Jindal report

Report on summer
internship at JSW
Time motion study on wagon tippler
Submitted by: Ajay Joshi (SKSVMACET)
Vijay Kumar GP (BITM)
Raviprakash MG(PESIT)
Sai Srinivas P (SIT)
Syed Bashu S (GECK)
Karthik S Athreya (SJCE)
Guided by: Basavaraj Bomman
Siddaram

JSW Page 1
INTRODUCTION:-
As part of the curriculum, the summer internship was carried out for a period of 4 weeks at JSW Steel
Limited, Ballari, and Karnataka. The first week was visiting the individual departments involved in
steel making, where we came to understand how steel and products were produced. The rest of the
month was spent in the Wagon tipplers under the Raw material handling systems (RMHS) where
the internship was continued.
ABOUT THE COMPANY
JSW Steel Limited, Ballari, Karnataka.
JSW (Jindal South West) Steel Ltd is an Indian steel company owned by the JSW Group based in
Mumbai, Maharashtra, India. JSW Steel is India’s leading private sector steel producer and amongst
the world’s most illustrious steel companies with an installed capacity of 18 MTPA. JSW Steel boasts
of one of the largest blast furnace with a capacity of 3.3 MTPA, taking JSW’s overall capacity to
12 MTPA at Vijayanagar, Karnataka, its flagship steel plant. With its plants located across 6 strategic
locations in South and West India, JSW Steel will continue to raise the bar with its high quality &
diverse product range.
JSW Steel offers the entire gamut of steel products – Hot Rolled, Cold Rolled, Galvanized,
Galvalume, Pre-painted Galvanized, Pre-painted Galvalume, TMT bars, Wire Rods & Special Steel
Bars, Rounds & Blooms. JSW Steel has manufacturing facilities at Toranagallu in Karnataka,
Vasind&Tarapur in Maharashtra and Salem in Tamil Nadu.

JSW Page 2
JSW STEEL PRODUCTS
Hot rolled coils Wire rods
Pre-Painted
Products
Hot slabs
Cold rolled
coils
TMT Bars
Special steel
Galvanised sheets
Colour Coated Steel
Hot rolled
sheets

JSW Page 3
WEEK 1 :- (PLANT VISIT)
Raw Material Handling System
Beneficiation Plant
Agglomeration
Coke Ovens
Blast Furnace and Corex Plant
Steel Melting Shop
Hot Strip Mill
Cold Roll Mill
Wire Rod Mill
Bar Rod Mill
Logistics

JSW Page 4
1. RMHS (Raw Material Handling System):-
RMHS department handles the raw materials which are brought into the plant(via trains and trucks).
The raw materials are dumped from the train wagons with the use of wagon tipplers and send for
sorting via v shaped conveyor belts. The basic steps involved in the RMHS plant are
a. Stacking:- different materials are stacked respectively by their quality and grade.
b. Blending:- raw materials of different grades are blended to achieve a specific grade and
quality. This raw material is then sent into the silos for storage.
c. Supply management:- as per the requirement of the subsequent plants the raw materials
are transported from the silos to the plants via rails.
Major facilities at RMHS:-
i. Wagon Tipplers (8no.) to unload the material received through Rail.
ii. Truck Unloading Stations (5no.) to unload the material received through Road.
iii. Track Hoppers (2no.) to unload BOBSN, BOBRN type wagons.
iv. Stacker cum Reclaimer(19no.) to stack the material as well as reclaim
v. Conveyor Belt systems for transportation of materials.
vi. Bins, Bunkers, Crushers, Screening houses.
vii. Pollution Control Equipment (Dedusting system).

JSW Page 5
2. Beneficiation :-
It’s the process which removes the gangue minerals from ore to produce a higher grade product
(concentrate), and a waste stream (tailings). Some beneficiation processes are froth flotation and
gravity separation.
 The capacity of BP-2 is 20MTPA.
 7 Modules
 Largest BP in India.
3. Agglomeration :-
Agglomeration is the accumulation of smaller particles to form a larger particle. In JSW
agglomeration is of two types:-
I. Pelletization (pellet plant):
II. Sintering(sinter plant)

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1.Pellet plant:-
In a pellet plant, ore from the beneficiation plant, having size less than 3mm is sent to
transform into 8 to 16 mm size balls with the help of balling disc or balling drum. The ore
from the BP has high moisture which is reduced by adding dry dust(ESP dust) which are
collected from the plants with the help of electrostatic precipitator. This is then mixed with
the fluxes and sized into the required shape. The pellets are screened to remove the unwanted
pellet sizes and the remaining pellets are sent off to the drying and cooling zone. After this,
the pellets are sent to the blast furnace via conveyor belts.
2 Sinter plant:-
The base mix from the beneficiation plant are collected from the conveyor and mixed with
the required moisture and flux as per the requirement of the blast furnace. Its transferred into
trolley cars, which move with help of rollers, it moves into the furnace (burners). Here the top
• 2.3 MTPA
• 204 m2 Sintering Area
• Bin Blending
SP-1
• 2.3 MTPA
• Base Mix
• WHRS & Steam Injection
SP-2
• 5.75 MTPA
• Base Mix
• WHRS
SP-3
• 2.5 MTPA
• Base Mix
• WHRS & Steam Injection
SP-4

JSW Page 7
layer of the base mix is heated at 1200C. With the help of Waste gas blower fans, the air is
sucked from the bottom of the car to ensure thorough combustion takes place. The waste
gasses are blown out with the help of ID impeller fan to the surrounding. It is dumped in form
of cakes at the sinter cooler where the cooling array rotates at a speed of close to 1 revolution
per hour. The heat lost is recovered by the Waste Heat Recovery System(WHRS) to produce
steam which is used in other plants and energy production.
3 Coke Ovens :-
Coke is a fuel with few impurities and a high carbon content, usually made from coal. This
coke making is done in coke ovens. The blended coal from RMHS is processed to form coal
cakes. The cakes are fed into batteries (coke oven) where volatile materials are removed as by
products (like tar and ammonia) and coke is obtained. . There are 4 Coke Ovens in JSW.
The capacity of Coke Oven-3 is 1.5MTPA and Coke Oven-4 is 1.9MTPA.No. Of Ovens in
CO-3 and CO-4 is 224 and 288 respectively. Coals are blended for coke making to:
a) Obtain the desired coke quality and yield
b) Control oven wall pressure
c) Optimize by-products yield for conventional slot ovens
d) Gas (used to power the coke ovens), tar, ammonium compounds etc
Minimize cost (or, in the better operations, maximize value)

JSW Page 8
There are two types of coke ovens :-
i. Recovery coke making( in the absence of oxygen) :
 By-products are recovered
 High cost of erection &commissioning
 Retrofitting is very difficult.
 High operational cost.
 Very difficult to maintain pollution norms.
ii. Non-Recovery coke making( in the presence of oxygen):
 By-products are combusted & can be used to generate power
 Low cost of erection & commissioning
 Flexible for retrofitting.
 Low operational cost.
 Extremely environment friendly.
In Coke Ovens 1 & 2 Cooling of coke is done by Wet Quenching. In Coke Ovens 3 & 4 Cooling is
done by Dry Quenching.
4 Blast furnace :-
The blast furnace is a counter current reducer.It is a refractory lined steel shell with a cooling
system. In a blast furnace, fuel, ore, and flux (limestone) are continuously supplied through
the top of the furnace, while air (with oxygen steam enrichment) is blown into the bottom of
the chamber, so that the chemical reactions take place throughout the furnace as the material
moves downward. The end products are usually molten metal and slag phases tapped from the
bottom, and flue gases exiting from the top of the furnace. The downward flow of the ore and
flux in contact with an upflow of hot, carbon monoxide rich combustion gases is a
countercurrent process.

