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Two Days’ Plant Level Training and Capacity Building Program at JK Lakshmi Cement, Sirohi

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Date(s) - 29/05/2017 - 30/05/2017
All Day



Bureau of Energy Efficiency (BEE) in partnership with Institute of Industrial Productivity (IIP) has established a Knowledge Exchange Platform (KEP) to promote transfer and uptake of best practices and technologies in industries covered under the Perform Achieve and Trade (PAT) scheme. As part of its mandate, KEP has organized various sector level best practice exchange workshop, technology exhibitions, policy discussions, exchange visits, communication and other outreach activities, which has been helping the industries in meeting their objectives of achieving energy efficiency.

As PAT is moving into second and subsequent cycles of implementation, the targets for energy efficiency at industry level are expected to become challenging, more so, for the cement sector. KEP has always tried to improvise its strategy to meet the continuously changing needs and requirements of the industry with regard to achieving energy efficiency and with this mandate KEP is providing value added services for training and capacity building of the industries under the SPARC model (Service Package for Advancing Resource Conservation). The whole idea behind organizing such training programs is that, with the enhanced target under the PAT scheme in each cycle the industry will need much more customized and hand holding support to identify their plant specific opportunities for energy efficiency. The two days training and capacity building workshop was organized at JK Lakshmi Cement Limited, Sirohi plant on 29th and 30th May, 2017 which was attended by 23 officials working in mechanical, electrical, instrument, mining and process departments .

The workshop was organized to achieve the following objectives:

1. To create awareness in the plant personnel at operational level on various provisions of PAT scheme, international standards and energy management approaches such as ISO 50001, Total energy management approaches etc. – the challenges and opportunities
2. Identify and assess plant specific opportunities and potential for achieving energy efficiency under PAT scheme (2nd and subsequent cycles)
3. New, cutting edge and innovative technologies on Thermal & Electrical efficiency suitable for the specific to the plant operations.
4. Build the capacity of the plant personnel to handle the operational and technical aspects of implementing new energy efficient technologies and approaches.

The workshop was inaugurated by Shri B.B. Wadhawan, Vice president (Engineering), JK Lakshmi Cement Limited, Sirohi. In his inaugural address, Shri Wadhawan advised the plant engineers that they should not be complacent of the fact that the plant has already implemented energy saving measures and achieved the desired energy efficiency level. This is one of the threats under SWOT analysis and should try their best not to get affected by this factor. He felt that the organization of Capacity Building Program followed by 3 days Small Group Activity Program by KEP will assist the industry in achieving the targets under PAT-2 cycle.

Shri K.K. Chakarvarti, Expert Consultant, and Shri Nagesh Kumar, Expert Consultant, while giving the introduction to the workshop, in the inaugural session explained the participants about the importance and need for capacity building of plant engineers.

Before beginning the technical sessions of the workshop, Shri K.K. Singh, Sr. Engineer (Process), JK Lakshmi Cement Limited, provided an overview on the design and operation of different processes and utilities in the plant so that the participants could keep the plant specifications and needs in perspective while understanding and relating with the suggestions/ opportunities identified in the technical sessions.

The two day workshop was divided into 8 technical sessions carefully designed to meet the plant specific needs. The first technical session was focused on providing an overview to the participants on energy management and approaches and how they relate with the PAT scheme. It covered various EnMS approaches like ISO 50001, standards, energy audits etc., which could help industries not just achieve some of the international standards and continuously improve their energy performance but also meet their PAT targets.

The 2nd technical session was focused on Fuel and combustion systems covering the aspects of optimizing these operations in Cement Kiln as well as achieving heat balance of kiln. The 3rd session covered electrical systems specifically focused on transformers, how to avoid distribution loss and power factor improvement. Electrical motor efficiency is increasingly becoming important for enhancing the overall energy performance of any plant. BEE is also advocating the use of energy efficient motors viz. IE3, IE4. The session therefore focused on energy efficiency issues and conservation aspects with regard to electrical motors. The resource persons (Shri Chakarvarti and Shri Nagesh Kumar) illustrated this through various case studies and examples.

The fourth technical session on Day 1 was focused on energy efficiency of utility systems particularly the pumps, pumping system and VFDs. In this session also the participants were provided practical understanding of these aspects through case studies.


Participants during the 2 Days’ Plant Level Training & Capacity Building workshop

The second day was designed to cover four technical sessions. The first and second technical session was focused on enhancing electrical savings in compressors and compressed air systems which was illustrated through both technical options as well as how they can be implemented through practical examples. The third technical session covered the energy efficiency improvement in electrical systems such as fan systems and cooling towers. The potential for energy savings in these utility areas was explained through case studies. The last technical session covered the best practices and case studies of successful applications (avoiding the pressure drops in dampers fitted in fans which are already provided with VFDs, restricting the false air infiltration in preheaters, optimizing the operation of coal firing blowers, increasing the efficiency of preheater top cyclone, reducing the pressure drop in preheater down comers etc.) and how the power can be saved, explained through relevant case studies. Detailed discussions were held with the participants to explain how these best practices can be implemented in plant’s context.

The workshop was concluded with a feedback session where the participants were requested to provide their inputs/suggestion for improving and enhancing the effectiveness of such in plant training and capacity building programs.

KEP is always open to modification/changes in its strategies and approaches based on the feedback from stakeholders, so that all the activities/events being organized under KEP are responsive to industry needs and are customized to specific requirements. In this regard, KEP also sought a structured feedback from the energy professionals of the plant in which 82 % of the respondents mentioned that this training program helped in learning about one or more specific ideas that they will be able to implement in the area of energy efficiency and new approaches to energy management. 86% respondents felt that they have acquired new and/or advanced skills/ knowledge on energy efficiency and the training program has helped in building their capacities for better able to build my capacities for better decisions/actions at the plant level.

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