Vocational training report on AutoCAD 2D and 3D basics

1. BHILAI STEEL PLANT
VOCATIONAL TRAINING REPORT ON:
Study of Hydraulic System used in Ladle &Turret.
Submitted By:
Vasudev
Vaibhav sharma
Anmol puri goswami
Manish Kumar
Ajit kumar gupta
Sunmeet sahota
Submitted To:
Mr. Sovan Mishra GM(CCS-MM)
Mr. Mahendra Dilawar (Mgr. CCS-MM)

2. The purpose of a specific hydraulic system may vary, but all hydraulic systems work through the same basic concept.
Defined simply, hydraulic systems function and perform tasks through using a fluid that is pressurized. Another way to
put this is the pressurized fluid makes things work.
The power of liquid fuel in hydraulics is significant and as a result, hydraulic are commonly used in heavy equipment. In
a hydraulic system, pressure, applied to a contained fluid at any point, is transmitted undiminished. That pressurized
fluid acts upon every part of the section of a containing vessel and creates force or power. Due to the use of this force,
and depending on how it’s applied, operators can lift heavy loads, and precise repetitive tasks can be easily done.
Hydraulics
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3. Pascal’s Law
Pascal's law is a principle in fluid mechanics given by Blaise
Pascal that states that a pressure change at any point in a
confined incompressible fluid is transmitted throughout
the fluid such that the same change occurs everywhere.
The force given by fluid is given by the multiplication of
pressure and area of cross-section. As the pressure is same
in all the direction, the smaller piston feels a smaller force
and a large piston feels a large force. Therefore, a large
force can be generated with Smaller Force input by using
hydraulic systems
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4. Hydraulic Advantage
Let ,
a = Area of cross –section of piston at C
A = Area of cross – section of piston at D
f = downward force be applied on the piston C.
Then the pressure exerted on the liquid,
P = f / a
Acc to Pascal’s law, this pressure is transmitted equally to piston of cylinder D.
Upward fore acting on the piston of cylinder D will be :
F = PA = (f/a)A
As A ≫a, F ≫f i.e. small fore applied on the smaller piston will be appearing as a very
large force on the large piston. As a result of which heavy load placed on larger piston is
easily lifted upwards.
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5. Hydraulic
System
Components
The major components
that make up a hydraulic
system are :
Reservoir
The purpose of the hydraulic reservoir is to hold a volume of fluid, transfer heat from the
system, allow solid contaminants to settle and facilitate the release of air and moisture from the
fluid.
Pump
The hydraulic pump transmits mechanical energy into hydraulic energy. This is done by the
movement of fluid which is the transmission medium. All hydraulic pumps work on the same
principle, which is to displace fluid volume against a resistant load or pressure.
Valves
Hydraulic valves are used in a system to start, stop and direct fluid flow. Hydraulic valves are
made up of poppets or spools and can be actuated by means of pneumatic, hydraulic, electrical,
manual or mechanical means.
Actuators
Hydraulic actuators are the end result of Pascal’s law. This is where the hydraulic energy is
converted back to mechanical energy. This can be done through use of a hydraulic cylinder
which converts hydraulic energy into linear motion and work, or a hydraulic motor which
converts hydraulic energy into rotary motion and work.
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6. ADVANTAGES OF HYDRAULIC SYSTEM:
1. Ease and accuracy of control: By the use of simple levers and push buttons, the operator of a hydraulic system can easily start, speed up
and slow down.
2. Multiplication of force: A fluid power system (without using cumbersome gears, pulleys and levers) can multiply forces simply and
efficiently from a fraction of a pound, to several hundred tons of output.
3. Constant force and torque: Only fluid power systems are capable of providing a constant torque or force regardless of speed changes.
4. Simple, safe and economical: In general, hydraulic systems use fewer moving parts in comparison with mechanical and electrical
systems. Thus they become simpler and easier to maintain.
DISADVANTAGES OF HYDRAULIC SYSTEMS:
1. Handling of hydraulic oils which can be quite messy. It is also very difficult to completely eliminate leakage in a hydraulic system.
2. Hydraulic lines can burst causing serious human injuries.
3. Most hydraulic fluids have a tendency to catch fire in the event of leakage, especially in hot regions.
4. Contaminants present in the hydraulic fluid will damage the system performance and productivity. Hence, it requires continuous
filtration.
5. Hydraulics fluids, if not disposed properly, can be harmful to the environment.

8. Desired
Properties Of Hydraulic Fluid
Hydraulic Fluids
A hydraulic fluid or hydraulic liquid is the medium by which power is
transferred in hydraulic machinery.
Hydraulic oil delivers power, lubricates components, dissipates heat, and
carries away contaminates. To perform these functions, hydraulic oils
contain specific additives to enhance their ability to stand up to the pressure,
temperature extremes, and other operating conditions to which they are
subjected..
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•Viscosity.
•Compressibility.
•Wear Resistance.
•Oxidation Stability.
•Thermal Stability.
•Filterability.
•Rust and Corrosion
Protection.
•Foam Resistance.

9. Defination
Mechanical power is converted into hydraulic energy using the flow and pressure of a
hydraulic pump. Hydraulic pumps operate by creating a vacuum at a pump inlet, forcing
liquid from a reservoir into an inlet line, and to the pump. Mechanical action sends the liquid
to the pump outlet, and as it does, forces it into the hydraulic system.
Hydraulic Pumps भिलाई इस्पात संयंत्र
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10. Classification
Of Hydraulic
Pump
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11. An actuator is a device that converts fluid power into mechanical force and motion. Either linear
(straight line) or rotary motion can be obtained by using a suitable actuating device. Cylinders,
motors are the most common types of actuating devices used in fluid power systems.
Cylinder: An actuating cylinder is a device that converts fluid power to linear, or straight line, force and
motion. Cylinder are of two types:
1.Single Acting Cylinder: The single-acting piston-type cylinder uses fluid pressure to provide the force in
one direction, and spring tension, gravity, compressed air, or nitrogen is used to provide the force in the
opposite direction.
2.Double Acting Cylinder: Double-acting cylinder means that fluid under pressure can be applied to either
side of the piston to apply force and provide movement.
Motors: A fluid power motor is a device that converts fluid power energy to rotary motion and force. Fluid
motors are usually classified according to the type of internal element, which is directly actuated by the flow.
The most common types of elements are the gear, the vane, and the piston.
Actuators: भिलाई इस्पात संयंत्र
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12. Basic Elements
Symbols and Notations:
Flow Control Valve
Actuators
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13. Hydraulic Valves:
Pressure Control Valve: The pressure relief valves are used to protect the
hydraulic components from excessive pressure. This is one of the most important
components of a hydraulic system and is essentially required for safe operation of
the system. Its primary function is to limit the system pressure within a specified
range.
Various types of pressure control valves are:
• Pressure Relief Valve
• Unloading Valve
• Sequence Valve
• Counter balance Valve
• Pressure Reducing Valve
Direction Control Valve: DCV are used to control the distribution of
energy in a fluid power system. They provide the direction to the fluid
and allow the flow in a particular direction. Directional control valves can
be classified in the following manner
1.Type of construction:
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• Spool valves
• Poppet valves
2.Number of ports:
• Two- way valves • Three – way valves • Four- way valves.
3.Number of switching position:
• Two – position • Three – position
4.Actuating mechanism:
• Manual actuation • Mechanical actuation
• Hydraulic actuation
• Solenoid actuation

14. Needle Valve
Specific Fluids Circuit
Flow Control Valve
Actuators
Needle valves are used to throttle or shut-off flow of fluids. They usually will vary flow with
pressure or viscosity change. Some valves can be pressure and/or temperature compensating.
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15. Pressure Control Valve
Control Valves
Direction Control Valve
Actuators
Directional control valves are used to direct fluid flow into the appropriate lines for the designated
operation. These valves are usually electrically controlled.
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16. PrPersessusruereSwSwitcithc:h
Device that operates on electrical contact when a present fluid is reached. The switch makes an electrical contact
on either pressure rise or pressure fall from a certain pressure level.
Working:
When the inlet pressure force is greater than the spring pre tensioned force, it switches the electrical
contact will return to their normal state.
Filter:
It helps to remove dirt/contaminants and clear the oil on a continuous basis. The hydraulic
filters between pump and actuator are referred to as pressure filter.
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17. It is a type of safety valve used to control or limit the pressure in a system. The pressure is relieved by
allowing the pressurized fluid to flow from a auxiliary passage out of the system. The relief valve is
designed or set to open at a predetermined set pressure to protect pressure vessels and other equipment
from being subjected to pressures that exceeds their design limit. When the set pressure is exceed the relief
valve become the oath of least resistance as the valve is forced open and a portion of the fluid is diverted
through the auxiliary route.
Pressure Relief Valve: भिलाई इस्पात संयंत्र
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18. Safety Precautions:
• Take care to observe all general safety rules
adopted in valve servicing.
• NEVER allow high-pressure hydraulic
systems ad valves to operate on critical
parameters exceeding rated parameters
specified in the basic characteristics.
• To ensure against possible accident take
care to make regular eternal inspections of
hydraulic system and valve joints.
• To regularly replace filter cartridges
• Not to allow repair jobs unless the hydraulic
system is operative.
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19. Axial Piston Pump
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It is a positive displacement pump that has a number of pistons in a circular array within a cylinder block.
The piston and cylinder rotate around the centre, longitudinal axis. The piston and shoe move in and out of
the cylinder because they are sliding upon a stationary, variable angle. As the piston rotate they alternate
between being connected to an inlet port and outlet port. Used to power the hydraulic systems. schematic
of a variable displacement with built in pressure compensator. Under working condition on a moderate
system overload, The compensator piston reduce the swash plate angle just enough to prevent the system
pressure from exceeding the firing pressure adjusted on the compensator. On severe overloads the
compensator may swing the swash plate back to neutral to reduce pump flow to zero.

20. Fig. Above Shows wireframe schematic of Axial Pump assembly.
Axial Piston Pump भिलाई इस्पात संयंत्र
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21. Possible Failures and Troubleshooting
Failures Possible Reason Troubleshooting
External oil leaks through
the threaded connections, as
well as by the shaft end
sealing
Threaded connections
loosened; sealing elements
out of order; Shaft end lip-
type seal (outer) out of order
Tighten the fasteners; replace
the seals; replace outer seals
Pump does not provide the
required delivery. Pump
works with increased noise
and banging.
Air in the suction line;
separation of axial bearings;
control mechanism failure
Eliminate air leaks; check
the parts condition, if
necessary, wash or replace
Delivery not reset to zero Emergency valves does not
work; Control mechanism
failure
Check the parts condition, if
necessary, wash or replace.

22. What causes leaking hydraulic fluid?
• The most common cause of unplanned, excessive
internal leakage is wear of component surfaces
during normal operation.
• poor quality control tolerances during the
manufacturing of a component or incorrect overhaul of
rebuilt components.

23. How do you stop a hydraulic leak?
• By properly setting the pressures, installing accumulators and shock
suppressors where needed, verifying that the system is piped and hosed
correctly, and adding or adjusting pilot chokes, you should be able to reduce
or even eliminate shock and leakage in your hydraulic systems.
What are three signs or indications of a system hydraulic leak?
• In the case of hydraulic systems, there are three easily detectable
warning of
that give early
are abnormal noise, high
root cause conditions.
fluid
These
temperature and slow
symptoms
symptoms
operation.

24. It is mounted at the reinforced concrete base. A member turning about a vertical shaft is provided
with two diametrically opposite arms adapted to receive in each case a casting ladle. It holds the
molten steel teeming ladles and rotates to put it into casting position above tundish.
A few minutes before the metal in the ladle finishes, another ladle is placed on the reserve arm of
Ladle & Turret stand & kept ready. As soon as the metal in the first ladle finishes, the Ladle &
Turret is rotated by 180 º and the second ladle comes to casting position and the ladle is opened
for casting. Thus sequence of casting is maintained.
Ladle & Turret भिलाई इस्पात संयंत्र
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25. Fig. Shows Hydraulic Circuit developed inAutoCAD 2020 Electricals.
भिलाई इस्पात संयंत्र
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Single Solenoid 4/2 Valve
operated in case of
Emergency/ Power failure.

26. During the process of casting, metal slabs are formed via pouring molten steel present in ladle. The movement of ladle
is kept restricted with the guide of Ladle and Turret lock mechanism. L&T hydraulic circuit assembly consists of
variety of components and sub-assemblies. Where various components from the schematic are studied such as
Accumulator Unit, Pressure Relief Valve, Throttle Valve, Direction Control Valve, Pressure reducing valve, Check
valve, Hose and Isolation Valve.
The accumulator used enables system to cope with extremes of demand using a less powerful pump, to respond more
quickly to a temporary demand, and to smooth out the vibrations and load. The accumulator used is maintained at P0=
140 Bar; Pmax= 210 Bar controlled by application of pressure reliving valve.
Also 3 Direction Control Valve (i.e., 4/2 single solenoid valve, Lever operated float centre valve). All the three DCV’s
are well assisted with check valve to ensure unidirectional flow through the pilot/drain. DCV’s are also accompanied by
application of Throttle valve/Flow control Valve to regulate the flow or pressure of the flowing fluid.
The fluid initiates to flow from the tank passes by Isolation and check valve then with the application of DCV’s flowing
fluid is directed towards check valve with pilot/drain line fluid is regulated simultaneously from -Y102 and -Y101.
After check valve fluid flow is controlled by utilizing Flow Control valve/Throttle Valve by-passed with isolation
valves and check valves at minima points to measure the Pressure at a specific point in the line. Moreover, the drain
fluid is accompanied by sub-system of In-line pressure regulator and check valve maintained at pressure of 50 Bar.
Discussion and Summary:

27. Segment Clamping:
Fig. Shows Hydraulic circuit of Segment clamping for Segment 7-8

28. Pinch Roll:
Fig. shows Pinch Roll Hydraulics circuit.

29. Components observed and Rectified

32. Filter
Pinch Roll Hydraulic Cylinder.

33. We the undersigned solemnly declare that the report work entitled “STUDY
OF HYDRAULIC SYSTEM USED IN LADLE &TURRET ” based on our
work carried out during the course of our study under the supervision of
MR. MAHENDRA DILAWAR SIR and MR. SOVAN MISHRA SIR.
We assert the statement made and conclusions drawn are an outcome of the
project work. We further declare that to best of our knowledge and belief
that report does not contain any part of any work has been submitted for the
award of any other degree/certificate in the University.
Declaration:

34. We feel very proud to say that due to keen knowledge of the working members of the
BHILAI STEEL PLANT, it was very easy for me to gain a lot of knowledge regarding
STEEL MELTING SHOP-II.
▣ We are greatly thankful to Mr D.K.AGARWAL SIR , SMS-II for his kind support
and guidance to successfully complete my training. We have been highly benefitted by
this training and have gained a lot of knowledge about various processes and
techniques in SMS-II.
▣ Finally we would like to thanks all the employees of SMS-II, BSP, who have helped
us and co-operated with us during my training and project work.
Acknowledgment:

35. • www.researchgate.com
• www.Wikipedia.com
• Reference material provided.
• R K Bansal Book on Fluid Dynamics
References: