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Chapter - 1
STEEL SCENARIO
Iron was possibly used in Egypt, from the middle pre historic times (7000-6000 B.C.).
Accordingly, to Sir Flinders Petrie all such iron was of meteoric origin and that manufactured
iron did not come into general use until after the Assyrian invasion of Egypt in 666 B.C.
The art of smelting iron was known in India in ancient times. Reference to iron has been made
in the Rig Veda (2000 B.C.). It is probable that the Iron Age in India has started about
3,000 years before the industry started in European countries. In those days Hyderabad
and Madras in South India were the centers of production of Wootz, the ancient Indian
Steel which was highly priced in world market.
The famous Iron Pillar at qutub near Delhi indicates an amount of skill in the manipulation of
large mass of wrought iron.
The Iron Pillar according to this inscription is victory pillar created to commemorate the victory of
King Chandra (either Chandragupta II or Vikramaditya of the Gupta Dynasty) who is
described as having conquered the Vangas, crossed the mouth of the Indus and
subjugated the Bahlikas.
The antiquity of the Indian process is no less astonishing than its ingenuity. We can hardly doubt
that the tools with which the Egyptians covered their obelisks and temples of porphyry and
syenite with hieroglyphics were made of Indian Steel.
Quintus Curtius has mentioned that a gift of steel was made to Alexander of Macedon by Porus,
an Indian King whose country he had invaded. We can hardly believe that a matter of 30 Ibs.
Weight of steel would have been considered a gift worthy of acceptance by the conqueror of
the world.
The iron pillar at Dhar, the ancient capital of Malwa, 33 miles west of Indore has a length of
about 50 feet and weighs about 7 tons more than the Iron Pillar at Delhi.
There are a numerous beams and smaller pieces at the Sun Temple at Konark which is
on the sea coast about 20 miles from Puri in Orissa. One of these beams which was
originally used in the temple, measures 25.5. feet 11 inches and weighs 9,000 Ibs. The Sun
Temple was built in the earlier part of the 13th Century A.D. The beams were constructed
by welding short blooms together. There are not less then 20 beams in the temple though
none of them have become broken.
Sir George Birdwood wrote in the Note Book of the British Indian section of the famous
Paris Exhibition of 1878.
Records indicate that
Cupola Furnaces were in use in 28 B.C. itself
China produced 1,25,000 tons of Iron a year by 1100 AD.
French Scientist Mery discovered that human blood contains iron.
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A story says that a Russian student tried to make an iron ring to present his lover by chemically
extracting iron from his blood, but had died of anemia as human body contains only 3 grams of
iron
In 1714 Iron Reboyer, a Worlcer working in a Copper Plant had suddenly became weak and
was unable to drag his feet even. He drank Water from Mariatian Water fall, he recovered. It was
found that the water was containing iron.
In olden days Iron Water and Steel Wine were prepared with iron filings in Grape wine etc.,
Irons medicinal properties were also ascribed because of its Magnetic Property. Egyptians
were treating some patients using this property.
Earths Crust contains nearly 5% i.e. 755 x 110 15 tons or 755 Million Billion tons of iron.
96 out of every 100 Kgs. of metal consumed by Industry Agriculture and every day life was iron.
King Solomon gave a feast and honoring the workmen on completion of temple in Jerusalem.
He was asked who contributed more: Black Smith, Carpenter and Mason Finally, the king said
it was Black Smith.
DEVELOPMENT OF STEEL INDUSTRY IN INDIA
Iron & Steel making as craft has been known to India for a long time. However its
production started only after 1900. In a short span of 3 decades or so that capacity was
increased from 11 folds to about 16 Million tonnes by nineties. Progress in next 15 years is
slow, just more than double i.e. 34.821 million tonnes.
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MAJOR STEEL PRODUCING COUNTRIES
(million metric tons crude steel production)
Rank COUNTRY 2003 2004 2005 2006 2007 2008
1 CHINA 220 273 318 423 489 502
2 JAPAN 111 113 112 116 120 119
3 UNITED STATES 90 100 94 99 98 92
4 RUSSIA 63 66 66 71 72 69
5 INDIA 32 33 38 50 53 55
6 SOUTH KOREA 46 48 48 49 52 54
7 GERMANY 45 46 45 47 49 46
8 UKRAINE 37 39 39 41 43 37
9 BRAZIL 31 33 32 31 34 34
10 ITALY 27 28 29 32 32 31
WORLD TOTAL 968 1046 1107 1253 1345 1330
Note:- In the year 2008 India stood as fifth largest producer of crude steel in the world for the third
consecutive year.
WORLD CRUDE STEEL PRODUCTION :
1945 113 2001 860
1950 190 2002 904
1955 270 2003 971
1960 347 2004 1070
1965 451 2005 1148
1970 595 2006 1253
1975 644 2007 1345
1980 717 2008 1330
1985 719
1990 770
1995 752
2000 848
Year
Production
(Million Tonnes)
Year
Production
(Million Tonnes)
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PRODUCTION OF CRUDE STEEL
(Million metric tones)
CONSUMPTION OF STEEL
(Million metric tones of finished steel products)
China alone constitutes 25% of world steel production and consumption. China has more
than doubled its steel output from 220 mt in 2003 to 502 mt in year 2008. Presently India consumes
85% of its production in the domestic market and exports the rest.
2003 232 31
2004 263 32
2005 293 34
2006 361 46
2007 408 51
YEAR CHINA INDIA
2003 220 31.8
2004 290 34.25
2005 300 34.8
2006 423 50
2007 489 53
2008 502 55
YEAR CHINA INDIA
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Chapter - 3
MAJOR OPERATING STANDARDS AND NORMS
COKE OVENS & COAL CHEMICALS PLANT:
RECEIPT QUALITY OF COAL :
Moisture Ash VM Fixed Carbon
% % % %
Indigenous Prime coking (PCC) 6.0 25-30 25.0 40.0 (approx)
Indigenous medium coking (MCC) 6.0 17-20 25.0 50.0 (approx)
Imported hard coking 7.0 8 -10 26.0 57.0 (approx)
Imported soft Coking 7.0 8 -10 30.0 53.0 (approx)
BLEND PROPORTION :
MCC or PCC 15 % ) Blend proportions could vary from time to time
depending Imported hard coking 65 %) upon coal supply
linkages, coal quality and coal) availability.
Imported soft coking 20 %)
BLEND COAL QUALITY :
Ash 10-11 %
VM 25-26 %
Moisture 6-8 %
Thickness of plastic layer 20-22 mm
Size analysis %
0-3 mm size 74-75 %
0-0.5 mm 28-29 %
Bulk density 0.76
BATTERIES :
i) Oven charge weight (T) dry 32.0
ii) Coking time (Hrs) 17-18
iii) Specific Heat consumption 615 Mcal/TDCC
iv) a)C.V.of mixed gas for heating (Kcal/NM
3
) 1000
b) CV of Coke oven gas for heating (Kcal/NM
3
) 4240
v) Yields from dry coal carbonized (%)
a) Run of oven coke 75.00
b) 25 to 70 mm coke 62.00
c) 0 to 25mm coke 13.00
vi) Coke Quality :
Moisture < 0.50 %
Ash <15.00 %
Sulphur < 0.55 %
V.M < 0.60 %
Medium strength
+ 40 mm 80.0 (min)
- 10 mm 7.0 (max)
COKE DRY COOLING PLANTS :
i) Temperature of coke charged in the chamber (
0
C) 1000-1050
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ii) Temperature of cooled coke (
0
C) 150-180
iii) Steam generation from one chamber (T/hr) 22-25
iv) Steam pressure (ata) 39-40
v) Temperature of super heated steam (
0
C) 430-450
COAL CHEMICALS PLANT :
1) Yield from one tonne of dry coal carbonized:
a) Coke oven gas 330-350 NM3
b) Ammonia 0.3%
c) Crude benzol 0.6%
d) Crude tar 3.2%
2) Typical Characteristics of coke oven (Raw) gas:
Calorific value (Kcal/NM
3
) 4425
Density (kg/m
3
) 0.45
CmHn 2.8%
O
2
0.1- 0.3 %
CO 6.4%
H
2
59- 61 %
CH
4
25-26 %
N
2
3.5%
CO
2
2.15%
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MAJOR
PRODUCTION
UNITS
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RMHP
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Chapter - 5
COKE OVENS AND COAL CHEMICALS PLANT
COAL PREPARATION PLANT :
From the storage yard, the coking coal is sent to foreign object separation section (FOSS) to
remove foreign matter of above 150mm size. Iron traps for ferromagnetic articles and cylindrical
screens are provided for this. For averaging and proportioning of coal, 16 nos. of Silos, each of 800T
capacity are provided along with continuous action weigh-feeders of up to 120 tones per hour capacity
each. After blending, the material is crushed with the help of impact crushers. The crushing is carried
out in reversible hammer crushers, 2 operating and 1 standby. Crushing is done to take care of
petrographic non-uniformity, high hardness and mineral content of coal. The crushed and blended
coal (74-75% of -3mm size) is conveyed to two coal towers each of 4000 T capacity. Weigh bridges
are provided under coal towers to weigh the coal charge. System of pneumatic blow down of blend is
provided in the coal tower to take care of jamming or hanging of coal in the coal tower.
BATTERY :
The prepared coal charge from the coal tower is drawn by a charging car on the top of the
batteries and charged into the ovens as per sequence. The charged coal is gradually heated by the
heating walls of the oven in the absence of air to attain a temperature of 1000-1050
0
C at the central
axis of the coke mass towards the end of coking period. The coking period is generally specified
between 16 hrs and 19 hrs depending upon oven condition and production requirement. The volatile
matter of coal liberated during carbonization is collected in gas collecting mains in the form of raw
coke oven gas passing through stand pipes and direct contact cooling with ammonia liquor spray. The
gas cooled from 800
0
C to 80
0
C is drawn to coal chemicals plant by Exhauster.
The residual coke is pushed out of the oven by pusher car through a guide into coke bucket.
The red-hot coke is taken to coke dry cooling plant for cooling.
There are 4 batteries, each having 67 ovens. Each oven can hold 32 tons of dry coal charge.
The volumetric capacity of each oven is 41.6 m
3
.
The heat for carbonization is supplied by under firing of coke oven gas having CV of 4200
Kcal/Nm3 or mixture of BF gas & CO gas having CV 1000 Kcal/Nm
3
.
The heating system of batteries is of underjet compound type having twin-heating flues with
recirculation of waste gases. The dimensions of an oven are as follows.
a) General Dimensions:
Length 16,000 mm
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Height 7,000 mm
Width on coke side 435 mm
Width on pusher side 385 mm
Average width 410 mm
Oven taper 50 mm
b) Effective Dimensions:
Length 15,160 mm
Height 6,700 mm
Number of heating flues in one heating wall 32 Nos.
Distance between axes of ovens 1,400 mm
Number of charging holes 3
Number of gas-off take holes 2
Heating level (distance from the top of
the hairpin of the heating flue to the 1,100 mm
carbonizing chamber roof)
Temperature in heating flues is between 1300
0
C and 1360
0
C and final temperature of coke mass at its
central axis is between 1000 - 1050
0
C.
Following pressures are maintained:
a) Pressure of carbonizing chamber sole,
15 minutes prior to pushing coke +0.5 to +3 mm W.C.
b) Pressure in the gas collecting main +16 to +17 mm W.C.
c) Pressure in the heating system at hair
pin level for waste heat gases +/- 0.3 mm W.C.
The refractory requirement per battery is 14000 T silica bricks, 5700 T fire clay bricks and 130 T
lightweight insulation bricks.
Following oven machinery is provided.
Operating Total
Charging Cars 4 8
Coke pusher 6 4
Door Extractor 4 6
Electric Loco 4 6
COKE DRY COOLING PLANT :
There are four coke dry cooling plants, each having four chambers. Capacity of each chamber is 50-
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52 TPH. Each coke dry cooling plant consists of cooling chambers with individual lifter and lifting
shaft, waste heat boiler, dust catching arrangements and mill fan.
The cooling chamber has two technological zones. Red-hot coke is charged into the upper zone while
cooling takes place in lower zone by circulating gases. Gas is forced by mill fan into distribution
channels in the lower part of the chamber and fed into the cooling zone. The gas flows upwards and
gets heated. Circulating gases enter boiler, cyclones and return to bottom part of cooling chamber
because of mill fan.
The coke is cooled from 1000 - 1050
0
C to 150-180
0
C while the circulating gases are heated from
160-180
0
C to 600 - 800
0
C. 22-25 Tonnes/hour of steam at 35-40 atm pressure and 430-440
0
C is
produced from one chamber. The cooled coke from the cooling chamber is discharged onto the
conveyor continuously through a rotary discharging system.
COKE SORTING PLANT :
From the dry cooling plant, cooled coke is conveyed to a dedusting unit by conveyor. From the dedusting
unit, coke is conveyed to crushing section. Here the incomig coke fractions are first separated into
+70mm and -70mm fractions. The +70mm fraction is fed to a two roller-toothed crusher (2 nos. each
of 120 TPH capacity). The crushed product along with -70mm fraction is conveyed to coke screening
section where 25 -70mm and 0 - 25 mm fractions are separated using roller screens. 25 to 70mm
fractions(metallurgical coke) are conveyed to blast furnace. Bunkers of 600 tonnes capacity are also
provided for loading into wagons/trucks and dumpers for sending to coke yard.
0 to 25mm fractions are fed to vibrating screens provided to separate into nut coke (10 to 25 mm size)
and breeze coke (0 to 10mm). Nut coke is sent to blast furnace or to yard depending upon the
requirement. Breeze coke is sent by conveyor to Sinter Plant.
CONVEYORS
The following types of conveyors are used in coke ovens & coal chemical plant.
Width (mm) 1600 1400 1200 1000 800 650 500
Quantity (nos.) 9 49 6 11 - 4 2
Total no. of conveyors: 87
Total length (Mts) - 15000 (approximately)
COAL CHEMICALS PLANT :
The main by product in the process of coke making is raw coke oven gas and this has lot of valuable
chemicals. Coal Chemicals Plant recovers Ammonia (NH 3), Tar and crude Benzol from Co-Gas as
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per the process described below:
The primary By-products from Crude CO Gas are Ammonium Sulphate (NH 4)
2
SO
4
, Crude Tar,
Crude Benzol and cleaned coke oven gas.
QUALITY AND COMPOSITION OF COKE-OVEN GAS
Calorific value Kcal/N.cum 4300-4350
Density kg/Nm
3
0.45
CmHn % 2.8
O
2
% 0.5 (max)
CO % 6.4 - 7.0
H
2
% 59 - 61
CH
4
% 25 - 26
N
2
% 3.0-3.5
Yields of main Carbonization by-products based on coal are follows (percent on dry blend basis).
Crude Tar 3.2 %
Ammonia (NH3) 0.3% or 7-10 gm/Nm
3
of coke oven gas
Crude Benzol 0.6% or 20 gm/Nm
3
of coke oven gas
Generation of coke oven gas per ton of dry coal charged is 330-350 Nm
3
at calorific value of 4300
Kcal/Nm
3
GAS CONDENSATION SECTION :
The Coke Oven Gas (CO Gas) leaves the ovens at a temperature of 800
0
C and is cooled from
800
0
C to 80
0
C in goosenecks and in gas collecting mains at the batteries by spraying Ammonical
liquor (Flushing liquor). 60-70% of Tar present in CO-Gas is condensed here. The CO-Gas along with
Tar and liquor comes to a separator to remove liquor and condensed Tar. The cooled CO-Gas is then
taken to primary gas coolers ( each having a heat transfer area of 2425m
2
) where it is cooled indirectly
by water to about 25 to 30
0
C. Along with the Tar, some amount of Naphthalene in coke oven gas is
also condensed.
The gas is then sent to Electro Static Precipitators ( each of 27000 Nm
3
/hr capacity) to remove
the foggy Tar (about 5%) from CO gas. In ESP, foggy Tar particles are electrically charged and collected
on the surface of the electrodes and separated. The gas purified from Tar is compressed in Exhauster
to a pressure of max.2800 mm water column. There are five electrically driven exhausters provided
and each having capacity of 76000 Nm
3
/hr.
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Tar and Ammonia Liquor (Flushing liquor) from the separator are delivered to mechanized
decanters , each of having capacity of 370 m
3
. Here the crude Tar, Flushing liquor and sludge (coal
and coke dust particles in Tar) are separated based on their density difference. The separated flushing
liquor from decanter is collected in Tanks of capacity of 200 m
3
from where it is pumped continuously
by flushing liquor-pump to gooseneck and gas collecting mains of coke ovens. There are 8 Nos. of
Flushing liquor pumps of having capacity of 1100 m
3
/hr.
Tar separated from the decanters is collected in an intermediate Tar tank of having capacity of 50 m
3
from where it is once again pumped to Tar decanters (each of capacity 370 m
3
), which are exclusively
provided to remove further water from Tar. The gas condensate which is collected after the primary
gas coolers, Electrostatic precipitators and exhauster is taken to a underground 50 m
3
tank from
where it is pumped to Tar Decanters for separation. The flushing liquor separated from Tar decanters
is collected in Flushing liquor tanks. The clear Tar taken in another 50 m
3
tank from where it is pumped
to final gas cooler.
AMMONIUM SULPHATE SECTION:
The CO-Gas from the Exhausters under pressure is sent to saturators in Ammonium Sulphate section
through pre-heaters.
Acidity of the saturator bath is maintained at 4 to 5% and Sulphuric Acid is used for this purpose.
Ammonia present in CO Gas reacts with sulphuric acid and forms Ammonium sulphate crystals.
Nitrogen at 600 -750 Nm
3
/hr is used for agitation purpose in each saturator and this keeps the crystals
in motion. Once the crystals grow bigger in size, it settles at the bottom of the saturator.
There are five saturators of 6400 mm diameter having cylindrical body and conical bottom.
The Ammonium sulphate, (NH
4
)
2
SO
4
, crystals settled at the bottom of saturators is sent to the
centrifuges by pumps where the crystals are separated continuously from the liquor (mother liquor).
There are 5 Nos of centrifuges.The crystals from centrifuges are dried in a fluidized bed drier and
stored. The dried Ammonium Sulphate crystals are bagged in 50 kg bags and shipped. This is used as
a fertilizer for agricultural purpose and having Nitrogen content 21%.
15 days production can be stocked in the godown. Sulphuric acid required for the production
of Ammonium sulphate, caustic soda & soda ash required for coal chemical plant are stored in Reagent
storage. A month requirement of Sulphuric Acid can be stored here.
FINAL GAS COOLING AND NAPHTHALENE WASHING :
From the saturator the CO-Gas enters the Acid trap where the acid droplets that might be
carried along with the CO-Gas are separated and sent to saturator. The acid free of COGas enter the
final gas cooler. There are two final gas coolers of diameter 5000 mm and height 45.5 meters. Each
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cooler has got two sections. In the top section CO-Gas is sent from the bottom and cooled service
water is sprayed from the top. There are perforated plates in this section, which provides the necessary
contact for the water and CO-Gas.
The CO-Gas enters the final gas cooler minimum at 55
0
C. Cooling of the CO-Gas is done by
direct water spray through a closed cycle system. In this way Naphthalene that is present in CO-Gas
is scrubbed by water & this enters the bottom of the bottom section. The bottom section, Naphthalene
washer, having Tar will come in contact with warm water from top section. Lighter than Tar the water
comes to the top and leaves the cooler. During this process whatever Naphthalene is present in (or
dissolved) in the water gets dissolved in tar because the solubility of Naphthalene in Tar is many times
higher than water. Then this Tar is taken out and stored in tanks and then sent to Tar Distillation Plant
(TDP) for processing.
BENZOL RECOVERY :
Cooled Coke Oven Gas from final gas cooler (FGC) will successively pass through two benzol
scrubbers in each of the two streams. All four Benzol scrubbers are of 5000mm diameter and height
48.5m.
Recovery of benzol hydrocarbons is carried out by solar oil, a petroleum fraction, in counter
current. The Benzol content in CO-Gas before scrubbers is 27gms/Nm
3
and after scrubbers it is 6gm/
Nm
3
. Aluminum packing is provided in all the scrubbers for efficient contact.
DRY PURIFICATION UNIT :
700 -1000 Nm
3
/hr of coke oven gas is sent to dry purification system when H
2
S content of the gas is
required to be removed from 0.6-0.7 gms/Nm
3
to 0.02 gm/Nm
3
. The H
2
S free CO Gas is sent to
laboratories and other special consumers like GETS at BF, CO Gas is supplied to dry purification unit
after the electrostatic precipitators. Synthetic bog ore is used as purification mass. Spent purification
mass containing 24 to 25% sulphur is transferred to dump.
TAR DISTILLATION PLANT :
It is designed to process 1,15, 200 Ton/year of Tar. The crude tar having maximum water content 5%
is heated in the pipe still furnace to 115
0
C and sent to the 1st stage Evaporator, where the Tar is
separated from water and stored as dehydrated Tar. Further, this Tar is heated in the pipe still up to
400
0
C and taken to the 2
nd
stage evaporator.
Here the vapours and the residues (called pitch with softening temperature 67 to 73
0
C) are separated
and this vapour is sent to the Rectification Column.All the products are withdrawn at different levels
based on their boiling points difference and cooled and stored.
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Naphthalene fractions are crystallized in the crystallizes and then pressed to form a cake in a Hydraulic
press and bagged and shipped. Pitch or Residue at the bottom of the 2
nd
stage evaporator is soft in
nature and it is made hard by sending compressed air in pitch reactors. Due to the polymerization and
condensation, which takes place in the reactor, the pitch becomes harder and withdrawn from the
reactor. Pitch creosote mixture is prepared by mixing soft pitch and Anthracene Oil.
Major facilities of the plant are :
a) 2 drum crystallizes, 8 mechanical crystallizer and 2 centrifuges and 2 hydraulic presses for
naphthalene. There is 10 days storage capacity for crude naphthalene.
b) 9 mechanical crystallizes, 3 centrifuges and 16 days storage capacity for crude Anthracene.
c) Washing section for making Sodium Phenolates.
d) 4 still reactors, head Tanks, pipe still for production of pitch with softening temperature of 75
to 95
0
C.
e) Facility for preparing Pitch Creosote Mixture.
f) 23 days storage for Tar and Tar products.
MECHANICAL BIOLOGICAL AND CHEMICAL TREATMENT OF
PHENOLIC EFFLUENTS :
Before treatment After treatment
mg/ltr mg/ltr
Phenols 400 not more than 1
Rhodonites 400 not more than 10
Tar & Oil 500 not more than 25
Biological Oxygen demand 2500 not more than 300
AMMONIA (NH
3
) 500 not more than 100
In CO&CCP amount of phenolic effluents are 120 m
3
/hr and this water is treated in the unit and is
transferred into the net- work of sanitary domestic sewerage plant.
