​Prepared By: -

Himanshu Shekhar Pandey

University ID: ASU2012010100029

AT
New OHP, Part-B (Package-061)
Bhilai Steel Plant, Bhilai (Durg), Chatthisgarh

Submitted To

​Engineering Projects (India) Limited

Core-3, Scope Complex
7, Lodhi Road, New
Delhi
Table of Contents

Engineering Projects (India) Limited SAIL, Bhilai Steel PLant 2

Certificate 2
Table of Contents 3
Acknowledgement 4
Abstract 5
1. Introduction 6
2. Ore Handling Plant, New OHP, Part-B, Package 61 13
Bibliography 32

Table of Figures
Figure I - Bucket Wheel Reclaimer Number 1, OHP-II 13
Figure II - Track Hopper Inside View, OHP-II 16
Figure III - Side Elevation of Wagon Tippler with Side Arm Charger (Design) 19
Figure IV - Front Elevation of Wagon Tippler with Side Arm Charger (Design) 21
Figure V - Front Elevation of Twin Boom Stacker (Design) 22
Figure VII - Side Elevation of Twin Boom Stacker (Design) 23
Figure VIII - Structural View of Twin Boom Stacker, OHP-II, Package 061 25
Figure IX - Front View of Bucket Wheel Reclaimer (Design) 27
Figure X - Top View of Bucket Wheel Reclaimer (Design) 28
Figure XI - output shaft of the hydraulic drive is equipped with a pinion, meshing with the toothed
rim of the slewing bearing 30
Acknowledgement
I express my sincere gratitude and regards to ​Engineering Projects (India) Limited​, New Delhi for
providing me an opportunity to experience and study the Mechanical equipment used in the New
Ore Handling Plant (Package-61) Project.

First & foremost my heartily thanks to ​Shri. Vinoo Gopal Sir (Director - Projects) ​and S​ hri. Salil
Kumar (Executive Director – Consultancy & Engineering)​ for providing me the opportunity and
making this experience more friendly and informative.

I would like to express my gratitude to ​Shri. K Mitra (Executive Director)​, ​Shri. G.S Prasad (GGM)
and ​Shri. A Gowthaman (AGM)​ for guiding me throughout my internship and providing an
environment full of learning and information.

Also ​Shri. B.K Saha​ (Senior Manager) for giving me an insight of his knowledge towards the working
erection equipment and their respective design specifications.

Finally, my sincere gratitude to ​Shri. Ram Sagar (Liasoning Officer – HR)​ for helping me throughout
the course of internship with his knowledge and care, his invaluable experience provided me an
insight towards the working of Bhilai Steel Plant.
Abstract
This report provides an insight towards the design and erection of the mechanical equipment used in
the erection of New Ore Handling Plant (OHP-II) for the augmentation of raw material receipt and
handling facilities in Bhilai Steel Plant. Present facilities in OHP to receive, unload & store raw
material in OHP is insufficiently mostly due to logistical problems in placement of rakes in yard,
weighing, placement of rakes in tippler and collection of empty wagons, transportation of raw
material to the yard etc. This sis causing lot of wagon detention and thereby heavy demurrages are
paid to the Railway authority. Additionally logistics for stockpiling in the manner desired and
reclamation also posed bottlenecks.

PART-B of the Augmentation of Raw material receipt & handling facilities with new OHP shall consist
of all other facilities as per the scope of work and pertains to the management of the additional
quantity of raw material required to produce & MPTY of Crude Steel in Bhilai Steel Plant. The major
facilities envisaged are Wagon Tippler , two new Track Hoppers with two unloading tracks and a new
OHP (OHP-II) with six numbers of beds of stockpile, three stackers and four reclaimers and related
conveyors to feed new Blast Furnace BF#8 and Sinter Plant -III (both modules).
1. Introduction
1.1 General Information of the Organization

1.1.1 History and the working of Organization

​The Bhilai Steel Plant, located in ​Bhilai​, in the Indian state of ​Chhattisgarh​, is ​India​'s first and main
producer of ​steel​ rails, as well as a major producer of wide steel plates and other steel products. The
plant also produces and markets various chemical by-products from its ​coke ovens​ and coal chemical
plant. It was set up with the help of the ​USSR​ in 1955.

The eleven-time winner of the Prime Minister's Trophy for best integrated steel plant in the country,
Bhilai Steel Plant (BSP), has been India's sole producer of rails and heavy steel plates and major
producer of structural steel. The plant is the sole supplier of the country's longest rail tracks, which
measure 260 metres (850 ft). The plant also produces products such as wire rods and merchant
products. Bhilai Steel Plant has been the flagship integrated steel plant unit of the Public Sector steel
company, the ​Steel Authority of India Limited​ and is its largest and most profitable production
facility. It is the flagship plant of SAIL, contributing the largest percentage of profit.

