Cement plant industrial background

Excellence in Engineering
Project & Maintenance Management

Providing world-class technical solutions for cement plants worldwide with 40+ years of industry expertise.

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OUR COMPREHENSIVE APPROACH

From initial planning to flawless execution and sustainable maintenance - we cover the entire project lifecycle

Planning

Layout Planning:

  • Land initial layout planning of plant and machinery
  • Design of approach roads for smooth logistics flow

Basic Engineering:

  • Civil: GA drawings, floor layouts, elevations
  • Electrical: Room layouts, cable routing
  • Automation: CCR, PLC, PID designs
  • Lighting: Panel and distribution design

Detailed Engineering:

  • Civil: Soil testing, piling, foundation design
  • Mechanical: Platform design, piping systems
  • Electrical: Load compilation, distribution planning
  • Procurement: Technical-commercial evaluations

Execution Phase

Civil Works:

  • Land development and site preparation
  • Layout marking as per approved drawings
  • Soil verification and piling works
  • Foundation and structural construction

Mechanical Works:

  • Machinery receipt, inspection and storage
  • Equipment erection and installation
  • Fabrication of mechanical structures
  • Safety platforms and access installation

Electrical Works:

  • Panel and transformer installation
  • Cable laying and tray installation
  • Lighting systems setup
  • Substation establishment

Instrumentation & Commissioning:

  • No-load trials of equipment
  • Group trials under load conditions
  • Full-scale plant operation validation

Maintenance Strategy

Maintenance Planning:

  • Comprehensive maintenance schedules
  • Spare parts management (ABC analysis)
  • Critical/Insurance spares identification
  • Regular operational spares planning
  • Consumables inventory management

Cement Plant Maintenance:

  • Preventive maintenance of key equipment:
  • - Preheaters & Rotary Kiln
  • - Cooler systems
  • - VRMs & Ball Mills
  • - Stacker-Reclaimer Systems
  • - Crushers & Packers
  • - Storage Silos
  • - ESP and bagnhouse -Chetna engineering services can guide for zero emission.

OUR CO. CAN PROVIDE FOLLOWING SERVICES

TECHNICAL STUDIES AND OPTIMIZATION IN CEMENT PLANTS

  1. Technical study of pyro section and optimization
  2. Technical study of mills and optimization
  3. Fan study and optimization
  4. Energy audit of kiln and mills
  5. Civil structure stability study and suggestions
  6. Mechanical stability study and suggestions
  7. Quality study of limestone from mines to kiln feed and suggestion for best raw mix based on available limestone and additives
    8. In quality control and assurance management area company can undertake followings,
    i) Study of mines limestone quality and suggest for optimal raw mix with focus on Mines life enhancement,local additives usages, available fuels quality and best productivity.
    ii)Studied of Raw mill silo blending, effectiveness of preheater system in pyro processing, clinker quality through various stages samples quality data and suggest for improvement.
    iii) Studies of volatization cycles in kiln & preheater system.
    iv) Explore & suggest for usages of alternative raw materials ,gypsum and fuels for cost reductions.
    v) Support in value added product development /manufacturing like LC3 (Lime stone clay cement), Oil well cement, Water repellent cement etc.
    vi) Plant Laboratory study/Audit for improvement .
  8. We have experts for oil well cement production. We can guide maintain production as well as quality of oil well cement (OWC)
  9. White cement process study and suggestions by experts
  10. Raw mix homogenisation
  11. Kiln feed chemistry management
  12. Clinker quality improvement programme
  13. Blaine vs residue optimisation
  14. Coal quality impact analysis
  15. Process mineralogy and microscopy audit.

MAJOR MAINTENANCE WORK IN CEMENT PLANTS

  1. Major maintenance of kilns: like KILN Tyre and support roller, thrust roller and girth gear and pinion maintenance and alignment
  2. Ball mills - slide shoe, trunnion repairs, girth gear and pinion repair maintenance and alignments
  3. Gear box repairs - spur gear, worm gear, helical gears and planetary gear boxes - small to large size
  4. Hot kiln alignment and implementation of suggestions. Machining of tyre, s.rooler steps in running of kiln
  5. Cracks repair and reconditioning by special welding technology:
    • Kilns shell repairs by welding, tyre cracks repair by thermit welding or special arc welding
    • Machining of kiln Tyres, supporting rollers if step formation happened
    • Ball mill shell crack repairs, trunnion crack repairs, slide shoe crack repair by special welding procedures and machining
    • VRM's rocker arm, table, roller hub, bridge cracks repair by special welding techniques
  6. Kiln and cooler, ball mills, VRM's maintenance and alignment work
  7. Compressors and blowers' maintenance
  8. Audit of castings used in cement plant as wear liners and suggestions for proper chemical composition and treatment process for achieving optimum life

