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S.No. Objective ProjectCapex
(Lac Rs.)
Saving
(Lac Rs. per
annum)
Payback
(years)Unit-1 Unit-2 Target Date Originator
Execution
Responsiblities
Performance
ValidatorRemarks Approval Status as on date
1Performance
ImprovementCFD analysis of SA,PA ,ID fan ducts 12 - - Completed During shut down 28-May-13 Process Completed
2 Quality Tube chemfering M/C 1 30-May-13 PCDC Completed
3 Reliability Pull cord Scheme Modification 2 - Electrical Electrical Completed
4 Energy SavingVFD require for all raymond mill
classifier Motor10 - Electrical Electrical Completed
5Auxiliary Power
Reduction
High efficiency DM transfer pump
installation (80% instead of current
design 50.7%)
0.6 0.4 1.4 Completed - 25.12.13 PCDC PCDC − Completed
6Auxiliary Power
Reduction
High efficiency portable water
transfer pump installation (80%
instead of current design 14.7%)
0.4 0.3 1.3 Completed - 25.12.13 Process PCDC − Completed
7 Plant Reliability Increasing the belt speeds of CHP 4.0 0.8 5.4 Pending - 30.11.2013 EEDC PCDC − Completed
8 RelaibilityOnline Vibration condition
monitoring system10 - - 20.11.2013 PCDC Instrumentation Completed.
9Performance
Improvement
LT installation in lime bunkers of
both units.15-May-13 Instrumentation Instrumentation Completed
10 Relaibility Lime Plant Shed . 66 30-Jun-13 PCDC PCDC Completed
11 Relaibility EH Oil Filtration System 13 15-Jun-13 PCDC PCDC Completed
12Reduce plant
down time.
Platforms for GMF for rod gate
operation3 15-Jun-13 PCDC Completed.
13 Platform ACC gear box platforms -Both units 4 30-Jul-13 MECH PCDC Completed
14Performance
improvement.
Bucket elevator modifcation in
Lime plant12 30-Jun-13 PCDC Completed
15Performance
improvement.Vent filter erection in Lime plant 4.6 10-Jun-13 PCDC Completed
16Vaccum
Improvement.Ejector erection at U-2. 30 0.7 30-Jul-13 Process PCDC process Completed
17 House keeping Fly ash silo Shed 5.5 30-Jun-13 PCDC Completed
18 Lime Plant Lime plant platform 2 15-Jun-13 PCDC Completed
19Auxiliary Power
Reduction
Installation of Additional VFD's (29
Nos)81 4.5 30-Jun-13 Instrumentation Instrumentation Completed.
20Performance
Improvement
Failure of Secondary super heater
coil in panel 7 & 8 in T-11 area, a
permanent solution is required to
avoid the same.
- - - 31-Aug-13 Mech Completed
21Performance
Improvement
Damage of Thermocouple in
Steam lines - 3 times thermocouple
got failed
- - - Pending Mech Completed
22Heat Rate
ImprovmentHeat Rate Improvment 1860 800 2.325 30-Aug-10 Mech Completed
23Heat Rate
Improvment
Steam leakage from LP front and
Rear gland.- Both turbine0.00 7.67 0.00 30-Aug-10 Mech Completed
24 ReliabilityModification in TG Chiller
Protection System2 Electrical Electrical Completed
25Predictive
maintainence
Tan Delta in Capacitence testing
kit procurement17 Electrical Electrical Completed
26Heat Rate
Improvment
Actual Heat Rate assesment of
Turbine- - - Completed Completed Process Process Completed
27 ReliabilityWater Spray Distrubution for
Switchyard Earthing System0.3 Completed Electrical Electrical Completed
28 Safety Replacement of Syenthetic Paint 5 Completed Electrical Electrical Completed
29House keeping /
BeautificationWind mill generator - - - - - Completed Electrical Electrical Completed
30 House keeping Bed material storage facility. 3 - - - - Process Completed.
31Performance
Improvement
Serious Measurement Error in Unit 1
& 2 Extraction 4, 5 & 6th Steam
temp. All are showing less value.
15 97.2 0.9 10-Oct-13 Pending Completed Instrumentation Instrumentation Completed.
32Heat Rate
Improvment
Installation of thermocouples in
high energy drains lines to identify
and monitor passing on continuous
basis.
4.5 1.3 3.1 10 - - Instrumentation Instrumentation Completed.
33Auxiliary Power
Reduction
High efficiency DTP installation
(80% instead of current design
65.7%)
6.0 3.2 1.9 Not feasible EEDC NEW − − Completed.
Project Completed
SHREE CEMENT LTD.
SHREE MEGA POWER (2x150 MW)
LIST OF INTERNAL PROJECT
Running Job Status
Page 1 of 5
S.No. Objective ProjectCapex
(Lac Rs.)
Saving
(Lac Rs. per
annum)
Payback
(years)Unit-1 Unit-2 Target Date Originator
Execution
Responsiblities
Performance
ValidatorRemarks Approval Status as on date
34Heat Rate
Improvment
Finalisation of Installation of FLUE
GAS Heat Recovery system-
Additional APH installations in
boilers/ Additional Heat pipe APH
− 180 − 30-Jul-13 EEDC − − Completed.
35Heat Rate
Improvment
Bed material filling from Bed ash
silo to bunker with Pneumatic
system.
30 13.2 2.2 30-Apr-13 PCDC Completed.
36 Quality Welding inspection gauges 1 30-Jun-13 PCDC Completed.
37 QualityAccostic leak detector for field
testing.5 30-Jun-13 PCDC Completed.
38 Quality Robot for welding (EMAT) 4 30-Apr-13 PCDC Completed.
39 QualityUltrasonic Flaw Detector (Phased
Array)40 30-Apr-13 PCDC Completed.
40 House keepingShed for scaffolding storage at 9.0
mtr.20 30-Jun-13 PCDC Completed.
41 Plant Reliability Nitrogen flooding system 2.8 - 0.0 Completed Completed - EEDC PCDC EEDC - Done Completed
42 Security Bondary wall fencing work 6.2 - - - PCDC PCDC Done Completed
43 Maintenance. Boiler elevator - - - - - - PCDC PCDC Completed
44 Dummy shaft for TG centering 7 60 0.12 - - - Mech Mech Completed
45To improve
boiler reliability
Replacement of water wall
panel in cick off zone to
avoid erosion as well as
break down of boiler U#5
18 4x18 MW Shut needed Complete
46
Blow down
water
recovery in
GPP boiler
Collection of blow down
water and used in CT make
up after sand filter
3 1.7 WTP Complete
47 Reliability
Cooling water make up
piping replacement with
HDPE from WTP to GPP 2,3&4
5.5 GPP Work completed.
48Safety and
housekeeping
instaalation of rack and
pinion type lift for AQC1 & 2
boiler
36.5 AQC 1, 2 25.01.2014Supllier will dispatch mat for
AQC 2 till jan 2014ED Total job completed.
49Reliability and
improvement
Replacement of boiler
section 1 and 2 subheaders14.1 105 PH1 WHRB 30.01.2014
M/s s r engg will moblize site
for fab and rec by 31.12.2014contract cell Total job completed.
50Auxiliary Power
Reduction
High efficiency lime mill
blower fan installation (80%
instead of current design
70%)
5 1.5 3.37 - - 30.03.2014 EEDC MechFlaktwood has sent scheme which is
under technical review.
24 Commissioning HVAC PLC commissioning - TG 0 Completed Completed Instrument Completed
38 ReliabilityInstallation of 3 Nos. of 6 KVA
UPS at each floor of admin0 Completed Instrument Completed
41Performance
ImprovementNew Bag Filter for Vaccum 23 Completed 23.03.2014 PCDC Completed
22 Cost SavingMono rail crane for TG
overhauling time reduction15 60 0.25 - - - Mech Mech On hold
38Safety
Awareness
Amplifier and speaker installation
at Main Gate/ Surroundings0.25 Completed 30.05.2014 Instrument
Amplifier and 1 Nos. of speaker
installed as per requirement.
17 Reliability
HT cables for tie lines to
increase the load to cement
plant from 26 MW to 34 MW
100 36 2.78 - - - Electrical Electrical On hold
48
Energy
saving/Profitibilit
y
Capacity enhacement between
SMP to cement plant105 3.5 Hold _
Mr.Bhavesh
Patel/Mr.Rakesh
Jain
Electrical On hold
Page 2 of 5
Date: 03 May 14
SN Objective ProjectCapex
(Lac Rs.)
Saving
(Lac Rs.
per
annum)
Payback
(years)
UNIT OF
EXECUTIONTarget Date Execution Responsiblities Remarks Status as on date
1
Reliability
/generation
improvement
Replacement of AQC inlet duct & damper. 131 66 1.98Praposal send for
approval
2Capacity
inhencement
GPP 2 ACC additional four cell installation for vacuum
improvement and TG SSC improval800 257 3.1 GP2 ACC
Praposal send for
approval
Total scheme is ready with offer and approval. Final call
has to be taken to proceed.
3 Reliability in ACCGPP3 fan blades replacement with new materials and
design22 5.04 4.37 GP3 ACC Completed
4 False Air reductionNew expansion bellow installation with header
modification in PH 3 boiler12 11 PH4
15 Days
Shutdown
needed
Mechanical completedAfter calculation of saving modification to be done in Blr
# 4 to 7
5 Reliability Stand by DC supply Source from GPP 3 to GPP -4 0.5GPP 3 TO GPP
425/7/14 Electrical Work is under progress Cable laying done.
6 Plant Reliability Strengthing of Earthing system in GPP -4 1 GPP 4 16/9/14 Electrical Work is under progress 20% completed.
7 safety HT Insulation Coating in GPP -4 , 4 GPP 4 19/11/14 Electrical After GPP # 4 shutdown.
8 Reliability Installation of Lighting Energy saver in GPP-4 1.6 1.03 1.55 GPP 4 15/10/2014 Electrical Approved Material indented
9For better
Communication PA system installation in GPP#4 8 GPP-4 30-9-14 GPP INSTT PO placed for required Items
10 Plant Reliability Gas Flow meter Installation in AQC O/L Duct 6.2GPP-2, AQC
Boiler30-10-14 GPP INSTT PO placed for required Items
11 Plant Reliability, New Flow meter ( Nozzle ) installation in AQC -8 to
GPP-4 steam line2.0 GPP-3 30-7-14 GPP INSTT Material received.
12 Plant Reliability, New Flow meter ( Nozzle ) installation in AQC -6 to
GPP-4 steam line2.0 GPP-3 30-7-14 GPP INSTT Material received.
13
Better Controlling
& System
Reliability
Installation of Control,vale in Exhaust Spray line in
place of SOV4 GPP-2/3 GPP INSTT
Material procurement, E
& C to be doneApproval Required
14
Better Controlling
& System
Reliability
Installation of 2 nos DPP level transmitter as per 2/3
Logic in DPP5 GPP-2/3 E & C to be done
Material Received But
approval Required for
issue the material
TG Shut required
15
Better monitoring
& System
Reliability
Installation of Draft Tx In AQC boiler Eco hopper from
4 to 8 2 GPP-2/3 E & C to be done
Material Received But
approval Required for
issue the material
SHREE CEMENT LTD
SHREE POWER PLANT
LIST OF INTERNAL PROJECT
Running Job Status
GPP RAS
Page 3 of 5
SN Objective ProjectCapex
(Lac Rs.)
Saving
(Lac Rs.
per
annum)
Payback
(years)
UNIT OF
EXECUTIONTarget Date Execution Responsiblities Remarks Status as on date
16
Better Controlling
& System
Reliability
8 nos VND Installation in AQC-3 to AQC-7 boilers. 20 GPP-2/3 30.10.14
Material
procurement, E & C
to be done
Material to be order
17
Better Controlling
& System
Reliability
2 nos VND Installation in AQC-8 5 GPP-3 30.10.14
Material
procurement, E & C
to be done
Material to be order
18Generation cost
reduction
ACC additional 2 cells/ turbine to improve vacuum and
HR for both turbine800 242 3.31 2x50MW
Praposal send for
approval
19
Heat saving &
operation
requirement
Replacement of BAC of boiler 9 and 10 38.8 12.3 2x50MW 31-05-14 Mechanical Recd.the materialBoiler #9 cooler replaced and B#10 , one cooler
replaced, another to be done in shutdown
20 Heat rate Reduction pr drop between boiler drum and SH by
increasing the size of saturated steam links23.1 13.7 CPP Shut needed Mechanical Piping material ordered Material received shutdown required
21HR and as well as
reliabilityReplacement of 1 to 3rd stage diaphram in TG 7 and 8
FOC
Supply
by QJPS
2x50MW Shut needed Mechanical FOC basisDiaphragm dispatched from China to be replace in
Overhauling
22System Reliability
Preservation of TG#3,4,5 and 6 ACC with injection of
Compressed air4x18 MW completed Process Complete
23
Cost Optimisation
Re-use of AFBC Bed Ash in AFBC Boiler Light up by
sieving it to required size resulting in saving of Approx
8 to 10 MT of New Bed Material per light up
CPPDuring Boiler
Start-upProcess
planning to procure AFBC Bed ash from other plants
which are using Bitumnous fuel.
24System Reliability
Provision of Sample collection point in Super Heater
for parameter testing during Boiler Prreservation4 x 18 MW completed Process/Mech Material under procurement
25Heat Saving
Insulation of Condensate return line with ACC A Frame
resulting in saving of approx 0.5 DEG C1 0.4 2x50MW completed Process Insulation contractor finalised and order released
26System Reliability
Refractory dry out of New Bed Ash Cooler refractory
by in house Burner arrangment 2x50MW completed Process
Completed in Boiler#9 Bed Ash Cooler and planning for
B#10 Bed Ash Coolers
27
System Reliability/
Performance
improvement
ACC Fins cleaning from inside with use of Fire Hydrant
System2x50MW completed Process
Provision of Fire Hydrant
point in each cellCompleted one time in both ACC.
28 Cost Optimisation
Generation of Gypsum (Fly Ash) from One CFBC by
consuming Raw Mill Powder and LCV from other by
CFBC Boiler for optimised cost recovery
2x50MW Process Under review
29 System reliabilityStart up vent control valve to be installed in AFBC
boiler 5.5 CPP 30.07.2014 Instrument CV received hand wheel to be receive.
30 System reliabilityGland Seal Mechanical C/V to be replaced with
Pneumatic C/V in TG-7/TG-88.68 CPP 15.07.2014 Instrument
In TG-8 Control valve installed after eastablishing
opeartion installation will be done in TG-7
31 Energy Saving Low DP control valve (100 %)to be install in blr-9,10 5 1.19 CPP 30.05.2014 Instrument Complete
32System Reliability
& AutomationRO-1 Automation to be done 3 2x50 WTP 15.07.2014 Instrument PO released for Valves
33System
effectiveness3 No. Package AC to be installed in HT VFD room 4.37 2X50MW CPP 30.07.14 Instrument
Work order released ,
Ducting work 50 %
completed, Shifting &
Erection of PAC to be
done
0.3
34System Reliability
& AutomationControl Valve installation in RO-I reject line 1.5 2x50 MW WTP 15.07.14 Instrument Material Received , 0.5
35System Reliability
& AutomationControl Valve installation in RO-I reject line 1.5 4x18 MW WTP 15.07.14 Instrument
Material Received ,
Approval required 0.5
36System
RequirementDew Point transmitter to be install in unit -7 & 8 Drier 1.1 2x50 MW CPP 05.07.14 Instrument Material to be procured 0.1
CPP RAS
Page 4 of 5
SN Objective ProjectCapex
(Lac Rs.)
Saving
(Lac Rs.
per
annum)
Payback
(years)
UNIT OF
EXECUTIONTarget Date Execution Responsiblities Remarks Status as on date
37 ImprovementApplication of Photo Glow Paint , HT LT insulation
coating , stanvac Stanfloor material in 2x50 MW MCC10.6 15/7/2014 Electrical
All the material
received at sitealmost 90 % of work completed.
38 Reliability Aegis Ring to be fitted in all HT motors 1.4 10-Oct-14 Electrical
2 nos of Aegis ring had
been ordered but
material not received at
site.
PO placed
39 Improvement Motor Testing Pad 9After GPP # 5
erectionElectrical
Material received at
site.
40 Reliability 2 Nos Battery Replaced in U 7&8 0.1 15/9/2014 Electrical
Material had been
ordered but not
received the material .
PO placed
41 Reliability Change Rapper Coil in ESP -3 for proper lifting. 3 Electrical Concern to 4x18 MW Material receieved at site but job hold due to 4x18 under
shutdown.
42 ImprovementUpgradation of Siemens PLC for Synchronization of U
9& 1025/8/2014 Electrical
43 ReliabilityDC Lighting arrangemant in 220 KV Switchyard
Control room.0.35 15/7/2014 Electrical Work is under progress 20 % work completed
44 ReliabilityReplacement of Disc insulator at Tower 62 & Tower
97.1 Electrical
material is ready but
Shutdown RequiredWO placed
45 Reliability
Commissioning & Reshufling of P127 , 7SR12 & P14NB
relays in 11KV Incomers at 220 KV SWD ,35 MVA
Trafo& O/G Feeders respectively as per
recoomendation of Power Consultant
2 25/8/14 Electrical Material received at site 90 % work completed.
46 safety HT Insulation Coating 132 KV U 9& 10 Load Centre 2.5 Electrical Approval to be taken.
47Enegy Saving &
safety
Firex FM 71 material is being used to block the cable
trays opening enteries to prevent air ingressment in
ACC cells.
1.24 25/07/14 Electricalmaterial received at
site.40% work completd.
47
GPP steam
recovery in
Dearator 8
GPP excess steam utilisation in dearator 1.5 1.3 2x50MW 5/7/2014
48
Utilization of reject
water in mines for
road spray
Shifting of reject water by pipe line to avoid tanker
engagement[ WTP to Mines]3 1.7 WTP 15-07-14
Material indented .Option for water diversion for zypsum
plant is also in line.
49Safety and
reliabilityAll PH boiler RAV (HP and LP) plateform sealing work 1 GPP 31-07-14 Mechanical Completed in 3,6,7and in4,5 under progress
50 Cost optimization
132 and 220 KV line rerouting at Bangur gram ,Mandi
chauraha & Khera gate for railway line laying from
Bangur gram to ras site.
400 RAS 15/10/14 ElectricalMaterial ordered 60 %
material received
CPP+GPP RAS
Page 5 of 5