At Bhilai IS0:14001 has been awarded for Environment Management System in the Plant, Township
and Dalli Mines. It is the only steel plant to get certification in all these areas. The Plant is accredited
with SA: 8000 certification for social accountability and the OHSAS-18001 certification for
Occupational health and safety. These internationally recognised certifications add value to Bhilai's
products and helps create a place among the best organisations in the steel industry. Among the
long list of national awards it has won, Bhilai has bagged the ​CII-ITC Sustainability award​ for three
consecutive years.

1.1.2 Facilities Provided by Bhilai Steel Plant

Captive Mines

Iron Ore Dalli-Rajhara Iron Ore Complex, 80 kms from Bhilai

Limestone Nandini, 23 kms from Bhilai
Dolomite Hirri, 150 kms from Bhilai

Coke Ovens

Battery No. of Oven Coal Handling Capacity Useful Volume of Sp. Het Conspn.
No. Ovens Height (m) per oven (T) oven per cu. M. Kcal/kg
1 to 8 65 4.3 16.8 2.6 625 - 675
9 & 10 67 7.0 32.0 41.6 625 – 675

Blast Furnace

▪ 3 of 1033 Cu m capacity each

▪ 3 of 1719 Cu m capacity each

▪ 1 of 2355 Cu m capacity

Hot Metal Capacity: 4.70 MT / year

 
Steel Melting Shop

Steel-making through BOF, VAD/Ladle Furnace/RH-Degasser and Continuous casting route

▪ 3 converters of 110/130 T

▪ VAD unit, 2 RH degasser,2 Ladle furnace

▪ 4 Slab Casters, 1 bloom caster, 1 Combi caster

Annual Capacity: 1.425 MT Cast steel

Converter Shop :

▪ 3 BOF 110/130 T Convertors

▪ Secondary Refining facilities : 1 VAD unit, 2 RH degassers, 2 Ladle furnaces, 1

Desulphurisation Unit

Continuous Casting Shop:​ 4 Slab Casters, 1bloom caster, 1Combi caster

Steel-making through Twin Hearth Furnace (THF) route :

▪ 4 THFs of 250 T capcity each

▪ Annual capacity 2.5 MT ingot steel

 Blooming & Billet Mill

▪ 14 pairs of recuperative soaking pits

 ▪ Capacity to produce 2.14 MT/year of blooms

▪ Capacity to produce 1.50 MT/year of billets

Rail & Structural Mill

Capacity - 7,50,000 T

Products

▪ Rails - R52 Kg/m & R60 Kg/m ; UTS 880 N/mm2 rails as per IRST-12/96 specifications ,
Euronorms and international standards.

▪ Thick web asymmetric rail Zu 1-60

▪ Beams - 600,500,450,400,350,300 & 250.

▪ Channels - 400,300 & 250.

▪ Angles - 200 & 150.

▪ Crossing Sleeper.

▪ Crane Rails - KP80, 100,120 & 140.

▪ Bhilai is the sole supplier of the country's longest rail tracks of 260 metres.

Bhilai Rails

▪ Largest producer and leading rail maker of the world.

▪ Four and a half decades of experience in rail making.

▪ Produced over 15 million tonnes of rails; 2.7 lakh km in length.

▪ Indian Railways- World’s second largest rail company moves exclusively on Bhilai rails.

▪ Bhilai rails are subjected to world’s highest traffic density and axle loads.

▪ Rails exported to 10 countries with exports to South Korea, New Zealand, Argentina, Turkey,
Iran, Egypt, Ghana, Bangladesh and Malaysia.

Technological Superiority

▪ Steel from LD Convertor – Ladle furnace - RH Degasser – Concast route; achieving world best
level of degassing/refining to less than 1.5 ppm of hydrogen in liquid steel in 100% of heats.

▪ Capability to produce as rolled lengths of 80 meter and welded panels upto 260 meters

▪ High degree of Straightness due to world’s most advanced and Laser straightness
measurement based end straightening machine.
 ▪ World class tested rails passing through state of art online NDT equipment; Laser
straightness measurement, Ultrasonic and eddy current testing machines

▪ Computer controlled automatic rail handling system and automatic yard mapping for rail
storage.

▪ Computerised Rail Tracking system for collection and storage of all process and testing
related data of each rail.

Bhilai Rails- Universally Certified

▪ RDSO, Indian Railways

▪ RITES Ltd

▪ ISO-9001-2000 certified by LRQA (Lloyds Register Quality Assurance)

▪ ISO 14000 certified by BIS

▪ Crown Agents, London

▪ General Superintendence Company, Geneva

▪ Lloyds Register Of Shipping

▪ Robert W Hunt & Company

▪ Overseas Merchandise Inspection Company, Tokyo

▪ Egyptian Railways Inspection Team

▪ Tuboscope Vetco Gmbh, Deutcheland

Bhilai’s Special Purpose Rails

▪ Copper Molybdenum Corrosion resistant rails

▪ High yield strength/ UTS vanadium micro-alloyed rails

▪ High conductivity metro rails

▪ Copper-Chromium alloyed High strength Rails

 Merchant Mill

Capacity - 5,00,000 Tonnes

Products

▪ Plain Rounds : dia 28, 32, 36,40, 50,53, 56, 63 & 67

▪ TMT Bars : 25,28, 32, 36, 40 & 45

 ▪ Lt. Structurals :Channel 100 x 50, 75 x 40

▪ Angles : 50 x 50 x 5 upwards to 90 x 90 x 10

* Customised product campaigns are being taken up for shorter durations in case of light structurals
and rounds for compliance of smaller quantity orders as per committed delivery within the month.