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Inputs (Stored in stock house and charged from top):-
Ferrous (Sinter, pellet , Lump ore , Small Sinter from agglomeration plant)
Fuel: Coke, Nut Coke
Additives: Dolomite, Dunite, Limestone & Quartzite.
Gases: Air, Oxygen and steam all at 1200 𝑜
𝐶 are blown from bottom of furnace.
The driving forces in the blast furnace are:-
a. The blast furnace is filled with alternate layers of coke and ore containing burden
b. Hot blast s blown into the furnace via tuyeres.
c. Hot blast gasifies the reductant components in the furnace, those being coke as well as
auxiliary materials injected via tuyeres.
d. In this process, the oxygen in the blast is transformed into gaseous CO. The resulting gas
has temperature of between 2100 to 2300.Coke is consumed and voidage is created.
Molten Iron along with slag is collected from the bottom of the furnace and slag is separated.
This molten metal is then collected in torpedoes and sent to the steel melting shop.
5 Steel Melting Shop:
The molten metal from the blast furnace, Corex and DRI plants is sent to the Steel Melting
Shops (SMS plant). In here, the iron is converted into steel by reducing the carbon content.
The molten metal is treated in the Basic Oxygen Furnace, where heated oxygen is blasted at
high speed and pressure and the carbon is removed in the form of CO and CO2 gases. Then
other impurities like sulphur, manganese etc are removed by other process like
desulphurization. The remaining impurities forms oxides which is removed with the help of
lime stones (by forming complexes ).

JSW Page 10
The molten steel is sent to the continuous caster to form billets and slabs.
6 Hot strip mill:-
Hot rolling has four metallurgical stages: reheating, roughing, final rolling and cooling. The
slab temperature level and uniformity are controlled with the slab dropout temperature (DOT)
and the slab residence time in the furnace. The raw material for HSM is Slabs of Iron made by
SMS plants. The slab is fed to furnace. HSM has 3 furnaces each of capacity 350 tons/hour.
Slab now has temperature around 1300 ‘C. The scales formed on the surface of the slab due to
oxidization of Iron on exposure to atmosphere is removed by HSB (Hydraulic Scale Breaker).
The slab now sent to R1(rough mill-1) of 2 passes here slab thickness reduced slightly. Edger
is on sides which maintain the width of the slab. R2 also performs same actions as R1 with 5-
7 passes. In R2 thickness has been reduced to major extent. Shear cutter cuts the slab both in
front and back side.
The Finishing mill reduces the thickness of the slab according to the requirement which
ranges from 1.2mm to 24mm. The Finished strip sent to ROT(Run Out Table) where
calculated amount of water is poured to get certain properties to meet the customer demand.
Then the strip will be sent to DC (Down Coiler) here the strip is rolled and coiled. While
coiling the temperature of the strip is around 650 ‘C.

JSW Page 11
The coiled strip is sent to the strip yard where it cools down in atmospheric condition. And
the strip coil is sent to customer as and when required.
7 Cold roll mill:-
Cold rolling is the process of reducing the thickness of the hot rolled sheet at temperatures
below the recrystallization temperature and increasing its hardness and stiffness. The hot
rolled sheets are uncoiled sent to the PLTCM (Pickling line and Tandem cold mill), here the
sheet is initially treated with NaOH solutions to remove impurities. This is then cold rolled
and coiled.
These sheets can be galvanised and annealed as per customer requirement. The cold rolled
sheets and heated and then passed through liquid zinc to get and even coating and if annealing
is required, the sheets are passed through a series of rollers.

JSW Page 12
8 Bar rod mill & Wire rod Mill:-
Input raw material for bar rod mill are cast billets coming from continuous casting process
(CCP) division of SMS to the billet yard of LP mill, through four billet roller table (cold
charging) and single billet roller table (hot charging). Then the billets are charged in the
reheating furnace and then passed onto Descalar where scales are removed by spraying water
on to the billet by nozzles on a circular header surrounding the billet passing through.
And then passes through toggle shear, which is an emergency dividing shear consisting of a
pair of knives used primarily to cut a billet in the event of a cobble in the mill, thus limiting
the amount of material fed into the cobble.
Next the billet is passed through No Housing Stands which comprises of Roughing mill stand,
Intermediate mill stand and finishing mill stand which reduces the size and shape of the billet
as per the requirement of the customers. Product is guided into a set of rotating circular blades
that separates the two rounds. The separated products are then directed to the No-Twist Mills
for further reduction. Then the product is cooled and shear to the required length.
The wire rod mill is of similar process where the wire is produced and after the NTM, the
wire passes through the laying head which coils the wires and then goes for cooling and
collected with the help of verticals stand and packed.

JSW Page 13
9 Logistics:-
Logistics is the management of the flow of resources between the point of origin and the point
of destination. In order to meet some requirements, for example of customers or corporations.
The resources managed in logistics can include physical items such as food, materials,
equipment, liquids, and staff as well as abstract items such as information, particles, and
energy. The logistics of physical items usually involves the integration of information flow,
material handling, production, packaging, inventory, transportation, warehousing, and often
security.
The objectives of logistics department are:-
 Operating responsibility of Logistics is repositioning of raw materials, work in
process & finished goods where required at lowest cost possible & quality service.
 It is difficult to accomplish any Receipt/ Dispatch processes, repositioning of
products & manufacturing without a Professional Logistics Support.

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WEEK 2:- DEPARTMENT ALLOCATION AND PROJECT
RAW MATERIAL HANDLING SYSTEMS (RMHS)
1. OBJECTIVE: Raw Material Handling System (RMHS)
The objective of RMHS department is to receive, store, reclaim and feed the raw materials without
any deviations in their quality or in required proportions and size to the internal customers in time at
optimum cost ensuring fulfilment of Safety and Environmental norms.
2. Major Performance parameters:
Following are the major performance parameters for fulfilling the above objective:
2.1 Turnaround time of rake: <10 hrs
2.2 Moisture content in BF burden : <25KG/THM (Tons per Hot Metal)
2.3 Fine content in BF burden : <25KG/THM
2.4 Chemical fluctuation of raw material: < 0.35 T.Fe.s deviation (Total Fe. Standard)
2.5 Spillage: <0.075% of total material handled.
2.6 Dust emission Level in junction houses: <150mg/Cu.m
Acronym of Plants in JSW Complex:
ACRONYM EXPANSION
PP Pellet Plant
CPP Captive Power Plant
SP Sinter Plant
RMHS Raw Material Handling System
RM cell Raw material cell
BF Blast Furnace
CO Coke Oven

