TABLE OF CONTENTS

Page No. Title Page Acknowledgements Table of Contents Introduction Achievements Chapter 1 Organizational Set-up & Profile of the Company Unit 1.1 Historical Background of the Company Unit 1.2 Cement the Building Block of the Society Unit 1.3 Cement Industry in India Unit 1.4 Profile of the Company Chapter 2 Description of the Processes & the Operational Methods Used in the Cement Industry Unit 2.1 Mining Operations Unit 2.2 Stacking & Reclaiming Unit 2.3 Crushing Unit 2.4 Raw Milling & Blending Unit 2.5 Intermediatory Parts & Processes of the Cement Manufacturing Process Unit 2.6 Unit 2.7 Unit 2.8 Unit 2.9 Chapter 3 Burning & Cooling Einish Milling Pollution Control Miscellaneous Functioning of Various Departments of GACL Unit 3.1 Store Department Unit 3.2 Production Department Unit 3.3 Sales & Distribution Unit 3.4 Quality Control Department Unit 3.5 Environment Department Unit 3.6 Personal Department Unit 3.7 Instrumentation Department Unit 3.8 Accounts Department Unit 3.9 Audit Department Unit 3.10 Electrical Department Unit 3.11

DG Power Plant Unit 3.12 Civil Department Unit 3.13 Mines Unit 3.14 EDP Unit 3.15 Costing Department Unit 3.16 Packing Department Unit 3.17 Central Control Room

INTRODUCTION
Gujarat Ambuja Cements Ltd. (GACL) was established at Darlaghat, village Suli, tehsil Arki, District Solan, Himachal Pradesh inn the year 1994. The plant is located 45 km from Shimla and approximately 2km from Darlaghat. As India is the second largest producer of cement in the world this cement industry is one of the few industries in India to achieve the world competitiveness. The cement industry matches world standards on all parameters. The quality of cement compares with internationally accepted Britain and American standards. Also the companys productivity, energy efficiency and environment standards are among the best in the world. The plant started its commercial production in 1995 having a rated capacity of 1.5 - 2 million tones per annum then, now around 6-7 million tones per annum. It is the first plant in India which has been awarded ISO9002 Quality system certified by Bureau of Indian Standards. The company has always maintained the corporate philosophy of sustainable development. It maintains the emission norms well below the standard laid below the standards laid down by the Government Regulatory Institutions. The company has been adjudged the best and the most effective mines in its area by the Indian Bureau of Mines. The mining activities of Ambuja cements is the best examples in Indian mining industry scenario for state of the art mining with proper environment control. The mining situated at the serial distance of km from the plant. Which is situated around Kashlog village named Kashlog mines in Himachal Pradesh. The area spread around 4.8 sq. km. and is located in the North West direction of Shimla. It has a good transportation system by roads which are also connected to the main cities near the place. This limestone deposits are located in the lower Himalayas, the terrain is hilly with deep valleys. This is one of the most famous once among the cement manufacturing plants of the country and the main processes involved in the manufacture of cement are mining and crushing, pyroprocessing, grinding. Storage and packing. There is one operating kiln driven with one raw mill, two cement mills, a Dg hall,

quality laboratory and a cental control room (CCR). Basically it consists of 16 departments working 24 hours each day and seven days a week with three working shifts each day. Mainly this plant is run automatically and is magnificent in terms of results, because of this it has bagged many awards to add to its kitty. The main products of cement manufactured here are OPC (Ordinary Portland cement) and PPC (Portland pozzalana cement).

CHAPTER 1 ORGANIZATIONAL SETUP AND PROFILE OF THE COMPANY Gujarat Ambuja cement Limited, one of the leading cement manufacturers of India was initially incorporated in the joint sector with the government of the state of Gujarat in the year 1983 as a private limited company. In the year 1985, it went public and now is one of the 30 companies listed in the Mumbai stock exchange. Unit 1.1 Historical background of the company: The co-started in the year 1983 at Ambuja nagar , in Gujrat with a company of 0.7 million tones. This plant was commissioned in 1985. The second plant came up at the same place, near the plant with the name Gajambuja cement. This plant was commissioned in 1993. Then the company made a plan to take advantage of the demand in the Northern Region of India. As a result, it started Unit at Darlaghat in Himachal Pradesh with a view to use the vast amount of raw material i.e. Lime stone at Kashlog, which is quite near to Darlaghat. The plant commissioned in 1995 is known as Gujrat Ambuja Cements, Himachal Unit. Later the company put up another unit at Ambuja Nagar Gujrat.,near the two existing unit in 1996. This unit was named as Gaj Line II. Apart from all these the company has a grinding unit at Ropar (Punjab ), clinker is supplied to that unit from Himachal Unit. The company has its own fleets of ships and also jetties at Magdalla. Muldwarka (Gujrat) and Panvel (Maharastra ) which are used for water mode of transportation, both for domestically as well as export purposes . In 1997 itself GACL took over Modi.Cement Ltd., in Madhya Pradesh now renamed as Ambuja Cement Eastern Ltd. This plant added a capacity of 1.5 M.T. per annum. The Himachal Unit of Ambuja Cement is unique in many ways. The site at Darlaghat situated at 45 km from the capital city Shimla is fortified by lush green

mountains on both sides, rich with virgin soil, and attractive design with over land belt conveyer nearly 2.8 km long from the mining site at Kashlog to the production site, passing through tunnels carved through mountains. The plant was installed and commissioned in a period of 22 months in spite of difficult terrain and harsh weather conditions. The plant site is 1550 mts above mean sea level. It is the highest altitude plant in Asia. It is a marble and monument of human endeavor, team spirit, engineering skill I Can attitude. The production capacity of the plant was upgraded from 2 M.T.P.A. to 6-7 M.T.P.A. The plant is equipped with BAT (Best Available Technology).

Unit 1.2 Cement the building block of the society : Construction of houses or shelter is one of the oldest industries of human civilization and cement of one kind; other has been used in prehistoric times for construction purposes. Cement can be defined as any substance, which can join or unit mass,Cement, as used for construction purpose is a fine powder which when mixed with water allowed to set and harden can join different component together to give mechanically a strong structure. Thus Cement can be used as a bonding material for brick or other solid blocks of different sizes to form a mamolith. Cement is one of the most important building materials, which was introduced in England in1824 by Joseph Aspidin, it is also called Portland Cement because of its resemblance to the famous Portland rock of England. Chemically, cement is a finally a hard mass when treated with water. Generally three types of cements commonly in use these are: I. II. III. Ordinary Portland cement (OPC). Portland pozzoalana Cement (PPC). Silicate cement.

Unit 1.3 Cement Industries in India: The cement industry is 9 decades old. The first cement was made under the auspices of the house of TATA at Porbandar (Saurashtra) in 1914. It started with two vertical shaft kiln of stone masonry with the capacity of about 20 tones of clinker per day each. In 1920 these vertical shafts kiln was replaced by two 50 tones per day dry processed rotary kiln with common waste boiler for generation of power. These kilns are still in operation but without the waste heat boiler and making whit cement. In 1925, the cement production capacity was 0.5 M.T. Growth of cement industry was very slow in the sense that in 1930 when the production was only 6 lakh tn cement per year the there was a cut-throat competition indigenous cement manufacturers and cement imported from England and Japan, because of this some factories had to stop its production from time to time and even changed hand. By keeping in view a cement marketing organization was set up in 1930 to ensure the equitable sale of cement and to counteract competition from imported cement. But it did not help much and in 1936 four out of five cement manufacturer in India, eight factories to their credit joined together to from Associated Cement Company Ltd. (ACC). As a matter of fact, the first factory with indigenously built machinery was set up in Chaibasa (Bihar) in 1947. The cement industry however, has been making commendable progress in 90s, with the execution of extension and other new schemes mainly by established enterprises. The output excluding that of mini cement, has risen to 76.33 MT in 1998-99. Ninth plan greatly emphasizing on the construction of houses in urban and rural areas and the development or irrigation projects. This plan had also given importance to formation of national as well as state highways. There is a proposal to add about 30 millions tones of production capacity during this period. The cement industry saw a prospective phase of boom. The growth has been estimated on the basis of relatively low per capita consumption compared to other countries but an accelerated growth in infrastructure may facilitate the emergence of new trend and take off.

Unit 1.4 Profile of the company Today GACL is a public limited company; Ambuja Cements has grown from 0.7 million tones capacity to a remarkable 6.8 million tones per annum. It is rated as the most profitable cement company in India, posting the highest profit per tonne of cement produced and offering the highest returns to share holders among cement companies. The board for industrial and financial reconstruction (BIFR) sanctioned and rehabilitated some scenes giving birth to the name of Ambuja Cement Eastern Limited (ACEL).

Subsidiary Companies:The list of subsidiary companies of Gujrat Ambuja Cements Limited is as follows: Ambuja Cements Eastern Limited (ACEL) formerly known a Modi Cements Limited has become a subsidiary company since 1997 pursuant to investments made by the company in terms of BIFR order. Cement Ambuja International Limited, Mauritius. Midigama Cements (Private) Limited, Sri Lanka. GACL Finance Limited. Concrete Investments Limited. Indo Nippon Special Cements Limited. Ganpati Greenfields limited. Home trust Housing Finance Company Limited.

The Product: All along the company has maintained a policy of providing a superior product, which has achieved for the company a leading position in the competitive market with total commitment to quality. The Ambuja team had adopted latest quality equipment and techniques to constantly monitor quality in fact and because of this the company has under its belt many prestigious awards. The honorable ISO 9002 and ISO 14001 certification for Environment Management System. The company manufactures two major kinds of cements OPC and PPC. There are also several gradations found in the type of OPC as 55, 43 and 33 grades. All the plants continued to run affectionately at 100% capacity utilization. The total production during the year 1997-98 is given by the following table (Quantity in lakh tonnes):

Sales during the year 1997-98 were 5.06 million tonnes, as against 4.09 million tones in the previous year.