BENZOL DISTILLATION PLANT :
The plant consists of
i) Benzol recovery & distillation using Solar Oil as scrubbing medium.
ii) Benzol refining & Rectification plant using continuous hydro refining process for production of
Caprolactum grade Benzene, Nitration grade Toluene, Light Solvent Oil.
The Recovery & Distillation unit has two streams each consisting of one final gas cooler two
scrubbers connected in series. In scrubber the Solar Oil and CO-Gas is subjected to counter current
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flow and thus Solar Oil absorbs and Benzol from CO-Gas and becomes benzolised oil. This benzolised
oil is taken to a stripping column, where with the help of direct steam, the benzol is stripped, removed
and cooled. The de-benzolised oil is the bottom product, which is reused for scrubbing the CO Gas.
BENZOL REFINING & RECTIFICATION :
The benzol refining & rectification section is designed to handle Crude Benzol recovered from
the benzol distillation unit. It can handle 110 tons of crude benzol per day and operating period is 330
days/annum.
The Crude Benzol recovered in Benzol Distillation Plant is processed in Hydro-refining unit to
produce BTXS refined. Crude Benzol is refined by using hydrogen, recovered from CO gas by Pressure
Swing Adsorption (PSA) process. The refining process is carried out of 25 kg/cm
2
pressure. The
refining process involves removal of sulphur compounds in two catalytic bed reactors called
pre-reactor and main reactor. The product, which is sulphur free, is called BTXS refined and is further
subjected to rectification process where different products like Benzene, Toluene, SOL-110 and Light
Solvent Oil are made.
This rectification process involves a series of distillation processes like pressure distillation,
extractive distillation where NFM solvent is used to remove non-aromatics from Benzene & Toluene.
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CALCINING AND REFRACTORY
MATERIAL PLANT
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Chapter - 7
CALCINING AND REFRACTORY MATERIAL PLANT
CRMP, i.e. Calcining & Refractory Materials Plant is an integrated unit of Visakhapatnam Steel Plant.
This plant plays a significant role in the manufacturing of liquid steel. The main customer of CRMP is
Steel Melting Shop (SMS).
1) Calcining Plant
CRMP has two units
2) Brick Plant
Calcining Plant
Calcining plant produces lime and calcined dolomite, which are used for refining of hot metal to steel
in the converter. This plant has 5 rotary kilns of 325 tons/day capacity. Lime is produced by calcining
limestone and calcined dolomite is produced by calcining dolomite. Limestone (SMS grade) is procured
from United Arab Emirates and Dolomite (SMS grade) from Madharam mines of VSP. The size of
limestone is (30 - 60) mm and size of dolomite is (25 50) mm. Both the raw materials are received
and stacked at RMHP. RMHP reclaims these materials and conveys to LSDS (Limestone & Dolomite
Screening Plant) via a stream of conveyors. LSDS has two screens (VS6 & VS7) to screen out the
minus fraction from raw materials. The minus size is sent to RMHP for use in Sinter Plant. The +30mm
size limestone is stored in bunker 5 and +25mm dolomite is stored in bunker 6. These materials are
then conveyed to the stone bins of all the kilns by operating the weigh feeders below the two
bunkers. Limestone and dolomite are charged to separate kilns.
The material from the stone bin flows by gravity into the preheater. Material in side the preheater gets
preheated by the hot flue gas coming out of the kiln and is then charged into the kiln by activation of
hydraulically operated rams. The feeding of raw material into the kiln can be varied by regulating the
frequency of the ram pushing.
The fuel used for firing of the kiln is PCM (Pitch Creosote Mixture). This is supplied by CCP (Coal
Chemicals Plant) through pipelines. The calorific value of PCM is 9000 Kcal/Kg. This fuel is stored in
four tanks in pump house. Pump house pumps the fuel to the kilns through PHF unit (Pumping,
Heating & Filtering Unit) of each kiln at 4 - 8 kg/cm2 pressure. This fuel generates a temperature of
1250
0
C - 1300
0
C inside the kiln to calcine limestone & dolomite. The product of the kiln, i.e. lime and
calcined dolomite are discharged to a contact cooler provided for each kiln. The cooled product is
discharged and sent to the Flux Storage Building. Lime and calcined dolomite are screened and
stored separately in Flux Storage Building. There are two 10mm screens in FSB as SMS requires
+10mm size only. The stored material is then sent to SMS as per demand. Some +10mm size lime is
also sent to PCM (Pig Casting Machine). The -10mm size is sent to Briquetting plants, Sinter Plant,
Water Treatment Plant and to outside sales.
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The hot flue gas coming out of the rotary kiln is passed through the preheater, cyclone and bag filter
by ID Fan. Dust, carried by the hot gas, is separated in cyclone and bag filter and stored in dust
hoppers and despatched to Sinter Plant by pneumatic tankers. The clean gas is then let off through
chimney.
Brick Plant
Brick plant produces Pitch Bonded Magnesia Carbon Bricks for lining of Converters and Steel Ladles.
Total twelve shapes of bricks are currently produced :- CD1 to CD8 and LB1 to LB4.
The main raw materials of brick are Sea Water Magnesia (SWM) and Fused Magnesia (FM). Sea
Water Magnesia is imported from Ireland and Israel. Fused Magnesia is imported from China. Graphite
Flakes is used as additives and Aluminium Powder is used as antioxidant. Liquid pitch is used as
binder, which is supplied by CCP (Coal Chemicals Plant) by tankers. In mill house, SWM is crushed,
ground and screened into different sizes of (0 - 0.2), (0 - 0.5), (0.5 - 1.6), (1.6 - 3) & (3 - 5) mm and
stored in separate blending bunkers. Graphite & aluminium powder are stored in separate blending
bunkers. These fractions of SWM and additives are collected by scale car from blending bunkers in
predetermined quantities and discharged into mixer. Pitch is added during mixing and mixing is done
as per set mixing program. The mixer temperature is maintained between 140
0
C and 180
0
C.
The Brick Plant has two 1600 T capacity hydraulic presses to press these bricks. After pressing the
green bricks are placed on takeoff belt. The green bricks are lifted from the takeoff belt and placed on
a tempering pallet manually. Pallet filled with the green bricks is then placed on a tempering car. The
tempering of bricks is done at a temperature of 300
0
C - 350
0
C. The tempered bricks are then packed
on packing pallets, strapped with polyethylene straps and stored in Brick store. These bricks are
despatched to SMS as per requirement of SMS and RED.
Moreover, bottom jointing mass and back filling mass are also produced in the Brick Plant for use
during converter relining. For production of bottom jointing mass resin is used as binder in place of
pitch.
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BLAST FURNACE
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Chapter - 8
BLAST FURNACE
8.0 BURDEN HANDLING AND FURNACE CHARGING :
Burden materials are received in the stock houses, one for each furnace through a junction
house. Coke is handled by two conveyors (one stand by) of 1600 mm width and 350 TPH capacity,
sinter, lump ore by two conveyors (one stand by) of 1400 mm width and 800 TPH capacity, Sized ore
and additives will be handled by one reserve conveyor of 1400 mm width and 800 TPH.
Junction house has a cross over through rolling reversible conveyor and stationary reciprocating
conveyor. For each furnace, there are 5 bins for sinter, 5 bins for coke, 3 bins for lump ore, 1 bin for nut
coke, 3 bins each for limestone/LD slag and quartzite/used silica bricks and manganese ore.
Coke, sinter and iron ore are screened in screens up to 400 m
3
/hr capacity to remove the fines.
The screened material is fed to the inclined conveyor for burden handling to top through a horizontal
conveyor. Conveyors for burden handling to top are of 2000 mm width & 2160 m
3
/hr capacity and are
operated continuously. The materials are positioned in conveyor in separate batches at certain intervals
and in a certain sequence as per preset program. PLC system is a certain sequence as per preset
programs. PLC system is provided for batching, weighing and feeding of the burden to the furnace
top.
The Paul wurth, bell less top system is installed for furnace charging. The system consists of
two bunkers of 47 cubic meter capacity each, charging moving hopper & rotating trough. All drives are
hydraulically operated except for trough rotation and tilting which are electrically operated. Semi clean
BF gas and nitrogen are used for pressure equalization in charging bunkers. Nitrogen is used for
cooling rotating trough drive and for blowing off stock bin gates and sealing valves of charging
arrangement. Mechanical gauge rod on side and radar probe on the other side are provided for
measuring stock level.
Exhaust station and air cleaning plant are provided for burden handling system. The exhaust
air is directed to electrostatic precipitators (2 nos.) for cleaning. The plant capacity is 3. 65 x 10 m
3
/hr.
The dust content of air is reduced from 2.85 gm/cum to 0.1 gm/cum, 200 tons of dust is collected
every day. The dust collected is balled in granulation plant and is transported in trucks to Sinter plant.
The burden handling system premises are hydraulically flushed 600 m
3
/hr water). Total effluents
generation is 600 .3/hr. After primary settling, the water is pumped to sinter plant for further use.
8.1 HOT BLAST STOVES :
There are four hot blast stoves for each furnace with a total heating surface of 224, 000 m
2
.
The dome can be heated to a temperature of 1450
0
C maximum while the waste flue temperature is up
to 400
0
C. The stoves are capable of giving a blast temperature up to 1300
0
C. Stoves are heated by a
mixture of blast furnace gas and coke oven gas having a calorific value of 1,100 Kcal/Ncum. Pressure
of mixed gas before burners is 600mm W.C.
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Gas mixing station is provided to mix BF gas, CO gas in required proportion and to get the
necessary Calorific value. Separate stations are provided for each furnace. Mode of operation of
stoves is successive (parallel also can be operated).
High temperature zone is lined with silica and mullite corundum refractories, medium
temperature zone, with kaoline refractories and low temperature zone with fire clay refractories. The
shell of dome and cyclindrical part is heat insulated with a heat proof gunnite concrete in high temperature
zone. Gaps between shell and walls are filled with mats from fibrous materials. Checker-work is lined
with hexahedral refractories with round cells of 41mm dia. Combustion chamber is in-built construction
of elliptical shape. The chimney is of 80 m high, 3.5m diameter at the mouth. It is of reinforced
concrete and fire clay lined. Stack for back drought is made of metal with refractory lining. Air supply
for burners is centralized. Three fans (one stand by) of 120, 000 m
3
/hr, 1080 mmwc capacity each are
provided for the purposes.
Water cooling arrangement has been provided for cooling of hot blast valves and burner cut
off valves.
8.2 FURNACES :
Two blast furnaces of 3,200 m
3
useful volume, each capable of producing 1.7 MT of hot metal
per year while operating for 350 days are installed. The basic characteristics of furnace are :
Useful height from iron notch center line to trough bottom in
vertical Position ........ 33,100 mm
Height of hearth ........ 4,600 mm
Height of Bosh ........ 3,400 mm
Height of belly ........ 1,900 mm
Height of shaft ........ 20,000 mm
Height of top ........ 2,300 mm
Height of dead layer ........ 1,203.5 mm
Diameter of Hearth ........ 12,000 mm
Diameter of belly ........ 13,000 mm
Diameter of top ........ 8,900 mm
Bosh Angle ........ 79
0
1037mm
Shaft Angle ........ 83
0
4322mm
Number of Tuyeres ........ 32.................
Number of Tap Holes ........ 4.................
No slag notches are provided.
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The lower part of the hearth bottom is lined with graphitized carbon blocks while upper part is
with high refractory mullite bricks in the center and with carbon blocks in the periphery. Side walls of
the hearth are lined with carbon blocks in lower part and alumina silicate bricks are used for lining of
bosh, belly and shaft. Furnace top is lined with non cooled steel slabs of suspended construction,
while non cooled cast iron slabs are used for furnace dome. Insulation layer was provided between
slabs and shell of dome.
Lower part of the hearth bottom is air cooled. Peripheral cooling plates are used for cooling of
upper part of hearth bottom, hearth, tuyere zone, bosh, belly and lower part of shaft. For middle part
of the shaft, peripheral plates with independently cooled projections are used. There are 664 cooling
plates. Besides, there are 32 breast coolers, 32 tuyere coolers, 32 tuyeres and 8 nozzles in furnace
dome. The water requirement for cooling is 5555 m
3
/hr max.) per furnace at 80 mmwc. Clean
recirculating water with suspended matter up to 50 mg/litre is used.
The hot metal is discharged into 140T hot metal ladles by rocking runners in cast house. Hot
metal ladle cars are moved by a pusher car. At every notch, a notch opening machine and an electric
gun is provided. The cast house is circular in shape and two circular cranes 20/5+5 T and a circular
platform (5m width) for maintenance and observation of tuyers stock is also provided.
There are 10 to 20 casts in a day. Cast house has good aeration. Provision has been made for
gas and dust exhaust from iron notches, rocking runner covers and from housing of the drum of the
conveyor from burden handling to top. Four mill fans (one stand by) of 160,000 m
3
/hr capacity and 900
kgf/cm
2
pressure and two exhaust fans (1 stand by) of 492000 m
3
/hr capacity and 430 Kgf/cm
2
electrostatic precipitators, two horizontal type three fold precipitators having needle type discharge
electrodes and S shape collecting electrodes (12m height) are provided. Dust is granulated and
dispatched to sinter plant by dump track. Clean gas is fed to chimney of 5m dia, and 100m height. The
total capacity of the plant is 972, 000 m
3
/hr. Dust content is reduced from 2.5 gms/m3 to 0.1 gms/m3.
About 60T of dust is collected daily from two precipitators.
There are four railway tracks for hot metal transportation [two on either side,] one service
sub-track and one track for flue dust disposal. Independent running railway tracks are provided for
delivery of metal to each SMS. Two rail weigh bridges are provided for weighing hot metal sent to SMS
& PCM. For auxiliary freights, automobile transport is provided.
The furnace process control is computerized.
Four gas off takes run vertically from furnace dome, which are connected to each other in
pairs, firstly forming two vertical off takes and these two joining to form one central vertical off takes
and these two joining to form one central vertical off take which is connected to a dust catcher of 12m
dia through a down comer. Dust catcher and gas pipe lines are lined with fire clay bricks. Moistening
and discharge of dust is carried out by a screw conveyor. The furnace can be separated from dust
catcher by 3,000 mm dia cut off valve in upper part of the dust catcher.
8.3 CAST HOUSE SLAG-GRANULATION PLANT :
The molten slag produced by the furnaces is fed to cast house slag granulation plant to produce
granulated slag. Two granulation plants are provided for each furnace adjoining the cast houses on
two opposite sides.
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Slag is dicharged from the furnace 10 to 20 times a day, duration of each discharge being up
to 60 minutes. Each granulation unit comprises two process lines (one stand by), designed to receive
all slag through two iron notches. Each process line comprises of one granulator, one slag air lift, one
granulated slag dehydrator, one receiving bin and water supply recirculating system. Steam from
receiving hopper is discharged to atmosphere through a chimney.
The granulated slag from the dehydrator is discharged into an intermediate hopper and from
there it is fed to final storage through a conveyor system. The granulation of liquid slag is done by
water jets and the granulation water is delivered by dredged pumps in a quantity of 2000 m
3
/hr at a
minimum pressure of 5atg in the granulator. Temperature of pumped water is around 90 degrees C.
with an average suspended matter content of upto 2 g/litre. Through put of make up water is 300m3
per granulation plant.
For air lifting thickened pulp from receiving bin to separator, compressed air is used. The plant
is designed for maximum slag discharge rate of 10 T/min and hot metal content in the slag will be 12.7
kg/T.
The granulation plant works for 350 days in a year. The combined conveying system for handling
granulated slag from both furnaces has a capacity of 600 TPH. Two conveyor systems one acting as
standby is provided.
The storage is open dump type and can hold about one month production. From the storage
slag is loaded in railway wagons and in trucks by grab cranes.
8.4 PIG CASTING :
Four double strand pig casting machines of 1700 TPD capacity are installed to pour off grade
metal and metal diverted due to stoppages in SMS (one machine reserve). The machines can handle
one furnace production. Each PCM is served by a 75 T, overhead trolley to tilt the 140 T hot metal
ladle. Pig weight is about 45 kgs. Facilities for lime washing of moulds and a re-circulating water
system for cooling the pigs, including a settling tank, is provided.
The cold pig from machines are collected in wagons and sent to open gantry pig iron storage
yard. The yard is of 300 x 40 m size and cold pigs are stored in separate lots according to grade. Two
150 T Rail weigh Bridges are provided to weigh outgoing loaded wagons.
8.5. HOT METAL LADLE REPAIR SHOP :
The main objectives of this shop are as follows :
a) To ensure placement of hot & clean metal ladles to each furnace in time for the casting as per
the casting schedule.
b) To ensure quick despatch of Hot metal loads to their planned destination and also ensure early
withdrawal of empties from PCM/SMS in order to thoroughly clean inspect and clean the same
before placement.
c) To effectively coordinate with Rail Traffic department / 2BFs/ SMS/PCM to ensure achieving of
above objectives.
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The entire shop working rotates around the three above objectives. The main equipment/tools/devices
provided in the shop to achieve those objectives are as below :
a) 2 Nos. of 120/50 tons capacity E.O.T. cranes (for Hot Metal ladles cleaning purposes).
b) 30 Nos. of conventional open top metal ladles (capacity 140 tons each) and 7 Nos. of Torpedo
ladles (capacity 300 tons each) to hold & transfer liquid Hot Metal.
c) 4 Nos. of metal ladle pits with stands to hold conventional ladles during mechanical repair jobs
/ RED lining jobs.
d) 1 No. 42 tons capacity punch and 2 Nos. of four beak anchor hooks to remove skull from metal
ladles and clean them.
e) 2 Nos. of drying installation to dry and preheat freshly lined conventional ladles before taking
hot metal in them to avoid explosion and thermal shock.
f) Separate torpedo ladle repair shop is there to maintain the torpedo ladle cars in all respects.
8.6 BLAST FURNACE MASSES AND COMPOUND SHOP :
Refractory masses required in cast house viz., Runner mass, Mudgun mass, Tap hole frame mass
are prepared in Masses Compound shop.
The raw materials required for preparing mass are received at various sizes from the different sources.
These are crushed in various stages and stored in final storage bins. 12 final storage bins are provided
for storage of raw materials. There are 6 operating groups for raw material handling and preparation
of masses.
The raw materials for preparation of different masses are :
G
Coke Breeze
G
Pitch
G
Grog
G
Plastic fire clay
G
Silicon Carbide
G
Calcined Bauxite
G
Powder Resin
G
Liquid Resin
G
Wash Oil / L.C Oil
G
Special binder
There are two storage tanks (25 m3) for wash oil/L.C Oil. Two pan mixers are used for preparation
of the mass.
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All the groups can be operated through PLC and if required they can be operated in local
mode.
There is a 5 Tons capacity crane for handling the mass boxes.
8.7 GAS EXPANSION TURBINE STATION :
This is intended for generation of electric power utilizing the potential energy of the compressed BF
gas. One turbine is provided for each furnace. Each turbine operates the turbo generators of 12 MW
nominal rating with exciter placed on one shaft with the turbo generator. Air coolers are provided for
turbo generators. (The gas is heated up to 120 degrees C. in heater. The station operates for 8000
hours in a year annual generation of electric power is about 123. 8 to 184. 6 X 10000000 KWH.
8.8 GAS CLEANING PLANT :
The rated dust content in gases after the dust catcher, when the blast furnace is operating at high top
pressure is 6.3 gms/normal cubic meter and at low top pressure up to 15 gms/Normal cubic meter.
Further cleaning up to 4 mg/Normal cubic meter is accomplished in wet gas cleaning plant, consisting
of high pressure scrubber of 9000 mm dia, two venturi pipes with adjustable drop of pressure by
changing throat cross section, 2, 600 mm dia spray catcher and the cyclone sprary catcher. In the
scrubber, gas is cooled and cleaned of coarse fractions of dust. In venturi pipes and septum valves,
the coagulations of fine fraction of dust takes place with subsequent separation of them in spray
catchers.
A BF gas flare stack is provided for prevention of excess of the preset pressure in out door distributing
BF gas pipe lines and centralized burning of the discharged temporary surpluses of BF gas. Capacity
is 200 to 240 x 10
3
normal cubic meter per hour, height-60m. Four burners of 60 normal cubic meter
per hour are provided.
8.9 NITROGEN SUPPLY AND BLOCK OF RECIPIENTS :
Nitrogen of 97% purity is used for charging apparatus and for other equipment requirement is 38, 370
normal cubic meter per hour. Nitrogen is supplied from Oxygen plant. To provide for emergency
Nitrogen reserve, and to compensate non-uniform consumption, a block of recipients consisting of
two 100 cubic meter vessels for 10 Ksca pressure and five 125 cubic meter vessels for 35 to 40 Ksca
pressure are provided. A Nitrogen control station is provided as a part of block of recipients, where
pressure is reduced from 35 to 40 Ksca to 8 to 10 Ksca.
8.2.0 AIR CONDITIONING STATION :
To supply air to all units, two central air conditioners 200000 m
3
/hr capacity are installed. In cold
season one unit will be in operation. Air is subjected to cleaning in cell filters, adiabatically cooled and
humidified in the spray chambers in summer. Air at a temperature of +30 degrees C and 90
%
humidity
is supplied through yard pipe lines. In cold season, air is subjected to only cooling. The total requirement
is 392, 000 m
3
/hr.
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8. 2.1 CONVEYORS :
The details of conveyors in blast furnace as follows :
Width (mm) Length (M) Quantity (Nos.)
1600 1542 12
1400 2250 18
1200 1138 4
1000 1890 10
8.2.2 PROCESS CONTROL COMPUTERIZATION IN BLAST FURNACE :
8.2.2.1 Scope :
Two systems have been envisaged in the Blast Furnace Automation Control system.
8.2.2.1.1 Burden Handling System :
To control the proportioning of burden materials with due consideration for coke moisture content &
batching accuracy. This system also gives relevant data connected with the operation of the Burden
handling Complex to the process personnel. This consists of the following major local systems for
monitoring and control.
i) Material levels in the bins
ii) Material batch weights
iii) Coke moisture content
iv) Availability of materials and transfer of the material batches to the Blast furnace top
v) Over filling of chutes
8.2.2.1.2. The centralised monitoring and control system for the Blast Furnace comply with the following
main functions.
a) Automatic data acquisition on the process run, state of equipment.
b) Automatic processing of incoming data and making them available to the technological
personnel in a convenient form.
c) Occasional calculation of process parameters and taking the process data to the service
personnel.
d) Delivery of corrective responses to local control circuits.
e) Optical and acoustic signaling for variations of basic process parameters from nominal
values and for operating conditions of the equipment.
f) Occasional filling-out of reports.