JSW Page 15
LCP Lime Calcinations Plant
HMPT Hot Metal Pre-treatment Plant(De-Sulphorisation)
JSWEL Jindal South West Energy Ltd
BOF Basic Oxygen Furnace
SMS Steel melting Shop
HSM Hot Strip Mill
WRM Wire Rod Mill
BRM Bar rod Mill
CTL Cut to length mill
CRS Central Repair Shop
RWTP Raw Water Treatment Plant
3. Introduction to RMHS:
As the name itself indicates the department is responsible for handling the
1. Raw materials which are required for producing the products in Iron making,
Agglomerations, Power Plants and Steel Making units for example Iron Ore, Coal and Fluxes
etc
2. Intermediate products for use in Iron making and SMS like Coke, Calcined lime, Sinter and
Pellets etc.
3. The products from these internal plants to storage yards or on-line feeding without storage to
Iron making and SMS units
4. Internally generated fines after screening in RMHS and internal customer plants which can be
re used for production process.
4. Activities in RMHS:
1. Receiving the material through Rail and Road, tippling in Wagon tipplers and Truck
unloading stations on to the transporting conveyors to Stacker re-claimer or online feeding
2. Stacking the material in piles and then reclaiming as and when required by internal customer.
3. Receiving the Internal plant products, stacking, reclaiming as and when required by internal
customers.
4. Crushing and Screening as and when required.
5. Mixing the material in a definite proportion, stacking and feeding to sinter plant as and when
required.
Apart from supplying direct raw materials to the Corex & Blast furnaces, RMHS also supplies raw
material to various plants producing the ingredients required for producing hot metal and Power. As a
policy of “Nothing to be wasted”, RMHS recycles the waste materials like BOF Sludge, LD Slag,
Mill-scale and fugitive dust.

JSW Page 16
5. Installed Capacities of JSW at 10 MT Level
RMHS in JSW initially was designed to handle raw material for a hot metal production of 0.8MTPA.
There has been a continuous growth in JSW plant capacity as seen from Table 1. RMHS handling
capacity and facilities also increased to the growing requirements.
 Table (1) Growth since Inception.
YEAR HOT METAL PRODUCTION
1998 0.8 MTPA
2000 1.6 MTPA
2004 2.5 MTPA
2007 4 MTPA
2009 7 MTPA
2011 10 MTPA
 As on date the RMHS is able to supply material for the following installed capacities.
Hot metal production 10 MTPA
Sinter Production 13.5 MTPA
Pellet production 6.14 MTPA
Power production 1460 MW
 RMHS CAPACITY at 10MT Level
RECEIPT 45 MTPA
(1.25 lakh Tons/day) average.
FEEDING 45 MTPA
(1.25lakh Tons/day)
6. RESOURS in RMHS
To achieve the objectives of the department and to fulfil the internal customer requirements
RMHS department has major facilities as mentioned below.
1. Material Yards, Bulk Material Handling equipments, auxiliary supporting equipments.
2. Conveyor Belt systems for transportation.
3. Bins, Bunkers, Crushers, Screening houses and Vibro-feeders etc..
4. Pollution Control Equipments.

JSW Page 17
5. Human resources for operation and maintenance of above facilities.
6. Supporting Departments and Internal Customers
6.1 Supporting Departments:
 RM CELL: Planning of raw material as per Business plan
 COMMERCIAL DEPARTMENT: Coordination with suppliers, ports, mines and
Transporters.
 LOGISTIC DEPARTMENT: Coordination with ports and railways for receipt of materials
through rakes.
6.2 Internal Customers:
RMHS is taking care of requirements of following internal Customers.
Plant Commissione
d date
Installed
Capacity
(MTPA)
Material required for 1
tonne of Product
(Tonnes)
Qty to be supplied
by RMHS
(MTPA)
Product
COREX 1
COREX 2
Aug-1999
Apr-2001
0.8
0.8
Total 1.6
4.33
4.33
3.10
3.10
Total 6.2
HOTMETAL
BF1
BF2
BF3
BF4
Apr-2004
Aug-2006
Feb-2009
Jul-2011
0.9
1.3
2.98
2.99
Total 8.17
2.80
2.80
2.7
2.7
2.63
3.64
8.09
8.09
TOTAL 22.45
HOTMETAL
PP1
PP2
Nov-2000
Jul-2011
3.3
2.84
Total 6.14
1.20
1.1
3.985
3.405
Total : 7.400
PELLETS
CO1
CO2
CO3
CO4
Nov-2004
Mar-2006
Jan-2009
Jul-2011
0.8
0.8
1.49
2.76
Total: 4.85
1.41
1.41
1.41
1.41
1.143
1.143
2.112
2.483
Total 6.881
COKE

JSW Page 18
BOF1,2,3
BOF4,5,6,7
SMS1
SMS2
Aug-1999
Oct-1999,
FEB2006,
JAN99,FEB0
9,DEC11,MA
R11
3.51
5.76
Total 9.27
TOTAL 5.45
TOTAL 8.90
Only C-Ore by RMHS
0.069
0.112
TOTAL : 0.181
Only C-Ore by
RMHS
0.069
0.112 TOTAL :
0.181
LIQUID STEEL
Plant Commissione
d date
Installed
Capacity
(MTPA)
Material required for 1
tonne of Product
(Tonnes)
Qty to be supplied
by RMHS
(MTPA)
Product
SP1
SP2
SP3
SP4
Jul-2006
Aug-2008
Mar-2011
Jul-2011
2.52
2.54
5.63
2.62
Total 13.31
1.22
1.22
1.22
1.22
3.07
3.11
6.909
3.210
Total 16.299
SINTER
LIME
KILNS
DOLO
KILNS
0.9
0.27
TOTAL 1.17
2.2
2.35
1.985
0.632
TOTAL 2.60
CALCINED
LIME
SBU-1
SBU-2
CPP3
CPP4
2x130MW
2x300MW
1x300MW
1X300MW
ELECTRIC
POWER
OBP1 0.36 1.26 0.4536 WASHED ORE
OBP2 2010,11 9.57 1.42 13.94 WASHED ORE
7. Sections in RMHS:
As seen from above, to cater to all the internal customers, RMHS has to operate through the
length and breadth of almost entire JSW plant. .To have a smooth control over the operation
in such huge area, RMHS operates notionally in following subgroups.

JSW Page 19
 RMHS 1 (Covering 4MT area WT 1 to 6, SR1 to SR7 stacking & feeding Corex 1&2,
BF1, BF2, Coke oven 1&2, LCP#1 and 2,PP1, SP1, CPP#1)
 RMHS 2A-7MT area (Stacking & reclaiming SR1 to SR4,and feeding BF3, SMS2,
LCP#2and 3, Coke 3 and CPP#2)
 RMHS 2A-10MT area (Stacking & reclaiming from SR5 to SR6, and feeding BF4,
Coke4)
 RMHS2B-7MT area (Stacking & reclaiming SR#7 &8, TBS1, BR1, feeding to
SP#3)
 RMHS2B-10MT area (Stacking & Reclaiming SR#9 and 10 and feeding to SP#2
and SP#4)
 BP2-RMHS ( Stacking & Reclaiming TBS#1,2 and 3, BR#1,2 and3,Feeding IOF to
BP2 plant )
 Energy yard (WT 7 & 8, Stacking & Reclaiming from SR-11 &12,Feeding Steam
coal to Power Plant + IOF to BP2)
10. Resources -Details
 10.1 Raw Material Yards: For receiving and storing the material coming in by
Conveyors/trucks. YARDS have been created at various places. Following are the various
yards, material stored and capacity of the yards.
10.1.1. Material wise Yard Capacity:
Material RMHS1
yard
7MT yards 10MT
yards
Energy
yard
BP2 yard Total
Iron Ore 2,50,000 1,60,000 1,85,000 - 5,70,000 11,65,000
Coal 3,80,000 3,65,000 1,70,000 2,20,000 - 11,35,000
Fluxes 2,00,000 1,80,000 1,35,000 - - 5,15,000

