1

1.OVERVIEW OF VSP

Visakhapatnam Steel Plant, the one and only one unit of Rashtriya Ispat Nigam Limited, the first coastal based Steel Plant of India is located 16km SouthWest of the City of Destiny i.e. Visakhapatnam. Bestowed with modern technologies, VSP has an installed capacity of 3 Million Tones per annum of Liquid Steel and 2.65 Million Tones of saleable Steel. At VSP, there is emphasis on total automation, seamless integration and efficient up gradations, which result in wide range of long and structural products to meet stringent demands of discerning customers within, India and abroad. VSP became the first Integrated Steel Plant to achieve the distinction of covering all the processes and products under ISO 9002, ISO 14000 & OHSMS1800 for the entire plant. By planting more than 3 Million plants, VSP has made Steel Plant, Steel Township and surrounding areas into lush greenery. This has made the Steel Township a greener, cleaner and cooler place, which can boast of 3C to 4C lesser temperature even in the peak summer compared to Visakhapatnam City. VSP exports Quality Pig Iron and Steel Products to Far East, South East, Middle East, USA, Canada, Australia, Europe and Africa. RINL - VSP was awarded 'STAR TRADING HOUSE' Status.

1.1 Achievements:Commissioned in 1989, VSP has crossed many milestones in the fields of production, productivity and exports. Some of the peak achievements are:  Coke rate of the order of 540kg/ Ton of Hot Metal  Average converter life of 649 heats  An average of 11.5 heats per sequence in Continuous Bloom Caster  Specific Energy Consumption of7.51 G. Cal/ Ton of Liquid Steel  Specific Refractory Consumption of 15.2 Kg/ Ton of Liquid Steel  Labour Productivity of230 Ton/man/year

1.2 Technology:The process of Technology and Equipment selected for major production units viz. CokeOvens, Sinter Plant, Blast Furnace, Steel Melting Shops and Rolling Mills are based on proven modern technology. In Plant sizing facility for Iron Ore, selective crushing of coal with Pneumatic Separation facility completely mechanized blending facility for major raw materials and on ground blending of Sinter Base Mixes, These ensure consistent quality of raw materials for stable operation of Blast Furnace. In seven meter tall Ovens with Dry-Quenching of coke using Nitrogen Gas, the Steam generated is to be used for Power Generation,.3200 Cu.M Blast Furnaces - 2 numbers with conveyor and Bell less top charging equipment ,are the largest in the country. Gas Expansion Turbines are provided for Power generation by utilizing the Blast Furnace Gas top pressure.

1.3.Products & By-products:Pig Iron, Billets, Plain Rounds, Reinforcement Bars, Plain and Ribbed Rods, equal and unequal angles, channels, and beams are the main products of VSP. The By-Products of VSP are Naphthalene, Pitch, Coal Tar, Benzene, Toluene, Xylene etc., Chemical ByProducts from its modern Coke-ovens Plant will be useful in many industries .

1.4.Major facilities:3 Batteries

1. Coke Ovens

each of 67 Ovens having height of7 meters. Useful volume 41.6 Cu.M.

2. Sinter Machines

2 Sinter Machines of Dwight Lloyd type. Each having 312 Sq. M area

3. Blast Furnaces

2 Blast furnaces each having 3200 Cu. M. Useful Volume 3 LD Converters,

4. Steel Melting Shop

each having 133 Cu.M. of Volume and 6 No. of 4 Stand continuous Bloom Casters.

5. Light and Medium Merchant Mill 7,10,000 Tones per year Capacity 8,50,000 Tones per year Capacity

6. Wire Rod Mill

7. 7.Medium Merchant and Structural Mill

8,50,000 Tones per year Capacity

1.5 Process: The entire process used in VSP is broadly divided into following groups:  Preparation of Raw Materials ( Coke, Sinter, Ore lumps etc.,)  Production Of Pig Iron  Production Of Bulk Liquid Steel  Conversion Of Bulk Liquid Steel  Recovery of valuable By-Products from Coke-oven Gas

