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Report on RINL - Visakhapatnam Steel Plant

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RASHTRIYA ISPAT NIGAM LIMITED –
VISAKHAPATNAM STEEL PLANT
PROJECT REPORT
Dissertation Report Submitted in fulfillment for ...
GRADUATE APPRENTICESHIP TRAINING
Under National Apprenticeship Training Scheme (NATS)
Instituted by Board of Apprenticeshi...
GRADUATE APPRENTICESHIP TRAINING
Under National Apprenticeship Training Scheme (NATS)
Instituted by Board of Apprenticeshi...
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Report on RINL - Visakhapatnam Steel Plant

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Rashtriya Ispat Nigam Limited,
RINL - Visakhapatnam Steel Plant, Vizag Steel Plant,
Report File For Raw Material Handling Plant Department and All Service and Production Departments Details are entered in this Report File.

Rashtriya Ispat Nigam Limited,
RINL - Visakhapatnam Steel Plant, Vizag Steel Plant,
Report File For Raw Material Handling Plant Department and All Service and Production Departments Details are entered in this Report File.

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Report on RINL - Visakhapatnam Steel Plant

  1. 1. RASHTRIYA ISPAT NIGAM LIMITED – VISAKHAPATNAM STEEL PLANT PROJECT REPORT Dissertation Report Submitted in fulfillment for the award of Certificate of Graduate Apprenticeship Training in Mechanical Engineering from RINL - VSP Submitted To: Department of RAW MATERIAL HANDLING PLANT (RMHP), RINL - VSP Submitted By: Md Anzar Aman 012656 Under the Guidance of D . J . R SRINIVAS General Manager (Mech.) Department of Raw Material Handling Plant (RMHP) GRADUATE APPRENTICESHIP TRAINING Under National Apprenticeship Training Scheme (NATS) Instituted by Board of Apprenticeship Training / Practical Training Ministry of Education, Government of India. Session: 2022 - 2023
  2. 2. GRADUATE APPRENTICESHIP TRAINING Under National Apprenticeship Training Scheme (NATS) Instituted by Board of Apprenticeship Training / Practical Training Ministry of Education, Government of India DEPARTMENT OF RAW MATERIAL HANDLING PLANT CERTIFICATE This is to certify that the work embodied in this Project, Dissertation Report entitled as “Detailed Report on Raw Material Handling Plant (RMHP), RINL – VSP” being Submitted by Md Anzar Aman [Trainee No. : 012656] in complete fulfillment of the requirement for the award of “Graduate Apprenticeship Training” in Mechanical Engineering discipline to Rashtriya Ispat Nigam Limited – Visakhapatnam Steel Plant, Visakhapatnam (A.P.) during the year 2022 -2023 is a record of bonafide piece of work, carried out under my supervision and guidance in the Department of Mechanical Engineering, Raw Material Handling Plant, RINL – VSP. Approved by Mr. D. Mallikarjuna Rao Mr. D.J.R Srinivas Dy. Manager (Mech.) General Manager (Mech.) RMHP, RINL - VSP RMHP, RINL - VSP Mr. A.K Dhawan Head of Department RMHP, RINL - VSP
  3. 3. GRADUATE APPRENTICESHIP TRAINING Under National Apprenticeship Training Scheme (NATS) Instituted by Board of Apprenticeship Training / Practical Training Ministry of Education, Government of India DEPARTMENT OF RAW MATERIAL HANDLING PLANT CERTIFICATE OF APPROVAL This dissertation entitled “Detailed Report on Raw Material Handling Plant (RMHP), RINL – VSP” being submitted by Md Anzar Aman [Trainee No. : 012656] has been examined by us & hereby approve for the complete fulfilment of the requirement for the award of “Graduate Apprenticeship Training”, in Mechanical Engineering discipline to Rashtriya Ispat Nigam Limited – Visakhapatnam Steel Plant, Visakhapatnam (A.P.), for which it has been submitted. It is understood that by this approval the undersigned do not necessarily endorse or approve any statement made, opinion expresses or conclusion draw there in, but the dissertation only for the purpose for which it has been submitted. DEPARTMENT AUTHORIZATION Date:
  4. 4. GRADUATE APPRENTICESHIP TRAINING Under National Apprenticeship Training Scheme (NATS) Instituted by Board of Apprenticeship Training / Practical Training Ministry of Education, Government of India DEPARTMENT OF RAW MATERIAL HANDLING PLANT CANDIDATE DECLARATION I hereby declare that the Project dissertation work presented in the report entitled as “Detailed Report on Raw Material Handling Plant (RMHP), RINL – VSP” submitted in the complete fulfillment of the requirements for the award of “Graduate Apprenticeship Training”, in Mechanical Engineering discipline to Rashtriya Ispat Nigam Limited – Visakhapatnam Steel Plant, Visakhapatnam (A.P.), is an authentic record of our own work. I have not submitted the completion of this report for the award of any other Training Scheme. Trainee Name Trainee No. Md Anzar Aman 012656 Date: This is to certify that the above statement made by the candidates is correct to the best of my knowledge. Mr. D.J.R Srinivas General Manager (Mech.) RMHP, RINL - VSP
  5. 5. ACKNOWLEDGMENT I am heartily thankful to the Management of Rashtriya Ispat Nigam Limited – Visakhapatnam Steel Plant for providing me all the facilities and infrastructure to take up my Apprenticeship Training to the final stage. It is the constant supervision, moral support and proper guidance of our respected H.O.D Mr. A.K Dhawan, RMHP Department, RINL – VSP, who motivated me throughout my Apprenticeship Training Program. I am also very thankful to Mr. D.J.R Srinivas, Deputy General Manager, RMHP Department, RINL - VSP, for his constant support & motivation. I express deep sense of gratitude & respect to my learned Trainer Mr. D. Mallikarjuna Rao, Deputy Manager in RMHP Department of Mechanical Engineering, during all phases of my Training. Without his enthusiasm and encouragement this dissertation would not have been completed. His valuable knowledge and innovative ideas helped me to take the Training to the final stage. He has timely suggested actions and procedures to follow for which i am really grateful and thankful to him. I am thankful to all the RMHP Employees and other Non Technical staffs of Mechanical Engineering, RMHP Department for their cooperation. Constant help, moral and technical support of our RMHP Department each and every employees, who motivated us to complete the work. I express my heartily thanks to all of them for their co-operation.I really admire the fond support of our L&DC Team for their co-operation and constant help. It gives immense pleasure to acknowledge the encouragement and support extended by them. Last but not the least i am extremely thankful to all who have directly or indirectly helped me for the completion of my Apprenticeship Training Program. Md Anzar Aman 012656
  6. 6. TABLE OF CONTENTS S.NO TITLE PAGE NO. COVER PAGE 1 CERTIFICATE 2 CERTIFICATE OF APPROVAL 3 CANDIDATE DECLARATION 4 ACKNOWLEDGEMENT 5 TABLE OF CONTENTS 6 – 11 LAYOUT OF RINL – VSP 12 INTRODUCTION OF RINL – VSP  Overview  The Journey of RINL  Vision  Major Sources of Raw Materials  Major Units  Main Products of VSP  Core Values  Genesis, Inception & Formation of Steel Plant  Mission  Objectives 13 – 15  PRODUCTION DEPARTMENT 1. 1.1  RAW MATERIAL HANDLING PLANT Overview The RMHP in any Organisation is needed 16 – 17 2. 2.1 2.2 2.3 2.4  COKE OVEN & COAL CHEMICAL PLANT Overview Facilities Salient Features Capacity Commissioning Dates 18 – 20 3. 3.1 3.2 3.3 3.4 3.5  SINTER PLANT Overview  Sinter Plant – 3 New Technology Facilities Salient Features Capacity Commissioning Dates 21 – 23 4. 4.1 4.2 4.3 4.4 4.5 4.6  BLAST FURNACE Overview  Blast Furnace – 3 Record Performance of Blast Furnace Department New Technology Features Salient Features Capacity Commissioning Dates 24 – 26
  7. 7. 5. 5.1 5.2 5.3 5.4 5.5 5.6  STEEL MELT SHOP & CONTINUOUS CASTING Overview  Steel Melt Shop – 2  Continuous Casting Department New Technology Facilities Characteristics of VSP Convertors Salient Features Capacity Commissioning Dates 27 – 29 6. 6.1 6.2 6.3 6.4  LIGHT & MEDIUM MERCHANT MILL Overview Facilities Salient Features Capacity Commissioning Dates 30 – 31 7. 7.1 7.2 7.3 7.4 7.5  WIRE ROD MILL Overview Facilities Salient Features Capacity Product Mix Commissioning Dates 32 – 33 8. 8.1 8.2 8.3 8.4  MEDIUM MERCHANT & STRUCTURAL MILL Overview Facilities Salient Features Capacity Commissioning Dates 34 – 34 9. 9.1 9.2 9.3 9.4 9.5  SPECIAL BAR MILL Overview Facilities Salient Features Capacity Product Mix Commissioning Dates 35 – 36 10. 10.1 10.2 10.3 10.4 10.5 10.6  STRUCTURAL MILL Overview Facilities Salient Features Capacity Starting Material Product Mix Commissioning Dates 37 – 38 11.  SERVICE DEPARTMENTS 39 – 52 1. Mines a) Madharam Dolomite Mine (MDM) b) Jaggayyapeta Limestone Mine (JLM) c) Garbham Manganese Mine (GMM) d) Saripalli Sand Mine (SSM)
  8. 8. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. Calcining & Refractory Material Plant (CRMP) Central Machine Electrical (CME) Civil Engineering Department (CED) Distribution Network Department Electrical Repair Shop (ERS) Electro Technical Laboratory Energy Management Department Engineering Shops & Foundary (ES & F) a) Central Machine Shop (CMS) b) Structural Steel Shop (SSS) c) Foundary d) Forge Shop e) Utility Equipment Repair Shop (UERS) Environment Management Department (EMD) Field Machinery Department (FMD) Information Technology (IT) M & CR Plant Design Production, Planning & Monitoring Department Quality Assurance & Technological Development (QA & TD) Research and Development (R & D) Refractory Engineering Department Roll Shop and Repair Shop (RS & RS) Safety Engineering Department (SED) Spares Management Department (SMD) Structural Engineering Department (St. ED) Thermal Power Plant (TPP) Traffic Department Technical Improvement Cell TQM – ISO Cell Utilities Department Works Contract Department Water Management Department Budget Plan & Control Systems and Procedures Personnel Department Legal Affairs (LA) Management Services (MS) Training and HRD Town Administration and Administration (TA) Medical and Health Services (M & HS) Marketing Department Material Management Department Finance and Accounts Department Corporate Strategic Management