Domestic Markets:The power of the brand: In Gujrat,the principle of Ambuja, went up by 56%,taking its share to 26% from 21%. In Mumbai sales increased by 48%. Making Ambuja the number one brand of the countries largest cement market. In northern markets of Punjab and Himachal Pradesh it has increased its share to 35% Ambuja cement continues to remain the brand of first choice in all its major markets Efficient commissioning: - GACL has achieved excellence in commissioning and stabilizing plants speedily. - The first plant in Gujrat was set up in twenty-two months. - The second plant at the same site was commissioned even faster, in thirteen months time, as against the normal 3 years. - The plant at Himachal Pradesh in the hilly terrain was established within four months. - These helped to keep the project cost at the lowest in the country. Financial position of the company: It is well know that the GACL is a leading manufacturer of the new millennium. It had a turnover of Rs. 1130.95 crore in 1999-2000. Net profit after tax was Rs. 131.66 crore. The total project cost of the Himachal unit including the units at Darlaghat and Ropar is about 600 crores.

Research and Development: Specific is in which research and development is carried out by the company: Evaluation of the fly ash from power plant and utilize it for blended cement. Evaluation of blast furnaces granulated slang from steel plant and utilize it for blended cement.

Development of beneficiation system of gypsum. Benefits derived as a result of above: Increase in cement production. Reduction in cost of production. Future plan of action: Development of blended cement using industrial wastes. Utilization of furnace oil sludge and lube oil residue as fuel. Establishment of full sludge concrete testing laboratory. Grading management:The company believes that it owes success to the spiritualism of self confidence behind working as a cohesive unit taking indivisually to its utmost high always working with logic of I can. This empowerment to people has been inspiring the team to keep turning outstanding performance. Recognizing this, the management has consciously encouraged this culture and has created conductive atmosphere to foster this spirit. Managerial Grade: M-0, M-0A, M-1A, M-2, M-2A, M-3. Supervisory Grade: M-5A, M-5B. Workers: Cement Wage Board Rates. The motto of the company is DO IT RIGHT THE FIRST TIME. The company till now had been having a successful run and still maintaining the

quality as well as the name-fame of the brand so called Ambuja cement. Facilities at Site:(1) Housing facilities- Housing colonies are available at plant site. (2) Medical facilities- There is a medical center situated in the campus itself, led by a panel of Doctor. (3) School- Ambuja Vidya Niketan Public School is affiliated to C.B.S.E .and imparts education to children studying in nursery and KG classes to 10th class. (4) Recreation Clubs- There is adequate for recreation of their employees and family members, especially at plant site. Various indoor and out door games equipment, gymnasium(GYM), a library, cultural activities and regular film shows in auditorium are also provided here. (5) Bank and Post Office- Banking facilities are available in the company premises along with the post office. HSBC, ICICI, Allahabad bank facilities are also provided here. (6) Co-operative society- For meeting the daily needs of the people here GACL has set up a employees consumer co-operative store. It also has a STD, ISD, PCO, Barbers shop, vegetable fruit shop facilities available. (7) Mess and Canteen- Mess facilities for bachelor employees and for vocational trainees are also provided within dormitory. Canteen services for employees are available at the factory gate and in plant as well as in the co-operative store.

CHAPTER 2 DESCRIPTION OF PROCESSES AND OPERATIONAL METHODS USED IN THE CEMENT INDUSTRY. Cement is a substance applied to the surface of the solid bodies to make them cohere firmly or, more specifically, a soft and pasty state (which hardens on drying) to bind together bricks, stones etc in building (SOED). Portland cement is a calcined material compressing lime and silicates which is mixed with sand and stone and upon hydration forms a plastic material which sets and hardens to a rock-like material, concrete. This is the main difference between cement and concrete. Limestone (Calcium carbonate) and other materials containing appropriate proportions of calcium, silicon aluminum, and iron oxides are crushed and milled to a fine flour- like raw metal. This is heated in the kiln firstly to dissociate calcium carbonate to calcium oxide with the evolution of carbon dioxide, and then to react calcium oxide with the other components to calcium silicates and aluminates which partially fuse at material burning temperatures up to 1450 degree Celsius. The reaction products leave the kiln as a black nodular material, Clinker. The clinker is finally inter ground with a small proportion of gypsum (to control the rate of hydration) and the fine product is cement. The various manufacturing processes used in the cement plant are discussed below. Unit 2.1 Mining Operation: Fully mechanized open cast mining method is adopted for quarrying the limestone. The ripper rips the deposit into a depth of 1m to loosen it and thereafter make it in to heap of loose material. Blasting and drilling are carried out on after initial opening of the quarry phases by ripping. All the big boulders are broken using the hydraulic rock breaker. The hydraulic excavators and front wheel loader are used for excavation and loading of blasting and ripped and material in to 35 tonne rear damp trucks. The transportations of limestone from

the working face of the mines to the crushing plant and the stock pile is called hauling. After hauling the limestone from the working faces are fed to the limestone crusher. It can crush up to a maximum size of 1m x 1m x 1m sizes limestone into required size, which is to be transported over land belt conveyor for the cement manufacturing.

Raw Material:The composition of Portland cement varies from plant to plant due to cement specifications and the mineralogy of available material. In general, however, an eutectic mix is sought which minimizes the heat input required for clinkering and the total cost of raw material, while producing the cement of acceptable performance. An approximate analysis for raw mix on ignited basis, or for clinker, is: Reserves:Knowledge of limestone and, to a lesser extent, shale reserves is necessary. There are various classes of reserves. Class A or proven reserves: Extensive drilling has confirmed quality, mineralogy, and variation, mining and legal availability. Class B or probable reserves: Sufficient drilling to allow presumption of quality and ability. Class C or indicated reserves: Widely spaced drilling gives extent and some knowledge of quantity. Class D or inferred reserves: Initial exploration and consideration of geology allow general assumption. Cement contains the following raw material:(1). Limestone- brought to the site from the Kashlog mines. It is 3 km aerial

distance far conveyed by conveyer belts passing through three tunnels. (2).Shale- It is also brought from kashlog mines in the same manner through conveyor belts and tunnels. (3) Iron ore- It is brought from Rajasthan to the site by the transportation by trucks. (4) Gypsum- It is also brought to the site from Rajasthan by trucks. It adds to the clinker for the formation of cement (OPC). (5) Red Ocher- It is also brought from Rajasthan by trucks. (6) Fly ash- It is brought from Ropar (Thermal Plant) to the site by trucks. It mixes with the clinker and the gypsum for the production of Pozzalana Portland cement. Unit 2.2 Stacking and Reclaiming Stacking: The raw material is deposited by stacking device moving continually to and fro over the central line of the stock pile. The function of the stacker is mainly storage and compilation of the incoming coal and lime stone. The material discharged from the the stacker site and rolls down the sides of the pile, thus causing a degree of segregation of the material depending upon the properties of the material concerned. Reclaiming: The material is dislodged from the pile by the action of the racking down device, which sweeps across the sectional face; Harrows are used for the racking down purpose. Blades of scrapper chain conveyor shift the dislodged material along the collecting conveyor that extends along one edge of the stock pile. At the factory there are two stacker and reclaimer. The basic difference is that stacker stores and complies the coal and lime stone coming and also the speed of the belt is adjusted by the stacker controls whereas the huge piles of raw materials which are prism shaped are made with the help of the reclaimer. These could be transported further through the conveyor belts to the various manufacturing cells.

Unit 2.3 Crushing: It is a process; the big boulders are crushed and are reduced in diameter for convenience in work. Here in the factory we have impact crusher. Impact Crusher: In impact crusher the feed material entering the crushing chambers and encounters the impacting bar. The fragments are flung against the upper breaker plates, rebound in to the crushing chamber, are again subjected to the pass through the upper gap into the space between two plates. Lime stone , clay or shale, coal, gypsum, are crushed to a maximum size of 25 mm, and are fed into the grinding site. Primary crushers should be capable of accepting short rock with the minimum of wastage or of preliminary size reduction. Typically feed should be less than 120cm which could be controlled by hydraulic brake. Commonly there are primary, secondary, tertiary crushers are in series. Most of these crushers are operated in open circuit. Frequently, sometimes the material is straight away fed crushed by ball type raw mills and roller mills respectively. Crushers may operate by compression or by impact. Compression machines comprises of single and double jaw crushers and gyratory crushers. Some of these types are discuss underDouble toggle jaw crusher has simple compression motion with jaw angle of 15-20 degrees. It is effective for hard abrasive materials with low (<5%) moisture and gives a reduction ratio of about 5:1. Single toggle jaw crusher also has a measure of vertical jaw motion which adds attrition to compression. Sticky materials can be handled but the wear rate increases.