2.WIRE ROD MILL

2.1 INTRODUCTION:

The wire rod mill of VSP is high speed 4 strand No-Twist continuous mill designed to produce 850000 T of wire rod coils. The mill is designed to produce plain wire rods from 5.5 mm to 12.7 mm diameter and Rebar in 8mm .10mm and 12 mm diameter in coil form, However sizes up to 14 mm are being rolled presently . The mill is constructed at an elevated level of + 5350mm. Rolled billets of 125mmX125mm square cross section, length ranging from 9.8 m to 10.4 m and weighing approx 1250 kgs are used as input material. The mill is designed to roll steel stock of 0.9% max, carbon content. The rolled billets received from billet mill are placed on charging grid I & II at +0.00 level in packet form with the help of electro magnet cranes. The billets are moved toward cross transport by means of 4 rope operated pawl transfer. The charging grid I has AC drive and charging grid-II is operated by DC drive. The cross transport receives the billet individually from charging grid-II and transfer them to billet elevator takes the individual billets to mill floor level at +5.35M. Using billet transfer device and billet positioning device, the packet of 4 billets are made on approach roller table group-I, which are further carried forward to furnace entry using another 4 groups of roller tables arranged in tandem. After the billets are positioned in front of walking beam furnace, the walking beam of furnace, collects the billets from roller table and charge them into furnace. The furnace is combined type walking hearth cum walking beam furnace of 200 T/hr capacity. The walking beam is operated by 180 bar hydraulic pressure system the furnace is approx 42M long and 11M wide. The billets are heated to 1200 degrees C gradually in 4 different zone using 60 flat flame roof burners and 6 long flame burners at bottom soaking zone. The in-house generated mixed gas (mixture of Coke Oven gas, BF gas & LD gas) of calorific value 2000+/-15% Kcal/Nm3 is used as fuel. The mixed gas and combustion air is preheated to 2500C and 5200 C respectively in recuperators before combustion at burners. The heating time is approx 71 minutes and each walking beam cycle is 72 sec in which billet packets are moved by 900 mm. The complete process control is done by microprocessor based instrumentation control system. The homogenously heated billets are discharged by hydraulically driven discharging machine called peel bar into groove of

7 stand 1. A billet withdrawing machine is arranged between furnace exit and stand 1. It uses pinch roll to feed or return billets from or into furnace. The four shift able position billet switch is provided in front of withdrawing machine to feed four strands of mill individually. A 4 strand pendulum shear and high pressure (180 bar) water de-scaler is arranged between billet switch and stand 1. Presently these are taken out of operation. The roughing mill comprises of seven continuous 4- strand two high horizontal stands. The mill stand housings are of closed top design and roll are having morgoil oil film neck bearing. The rolls of 610 mm diameter X 1000mm length are used at stand no.1 to 5 placed at 21 housing and rolls of 490 mm diameter X 920mm are used in stand 6 & 7 placed at 16 housing . The primary reducer secondary reducer and universal spindles are used to connect Dc motor drive and mill stand. The feed stock reduces to 46 mm square after reduction in 7 roughing mill stands and moves at a speed of approx 1m/sec. The average reduction in each stand varies from 20-30%. The pass design is oval round sequence and stand 7 is having square pass. The ovals are twisted using twist roller guide at oval pass delivery and fed to round pass through roller entry guide. At all other places static guides are used for guiding the stock to roll groove. Four rotating crop and cobble shears are provided after stand 7, one for each line. The cold & split front end of the bar head is cropped automatically before feeding to intermediate stand. In case of disturbances in forward equipments/areas, the shear crops the complete stock into small pieces. The intermediate group of stand comprises of 6 two high horizontal stands. Rolls of 490mm X 800 mm are used in 16 housing for stand 8 to 10 and rolls of 375 mm x 700 mm are used in 12 housing at stand 11 to 13. Roll material is SG cast iron. Roll neck bearing is of Morgoil design. The stock is reduced to approx 23mm round and moves at about 5m /sec after stand no.13. The primary reducers and universal shafts are used to connect DC mill drives and mill stands. The roll pass sequence is oval square and stand 14 is having round pass. The ovals are twisted by twist roller guides installed at each oval pass delivery and fed to round pass using roller entry guides. At all other places, static guides are used for guiding the bar. All the twist guides and roller entry guide rollers in roughing and intermediate mill are cooled by water & lubricated by oilair mixture. Roll passes in mill stands are cooled by water at 3-4 kg.cm2 pressure. Material from stand no 13 is fed to individual finishing lines using rod feed troughs.

