Hydraulics in Vizag Steel Plant

Modification of Furnace Hydraulic System in M.M.S.
1. INTRODUCTION TO VISAKHAPATNAM STEEL PLANT (VSP)

Visakhapatnam Steel Plant, the first coast based Steel Plant of India is located, 16km south west of City of Destiny i.e., Visakhapatnam. Bestowed with modern technologies, VSP has an installed capacity of 3million tones per annum of liquid steel and 2.656 million tones of saleable steel. At VSP there is an emphasis on total automation, seamless integration and efficient up gradation, 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 successfully installed and are 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. Vsp exports quality pig iron and steel products to Srilanka, Myanmar, Nepal, middle EAST, USA, and south east Asia (pig iron). RINL-VSP was awards star trading house status during 1997-2000. Having a total manpower of about 16,613 vsp has envisaged a labour productivity of 265 tons per man year of liquid steel which is the best in the country and comparable with the international levels.
1.1 MAJOR UNITS:
DEPARTMENT
ANNUAL CAPACITY (1000T)
Coke ovens Sinter plant Blast furnace Steel melt shop LMMM WRM MMSM Table 1.1
2,261 5,256 3,400 3,000 710 850 850
Modification of Furnace Hydraulic System in M.M.S.M
1.2 MAIN PRODUCTS OF VSP:

STEEL PRODUCTS Angles Billets Channels Beams Squares Flats Rounds Re-bars Wire rods Table 1.2 BY-PRODUCTS Nut coke Lime fines Coke Dust Ammonium Coal Tar - Sulphate Anthracene oil HP Naphthalene Benzene Toluene Xylene Granulated slag
1.3 MAJOR DEPARTMENTS:

1.3.a Raw material handling plant (RMHP): Vsp annually required quality raw materials of viz.., iron ore, buxes (lime stone, dolomite), coking and non-coking coals etc to the tune of 12 to 13 million tons for producing 8 million tones 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, RMHP serves a vital function. This is provided with elaborate unloading, blending, stacking and reclaiming facilities. In vsp peripheral unloading has been adopted for the first time in the country.
1.3.b Coke ovens in coal chemical plant (co & ccp): Blast furnace, of any steel plant required huge quantities of strong, hard and porous solid fuel in the form of hard metallurgical coke for supplying necessary heat for carrying out of the reduction and refining reactions. Coke is manufactured by heating of crushed cooking coal (below 3mm) in absence of air at temperature of 1000c and above 16 to 18 hours. At vsp there are three coke oven batteries, 7 meter tall and having 67 ovens each. Each oven is having a volume of 41.6 cu meter and can hold up to 31.6 tons of dry coal charge. The carbonization takes place at 1000-1050C in absence of air for 16 -18 hours red hot coke is pushed out of the oven and
sent to coke. Dry cooling plants where nitrogen gas is used as the cooling medium. The heat recovery from nitrogen is done by generating steam and expanding into back pressure turbines to produce 7.5 powers each.
1.3.c Sinter plant(sp): Sinter is a hard and porous ferrous material obtained by agglomeration of iron ore fines, coke breeze, limestone fines, metallurgical waste like 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 and improving the quality of hot metal produced. Sintering in two sinter machines of 312 sq.m by heating the prepared feed on a continuous metallic belt made of pallets at 1200-1300 C. Hot sinter discharged from .sintering machine is crushed to 5mm-50mm size and cooled before dispatching to blast furnace.
1.3.d Blast furnace (BF): Hot metal is produced in blast furnaces that are tall vertical furnaces and each run with blast at high pressure and temperature. Raw material such as iron ore lumps/sinter, fluxes (limestone, dolomite) and coke are charged from the top and hot blast at 1100-1300 C and 5.75 KSCG pressure is blown almost from the bottom VSP has two 3200 cu.m blast furnaces (largest in India) equipped with PAUL WORTH bell-less top equipment with conveyor charging the two furnace with their circular cast house and 4 tap holes each are capable of producing 9720 tones of hot metal daily or 3.4 million tones of low sulphur hot metal annually. Provision exists for granulation of 100% liquid slag and utilization of blast furnace gas top pressure (115-2atm) to generate 12 mw of power in each furnace by employing expansion turbines.
1.3.e Steel melting shop (SMS): Steel is an alloys of iron with; carbon up to 1.8%. Hot metal produced in blast furnaces contains impurities such as carbon (3.5-4.25%), silicon (0.3-0.4%). Sulphur (0.4% max) and phosphorus (0.14% max) is not suitable as a common engineering material to improve the quality that impurities are to eliminated or decreased by oxidation process. VSP employees three top blown oxygen converts called LD-converters each having 133cum volume capable of producing three million tones of liquid steel annually 99.5 % of pure oxygen at 15-16 KSCG pressure is blow in the converter through an oxygen lance having
convergent-divergent copper nozzles at the blowing end. Oxygen oxidizes the impurities present in the hot metal that are fixed at slag with basic fluxes such as lime. During the process heat is generated by exothermic reactions of oxidation of metalloids like Si, Mn, P & C and temperature raises 1700C enabling refining and slag formation. This process can make different grades of steel of superior quality by controlling the oxygen blow or addition of various Ferro Alloys or special additives, such as FeSi, FeMn, Si-Mn, Coke breeze, Al in required quantities while liquid steel is being trapped from the converter into a steel ladle. Converter gas produces as a bi-product is used as secondary fuel.
1.3.f 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 bar is continuously withdrawn at the same rate at which liquid steel is teamed in the mould. Facilities at a continuous casting machine include a lift and turntable for ladles, copper mould, oscillating system turn dish, primary and secondary cooling arrangement to cool the steel bloom. Gas cutting machines is used for cutting the blooms in required lengths of 6m long. At VSP we have six-4strand continuous casting machines capable of producing 2.82 million tons per year blooms of size 250X250mm and 250X320mm. The 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. 1.3.g Rolling Mills: The blooms produced in SS CCD do not find much applications as such and required to be shaped into products such as billets, rounds, squares, angles (equal and unequal), channels, IPE beams, HE beams, wire rods, re-bars by rolling them in 3 sophisticated high capacity, high speed, fully automated rolling mills, namely light and medium merchant mill (LMMM), wire rod Mill (WRM) and medium merchants and structural mill (MMSM). 1.3.g.1 Light and medium merchant Mills (LMMM): LMMM comprises of two units. In the billet/break down mill 250X320 mm size blooms are rolled into billets of 125X125mm size after heating them in 2 nos. of walking beam furnaces of 200 tons per hour capacity each. This unit comprises of 7 stands (2 horizontal 850X1200mm) and 5 alternating vertical and horizontal stands
(730X1000mm&630X1000mm). Billets are supplied from this mill to bar mill of LMMM &WRM. The billets for rolling in bar mill of LMMM are first heated in two-stand roller heart furnace of 200 tons per hour capacities to temperature of 1150-1200C. The bat mill
comprises of 26 stands (8 stands double stand roughing train, 2nos. of 5 stands, double stand intermediate train and 2 nos. 4 stand single stand finishing trains).
The mill is facilitated with temperature heat treatment technology evaporative cooling system in walking beam furnaces, automated pilling and 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, and channels besides billets for sale.
1.3.g.2 Wire Rod Mills (WRM): Wire rod mill is a 4 stand, 25 stands fully automated and sophisticated mill. The bill has a 4-zone combination type-reheating furnace (walking beam cum walking hearth) of 200 TPH capacities for heating the billets received from billet mill of LMMM to rolling temperature of 1200oC. The mill produces rounds in 5.5-12 mm range and re-bars of 8-12 mm range. The mill is equipped with standard and retarded steel more lines for producing high quality wire rods and low, medium and high carbon grade meeting the stringent national and international standards viz. BIS, DIN, JIS, BS etc. and having high ductility, uniform grain size, excellent surface finish.
1.3.g.3 Medium Merchant and Structural Mills (MMSM): MMSM is a high capacity continuous mill consisting of 20 stands arranged in three trains. The feed material to the mill is 250X250 mm size blooms, which is heated to rolling temperature of 1200C in two walking beam furnaces each of rounds, squares, flats, angles (equal and unequal). T bars, Channels, IPE beams/HE beams(universal beams) having high strength and close tolerances.
2. MEDIUM MERCHANT & STRUCTURAL MILL
2.1 INTRODUCTION TO M.M.S.M :
Fig 2.1
In Medium Merchant and structural Mills (MMSM) the blooms of size 250X250mm are heated to temperatures around 1200C and rolled into different categories of bars and structural like rounds, squares, flats, angles, channels, HE and IPE beams by timely estimation of demand. The mill train of MMSM consists of a total of 20 stands as follows Roughing train consists of 8 stands as 4 two high horizontal stands. 2 vertical stands, 2 combination stands,
Intermediate train has 6 mill stands as per detail given below: 2 high horizontal stands, 2 combination stands, 2 horizontal stands/2 universal stands.
Finishing train consists of 6 stands namely:
2 combination stands, 4 horizontal stands/4 universal stands.
2.2 PROCESS DESCRIPTION IN M.M.S.M:

The input material to the mill is continuous cast blooms of size 250x250mm. Two walking beam type furnaces are provided for reheating the blooms. For charging the furnace, the blooms are loaded on the bloom charging grids in batches by magnet cranes. Blooms are visually inspected on the charging grids and weighed one by one on a weigh scale incorporated in the charging roller table, aligned in front of the furnace and charged into the walking beam furnace by a bloom charging device. The heated blooms from the furnace are discharged one by one onto the delivery roller table by bloom discharging device for feeding them to the first stand of roughing train. During transportation to the first roughing stand, the blooms are discalced on all 4 sides by a hydraulic declare. The mill train consists of continuous roughing, intermediate and finishing group of stands. Depending on the section being rolled the combined stands, provided on each of the continuous trains, are arranged in a horizontal or vertical position. In case of the rolling of beams suitable number of horizontal stands, provided in the continuous intermediate and finishing trains are replaced by universal stands. Generally, shears installed before the intermediate train and furnishing train cuts the front ends of the bars. Front end cropping, dividing of finished bars into multiple sale lengths for cooling bed, emergency cutting and test piece sample cutting is done by the shear provided after the finishing group. In line size measurement is done for rounds, squares and flats on equipment provided after finishing group of stands. Following the shear after the finishing train is a series of water boxes and roller tables complete with water spraying nozzles for controlled and rapid cooling of divided bars after which they are directed with the help of a diverter switch to the double sided cooling bed. The finishing of cooled bars is done on inline automatic finishing lines installed after each cooling beside. This finishing line is provided with facilities for straightening, cutting, inspecting, sorting according to surface quality and length, counting, piling, bundling, tying, weighing and tagging with embossed metallic tags. EOT cranes having 20-ton capacity, 10m crane rail height and fitted with rotating rolling, spreader beam magnet/slings is available for removing piled and bundled products to the storage area.
2.3 MMSM PRODUCTS

Rounds 40 45 46.5 48 50 53 56 60 63 65 70 71 80 Angles 75*75*8 90*90*6 90*90*8 100*100*8 100*100*10 Mc 100*50*5 125*65*5.3 150*75*5.7 Ismb 150 175 Flat 150*10 150*12 Blt 65*65 75*75 90*90
Table 2.1
Fig no. 2.2
3. WALKING BEAM REHEATING FURNACE
3.1 IMPORTANT COMPONENTS OF THE FURNACE:

The reheating furnace includes the following components: Furnace structural framework Walking beam driving mechanism Walking beam and fixed beams Combustion air fan Burners Waste gas exhaust system Refractory and insulation Fuel system, evaporation cooling system, lubrication and hydraulic system.
The specifications of the blooms being fed into the furnace are:
Blooms Thickness Width Length Weight _ _ _ _ _ size 250mm 250mm 6000mm 2900kg
3.2 EUIPMENT SPECIFICATIONS:

The walking beam furnace is used for heating blooms of place carbon steel, low alloy steel, free cutting steel, medium and high carbon steels from ambient to about 100C. The furnace is charged in two rows foe 6mt long blooms and also with a provision of charging 12mt blooms. The particulars about the walking beam furnace are as given below.
Type
Top and bottom fixed walking Beam furnace
Number Nominal output charge temperature at Inlet Discharge temperature at outlet Temperature different b/w surface and core
_ _ _ _ _
Two 250T/hr Ambient 1200C 30C
3.3 FURNACE CONSTRUCTION FEATURES:

The furnace is fabricated from steel plates adequately reinforced with structural steel member for the robust construction steel plants and steel members of heavy section are provided to support the hearth.
a) Charging and discharging doors: The furnace is provided with charging and discharging doors of suitable dimensions. The doors are fabricated from structural steel sections and lined with refractory materials. The doors are balanced by counter weights and operated through electric drives. The discharge doors are of water cooled type. The door openings and door peripheries are fitted with heat resistant casting.
b) Side doors: A sufficient number of side doors are arranged over the entire furnace length at the work load level. Arrangement for manual operation, locking in open position and wedged guides for ensuring proper tightness in closed position is provided. These doors and the opening periphery are made of heat resistant casting with refractory lining, cleanout doors at the furnace hearth level are also provided. For sealing the gaps at the bottom hearth around walking beam post, water troughs made out of corrosion resistant steel plates of adequate thickness are provided.
c)
Charging and discharging side front walls: The charging and discharging side front walls are equipped with water cooled lintels that support the roof noses.
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3.4 WALKING BEAMS(SKIDS):