8.2.2.1.3 Lan system is implemented in Blast Furnace department connecting all the sections of the
department with the main net work. Data is logged on to the system in all the section and
made available for use & reference by the concerned.
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C = 4.0 - 4.5%
Si = 0.4 - 0.7%
Mn = 0.10%
P = 0.11% max
S = 0.04% max
Temperature = 1250 - 1425 Degree C.
1300 to 1350
0
C Through Mixer route
1350 - 1450
0
C Through TLC (Torpedo Ladle Car) route.
BULK MATERIAL HANDLING SECTION (BMHS) :
The following bulk materials are used in converter shop of SMS.
Calcined Lime and calcined dolo - used as flux in LD-Converter.
Cao = 89 - 90%
LOI (Loss On ignition) = 6-8%
SiO
2
= 2.5% Max
Size = 10-25 mm
Mgo of dolo = 28 to 32%
Requirement = 6-10 T as per heat weight and hot metal composition, iron Ore Lump - Used as
Coolant in steel making.
Fe = 66.9%
SiO
2
= 0.9%
AI
2
O
3
= 1.6%
M
n
O
2
= 0.05%
Size = 15 - 60 mm
Requirement = 0.5 - 3T as per blowing conditions.
Raw or Calcined Dolo - Used to increase lining life of Converter.
Lump Coke - Used to preheat the lining of newly lined converter.
One of the requirements for continuous casting process is that the liquid steel should be killed (fully
deoxidized). For this and to make different grades of steel, ferro alloys (FeSi, SiMn, FeMn, etc) Coke
breeze/Petroleum coke and Aluminium are added in the ladle during tapping of steel from converter to
ladle.
CONVERTER BAY :
Hot metal contains different impurities (C,Si,Mn,S,P) above safe level which make Pig Iron brittle. But
steel is nothing but refined hot metal. Refining is only possible when things are in molten
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phase. Refining is done by blowing oxytgen in the LD converter Charged with Hot Metal, Scrap, Flux,
Iron Ore, etc. In this refining process, temperature of liquid steel is aimed at 17000 C (average).
Different grades of steel is made by adding various ferro alloys & additives (FeSi, FeMn, Coke Breeze
or Petroleum Coke, Aluminium, etc) in different quantities during tapping of liquid steel from converter
to steel ladle.
There are 3 LD convertors in SMS. Characterstics of converter design are given below:
Capacity = 150 Tonne
Effective Volume = 133 cum
Converter specific volume = 0.886 Meter Cube per Tonne
Height to Diameter Ratio = 1.36
Refractory for converter lining is MgO based e.g. Sea water Magnesia, Magnesia carbon,
Pitch Bonded
Oxygen is blown in the converter through oxyzen lance. It consists of three concentrically
arranged steel tubes with connecting branches for Metal - Flexible - Hoses. Central pipe is for supplying
oxyzen, intermediate pipe is for incoming cooling water and outside pipe is for outgoing water. At
lower part of lance there are 5 nos. Convergent - Divergent copper nozzles syrnetrically arranged at
17.50 to the lance axis.
CHARACTERISTICS OF OXYGEN LANCE :
Lance Travel = 16000 mm
Oxyzen working pressure = 16 KSCG
Water Working Pressure = 12 KSCG
No.of Nozzles = 5
Water consumption = 130 Cum/hr
Oxygen flow rate = 400-450 NM
3
/min
During blowing LD gas is generated. This is a very poisonous gas because its main component
is carbon monoxide. LD gas cooling, cleaning and collection system comprises of tube bar-tube type
skirt, gas cooling hood and stack, Closed loop type gas cooling arrangement with finfan cooler, kinpactor,
gas duct, ID fan, change over valve, flare-stack, gas holder, etc. When the gas composition is
acceptable, it is recovered and collected in gas holder. Unacceptable LD gas is discharged through
Flare Stack.
LD gas Collection system - Gas collection with suppressed Combustion.
LD gas Cooling - Gas cooling with closed loop hot water pressurised
cooling system.
LD gas cleaning - Wet type cleaning system with adjustable
throat venturi.
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Slag Splashing : After tapping of liquid steel, slag splasting is done after adding calcined dolo in the
slag to improve the lining life of converters.
SCRAP YARD :
Scrap is used as coolant. Scrap may be heavy (wt. up to 1.5 T) or light. Length should be less
than 1.5 M. Some times cast pig iron is used as scrap in case of shortage in steel scrap. Purpose of
scrap yard is to supply scrap to the converter periodically without any interruption Following equipments
are available in scrap yard.
1) Scrap Box Tansfer Car
2) Scrap Weigh Bridge
3) Scrap Box
4) Magnetic EOT Crane
Scrap should not have dust, moisture or water, grease, oil, etc. Generally 15T of Scrap is charged in each heat.
SLAG YARD :
The Slag generated in LD converter during refining of hot metal is collected in vessels called slag pots
(16/18 Meter cube capacity). This slag is dumped in the pits (4 nos.) which are present in slag yard.
For doing so, slag pots, slag pot transfer cars (3 nos.) slag dump cars (2nos.), EOT cranes (2 nos.),
etc. are needed.
LADLE PREPARATION BAY :
Ladles after prolonged use get wornout and need to be repaired. After one or two heats, plates for
slide gate control mechanism, for teeming liquid steel, need to be changed or repaired. All these and
many other activities are done in Ladle preparation bay. There are 26 steel ladles and 5 hot metal
ladles in SMS.
This bay will house the following main facilities:
Horizontal Ladle Stand - For slide gate fixing, Plate changing, etc.
Vertical Ladle Stand - For heating ladle
Relining Pits - For Relining the ladles
Ladle Drier - By burning coke-oven gas, ladle is heated
EOT Crane(3 nos.) - To handle the ladle
(Main hoist capacity 100T)
On line drier - To heat the ladle before releasing for tapping.
ARGON RINSING STATION (ARS) :
The liquid steel which is tapped from LD converter is not homogenious in composition and temperature.
To make the liquid steel suitable for continuous casting purpose by making it homogenous, inert
gas rinsing is done. Generally Argon gas is used for this purpose. Both bottom and top purging
facilities are available. Bottom purging is superior than top purging. When both are used at a time, it
is more effective.
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In general, 12 minutes rinsing is done. For all the 3 LD Converters steel transfer car track, 3
ARS are available. In case of LD-2 steel transfer car track, IRUT (Injection Refining & Up Temperature)
is installed. Along with steel temeperature rising, Argon Rinsing is also done simultaneously. To
raise the temperature at IRUT, oxygen blowing is done and simultaneously Aluminium is added.
In ARS, Aluminium is also added for complete deoxidation (to reduce oxyzen potential of liquid
steel below 10 PPM) and to increase Al% in liquid steel in certain grades of steel to make it suitable for
continuous casting purpose.
There is one ladle furnace in ARS Bay. In Ladle Furnace, composition adjustment and liquid
Steel-temperature raising can be done. Simultaneously Argon Rinsing is also done along with the
above said activities. In Ladle furnace, temperature of liquid steel is raised by electric arcing. There
are 3 graphite electrodes for this purpose.
When rinsing is over after achieving desired temperature and composition (varies from one
steel grade to another) ladle covering compound is added at the top layer of liquid steel in the ladle.
This reduces heat loss from ladle.
TUNDISH PREPARATION BAY :
Tundish is a refractory lined container having 4 nozzles through which liquid steel is poured in
all 4 moulds of a C.C.machine at a time. Pouring of liquid steel from tundish to mould is controlled by
stopper-rod mechanism. During casting, Tundish is placed over mould, and below steel ladle. Tundish
maintains the constant ferrostatic pressure and it helps in floating of the nonmetallic inclusions at the
top layer of liquid steel and thus non-metallic inclusions are prevented from entering into mould.
In Tundish preparation bay, used tundishes are cooled by water/compressed air and lining Is
demolished. All the relining activities, stopper-rod asembly fixing, etc. are done in this bay.
CONTINUOUS CASTING MACHINES (CCM) :
Continuous Casting may be defined as teeming of liquid metal in a mould with a false bottom
through which partially solidified ingot (same shape as mould) is continuously withdrawn at the same
rate at which liquid metal is poured in the mould.
Facilities and Equipments at CCM platforms: Lift and Turn Stand:
To accommodate the steel ladles and place them in casting position as and when required to
facilitate sequence casting. It lifts the ladle and places the ladle at casting position by turning it and
swing back the empty ladle after completion of casting.
Mould Oscillating system :
To facilitate easy withdrawl of continuously Cast bloom (partially solidified) from the mould.
Oscillation frequency : 40-100 cycle/min
Mould Oscillation stroke : 7 mm
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Copper Mould :
The foremost important factor in the continuous casting is the copper mould which decides the
efficiency of the process. The material selected for mould and the design of mould play a prominent
role in obtaining the bloom of greater surface finish, better mechanical properties with minimum of
casting defects. A mould with good design associated by good cooling system gives quality blooms,
provided a great care, is excercised during casting.
In VSP, square (250mm x 250mm) and rectangular (320mm x 250mm) cross sectional moulds
are used. These moulds are provided taper towards bottom (327 x 255 top, 324x252.5 bottom in case
of 320x250 bloom) to maintain the contact between partially solidified strands and is made of copper
which is necessary for achieving the necessary cooling rate.
Copper is an ideal material for mould because it is having
i) good thermal conductivity.
ii) mechanical strength must be retained at operating temperature 250 degree C.
iii) recrystallization temperature above 300 degree C.
iv) low friction coefficient and good resistant to wear.
v) chemical immunity w.r.t. steel.
Cu-Ag 0.1 P-F 25-possess all the above properties.
Length of mould at VSP is 1.0 m
Radius of mould / Machine 12 m
STRAND COOLING :
Strand cooling is carried in two stages: Primary and Secondary cooling.
Primary Cooling :
The soft water is used for this purpose with PH 7-9, total hardness- 0.2 dh. This water is
repeatedly pumped through the moulds in a closed cycle with recooling blot. This water has to be
treated and anticorrosive agent etc., should be added. This water is supplied at a pressure of 5-6 bar.
The inlet water comes from the bottom & leaves the mould through the outlet valve which is located at
the top of mould. This is indirect type of cooling.
Secondary Cooling :
The water that is sprayed over the strand should cool the strand uniformly thoughout the length, to
avoid under cooling of some parts of strand. The pressure will be 6 bar. The countoract flow problem
due to corrossion, the pipeline will be made up of stainless steel. In secondary cooling, strand (bloom)
will be completely solidified, leaving no liquid steel at all. The secondary cooling zone begins from
just below the mould.
Water for secondary cooling should have
PH 7-9, Total hardness 20 DH
Carbonate hardness 0.7 DH
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Dummy Bar :
The function of Dummy Bar is to seal the mould bottom, for the starting of casting and to
withdraw solidified shell until the hot strand has passed the straightening and withdrawing machines.
Backup Roller sections N1 & N2 :
These sections are intended for supporting and directing the dummy bar and strand in course
of casting. N1 is a four roll section installed on posts underneath the secondary cooling sections, while
N2 is a six roll section installed after the 4-high stand.
Withdrawal and straightening rollers :
There are four strands which are used for withdrawing and straightening the curved bloom.
These 4 stands are designated as TK1, TK2, TK3, TK4.
TK1 - 4 high strand
TK2 - 2 high strand
TK3 - 2 high strand
TK4 - 2 high strand
Casting Powder :
The main purpose of casting powder is to act as a lubricant to prevent the sticking of steel to
mould. Casting powder must be added continuously at regular intervals. The meniscus must always
be covered enough that it appears dark, but layer thickness should not exceed 30 mm.
Casting powder should meet the following requirement :
i) reduce strand friction
ii) should protect liquid steel against reoxidation.
iii) prevent surface heat loss.
iv) promote uniform heat transfer from meniscus to mould in order to avoid longitudinal
cracks.
v) rapid and uniform spreading on the bath surface.
vi) it should also absorb some oxides in the steel without great change of its viscocity.
Technical details of CC machines
Average Casting speed for 320x250 bloom size is 0.78 M/min for 250x250 bloom size is 0.82
M/min
Gas Cutting Machines(GCM) :
The strand, which continuously comes from the copper mould after getting completely solidified,
should be cut as per our requirement, to facilitate easy handling, etc. In order to cut the blooms
accurately, a gas cutting machine, using acetylene and oxygen, is used.
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Since the bloom travels with certain speed, the machine used for cutting the bloom should
travel along with the bloom. For this grippers are used, which grips the bloom and travels along with it,
taking the oxy-acetyline flame with it. Each CC machine has been provided with 4 cutting machines to
cut the four blooms at a time.
Details of gas cutting machines :
The pressure of the acetylene : 0.6 kg/sq.cm
Length of the bloom : 5.5 to 5.8 m for 250 x250mm size
6.0 to 6.4m for 320x 250 mm size
Time required for cutting one bloom : 1-1.5 min
The pressure of oxygen : 15 kg/cm2
Bloom Storage Yard (BSY) :
To sychronise the production in continuous casting machine and requirement of rolling mills
for blooms, Bloom storage yard (BSY) has been established. Inspection and selective conditions are
also carried out in BSY. After cutting the blooms at GCM they are moved to cooling beds and after
cooling they are transferred to racks. The BSY is served by 11 nos. EOT cranes with rotating cabins
and magnet facility. Blooms of particular grade of steel are stored at a particular place. Every bloom is
marked by heat no. and machine no.
The sequence of operations in brief at different sections of continuous casting shop is given
below :
1) Steel ladle from converter after tapping is transferred to Argon Rinsing station.
2) In rinsing station : Argon purging (bottom or top or both) is carried out for a period not less than
12 minutes. During rinsing, Aluminium is also added.
3) The sample and temperature are taken. The sample is sent to lab and composition is verified.
If temperature and composition are satisfied, liquid steel is sent to casting platform. If
temperature or composition corrections are required, they are done either at ARS or IRUT or
LF.
4) In CCM, first of all, dummy bar is inserted through the mould. Some small scrap is charged into
mould to enhance cooling rate of liquid steel, to enable the operator to withdraw the dummy
bar.
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5) In CCM, the ladle with liquid steel is placed on the lift and turn stand and will be fixed with
hydraulic cylinder for operating slide gate mechanism to control teeming of liquid steel to
Tundish from ladle.
6) Meanwhile tundish is preheated to about 1000
0
C. Stopper are checked before the tundish is
placed into casting position. After placing the tundish at casting position, nozzles are posi-
tioned exactly in the centre of the mould.
7) Ladle is brought to casting position by turning the lift and turn stand. Stoppers of the tundish
are kept closed. Slide gate of ladle is opened by hydraulic mechanism. If liquid steel stream
is not proper or liquid steel is not coming, oxygen lancing is carried out in ladle nozzle.
8) Liquid steel is continuously fed into the tundish and the level in tundish is carefully observed.
When it is 2/3 full, stoppers will be opened to allow the steel to fill the mould.
9) Before feeding liquid steel into mould water circulation in the mould is to be ensured
10) After the steel meniscus reaches certain level, dummy bars withdrawal will be started.
Secondary cooling water spray is also started.
11) After the dummy bar passes over the withdrawal rollers, it will be disengaged.
12) Continuously coming bloom is cut by gas cutting machine. The required length of cut blooms
are sent to BSY after marking the heat no. and CC machine no. by hot chalk.
13) These blooms are stacked, inspected and heat no. is written by paint over cross section of
bloom. Blooms are sent to rolling mills as per requirement.
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Chapter - 10
LIGHT AND MEDIUM MERCHANT MILL
INTRODUCTION :
Visakhapatnam Steel Plant has three sophisticated Rolling mills, designed to produce 2.656 million
tones per annum of finished products from continuously cast blooms with a wide range of product mix.
The mills are :
a. Light & Medium Merchant Mill (LMMM)
b. Medium Merchant & structural Mill (MMSM)
c. Wire Rod mill (WRM)
SOME OF THE SALIENT FEATURES OF THE MILL ARE :
a. High capacity and high speed.
b. Automatic minimum tension control in stands
c. Double sided cooling beds of walking beam type.
d. High capacity and high productive sawing lines.
e. Automatic bundling machines.
f. Computerization at the sequential process control and material tracking
g. Adoption of closed circuit TV at furnaces.
h. evaporative cooling system and waste heat recovery.
These features help to optimize the production and assure quality products from the mill.
BLOOM STORAGE AND INSPECTION :
The SMS supplies continuous cast blooms in killed and semiskilled quality of ordinary grade, high
carbon and low alloy steels. The bloom storage is at right angles and common to all mills. Bloom
inspection and storage, if necessary, is carried out in the common storage.
LIGHT AND MEDIUM MERCHANT MILL :
Keeping in view the latest developments the light and medium merchant mill is designed with the
operation floor on a second storie elevation, namely +5.0 mts. This arrangement has many
advantages. It provides better drainages for both lubricants and water and mill scale. The oil cellars
can be placed at slightly below the ground level with out deep excavations but ensuring adequate
drainage. The oil and water pipes and cable trenches are readily accessible.
Blooms for LMMM are placed on charging grids (3 nos) of 150 tonnes per hour capacity each by 16
tonnes claw cranes (2 nos). The blooms are then delivered to the furnace approach roller table (+5.8mts)
by an inclined elevator from bloom storage roller table (+0.8mts)
The approach roller table is provided with a weighing scale, a tilter and disappearing stops. The
blooms are positioned in front of the furnaces and then pushed by hydraulic pushers on to the charging
skids of the furnaces. There are two nos. of walking beam type furnaces of 200 T/hr capacity with
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double row charging. The blooms also can be discharged from the charging side of the furnaces in
case of emergency. Heated blooms are placed piece by piece by discharging devices on to the furnace
delivery roller table. The blooms are descaled by high pressure de-scaler.
The continuous Break-Down group (non-reversing) consists of 7 stand -2 Horizontal (850x1200mm)
and 5 alternating vertical and horizontal (730X1000mm and 630X1000mm).
In 5 Box passes and one each of diamond and square passes, the blooms are reduced to 125 mm
square in the 7 stands. The finishing speed will be 1.3 to 1.6 mts/sec. A four crank shear installed
behind the mill stands is designed to crop both ends and to cut billet lengths as per requirement of
WRM & Sales as per requirement to achieve optimum yield in cutting. Billets feeding the LMMM are
cropped at the front and back ends.
Normally one Bloom is rolled for LMMM and the next one for the WRM alternatively, Billets are also
sold. The billets for WRM and for sale are cooled on 2 turn over - type cooling beds to a maximum
discharge temperature of 400
0
C. These billets are picked up by magnet cranes of 16 T capacity in the
intermediate billet storage and transferred to the transfer grids in the shipping area or dispatched for
sale.
Billets after cropping by the 4 crank shear and having a length of about 32 mts are transported to the
in-line 2 strand roller hearth furnace of 200 T/h Capacity. Billets normally arrive at the furnace with a
surface temperature of 1100
0
C. Billets are heated and soaked to a discharging temperature of 1150
0
C to 1130
0
C.
The continuous multi-line mill comprises 8 stand double strand roughing train, 2 Nos, 4 Stand Single
strand finishing trains.
Loopers are provided in between the finishing stands for tension free rolling in order to obtain good
surface quality and tolerances. Housings are of closed top type. Roll necks are mounted in anti friction
bearings.
Shears for cropping and emergency cutting are arranged ahead of the first of roughing mill stand and
upstream of intermediate mills. Snap shears for emergency cuts only are ahead of finishing mill. The
rotating shears after the finishing mills crop the materials leaving at rolling speed. And cut into multiples
of specified sales lengths.
The finished bar now enters the cooling stretches. There are two cooling stretches each installed just
downstream the last stand of the finishing mill. The purpose of the cooling stretches is to cool down
the rebars to such an extent so as to produce desired mechanical properties. It also serves to control
the scale formation.
The bar leaving the last stand of the finishing mill passes through a cooling stretch. The cooling
efficiency of this installation is such that a surface layer of the bar is quenched into martensite, the
core remaining austenite. The quenching treatment is stopped when a determined thickness of
martensite has been formed under the skin when the rebar leaves the cooling stretch, a temperature
gradient is established in the cross-sections of the bar causing heat to flow from center to the
surface, which results in self-tempering of the martensite Finally during slow cooling of the rebar on
the cooling bed, the austenitic core transforms into ferrite and pearlite. To achieve the required
mechanical properties, it is sufficient to maintain the tempering temperature within a predetermined
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range. The obvious control variables are the length of the quenching line and the cooling water flow
late at suitable number of cooling pipes whose diameter, are chosen as a function of product diameter.
Air Strippers are fitted at the end of cooling pipes to make sure that the material leaves the stretch in
dry condition. The pinch roll units; downstream the cooling stretch guarantees the correct bar speed
during the cooling process. These pinch rolls are speed synchronized with the exit stands of finishing
mill 1 & II so that bar speed remains same when the bar tail has left exit stand of finishing mill. They
also serve to enter the material into the rotary shear. A total cooling bed of 130 mts X 12 mts has been
provided for cooling down the rolled section at about 808
0
C maximum for straightening.
In the downstream of the cooling beds there are multi strand straightening machines (maximum 8
straightening strands) The number of straightening rolls are 8 (top 4 and bottom 4). The bar groups
from the straighteners are collected in layers for the downstream cold shear by cross - transfers. The
2 cold shears have cutting pressure of 500 MPa each. Desired finished lengths normally 12 mts are
set by girder type gauge carriages. Tail lengths less than 6 mts are discharged into cradles near the
cold shears. Downstream file cold shears, rounds, and rebars are transported to bar bundling facility.
There are two bundling facilities. The bar bundling facilities have provision for counting the bars, and
strapping the collected bars into bundles of 4500 Kgs and 10000 Kgs.
Strapping of bar bundles and packs is by means of wire and straps.
The finished section packs/bundles are finally transported to the weighers and the loading grid permits
the bundles to be picked up by magnetic cranes in the finished product storage area having lifting
magnets of 20 Tonnes capacity.
ELECTRICAL EQUIPMENTS IN LMMM
The mill stands are driven by individual main drive motors. The motors are separately excited and
compensated DC shunt motors in two frame sizes.
The armature circuits of the motors are provided with individual thyristor power supply comprising 11
KV converter transformer, thyristor converter, reactor, single pole high speed circuit breaker and double
pole no-load contractor, in ratings to match the motor overloads. Field circuits of the motors are fed by
individual thyristor power supply systems fed from 415V, 3-Phase supply source, over isolation
transformer.
For AC drives the motors provided are generally squirrel cage type for continuous operation drives
and slip ring type for intermittent duty drives. Geared motors for individually roller table drives have
also been foreseen. AC motors provided are totally enclosed Fan-cooled.
Variable frequency motors for roller table drives are fed over variable voltage -variable frequency
(VVVF) supply sources.
AUTOMATION AND CONTROL SYSTEM IN LMMM :
PLCs in LMMM :
Different makes of PLCs are used in various areas of automation for operation control.
AEG-PLC : ( 38 Nos)
Total mill control
Reference generation for all drives
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Sequence and interlocking for process equipments.
Position control for drives.
Video interface for the operator in the control pulpit
ALLEN BRADLEY-PLC ( 5 Nos)
Walking beam furnace control system - 2 Nos.
Cobble detection system for merchant bar mill - 1 No.
Strapping machine control system - 2 Nos. with 9 nos. Remote I/O
GE FANUC-PLC (7 Nos)
Total mill control
Reference generation for all drives
Sequence and interlocking for process equipments.
Position control for drives.
Video interface for the operator in the control pulpit
Roller hearth furnace control system
Air oil lubrication system control
SIEMENS PLC (1 No)
Booster water station
LEVELS OF AUTOMATION IN LMMM :
Programmable Logic Controllers (PLCs) provided at level-1 finally control the process equipment
directly, each in its own area for sequencing and interlocking functions. The system envisaged is
interfaced with the main and auxiliary drive analogue control system so as to perform as one integrated
unit.
The control at Level-2 is basically decentralized and distributed in concept so as to offer a higher
degree of operational flexibility. A number of microcomputer subsystems provided at this level, operate
and control function for equipment distributed in various areas of the mill.
For operators communication with the system dialogue terminals (VDU and Keyboard units) have
been envisaged in control pulpits of the mill. Printers for hard copy print out of rolling schedule, shift
reports etc.
The control system envisaged is basically automatic with provision of manual control locally for
equipment to take care of local disturbance during operation and also the maintenance needs.
UPGRADATION OF PLCs :
Most of the important PLCs of the Billet mill and Bar mill are being upgraded to latest GE FANUC
make.
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Modifications done in MMSM to improve productivity
1) Roll-pass design modification in MC100,MC125&MC150 for more pass-life in finishing stands
2) Roll-pass design modification in Rounds to make exit stand horizontal,for easy adjustment in
mill during rolling
3) Double bars to batching in rounds,thus increasing output from Cooling bed
4) Diameter of cold saw blades reduced to 1460mm from 1604mm and 1500mm,thus increasing
stability of the blade
5) Hydraulic feeder modified to mechanical feeder,thus reducing hydraulic leakage in piling
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Chapter - 13
ROLL SHOP AND REPAIR SHOP
Roll shop & Repair shop (RS&RS) is a prime service department to the three rolling mills of
VSP. Located in the complex of Rolling Mills, RS&RS caters to the mill requirements of Roll pass
design, Guide design, Supply of roll assemblies, guide assemblies and maintenance spares all in one
department which is unique in the steel industry. For the first time in the country, CNC technology has
been adopted for grooving of steel mill rolls for achieving high repetitive accuracy and higher productivity
compared to conventional ones.
The main activities of the RS&RS is Roll pass design, Roll Turning, assembly of rolls with
bearings, preparation of guides and manufacture/repair of mill maintenance spares.
Roll Pass Design section
Design of grooves for development of new sections, modification of existing pass designs for
improving the productivity and quality. Preparation of rolling schedules, groove detail and distribution
and template drawings, part programming for grooving of rolls on CNC lathes.
Roll Turning shop :
The activities involved are Turning/Notching/Branding of Rolls used for rolling of various products in
the three mills. The shop is equipped with the following sophisticated Machines :
1) Heavy duty CNC Lathes
2) CNC Template milling machine
3) CNC Notch milling machine
4) Roll Branding M/cs
Bearing Shop :
The activities involved are assembly of Rolls with Heavy duty bearings Types of Bearings used are as
given below:
LMMM & MMSM WRM
G 4 row tapered roller bearings G Morgoil bearing (Oil film bearings)
G 4 row cylindrical roller bearing G 2 row axial tapered roller bearings
G Deep groove ball bearings
G 2 row axial tapered roller bearings
G 2 row angular contact ball bearings
Guide Shop :
Mill guides are used for inter-stand guiding of the material. Entry guides ensure correct direction of
the head end of the stock entering the rolls and hold the stock in the required position. Delivery/exit
guides serve to control direction of the stock leaving the rolls after rolling. Delivery twist guides are
used for twisting the stock. The guides can be of static or roller type. In the Specialized Repair Shop,
assembly, servicing, repair of mill guides, redressing of guide rollers, resharpening of shear blades,
manufacture of fast moving spares are done.
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Roll Set
Assembly/
Disassembly
Blank
Rolls
Roll Turning Area
R
O
L
L
I
N
G
M
I
L
L
S
(
L
M
M
M
;
W
R
M
)
Turned
Rolls
Used
Rolls
Assembled
Roll Sets
Used
Roll Sets
Bearing Assembly Area
CNC MACHINES FOR
ROLL TURNING;NOTCH-
MILLING; BRANDING
AND TEMPLATE
MILLING
SPECIAL PURPOSE
M/CS/EQUIPMENT
FOR MACHINING
GUIDE ROLLERS
AND REPAIR OF
STATIC GUIDES
WRM GUIDE ASSEMBLY
LMMM GUIDE ASSEMBLY
Guide Repair and Assembly Area
Assembled
Guides
Used
Guides
ROLL SHOP-I
ROLL SHOP-II
AREA REPAIR
SHOP
LMMM &
WRM
MMSM
Mfg / Repair of
Mechanical spares
LMMM ; WRM
& MMSM
Supply of Rolls , Guides
And Bearings.
Supply of Rolls , Guides
And Bearings.
Geographically this department is in three areas viz
1) Roll shop-I :- Supply of rolls and guides to LMMM & WRM.
2) Roll shop-II :- Supply of rolls and guides to MMSM.
3) Area repair shop :- Manufacturing of mechanical spares of three mills
Roll Shop-I comprises of a Roll Turning Shop, Bearing shop, a Specialized repair shop catering to the
needs of LMMM and WRM. Roll turning shop is equipped with six CNC lathes, CNC template machine,
Notch Milling machine Branding Machine etc. The grooved rolls are assembled with bearing chocks
in the bearing shop. Used bearings are dismantled, cleaned, inspected, serviced and reassembled
on the rolls at regular intervals. Separate bearings for taking radial loads and axial loads are used.
ROLL SHOP & REPAIR SHOP
PROCESS LAYOUT OF ROLL SHOP- I
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Roll Shop-II comprises of roll turning shop, Bearing shop and guide shop catering to the requirement
of MMSM. Roll turning shop is equipped with six CNC lathes for grooving new rolls, as well as redressing.
The grooved rolls are assembled with bearings in the bearing shop. Chocks with bearings serviced
periodically. Assembly and service and repair of guides, preparation of strippers used in rolling of
Angles, channels and beams are done in guide shop.
Cassette/
Bearing
Servicing
R
o
l
l
S
t
o
r
a
g
e
T
u
r
n
e
d
R
o
l
l
s
U
s
e
d
R
o
l
l
s
Blank
Rolls
S
Conventional Machines
(NH-22,Shaper,Drilling)
for repair of guide roller
and static guides
U
s
e
d
G
u
i
d
e
s
G
u
i
d
e
s
CNC MACHINES FOR
ROLL TURNING (CNC
Lathes 6 nos) and ROLL
BRANDING M/C (1 NO.)
Roll Turning Guide assembly
Bearing Servicing
C
a
s
s
e
t
t
e
s
PROCESS LAYOUT OF ROLL SHOP - II
MMSM
(Medium merchant and structural Mill)
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Area Repair Shop is a machine shop with general purpose machine tool like lathes, shapers, milling,
slotting, drilling and grinding machines, vertical press fabrication etc. The main activities involved are
Repair and manufacture of spares for the mills and Roll Shop.
PROCESS LAYOUT - AREA REPAIR SHOP
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SERVICE UNITS
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Chapter -14
AIR-CONDITIONING SYSTEM DEPARTMENT (ACS)
INTRODUCTION
Air-conditioning and refrigeration system is very important in any big process industries like steel
plant, power plant, oil refineries etc. The air-conditioning requirements are increasing day by day due
to growth in automation level, computerization etc. For the plant to function efficiently, air-conditioning
is very important to maintain design comfort temperature, humidity & air quality. ACS department in
Visakhapatnam steel plant is maintaining variety of air-conditioning units to suit different conditions,
requirement as per the application.
For high ambient air-conditioning units running on moving machines of coke oven batteries
(Door Extractor car, Charging car, Pusher car, Loco car), heavy duty hot metal cranes, liquid
steel handling cranes, bloom handling cranes, Tundish handling etc .
Air Handling units working on chilled water for Electrical control rooms, IBM computer center,
PLC rooms, etc.
Air-conditioning with humidity control, 100 % fresh air for special applications like MBU (Main
Burn unit), Operation theatre, Labs etc.
Comfort Air-Conditioning in Conference Halls and Auditoriums.
Package air conditioners of 5.0 TR, 7.5 TR, 10 TR for pulpit operators, conference halls, control
rooms etc. Package units are of water-cooled and air cooled condensers depending upon the
availability of cooling water.
Panel ACs are directly cooling the PLC panels of CNC lathe machines. Oil chillers for cooling
spindle oil in CNC lathe, Deep Freezer operating at -80
0
C for storing bearings.
Window / Room Air Conditioners , water coolers for personal comfort.
BRIEF DESCRIPTION OF THE SHOP
Air-conditioning system departments role is to maintain Air conditioning units inside and outside the plant :
Maintenance of different Air conditioning and refrigeration units inside the plant e.g. Air handling
units, package ACs , Fan coil units, Crane ACs, Window ACs, Split ACs, Water coolers, Panel
/ pendant ACs, Oil chillers, Deep freezers, cabin of Yard machines in RMHP, Sinter Plant etc.
Operation cum maintenance of different Central AC plants & Package AC systems outside
plant & Township e.g. Main Administrative building, VSGH, Ukkunagaram club, Steel club, Ukku
house, T&DC auditorium, Township telephone exchange , Gurujada kalashetram, Hill Top guest
house, T&DC Library, Centre for HRD etc.
As the units to be maintained are spread out through out the plant ,outside plant and township, 9
zones are created to improve the response time, logistics, accessibility etc: The Zones are:
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S.No Equipment Range Qty
01 Central Ac Plant 30 TR - 120 TR 24
02 Air Handling Unit 10 TR - 120 TR 183
03 Fan Coil Unit 1.0 - 2.0 TR 244
04 Package Ac 5.0 -10.0 TR 260
06 Window /Split Ac 1.0 - 2.0 TR 1200
08 Water Coolers 40 L 354
09 Panel / Pendant Ac 250 -1500 W 108
10 Oil Chiller 3.0 TR 6
11 Deep Freezer - 100 OC 01
Zone Area covered
COCCP Maintaining AC units of COCCP & RMHP.
SP Maintaining AC units of Sinter Plant, BF & TPP.
SMS Maintaining AC units of SMS & ASP area.
CRMP Maintaining AC units of CRMP , Central Stores,
Energy & Telecom, Central Computer centre,
ED(W) conference hall , Pay section etc.
LMMM Maintaining AC units of LMMM & MRS area.
WRM Maintaining AC units of WRM, MMSM & Roll shop.
Workshop Repair activities of Window ACs, Water coolers,
Panel/Pendent ACs, ERS coordination etc.
Outside All central AC plants & Package AC plants
Plant operation & maintenance.
EQUIPMENT SUMMARY OF ACS DEPARTMENT ZONES OF ACS DEPARTMENT
What is Air conditioning?
Air conditioning is the precise control of temperature, humidity, and air flow and air cleanliness. Air
conditioning is defined as the process of treating air so as to control simultaneously the temperature,
humidity, cleanliness and distribution to meet the requirements of the conditioned space.
CONTRIBUTION TOWARDS ENVIRONMENT:
Lot of proactive measures are taken to ensure the reduction of Refrigerants like CFC, HCFC which
are the main cause of ozone depletion in the atmosphere.
In-line with VSP vision Be a respected corporate citizen, ensure clean and green environment
and develop vibrant communities around us., sustainability plan has been drawn to phase out
CFC Refrigerants like R-12 , R-114 , R-13 by 2010 as per the Montreal Protocol and ODS Phase
out Rules -2000 by Ministry of Environment & Forest (MoEF) to phase out CFC Refrigerants
which is the main cause of ozone depletion in the atmosphere.
The action plan approved for phase out as per sustainability plan is :
The consumption of various refrigerants like HCFC & CFC with absolute and specific consumptions
for the last few years are given below:
2006 45 - - - completed
2007 35 24 - - completed
2008 34 25 4 - completed
2009 34 25 4 1
2010 34 20 5 -
Total 182 94 13 1 58 % completed
Equipment
YEAR
Water
cooler
Panel /
Pendent AC
Crane
AC
Deep
Freezer
Remarks
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ABSOLUTE CONSUMPTION OF HCFC REFRIGERANTS
0
500
1000
1500
2000
2500
Target (in Kgs) 2141 1762 1316 1090 1030 980
Consumption 2074 1491 1292 1083 1028 735
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Target (in Kg/TR) 0.35 0.3 0.24
Consumption (Kg/TR) 0.27 0.25 0.18
2005-06 2006-07 2007-08
SPECIFIC REFRIGERANT CONSUMPTION OF CFC
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Chapter - 15
CAPITAL REPAIR GROUP
CAPITAL REPAIR GROUP
15.1.0 INTRODUCTION :
Capital Repair Group(CRG) was formed in the year 1998 to cater the need of Refractory and Mechanical
Maintenance and Repair of major installation in Coke Ovens and Coal Chemical Plants (CO&CCP) of
Visakhapatnam Steel Plant (VSP). CRG office is located in the CO&CCP zone in a dedicated building
opposite to Battery No.2. CRG is having two sections viz., Refractory Section and Mechanical Section.
15.2.0 REFRACTORY SECTION:
15.2.1 Refractory section is responsible for the following activities in CO&CCP:
15.2.1.1 Planning, procurement and management of Refractory and Acid Proof
materials as per the need in various installation in CO&CCP.
15.2.1.2 Hot full wall and end vertical repairs in coke oven batteries.
15.2.1.3 Cold Repair of coke oven batteries.
15.2.1.4 Regular running maintenance jobs in Coke Oven Batteries, Coke Dry Cooling Plant
(CDCP), various chutes of Coke Sorting Plant.
15.2.1.5 Capital Repair and Refractory Maintenance of CDCP chambers and its Dust Catching
Bunkers, Dust Cyclones & Boilers.
15.2.1.6 Predespatch Inspection of refractories being procured by VSP.
15.2.2 Materials being used by CRG Refractories :
15.2.2.1 Coke Oven Batteries :
VSP has got 3 numbers of 7 m tall coke oven batteries. The 4th battery is about to be
commissioned. In April, 2009 Each batteries has got zones as follows:
15.2.2.1.1 Bus flue or Sole Flue Zone : It is mainly made up of fireclay bricks & mica insulation
bricks.
15.2.2.1.2 Regenerator Area : It is made up of silica bricks with fire clay checker bricks. In the front
area fireclay bricks and insulation bricks are also used.
15.2.2.1.3 Inclined Flue Zone : This zone is mainly made up of silica bricks.
15.2.2.1.4 Vertical Flue Zone : This zone is also comprises of silica bricks
15.2.2.1.5 Roofing of vertical flue zone : This zone is also made up of silica bricks
15.2.2.1.6 Oven Roofing Zone : Just above the oven, there is a covering of silica bricks, but above
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that layers, entire bricks work up to top layer is made up of fire clay bricks and insulation
bricks.
Each battery requires around 14000 MT of Silica bricks, 6000 MT of Fireclay bricks and
1000 MT of Insulation bricks for its construction. The 120 M high chimney is lined with
approximately 1000 MT of Fireclay bricks.
15.2.2.2 Coke Dry Cooling Plant :
CDCP consists of fireclay bricks at the Cooling Chamber and Dust Setting Bunker while,
the boiler panels are cast with insulation and fireclay castables. The dust cyclones,
discharging device, blowing devices are lined with fused cast basalt slabs.
15.2.2.3 Coke Sorting Plant :
All the chutes of CSP are lined with fused cast basalt slabs.
15.2.2.4 Coal Chemicals Plant :
15.2.2.5 Major installation in Ammonium Sulphate Plant (ASP) of CCP are lined with Acid proof
bricks and tiles including the floor areas. The pipe still furnace of Tar distillation section
and furnace of HRED section of Benzol Plant is lined with insulation and fireclay castables.
15.3.0 MECHANICAL SECTION :
15.3.1 CRG- Mechanical Section is responsible for repair and maintenance of following
equipments in Coke Oven Zone :-
15.3.1.1 Entire Coke Oven gas withdrawals system in batteries which include Stand Pipes, Goose
Neck, Valve Box, Gas Collecting Mains.
15.3.1.2 Capital repair of Gas Collecting Mains including its full replacement.
15.3.1.3 Repair and maintenance of Coke Oven Battery anchorage systems which include Flash
Plate, Buck Stays, Door Frame, Longitudinal & Transverse Tie Rods, Regulating Springs
and Brackets.
15.3.1.4 Repair and maintenance of heating system equipments like Reversing mechanism, Waste
Heat Box and its branch pipe etc.,
15.3.1.5 Regular mechanical maintenance of batteries except battery machines.
15.3.1.6 Regular repair and revamping of coke oven doors.
15.3.1.7 Apart from the above jobs CRG Mechanical Section is associated with the procurement
of mechanical items required for CRG, along with CO&CCP shop Mechanical Section.
15.4.0 Major Achievement of CRG :
15.4.1 Hot Full Wall repair was done for the first time in India.
15.4.2 Rehabilitation of all the three batteries after a crisis period from 1998 to 2000 in a short
span of time.
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15.4.3 Completion of Cold Repairs of Battery No.2 in a record time of 11 months.
15.4.4 Replacement of Gas Collecting Main in Battery No.1 on coke side in record time.
15.4.5 Capital repair of 12 cooling chambers including DCB of CDCP.
15.4.6 Capital Repair of 4 nos of saturators and 4 nos. of Acid Tanks.
15.4.7 Replacement of Gas Collecting Main in Battery No. 3 on coke side along with main liquor
supply line (partly) and pusher side valve box, Stand pipe assembly (11 Nos) in a record
time of 38 days.
15.4.8 QMS, EMS, DHSMS, 5S Implementation.
15.5.0 Major Repair done by CRG since inception :
15.5.1 Battery No.1 :
G
Repair period: January, 1999 to March, 2005.
G
End vertical repair of 52 ends
G
Full Wall repair of all the heating walls.
15.5.2 Battery No.2 :
Repair period: March, 1999 to March, 2001.
G
Initial hold up repair with 27 heating walls hot end vertical repair till December, 1999.
G
Cold Repair of entire battery from May, 2000 to March, 2001.
15.5.3 Battery No.3 :
G
Initial repair of anchorage system was done from November, 1998 to August, 1999.
G
Completion of hot repair of 123 end flues till June, 2008 in phases.
15.5.4 CDCP :
Capital Repair done on all 12 number of Cooling Chambers and Dust Setting Bunkers
and Dust Cyclones.
15.6.0 CONCLUSION :
CRG is dedicated to keep all the installation in proper health and in its constant endeavour
to prolong the life of Coke Oven Batteries and other units. CRG is involved in regular
inspection of all the lining condition and mechanical installation of Coke Oven Batteries
and its timely maintenance and repair.
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Chapter - 16
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Chapter - 17
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Chapter - 18
CIVIL ENGINEERING DEPARTMENT
1) HISTORY :
Civil Engineering Department was formed by taking over from construction after operation/process
started i.e.., in the year 1990. The activity of the department has fully geared up in 1991 when Blast
Furnace Godavari commissioned.
2) OBJECTIVES OF THE DEPARTMENT :
This department is a service oriented and caters the needs of all units/shops in the Plant pertaining to
civil works like
a. Maintenance and repair of industrial buildings, repair of foundations for machines etc.,
b. Road repairs and maintenance, and formation of additional roads for providing additional/ improved
facilities.
c. Up keeping of ablution of toilet blocks.
d. (I) Checking the alignment of line and level of equipments, EOT crane and other yard mobile
equipment/cranes situated in various departments for effective working of the equipment at
various locations in the shops/yards, as and when shops/customer requirement arises for repairing/
corrective measures are to be taken.
ii) Fixing of coordinators and bench marks for taking up any new roads equipment/buildings/
equipment foundations and certificating the same while and after erection/completion of the jobs
both inside and outside the Plant i.e., Township.
e. Environmental protection and beautification of the Plant by developing parks, landscapes, tree
plantation.
f. Operational requirements like attending capital civil repairs, breakdown jobs, AMR scheme jobs.
g. Cleaning of storm water drains, canteen & surface drains throughout the Plant for prevention of
inundation, water logging, etc., and keep the hygiene & environment around the shops in the
plant.
h. Repainting of equipment in the shops periodically for preventing corrosion.
i. Periodical inspection of RC buildings, underground tunnels, box drains, cooling towers for effective
functioning of the same and suggest remedial measures for up keeping the same.
j. To maintain safety standards as per norms while attending jobs at height, civil repair works as
well as underground box drain cleaning jobs for gas safety.
k. Drinking water facilities are made at Shop level for workmen apart from providing facility at
kiosk.
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l. Maintenance of diversion channel to let out affluent water/storm water.
m. Maintenance of Ash Pond to dibert the ash collected in Ash Pond, through ash slurry pipelines
connected from Thermal Power Plant.
3) Employee profile for undertaking the services for the above is as follows:
S.No Grade Nos
1) E-7 01
2) E-6 to E-0 35
3) JO/JSO 02
4) Foreman/Chargemen 09
5) Technicians 12
6) Mali 02
TOTAL 61
4) Management System and Support provided by the Company.
i) All ISO standards for ISO-9001 for QMS, ISO-14001 for Environment &OHSMS (Safety & Health)
as per ISO-18001 are formulated and being implemented.
5) Regulatory Constraints:
All activities shall be governed as per Factories Act & Labour Act for the employees.
All new buildings for development activities required to be approved by Director of Factories
before execution of the work besides clearance obtained from our Design & Engineering
Department.
All contract employees deployed on the work shall be issued gate passes after obtaining safety
induction by SED and site safety induction for the particular special work in the presence of
department representative.
For hazardous environment works identified, the contract workers who are engaged shall undergo
health check in our OHSRC.
All statutory obligations like PF, ESI etc., of the contract employees shall be looked after by the
concerned contractual agency and monitored by the Engineer-in-charge of the work.
For all minor/major materials consumed in the works, MRC clearance shall be obtained from
State Government authorities for certification of final bills.