CEMENT PLANTS PROJECTS

  1. Expansion project or retrofit project of any section of cement plant - like: preheater, kiln, Cooler, raw mill, cement mills and roller press etc. major maintenance
  2. Fly ash classification and blending of fines fly ash with OPC and coarse feeding system to cement grinding mill - New project designed by Chetna engineering services
  3. Green field project management /coordination (concept to commissioning)

FLYASH HANDLING PROJECTS

  1. Port based large ship LOADING - pumping system for fly ash, cement or powdery material designed by Chetna engineering services
  2. For distant storage and pumping of fly ash classification plant inside power plant disposal area pump station (vacuum system) design and engineering developed by Chetna engineering services
  3. Flyash low weight blocks manufacturing plant project management concept to commissioning. Design and engineering developed by CHETNA ENGINEERING SERVICES
  4. Diesel fired hot air generator for bulkers fly ash where moisture content is more
  5. Green field projects management /coordination (concept to commissioning)
  6. Stationary packer for jumbo bag loading with storage bin and bottom weighing system design and engineering by CHETNA ENGINEERING SERVICES
  7. Design engineering, supply and commissioning of jumbo bag packing with weighing system

TRAINING PROGRAMMES & OTHER SERVICES

  1. Training of technicians (classroom and on site) for cement plant operation and maintenance under INSTITUTE OF SKILL DEVELOPMENT PROGRAMME
  2. Lime plant maintenance and trouble shootings
  3. Supply of trained Engr's/ccr operators/mill right fitter for commissioning of cement plants new project or maintenance
  4. Steel plant study , trouble shooting and upgradation.
  5. Petro chemical plants study , trouble shooting and upgradation.
  6. sugar plant study and trouble shooting and upgradation.
  7. Due Diligence of cement plants.

1st Jan 2024

Year Established

10

Projects Executed

Projects Executed

jaycee Build Corp LLP

Fly Ash grinding mill circuit - Basic & Detail Engineering

Thyssen - Pune Maharashtra

Root cause analysis for cracks in pre-heater cyclone and ductings

Alpa China(Powder Equipment)

Improvement of classifying system with suggested modifications

Buddha Kia Minerals - Chera Punji, Meghalaya

Lime Plant inspection and operational guidance.

Unity Cement(PMC Cement Pvt. Ltd.)

Technical Study of Pyro Processing
New Pre Heater Project Management

Tata chemicals Ltd - Mithapur

Technical Study of Pyro Processing
New Pre Heater Project Management

Dalmia cement Umarangshu assam -- RCA.

Technical Study of Pyro Processing
New Pre Heater Project Management

Safe cement - Jaipur Rajsthan

green field project coordination

Adani cement - Rajpura.

HRP roller replacement and reconditioning of adani cement Rajpura .

United cement - Nepal

plant up gradation)/ CSP/stacker reclaimer projects.

ABOUT CHETNA ENGINEERING

Company Profile

Chetna Engineering

Chetna engineering services offers variety of services in the field of project planning / execution/ operation & Maintenance of Cement plants, Thermal power Plant, Steel plant, Steel Casting plant, Fly-ash processing plant, Mineral processing plant (Like GGBS).

It has highly experienced professionals who are having excellence of proficient level of project planning/ project execution/ commissioning capacity enhancement & smooth operation of the plant.

Chetna engineering services offers excellent maintenance planning along with the recommended spares which are important to maintain the plant. Listing of insurance spares and general spares category wise (as per ABC Analysis). Codification, costing, total inventory projection and control provisions.

Mr. Pramod Kumar Mishra, CEO

Mr. Pramod Kumar Misra

CEO & Managing Director (B.Tech Mechanical)

40+ Years experience in core competency of project and operation and maintenance.

Experience Highlights:

  • Sanghi Cements (India) as AVP Proj & Maint
  • Dangote Cement (Nigeria) as Senior GM Project
  • ARM Group (Tanzania) as Plant Head
  • National Cement company (Kenya) as COO
  • Amrit Cement (Meghalaya) as Plant Head
  • JC Build Corp LLP as Vice President Tech & Proj
  • Polaris Steel Casting Pvt. Ltd as MD

Mobile No: +91 7028600688

Email ID: pramodkmishra2008@gmail.com

Our Associated Executive Director

Dedication. Expertise. Passion. Each member brings a sense of passion to their work.

Mr. S N Arya

Mr. Ravinder Mohan Bhardwaj

Executive Director ( Maintenance & projects)

B.Tech mechanical from IIT Delhi.

50+ years experience in cement plant operations and kiln optimization

Mr. M.M Kothari

Mr. Rajiv Kapoor

Executive Director (Process and Developmental projects)

B.Tech ( chemical) from IIT Roorkee.

35+ years experience

Our Associated Technical Director

Dedication. Expertise. Passion. Each member brings a sense of passion to their work.

