Today, for a cement plant, consistently producing high-quality cement is just not
enough as the challenge lies in achieving continual operational excellence in terms
of reducing input cost, usage of fewer resources and meeting stringent environmental
regulations. All of these cannot be achieved by only enhancing process control.
It actually requires technologically advanced and innovative solutions.
The solutions that the Control & Automation's (C&A) business unit of L&T Electrical
& Automation offers and helps you effectively meet the challenges are built on over
four decades of experience in the cement industry. We offer the right blend of advanced
control technology, optimal sizing of electrical equipment and seamless data connectivity
from field instruments to the board-room , which helps users in taking faster decisions
/ actions to increase overall plant efficiency.
From mines to packing plant operations, our subject matter experts with
domain knowledge of control and engineering processes play a front role in providing
seamless integrated solutions.
These are cost effective solutions that improve the reliability, availability, maintainability
and safety of operations. Our services provide you with the opportunities to maximize
production uptime and lower the life cycle cost. We engage with your project team
upfront during pre-bid stage to facilitate the basic engineering and critical specifications.
It helps us to deliver total solutions on-time with minimum cost of ownership.
Our end-to-end offerings for Cement Plant include: Integrated Electrical
& Automation solution for Cement Plants, Grinding Units, Captive Power Plants and
Waste Heat Recovery Systems.
We undertake turnkey contracts for Design/Engineering, Procurement, Erection and
Commissioning of complete Electrical and Automation system for cement plants. Our
Integrated solutions include Switchyard, Power Distribution Transformers, MV/LV
Switchboards, PF Correction Equipment, MV/LV AC Drives, Plant Instrumentation, DCS
, i Visionmax -SCADA, Plant Surveillance System, Lab Automation,
IT Backbone and Plant Information System.
Our service includes Switchyard Design, Fault Level Calculation, Preparation of
Relay Co-ordination Chart, Cable/Core Schedule, Instrument Sheets, Loop Diagrams,
Earthing Design and Automation Network. We also provide services such as Erection
of Equipment, Statutory Approvals, Integrated Trials and O&M.
Integrated Solution for long conveyer system
Today, coastline plants & mines are planned and designed to handle bulk material
economically and reliably. Therefore, operators are investing in bulk material handling
system which includes conveying, stacking and wagon loading. Each facility has its
own cargo handling capacity and requirement and it, therefore, requires customised
solution to avoid material spillage, equipment damage and dust emission. Our electrical
and automation solution plays a vital role in improving operation speed, efficiency
and safety of these systems. C&A provides seamlessly integrated E, C&I system for
a facility comprising conveyors, stacker reclaimer, storage yard / silos, truck
or wagon loading / unloading including wagon tipplers. Our tailor-made solution
optimizes the overall performance, reliability and energy efficiency.
Our offering:
- Instrumentation comprising Pull Cord/Belt Sway switches, Belt Weighing system, Belt
monitoring system, Silo level monitoring, Condition Monitoring systems etc.
- Power Distribution system including power & distribution transformers, MV and LV
power distribution Motors and Variable Speed Drives for long conveyor control Automation
system with redundancy at various level servers, data network, controllers, power
supplies and IO network for maximum plant availability
- Automatic operation and visualisation of entire facility from Control Room using
SCADA platform
- Lifecycle Services including system upgrades and long term AMC contracts
Energy Saving Drives and Slip Power Recovery Systems (SPRS)
Energy Saving Drives are used in applications ranging from small fans and pumps
to the large Mill drives and compressors. With recent advancements in IGBT devices,
VFD technology can now address Medium Voltage and, therefore, directly operate Medium
Voltage motors resulting in energy saving of larger magnitude and reduction of electrical
assets like transformers and associated switchgear. We offer a compact design with
Smart Harmonics Technology which ensures a very low THD, without the need for additional
filters. C&A continues to be a dominant player in SPRS for over three decades. With
our new technology, we bring SPRS with IGBT based Inverter and Active Front End
(AFE) which overcomes the legacy problem of poor power factor, while providing energy
saving. G-Vertor SPRS is now available for speed control of Slip ring
motors up to 5 MW.
Power Management System
Cement plants need electrical power which is sourced from utilities, captive power
plants and renewable energy systems. The emphasis is on efficient use of all such
power sources along with effective management of loads, power quality and assets.
To achieve this, one needs an integrated and comprehensive power management system
which can meet current and future requirements.
C&A provides complete Power Management Solution for a cost effective and efficient
energy utilization by maintaining continuous and reliable power, avoiding penalty
in case maximum demand is exceeded, improving power quality, reducing maintenance
cost and thus increasing profitability in terms of lower production costs. For some
industries, energy costs constitute as much as 20-30% of their total operating costs
and hence even a small improvement in operational efficiency can have a dramatic
impact on its bottom line.
C&A's i Vision max provides comprehensive information on
optimization potentials and utilization parameters to be correlated with KPIs viz.,
energy efficiency, production rates, process efficiency, power quality, asset optimization
and further supports the decision-making process with up-to-date information. It
enables clear overview of the electrical network and provides means for monitoring
and managing load. Tight integration of all subsystems ensures system stability
and helps avoid system collapse. It incorporates all the features of high-end electrical
SCADA system. The features include: Real Time Control, Load Shedding, Alarm, Event
& Reporting, Synchronization & Load Sharing, Energy Accounting ,Power Quality Monitoring,
Asset Management,Load Forecasting,Economic Dispatch, Availability Based Tariff (ABT)
functionality, Renewable Integration.
Asset Management & Optimization Solution (AMOS)
C&A offers Asset Management & Optimization System (AMOS) for managing the asset
life cycle through a pool of application and product experts.The systems vary from
simple Drives & Automation to large E,C&I installations in Power, Infrastructure,
Oil & Gas, Cement, Port and Nuclear sectors. The services result in improvement
in the plant availability and productivity and, thereby, maximise asset sweating.
Our services start right from the project implementation stage and are available
till the end of life cycle and beyond through optimized migration plans.
Our Service Modules cover:
- Spares Management
- Remote Monitoring & Assistance
- Annual Maintenance Contracts
- Operation & Maintenance Services
- Energy Audits
- Training Services
Post site hand-over, our engagement with you goes up manifold. We undertake comprehensive
O&M of your plant's E&I assets. In the event of technological advancements, we provide
suitable upgrade solutions with minimal cost of ownership.
Cyber Security
With over three decades of experience in technology improvements and changes in
the industry needs as well as processes, C&A today is well equipped to offer its
expertise in securing an organization from cyberattacks for an uninterrupted growth
in a highly competitive economy. C&A leverages on its own experience to secure your
information assets and infrastructure to avoid business disruption and achieve regulatory
compliance in the changing threat landscape. We offer proven methodology to help
our customers put up an in-depth defence and compliance to global security standards.
Our team of experts work in close co-ordination with customers in order to ensure
that all gaps are identified for the necessary critical infrastructure. This ensures
data protection, compliance to mandatory requirements as well as ensuring that industry
best practices are implemented.
Our services include:
- Assess the Cyber Security Risk
- Study Organization's Security Standard and map it with Global Standards
- Formulate Audit approach
- Prepare assessment checklist / templates
- Assessment / Discovery of compliance of Assets
- Publish Gap / Compliance Analysis Report
- Prepare remedial plan
- Evergreen Compliance
- Conduct training & awareness programmes