Gyratory crusher operates by pressure between a gyrated cone or a spring -loaded crushing ring .Hard , abrasive materials can be handled with reduction ratios about 5:1. Compression type crushers normally produce a cubic product with a low portion of fines; being choke fed, plugging will result with feed moisture in excess of about 5%. Wear is low but the reduction ratio is about 8:1. Impact machines may be hammer mills or impact crushers. These are usually preferred for limestone with quartz contents of less than 10%, Wear is grater than for compressions one,larger proportion done in this industry. Hammer mills (single and double horizontal shaft) operate by the materials falling into the circle of rotating hammers and being impacted both by hammers and the breaker plate. The feeder elevation and the velocity with which the materials enters the circle is criti9cal; if too low, then the material bounces on top of the hammers, and if too high, then it penetrates through the circle and can damage the rotor discs. The discharge is partially and wholly screened by gates against which secondary reduction by attrition takes place. There should be dry material used for avoiding plugging. Impact crushers (vertical or horizontal) are similar in operation is similar as discussed above in hammer mills case but relatively wet material can be dealt here. DRYING here in the raw mills is taken care effected by either combined crusherdryers, or in rotary dryers which can either use dedicated hot gasses generators or waste heat from kiln exhaust. In each case the air flows which involve dust collection while the high humidity of the used gas usually favors electrostatic precipitators over bag houses. of fines but moisture contents upto 12% is accepted and reduction ratios upto 50:1 is possible as is

Unit 2.4 Raw milling and blending <Grinding>: Grinding of raw mix:- This process takes place in a high capacity raw mill. The raw mill has four -roller operation. The rollers are used to grind the raw mix. The rollers are held in position and pressed down by a pressure ring, which is stationary. The material is fed centrally on the grinding table and carried by centrifugal force. The rollers are lubricated in order to avoid friction and increase the efficiency of the grinding of the raw mix. Raw Milling - Most modern raw mills are vertical roller mills, through ball mills are still common and roll presses may be used for pre-grinding to increase system capacity and reduce power consumption. Roller mills can typically handle raw materials with aggregate moisture of 15% while ball mills are limited to 8%. Ball mills are used for drying, which should be air-swept with an air velocity of about 3 - 4 m/ sec above load. Normally five or six pre-heater system is issued with the kiln minimally. Alternatively hot gas generators are used for the drying purposes. Most of the power consumed in the mills is converted to heat and this eqjuates to drying Approximately 1T moisture per 1000 KWH. Virtually all the raw mills now a days incorporate closed circuits with classification in a cyclone or mechanical separator and return of coarse material for regrinding. Roller mills have lower specific power consumption than ball mills. Loesche mills comprise 2 - 4 conical which are hydraulically pressed onto a horizontal rotating grinding table. The roller axis is inclined at 1.5 degrees to the table and, as axis of rollers and the table do not interest in the plane of table ,

the relative motion includes both rolling and sliding which enhances comminution. Feed material is directed on to the centre of the table and is thrown outwards by the rotation under the rollers and into a rising air current at the periphery which is directed by means of a lower ring. The air sweep passes through an integral rotary classifier; fines pass out with the air current and the coarse material falls back onto the feed table. Material drying ochers in air suspension and classifier. Circulating load is about 800%. Smooth running depends upon stability of the material bed; occasional vibration may be due to abnormal feed, particularly dry or fine material. External circulation is frequently employed to optimize mill efficiency. Primary roller mill controls are:a) Mill differential pressure which controls circulating load(usually 500700 mm WG). b) Inlet gas temperature(normally up to 500 degree Celsius). c) Inlet gas flow. Blending- A substantial amount of homogenization of raw material is achieved in the blending silo before it is supplied to the raw grinding mill. So the raw mill silo acts as a buffer store. There are various blending silo designs. The two major type involves turbulence (in which the material is tumbled about by the injection of air-pads on the silo floor) and controlled flow (where sequenced light aeration of segments of airpads causes layers of material in the silo to blend by differential rates of descent within the silo). Controlled flow silos may have multiple discharge chutes, or an inverted cone over a center discharge with in the meal is fluidized. Compressor power consumption is approximately: Turbulent mixing (air-merge) Controlled flow, Inverted cone Multi outlet 0.25-0.50 0.10-0.13 1.5-2.5 KWT/T

Turbulent mixing can be operated batch wise or continuously. Modern blending silos are generally controlled flow type.

Unit2.5 Intermidiatory parts and processes of the cement manufacturing process: Glass bag house:- As the name suggests it is a chamber with glass covering on the top. At the bottom of the house there are electrostatic precipitators. The heavy raw material gets sunk in the bags at the bottom and the finer particles in the form of gas are taken out to the main stack by a fan where they are let out by a chimney. Pulverization of coal:- The fuel used for the burning of clinker is coal. Coal with a volatile content of 18-22% is used. Coal is stored in out side stock piles. It is stacked and reclaimed in similar fashion s limestone. It is then conveyed to the coal grinding mill where it is ground to the required fitness and is used as and when required. Indirect firing method is used for the burning of the clinker. I this system the coal is simultaneously ground and dried as it is stored in the bin and with this system exhaust air from the mill is deduced and discharged into the atmosphere. Preheating and Precalcination:- Heat liberated in the rotary kiln can be advantageously utilized for preheating the material. To this inlet zone of the kiln may be equipped with steel or ceramic materials ,which assist the exchange. Preheating and Precalcination:- Heat liberated in the rotary kiln can be advantageously utilized for preheating the material. To this inlet zone of the kiln may be equipped with steel or ceramic materials, which assist the heat exchnge. Preheater cyclones:- In the preheater about 80% of the heat transfer takes placetakes place in the gas ducts and only about 20%in the cyclones. Gas ducts

and cyclones are lined with some refractory material. The preheater consists of six cyclones arranged upon the other. Gas ducts connect the cyclanes. The cross-section of the uppermast gas ducts is circular. Air Slides:- These are the means of internal transport. These have four slides arranged alternatively. The fixed slides have the function of giving a push to the moving slide carrying the material. Kiln Feed:- Both the chemical composition and the rate of feed of raw mill to the kiln must be consistent to avoid kiln instability and to minimize fuel consumption. Short term feed fluctuation as well as average feed rate should be monitored. Kiln feed is monitored by Chemical analysis on one or two hourly grab samples to determine statistical variation. Analysis is of usually of major oxides but may also be carbonate titration. If oxides measured, Statistics should use C3S or LSF. Kiln feed is normally conveyed by bucket elevator to the top of the preheater to minimize power consumption. If this conveying is effected pneumatically, de-aeration is desirable before injection as an entraining air otherwise add to the kiln ID fan load and may reduce the Kiln capacity. Kiln feed to the clinker ratio is typically 1.65-1.75 and, after determination, should be periodically reconciled with clinker and cement inventories and with measured dust loss in the pre heater exhaust. KILN FEED = CLINKER + LO1 + BYPASS DUST + DOWN COMER DUST -COAL ASH. Where both bypass dust and down comer dust are converted to ignited basis. Unit 2.6 Burning and cooling (Kiln Operation):The basic cement kiln system comprises a pre heater in which feed material is prepared by heat exchange with hot exhaust gas, a fired rotary kiln in

which the clinkering reaction occur, and a cooler in which the hot clinker exchanges heat with the ambient air. Kiln feed is subjected to successive reaction as its temperature increasesTEMPERATURE 100 degree Celsius >500 degree Celsius >860 degree Celsius >900 degree Celsius Fe2O3 and SiO2. >1200 degree Celsius >1280 degree Celsius reaction of CaO. PROCESS Evaporation of free water. Evolution of combined water. Caco3 = CaO + Co2 Reactions between CaO and Al2O3, Liquid formation. Formation of C3S and complete

Cyclone preheated kiln have developed rapidly in past few years. The first unit was 4-stage pre heated. Larger kiln now have even two or three strings together with preclinker (secondary combustion vessel between kiln and preheated) allowing to greatly increase the capacity per day by large. In cyclone preheated kiln without precalciners the feed is 20-40% calcined at the kiln entrance. In addition calciner vessel allows calcinations up to 90% before the meal enters the kiln. Precalcination should not exceed 95% as completion of the endothermic reaction would allow a dangerous material temperature rise before entering the kiln with probable build up and plugging.

Kiln System There are basically five types of kiln, defining the meaning of their names Wet process kilns Semi-dry process kilns Dry kilns

Pre-heater kilns Pre-calciner kilns Here in GACL there is only one rotary kiln which is dry in nature. Clinker free lime should be as high as possible to avoid the problems of

hard burning, but safety below the onset of mortar expansion, typically between 0.5-2% excessive heating should be investigated immediately and may be indicative of incorrect feed rate measurement or feed chemistry. Over burning always account for wastage of kiln repertories like fuel, increases power consumption by cement mill and reduces cement strength. Secondary air temperature should be as high as possible in order to recover the maximum heat; usually 800-1000 degree celcius, this involves optimizing clinker bed depth and air volumes injected to the first cooler compartments. Measurement of temperatures in the kilns is done by

thermocouples which can be misleading due to radiation as this is done in the hood. Mainly 60% of the fuel is fed to the calciner while 40% of fuel is burned in the kiln. Kiln operation is noticeably also depends on the type of bricks used. Basically, they are tapered fitted in a circle and in the end the last brick fitted is called as key brick because of its shape as per the requirement which works like a lock. This arrangement is laid once or twice in one year as per the usage and the requirement of the company. For kiln with grate coolers, the burner tip should be in the plane of the kiln nose (hot) or slightly inside the kiln providing it does not suffer damage from the falling clinker. sections of heavy coating, usually in the burning zone. Kiln Control Kiln rings are

Kiln operation is a complex artof which the principal control variables are: 1. 2. 3. Typical Aim Burning zone temperature (pyrometer or indirectly from kiln drive power) 1500 degree celcius Feed-End temperature 1000 degree celcius Feed-End oxygen 2.0% Control is affected by adjustments to the kiln speed. Kiln speed should be such that volumetric loading is within the range of 10-13%. Typically in the cyclone preheater kilns rotate at 2-2.4 rpm and have material retention time of upto 20-40 mins. Precalciner kilns rotate at 3.5-4.5 rpm for similar retention times. Kilns are frequently operated to the limit of the ID fan. In this case low oxygen must be corrected by reducing both feed and fuel. The oxygen level required at the kiln inlet will depend on kiln stability and combustion efficiency; with a good flame, 1-2% 02 should result in less than 100 ppm CO while an unstable flame may yield in excess of 0.1% CO with 3% O2. Useful information on kiln operation can be obtained from frequent (2hourly) analysis of clinker for SO3, and periodic (8-hourly) sampling of the underflow from the bottom cyclone stages for SO3 and Alkali determination. Normal SO3 levels (0.6% in clinker and 2-3% in the underflow) should be determined and maintained. In precalciner kilns, retention time and heat loading are particularly low and alkalis (K,Na) tend to pass through to clinker while sulphur is volatilized and builds a cycle at the back of the kiln. If the kiln is burned too hot, this cycle increases excessively until build-up or cyclone

plugging occurs. This is matched by an abnormally low SO3 content in the clinker. Eventually, if the kiln is allowed to cool, this sulphur is released and transit high clinker SO3 results. Such variation in clinker SO3 will also give rise

to varying grindability in the finish mill. Here in this plant everything regarding the kiln control is done automatically. Kiln Start-Up and Shut-Down The various steps in this process are kiln warm up; warm-up for shorter stops where the kiln is still hot, say stops of less than 24 hrs., are conventionally accelerate to half the shut down time. Shut down may either be: Emergency, in which case all equipment up-stream of the failure must be stopped immediately, or Controlled, in which case feed bin and coal system should be emptied, the kiln load run out as far as possible, and the cooler emptied. The burner pipe is withdrawn, or cooling air is continued through the burner, and the kiln is rotated on a schedule for about 2 hrs. until cold with the ID Fan running at reduced speed. Kiln Refractories Typically, brick from the kiln nose to the back of the high alumina brick section should be replaced if found to be 10 cms. or less thickness, but this rule of thumb varies in different operating conditions. Normally the life period of bricks is 6-8 months. A useful practice is to drill through the brick every meter whenever the kiln is down and coating has been striped. Changes in fuels, feed, or burning conditions will affect the location of the burning zone. Roughly the basic brick should extend back to the top of the coated zone. Coating location and refractory condition are usually monitored during operation with a shell scanner. Warm areas of the shell can be controlled by the use of a fixed fan array or moveable fans which can be directed at the area.

With considerable variation, installed brick thickness is related to internal kiln diameter: < 4.2 m Diameter 4.2-4.7 m 3.7-5.2 m > 5.2 m 180 mm 200 mm 225 mm 250 mm

and brick specific gravities are approximately: Magnesite Spinel Dolomite 3.05 2.95 2.80 70% alumina % alumina 2.30 2.05

Preheater cleaning: It done by using air-lances, jack-hammers, high pressure air and water blasters to avoid plugging and build-up materials. Kiln Fuels Traditional kiln fuels are gas, oil or coal. The choice is normally based on price and availability. It must be noted, however, that fuels are usually priced in terms of gross heat (heat available assuming water in combustion product is condensed to recover latent heat of vaporization). In practice, the only net heat employed (assumed that water in combustion gas is released as vapor). Flame temp. (degree celcius) Combustion gas (Nm3/Million cal) Total exhaust gas (Nm3/Tonne clinker) COAL 2250 1.23 1360 OIL 2350 1.31 1420 GAS 2400 1.45 1550 Coal, much more than oil or gas, is liable to compositional variation. Combustion Comprises (Mixing/Ignition/Combustion Reactions/Product Dispersion)

In the most industrial processes, mixing is the slowest and therefore, rate determining step. Coal Firing Coal firing for cement kilns falls into two basic systems. Direct firing

involves grinding of coal and feeding directly to the burner with all of the drying/carrying entering as primary air (typically 15-30% of total combustion air). Indirect firing involves intermediate storage of ground coal and separate cleaning and venting of the drying/carrying air. There are several variations on the basic coal firing systems. There is a common assumption that indirect firing yields higher thermal efficiency by reducing primary air and by excluding the waste vapor from coal drying. Such claims are largely invalid due to the poor fuel/air mixing of low primary air burners while water vapor in the flame has a catalytic effect on combustion. Of more importance is the ability of an indirect system with a single mill to supply two or more burners where a pure direct system requires one mill per burner. Note that significantly volatile matter and with it the heat content may be lost by venting the milling system. Clinker Cooling The clinker cooler serves to cool clinker form the 1200 degree celcius at which it leaves the kiln to less than 100 degree celcius by exchange of heat with ambient air which is, thereby, preheated before entering the kiln (or precalciner) as combustion air. By far the preponderant type is the Reciprocating Grade Cooler first introduced by Fuller Company. This comprises of a series of undergrate

compartments with separate fans which allow individual control of pressure and volume of injected cooling air. There are basically three types of coolers -

Rotary coolers which are simple rotating drums which lift the clinker to fall through the incoming combustion air stream effecting heat exchange, these are preferred for small kilns - planetary coolers comprise a ring of tubes attached to the kiln shell and turning with the kiln, which serve as multiple rotary coolers, they are not so fondly used due to some mechanical problems - g-coolers are effective in producing low temperatures clinker in combination to the planetary coolers, a low air volume grade cooler or to increase the cooling capacity. Clinker, after the primary cooler and clinker breaker, is allowed to settle slowly in a bed with heat exchange to air cooled tubes. Kiln Mechanical Although it appears to be a straight, cylindrical, steel tube it does, in sag between support piers deform in cross-section. While the cross-section is

generally considered elliptical, the orientation of the long axis usually varies from one area of the kiln to other. The kiln in GACL is 70 m x 30 m x 30 m approx. the temperature of the kiln shell is measured with help of optical pyrometer. The kiln shell is designed to provide a gas tight support to the refractory lining of the kiln. The shell also imparts rotary motion to the refractory lining in order to convey the raw meal through the kiln and to discharge the clinker produced. There are roller shafts for providing roller thrusting. Kiln Seals: These are required at the inlet and the discharge ends to exclude false air. False air at the feed end not only reduces capacity and efficiency but, introducing cold air in the middle of any volatile cycle, tends to cause serious

build-up and also interferes with both material and gas flow. Kiln Shell Design: It has historically been based on consideration of kiln shell as a beam of cylindrical cross-section. The shell thickness is selected to maintain calculated material stress levels well within the steels capabilities as per the particulate usage. Tire Thrusting: It is the excessive thrust loading on a tire is indicated by hard contact between the kiln tire and its retaining mechanism. Kiln Drives: They generally utilize the girth gears and pinions designed to give over 20 years of continuous service if lubrication and alignment are maintained. As older kilns are upgraded it is common for drive speeds to be increased and this is usually accomplished in one of three ways. Gear reducer ratio changes. Weakening of d.c. motor field strength. Utilizing higher than rated motor frequency on a.c. induction motors with variable frequency drives. Kiln Alignment and Requirement Most kiln designers limit bearing pressure between rollers shaft and bearing. Kiln support rollers are designed to bear the weight of the kiln as well as some of the downhill thrust acting along the axis of the inclined kiln. Corrosion - In this the kiln shell is not normally a serious problem unless high levels of sulphur or chloride are present. Emergency Power: Electricity supply is always prone to interruption and this can result in significant damage until precautions are taken. The best system to be used is a Diesel Generator (of 1MW) to be used which starts automatically upon

failure of the main power supply. Unit 2.7 Finish Milling Cooling Air Fans: The correct choice of cooling fan is of major concern with regard to efficiency and the electric energy or power consumption of cooler. Good heat recovery is possible only if the cooler is operated with a bed of clinker with a corresponding high air flow resistance. For this reason fan in the hot zone should be able to develop a sufficiently high pressure. The minimum pressures for the fan supplying air to the recuperative one are for single stage cooler 30 mm bar. There are two chambers in a cooler. One is a material chamber and other is an air chamber. The material chamber has a conveying system called pan conveyors. The raw material becomes red hot in this chamber from the heat generated in the kiln. Clinker Storage Clinker as discharged from the cooler is liable to be, at least intermittently, at high temperature. A convenient transport system avoiding intermediate

transfer is a steel deep-pan conveyor which can elevate the clinker at upto 45 degrees to the top of the clinker storage. In combination with cement storage, there should be adequate clinker capacity to maintain cement shipments during kiln maintenance. While total

clinker capacity should be equivalent to at least 14 days of kiln production, there must also be separate storage for different types of clinker which is high lime free also. Clinker is fed into it by two speed bucket elevators and discharged through for bottom outlets. Clinker storage serves also to blend the clinker and a silo should not be filled and discharged to milling at the same time unless the silo

has multiple discharge points to avoid short-circuiting. Finish Milling Finish milling is the grinding together of clinker with some 3-5% gypsum, natural or systematic, for set control, and other additives (e.g. pozzolan, slag and limestone) where appropriate for performance and permitted by specification. Finish grinding involves the largest and consumption of power in cement manufacture and should be optimized. Separators Several types of separators are employed in mill circuits and there are numerous variations in each Grit Separators Mechanical Separators High Efficiency Cyclone Separators Rotary Classifiers Cement Storage and Dispatch The storage of cement is dealt in the same silo fashion. There are four big silos 20-25 ft. in height having capacity of 50 thousand tones. It is

dispatched after packed in 50 kg bags filling the trucks (25 T each approx.) as the transportation here is by road to all other parts of the country. Daily 10001500 trucks or even more are dispatched from the GACL unit of Himachal Pradesh. Cement Mill In a cement mill there is a rotary furnace, which carries rollers inside it. When the raw material in the form of clinker, gypsum, etc. gets internally it

through the belt conveyor from the kiln it is given a rotary motion. The rotary motion refurnace, when the raw material in the form of clinker and gypsum etc. then it comes in contact with so many rollers falling up and down the clinker gets crushed and there are again recirculated to the furnace by an o-sepa fan. The function of the o-sepa fan is mainly separation of course and fine particles during crushing. The fine particles gets collection in the furnace, while the fine are stored in a R.C.C. silo. Unit 2.8 Pollution Control Three principal types of dust collection are used in cement plants. Cyclones Efficiency of cyclones is 95%. Normally inlet and outlet validity is 10-20 m sec. Electrostarts Precipitators: This comprises of an array of discharge wires at 50-100 kv negative potential and earthed collected plates. Bag ______: These filters comprise of either woven fabric (which ___________ shaking or reverse air flow for cleaning) or needle felts (which are cleaned by reverse air pulse). Efficiency is round about 99% and normally the fabric used is polyster which can be operated upto 150 degree celcius, while polyamide can be used to 230 degree celcius and glass fiber to 280 degree celcius. Conditioning of kiln exhaust gas is necessary before dust collection. The exhaust gas from many kilns is used for drying raw materials and this process serves both to cool the gas and to raise its humidity before dust collection. Pollution Control Environmental regulation is, of course, very much a matter of national and

local ordinance. However, certain generalizations can be made about air, water, solid, and noise pollution. Cement plants are primarily concerned with air

emissions. It is done in various departments. Water Discharge Solid Waste Noise Air Pollution Unit 2.9 Miscellaneous The following points are among many which require constant or periodic consideration: Stockpile - This inventories are often calculated from production and consumption figures. At least monthly, all piles should be surveyed and their capacity calculated from standard bulk density assumptions. Silos - These for most materials are prone to developing dead material which is not wasteful of capacity and misleading as to inventory. designed for mass flow, funnel flow. Weigh-Feeders - They should be calibrated regularly and cross checked against both inventories and indicated feed rates at other stages of the process. Equipment Numbering - It is done to have easy identification and location. A typical system comprises area, equipment type and a serial number like AES where A is for area, E for equipment and S for serial number. Safety Lockout - The electrical equipment for maintenance is vital and standard. Operators Data logging - It is very important to know how the equipment ___________ and run. This helps us to know about the machine and explore Silos happens are

the working to the fullest. The Shift Supervisor - Here in GACL there is three shift system (i) 6 AM-2 PM (ii) 2 PM - 10 PM (iii) 10 PM - 6 AM. The handling of charges during shifting of work is a daily routine here. Process Alarms - This is a safety precaution, a measure that should be designed carefully. As certain events are critical and must be dealt immediately. Critical alarms should be designed so that the problem can be dealt with and corrected without any loss of life and equipment. It is also useful to devise such alarms to give attention to the unit where failures can be dealt in a proper manner.

Chapter 3

Functioning of Various Departments of GACL

GACL Darlaghat is a big cement manufacturing organization. It has 16 main departments. The working of all of them will be discussed in this section of this report. Unit 3.1 Store Department The main purpose for the formation is that every department require some material for its proper functioning, and this comes from the store department. This department performs the function of the receipt, issue and procurement of material. It helps in the smooth functioning of an organization because it

supplies the required material as per the requirements. One of its main function is inventory management i.e. the management of all tangible goods in store. Inventory management is one of the most important job because there should be optimum stock. Inventory includes the Raw material used in the process. Work in progress includes the material that is in between the raw material and finished goods. Finished goods means the goods which are ready for sale. It also manages store and spare which generally deals with consumable items and the items of plant management. The inventory may increase (first two reasons stated below) or decrease (all other) because of the following reason New Receipt - material received by the department. Return Department - material issued but not accepted by the concerned department.

Reject - material rejected due to some defects by the store department. Consumption of plant material - the material consume in the plant for production. Chargeable item to the contractors - some works are given to the contractors by the company so if the contractors need anything that provided on chargeable basis. Transfer to other sites - if some material is required by some other site then it is issued to it and put into that sites account. In the case of recording then the store department itself sends indent about to the purchase department about the things which are used frequently. Working of the store department - when a department needs an item that will send an indent. Indent is the formal requirement of the material by the user department. It indicates the items needed by the concerned department and the items code as all the items are categorized and coded. After receiving the

indent the store department will scrutinize the physical stock of that department lying in the store. If the demanded quantity will be available in the store then the store department will issue the concerned material to that department and if not available then it will purchase order first and then send to the purchase department. Then the purchase department will negotiate and purchase the material and send it to the store. Then they call the person of the particular department for the checking and verification of that particular materials. After inspection if there is no defect then the store department makes the goods receipt note and handover the material to the custody section. One copy of the goods receipt note made by the store department will send to accounts

department for payment and one to the concerned department and one it will keep with itself for the personal records. Custody section means where all the material is kept. Materials can be categorized in various types - Spares (Sp), Consumable stores (Cs), Explosive (Ex), Repaired item (Rp), Capital item (CI), Capital furniture (CF). This categorized material coded accordingly and kept in bins made for it. These materials are kept according to their weight, category. Also sheds are used here for keeping the heavy materials. Materials are also issued to contractors on loan basis. Store department receives the goods on the credit term of 30 days. If the goods return within 30 days then these will not take return back by the department but if suppose the item (machine) has installed and it is in operation and rejected after 30 days then this item will be on returnable basis. It also deals with the unloading of raw material. When the trucks of raw material come to the site, first they take the gate entry and then they are weightbridge the weight of the truck is measured, and afterwards the truck is unloaded at the unloading point. By weighting the truck the store department comes to know that how much material has come to the store what is its total quantity. It also helps in selecting the sacks which is the method of consumer satisfaction by performing this function. There are certain standards regarding the bag sizes, therefore only those sacs are selected who fulfill this condition this done because company name and customer satisfaction. Each sack when filled with cement weighs 50 kg each. Unit 3.2 Production Department Production here means conversion of raw material into finished goods.

GACL is a cement manufacturing unit and it produces cement. Cement is the main finished goods. It produces two types of cement namely: 1. 2. Ordinary Portland cement Pozzalona Portland cement Production department is the principal department in a manufacturing unit management fixes some target (weekly/monthly) for the production of cement and now it depends upon the production department to achieve that target. Production department with the help of other department viz. electrical, instrumentation, quality control, mechanical etc. achieves that target. Production department uses machine and material with greater care and efficiency so that to achieve that target within the time Perivale. This department is adjacent to electrical for continuous supply of electricity, instrumentation for the control mechanism. Quality control for the information regarding the cement produced is of good quality or not. Production process is fully computerized the production department employees see on computer the working process, if there will be any problem or disturbance then they easily find it and inform the concern department e.g., electrical, instrumentation and mechanical department. So the main aim of the production department is to achieve the target with (efficiency) optimum utilization of machine and material.

Functioning of Various Departments of GACL

Unit 3.3 Sales and Distribution Distribution outlet GACL Plant: Transporter, Stockiest, Direct Party, Dumps, Sub-dealer, Customer Distribution Channels 1. Stockiest or Dealer:

Stockiest have direct link with the company.

The company appoint

stockiest on security or non-security basis. But stockiest must be in a good financial position and they must have the right place for dealing. 2. Sub-Dealer: These are not linked with company. They purchase cement direct from the stockiest and sell it according to their convenience. 3. Direct Party: A person/firm purchase cement in truck from company for their use e.g. Supplies to Government orders. They are of M/s based. 4. Dump: Dumps are GACLs stock house from where company distribute the cement to its dealers. There are four dumps in north: 1. 2. 3. 4. Ambuja Nagar Panchkula Saharanpur Delhi

Transport Company GACL has made an agreement with truck transport companies which are used for transportation of cement. There are: 1. 2. 3. 4. S.D.T.O. Transport Company ADKM Transport Company B.L.L. Transport Company Auto Hirer. Order Processing System

This is one of the major logistic function for company. It involves the flow of information about orders from point to point to achieve the objective of placing the order. Both the company and its customers are benefited when the order processing system is carried out efficiently. Effective order processing involves transmission of the customer order, paper processing retrieval from the warehouse, packing and dispatch through the transporter, adjustment of the inventory level and transmission of the information to the department of production planning. In Gujarat Ambuja Cement Limited also processing is given importance. Previously it had a lengthy and cumbersome process with the order being transmitted to the place of production via a fax or telephone, even sometimes with the help of courier service. But now the company has adopted the modern concept of electronic data exchange. According to this system all the major offices of the company are linked by a network system commonly called as wide are network. This includes the production site at Darlaghat, Marketing office at Shimla, Regional Marketing office at Chandigarh. All the orders are fed into the computers of the respective offices, which are linked to the central network. Then the data gets transferred to the computers of the production site through the modern which are connective links of the network. This is called distribution and management system (VASMIS). The working process of the system is as follows. The company is involved in trading with three categories of customer. They are Stockiest, Direct Party and Dumps.

As per the customer categorization the orders also come in three types. All the orders are collected by the respective office i.e. the Marketing offices at Chandigarh. The respective offices at Shimla and Chandigarh sends these

orders to the production unit through Modem. These orders come in certain for mat. It mainly contains areas like order number, stockiest code and consignee address. As such stockiest has a unique identification code and rate per each stockiest is fixed according to its location. So the total amount in monetary terms gets executed automatically after entering the stockiest code. The orders of the direct parties are generally collected by the respective marketing offices and sent to the production site via Modem. These orders also come in a certain format. These orders contains orders linked consignee, party, product specification (type of cement required) packing specification, total quantity required, rate per metric tones, total amount of price to be paid, delivery specification etc. First these orders come to the accounts department where the details of pricing are filled up, then they come to the sales and distribution department for execution he orders from the dumps also come through the office at Chandigarh as there are no dumps available in Himachal Pradesh. They come in form of bulk a orders. These orders do not contain any detects like party consignee etc. They place the requirement as per the forecast made by the marketing department. They come directly to the sales and distribution department and subjected to execution. Then it is the duty of the sales and distribution department to execute the orders according to the degree of their priority. As the beginning of each day analysis of new orders and the pending ones are done and as per laid policy

decision is taken as to which orders are to be executed on that day. Then such orders are put on the network. Which are then displayed on the screen of the computers at the transport organization offices.

