Concrete

Predictive maintenance is a top priority in industrial IoT

Published

2 weeks ago

August 23, 2024

Roshna

Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries, ABB India, discusses how advanced digital solutions are revolutionising the cement industry by enhancing operational efficiency, reliability, and sustainability.

How does ABB Ability™ Knowledge Manager help cement plants connect business KPIs to operations and optimise their performance?
ABB Ability™ Knowledge Manager (KM) is a true manufacturing operations management solution which, in a single platform, integrates data from operational, control, production, quality, downtime and business systems and converts data into actionable information.
At its core, ABB Ability™ Knowledge Manager offers industry-specific process and quality data warehousing, presenting information in a meaningful way. This single, powerful tool meets various needs: production information and downtime management, production scheduling, energy cost tracking and benchmarking, plant emissions monitoring and alarm analytics. Its user-friendly and intuitive statistical analysis tools boost both production and quality.
Statistical production analysis offers powerful tools to monitor quality-related process variables effectively. It helps verify if these variables are randomly scattered around the mean and normally distributed, and it detects variability and process changes to prevent instability. Some key tools we use include X charts (Shewhart), EWMA charts, CUSUM charts, histograms, and multivariable X-Y correlation graphs.
To enhance transparency across a plant or fleet of plants, our KM is available via a mobile app for smartphones and tablets. This allows plant and company managers to view operational performance anytime, anywhere. ABB Ability™ KM is highly scalable to meet customer needs, with flexibility for plant-level, regional, and enterprise-level deployment. It helps cement customers track processes, quality, operations, emissions, and downtime using standardised custom templates, IoT connectors and seamless ERP integration, all backed by excellent security policies.

How does ABB’s shift from reactive to predictive maintenance impact the operational efficiency and reliability of cement plants?
Predictive maintenance is a top priority in industrial IoT because it combines data, domain expertise, IoT platforms and AI. This combination allows manufacturers to predict anomalies in their plants. I believe, by using a modern asset optimisation system, cement manufacturers can shift from reactive to predictive maintenance strategies, avoiding unnecessary maintenance and reducing operating costs. This is achieved through the vast amount of data generated by smart devices connected in the plant, such as motor control centers, numerical relays, smart transmitters, and various asset models for motors, transformers, grinding circuits and conveyors.
ABB Ability™ Predictive Maintenance service leverages digital applications for quick detection of impending issues, root-cause analysis with recommendations, and assessment of severity levels and health indexes. It offers ready-to-use standard models that are easy to deploy and scale, helping to identify active conditions, assess health with severity and ensure easy deployment.

What are the key features of ABB’s AI-based Asset Performance Management (APM) suite, and how does it enhance asset optimisation in cement plants?
Predictive asset models can help cement plants operate with fewer workers, and to manage operations remotely. An APM solution, powered by predictive asset models, would give the remote teams full visibility into data that would tell them the health of all the assets in the plant. Think of AI-enabled APM as the most cost-effective way to extend the life of the aging (and newer) assets, to decide on the optimal timing for scheduled maintenance turnarounds (one of the biggest costs in a plant) and plan better. The new AI-based APM helps develop models, algorithms, dashboards and reports using a maintenance-oriented platform. It integrates with enterprise-level systems and evolves into digital strategic asset management. This makes transitioning from predictive to prescriptive maintenance and management possible.
ABB was approached by one of Asia’s largest manufacturers of grey cement, ready mix concrete and white cement. The customer has 19 integrated plants, one clinkerisation plant, 25 grinding units and seven bulk terminals. Working together with ABB domain experts, the company used maintenance-oriented algorithms that alerted the client to the potential failure of a particular part or electronic device, allowing it to perform predictive rather than reactive maintenance. Combined with a range of other digital solutions, including ABB Ability™ Expert Optimizer and ABB Ability™ Collaborative Operations, the customer was able to achieve ROI in eight months, a reduction in costs by 3-5 per cent and increase in the life cycle of assets. In this way, cement manufacturers can fully utilise the power of digitalisation to reduce energy usage and emissions, paving the way for the smart, sustainable and profitable cement plants of the future

With increasing digitalisation, how does ABB ensure the cybersecurity of cement plant operations and protect against potential cyber threats?
More and more cement producers on the digitalisation path would like to take a more proactive approach to cyber security. ABB’s analytics solutions and services continuously monitor, diagnose and resolve security issues, helping safeguard people, assets and reputation. Because technology and cyber threats can both change unpredictably, the strategy needs to be reviewed periodically, including performing simulations under different circumstances, like a major ransomware incident.
ABB realises that its customers are concerned about protecting against and minimising the risk of a cybersecurity incident. While asset owners have prime responsibility for any incident response procedures, ABB actively monitors for any cybersecurity threats that pose a potential impact to ABB control systems. All in all, ABB is well positioned as a systems integrator – a factor that is foundational to the company’s cybersecurity strategy in the industrial controls arena. There are two aspects to this. The first is that the customer can trust that implementation of a third party solution in ABB’s reference architecture will result in optimal value. The second is that the cement manufacturer can rest assured that if there is a failure or a problem with implementation, it will, in all probability, not impede the availability or safety of assets and will ease their recovery. ABB has been ensuring its customers by following the highest level of security policies during design, development, deployment and communications by adhering to the industry best practices.

– Kanika Mathur

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Chhattisgarh MP criticises sudden cement price hike

The state’s cement industry benefits from low labour costs and abundant resources.

Published

5 hours ago

September 9, 2024

admin

Senior BJP leader and newly elected MP Brijmohan Agrawal has strongly condemned the recent surge in cement prices in Chhattisgarh, urging immediate intervention from both state and central authorities. Agrawal warned that the abrupt price increase would negatively affect critical infrastructure projects, including roads, bridges, schools, and housing under the Prime Minister’s Aawas Yojana (PMAY).

In letters addressed to Chief Minister Vishnu Deo Sai, Union Finance Minister Nirmala Sitharaman, and the Competition Commission of India, Agrawal alleged that a cartel of cement companies was behind the price hike. Cement prices have risen by Rs 50 per sack since September 3, impacting local projects despite Chhattisgarh’s wealth of mineral resources, including iron, coal, and energy.

Agrawal emphasised that the state’s cement industry benefits from low labour costs and abundant resources, yet has chosen to impose a financial burden on the public. The price of cement has jumped from Rs 260 to Rs 310 per bag in a day, with costs for government projects rising from Rs 210 to Rs 260 per bag.

He called for government action to reverse the price increase, warning that it could disrupt public works and inflate costs, potentially harming both state and national interests.

(ET)

Concrete

Indian cement makers to invest $ 14.3 bn

The bulk of this growth will come from the top-three cement producers–Ultratech, Ambuja and Shree Cement

Published

3 days ago

September 6, 2024

admin

Indian cement manufacturers are set to invest approximately USD 14.3 billion over the next four years to increase capacity by 25 %. This move, driven by rising domestic demand, is expected to add an additional 160-170 million tons of cement production annually. The industry’s expansion will be predominantly funded through internal accruals, with minimal reliance on debt. The expansion is spurred by government’s massive infrastructure push, with plans to invest USD 1.7 trillion in infrastructure projects by 2030. According to S&P Global Ratings, the demand for cement in India is projected to grow at a compounded annual growth rate (CAGR) of 7 % over the next four years, aligning with the planned capacity additions.
The bulk of this growth will come from the top-three cement producers–Ultratech, Ambuja and Shree Cement, which will account for over 70 % of the country’s total capacity increase. This expansion equates to an annual capital expenditure of close to Rs 300 billion, which will be more than double the average annual capex of the past decade. The leading cement companies, which produce 70 % of India’s total cement output, are in a strong financial position to support this expansion. Rising cement prices have bolstered their balance sheets, allowing them to reduce debt significantly while maintaining robust cash flows.

Concrete

SEBI Places JSW Cement’s Rs.4,000 Cr IPO on Hold

SEBI halts JSW Cement’s ?4,000 crore IPO.

Published

5 days ago

September 4, 2024

admin

The Securities and Exchange Board of India (SEBI) has placed the proposed ?4,000 crore Initial Public Offering (IPO) of JSW Cement on hold, citing regulatory concerns. This development comes as a significant pause in the cement manufacturer’s plans to raise capital through the public markets, a move that was expected to bolster its expansion and growth strategies in the competitive construction sector.

IPO Overview: JSW Cement, a key player in the Indian cement industry, had announced its intentions to launch a ?4,000 crore IPO. The offering was aimed at raising funds to support the company’s ongoing expansion projects, reduce debt, and improve operational efficiency.

SEBI’s Decision: SEBI, the regulatory body overseeing the capital markets in India, has decided to withhold its approval for the IPO. The decision was made after careful scrutiny of the draft red herring prospectus (DRHP) submitted by JSW Cement. While specific reasons for the hold have not been disclosed, it is understood that SEBI has sought further clarifications on certain aspects of the filing.

Impact on JSW Cement: The postponement of the IPO is likely to impact JSW Cement’s financial planning and expansion initiatives. The company had intended to use the proceeds from the IPO to fund new projects, including the construction of additional cement plants, modernization of existing facilities, and investments in sustainable practices.

Market Reactions: The decision by SEBI has led to a cautious response in the market. Investors and market analysts are closely monitoring the situation, as the delay could affect investor sentiment towards the company and its future fundraising efforts. The construction sector, which heavily relies on capital-intensive projects, may also be impacted by this development.

SEBI’s Concerns: SEBI’s decision to put the IPO on hold highlights the regulatory body’s commitment to ensuring transparency and investor protection in the capital markets. The regulator may be seeking additional information regarding JSW Cement’s financials, corporate governance practices, or other disclosures to ensure that the IPO meets all necessary requirements.

JSW Cement’s Response: JSW Cement is reportedly working closely with SEBI to address the concerns raised and to provide the required clarifications. The company remains optimistic about receiving the necessary approvals in due course and proceeding with the IPO as planned.

Industry Context: The Indian cement industry has seen significant activity in recent years, with companies looking to expand their capacities to meet growing demand. IPOs have become a popular route for raising capital, allowing companies to fund expansion and reduce debt. However, the regulatory environment remains stringent, with SEBI playing a crucial role in maintaining market integrity.

Future Prospects: While the IPO is currently on hold, JSW Cement’s long-term growth prospects remain robust, driven by its strong market position and ongoing investments in capacity expansion. The delay in the IPO may prompt the company to explore alternative fundraising options, such as debt financing or private equity, to meet its immediate capital needs.

Regulatory Environment: SEBI’s decision underscores the importance of regulatory compliance in the IPO process. Companies looking to tap the capital markets must ensure that their disclosures are thorough and transparent, meeting all regulatory standards to gain investor confidence.

Conclusion: The hold placed by SEBI on JSW Cement’s ?4,000 crore IPO is a reminder of the challenges that companies face in navigating the regulatory landscape. While this may delay the company’s fundraising plans, it also provides an opportunity to strengthen its disclosures and align with regulatory expectations, ultimately benefiting both the company and its investors.

JSW Cement now faces the task of addressing SEBI’s concerns to move forward with its IPO, a crucial step in its growth trajectory within the Indian cement industry.