Sawan Jasoliya

1. Plant Condition and Major Operational Issues Since Commissioning Since commissioning, the plant has experienced several persistent mechanical, process and operational issues that adversely affected reliability, productivity, energy efficiency and clinker quality. A. Kiln and Cooler Reliability 1. Frequent breakdowns and stoppages associated with kiln supporting roller mechanisms, including high bearing temperatures. 2. Frequent cooler mechanical problems and breakdowns. 3. Frequent kiln coating collapses, resulting in red-hot clinker reaching the DPC and causing clinker quality deterioration. 4. Very low and inconsistent refractory life. 5. Frequent material puffing from the kiln inlet, accompanied by continuous material spillage. 6. Excessively hot kiln hood, with almost zero draft, resulting in unstable kiln operation and frequent hood roof damage. B. Preheater / Calciner Problems 7. Frequent material flushing / build-up at different locations in the preheater. 8. Very high prehea...

6th April 2026 The last three days have been deeply satisfying. Not just productive, but meaningful. Saturday started with clarity. In the morning standing meeting, I explained my concept of *11S3*. 110 days of operation + 11 days of shutdown makes one cycle of 121 days. Three such cycles in a year. 363 days. That translates into 330 strong kiln running days with planned, controlled shutdowns. For the team, this was a moment of connection. They could finally see the logic behind the number I have been repeating as our annual target. It is not just a number. It is a structured way of running the plant. Simple. Practical. Proven. More importantly, I explained what makes it work. The strength lies in building the pillars of TPM. One by one, I connected each pillar to what we have been doing over the past seven months. That realization was important for them. Nothing we are doing is random. Everything is part of a system. Sunday was refreshing in a different way. A road trip around the pla...

Unplanned stoppages are bad.  But shutdowns can be a big opportunity — A really big opportunity… IF ONLY WE ARE PREPARED, our job-lists are ready. There are two types of job-lists for any shutdown: 1. Standard Job-List This is the list of jobs that we perform as part of our standard inspection and maintenance routines (mostly preventive maintenance). Process Department: checks refractory conditions in cooler, kiln, and preheater; dip tube, feedpipe, flap valve condition, etc., and carries out the necessary maintenance. Mechanical Department: checks DPC, cooler, kiln supporting roller bearings, drive, HTD, bucket elevator, blowers, process fans, mill internals, screw conveyors, etc., and performs the required maintenance. Electrical Department: checks HT/LT panels, circuit breakers, cable terminations, MCCs, motors, lighting systems, earthing, and ensures functionality of interlocks and protection systems. Instrument Department: calibrates and maintains field instr...