Unit 3.4 Quality Control Department Gujarat Ambuja Cement Ltd. is a modern cementing plant. It is the first plant in India, which has been awarded ISO-9002 quality system certification by Bureau of Indian Standards. The plant laboratory is responsible for analysis of raw material and fuel. mix design which should reflect individual raw materials costs, production costs (principally drying, grindability, burnability) and product quality. preblending of raw materials and blending of kiln feed to minimize chemical variation into the kiln. process controls involves raw materials moisture, raw meal fineness, clinker free lime, degree of calcinations and volatile components of hot

meal at the kiln inlet, proportioning of clinker and gypsum, and fineness of milled cement. chemical analysis and physical testing of cement to confirm and certify compliance with specification. miscellaneous functions such as water treatment and laboratory measurements associated with process engineering and pollution control. Quality means commitment made by the producer regarding product to the consumer. Here in this laboratory segregated raw material from the feed and mines is tested and passed. Here is placed an imported machine of X-Ray from Denmark with its samples for verificational check, setted-up by FLS (FULLER). Various other apparatus are also present here like Blains for

measuring the cement strength. It is here where it is told how much percent of various components should be added or removed or maintained by checking the percentages (%) of all the components of cement likely Lime, Shale, Gypsum, Iron Ore. It is in this section where a check on mixing of SiO2, A12O3, Fe2O3, CaCO3 is kept under vision. This is the one department mainly responsible for the difference between manufactured OPC and PPC. Quality Policy and Implementation The quality policy of Gujarat Ambuja Cement Ltd. is: To achieve total customer satisfaction by providing product and services that meet or exceed customer expectation based on agreed specifications. All the people and element of our organization be committed to excellence; it means that Do it right the first time. To built quality operations to ensure quality product and services and thereby achieving excellence in

consistent quality satisfying the consumer needs has been the objective of the Ambuja cement quality policy. Quality Planning The requirement of quality system are met by following procedure which is described in detail as follows: The identification and acquisition of any control/process equipment (including inspection and test equipment) fixtures, resources and skill that may be needed to achieve the required quality procedure and applicable documentation. The updating, as necessary, of quality control inspection and testing techniques including the development of new instrumentation. The identification of quality is the acceptability for all features and requirement including those which contain a subjective element. Quality Control Procedure Calibration of process equipment is being done by instrumentation, periodic calibration for various testing equipment are carried out and records of such calibration are kept. The measurement to be made and the accuracy required is determined and accordingly appropriate inspection, measuring test equipment is selected, which is capable of the necessary accuracy and precision. All the measuring and test equipment are calibrated periodically using standard calibration devices. Standards suitable tags are provided to identity the calibration status. Proper calibration records for inspection measuring the test equipment

are maintained. The validity of previous inspection and test result will be assessed and documented when inspection measuring or test equipment is found to be out of calibration. It is ensured that the environmental condition for inspection, calibration and measurement are suitable. The inspection measuring and test equipment are properly handled pre served and stored to ensure it accuracy and reliability. Chemical Analysis - process control requires on-line or rapid off-line analyses in order to adjust the raw material proportions to the raw mill. Here in this plant XRay Flouroscence is employed using either pressed powder or fuse disk samples to draw better inferences. Sampling or samples tested here are every one or half hour basis. The strength of cement depends on six basic factors 1. 2. 3. 4. 5. 6. Chemical Composition Mineralogy Particle Size Retardation, mainly sulphate form and activity gypsum control with lime. Dilution of active components Prehydration of hydraulic components Quality Policy To achieve total customer satisfaction by providing products and ensure service that meet or exceed customer expectation based on agreed satisfactory. All the people and element of our organization be committed to

excellence. It means that Do it right the first time. To build quality into operation and to ensure quality product and services, thereby achieving excellence in organizational performance. Unit 3.5 Environmental Department Right at the time when company started its operation it had promised the people to keep the environment clean the company has managed to live upto the promise. The pollution levels at the company plant are even lower than the stringent Swiss standard. The people at Ambuja have taken it upon themselves the responsibility of greening the mining area. This plant is located in an ecologically sensitive zone. A separate department called environment department has set up hot only to check the pollution level in plant site and nearby villages but also engaged in the plantation and other community welfare programmes. Environmental Policy The Gujarat Ambuja Cement Ltd. an environmentally conscious company has always been committed to sustainable development. We at Himachal Unit both plant and mines, therefore will strive to: Adopt Eco-Friendly practices and technologies. Maintain and strive to go beyond compliance with environmental regulations. Build environmental awareness amongst the employees and neighbouring community. Utilize all resources efficiently.

Join together in common endeavour for continual improvement. Accelerate plantation within outside our facilities. We shall achieve our goals by setting appropriate objective and targets, the Ambuja way. Unit 3.6 Personal Department The various function that this department performs are recruitment, selection and training of the employees. Recruitment IN GACL the recruitment based process is need based analysis of recruitment process in GACL reveal that whenever vacancies are created by ill health demotions and separation the young talented and experienced personnel are recruited and selected. After deciding about the number of people to be recruited, the qualification for individual positions are identified and then vacancy is advertised in leading newspaper of India. Recruitment can be internal also. Vacancies are filled by promotion of the existing employees. After responding to the vacancies in the newspaper candidates apply for the job. All the candidates who fit for the job their qualification matches the job then they are called for the interview by the company. Selection Then comes the selection of the suitable candidates. Selection of the suited candidates is promoted by company is interviewed by one or more people (interviewers). The panel for interview consists of different persons from different

department. Mainly there must be one person from personnel department and other from the concerned department. Panel asks different questions to the

candidate. Interview may be structured, semi structured or unstructured. After evaluating the performance of candidate the candidate are short listed. Interview is supplemented by data from the application form and the

information obtained from persons listed as references. References checks and letters of recommendation may be necessary to verify the information given by the candidates. Short listed candidates who are suited for the job then selected for the job before the formal selection prospective employees are interviewed by the vice president operation and then only candidate is selected for the job. Selection procedure is followed by approval and issuing a letter for * M-O. O-OAA. To M-1 Grade approval & offer letter is issued by managing director. For * M-1A Grade selection is approved by managing director and appointment letter is issued by concerned director. For * M-2A, M-3, M-4, M-5, M-SB, S & S-2 grade selection is approved by concerned director and appointment letter is issued by joint president or vice president. These are applicable at site at production department. Mechanical, instrumentation and electrical for commercial department approval is made by concerned director and appointment letter is issued by Dr. Vice President or V.P. Commercial for mines and geology department approved is made by concerned director and appointment letter is issued by joint president mines and geology. For Account or EDP (info. Tech) system and Audit approval

is made by concerned director and letter is issued by joint president finance. Total No. of employees - 385. Grading in the Co. is done in the following manner: Managerial grade include top level Mgr. and Middle level Managers total No. of employees in Managerial grade

GRADE M-OA. M-1. M-1A M.D.G.M. M-2, M-2A M-3 M-4

DESIGNATION Asstt. Vice President

Sr. Mgrs. & Mgrs. Dy. Mgrs. & Asstt. Mgrs. Sr. Officers, Sr. Engineers Sr. Account Officers & Engineers

At the supervisory level the Co- has 98 employees and their grade is M5A, for the clerical job the no. of employee- 18 M-5A, M-5B-Sr. Asstt. Sr. Officer. Sr. Engineer foreman. Charge head. Asstt. Charge head. At the lowest level The grades are: WRK & W - B Total No. of employees in these grades are 116 These grades includes: Hemo: Heavy earth equipment movement operators Machine attendees, spotters, Blaster. Helpers. Electricians. Training of the Employees

Training provided by the company to its employees is need based. Head of every department identifies the training needs of his subordinates and sends the list of the personnel department and personnel department prepare a training calendar for the year and the trainees. They have to work as per the training calendar. The training is imparted both on job and off the job. Often outside facility from various professional institutes and from the industry are invited for training of the employees. The company not only conduct training programmers to input technical skill to the employees but workshop on personality development and quality control etc. are also often conducted by renowned person from the industry are also invited to give lectures and valuable suggestion and answer to the queries of the employees. The company owns a regional training centre at Ambuja Nagar in Gujarat which offers specialized training course. Employees from other plants and office are also sent here for training courses the company also sends and employees to other training institute if necessary. Welfare Measures One of the main strength of Gujarat Cement Ambuja Cement Ltd. is the dedicated work force, which has played a crucial role in the growth and success of the company. This has been possible due to the various facilities provided by the company for the welfare of its employees the various welfare measures adopted by the company at its Himachal plant are as following: a) Housing: The company provides good housing accommodation to its employees at the Darlaghat plant of separate residential colony has been built by company for its employees having 264 flats.

b) Education: The company has opened school named D.A.V. Ambuja Vidya Niketan which provides quality education to the employees children and also to the children of resident nearby village. The company has also provided hostel facilities at Shimla and Chandigarh for the employees children who are pursuing higher education in the above mentioned cities. c) Medical: The company provide excellent medical facilities to its employees inside the plant. There is a hospital in the premises of the plant having four well qualified doctors twelve other people in the medical staff. The company has also arranged for these visiting specialists doctors who visit the plant once in a week the company also runs a mobile van which provides medical facilities to the nearby village. d) Transportation: The company provides good transport facilities to the workers to enable them to reach their work place at time also bus facility to Shimla and Chandigarh. The company provides car and motorbike to its employees for their routine needs and convenience. e) Library: There are two library in Himachal Plant. One is the technical library staff of the plant and the other is general library having subscription of many renowned magazines and journals. f) Recreation: The company provides samples recreation facilities to its employees. A club at the Himachal Plant is a good source of entertainment for the employees. g) Cooperative Stores: A cooperative store in the plant cater to the daily needs of the employees. Every daily needs item is available in the store. h) Intramural: These services provides within the establishment. These include

free uniform, raincoats, gum boot, free tea and snacks coupons, canteens and mess etc. The company also provides safety shoes and safety helmets to its employees and workers. Personal Manuals (Personal Policies) 1) Leave entitlement (for on grade employees) Privilege leave - 30 days leave with full pay after every 11 months continuous employment. The PL is counted from the date of joining in employment and it can be only availed after conformation of service or on completion of six months of continuous employment whichever is later. Casual leave - 10 days leave with full pay every year. The CL is counted from the date of confirmation or the conformation of 6 months of employment whichever is earlier. Leave entitlement for engineers/officers on 1 year probation - 10 days PL with full pay during 1 year probation period on month wise calculation. Leave entitlement for trainees - for first year training stiffened 10 days leave and for second year 20 days with full pay. Leave entitlement for wage board objectives -

a) 18 days earned leave (EC) is 1 day EL for every 20 days attendance. It is clarified that no earned leave shall be earned during the period when an employee is on leave. b) 7 days casual leave (CL) in one calendar year. CL is credited proportionately if the employee does not complete one year. c) 12 days sick leave (SL), 1 day SL per month. However, if it is a fraction of leave less than one day it will be counted as one day for calculation

purposes. Compensatory off: employees cover under M-4, M-5A and M-5B grades and work trainees are entitled for compensatory off against duty on paid holiday, weekly offs or normal additional 8 hrs. working. Holiday - 7 holidays (3 national and 4 festival ones) are observed at plant site every year. The list of holidays is declared on the 1st of January of every year. 2) Traveling rules - traveling rules as described below are applicable for all the officers tours undertaken by the employees of the company at all the location. Mode of Travelling and Conveyance Grade M-O M-OA M-1/M-1A M-2/M-2A M-3, M-4 M-5A/M-5B Mode Air/1st AC Air/1st AC Air/1st AC Air/2nd AC Air/2nd AC/1st 2nd 3rd class 3rd AC/1st class Conveyance Taxi Taxi Taxi Public taxi/3 wheeler/coaches Public taxi/pb.tpt./autorks Public taxi/auto/public tpt.

3) Regarding Transfer # rules regarding expenses on transfer. # additional increment for staff transferred on green field locations. # rules regarding deputation and deputation allowances. # rules regarding transit leave and doing time. # displacement allowances. 4) Policy regarding allotment of accommodation of staff in township. 5) Policy regarding loans $ loans provided are interest free.

$ loan scheme for employee and for house old items, computers, two wheelers, cars. $ medical expenses for self and family member. $ higher education expense for self and family members. $ major repairing expenses for self and children. $ major repair of house or flat owned by the employees. 6) Policy to provide scholarships to employees children - this is based on the merit provided based on the stream. For medical/engineering these are given every year. 7) Scheme for educational allowances - with a view to improve the quality for every staff member, the company encourages those who wish to acquire additional professional qualification as relevant to their responsibility and expenses incurred on their count by the staff is reimbursed by the management. This scheme is available to all confirmed employee at M-3 grade and who have served at last three years for the company. The various qualification and the amounts are as follows half year degree/PG degree prog. Rs.2500/year half year diploma/PG diploma prog. prog. of less than one year but more than three month duration Rs.1500/year Rs.1000/year

8) Regarding issue of uniforms, safety shoes, helmet and rain coats and gum boots - all image board operative are provided two sets of uniform, one pair of safety shoes every year. Each employee working inside the plant and mines are provided with safety helmets which they have to wear compulsory while at work.

All employees working at the plant are provided with rain coats for a period of 3 years and for those working at the mines are given rain coats and gum boots for a period of 2 years. Unit 3.7 Instrumentation Department The main function of this department is also related to maintenance and upkeep of plant and machinery. The department also looks for

telecommunication and the cable network in the plant. Overall control of the plant is managed by this department. This is the department which looks after each and every activity going in the plant. Anything to inquire about or to ask go to this department. Unit 3.8 Accounts Department Accounts department deals in receipt and payment. This department is divided into three sectors: i) Sales Accounting - This sales department deals with the receipt and payment concerned with the sales of cement. The department to various parties, dealers, stockiest and credit note are also issued by this department to the stockiest. ii) Purchase Accounting - This department keeps all the records related to the purchase and transportation cost of that purchase. iii) General Accounting - This section does all the work except sales and purchase accounting. This section makes trial balance and consolidated balance sheet for all other branches. It marks on daily bases each flow statement and sends it to corporate office Mumbai. Other records which it keeps are scarp sales accounting. It also does the insurance related

work. Insurance of those machine and items which are very costly mean capital items. Unit 3.9 Audit Department Audit is the examination of the books, accounts and vouchers of the business. The purpose of this department is to satisfy criterion of balance sheet shows a true and fair view of the state of affairs of the business and the profit or loss incurred by the business during the financial period, and for this particular purpose a system called the systems audit department has been set up there. This department is called so as per its functioning, also of each and every department in this organization a designed procedure has been given by this department and frequently checks are done by the employees of this department to see that there should be no malfunctioning in the organization. The various checks, timely execution of orders, invoicing, material reconciliation, rates, etc. are dealt within this department. Unit 3.10 Electrical Department This department caters to the entire plant related electrical joint, as it has electrical workshops scattered in all the plant. Basically, the machinery

necessary equipment is designed and given by Kirloskar. Income supply of electricity is of 132 KV has step down into 6.6 KV and 415 KV for distributing in the pant, residential colony, offices and for other purposes. This department helps the production department to produce the cement by supplying uninterrupted stable power. This department also takes up

maintenance jobs for the smooth functioning of the plant. Here there is set a big electric power switchyard station where there are big transformers for stepping

up and stepping down the electricity supply. In the electrical workshops the motors which are not working properly are repaired, oiled and checked before taking them again in work. There are

roundabout 15-20 DC Motors which cost about Rs.70,000-80,000 each. Then comes AC Motors which are roundabout 1300-1500 in number in the plant and are costing 15,000-20,000 each. After this there are HT Motors which are 20-25 in number in the plant and depending on there capacity is their cost like a HT Motor of 2000 KW costs about 25 lakhs. DC Motor - It basically consists of main poles and inter poles, with armature winding on rotor (moving) and field winding on stator (static). It also has carbon brushes for output current. AC Motor - It consist of rotor and stator a arrangement just as opposite in above case i.e. AC Motor and has a basket winding, a laminated coil which is stamped called core, duty, insulation, connections (Delta or Star), phases (1/2/3), may be of ckh or kh i.e. with gear or without any gear. If gearbox present then it

consists of three pinion arrangement primary, secondary, final to reduce the rpm. AC Motor also has a squirrel gauge arrangement. Here always the length of stator is always equal to the length of the rotor. HT Motor - This is an extended version of AC Motor with a slip ringed version. Gear oil is used here for lubrication purposes along with grease and sealant is used to seal off the motor. Unit 3.11 DG Power Plant Gujarat Ambuja Cement Ltd. has a captive power plant of 24 MW DG hall at Himachal Pradesh. Here there are 4 diesel generators stated up for providing

necessary power supply to the plant. This power plant ensure uninterrupted stable power to the cement plant during the time of power failure, low voltage, etc. These diesel generators are setted-up here by WARTSILA DIESEL, which are made in Finland and imported here. The main concern of this section is to run the kiln drive which requires about 9 MW of power supply in case of a breakdown. These are IC Engines (internal combustion) with V-type cylindrical arrangement than L-type of model type 18V32 where 18 is the no. of cylinders. V is the type of arrangement. 32 is the diameter in cm of the bore. Generally here Furnace Oil is used instead of Diesel or Petrol. These are 4-Stroke engines with a crank shaft and cam shaft arrangement. The concepts of Turbo Chargers (TC) put into action for increasing the efficiency of the engine. The basic

process goes in this manner that FO is fed to the storage tanks then to settling tanks for purification then to day tanks and FO separator where there are pump and heaters used to further purify this oil fed to the generators. After this it goes to the feeder unit to the booster unit to pump and filter units and lastly according to the load is fed to the Engine. Here there are three stages first the valves open then close and lastly fuel is fed. At this point the ignition starts in this manner according to the V branches of cylinders A,B 1-7-4-2-8-6-3-9- according to mass balance relations. In the engine there is an alternator, a fly wheel, water used as coolant, air pressure rotation, Lube Oil used as a lubricant and for the extraction of heat. At every 40 degree movement of fly wheel there occurs a Power-Stroke. Spur gears are also used here. Unit 3.12 Civil Department