Operation: Blooms are moved forward step by step, avoided any friction or rubbing during its conveyance through the furnace. The blooms are gently lifted from the stationary beams, moved forward by walking beams and gently placed on stationary beams. Both walking and stationary beams are properly supported on vertical posts. The walking beams supporting posts are fastened to a movable frame which are equipped with rollers and permit the horizontal movement for the transfer of the blooms. The walking beams and stationary beams are fabricated out of seamless steam tubes.
Vertical and Horizontal movements: Vertical and Horizontal movement of the beams are the beams are obtained through separate hydraulic cylinders. The operation of the cylinders ensures gradual start up and gradual stoppage during lifting and lowering and horizontal movement. Charging and discharging equipment: The blooms are conveyed and positioned in front of the furnace on roller table by electrical control. After positioning the blooms on the roller table, the blooms are transferred on the charging table by means of charging device in single row or in two rows. The blooms are discharging from the furnace separately from each row by means of discharging device. Two discharging device are suitable for single row or two row operation. Hydraulic power station: A centrally located hydraulic power is provided for the furnace for operation of the various hydraulic cylinders for walking beam mechanism. The power unit consists of fluid tanks, pumps with drive and control, necessary solenoid valves, flow control valves, check valves, pressure relief valves, filters etc. Ore stand by pump with drive is also provided. Grease lubrication system: An automatically controlled centralized lubrication system is provided with necessary safety arrangement for lubrication of moving parts.
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Skids and support tube cooling system: Evaporation cooling system (ECS) is provided for cooling of the skids and support tubes. Steam generated is diverted to plant steam network. The evaporation cooling system comprises of separating drums, re-circulating pumps, de-mineralized water, water storage tanks, feed pumps with necessary pipes, valves, fitting, gadgets and necessary instrumentation. Besides cooling of skids tubes and support tubes by ECS, following items are also cooled by water. a. b. c. d. Charge and discharge lintels. Discharge doors. Hydraulic oil. T.V cameras.
3.5 COMBUSTION SYSTEMS:

a) Burner: Adequate number of burners of suitable design to fire mixed
gas in
preheating, heating(top & bottom) and soaking zones are provided. The burners are provided with peepholes and ignition ports for easy operation and firing. The burner connected load is 20% higher than fuel consumption rate, which is calculated on the basis of maximum furnace output.
b)
Combustion air fan: The furnace is provided with two numbers of combustion air fan, one in operation and one as a standby. The fan is of centrifugal type, directly coupled to air required for maximum connected load of the burners considering 10% excess of air. The blowers are equipped with adjustable directional blades on the suction side.
c) Waste gas exhaust system: i. Chimney : products of combustion are exhausted from the preheating section of the furnace through underground flue channel leading to chimney. The height of the chimney is decided considering draft and statutory regulations. The chimney is of self-supporting type, construction out of reinforced steel plate and lined with refractory material.
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ii.
Dampers: A damper for automatic pressure controlling the waste gas is made of heat resistant material to withstand the temperature of the waste gases.
iii.
Air and gas recuperators: Connection type multi-tubular air and gas recuperator is provided in the waste gas fuel channel. The unit is designed for designed for
preheating the inlet air to the burner manifold to a temperature of around 450C and a mixed gas leading to the burner manifold to a temperature of around 380C. The recuperator tube is made to suitable heat resistant steel to withstand the high temperature of water gas. Hot air bleed off arrangement in the duct leading to the burner is provided.
iv.
Dilution air fan: A centrifugal blower complete with accessories is provided for supplying cold air in the waste gas flue upstream of the recuperator to prevent the recuperator tubes from overheating.
v.
Lagging:
The combustion air pipe and gas pipe and pipe between the recuperators and the burners is lagged externally with insulating materials or lines internally with refractory material depending on the diameter. The lagging is protected by galvanized sheet steel wrapping.
3.6 REFECTERIES AND INSULATINOS :
The roof of the furnace is flat suspended type which is built up with shaped roof hanged bricks made out of superheat duty fire bricks. The roof hanger bricks are backed up with a layer of insulating matter. The roof brick hanger is made up of heat resistant steels
The wall is lined with a high alumina fire bricks up with cold faced insulating bricks and insulating blocks The furnace hearth is lined with high alumina fire bricks backed up with cold faced insulating bricks and insulating blocks 13
The doors are lined with high temperature insulating castables. The waste gas flue upstream of the recuperator is lined with high heat duty fire bricks baked up with cold faced insulating bricks. Down stream of recuperator is line up with medium heat duty fire bricks backed up with cold faced insulating bricks. One ventilation course of red brick is provided between the refractory brick and concrete walls. Thickness of the refractory layers in the waste gas flue is so chosen that the maximum temperature on the flue concrete face does not exceed 150C. The movable and stationary beams are lined with high alumina castables backed up by insulation materials.
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4. BASIC HYDRAULICS
4.1 FUNDAMENTALS OF HYDRAULICS:

The word hydraulics generally refers to power produced by moving liquids. Modern hydraulics is defined as the uses of confined liquid to transmit power multiply force, or produce motion.
Though hydraulic power in the form of water wheels and other simple devices has been in use for centuries, the principles of hydraulics werent formulated into scientific law until the 17th century. It was then that French philosopher Blaise Pascal discovered that liquids cannot be compressed. He discovered a law which states: Pressure applied on a confined fluid is transmitted in all directions with equal force on equal areas.
4.2 BASIC HYDRAULIC SYSTEM:
fig 4.1
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This type of circuit consists of a pump which develops the required pressure, a relief valve, direction control valve, and cylinder. The piston in the cylinder either extends or retracts as per the selection of the directional valve. a) TANK: Tank is one of important device to store the large amount of oil Which is used in the hydraulic system.
b) PUMP: The function of pump is to convert mechanical energy to hydraulic energy by pushing the hydraulic fluid into the system. The hydraulic energy delivered to the system by the pump is in the form of fluid flow. Thus pump can produce the flow necessary to the development of pressure but a pump cant produce pressure since it cant create or fluid flow resistance on its own.
c) DIRECTION CONTROL VALVES: Start, stop and direction of flow of a pressure fluid is controlled by means of a directional control valve and thus the direction of movement or holding positions of a user is determined. d) FLOW CONTROL VALVES: The speed of an actuator depends on the rate at which the fluid enters the actuator. Control of this fluid flow is very important in controlling the speed of the machine parts. Different types and designs of flow control valves are available depending on maximum flow rate. Speed of the actuator can be controlled by either controlling the flow rate into it or by controlling the fluid flow from the actuator.
e) HYDRAULIC CYLINDERS: Now a days almost all earth moving, equipment are provided different types of hydraulic cylinders. Hydraulic cylinders are devices which produce mechanical output for pumped for pumps oil into the cylinder chamber.
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4.3 ADVANTAGES OF HYDRAULICS:

Operates at variable speed by varying the pump delivery or using a flow control valve. Hydraulic actuators can be reversed instantly while in full motion without damage. Over load production by means of pressure relief valve. High power to weight ratio. Movement from stand still is possible under full load
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5. HYDRAULIC SYSTEM IN REHEATING FURNACE
5.1 INTRODUCTION TO FURNACE HYDRAULICS:

Walking beam furnace as the name implies, it is having fixed and moving beams otherwise known as skids which move from one end of the furnace to the other end with adjustable stroke length. On these beams, blooms will be charged at the charging end and will be discharged or extracted from other end as the bloom moves through a fixed distances for every forward cycle of the system. As the bloom goes from charging end to the discharging end the blooms becomes red hot to a temperature of 1200c by receiving heat from furnace on burning CO gas and hot air Furnace will have two types of beams or skids. One type is called fixed beam and the other type is called moving beam or walking beam. Fixed and walking beams are placed alternatively one besides the other. Walking beam cycle starts lifting the blooms from zero position [same level as fixed beams] to upward position for 100mm and moves the bloom forward for 400mm and goes down keeping the bloom on the fixed beam and still goes down 100mm below the fixed beam level and goes back for about 400mm and comes to original basic position and moving upward to zero position. Like this 100 blooms will be charged in to the furnace for each bloom cycle repeats and moves the bloom towards discharging end simultaneously heating and soaking of the blooms takes place and finally when the bloom comes to the discharging end the bloom attains the desired temperature required for rolling. This bloom is taken out with the help of a bloom extracted and kept on a roller convey or which feeds the bloom to the mill.
5.1.a FURNACE HYDRAULIC SYSTEM: This system facilitates the movement of the walking beam such upward, downward and translator movement. This system also provides a smooth cycle movement without any rapid or jerk movements so as to avoid any mishandling of the blooms.
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5.1.b HYDRAULIC EQUIPMENT: Hydraulic equipments consist of the following components: Complete reservoir, useful capacity of 3000 lit, fitted with heaters, coolers, level and temperature indicators and temperature controllers. 3 oil conditioning motor pump sets [including 1 as stand by] to continuously filter and cool the oil contained in the tank. 2 pilot pressure motor-pump sets [including 1 as stand by] one pump is running permanently. The stand by pump will automatically start in case of any pressure failures or filter clogging of the running pump. 3 main motor pump sets [life and transfer pump sets] two pumps will be running permanently one pump the cylinder only. The other feeds in turn the lift cylinders and the transfer cylinders 1valve/manifold block stand. The oil delivered by the main pumps and the pilot pressure pump flows through the stand mounted valves and manifold Before feeding the lift and transfer cylinder. Loose manifold blocks and miscellaneous items.
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5.2 SPECIFICATIONS OF FURNACE HYDRAULICS : a) RESERVOIR:
Fig 5.1
It is mainly used to store the oil that is used in the hydraulic. In this the tank has storage capacity of 4000lit at a time. And the tank has several valves for the transfer of oil from different directions.
20
Fig 5.2
21
S.NO 1
SPECIFICATIONS 1.1
NAME Oil tank with a total capacity of 4000lit.
TYPE Garma
1.2.1
Tropicalized minimum level switch (800mm long).
Garma (alarm)
1.2.2
Tropicalized stopping switch (900mm long).
Garma
1.2.3
Tropicalized stopping switch (1000mm long).
Garma
5 6
1.3.1 to 3 1.4.1 to 5
Optical indicator. Thermostat and thermometer.
Vcc (vc 3106) Ikl
7 8 9 10
1.6.1 to 3 1.7 1.8 1.10
Immersion heater Air filter. Drain valve. Hydraulic returns filter with electrical indicator.
Salva Arofiltre Sate valve Hydac
11 12 13 14 15 16
1.11 1.12 1.13 1.15 1.16 1.17
Stop valve Non-return valve Non-return valve Oil cooler Thermostatic valve Oil cooler Table 5.1
Bac Mg Mg Picker Danfoss
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b) OIL RECIRCULATION STATION:
Fig 5.3 There are two conditioning motor pump set with the capacity of 150L/min plus one as stand by. The oil delivered by the pump goes to the filters stated as 10 microns and through the cooler.
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Fig 5.4
S.NO 1 2 3
SPECIFICATIONS 2.1.1 to 3 2.2.1 to 3 2.3.1 to 3
NAME Pump Motor Coupling
TYPE Cpl 104 Siemens G 338/4p Coupling
2.4.1 to 3
Pump suction Valve
Dn 40 PN16(40)
2.5.1 to 3
Manliness pressure 686205 type check connection
24
6 7 8 9 10 11 12 13
2.6.1 to 3 2.7 2.8 2.9 2.10 2.11 2.12.1 to 2 2.13
Non return valve
SPRC 210 R25M(25)
Ball type gate valve DN 25 PN16(25) Plug Pressure gauge Isolating valve 7050 D3-2k-7055 100 E type RPA2.3.3.CL(6)
Ball type gate valve DN 50 PN16(50) Non-return valve Pressure relief valve SPRC 410 F50M DS DC 212 F50
14
2.14
Hydraulic return line filter
VR2/D/1/24
15 16
2.18 2.20.1 to 3
Motor pump Suction flexible connection
Base frame DN 40 PN16(40)
17
2.21
Tank filling pump Table 5.2
MPG2/1/0/M/0.75klo/415
b) PILOT STATION:
Fig 5.5
25
There are two pilot pressure pumps, including one as stand by with the unit capacity of 18 L/min. Each pump is equipped with one filter, mesh size 5 microns and one electrical clogging indicator. There is a single pressure relief valve for relieving the oil of more than 80bar.
Fig 5.6
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SPECIFICATIONS S.NO 1 3.27.1 to 2
NAME
TYPE
Pilot pump suction flexible connection
DN 20 B type (20)
3.4.1 to 2
Pilot pump suction valve
DN 20 PN16
3 4
3.1.1 to 2 3.3.1 to 2
Pilot pump Pilot pump motor coupling
CPL 13S GE 282 coupling
5 6 7
3.5.1 to 3 3.6.1 to 3 3.7.1 to 4
Pressure switches Shut valve Non-return valve
B2T 1132-SS-F3 RPA 2.3.2.CL(6) SPRC 210 R15M (12)
3.8.1 to 2
Hydraulic filter with electric contact
DFBN 60 G5D1/L48
9 10 11
3.9 3.10 3.11
Pressure gauge Isolating valve Pressure relief valve
0-100bar, E type SPM 101 1(1/4) DVDA 202
12 13
3.12 3.13
Chock valve
VRF 40 (1/2)
Accumulator with a IHVIO 250 capacity of 10lit
14 15
3.14 3.17
Accumulator Non-return valve
DI 16 MS SPRC 210 R15M (10)
16
1.18.1 to 2
Two position DC valve with 48V DC
2204835 (7)
17
3.19.1 to 2
Pressure relief valve
ZUDAIAT 2Z07B
18 19
3.20 3.22
Diaphragm Pr. Relief valve Table 5.3
1.5 DVD 212 E15B
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c) MAIN-PUMP STATION:
Fig 5.7 There are two motor pump sets plus one as standby operating either as semi open circuit or in closed circuit. One pump exclusively used for lifting. The other pump is used for lifting and transfer. The stand by pump may replace either pump via a set of manual valves. Each set includes one pump of axial piston and variable displacement type, fed by a boost pump coupling to the main pump.
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Fig 5.8
S.NO 1 2 3 4 5
SPECIFICATIONS 4.1.1 to 3 4.2.1 to 3 4.3.1 to 3 4.4.1 to 3 4.5.1 to 6
NAME Pump Motor Coupling Suction valve Pressure relief valve
TYPE 2VPN0226/AKOO LA2 206 90 KW/VP DN 50 PN16 2217289 (24)
6 7 8
4.6.1 to 8 4.7.1 to 3 4.8.1 to 3
Delivery valve Pilot valve Drain line nonreturn valve
DN 40 PN250(40) DN 15 PN250(15) SPRC 210 R25M(25) 686205 1/4
4.9.1 to 6
Manliness pressure check connection
10 11
4.10.1 to 6 4.11.1 to 6
Non-return valve NRV for pump station
2217487-B 2.10.8718-(1 )
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12
4.12.1 to 3
DC valve
W43MC06CI PO7 ZBF
13
4.15.1 to 4
DC valve
W43MC03M5 PO7 ZBF
14 15 16
4.16.1 to 10 4.17.1 to 3 4.18.1 to 3
Flow control valve Boosting pump Pump side valves (drain valve)
ZRHA 3EE 2Z07 CPL 138S DN 15 PN 250
17 18 19 20 21 22 23
4.19.1 to 3 4.20.1 to 6 4.21.1 to 3 4.22.1 to 3 4.23.1 to 3 4.24.1 to 3 4.25.1 to 8
Suction valve Non return valve Security valve Drain line hose Pump side valves Pilot line hose Delivery hose Table 5.4
DN 50 PN16 (50) SPZ5E10 (10) DSDA 212 R25B SAE 100R2 SAE 100 R2 3/8 SAE 100 R2 3/8 SAE 100 R10
d) LIFT & TRANSFER MANIFOLD BLOCK:
Fig 5.9
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The oil coming from the lift pumps arrives at P3 and P4. The oil entering P1 and P2 comes out of C% and C6 towards the lift cylinder, where as the oil entering P3 and P4 alternatively comes at C5 and C6 towards the lift cylinder or at C7 and C8 towards the transfer cylinder. The fluids directed by means of two directional valves pilot controlled by the solenoid valve 5.2. The following components are also mounted on the same manifold block. One solenoid operated valve to pilot control the non return valve mounted on the lift cylinder. One pressure relief valve set at 25 bar approximately One pressure switch.
Fig 5.10
31
S.NO 1 2
SPECIFICATIONS 5.1 5.2
NAME Manifold block S3/S4 valve
TYPE 1.23.11441 W42MCO 3MS PO7ZBF
3 4
5.3.1 to 2 5.4
DC valve DC valve
2179411 (25) W42MC 22BI PO7 ZBF
5.5.1 to 2
Pressure relief valve
221.7020 (25)
6 7 8
5.6 5.7 5.8
Pr. relief valve Non-return valve Block to drain valve
221.7020 (25) 2217487B DN15 PN250(15)
9 10 11 12 13 14
5.9 5.10 5.11 5.12.1 to 4 5.15.1 to 4 5.16
Non-return valve Pressure switch Isolating valve Minims Isolating valves Flow control double valve
2217487B (25) B2TM48SS-F3 RPA.2.3.2.CL(6) 686205 DN 32 PN250 ZRHA IFF Z07(7)
15
5.17
Manifold block at transfer cylinder Table 5.5
1.23.11492
5.3 WORKING OF EXISTING HYDRAUIC SYSTEM
UPWARD HALF MOVEMENT OF WALKING BEAMS: 1. (Position 0 to Position 1): In this two pumps are utilized (4.1.1 and 4.1.2).
Order to start (given by the PLC). Energization of solenoid S3(valve 5.2): lift cylinder are then fed by
pump.
32
Energization of solenoid S1.1, S2.1, S1.2 &S2.2, pressure is then