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6) Our Key Customers & their requirements:
Our Key customers are all departments in the overall Plant like C&CCD, RMHP, TPP, SP, SMS,
BF, Rolling Mills, CRMP, Stores, Personnel Department, Traffic, FMD, EMD, EnMD, WMD, St.ED,
WCC, CISF, Marketing, Pay & Finance etc., and our function is to attend jobs related to day to
day needs of civil repairs and maintenance jobs pertaining to Area Shop Offices, Canteens,
Laboratories, Control Rooms, Area Repair Shop buildings besides all RC industrial structures,
machine foundations, foundations of the yard equipment, leakage prevention in underground
RC tunnels belonging to conveyors, cable tunnels, etc., periodical painting of equipment for
preventing corrosion and increasing the life span of the equipment, beautification of areas/parks/
gardens, environmental hygiene of the Plant with regard to maintenance of good roads, upkeep
of buildings and surroundings, canteens, ensuring water supply at various places of working and
in buildings on RCC roads, vacuum cleaners are used to arrest dust in order to improve hygienic
conditions.
7) Major Technologies & Facilities :
a. All civil works are estimated and prepare bill of quantities for the requirements projected by the
respective shops as well as works departments which require periodical maintenance of the civil
buildings & equipment painting.
b. All civil works are being carried out by deploying contractual agencies for execution of civil works
including supply of materials.
c. All works after awarding will be supervised as per specifications to suit the needs and requirements
of shops and measurements taken and quantified for making payments to the agencies.
d. Departmentally surveys are conducted for capital repairs, etc.
8) Relationship & Communication Mechanism with Key Customers :
Associating and attending all the points raised in Department Safety Committee meetings, MOU
meetings, SFC meetings for upkeep of buildings, facilities and improvements for good working
conditions, space requirements, repair of machine foundations as and when damaged, water
supply & sanitary repairs & maintenance, etc. Urgent repairs/requirements will be projected by
departments by IOMs, telephonic messages, etc. shall be attended.
9) By constructing & developing new buildings, rooms, roads, extra civil facilities like pavements,
hard standing in various places of the yards create good, safe environmental working conditions
in the entire Plant and adding welfare measures to the employees and provide effective working
conditions.
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10) Continuous Improvement :
a. Conversion of main roads into RCC roads for safe, accident free, strain less riding over roads in
3 years plan.
b. Repair & renovation of RC structures using modified polymer mortars and polymer concretes for
speedy completion without compromising with strength and without hindrance to production.
c. Using special concretes, the foundation blocks under heavy equipment and machinery are made
ready within 24 hours of casting instead of conventional concrete taking 28 days for attaining
strength and equip the foundation ready for erection/use for production use.
d. Cost reduction measures wherever possible are being adopted for road making/repairing like
using SMS slag instead of soling/metalling using BF slag for leveling the areas under concrete
pavements, etc.
e. To contain lateral movement/vibration of foundation, etc., HILTI bolts are used to make effective
use of foundation structures whenever necessary. This fixing will improve stability and life of
structure.
f. Necessary modifications are made to Weigh bridges to record actual weighment of materials,
hot metal, etc.
g. Dust catchers are constantly being used in Shop floors helping dust prevention in areas like
BHS-1 & BHS-2 of BF in order to improve environmental standards.
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Chapter - 19
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Chapter - 20
ELECTRO TECHNICAL LABORATORY
Introduction:
In view of the high degree of sophistication and automation used in VSP, a specialized group for
supporting electronics in drives and PLCs necessitated. Electro Technical Laboratory (ETL) precisely
does the above function. ETL supports electrical groups of different production shops for maintaining
100% availability of the Electronics pertaining to drives and PLCs.
There are approximately 1200 Thyristor Controlled Drives in VSP including..
- Crane Controls
- AC/DC motor controls
- Uninterruptible power supplies
- Computer Numerically Controlled Machines in different shops
There are approximately 300 programmable Controllers Controlling various drives, Process Parameters
and other related equipments of the Plant.
ETL department comprises of Field services, Central laboratory services and Planning.
Field Services:
The department caters to the needs of almost all the Production departments. The following functions
come under the scope of the department:
Predictive and preventive maintenance of thyristor controlled drives and PLCs in order to keep
the breakdown time of the systems at the minimum.
Support shop electrical groups in trouble shooting the systems in case of breakdowns.
Study and analysis of the day-to-day activities to maintain the systems trouble free.
Study and analysis of the performance of the systems by maintaining history records of the
equipment and taking corrective action/ improvisation.
Laboratories:
ETL Laboratories are located centrally in Integralid Aulomolic Devices Repairshop (IADRS) building.
The Laboratories cater to the electronic PCB repair needs.
The major sections of ETL Laboratories are:
Thyristor Controlled Drives Cards Repair Laboratory
Digital Electronic Card Repair Laboratory
General Electronic Laboratory
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The functions carried out by Laboratories are:
Repair of all electronic PCBs pertaining to drive automation.
Repair of most of the electronic PCBs pertaining to Programmable Controllers.
Maintenance of history records for all Electronic PCBs.
Study of the performance of cards, type wise and cardwise, analyzing the defects of the cards
and taking corrective actions to reduce the card failure.
Development of various testing facilities, test jigs, testing procedures, PCB drawings for easy
and quality repair of PCBs.
PLANNING :
Planning section takes care of procurement and storing of various spare PCBs, instruments like
Digital oscilloscopes, function generators, IC testers and components etc. for smooth maintenance of
the equipments.
UPGRADATION :
ETL does the assessment of the old equipment and their maintainability with respect to obsolescence/
supplier support/ spares availability and recommends for upgradation. During upgradation, ETL involves
in engineering, technical specifications, technical recommendations and commissioning of PLCs,
Thyristorised DC drives/ AC drives, UPS & Cranes.
Expansion:
ETL department is actively involved in the expansion activities of the plant.
ETL department takes active participation in preparation of specifications for various electrical &
automatic systems proposed in the expansion plan.
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Chapter - 21
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Chapter - 22
ENGINEERING SHOPS AND FOUNDRY
Engineering shops & Foundry is a set up to meet the requirements of Ferrous & nonferrous
spares of different departments. The Engineering shops & Foundry is divided into Central Machine
Shop (CMS), Steel Structural Shop (SSS), Forge shop (FS), Foundry (FDY), and Utility equipment
repair shop (UERS).
DESCRIPTION OF SHOP FACILITIES
CENTRAL MACHINE SHOP
INPUTS :- Iron & Steel castings, forgings, rolled sections, repair and rectification parts, non ferrous
castings.
Products and Services:- Shafts, Pinions, Gears, Crane Wheels, Rollers, Machining of various
fabrication jobs done in SSS, Repair & reconditioning of various assembly jobs like L&T Column, TK
stands, pulleys, provisioning of gear boxes.
The shop operates on two-shift basis for 300 days in a year and annual production is 5, 200t. For
preparing the raw material for machining, material saws, facing and centering machines, hacksaws,
and gas cutting facilities are provided. The machining section has over 100 major machines including
lathes, milling, boring, and planning, slotting, shaping, grinding and other machines. The assembly
section undertakes medium repair and general overhauling of mechanical equipment. Horizontal and
vertical presses, induction heaters are provided. The tool room has facilities for manufacturing of
special tools, jigs and fixtures, re-grinding of tools and cutter and brazing of tipped tools. The heat
treatment section is provided with annealing, normalizing, tempering furnaces, carbonizing furnaces,
heat treatment furnace with protective gas atmospheres, high frequency hardening machine, quenching
tanks will oil cooling arrangements, welding generator and transformers for normal welding, submerged
arc welding machines etc. Facilities for surface grinding, pipe bending and threading are also provided.
FORGE SHOP
Inputs : Ingots from foundry, blooms from SMS, billets, rods from Mills etc.
Products : Raw material for shafts, couplings, gears, pinions, flanges bull head hammers for sinter
plant hammer crusher, drill rods for blast furnace, v-hooks for SMS, straightening of pallet middle
frames of sinter plant.
The shop is designed for production of forging for shafts, coupling flanges etc. and also of
forged shapes such as crusher hammer heads, special bolts, nuts, etc. There is a facility for repair
and testing of chairs is also existing. The annual production from the shop is about 2,800 tons based
on 300 working days per year and two shifts per day. In heavy forging section, open die forgings of
long shafts, gear blanks, couplings etc. is made with the help of 2-ton bridge type pneumatic hammers.
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Each hammer will be provided with twin chamber heating furnaces. Floor type manipulator and Jib
Crane are provided for handling heavy jobs. In general forging section, 1 ton, 500 Kg, and 200 Kg
hammers with separate heating furnaces are provided. A 2-ton drop stamp hammer with a heating
furnace trimming press etc. is provided for stamping. For cutting them to size, a cold saw, a billet
shear and gas cutting facilities are provided. For stress relieving, a bogie type-annealing furnace is
provided.
STRUCTURAL SHOP
INPUTS: - Various sizes of plates, angles, channels, beams, flats, rounds for fabrication of jobs.
PRODUCTS & SERVICES: All types of fabrication jobs, repair of slag pots of SMS, Mfg. And repair of
tundishes for SMS, Mfg. Of scrap boxes for SMS, for sinter plant, hot metal ladle for SMS, 500 meters
launder for SMS, mfg. Of KAMAG body for FMD, repairing of buckets for LMMM, WRM.
The annual production of fabricated structures are about 3,600 tones The shop operates on 2 shift
basis for 300 days in a year. For marking, cutting to size, forming and bending, guillotine shear,
circular saw plate bender, gas cutting unit etc. Are provided. For welding, transformer, automatic, and
semiautomatic machines and submerged arc welding machines are provided. Painting is carried out
partly with help pf spray guns and partly by hand. Wire brush, spray guns etc. Are provided. A
maintenance section equipped with lathe, shaper, drill etc. are provided for running repair of shop
equipment.
FOUNDRY
INPUTS: Pig Iron, MS scrap, Ferro alloys, graphite electrodes, sodium silicate, silica sand CO2 gas,
moulding additives etc.
PRODUCTS:- Steel, cast iron & non ferrous castings, Emergency containers, tundish covers, bull
gear for SMS, hot metal runners, ladle paw for blast furnace, coke roll liners, sprockets, pallets for
sinter plant, raw supports, bowl for RMHP, guide troughs for WRM, face of scrap bucket for MMSM,
slag pot segments for SSS repair, ingots for forge shop, non ferrous castings like bushes (below 20 kg) etc.
Iron castings up to a weight of 5 tons will be produced. A main frequency coreless induced furnace
with two 2-ton capacity crucibles and a 5T capacity main frequency coreless induction furnace for
melting iron are provided. There is a centralized sand preparation unit. A drier and a bin is provided for
green sand. Belt conveyors transport green sand, prepared mix and burnt sand. Moulds and cores are
drier in 3 ovens lip pour ladles with capacity between 50 kg and 10 tons is provided for handling hot
metal. Two swing frame grinders and two pedestal grinders are provided for finishing of iron castings.
Total annual production is 3,200Tons.
Steel castings up to maximum piece weight of 10 T and Steel Ingots up to 1.3 tons for forging are
produced. An 8 Ton arc furnace and a two-ton medium frequency electric induction furnace is installed
for melting of steel scrap and pig iron. Each of the two sand mixers is having
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1.5-ton batch. A bogie hearth furnace for annealing/ normalizing of plain carbon steel castings and
fixed hearth furnace for heat treatment of manganese steel castings with quenching facility is provided.
The woodwork shop manufactures patterns for foundries. The principal equipment for pattern making
are saws, disc grinding, wood working lather, adequate facilities are provided for saw grinding, painting,
timber and pattern storage etc.
UTILITY EQUIPMENT REPAIR SHOP
INPUTS : sheets, plates, channels, angles, beams, billets, rounds for forge shop for manufacturing
Shafts, steel and iron castings.
PRODUCTS & SERVICES:- Manufacturing. Of impellers to various departments, repair of GCP Id
fan, repair of steam exhausters for SMS, supply of cones & ducts of various sizes, in house
manufacturing of MBC impeller for CCCD, buildup & machining of various components, reclamation
jobs like valve repairs, conveyor idlers, PCM rollers etc. Total annual production is 950 Tons.
Repair of ventilation, air conditioning and water supply equipment is carried out here. There is a
machining section having 15 major machines like lathes, milling, slotting, shaping and grinding
machines, Sheet bending machines, Guillotine shear & semi-folding machine are provided in fabrication
section. 250 kg pneumatic hammer with necessary facilities and a welding section for semi automatic,
automatic and shielded arc welding machines are provided in plumbing section. There is a separate
equipment repair section.
ELECTRICAL SECTION :
Catering to the electrical maintenance requirements of equipments of all shops
Ensuring equipment availability paying timely attention to running complaints and break down
To take up-gradation and technological improvements activities to overcome the problems of
obsolete equipments.
CENTRAL PLANNING SECTION (CPS) :
Central planning section of Engineering Shops & Foundry plays an important role in coordinating
various departments and the shops of ESF for supply of spares, castings, fabricated structures and
repair and does the following activities.
Scrutiny of annual jobs, monthly jobs projected by customer dept.
Preparation of monthly plan based on annual, monthly and MBC projection
Preparation of material procurement plan based on the annual requirement
Inspection of semi/ finished jobs of 5 sections
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Daily monitoring of jobs progress and preparation of daily production report
Preparation of monthly progress
Computerization of details of inter-shop and dispatch to departments.
Drawings control as per the ISO guidelines
Excise duty requirements of ESF
FLOW CHART OF WORK ORDER and JOB PROCESSING
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Chapter - 23
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2A. Monitoring of ambient air quality
VSP is the first steel plant to implement automatic continuous monitors so as to asses the
ambient air quality parameters on a real-time basis to estimate the air pollution load more accurately.
Accordingly, 4 nos Continuous Ambient Air Monitoring Stations (CAAMS) are being installed at a cost
of Rs. 1.65 crore. These systems are provided to monitor continuously the accurate emission of SPM
as well as SO2, NOx, HC & CO. One station at BC gate is provided with weather monitoring facility.
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2B. Continuous monitoring of Stacks
At present there are 20 major stacks prescribed by the APPCB for monitoring the SPM. Twenty (20)
continuous on-line stack monitoring equipment are installed at a cost of Rs. 3.85 crores. These systems
are provided to monitor continuously the accurate estimation of SPM as well as SO2, NOx. This helps
in accurate estimation of the pollution load and to fine tune operational parameters to reduce emissions.
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Chapter - 24
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Chapter - 25
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Chapter - 26
INFORMATION TECHNOLOGY DEPARTMENT
VSP is the first Steel Plant in India where integrated Automation and computerization is
envisaged right from the DPR stage. Almost all the production and business processes are controlled
by computer in one form or the other. These computers and the related automation systems are
meant to aid all levels of personnel involved in operation and maintenance of the plant. They provide
valuable information for the top management to take both long and short-term decisions.
Steel industry is a combination of complex and large-scale operations and processes. It also
needs fast processing of order data, its distribution to various production units, collection and
dissemination of production and technical data. Computers are being used in steel industry since
1960 for process automation and production controls.
VSP has sizable amount of computerization in built into its design in line with the latest trends
in technology. The main objective of computerization in VSP is to assist the operators in controlling
repetitive jobs, to optimize utilization of scare resources by real time process control and assist in
operation and production management.
The computerization and automation in VSP is envisaged in three levels for effective integration
between planning and processes. The highest level assists management decision- making by collection,
analysis and providing the production and management information on a real time basis and the
lowest level assists the actual process operators by reducing their tedium in the form of automation.
Thus the structure is designed for assisting all levels of operation and management of the plant.
BUSINESS APPLICATION SYSTEMS :
This is for top level of the hierarchy and is consisting of a Central Computer. All the large on-
line business applications covering different business functions of the plant are implemented in this
computer. This generates all the information/reports for the management control. It also stores and
provides long-range plant operating, maintenance, commercial and finance data. Based on the long-
range information this computer plans the production scheduling for the shops. It generates data
regarding the products to be produced, maintenance plans and dispatch plans. These production and
maintenance plans are transmitted to the concerned process control computers/personnel.
Subsequently the actual plant operational, maintenance data are collected.
Some of the important business applications running in VSP are listed below:
1. Payroll System
2. Costing System
3. Financial Accounting System
4. Marketing System
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5. Attendance Recording System
6. Library Information System
7. Materials Management System
8. Maintenance Management System
9. Production Planning and Control System
10. Wagon Information Tracking System
11. On-line TC printing System
12. Human Resource Information System
13. Raw Material Management System
14. Coke Ovens Heating and Regulating system
PROCESS CONTROL SYSTEMS :
The main jobs of the process control computers are memorizing production schedules given by zonal
computers, monitoring the shop production and the material flow in the shops and storing and execution
of process control parameters and algorithms to control the process. They also control the lower level
automation systems. The most important aspect of these computers is the man machine dialogue
envisages. Such computer systems are envisaged in the Blast Furnaces, Steel Melt Shop, Continuous
Casting Machines & Rolling Mills. Apart from these computers, there is a 'Supervisory Control And
Data Acquisition (SCADA)' computer to monitor and control Gas, Power, Water and their distribution
in the plant.
Some of the important process control computers in VSP are listed below :
1. Blast Furnace
a. Display of Mimics
b. Display of on-line trends of furnace parameters
c. Display of historical trends of furnace parameters
d. Paulwurth Report generation
e. Shift Report Generation
f. Daily Report Generation
2. Converter Shop
a. Production scheduling and control
b. Process calculation including dynamic control
c. Logging and reports
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3. Continuous Casting Shop
a. Display of on-line casting machines parameters
b. Display of LD Converter blowing details
c. Display of Mixer hot metal analysis
d. Display of Argon Rinsing station steel analysis data
e. Breakout report generation for casting machines
4. Wire Rod Mill & MMSM
a. Mill control
b. Roll shop management
c. Material Tracking
d. Mill fault monitoring system
e. Logging and reports
5. SCADA
a. Monitoring of plant utilities like Steam, Oxygen, Argon, Compressed air
and Chilled water etc.
b. Power supply from AP Transmission Corporation and VSP's TPP.
c. Coke oven and BF gas parameters monitoring
FIELD LEVEL AUTOMATION SYSTEMS :
This level consists of local automation systems. These systems do logic, sequence, loop control and
indication of process parameters to operation personnel in the plant for taking up timely corrective
actions to achieve the quality production. This level consists of Programmable Logic Control (PLC)
Systems, analog (split architecture type) and microprocessor based instrumentation systems.
The above concept of hierarchical and integrated computer systems in line with the latest technology
is introduced in VSP for the first time in India. This system is contributing a lot in achieving the quality
and productivity of steel with an integrated control of production and processes. Thus VSP is a
trendsetter in computerization in basic industries in India with latest systems and opening new vistas
in computerization in our country.
INTRANET WEB SITE
An intranet web site is also maintained by VSP IT Department and many facilities are hosted in this
site for the convenience of the different sections of the plant and for the benefit of the employees. The
content in this site is updated regularly. Some of the important features/modules hosted in this site are
listed below.
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1. Applications
a. Employee Profile
b. Telephone Directory
c. Library On-line Information
d. Daily Production Report
e. Marketing MIS
2. Departmental Pages
a. Presentations of different business applications developed by IT Department.
b. 'Ukku Vani', a monthly news letter of VSP by Corporate Communications department
c. Presentations of the developmental programs conducted by the HRD department
d. The frequently used application forms used by the employees are posted by Finance
& Accounts department
e. Highlights and MIS reports of many other production and service departments.
3. UTILITIES
a. Circulars
b. Chat
c. Forum
d. Polls
e. Downloads
f. News
4. Data Up loaders :
Data up loaders have been provided for all the stockyards, branches, regional offices and
headquarters to transmit various formatted and non-formatted data and information between
themselves over the VSP's Virtual Private Network.
NETWORK
VSP is having a Gigabit Ethernet Data Communication Network, working on Optical Fiber Cable
(OFC) network. This supports data transfer at the rate of 1000 Mbps on all the main links. The campus
network is divided into eleven zones. These zones are inter-linked to the central core switch using
Single mode type optical fibers. The Central core switch is located at Central Computer Centre.
The 11 Zonal switches are located at Coke Ovens, Sinter Plant, SMS, Central stores, BC Gate,
LMMM, MMSM, Central computer centre, Admin building, Township and General Hospital. Further, a
total of 200 access switches are connected to the network through the 11 zonal switches, using
Multimode/ single mode types fiber optical cable,. The access switches provide connectivity to
approximately 3000 nodes throughout the plant premises, Administration building area and township.
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Chapter - 27
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Chapter - 28
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Chapter - 29
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Chapter - 30
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Chapter - 31
QUALITY ASSURANCE AND TECHNOLOGY DEVELOPMENT
QATD stands for Quality Assurance and Technology Development.
QUALITY ASSURANCE
Planned and systematic actions necessary to provide adequate confidence that a product or
service will satisfy given quality requirements.
QUALITY
Quality can be defined in many ways
a) The totality of features and characteristics of a product or service that bear on its ability to
satisfy stated or implied need or fitness of the product or services for the use.
b) Quality is also defined as inversely proportional to the variability.
In other words the quality of product is assured by initiating the control activity right from input
and continued through out the process till product is dispatched to the customer for use. To Assure the
quality the technology has to be continuously modified or improved depending upon the demands
from time to time. This is where the technology development comes into picture. Development is the
continual improvement incidental to the challenges faced to ensure the quality either in input or in the
process or in the inspection of the products.
Quality assurance starts right from checking the quality of raw materials for the compliance to
the purchase specification and quality of in process materials to adherence of set norms and finally
the checking of the products for meeting the specification or customer requirements.
Quality Assurance at VSP consists of Quality control, Process control, Inspection and Testing.
Quality control deals with testing of raw materials, in-process materials and finished / semi-
finished products.
Process control monitors the salient process parameters adherence of the set norms at various
stages.
Inspection and Testing ensures the quality of the products dispatched to the customers.
Quality Assurance is one of the vital functions of any successful organization in the present
day competitive industrial world. The role of QA&TD department in Visakhapatnam Steel Plant is in
line with the above.
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QUALITY ASSURANCE AND TECHNOLOGY DEVELOPMENT
SECTIONS OF QA & TD DEPARTMENT
1. CO & CCP LAB
! Central Laboratory
! Tar Distillation Plant Laboratory
! MBC Laboratory
! Sample Preparation Station - 1
2. IRON LAB
! Iron Laboratory
! Raw Material Bins Laboratory
! Sample Preparation Station - 3
3. POWER PLANT LAB
! Thermal Power Plant Laboratory
! Chilled Water Treatment Plant Laboratory
4. STEEL LAB
! Steel Laboratory
! Sample Preparation Station - 2
5. ROLLING MILLS LAB
! Bloom Inspection
! Billet Inspection
! Light and Medium Merchant Mill Express Laboratory
! Wire Rod Mill Express Laboratory
! Medium Merchant and Structural Mill Inspection
! Spark Testing
6. CENTRAL LAB
! Mechanical Testing (for MMSM Products)
! Refractory Testing
! Metallography
! Non Destructive Testing
! Oil & Water Testing
! Wet Analysis
! Instrumental Analysis
! Environmental Lab
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IMPORTANT EQUIPMENT & INSTRUMENTS AT QA & TD
CO & CCP LAB
! UV Spectrophotometer
! Coal/ Coke Analyzer
! Gas/ Liquid Chromatography
! CHNS analyzer
! CRI/ CSR equipment
! Plastometer
IRON LAB
! Optical Emission Spectrophotometer
! X-RAY Florescence Spectrophotometer
! RI/ RDI Apparatus
POWER PLANT LAB
! Spectrophotometer
! Flame Photometer
! Turbidity meter
! Conductivity meter
! PH meter
STEEL LAB
! Optical Emission Spectrophotometer
! X-Ray Florescence Spectrophotometer
! NO Analyzer
! NOH Analyzer
! C & S Analyzer
ROLLING MILLS LAB
! Universal Testing Machine 20T, 40T, 60T
! Upset Testing Machine
! Hardness Tester
CENTRAL LAB
! Optical Emission Spectrophotometer
! X-Ray Florescence Spectrophotometer
! Ultrasonic thickness guage
! Ultrasonic flaw detector
! Magnetic particle tester
! Radiation survey meter
! Metallurgical microscope
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! Quantitative metallograph
! Vitrinite Reflectance measurement
! UV Spectrophotometer
! Atomic Absorption Spectrophotometer
! Oil Testing equipment
! Flame Photometry
! Total Organic carbon analyzer
! Universal Testing Machine 1000kN, 500kN, 50T, 20T
! Compression Testing Machine 50T
! Rockwell B Hardness Tester
! Rockwell C Hardness Tester
! Brinell Hardness Tester
! Ash Fusion Point tester
! High temperature furnace for Refractory tests
In addition to the above, all the labs are well equipped with sample preparation machines, weighing
balances, furnaces and ovens.
ACTIVITIES
1) Testing
2) Process Control
3) Inspection
4) Certification
5) Handling of Customer Complaints
6) Product Development
7) Pollution control analytical activity
8) Metallurgical failure analysis
Testing :
! Incoming raw materials (Coal, Iron Ore, Limestone, Dolomite,
Sand, Quartzite, Manganese ore and Ferro alloys)
! Coke
! Sinter
! Hot metal
! Slag ( BF & SMS)
! Liquid Steel
! Semi-finished Steel Products
! Finished Steel Products
! By-products of Coke Ovens
! Gases, Water, oils and lubricants
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! Refractories
! Effluents
Process Control :
G Monitoring of charge coal blend composition on Coke Oven battery parameters
G Charge calculation and monitoring of operating parameters at Sinter Plant and Blast
Furnaces.
G Monitoring of blowing parameters and additions at converter shop, trimming of chemical
composition at argon rinsing station and casting parameters at continuous casting
machines
G Monitoring of heating regime of reheating furnaces and cooling parameters at rolling
mills.
Inspection :
G 100% visual inspection of semis like blooms and billets
G Inspection at intermediate stages of production of steel
G On-line inspection and audit checks of finished product like rebars, wire rods, angles,
channels, flats, beams etc.
G 100% spark testing of all value added products for segregation of mix-ups
Certification :
G Byproducts
Crude tar
PCM
Phenol fraction
Anthracene oil
Pitch, wash oil, naphthalene
Toluene, LSN, HBF
G Pig iron
G Granulated slag
G Semi products
G Finished products
Calibration :
In house calibration of Vernier calipers and Screw gauge is carried out.
Other Activities:
Application engineering: Through marketing department QA&TD department interfaces with the ultimate
users of the plant products and extends technical support.
Technology dissemination: QA&TD department interacts and mediates between various internal
customers/ internal suppliers for the overall improvement.
Publication of Technical Journal: QA&TD brings out "VIZAG QUEST" a technical journal every year
comprising articles reflecting the issues of Quality & Technology linkage of inputs, production,
modifications, maintenance practices.
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Chapter - 32
RAW MATERIALS DEPARTMENT
Raw materials dept. deals with all the bulk materials received through the RMHP. It is responsible
for the following broad functions.
Indenting.
Monitoring of the receipts as per requirement.
Accounting of the receipts.
Monitoring payment of Railway freight for the receipts.
Lodging claims for non receipt of material and follow up.
The following materials are dealt by RMD.
Coals (Coking coals & boiler coal)
Iron Ore (Fines, lumps, sized, Pellets)
Limestone & Dolomite (BF & SMS grade)
Sand & Quartzite (fines & lumps)
Manganese ore (lumps & fines)
All the raw materials are received in loose condition in open wagons (in case of receipts by rail) and
trucks (in case of receipts by road). The wagons are unloaded by the tipplers and the materials are
carried to the earmarked beds of RMHP by conveyors. The trucks are unloaded at the ground hopper
bunkers of RMHP.
The following are the sources, requirement (as per DPR at 3.0 million ton stage) and suppliers of the
various materials.
Material Source Dist. (in km) Quantity ('000 T) Supplier Mode
Iron ore fines Bacheli/Kirandul (Chattisgarh) 562 3250 NMDC Rail
Iron ore lumps -do- -do- 1753 -do- Rail
Iron ore sized -do- -do- Not envisaged -do- Rail
Prime Coking Coal Bhojudih/Munidih/ 950 1411 BCCL Rail
Sudamdih/Dugda (Jharkhand)
Medium Coking Coal Swang/Kedla/Kathara/ 980 1815 CCL Rail
Rajrappa (Jharkhand)
Imported Hard Coking Coal Australia/USA (Thro' 28 807 Imports Rail
VPT &Gangavaram Port) (Inland)
Imported Soft Coking Coal Australia 28 (Inland) Not envisaged Imports Rail
Boiler Coal Talcher(Orissa) 580 1764 MCL Rail
Imported Boiler Coal Indonesia 28(Inland) Not envisaged Imports Rail
BF Limestone Jaggayyapeta(A.P) 455 363 Captive Rail
BF Dolomite Madharam (A.P) 510 605 Captive Rail
SMS Limestone UAE/Thailand/Oman 28 (Inland) 754 Imports Rail
SMS Dolomite Madharam (A.P) 510 213 Captive Rail
Manganese ore Garbham( A.P) 100 187 Captive Road
Sand/Qtz. fines Local - 78 Captive/Local Road
Qtz. lumps Local - Not envisaged Local Road
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Material Moist% Ash% VM% Sulphur% MMR Size in mm
Hard 8.0 8.0-10.0 22-28 0.6 1.15-1.25 0-50
Soft 8.0 8.0-10.0 28-32 0.6 0.8-1.0 0-50
Material Moist% Ash% VM% Sulphur% CSN Size in mm
PCC 5.0-8.0 21.0 23.0 0.4 6 0-50
MCC 5.0-8.0 21.0 26.0 0.4 2-3 0-50
Material Moist% Ash% UHV(kcal/kg) Size in mm
Indigenous 12.0 38-40 2400-3360(F grade) -250
Imported 16.0 8.0-10.0 6000 0-50
The prime coking coal quantity as envisaged in the DPR is not available due to various reasons.
Hence the same is substituted by imported hard/soft coking coals. Hence the present requirement of
these two materials together is about 3.0 million tons. The materials from imported sources are received
by ships which are unloaded in either Visakhapatnam Port or Gangavaram Port and are stacked in the
designated plots at the port for subsequent transportation to plant by wagons. In case of Gangavaram
port which is being developed adjacent to the plant, the material will be transported to the plant
through conveyors on completion of the project. Most of the imported materials are envisaged to be
handled through Gangavaram Port in future.
The materials not envisaged in the DPR also have been procured due cost effectiveness, technical
advantage or necessity. Materials from new sources are procured in case of shortage from regular
sources to ensure continuous availability of raw materials to the plant. Similarly, BF coke is procured
from China to cover any gap between the production at Coke ovens and the demand in BF.
Continuous monitoring of the receipts is required due to the huge quantity of raw materials procured
and limited resources available for unloading and stacking. This is essential to ensure that the wagons
are not unduly held up (resulting in demurrage payable to Railways) and materials are stacked separately
without mix up.
Due to the huge movement of wagons over the Indian Railways, sometimes the rakes/wagons destined
for VSP get delivered at other destinations. Claims are lodged with Railways for the consignments not
received. RMD also scrutinizes the freight paid for different raw materials. In case freight is not charged
as per the railway circulars, claim is lodged with railways. Follow up with railways for settlement of the
claims is done by RMD.
QUALITY OF RAW MATERIALS : The quality of the various raw materials are given below.
Imported Coking Coals :
Indigenous Coking Coals :
Boiler Coal :
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Iron Ore:
Material Fe% Al
2
O
3
% SiO
2
% Size in mm
Fines 64.5 3.0 3.0 -10
Lumps 65.5 2.25 2.25 10-150
Sized 65 2.0 2.0 10-40
Limestone & Dolomite:
Manganese Ore:
Sand & Quartzite:
Material SiO
2
% Al
2
O
3
% Size in mm
Qtz. Lumps 98 2.3 10-60
Qtz. fines 96 2.3 -3
Sand 85 6.0 -3
Material CaO% MgO% SiO
2
% Size in mm
BF Limestone 44-45 1.0-2.0 9.0-11.0 6-40
SMS Limestone 54.5 1.5 0.5-0.6 30-60
BF Dolomite 29-30 19-20 3.0-4.5 6-80
SMS Dolomite 30-31 20-21 0.9-1.0 25-50
Material Mn% Fe% SiO
2
% Al
2
O
3
% Size in mm
Lumps 28.0 16.0 14.0 7.5 10-60
Fines 28.0 16.0 14.0 7.5 -10
The expenditure on account of the above raw materials constitutes about 60% of the total
expenditure of the company.
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Chapter-33
REFRACTORY ENGINEERING DEPARTMENT
Steel making process comprises of multiple stages where Iron or Steel is either in molten stages or in
very hot condition .These stages are usually handled by several furnaces, kilns and transportation or
storage vessels. The furnaces, kilns and vessels are basically made of steel or other metal and alloy
structure. In the process of steel making there is every possibility that the structure may get damaged.
Thus any such type of furnaces, kilns and vessels used in steel making process needs to be protected
from pyro-metallurgic reactions. As such, all the vessels are protected with some "refractory" lining
which endures the high temperature and subsequent chemical reactions to facilitate smooth operation
of steel making.
Refractory Engineering Department (RED) in Visakhapatnam Steel Plant meets the need of refractory
lining maintenance and refractory management of all the equipments engaged in the process of steel
making. Following are basic objectives of RED.
1) Planning, procurement and management of Refractory material as per production plan and
operational requirement.
2) Maximizing the availability of equipments by increasing the life of refractory lining for the
equipments required for steel making
3) Doing refractory maintenance in time and bringing down the refractory maintenance period
4) Bringing down the specific refractory consumption per ton of liquid steel
5) Optimization of refractory performance with cost and quality to get maximum benefit either in
terms of productivity or techno-economics
RED is mainly divided into following zones/sections which are scattered throughout the plant. The
central section is located at CRMP Area Shop Office Building.
a) Planning cell
b) Blast Furnace, Sinter Plant & Thermal Power Plant
c) Steel Melt Shop
d) Rolling Mills, Calcining & Refractory Materials Plant & Engg. Shops &Foundry
PLANNING CELL :
This section is located at CRMP ASO building, engaged in job of refractory item procurement (As per
standard specifications, drawings and repair plan), Material and equipment performance monitoring,
material planning for normal and capital repairs etc., RED procures around 37-40,000 tons of refractories
on an average in a year for catering the requirements of different zones starting from Sinter Plant to
Rolling Mills.
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BLAST FURNACE, SINTER PLANT & TPP :
This office is located near Blast Furnace ASO. Following maintenance activities are generally performed
in Blast Furnace zone.
i) Blast Furnace - Cat-I & Cat-II repairs are done for both BF-1 & 2
ii) BF Stoves - capital repairs are done. First Cat. I capital repair of BF-1 stove No.4 was completed
in 2005.
iii) Tuyeres - Refractory casting done on regular basis
iv) Open Top Ladles, Torpedo Ladles, Cast house maintenance and Pig casting machine runners'
maintenance - done on regular basis.
v) Sinter Machine furnace - Capital repairs are normally carried out.
vi) TPP boilers - casting and patching done for bottom ash hoppers on regular basis
vii) GETS- Refractory relining of pre-heaters.
STEEL MELT SHOP :
This office is located near Ladle Preparation Bay (LP BAY) area. Lining of Steel making LD Converters,
Steel teeming ladle, Tundish , Mixer Hot Metal Ladles, Emergency containers, Hot Metal Mixers and
Snorkel preparation in IRUT section are being done on regular basis by this zone.
Rolling Mills, CRMP& ES&F :
These offices are located near WRM area (for Rolling Mills zone), Foundry area (for ES&F zone) and
in Calcining Plant area (for CRMP Zone). Capital and regular repair in furnaces of LMMM, MMSM &
WRM, maintenance of Lime Flux Kilns at CRMP, Electric Arc Furnace and Induction/Reheating furnaces
at Foundry is being met through this wing of RED. The approximate quantity of refractories consumed
for the regular repair by these zones for the year 2007-08 is 442Tons (Rolling Mills), 90Tons (ES&F) &
296Tons (CRMP). Capital repairs are carried out for Rolling Mill Furnaces on annual basis.
The furnaces/Kilns/Vessels (equipments) maintained by RED in different production units are given
below. All these equipments are maintained either on running/regular repair basis or capital repairs
(once/twice in a year) basis.
Equipment Function Type/quality of refractories used
1. Blast Furnace:
a) 2 nos. Of Blast
Furnaces
Iron Ore to Iron making Mullite, Carbon block, High Alumina,
Fire-clay & Graphite Blocks
b) 2x4Nos. Of Hot Blast
Stoves
Heating of air for iron
making
Fire-clay, Silica, Mullite Corundum,
Fire-clay insulation, Ceramic paper,
Blanket & Alumina Castable
c) 7 Nos. Of Torpedo Ladle
Cars
Transportation of liquid
iron
High Alumina, High grog, Alumina
Carbon Fire-clay insulation & Alumina
Castable
d) 30 Nos. Of Open Top
Ladles
Transportation of liquid
iron
Fire-clay, High Alumina & Alumina
Castable
Kd< d
&
Relentless efforts of RED and the related production units have made it possible to increase the life
expectancy of refractory lining considerably in some major areas. Some of the figures are illustrated
below:
^
E
W h
z
A Lu C SMS ,
A S L SMS ,
A 1 SMS ,
S 8 C SMS <d>^
S 8 C vS <d>^
GM (TA & A)
ED (P&IR)
GM (MS)
DGM (P) - PP I/c
DGM (P) -
CER & NW
DGM (P) - CC
DGM (Admn.)
DGM (TA) I/c
DGM
(Land & Estate)
GM (P & LA)
DGM (P)-
Rules & Cord
DGM (P) Rectt. & Welfare
GM (Trg. & HRD)
DGM (Trg.)
AGM (Tenders)
GM (M&HS)
DGM
(Agro forestry)
DGM (CSR
the integrated steel plants of India, Human Resources at Visakhapatnam Steel Plant are breaking
records after records day after day achieving peaks of production, productivity and all round development
of the company.
Organization Structure of Personnel Department :
Human Resources have been given utmost importance with appointment of a Director
(Personnel) to look after whole gamut of HR functions at VSP. ED (P&IR), GM (TA&A), GM (CP & C),
GM (P&LA), GM (Trg. & HRD), GM (M&HS), DGM (CSR), DGM (Agro & Forestry) directly report to
Director (Personnel). While the GM (P&A) looks after recruitment, HR functions of Senior Officers, the
ED (P&IR) looks after HR functions of the rest of the manpower and gives due emphasis to Industrial
Relations, Employees Welfare, Rules & Policies, Plant Personnel, Contract Labour, Canteen
Management, etc.
AGM (P)
Rectt.
AGM (P)
Welfare
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With a view to extend personnel services at the door step, the Personnel Department
has decentralized its HR functions at shop-floor level with 11 number of Personnel Zones and Executive
Establishment Zones, Common Cadre (JOs), etc. The day-to-day HR functions are taken care at the
shop-floor level, while the corporate functions are dealt centrally from the Administrative Building. This
create access to the employees and help in speedy redressal of the grievance of the employees.
Human Resource Management :
Human Resources are treated as the most important of all resources in the Company.
Its development and welfare have therefore been given the utmost emphasis in the overall policy of
Human Resources Management of the Company. It is believed that people are the key to success and
the performance of the Company depends on them to a great extent. Hence special attention is given
towards people management. For this, the organization has developed the Human Resources Policy
to achieve the plans and targets of the Company. It enables individuals to work efficiently and take
pride in their work besides feeling important. It makes people feel safe, secure and trusted. People in
the organization are encouraged for their efforts through a system of rewards and recognition. Its
environment encourages team working, creativity and invectiveness. In the organization, the
peoples ownership for the work and responsibility is obtained through empowerment. Employees
are one of the main components.
Major components of Human Resource Management :
VSP has established number of Zonal Personnel Units in Works division and Mines at JLM
and MDM for smooth and effective functioning of Personnel Department with a view to maintain
peaceful, cordial and healthy Industrial Relations in the Company.
Integrated Resources Systems have been established in the Company by providing essential
linkages between major systems like manpower planning, recruitment, training, performance
appraisal, career development, employee welfare, motivation and organization development. Within
the broad framework of Human Resource Management thrust is given to :
a) Multi-skilling and job enrichment
b) Labour productivity and manpower utilization
c) Comprehensive employee services including welfare.
HR Policy :
To realize the full potential of employees, the Company is committed to :
i) Provide work environment that makes the employees committed and motivated for
maximizing productivity.
ii) Establish systems for maintaining transparency, fairness and equality in dealing with
employees.
iii) Empower employees for enhancing commitment, responsibility and accountability.
iv) Encourage team-work, creativity, innovativeness and high achievement orientation.
v) Provide growth and opportunities for developing skill and knowledge,
vi) Ensure functioning of effective communication channels with employees.
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A number of Human Resources initiatives have been introduced in VSP since inception. Some
of such practices are :
a) Three Union approach of Industrial Relations
b) Informal Grievance Redressal System
c) Multi-skilling and Multi-trade Concept
d) Contained Manpower
e) Gate Monitoring System
f) Special Social Security Schemes, etc.
g) New Work Culture
h) Integrated Human Resource Management
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Major achievements of the Department :
a) Mandays lost due to Industrial Relations problem have been brought to minimumlevel
b) Labour Productivity has been highest in the Steel Industry in India
c) Low absenteeism levels
d) Commitment of employees to the Core Values
e) Introduction of Non-Unionized Supervisory Cadre (Jr. Officer)
f) Empowerment of Human Resources
g) Job Rotation and Redeployment
h) Social counseling
i) Local Industrial Leadership in Human Resources functions
j) Computerization of Human Resources functions.
Conclusion :
Success of Human Resources functions of Visakhapatnam Steel Plant stems from the relentless
efforts of the VSP work force. This valuable asset of 16500 steel employees have contributed to
positive cultural changes, increased productivity and organizational excellence Undoubtedly
employees are the driving force behind the success of VSP and will continue to play a key role in
shaping the future of VSP. Personnel Directorate is continuously working on the periodic review of
personnel policies, rules and regulations, so that they come upto the changing needs and expectation
of employees.
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Chapter - 53
Computer Laboratory : 2 Computers labs are established in T&DC advanced Computers
Programmes & Computer literacy programs are being organize regularly. Every year 2000
employees under going training in various PC programmes.
Central Library : In VSP, the Central library was established in the year 1982 with small
collections of books, standards and journals, 25 e-journal, 20,000 Indians and International
standards in order to reach the available literature information to all employees are have
started using IT in our libraries. Recently, e-library started the and library was air- conditined
with modern furnature.
Audio-Visual section : T&DC has a visual section with AV aids such as LCD Projectors,
overhead projectors, 16mm film projector, Opaque film projector, P A System TV & VCR
etc., are available.
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The prime objective of HRD Group is to develop company's human resources by making them
emotionally mature and behaviorally trained to cope with the role requirements, attune them with
strong knowledge and information base to enable them create effective teams and also overhaul
systems & structures in HR area commensurate with the organizational Vision, Mission and Objectives.
The following activities are mainly handled by HRD:
G In-house Management Development Programmes
G External Programme Nominations (other than overseas)
G Performance Appraisal for Executives
G Organization Research & Organization Development
G Competency Mapping Exercise
G Membership with Professional Bodies
G Industry-Academy Interaction
G Guest Lectures by Eminent Personalities
In-house MDPs
Annual plan for in-house programmes is made based on training needs reflected in the Performance
Appraisals, Training Needs Survey, meetings of Training Advisory Committee, as well as top
management's priorities & strategies. The programmes are conducted in the 3 halls of Centre for
HRD in the steel township. Faculty is a mix of internal and external experts.
External Nominations
Employees are sponsored for programmes conducted at premier institutes. HRD Group scrutinizes
the proposals for external programmes with a view to ascertain their relevance to current organisational
needs, credentials of the organizers/faculty and also verifies skill profile of the proposed employees
as also the budget availability, before recommending for approval of the competent authority.
Executive Performance Appraisals
Appraisal Cell in HRD monitors and coordinates appraisal reports for all executives. Three sets of
formats are in use. The information available in the appraisal reports is disseminated, analyzed and
sent to concerned agencies for:' necessary action.
Organisation Research
A cell for OD interventions has been created in HRD Group to design and oversee various OD
interventions like internal surveys/studies. Results of such exercise are analysed scientifically for
aiding management to take important decisions on various HR issues. Besides, the Cell is involved in
various open internal communication fora organized for the employees at large.
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Competency Mapping
HRD organizes continual assessment of executives for 16 defined competencies and maintains confidential
records for futuristic decisions by top management concerning manning of key positions of the company.
Institutional Membership
RINL is a corporate member of different professional bodies of national and international repute.
Hence constant liaison is maintained with them by HRD for deriving all the benefits applicable and
also to duly process the invoices for renewal fees.
Industry-Academy Interaction
In order to maintain healthy industry-academy interactions, students from various institutions in the
country are permitted to have practical in-plant training in the areas of HRM, Marketing, Materials,
Management Services, Corporate Planning, Finance Management etc.
Guest Lectures
With a view to providing an avenue for knowledge sharing and networking with other institutions, talks
are arranged by inviting eminent personalities from different fields of specialization for the benefit of
employees and their families.
HRD Group is alive to the expectations of all the stake holders including customers and employees
and of the company and is ever ready to help the employees put in their best in the coming days at
RINL, where excellence is seen as a continuous journey and not merely as a temporary halt or goal.
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OTHER
DEPARTMENTS / TOPICS
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Chapter - 54
MINES DEPARTMENT
INTRODUCTION :
RINL/VSP is having captive mines at various places. Some of the raw materials are being met
from these captive mines for making of Iron & Steel. VSP is planning to acquire mines for fulfilling its
requirement of Iron Ore, Coal, Quartzite and Sand.
At present Visakhapatnam Steel Plant is operating four captive mines, namely
Madharam Dolomite Mine (MDM) - MADHARAM for Dolomite.
Jaggayyapeta Limestone mine (JLM) - JAGGAYYAPETA for Limestone
Garbham Manganese Mine (GMM) - GARBHAM for Manganese
Nellimarla/Sarepalli Sand Mine (SSM) - VIZIANAGARAM for Sand.
Visakhapatnam Steel Plant has also been allocated Coking Coal blocks i.e. Mahal and Tenughat-
Jhirki in Bokaro District of Jharkhand and the same are in the planning stage.
Besides these mines, VSP has been allotted quartzite mines at Kintada, Marrivalasa and Pindrangi in
Visakhapatnam District of Andhra Pradesh.
CAPTIVE MINES - LOCATION
Madharam Dolomite Mine : Located in Khammam district, Andhra Pradesh, details of which are
given in Annexure-I
Jaggayyapeta Limestone Mine : Located in Krishna district, Andhra Pradesh, details of which are
given in Annexure-II
Garbham Manganese Mine : Located in Vizianagaram district, Andhra Pradesh details of which are
given in Annexure-III
Nellimarla / Sarepalli Sand Mines : River sand is being excavated in the river Champavathi situated
at villages Nellimarla, Neelamrajupeta, and Sarepalli. The details of the said leases are given in
Annexure-IV. These leases are close to Vizianagaram, at a distance of 90 to 100 Km from
Visakhapatnam city. At present sand is transported from Sarepalli.
Kintada Quartzite Mine : Located in Visakhapatnam district at a distance of 50 km North East from
Visakhapatnam Steel Plant. The said lease is over an area of 3.24 hectares with reserves of about
2,02,000 tons.
Quartzite Leases in Marrivalasa & Pindrangi : Recently Govt of A.P . has granted two Mining
leases over an extent of 151 acres for Quartzite for a period of 30 years in favour of M/s RINL subject
to prior approval of Environmental clearances, Mining plan etc., which are in process.
Mahal and Tenugat-Jhirki Coking Coal Blocks : These blocks have been allocated to RINL by
Ministry of Coal to cater to its requirement of Medium Coking Coal. They are located in Bokaro District
of Jharkhand and would be underground mines. Consultants for conducting technical study and for
mine planning are in the process of being engaged.
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ANNEXURE - I
Madharam Dolomite Mine
LOCATION OF mine from
Madharam ..................................... 01 km.
Karepalli ......................................... 12 kms.
Yellandu ......................................... 16 kms
Khammam..................................... 50 kms.
Hyderabad ..................................... 245 kms
VISAKHAPATNAM (HQ) ............... 515 kms.
TOPO SHEET NO. : 65/C/2
LONGITUDE : 80
0
13' & 80 14'
LATITUDE : 17 31' & 17 34'
MINING LEASE - DETAILS
100 M Grid Interval
Drilling Pattern
Geological Reserve (in MT) SMS grade - 37.73
BF grade - 3.45
Total - 41.18
Balance Reserve (on 31/12/08) - 33.00 million tonnes
Life of the Mine (approx) 54 Years Present Stage
27 Years (After expansion @ 1.2 mt per annum)
Method of Reserve Calculation Cross Sectional Method
Bulk Density 1.5 T/Cum(loose)
Specific Gravity 2.71-2.78
Hardness (Morh's Scale) 3-4
Reserve Category Proved
Strike N-S Dip 20
0
- 65 towards East, South-East &West.
Geological Formation Pakhals
Tonnage Factor(Insitu) 2.5 T/CuM
SALIENT FEATURES OF EXPLORATION DATA
Dimension of the Ore body
2500 M
80 to 400M
30 M
Length-
Width-
Average thickness-
Extent 950Acres
Initial Lease granted by Govt. of A.P. on 14/7/1980
Period 20 years
Renewal Validity up to 13/7/2020
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ANALYSIS OF DOLOMITE
Content -50 +25mm 0 to -80 mm
%CaO 30.98 30.51
%Mg O 20.27 20.09
%Si O2 0.84 1.09
%Al2 O3 0.51 1.34
%Fe2 O3 0.91 1.51
%LOI 46.26 45,90
G
The Dolomite deposit in Karepalli area occurs in the form of bands, stretching over a length of
6 Km from North to South. The mining lease at MDM comprises Southern band extending to a
length of about 2.5 Km width ranging from 80 M to 400 M
G
MDM is in operation since 1989. The mine was designed for SMS & Brick grade with a throughput
capacity of 253,000 tpa in one- shift operation per day. However, VSP was operating the mine
and the associated crushing and screening plant in 1 - shift operation for production of SMS
(flux) grade ( - 25 mm to 50 mm ) and brick grade ( 9mm to 25mm ) dolomite. Subsequently,
Management decided to meet the requirement of BF grade dolomite from our captive source at
MDM only. Accordingly three different size specifications were made and certain minor
modifications introduced. The mines operated in 2 shifts for production leaving one for up -keep
of equipments and Development of Mines. Presently, only two grades viz. BF & Flux are being
produced since Brick grade is not required at the main plant.
G
After commissioning the plant at 6.3.Mtpa expansion stage, the requirement of dolomite will go
up to 1 Mtpa. To meet this target, Dasturco had recommended certain modifications which will
be taken up during expansion.
G
The mine is presently developed with three benches. The top bench is the overburden bench with
thickness varying between 0.5 M to 10 M, while the second and third benches are the production
benches with 8 M bench height. For the purpose of mineral conservation, the R.O.M material from
the top is stored at a suitable place for future recovery of dolomite from the admixed muck.
Pollution Measures : Dry fogging system was installed at Crushing and Screening Plant in
addition to the prevailing DE System i.e. Dust Extracting System with an approximate cost of
Rs.70 Lakhs. A wind barrier bearing dimensions of 75 meters length x 7.5 meters height was
constructed to avoid dust generating from Wagon Loading point towards green field.
G
Water Supply : Mineral water is being supplied for drinking purpose to the employees at Township
and Plant, and for other purposes mine discharge water is being used after natural filtration.
G
Power Supply : 11 KV Power Line is provided for power supply to Madharam. Due to frequent
power failures, 33 Kv line from Karepalli has been connected for uninterrupted power supply for
operation of Mines.
G
Afforestation : 87,000 saplings were planted in 160 acres within the mining lease area under
environmental protection.
G
Township : A township consisting of 184 quarters which includes A, B.C, Barracks and Hostel
building with modern amenities were constructed within the lease area. In addition other
infrastructure facilities like School, Hospital, Hostel Building, Community Welfare Centre,
Shopping Complex, Parks and Open Air Auditorium were also provided in the township. A Guest
House with four rooms was provided in the township.
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ANNEXURE - II
Jaggayyapeta Limestone Mine:
LOCATION OF mines from
JAGGAYYAPETA ......................................... 05 kms.
VIJAYAWADA............................................... 95 kms.
HYDERABAD ............................................... 200 kms
VISAKHAPATNAM ....................................... 400 kms.
VISAKHAPATNAM STEEL PLANT .............. 390 kms.
TOPO SHEET NO. : 65D/1
LONGITUDE : 80
0
02' & 80
0
06'
LATITUDE : 16
0
50' & 16
0
53'
MINING LEASE
200X100M grid interval
Drilling Pattern
Geological Reserve(in MT)-Approx. Proved 38.71
Balance Reserve(31/12-08) 31.38
Life of the Mine 68 Years as per present status
48.27years after expansion @ 6.5 lakhs per anum
Method of Reserve Calculation Cross Sectional Method
Bulk Density 1.50 T/Cum
Specific Gravity 2.72
Reserve Category "A" Category
Strike E - W Dip 2-5o due East
Geological Formation Precambrian Sedimentary formation
Tonnage Factor(Insitu) 2.5 T/Cum
SALIENT FEATURES OF EXPLORATION DATA
Dimension of the Ore
body(North block)
Length-2416M,Average Width-325M
Max.thickness-22.97M Mean-11.97M
Extent 1295 Hectares
Lease granted by Govt. of A.P. 08/08/1980(Initial)
Period 20 years
Validity upto 08/08/2020
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G
The limestone deposit at JLM extends over a length of about 5 Km in East-West direction
having an average width of 315-M. The thickness of the limestone varies from 5 M to 25 M
G
JLM is under operation since 1989 for supply of BF grade limestone to Visakhapatnam Steel
Plant. It is designed to produce 5, 00,000 tpa operating for single shift per day. Presently we
are producing about 4, 000,000 tpa only as SMS grade limestone fines is being used in BF to
the extent available as a substitute
G
After expansion of steel Plant to 6.3 MT stage, the requirement of the BF limestone will go up to
6, 31,200 TPA. To meet this target, certain modifications of plant and change in working system
(i.e. 2 shifts production and one shift upkeep of equipments & development of Mines) will be
introduced.
G
The only parameter to be followed is that the size of the limestone i.e. - 70 mm since the
metallurgical properties of the limestone available at the mines are meeting the requirement of
the customer i.e. RMD in VSP.
Water Supply : Mineral Water Plant was commissioned for drinking purpose for township and
mines employees. The required water in general is drawn from Paleru River
through infiltration well for township and mines. Water is also drawn from the
bore well which was dug in the township due to scarcity of water in the river.
Afforestation : About 1, 36,970 trees were planted within the mining lease area under
environmental protection.
Power Supply : HT line was constructed by APSEB for 33 KVA HT supplies to the mining area.
Main Receiving sub-station has been constructed in the lease area.
Railway Line : A railway line of 31 Kms joining Motumarri to Jaggayyapeta Limestone Mine
(JLM) was laid for movement of limestone to Visakhapatnam.
Township : A township consisting of 226 quarters of all categories mentioned in the above
with modern amenities were constructed. In addition other infrastructure facilities
like Schools, Hospital, hostel building, community welfare centre, shopping
complex and an open auditorium were also provided in the township. A four-
roomed guest house was also provided at the township.
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ANNEXURE - III
Garbham Manganese Mines
LOCATION OF mines from
GARIVIDI ...................................................... 16 kms.
KOMATIPALLI .............................................. 15 kms.
VIZIANAGARAM .......................................... 44 kms
VISAKHAPATNAM ....................................... 92 kms.
VISAKHAPATNAM STEEL PLANT .............. 120 kms.
TOPO SHEET NO. : 65 N/7
LONGITUDE : 83
0
25' 47" & 83
0
28'
LATITUDE : 18
0
22' 03" & 18
0
23' 02"
Mining Lease Area 653.69 Acres
Dimension of the Ore body 1200 M Length 40 M width
Spaced at 100 - 200 M interval.
Drilling Pattern
Geological Reserve estimated 1.02 million tonnes
Balance Reserves as on 31.12.2008 1.6 Lakh tonnes
Method of Reserve Calculation Cross Sectional Method
Bulk Density 1.80
Specific Gravity 2.00
Hardness (Mohr's scale) 2
Reserve Category Proved
Strike E -W Dip 55
0
due South
Geological Formation Archeans Khondalite Formation
Tonnage Factor 2.0 T/Cum
SALIENT FEATURES OF EXPLORATION DATA
Description I Lease II Lease
Extent 59.04 Ha 205.50 Ha
Lease granted by Govt. of A.P. 08/10/1982 28/01/1983
Period 20years &1st Renewal 20 years 20 years
Validity up to 07/10/2022 26/01/2023
Amalgamation given by Govt. 264.54 Ha
of A P for both the areas
Village Garbham Garbham
MINING LEASE
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G
The total leasehold area is 264.54 hectares and it is divided into three blocks, namely Central
Garbham, East Garbham and West Garbham. The above mining lease was granted to VSP
during 1982-83.The in-situ reserves of Manganese ore have been estimated at 0.86 MT and
some 0.16 MT could be recovered from waste dumps created by earlier operators before our
lease. The ore occurs up to a depth of 45 M but economical to mine up to 30 M depth only from
ground level. The manganese ore is of the following grade.
G
Mn- 28.00%, Fe-12.53%, Al2O3- 5.96%, SiO2- 21.43%, P-0.28.%, S -Traces
G
GMM is under operation since 1989 for supply of Manganese lumps and fines to Visakhapatnam
Steel Plant. It is designed to produce 50,000 MT by semi mechanized method per annum by
operating in general shift and engaging employees on Casual basis departmentally. Presently
we are producing about 16, 000 tones per/anum only. Initially it was designed for manual
mining and subsequently changed into semi mechanized mine.
G
After commissioning of steel Plant for 6.3 MT stage, the requirement of the Manganese lumps
and fines will be about 3400 tons and 10,800 tons respectively.
G
Ore exploitation is by open cast mines. GMM is presently equipped with a small fleet of
equipments like 1 cub.m capacity Hydraulic excavator, Loader, dozer, 4 Ashok Leyland Dumpers
of 10 ton Capacity etc., Initially Mines Dept. extracted the Mn. Ore in old dumps and continued
up to 2000. Subsequently in-situ mining was also taken up there. As approved by IBM, 4-meter
benches are developed and mining being done. The ore to overburden ratio is about 1:3 and
some areas it is around 1:5. The required size by the customer is (i) lump: - +10 mm to 60 mm
& (ii) fines:- -10 mm. EIA / EMP (Environment Impact Assessment / Environment Management
Plan) was approved by Ministry of Environment & Forests, New Delhi.
Infrastructure : 16 Kms from Garividi. Komatipalli is the nearest railway station on
Vizianagaram -Koraput Railway Line. The Mine is located 120 Kms from
Visakhapatnam. Material is transporting by road through private agency
Power : Power lines 11 KV and 440 KV are passing through the lease area.
Water : There is no perennial water source in the area. The drinking water is
available from the dug borewell. The Garbham main pit is quite old and
water logged. Water is drawn from this pit by the villagers for irrigation
purpose.
Miscellaneous facilities : The Office building is located in the mining lease area. A maintenance
shed has been constructed for maintenance of earth equipments.
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ANNEXURE - IV
NELLIMARLA SAND MINE - SAREPALLI SAND MINE
LOCATION of mines from : (in Kms)
Salient Features Mahal Tenughat-Jhirki
Location Bokaro Dt. Jharkhand Bokaro Dt. Jharkhand
Area 5.2 Sq Kms 2.5 Sq Kms
No. of seams 22 17
Depth of Mining From - 350 mtrs Not Known but expected to be the
same as Mahal
Quality Steel Grade I to Washery Grade III Steel Grade I to Washery Grade III
Geological Reserves 258.35 Million mt 203.98 Million mt
Inclination of Seams 15 to 250 15 to 25
0
Faults 13 Nos 10 Nos
Railway Line Running through centre of block No line inside block but north of block
River Damodar River is northern boundary Konar Nala is northern boundary
Gas content Degree III Degree III
SALIENT FEATURES OF MAHAL AND TENUGHAT-JHIRKI COKING COAL BLOCKS
NELLIMARLA ........................................ 02 SAREPALLI ............................ 02
VIZIANAGARAM.................................... 10 NELLIMARLA ......................... 07
VISAKHAPATNAM................................. 90 VIZIANAGARAM .................... 17
VISAKHAPATNAM ................. 105
TOPO SHEET NO. : 65N/8 TOPO SHEET NO:65-N/8
LONGITUDE : 83
0
26' 51" & 83
0
27' 27" LONGITUDE:83
0
28' to 83
0
28' 05"
LATITUDE : 18
0
10' 20" & 18
0
11' 00" LATITUDE:18
0
08' to 18
0
09'
Nellimarla Sarepalli
Extent 31.16Hec 64.67Hec
Lease granted by Govt. of A.P. 30.06.99 6.11.2002
Period 20years 20 years
Validity upto 1.07.2019 5.11.2022
Geological Reserves 379500Tonns 277004Tonns
MINING LEASE
G
The Nellimarla Sand Mine was started from the River bed at the rate of 40,000 Tons per Annum
except during monsoon months in 1999. Presently mining is being done from Sarepalli Mine as
the sand deposit in Nellimarla has got depleted.
G
The total activity of excavating sand from the river, loading into the trucks, transporting and
unloading at the main plant. VSP off loaded the job to Private agencies.. Despatches are being
regulated as per the requirement of Main plant at Vizag.
G
Environmental Clearance for Sarepalli Sand Mine was obtained from MOEF New Delhi in 2008
which includes public hearing..
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Chapter - 55
PROJECTS DIVISION
Projects Division of VSP consists of the following departments
a) Design & Engineering Department
b) Project Contracts Department
c) Construction Department
d) Project monitoring
Major activities of various departments are indicated against each of them.
Design & Engg. Department :
Design and Engineering department is the nodal point for realising the following aspects of
VISION, MISSION & OBJECTIVES of VSP.
G
Harness our growth potential & sustain profitable growth, (Vision)
G
To attain 16 MTPY liquid steel capacity through technological upgradation, operational efficiency
and expansion to produce steel at international standards of cost and quality : and to meet the
aspirations of stake holders, (Mission).
In a deregulated and competitive economy driven market, struggling with issues of managing
sustenance of performance, VSP has to focus on what to change. What to change to ? And how to
change ? Design & Engineering department shall handle the above issues in a structured and well
planned manner, so that VSP shall control its destiny, race towards excellence and sustainability with
required speed.
Once the units are handed over as per contractual provisions, services of the consultants or suppliers
will no longer exist. Any further improvements in production and ease of maintenance are taken care
of by Design & Engineering department giving specific emphasis to time, strategic initiatives like
Systematic approach, Bench marking, Six Sigma, etc.
D & E department consists of the following sections to handle the jobs.
G
Technology
G
Mechanical
G
Material Handling
G
Electrical & Instrumentation & Automotive
G
Civil & Structural
G
Utilities
G
Water System
G
Techno Economics and Project Cost Control (TEPCC)
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G
Projects
G
General Layout and Transport (GL & T)
G
Technical Documentation and Information Section (TDIS).
G
Special Alignments Group (SAG)
Design and engineering department activities are broadly categorized into the following :
G
Project reports & approvals
G
Conceptual planning & Basic Engineering
G
Detailed Engineering
G
Design Supervision
G
Supervision of testing & commissioning
G
Obtaining approvals & Liaison with Statutory bodies
G
Preparation of cost estimates & monitoring project cost
G
Indexing, storage & retrieval of technical documents
PROJECT REPORTS & APPROVALS
G
Providing of necessary information to the MOS, GOI from time to time
G
Selecting the most appropriate & state of art technologies & equipment
G
Preparation of project reports for capacity enhancement / modernization /
up-grade-tion.
G
Scrutiny, evaluation of project reports to ensure selection of appropriate technologies
& equipment.
G
Obtaining various approvals for projects from Government of India (GOI), Expenditure
Finance Commission (EFC), Public Investment Board (PIB), Environmental clearance,
etc.
G
Engaging consultants wherever required.
CONCEPTUAL PLANNING
G
Examine in depth the proposals for modifications / alterations for debottle necking and
for improvement, during operation of plant and carryout engineering of the same, if
considered beneficial.
G
Prepare concept, scheme, layout, cost estimate etc, for Additions, Modifications,
Replacements (AMR) and other non-AMR projects.
G
The expansion of the plant to 6.3 MTPY liquid steel and further.
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G
Preparation of schemes etc, for incorporation of stipulations made by statutory bod- is
like Ministry of Environment and Forests, Government of India. A.P. Pollution Control
Board, Director of Factories, Inspectorate of Explosives, Inspectorate of Boilers, etc.
G
Review the automation in various units of plant for replacement with latest technologies.
DETAILED ENGINEERING.
G
Preparation of clear & complete technical specifications.
G
Evaluation of offers w.r.t compliance with scope of work, meeting technical requirements
& function, latest technology for process, energy conservation & environment, to avoid
contractual problems at later stage etc and to bring all parties technically at par.
G
Preparation of technical recommendations & participation in Tender committee
meetings.
G
Approval of vendor drawings, Quality Assurance Plans (QAP), Billing schedules for
release of payments.
G
Evaluate tenability of claims raised by contractors during execution of contract.
G
Preparation of working drawings for Energy & water conservation, mitigation of pol-
lution in work environment, improve production, ease of maintenance & operation.
G
Accord clearance for layouts with coordinates for buildings, structures, under ground &
over ground for additional facilities
G
Indenization of suppliers drawings.
G
Design of road & rail net work.
G
Identification of areas for Horticulture, Afforestation and preparation of working draw-
ings for the same.
G
Coordinate with port trust & Gangavaram port for handling movement of imported coking
coal.
G
Coordinate with various suppliers, consultants and obtain all required data, drawings in
time.
DESIGN SUPERVISION :
G
Suggest and evaluate the change in material specification or equipment specification
during construction of the plant in case of non availability without affecting the
technological requirements.
G
Effect design modifications in respect of any mis match wherever caused due to site
conditions and non adherence of drawings, battery limits, issue sketches / schemes /
drawings wherever required.
G
Providing design supervision during construction and erection work to ensure the
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294
schemes / project is carried out in accordance with approved design specification /
drawings.
G
Interpretation of drawings and other data to the construction, erection agencies.
G
Inspection of structures, building columns and preparation of suitable modification
schemes wherever required.
SUPERVISION OF TESTING & COMMISSIONING
Design department shall finalise the procedures for preliminary acceptance and final
acceptance tests, performance guarantee tests and participate to ensure that the contractual obligations
agreed in the contract work is carried as per approved drawings and standards by various contractors.
OBTAINING APPROVALS & LIAISON WITH STATUTORY BODIES :
G
Obtaining Government of Indias clearance for projects, incorporating the changes in
the project based on various suggestions indicated by government.
G
Obtaining environmental clearance from PCB for the projects.
G
Furnish information / additional data / replies sought by Ministry / planning commission,
PIB etc.
G
Liaison with various statutory authorities to obtain approvals of factory inspector, state
electricity boards, explosive inspector, Boiler inspector Ministry of Environment and
Forests, etc.
INDEXING, STORAGE & RETRIEVAL OF TECHNICAL DOCUMENTS :
G
Receipt and codification of drawings and documents from various sources.
G
Retrieval and issue of drawings and documents to various departments.
G
Storage and preservation of documents.
G
Computerizations of Technical Documentation and Information.
G
Digitization of documents and drawings.
MAJOR PROJECTS / AMR SCHEMES :
Some of the major projects / schemes / latest technologies to improve production from concept
to commissioning (implemented or in the process of implementation) carried out by Design and
Engineering department are indicated below :
i) Slag splashing to improve lining life of L.D converters
ii) Oxygen enrichment in the cold blast air supply to BF
iii) Ensuring availability of utilities like nitrogen and cooling water during total & extended
power failure.
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iv) Implementation of water pumping scheme from Godavari to ensure reliable water supply
to VSP.
v) Implementation of automation in various units of plant including CCM & LD Shop.
vi) Upgradation / modernization of technology necessitated due to non availability of spares
i.e. PLCs instruments, electrics etc.
vii) Replacing the Soviet gas cutting machines with latest gas cutting machines at
Continuous Casting Department of SMS.
viii) Pulverized coal injection in the BFs to reduce coke rate.
ix) Upgradation / modernization of CCM-2 to increase the speed of machine and there by
production.
x) Modification of water box at Wire rod Mill.
xi) Upgradation of balance CCMS
xii) Augmentation of SMS water system to facilitate upgradation of balance CCMs.
xiii) Conversion of wire tying mks to strapping mks in rollingmills.
xiv) Implimation of fecalite for combined blawing of LD canvertes of SMS-1
xv) Additional bunkers for feroalloy charging
PROJECTS CONTRACTS DEPARTMENT :
Major activities are broadly categories as
G
Enlistment of contractors
G
Preparation of Special conditions of contract (SCC), General conditions of contract
(GCC), payment terms of contract.
G
Issue notice inviting tenders (NIT)
G
Formulate prequalification criteria (PQC)
G
Preparation & Issue of tender documents to tenderers
G
Scrutinise tender requisitions for PQC.
G
Scrutiny & evaluation of commercial offers
G
Preparation of contract documents
G
Handling arbitration cases
G
Preparation of estimate by areas consultants and getting the same.
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CONSTRUCTION DEPARTMENT :
The construction department supervises the work carried out by various contractors, ensures
that best work practices are adopted and the project is built in time.
Construction departments activities are broadly categorised into the following
G
Contract Management
G
Construction supervision to ensure quality
G
Accounting of materials & processing bills of contractors
G
Processing gate passes, work permits, shut downs, etc.
G
Monitoring and reporting of progress of work
G
Implementing statutory obligations
G
Ensure adherence to safety practices
CONTRACT MANAGEMENT :
G
Scrutinise extra claims put forth by agencies and recommend as the case may be for
due consideration.
G
Preparing all documents required for handing over / taking over the unit by works
division.
G
Prepare all documentation for closing of contracts.
CONSTRUCTION SUPERVISION, TO ENSURE QUALITY :
G
Coordinate with various departments of VSP and different agencies between civil,
structural, mechanical and electrical contractors for planning of erection and com-
missioning activities.
G
Ensuring overall quality of work at site by continuous supervision, collection of samples
as and when required.
G
Ensuring proper storage, handling of plant and equipment by the suppliers / contract- tours.
G
Check and give stage-wise clearance for the various construction activities.
G
Coordinate with all agencies / departments for start-up, trails and initial operation of
each unit.
MONITORING AND REPORTING PROGRESS OF WORK :
G
Review the progress of work by various agencies in different zones to ensure com-
pliancy with the time schedules.
G
Monitor the receipt of equipment and supplies at site for ensuring timely erection and
commissioning.
G
Monitoring timely erection, testing, commissioning of various units and follow up action
on progress of work at site.
ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES
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G
Review the performance of various agencies against the schedules / targets with a
view to ensure the project is implemented according to the schedule.
G
Preparation of various management reports like status of various civil, structural and
equipment erection work with reference to total quantities.
G
Maintain daily record of man power deployed by various agencies.
ACCOUNTING OF MATERIALS AND PROCESSING BILLS OF CONTRACTORS :
G
Prepare SI notes, scrutiny of material requisitions for drawal / return of material by
agencies.
G
Accounting of various materials supplied by contractors, issue of materials by VSP to
contractors.
G
Carryout joint measurements along with respective agencies, certification of the same,
process, scrutinize and recommend the RA bills and final bills of agencies for payment.
G
Enter measurements in M book, bill forms, and put up duly filled in forms.
G
Processing interim and final deviation statements of the works executed.
IMPLEMENTATION OF STATUTORY OBLIGATIONS :
G
Ensure compliance with all statutory laws of the land i.e. payment of minimum wages /
PF remittances / labour license / insurance / workmen compensation act etc by
contractors
G
Check wage sheets, PF remittance of workers submitted by contractors and certify
while forwarding the bills
PROCESSING OF GATE PASSES, WORK PERMITS, SHUT DOWNS ETC.
G
Processing the Gate pass for personnel, equipment, safety / height pass, work permits,
shut down permits.
ENSURE ADHERENCE TO SAFETY PRACTICES :
G
Enforce use of safety applicances by contractors / workers during erection, safety
training of all personnel deployed inside the factory for project work ; ensure use of
correct tools and tackles
PROJECT MONITORING :
Preparation of timely feed back information to Management on progress, delays and critical
activities of project AMR schemes and other projects.
Preparation and submission of the following progress reports to management regularly
G
Status of specifications / engineering / tendering / ordering / approval of vendor drawings.
G
Status of civil / structural / equipment erection with reference to total quantities
G
Status of construction activities / erection / testing & commissioning
G
Furnish periodical reports on actual expenditure with respect to estimates.
G
Interpretation of bar- charts to Management.
G
Analysis of delays occurred, delays likely to occur.
G
Preparation of various reports to Management regarding activities of project wing.
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Chapter - 56
Expansion of the plant to 6.3 MTPY (Liquid Steel)
GENERAL :
Keeping in view the upturn in global and domestic steel demand, VSP has envisaged to increase the
plant capacity to 6.5 Mt per year of hot metal and 6.3 Mt per year liquid steel with corresponding
increase in the production capacities of all its upstream and down stream units.
The product mix of plant was decided considering the likely future market in India up to 2012 - 13
based on information published by various agencies from time to time i.e a) Report on Task force
constituted by Govt. of India in September 1992., b) ICRA sector focus series # 4, 1995, c) Report of
the working group on Iron and Steel industry for the 9th five year plan, December 1996, d) Technical
paper presented by Dr. Sushim Banerjee - Published in Steel Scenario, Vol. 8, Qr-3., e) Paper presented
by ERU - Iron & Steel Review, January 2000.
The demand for bars and rounds from 2007 - 2008 and 2012 - 2013 is computed as around 8 to 10.8
MTPY, where as the computed future domestic availability of bars and rounds shall be 6.6 and 7.2
MTPY respectively. Therefore, there will be substantial domestic demand for bars and rounds in
future. In veiw of above, it was decided to expand the plant for production of long products.
The additional facilities envisaged to achieve 6.3 Mt per year liquid steel and corresponding changes
in the production capacities of upstream and downstream units are indicated as annexure - I.
PROJECT SCHEDULE :
All the facilities are required to be commissioned in 36 months, except the Special Bar Mill and Structural
MIll which are required to be commissioned in 48 months from date of approval of project by Govt. of
India i.e. 28-10-2005.
LAYOUT OF MATERIAL FLOW SHEET
The tentative plant material flow sheet indicating the capacities of major process equipment and the
raw materials required for 6.3 MT stage is indicated in the enclosed drg. no. DE EXP-001 and the
dispositions of various existing and proposed units in expansion is shown in drg. No.DE-EXP-002.
BRIEF DETAILS OF VARIOUS EXPANSION UNITS :
RAW MATERIAL HANDLING SYSTEM (RMHS) :
One number additional tippler each for ore and flux is envisaged to cater to the needs of expansion.
The coal is proposed to be inported and received at Gangavaram port and transported directly to coal
yard by conveyers.
One additional wheel on boom reclaimer will be provided at ore & flux yards. Two new base mix piles
dedicated for sinter plant will be provided adjacent to the existing base mix piles. One new twin boom
stacker and one blender reclaimer will be provided to manage movement to and from the piles.
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299
A new closed loop lump ore sizing system with associated facilities is envisaged. New facilities of flux
and fuel sizing as well as base mix proportioning, bedding are envisaged to cater to the needs of
Sinter machine-3 Closed loop crushing and screening facilities for flux materials and open loop
crushing for fuel sizing are envisaged.
SINTER MACHINE - 3
Considering about 80% sinter ratio in the burden for the new BF - 3, the requirement of charge sinter
will be 3.25 Mt per year. One new sinter machine of 400 sq.m area is envisaged.
Design basis of new sinter plant is :
Product sinter 3611,000 tonnes / year
Charge sinter 3250,000 tonnes / year
Screening at BF stock house 10%
Operating days in an year 330
Operating hours per year 7,920
Daily product sinter 10,950 tonnes / day
No. of strand 1
Product sinter size 5-50 mm
Temperature of sinter
at cooler discharge 100 oC
Blast Furnace - 3 :
The design basis of BF-3 to produce 2.5 Mt per year hot metal is indicated below.
Hot metal Capacity 2.5 MPTY
Production Capacity 7,150 thm/day (av.)
Useful volume 3,800 cu m
Productivity 2.15 t/cu m (working volume) / day
Top gas pressure 2.5 kg/sq cm (g)
Oxygen enrichment 3-6%
Hearth dia meter 13.0 m
No. of tuyers 34
No. of tap holes 4
Hot blast temperature 1200
0
C (1300 oC max)
Structure Free standing
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Copper staves will be installed in the high heat zone of BF i.e., both belly and lower stack in order to
get better thermal efficiency. Rest of the stack and throat portions are cooled by cast iron staves
similar to existing BFs. Three nos hot blast stoves shall be provided to supply hot blast at 1200 oC.
Maximum hot blast temperature shall be 1300 oC. The stoves will be fired with BF gas / mixed gas.
Enrichment of cold blast with oxygen is envisaged. Cast house is provided with slag granulation
system. Wet gas cleaning system (GCP) to achieve a gas cleanness of 5 mg/ NM3 with a moisture
content of 5 mg/NM3 in the gas shall be provided. Gas expansion turbine and generator is envisaged
to generate electric power utilizing pressure of the top BF gas. Coal dust injection system designed
for 200 kg/ ton of hot metal injection rate is envisaged.
STEEL MELT SHOP - 2 :
Annex - (1)
Converter Shop :
Two (2) nos. cu m LD converters (nominal capacity 150 tons of liquid steel), complete with bottom
inert gas stirring, oxygen lance system, flux and additive charging system, ferro-alloy storage and
charging system, relining device, cooling fan, lance deskulling and retipping facility, slag stopper
facility, gas cleaning plant, converter dog house, self propelled transfer cars and secondary emission
electrical equipment, instrumentation control, automation, process control computer (level-2) system,
utility services, hydraulics, pneumatic system and lubrication system and associated pipework along
with necessary allied technological structures are being installed at Visakhapatnam Steel Plant under
6.3 Mtpa expansion.
Design Basis :
No. of LD Converters 2 nos. of 150 m
3
each
Nominal Capacity of each Converter 150 t
Capacity of the new Plant 2.8 Mtpa
Overall height of Converter 9,085 mm
Height/Diameter ratio (inside new lining) 1.44
Specific Volume 1 m
3
/t
Converter Operation mode 2/2
Possible operating days per year 362
No. of heats/day 56 from 2 Converters
No. of heats per year 18, 760
Tapping weight 150 t (average)
Tapping temperature 1680
0
C
Blowing time 16 minutes (max)
Oxygen flow rate 600 Nm
3
/minute (max)
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301
Hot metal input 1025 kg/t
Scrap input 50-55 kg/t
Iron ore input 20 kg/t
Continuous casting machine :
The operating parameters of casters are as follows :
Heat size Nominal 150 tonne
Production of liquid steel 2.8 Mt
Production of cast billets 2.4 Mt
Production of cast rounds 0.330 Mt
Yield, liquid steel to cast
production 97.5 %
Caster availability 320 days / year
No. of Casters 3
No. of strands per caster 6
Sectional to be east
Billet easters 150mm x 150 mm; 200mm x 200mm
Billet cum ronnd caster 150mm x 150 mm squares
220mm, 280mm & 350mm tonnds
Average casting speed.
150 sq 3.5 m per min
200 sq 2.0 m per min
220 1.7 m per min
280 1.1 m per min
350 0.6 m per min
Average casting time in min.
150, 200 Sq 45
220, 280, 350 cp 50
WIRE ROD MILL - 2 (WRM-2) :
The mill will be designed to produce wire rod size of 5.5 mm to 20 mm. The capacity of wire rod mill-
2 shall be 6,00,000 tonnes / year. The mill shall comprise [8 stand roughing train, 6 stand intermediate
trains, two stand pre finishing train and two groups of 10 stand no twist blocks.] Single strand rushing
- 6 strands, Two strands Intermediates mill-10 stands, Two limm-pnefenising mill - 2 stands, No-twist
mill - standards reduial signamill - 4 stands.
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SPECIAL BAR MILL :
The Mill will produce bars of sizes 20 mm to 45 mm. The capacity of mill shall be 7,50,000 tonnes /
year. The mill shall comprise 6 stand roughing train, 6 stand prefinishing train and 6 stand intermediate
train, 3 steel finicshing / siging gramp.
STRUCTURAL MILL :
The mill shall use billets of 200 mm sq size and 12 m length. The capacity of mill shall be 7,00,000
tonnes / year. The mill will comprise 7 stand roughing train, The mill will produce beam 5 stand
intermediate train, and angles, channels, Flats, Tees, Rounds and spanners 5 stand finishing train.
CALCINING PLANT :
Considering specific consumption of flux as 66 kg per ton of liquid steel, two vertical shaft kilns of
capacity 500 TPD each are envisaged.
POWER PLANT :
The additional power requirement for the expansion units is about 200 MW. One (1) 67.5 MW generator
(TG-5) and a boiler to generate 330 ton/hour steam are envisaged. In order to meet the cold blast of
BF-3, one turbo blower (TB-4) is envisaged in TPP & BH.
Balance power is envisaged to be out sourced / purchased.
WATER SYSTEM :
In order to conserve water to the maximum extent, independent recirculating systems with cooling
towers, pump houses and treatment units have been envisaged. Make up water will be supplied to
individual recirculating system. The additional make up water require- ment to expansion units will be
around 13 MGD. Make up water requirement, zone wise is indicated in the enclosed annexure.
UTILITIES :
AIR SEPARATION PLANT : (ASP)
To meet the additional requirement of oxygen, nitrogen and argon, two ASP units of 850
TPD of oxygen each are envisaged. ASP is envisaged on BOO basis.
CHILLED WATER PLANT :
Three nos. chilled water plants of rating 1200 TR, 1200 TR and 6500 TR shall be located at BF-3, SP-
3 and mills area respectively to meet the expansion needs.
ENVIRONMENTAL MANAGEMENT :
AIR POLLUTION CONTROL MEASURES (APC) :
List of proposed air pollution control measures for new units of expansion are indicated as annex-II.
WATER POLLUTION CONTROL MEASURES :
To minimize pollution of receiving body the expansion plan envisages two approachers.
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303
i) Enhance thewaste water recycling to the extent practicable so as to reduce make up
water consumption.
ii) Aim for zero discharge of process effluent containing organic pollutants. Water
discharged through the storm water is collected at the outlets balacheruvu, Appikonda,
treated and refused in the plant to an extent of approx 5 MGD.
iii) Rain water percolation points shall be provicdeel for all buildings to recharge the
acquefices.
The specific consumption rate of make up water will be maintained within 4 cum / tls excluding power
plant. Make up water will not be used for non production facilities like dust suppression, slag granulation,
ash handling etc. The colling tower blow down water will be utilized within the plant to the maximum
extent practicable.
CONSTRUCTION VOLUME :
For construction purpose the total project has been decided under nine (9) zones which are RMHS,
SP, BF, Calcining Plant, SMS, RM, TPP, ASP (BOO), Power Plant (BOO basis).
The quantum of major construction work involved in 6.3 MTPY liquid steel expansion stage is given
below.
APPROXIMATE QUANTITIES OF CONSTRUCTION WORK
Item of work Unit Quantity
Earth work cu m 32,00,000
Piling 600 mm dia, 125 ton Nos 26,100
capacity
Concreting of all grades cu m 9,50,000
Structural steelwork ton 1,85,000
Roof sheeting & cladding sq m 7,00,000
Equipment Erection tonne 1,02,000
The tentative major construction materials for the above work are as follows :
Cement : 4,75,000 MT
Reinforcing steel : 1,20,000 MT
Coarse aggregates : 6,55,000 cum
Fine aggregates : 3,40,000 cum
Structural steel : 2,04,000 MT
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Sheeting material : 8,40,000 sq. m
Legend :
MGD : Million Gallons per Day
Mt : Million tonne
MT : Metric Tonne
MTPY : Million Tonne Per Year
TR : Tons of refrigeration
Cum : Cubic meter
Sq m : Square meter
TPD : Tonnes Per Day
MW : Mega Watt
Thm : Tonnes of hot metal
ESTIMATED COST OF THE PROJECT
Description Foreign Local Total
currency currency
equivalent (Rs in (Rs in
crores) crores)
A. Plant Cost
Land & site development etc. - 41 58
Civil work - 663 1213
Structural work - 787 1341
Plant & equipment 1,250 3,846 7837
Erection charge incl.
Supervision of erection, training etc. 127 387 932
Design, engineering, Project management
and consultancy Services - 353 342
Sub - total (A) 1,377 6,077 7,454
B. Other Fixed Investment
Spares 27 93 115
Start-up expenses - 42 42
Sub-total (B) 27 135 162
C. Total Fixed Investment (A+B) 1,404 6,212 7,616
D. Contingency 70 311 135
E. Interest during construction - 214 119
F. Development / expansion of mine 3 45 95
G. Total Capital Requirement 1,477 6,782 12225
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ANNEX - I
List of major addl. facilities / units envisaged in the expansion of plant to 6.3 MT
liquid steel
i. Raw Material Handling Plant :
a. Ore-side Ore tippler (1), ore stacking conveyors (1-stream),
Twin-boom stacker, wheel-on-book reclaimer,
Ore- beds-3, Lump ore Screening plant, Lump ore
crushing plant, reclaiming conveyors for Sinter Plant
/ Blast Furnace etc.
b. Coal Handling Plant Coal beds (5), Stacker-cum-reclaimer (2) reclaiming
conveyors etc.
ii. Sinter Machine - 3 1 x 400 sq.m grate area, to produce 3.25 Mt / yr. charge
sinter
iii. Blast Furnace - 3 1 x 3800 cu.m useful volume with all auxiliary facilities
and Pulverized Coal Injection to produce 2.5 Mt / yr
hot metal
iv. Steel Melt Shop - II 2 x 150 t. converters with secondary metallurgy
facilities to produce 2.8 Mt / yr liquid steel.
2 x 6 strand billet caster
1 x 6 strand round caster
v. Rolling Mills 1 x 600,000 t / yr : Wire Rod Mill - 2
1 x 750,000 t / yr : Special Bar Mill
1 x 700,000 t / yr : Structural Mill
vi. Calcining & Refractory Vertical shaft kiln : 2 x 500 t/day
Material Plant
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vii. Augmentation of 1 x 67.5 MW Turbo Generator (TG-5)
Existing Thermal 1 x 418000 N Cum / hr Turbo Blower (TB-4)
Power Plant & Blower 1 x 330 t/hr, multi - fuel fired boiler
House (TPP & BH)
viii Auxiliary Facilities Power systemrms, substations & power distribution
systems. Water systems / utilities / yard piping /
drainage / sewage and all other related service
facilities Additional yards, tracks, roads, flyover etc.
ix. Captive Mines i. Augmentation of MDM crushing & screening plant
from a throughput rate of 250 t / hr to 400 t / hr
and conveying system and uprating the loading
system from 350 t / hr to 2000 t/hr.
ii. Uprating the existing loading rate at JLM from 350
t/hr to 2000 t./hr.
iii. Provision of 30 t/hr crushing & screening unit in
GMM.
iv. Develop Kintada Quartize mine for and annual
production of 50,000 t.
x Power Plant (PP) 2 x 67.5 MW capacity with all necessary facilities.
(BOO Basis)
xi Air Separation Plant 2 x 850 t/day oxygen
(BOO Basis)
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ANNEX - II
LIST OF PROPOSED APC MEASURES FOR NEW UNITS RMHS, RMBBS, COKE
OVENS AND SINTER PLANT BF, LD SHOP, LIME KILN AND MILL FURNACES
Sl. Proposed New Emission Control Devices Design Target
No. Units/Facilities Point Source Fugitive
(Stacks) (Workzone)
1. Raw Materials - - Covered - closed Work zone
stockpile / conveyors dust level 5 mg / N
bedding and - Dry fogging cum (max)
blending system for - De stack outlet
station and conveyors transfer dusts below 50
material handling point, crushing mg/ N cu m
& screening plants - Open work zone
- De systems < 600 mcg / cu m
of material
transfer points
based on bag
filters
2. Sinter Plant - Emission - Stock House - Stack dust 50
Unit No. 3 Optimised Waste gas for mg / N cu m
Sintering Sinter M/c - Stack SO2 < 280
(EOS) is is cleaned in mg/N cu m - -
preferred the ESP. Stack No x < 200
- Use of low - DE System with mg / N cu m
H2S fuel gas ESP and bag - Closed work
Electrostatic filters one enrisaged. zone dust < 5
precipitator- mg/N cu m
Tall
combustion
Stack
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3. Blast Furnace - Heat BF Stock - Stack dust 50
No. 3 Recovery House DE mg / N cu m
from BF System with - Workzone dust
Stoves Tall ESP 5 mg / N cu m for
Stack for BF - BF Cast indoor
Stove Flues House DE
System with
ESP
- Fume
extraction for
Slag
Granulation
Plant
4. Steel Melt - Secondary - Stack dust 50
Shop New LD Emission mg/N cu m
converters control of LD
with LF, RH Shops Bag Filters for
LF and RH
with ESP - Fume
Extraction
System for
Casters in CCD
5. New Mills - Efficient - Stack dust 50
Mill Furnaces combustion mg / N cu m
control with - SO
2
200 mg/N
low NOx cu m at 3% 0
2
burners - NOx 370 mg/N
- Use of low cu m
H2S fuel gas
Stack
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6. Lime Kiln Stack De System Dust 50 mg/N
New Lime Kiln with bag cu m
Filters Dust content in
wrt zone : 5mg/Nm
3
7. Captive Power Stack ESP is - Dust 50 mg/N
Plant Envisaged cu m
for cleaning - SO2 500 mg/N
of exhaust cu m
1 x TG gases from - NOX 650 mg/N
(Unit#5) the boils cu m for coal fire
1 x TB - NOX 150 mg/N
(Unit # 4) cu m for gas fire