  9. 9. 42. 43. 44. 45. 46. Design and Engineering Department (D & E) Construction Department Contracts Department Project Monitoring Department Vigilance Department 12. DETAILED REPORT ON RAW MATERIAL HANDLING PLANT 53 – 124 1. RAW MATERIAL HANDLING PLANT 53 – 57 1.1 1.2 1.3 1.4 1.5 1.6 The RMHP in any Organisation is needed Raw Materials Flow Chart Layout of Storage Yard Augmentation of Iron Ore Storage Function of RMHP Section of RMHP 2. ORE HANDLING PLANT 58 – 62 2.1 2.2 2.3 2.4 2.5 Raw Materials – O.H.P Materials Handling – O.H.P Materials dispatch to O.H.P Customers Expansion of O.H.P Details of Equipments of O.H.P 3. WAGON TIPPLER 63 – 73 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 Description of Wagon Tippler Arrangement Operational Description Brief Items of Rotary Wagon Tippler Purpose & Technical Parameter of Rotary Wagon Tippler Electric Wagon Pusher Car Types of Wagon Tippler Types of Wagon Design Layout of Tippler Hydraulic Ore Tippler – 4 Why Hydraulics ? 4. ORE STOCK YARD 73 – 76 4.1 Machining Equipments used in Ore Yard a) Twin Boom Stacker b) Wheel on Boom Reclaimer c) Blender Reclaimer 5. LUMP ORE CRUSHING PLANT (LOCP) 76 – 77 5.1 5.2 5.3 Crushing & Screening Crushing & Screening Process Layout Crusher Operation 6. IRON ORE SEPARATION AUGMENTATION (IOSA) 78 – 86 6.1 Process for separation of Iron Ore 7. PLANNING 87 – 88 7.1 7.2 7.3 Operational Planning Department Electrical Planning Department Mechanical Planning Department
  10. 10. 8. INDENT 88 – 90 8.1 8.2 8.3 8.4 8.5 Purchase Indent for following Department Indents from Works Division Budget Approval Indent Raising Purchase Action on Receiving Indent 9. STORES 90 – 92 9.1 9.2 9.3 9.4 Functions of Stores Codification Objectives of Codification Advantages of Codification 10. AREA SHOP OFFICE (ARS) OF RMHP 92 – 94 11. COAL HANDLING PLANT (C.H.P) 95 – 99 11.1 11.2 11.3 11.4 Raw Material C.H.P Materials dispatch to C.H.P Customer Expansion of C.H.P Details of Equipments of C.H.P 12. COAL STOCK YARD 99 – 105 12.1 12.2 Equipments of C.H.P Machining Equipments used in Coal Stock Yard a) Swivelling Boom Stacker b) Wheel on Boom Reclaimer c) Stacker cum Reclaimer 13. RING GRANULATOR (RG) 105 – 109 13.1 13.2 13.3 13.4 Crushing Principle of Ring Granulator Type Coal Crusher Ring Granulator type Coal Crusher consists of following parts Work involved during prevention maintenance of Ring Granulator type Coal Crusher Boiler Coal Crushing & Screening 14. GANGAVARAM PORT LIMITED (GPL) 109 – 124 14.1 14.2 14.3 14.4 14.5 14.6 14.7 GPL Conveyors Ore Conveyors Specification Conveyor Component Specification Conveyor Protective Devices GEARS a) Gear Terminology b) Types of Gears c) Advantages of Gears d) Disadvantages of Gears GEARBOX a) How a Gearbox works ? b) Gearbox : Speed Vs Traction c) Types of Gearboxes d) Industrial Gearboxes & It’s Uses FLUID COUPLING a) Main Parts 114 – 121 121 – 123 123 – 124
  11. 11. b) Fluid Coupling Working Principle c) Types of Fluid Coupling d) Advantages of Fluid Coupling e) Disadvantages of Fluid Coupling CONCLUSION 125
  12. 12.  LAYOUT OF RINL - VSP
  13. 13. INTRODUCTION OF RINL - VSP  OVERVIEW Rashtriya Ispat Nigam Limited, the corporate entity of Visakhapatnam Steel Plant is a Navaratna PSE under the Ministry of Steel. Visakhapatnam Steel Plant fondly called Vizag steel. It is the first shore based Integrated Steel Plant in the country and is known for its quality products delighting the customers. It is a market leader in long products and it caters to the needs of diverse Industrial sectors. It is the first Steel plant to be certified ISO 9001:2008 (presently2015), ISO 14001:2004 (presently2015), OHSAS 18001:2007 and ISO/IEC 27001:2013 Standards. It is also the first PSE to be certified ISO 50001:2011 - Energy Management Systems and has acquired CMMI Level 3 Certification for s/w development.  THE JOURNEY OF RINL  Formative Years Relentless crusade by Shri Tenneti Vishwanadhan led to setting up of Vizag Steel Plant. The site was formally inaugurated by the then PM Late. Mrs. Indira Gandhi, on 20th January 1971.  Marched towards glory with Soviet help Detailed project report for 3.4 MT of liquid steel was preparedby M.N. Dastur Company and GIPROMEZ of USSR (1985 – 1987).  Maiden marl on the map of Indian Steel Market First Casting of Hot metal into Pig Iron in 1989 – 90; Push cars made operational; BF erection in progress, 1982 – 1983.  Construction Site First concrete pouring for expansion in 2006; Captive mines made operational.  VISION To be the most efficient Steel Maker having the largest single location shore based steel plant in the country.  MAJOR SOURCES OF RAW MATERIALS S.No RAW MATERIALS SOURCES 1. Iron Ore Lumps & Fines Bailadila, Chattisgarh
  14. 14. 2. BF Lime Stone Jaggayyapeta, AP 3. SMS Lime Stone Dubai SMS Lime Stone Dubai 4. BF Dolomite Madharam, AP BF Dolomite Madharam, AP 5. SMS Dolomite Madharam, AP SMS Dolomite Madharam, AP 6. Manganese Ore Chipurupalli, AP Manganese Ore Chipurupalli, AP 7. Boiler Coal Talcher, Orissa Boiler Coal Talcher, Orissa 8. Imported Boiler Coal Indonesia Imported Boiler Coal Indonesia 9. Imported Coking Coal Australia / US Imported Coking Coal Australia / US 10. Medium Coking Coal (MCC) Kathara / Swang / Rajarappa / Kedla 11. Imported LAM Coke China Imported LAM Coke China 12. Quartzite Lump & Fines Local Quartzite Lump & Fines Local 13. Sand Sarepalli, AP Sand Sarepalli, AP  MAJOR UNITS DEPARTMENT ANNUAL CAPACITY UNITS (3.0 MT STAGE) Coke Ovens 2,701 4 Batteries of 67 Ovens & 7 Mtrs. Height Sinter Plant 5,256 2 Sinter Machines of 312 Sq. Mtr. grate area each Blast Furnace 3,400 2 Furnaces of 3200 Cu. Mtr. Volume each Steel Melt Shop 3,000 3 LD Converters each of 133 Cu. Mtr. Volume and Six 4 strand bloom casters LMMM 710 2 Strand finishing Mill WRM 850 4 Strand high speed continuous mill with no twist finishing blocks MMSM 850 6 STAND FINISHING MILL  MAIN PRODUCTS OF VSP STEEL PRODUCTS BY – PRODUCTS Blooms Nut Coke Granulated Slag Billets Coke Dust Lime Fines Channels, Angles Coal Tar Ammonium Sulphate Beams Anthracene Oil Squares HP Naphthalene
  15. 15. Flats Benzene Rounds Toluene Re-bars Zylene Wire Rods Wash Oil  CORE VALUES  INITIATIVE : Have a self – propelled & proactive approach.  DECISIVENESS : Decide with speed & clarity.  ETHICS : Be consistent with professional & moral values  ACCOUNTABILITY : Take responsibility for actions.  LEADERSHIP : Lead by example  SPEED : Demonstrate swiftness and efficiency in everything we do  MISSION To attain 20 million ton liquid steel capacity through technological up-gradation, operational efficiency and expansion; to produce steel at international standards of cost and quality and to meet the aspiration of the stake holders.  OBJECTIVES  Achieve Gross Margin to Turnover ratio > 10%.  Plan for finishing mill to integrate with 7.3 MT capacity and commission the same by 2017- 18.  Achieve rated capacity of new & revamped units by 2017-18.  Capture markets for high – end value added products by focusing on sector specific applications and customer needs.  Globalisation of operations through acquisition of mines and setting up of marketing network abroad. I D E A L S.  Diversify through operationalizing of Bhilwara Mines, setting up of Pelletization Plant, DRI- EAF unit, Wheel & Axle Plants.  Create high performance and safe work culture by nurturing talent and developing leaders.  To grow in harmony with the environment & communities around us. I D E A S S L
  16. 16. P. Dept. – 1 RAW MATERIAL HANDLING PLANT (RMHP) 1. OVERVIEW Visakhapatnam Steel Plant is one of the most modern steel plant not only in the country but also in the world. This has latest raw materials stacking and blending system. RMHP has the concept of peripheral unloading which considerably reduces delay in taking over and handing over of rakes bringing raw materials to the plant, there by increasing the availability of wagons. The Raw Material Handling Plant is handling more than 24 million tons of various raw materials for 6.3 MTA Raw Material Handling plant is meant for transporting materials from Raw Material yard / Base mix yard to various units of the plant. The Major Raw materials required for Iron and Steel making are Iron ore lump, Iron Ore fines, Sized iron ore, Flux limestone / dolomite, manganese, Quartzite coking coal ( for Boiler operation & For Pulverized coal injection ) and coke. Lump iron ores, iron ore fines and flux such as limestone and dolomite received by railway rake are unloaded in wagon tippler and stored yard with the help of various stockyard machines. Fig. 1.1 Overview of RMHP Iron ore lump, flux such as limestone and dolomite, Coke is reclaimed by suitable stock yard machine and are crushed in Ore crushing plant, Flux crushing plant and coke crushing plant respectively to produce the size required. The above material is proportionately stacked by suitable stacking machine in base mix yard and blended while reclaiming by blender reclaimer. The prepared base mix is then transported to Sinter plant for sinter production. For feeding material to new Blast Furnace, sized ore and flux are reclaimed by stock yard machine from respective yard and are transported by
  17. 17. conveyor. Sinter produced in sinter plant and coke from existing/new coke ovens is transported directly to BF-3 stock house by conveyor. Purchased coke and necessary calcined lime from stock yard and new lime calcining plant respectively are transported to SMS by conveyor. The waste product from the plant is mainly dust and method of their disposal is through dust suppression system and inter plant transportation. 1.1 The Raw Material Handling Plant in any organization is needed : a) To have adequate storage capacity to store various raw materials depending up on the capacity of the beds in the stock yard. b) To blend raw materials, if needed, received from various sources, in order to supply homogeneous raw materials. c) To ensure methodical stacking and reclaiming of raw materials without mixing up of different raw materials. d) To process the raw materials and bring down the size to the size as required by the customer departments to improve their productivity and product quality.
  18. 18. P. Dept. – 2 COKE OVEN & COAL CHEMICAL PLANT 2. OVERVIEW Coal is converted into coke by heating the prepared coal blend charge in the coke ovens in the absence of air at a temperature of 1000o C-1050o C for a period of 16/19 hours. 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 800o C to 80o C is drawn to Coal Chemical 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. The main by-product in the process of coke making is crude coke oven gas and this has a lot of valuable chemicals. Coal Chemical Plant recovers Ammonia (NH3), Tar and Benzol from CO-Gas. The primary by-products from Crude CO Gas are Ammonium Sulphate (NH4)2SO4, Crude Tar, Crude Benzol and cleaned coke oven gas. The cooled coke from CDCP (Coke Dry Cooling Plant) is separated into 3 fractions, BF Coke i.e. +25-70 mm, which is sent to Blast Furnaces, Coke Breeze i.e. +0-15 mm, which is sent to Sinter making and nut coke i.e., +15-25 mm, which is also used in the Blast Furnaces. Fig. 2.1 Overview of Coke Oven 2.1 FACILITIES  There are 5 batteries, each having 67 ovens.  The volumetric capacity of each oven is 41.6 cubic metre.  Dry Coal charge / Oven is 32 tons
  19. 19. 2.2 SALIENT FEATURES  Largest and technologically unique Coke Oven Batteries in the country at the time of commissioning  7 meter tall coke ovens batteries.  100 % Dry Quenching of coke using Nitrogen gas.  Power generation, from the waste heat recovered, at BPTS (Back Pressure Turbine Station). 2.3 CAPACITY  Production capacity (for 5 Batteries) – 3.700Mt of BF coke per annum 2.4 COMMISSIONING DATES  Battery No. 1 – 1st Pushing – 06.09.1989  Battery No. 2 – 1st Pushing – 31.10.1991.  Battery No. 3 – 1st Pushing – 30.07.1992  Battery No. 4 – 1st Pushing – 12.04.2009  Battery No. 5 – 1st Pushing – 22.12.2020
  20. 20. Fig. 2.2 Overview of Coal Chemical Plant
  21. 21. P. Dept. – 3 SINTER PLANT 3. OVERVIEW Sintering is an agglomeration process of fine mineral particles into a porous mass by incipient fusion caused by heat produced by combustion within the mass itself. Iron ore fines, coke breeze, limestone and dolomite along with recycled metallurgical wastes are converted into agglomerated mass at the Sinter Plant, which forms 70-80% of iron bearing charge in the Blast Furnace. The vertical speed of sintering depends on the suction that is created under the grate. At VSP, two exhausters are provided for each machine to create a suction of 1500-1600 mm water column under the grate. Fig. 3.1 Overview of Sinter Plant  SINTER PLANT – 3 For meeting the requirement of new Blast Furnace-3 to produce 2.5 Mtpa Hot metal, One number of Sinter machine of 400 sq.m is envisaged. The Raw materials required to produce Product sinter are Base mix consisting of 100% iron bearing material including revert material including revert materials, flux, coke, floating return fines and calcined lime which is fed into Blast Furnace-3. Considering 80% sinter ratio in the burden of new Blast Furnace, the requirement of Sinter charge will be 3.25 Mtpa for production of 2.5 Mtpa Hot metal. Hence, new sinter will receive Base mix which will be prepared in bedding and blending yard by mixing all iron bearing materials and about 80% of flux and fuel. Balance flux and fuel, as well as
  22. 22. calcined lime, will be added in proportioning section of Sinter plant. The facilities envisaged are Proportionating system, Mixing and Nodulizing system, Sinter Machine section, Sinter cooler section, Sinter stabilizing section and Waste gas system. Fig. 3.2 Round Sinter Plant – 3 3.1 NEW TECHNOLOGY  Circular Cooler  Multi – slit burner The benefits derived are being more energy efficient and utilization of heat recovered from Sinter cooler to pre – heat the combustion due to which energy consumption is reduced has been incorporated in the new Sinter Plant – 3. Sinter produced in Sinter Plant will be supplied to the Blast Furnace through conveyor system. 3.2 FACILITIES  Sinter Machine -1 with 378 M² grate area (after Modernization)  Sinter Machine – 2 with 312 M² grate area  Sinter Machine – 3 with 408 M² grate area 3.3 SALIENT FEATURES
  23. 23.  Base mix (homogeneous mixture of all raw materials) blending yard with six beds each of 1,10,000 tons storage capacity. a) M/C – 1&2  Sinter Machine – 1 (after modernization) is provided with Chamber type Ignition Furnace with roof mounted energy efficient burners. Machine – 2 is provided with an ignition furnace of horizontal burners.  Sinter Bed Height 650 mm for M/C – 1 (after Modernization) & 500 mm for M/C – 2.  Straight Line Sinter Cooler.  Sinter Heat Recovery Power Plant (SHRPP) with a capacity of 20.6 MW electrical power generation by utilizing waste heat recovered from Sinter Coolers of Machine 1 &2 b) M/C – 3  Bed Height 700 mm.  Chamber type Ignition Furnace with roof mounted energy efficient burners.  27 m long extended hood with hot air supply through 4 feed points.  Circular Sinter cooler with waste heat recovery system.  Lime addition at Mixing and Nodulizing Section of Sinter Machine building. 3.4 CAPACITY a) Production Capacity :  Sinter Machine – 1 : 3.640 MT of Gross Sinter per annum (after Modernization)  Sinter Machine – 2 : 2.85 MT of Gross Sinter per annum.  Sinter Machine – 3 : 3.611MT of Gross Sinter per annum. 3.5 COMMISSIONING DATES  Base mix preparation from RMB ( Raw Materials Bin) - 03.11.1989  Machine – 1 commissioned (3.0 Mt stage) - 14.11.1989  Machine – 1 Hot trials for commissioning (after modernization) - 08.08.2017  Machine – 2 commissioned - 27.12.1991  Machine – 3 Integrated trial run for commissioning - 04.07.2013
  24. 24. P. Dept. - 4 BLAST FURNACE 4. OVERVIEW Iron is produced in the Blast Furnace by smelting iron bearing materials with the help of coke and air. The solid charge materials like sinter, sized iron ore, coke etc. are charged in the vertical shaft of the Blast Furnace from top and hot air blast is blown through tuyeres located at the bottom. The oxygen present in hot air combines with the carbon of coke and generates heat and carbon monoxide (reducing agent). The reducing gases, while ascending upwards comes into contact with the descending charge materials. Eventually the charge gets reduced and hot metal, slag and BF gas are produced. Hot metal and slag is tapped from tap hole. The Blast Furnace gas which comes out from top of the furnace is cleaned and used as fuel in the plant. Fig. 4.1 Overview of Blast Furnace  BLAST FURNACE – 3 To achieve the desired hot metal production of 6.5 Mtpa, additional one number of BF is installed with a capacity of 3800 Cu.M producing 2.5 Mtpa . The Raw materials required for manufacturing process are Sinter, Sized ore, Quartizite, Coke and Injection coal. Raw materials and coke from stock yard are transported to the stock house bunkers through junction houses. The main charging conveyor feeds the burden into the Blast Furnace. Hot stoves deliver the hot blast into the Blast Furnace via bustle main and tuyeres. Pulverized coal from coal grinding plant to coal distributor which distributes the coal into individual tuyeres. Inside Blast Furnace, the iron ore is reduced to form iron and slag, which collects at the hearth. From there, Hot metal and slag is periodically tapped through tap holes. Hot metal is channeled via tilting runners into torpedo ladle cars, which carries it away. Slag is granulated in the slag granulation plant, dewatered and subsequently carried away by a conveyor to slag storage yard. The Blast Furnace top gases
  25. 25. enter into the dust catcher for primary cleaning and then to annular scrubber for final cleaning. The facilities envisaged are Stock house and Charging system, Cooling elements and system, Cast House, Gas cleaning Plant. Hot Blast stoves, Pulverized Coal Injection system, Slag Granulation and Stock House. 4.1 RECORD PERFORMANCE OF BLAST FURNACE DEPARTMENT :  TECHNO – ECONOMICS : Productivity 2.23 t/m³/day Feb ‘06 Power 51.31 kwh/thm Feb ‘06 Fuel Rate 509 kg/thm Jan ‘04 Heat Constant 450 Mcal/thm Apr ‘05 Nut Coke usage 56 kg/thm Mar ‘04  PRODUCTION  DAY PEAKS Blast Furnace – 1 6820 Tons 23.03.06 Blast Furnace – 2 6805 Tons 21.03.06 Shop 13325 Tons 10.02.06 PCM Pouring 6723 Tons 31.03.93  MONTHLY PEAKS Hot Metal 374419 Tons Mar ‘06 PCM Pouring 107463 Tons Mar ‘93 Pig Iron Dispatch 110387 Tons Mar ‘94 G. Slag Dispatch 150942 Tons May ‘02 4.2 NEW TECHNOLOGY  Pulverized Coal Injection  Copper staves in high heat zones  Hearth bottom cooling with water The benefits derived are reduced coke consumption, improved productivity, improved process control & better campaign life. The hot metal produced (7150 tons/day) at a temperature of 1500 degrees temp is transported to Steel melt Shop by Torpedo Car. 4.3 FEATURES  Three Blast Furnaces of 3800 m³ useful volume each. 4.4 SALIENT FEATURES a) BF – 1&2  New generation Paul – Wurth “Bell-Less” Top with conveyor charging  BF Cooling element (Cast Iron Staves & Copper Staves)  High heat zone copper staves
  26. 26.  Double compensator tuyeres, with PCI injection facility and extended tuyere platform.  Circular type flat cast house with full castable runner system  Hydraulic Drilling Machine, Mud Gun, Manipulators.  Silence to bin pressure relief.  New scrubber with annular gap element for better gas cleaning.  HMI based control room.  Equipped with above burden temperature Probes.  Automation with PLC in BF -1 and PCS in BF – 2.  Pulverized Coal Injection system b) BF – 3  New Generation Parallel Hopper Bell Less Top  BF Cooling elements (Cast Iron Staves & Copper Staves)  Flat Cast house Equipment (by TMT).  INBA Slag Granulation system  Annular Gap Scrubber  Pulverized Coal Injection system  Hot Stoves (internal combustion chamber)  Automation with DCS 4.5 CAPACITY  Production Capacity – 7.5 MT per Annum for shop – 2.5 MT per Annum for BF – 1, 2 & 3 each 4.6 COMMISSIONING DATES  Furnace – 1 – 1st campaign since 28.03.1990 / 2nd campaign since 30.07.2014  Furnace – 2 – 1st campaign since 21.03.1992 / 2nd campaign since 21.10.2017  Furnace – 3 – 1st campaign since 24.04.2012
  27. 27. P. Dept. - 5 STEEL MELT SHOP & CONTINUOUS CASTING 5. OVERVIEW Steel is made in steel melting shop in the refractory lined vessels called LD Converters by blowing oxygen through the hot metal bath. While iron making is a reduction process, steel making is an oxidation process. The oxygen reacts with impurities like carbon, silicon, phosphorous, Sulphur, etc. present in hot metal to produce steel. No external fuel is required as the silicon & carbon releases huge amount of heat energy. Also the carbon reaction releases large quantities of gas rich in carbon monoxide along with huge amount of dust. The gases released from the converter are collected, cooled, cleaned and recovered for use as fuel in the steel plant. The entire molten steel at VSP is continuously cast at the radial type continuous casting machines resulting in significant energy conservation and better quality steel. 100% Continuous casting on such a large scale has been conceived for the first time in India. Fig. 5.1 Overview of Steel Melt Shop & Continuous Casting  STEEL MELT SHOP – 2
  28. 28. Steel making capacity of the plant is correspondingly increased by utilizing higher availability of Hot Metal. The Raw materials required for manufacturing process are - Hot Metal, Scrap, Flux, Ferro alloys. New Steel melt shop comprises of two converters each of 150 cu.m capacity. Two Numbers of Laddle Furnaces were envisaged to make the operation of the two converters independent of the requirements of continuous casting machines thereby acting as buffer between the converter and the caster. The steel temperature and steel chemistry will be homogenized in LF by inert gases and One number of RH degassing system is envisaged for production of special grade with low gas content. There are three numbers of six strand billet mill. Three casters are available for 200 days in a year and two casters are available for 165 days in a year. Cast Billets will be fed to new Special Bar Mill and Wire Rod Mill. A part of rolled billets will also be for sale. The other major facilities installed are Hot Metal Desulphurization Plant, Scrap Handling system, BOF Gas cleaning Plant, Secondary Emission control, Ferro-alloy handling facilities and Ladle & tundish preparation facilities.  CONTINUOUS CASTING DEPARTMENT VSP has six-4 strand continuous casting machines capable of producing 2.82 million Tones / year. Blooms of size 250 x 250 mm and 250 x 320 mm. Entire quantity of molten steel produced (100%) is continuously cast in radial bloom casters which help in energy conservation as well as production of superior quality products. Facilities at continuous casting machines include a lift and Turn table for ladles, Copper mould, oscillating system tundish, Primary & Secondary Cooling arrangement to cool the steel bloom. Gas cutting machines for cutting the blooms in required lengths ( Av. 6 meters long ). 5.1 NEW TECHNOLOGY  Convertor Shop – Combined Blowing, Secondary Fume Extraction system, Contour & Bath level measurement : The benefits derived are reduced consumption of ferroalloys, better yield and quality, cleaner environment and measurement of refractory lining.  Continuous Casting Machines – Auto mould level control & 100% Billet casting : The benefits derived are reduced in break outs and energy saving.  LF & RH – Electro magnetic stirrer : The benefits derived are cleaner steel 5.2 FACILITIES a) SMS – 1 :  Three LD converters (modernized with increase in volume to 150 cum. Each along with DOG House facility).  6 nos. of 4 – Strand Continuous Bloom Casting machines. b) SMS – 2 :  Three LD Converters of 150 cum. Volume each.  1 no. of 6 – Strand Continuous Billet – cum – Round caster.  2 nos. of 6 – Strand Continuous Billet casters.  1 no. of 5 – strand Continuous Billet – cum – Round caster.  Hot Metal Desulphurization Plant (HMDP).  DOG House.  RH Degasser. 5.3 CHARACTERISTICS OF VSP CONVERTORS :
  29. 29. Capacity 150 Tones per heat blow Volume 133 Cu. Meter Convertor Sp. Volume 0.886 Meter Cube per Tone Tap to Tap Time 45 Minutes – 60 Minutes 5.4 SALIENT FEATURES  100 % Continuous casting of steel.  Converters gas cooling, cleaning and recovery systems.  Computerisation of the converter process. 5.5 CAPACITY a) Production Capacity :  SMS – 1 : Original Installed Capacity is 3.0 MT of Liquid Steel per annum & 2.82 MT of CC Blooms per annum. After Modernization of all theb3 converters, capacity is enhanced to 3.5 MT of Liquid Steel & 3.29 MT of CC Blooms per annum.  SMS – 2 : 3.8 MT of Liquid Steel per annum & 3.7 MT of CC Blooms / Rounds per annum from Converters – D , E & F. 5.6 COMMISSIONING DATES  Converter – A – 1st Heat – 06.09.1990 / 1st Heat after Modernization – 16.03.2016  Converter – B – 1st Heat – 04.03.1991 / 1st Heat after Modernization – 22.05.2017  Converter – C – 1st Heat – 25.07.1992 / 1st Heat after Modernization – 27.10.2016  Converter – D – 1st Heat – 28.03.2014.  Converter – E – 1st Heat – 30.10.2013.  Converter – F – 1st Heat – 07.11.2016.
