section wise and application
wise, typical application includes
a. Pneumatic conveying/bulker unloading systems
b. Bag filter/ Baghouses purging
c. Air blasters
d. Blending/Storing Silos etc.
 Study of pipe lines for pressure drop optimization using portable pressure
data logging instrument and suggesting modifications (required if any) for
energy conservation
 Estimation of air consumption for artificial demand and Inappropriate end
uses
 Compressed air dew point analysis using advanced dew point sensors
 Compressed Air Quality Analysis using portable particle counters
 Measuring pressure drop across each treatment/filter equipment
 Fine tuning of drier operation
3 Demand Profiling
Classification of compressed air requirement application wise, operational
sequence wise
4 Risk Profiling

Classification of compressed air based on operational criticality

5 Recommendations on Energy Saving

Detailed reports on :
 Compressor, Dryer & Overall System Efficiency to confirm the Rated
Efficiency with the Actual Efficiency
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 Ultratech Cement Ltd Energy Study Date
Technical and Performance Technical Specification & Scope for
21st May 2019
Monitoring Cell Compressed Air System Energy Study

 Load Analysis including Full Load Time / Unload Time / Stop Time /
Number of Starts / Number of Load / Unload Cycles.
 Energy Analysis including Full Load Energy, Unload Energy, Total
Energy Consumption and Specific Power Ratio
 Cost Analysis including Full Load Costs, Unload Costs, Total Costs,
Cost Per M3 / CFM
 Air Delivery - Average Flow, Max Flow and Total Air Delivery
 Compressed Air Quality and Treatment Requirements
 Compressor Optimisation and Control Strategy
 Recommendation for energy efficient compressors, its drives and
controls
 Recommendation on HVAC of compressor rooms
 Pressure profile of the present piping system
 Air Treatment Requirements
 Storage Volume and Capacity Requirements

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