Civil department handles jobs like cleanliness of the plant, maintenance of the building and construction jobs, etc. This department has mainly three wings a) Project wing - this project does also the major construction work. b) Developing wing - this wing does all the modification in the existing projects. c) Maintenance wing - this does all the maintenance, repair-jobs and keep everything clean at the plant site. Additional function performed by this department are - rural department, construction of the road, construction of temples and pedestrians. Unit 3.13 Mines Limestone is the main raw material for the production of cement. Limestone mines are 3 KM (serial distance) a far from plant site. The limestone from mines situated at Kaslog is transferred to the plant from the conveyor belt which is 2.8 KM long. Mining Operation - Fully mechanized open cast mining method is adopted for quarrying the limestone. The ripper rips up to a depth of 1M to loosen it and there after marks of heap of loose material. Blasting and drilling is carried on after initial opening of the quarry phase by ripping. All the big boulders are broken by using the hydraulic rock broker. The hydraulic excavators and front wheel loaders are used for excavations and toaching of blasted and ripped limestone into 35 tones rear dump trucks. The transportation to the limestone from the working faces of mines to the crushing plant and stock pile yard is called hauling. After hauling the limestone from here is fed to the limestone crusher (impact crusher) by rear dump truck. A push feeder arrangement is

made at the inlet point of the cursor. It can crush a maximum of 1Mx1Mx1M sized limestone into required size, which is to be transported through over land belt conveyor for the cement manufacturing. Unit 3.14 EDP GACL is a fully computerized manufacturing unit. All the computers are connected through LAN. The main function of this department is to development software for the plant to take care of the various commercial application. The department also provided software support to the plant. This department also provides computer training to the employees of the organization when new system develops. Unit 3.15 Costing Department The costing department is one of the main departments in the calculation of profit or loss for the year by valuation of stock. This department takes into consideration all the expenditure done in the company and compare the budgeted than the department inform the management and particular department to control the expenditure. By making these statements the cost department helps the management to take important decision.
Cost by process area Quarrying and crushing On-site raw materials to raw milling Raw milling and additives Blending Burning and Cooling Finish milling and additives Bulk handling and load out Manufacturing overhead Sub-total Bag premium Cost by natural expense Operating salaries Operating and service labor Supplies, rentals, services Purchased raw materials Fuel Power Mobile equipment Maintenance including labor Grinding media Refractories

Unit 3.16 Packing Department Packing department related with the packing of cement.

Process - After grinding the finished product is collected in cement silo, from the cement silo the cement is sent to packing plant for packing through air slides. In this process, firstly cement comes to cement hopper and the bucket elevator. Through bucket, cement comes to packing plant. The cement is then packed in plastic bags and loaded in trucks. The packing is three fully automatic rotary packing. Rotary Packers - There are three rotary packers in this plant. Every packer has six nozzles. Capacity of each nozzle is 80 TPH. In one hour 1600 boys are filled by rotary packer. Truck Loader - After the packing of the cement in the bags, the bags are loaded into the truck with the help of truck loader machine which consist of moveable conveyors and luffing conveyors. These conveyors make the loading process fast and convenient. In 10 minute 200 bags are loaded into the truck. Bulk Loading of Clinker - There are three belts loading terminal in plant. By this clinker are loaded into the truck and sent to Ropar grinding unit. Unit 3.17 Central Control Room All the control operations pertaining to the control of the accessories involved in the plant are done through this room. All the units if anyone of them malfunctions will have direct access to operational computers installed in the central control room. For a brief description of this CCR there are 3 pannels of touch sense oriented computers setted by TATA Honeywell having model number TDC3000, each panel shows similar thing and gives same information. Besides, this there is one more panel along side for running any machine by giving command and

one panel at instrumentation section runned manually for line process. This in the main attention oriented area of the plant which gives an overall view of the plant (detailed in nature) by just pressing a few buttons. This is the place to gather each and every bits and pieces of information. Here also there are

sections like Technical Library where all the books, journals, magazines and other reading material is available taken care of cement plant operations plus a Drawing Office which has a record of all the mechanical and particular drawings of each and every equipment working in the plant. It also has the quality control laboratory inside it which checks every hourly feeded raw meal. Conclusion GACL is a fast growing enterprise. A detailed study of the company shows that it has a bright prospective future. Cement industry itself shows a growth rate of 8-15%. In future, the company has also set-up its operational plants abroad in other countries where the cement demand is in excess of supply. Therefore the company has got a good chance there also. The

companys sale has grown by 10.54%. The net profit has jumped to 16% in 1998-99. The earning per share is rising, which rose by 16.93%. All these points infer to one conclusion i.e. the company has a very good and positive future. The dedicated workforce at Ambuja is the main reason for its tremendous success. It is because of sheer devotion and commitment by this workforce, therefore the company has achieved a regular production of 6-7MTPA by only consuming 5MT. Making the most efficient use of existing asset and working hard is the key to success.

Give a man an order and hell do the work reasonably well. But let him see his own target, give him freedom and authority and his tasks becomes a personal mission I Can This has worked miracles for the company. The company owes it

success will to this spirit. But the company should constantly review the needs and requirements of its employees and take necessary steps to fulfill them. Also the channel in the cement manufacturing should be constantly kept under the vision of check so the work can go hand in hand easily without any problems and this unit can compete with many other Foreign and Indian plants in this market of cement without any problem. This excellence performance is the reflection of the responsible and the mature attitude of its major players. Their individual performance sets an example for others to follow. Among those who played a major role in taking the cement industry to the present high position, one name will always shine bright GUJARAT AMBUJA CEMENTS.

GLOSSARY

State Gujarat H.P. Punjab Punjab Rajasthan M.P. Maharashtra W.B. Total

Location Ambujanagar Darlaghat Ropar (G) Bhatinda (G) Rabriyawas Raipur Gadchandur Sankrail (G) (G) - Grinding Unit

Million Tonnes 4.00 1.16 1.34 0.50 1.50 1.50 2.00 0.50 12.50

Board of Directors
Suresh Neotia Vinod Neotia M.L. Bhakta N.N. Pal Nmesh Kampani M.T. Patel Harshavardhan Neotia O.V. Bundellu IDBI) A.L. Kapur P.B. Kulkarni A.V. Rao Pulkit Sekhsaria Anil Singhvi B.L. Taparia Secretary N.S. Sekhsaria Managing Director Whole-Time Director Whole-Time Director Whole-Time Director Whole-Time Director Whole-Time Director Whole-Time Director & Company Non-Executive Chairman Non-Executive Director Non-Executive Director Non-Executive Director Non-Executive Director Non-Executive Director Non-Executive Director Non-Executive Director (Nominee -

Awards and Recognition

National Award for Commitment to Quality by the Prime Minister of India. National Award for Outstanding Pollution Control by the Prime Minister of India. ISO: 9002 Quality Certification ISO: 14001 certification for environmental systems. Best Award for the highest exports by CAPEXIL. Economic Times Harvard Business School Association Award for Corporate Excellence Best Productivity Award Mines Safety Awards

Location of the Plants and Offices

Ambujanagar 40 Kms. away from Veraval in Saurashtra, Gujarat. This location has 3 units namely Ambuja, Gajambuja and Gajambuja II. To reach Ambujanagar, there are two trains available namely Girnar Express and Somnath Express from Ahmedabad at 9.50 p.m. and 11.00 p.m. respectively. Ambujanagar is accessible by air from Mumbai. There is flight form Mumbai to Diu. Diu is around 42 Km. away from Ambujanagar. Darlaghat Near Shimla in Himachal Pradesh with one unit. Accessible by rail and road. Shatabadi Express plies between New Delhi and Kalka. You may go by road to Darlaghat, which is 92 Kms. away. Gadchandur Near Chandrapur, Maharashtra, one unit. Accessible by road from Chandrapur. Flights are also available to Nagpur from Mumbai. The plant site is around 72 Kms. from Nagpur. Bhatinda Punjab, Grinding unit. 203 Kms. by road from Chandigarh and rail from Delhi. Ropar Punjab, Grinding unit. 40 Kms. by road from Chandigarh and rail from Delhi. Muldwarka 8 Kms. away from Ambujanagar, coastal line. Its a Bulk Cement Terminal (BCT) which dispatches Cement and Clinker and receives imported coal. Magdalla Near Surat in Gujarat. Bulk Cement Terminal (BCT). Surat is accessible by road and rail. Panvel Near Mumbai, Maharashtra. Bulk Cement Terminal (BCT). Accessible by road and harbour line local trains from Chatrapatti Shivaji Terminus Station - Mumbai. Corporate Office Nariman Point, Mumbai/Kalina, Santacruz (E), Mumbai. Regional Offices Ahmedabad, Calcutta, Delhi. Associate Companies Ambuja Cement Eastern Ltd. (ACEL) million - Sankrail, W. Bengal Ambuja Cement Rajasthan Ltd. (ACRL) Terminal in Sri Lanka Colombo Capacity (million tones) 18 million - Bhatapara, M.P. 100 1.5 million - Rabriyawas, Rajasthan 0.5 million - Galli - 120 Kms. from

General Information
1.0 Working Decorum 1.1 Work Culture There are professional teams of people who take care all the functional and operational requirements. We are professionally managed organization, We value

which encourages performance oriented productive environment.

employees, who have sense of integrity, loyalty, responsibility and a high degree of commitment. 1.2 Dress Code Most of the colleagues observe a formal code of dressing. Male

members are usually dressed in formal attire whereas ladies prefer to follow the conventional mode of dressing. This code also applies, when employees

undergo training or go on official tours. 1.3 Hours of Work You might like to know the office timings of other locations. Sites Ambujanagar General office timings are from 9.00 a.m. to 6.00 p.m. with one hour lunch break from 1.00 p.m. to 2.00 p.m., Monday to Saturday. Shifts Timing Morning shift Evening shift Night shift 6.00 a.m. to 2.00 p.m. 2.00 p.m. to 10.00 p.m. 10.00 p.m. to 6.00 a.m.