Mr. R M Sahu

Mr. R M Sahu

Associate Technical Director (Process & Quality Control)

B.E (Chemical)

35+ years experience

Mr. M.M Kothari

Mr. M.M Kothari

Associate Technical Director (Projects)

35+ years experience

Mr. M.M Kothari

Mr. Umesh Singh

Associate Technical Director (Maintenance and retrofit)

35+ years experience

Mr. Rakesh Gattani

Mr Prakash Chandra Joshi.

Associate Technical Advisor (Cement Process & quality operation optimization.)

35+ years experience

Our Associated Technical Experts

Seasoned professionals with specialized expertise in their respective fields

Mr. Akhilesh Dubey

Expert (Project & Maintenance)

35+ years experience

Mr. Rakesh Gattani

Expert (Quality Control)

MSC (Physics), MS (Quality Management)

35+ years experience

Mr. Rakesh Gattani

Mr. Rajeev Srivastava

Expert(Civil)

B.E (Civil)

35+ years experience

Mr. Rakesh Gattani

Mr. Vitthal Waghmare

Expert(Design & Engineering)

35+ years experience

Mr. Rakesh Gattani

Mr. Sailesh V Dalvi

Expert(Process Lime Plant)

BSC (Chemistry)

35+ years experience

Mr. Rakesh Gattani

Mr. G.R Chawda

Expert(Electrical)

B.E (Electrical)

35+ years experience

Mr. Rakesh Gattani

Mr. Ashok Kumar Tiwari

Expert(Quality Control)

MSC (Chemistry)

35+ years experience

Mr. Rakesh Gattani

Mr.Prabhu Bijapure

Expert(instrumentation and automation)

40+ years experience

Mr. Rakesh Gattani

Mr. KM Mallick

Expert(maintence & Project)

35+ years experience

Mr. Rakesh Gattani

Mr.Sudesh kumar sharma

Expert(process).

M.Tech Metallurgy

40+ years experience

Mr. Rakesh Gattani

Mr.Sandeep Bajpai

Expert(electrical)

35+ years experience

Mr. JP Mote

Mr.JP Mote

Expert(geologist)

35+ years experience

Mr. JP Mote

Mr. C S Mishra

Expert( soda ash & cement plant)

35+ years experience

Mr. JP Mote

Mr. Ashok Gundetti

Expert(Process)

BS(process engineering)- BITS Pillanl

35+ years experience

Mr. JP Mote

Mr.Narendra Singh Thakur

Expert(Process)

M.Sc.( chemistry)

35+ years experience

Mr. JP Mote

Mr.Rajesh Tukliya

Expert(Project)

BE( Mechanical)

30+ years experience

Mr. JP Mote

Mr.S P Mishra

Expert(Steel plant)

BE( Mechanical)

40+ years experience

Mr. JP Mote

Mr. Jainendra Kumar

Expert(Sugar plants)

BE ( mechanical ) MIT - Patna.

35+ years experience

Mr. JP Mote

Mr. Arvind Kumar Mishra

Expert(Petro chemical plant)

B.Tech electrical.from HBTI kanpur.

35+ years experience

Mr. JP Mote

Mr. Manjinder singh Sura

Expert( Maintenance and project)

39+ years experience

Our Associated Sr. Technical Assitants

Seasoned professionals with specialized expertise in their respective fields

Mr. Rakesh Gattani

Mr. AG Shani

SR Technical Assistant

35+ years experience

Expertise : Kiln,cooler ,Mills,major gear boxes including planetary gear box repair & alignment

Mr. Rakesh Gattani

Mr. Vishwas

SR Technical Assistant

35+ years experience

Expertise : Kiln,cooler ,Mills,major gear boxes including planetary gear box repair & alignment

Mr. Rakesh Gattani

Mr. Prem Narayan Yadav

SR Technical Assistant

35+ years experience

Expertise : Kiln,cooler ,Mills,major gear boxes including planetary gear box repair & alignment

Mr. Rakesh Gattani

Mr. Umesh Muni Shah

SR Technical Assistant(Welding)

35+ years experience

Associated Companies

  1. Cement plant engineering chennai ( CEO Mr Lognathan is our technical director - projects).Design tribe Hyderabad for civil/mech/E&I 
  2. Ronak Patel -- E&I design and engineering expert. his Co. Walnut Control System Pvt. Ltd.
  3. Ritz india ltd ----- Fan engineering expert.
  4. Suru engineering --- powder technology expert ( ultra fines and fines) -- Mr sanjay Nikam is also one of technical director of our co . He is external Faculty of IIT - Mumbai .
  5. Allen Smith Bombay --- Hot kiln alignment expert.

CONTACT US

Get In Touch

Address

Flat No.1404, Block-B1
Majestique Rhythm County,
Autadwadi,Handewadi,
Pune, Maharashtra, India
PO: 412308

Chetana Engineering Services Phone No.

+91 7709870688
Email - chetna.engservices24@gmail.com

Prop.Promod Kumar Misra

+91 7028600688
Email ID: pramodkmishra2008@gmail.com

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