Wire Rod Mill

Capacity - 4,20,000 T

▪ Wire Rods (Plain, Electrode Quality & TMT) in 5.5, 6, 7, 8 & 10 mm plain and ribbed, and 12
mm plain in coil form

▪ 8, 10, and 12 mm TMT (SAIL, 2015)

Plate Mill

Capacity 9,50,000 T
Plate Thickness 8-120 mm
Width 1500-3270 mm
Length 5-12.5 M

The modern Plate Mill rolls out heavy and medium plates, as well as those for pipe manufacturers.
Plates of wide variety, in any required size, and strength, chemical and physical properties, can be
produced here. It has capacity to produce high pressure, boiler quality and high tensile steels.
Shipbuilding plates, conforming to Lloyds specifications, and pressure vessel boiler plates,
conforming to various ASTM, ASME standards, have withstood the challenges of nature and time.
Some of the unique features of the mill are on-line finishing facilities and off-line normalising
facilities. Bhilai has the widest plate mill in the country, and it uses continuously cast slabs as input.
Liquid steel produced under controlled conditions in the LD Converters is rinsed with argon gas to
homogenise the composition as well as to remove non-metallic inclusions before continuous casting
so as to ensure the production of high quality feedstock for the Plate Mill. As per customers'
requirement or specifications, plates are normalised in a roller hearth normalising furnace​.
2. Ore Handling Plant, New OHP, Part-B, Package 61
2.1 Introduction

Bhilai Steel Plant​, in its approach note for corporate plan 2011-12 indicated that the production
potential of BSP would be 7.0 MPTY of crude steel, subject to implementation of strategies to
overcome the present constraints and providing certain additional facilities.

Present facilities in OHP to receive, unload & store raw material in OHP is insufficiently mostly due to
logistical problems in placement of rakes in yard, weighing, placement of rakes in tippler and
collection of empty wagons, transportation of raw material to the yard etc. This sis causing lot of
wagon detention and thereby heavy demurrages are paid to the Railway authority. Additionally
logistics for stockpiling in the manner desired and reclamation also posed bottlenecks.

PART-B of the Augmentation of Raw material receipt & handling facilities with new OHP shall consist
of all other facilities as per the scope of work and pertains to the management of the additional
quantity of raw material required to produce & MPTY of Crude Steel in Bhilai Steel Plant. The major
facilities envisaged are Wagon Tippler , two new Track Hoppers with two unloading tracks and a new
OHP (OHP-II) with six numbers of beds of stockpile, three stackers and four reclaimers and related
conveyors to feed new Blast Furnace BF#8 and Sinter Plant -III (both modules).

The following agencies shall remain parties to the contract

a. Employer: M/s Bhilai Steel Plant (BSP), Bhilai, Steel Authority of India Ltd.
b. Consultant: M/s Mecon Ltd. , Ranchi
c. Contractor: M/s Engineering Projects (India) Ltd.

Figure I - Bucket Wheel Reclaimer Number 1, OHP-II

2.2 Brief System Description

The turnkey package of this Contract Document comprises of the following sub-systems:

- New ore Handling Plant (OHP-II) including receiving, unloading, Stacking & Reclaiming and
finally transporting of raw materials required for Blast Furnace #8, Sinter Plant – III.
- New conveyor line for New Lime Dolomite Plant RMP 3 and for proposed SMS – III.

2.2.1 New Ore Handling Plant (OHP-II)

The raw material to be handled by the proposed system is mainly, Iron Ore Lump, Iron Ore Fines,
Lime Stone (BF grade), Lime Stone (SMS grade), Dolomite (BF grade) Dolomite (BF grade), Quartzite,
and Manganese Ore. These raw materials are mainly required for Blast Furnace, Sinter Plant,
Lime-Dolomite Plant, SMS. All the raw materials will be received at the plant boundary by rail. The
type of Wagon will be BOXN, BOXNHA, Boy, BOBRN, BOST, BOBS, BOXNEL, BOYL, BOXN HS etc.
which will transport the raw materials depending upon the location of loading and type of raw
materials.