  30. 30. P. Dept. - 6 LIGHT & MEDIUM MERCHANT MILL 6. OVERVIEW The cast blooms from continuous casting department are heated and rolled in the two high speed and fully automated rolling mills namely Light & Medium Merchant Mill (LMMM) and Medium Merchant & Structural Mill (MMSM). The billets produced in LMMM are further rolled in Bar Mill / Wire Rod Mill (WRM). The finished products include wire rods & long products like reinforcement bars, rounds, squares, flats, angles, channels, billets etc. Blooms from Continuous Casting Division are rolled into billets, some of which are sold and rest are sent to Bar Mill/WRM. The continuous two-line Bar Mill comprises of 8 Stand Double Strand roughing train, 2 nos. of 4 Stand Single Strand intermediate train & 2 nos. of 4 Stand Single Strand finishing train. 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. Fig. 6.1 Overview of Light & Medium Merchant Mill 6.1 FACILITIES a) Breakdown Mill  7 Stand Break – Down Mill.
  31. 31. b) Bar Mill  8 Stand Roughing Mill (2 Strand rolling).  2 X 4 Stand Intermediate Mill (Single Strand rolling).  2 X 4 Stand Finishing Mill ( Single Strand rolling). 6.2 SALIENT FEATURES  Evaporating cooling systems in Rolling Mill furnaces.  Computerised Rolling Mill.  Tempcore cooling process facilitating high strength with good bendability and weldability. 6.3 CAPACITY  A Mill of 0.88 MT per annum. 6.4 COMMISSIONING DATES  Billet Mill – Trial Operation – 28.09.1990.  Bar Mill – Trial Operation – 29.10.1991.
  32. 32. P. Dept. - 7 WIRE ROD MILL 7. OVERVIEW WRM – 1 : The Mill is high speed 4 strand No-Twist continuous mill designed to produce 8,50,000 Tons of wire rod coils per year. Rolled billets of 125 mm x 125 mm square cross section, length ranging from 9.8 m to 10.4 m and weighing approximately 1250 kgs are used. The mill is designed to roll steel stock of 0.9% max. carbon content. WRM – 2 : The Mill is designed to produce 6,00,000 tons per year of rounds in coil form. The Mill is designed to roll low, medium and high carbon steel, case hardening steel, cold heading quality steel, electrode steel, spring steel, bearing steel and free cutting steel. The mill shall use continuous cast billets of 150 mm X 150 mm square cross section, 12 m length and weighing 2100 kgs approximately, are used as input material. The wire rod size will be in the range of 5.5 to 20 mm (dia). Provision is kept for the mill for producing 7.7 ltpy depending on the market demand. The rolling mill will use the cast billets of size 150 x 150 mm having length of about 12 mtrs and rolled billets of size 125 x 125 x 9.7 to 10.2 mtrs. The mill will roll Low carbon (85,000 tons/ yr), Medium carbon (93,000 tons/yr), High carbon (93,000 tons/yr), Spring steel (25,000 tons/yr), Cold heading (1,34,000 tons/yr), Welding rod (85,000 tons/yr), Bearing steel (25,000 tons/yr), Free cutting steel (35,000 tons/yr) and Case hardening (25,000 tons/yr). The billet will be charged into 200 ton / hr capacity reheating furnace, one by one. The billets after getting heated upto 1200 deg C will be discharged. The billets will be rolled down in the breakdown mill and passed through pre-finishing mill. The finished product will come out of reducing and sizing mill in coil form. Fig.7.1 Overview of Wire Rod Mill The Output of size wise product mix are :  5.5 dia (mm) – 1,50,000 tons/yr.  6.0 – 7.5 dia (mm) – 2,40,000 tons/yr.  8.0 – 16 dia (mm) > 1,75,000 tons/yr.  17 – 20.64 dia (mm) – 35,000 tons/yr.
  33. 33. 7.1 FACILITIES a) WRM – 1  7 Stand Roughing Mill (4 Strand rolling).  6 Stand Intermediate Mill (4 Strand rolling).  4 X 2 Stand Pre – finishing Mill (Single Strand rolling).  4 X 10 Stand Finishing Mill (MORGAN BLOCK – Single Stand rolling). b) WRM – 2  6 – Stand Single strand Fast Roughing Mill.  2 – Strand insulated Roller Table.  6 Stand Intermediate Mill – I.  4 Stand Intermediate Mill – II.  2 X 2 pre – finishing train.  2 X 8 – Stand No – Twist blocks.  2 X 4 – Stand Reducing and Sizing Mill (RSM). 7.2 SALIENT FEATURES  Highly automated and computerized Rolling Mill.  Controlled cooling of Wire Rods, by ‘Stelmor’ process with Optimesh technology giving high strength and good ductility.  Closed loop control for laying temperature with Morgan pantented METCS (Morgan enhanced temperature control system) in WRM – 2 to enhance Metallurgical properties. 7.3 CAPACITY  WRM – 1 : 1.050 MT per annum.  WRM – 2 : 0.60 MTT per annum 7.4 PRODUCT – MIX a) WRM – 1  Plain Rod – 5.5 mm to 12.7 mm diameter. However, sizes up to14 mm are also being rolled presently.  Rebar – 8 mm, 10 mm and 12 mm diameter in coil form. b) WRM – 2  Plain Road – 5.5 to 20.0 mm in step of 0.5 , Plain rod Dia 20.64 mm can be rolled in future. 7.5 COMMISSIONING DATES a) WRM – 1  Walking Hearth Furnace – lighting up – 09.11.1990.  Strand 1 & 2 trial operation – 16.03.1991.  Strand 3 & 4 trial operation – 21.11.1990. b) WRM – 2  Integrated hot trial run for commissioning – 04.02.2014
  34. 34. P. Dept. – 8 MEDIUM MERCHANT & STRUCTURAL MILL 8. OVERVIEW The Medium Merchant and Structural Mill (MMSM) is one of the modern rolling mills of Visakhapatnam Steel Plant. This is a single strand continuous mill having production capacity of 8,50,000 tons per year. The important feature of this mill is that Universal beams (both parallel and wide flange) have been rolled for the first time in India using Universal stands. Parallel flange beams have an advantage over conventional beams because, for the same weight, the section is stronger and stiffer due to greater moment of inertia and higher radius of gyration. Fig. 8.1 Overview of Medium Merchant & Structural Mill 8.1 FACILITIES  8 Stand Roughing Mill.  6 Stand Intermediate Mill.  6 Stand Finishing Mill. 8.2 SALIENT FEATURES  Evaporating cooling systems in Rolling furnaces.  Sophisticated, high speed rolling mills with computerized controls. 8.3 CAPACITY  A Mill of 1.070 MT per annum 8.4 COMMISSIONING DATES  Walking Beam Furnace 1 – Light Up – 22.11.1992.  Walking Beam Furnace 2 – Light Up – 24.12.1991.  Mill Inauguration – 28.03.1992
  35. 35. P. Dept. – 9 SPECIAL BAR MILL 9. OVERVIEW The Mill is designed to produce 7,50,000 tons per year of plain rounds in straight length and in coil form by using an input of Continuous cast billets of 150 mm x 150 mm x 12 m and weighing approximately 2050 kgs. The mill is designed to roll medium and high carbon steel, case hardening steel, cold heading quality steel, electrode steel, spring steel, bearing steel and free cutting steel. The bar size shall be in the range of 16 mm to 40 mm. Provision will be kept in the mill for producing 900,000 tons per year of special bar when the market demand increases. The mill will roll medium and high carbon steel, case hardening steel, cold heading quality steel, electrode steel, spring steel, bearing steel and free cutting steel. The mill shall use continuous cast billets of 150 mm square size and 12 m length. Considering the yield of 96% for losses due to scale, shear cropping, cobbles etc the requirement of billets for producing 750,000 tons of bar shall be about 781,000 tons. Fig. 9.1 Overview of Special Bar Mill 9.1 FACILITIES  6 Stand Roughing Train.  6 Stand Intermediate Train.  6 Stand Pre – Finishing Train.  3 Nos. Stand Finishing Train (Sizing train).  Pendulum sher, Flying shear 3 no.s and dividing shear.  Controlled cooling facilities.  Straight Form : Chain transfers, Cold Shear, Bundling Facilities and Strapping Machines.  Coil Form : Garret coilers, Cooling conveyors, Hook conveyors, Compacting and Strapping Machines. 9.2 SALIENT FEATURES  Continuous Mill consisting of 21 stands of housing – less design.
  36. 36.  20 – 45 mm size in straight & coil form (Reduced wastage for end user).  Free size rolling (Customized sizes with closed tolerances).  Low temperature rolling for finer grain structure.  Online automatic measuring measuring gauge for better quality control.  Automatic bar Bundling & Strapping machines for packing of finished products. 9.3 CAPACITY  0.75 MT per annum. The enhanced production capacity is 0.90 MT per annum. 9.4 PRODUCT MIX a) Round Form Outputs :  Round – 20 mm to 45 mm diameter (with a special provision to roll 16 mm to 18 mm).  Coils – 2.0 tons (as per billet weight). b) Straight Form Outputs :  Straights – 12.0 m bundle with 6 straps. 9.5 COMMISSIONING DATES  Mill : Commissioned on 3rd Apr 2015.
  37. 37. P. Dept. - 10 STRUCTURAL MILL 10. OVERVIEW The Mill is designed to produce 7,00,000 tones per year of structural section in straight length in approximately 3733 rolling hours and 8,50,000 tones per year of structural sections in straight length in approximately within 4533 rolling hours.an input of Continuous cast cold bloom of 200 mm x 200 mm x 12 m and weighing approximately 3760 kgs. The Structural Mill shall be able to produce a wide range of products inclusive of plain round, rebars, semis, besides structurals and product-mix of the mill shall have to be decided depending upon the market demand and supply patterns at the time of implementation. Provision will be kept in the mill for producing 850,000 tons per year of structurals when the market demand increases. The mill will roll constructional steel conforming to standards of structural products. The mill shall be operated in 3 shifts per day and 300 days in an year. Operation of about 5000 hours shall be considered for producing 850,000 tons per year at an average production rate of 170 tons per hour. The mill shall use continuous cast billets of 200 mm square size and 6 m length. Considering yield of 92.0% for losses due to scale, shear cropping, cobbles etc, the requirement of billets for producing 700,000 tons of bar shall be about 761,000 tons. Fig. 10.1 Overview of Structural Mill 10.1 FACILITIES  Walking beam re – heating furnace, 200tph capacity with cold storage charge, and relevant charging and discharging services.  Furnace exit area with pinch roll and high pressure water static descaler.  Exit furnace table for the feeding of continuous rolling mill.  Continuous rolling mill composed of 17 rolling stand “housing less type” namely 1) Roughing mill composed of 7 stands arrange in H – V disposition. 2) Intermediate mill composed of 5 stands arranged either in H or H/V/U or H/U disposition.
  38. 38. 3) Finishing mill composed of 5 stands arranged either in H or H/V/U or H/U or H/V disposition.  A crop type start/stop crank shear arranged after stand no. 7.  A crop type start/stop rotary shear arranged after stand no. 12.  Dividing shear for multiple length cut after stand 17.  Double sided 90 m long cooling bed.  Straightening machine.  84 m long batching area.  Three saw for cutting to length in each line.  Stacking, strapping, weighting and collection stations. 10.2 SALIENT FEATURES  Continuous Mill consisting of 17 stands of housing – less design.  Mode Optimization for cut length of bars.  On line automatic measuring gauge for better quality control.  Automatic bar bundling & strapping machines for packaging of finished products.  Basalt Rock Liner in the scale Flume tunnel to prevent wear out of the base of the tunnel.  Minimum tension control and tension free (loop) control.  Optimized roll pass design for all product.  Start/Stop type flying shears along the mill for emergency chopping of rolled stock. 10.3 CAPACITY  Mills : 0.70 MT per annum. The enhanced production capacity is 0.85 MT per annum. 10.4 STARTING MATERIAL  Continuous cast cold bloom : 200 X 200 X 12,000 mm – weight 3,760 kg 10.5 PRODUCT MIX  Beams : ISMB 100, 125, 150 mm ; ISJB 150, 175 mm ; ISLB 100, 125, 150 mm.  Channels : ISMC 75, 100, 125, 150, 175 mm; ISJC 100, 125, 150, 175 mm.  Angles : 55, 60, 65, 75, 80, 90, 100 mm.  Flat : 70 to 180 mm (thickness : 8 to 30 mm).  Special sections like 1) Squares : 45 to 80 mm 2) HE (columns with parallel Flanges) : 100 to 120 mm 3) IPN (Beams with tapered Flanges) : 100 to 180 mm 4) IPE (Beams with parallel Flanges) : 100 to 180 mm 5) TEE : 60 X 60 7 mm 6) Unequal angles : 80 X 50 , 90 X 60 , 125 X 75 mm 10.6 COMMISSIONING DATES a) Mill : Hot trial commissioning on 30.04.2015 and production commencing from 15.02.2016
  39. 39. 11. SERVICE DEPARTMENTS 1. MINES Brief about Captive Mines of Visakhaptanm Steel Plant a) MADHARAM DOLOMITE MINE (MDM) MDM is located at Madharam village in Singareni Mandal of Khammam District, A.P. The mining lease is for exploitation of Dolomite covering an area of 384.46 Hectares for about 20 years. The lease area is a captive source for Rashtriya Ispat Nigam Ltd (RINL) / Visakhapatnam Steel Plant (VSP) for use of Dolomite in its Iron and Steel making processes. The capacity of the mine is to produce 7,80,000 tonnes of Dolomite per annum. It is an open cast mechanized mine of VSP to cater to the requirement of Dolomite. b) JAGGAYYAPETA LIMESTONE MINE (JLM) Jaggayyapeta Limestone mine (JLM) is located 5 Km south – West of Jaggayyapeta connected by a black – top road in Krishna District, A.P. This is a captive mine of VSP to cater to the requirement of BF Grade Limestone of VSP. This mine is an open cast mechanized mine with a capacity of 4,50,000 tonnes of BF Grade Limestone per year. The Limestone reserve of 130 million tones is occurring in the area. c) GARBHAM MANGANESE MINE (GMM) Garbham Manganese mine (GMM) is a captive source for manganese ore for VSP. It is located 16 Km away from Garividi connected by the black – top road in Merakamududam Mandal, Vizianagaram District, A.P. There are two mining leases adjacent to each other covering an area of 264.54 Hectares. The present reserve of Manganese is 7,03,760 tonnes as on 01.01.2008 with a life of 46 years producing 15,000 tonnes per annum. The annual production ofthe mine is @ 16,000 tonnes. d) SARIPALLI SAND MINE (SSM) This is a captive source for catering to the requirement of Silica sand for VSP. This is located in Champavati River near Nellimarla Mandal of Vizianagaram District, A.P. The sand is transported from this mine to VSP. The totalreserve of sand is 3,20,000 tonnes. 2. CALCINING & REFRACTORY MATERIAL PLANT CRMP consists of two units - Calcining Plant & Brick Plant. In calcining plant, Limestone & Dolomite are calcined for producing Lime & Calcined Dolomite which are used for refining of steel in the converters. In Brick Plant, bricks and refractory masses are produced, which are used in the Steel Converter as working lining. 3. CENTRAL MAINTENANCE ELECTRICAL (CME) Maintenance of all H.T motors, L.T motors and DC motors of above 200KW. There are 810 such large rotating electrical machines spread through out the plant including 3 Nos. of 60 MW Turbo - Generators, 1 No of 67.5M TG in TPP, 2 nos of Back Pressure Turbo Generators of 7.5 MW each and 2 Nos. of Gas Expansion Turbo- Generator of 12 MW each. The service provided are as mentioned below.
  40. 40.  Repairs, Maintenance and condition monitoring of all rotating Electrical machines of the plant. The job includes transportation, Overhauling and re-erection with precision alignment.  Maintenance of Electrics of all street lights, Tower lights and Weigh Bridges through out the plant. 4. CIVIL ENGINEERING DEPARTMENT  Inspection of all Civil Buildings in the plant.  Attending Civil Maintenance jobs in various zones of the plant  Road repair works  Laying of additional roads…….. RCC / BT Roads  Attending special jobs during Capital Repairs / Shutdowns.  Repainting of Equipments in various zones of the plant  Horticulture / Development of parks  Cleaning of storm water drains / Box drains, diversion channel  Upkeep of Toilets in buildings / shops of the plant  Preparation jobs for VIP visits  Ash Pond maintenance jobs  Survey jobs  Special jobs: Core cutting in concrete structures, Pressure grouting, Roof treatment, Anti - terminate treatment etc.  Civil jobs for infrastructure: Scooter sheds / Rest rooms, office room extension etc.  Security related jobs: Maintenance of Boundary wall Watch towers, peripheral road 5. DISTRIBUTION NETWORK DEPARTMENT Distribution Network (DNW) Department deals with receipt, transmission of electrical power at 220KV level and distribution of power at 33 KV, 11 KV and 6.6 KV level. Operation and maintenance of power handling equipment under DNW at 220 KV, 33 KV, 11 KV & 6.6 KV levels, maintenance of TPP 220 KV equipments and maintenance of other shop’s 33 KV, 11 KV, 6.6 KV equipments (except operations of 220 KV, O&M of 33 KV, 11 KV, 6.6 KV equipment at TPP & other shop HVMCC board with Vacuum Contactors, other Vacuum Contactors) are under DNW purview. DNW department also coordinates with AP Transco and APEPDCL for import of power. 6. ELECTRICAL REPAIR SHOP (ERS) ERS is a central repair shop to carry out repair activities like overhauling, rewinding, testing etc., of various types of AC Motors, DC Motors, HT Motors, Submersible pumps, Distribution transformers, Welding Machines, Control Transformers, Lifting magnets, Coils etc., of the plant. The Main Functions of ERS are:  Overhauling of motors  Rewinding of motors, magnets, transformers, pumps, coils etc.  Testing of Electrical equipment  Emergency Site Repairs
  41. 41.  Performance assessment of electrical motors 7. ELECTRO TECHNICAL LABORATORY ETL Department supports the electrical sections of different production shops all over the plant in maintaining electronics pertaining to Drive automation, Programmable Logic Controllers, Crane Drives, Uninterrupted Power Supplies, Electrostatic Precipitators, Special Machines like CNC Machines etc. The following are the main activities : • Preventive Maintenance and trouble shooting of the concerned electronics. • Procurement of spare electronic modules. • Repair of defective electronic modules. • Aid the up gradation of obsolete electronics in preparation of specifications and commissioning. 8. ENERGY MANAGEMENT DEPARTMENT EMD deals with handling and distribution of gaseous by-product fuels (BF Gas, Coke Oven Gas, LD Converter Gas) and other utilities such as Steam, Compressed Air, Instrumentation Air, Nitrogen Chilled Water, Oxygen, Demineralised Water, Argon, Acetylene and Fuel Oil in the plant besides conducting various thermo technical studies and reviewing energy consumption regularly. It also looks after gas safety aspects in the plant. 9. ENGINEERING SHOPS & FOUNDARY (ES & F) Engineering Shops & Foundry department is set up to meet the requirements of spares, repair of assemblies and reclamation of various jobs of different departments. This complex consists of : a) Central Machine Shop (CMS) b) Steel Structural Shop (SSS) c) Foundry d) Forge Shop (FS) e) Utility Equipment Repair Shop (UERS). a) CENTRAL MACHINE SHOP (CMS) In Central machine shop, various spares like Gears, Shafts, Crusher liners, hammers, machined castings and fabricated jobs are made. In addition to the manufacturing spares, assembly and repair jobs like gear boxes, Crusher, bearing housings, stands of SMS are taken up. Over 100 major machines including lathes, milling, Plano milling, boring, slotting, shaping, grinding etc. are available to take up machining of spares. 2 presses of 630 ton, 315 ton and dynamic balancing machine of 25 ton capacity, are provided at CMS for repair of assemblies. b) STEEL STRUCTURAL SHOP At Structural shop of ES&F, structural jobs of various departments like coke bucket, ladle, SRC body, Wagons, Shells, ducts etc. are being fabricated or repaired as per the requirement of
  42. 42. departments. The equipments available are Bending machine-25mm capacity, Shearing machine - 25mm capacity, CNC profile gas cutting machine, welding machines, gas cutting sets, other tools and tackles. c) FOUNDARY In Foundry, castings of Iron, steel and non-ferrous are produced based on the projection of customer departments. 8 ton Arc furnace, 2nos of 5ton Induction furnaces and 1 ton crucible furnace for non-ferrous jobs and sand plant for preparation of sand for moulds are available for making castings. Major jobs like Hot metal runners of 10 tons weight , Bottom funnel(5 ton), Emergency containers(7 ton), lower mantle and Bowl liners(3 tons each) etc are produced. d) FORGE SHOP (FS) In Forge shop, preparation of raw materials for shafts, coupling flanges, gears etc and also of forge shapes such as crusher hammer heads, V -hooks, drill rods with the help of 0.5 ton, 2 ton, 3 ton pneumatic hammers, manipulators, heating furnaces is carried out. e) UTILITY EQUIPMENT REPAIR SHOP (UERS) In Utility Equipment Repair Shop, repair of ventilation equipments, valves, fans and impellers is carried out. Equipments like shearing machine, bending machine, presses, lathes etc are provided to take up different repair and manufacturing activities. 10. ENVIRONMENT MANAGEMENT DEPARTMENT (EnMD) The environmental parameters related to ambient air, stacks, effluents, work-zone environment, sound, waste management, sub-soil water, marine water and the fugitive emissions (from the coke oven batteries) are regularly monitored by the Environment Management Department (EnMD) as stipulated under consent conditions and statutory orders from APPCB/CPCB/MoEF. All these monitoring activities are carried out as per frequency prescribed by the APPCB/CPCB/MoEF and compliance with all norms is ensured. 11. FIELD MACHINERY DEPARTMENT (FMD) FMD deals with operation and maintenance of Heavy Earth Moving Equipment, Material Handling Equipment like Cranes, Fork lifts, Tractor trailers and Vehicles. Our equipments are utilized for material transportation, maintenance jobs, house keeping etc. FMD is one of the critical service department, whose services are directly involved in operational activities at many production departments like Coke Ovens, Sinter Plant, Blast Furnace, Steel Melting Shop etc. In addition to the above, vehicles and fire tenders of VSP / CISF are maintained by FMD. 12. INFORMATION TECHNOLOGY (IT)  Formulation of Organizational IT-Policy, IT-Security Policy and IT-Vision.  Identification of IT enabled projects for various processes and implement them. 13. M & CR a) Functions :  Modernization of major plant equipment (BF-1&2, SMS Converter shop, Sinter
  43. 43. machines-1&2 etc.) through “Revamping, Up gradation and Capital repairs” as per sustainability and roll on plan of VSP.  To execute the modernization of major plant equipment with support of works department and concerned contractor / agency. b) Duties :  To finalize technology and design in construction with D&E, works department for modernization or major plant equipment.  To finalize contracts in consultation with project contracts department for modernization of major plant equipment.  To execute the modernization of major plant equipment with support of works department and concerned contractor / agency. 14. PLANT DESIGN  Major functions of this unit are  Development of detailed Manufacturing Drawing and Replacement Specification drawings  Suggesting New Designs and detailing by doing elaborate engineering study and Analysis  Standardization 15. PRODUCTION, PLANNING AND MONITORING DEPARTMENT  Formulation of Annual and Monthly Production Plan.  Analyzing Plant performance against targets on a periodic basis and put up for information.  Formulation of techno – economic norms and reviewing the same against targets periodically.  Raw material requirement projection of Coal, Ore and fluxes.  Preparation of MIS on Inward and outward traffic w.r.t. incoming raw materials and outward dispatches. 16. QUALITY ASSURANCE & TECHNOLOGICAL DEVELOPMENT (QA & TD) The QA & TD dept. has been set up to take care of activities pertaining to Quality Control of Raw Materials, Semi finished products and finished products. The QA & TD labs are provided at major department like CO&CCP, SP, BF, SMS, Rolling Mills etc., in addition to Central Laboratory. The department monitors the process parameters for production of quality products. QA & TD carries out analysis, testing and final inspection including spark testing of finished products and assigns grades to them. 17. RESEARCH AND DEVELOPMENT (R & D) R&D Department started functioning from 2005 in RINL. This department takes up various improvement projects related to the areas given under:  Pursuing innovative and path breaking technologies to create a vibrant, viable and sustainable future for RINL
  44. 44.  Developing technologies to enrich raw materials of lean variety  Product development to meet ever increasing demands on steel quality  Meeting the challenges of energy and environment  Create knowledge through basic research in the area of Iron and Steel  Improve the technological capability of the human resources through interventions like exposure to information, advanced knowledge and new technologies R&D projects are carried out internally and jointly with the help of external agencies viz., research organizations and academic institutions like IITs, NITs, CSIR laboratories, Universities etc. 18. REFRACTORY ENGINEERING DEPARTMENT In Visakhapatnam Steel Plant the pyrometallurgic processes involved from Raw Materials Processing to Finished Products units, everywhere Refractory material is involved. Refractory Engineering Department plays it’s role by maintaining the refractories in furnaces, kilns and vessels required for different operations of steel making process. In order to augment timely production, the main objective of RED is to make pyrometallurgic machines / equipments available in time with prolonged service period. RED section are scattered in all the major production units (viz., SP, TPP, BF, SMS, Roiling Mills, ES&F etc.). 1. The central section is located at CRMP & RED Area Shop Office Building. The main functions of RED are: • To plan & procure the refractory required during regular maintenance and capital repair of all types of furnaces, kilns and vessels in steel making • To carry out all the refractory repair & maintenance including regular and running repairs and also capital repaint • To arrange for supervision, inspection and corrective action of vital equipments. a) like LD converter, Steel ladle, Tundish in SMS round the clock b) TLC, Open top ladle of BF c) Furnaces of CRMP, ESF & Rolling mills. Round the clock supervision of capital repair of furnaces of rolling mills, hot blast stoves, Mixer, CRMP. 19. ROLL SHOP & REPAIR SHOP (RS & RS) Roll shop & Repair shop is in the complex of Rolling Mills catering to the needs of mills in respect of roll assemblies, guides few Maintenance Spares and roll pass design. Geographically this dept. is in three areas as Roll shop-1, Roll shop-II and Area Repair Shop. The main activities of this shop is Roll pass Design, grooving of rolls, assembly of rolls with bearings, preparation of guides and their service and manufacture / repair of mill maintenance spares. For the first time in the country, VSP has adopted CNC technology for grooving of steel rolling mill rolls. High constant respective accuracy, higher productivity, use of standard tool for any groove turning, elimination of the use of different templates, easier to incorporate groove modification etc., are some of the advantages of CNC lathes over the conventional one.
  45. 45. 20. SAFETY ENGINEERING DEPARTMENT Safety Engineering Department advises and assists the management in the fulfillment of obligation concerning prevention of accidents and maintaining a safe working environment. SED imparts safety training as well as refresher safety training to the regular employees as well as contractor workers. SED conducts safety inspections, safety audits, mock drills and co-ordinate with the departments for corrective actions in respect of unsafe conditions and unsafe actions. SED conducts safety campaigns and safety competitions amongst the employees to promote safety. SED ensures that high quality safety appliances are procured and issued to the employees. SED coordinates and liaison with AP Factories departments. 21. SPARES MANAGEMENT DEPARTMENT (SMD) SMD is a nodal agency between Works and Materials Management department: 2. The main functions of SMD are:  Rationalized spares are procured by SMD department viz., Bearings, Electrodes, Conveyor belts, Idlers, LV Switchgear, Cables, etc., to cater the needs of various departments.  All the indents and Technical recommendations viz., Operation, Mechanical, Electrical, Instrumentation, Refractory etc., are processed thro’ SMD department for procurement of spares thro’ Materials Management department.  SMD department controls Inventory of spares, indenting & consumption budget. 22. STRUCTURAL ENGINEERING DEPARTMENT (St. ED) The main objective of Structural Engineering Department is to maintain Steel structures located inside the plant area including Boundary Lighting Towers & Watch Towers and the main functions are as below:  Inspection of all steel structures and chimneys as per schedule of inspection and inspection of roof sheeting works as per schedule of inspection.  All units of every zone are inspected at least once in a year. Critical units like CDCP’s of C&CCD, Service benches of C&CCD are inspected twice in a year. Inspection of roof dust cleaning of identified units of CRMP, SP, & SMS is being done four times in a year.  Repair / Replacement of damaged steel structures and sheeting in various zones inside the plant area.  Arresting roof leakages in all structural buildings inside the plant area.  Re-painting of ODPL pipe lines and repainting of structures as a Preventive Maintenance.  Removal of dust from roof and gutters of different units.  Preparation jobs for VIP visits.  Special Jobs: Providing polycarbonate sheets as energy conversion in all zones.  Infrastructural Jobs: Providing scooter sheds, Rest Rooms, storage racks etc.  Security related jobs: Maintenance of watch towers and Flood light towers inside the plant area. 23. THERMAL POWER PLANT The average power demand of all units of VSP when operating at full capacity will be around 230 MW. The captive Generation capacity of 286.5 MW is sufficient to meet all the plant needs
  46. 46. in normal operation time. In case of partial outage of Captive Generation Capacity due to brake down/ shutdown/ or other reasons, the short fall of power is availed from State Grid. The Captive Generation capacity comprises of :  TPP : 247.5 MW (3 X 60 MW + 1 X 67.5 MW)  Back Pressure Turbines (C&CCD) : 2 X 7.5 MW  Gas Expansion Turbines (BF) : 2 x 12 MW Power plant also meets the Air Blast requirement of Blast Furnaces through 3 Turbo Blowers each of 6067 NM3/Min capacity. In addition to the above, Power Plant also supply process steam, DM Water, Chilled Water, Soft Water to various units of VSP. 24. TRAFFIC DEPARTMENT VSP has a well planned rail network with Yards / Stations, Locos and Wagons which are maintained by Traffic department. For the convenience of Operational activities, the rail network is divided into six yards / stations and each yard has specified functions attached to it. VSP has the distinction of having peripheral yard concept to improve the turn – round time of wagons and to avoid duplicating of the rail facilities by Railways and VSP. All the Raw-material rakes are delivered by Railways directly at Pre-tippler lines. The main functions of Traffic department are to carry out in-plant rail movements like handing over of empties to Railways after tippling, transportation of Hot metal from BFs to SMS / PCMs, taking over of empty rakes from Railways and distribution to various loading points and after loading of the finished products and weighment handing over of load rakes to Railways. 25. TECHNICAL IMPROVEMENT CELL TIC functions as nodal agency for coordinating and monitoring the various activities as envisaged in company procedure for processing and implementing of AMR schemes. 26. TQM – ISO CELL  Ensuring the implementation and maintenance of Quality Management System requirements for ISO 9001 : 2008.  Liaisoning with certifying agency for conducting audits for Quality Management System, Environment Management System, Occupational Health & Safety Management System and Energy Management System.  Conducting Internal Audits for Quality Management System, Environment Management System, Occupational Health & Safety Management System 27. UTILITIES DEPARTMENT Utilities dept. Consists of : 1. Air Separation Plant, designed to produce and meet the consumer requirements of gaseous oxygen, Nitrogen and Argon through pipe lines and through gas cylinders.
  47. 47. 2. Compressor Houses – 1 & 2, designed to produce and meet the consumer requirements of Plant air and Industrial grade dry air. 3. Chilled water plants – 3 & 4, designed to produce chilled water for meeting the consumer air conditioning requirements. 4. LPG is being procured and distributed through pipe lines for CCD & Engineering Shops and for maintenance agencies through cylinders. DA gas is being procured and distributed for Billet cutting at MMSM & for critical maintenance agencies through cylinders. 28. WORKS CONTRACTS DEPARTMENT  Processing for and obtaining administrative approval on receipt of contractual proposal from indenting departments, tendering and awarding of work.  Convening tender Committee meetings and preparing recommendations for awarding work.  Preparing COM / Board Note for decisions at those forum.  Participating in Claims and Arbitration proceedings and legal cases pertaining to contracts.  Registration of agencies under various categories & classes of works regularly. 29. WATER MANAGEMENT DEPARTMENT Water Management Department basically caters water needs throughout the plant for various processes of making Steel and drinking water inside the plant and Township. It consists of 30 pump houses, 8 treatment plants, 4 Overhead tanks, 22 cooling towers, 10 sewage pump houses, STP & ETP. Its prime functions are as follows:  Receipt of Raw water from State Government, Treatment and distribution of Makeup water and drinking water in & Township.  Operation and Maintenance of Various Recirculating Pump houses, Cooling towers, Treatment plants, pipe line tunnels etc.  Maintenance of underground Makeup and Fire & Drinking water network.  Operation and Maintenance of Effluent Treatment Plant & Sewage treatment plants and pump houses.  Recovery of township sewage water through Ultra Filtration process and reuse in plant as make water. 30. BUDGET PLAN AND CONTROL  Identification of Budget requirement under various heads.  Control of the Budget and Spares, Consumables & Raw Materials Inventory. 31. SYSTEMS AND PROCEDURES  Streamlining the contract management system to ensure consistency of approach and adoption of sound principles of contract management.  Monitoring pollution control activities of the Plant and interaction with the State and Central Pollution Control Board. 32. PERSONNEL DEPARTMENT
  48. 48. Personnel Department (Corporate Personnel, Central Employee Relations and Plant Personnel)  Manpower Planning  Employees induction  Service matters, policy & rules  Industrial relations  Employees welfare  Corporate Social Responsibility (CSR)  Replies to parliamentary questions  Official Language implementation 33. LEGAL AFFAIRS (LA)  Legal Affairs deals with all legal matters including arbitration, coordination with Standing Councils, Legal Advices etc. 34. MANAGEMENT SERVICES (MS)  Quality Circle  Suggestion Scheme  Incentive Scheme  Reward Scheme  Procedural Orders etc. 35. TRAINING & HRD  Leadership Training  Training on Motivation and Attitude  Team Building  Skill Training  Induction and Orientation  Plant Practice Lectures  Basic Engineering Lectures  Plant Specialized Training  Management Development  On the Job Training  Multi Skilling / SUPW and Mentoring 36. TOWN ADMINISTRATION & ADMINISTRATION (TA)  Matters relating to Land & State
  49. 49.  Civil Maintenance  Electrical Maintenance  Water Supply  Roads and Drain Maintenance  Horticulture and Afforestation  Peripheral Development and  Public Health in Township (Ukkunagaram)  Interact with District Authorities for various welfare activities, land acquisition matters etc. 37. MEDICAL & HEALTH SERVICES (M & HS) The Medical & Health Services Division of RINL consist of Visakha Steel General Hospital (VSGH) & Peripheral Units viz. Pedagantrya Health Centre (PGHC), Health Centre – II, Occupational Health Services & Research Centre (OHSRC), Emergency Unit – I & II and Hospitals in Mines –Jaggayyapeta Limestone Mines and Madharam Mines. The special features of Visakha Steel General Hospital are:  Full fledged Modern American Designed ICU and MBU capable of treating 6 patients at a Time  Full fledged Modern Radiology with Central A/c systems  Well equipped Path. Lab with Blood bank facility  Cluster type Wards & Casualty with Central Nursing Station  Modern Operation Theatre comples with Shadowless cold lights and 100% bacterial free A/c system 38. MARKETING DEPARTMENT VSP has 23 no of Branch Sales Offices all over India and five Regional Offices viz. North Delhi, South - Chennai, West - Mumbai, East - Kolkata and Andhra - Visakhapatnam. Main Activities of the Marketing are as follows :  Collecting Market feedback and Customers requirements for the preparation of Annual Sales Plan in coordination with Works Department, for the sale of Pig Iron, Steel and Byproducts.  Preparation of Marketing Policies.  Finalization of MOUs, Spot sale agreements etc, in Domestic and Export Markets.  Preparation of Monthly Rolling Plans in coordination with Works Department for meeting the sale commitments.  Processing of Materials like straightening of coils, cutting, bending, bundling, packaging etc. at the plant premises and in the branches to meet customers requirements.  Dispatch of products to various stockyards by road or rail or to customers from the plant on direct dispatch basis.  Operation of the contracts for transportation of products by road and stockyard handling/consignment agency contracts for domestic sales, stevedoring contracts and third party inspection agency for exports.  Sale of products at branches, Headquarters and on direct dispatch basis to the customers in domestic markets and on Ex-works and fob Visakhapatnam basis in exports subject to tying up of commercial
  50. 50. and financial terms and conditions. Ensure documentation as per the procedures and as per the statutory requirements.  Rendering after sales services, obtaining customer feedback and Customer Relations Management.  The details/information on the following aspects of Marketing are available in www.vizagsteel.com, Marketing Module. a) Rolling Plan b) Products c) Prices d) Exports e) Network f) Customer Relation  Further, five Consignment Sale Agencies are also functioning at Jamshedpur, Raipur, Pondicherry, Jammu and Guwahati. 39. MATERIALS MANAGEMENT DEPARTMENT  Procurement of all materials such as Raw-materials, Spares and consumables required for the entire Plant Operations.  To enter into long term agreements for supply of major & minor raw-materials with indigenous and imported suppliers.  To affect economy in the cost of materials by Purchasing materials of the right quality, in the right quantity at the right time from the right source at the right place.  To arrange inspection of materials prior to handing over to Production Units to ensure quality materials only are issued to Production Units.  Storage of materials & issue the same to the Production Units as per their requirement.  To develop and encourage ancillary industries so that the availability of the materials at right time is ensured. 40. FINANCE & ACCOUNTS DEPARTMENT  Corporate Treasury Functions - Arrangements for Long term & Short term Funds, Working Capital, Submission of periodical reports to Banks as required, Strategies for Long term / Short term investments.  Accounting of all monetary transactions and preparation of Financial statement of the company, statutory compliance of Taxation, Company Law & Provident Fund and getting them audited as required under Companies Act / relevant Act.  Maintaining records w.r.t. to the cost of products in line with the Cost Accounting Records & Rules Prescribed.  Release of payments to suppliers / providers of goods and services.  Release of salaries & allowances to the employees of the company.  According concurrence / consultation to the proposals for investments & expenditure as per the extant policies, procedures and the Delegation of Powers.