JSW Page 20
 Note: All Figures in Tonnes
 10.2 Bulk Material Handling Equipments in RMHS:
 10.2.1 Total Number of equipments.
Equipment RMHS1 RMHS2
A
RMHS 2B Energy
Yard
BP2-
RMHS
TOTAL
Wagon Tippler 4 2 - 2 - 8
Track Hopper - - - - 2 2
TUS 2 1 1 - 1 5
Stacker Re-claimer 7 6 4 2 - 19
Twin boom Stacker 1 - 4 - 3 8
Barrel Re-claimer 1 - 3 - 3 7
Transfer Car 1 - 3 - 3 7
Products as Raw
material
90,000 2,75,000 3,20,000 - - 6,85,000
Waste generated
as Raw
35,000 75,000 75,000 - - 1,85,000
TOTAL 9,55,000 10,55,000 8,85,000 2,20,000 5,70,000 36,85,000

JSW Page 21
 10.2.2 Individual Equipment Capacity.
Equipments Make Capacity Area Qty Remarks
Wagon tippler 1 L&T India 20 Tips/hr, RMHS-1 01
14 rakes a
day
(from4
tipplers)
Wagon tippler 2 L&T India 20 Tips/hr, RMHS-1 01
Wagon tippler 3 ELECON 20 Tips/hr, RMHS-1 01
Wagon tippler 4 ELECON 20 Tips/hr, RMHS-1 01
Wagon tippler 5 (
Tandem Wagon tippler)
DHI-DCW China 36 Tip/hr RMHS-1 01
12 rakes a
day (from 2
tipplers)Wagon tippler 6 (
Tandem Wagon tippler)
DHI-DCW China 36 Tip/hr RMHS-1 01
Wagon tippler 7 Wuhan Power
Equipments China
25 Tips/hr Energy Yard 01
8 rakes a day
(from 2
tipplers)Wagon tippler 8 Wuhan Power
Equipments China
25Tips/hr Energy Yard 01
Track hopper 1 CSIT & EC China 13 Hoppers, 6
Rakes a Day
RMHS-2B 01
12 rakes/day
Track hopper 2 CSIT & EC China 13 Hoppers, 6
Rakes a Day
RMHS-2B 01
Stacker Re-claimer 1 L&T India Stack: 1250 TPH,
Reclaim: 667 TPH
RMHS-1 01
Reclaim: 667 TPH
RMHS-1 01

JSW Page 22
Reclaim: 667 TPH
RMHS-1 01
Stacker Re-claimer 4 FFE Minerals
India
Stack: 1500 TPH,
Reclaim: 667 TPH
RMHS-1 01
Stacker Re-claimer 6 ShouGang China Stack:1200 TPH,
Reclaim: 700 TPH
RMHS-1 01
Twin boom Stacker L&T India Stack: 1000 TPH RMHS-1 01
Barrel Re-claimer L&T India Reclaim:1000TPH RMHS-1 01
Stacker Re-claimer 1 Elecon India Stack: 2000 TPH,
Reclaim:1500 TPH
RMHS - 2A 01
Reclaim: 1500 TPH
RMHS -2A 01
Reclaim: 1500 TPH
RMHS -2A 01
Reclaim: 1500 TPH
RMHS -2A 01
Stacker Re-claimer 5 DHI-DCW China Stack: 2000 TPH,
Reclaim: 1500 TPH
RMHS -2A 01
Stacker Re-claimer 6 DHI-DCW China Stack: 2000 TPH,
Reclaim: 1500 TPH
RMHS -2A 01
Truck Unloading Station 25 Trucks/hr/ Station RMHS -1,2A&
2B
04
Truck lifting Hydraulic
station
JP Engg &
Hydraulic
Equipments
25 Trucks/Hr/ Station RMHS -2A 1
Reclaim: 1500 TPH
RMHS -2B 01

JSW Page 23
Stacker Re-claimer 9 CSIT & EC China Stack: 2000 TPH,
Reclaim: 1500 TPH
RMHS -2B 01
Stacker Re-claimer 10 CSIT & EC China Stack: 2000 TPH,
Reclaim: 1500 TPH
RMHS -2B 01
Barrel Re-claimer 1 Elecon Reclaim: 1500 TPH RMHS -2B 01
Barrel Re-claimer 2 Elecon Reclaim: 1500 TPH RMHS -2B 01
Barrel Re-claimer 3 Metso Minerals Reclaim: 1500 TPH RMHS -2B 01
Transfer cars Elecon India - RMHS -2B 3
Twin boom Stacker 1 Elecon India Stack: 2000 TPH RMHS -2B 1
Twin boom Stacker 2 Elecon India Stack: 2000 TPH RMHS -2B 1
Twin boom Stacker 3 Metso Minerals Stack: 2000 TPH RMHS -2B 1
Twin boom Stacker 4 Metso Minerals Stack: 2000 TPH RMHS -2B 1
TUS 25Trucks/hr /Station RMHS -2B 1
Truck lifting Hydraulic
Station
JP Engg &
Hydraulic
Equipments
25Trucks/hr /Station RMHS -2B 1
Stacker Re-claimer 11 NHI China Stack:2000 TPH,
Reclaim: 1500 TPH
Energy Yard 01
Stacker Re-claimer 12 NHI China Stack: 2000 TPH,
Reclaim: 1500 TPH
Energy Yard 01
Twin boom Stacker 1 CHEC China Stack: 2000 TPH BP2- RMHS 01
Twin boom Stacker 2 CHEC China Stack: 2000 TPH BP2- RMHS 01
Twin boom Stacker3 CHEC China Stack: 2000 TPH BP2- RMHS 01
Barrel Re-claimer 1 CHEC China Reclaim: 1500 TPH BP2- RMHS 01

JSW Page 24
Transfer car 1 - BP2 RMHS 2
Hammer crushers-
(Flux crushing)
Jiangsu Hengye
China Make
Metso crusher
150 TPH
170 TPH
100 TPH
RMHS 2B -
7MT
RMHS 2B-
10MT
04
08
01
Primary:2Sec
ond.:2
Primary:4Sec
ond.4
Roller crusher-
(Coke crushing)
China shang dung
China shang dung
Two Roll:30 TPH
Four roll: 70 TPH
RMHS 2B-
7MT RMHS
2B-10MT
5
6
Primary:3Sec
ond.:2
Primary:3Sec
ond.:3
11. Pollution Control Equipments in RMHS:
Dust is the main cause of Pollution in RMHS area. Fine dust is generated during discharge of material
from one Transfer point to the other of conveyor and also while reclaiming the material. Dust is also
generated due to the continuous movement of Trucks and tippers in the area. Continuous efforts have
been taken up to reduce the dust emission. Installation of Following dust control measures speaks up
the commitment in reducing the dust emission.
 Industrial Vacuum Cleaning Machine: Fine dust heaps collected at Junction houses, tippler
areas cleaned with these machines. The suction point is extended to all floors with
permanently installed piping system.
 Plain water sprays system: Whenever Material on the belt detected by Belt Load detector on
a moving conveyor, the water and air mixture is sprayed at the point of discharge. Also water
mist is sprayed in wagon tippler at the point of Unloading.
 Pre-wetting system: Water is dripped in to the unloading wagons at the entrance of wagon
tippler by Pre-wetting system so that dust does not emanate while unloading.
 Dry-Fog system: Whenever material on the belt detected by Belt load detector, system starts
spraying a Fog produced by high pressure air and water and is sprayed in the discharging
chute area so that dust is suppressed.
 Yard Sprinklers: High pressure water is sprayed on material heap, and vehicle moving area
with the help of water sprinklers for avoiding dust raise.
 De- dusting system: System comprising of Induced draught fan sucking the air through pipes
connected to discharge chutes and conveyor hoods. Air with dust passes through filter bag
house .Dust gets stuck on the filter cloth and clean air is discharged to the atmosphere. The
dust is shaken off at regular intervals with compressed air and collected through a system of
screw conveyors.
 Conveyor hoods: Covering the conveyors by hoods all along the conveyor gallery dust
spreading is avoided.

JSW Page 25
 Tarpaulin covering: Raw material heaps in yard are covered with tarpaulin cover to protect
from rain and also avoid dust carry away with wind.
 Wind-Screen: Wind Screens are installed in RMHS 1 & Energy yards to reduce velocity of
wind into yards so that emission can be avoided.
 Air compressors: Air compressors are installed for supplying air at high pressure to fulfil the
De-dusting system requirement also to create water spray/ mist. Water is supplied through
high pressure pumps in Water pump house.
DESCRIPTION OF WAGONS
Most wagons are made of steel, except for a few special-purpose wagons. Some specialized wagons
have been made with stainless steel or special steel alloys to reduce corrosion. Some Recently [12/04]
with the rising price of steel IR has been looking into using steel substitutes, and plans have also been
drawn up for the production of aluminium-body wagons (see BOBNAL, BOBRAL below). It is
thought that about 750 aluminium wagons will be built in 2005-2006. Interestingly, some of these are
said to be of a 4-wheel design. The tare weight is expected to be reduced by about 4.2 tonnes. A few
aluminium wagons are already in use on a trial basis. Aluminium wagons besides being of a lower
cost and having a lower tare weight, also have the advantage of suffering less corrosion in many
circumstances. A typical rake with aluminium wagons instead of steel ones would carry almost 240t
more goods.
As seen in the permanent way section, many BG routes have rails that allow axle loads of up to 25t, or
in many cases 22.5t. However, normal operating procedures on IR restrict BG wagons to 20.3t of axle
load. Now [3/05] it has been proposed that this be raised to 23t.
Descriptions of some wagon types follow below:
BOX High-sided bogie open wagon. Side discharge arrangement. 55 ton capacity, 25 ton tare. Used
for coal and other bulk goods. About 7,000 of these are in use [2006]; this class is in decline since the
advent of the BOXN and other variants. There used to be over 14,000 of these in the 1990s, and about
8,800 as late as 2005. BOXT, BOXR, and BOXC are the same with transition, screw, and CBC
couplers, respectively.

JSW Page 26
BOXNBOX variant:
High-sided bogie open wagon with pneumatic brakes, high tensile CBC couplers, CASNUB cast
steel bogies, cartridge tapered roller bearings. Perhaps the most common wagon, there are around
64,000 or more of these in use [2002-2006]. Used for bulk movement of material commodities (coal,
iron ore, stone, etc.).
Max. axle load 20.32t
Spring grouping per bogie - outer 12
Spring grouping per bogie - inner 8
Tare 22.47t
Payload (RDSO spec.) 58.81t
Payload (revised, incl. tolerance) 64+2 = 66t (RC 13/2007)
Gross load (RDSO spec., excl. tolerance) 81.28t
Gross load (revised, incl. tolerance) 86.47+2 = 88.47t
Capacity 56.3m3
Width 3.2m
Height 3.225m
Length over headstock 9.784m
Length over coupler faces 10.71m
Distance between bogie centres 524m
Standard rake size (2007) 59
Total train load (incl. BVZC, RDSO spec.,
excl. tolerance) 4809.3t
Total train load (incl. BVZC, CC+8+2) 5399.32 (BOXNM1) A.L. - 22.9 tt
Total train load (incl. BVZC, revised, incl. tolerance) 5233.53t
RDSO design speed (loaded) 60 (CC+8+2), 75 (CC)
RDSO design speed (empty) 80 (CC+8+2), 80 (CC)
CRS sanctioned speed (loaded, SER) 60km/h (CC+8+2), 75km/h (CC)
CRS sanctioned speed (empty, SER) 80km/h (CC+8+2), 80km/h (CC)

JSW Page 27
AAR 'E' high-tensile coupler with high-capacity draft gear. CASNUB 22 NLB Cast Steel bogies. Air
brakes and parking brakes. Rated speed 80km/h (some older ones were rated at 75km/h).
BOXN-HA
The BOXNHA type is a BOXN variant with improved bogies and higher capacity, fit for 100km/h.
(Suffix 'HA' = 'high axle load'.) Uses IRF 108HS cast steel bogies with secondary suspension, CBC
couplers, and single-pipe air brakes. The wagon is similar to the BOXN wagon in length and width,
but taller by 225mm. Rake loads rise to 3783t from the 3411t of ordinary BOXN wagons.
These wagons were designed for higher speed (100km/h) operations with higher axle loads (22.1t
for coal, 23.5t for iron ore). 301 of these wagons were produced between Nov. 1999 and March
2000 and at first allocated to the Hospet - Chennai section. However, the track on this section could
not handle the higher axle loads (the wagons required 52kg 90 UTS rails) and upgrade plans were
dropped, so the decision was made to run the BOXN-HA wagons with reduced loading and stop the
manufacture of more of them. About 400 more of them were eventually manufactured before
production was halted permanently. RDSO later developed the BOXN-HS variants (see below) which
later became more widely used for high-speed iron ore and coal loads. BOXN-HA production has not
resumed although now many main line sections have 60kg rails and are quite capable of handling
the wagons' higher axle loads. It appears that the poor condition of some bridges and other track
structures may have been the reason behind halting the BOXN-HA production. Had this wagon come
into general use, freight rakes of 5220 tonnes could have been run. These wagons number about 731
as of 2006.
Max. Axle load 22.9t
Some variants 23.5t.
Spring grouping per bogie - outer 14
Spring grouping per bogie - inner 14
Tare 23.17t
Payload (RDSO spec.) 65.23t
Payload (revised, incl. tolerance) 66+2 = 68t
(RC 102/2007)
Gross load (RDSO spec., excl. tolerance) 88.40t
Gross load (revised, incl. tolerance) 91.17t
Capacity NA
Width 3200mm

JSW Page 28
Height 3450mm
Length over headstock 9780mm
Length over coupler faces 10713mm
Distance between bogie centresNA
Standard rake size (2007) 59
Total train load (incl. BVZC, RDSO spec.
, excl. tolerance) 5229.4t
Total train load (incl. BVZC, CC+8+2) NA
WAGON TIPPLERS AND CYCLE TIME:-
The Wagon tippler is one kind of special bulk material handling machinery that has been
extensive utilized in port, steel plants & power plant. Wagon Tipplers are used for unloading of raw
materials received through railway wagons by inverting the same on its own centre of gravity
through an angle ranging from 145°- 170° there by discharging its content in the hopper. Tippler is
designed to handle wagon having gross weight of 110 tons, height from 2250 mm to 3735mm and
maximum overall width of 3500mm.Side arm charger places wagon of the rake on the tippler table
which is then tipped by the Tippler. Material discharged into the hoppers is conveyed to the
downstream conveyors through apron feeders. With a great demand in Material Handling Wagon
Tipplers are categorized as:-

JSW Page 29
1. Side Discharge Tippler.
2. Rotary Tippler
Side Discharge Type:
These are the types of the tippler in which during operation wagons got rested on the side
beam/pad after tippling to 10° and clamps got engaged after 40°. Tippling of the wagon limited to
145° for unloading the content in the wagon. Clamping is done to wagon from the top & quantity of
the clamps may be four or six depending on the design.
Rotary Type:
These are the types of the tippler in which during operation wagons got rested on the side
beam/pad by hydraulic cylinders and clamps engaged on the wagon at Zero degree. Tippling of the
wagon limited to 170° for unloading the content in the hopper. Clamping is done to wagon from the
top & qty of the clamp eight or twelve i.e. four or six on either side depend on the design or the
requirement of the customer.

JSW Page 30
Types of Rotary Tippler:
These types of the tippler called tandem type in which no of wagons tippled at a time vary, which
may be double wagon, triple wagon or four wagon at a time depending on the requirement. At JSW
we have two tippler where two wagons are tippled at a time.
Double Wagon Tippler Four Wagon Tippler
TIPPLER TYPE & CAPACITY IN RMHS
Equipment Make Type Capacity
Tips/hr
Area Commissioning Qty Total Rakes
/day
WT 1 &2 L&T
India
Side
Discharge
20 RMHS-
1
1998 02 8
WT 3&4 Elecon
India
Side
Discharge
36 RMHS-
1
2012 02 12
WT 5&6 DHI
DCW
China
Rotary
(Tandem)
25 Energy
Yard
2011 02 8
WT 7&8 Wuhan
Power
Eqpts.
China
Rotary

JSW Page 31
WAGON TIPPLER: Wagon Tippler is heart of the Bulk Material Handling system 90% of the raw
material is received through Rail which is unloaded at tippler. Following are the equipments involved
in the tippler small malfunctioning in any will stop the tippling process completely.
 Table
 Clamp
 Side Arm Charger
 Wheel Gripper
 One way stopper
 Weigh Bridge
 Hopper
 Apron Feeder
Side Discharge Tippler: Table is structure which can tipple one wagon at time. Wagon rested on the
side beam during tippling after 10°and clamps operated after 40° of tippling. The drive unit is rack
and gear system which may be electromechanical or hydraulic.
TABLE
Rotary Tippler: Table is the C-type frame that can tipple one/two/three/four wagons at a time
depending on the design. For tipping of the wagons, the hydraulic locking cylinder is used to support
the sides of the wagon by side beam and clamping the wagon solidly from top. The drive unit is rack
and gear system which may be electromechanical or hydraulic.
TABLE-END RING/FRAME
END FRAME
END RING

JSW Page 32
Two end rings/frames are respectively positioned (15 meter) at each end of the tippler each of them
tied to each other with the help of side beam. An open sector rack is installed which centers the circle
of each end ring/frames and engages the driving unit of the tippler. One where the wagon enters is the
fixed part & where the wagon exits is the floating part.
TABLE-SIDE PAD/BEAM
Side Discharge Tippler: It is a heavy structure which tie both the end frames of the tippler & restrict
there misalignment. Table rest over it while tippling.
Rotary Tippler: The side wagon beam is a structure with the box section long in 14.44m. A plate
sized in 12.8 x 2.34m is attached to the side wagon beam whose extension by Hydraulic Cylinder just
contacts the wagon in the tippler before the unloading cycle.
In both rubber liners are provided to avoid the slipping of the wagon while operation.
TABLE-SUPPORT ROLLER
The idler consists of 1 set of concaved-margin roller (Fixed) and 1 set of fillet roller
(Floating); it is installed on the braced frame and consists of 8 idlers in total. The idler contact surface
has a diameter of 630mm.4 fillet rollers are installed at the outlet end, and 4 concaved rollers are
installed at the inlet end. At JSW for side discharge tippler we do not have support roller table for the
same rotates over the drive pinion.

JSW Page 33
TABLE-LIMIT SWITCH
Photo electric device & over travel limit switch:
There are sensors that arranged cross the platform obliquely to indicate the inlet and outlet of the
tippler. The limit switch is heavy-duty type and is installed at the ground at the inlet end of the tippler.
The pressure bar is installed at both ends. These limit switches are provided according to the safety
measures for rigid coupling, and are used for standby for the normal limit detected by the encoder
installed on the driving unit.
TABLE-TECHNICAL PARAMETERS
Type Side discharge/Rotary type
Driving mode for tippling Toothed rack
Supporting means Support Roller/Drive pinion
Tipping capacity (wagon/hr) 20-25
Length: 10715-13729mm
Width 3136-3200mm
Height 3161-3735mm
Track type (kg/m) 60kg (India standard railway track)
Rated loading capacity 120t
Rotation cycle 60s
Angle of rotation 145-170°
Driving motor Mechanical/Hydraulic
Hydraulic drive Axial Piston Pump
Working Pressure 120-160 bar
Driving Gear/Pinion
Tooth number: 21
Modulus: 22
CLAMP

JSW Page 34
Clamping is the important operation of the tippler which are use to hold the
wagons solidly so that gross wt wagon near to 100 tons can be tippled to certain angle to
unload the content in the hopper. No of clamps for each tippler varies as design &
requirement. They are attached side wagon beam in rotary type or mounted over the beam
in side discharge type. Wagon is positioned on the table so that the clamping mechanism is
homogenously distributed on the wagon and are not related to wagon size. The cushioning
device on the clamp face will contact the wagon when the wagon clamping mechanism runs.
The wagon clamping mechanisms are operated by the hydraulic cylinder that is installed
at the internal side of the wagon-clamping mechanisms.
CLAMP- TECHNICAL PARAMETERS
• Hydraulic Drive Vane Pump
• Mode for wagon-clamping Hydraulically
• Working Pressure 45-60 bar
• Wagon-clamping cylinder 4-12
• Mode of Side Pad mechanism Hydraulically
• Side Pad Cylinder 0-4 cylinders
• Working Pressure 40-60 bar
• Operation starts 0 degree/40 degree
• Supporting means side beam/ springs
Above parameters will vary for each tippler depending on the design, supplier &
customer requirement.
SIDE ARM CHARGER
The SAC is the traction device with side arm which is designed to haul the
marshaled train with a maximum load of 7000T (59 wagons) into the wheel clamper/entry
point and one loaded wagon into the tippler. The SAC travels along the inlet end of the
tippler, position the wagon at centre of the table moves back to initial position for pulling
the loaded wagon in the table & pushing the empty wagon from the exit point of the tippler.
The center distance of the travel rail is 1600mm and it takes up transmission by vertical
toothed rack. It is a heavy-duty packaged-type box section structure which is designed to
meet the load and stress required for hauling the loaded track wagons into the oblique
surface of the tippler.

JSW Page 35
SIDE ARM CHARGER-ARM
It is the heavy structured arm installed in the rotation axis which is lifted and
lowered with joint action of hydraulic cylinder and crank link mechanism by single hydraulic
cylinder. At both ends of the arm, there are wagon hooking device for connecting and
hooking the wagon hook, hauling and pushing the wagon. The wagon hook in the arm is
controlled by a small hydraulic cylinder installed in the SAC arm to achieve hydraulically
unhooking.
The connecting device and proximity switch are also attached to the end of the
connecting device of the arm for detecting whether the connecting device of the SAC
coupled/decoupled with the wagon hook.
SIDE ARM CHARGER-DRIVE UNIT
The SAC is driven by 2 to 6 independent vertical travel driving units depending on the
design in which every driving unit has an output gear that is machined and engages with the toothed
rack installed on ground. Each set of vertical travel driving unit is installed in the SAC body and is
fixed to the machined surface with bolts. The bottom of the driving unit lies in the machined hole of
the flange below the SAC body.

JSW Page 36
SIDE ARM CHARGER- WHEEL
The Travel Wheel is one part of the vertical wheel assembly and installed at each
corner of below the SAC body. There are four travel wheels which moves over the rail track provided
for movement of the side arm charger. The track can support the yielded vertical load.
Four Guide Wheels are provided below the SAC body and contact the guide block of
the toothed rack. When the wagon of the rake is hauled to advance by the SAC, these guide wheels
will balance the horizontal force yielded by the SAC arm while pulling the wagons to table centre
position. Design of SAC toothed rack shall meet driving force and counterforce yielded during
hauling the loaded 7000T wagons in track.
SIDE ARM CHARGER-FESTOON TROLLEY
Cable bearer, Travel limit & Rack switch

JSW Page 37
The power and control lines are connected to the SAC with the cable system hanging above
the adjacent track and are parallel to the SAC. The cable is hanged with the cable bearer called
festoon trolley. The limit switch is installed in the cable track to control the stop position of SAC (for
coupling, positioning of the wagon at centre of the table, decoupling & coming back to initial position
for coupling) and provide a safety interlock device when SAC moves. One track side limit switch is
jointly operated with photoelectric encoder in the SAC driving motor to monitor and control
movement of the side arm charger in the track.
SIDE ARM CHARGER-TECHNICAL PARAMETERS
Hydraulic Drive Axial piston pump
Maximum operating pressure 160 bar
Working Pressure 200-250 bar
Traction force of rear hook 800kN
Effective haul travel 48m
Travel speed 0.1~1.2m/s
Driving motor Hydraulic
Number: 2-6
Main driving gear
Modulus m=22
Pressure angle α=20°
Number of teeth Z=15
Above parameters will vary for each tippler depending on the design, supplier & customer
requirement
WHEEL GRIPPER
Wheel-clamping device is used for gripping and maintaining the wagons in track to be positioned
along the track. Each device consists of one pair of wheel-clamping device pincers at both sides. The
pincers are parallel to the track. The clamping of the wagon wheels is actuated by the hydraulic
cylinders. It operates when one wagon enters in the table while positioning it is required to decouple
the same from other wagons, next wagon stopped by the clamping of the pincers & the wagon is
decoupled to position the same in the centre of the table by side arm charger.
ONE WAY STOPPER
One stopper is installed on the ground at the outlet rail of the equipment to prevent the
empty track wagon to return to the tippler space. It can allow the wagon roll away from the tippler
room and up to the outlet track when the wagon stopping device lowers. When the rare wheels of the

JSW Page 38
rotating wagon pass through the stopper device, the stopping device will automatically lift to prevent
the track wagon to return to the tippler space.
WEIGH BRIDGE & HOPPER
Weigh Bridge: As the name suggest it is used for weighment of the raw material received. As the
Raw Material is very important for Steel Making & Power generation so the cost of the material is
directly related to the production. For weighment of the quantity of the material received weigh bridge
is provided below the table having four or six load cells which. provides the details of the empty &
full wagons to control desk.
Hopper: The content of the wagon is unloaded in the hopper through which material flows to
downstream conveyors via chain conveyor. It may be of Steel or RCC.
APRON FEEDER
It is the chain conveyor of length 15mtr which is provided below the hopper to discharge the
material unloaded to down stream conveyor generally called conveyor deck assembly. It is provided
with Drive shaft with Sprocket, Chain & Tail wheel assembly. Sprocket & Tail wheel acts as a guide
for the movement of the chain. Pan plates which may be casted/ fabricated are bolted over the chain &
full chain assembly moves over the carrying & return deck roller

JSW Page 39
Deck Roller: These are the rollers mounted so to act guide track for apron chain. They must be
strong enough to bear the load approx. 120t. Carrying rollers mounted at a spacing of 500mm while
return roller mounted at spacing double than carrying roller.
Skirt Board: It is the metallic part which is provided between the hopper & apron conveyor deck.
It act as a guide for the material to flow in forward direction & prevent the spillage of the material.
Wear plate called liners as bolted over the skirt board along the full length which are replaced when
they get worn out.
Drive: As the load on the apron chain is very high approx. 120T so hydraulic drive is generally
preferred. It may single/dual drive depending on the design capacity.
Scrapper/Dribble Conveyor: It is the chain/belt conveyor provided below the apron chain to
convey the material (fines) coming to return side of the chain to the downstream conveyor, generally
during monsoon season. It is having chain/belt, idlers/links, drive shaft with sprocket/head pulley, non
drive shaft with sprocket/tail pulley.

JSW Page 40
APRON FEEDER-TECHNICAL PARAMETERS
 Length 15 mtr
 Capacity 120 T
 Drive Motor Hydraulic
 Pump Axial Piston
 Operating Pressure 80-100 bar
 Cooling Air/water cooled
Length & the Capacity of the Apron feeder is different for different types of tippler depending on
the requirement. Speed of the Apron Feeder can be varied as per requirement.

JSW Page 41
TIME MOTON STUDY ON WAGON TIPPLER:
Method for establishing employee productivity standards in which (1) a complex task is broken into
small, simple steps, (2) the sequence of movements taken by the employee in performing those steps
is carefully observed to detect and eliminate redundant or wasteful motion, and (3) precise time taken
for each correct movement is measured. From these measurements production and delivery times and
prices can be computed and incentive schemes can be devised. Generally appropriate only for
repetitive tasks, time.
The Goals of Motion Study
•Improvement (Kaizen)
•Planning / Scheduling (Cost)
•Safety
Some Techniques of Industrial Engineering
•Measure –Time and Motion Study –Work Sampling
•Control –Work Standards (Best Practices)
•Accounting –Labour Reporting
•Improve –Small group activities
Time Study
•Observation –Stop Watch –Computer / Interactive
•Engineering Labour Standards.
•Job Order / Labour reporting data
Time Study (Stopwatch Measurement) procedure:-
1. List work elements
2. Discuss with worker
3. Measure with stopwatch (running VS reset)
4.Repeat for n Observations
5.Compute mean and std dev of work station time
6.Be aware of allowances/foreign element, etc.

JSW Page 42
TOTAL TURN AROUND TIME (TAT):-
The total time undergone by the rake to completely unload the raw material and place in definite
position.
The activities that the rake under goes are as follows:-
Sl
no.
Activities Time taken
1 Brake release and Tarpaulin removal 30 min
2 Placement of wagon to tippler 30 min
3 Tippling start time 10 min
4 Tippling completion time 4 hr 30 min
5 Wagons cleaning time 30 min
6 Rake release 1 hr
TOTAL TIME 7 hr 10 min
CYCLE TIME AND ITS IMPORTANCE:
Cycle time- The total time taken by wagon tippler to position and unload the raw material from the
wagon is termed as cycle time. And it’s the sum of all time taken by all activities that are occurring
during tippling.
IMPORTANCE:-
1. To reduce the demurrage cost. As the demurrage is Rs 8850 for a rake for one hour.
2. If the cycle time is reduced that enhances the raw material intake and indirectly increases the
productivity.
Different activities in cycle (tippling cycle):-
1. Pulling of load rake: The load rake is pulled by the SAC till the decoupling position.
2. Decoupling: By the human interruption the load wagon is de coupled manually, and signal is
sent to control room for next activity
3. Load wagon position on tippler table (Inhaul): The SAC pulls the loaded wagon to the
center of the table for tippling.
4. SAC coupler release:-SAC coupler gets detached from the load wagon and moves further.
5. Empty pushing: The SAC pushes the empty wagon to the safer distance that was tippled in
previous cycle outwards (outhaul).

JSW Page 43
6. Arm raise: The SAC arm is raised at safety distance, thus gives the signal for weight
capturing.
7. Gross weight Capturing:-The gross weight is recorded by the load cell situated under the
tippler table.
8. Tippling: The tippler table rotates to 1380
.
i. Tippling start to 1200
fast tipple
ii. 1200
to 1380
fast tipple
9. Pause time: After tippling at the 138 degrees position the table pauses for few seconds for
completing tippling of materials.
10. Table return: After tippling of raw materials the table starts to lower to initial position.
i. 1380
to 150
fast return
ii. 150
to 00
slow return
11. Tare weight capturing: The tare weight of the empty wagon is captured by the load cell and
signal is sent to control room.
NOTE: A. There are other parallel and sub activities occurring during the cycle.
B. The cycle is controlled by PLC with auto and manual intervention.
Non Value added processes observed during TAT and suggested solutions:
 During tarpaulin removal, the labourers doesn’t seem to remove the tarpaulins in
order. They skip a few and hence need to come back and remove it. This increases the
total time required for the activity. This can be reduced by correct supervision and
instructions given to the labourers.
 The activity of wagon number recording can be eliminated by installing cameras at
the entry points so that it captures and ID’s the wagon. Thus, wagon numbers can be
noted down within no time when compared with present scenario. And even
manpower can be reduced by one.
 Tarpaulin removal process and brake release can be done by the same labour, by
properly training him.

JSW Page 44
CYCLE TIME STUDY OF WAGON TIPPLER 1 & 2
Sample 1
 Make: L&T
 Speed: mode 1
Speed 1
 Material : iron ore fines (iof)
 Feed: 5 Mt yard
 Tippler: 2
 Capacity : 20 tips/hr
Average time taken for different activities of the cycle as recorded:
Sl no Activities Time taken (sec)
1 Pulling of load wagon 39.54
2 Decoupling 10.64
3 Load wagon positioning on tippler table 18.58
4 SAC coupler release 17.62
5 Empty pushing 12.62
6 Arm raise 17.5
7 Gross weight capturing 2.2
8 Tippling 38.86
9 Pause time 4.16
10 Table return 35.38
11 Tare weight capturing 2
Total cycle time 3.31 min

JSW Page 45
39.54
10.64
18.58 17.62
12.62
17.5
2.2
38.86
4.16
35.38
2
0
5
10
15
20
25
30
35
40
45
1 2 3 4 5 6 7 8 9 10 11
time taken for each activity
Series2
1
20%
2
5%
3
9%
4
9%5
6%
6
9%
7
1%
8
20%
9
2%
10
18%
11
1%
Time taken in % for Iof's

JSW Page 46
Sample 2
 Make: L&T
 Speed: mode 1
Speed 2
 Material : coke
 Feed: 4 SR
 Tippler: 1
1 Pulling of load wagon 36.76
2 Decoupling 9.70
3 Load wagon positioning on tippler table 17.62
4 SAC coupler release 22.47
5 Empty pushing 8.62
6 Arm raise 12.25
7 Gross weight capturing 3.36
8 Tippling 38.29
9 Pause time 3.38
10 Table return 36.6
11 Tare weight capturing 4.45

JSW Page 47
39.54
10.64
18.58 17.62
12.62
17.5
2.2
38.86
4.16
35.38
2
0
5
10
15
20
25
30
35
40
45
1 2 3 4 5 6 7 8 9 10 11
time taken for each activity
Series2
1
20%
2
5%
3
9%
4
9%5
6%
6
9%7
1%
8
20%
9
2%
10
18%
11
1% Time taken in % for coal

JSW Page 48
Sample 1
 Make: Elecon India
 Speed: mode 1 and speed 1
 Feed: 5 Mt yard
 Tippler: 3
1 Pulling of load wagon 50
2 Decoupling 17
3 Load wagon positioning on tippler table 33
4 SAC coupler release 11
5 Empty pushing 19
6 Arm raise 28
7 Gross weight capturing 11
8 Tippling 41
9 Pause time 4
10 Table return 43
11 Tare weight capturing 11

JSW Page 49
75
14
32
23
16 15
7
105
12
17
0
20
40
60
80
100
120
1 2 3 4 5 6 7 8 9 10 11
time taken in sec(IOF)
1
24%
2
5%
3
10%
4
7%
5
5%
6
5%
7
2%
8
33%
9
4%
10
5%
TIME TAKEN IN SEC

JSW Page 50
Non value added activities observed during the cycle:
 Side arm charger (SAC) vertical movement is slow (in particularly lowering) at WT #1.That
affects the cycle time. (11 sec)
 Unnecessary backward movement of loaded wagon on the tippler table at WT #This is non
repetitive delay.(>15 sec)
 Gross weight capturing is taken only after the arm is fully raised that makes the tippling
delay.(7 sec)
 Non uniformity in the manual decoupling.(4 sec)
 Improper housekeeping.(5 sec)
With respect to WT 3 and 4 -
 Movement of SAC of WT3 is slower compared to SAC of WT4.
 Unnecessary backward movement of loaded wagon on tippler table which affects the cycle
time and is also a safety hazard.
Suggested solutions:
 With the use of some good and effective hydraulic during system and fast forwarding during
arm raise and slow forwarding during engaging can reduce cycle time.
 Gross weight capturing and SAC movement i.e activity 6 and 7 can be done parallel, that
reduces cycle time.
 Automation can be implemented for decoupling.
 Proper and effective pre wetting area can reduce the blockage in tippler table path.
Thus in an average >42 sec can be saved if these suggestions are considered.

JSW Page 51
Sample 1
 Make: DHI DCW China
 Speed: 15 for Apron feeder 1-4
25 for Apron feeder 2-3
 Feed: 5 Mt yard
 Tippler: 5
1 Pulling of load wagon 75
2 Decoupling 14
3 Load wagon positioning on tippler table 32
4 SAC coupler release 23
5 Empty Wagon pushing 16
6 SAC back to Arm raise position 15
7 Arm raise 7
8 Tippling 105
9 Pause time 12
10 Table return 17
Total cycle time 5 min 31 sec

JSW Page 52
75
14
32
23
16 15
7
105
12
17
0
20
40
60
80
100
120
1 2 3 4 5 6 7 8 9 10
time taken in sec
1
24%
2
5%
3
10%
4
7%
5
5%
6
5%
7
2%
8
33%
9
4%
10
5%
TIME TAKEN IN SEC

JSW Page 53
Non value added activities observed during the cycle:
 Inhaul weight recording issue results in unnecessary backward movement.
 Side arm charger of WT5 is slower than that of WT6.
 Improper housekeeping obstructs the continuum of labour movement.
 SAC raises its arm only after it comes to arm raise position.
 Non uniformity in decoupling.

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