2.2.1.1 Design Considerations

The Ore Handling Plant (OHP-II) has been planned based on the following assumptions:

A. Size of Raw Material

1. Lump Iron Ore 40 mm

2. Iron Ore Fines 8 mm

3. Lime Stone (BF/SP grade) 60 mm

4. Dolomite (BF/SP grade) 60 mm

5. Quartzite 50 mm

6. Lime Stone (SMS grade) 25 mm

7. Dolomite (SMS grade) 25 mm

8. Pellets 18 mm

9. Manganese Ore 25 mm

10. Coke Breeze 25 mm

B. No. of Days of Working per year : ​330 days

 C. Maximum material carrying of each wagon shall be as per IS: 10095-1982 reaffirmed 2001.
Iron-ore-lump will be received in Track-Hopper & all other material in Wagon Tipplers. Two
Track Hoppers have been considered for materials received in BOBS/ BOBRN wagons (mainly
iron-ore); whereas wagon tippler with side arm charger has been considered for unloading
the materials received in BOXN/BOST/ BOXNHA/BOY/BOBS, BOXNEL, BOYL wagons.

2.2.1.2 Unloading, Storage, Blending and Reclaiming in OHP-II

One number Wagon Tippler WT no.B1 along with a Track Hopper TH-B1 with two parallel tracks on it
have been envisaged for unloading iron ore(lump and fines), Limestone& Dolomite (both BF grade
and Sinter Plant grade), Manganese-ore, Quartzite etc.

The wagon Tippler shall be of Rota-side type capable of unloading BOXN and proposed BOXNHA,
BOXNHS, BOBS, BOY wagons as per IS: 10095-1982, reaffirmed 2001. The rated unloading capacity
shall be rated 20 Tips/hour. Adequate system of handling sticky rakes such as vibrator/ air blaster
shall be provided.

25 t wagon axle load and 110 t gross weights of wagons (BOX, BOXN, BOXNHA, BOXN HS, BOXN EL,
BOYEL) to be considered for design of Wagon Tippler and track hopper 2 nos. Weighbridges included
in scope.

The placement of rakes shall be done by Side arm chargers capable of handling a full rake BOXN,
BOXNHA, BOBS, Boy, BOXN EL, BOYEL wagons.

Two nos. of track hopper each of length 210 m excluding maintenance bay and holding capacity of
6000 t each considering material bulk density of 1.6 t / cu.m. shall be included in scope. The side
angle hopper with vertical shall be minimum 60 deg. Each hopper shall have four compartments.
Track Hopper envisaged to accommodate minimum 18 BOBS wagons.

Total 4 nos. Electric hoist of 5 t capacity shall be provided for maintenance of Paddle Feeder at both
ends of Track Hopper building. Two nos. double door pressurized cabin shall be provided for paddle
feeder inside the track hopper tunnel. Anti-derailment device/ check rail shall be provided in the
track hopper subject to approval of RITES. Supply/ laying of 60 kg/ m rail with continuous MS insert
plate within track hopper building only are in scope of work.

Two belt feeders below Wagon Tippler shall discharge the raw material on either of two conveyors
i.e. Z1-C1 or Z1-C2 which, in turn will discharge the material at Jn House JH-Z1. From Jn House JH-Z1,
conveyors Z3-C1 & Z3-C2 will carry the material and discharge at JH-Z3. There are three incoming
conveyors in Junction house JH-Z3. The tail end of two conveyors Z3-C1 & Z3-C2 will start from JH-Z1
and Belt conveyors Z3-C3 from JH-Z2. Junction house JH-Z2 is located in between the JH-Z1 &
ZH-JH-Z3. (SAIL, Bhilai Steel Plant, 2010)

The track hopper with four nos. paddle feeders of 1500 tph each, two on conveyors Z2-C1 and two
on conveyors Z2-C2 has been envisaged. From Jn Hose JH-Z2, either of three conveyors Z3-C1, Z3-C2
(coming from JH-Z1) & Z3-C3 (begin from JH-Z2) carry the material up to Jn house JH-Z3.Suitable
interchangeability is provided below Wagon Tipplers and Track Hoppers for the conveyors by
providing Diverter gates.

The raw material can be either transported via. Jn House Z4, Z5 or Z6 to the respective stacking
conveyors Z4B-C1, Z5B-C1 & Z6B-C1 for stockpiling or can be fed directly to the reclaiming conveyors
Z7-C1/ Z7-C2 which means convey material directly from WT/ Track Hopper to:

(a) To the Blast Furnace #8 Stock House

(b) To the Fuel & Flux crushing circuit of Sinter Plant – III.

The Stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 can form a stockpile 30 m wide, 350 m long and
10.5 m (maximum) high with the help of Twin boom Stackers.
 Figure II - Track Hopper Inside View, OHP-II

2.2.1.3 Storage and Reclamation of Ore

From the Wagon Tippler WT-B1 and the Track Hopper TH-B1, the raw material may
sometimes be fed directly to the consuming plant in case of emergency. However this shall
not happened under normal circumstances when the three Twin-boom stackers over
conveyors Z4B-C1, Z5B-C1 & Z6B-C1 since the raw material in the designated place of the
yard in bed nos. 1 to 6. Flexibility shall be in built in the Jn Houses Z4, Z5 and Z6 to ensure
stacking is trouble free.