  51. 51.  Organising for payment of Central Excise, Sales Tax, Income Tax & other statutory payments as per the provisions of the respective acts.  Internal Audit (including ERM audit), Stock Verification as per the requirement of the company.  Ensuring timely Statutory Audit and Govt. Audit for the Company’s accounts and attending to proprietary audit points by Govt. Audit.  Generation of various MIS reports relating to Finance function of the Company for enabling Management to take timely decision. 41. CORPORATE STRATEGIC MANAGEMENT CSM is a “think tank” of the organisation. The Deparment is engaged in formulation of VMO (Vision, Mission & Objectives) of the organisation and developing the strategy to achieve VMO. It has various wings which inter-alia includes Knowledge Management Cell (KM Cell). It has also developed the Corporate Plan of RINL. It takes up strategic tasks of the organisation. 42. DESIGN & ENGINEERING DEPARTMENT (D & E)  Liaisoning with Consultants and Government Authorities in connection with designs, specifications, approval of drawings and liaisoning work for various types of clearances.  Preparation of drawings, design and specification for AMR and Non-AMR jobs.  Assisting indenting departments in technical discussion with parties and preparation of technical recommendation.  Layout clearances of various facilities coming in the Plant and Township.  Operation of Consultancy contracts. 43. CONSTRUCTION DEPARTMENT  Exercising supervision of work at site both for quality and quantity checks.  Preparation of contractors bills, processing of extra items and closure of contracts.  Liaisoning with suppliers, MM department, Design & Engineering Department and Stores in connection with progress of work at site.  Arranging PAT/FAT will all concerned departments like works, design, consultants and suppliers in terms of contract and handing over the unit to works department for operation. 44. CONTRACTS DEPARTMENT  Awarding of contract from the point on receipt of administrative approval from indenting departments.  Conducting commercial discussions with parties.  Arranging Tender Committee meetings and preparing recommendations for awarding work.  Preparing COM/Board Note for decisions at those form.  Participating in claims and arbitration proceedings. 45. PROJECT MONITORING DEPARTMENT
  52. 52.  To monitor the physical and financial progress of all the works executed by Construction department.  To monitor the progress of works executed by D&E as well as Contracts department.  Preparation of various types of reports for information of Government and different level of Management.  Interaction with departments and consultant for updating the schedules and networks for Project Monitoring. 46. VIGILANCE DEPARTMENT Vigilance Department of RINL, set up in accordance with the Central Vigilance Commission (CVC) Act 2003, is headed by the Chief Vigilance officer (CVO). The CVO acts as a link between the organization and the CVC. Functions of the department can be broadly divided into three areas, viz. (i) Pro-active / Preventive vigilance; (ii) Punitive vigilance; and (iii) Collecting intelligence about the corrupt practices / acts committed or likely to be committed in the organization through Surveillance and Detection. At micro level, the Activities of vigilance Department include inter-alia timely investigation and disposal of complaints, monitoring and advising the Disciplinary Authorities for timely disposal of disciplinary cases initiated based on vigilance cases, putting up to the authorities concerned periodic reports in the prescribed timeframe, coordinating with the CVC, Administrative Ministry and the CBI for effective vigilance administration, implementation of anticorruption initiatives through awareness drives etc.
  53. 53. 12. DETAILED REPORT ON RAW MATERIAL HANDLING PLANT 1. RMHP Visakhapatnam Steel Plant is one of the most modern steel plant not only in the country but also in the world. This has latest raw materials stacking and blending system. RMHP has the concept of peripheral unloading which considerably reduces delay in taking over and handing over of rakes bringing raw materials to the plant, there by increasing the availability of wagons. The Raw Material Handling Plant is handling more than 24 million tons of various raw materials for 6.3 MTA. Raw Material Handling plant is meant for transporting materials from Raw Material yard / Base mix yard to various units of the plant. The Major Raw materials required for Iron and Steel making are Iron ore lump, Iron Ore fines, Sized iron ore, Flux limestone / dolomite, manganese, Quartzite coking coal ( for Boiler operation & For Pulverized coal injection ) and coke. Lump iron ores, iron ore fines and flux such as limestone and dolomite received by railway rake are unloaded in wagon tippler and stored yard with the help of various stockyard machines. Iron ore lump, flux such as limestone and dolomite, Coke is reclaimed by suitable stock yard machine and are crushed in Ore crushing plant, Flux crushing plant and coke crushing plant respectively to produce the size required. The above material is proportionately stacked by suitable stacking machine in base mix yard and blended while reclaiming by blender reclaimer. The prepared base mix is then transported to Sinter plant for sinter production. For feeding material to new Blast Furnace, sized ore and flux are reclaimed by stock yard machine from respective yard and are transported by conveyor. Sinter produced in sinter plant and coke from existing/new coke ovens is transported directly to BF-3 stock house by conveyor. Purchased coke and necessary calcined lime from stock yard and new lime calcining plant respectively are transported to SMS by conveyor. The waste product from the plant is mainly dust and method of their disposal is through dust suppression system and inter plant transportation. 1.1 The Raw Material Handling Plant in any organization is needed : a) To have adequate storage capacity to store various raw materials depending up on the capacity of the beds in the stock yard. b) To blend raw materials, if needed, received from various sources, in order to supply homogeneous raw materials. c) To ensure methodical stacking and reclaiming of raw materials without mixing up of different raw materials. d) To process the raw materials and bring down the size to the size as required by the customer departments to improve their productivity and product quality.
  54. 54. 1.2 RAW MATERIALS FLOW CHART
  55. 55. 1.3 LAYOUTS OF STORAGE YARD
  56. 56. 1.4 AUGMENTATION OF IRON ORE STORAGE 1.5 FUNCTIONS OF RMHP a) Receiving - Raw Materials from different Sources b) Processing - Iron Ore Lump & Boiler Coal c) Storing - Raw Materials in Stock Yard Beds & Hoppers d) Supplying - raw Materials to customer departments as per their demand a) Receiving Raw Materials :  Received through rail route (open wagons), by road (Trucks) and by high seas (Ship / Vessels).  Through Rail route : Iron Ore, BF Limestone, BF Dolomite, Boiler Coal, Coking Coal etc.  By Road : Quartzite, River Sand, Manganese Ore etc.  By High Seas : Coking Coal, Limestone (SMS Grade) b) Processing :  Iron Ore Lumps are Screened and Crushed in OHP and Stored & dispatched to Blast Furnace (BF).  Boiler Coal is Screened & Crushed in CHP and dispatched to Thermal Power Plant (TPP).
  57. 57. c) Storing Raw Materials :  Wagons are unloaded by Wagon Tipplers.  Trucks are unloaded in Ground Hoppers.  Materials are carried to and Stacked in different beds in Stock Yard by set of conveyors.  Materials are Stored in different beds of Stock Yards allocated for Ore and Coal. d) Supply / Reclaiming of Raw Materials :  The Raw Materials are reclaimed and sent to customer departments with the help of Reclaiming Equipment and sets of conveyors. 1.6 SECTIONS OF RMHP a) Ore Handling Plant (O.H.P) :  Wagon Tipplers  Track & Ground Hoppers  Stock Yard & Equipment  Screening and Crushing  Reclaiming routes to Customers  Ore control rooms  Drier  IOSA (Iron Ore Stock Yard for Augmentation) b) Coal Handling Plant (C.H.P) :  Wagon Tipplers & GPL Conveyors  Track & Ground Hoppers  Stock Yard & Equipment  Screening and Crushing  Reclaiming routes to Customers  Coal Control Room MAJOR RAW MATERIALS
  58. 58. 2. ORE HANDLING PLANT (OHP) 2.1 RAW MATERIALS – O.H.P 2.2 MATERIALS HANDLING – O.H.P 2.3 MATERIALS DISPATCH TO O.H.P CUSTOMERS Material Size Colour Source Iron Ore Fines -10mm Flash Red Bacheli/Kirandul Gua Sized Iron Ore 10 to 40mm Flash Red Bacheli/Kirandul Iron Ore Lump -150mm Flash Red Bacheli/Kirandul Lime Stone (BF Grade) 6 to 40mm Yellow /grey Jaggayya Peta Dolomite (BF Grade) 6 to 80mm Light grey Madharam Lime Stone (SMS Grade) -50mm Grey UAE/Oman/Jaisalmer Dolomite (SMS Grade) -50mm Yellow Madharam CRMP L/S Returns -25mm Grey CRMP LD Slag (Sinter Plant Grade) -10mm Grey SMS LD Slag (SMS & BF Grade) 10 to 30mm Grey SMS Material Size Colour Source Sand/Quartzite Fines -3mm Yellow/Brown Vizianagaram Quartzite Lump 10 to 30mm Yellow/ Brown Vizianagaram Mn Lump 10 to 40mm Black Vizianagaram Pellets 20mm Flash Red Kudremukh Sinter 7 to 40mm Shiny Black Sinter Plant Coke 10 to 60mm Black China/ Russia Department Material Tons/Day (Average) Qty (Tons)/Annum Sinter Plant Iron Ore Fines 15,000 56,08,000 Lime Stone 1,500 5,71,000 Dolomite 2,000 7,25,000 LD Slag 300 1,09,500 Sand/Quartzite Fines 200 61,300 CRMP L/S Returns 400 1,44,000 Blast Furnace Sized Iron Ore 5,900 21,57,000 LD Slag As per requirement ---- Mn Lump As per requirement 8,700 Sinter/Pellets As per requirement ---- Quartzite Lump As per requirement 8,400 Dolomite 200 60,000
  59. 59. 2.4 EXPANSION OF ORE HANDLING PLANT a) TIPPLING & STACKING ORE HANDLING PLANT No. of wagon Tipplers No. of Wagon Pusher cars Device for Tippling of Last -4 wagons No. of Tippling streams Capacity TPH Existing 3 6 3-No’s of In haul shunting device 3 1200 Expansion 1 2 2-No’s of dummy wagons for each Wagon Pusher will be attached permanently 1 1550 Augmentation 1 2 2-No’s of dummy wagons for each Wagon Pusher will be attached permanently 1 1550 b) CONSUMPTION OF ORE & FLUX AREA OF RMHP (EXISTING & EXPANSION) Material Existing Expansion Per Day Consumption Per Day Consumption Iron Ore Fines 12270 10230 Iron Ore Lump 6800 7575 Sized Iron Ore 5440 4760 BF – Dolomite 1500 1033 BF – Lime Stone 1100 1033 SMS – Lime Stone 1300 1600 SMS - Dolomite 500 500 c) RAW MATERIAL REQUIRED IN O.H.P PER DAY Material Existing Expansion Sinter/Sized Iron Ore 400 1,20,000 LD Slag As per requirement ---- Coke If required 6,000 CRMP Imported Lime Stone Dolomite 2,200 800 8,31,000 2,40,000
  60. 60. Tons Rakes Tons Rakes Iron Ore Fines 12270 3.5 22500 6.5 Iron Ore Lump 6800 1.8 14375 3.9 Lime Stone for SP 1100 0.3 2133 0.6 Dolomite for SP 1500 0.4 2533 0.7 Lime Stone for SMS 1300 0.4 2900 0.9 Dolomite for SMS 500 0.2 1000 0.3 Total 23470 6.6 43441 12.9 d) ORE & FLUX STOCK YARD
  61. 61. e) ORE & FLUX YARD AFTER 6.3 MTPA EXPANSION
  62. 62. f) RECLAIMING STREAM OF ORE & FLUX Description BF Circuit SP Circuit CRMP Circuit Drying Station Capacity Capacity in Ton No. of Streams Capacity No. of Streams Capacity No. of Streams Capacity No. of Streams Existing 1200 TPH 1 1200 TPH 1 450 TPH 2 50 TPH 1 Expansion 800 TPH 1 1200 TPH 1 2.5 DETAILS OF EQUIPMENTS OF O.H.P ORE HANDLING PLANT S.NO Description of Equipment Existing Expansion IOSA AMR Total 1 Conveyors Quantity 90 79 29 − 198 Length Kms 39 23 19 − 81 2 Wagon Tippler 3 1 1 − 5 3 Wagon Pusher 6 2 2 − 10 4 Dummy Wagons − 4 4 − 8 5 Apron Feeders 6 2 2 − 10 6 Twin Boom Stacker 5 1 1 1 8 7 Wheel On Boom Reclaimer 3 1 1 0 5 8 Blender reclaimer 3 1 1 1 6 No. of days of Stock envisaged by considering Existing, Expansion & Augmentation yard is 30 - Days Material Storage Days of storage as per current practice Augmentation: Additional storage envisaged Total Iron Ore Fines 13 17 30 Iron Ore Lumps 12 18 30
  63. 63. 9 Transfer Car 1 * 1 − 2 10 Cone Crushers 3 3 − − 6 11 Vibrating Screens 5 5 − − 10 12 Tailor Unloaders 6 2 2 − 10 3. WAGON TIPPLER 3.1 DESCRIPTION OF WAGON TIPPLER ARRANGEMENT The wagon tippler consists of gears and units, listed in the general drawing specification 01-PRH1-02-M- 0001. The rotor is set on the roller supports where it rotates about the horizontal axle. It consists of three ring disks. These disks on the sides are linked with the beams, and from the bottom side of the left and the right beam they are connected with the stationary platforms. Due to this the rotor is rigid metal work. For moving the open wagon into the rotor and stopping it in the required position the rail-road rails and friction brake devices are installed on the platform. Inside the rotor a mobile resting wall is set on the levers. The levers are arranged so, that make parallelogram gears, providing the wall with the ability to fix the open wagons of different width, making
  64. 64. flat-parallel motion. The wall in its turn consists of two parallel set beams hinge – connected. The wall is moved by the hydraulic cylinders making the whole unit of the hydraulic drive. The eight cylinders (four on each beam) bring the wall into motion. Each cylinder has a pilot controlled check valve that locks the cylinder piston space after the open wagon fixing and shutting off the control valve. On the rotor side beams two clamps are located on each side which fix the unloaded open wagon along its upper binding. The clamps consist of horizontal beams, whose support surfaces are lined with rubber plates to prevent damages of the open wagons. Each beam is hinge connected with two pairs of levers that make the parallelogram gears. The free ends of the levers are fixed in the hinge supports of the side beams. Each clamp is moved with the help of two hydraulic cylinders, one side of which is fixed through a hinge bearing on the side beam of the rotor, the other side is fixed as well, on the load-bearing levers. Each cylinder has also a pilot controlled check valve, locking to the rod space of the cylinder after the open wagon fixing and shutting off the control valve. On the clamps (right), located on the side of the material unloading, are set the fields for the replacing unloaded material onto the bin grate, apart from the rotor, during start age of unloading. On the resting wall are located also three vibrators for the forced surface conditioning of the open wagons from the material sticked to the walls and the floor. The vibrator unit is an arm with a vibrating beam and the vibrator HB11-50 fixed on it. The arm is hinge attached to the resting wall with an axle and is pressed to it with springs. During the fixation of the vibrating beams are pressed out of it, staying pressed to the walls of the open wagon and this provides the contact of the vibrating beam with the open wagon. As the resting wall is put on the mobile levers, rested on the hinge bearings, it has undesirable level of freedom (ability to move lengthwise). To fix it and to prevent from possible movements lengthwise, between the disks and the face surfaces of the wall roller rests are set. Two separate tilting drives (left and right) are basic gears of the wagon tippler. Each drive has one drive gear wheel. The drives are not connected with a rigid shaft; its functioning made by the metal construction of the rotor that provides necessary rigidity and strength even when one drive operates. The drives are supplied with shoe brakes with electromagnets of the direct current, and with additional mechanical fixation of the drive couplings, in case of necessary rotor stopping in an intermediate position for clearing the open wagons manually. The rotor rests on the roller supports through the circular rails (tyres). Each support has four rollers, connected in pairs with balance beams, hinge rested on the general frame. The rollers of the one outer support are made two – flanged, the others are unflanged. All of them are made of the high – strength steel 65T and designed for a long term of operating without a change. Together with the wagon tippler the electro – mechanical fixing arms in the starting position are also delivered. They are located on the foundations between the rails of the approach ways on the both sides of the wagon tippler. The purpose of the fixing arms is a strict alignment of the rails of the approach ways of the platform rails, and also protecting of the rotor from a casual turning during moving open wagon into it. The fixing arm consists of the fixing rod with a roll moving in four rolls fixed on the general frame. The fixing rod is put into motion with a screw ending drive the IIBM type.  Peripheral unloading system is the specialty of VSP  18 to 20 Wagons tippled per Hour.  The tippling process also depends on the availability of stacking streams (stackers, conveyors)
  65. 65.  The Wagons are placed in the Tippler with the help of PUSHER CARS.  Each Wagon Tippler has two pre – tippling lines and one pusher car in each line which are operated with power supplied from DSL / bus bars.  Each pusher car has six axles each having a motor of 37 KW capacity and aided with electro – magnetic brakes. 3.2 OPERATIONAL DESCRIPTION The wagon tippler operates in the following way : 1. Purposed for unloading open wagons are moved to the wagon tippler with a pusher and one by one are placed on its platform. Putting the open wagon to a certain position on the platform is made by the engine – driver assistant visually on the equal distances from the symmetry of the platform; 2. The engine drive of the wagon tipper, after getting the allowance instruction of the assistant, sends the command to the gears for tipping over. At this moment automatically, in a certain order, unfixing of the rotor takes, then the clamps lowering, the wall moving, and (after the hydraulic drive operate finishing) the drives switching as well. The drives of the tippler provide a smooth starting and smooth stopping of the motor in the rotor in the extreme positions. The wagon tippler construction makes it possible to turn the rotor to the angle of 175°, to stop it if it is necessary in any intermediate position. 3. After the rotor is stopped in the tippled over state the vibrators are switched on automatically. The operating period of the vibrators can be regulated and changed in the interval of 0….10 sec. 4. After unloading of the open wagon the tipping over drive motors are switched to the reverse motion, and all the gears moving are repeated in the reverse order (the motor returns to the starting position, the clamps are lifted, the wall is removed, the rotor is stopped). And besides, the switching on of the clamps takes place at the movement when the rotor turns to 90° as minimum, and the wall removing is made after the full stop of the rotor. 5. After the rotor returns to the starting position the next open wagon is moved by the pusher and simultaneously the open wagon pushes off an empty one. 6. In case of not full dump of the open wagon the tipping over procedure is related. And in case of necessity the cleaning is made manually, and the wagon should be stopped over 90°, the drive is braked the drive pulleys are stopped, and also the safety measurements for the personnel should be observed. 3.3 BRIEF ITEMS OF ROTARY WAGON TIPPLER 1. 3 – Rotor Disc 2. Resting Wall 3. Hydraulic Clamp Arrangement 4. Vibrator Units for discharge the total material 5. Rail Alignment System 6. Dust Suppression System 7. Lubrication System 8. VVVF Drives with 30 KW Motor each 9. CCVM System to locate the Wagon in proper position
  66. 66. 10. Electromagnetic Brake Arrangement 3.4 PURPOSE & TECHNICAL PARAMETERS OF ROTARY WAGON TIPPLER The Wagon Tippler can be used in the coal and raw material handling storage of the intended iron and steel works, Thermoelectric station as well as in the river and seaports to transfer the granular material from the railway trains. Technical data and service condition of the wagon tippler are as followings : Turning angle of the Rotor 175° Time of open Wagon unloading (Direct and reverse motion) 63 - 75 seconds General mass with the freight Up to 110 tone Height from the rail head 2250 - 3735 mm Width 3078 - 3500 mm Length according to the Automatic Couplers axles 10715 - 13729 mm Kind of the Current Alternating Current (AC) Voltage 415 V Frequency 50 Hz Installed Power 88 KW Overall dimension of the Wagon Tippler – Length X Width X Heigth 16700 X 9620 X 8720 Expiry operation term before the first overhaul 5 Years The norms operation term 20 Years Climate made design T2 Type Rotary Gravity Clamping Rail Guage 1676 mm (5’ 6” Broad Gauge) Carriage track 1360 mm gauge (optional) Tippling Time per Cycle ( Forward – 30 seconds , Pause – 10 seconds , Backwards – 20 seconds ) Total 60 seconds Overall dimension of tippler (L – 19800 mm, B – 9600 mm, H – 8505 mm, L of platform – 16700 mm) Loading equalizing roller support 3 Nos. Total no. of rollers 12 Diameter of roller 750 mm Width of roller working surface 115 mm Reduction Gear Boxes 2 nos. of Helical Gear Boxes, Reduction Ratio 40 Open drive Spur straight tooth Reduction ratio 14 Brakes 2 Nos. D.C. Electromagnetic brakes dia. 500 mm Prime Motors 2 Nos. slip ring induction motors

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