ABB Extends Drive Lifespan at ACC’s Jamul Cement Plant
ABB has signed a multi-year ABB Motion OneCare service agreement with ACC Limited, part of the Adani Group, to enhance operational reliability and equipment performance at its Jamul cement plant in Chhattisgarh. The agreement covers drive reconditioning, digital monitoring and energy assessments to extend equipment lifespan and improve operational efficiency.
The first phase, completed in April 2026, involved reconditioning 25 ABB ACS800 variable speed drives on-site without requiring a major production shutdown. By retaining existing cabinets and refurbishing equipment instead of replacing entire panels, the initiative avoided approximately 16 tonnes of CO? emissions.
A second phase, scheduled for the fourth quarter of 2026, will involve reconditioning another 25 ACS800 drive modules. ACC has also implemented ABB Ability Digital Powertrain Insights to enable predictive maintenance and minimise unplanned downtime.
The ACS800 drives, installed in 2010, had operated reliably for over a decade. However, ageing electrical components and increasing fault incidents prompted ACC to undertake a comprehensive equipment assessment. ABB's evaluation confirmed that the existing cabinets and enclosures remained structurally sound, making targeted reconditioning a cost-effective alternative to complete replacement.
Under the agreement, ABB has developed a maintenance programme aligned with ACC's operational schedules and budget requirements. The digital monitoring system provides continuous insights into equipment temperature, current, vibration and fault patterns, helping maintenance teams identify potential failures before they disrupt operations.
Amit Gupta, Local Division Manager, Motion Services, ABB India, said the initiative focuses on restoring equipment with remaining operational value while providing tools to prevent future failures and improve long-term reliability.
The project also supports circular economy practices by extending the useful life of existing industrial assets. According to ABB, drive reconditioning can reduce lifecycle emissions by 50-80 per cent compared with complete equipment replacement.
Vinod Bahety, CEO – Cement Business, Adani Group, highlighted the importance of transitioning from reactive maintenance to a structured approach supported by technical expertise and actionable insights. He noted that the agreement enables ACC to improve equipment reliability without undertaking a complete system overhaul.
The initiative demonstrates how targeted equipment upgrades, predictive maintenance and digital technologies can help cement manufacturers improve operational efficiency, reduce emissions and extend the lifespan of critical industrial assets.
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