Four nos. Bucket wheel reclaimers have been envisaged from bed no. 1 to 6.

All stacking line conveyors feeders and stackers etc. have a rated capacity of 1500 tph and a
designed capacity of 1800 tph.

All reclaim line equipment shall have a rated capacity of 1500 tph and a designed capacity of
1800 tph in the ore handling area. Reclamation takes place by the conveyors Z7-C3 (Bed no.
1), Z4A-C1 (Bed 2 or 3), Z5A-C1(Bed no. 4 or 5) and Z6A-C1 (Bed no. 6) and the reclaimed
material via Jn House Z4A,B<Z5A,B,Z6A and Z6B shall reachJn house Z&.

Reclamation from OHP takes place for the following circumstances:-

- Feeding of iron ore lump, dolomite, limestone, manganese, quartzite, pellet etc. to
BF#8 stock house.
- Transporting Limestone/ Dolomite (SP grade) and iron-ore fines to fuel & flux
crushing area for Sinter Plant – III.
2.3 General Technical Specifications – Material Handling Equipment

This topic covers the major technical equipment envisaged in this New OHP-II package broadly as
listed below:

1. Wagon Tippler with Side-arm charger

2. Twin Boom Stacker
3. Bucket Wheel Reclaimer
4. Paddle Feeder

2.3.1 Technical Specification of Wagon Tippler with Side-arm charger

2.3.1.1 Scope of Work

The scope of work includes the design, engineering, assembly, manufacture, shop testing, supply,
dismantling, packing and loading at site, erection, testing and commissioning of the following items
at plant site.

2.3.1.2 Technical Specification/ Design Data

1. Side Arm Charger

Application

The side arm charger (SAC) to be used for wagon positioning at the wagon tippler for unloading of
materials. It shall be used for pushing/ pulling a rake of 59 wagons as per IS: 10095-1982,
Reafirmed-2001 and locating wagons one by one on tippler.

Working

A train of 59 loaded wagons to be brought in by a locomotive pushing/ pulling and stopped with the
leading wagon with range of the Side Arm Charger using track side marker boards. The loco is
decoupled and dispatched and the charger shall be driven to the leading wagon. Its arm gets
lowered and coupled to the first wagon of the train. The train is hauled forward by the charger until
the first wagon is about 4 meters away from the tippler. The charger then stops and the first wagon
get uncoupled from the train. The charger then inches forward the leading wagon on to the tippler
which automatically decouple itself & Arm is raised before it travels back to the train. The tippler
rotates itself for tippling the wagon. On reaching near the standing train, the charger arm is lowered
and gets coupled to the train ready for repeating the cycle.

In the next cycle the train is drawn up by one wagon length, the front wagon gets decoupled and the
next cycle is repeated. When the next wagon is located on the tippler table the previously tippled
wagon gets ejected simultaneously.On the out haul side the empties form a new train ready for
collection by a locomotive. (SAIL, Bhilai Steel Plant, 2010)

Specifications/ Technical Parameters:

Quantity 1
Type With hydraulic travel drive and hydraulically operated
coupling/ decoupling arm.
Type of wagon to be handled BOXN, BOBRN, BOST, BOXNHA, BOY, BOBS, BOXNHS
No of wagons to be pulled/ pushed 59 wagons fully loaded (Gross Load = 6000 t min.)
Gross Design weight of wagon As per IS: 10095-1982, Reaffirmed-2001
Draw Bar pull Minimum 37.5 t ( Pushing/ pulling effort for 59 nos. loaded
wagons)
Mode of Control Operator’s cabin, Tippler ( located on the charger Control
Room either individual or jointly with the tippler )
Speed 0.5 m/sec forward & 0.5 m/sec reverse, (with full rake of
loaded wagons) and one slow speed for coupling
Duty 24 hrs/ day (continuous)
Power Supply Festoon cable system
Travel Drive Hydraulic motor driven through power packs, positive driven
through rack and pinion
System Working Pressure 180 bar (max) including charge pressure

Figure III - Side Elevation of Wagon Tippler with Side Arm Charger (Design)

2. Wagon Tippler

Application

Rota-side Wagon Tippler is used for mechanised unloading of broad gauge wagons, as described in
IS: 10095-1982, Reaffirmed 2001, carrying raw materials such as lump iron ore, iron ore fines, Mn
ore, pellet, Quartzite, limestone, etc.

The wagon tippler is fed with loaded wagons one by one by the Side Arm charger. Tippled empty
wagons are collected on the empty side by ejection through side arm charger while placing loaded
wagons on the tippler. The wagon tippler unloads the materials into receiving hoppers for onward
transportation to stock yard.
Specifications

The Wagon Tippler is of robust construction and designed for continuous duty. Wagons are clamped
automatically by a hydraulic actuated system, and is suitable for all wagons envisaged in IS:
10095-1982, Reaffirmed 2001. The geometry of clamping system is designed to accommodate
dimensions of full range of wagons mentioned below.