applied.
Energization of solenoid S12.1, S12.2 & S12.3: pilot pressure is then

equal to 27 bar.
Energization of solenoid S8.1 & S10.1 and energization of solenoids

S5.1: pilot pressure of 27 bars is obtained at port C20 of the pump positioned. This positioned actuates the mechanical servo valve which controls the pump swash plate, actuator cylinder. The swash plate is then F position (forward) and then flow delivered through port C1 will achieve the upward movement through the lift cylinder.
FORWARD MOVEMENT OF WALKING BEAMS: 2. (Position 1 to Position 2): In this one pump is utilized (4.1.1) Order to start (given by the PLC). Energization of solenoids S1.1 & S2.1. If they are no longer energized pressure is then applied to the pump. Energization of solenoids S4 transfer cylinder is then fed by pump. Energization of solenoids S12.1 and S12.3 pilot pressure is then equal to 20 bars. Energization of solenoids S7.1 pilot pressure of 20 bars is then obtained at port C20 of the pump positioned. This positioned actuates the mechanical servo valve which controls the swash plate actuator cylinder. The swash plate is then in F position (forward) achieves the forward movement through the transfer cylinder.
DOWNWARD MOVEMENT OF WALKING BEAMS: 3. (Position 2 to Position 3): In this two pumps are utilized (4.1.1 &4.1.2). Order to start (given by PLC). Energization of solenoids S1.1, S2.1, S1.2 &S2.2. If they are no longer energized pressure is then applied to the pumps. Energization of solenoids S12.2 and S12.3 pilot pressure is then equal to 13 bars.
33
Energization of solenoids S8.1 & S10.1 and energization of solenoids S5.1. Pilot pressure of 13 bar is obtained then at port C20 of the positioned. Start of a time delay of 1.75 seconds. The positioned actuates the mechanical servo valve which controls the swash plate actuator cylinder. The swash plate s then in F position (forward) and the flow delivered through port C1 will achieve upward movement and the downward movement through the lift cylinder. BACKWARD MOVEMENT OF WALKING BEAMS: 4. (Position 3 to Position 4): In this one pump is utilized (4.1.1). Order to start (given in PLC). Energization of solenoids S1.1, S2.1, if they are no longer energized, pressure is then applied to the pumps. Energization of solenoids S12.1 & S12.3: pilot pressure is then equal to 20 bars. Energization of solenoids S7.1 & S9.1 &S6.19: pilot pressure of 20 bars is then obtained at port C2 of pump positioned.
This positioner actuates the mechanical servo-value which controls swash plate actuator cylinder. The swash plate is then in R position (reverse) and the flow delivered through port C2 will achieve the backward movement through the cylinder transfer cylinder. DOWNWARD HALF MOVEMENT OF WALKING BEAMS: 5. (Position 1 TO Position 0): This movement is performed then the IDLE mode is interrupted with the walking beams in up position (Position 1). This movement is the same as the one described in above point i.e. downward movement of walking beams (Position 2 to Position 3). FULL UPWARD MOVEMENT OF WALKING BEAMS: 6. (Position 4 to Position 1): This movement is performed when cycles of walking beams come one after the other without any interruption.
34
5.4 MERITS AND DEMERITS OF EXISTING FURNACE HYDRAULIC SYSTEM:
5.4.a MERITS: Proven system from long years. Smooth control of the cycle is possible. This system is immunes to all safety controls. Frequent adjustments not required. System is robust and durable.
5.4.b DEMERITS: More interruption and higher down time. System is proven but due to obsolescence of spares is problem. Advancements of the pump control superseding is problem. Debugging in the commissioning stage is quite time taking. Requires continuous monitoring of the system. Chance of catastrophic any mal operation. Spares cost is high compared to new system. Difficult to understand by all people and at requires theoretical and practical knowledge about the system. Servo related problem occurring due to the cleanliness of the oil.
35
6. MODIFICATION OF FURNACE HYDRAULIC SYSTEM
6.1 NEED OF MODIFICATION:

In the event of occurrence of a repeat problem the solution is available in case of a one-off problem it becomes laborious as there are numerous check points.
Due to technological obsolescence and the high rate of up gradation the availability of spares and its associated techno economics influence the running of the system.
In such cases sustaining an old system economically is not feasible and up gradation to an updated system is not a matter of choice hut a matter of compulsion.
6.2 BASIC THINGS IN MODIFIED HYDRAULIC SYSTEM: a) Servo valve:

An electro hydraulic servo valve is a device that takes an electrical current and turns it into hydraulic flow which can then create linear, rotational, uni-directional or reciprocating mechanical motion. Servo valves were invented during the late 1940sfor military use. In the 1960s MTS Systems Corporation began using servo valves in displacement and force controlled test equipment. There are several types of servo valves, including the flapper nozzle style 4-way valve.
Servo valve
Fig 6.1
36
Servo valve parts:
Fig 6.2
fig 6.3
37
b) Proportional valve: An electrical input from some source is wired to an amplifier card which in turn, controls a coil on the proportional valve. Since the electrical input from most sources is generally much lower in power than the amount of current required to operate the coil, the input current must be amplified. This function is fulfilled by an amplifier card. The amplifier may be mounted on the valve, sometimes termed OBE (on board electronics) or be remote from the valve. The source of the input may come from several devices, including a potentiometer controlled by the machine operator, from preset potentiometers, a joystick, or from a PLC.
Fig 6.4 The amplifier card drives the valve coil with a current signal. As the current flows through the coil, electromotive force is developed, causing the armature of the solenoid assembly to move. The armature, in turn, inputs force to the valve spool, in a flow control, pressure reducing, or directional control valve, or the poppet in a pressure relief valve. The spool or poppet is offset by a spring. Therefore, the force input by the solenoid assembly is opposed by the force
6.3 COMPARISION BETWEEN PROPORTIONAL & SERVO VALVES:

Proportional Valve - Open loop control - less costly than servo valves - require more power (50W) - moderate filtration (30 - spools are overlapped - flow-current characteristics very nonlinear - hysteresis large 0.5% - can be used as flow, pressure and m) Servo valve - Close loop control - very expensive - low power input (.1 - .3W) -high filtration (1-5 m)
- spools critically lapped -flow-current characteristics linear - very low hysteresis 0.1% - used primarily in closed loop to
38
Directional control valves (pressure Compensation) - can be used in closed loop control if Expectations not high
creates flow and pressure control
- when used in closed loop, high - performance is expected
In general proportional valves find most of their applications in open loops situations where pressure and flow are required to change continuously, where multiple fixed flow and pressure valves can be replaced by a single valve and where acceleration and deceleration under control are required.
6.4 WORKING OF MODIFIED HYDRAULIC SYSTEM:
UPWARD HALF MOVEMENT OF WALKING BEAM: 1. (Position 0 to Position 1): Two pumps are utilized (4.1.1 & 4.1.2) Order to start (given by PLC) Energization of solenoid S3: lift cylinder are then fed by pump 4.1.1. Energization of solenoids S1.1, S1.1, S2.1. Description is given with reference to the walking beam movement as given in the walking beam cycle. PLC output Q156, R5 and R7 activates the amplifier cards to apply command voltage P.X.1 to the proportional valve of main pump. This results in the pump swash plate movement in forward direction to an angle proportional to the command voltage. Walking beam starts upward movement through lift cylinder. Flow is released to the pipe at the rear end of the cylinder. The non return valve 6.2.1 and 6.2.2 open without external action. The oil trapped at front end of the cylinders flows back towards the pump. However, since the amount in the rear end is greater than at front end, the different is sucked by the pumps from the boost lines. Each cylinder reaches the limit switch at slow control position. Now PLC output W156 will go in OFF condition and Q158 will go in ON condition. This results to activate amplified cards such that command voltage P.X.3 applied to the proportional valve of main pumps. The swash plate
39
moves towards zero degree to an angle proportional to command voltage P.X.3. Each cylinder reaches the limit switch at stop control position. PLC output R5, R7 goes to OFF condition which results in the application of zero command voltage to the proportional valve of main pumps. This positions the swash plate at zero angle position. At same time PLC output Q159 activate the amplified cards to apply command voltage P.X.4 with not change the swash plate position till the PLC outputs R5, R7, R9, R6, R8 and R10 are in OFF condition.
FORWARD MOVEMENT OF WALKING BEAMS: 2. (Position 1 to Position 2): One pump is utilized (4.1.1) Order to start (given by PLC) Energization of solenoids S1.1 & S2.2 Z Energization of solenoid S4. Transfer cylinder is then fed by the pump. The PLC output Q157 & R5 activates the amplifier cards to apply command voltage P.X.2 (equivalent to 20 bar in existing system) with ramp R.X.@ to the proportional value of main pump. This results positioning of swash plate F position to the angle proportional to the command voltage P.X.2. Walking beam starts forward movement through transfer cylinder. The cylinder being of the double rod type, there is as much oil entering the cylinder (inlet end) as oil coming out from the outlet end. Therefore pump does not require any make up oil except for compensating leaks. The cylinder reaches the limit switch at slow down control position. PLC output Q157 goes in OFF condition and at same time PLC output Q 159 goes ON condition. This activates the amplifier cards to apply command voltage P.X.4 with ramp R.X.4 to the proportional valve of main pump. Swash plate moves towards angle zero degree to an angle proportional to the command 4. The cylinder reaches the limit switch at Stop control position. PLC output R5 goes to OFF condition with results in the application of zero command voltage to the proportional valve of main pump. The swash plate goes to zero degree angle position. However PLC output Q 159 will remain ON but this will not change the swash plate position till the PLC output R5, R7, R9, R8 and R10 are on OFF condition. 40
Each cylinder reaches the limited switch at stop position. Reaches the limit switches located at the cylinder stop position authorizes initiation to the next movement. De-energisation of solenoid S4 and energization of solenoid S3. Lift cylinders are then fed by pump 4.1.1. This is normal stand by position which is also utilized between two cycles. DOWNWARD MOVEMENT OF WALKING BEAMS: 3. (Position 2 to Position 3): Two pumps are utilized (Items 4.1.1 & 4.1.2) Order to start (given by PLC) Eneregization of solenoids S1.1, S2.1, S1.2 & S2.2 Pressure is then applied to the pumps. PLC output R5 and Q158 activates the amplifier cards to apply command voltage P.X.3 with rampR.X.3 to the proportional valve of the main pump. Counting time delay of 1.75 second approx. Starts. This results in the swash plate movement to achieve upward movement of walking beam through lift cylinder. Flow is released to the pipe line the rear end of the cylinder. The non-return valve 6.2.1 and 6.2.2 open without external signal. The oil trapped at front end is greater than at front end, the difference is sucked by the pumps from the boost lines. At half time of the delay, Energisation of solenoid S1: pilot control check valves of lift cylinders are maintained in the open position. End of the time delay. PLC output R5 & A158 goes to OFF condition and at the same time PLC output R6 & R8 & Q156 becomes one. This activates the amplifier card such that a command voltage P.X.1 with ramp R.X.1. Applies to the proportional valve of main pump. The swash plate which was in F position goes through an angle zero. Degree to reach a reverse angle proportional to the command voltage P.X.1. Pump gives flow in reverse direction to achieve downward movement of walking beam through lift cylinder. Each cylinder reaches the limit switch at slow down control position. Now PLC output Q156 will go in On condition. This result to activate amplifier cards such that command voltage P.X.3 applied to the proportional valve of main pumps. The swash plate moves towards angle zero degree to an angle proportional to command voltage P.X.3. PLC output R6, R8 goes to OFF condition which results in application of zero command voltage to proportional valve main pumps. This positions the swash plate at zero angle position. At same time PLC output Q159 activate the amplifier cards to apply command voltage P.X.4 with ramp R.X.4 to proportional valve of main pump.
41
But this will not change the swash plate position till the PLC outputs R5, R7, R9, R6, R8 and R10 are in OFF condition. Each cylinder reaches the limit switch at stop position. Reaching the limit switches located at the cylinders stop position authorizes initiation of the next movement. BACKWARD MOVEMENT OF WALKING BEAM: 4. (Position 3 TO Position 4): One pump is utilized (Item 4.1.1) Order to start (given in PLC) Energization of solenoids S1.1, S2.1 and de-energization S1.2 & S2.2 then pressure is applied to the pump. Energization of solenoid S4: Transfer cylinder is then fed by pump 4.1.1. The PLC output Q157 & R6 activate the amplifier cards to apply command voltage P.X.2 to the proportional valve of main pump. This results positioning of swash plate to an angle proportional to the command voltage P.X.2. Walking beam starts backward movement through transfer cylinders. The cylinder being of the double rod type, there is as much oil entering the cylinder as oil coming out from outlet end. Therefore pump does not require any make-up oil except for compensating leaks. The cylinder reaches the limit switch at slow down control position. PLC output Q157 goes in OFF condition and at same time PLC output Q159 goes in ON condition. This activates the amplifier cards to apply command voltage P.X.4 with ramp R.X.4 to the proportional valve of main pump. Swash plate moves towards angle zero degree to an angle proportional to the command voltage P.X.4. The cylinder reaches the limit switch at stop control position. PLC output R6 goes in OFF condition which results in the application of zero degree angle position. However PLC output Q159 will remain ON but this will not change the swash plate position till the PLC outputs R5, R6, R9, R8, and R10 are in OFF condition. De-energization of solenoid S3 lift cylinders are than fed by pump 4.1.1. This is the normal stand-by position which is also utilized between two cycles. UPWARD HALF MOVEMENT OF WALKING BEAM: 5. (Position 4 to Position 0): Same movement as the one described in upward half movement of walking beams.
42
DOWNWARD HALF MOVEMENT OF WALKING BEAM: 6. (Position 1 to Position 0): This movement is performed when idle mode is interrupted with the walking beam in up position. The following hydraulic solenoid valves will be removed from the existing system.
FULL UPWARD MOVEMENT OF WALKING BEAM: 7. (Position 4 TO Position 1): This movement is performed when cycle of walking beam come one after the other without any interruption. Same movement as the one described in upward half movement of walking beams. There is no change in scheme of selecting two pumps for running from the three pumps available. Hence there will not be any change in the operation of walking beam cycle with the selection of other combination of pumps.
6.5 MERITS AND DEMERITS OF MODIFIED HYDRAULIC SYSTEM:
MERITS: Minimum down time (no pump related problems). Minimum availability of the system. Improvement in TEF (Techno economic factors). Cost of installation of the project is less (old system main pump cost is equal to the total project of the new system). Less system problems due to few manual controls. Less human involvement due to more user friendly PLC. Low temperature raise in the system. Less leakages of oil at pump area. Less sound and smooth in operation
43
DEMERITS: More chances of double booster pump failures in the main pump. More vibration in pilot station causes pipe failures. Main pump drain hose failures due to improper pressure rated hoses. Aversion of the people due improper knowledge of the system. Chances of miscommunication between electrical and mechanical for fine tuning of the system due to PLC.
44
7. CONCLUSION
7.1 CONCLUSION ABOUT EXISTING FURNACE HYDRAULIC SYSTEM:
The present hydraulic system in terms of performance and reliability is more than satisfactory. In the event of occurrence of a repeat problem the solution is available in case of a one-off problem it becomes laborious as there are numerous check points compared to the modern hydraulic system.
Due to technological obsolescence and the high rate of up gradation the availability of spares and its associated techno economics influence the running of the system. In such cases sustaining an old system economically is not feasible and up gradation to an updated system is not a matter of choice hut a matter of compulsion.
Due to more human involvement with manual adjustments failures of a higher order are possible and closer monitoring of the system is required.
45
7.2 CONCLUSION ABOUT MODIFIED FURNACE HYDRAULIC SYSTEM:
The success or failure of a new system depends on various factors such as availability, reliability, maintainability etc. in addition to the above, techno economics plays a very vital role in the success of an implement system.
The main benefits derived from the implementation of new system are:
Reduction of delays by 90% compared to previous system. Ready availability of spares. Cost competitive with respect to cost of new system versus sustainability of the old system. Improved system performance due to lower system oil temperature. Keys human interference due to incorporation of PLC. Indigenization as a substitute to imported spares. System is less cumbersome with lesser number of valves & associated controls.
46
7.3 RECOMMENDATIONS FOR MODIFIED HYDRAULIC SYSTEM:
After modification, we found some more alterations in the modified system to be done in future for the improvement of the system. The alterations are listed below, In corporation of superior oil refining systems like centrifuge, ELCs etc. Provision of flexible hoses in the discharge line of pilot pumps in order to minimize the impact of vibration or provision of vibration isolator pads for pump & motor base. Provision of flexible hoses in the suction line of pilot pumps to avoid air entry In to the pump (by this we can eliminate rubber compensator). Replacement of higher rating hoses in place of existing hoses. Simplification of design by replacing the double booster pump with a single booster pump. so as to eliminates repetitive coupling failures. Fine tuning of the PLC to smoothen the forward/backward movement of the cycle. Finally for the successful running of any hydraulic system the various parameters like temperature of the system, quality of oil with respect to NAS etc should be maintained in certain limits.
47
8. BIBLOGRAPHY
Project report of study of hydraulic system (2008-2009). Fluid Mechanics and Hydraulic Machinery by R.K.JAIN. Oil Gear Tower literature. Rexroth literature. T&DC Hydraulic Manual of VSP. Other details from MMSM planning.
48
9. ANNEXURE
HYDRAULIC SYMBLOS
Lines -continuous line - flow line -dashed line - pilot, drain -Envelope - long and short dashes around two or more component symbols. Circular -large circle - pump, motor -small circle - Measuring devices -semi-circle - rotary actuator Square -one square - pressure control function -two or three adjacent squares - directional control Diamond -diamond - Fluid conditioner (filter, separator, lubricator, heat exchanger) Miscellaneous Symbols -Spring -Flow Restriction Triangle -solid - Direction of Hydraulic Fluid Flow -open - Direction of Pneumatic flow
Pumps and Compressors

Fixed Displacement hydraulic pump -unidirectional -bidirectional
49
Variable displacement hydraulic pump -unidirectional -bidirectional Compressor
Motors
Fixed displacement hydraulic motor -unidirectional -bidirectional Variable displacement hydraulic motor -unidirectional -bidirectional Pneumatic motor -unidirectional -bidirectional Rotary Actuator - hydraulic - pneumatic
Cylinders
Single acting cylinder -returned by external force -returned by spring or extended by spring force Double acting cylinders -single piston rod (fluid required to extend and retract) -double ended piston rod Cylinders with cushions - single fixed cushion
50
- double fixed cushion - single adjustable cushion - double adjustable cushion
Directional Control Valves

Directional control valve (2 ports / 2 positions) -Normally closed directional control valve with 2 ports and 2 finite positions. -Normally open directional control valve with 2 ports and 2 finite positions. Directional control valve (3 ports / 2 positions) -Normally closed directional control valve with 3 ports and 2 finite positions. -Normally open directional control valve with 3 ports and 2 finite positions. Directional control valve (4 ports / 2 positions) -directional control valve with 4 ports and 2 finite positions Directional control valve (4 ports / 3 positions) -directional control valve with 4 ports and 3 finite positions *-(center position can have various flow paths) Directional control valve (5 ports / 2 positions) Normally a pneumatic valve -directional control valve with 5 ports and 2 finite positions Directional control valve (5 ports / 3 positions) Normally a pneumatic valve -directional control valve with 5 ports and 3 finite positions Proportional directional control valve Electro-hydraulic servo valve -The spool positions on these valves is variable allowing for variable flow conditions. -single-stage direct operation unit which accepts an analog signal and provides a similar analog fluid power output -two-stage with mechanical feedback indirect pilot operation unit which accepts an analog signal and provides a similar analog fluid power output
Control Methods
51
Manual Control -general symbol (without showing the control type) -pushbutton -lever -foot pedal Mechanical Control -plunger or tracer -spring -roller -roller(one direction only) Electrical Control -Solenoid (the one winding) Pilot Operation -pneumatic -hydraulic Pilot operated two-stage valve -Pneumatic: Sol first stage -Pneumatic: Air pilot second stage -Hydraulic: Sol first stage -Hydraulic: Hyd pilot second stage
Check valves, Shuttle valves, Rapid Exhaust valves

-check valve -free flow one direction, blocked flow in other direction -pilot operated check valve, pilot to close -pilot operated check valve, pilot to open Shuttle valve -to isolate one part of a system from an alternate part of circuit.
52
Rapid exhaust valve/Pneumatic -installed close to an actuator for rapid movement of the actuator.
Pressure Control Valves

Pressure Relief Valve(safety valve) normally closed - line pressure is limited to the setting of the valve, secondary part is directed to tank. Proportional Pressure Relief - line pressure is limited to and proportional to an electronic signal Sequence Valve - when the line pressure reaches the setting of the valve, valve opens permitting flow to the secondary port. The pilot must be externally drained to tank. - pressure downstream of valve is limited to the setting of the valve
Pressure Reducing valve
Flow Control Valves

Throttle valve -adjustable output flow Flow Control valve -with fixed output (variations in inlet pressure do not affect rate of flow) -with fixed output and relief port to reservoir with relief for excess flow (variations in inlet pressure do not affect rate of flow) -with variable output -fixed orifice -metered flow toward right free flow to left -pressure compensated flow control fixed output flow regardless of load -pressure and temperature compensated -with variable output and relief port to reservoir Flow dividing valve
53
-flow is divided equally to two outputs.
Shut-Off Valve
-Simplified symbol
Filters, Water Traps, Lubricators and Miscellaneous Apparatus

Filter or Strainer -manual drain Water Trap -with manual drain -with automatic drained Filter with water trap -with manual drain -automatic drain Air Dryer refrigerant, or chemical removal of water from compressed air line Lubricator -oil vapor is inducted into air line
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Hydraulics in Vizag Steel Plant

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Modification of Furnace Hydraulic System in M.M.S.

1. INTRODUCTION TO VISAKHAPATNAM STEEL PLANT (VSP)

1.1 MAJOR UNITS:

ANNUAL CAPACITY (1000T)

2,261 5,256 3,400 3,000 710 850 850

Modification of Furnace Hydraulic System in M.M.S.M

1.2 MAIN PRODUCTS OF VSP:

1.3 MAJOR DEPARTMENTS:

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

2. MEDIUM MERCHANT & STRUCTURAL MILL

2.1 INTRODUCTION TO M.M.S.M :

Finishing train consists of 6 stands namely:

Modification of Furnace Hydraulic System in M.M.S.M

2 combination stands, 4 horizontal stands/4 universal stands.

2.2 PROCESS DESCRIPTION IN M.M.S.M:

Modification of Furnace Hydraulic System in M.M.S.M

2.3 MMSM PRODUCTS

Fig no. 2.2

Modification of Furnace Hydraulic System in M.M.S.M

3. WALKING BEAM REHEATING FURNACE

3.1 IMPORTANT COMPONENTS OF THE FURNACE:

3.2 EUIPMENT SPECIFICATIONS:

Top and bottom fixed walking Beam furnace

Two 250T/hr Ambient 1200C 30C

Modification of Furnace Hydraulic System in M.M.S.M

3.3 FURNACE CONSTRUCTION FEATURES:

Modification of Furnace Hydraulic System in M.M.S.M

3.4 WALKING BEAMS(SKIDS):

Modification of Furnace Hydraulic System in M.M.S.M

3.5 COMBUSTION SYSTEMS:

Modification of Furnace Hydraulic System in M.M.S.M

3.6 REFECTERIES AND INSULATINOS :

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

4.1 FUNDAMENTALS OF HYDRAULICS:

4.2 BASIC HYDRAULIC SYSTEM:

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

4.3 ADVANTAGES OF HYDRAULICS:

Modification of Furnace Hydraulic System in M.M.S.M

5. HYDRAULIC SYSTEM IN REHEATING FURNACE

5.1 INTRODUCTION TO FURNACE HYDRAULICS:

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

5.2 SPECIFICATIONS OF FURNACE HYDRAULICS : a) RESERVOIR:

Modification of Furnace Hydraulic System in M.M.S.M

Modification of Furnace Hydraulic System in M.M.S.M

NAME Oil tank with a total capacity of 4000lit.

Tropicalized minimum level switch (800mm long).

Tropicalized stopping switch (900mm long).

Tropicalized stopping switch (1000mm long).

Optical indicator. Thermostat and thermometer.

Vcc (vc 3106) Ikl

1.6.1 to 3 1.7 1.8 1.10

Salva Arofiltre Sate valve Hydac

1.11 1.12 1.13 1.15 1.16 1.17

Bac Mg Mg Picker Danfoss

Modification of Furnace Hydraulic System in M.M.S.M

b) OIL RECIRCULATION STATION: