⁠Integrated Cement Plant Operation & Maintenance Solutions

End-to-End O&M for Higher Uptime, Lower Cost, Safer Plants

From quarry to clinker and cement grinding, we operate and maintain your plant like our own—optimizing throughput, energy, and reliability while meeting every safety and environmental standard.

Scope of Services

End-to-end O&M for integrated cement plants—higher uptime, lower energy, safer operations. Operations, preventive & predictive maintenance, shutdowns, reliability, and compliance.

Operations (24×7)

Kiln & calciner, cooler, raw & cement mills, VRM/ball mills, preheater, baghouse/ESP, material handling, packing & dispatch, utilities (compressors, CHP, WHRS, CPP).

Preventive & Predictive Maintenance

Planned maintenance, lubrication management, vibration analysis, thermal imaging, alignment & balancing, condition monitoring (bearing, gearbox, kiln shell).

Shutdowns & Turnarounds

Detailed job cards, critical path planning, spares kitting, contractor management, QA/QC, commissioning & ramp-up to nameplate capacity.

Reliability Engineering

RCM, FMEA, bad-actor elimination, RCA with CAPA tracking, MTBF/MTTR improvement, spares criticality analysis.

our executed and current projects

ACC ADANI CEMENT

KYMORE CEMENT WORKS:

O&M of CPP CHP & Coal CraneScope inclusive of:

1.⁠ ⁠To carryout Operation & Maintenance of the CPP CHP & Coal cranes.
2.⁠ ⁠Round the clock deputation of manpower for trouble-free operation & maintenance of complete system.
3.⁠ ⁠Preventive, Pro-active & breakdown maintenance.
4.⁠ ⁠Carry out all minor & major shutdown repair & maintenance.
5.⁠ ⁠WBI, TLM, maintenance log and equipment history card to be maintained.
6.⁠ ⁠Housekeeping to be maintained at CHP & coal crane area.
7.⁠ ⁠To provide the information on the equipment to ACC on day-to-day basis and write important notes in shift logbook and follow up action for the previous shift/day
8.⁠ ⁠To maintain sub-store of CHP as per AWMS standard and keep track of Inventory & inform concerned ACC HOD/Engineer for procurement of spares & consumables every week.
9.⁠ ⁠Area housekeeping & equipment cleaning to be maintained
14.⁠ ⁠To ensure uninterrupted coal supply & availability of plant.

ACC ADANI CEMENT

1.⁠ ⁠AMETHA CEMENT WORKS
2.⁠ ⁠KYMORE CEMENT WORKS
3.⁠ ⁠⁠TIKARIA CEMENT WORKS

Areas Covered

Health & Safety
Housekeeping
Shift Operation
Stacker–Reclaimer Operations
Circuit Attendants
Supervisors, etc.

Objective

To achieve sustainable plant operation and reliability, ensuring safety and good housekeeping at the workplace.

Battery Limits

LS crushing to Cement Grinding, including Wagon Tippler operations and Clinker loading.

Maintenance Scope

Maintenance of the following equipment is included in the scope:

Crusher Section
Wagon Tippler & BCFC Fly Ash Circuit
Clinker Handling
Stacker and Reclaimer
Roller Press
Coal Mill
Kiln and Cooler
Cement Mill
Utility/Workshop
LMV Operation & Maintenance
Water Supply and Compressor Operation

Equipment-wise Maintenance Details

1. Crusher

Complete overhauling of the entire crusher circuit, including: Blow bar replacement Chute liner replacement Belt and pulley replacement Conveyor belt jointing/replacement Pulley bearing replacement Apron plate replacement Chain link jointing Drive alignment Bull gear/pinion replacement & matching Chute patch-up Crusher rotor replacement Wobbler shaft replacement Hydraulic circuit overhauling/replacement V-belt replacement and alignment Belt scrapers and side skirt replacement Any other machinery not mentioned but present or added later
2. Raw Mill Roller Press and Feeding Circuit

Maintenance includes: Raw mill weigh feeders Feed chutes Magnetic separators Belt conveyors Diverting gates Roller press circuit Separator inspection & bearing replacement Elevator chain and bucket replacement Belt jointing Blower replacement and bearing replacement Rotary feeder replacement Air slide cloth replacement Pulley replacement Patch work V-separator blades repair/replacement Hydraulic pump replacement Filter replacement Nitrogen charging Accumulator and bladder replacement Roller and roller bearing replacement Thrust bearing replacement Any additional machinery in the circuit
3. Coal & Cement VRM and Feeding Circuit

Includes routine and major maintenance of: Mill feeding conveyors and chutes Weigh feeders Magnetic separators Diverting gates Rotary feeders Screw conveyors Slide gates Coal firing systems Fine coal bin CO₂ & purging system Mill pull rod replacement/tightening Hydraulic cylinder seal replacement Roller replacement Air slide cloth replacement Elevator inspection Friction liner replacement Rubber pads replacement Bucket replacement Bag house rotary feeders Reject & product elevators Vibro feeders Hydraulic pump & coupling replacement Nitrogen charging Accumulator replacement Any other machinery not mentioned
4. Raw Meal Silo, Preheater, Kiln & Cooler

Includes maintenance of: Raw meal silo internal extraction system Air slides and gates Elevators PH feed air slides Pneumatic gates & rotary feeders PH cyclone flaps Diverting gates Dispersion plates Dip tubes Pyroredox TAD dampers Cyclone downpipes Kiln inlet seal & air blasters Kiln girth gear, drive gearboxes Torsion shaft, auxiliary drive Support rollers, tyres, thrust rollers Outlet seals Cooler hydraulic line valves Cooler grate plates Drive shafts & wheel replacement Bearing replacement Taper block replacement Water nozzle replacement Clinker roll crusher rolls DBC roller replacement Bucket replacement Alignment Double flap valve maintenance Chute repair Any additional equipment in circuit
5. Stacker–Reclaimer (Limestone, Coal, Gypsum & Corrective)

Scope includes: Conveyor belt & pulley replacement Pulley bearing replacement Chute and liner replacement Bucket replacement Reclaimer chain link replacement Wheel replacement Drive alignment Wire rope replacement Harrow slicing rod replacement Hydraulic pump replacement Minor patch work Any other equipment in circuit
6. Clinker Feeding Circuit

Includes: Clinker silo bottom system DBC roller replacement Bucket replacement Gearbox and bearing maintenance Major belt replacement in clinker feeding circuit Any other related machinery
7. BCFC Fly Ash System

Maintenance of: Wagon placer Rails Unloader Wagon shifter Material transfer system Elevators Air slides Compressors Blowers Silo extraction Bulker loading points Complete BCFC circuit
8. Coal, Corrective & Wagon Tippler

Includes: Major belt and drive replacement Routine maintenance support to material handling vendor Additional machinery as required

All Other Information

Utility

Maintenance of: Compressors for plant operation Fly ash unloading systems Crusher to cement mill packing plant Pump house Water treatment plant (excluding OEM AMC items) Support in shutdown jobs, moderate fabrication, erection, chute & platform repairs, ensuring safe circuit operation. Workers must be capable of performing shutdown jobs across all plant sections.
LMV Operation & Maintenance

Operators should: Identify and rectify routine LMV issues (starting, ignition, etc.) Perform daily inspections as per checklist Report abnormalities immediately Follow vehicle safety guidelines Operate Tata Yodha, pickup van, Farana crane, forklift, bobcat, etc. Ensure daily and weekly cleaning of machines
Water Supply and Compressor Operation

Multiskilled operators should: Maintain water pumps (gland packing, pipeline joints, priming, bearing replacement) Maintain compressors (filter, separator, cooler cleaning/replacement, etc.)
Float Assembly Preparation (Workshop)

Team must be capable of: Handling high-bore bearings and gearbox float adjustment Equipment assembly and fabrication Gearbox, pump, fan, blower, separator barrel assembly Brass liner matching Precision fabrication (plate & structural steel) Fan and drive alignment using dial gauge Welding (SS plate cutting, pug cutting, plasma cutting, lancing, pipe welding, brazing) Rigging and heavy lifting (with safety awareness) Working on hydraulic press for assembly/dismantling
Lubrication

Includes: Lubrication as per schedule with Maintenance Engineer Managing lubrication cell Lubricant top-up in gearboxes, hydraulics, bearings Reporting missing grease nipples/hoses or abnormalities Sump cleaning, oil replacement & filtration Installing offline filter machines Lubricant sample collection Cleaning mechanical breathers & replacing desiccant breathers Ensuring cleanliness of bearing housings and lubrication points
Material Binning & Stores Support

Tasks include: Unloading of materials Material receipt as per guidelines Preparing GRNs Binning & tagging Issuing materials Regular physical inventory checks Avoiding shortages; penalties for negative stock Preparing return slips for rejected materials Tracking refurbishment jobs Sending bills/invoices to scan center within 3 days Maintaining housekeeping in stores Following storage guidelines
Maintenance of Rail Tracks (7 km)

Includes: a. Complete track maintenance, including leveling using jacks and compaction with ballast b. Clearing bushes and maintaining cleanliness c. Maintaining drainage to avoid water accumulation d. Keeping tracks ready for wagon placement per Indian Railways standards

Sl. No	Parameters	Target Values	KPI
1	Belt, Crusher & Stacker availability	Net Availability Index (NAI)	≥ 90%
2	Material size after crusher	Dimensions of crushed product	90% ≤ 75mm
3	Housekeeping	100% upkeep across plant area	Full compliance as per 5S and AWMS rules

Sl. No	Parameters	KPI	Target Values
Clinker loading circuit
1	Availability of circuit	Net Availability Index (NAI)	≥90%
2	Housekeeping	100% housekeeping across plant area	Full compliance as per 5S and AWMS rules

S. No	Parameters	KPI
SLAs for Cement Production (Mill)
1	Cement Mill Output	PRI ≥ 90%
2	Total grinding energy	≤ 33 KWh/T of cement
3	Net Availability of mill	NAI ≥ 95%
4	Mill reliability	MTBF ≥ 44 Hrs
5	Maintenance spares & goods	≤ Rs. 0.4 crore per year
6	CEMS availability	≥ 95%
7	Lubrication controls	Oil usage ratio ≤ 0.1
8	Environment compliance	Meet all EC/CTO rules
9	Pollution control upkeep	Stack output ≤ 20 mg/NM3
10	Housekeeping	Full compliance with 5S & AWMS rules

Sl. No	Parameters	Target Values	KPI
1	Material size after Corrective Crusher	Dimensions of crushed product	90% ≤ 50mm; Max 80mm
2	Tippler, Belt, crusher and Stacker availability	Net Availability Index (NAI)	≥90%
3	Housekeeping	100% upkeep around plant area	Full compliance as per 5S and AWMS rules

S. No	Parameters	KPI
SLAs for Clinker Production (Kiln)
1	Kiln Output	PRI ≥ 90%
2	Thermal Energy Consumption	≤ 697 KWh/T
3	Electrical Energy Consumption	≤ 53 KWh/T
4	Net Availability of Kiln	NAI ≥ 95%
5	Kiln Reliability	MTBF ≥ 231 Hrs
6	Maintenance spares & goods	≤ Rs. 2.79 crore per year
7	CEMS availability	≥ 95%
8	Lubrication management	Oil usage ratio ≤ 0.1
9	Environment compliance	Meet all EC/CTO rules
10	Pollution control upkeep	Stack output ≤ 20 mg/NM3
11	Housekeeping	Full compliance as per 5S & AWMS rules

S. No	Parameters	KPI
SLAs for Cement Production (Mill)
1	Cement Mill Output	PRI ≥ 90%
2	Total grinding energy	≤ 33 KWh/T of cement
3	Net Availability of mill	NAI ≥ 95%
4	Mill reliability	MTBF ≥ 44 Hrs
5	Maintenance spares & goods	≤ Rs. 0.4 crore per year
6	CEMS availability	≥ 95%
7	Lubrication controls	Oil usage ratio ≤ 0.1
8	Environment compliance	Meet all EC/CTO rules
9	Pollution control upkeep	Stack output ≤ 20 mg/NM3
10	Housekeeping	Full compliance as per 5S & AWMS rules

S. No	Parameters	KPI	Target Values
Other SLA Clauses – Ametha Cement Works
1	Safety	Achieve LTIFR target of the plant	Zero harm
1	Coal/petcoke unloading per rake (N Box)	Rake should unload in free time	≤ 5 hrs
2	Gypsum unloading per rake (N Box)	Rake should unload in free time	≤ 5 hrs
3	Dead freight / overweight penalties	Overweight freight should not be there; penalty recovered from vendor	≤ 1%
4	Demurrage due to slow loading / no availability of circuit	Demurrage applicable as per Railways	Zero
5	Derailment of wagons / engine	Demurrage as claimed by Railways	Zero
6	Demurrage due to poor rail track, switch issues, coordination issues	Demurrage as claimed by Railways	Zero

Our Operating Model

Discover & Baseline → Stabilize & Secure → Optimize & Transform

30-Day Baseline: Asset register, criticality map, P&IDs, PM plans, safety gap assessment, KPIs baseline.
90-Day Stabilization: Close safety criticals, backlog burn-down, spares rationalization, priority RCAs, early energy wins.
Run-Phase: Calendarized PM, predictive routes, weekly R&M dashboards, process optimization loops.
Transform: Advanced analytics, reliability projects, debottlenecking, WHRS/Alt-fuel enablement, digital twins (where applicable).

How soon can you mobilize?

Usually within 2–4 weeks post-award, depending on scope and site readiness.
Do you work with our existing OEMs/AMCs?

Yes. We coordinate with OEMs, integrate warranties, and rationalize overlapping scopes.
Can you adopt our CMMS?

Yes. We can run your CMMS or deploy one; we’ll migrate asset data and PM plans.
How are SLAs enforced?

KPIs are reviewed in monthly governance; gain-share/penalties can be built into the contract.