The Dindi Balancing Reservoir (DBR) dam project was allotted by the Telangana Govt. to Ravitej Projects in 2017. The project aimed for completion within 24 months and required five-end products, totaling 8 lac tonnes (800 000 metric tonnes) of aggregates required to complete the project. Ravitej Projects not only managed to deliver the project in just 18 months, six months ahead of schedule, but it also saved 50% on manpower costs and 5-6% on overall project costs with the help of Metso. The company aims to deliver key projects in India with Metso’s advanced equipment and strong service support throughout the country.

CHAPTER ONE

Meeting varied aggregate requirements on schedule

Ravitej Projects has been undertaking different types of projects in the road sector, irrigation and the power sector. The many types of projects have required different raw materials, i.e. aggregates, and have also involved stringent deadlines with respect to the delivery of the project.

The only way for Ravitej to meet these challenges was to have the right equipment to cater to the varied requirements for the needed aggregates and strong production to finish the project on schedule. Mobility, specifically the ability to move production assets easily from one location to another, was also a key consideration for Ravitej Projects’ ability to keep up with delivery deadlines. With these requirements in mind, Ravitej opted for Metso’s Nordwheeler two-stage crushing and screening plants for the projects it has throughout India.

“Our relationship with Metso started way back in 2007, and today we have seven Nordwheeler plants from Metso. Metso has been a backbone for us over these years and we have always trusted Metso when the stakes are high. When we were awarded with this prestigious dam project in Telangana state, i.e. the Dindi Balancing Reservoir project, our requirements changed completely from our previous project, and we opted to go with Metso again.The purpose of the project is to store the backwaters of the Krishna River; the aim is to replace fluoride water with clean and safe drinking water and to irrigate 150 lac acres of land, which is one of the prime concerns of the Telangana Government,” stated Mr. P. Adinarayana, a Partner at Ravitej Projects Pvt. Ltd.

The purpose of the project is to store the backwaters of the Krishna River; the aim is to replace fluoride water with clean and safe drinking water and to irrigate 150 lac acres of land, which is one of the prime concerns of the Telangana Government.
Mr. P. Adinarayana, a Partner at Ravitej Projects Pvt. Ltd.

Once the requirements were shared with the experts at Metso, the team immediately understood the stringent requirements of the dam project and designed the plant with consideration to the quantity of aggregates that would be required for the project. Mr. P. Adinarayana added, “Here the requirement was not of GSB (minus 40mm aggregates), which is normal with road projects; rather, the requirement was for minus 80mm aggregates, which is unique. Based on experience, and as suggested by Metso, we understood that the GP220™ cone crusher is the first and only crusher in India that can produce minus 80mm with the use of a different set of liners.”

After analyzing Ravitej’s specific demands for this new project, the design team, the technical team and the projects team at Metso suggested a two-stage Nordwheeler crushing and screening plant with some additional alterations and additions to accommodate this specific application.

CHAPTER TWO

A plant tailored to the requirements

“Ravitej Projects always prefers to go with Metso’s Nordwheeler plants to fulfill their aggregates needs. The prime challenge in designing the solution for them was their specific requirement of minus 80mm aggregates. To meet this specific requirement, we had to redesign the standard GP220™ ECS liners with ECLS (large setting) liners. For the primary stage, we supplied a NW106™ plant with a C106™ jaw crusher and a 110kW motor. It has a 6-cubic-meter onboard hopper along with an extended 23-cubic-meter hopper to support continuous dumper loading. Because of this extended hopper, the plant was able to reach the maximum capacity of 300 tonnes per hour,” explained Mr. Niraj Srivastava, Vice President, Technical Support, Metso India.

He added, “For the secondary stage, we supplied a NW220GPD™ plant with a GP220™ cone crusher with ECLS-large setting liners, a 200kW motor and IC50C™ automation. It has an onboard, four-deck dual-slope screen that is 1.8 meters wide and 5.5 meters long. To get the fifth end product, we supplied a two-deck CVB-1845 screen, which is 1.8 meters wide and 4.5 meters long. These two screens from Metso enabled Ravitej to produce five end products: 0-5mm, 5-10mm, 10-20mm, 20-40mm and 40-80mm.”

We feared that we wouldn’t be able to deliver the Dindi Balancing Reservoir project within the 24-month deadline. But, with Metso’s machinery and support, we were able to complete the project in just 18 months. The plant was designed to produce 250 tonnes per hour, but we succeeded in producing as much as 300 tph.
Mr. P. Adinarayana, a Partner at Ravitej Projects Pvt. Ltd.

With the change in the designs, the Nordwheeler plant met the varied requirements for the five end products and the project was also completed well ahead of schedule. The planned 24-month project was completed in just 18 months, and Ravitej was able to produce 8 lac tonnes of aggregates in a short span of time.

By completing the project ahead of schedule, Ravitej to save 5-6% on the overall project costs. Mr. P. Adinarayana shared, “We feared that we wouldn’t be able to deliver the DBR (Dindi Balancing Reservoir) project within the 24-month deadline. But, with Metso’s machinery and support, we were able to complete the project in just 18 months. The plant was designed to produce 250 tonnes per hour, but we succeeded in producing as much as 300 tph.” He added, “We thank Metso for this achievement and for their excellent after-sales support. Their 100% efficient service support enabled us to complete the project ahead of schedule and to save 5-6% on the overall project, which is estimated at approx. INR 500 crores.”

CHAPTER THREE

Cost savings with automation

The automation and service support from Metso also played a key role in completing the project on time. Any problems were addressed immediately with the help of automation, and this resulted in increased uptime for the plant, enhanced production and a reduction in the overall cost of production.

Mr. Jasti Srinivas, Managing Director, Ravitej Projects Pvt. Ltd. shared, “The crusher’s efficiency is optimized with the help of automation. IC50C™ automation from Metso has been instrumental in delivering what was required in this project. A problem may occur in any piece of equipment, but the key is how quickly it is resolved. With Metso IC50C™ automation, it’s easy to identify the problem area, as it displays an error code. Simultaneously, Metso’s brilliant service support is always there to help us quickly, thus reducing downtime. Because of these two add-ons from Metso, we were able to go beyond 250 tph with this plant and we were able to save approximately 50% on manpower costs alone. With automation, the entire cone crusher department can be handled by just one skilled laborer sitting at the control room panel.

He added, “The main differentiator between Metso and its competitors is service. We have been getting quality service from Metso for more than ten years now, and I am confident that this brilliant support will continue also in the future. Because of our endless faith in Metso and its people, we have been giving them repeat orders. I think Metso’s success is the confidence it gives to its customers.”

The main differentiator between Metso and its competitors is service. We have been getting quality service from Metso for more than ten years now, and I am confident that this brilliant support will continue also in the future.
Mr. Jasti Srinivas, Managing Director of Ravitej Projects Pvt. Ltd.
Ravitej Projects in brief

Ravitej Projects Pvt. Ltd has been associated with different types of industries, e.g. the road sector, irrigation, and the power sector. For roads, Ravitej has implemented projects for the NHAI (National Highway Authority of India), and the company has been working on irrigation projects allotted by PWD and CPWD. The company’s annual turnover is approximately INR 200 crores and has been instrumental in delivering key projects in India. Ravitej is known for its timely delivery of projects and the quality of its work – and this has been the prime reason for Ravitej being the preferred choice in the industry.