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VISAKHAPATNAM STEEL PLANT

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VISAKHAPATNAM

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AN OVER VIEW OF VSP

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TRAINING & DEVELOPMENT CENTRE

,
VISION

&

To be a continuously growing world - class company

Harness our growth potential and sustain profitable

growth.

Deliver high quality and cost competitive products and

be the first choice of customers.

Create an inspiring work environment to unleash the creative energy of people.

Achieve excellence in enterprise management. Be a respected corporate citizen, ensure clean and green
environment and develop vibrant communities arounds us.

MISSION
To attain 10 millon 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 aspirations of the stakeholders.

CORE VALUES
Committment Customer Satisfaction Continuous Improvement Concern for Environment Creativity & Innovation
VSP BELIVES IN THE BEST AND ENDEAVOURS TO GIVE THE BEST

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

"VSP's determination is delete defects in the process" "VSP' believes in the best and endeavours to give the best" "VSP's enemy is wastage and we fight against it. "VSP' is our Plant - It stands for Quality VSP is our Plant - Where innovation never ends VSP is our Plant - Operate it safely VSP is our Plant - We are committed to it. VSP is our Plant - Develop it continuously VSP is our Plant - We think about it's growth. VSP is our plant - keep it clean always. VSP is our plant - and we work for customer's satisfaction. VSP is our plant - We sustain it's growth. VSP is our Plant - It gave us a status in the society. VSP is our plant - Maintain it properly Work safely - live happily

We Shall

LAYOUT OF VISAKHAPATNAM STEEL PLANT

CRMP RED

RMD Trafic

MAIN ROAD OR PLANT PLAZA ROAD

AC & VS Utlities

RMHP

PEM

SP

BC Gate

SSD

PD

BF

TPP

MILL AROS

ETL

EMD WMD

SMS

ERS WKS CONTS CME

EnMD QATD

11-DNW

DNW Inst Tele

FMD

LMMM

LMMM

ED (W)

WRM

MMSM

Rs & Rs

E.S & F

SYSTEMS

SED

CMM

CED H&L

SPC

MMSM

TS

MMSM

Admm Building

BUS STOP

T &

D C

PP GATE OR MAIN GATE

SBI

32

COKE OVENS COAL CHEMICAL PLANT

1.0

AN OVERVIEW OF VSP

Visakhapatnam Steel Plant, the first coastal based Steel Plant of India is located, 16 KM South West of city of Destiny i.e. Visakhapatnam. Bestowed with modern technologies, VSP has a installed capacity of 3 Million Tonnes per annum of Liquid Steel and 2.656 Million tonnes of saleable steel. At VSP there is emphasis on total automation, seamless integration and efficient upgradation, which result in wide range of long and structural products to meet stringent demands of discerning customers within India and abroad. VSP products meet exalting International Quality Standards such as JIS, DIN, BIS, BS etc. VSP has become the first integrated Steel Plant in the country to be certified to all the three international standards for quality (ISO-9001), for Environment Management (ISO-14001) & for Occupational Health & Safety (OHSAS-18001) The certificate covers quality systems of all operational, maintenance, service units besides Purchase systems, Training and Marketing functions spreading over 4 Regional Marketing Offices, 20 branch offices and 22 stock yards located all over the country. VSP by successfully installing & operating efficiently Rs. 460 crores worth of Pollution Control and Environment Control Equipments and converting the barren landscape by planting more than 3 million plants has made the Steel Plant, Steel Township and surrounding areas into a heaven of lush greenery. This has made Steel Township a greener, cleaner and cooler place, which can boast of 3 to 40 C lesser temperature even in the peak summer compared to Visakhapatnam City. VSP exports Quality Pig Iron & Steel products to Sri Lanka, Myanmar, Nepal, Middle East, USA & South east Asia (Pig iron). RINL-VSP was awarded "Star Trading House" status
1

MAIN GATE

CISF Pass Section

BC ROAD

Project Office

during 1997-2000. Having established a fairly dependable export market, VSP plans to make a continuous presence in the export market. Having a total manpower of about 16,613 VSP has envisaged a labour productivity of 265 Tonnes per man year of Liquid Steel which is the best in the country and comparable with the international levels.

STATISTICAL INFORMATION
I. Production Performance ('000 Tonnes)
Year 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 Hot Metal 2,510 2,943 3,165 3,485 3,941 4,055 3,920 Liquid Steel 2,225 2,656 2,909 3,083 3,356 3,508 3,560 Saleable Steel 21,932 2,382 2,507 2,757 3,056 3,169 3,173 Labour Productivity 161 192 211 228 253 262 265

2.0

BACK GROUND

With a view to give impetus to Industrial growth and to meet the inspirations of the people from South India, Government of India decided to establish Integrated Steel Plants in Public Sector at Visakhapatnam (AP) and Hospet (Karnataka) besides a special Steel Plant at Salem (Tamil Nadu). The announcement was made in the Parliament on 17th April' 1970 by the then Prime Minister of India late Smt. Indira Gandhi. A site was selected near Balacheruvu creak near Visakhapatnam city by a Committee set up for the purpose, keeping in view the tropographical features, greater availability of land and proximity to a future port. The foundation stone for the plant was laid by Smt. Gandhi on 20.01.1971. Seeds were thus sown for the construction of a modern & sophisticated Steel Plant having annual capacity of 3.4 Million Tonnes of hotmetal. An agreement was signed between Governments of India and the erstwhile USSR on June 12th, 1979 for setting up of an Integrated Steel Plant to produce structural & long products on the basis of detailed Project report prepared by Dr. M.N. Dustur & Company. A Comprehensive revised DPR jointly revised by Soviets & Dr. Dastur & Company was submitted in Nov' 1980 to Govt. Of India.
2

II. Commercial Performance (Rs. Crs.)

Year 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 Sales Turnover 3,037 3,436 4,081 5,059 6,174 8181 Domestic Sales 2,677 3,122 3,710 4,433 5,406 7932 Exports 295 322 371 626 768 249

III. Financial Performance (Rs. Crs.)

Year 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 Gross Margin 15 252 504 690 1,049 2,073 3,266
31

Cash Profit (-) 346 (-) 130 153 400 915 2,024 3,093

Net Profit (-) 562 (-) 291 (-) 75 521 1,547 2,008

% % %

ISTD Award for "Best HR Practices" - 2002 Prime Ministers Trophy for "Best Integrated Steel Plant-2002-03 "World Quality Commitment International Star Award" in the Gold category conferred by Business Initiative Directions, Paris

The construction of the Plant started on 1st February 1982. Government of India on 18th Feb'82 formed a new Company called Rashtriya lspat Nigam Ltd. (RINL) and transferred the responsibility of constructing, commissioning & operating the Plant at Visakhapatnam from Steel Authority of India Ltd. to RINL. Due to poor resource availability, the construction could not keep pace with the plans which lead to appreciable revision of the plant cost. In view of the critical fund situation and need to check further increase in the plant costs, a rationalized concept was approved which was to cost Rs. 6849 crores based on 4th Quarter of 1988. The rationalized concept was based on obtaining the maximum output from the equipments already installed, planned / ordered for procurement and achieving higher levels of operational efficiency and labour productivity. Thus the plant capacity was limited to 3.0 Million tonnes of Liquid Steel per annum. In the process one of the Steel Melt Shops and one of the mills were curtailed. The availability of resources were continued to be lower than what was planned and this further delayed the completion of the construction of the plant. Finally all the units were constructed and commissioned by July' 92 at a cost of Rs. 8529 crores. The plant was dedicated to nation by the then prime Minister of India Late Sri P.V. Narasimha Rao. Since Commissioning VSP has already crossed many mile stones in the fields of production, productivity & exports. Coke rate of the order of 509 Kg/Ton of Hot metal, average convertor life of 2864 heats an average of 23.6 heats per sequence in continuous Bloom Caster. Specific energy consumption of 6.07 G Kal/ton of liquid steel, a specific refractory consumption of 8.94
3

% %

"Organizational Excellence Award" for 2003-04 conferred by INSSAN National Energy Conservation Award, 2004 and Special Prize from Ministry of Power, Govt. of India. The above awards are besides a number of awards at

the local, regional & national level competitions in the area of Quality Circles, Suggestion Schemes etc.

6.0

Hallmark of Vizag Steel as on organization

Today, VSP is moving forward with an aura of confidence

and with pride amongst its employees who are determined to give their best for the company to enable it to reach new heights in organizational excellence. Futuristic enterprises, academic activity, planned & progressive residential localities are but few of the plentiful ripple effects of this transformation and each one of us take immense pride to uphold the philosophy of mutual (i.e., individual and societal) Progress.

30

kg and a labour productivity of 265 Ton/man year are some of the peaks achieved (during the year 2004-05) in pursuit of excellence.

Some of the important awards received by VSP are :

2.1

VSP Technology : State-of-the-Art

% % % % % % % % % % % % % % % % %

ISO 9002 for SMS and all the downstream units - a unique distinction in the Indian Steel Industry. Indira Priyadarshini Vriksha Mitra Award - 1992-93 Nehru Memorial National Award for Pollution Control 1992-93 & 1993-94 EEPC Export Excellence Award - 1994-95 Cll (Southern Region) Energy Conservation Award- 1995-96 Golden Peacock (1st Prize) "National Quality Award-96" IIM in the National Quality Competition - 1996 Steel Ministers' Trophy for "Best Safety Performance" - 1996 Selectedfor"WorldQualityCommitmentAward-1997"ofJ*Ban,Spain Gold Star Award for Excellent Performance in Productivity Udyog Excellence Gold Medal Award for Excellence in Steel Industry. Excellence Award for outstanding performance in Productivity Management, Quality & Innovation. Ispat Suraksha Puraskar (1st Prize) for longest Accident Free Period 1991-94 Best Labour Management Award from the Govt. of AP SCOPE Award for Best Turnaround - 2001 Environment Excellence Award from Greentech Foundation for Energy conservation - 2002 Best Enterprise Award from SCOPE, WIPS - 2001-02 Best Enterprise Award from SCOPE for surpassing MOU targets-2003-04
29

@ 7 meter tall Coke Oven Batteries with coke dry quenching @ Biggest Blast Furnaces in the Country @ Bell-less top charging system in Blast Furnace

@ 100% slag granulation at the BF Cast House @ Supressed combustion-LD gas recovery system @ 100% continuous casting of liquid steel.
@ "Tempcore" and "Stelmor" cooling process inLMMM & WRM respectively @ Extensive waste heat recovery systems @ Comprehensive pollution control measures

2.2

Major Sources of Raw Materials

Source Bailadilla, MP Jaggayyapeta, AP UAE Madharam, AP Madharam, AP Chipurupalli, AP Talcher, Orissa Australia Gidi/Swang/Rajarappa/Kargali
4

Raw Material Iron Ore Lumps & Fines BF Lime Stone SMS Lime Stone BF Dolomite SMS Dolomite Manganese Ore Boiler Coal Coking Coal Medium Coking Coal (MCC)

conveyor belt is collected and sent to Central Stores for further disposal. This is helping in earning the revenue through auctioning of the scrap belt sent to stores.

2.3

Water Supply
Operational water requirement of 36 mgd is being met

from the yeleru Water supply Scheme.

4.16

Central Maintenance Electrical (CME) Dept

The Function of CME

2.4

Power Supply
Operation power requirement of 180 to 200 MW is be-

1.

Repairs and Maintenance of all the Large Rotating Electrical machines of the Plant. The job includes transportation, Overhauling, Re-erection including precision alignment.

ing met through Capitve Power Plant. The capacity of the power plant is 286.5 MW. VSP is exporting 60 MW power to APSEB.

2.5

Major Units
Annual Units (3.0 MT Stage) Capacity ('000 T) 2,261 5,256 3,400 3,000 710 850 850 3 Batteries of 67 Ovens & 7 Mtrs. Height 2 Sinter Machines of 312 Sq. Mtr. grate area each 2 Furnaces of 3200 Cu. Mtr. volume each 3 LD Convertors each of 133 Cu. Mtr. Volume and Six 4 strand bloom casters 4 Strand finishing Mill

Department

2.

Maintenance of electric of all the illumination throughout the Plant, which includes street lights, tower lights, security bondy light.
Coke Ovens Sinter Plant Blast Furnace Steel Melt Shop Lmmm WRM MMSM

3.

Training of Shop Maintenance Crews in the Basics of Motor Maintenance and precision alignment.

4.17

Steel Township
The Steel Plant can take pride in having a clean green

2 x 10 strand finishing Mill 6 strand finishing Mill

well planned township with provision of about 8000 quarters, markets, community welfare centres, clubs,. Parks etc. for its employees & their families besides having a modern hospital with 155 beds.

2.6

Main Products of VSP

By-Products Nut Coke Granulated Slag Coke Dust Lime Fines Coal Tar Ammonium Sulphate Anthracene Oil HP Napthalence Benzene Toulene Zylene Wash Oil
5

5.0

Achivements & Awards

The efforts of VSP have been recognized at various

forums. Some of the major awards received by VSP are in the area of energy conservation, environment protection, safety, quality, Circles, Rajbhasha, MOU, sports and a number of awards at the individual level.
28

Steel Products Angles Billets Channels Beams Squares Flats Rounds Re-bars Wire Rods

3.0
3.1

MAJOR DEPARTMENTS
Raw Material Handling Plant (RMHP) 4.

quantity etc., are recorded. As all works are carried out through work order system, accuracy of data is ensured which enables in reducing the shut down periods. The activies of CMM are broadly divided into Planned & Unplanned maintenance and Capital Repairs. Planned & Unplanned activities : " Planned activities are taken up by planning on regular & periodical interactions with respective customer departments. " Unplanned/breakdowns are attended immediately and given top priority over planned jobs to restore the equipent back to normalcy so as to reduce the production loss. CAPITAL REPAIRS (CR) : " CMM plays an important role in planning & coordination of CR activities in the plant. " Pre-CR activities are given top priority to reduce total shut down periods. " Daily feed back and summary of all CR activities carried out by CMM are recorded. This system helped in Improving our shut down period. 5. CMM department is playing major role in improving life of conveyor belts by adopting innovative technological advancements across the globe. 6. In addition to maintenance activities, as part of Concern towards Environment, solid waste in the form of scrap
27

VSP annually requires quality raw materials viz. Iron Ore, fluxes (Lime stone, Dolomite), coking and non coking coals etc. to the tune of 12-13 Million tonnes for producing 3 Million Tonnes of Liquid Steel. To handle such a large volume of incoming raw materials received from different sources and to ensure timely supply of consistent quality of feed materials to different VSP consumers, Raw Material Handling Plant serves a vital function. This unit is provided with elaborate unloading, blending, stacking & reclaiming facilities viz. Wagon Tipplers, Ground & Track Hoppers, Stock yards Crushing plants, Vibrating screens, Single/ twin boom stickers, wheel on boom and Blender reclaimers. In VSP peripheral unloading has been adopted for the first time in the country.

3.2

Coke ovens & Coal Chemical Plant (Co&CCP)

Blast Furnaces, the mother units of any Steel plant require huge quantities of strong, hard and porous solid fuel in the form of hard metallurgical coke for supplying necessary heat for carrying out the reduction and refining reactions besides acting as a reducing agent. Coke is manufactured by heating of crushed coking coal (below 3 mm) in absence of air at temperature of 10000 C and above for about 16 to 18 hours. A Coke Oven comprise of two hollow chambers namely coal chamber and Heating Chamber. In the heating chamber a gaseous fuel such as Blast Furnace Gas, Coke Oven Gas etc. is burnt. The heat so generated is conducted through the common wall to heat & carbonize the Coking Coal placed in the adjacent coal chamber. Number of ovens built in series one after the other form a Coke Oven Battery.
6

4.15
1.

Central Maintenance Mechanical

Central Maintenance Mechnical (CMM) department is one of the major service departments in VSP which is carrying out major mechanical maintenance and conveyor belt replacement activities throughout the plant.

At VSP there are three Coke Oven Batteries, 7 Metre tall and having 67 Ovens each. Each oven is having a volume of 41.6 cu. metre & can hold upto 31.6 Tonnes of dry coal charge. The Carbonization takes place at 1000 - 10500 C in absence of air for 16-18 hours. Red Hot Coke is pushed out of the oven and sent to Coke Dry Cooling Plants for cooling to avoid its combustion. There are 3 Coke Dry Cooling Plants (CDCP) each having 4 cooling chambers. The capacity of each cooling chamber is 50-52 TPH. Nitrogen gas is used as the Cooling medium. The heat recovery from nitrogen is done by generating steam and expanding in two back pressure turbines to produce 7.5 power each. The Coal chemicals such as Benzole (& its products), Tar (& its products), Ammonium Sulphate etc. are extracted in Coal Chemical Plant from C.O. Gas. After recovering the Coal chemicals the gas is used as a by product fuel by mixing it with gases such as BF Gas, LD Gas etc. A mechanical, biological & Chemical treatment plant takes care of the effluents.

2.

In order to Improve response time CMM activities are carried out through five zonal offices. They are. " Coke Zone : Supports the needs of C & CCD and RMHP and the maintenance activities of conveyors through out the plant. " Iron Zone : Supports Sinter Plant, Blast Furnace & CRMP in their maintenance activities. " Steel Zone : Supports SMS & ASP in the maintenance activities and looks after the maintenance of EOT cranes in Central Stores & Gantry cranes of ES & F. " Mills Zone : Supports LMMM, WRM & MMSM in their maintenance activities. " Workshop : Looks after maintenance of all weighbridges and supports in fabrication works of departments like CISF, Finance, Personnel etc.,

3.3

Sinter Plant (SP)

Sinter is a hard & porous ferrous material obtained by agglomeration of Iron Ore fines, Coke breeze, Lime Stone fines, Metallurgical wastes viz. Flue dust, mill scale, LD slag etc. Sinter is a better feed material to Blast Furnace in comparison to Iron Ore lumps and its usage in Blast furnaces help in increasing productivity, decreasing the coke rate & improving the quality of Hot Metal produced. Sintering is done in 2 nos. Of 312 Sq. Metre, Sinter Machines of Dwight Lloyd type by heating the prepared feed on a continuous metallic belt made of pallets at 1200-13000 C.
7

3.

CMM is the first maintenance section in VSP, which is implementing one of the best ten practices i.e., "Work Flow and Control Management" as a part of QMS. In this system internal work order is issued to the respective zone and feedback is received at Central Office after work is completed. In the feedback, duration, manpower and identification of conveyor belt, supplier name &
26

Hot Sinter discharged from Sintering machine is crushed to +5 mm - 50 mm size and cooled before despatching to Blast Furnaces. Parameters of Sintering Machines are _ Effective area _ Sintering area _ Sinter bed height _ Capacity _ No. Of wind boxes : : : : : 312 Sq. metre 276 Sq. metre 300 mm 450 T P H each 26

4.13

Electrical Repair Shop (ERS)

Electrical repair shop is provided for medium & capital repair of different types of LT & HT AC motors, DC motors, lifting magnets, transformers coils etc. ERS also carries out repair of large electrical eqpt at site. The Shop has dismantling & assembling section, winding section, varnishing section, testing section etc.

4.14.0 Electro Technical Laboratory (ETL)

In view of the high degree of sophistication and automation used in VSP, a specialized groups for supporting electronics in drives and PLCs necessitated. Electro Technical Laboratory(ETL) precisely does the above function. ETL supports electrical groups of different production shops for maintaining 100% availability of the Electronics pertaining to drives and PLCs. There are approximately 1200 Thyristor Controlled Drives in VSP including

The dust laden air from the machines are cleaned in scrubbers & electrostatic precipitators to reduce the dust content to 100 mg/ m3 level before allowing to escape into the atmosphere and thus helping in maintaining a clean & dust free environment.

3.4

Blast Furnaces (BF)

Hot Metal is produced in Blast Furnaces, which are tall vertical furnaces. The furnace is named as Blast Furnace as it is run with blast at high pressure & temperature. Raw Materials such as sinter/ Iron Ore Lumps, Fluxes (Limestone/Dolomite) and Coke are charged from the top and hot blast at 11000 C 13000C- and 5.75 KSCG pressure is blown almost from the bottom. The furnaces are designed for 80% Sinter in the burden. VSP has two 3200 cu. metre Blast Furnaces (largest in India) equipped with Paulworth Bell less top equipment with conveyor charging. Rightly named as "Godavari" & "Krishna" after the two rivers of AP, the furnaces will help VSP in bringing prosperity to the state of Andhra Pradesh. Provision exists for granulation of 100% liquid slag at blast furnace cast house and utilization of blast furnace gas top pressure (1.5-2.0 atmospheric pressure) to generate 12 MW of
8

% % % %

Crane Controls AC/DC motor controls Uninterruptible power supplies Computer Numerically Controlled Machines in different shops There are approximately 300 programmable Controllers

Controlling various drives, Process Parameters and other related equipments of the plant.

ETL comprises of field services, central laboratory services and planning.

25

20)

Furnace temperature measurement and control : All three mills have micro processor based controllers of Toshiba, Japan Make. LMMM and WRM are also provided with microprocessor based recorders whille MMSM is provided with date acquisition system. LMMM protection/ starting interlocks are incorporated in PLCs supplied by M/s SPA computers.

power in each furnace by employing gas expansion turbines. The two furnaces with their novel circular cast house and four tap holes each are capable of producing 9720 tonnes of Hot Metal daily or 3.4 Million Tonnes of low sulphur Hot Metal annually.

3.5.1 Steel Melting Shop (SMS)

Steel is an alloy of Iron with carbon upto 1.8%. Hot Metal produced in Blast Furnaces contains impurities such as Carbon (3.5-4.25%) Silicon (0.4 - 0.5%), Manganese (0.3-0.4%), Sulphur (0.04% max) and Phosphorous (0.14% max) is not suitable as a common Engineering Material. To improve the quality the impurities are to be eliminated or decreased by oxidation process. VSP produces steel employing three numbers of top blown Oxygen Convertors called LD Convertors (L & D stand for Linz & Donawitz - two towns in Austria where this process was first adopted) or Basic Oxygen Furnaces/Convertors. Each convertor is having 133 cu. Metre volume capable of producing 3 Million Tonnes of Liquid Steel annually. Besides Hot Metal, Steel Scrap, Fluxes such as calcined lime or Dolomite form part of the charge to the Convertors. 99.5 % pure Oxygen at 15-16 KSCG pressure is blown in the Convertor through oxygen lance having convergent Divergent copper nozzles at the blowing end. Oxygen oxidises the impurities present in the Hot metal, which are fixed as slag with basic fluxes such as lime. During the process heat is generated by exothermic reactions of oxidation of metalloids viz Si, Mn., P and Carbon and temperature rises to 17000 C enabling refining & slag formation.

21)

Boilers: For safe operation of 5 boilers, instrumentation system supplied by M/s BHEL has been installed and is in operation. The important systems consists of Furnace Safeguard supervisory System & electro hydraulic turbine control system.

22)

A number of Pump Houses are in operation in various zones of the Plant for providing make up water, cooling water for fire fighting, chiller water pump houses etc. In all the pump houses, instrumentation has been provided for the measurement of flow, pressure, sump level, bearing temperature monitoring of motors etc.

23.

A most modern instrumentation lab with the state of the art calibrators have been set up for repair and calibration of ISO instruments. The master standard instruments are being regularly calibrated at the national; standard laboratories to ensure their accuracy. This lab facilities are also utilised for repair of all types of instruments used in various zones of the plant.

24

Different grades of steel of Superior quality can be made by this process by controlling the Oxygen blow or addition of various ferro alloys or special additives such as Fesi, FeMn, Si-

11)

Measurement of temperature at sinter machine hearth with S type thermocouple.

12)

Measurement of pressure and temperature of wind boxes.

Mn, Coke Breeze, Aluminum etc. in required quantities while liquid steel is being tapped from the convertor into a steel ladle. Convertor/LD Gas produced as by product is used as a secondary fuel. 13)

Measurement at burden handling system: Each BHS has 17 nos. of bins - 8 nos. of ore and siner, 6 nos. of coke and 3 nos. for additives.

Characteristics of VSP Convertors :

Capacity Volume Convertor Sp. Volume Tap to Tap Time Height to Diameter ratio Lining i) Working ii) Permanent Av. Lining Life 150 Tones per heat/blow 133 Cu. Metre 15) 0.886 Metre Cube per tonne 45 mts - 60 mts 1.36 Tar Dolomite Bricks Crome Magnesite Bricks 2445 heats (2004) 17) 16) 14)

In BHS of BF, SILOPILOT, level measuring system is provided in the bins. Measurement of Weights of Hopers. The burden level in the furnance is measured at regular interval by means of Selsyn operated stock rod. Top pressure is measured and controlled by means of control valves at throttle group of value at GCP. For converter instrumentation, DCS system supplied by M/s George Kent, UK has been installed for monitoring and control of process parameters such as flow, temperature, pressure, gas analysis.

Liquid Steel produced in LD Convertors is solidified in the form of blooms in continuous Bloom Casters. However, to homogenise the steel and to raise its temperature, if needed, steel is first routed through, Argon rinsing station, IRUT (Injection Refining & Up temperature) / Ladle Furnaces.

18)

Specialised gas analysers such as H2, O2, CO & CO2 have been provided for analysis and safe operation of gas recovery plant.

3.5.2 Continuous casting Department (CCD)

Continuous casting may be defined as teaming of liquid steel in a mould with a false bottom through which partially solidified ingot/bar (Similar to the shape & cross section of the mould) is continuously withdrawn at the same rate at which liquid steel is teamed in the mould.
10

19)

Measurement of liquid steel temperature : For measuring the temperature of liquid steel throw away type thermocouples are being used.

23

%
4) 5)

Need based standardization, using the above data base. Approval of drawings supplied by Various Suppliers. Engineering Assitance to all Departments.

4. 12.

Instrumentation Department
Instrumentation helps us in monitoring and controlling

Facilities at a continuous casting machine 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 metres long) At VSP we have six-4 strand continuous casting machines capable of producing 2.82 Million Tonnes/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.

the process so that product quality is improved, yeild is maximised, energy consumption is optimal and safety of the plant is ensured. The important instrumentation system installed in various zones of VSP are breifly given below: 1) 2) 3) 4) 5) In motion weighing of Raw Materials received. Belt scales provided on conveyors. Level measurements in Bins & Bunkers. Temperature monitoring and Flow Monitoring of Ore & Coal crushing plants. Blending of coal in mixing bins for attaining derived ash content through desimeter(weigh batchers). 6) 7) 8) Parameters measured & controlled at CO Battery. Suction and temperature measurement at exhausters: Temperature, pressure and analysis of circulating gases in coke dry cooling plant: 9) Pressure, temperature, flow, level and other parameters in the coal chemical plant. 10) Proportionating of materials at RMB for base mix preperation through weigh batchers and controlled by varying the speed of the disc feeders and vibro feeders.
22

3.6

Rolling Mills

Blooms produced in SMS-CCD do not find much applications as such and are required to be shaped into products such as Billets, rounds, squares, angles (equal & unequal), Channels, I-PE Beams, HE Beams, Wire rods and reinforcements bars by rolling them in, three sophisticated high capacity, high speed, fully automated rolling mills, namely Light & Medium Merchant Mills (LMMM), Wire Rod Mill (WRM) and Medium Merchant and Structural Mill (MMSM).

3.6.1 Light & Medium Merchant Mill (LMMM)

LMMM comprises of two units. In the Billet/Break down mill 250 x 320 mm size blooms are rolled into Billets of 125 x 125 mm size after heating them in two nos. of Walking beam Furnaces of 200 Tons/hr capacity each. This unit comprises of 7 stands (2 horizontal 850 x 1200 mm) and 5 alternating vertical & horizontal stands (730 x 1000 mm & 630 x 1000 mm) Billets are supplied from this mill to Bar Mill of LMMM & Wire Rod Mill. The billets for rolling in bar mill of LMMM are first heated in 2 strand roller hearth furnace of 200 T/h capacity to tempera11

ture of 11500 C-12000 C. The bar mill comprises of 26 stands - 8 stand double stand roughing train, 2 nos. of 5 stands, double strand Intermedial train & two nos 4 stand single strand finishing trains. The mill is facilitated with temp core heat treatment technology evaporative cooling system in walking beam furnaces, automated pilling & bundling facilities, high degree of automation and computerization. The mill is designed to produce 710,000 tons per annum of various finished products such as rounds, rebars, squares, flats, angles, channels besides billets for sale.

PEM is doing the planned maintenance jobs and major breakdown on the equipments like main exhausters, mbc blowers, mill fans, cph pumps, cdcp feed pumps, cdcp circulating pumps, main exhausters, straight line cooler fans, boiler id fans etc.

4. 11 Plant Design (PD)

Major Functions
1) Development of detailed Manufacturing Drawing and Replacement Specification drawings for:

3.6.2 Wire Rod Mill (WRM)

Wire Rod Mill is a 4 strand, 25 stands fully automated & sophisticated mill. The mill has a four zone combination type reheating furnace (walking beam cum walking hearth) of 200TPH capacity for heating the billets received from billet mill of LMMM to rolling temperature of 1200 0C. The heated billets are rolled in 4 strand. No twist continuous mill having a capacity of 8,50,000 tonnes of Wire Rod coils and having the following configuration. - 7 stand two high 4 strand horizontal roughing train. - 6 stand two high 4 strand horizontal Intermediate Mills. - 2 stand 4 strand pre finishing Mill. - 10 stand 4, strand. No twist finishing mill. The mill produces rounds in 5.5 - 12 mm range and rebars in 8-12 mm range. The mill is equipped with standard and retarded stelmore lines for producing high quality Wire rods in Low, Medium & High carbon grade meeting the stringent National & International stan12

& & & &

2)

Import Substitution of Spares and Fast Wearing items. Proprietary Substitution. Salvaging damaged equipment/sub assemblies/parts. Modifications of the existing equipment and structures. Suggesting New Designs and detailing by doing elaborate Engineering Study and Analysis for:

% % % %
3)

Better Operational requirement. Minimizing the rate of frequent break downs. Reducing Consumption rate of parts. Indegenising a part/sub-assembly/assembly of imported equipment. Standardization: To identify the existing standardization in machine elements to have reduced inventory.

% %

Preparation of Standards/Norms.
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vehicles of works departments of VSP.FMD takes care of the operation, maintenance and repairs of the following types of equipment. 1. Earthmoving Equipments a) Dumpers b) Dozers c) Loaders d) Excavators e) Tippers f) Selfloading & unloading trucks. 2. Mechanical Handling Equipment a) Cranes b) Tractor trailors c) Forklifts(maintenance only) 3. Vehicles a) Jeeps b) Trucks In addition, it also maintains miscellaneous equipments like industrial vaccum cleaners, Hydraulic access platform truck, pneumatic tankers, Thermal insulated tankers etc. These transportation equipments are used for transportation of different types of materials like Coke, Ores, Limestone, Debris, SMS slag, bricks, various materials from Stores, tools, tackles etc.

dards viz. BIS, DIN, JIS, BS etc. and having high ductility, uniform grain size, excellent surface finish.

3.6.3 Medium Merchant & Structural Mill (MMSM)

This mill is a high capacity continuous mill consisting of 20 stands arranged in 3 trains. _ _ _ Roughing train having a 8 stands (4 two high horizontal stands, 2 vertical stands and 2 combination stands) Intermediate Train has 6 mill stands as per details given below. 2 high horizontal stands 2 combination stands 2 horizontal stands / two universal stands Finishing Train - consists of 6 stands namely 2 combination stands 4 horizontal stands / 4 universal stands

4.10

Power Engineering Maintenance (PEM)

Power Engineering Maintenance (PEM) department is

doing Capital repairs, Breakdown maintenance, Preventive maintenance of Rotary Equipments like Turbo-Generators, Turboblowers, Turbo compressors, high capacity exhausters, fans pumps and hydraulic coupling. In addition to the above, PEM is also doing INSITU Balancing for high speed rotors through out the plant and Tarpedo Laddles maintenance jobs.

The feed material to the mill is 250 x 250 mm size blooms, which is heated to rolling temperatures of 1200 0C in two walking beam furnaces. The mill is designed to produce 8,50,000 tons per annum of various products such as rounds, squares, flats, angles (equal & unequal), T bars, channels, IPE beams / HE beams (Universal beams)

4.0
4.1

AUXILIARY FACILITIES
Power Generation & Distribution

The average power demands at all units of VSP when operating the full capacity will be 221 MW. The captive generation capacity of 270 MW is sufficient to meet all the plant needs in normal operation time. In case of partial outage of captive generation capacity due to break down, shutdown or other reasons.
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The short fall of power is availed from APSEB grid. The agreement with APSEB provides for exporting of surplus power to APSEB. The captive generating capacity comprises of _ _ _ TPP - 247.5 MW ( 3x60 MW + 1 X 67.5 MW) Back pressure Turbines (C&CCD)* - 2 x 7.5 MW Gas Expansion Turbines (BF/ces)* - 2x12 MW (*Power availability from BPT & GET is around 22MW) Power plant also meets the Air Blast requirements of Blast Furnaces thro' 3 Turbo blowers each of 6067 NM 3/hr capacity. Power from APSEB is received at Main Receiving Station thro' 220 KV overhead distribution lines. The entire plant is configured as 5 electrical load blocks (LBSS 1 to 5) and stepdown substations are provided in each block with 220 KV transformers to step down to 33/11/6.6 KV for further distribution. 5.

shop. Used bearings are dismantled, cleaned, inspected, serviced and reassembled on the rolls at regular intervals. Separate bearings for taking radial loads and axial loads are used. Types of Bearings used in LMMM & MMSM 4 row tapered roller bearings 4 row cylindrical roller bearings Deep groove ball bearings 2 row axial tapered roller bearings 2 row angular contact ball bearings

D D D D D

Types of bearings used in WRM

D D
6.

Morgoal bearing (Oil film bearings) 2 row axial tapered roller bearings Roll Shop-II comprises of roll turning shop, Bearing shop and guide shop catering to the requirement of MMSM. Roll turning shop is equipped with six CNC lathes for grooving new rolls, as well as redressings. The grooved rolls are assembled with bearings in the bearing shop. Chocks with bearings serviced periodically. Assembly and service and repair of guides, preparation of strippers used in rolling of Angles, channels, rounds and beams is done in guide shop.

4.2

Water Management (WMD)

The total water requirements at full capacity utilization of 3 MT/yr is 70 MGD, which is met from Yeluru Water Scheme of A.P. This involved construction of a reservoir at Yeleswaram and a 153 Km long lined canal to the Kanithi Balancing Reservoir at plant site. Kanithi Balancing Reservoir has a usable storage capacity of 12.6x106 M3 sufficient to meet plant as well as town ship requirements for 45 days. There is a network of 28 Pump Houses and 23 cooling Towers spread all over the plant to cool and recycle water, thus helping in conservation of water. Water losses during the process are made up from Kanithi reservoir.

4.3

Traffic Dept.

4.9

Field Machinery Department (FMD)

Field Machinery, is meant for meeting the requirements

A Steel plant of the size of VSP has to handle around 60-65 MT traffic comprising of incoming traffic (different raw
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of earthmoving equipment, mechanical handling equipments, and

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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. 2. 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. 3. The Roll Pass Design section takes care of design of grooves for development of new sections, modification of existing pass designs for improving the productivity and quality. Preparation of rolling schedules, groove detail and distribution and template drgs, part programming for grooving of rolls on CNC lathes. This section also looks after procurement of rolls, establishment and improvement of their performance, failure analysis of rolls etc. 4. Roll Shop-I compraises of a Roll Turning Shop, bearing shop, a Specialized repair shop and roll storage area catering to the needs of LMMM and WRM. Roll Turning shop is equipped with six CNC lathes, CNC template machine, Notch Milling machine etc. The grooved rolls are assembled with bearing and chocks in the bearing
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materials etc.), outgoing traffic (finished / saleable steel products, pig iron, granulated slag, byproducts etc.) and in process traffic viz. Cast P I, Mill scrap, Mill scale, hot metal, etc. Of this 50% is transported by belt conveyors, 45% by Rail Transport and 5% by Road. VSP has the distinction of having peripherial unloading system for the 1st time in Steel Industry. To handle this huge quantities of traffic, VSP has a fleet of 31 locomotives, 27 HM ladle cars, 7 torpedo ladle cars, 59 captive wagons of different types, 5 internal Railway stations, loco and wagon repair shop, number of weigh bridges besides taking on loan approx. 600 wagons daily from Indian Railways.

4.4

Engineering shops & Foundry (ES & F)

Engineering Shops are set up to meet the requirements of Ferrous & Non Ferrous spares of different departments. This complex is divided into 1. Forge Shop 2. Structural shop 3. Foundry 4. Central machine shop 5. Wood Working Shop and 6. Utility Equipment Repair Shop (UERS). The Forge shop is designed for production of shafts, coupling flanges etc. and also of forge shapes such as crusher hammer heads, special bolts, nuts etc. In the Structural shops the fabricated structurals of about 4500 tonnes are produced annually and the input consisting of sheets, plates, channels, angles beam etc. In Foundry Iron castings upto a weight of 5 tons and non ferrous casting upto a weight of 1 ton are produced. 2600 tonnes of iron castings and 200 tones of non ferrous castings are produced annualy In steel foundry, steel casting upto maximum piece weight of 10T are produced. Steel ingots upto 1.3 tonnes for forging are also produced.
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In the Central Machine Shop, various spares are made. The machining section has over 100 major machine tools including lathes, milling, boring, planning, sloting, shapping, grinding and other machines. The Wood working Shop manufactures patterns for foundries. The shop will require 300 cu.m per year of wooden patterns. In Utility Equipment Repair Shop. The Repair of ventilation, air conditioning and water supply equipment is carried out.

4.6

Quality Assurance and Technology 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 dept. like C&CCD, BF, SMS, Rolling Mills etc. The dept. controls the process by providing process charts for production of quality products. QA & TD carries out final inspection & testing including spark testing of finished products and assigns grades to them.

4.5

Utilities Dept :

Utilities dept. Consists of 1. Air Seperation Plant 2. Compressor Houses 3. Chilled water plants and Acetylene plants. The ASP is designed to meet the maximum daily demand of gaseous oxygen, gaseous nitrogen and gaseous argon. It has 3 units of nominal capacity of 500 tons/day of oxygen. Compressor Houses (CH) produce Compressed Air required for the operation of pneumatic devices, for instruments and controls, pneumatic tools and for general purpose in the various production units of steel plants. CH-I has 4 compressors of capacity of 15,000NM3/hr. Chilled Water plants (2 Nos) produce chilled water required for use in the ventilation and air conditioning system in areas such as office rooms, electrical control room etc. These plant have twleve units each with a capacity to cool 180 Cu. M/hr of water from 16 deg.C to 7 deg.C. Acetylene plant produces Acetylene gas required for general purpose cutting and welding. The acetylene plant has three generators each having capacity of 30 NM3/hr.

4.7

Calcining & Refractory Material Plant (CRMP)

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 calcining plant there are five flux kilns, each of 325 T/ day capacity, At the discharge end of the kiln, fuel is fired through a burner to generate required heat for calcination. Due to the kiln rotation & inclination, material flows from the feed and to the discharge end & gets calcined. The brick plant has two LAEIS 1600 Ton presses & a tempering kiln (upto 3000 C temperature) for making bricks.

4.8
1.

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

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VISAKHAPATNAM STEEL PLANT

FLOW CHART (3.0 MT STAGE)