8 The 4-prefinishing blocks, one at each line, are installed ahead of stand 13. The rod feed troughs guides the stock coming out from stand 13 to prefinishing block via horizontal looper. The prefinishing block is having one horizontal and one vertical stand enclosed in a closed housing & driven by a one common drive. The stock size is reduced to approx 19 mm round at this stage and speed goes up to as high as 8 M/sec. The tungsten carbide roll rings of 8 diameter are used in these stands for rolling of stock. These rings are mounted on a tapered shaft at 400 bar hydraulic pressure. A water cooling stretch named A1 water box is installed ahead of these prefinishing block to facilitate partial cooling of stock before final rolling at finishing block. These facilities are used mainly during high carbon & rebar rolling for grain refinement & increased UTS in final wire rod. Water cooling at 6 bar pressure for stripping of water droplets from stock surface.

A crop & dividing shear is provided ahead of water cooling stretch to crop cold front end of bar before feeding to finishing blocks. Also, this gives a dividing cut to bar in the event of trouble in equipments in forward stream and the bar gets diverted to a chopper located at down +0.00 level which is common for line 1 & 2 and line 3& 4 . Horizontal looper is provided before 10 stands No twist finishing block. The looper ensures tension free rolling. The loop height control is automatic through computer using field signals from loop scanners provided individually for all horizontal loopers. The 10 stand no twist finishing block is driven by two 2000KW motors arranged in tandem connected through 3 high speed increaser to the common line shat of block. The max. speed of stock goes up to 76 m/sec during rolling of 5.5 mm section. The bar speed gradually comes down as the finished size increases. The stands are arranged at 45o to rolling line and 90o to each other to facilitate twist free rolling. The tungsten carbide roll rings are mounted/Dismounted on top & bottom tapered shafts of each stand by hydraulic pressure, initial 2 stands in finishing block are provided with 8 C roll rings. And balances 8 stands are provided with 6 TC roll rings. The pass sequence is oval round. The roller entry guides are provided at entry of each round pass. Oil-air mixture is used for guide roller lubrication and rollers are water cooled. TC rings are cooled by 6 bar water pressure. All the 25 stands are used for rolling of 5.5 to 6.5mm size. For rolling 7mm to 8mm, only 23 stands are used and balance are kept as dummy. Only 21 stands are used for 9mm and

9 10mm, for 12 & 12.7 mm sizes 19 stands are kept in operation and for 14mm rolling only 17 stands are used and rest are kept dummy. The rolling groove life varies from 9000-10000 T in stand 1 to 800 DT in stand 25. After rolling of specified tonnage , roll or pass changes are carried out. Snap shears are provided at entry of pre-finishing block and finishing block to stop metal entry inside block in the event of cobbles or any other trouble with the blocks. After final rolling at finishing blocks, controlled cooling of wire rod starts using retarded stelmor cooling system. Three water cooling boxes and in between two equalizing zones are provided ahead of finishing block. The wire rods coming out form finishing block are cooled down to a temperature required for laying depending upon the steel quality. One pinch roll unit is located ahead of water cooling stretch to carry the product to laying head positioned at 10 o to horizontal . The laying head deposits the wire rod loops onto stelmor roller conveyor. Tungsten carbide roll rings are mounted on pinch roll for pinching of rod. Each stelmor conveyor conveys fanned out loops from each line across 10 air cooling zones up to coil forming chamber located at the end of conveyor. By varying the conveyor speed and fan on/off sequence cooling rate can be changed to get desired mechanical properties in finished wire rods. The vertical coil formed inside the chamber on mandrel is received by downender and loaded onto c-hook horizontally at downender station. The c-hooks are carried by a power & free hook conveyor circuit, 180 c-hooks are carried on 5 interconnected hook conveyor circuits divided into two sectors. Each hook is having a bar code plate which is read by reading units connected to computer for identification of coil loaded onto hook. Each sector is equipped with inspection loop, 3 automatic compacting & tying machines and 3 coil unloading stations called turnstiles. Coils are ties by 6mm wire rods at 4 places in hydraulic coil compactors. The quality department personnel take the sample at inspection loop to check size and test mechanical properties. The appropriate grade is fed to production control computer. The coils are finally taken out from turnstiles by EOT magnet cranes. The identification labels are attached to coils at coil labeling area located before coil unloading station. The coil identification details like heat no, grade and size is available on production control computer mask at these stations. All hydraulic & water systems are installed in cellars 1 to 7 at +0.00 level for mill & furnace equipments. The hydraulic systems for coil handling area equipments are at 8 to 10 located below zero level.

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2.2 Electrical Equipment:The mill stands are driven by main drives of DC motors. Individual motors are employed for driving stands up to intermediate plan and two motors in random are provided for each of the four finishing blocks. Closed circuit centralized ventilation system is used for main drive motor along with other auxiliary DC motors. Main drive motor armature circuit is provided with individual thyristor power supplying system comprising llkV converter transformer non-reversible fully 3-phase thyristor or converters DC reactor, single pole high speed DC circuit breaker double pole no load DC contactor. The feed circuits of motor are fed by individual thyristor supply system comprising isolation transformer and 3 phase fully controlled thyristor converter. Total drive motors of the mill consists of  DC main drive motor-25 Nos.  DC aux. drive motor- 20 Nos. of AISE type.  DC aux. drive motors of 48 Nos. of industrial type.  AC motors.

2.3 Automation and Control Systems:A distributed control philosophy with three level hierarchical structures is being adopted for wire rod mill automation system. At the top of the control hierarchy production computer (PCC). SIEMENS R 30 with 512 k words memory is provided.

A process control computer Siemens R 30 K with 128 K word memory for control of rolling process and a mill fault monitoring computer Siemens R-IO with 128 K memory for acquisition monitoring lobbing of mill faults are provided in the middle of the control hierarchy.

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At lower level: Programmable logic controllers-Siemens simatic S-150 are used to realize the subordinate control function. The production computer is responsible for the following functions.  Automatic online material tracking up to coil un loader.  Acquisition and compilation of production data/production schedule.  Generation, storage and distribution of rolling program/cooling program.  Generation of production report.  Organization of reference values.  Roll shop management.  Output to VDUs.  Print out of various masks as required.  Communication with level 2.  The process control computer is responsible for  Storage of current rolling programs/cooling programs.  Generation of reference values and automatic control main and in-line aux. Drives.  Cascade control.  Loop control.  Cable detection and initiation of operation of shear n intermediate and finishing blocks.  Optimization of and out length control shears.  Control of water and air cooling rods.  Division of coil in reform tub.  Spindle positioning in mill stands.  Data communication function.  Communication with level 1 & 3.  The Programmable Logic Controllers are used for the following control functions.  Inter locking and sequence control of all DC drives except the switch in logic for individual thyristors for converters.  Starting/inter locking and sequence control of AC drives.  Interlocking control of solenoid valves.

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3.PROGRAMMABLE LOGIC CONTROLLER

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3.1 Introduction:3.1.1 Logic:Any industrial process or machine is determined by sequence of events which are specific to its operation. This sequence is then arranged into a set of logic functions.

This Logic scheme is turned into a physical system using the basic building blocks of the particular technology selected, i.e. Mechanical, Fluidic, Pneumatic, Electromechanical, and Electronics.

Relay Logic Circuits (RLC) form the basis for Programmable Logic Controllers (PLC). Example of RLC:-

L1-L2 (AC/DC) PB1 PB2 R1 R12

Control voltage

Start Pushbutton Stop Pushbutton Relay Auxiliary Relay

3.1.2 Circuit Functioning:-

When PB1 is pressed, R1 & R12 coils pickup. This makes R12 Normally Open (NO) contact to close. Once R12 contact closes even if PB1 is released, R12 will remain ON as there is an alternative path for the coil (Termed as Latching). The only way to break the latch is to press PB2.These circuits are hard wired.

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3.2 Drawbacks of RLCs:-

1. Bulky Circuits : a) External components like counters, timers etc. need to be used apart from relays. b) Additional auxiliary relays need to be used in parallel to actual relays if required but relays had limited number of auxiliary contacts. 2. Troubleshooting was very difficult: a) Tedious process is involved in tracing the entire loop if a particular relay was not becoming ON. 3. Inflexible: a) Changes in the logic need change in wiring. In some cases it would be impossible, as the required contacts (Normally Closed (NC)/Normally Open (NO)) would not be available. 4. It would not be feasible to build RLC for complicated logic. PLCs overcome the above drawbacks. PLCs challenge relays, stepping switches, drum sequencers etc. It is composed of electronic circuit with a microcomputer centered.

3.3 Definition of PLC:A Programmable Logic Controller (PLC) is an industrial computer that accepts inputs from switches and sensors, evaluates these in accordance with a stored program, and generates outputs to control machines and processes.

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3.4 Working of PLC:-

Most of the PLCs execute Scan sequence.

1. House keeping consists of internal checksums and diagnostics that the processor executes every scan cycle. This can be done at the beginning or ending of the scan cycle(depending on PLC). 2. Input Scan consists of reading the current state for each input connected to the PLC system and updating the memory table. 3. Logic Scan consists of reading the user program is in PLC memory. Programs can be in ladder logic, instruction list, sequential flow charts, functional blocks, structure text, c code or state logic depending on the manufacture of system. Some system supports programming using combination of languages within the same program. 4. Service Communications consists of opening the window of time for the processor to communicate to other devices. These can be programming devices, operator interface devices, remote IO controllers, other PLCs or any other devices having communication capability that is compatible with the PLC system.

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3.5 Block Diagram:-

3.5.1 Power supply:

These are required for the circuits of PLC to function. These are designed and rated only to operate the internal structure and not the field elements. External supply to PLC can be AC/DC. PLC power supply converts these to the appropriate voltages required for internal functioning of PLC circuits.

3.5.2 Common Voltages:

AC: 110V, 220V

DC: 24V, 110V

3.5.3 Processor: It is the heart of the PLC and interfaces the input and output subsystems through software written to it.

3.5.4 Input Subsystems:

Sensing elements are wired to the input section of PLC. They sense the dynamic status of

the machine operation. Inputs can be analog or digital.

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3.5.4.1 Digital Inputs: These Inputs have only two states viz., ON/OFF. Therefore these are also called as discrete inputs. Elements used to give the various commands for e.g. Push Buttons, Limit switches etc., are directly connected to the input of PLC. 3.5.4.2 Analog Inputs: These Inputs have multiple states and rather continuously changing one and are having a range of values. Electrically these are categorized into two: 1. Voltage: The commonly used ranges are: 1. 0 to 10 V DC - Unipolar 2. -10to+l0VDC -Bipolar 3. 0 to 5 VDC 2. Current: The commonly used ranges are: 1) 0 to 20 mA. 2) 4 to 20 mA. The field parameters like pressure, flow etc., are converted to electrical parameter through Transducers and are converted further to voltage or current signals through transmitters. The output of transmitter is connected to analog input of PLC. The PLC then converts the signals to their equivalent digital values through A-D converters.

3.5.5 Output Subsystems:

The actuating elements are wired to the output section. Outputs are classified into two and they are similar to Inputs classification. In case of Analog Outputs the digital value is converted into Analog signals and signals are fed to actuators such as control valves.

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3.6 Classification of I/O s:

There is another classification of PLC Inputs and Outputs. 1)Local I/O s 2)Remote I/O s Local I/O s: If PLC I/Os are connected directly to the PLC CPU system then the l/Os are termed as Local I/Os. Input and Output wiring is done directly to CPU system. Remote I/Os: If PLC I/Os are connected through remote communication card to the PLC system then the l/Os are termed as Remote I/Os. I/Os are wired and communicate to the interface unit and this in turn communicates to the communication card on the PLC system.

3.7 Advantages
Ease of programming Ease of maintenance Designed for industrial environment Quick installation Adaptable to change

y y y y y

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4.WRM DESIGN
Mill Capacity : 8, 50,000 TPY. Products : 5.5 to 12.7mm round & Rebars in coils Rolled billet size: 125mm x 125mm x 10.4m length, 1250 kg. Plane : 5.5mm,6,6.5,7,7.5,8,9,10,11,12,12.7,13,14 Rebars : 8, 10, 12 : 3000-3200 T/D (avg) Max Speed : 76 m/sec Cooling Process : Retarded stelmor cooling control process Grades : LC IS2062, Law Carbon: 0.008-0.3%, 0.4-0.5% HC : 55 to HC 85 EQ : Electrode Quality HQ CHQ : Cold head quality HSCR : High Strength Corrosion Resistance CAQ : Coil Armored quality Fe 415, Fe 500, also rolled.

1 to 13 Stands : Fixed on bolts, Horizontal Periodical Graphite 14 to 15 Stands : Cantilever, ring rolls, tungsten carb ide All are horizontal rollers 4.1 Pass Design : Box Pass Box Oval Pass Round Pass Diamond (square) 4.2 Rolling Design : A1V1=A2V2 sectional area V= Velocity After Stand 7
After Stand 13 After Stand 15

STD 1 All Even 2, 4, 6, 8, 10, 12.. All Odd 3, 5, 7, 9, 11, 13 7,9,11

since A= Cross A2 = 46*46mm2

A2 = 21 - 24.5mm2 A2 = 16-19.6mm2

20 4.3 Guides : Static Roll entry guides, roller twist guides. 8mm rods rolled up to STD 23 10mm rods rolled up to STD 21 12mm rods rolled up to STD 19 14mm rods rolled up to STD 17 Down stream rolls becomes dummy.

4.4 Sequence Of Equipments :

1. Charging Grid 1 2. Charging Grid 2 3. Cross transportation 4. Billet elevator 5. Billet transfer device 6. Billet positioning device 7. Furnace approach roller table 8. Furnace 9. Billet ejector 10. Billet withdrawing mill 11. Billet transfer switch 12. Pendulum shear (not being used presently) 13. Roughing mill 7 Stands 14. RM Shear 15. Intermediate mill 6 Stands 16. Horizontal Looper 4 Snap Shears 17. IB looper 4 Stands 18. Water cooling IB boxes 4 stands 19. FB Shear 4 Stands 20. Horizontal Looper 4 Stands 21. Finishing blocks 4 Chopping Shears 22. Water Cooling Boxes B1, 2, 3(4*3) 23. Pinch Roller 4 24. Laying head 4 25. Stelmor Group 1 to 5 (4 stands) 26. Down ender 27. Coil receiving Stands 4 28. Coil weighing stands 4 29. Coil unloading stands 4 30. Large Compactor 2

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5. Equipment Details Functional Description

5.1Charging Grids :  1. Two charging grids operate in tandem located in billet storage bay. The  storage capacity is sufficient store the product of 1 hour.  2. The billets are picked up by magnetic crane up to max 10, deposited in groups.  3. A billet layer is transported to C.G.2 up to max of 20 billets, gaps are to be formed between the max 4 groups to permit the folding dogs of 4 dragging cars to restore up right position.  4. The rope transfer trains of the grid are provided with 2 transfer carriages each, and each one is equipped with 2 tandem arranged folding dogs.  5. Billet layers are moved by alternating forward and backward movement of dragging cars with a pitch of 3300mm.  6. Max of 4 layers pushed together.  7. CG1 & CG2 are identical in their rails so that billet layers are transferred from CG1 to CG2.  CG1 will take up billets from CG1 and transport then to billet cross transport.  CG1 operates at a continuous speed at 80 mm/s until the first billet has reached the end of charging grid. Then speed reduced to 40 mm/s. after first billet has been pushed to the unloading position the dragging car stops. The next start in forward direction is affected as soon as cross transport has been moved one step to elevator. CG gear ratio : I = 315:1 CG1 CG 2 AC motor (Slip ring induction) DC motor n = 750 rpm n = 0-575/1725 rpm N = 50kw N = 37kw V= 0.1 m/s Conveyor speed v = 0.08 m/sec Retraction speed = 0.023 m/sec Total loading capacity = 100*2 = 200 max

Inter Locks:
Manual mode, Auto mode 1. Switching over dragging cars from forward to reverse only after forward movement completely terminated A. CG2 shifted to 1400 to 3480mm, 2800 to 3480 mm in forward direction. B. Priority of backward shifting of grid 2 or C. Grid 2 not in collision range. R Interlock fulfilled

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5.2Billet Cross Transport:

     It is arranged between CG2 and Elevator It transports billets stepwise from CG2 to elevator 9 billets in total can be put on CT with gap at 1000mm gear ratio I = 180:1 3 phase AC(slip ring induction motor) n = 750 rpm, N = 32KW

INTER LOCKS:  Auto start/stop or  Cyclic operation from CPA It has 4 interlocks F1,F2,F3,F4.  F1: when & As long as unloading place at the end of CG 2 is occupied  F2: When & as long as priority change operation is released or signal place 4.2 at the end of CG2 is empty  F3: When & as long as signal elevator not in the range of unloading place at the end of CT present.

5.3 BILLET ELEVATOR:

It transports billets step by step from CT to the billet transfer device. It brings from +1065 to +6200mm, slope of elevator 350 , total 11 billets can placed. Billet 1 is in the unloading position between CT & Elevator Billet 2 to 11 are in the depositing position of elevator Billet 1 is retracted by means of dogs from CT, free position allows CT to move one step further billet 11 is moved to unloading position & elevator stops. Billet transfer device moves back to billet elevator. Technical Date : I = 180:1 n = 750 rpm, N = 32 KW, 3 phase AC (slip ring induction motor)

INTER LOCKING:

Billet elevator started in forward when unloading position at the end of Billet elevator is clear (OR) position 11 is clear where as the loading position at the end of the CT is occupied

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6.cross transport segments

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SEGMENT 1

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SEGMENT-2

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SEGMENT- 3

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SE

-4

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SEGMENT 5

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SEGMENT-6

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SEGMENT 7

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SEGMENT-8

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SEGMENT 9

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SEGMENT-10

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SEGMENT 11

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SEGMENT 12

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SEGMENT 13

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SEGMENT- 14

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SEGMENT-15

F 104.0-CROSS TRANSPORT RESET CONDITION I 84.3-CBAO2 BILLET CT LOCAL CBAO1 I 24.3-LAMP TEST Q 26.6-PULPITBC CT READY FOR ON

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SEGMENT-16

I 48.0-CBAO1 BLOCK=0 I 24.0-PULPITB BILLET CHARGED.GRD.1&2 CT RELEASE I 72.1-CROSS TRANSPORT BLOCKING=0 I 49.1-CBAO1 EMERGENCY STOP=0 I24.3-PULPITB LAMP TEST Q26.6-PULPITB CROSS TRANSPORT BLOCKED

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SEGMENT-17

F 105.3-CROSS TRANSPORT AC CONTACTOR FORWORD .ON Q 8.5-BILLET PUSHER FORWORD F 2.6-EH11 F 2.5-KA1

SEGMENT-18

I 2.3-CROSS TRANSPORT.FRQ.CONTROL UNIT FORWORD I 2.5-CROSS TRANSPORT.ISOLATOR CONTACTOR Q 2.3-CROSS TRANSPORT.FRQ.CONTROL UNIT FORWORD F 2.3-RM11

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SEGMENT-19

I 2.4-CROSS TRANSPORT.FRQ.CONTROL UNIT REVERSE I 2.5- CROSS TRANSPORT ISOLATOR CONTACTOR Q 2.4- CROSS TRANSPORT.FRQ.CONTROL UNIT REVERSE F 4.3-RM21

SEGMENT-20

F 8.0-KE11 Q 2.3- CROSS TRANSPORT.FRQ.CONTROL UNIT FORWORD

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SEGMENT-21

F 8.2-KE21 Q 2.4- CROSS TRANSPORT.FRQ.CONTROL UNIT REVERSE

SEGMENT-22

F 9.2-STO F 180.1-BILLET CROSS TRANSPORT E -FAULT T 13-SWITCH ON DELAY LAMP TEST MICI Q 2.5- CROSS TRANSPORT FAULT LAMP

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SEGMENT-23

F 104.0- CROSS TRANSPORT RESET CONDITION I 50.4-CBAO1 CROSS TRANSPORT AUTO I 84.3-CBAO2 BILLET CROSS TRANSPORT LOCAL CBAO1 F 105.4- CROSS TRANSPORT PREPARED FOR AUTO OPERATION

SEGMENT-24

I 13.5- CROSS TRANSPORT.SHIFTING RELEASE CYCLIC OPERATION RELEASED=0 Q 2.3- CROSS TRANSPORT.FRQ.CONTROL UNIT FORWORD I 13.7- CROSS TRANSPORT NUT IN RANGE.UNLOADED PLC GRID.2 F 105.6- CROSS TRANSPORT NUT IN THE RANGE OF UNLOADED

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7.CONCLUSION:A Programmable Logic controller is a device, which is capable of being programmed to perform a controlling function. The basic function of a PLC is to provide desired OUTPUT commands to machine or process based on some combination of a set of INPUT conditions to that machine or process. The internal wiring of a PLC is a fixed and the logical function that it must perform are programmed into memory, hence the name programmable controller. As the capability and reliability of microprocessor components increased and their costs decreased, the PLC evolved into a computer system with an assortment of capabilities like arithmetic operations, digital/analog conversions, data comparison, word manipulations of complex functional and equation solving.

8.BIBILOGRAPHY:BOOKS:
y y y y y

Programmable logic circuits by Allen Bradley Automated Manufacturing system.PLC By Hugh Jack Modern PLC by Gill & Mac Millan Programmable logic controllers by Wilcox Referred manual from R.I.N.L(Rhastriya Ispat Nigam Limitted)