The tippler shall consist of following:

- A cradle consisting of a pair of heavy welded steel plate and sector rigidly connected by a
large torsion box girder fitted at each end with pivot shafts. The whole cradle is carried on
these pivot shafts mounted on heavy duty spherical roller bearing with robust sealing
arrangement.
- 25 t wagon axle load and 110 t gross weights of wagons (BOX, BOXN, BOXN HA, BOXN HS,
BOXN EL, and BOYEL, BOBSN & BOBRN) to be considered for design of Wagon Tippler and
track hopper.
- A rail table carried on a roller in a slotted bearing supported from an extension of the end
sectors.
- Four transverse top clamps beams which shall be carried on arms pivoted from the main
torsion box girder. These arms are connected at their lower end to a ballast box which
carries pawl for mechanical locking.
- Drive unit with hydraulic power pack etc.
- To cope up with occasional jamming of sticky material, the top clamps shall be automatically
locked while the wagon is in inverted position, and disengage automatically as the tippler
returns the wagons to its normal upright position.
- The drive design incorporates controlled hydraulic drive and is controlled from remote
control post.

- The design working pressure does not exceeds 180 bars for hydraulic system/components.
- The bearing is of antifriction type and equipped with dust seal. Adequate platforms are
provided around tippler for ease of maintenance.
- The tippler is interlocked electrically with side arm charger and succeeding equipment
(feeders, conveyors etc.) with respect to operational and safety requirements.

Technical Parameters

Number 01 (for Ore/fines, Limestone, Quartzite, Manganese Ore etc.)

Type Hydraulic Rota-side, Indoor type

Type of Wagon BOXN/ BOBRN/ BOST/ BOXNHA/ BOXNHS/ BOY

Capacity

No of tips/hour 20 (Rated), 22 (Design)

Rail gauge 1676 mm

Angle of tippling Minimum 165 deg. anti-clockwise looking from wagon entry side

Duty 24hrs/day (continuous)

Type of clamping Hydraulic

Type of drive Hydraulic motor

Vibrators Electromagnetic type 2 nos.

Rail size 60kg/m

2.3.2 Technical Specifications of Twin Boom Stacker

2.3.2.1 Scope of Work

The scope of work includes the design, engineering, assembly, manufacture, shop testing, supply,
dismantling, packing and loading at site, erection, testing and commissioning of the three numbers
of Twin Boom Stacker.

2.3.2.2 Technical Specifications/ Design Data

1. Stacker

The stacker is of twin boom luffing type and is provided in the storage yard. Boom conveyors are at
right angle to stacker travel while stacking. Height of boom of the Stacker should have adequate
clearance from working re-claimer and Stacker’s interchanging facility with all other unloaders of the
yard. The stacker receives the material from on-ground yard conveyor through a tripper.The tripper
forms an integral part of stacker. Boom conveyors shall be provided with hydraulic luffing motion. It
is possible to form centrally located stockpile in any boom position. Position indicator is provided for
luffing.

All motions of the stacker is synchronized and have WVF drive control so that the material is stacked
at a uniform rate irrespective of the direction of travel of the stacker.

Auto stop arrangement is provided for Stacker’s hoist mechanism to prevent damage of structure
and hoisting. Indication of hoisting height is provided in the operator’s cabin.

2. Mechanical Specification

- The stacker covered in this specification is complete with bogie mounted tripper. The tripper
has minimum possible height to reduce belt tension and power requirement of the
conveyor, on which the machine is mounted. The stacker is of four corner support type.
- The design of the bogie and carriages of the equipment is of such that differential movement
of the wheel sets of the machine on two rail tracks does not result in skewing effect. The
traverse bogies are provided with material guard plate as well as rail cleaners at both ends
 so that the machine can travel even if there’s spillage or overflow of material on rail track
and the L.T drive is selected accordingly.
- Materials used for equipment are of good quality and free from fractures, cracks, blow
holes, lamination, pitting’s etc.
- The boom conveyor is designed such that no spillage occurs when the stacker moves
opposite to the direction of material flow of yard conveyor.
- The machine is provided with adequate nos. of buffers.
- Screw take up travel is 1000mm in Stacker, Boom Conveyors. Material of construction is of
‘’Stainless steel with bronze nut.
3. Drives

- The long travel drive mechanism is provided with multiple drives on each side. In the event
of a failure, any drive motor, the corresponding motor on the other side shall be
automatically disconnected. However, the machine will be operable with the remaining
drives.
- Double ended motors are provided in long travel drives, so that brake can be fitted to the
free end of motor to ensure better maintenance and operation.
- The equipment is supported on wheels mounted in bogies and driven by electric motors
through reduction gears. No use of chain drives and opens gears.
- For long travel, individual wheel drive is provided. Min. 50% of long travel wheels is
positively driven.
- For travel motion, rotating axle drive management with `L’ type supports are provided.
- Long Travel motors are of VVVF controlled in order to accommodate speed variation of 5 to
30 m/min. Minimum 12 nos. (Excluding tripper) no. 630 mm dia. LT wheels are considered.

4. Gears and Gear Boxes

- Straight and helical, spur gearing are used. All spur gears have 20 degree pressure angle with
involute teeth profile.
- First and high speed reductions are through helical gears only.
- All first reduction pinions and also other pinions, depending on feasibility are integral with
the shafts.
- Gear materials used are of hardened and tempered alloy or carbon steel with machine cut
teeth. Surface hardness is from 255 to 300 BHN and for gear it’s from 220 to 225 BHN.
Difference in hardness of pinion and gear is not more than 20 BHN.
- All gear shafts are supported in bearings mounted in gear box.
- The housing of gear boxes is of cast steel or fabricated. Fabricated gear boxes are made up
of minimum 8 mm thick steel plate and are stress relieved.

5. Hydraulic Luffing System

- Hydraulic luffing of the boom is provided for stacker with following respective ranges:
luffing : (+) 14 to (-) 10 deg.
- Two pumps, two electric motors with dual line system are provided to ensure that in the
event of one of the drive unit failing, full operation can be maintained without interruption.
- The acceleration and deceleration of raising and lowering of the boom is to be smooth and
operation is done without giving any jerk to the boom. Suitable fail safe solenoid operated
valves are provided for hydraulic cylinders.
2.3.2.3 Specifications/ Technical Parameters

1. Type Rail mounted, self-propelled twin boom, luffing type

2. Nos. 03

3. Capacity, tph Rated : 1500

Design : 1800
4. Boom length, m To suit the stock-pile width of 30 m

5. Track centres 7.0 m, Rail size 60 kg/m

6. Duty Continuous, 20 hrs/day, 350 days a year

7. Length of travel 350 m

8. Travel speed (VVVF drives) Forward 20 m/min

Reverse 30 m/min
9. Hoisting speed/ Luffing range (w.r.t 2 m/min (approx.) to suit the stock-pile width/length
discharge pulley)

10. Cross section of the stock file Triangular

11. Bottom width of stock pile 30 m

12. Height of stock pile w.r.t to rail level 10.5 m

13. Length of stock pile 350 m

14. Material to be handled Iron Ore, Iron Ore fines, Limestone, Quartzite,
Dolomite etc.
15. The height of the boom end is automatically adjusted to limit the height of the free of the
discharge materials. The boom hoist is automatically get so adjusted that the height of free
fail does not exceed 2 m and not less than 1 m.

16. The working inclination of the stacker boom conveyor w.r.t horizontal is within -12 degrees
to +14 degrees. However, it’s designed so that boom may be lowered to touch the ground or
raised up to +20 degree.

17. Tripper conveyor shall have a maximum inclination of 12 degrees. Suitable hold down pulley
is provided on the tripper car to prevent belt uplifting during starting of yard conveyor.

18. Two nos. of electric hoists of min 3 T capacity are provided in E-House.
 19. The bulk density to be considered for Structural Design and that for power calculation is 2.2
T/cub. m. It is only for volumetric capacity calculation that the Bulk Density is to be
considered 2.0 T/cub. m.

20. RCC jacking pads are provided near tail end of all Reclaiming conveyor and Drive end of all
stacking conveyors.

21. Min 2 nos. multi blade torsion arm type/ sprung blade type external (pre scraper & main
scraper) and one no. diagonal type internal scraper to be provided on boom conveyor. Pre
scraper and main scraper to be provided for tripper conveyor also.

(SAIL, Bhilai Steel Plant, 2010)

2.3.3 Technical Specification of Bucket Wheel Reclaimer

2.3.3.1 Scope of Work

The scope of work includes the design, engineering, assembly, manufacture, shop testing, supply,
dismantling, packing and loading at site, erection, testing and commissioning of the following items
at plant site.

2.3.3.2 Technical Specifications of Bucket Wheel Reclaimer

1. Bucket Wheel Reclaimer

- Four numbers of bucket wheel reclaimer are provided for reclaiming Iron Ore lump, Iron Ore
fines, Limestone, Mn Ore and Dolomite. The reclaimer is of bucket wheel type. The material
received from the bucket wheel is discharged on the ground conveyor (through the boom
conveyors and chute) for onward supply to consumer shops. The slewing mass of the
machine is balances to contain the centre of gravity well within the slew bearing diameter.

2. Mechanical Specifications

- The design of the bogie and carriages of the equipment are such that the differential
movement of the wheel sets of the machine on two rail tracks resulting in skewing effects
does not occur. The traverse bogies are provided with material removing guard plate as well
as rail cleaners at both ends so that the machine can travel even if there’s spillage or
overflow of material on rail track and the L.T drive is selected accordingly.
- For travel motion, rotating axle management with `L’ type supports are provided.
- The reclaimer platform is supported on a turn table by a ball race slewing bearing with an
external toothed rim. The slewing drive is of hydraulic type with integral hydraulically
operated brake and proportioning valve to ensure smooth motion of the turn table during
stoppage and reversal.
- The output shaft of the hydraulic drive is equipped with a pinion, meshing with the toothed
rim of the slewing bearing.

Figure IX - Top View of Bucket Wheel Reclaimer (Design)

3. Drives

- The long travel drive mechanism is provided with multiple drives on each side. In the event
of a failure, any drive motor, the corresponding motor on the other side shall be
automatically disconnected. However, the machine will be operable with the remaining
drives.
- Double ended motors are provided in long travel drives, so that brake can be fitted to the
free end of motor to ensure better maintenance and operation.
- The equipment is supported on wheels mounted in bogies and driven by electric motors
through reduction gears. No use of chain drives and open gears.
- For long travel, individual wheel drive is provided. Min. 50% of long travel wheels is
positively driven.
- For travel motion, rotating axle drive management with `L’ type supports are provided.
- For Bucket-wheel drive, low-speed high-torque hydraulic motors are provided. B/W and
Boom conveyors drive are of reversible type. Bucket wheel drive suitable for inching
operation speed monitor is provided is B/W drive. Slewing motors suitable for reversing,
plugging control, frequent starting and mechanical braking duties bucket wheel drives are
suitable for inching operation. (SAIL, Bhilai Steel Plant, 2010)

4. Gears and Gear Boxes

- Straight and helical, spur gearing are used. All spur gears have 20 degree pressure angle with
involute teeth profile.
- First and high speed reductions are through helical gears only.
- All first reduction pinions and also other pinions, depending on feasibility are integral with
the shafts.
- Gear materials used are of hardened and tempered alloy or carbon steel with machine cut
teeth. Surface hardness is from 255 to 300 BHN and for gear it’s from 220 to 225 BHN.
Difference in hardness of pinion and gear is not more than 20 BHN.
- All gear shafts are supported in bearings mounted in gear box.
- The housing of gear boxes is of cast steel or fabricated. Fabricated gear boxes are made up
of minimum 8 mm thick steel plate and are stress relieved.

5. Luffing and Slewing Hydraulic System

- Hydraulic luffing and slewing of the boom is provided for reclaimer with following respective
ranges

Luffing : (+) 7 to (-) 12 degrees.

 Slewing : 220 degree (110 degree on either side of the track)

Slewing speed is from 0.09 – 0.2 rpm (Stepless)

- Two pumps, two electric motors with dual line system are provided to ensure that in the
event of one of the drive unit failing, full operation can be maintained without interruption.
- The acceleration and deceleration of raising and lowering of the boom is to be smooth and
operation is done without giving any jerk to the boom
- The hydraulic circuit is so designed to minimise the surge pressure. Suitable accumulators of
adequate size are used to withstand maximum rate of surge pressure as well as the back
surge pressure.
- Pump and pump motor are designed to operate under load conditions at a minimum 125%
of the system operating pressure and give a flow rate of 125% of system operating flow rate.
- Lockable type of valve is provided to avoid tampering.
 Figure X - output shaft of the hydraulic drive is equipped with a pinion, meshing with the toothed rim of the slewing
bearing
2.3.3.3 Technical Parameters of Bucket Wheel Reclaimer

1. Type Rail mounted, self-propelled boom type luffable,

slewable bucket wheel reclaimer mounted on
rail
2. Nos. Four
3. Capacity, tph Rated : 1500 t/h
Design : 1800 t/h
4. Boom length, m To suit the stockpile of given cross section
5. Track centres 7.5 m, rail size 60 kg/m
6. Track rail size To suit equipment kg/m
7. Duty Continuous, 20 hrs/day
8. Length of travel Approx. 400.0 m
9. Travel Speed 5-20 m/min, VVVF controlled
10. Slew Speed/ Range 0.09 to 0.2 rpm (approx.) , VVF controlled, 110
degree on either side
11. Luffing Mechanism
a) Speed 5 m/min at centre of bucket
b) Range +7.0 ͦ to (-) 12 ͦ
12. Stockpile Cross section of Triangular trapezoidal
13. Bottom width of stock pile 30.0 m
14. a) Height of stock pile w.r.t to rail level 10.5 m
b) Length of stock pile 350 m
Bibliography

SAIL. (2015, August). ​Facilities of Bhilai Steel Plant.​ Retrieved 2015, from Steel AUthority Of India:
http://www.sail.co.in/bhilai-steel-plant/facilities

SAIL, Bhilai Steel Plant. (2010). ​Augmentation of raw materials & handling facilities with new OHP,
Part-B (Package-061) of Bhilai Steel Plant.​ New Delhi: M/s Engineering Projects (India) Limited.