MT's Guide PDF

ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES
1
Chapter - 1
STEEL SCENARIO
Iron was possibly used in Egypt, from the middle pre historic times (7000-6000 B.C.).
Accordingly, to Sir Flinders Petrie all such iron was of meteoric origin and that manufactured
iron did not come into general use until after the Assyrian invasion of Egypt in 666 B.C.
The art of smelting iron was known in India in ancient times. Reference to iron has been made
in the Rig Veda (2000 B.C.). It is probable that the Iron Age in India has started about
3,000 years before the industry started in European countries. In those days Hyderabad
and Madras in South India were the centers of production of Wootz, the ancient Indian
Steel which was highly priced in world market.
The famous Iron Pillar at qutub near Delhi indicates an amount of skill in the manipulation of
large mass of wrought iron.
The Iron Pillar according to this inscription is victory pillar created to commemorate the victory of
King Chandra (either Chandragupta II or Vikramaditya of the Gupta Dynasty) who is
described as having conquered the Vangas, crossed the mouth of the Indus and
subjugated the Bahlikas.
The antiquity of the Indian process is no less astonishing than its ingenuity. We can hardly doubt
that the tools with which the Egyptians covered their obelisks and temples of porphyry and
syenite with hieroglyphics were made of Indian Steel.
Quintus Curtius has mentioned that a gift of steel was made to Alexander of Macedon by Porus,
an Indian King whose country he had invaded. We can hardly believe that a matter of 30 Ibs.
Weight of steel would have been considered a gift worthy of acceptance by the conqueror of
the world.
The iron pillar at Dhar, the ancient capital of Malwa, 33 miles west of Indore has a length of
about 50 feet and weighs about 7 tons more than the Iron Pillar at Delhi.
There are a numerous beams and smaller pieces at the Sun Temple at Konark which is
on the sea coast about 20 miles from Puri in Orissa. One of these beams which was
originally used in the temple, measures 25.5. feet 11 inches and weighs 9,000 Ibs. The Sun
Temple was built in the earlier part of the 13th Century A.D. The beams were constructed
by welding short blooms together. There are not less then 20 beams in the temple though
none of them have become broken.
Sir George Birdwood wrote in the Note Book of the British Indian section of the famous
Paris Exhibition of 1878.
Records indicate that
Cupola Furnaces were in use in 28 B.C. itself
China produced 1,25,000 tons of Iron a year by 1100 AD.
French Scientist Mery discovered that human blood contains iron.
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A story says that a Russian student tried to make an iron ring to present his lover by chemically
extracting iron from his blood, but had died of anemia as human body contains only 3 grams of
iron
In 1714 Iron Reboyer, a Worlcer working in a Copper Plant had suddenly became weak and
was unable to drag his feet even. He drank Water from Mariatian Water fall, he recovered. It was
found that the water was containing iron.
In olden days Iron Water and Steel Wine were prepared with iron filings in Grape wine etc.,
Irons medicinal properties were also ascribed because of its Magnetic Property. Egyptians
were treating some patients using this property.
Earths Crust contains nearly 5% i.e. 755 x 110 15 tons or 755 Million Billion tons of iron.
96 out of every 100 Kgs. of metal consumed by Industry Agriculture and every day life was iron.
King Solomon gave a feast and honoring the workmen on completion of temple in Jerusalem.
He was asked who contributed more: Black Smith, Carpenter and Mason Finally, the king said
it was Black Smith.
DEVELOPMENT OF STEEL INDUSTRY IN INDIA
Iron & Steel making as craft has been known to India for a long time. However its
production started only after 1900. In a short span of 3 decades or so that capacity was
increased from 11 folds to about 16 Million tonnes by nineties. Progress in next 15 years is
slow, just more than double i.e. 34.821 million tonnes.
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MAJOR STEEL PRODUCING COUNTRIES
(million metric tons crude steel production)
Rank COUNTRY 2003 2004 2005 2006 2007 2008
1 CHINA 220 273 318 423 489 502
2 JAPAN 111 113 112 116 120 119
3 UNITED STATES 90 100 94 99 98 92
4 RUSSIA 63 66 66 71 72 69
5 INDIA 32 33 38 50 53 55
6 SOUTH KOREA 46 48 48 49 52 54
7 GERMANY 45 46 45 47 49 46
8 UKRAINE 37 39 39 41 43 37
9 BRAZIL 31 33 32 31 34 34
10 ITALY 27 28 29 32 32 31
WORLD TOTAL 968 1046 1107 1253 1345 1330
Note:- In the year 2008 India stood as fifth largest producer of crude steel in the world for the third
consecutive year.
WORLD CRUDE STEEL PRODUCTION :
1945 113 2001 860
1950 190 2002 904
1955 270 2003 971
1960 347 2004 1070
1965 451 2005 1148
1970 595 2006 1253
1975 644 2007 1345
1980 717 2008 1330
1985 719
1990 770
1995 752
2000 848
Year
Production
(Million Tonnes)
Year
Production
(Million Tonnes)
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PRODUCTION OF CRUDE STEEL
(Million metric tones)
CONSUMPTION OF STEEL
(Million metric tones of finished steel products)
China alone constitutes 25% of world steel production and consumption. China has more
than doubled its steel output from 220 mt in 2003 to 502 mt in year 2008. Presently India consumes
85% of its production in the domestic market and exports the rest.
2003 232 31
2004 263 32
2005 293 34
2006 361 46
2007 408 51
YEAR CHINA INDIA
2003 220 31.8
2004 290 34.25
2005 300 34.8
2006 423 50
2007 489 53
2008 502 55
YEAR CHINA INDIA
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6
7
8
9
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Chapter - 3
MAJOR OPERATING STANDARDS AND NORMS
COKE OVENS & COAL CHEMICALS PLANT:
RECEIPT QUALITY OF COAL :
Moisture Ash VM Fixed Carbon
% % % %
Indigenous Prime coking (PCC) 6.0 25-30 25.0 40.0 (approx)
Indigenous medium coking (MCC) 6.0 17-20 25.0 50.0 (approx)
Imported hard coking 7.0 8 -10 26.0 57.0 (approx)
Imported soft Coking 7.0 8 -10 30.0 53.0 (approx)
BLEND PROPORTION :
MCC or PCC 15 % ) Blend proportions could vary from time to time
depending Imported hard coking 65 %) upon coal supply
linkages, coal quality and coal) availability.
Imported soft coking 20 %)
BLEND COAL QUALITY :
Ash 10-11 %
VM 25-26 %
Moisture 6-8 %
Thickness of plastic layer 20-22 mm
Size analysis %
0-3 mm size 74-75 %
0-0.5 mm 28-29 %
Bulk density 0.76
BATTERIES :
i) Oven charge weight (T) dry 32.0
ii) Coking time (Hrs) 17-18
iii) Specific Heat consumption 615 Mcal/TDCC
iv) a)C.V.of mixed gas for heating (Kcal/NM
3
) 1000
b) CV of Coke oven gas for heating (Kcal/NM
3
) 4240
v) Yields from dry coal carbonized (%)
a) Run of oven coke 75.00
b) 25 to 70 mm coke 62.00
c) 0 to 25mm coke 13.00
vi) Coke Quality :
Moisture < 0.50 %
Ash <15.00 %
Sulphur < 0.55 %
V.M < 0.60 %
Medium strength
+ 40 mm 80.0 (min)
- 10 mm 7.0 (max)
COKE DRY COOLING PLANTS :
i) Temperature of coke charged in the chamber (
0
C) 1000-1050
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ii) Temperature of cooled coke (
0
C) 150-180
iii) Steam generation from one chamber (T/hr) 22-25
iv) Steam pressure (ata) 39-40
v) Temperature of super heated steam (
0
C) 430-450
COAL CHEMICALS PLANT :
1) Yield from one tonne of dry coal carbonized:
a) Coke oven gas 330-350 NM3
b) Ammonia 0.3%
c) Crude benzol 0.6%
d) Crude tar 3.2%
2) Typical Characteristics of coke oven (Raw) gas:
Calorific value (Kcal/NM
3
) 4425
Density (kg/m
3
) 0.45
CmHn 2.8%
O
2
0.1- 0.3 %
CO 6.4%
H
2
59- 61 %
CH
4
25-26 %
N
2
3.5%
CO
2
2.15%
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14
15
16
17
18
19
20
21
22
23
24
25
MAJOR
PRODUCTION
UNITS
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27
RMHP
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29
30
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32
33
34
35
36
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Chapter - 5
COKE OVENS AND COAL CHEMICALS PLANT
COAL PREPARATION PLANT :
From the storage yard, the coking coal is sent to foreign object separation section (FOSS) to
remove foreign matter of above 150mm size. Iron traps for ferromagnetic articles and cylindrical
screens are provided for this. For averaging and proportioning of coal, 16 nos. of Silos, each of 800T
capacity are provided along with continuous action weigh-feeders of up to 120 tones per hour capacity
each. After blending, the material is crushed with the help of impact crushers. The crushing is carried
out in reversible hammer crushers, 2 operating and 1 standby. Crushing is done to take care of
petrographic non-uniformity, high hardness and mineral content of coal. The crushed and blended
coal (74-75% of -3mm size) is conveyed to two coal towers each of 4000 T capacity. Weigh bridges
are provided under coal towers to weigh the coal charge. System of pneumatic blow down of blend is
provided in the coal tower to take care of jamming or hanging of coal in the coal tower.
BATTERY :
The prepared coal charge from the coal tower is drawn by a charging car on the top of the
batteries and charged into the ovens as per sequence. The charged coal is gradually heated by the
heating walls of the oven in the absence of air to attain a temperature of 1000-1050
0
C at the central
axis of the coke mass towards the end of coking period. The coking period is generally specified
between 16 hrs and 19 hrs depending upon oven condition and production requirement. The volatile
matter of coal liberated during carbonization is collected in gas collecting mains in the form of raw
coke oven gas passing through stand pipes and direct contact cooling with ammonia liquor spray. The
gas cooled from 800
0
C to 80
0
C is drawn to coal chemicals plant by Exhauster.
The residual coke is pushed out of the oven by pusher car through a guide into coke bucket.
The red-hot coke is taken to coke dry cooling plant for cooling.
There are 4 batteries, each having 67 ovens. Each oven can hold 32 tons of dry coal charge.
The volumetric capacity of each oven is 41.6 m
3
.
The heat for carbonization is supplied by under firing of coke oven gas having CV of 4200
Kcal/Nm3 or mixture of BF gas & CO gas having CV 1000 Kcal/Nm
3
.
The heating system of batteries is of underjet compound type having twin-heating flues with
recirculation of waste gases. The dimensions of an oven are as follows.
a) General Dimensions:
Length 16,000 mm
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Height 7,000 mm
Width on coke side 435 mm
Width on pusher side 385 mm
Average width 410 mm
Oven taper 50 mm
b) Effective Dimensions:
Length 15,160 mm
Height 6,700 mm
Number of heating flues in one heating wall 32 Nos.
Distance between axes of ovens 1,400 mm
Number of charging holes 3
Number of gas-off take holes 2
Heating level (distance from the top of
the hairpin of the heating flue to the 1,100 mm
carbonizing chamber roof)
Temperature in heating flues is between 1300
0
C and 1360
0
C and final temperature of coke mass at its
central axis is between 1000 - 1050
0
C.
Following pressures are maintained:
a) Pressure of carbonizing chamber sole,
15 minutes prior to pushing coke +0.5 to +3 mm W.C.
b) Pressure in the gas collecting main +16 to +17 mm W.C.
c) Pressure in the heating system at hair
pin level for waste heat gases +/- 0.3 mm W.C.
The refractory requirement per battery is 14000 T silica bricks, 5700 T fire clay bricks and 130 T
lightweight insulation bricks.
Following oven machinery is provided.
Operating Total
Charging Cars 4 8
Coke pusher 6 4
Door Extractor 4 6
Electric Loco 4 6
COKE DRY COOLING PLANT :
There are four coke dry cooling plants, each having four chambers. Capacity of each chamber is 50-
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52 TPH. Each coke dry cooling plant consists of cooling chambers with individual lifter and lifting
shaft, waste heat boiler, dust catching arrangements and mill fan.
The cooling chamber has two technological zones. Red-hot coke is charged into the upper zone while
cooling takes place in lower zone by circulating gases. Gas is forced by mill fan into distribution
channels in the lower part of the chamber and fed into the cooling zone. The gas flows upwards and
gets heated. Circulating gases enter boiler, cyclones and return to bottom part of cooling chamber
because of mill fan.
The coke is cooled from 1000 - 1050
0
C to 150-180
0
C while the circulating gases are heated from
160-180
0
C to 600 - 800
0
C. 22-25 Tonnes/hour of steam at 35-40 atm pressure and 430-440
0
C is
produced from one chamber. The cooled coke from the cooling chamber is discharged onto the
conveyor continuously through a rotary discharging system.
COKE SORTING PLANT :
From the dry cooling plant, cooled coke is conveyed to a dedusting unit by conveyor. From the dedusting
unit, coke is conveyed to crushing section. Here the incomig coke fractions are first separated into
+70mm and -70mm fractions. The +70mm fraction is fed to a two roller-toothed crusher (2 nos. each
of 120 TPH capacity). The crushed product along with -70mm fraction is conveyed to coke screening
section where 25 -70mm and 0 - 25 mm fractions are separated using roller screens. 25 to 70mm
fractions(metallurgical coke) are conveyed to blast furnace. Bunkers of 600 tonnes capacity are also
provided for loading into wagons/trucks and dumpers for sending to coke yard.
0 to 25mm fractions are fed to vibrating screens provided to separate into nut coke (10 to 25 mm size)
and breeze coke (0 to 10mm). Nut coke is sent to blast furnace or to yard depending upon the
requirement. Breeze coke is sent by conveyor to Sinter Plant.
CONVEYORS
The following types of conveyors are used in coke ovens & coal chemical plant.
Width (mm) 1600 1400 1200 1000 800 650 500
Quantity (nos.) 9 49 6 11 - 4 2
Total no. of conveyors: 87
Total length (Mts) - 15000 (approximately)
COAL CHEMICALS PLANT :
The main by product in the process of coke making is raw coke oven gas and this has lot of valuable
chemicals. Coal Chemicals Plant recovers Ammonia (NH 3), Tar and crude Benzol from Co-Gas as
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per the process described below:
The primary By-products from Crude CO Gas are Ammonium Sulphate (NH 4)
2
SO
4
, Crude Tar,
Crude Benzol and cleaned coke oven gas.
QUALITY AND COMPOSITION OF COKE-OVEN GAS
Calorific value Kcal/N.cum 4300-4350
Density kg/Nm
3
0.45
CmHn % 2.8
O
2
% 0.5 (max)
CO % 6.4 - 7.0
H
2
% 59 - 61
CH
4
% 25 - 26
N
2
% 3.0-3.5
Yields of main Carbonization by-products based on coal are follows (percent on dry blend basis).
Crude Tar 3.2 %
Ammonia (NH3) 0.3% or 7-10 gm/Nm
3
of coke oven gas
Crude Benzol 0.6% or 20 gm/Nm
3
of coke oven gas
Generation of coke oven gas per ton of dry coal charged is 330-350 Nm
3
at calorific value of 4300
Kcal/Nm
3
GAS CONDENSATION SECTION :
The Coke Oven Gas (CO Gas) leaves the ovens at a temperature of 800
0
C and is cooled from
800
0
C to 80
0
C in goosenecks and in gas collecting mains at the batteries by spraying Ammonical
liquor (Flushing liquor). 60-70% of Tar present in CO-Gas is condensed here. The CO-Gas along with
Tar and liquor comes to a separator to remove liquor and condensed Tar. The cooled CO-Gas is then
taken to primary gas coolers ( each having a heat transfer area of 2425m
2
) where it is cooled indirectly
by water to about 25 to 30
0
C. Along with the Tar, some amount of Naphthalene in coke oven gas is
also condensed.
The gas is then sent to Electro Static Precipitators ( each of 27000 Nm
3
/hr capacity) to remove
the foggy Tar (about 5%) from CO gas. In ESP, foggy Tar particles are electrically charged and collected
on the surface of the electrodes and separated. The gas purified from Tar is compressed in Exhauster
to a pressure of max.2800 mm water column. There are five electrically driven exhausters provided
and each having capacity of 76000 Nm
3
/hr.
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Tar and Ammonia Liquor (Flushing liquor) from the separator are delivered to mechanized
decanters , each of having capacity of 370 m
3
. Here the crude Tar, Flushing liquor and sludge (coal
and coke dust particles in Tar) are separated based on their density difference. The separated flushing
liquor from decanter is collected in Tanks of capacity of 200 m
3
from where it is pumped continuously
by flushing liquor-pump to gooseneck and gas collecting mains of coke ovens. There are 8 Nos. of
Flushing liquor pumps of having capacity of 1100 m
3
/hr.
Tar separated from the decanters is collected in an intermediate Tar tank of having capacity of 50 m
3
from where it is once again pumped to Tar decanters (each of capacity 370 m
3
), which are exclusively
provided to remove further water from Tar. The gas condensate which is collected after the primary
gas coolers, Electrostatic precipitators and exhauster is taken to a underground 50 m
3
tank from
where it is pumped to Tar Decanters for separation. The flushing liquor separated from Tar decanters
is collected in Flushing liquor tanks. The clear Tar taken in another 50 m
3
tank from where it is pumped
to final gas cooler.
AMMONIUM SULPHATE SECTION:
The CO-Gas from the Exhausters under pressure is sent to saturators in Ammonium Sulphate section
through pre-heaters.
Acidity of the saturator bath is maintained at 4 to 5% and Sulphuric Acid is used for this purpose.
Ammonia present in CO Gas reacts with sulphuric acid and forms Ammonium sulphate crystals.
Nitrogen at 600 -750 Nm
3
/hr is used for agitation purpose in each saturator and this keeps the crystals
in motion. Once the crystals grow bigger in size, it settles at the bottom of the saturator.
There are five saturators of 6400 mm diameter having cylindrical body and conical bottom.
The Ammonium sulphate, (NH
4
)
2
SO
4
, crystals settled at the bottom of saturators is sent to the
centrifuges by pumps where the crystals are separated continuously from the liquor (mother liquor).
There are 5 Nos of centrifuges.The crystals from centrifuges are dried in a fluidized bed drier and
stored. The dried Ammonium Sulphate crystals are bagged in 50 kg bags and shipped. This is used as
a fertilizer for agricultural purpose and having Nitrogen content 21%.
15 days production can be stocked in the godown. Sulphuric acid required for the production
of Ammonium sulphate, caustic soda & soda ash required for coal chemical plant are stored in Reagent
storage. A month requirement of Sulphuric Acid can be stored here.
FINAL GAS COOLING AND NAPHTHALENE WASHING :
From the saturator the CO-Gas enters the Acid trap where the acid droplets that might be
carried along with the CO-Gas are separated and sent to saturator. The acid free of COGas enter the
final gas cooler. There are two final gas coolers of diameter 5000 mm and height 45.5 meters. Each
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cooler has got two sections. In the top section CO-Gas is sent from the bottom and cooled service
water is sprayed from the top. There are perforated plates in this section, which provides the necessary
contact for the water and CO-Gas.
The CO-Gas enters the final gas cooler minimum at 55
0
C. Cooling of the CO-Gas is done by
direct water spray through a closed cycle system. In this way Naphthalene that is present in CO-Gas
is scrubbed by water & this enters the bottom of the bottom section. The bottom section, Naphthalene
washer, having Tar will come in contact with warm water from top section. Lighter than Tar the water
comes to the top and leaves the cooler. During this process whatever Naphthalene is present in (or
dissolved) in the water gets dissolved in tar because the solubility of Naphthalene in Tar is many times
higher than water. Then this Tar is taken out and stored in tanks and then sent to Tar Distillation Plant
(TDP) for processing.
BENZOL RECOVERY :
Cooled Coke Oven Gas from final gas cooler (FGC) will successively pass through two benzol
scrubbers in each of the two streams. All four Benzol scrubbers are of 5000mm diameter and height
48.5m.
Recovery of benzol hydrocarbons is carried out by solar oil, a petroleum fraction, in counter
current. The Benzol content in CO-Gas before scrubbers is 27gms/Nm
3
and after scrubbers it is 6gm/
Nm
3
. Aluminum packing is provided in all the scrubbers for efficient contact.
DRY PURIFICATION UNIT :
700 -1000 Nm
3
/hr of coke oven gas is sent to dry purification system when H
2
S content of the gas is
required to be removed from 0.6-0.7 gms/Nm
3
to 0.02 gm/Nm
3
. The H
2
S free CO Gas is sent to
laboratories and other special consumers like GETS at BF, CO Gas is supplied to dry purification unit
after the electrostatic precipitators. Synthetic bog ore is used as purification mass. Spent purification
mass containing 24 to 25% sulphur is transferred to dump.
TAR DISTILLATION PLANT :
It is designed to process 1,15, 200 Ton/year of Tar. The crude tar having maximum water content 5%
is heated in the pipe still furnace to 115
0
C and sent to the 1st stage Evaporator, where the Tar is
separated from water and stored as dehydrated Tar. Further, this Tar is heated in the pipe still up to
400
0
C and taken to the 2
nd
stage evaporator.
Here the vapours and the residues (called pitch with softening temperature 67 to 73
0
C) are separated
and this vapour is sent to the Rectification Column.All the products are withdrawn at different levels
based on their boiling points difference and cooled and stored.
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Naphthalene fractions are crystallized in the crystallizes and then pressed to form a cake in a Hydraulic
press and bagged and shipped. Pitch or Residue at the bottom of the 2
nd
stage evaporator is soft in
nature and it is made hard by sending compressed air in pitch reactors. Due to the polymerization and
condensation, which takes place in the reactor, the pitch becomes harder and withdrawn from the
reactor. Pitch creosote mixture is prepared by mixing soft pitch and Anthracene Oil.
Major facilities of the plant are :
a) 2 drum crystallizes, 8 mechanical crystallizer and 2 centrifuges and 2 hydraulic presses for
naphthalene. There is 10 days storage capacity for crude naphthalene.
b) 9 mechanical crystallizes, 3 centrifuges and 16 days storage capacity for crude Anthracene.
c) Washing section for making Sodium Phenolates.
d) 4 still reactors, head Tanks, pipe still for production of pitch with softening temperature of 75
to 95
0
C.
e) Facility for preparing Pitch Creosote Mixture.
f) 23 days storage for Tar and Tar products.
MECHANICAL BIOLOGICAL AND CHEMICAL TREATMENT OF
PHENOLIC EFFLUENTS :
Before treatment After treatment
mg/ltr mg/ltr
Phenols 400 not more than 1
Rhodonites 400 not more than 10
Tar & Oil 500 not more than 25
Biological Oxygen demand 2500 not more than 300
AMMONIA (NH
3
) 500 not more than 100
In CO&CCP amount of phenolic effluents are 120 m
3
/hr and this water is treated in the unit and is
transferred into the network of sanitary domestic sewerage plant.
BENZOL DISTILLATION PLANT :
The plant consists of
i) Benzol recovery & distillation using Solar Oil as scrubbing medium.
ii) Benzol refining & Rectification plant using continuous hydro refining process for production of
Caprolactum grade Benzene, Nitration grade Toluene, Light Solvent Oil.
The Recovery & Distillation unit has two streams each consisting of one final gas cooler two
scrubbers connected in series. In scrubber the Solar Oil and CO-Gas is subjected to counter current
44
flow and thus Solar Oil absorbs and Benzol from CO-Gas and becomes benzolised oil. This benzolised
oil is taken to a stripping column, where with the help of direct steam, the benzol is stripped, removed
and cooled. The de-benzolised oil is the bottom product, which is reused for scrubbing the CO Gas.
BENZOL REFINING & RECTIFICATION :
The benzol refining & rectification section is designed to handle Crude Benzol recovered from
the benzol distillation unit. It can handle 110 tons of crude benzol per day and operating period is 330
days/annum.
The Crude Benzol recovered in Benzol Distillation Plant is processed in Hydro-refining unit to
produce BTXS refined. Crude Benzol is refined by using hydrogen, recovered from CO gas by Pressure
Swing Adsorption (PSA) process. The refining process is carried out of 25 kg/cm
2
pressure. The
refining process involves removal of sulphur compounds in two catalytic bed reactors called
pre-reactor and main reactor. The product, which is sulphur free, is called BTXS refined and is further
subjected to rectification process where different products like Benzene, Toluene, SOL-110 and Light
Solvent Oil are made.
This rectification process involves a series of distillation processes like pressure distillation,
extractive distillation where NFM solvent is used to remove non-aromatics from Benzene & Toluene.
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50
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CALCINING AND REFRACTORY
MATERIAL PLANT
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Chapter - 7
CALCINING AND REFRACTORY MATERIAL PLANT
CRMP, i.e. Calcining & Refractory Materials Plant is an integrated unit of Visakhapatnam Steel Plant.
This plant plays a significant role in the manufacturing of liquid steel. The main customer of CRMP is
Steel Melting Shop (SMS).
1) Calcining Plant
CRMP has two units
2) Brick Plant
Calcining Plant
Calcining plant produces lime and calcined dolomite, which are used for refining of hot metal to steel
in the converter. This plant has 5 rotary kilns of 325 tons/day capacity. Lime is produced by calcining
limestone and calcined dolomite is produced by calcining dolomite. Limestone (SMS grade) is procured
from United Arab Emirates and Dolomite (SMS grade) from Madharam mines of VSP. The size of
limestone is (30 - 60) mm and size of dolomite is (25 50) mm. Both the raw materials are received
and stacked at RMHP. RMHP reclaims these materials and conveys to LSDS (Limestone & Dolomite
Screening Plant) via a stream of conveyors. LSDS has two screens (VS6 & VS7) to screen out the
minus fraction from raw materials. The minus size is sent to RMHP for use in Sinter Plant. The +30mm
size limestone is stored in bunker 5 and +25mm dolomite is stored in bunker 6. These materials are
then conveyed to the stone bins of all the kilns by operating the weigh feeders below the two
bunkers. Limestone and dolomite are charged to separate kilns.
The material from the stone bin flows by gravity into the preheater. Material in side the preheater gets
preheated by the hot flue gas coming out of the kiln and is then charged into the kiln by activation of
hydraulically operated rams. The feeding of raw material into the kiln can be varied by regulating the
frequency of the ram pushing.
The fuel used for firing of the kiln is PCM (Pitch Creosote Mixture). This is supplied by CCP (Coal
Chemicals Plant) through pipelines. The calorific value of PCM is 9000 Kcal/Kg. This fuel is stored in
four tanks in pump house. Pump house pumps the fuel to the kilns through PHF unit (Pumping,
Heating & Filtering Unit) of each kiln at 4 - 8 kg/cm2 pressure. This fuel generates a temperature of
1250
0
C - 1300
0
C inside the kiln to calcine limestone & dolomite. The product of the kiln, i.e. lime and
calcined dolomite are discharged to a contact cooler provided for each kiln. The cooled product is
discharged and sent to the Flux Storage Building. Lime and calcined dolomite are screened and
stored separately in Flux Storage Building. There are two 10mm screens in FSB as SMS requires
+10mm size only. The stored material is then sent to SMS as per demand. Some +10mm size lime is
also sent to PCM (Pig Casting Machine). The -10mm size is sent to Briquetting plants, Sinter Plant,
Water Treatment Plant and to outside sales.
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The hot flue gas coming out of the rotary kiln is passed through the preheater, cyclone and bag filter
by ID Fan. Dust, carried by the hot gas, is separated in cyclone and bag filter and stored in dust
hoppers and despatched to Sinter Plant by pneumatic tankers. The clean gas is then let off through
chimney.
Brick Plant
Brick plant produces Pitch Bonded Magnesia Carbon Bricks for lining of Converters and Steel Ladles.
Total twelve shapes of bricks are currently produced :- CD1 to CD8 and LB1 to LB4.
The main raw materials of brick are Sea Water Magnesia (SWM) and Fused Magnesia (FM). Sea
Water Magnesia is imported from Ireland and Israel. Fused Magnesia is imported from China. Graphite
Flakes is used as additives and Aluminium Powder is used as antioxidant. Liquid pitch is used as
binder, which is supplied by CCP (Coal Chemicals Plant) by tankers. In mill house, SWM is crushed,
ground and screened into different sizes of (0 - 0.2), (0 - 0.5), (0.5 - 1.6), (1.6 - 3) & (3 - 5) mm and
stored in separate blending bunkers. Graphite & aluminium powder are stored in separate blending
bunkers. These fractions of SWM and additives are collected by scale car from blending bunkers in
predetermined quantities and discharged into mixer. Pitch is added during mixing and mixing is done
as per set mixing program. The mixer temperature is maintained between 140
0
C and 180
0
C.
The Brick Plant has two 1600 T capacity hydraulic presses to press these bricks. After pressing the
green bricks are placed on takeoff belt. The green bricks are lifted from the takeoff belt and placed on
a tempering pallet manually. Pallet filled with the green bricks is then placed on a tempering car. The
tempering of bricks is done at a temperature of 300
0
C - 350
0
C. The tempered bricks are then packed
on packing pallets, strapped with polyethylene straps and stored in Brick store. These bricks are
despatched to SMS as per requirement of SMS and RED.
Moreover, bottom jointing mass and back filling mass are also produced in the Brick Plant for use
during converter relining. For production of bottom jointing mass resin is used as binder in place of
pitch.
59
BLAST FURNACE
60
61
Chapter - 8
BLAST FURNACE
8.0 BURDEN HANDLING AND FURNACE CHARGING :
Burden materials are received in the stock houses, one for each furnace through a junction
house. Coke is handled by two conveyors (one stand by) of 1600 mm width and 350 TPH capacity,
sinter, lump ore by two conveyors (one stand by) of 1400 mm width and 800 TPH capacity, Sized ore
and additives will be handled by one reserve conveyor of 1400 mm width and 800 TPH.
Junction house has a cross over through rolling reversible conveyor and stationary reciprocating
conveyor. For each furnace, there are 5 bins for sinter, 5 bins for coke, 3 bins for lump ore, 1 bin for nut
coke, 3 bins each for limestone/LD slag and quartzite/used silica bricks and manganese ore.
Coke, sinter and iron ore are screened in screens up to 400 m
3
/hr capacity to remove the fines.
The screened material is fed to the inclined conveyor for burden handling to top through a horizontal
conveyor. Conveyors for burden handling to top are of 2000 mm width & 2160 m
3
/hr capacity and are
operated continuously. The materials are positioned in conveyor in separate batches at certain intervals
and in a certain sequence as per preset program. PLC system is a certain sequence as per preset
programs. PLC system is provided for batching, weighing and feeding of the burden to the furnace
top.
The Paul wurth, bell less top system is installed for furnace charging. The system consists of
two bunkers of 47 cubic meter capacity each, charging moving hopper & rotating trough. All drives are
hydraulically operated except for trough rotation and tilting which are electrically operated. Semi clean
BF gas and nitrogen are used for pressure equalization in charging bunkers. Nitrogen is used for
cooling rotating trough drive and for blowing off stock bin gates and sealing valves of charging
arrangement. Mechanical gauge rod on side and radar probe on the other side are provided for
measuring stock level.
Exhaust station and air cleaning plant are provided for burden handling system. The exhaust
air is directed to electrostatic precipitators (2 nos.) for cleaning. The plant capacity is 3. 65 x 10 m
3
/hr.
The dust content of air is reduced from 2.85 gm/cum to 0.1 gm/cum, 200 tons of dust is collected
every day. The dust collected is balled in granulation plant and is transported in trucks to Sinter plant.
The burden handling system premises are hydraulically flushed 600 m
3
/hr water). Total effluents
generation is 600 .3/hr. After primary settling, the water is pumped to sinter plant for further use.
8.1 HOT BLAST STOVES :
There are four hot blast stoves for each furnace with a total heating surface of 224, 000 m
2
.
The dome can be heated to a temperature of 1450
0
C maximum while the waste flue temperature is up
to 400
0
C. The stoves are capable of giving a blast temperature up to 1300
0
C. Stoves are heated by a
mixture of blast furnace gas and coke oven gas having a calorific value of 1,100 Kcal/Ncum. Pressure
of mixed gas before burners is 600mm W.C.
62
Gas mixing station is provided to mix BF gas, CO gas in required proportion and to get the
necessary Calorific value. Separate stations are provided for each furnace. Mode of operation of
stoves is successive (parallel also can be operated).
High temperature zone is lined with silica and mullite corundum refractories, medium
temperature zone, with kaoline refractories and low temperature zone with fire clay refractories. The
shell of dome and cyclindrical part is heat insulated with a heat proof gunnite concrete in high temperature
zone. Gaps between shell and walls are filled with mats from fibrous materials. Checker-work is lined
with hexahedral refractories with round cells of 41mm dia. Combustion chamber is in-built construction
of elliptical shape. The chimney is of 80 m high, 3.5m diameter at the mouth. It is of reinforced
concrete and fire clay lined. Stack for back drought is made of metal with refractory lining. Air supply
for burners is centralized. Three fans (one stand by) of 120, 000 m
3
/hr, 1080 mmwc capacity each are
provided for the purposes.
Water cooling arrangement has been provided for cooling of hot blast valves and burner cut
off valves.
8.2 FURNACES :
Two blast furnaces of 3,200 m
3
useful volume, each capable of producing 1.7 MT of hot metal
per year while operating for 350 days are installed. The basic characteristics of furnace are :
Useful height from iron notch center line to trough bottom in
vertical Position ........ 33,100 mm
Height of hearth ........ 4,600 mm
Height of Bosh ........ 3,400 mm
Height of belly ........ 1,900 mm
Height of shaft ........ 20,000 mm
Height of top ........ 2,300 mm
Height of dead layer ........ 1,203.5 mm
Diameter of Hearth ........ 12,000 mm
Diameter of belly ........ 13,000 mm
Diameter of top ........ 8,900 mm
Bosh Angle ........ 79
0
1037mm
Shaft Angle ........ 83
0
4322mm
Number of Tuyeres ........ 32.................
Number of Tap Holes ........ 4.................
No slag notches are provided.
63
The lower part of the hearth bottom is lined with graphitized carbon blocks while upper part is
with high refractory mullite bricks in the center and with carbon blocks in the periphery. Side walls of
the hearth are lined with carbon blocks in lower part and alumina silicate bricks are used for lining of
bosh, belly and shaft. Furnace top is lined with non cooled steel slabs of suspended construction,
while non cooled cast iron slabs are used for furnace dome. Insulation layer was provided between
slabs and shell of dome.
Lower part of the hearth bottom is air cooled. Peripheral cooling plates are used for cooling of
upper part of hearth bottom, hearth, tuyere zone, bosh, belly and lower part of shaft. For middle part
of the shaft, peripheral plates with independently cooled projections are used. There are 664 cooling
plates. Besides, there are 32 breast coolers, 32 tuyere coolers, 32 tuyeres and 8 nozzles in furnace
dome. The water requirement for cooling is 5555 m
3
/hr max.) per furnace at 80 mmwc. Clean
recirculating water with suspended matter up to 50 mg/litre is used.
The hot metal is discharged into 140T hot metal ladles by rocking runners in cast house. Hot
metal ladle cars are moved by a pusher car. At every notch, a notch opening machine and an electric
gun is provided. The cast house is circular in shape and two circular cranes 20/5+5 T and a circular
platform (5m width) for maintenance and observation of tuyers stock is also provided.
There are 10 to 20 casts in a day. Cast house has good aeration. Provision has been made for
gas and dust exhaust from iron notches, rocking runner covers and from housing of the drum of the
conveyor from burden handling to top. Four mill fans (one stand by) of 160,000 m
3
/hr capacity and 900
kgf/cm
2
pressure and two exhaust fans (1 stand by) of 492000 m
3
/hr capacity and 430 Kgf/cm
2
electrostatic precipitators, two horizontal type three fold precipitators having needle type discharge
electrodes and S shape collecting electrodes (12m height) are provided. Dust is granulated and
dispatched to sinter plant by dump track. Clean gas is fed to chimney of 5m dia, and 100m height. The
total capacity of the plant is 972, 000 m
3
/hr. Dust content is reduced from 2.5 gms/m3 to 0.1 gms/m3.
About 60T of dust is collected daily from two precipitators.
There are four railway tracks for hot metal transportation [two on either side,] one service
sub-track and one track for flue dust disposal. Independent running railway tracks are provided for
delivery of metal to each SMS. Two rail weigh bridges are provided for weighing hot metal sent to SMS
& PCM. For auxiliary freights, automobile transport is provided.
The furnace process control is computerized.
Four gas off takes run vertically from furnace dome, which are connected to each other in
pairs, firstly forming two vertical off takes and these two joining to form one central vertical off takes
and these two joining to form one central vertical off take which is connected to a dust catcher of 12m
dia through a down comer. Dust catcher and gas pipe lines are lined with fire clay bricks. Moistening
and discharge of dust is carried out by a screw conveyor. The furnace can be separated from dust
catcher by 3,000 mm dia cut off valve in upper part of the dust catcher.
8.3 CAST HOUSE SLAG-GRANULATION PLANT :
The molten slag produced by the furnaces is fed to cast house slag granulation plant to produce
granulated slag. Two granulation plants are provided for each furnace adjoining the cast houses on
two opposite sides.
64
Slag is dicharged from the furnace 10 to 20 times a day, duration of each discharge being up
to 60 minutes. Each granulation unit comprises two process lines (one stand by), designed to receive
all slag through two iron notches. Each process line comprises of one granulator, one slag air lift, one
granulated slag dehydrator, one receiving bin and water supply recirculating system. Steam from
receiving hopper is discharged to atmosphere through a chimney.
The granulated slag from the dehydrator is discharged into an intermediate hopper and from
there it is fed to final storage through a conveyor system. The granulation of liquid slag is done by
water jets and the granulation water is delivered by dredged pumps in a quantity of 2000 m
3
/hr at a
minimum pressure of 5atg in the granulator. Temperature of pumped water is around 90 degrees C.
with an average suspended matter content of upto 2 g/litre. Through put of make up water is 300m3
per granulation plant.
For air lifting thickened pulp from receiving bin to separator, compressed air is used. The plant
is designed for maximum slag discharge rate of 10 T/min and hot metal content in the slag will be 12.7
kg/T.
The granulation plant works for 350 days in a year. The combined conveying system for handling
granulated slag from both furnaces has a capacity of 600 TPH. Two conveyor systems one acting as
standby is provided.
The storage is open dump type and can hold about one month production. From the storage
slag is loaded in railway wagons and in trucks by grab cranes.
8.4 PIG CASTING :
Four double strand pig casting machines of 1700 TPD capacity are installed to pour off grade
metal and metal diverted due to stoppages in SMS (one machine reserve). The machines can handle
one furnace production. Each PCM is served by a 75 T, overhead trolley to tilt the 140 T hot metal
ladle. Pig weight is about 45 kgs. Facilities for lime washing of moulds and a re-circulating water
system for cooling the pigs, including a settling tank, is provided.
The cold pig from machines are collected in wagons and sent to open gantry pig iron storage
yard. The yard is of 300 x 40 m size and cold pigs are stored in separate lots according to grade. Two
150 T Rail weigh Bridges are provided to weigh outgoing loaded wagons.
8.5. HOT METAL LADLE REPAIR SHOP :
The main objectives of this shop are as follows :
a) To ensure placement of hot & clean metal ladles to each furnace in time for the casting as per
the casting schedule.
b) To ensure quick despatch of Hot metal loads to their planned destination and also ensure early
withdrawal of empties from PCM/SMS in order to thoroughly clean inspect and clean the same
before placement.
c) To effectively coordinate with Rail Traffic department / 2BFs/ SMS/PCM to ensure achieving of
above objectives.
65
The entire shop working rotates around the three above objectives. The main equipment/tools/devices
provided in the shop to achieve those objectives are as below :
a) 2 Nos. of 120/50 tons capacity E.O.T. cranes (for Hot Metal ladles cleaning purposes).
b) 30 Nos. of conventional open top metal ladles (capacity 140 tons each) and 7 Nos. of Torpedo
ladles (capacity 300 tons each) to hold & transfer liquid Hot Metal.
c) 4 Nos. of metal ladle pits with stands to hold conventional ladles during mechanical repair jobs
/ RED lining jobs.
d) 1 No. 42 tons capacity punch and 2 Nos. of four beak anchor hooks to remove skull from metal
ladles and clean them.
e) 2 Nos. of drying installation to dry and preheat freshly lined conventional ladles before taking
hot metal in them to avoid explosion and thermal shock.
f) Separate torpedo ladle repair shop is there to maintain the torpedo ladle cars in all respects.
8.6 BLAST FURNACE MASSES AND COMPOUND SHOP :
Refractory masses required in cast house viz., Runner mass, Mudgun mass, Tap hole frame mass
are prepared in Masses Compound shop.
The raw materials required for preparing mass are received at various sizes from the different sources.
These are crushed in various stages and stored in final storage bins. 12 final storage bins are provided
for storage of raw materials. There are 6 operating groups for raw material handling and preparation
of masses.
The raw materials for preparation of different masses are :
G
Coke Breeze
G
Pitch
G
Grog
G
Plastic fire clay
G
Silicon Carbide
G
Calcined Bauxite
G
Powder Resin
G
Liquid Resin
G
Wash Oil / L.C Oil
G
Special binder
There are two storage tanks (25 m3) for wash oil/L.C Oil. Two pan mixers are used for preparation
of the mass.
66
All the groups can be operated through PLC and if required they can be operated in local
mode.
There is a 5 Tons capacity crane for handling the mass boxes.
8.7 GAS EXPANSION TURBINE STATION :
This is intended for generation of electric power utilizing the potential energy of the compressed BF
gas. One turbine is provided for each furnace. Each turbine operates the turbo generators of 12 MW
nominal rating with exciter placed on one shaft with the turbo generator. Air coolers are provided for
turbo generators. (The gas is heated up to 120 degrees C. in heater. The station operates for 8000
hours in a year annual generation of electric power is about 123. 8 to 184. 6 X 10000000 KWH.
8.8 GAS CLEANING PLANT :
The rated dust content in gases after the dust catcher, when the blast furnace is operating at high top
pressure is 6.3 gms/normal cubic meter and at low top pressure up to 15 gms/Normal cubic meter.
Further cleaning up to 4 mg/Normal cubic meter is accomplished in wet gas cleaning plant, consisting
of high pressure scrubber of 9000 mm dia, two venturi pipes with adjustable drop of pressure by
changing throat cross section, 2, 600 mm dia spray catcher and the cyclone sprary catcher. In the
scrubber, gas is cooled and cleaned of coarse fractions of dust. In venturi pipes and septum valves,
the coagulations of fine fraction of dust takes place with subsequent separation of them in spray
catchers.
A BF gas flare stack is provided for prevention of excess of the preset pressure in out door distributing
BF gas pipe lines and centralized burning of the discharged temporary surpluses of BF gas. Capacity
is 200 to 240 x 10
3
normal cubic meter per hour, height-60m. Four burners of 60 normal cubic meter
per hour are provided.
8.9 NITROGEN SUPPLY AND BLOCK OF RECIPIENTS :
Nitrogen of 97% purity is used for charging apparatus and for other equipment requirement is 38, 370
normal cubic meter per hour. Nitrogen is supplied from Oxygen plant. To provide for emergency
Nitrogen reserve, and to compensate non-uniform consumption, a block of recipients consisting of
two 100 cubic meter vessels for 10 Ksca pressure and five 125 cubic meter vessels for 35 to 40 Ksca
pressure are provided. A Nitrogen control station is provided as a part of block of recipients, where
pressure is reduced from 35 to 40 Ksca to 8 to 10 Ksca.
8.2.0 AIR CONDITIONING STATION :
To supply air to all units, two central air conditioners 200000 m
3
/hr capacity are installed. In cold
season one unit will be in operation. Air is subjected to cleaning in cell filters, adiabatically cooled and
humidified in the spray chambers in summer. Air at a temperature of +30 degrees C and 90
%
humidity
is supplied through yard pipe lines. In cold season, air is subjected to only cooling. The total requirement
is 392, 000 m
3
/hr.
67
8. 2.1 CONVEYORS :
The details of conveyors in blast furnace as follows :
Width (mm) Length (M) Quantity (Nos.)
1600 1542 12
1400 2250 18
1200 1138 4
1000 1890 10
8.2.2 PROCESS CONTROL COMPUTERIZATION IN BLAST FURNACE :
8.2.2.1 Scope :
Two systems have been envisaged in the Blast Furnace Automation Control system.
8.2.2.1.1 Burden Handling System :
To control the proportioning of burden materials with due consideration for coke moisture content &
batching accuracy. This system also gives relevant data connected with the operation of the Burden
handling Complex to the process personnel. This consists of the following major local systems for
monitoring and control.
i) Material levels in the bins
ii) Material batch weights
iii) Coke moisture content
iv) Availability of materials and transfer of the material batches to the Blast furnace top
v) Over filling of chutes
8.2.2.1.2. The centralised monitoring and control system for the Blast Furnace comply with the following
main functions.
a) Automatic data acquisition on the process run, state of equipment.
b) Automatic processing of incoming data and making them available to the technological
personnel in a convenient form.
c) Occasional calculation of process parameters and taking the process data to the service
personnel.
d) Delivery of corrective responses to local control circuits.
e) Optical and acoustic signaling for variations of basic process parameters from nominal
values and for operating conditions of the equipment.
f) Occasional filling-out of reports.
8.2.2.1.3 Lan system is implemented in Blast Furnace department connecting all the sections of the
department with the main net work. Data is logged on to the system in all the section and
made available for use & reference by the concerned.
68
69
70
71
72
73
C = 4.0 - 4.5%
Si = 0.4 - 0.7%
Mn = 0.10%
P = 0.11% max
S = 0.04% max
Temperature = 1250 - 1425 Degree C.
1300 to 1350
0
C Through Mixer route
1350 - 1450
0
C Through TLC (Torpedo Ladle Car) route.
BULK MATERIAL HANDLING SECTION (BMHS) :
The following bulk materials are used in converter shop of SMS.
Calcined Lime and calcined dolo - used as flux in LD-Converter.
Cao = 89 - 90%
LOI (Loss On ignition) = 6-8%
SiO
2
= 2.5% Max
Size = 10-25 mm
Mgo of dolo = 28 to 32%
Requirement = 6-10 T as per heat weight and hot metal composition, iron Ore Lump - Used as
Coolant in steel making.
Fe = 66.9%
SiO
2
= 0.9%
AI
2
O
3
= 1.6%
M
n
O
2
= 0.05%
Size = 15 - 60 mm
Requirement = 0.5 - 3T as per blowing conditions.
Raw or Calcined Dolo - Used to increase lining life of Converter.
Lump Coke - Used to preheat the lining of newly lined converter.
One of the requirements for continuous casting process is that the liquid steel should be killed (fully
deoxidized). For this and to make different grades of steel, ferro alloys (FeSi, SiMn, FeMn, etc) Coke
breeze/Petroleum coke and Aluminium are added in the ladle during tapping of steel from converter to
ladle.
CONVERTER BAY :
Hot metal contains different impurities (C,Si,Mn,S,P) above safe level which make Pig Iron brittle. But
steel is nothing but refined hot metal. Refining is only possible when things are in molten
74
phase. Refining is done by blowing oxytgen in the LD converter Charged with Hot Metal, Scrap, Flux,
Iron Ore, etc. In this refining process, temperature of liquid steel is aimed at 17000 C (average).
Different grades of steel is made by adding various ferro alloys & additives (FeSi, FeMn, Coke Breeze
or Petroleum Coke, Aluminium, etc) in different quantities during tapping of liquid steel from converter
to steel ladle.
There are 3 LD convertors in SMS. Characterstics of converter design are given below:
Capacity = 150 Tonne
Effective Volume = 133 cum
Converter specific volume = 0.886 Meter Cube per Tonne
Height to Diameter Ratio = 1.36
Refractory for converter lining is MgO based e.g. Sea water Magnesia, Magnesia carbon,
Pitch Bonded
Oxygen is blown in the converter through oxyzen lance. It consists of three concentrically
arranged steel tubes with connecting branches for Metal - Flexible - Hoses. Central pipe is for supplying
oxyzen, intermediate pipe is for incoming cooling water and outside pipe is for outgoing water. At
lower part of lance there are 5 nos. Convergent - Divergent copper nozzles syrnetrically arranged at
17.50 to the lance axis.
CHARACTERISTICS OF OXYGEN LANCE :
Lance Travel = 16000 mm
Oxyzen working pressure = 16 KSCG
Water Working Pressure = 12 KSCG
No.of Nozzles = 5
Water consumption = 130 Cum/hr
Oxygen flow rate = 400-450 NM
3
/min
During blowing LD gas is generated. This is a very poisonous gas because its main component
is carbon monoxide. LD gas cooling, cleaning and collection system comprises of tube bar-tube type
skirt, gas cooling hood and stack, Closed loop type gas cooling arrangement with finfan cooler, kinpactor,
gas duct, ID fan, change over valve, flare-stack, gas holder, etc. When the gas composition is
acceptable, it is recovered and collected in gas holder. Unacceptable LD gas is discharged through
Flare Stack.
LD gas Collection system - Gas collection with suppressed Combustion.
LD gas Cooling - Gas cooling with closed loop hot water pressurised
cooling system.
LD gas cleaning - Wet type cleaning system with adjustable
throat venturi.
75
Slag Splashing : After tapping of liquid steel, slag splasting is done after adding calcined dolo in the
slag to improve the lining life of converters.
SCRAP YARD :
Scrap is used as coolant. Scrap may be heavy (wt. up to 1.5 T) or light. Length should be less
than 1.5 M. Some times cast pig iron is used as scrap in case of shortage in steel scrap. Purpose of
scrap yard is to supply scrap to the converter periodically without any interruption Following equipments
are available in scrap yard.
1) Scrap Box Tansfer Car
2) Scrap Weigh Bridge
3) Scrap Box
4) Magnetic EOT Crane
Scrap should not have dust, moisture or water, grease, oil, etc. Generally 15T of Scrap is charged in each heat.
SLAG YARD :
The Slag generated in LD converter during refining of hot metal is collected in vessels called slag pots
(16/18 Meter cube capacity). This slag is dumped in the pits (4 nos.) which are present in slag yard.
For doing so, slag pots, slag pot transfer cars (3 nos.) slag dump cars (2nos.), EOT cranes (2 nos.),
etc. are needed.
LADLE PREPARATION BAY :
Ladles after prolonged use get wornout and need to be repaired. After one or two heats, plates for
slide gate control mechanism, for teeming liquid steel, need to be changed or repaired. All these and
many other activities are done in Ladle preparation bay. There are 26 steel ladles and 5 hot metal
ladles in SMS.
This bay will house the following main facilities:
Horizontal Ladle Stand - For slide gate fixing, Plate changing, etc.
Vertical Ladle Stand - For heating ladle
Relining Pits - For Relining the ladles
Ladle Drier - By burning coke-oven gas, ladle is heated
EOT Crane(3 nos.) - To handle the ladle
(Main hoist capacity 100T)
On line drier - To heat the ladle before releasing for tapping.
ARGON RINSING STATION (ARS) :
The liquid steel which is tapped from LD converter is not homogenious in composition and temperature.
To make the liquid steel suitable for continuous casting purpose by making it homogenous, inert
gas rinsing is done. Generally Argon gas is used for this purpose. Both bottom and top purging
facilities are available. Bottom purging is superior than top purging. When both are used at a time, it
is more effective.
76
In general, 12 minutes rinsing is done. For all the 3 LD Converters steel transfer car track, 3
ARS are available. In case of LD-2 steel transfer car track, IRUT (Injection Refining & Up Temperature)
is installed. Along with steel temeperature rising, Argon Rinsing is also done simultaneously. To
raise the temperature at IRUT, oxygen blowing is done and simultaneously Aluminium is added.
In ARS, Aluminium is also added for complete deoxidation (to reduce oxyzen potential of liquid
steel below 10 PPM) and to increase Al% in liquid steel in certain grades of steel to make it suitable for
continuous casting purpose.
There is one ladle furnace in ARS Bay. In Ladle Furnace, composition adjustment and liquid
Steel-temperature raising can be done. Simultaneously Argon Rinsing is also done along with the
above said activities. In Ladle furnace, temperature of liquid steel is raised by electric arcing. There
are 3 graphite electrodes for this purpose.
When rinsing is over after achieving desired temperature and composition (varies from one
steel grade to another) ladle covering compound is added at the top layer of liquid steel in the ladle.
This reduces heat loss from ladle.
TUNDISH PREPARATION BAY :
Tundish is a refractory lined container having 4 nozzles through which liquid steel is poured in
all 4 moulds of a C.C.machine at a time. Pouring of liquid steel from tundish to mould is controlled by
stopper-rod mechanism. During casting, Tundish is placed over mould, and below steel ladle. Tundish
maintains the constant ferrostatic pressure and it helps in floating of the nonmetallic inclusions at the
top layer of liquid steel and thus non-metallic inclusions are prevented from entering into mould.
In Tundish preparation bay, used tundishes are cooled by water/compressed air and lining Is
demolished. All the relining activities, stopper-rod asembly fixing, etc. are done in this bay.
CONTINUOUS CASTING MACHINES (CCM) :
Continuous Casting may be defined as teeming of liquid metal in a mould with a false bottom
through which partially solidified ingot (same shape as mould) is continuously withdrawn at the same
rate at which liquid metal is poured in the mould.
Facilities and Equipments at CCM platforms: Lift and Turn Stand:
To accommodate the steel ladles and place them in casting position as and when required to
facilitate sequence casting. It lifts the ladle and places the ladle at casting position by turning it and
swing back the empty ladle after completion of casting.
Mould Oscillating system :
To facilitate easy withdrawl of continuously Cast bloom (partially solidified) from the mould.
Oscillation frequency : 40-100 cycle/min
Mould Oscillation stroke : 7 mm
77
Copper Mould :
The foremost important factor in the continuous casting is the copper mould which decides the
efficiency of the process. The material selected for mould and the design of mould play a prominent
role in obtaining the bloom of greater surface finish, better mechanical properties with minimum of
casting defects. A mould with good design associated by good cooling system gives quality blooms,
provided a great care, is excercised during casting.
In VSP, square (250mm x 250mm) and rectangular (320mm x 250mm) cross sectional moulds
are used. These moulds are provided taper towards bottom (327 x 255 top, 324x252.5 bottom in case
of 320x250 bloom) to maintain the contact between partially solidified strands and is made of copper
which is necessary for achieving the necessary cooling rate.
Copper is an ideal material for mould because it is having
i) good thermal conductivity.
ii) mechanical strength must be retained at operating temperature 250 degree C.
iii) recrystallization temperature above 300 degree C.
iv) low friction coefficient and good resistant to wear.
v) chemical immunity w.r.t. steel.
Cu-Ag 0.1 P-F 25-possess all the above properties.
Length of mould at VSP is 1.0 m
Radius of mould / Machine 12 m
STRAND COOLING :
Strand cooling is carried in two stages: Primary and Secondary cooling.
Primary Cooling :
The soft water is used for this purpose with PH 7-9, total hardness- 0.2 dh. This water is
repeatedly pumped through the moulds in a closed cycle with recooling blot. This water has to be
treated and anticorrosive agent etc., should be added. This water is supplied at a pressure of 5-6 bar.
The inlet water comes from the bottom & leaves the mould through the outlet valve which is located at
the top of mould. This is indirect type of cooling.
Secondary Cooling :
The water that is sprayed over the strand should cool the strand uniformly thoughout the length, to
avoid under cooling of some parts of strand. The pressure will be 6 bar. The countoract flow problem
due to corrossion, the pipeline will be made up of stainless steel. In secondary cooling, strand (bloom)
will be completely solidified, leaving no liquid steel at all. The secondary cooling zone begins from
just below the mould.
Water for secondary cooling should have
PH 7-9, Total hardness 20 DH
Carbonate hardness 0.7 DH
78
Dummy Bar :
The function of Dummy Bar is to seal the mould bottom, for the starting of casting and to
withdraw solidified shell until the hot strand has passed the straightening and withdrawing machines.
Backup Roller sections N1 & N2 :
These sections are intended for supporting and directing the dummy bar and strand in course
of casting. N1 is a four roll section installed on posts underneath the secondary cooling sections, while
N2 is a six roll section installed after the 4-high stand.
Withdrawal and straightening rollers :
There are four strands which are used for withdrawing and straightening the curved bloom.
These 4 stands are designated as TK1, TK2, TK3, TK4.
TK1 - 4 high strand
TK2 - 2 high strand
TK3 - 2 high strand
TK4 - 2 high strand
Casting Powder :
The main purpose of casting powder is to act as a lubricant to prevent the sticking of steel to
mould. Casting powder must be added continuously at regular intervals. The meniscus must always
be covered enough that it appears dark, but layer thickness should not exceed 30 mm.
Casting powder should meet the following requirement :
i) reduce strand friction
ii) should protect liquid steel against reoxidation.
iii) prevent surface heat loss.
iv) promote uniform heat transfer from meniscus to mould in order to avoid longitudinal
cracks.
v) rapid and uniform spreading on the bath surface.
vi) it should also absorb some oxides in the steel without great change of its viscocity.
Technical details of CC machines
Average Casting speed for 320x250 bloom size is 0.78 M/min for 250x250 bloom size is 0.82
M/min
Gas Cutting Machines(GCM) :
The strand, which continuously comes from the copper mould after getting completely solidified,
should be cut as per our requirement, to facilitate easy handling, etc. In order to cut the blooms
accurately, a gas cutting machine, using acetylene and oxygen, is used.
79
Since the bloom travels with certain speed, the machine used for cutting the bloom should
travel along with the bloom. For this grippers are used, which grips the bloom and travels along with it,
taking the oxy-acetyline flame with it. Each CC machine has been provided with 4 cutting machines to
cut the four blooms at a time.
Details of gas cutting machines :
The pressure of the acetylene : 0.6 kg/sq.cm
Length of the bloom : 5.5 to 5.8 m for 250 x250mm size
6.0 to 6.4m for 320x 250 mm size
Time required for cutting one bloom : 1-1.5 min
The pressure of oxygen : 15 kg/cm2
Bloom Storage Yard (BSY) :
To sychronise the production in continuous casting machine and requirement of rolling mills
for blooms, Bloom storage yard (BSY) has been established. Inspection and selective conditions are
also carried out in BSY. After cutting the blooms at GCM they are moved to cooling beds and after
cooling they are transferred to racks. The BSY is served by 11 nos. EOT cranes with rotating cabins
and magnet facility. Blooms of particular grade of steel are stored at a particular place. Every bloom is
marked by heat no. and machine no.
The sequence of operations in brief at different sections of continuous casting shop is given
below :
1) Steel ladle from converter after tapping is transferred to Argon Rinsing station.
2) In rinsing station : Argon purging (bottom or top or both) is carried out for a period not less than
12 minutes. During rinsing, Aluminium is also added.
3) The sample and temperature are taken. The sample is sent to lab and composition is verified.
If temperature and composition are satisfied, liquid steel is sent to casting platform. If
temperature or composition corrections are required, they are done either at ARS or IRUT or
LF.
4) In CCM, first of all, dummy bar is inserted through the mould. Some small scrap is charged into
mould to enhance cooling rate of liquid steel, to enable the operator to withdraw the dummy
bar.
80
5) In CCM, the ladle with liquid steel is placed on the lift and turn stand and will be fixed with
hydraulic cylinder for operating slide gate mechanism to control teeming of liquid steel to
Tundish from ladle.
6) Meanwhile tundish is preheated to about 1000
0
C. Stopper are checked before the tundish is
placed into casting position. After placing the tundish at casting position, nozzles are posi-
tioned exactly in the centre of the mould.
7) Ladle is brought to casting position by turning the lift and turn stand. Stoppers of the tundish
are kept closed. Slide gate of ladle is opened by hydraulic mechanism. If liquid steel stream
is not proper or liquid steel is not coming, oxygen lancing is carried out in ladle nozzle.
8) Liquid steel is continuously fed into the tundish and the level in tundish is carefully observed.
When it is 2/3 full, stoppers will be opened to allow the steel to fill the mould.
9) Before feeding liquid steel into mould water circulation in the mould is to be ensured
10) After the steel meniscus reaches certain level, dummy bars withdrawal will be started.
Secondary cooling water spray is also started.
11) After the dummy bar passes over the withdrawal rollers, it will be disengaged.
12) Continuously coming bloom is cut by gas cutting machine. The required length of cut blooms
are sent to BSY after marking the heat no. and CC machine no. by hot chalk.
13) These blooms are stacked, inspected and heat no. is written by paint over cross section of
bloom. Blooms are sent to rolling mills as per requirement.
81
82
83
Chapter - 10
LIGHT AND MEDIUM MERCHANT MILL
INTRODUCTION :
Visakhapatnam Steel Plant has three sophisticated Rolling mills, designed to produce 2.656 million
tones per annum of finished products from continuously cast blooms with a wide range of product mix.
The mills are :
a. Light & Medium Merchant Mill (LMMM)
b. Medium Merchant & structural Mill (MMSM)
c. Wire Rod mill (WRM)
SOME OF THE SALIENT FEATURES OF THE MILL ARE :
a. High capacity and high speed.
b. Automatic minimum tension control in stands
c. Double sided cooling beds of walking beam type.
d. High capacity and high productive sawing lines.
e. Automatic bundling machines.
f. Computerization at the sequential process control and material tracking
g. Adoption of closed circuit TV at furnaces.
h. evaporative cooling system and waste heat recovery.
These features help to optimize the production and assure quality products from the mill.
BLOOM STORAGE AND INSPECTION :
The SMS supplies continuous cast blooms in killed and semiskilled quality of ordinary grade, high
carbon and low alloy steels. The bloom storage is at right angles and common to all mills. Bloom
inspection and storage, if necessary, is carried out in the common storage.
LIGHT AND MEDIUM MERCHANT MILL :
Keeping in view the latest developments the light and medium merchant mill is designed with the
operation floor on a second storie elevation, namely +5.0 mts. This arrangement has many
advantages. It provides better drainages for both lubricants and water and mill scale. The oil cellars
can be placed at slightly below the ground level with out deep excavations but ensuring adequate
drainage. The oil and water pipes and cable trenches are readily accessible.
Blooms for LMMM are placed on charging grids (3 nos) of 150 tonnes per hour capacity each by 16
tonnes claw cranes (2 nos). The blooms are then delivered to the furnace approach roller table (+5.8mts)
by an inclined elevator from bloom storage roller table (+0.8mts)
The approach roller table is provided with a weighing scale, a tilter and disappearing stops. The
blooms are positioned in front of the furnaces and then pushed by hydraulic pushers on to the charging
skids of the furnaces. There are two nos. of walking beam type furnaces of 200 T/hr capacity with
84
double row charging. The blooms also can be discharged from the charging side of the furnaces in
case of emergency. Heated blooms are placed piece by piece by discharging devices on to the furnace
delivery roller table. The blooms are descaled by high pressure de-scaler.
The continuous Break-Down group (non-reversing) consists of 7 stand -2 Horizontal (850x1200mm)
and 5 alternating vertical and horizontal (730X1000mm and 630X1000mm).
In 5 Box passes and one each of diamond and square passes, the blooms are reduced to 125 mm
square in the 7 stands. The finishing speed will be 1.3 to 1.6 mts/sec. A four crank shear installed
behind the mill stands is designed to crop both ends and to cut billet lengths as per requirement of
WRM & Sales as per requirement to achieve optimum yield in cutting. Billets feeding the LMMM are
cropped at the front and back ends.
Normally one Bloom is rolled for LMMM and the next one for the WRM alternatively, Billets are also
sold. The billets for WRM and for sale are cooled on 2 turn over - type cooling beds to a maximum
discharge temperature of 400
0
C. These billets are picked up by magnet cranes of 16 T capacity in the
intermediate billet storage and transferred to the transfer grids in the shipping area or dispatched for
sale.
Billets after cropping by the 4 crank shear and having a length of about 32 mts are transported to the
in-line 2 strand roller hearth furnace of 200 T/h Capacity. Billets normally arrive at the furnace with a
surface temperature of 1100
0
C. Billets are heated and soaked to a discharging temperature of 1150
0
C to 1130
0
C.
The continuous multi-line mill comprises 8 stand double strand roughing train, 2 Nos, 4 Stand Single
strand finishing trains.
Loopers are provided in between the finishing stands for tension free rolling in order to obtain good
surface quality and tolerances. Housings are of closed top type. Roll necks are mounted in anti friction
bearings.
Shears for cropping and emergency cutting are arranged ahead of the first of roughing mill stand and
upstream of intermediate mills. Snap shears for emergency cuts only are ahead of finishing mill. The
rotating shears after the finishing mills crop the materials leaving at rolling speed. And cut into multiples
of specified sales lengths.
The finished bar now enters the cooling stretches. There are two cooling stretches each installed just
downstream the last stand of the finishing mill. The purpose of the cooling stretches is to cool down
the rebars to such an extent so as to produce desired mechanical properties. It also serves to control
the scale formation.
The bar leaving the last stand of the finishing mill passes through a cooling stretch. The cooling
efficiency of this installation is such that a surface layer of the bar is quenched into martensite, the
core remaining austenite. The quenching treatment is stopped when a determined thickness of
martensite has been formed under the skin when the rebar leaves the cooling stretch, a temperature
gradient is established in the cross-sections of the bar causing heat to flow from center to the
surface, which results in self-tempering of the martensite Finally during slow cooling of the rebar on
the cooling bed, the austenitic core transforms into ferrite and pearlite. To achieve the required
mechanical properties, it is sufficient to maintain the tempering temperature within a predetermined
85
range. The obvious control variables are the length of the quenching line and the cooling water flow
late at suitable number of cooling pipes whose diameter, are chosen as a function of product diameter.
Air Strippers are fitted at the end of cooling pipes to make sure that the material leaves the stretch in
dry condition. The pinch roll units; downstream the cooling stretch guarantees the correct bar speed
during the cooling process. These pinch rolls are speed synchronized with the exit stands of finishing
mill 1 & II so that bar speed remains same when the bar tail has left exit stand of finishing mill. They
also serve to enter the material into the rotary shear. A total cooling bed of 130 mts X 12 mts has been
provided for cooling down the rolled section at about 808
0
C maximum for straightening.
In the downstream of the cooling beds there are multi strand straightening machines (maximum 8
straightening strands) The number of straightening rolls are 8 (top 4 and bottom 4). The bar groups
from the straighteners are collected in layers for the downstream cold shear by cross - transfers. The
2 cold shears have cutting pressure of 500 MPa each. Desired finished lengths normally 12 mts are
set by girder type gauge carriages. Tail lengths less than 6 mts are discharged into cradles near the
cold shears. Downstream file cold shears, rounds, and rebars are transported to bar bundling facility.
There are two bundling facilities. The bar bundling facilities have provision for counting the bars, and
strapping the collected bars into bundles of 4500 Kgs and 10000 Kgs.
Strapping of bar bundles and packs is by means of wire and straps.
The finished section packs/bundles are finally transported to the weighers and the loading grid permits
the bundles to be picked up by magnetic cranes in the finished product storage area having lifting
magnets of 20 Tonnes capacity.
ELECTRICAL EQUIPMENTS IN LMMM
The mill stands are driven by individual main drive motors. The motors are separately excited and
compensated DC shunt motors in two frame sizes.
The armature circuits of the motors are provided with individual thyristor power supply comprising 11
KV converter transformer, thyristor converter, reactor, single pole high speed circuit breaker and double
pole no-load contractor, in ratings to match the motor overloads. Field circuits of the motors are fed by
individual thyristor power supply systems fed from 415V, 3-Phase supply source, over isolation
transformer.
For AC drives the motors provided are generally squirrel cage type for continuous operation drives
and slip ring type for intermittent duty drives. Geared motors for individually roller table drives have
also been foreseen. AC motors provided are totally enclosed Fan-cooled.
Variable frequency motors for roller table drives are fed over variable voltage -variable frequency
(VVVF) supply sources.
AUTOMATION AND CONTROL SYSTEM IN LMMM :
PLCs in LMMM :
Different makes of PLCs are used in various areas of automation for operation control.
AEG-PLC : ( 38 Nos)
Total mill control
Reference generation for all drives
86
Sequence and interlocking for process equipments.
Position control for drives.
Video interface for the operator in the control pulpit
ALLEN BRADLEY-PLC ( 5 Nos)
Walking beam furnace control system - 2 Nos.
Cobble detection system for merchant bar mill - 1 No.
Strapping machine control system - 2 Nos. with 9 nos. Remote I/O
GE FANUC-PLC (7 Nos)
Total mill control
Reference generation for all drives
Sequence and interlocking for process equipments.
Position control for drives.
Video interface for the operator in the control pulpit
Roller hearth furnace control system
Air oil lubrication system control
SIEMENS PLC (1 No)
Booster water station
LEVELS OF AUTOMATION IN LMMM :
Programmable Logic Controllers (PLCs) provided at level-1 finally control the process equipment
directly, each in its own area for sequencing and interlocking functions. The system envisaged is
interfaced with the main and auxiliary drive analogue control system so as to perform as one integrated
unit.
The control at Level-2 is basically decentralized and distributed in concept so as to offer a higher
degree of operational flexibility. A number of microcomputer subsystems provided at this level, operate
and control function for equipment distributed in various areas of the mill.
For operators communication with the system dialogue terminals (VDU and Keyboard units) have
been envisaged in control pulpits of the mill. Printers for hard copy print out of rolling schedule, shift
reports etc.
The control system envisaged is basically automatic with provision of manual control locally for
equipment to take care of local disturbance during operation and also the maintenance needs.
UPGRADATION OF PLCs :
Most of the important PLCs of the Billet mill and Bar mill are being upgraded to latest GE FANUC
make.
87
88
89
90
91
92
93
94
Modifications done in MMSM to improve productivity
1) Roll-pass design modification in MC100,MC125&MC150 for more pass-life in finishing stands
2) Roll-pass design modification in Rounds to make exit stand horizontal,for easy adjustment in
mill during rolling
3) Double bars to batching in rounds,thus increasing output from Cooling bed
4) Diameter of cold saw blades reduced to 1460mm from 1604mm and 1500mm,thus increasing
stability of the blade
5) Hydraulic feeder modified to mechanical feeder,thus reducing hydraulic leakage in piling
95
96
97
98
99
100
101
102
103
104
105
Chapter - 13
ROLL SHOP AND REPAIR SHOP
Roll shop & Repair shop (RS&RS) is a prime service department to the three rolling mills of
VSP. Located in the complex of Rolling Mills, RS&RS caters to the mill requirements of Roll pass
design, Guide design, Supply of roll assemblies, guide assemblies and maintenance spares all in one
department which is unique in the steel industry. For the first time in the country, CNC technology has
been adopted for grooving of steel mill rolls for achieving high repetitive accuracy and higher productivity
compared to conventional ones.
The main activities of the RS&RS is Roll pass design, Roll Turning, assembly of rolls with
bearings, preparation of guides and manufacture/repair of mill maintenance spares.
Roll Pass Design section
Design of grooves for development of new sections, modification of existing pass designs for
improving the productivity and quality. Preparation of rolling schedules, groove detail and distribution
and template drawings, part programming for grooving of rolls on CNC lathes.
Roll Turning shop :
The activities involved are Turning/Notching/Branding of Rolls used for rolling of various products in
the three mills. The shop is equipped with the following sophisticated Machines :
1) Heavy duty CNC Lathes
2) CNC Template milling machine
3) CNC Notch milling machine
4) Roll Branding M/cs
Bearing Shop :
The activities involved are assembly of Rolls with Heavy duty bearings Types of Bearings used are as
given below:
LMMM & MMSM WRM
G 4 row tapered roller bearings G Morgoil bearing (Oil film bearings)
G 4 row cylindrical roller bearing G 2 row axial tapered roller bearings
G Deep groove ball bearings
G 2 row axial tapered roller bearings
G 2 row angular contact ball bearings
Guide Shop :
Mill guides are used for inter-stand guiding of the material. Entry guides ensure correct direction of
the head end of the stock entering the rolls and hold the stock in the required position. Delivery/exit
guides serve to control direction of the stock leaving the rolls after rolling. Delivery twist guides are
used for twisting the stock. The guides can be of static or roller type. In the Specialized Repair Shop,
assembly, servicing, repair of mill guides, redressing of guide rollers, resharpening of shear blades,
manufacture of fast moving spares are done.
106
Roll Set
Assembly/
Disassembly
Blank
Rolls
Roll Turning Area
R
O
L
L
I
N
G

M
I
L
L
S

(
L
M
M
M
;
W
R
M
)
Turned
Rolls
Used
Rolls
Assembled
Roll Sets
Used
Roll Sets
Bearing Assembly Area
CNC MACHINES FOR
ROLL TURNING;NOTCH-
MILLING; BRANDING
AND TEMPLATE
MILLING
SPECIAL PURPOSE
M/CS/EQUIPMENT
FOR MACHINING
GUIDE ROLLERS
AND REPAIR OF
STATIC GUIDES
WRM GUIDE ASSEMBLY
LMMM GUIDE ASSEMBLY
Guide Repair and Assembly Area
Assembled
Guides
Used
Guides
ROLL SHOP-I
ROLL SHOP-II
AREA REPAIR
SHOP
LMMM &
WRM
MMSM
Mfg / Repair of
Mechanical spares
LMMM ; WRM
& MMSM
Supply of Rolls , Guides
And Bearings.
Supply of Rolls , Guides
And Bearings.
Geographically this department is in three areas viz
1) Roll shop-I :- Supply of rolls and guides to LMMM & WRM.
2) Roll shop-II :- Supply of rolls and guides to MMSM.
3) Area repair shop :- Manufacturing of mechanical spares of three mills
Roll Shop-I comprises of a Roll Turning Shop, Bearing shop, a Specialized repair shop catering to the
needs of LMMM and WRM. Roll turning shop is equipped with six CNC lathes, CNC template machine,
Notch Milling machine Branding Machine etc. The grooved rolls are assembled with bearing chocks
in the bearing shop. Used bearings are dismantled, cleaned, inspected, serviced and reassembled
on the rolls at regular intervals. Separate bearings for taking radial loads and axial loads are used.
ROLL SHOP & REPAIR SHOP
PROCESS LAYOUT OF ROLL SHOP- I
107
Roll Shop-II comprises of roll turning shop, Bearing shop and guide shop catering to the requirement
of MMSM. Roll turning shop is equipped with six CNC lathes for grooving new rolls, as well as redressing.
The grooved rolls are assembled with bearings in the bearing shop. Chocks with bearings serviced
periodically. Assembly and service and repair of guides, preparation of strippers used in rolling of
Angles, channels and beams are done in guide shop.
Cassette/
Bearing
Servicing
R
o
l
l

S
t
o
r
a
g
e
T
u
r
n
e
d

R
o
l
l
s
U
s
e
d

R
o
l
l
s
Blank
Rolls
S
Conventional Machines
(NH-22,Shaper,Drilling)
for repair of guide roller
and static guides
U
s
e
d

G
u
i
d
e
s
G
u
i
d
e
s
CNC MACHINES FOR
ROLL TURNING (CNC
Lathes 6 nos) and ROLL
BRANDING M/C (1 NO.)
Roll Turning Guide assembly
Bearing Servicing
C
a
s
s
e
t
t
e
s
PROCESS LAYOUT OF ROLL SHOP - II
MMSM
(Medium merchant and structural Mill)
108
Area Repair Shop is a machine shop with general purpose machine tool like lathes, shapers, milling,
slotting, drilling and grinding machines, vertical press fabrication etc. The main activities involved are
Repair and manufacture of spares for the mills and Roll Shop.
PROCESS LAYOUT - AREA REPAIR SHOP
109
SERVICE UNITS
110
111
Chapter -14
AIR-CONDITIONING SYSTEM DEPARTMENT (ACS)
INTRODUCTION
Air-conditioning and refrigeration system is very important in any big process industries like steel
plant, power plant, oil refineries etc. The air-conditioning requirements are increasing day by day due
to growth in automation level, computerization etc. For the plant to function efficiently, air-conditioning
is very important to maintain design comfort temperature, humidity & air quality. ACS department in
Visakhapatnam steel plant is maintaining variety of air-conditioning units to suit different conditions,
requirement as per the application.
For high ambient air-conditioning units running on moving machines of coke oven batteries
(Door Extractor car, Charging car, Pusher car, Loco car), heavy duty hot metal cranes, liquid
steel handling cranes, bloom handling cranes, Tundish handling etc .
Air Handling units working on chilled water for Electrical control rooms, IBM computer center,
PLC rooms, etc.
Air-conditioning with humidity control, 100 % fresh air for special applications like MBU (Main
Burn unit), Operation theatre, Labs etc.
Comfort Air-Conditioning in Conference Halls and Auditoriums.
Package air conditioners of 5.0 TR, 7.5 TR, 10 TR for pulpit operators, conference halls, control
rooms etc. Package units are of water-cooled and air cooled condensers depending upon the
availability of cooling water.
Panel ACs are directly cooling the PLC panels of CNC lathe machines. Oil chillers for cooling
spindle oil in CNC lathe, Deep Freezer operating at -80
0
C for storing bearings.
Window / Room Air Conditioners , water coolers for personal comfort.
BRIEF DESCRIPTION OF THE SHOP
Air-conditioning system departments role is to maintain Air conditioning units inside and outside the plant :
Maintenance of different Air conditioning and refrigeration units inside the plant e.g. Air handling
units, package ACs , Fan coil units, Crane ACs, Window ACs, Split ACs, Water coolers, Panel
/ pendant ACs, Oil chillers, Deep freezers, cabin of Yard machines in RMHP, Sinter Plant etc.
Operation cum maintenance of different Central AC plants & Package AC systems outside
plant & Township e.g. Main Administrative building, VSGH, Ukkunagaram club, Steel club, Ukku
house, T&DC auditorium, Township telephone exchange , Gurujada kalashetram, Hill Top guest
house, T&DC Library, Centre for HRD etc.
As the units to be maintained are spread out through out the plant ,outside plant and township, 9
zones are created to improve the response time, logistics, accessibility etc: The Zones are:
112
S.No Equipment Range Qty
01 Central Ac Plant 30 TR - 120 TR 24
02 Air Handling Unit 10 TR - 120 TR 183
03 Fan Coil Unit 1.0 - 2.0 TR 244
04 Package Ac 5.0 -10.0 TR 260
06 Window /Split Ac 1.0 - 2.0 TR 1200
08 Water Coolers 40 L 354
09 Panel / Pendant Ac 250 -1500 W 108
10 Oil Chiller 3.0 TR 6
11 Deep Freezer - 100 OC 01
Zone Area covered
COCCP Maintaining AC units of COCCP & RMHP.
SP Maintaining AC units of Sinter Plant, BF & TPP.
SMS Maintaining AC units of SMS & ASP area.
CRMP Maintaining AC units of CRMP , Central Stores,
Energy & Telecom, Central Computer centre,
ED(W) conference hall , Pay section etc.
LMMM Maintaining AC units of LMMM & MRS area.
WRM Maintaining AC units of WRM, MMSM & Roll shop.
Workshop Repair activities of Window ACs, Water coolers,
Panel/Pendent ACs, ERS coordination etc.
Outside All central AC plants & Package AC plants
Plant operation & maintenance.
EQUIPMENT SUMMARY OF ACS DEPARTMENT ZONES OF ACS DEPARTMENT
What is Air conditioning?
Air conditioning is the precise control of temperature, humidity, and air flow and air cleanliness. Air
conditioning is defined as the process of treating air so as to control simultaneously the temperature,
humidity, cleanliness and distribution to meet the requirements of the conditioned space.
CONTRIBUTION TOWARDS ENVIRONMENT:
Lot of proactive measures are taken to ensure the reduction of Refrigerants like CFC, HCFC which
are the main cause of ozone depletion in the atmosphere.
In-line with VSP vision Be a respected corporate citizen, ensure clean and green environment
and develop vibrant communities around us., sustainability plan has been drawn to phase out
CFC Refrigerants like R-12 , R-114 , R-13 by 2010 as per the Montreal Protocol and ODS Phase
out Rules -2000 by Ministry of Environment & Forest (MoEF) to phase out CFC Refrigerants
which is the main cause of ozone depletion in the atmosphere.
The action plan approved for phase out as per sustainability plan is :
The consumption of various refrigerants like HCFC & CFC with absolute and specific consumptions
for the last few years are given below:
2006 45 - - - completed
2007 35 24 - - completed
2008 34 25 4 - completed
2009 34 25 4 1
2010 34 20 5 -
Total 182 94 13 1 58 % completed
Equipment
YEAR
Water
cooler
Panel /
Pendent AC
Crane
AC
Deep
Freezer
Remarks
113
ABSOLUTE CONSUMPTION OF HCFC REFRIGERANTS
0
500
1000
1500
2000
2500
Target (in Kgs) 2141 1762 1316 1090 1030 980
Consumption 2074 1491 1292 1083 1028 735
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Target (in Kg/TR) 0.35 0.3 0.24
Consumption (Kg/TR) 0.27 0.25 0.18
2005-06 2006-07 2007-08
SPECIFIC REFRIGERANT CONSUMPTION OF CFC
114
Chapter - 15
CAPITAL REPAIR GROUP
CAPITAL REPAIR GROUP
15.1.0 INTRODUCTION :
Capital Repair Group(CRG) was formed in the year 1998 to cater the need of Refractory and Mechanical
Maintenance and Repair of major installation in Coke Ovens and Coal Chemical Plants (CO&CCP) of
Visakhapatnam Steel Plant (VSP). CRG office is located in the CO&CCP zone in a dedicated building
opposite to Battery No.2. CRG is having two sections viz., Refractory Section and Mechanical Section.
15.2.0 REFRACTORY SECTION:
15.2.1 Refractory section is responsible for the following activities in CO&CCP:
15.2.1.1 Planning, procurement and management of Refractory and Acid Proof
materials as per the need in various installation in CO&CCP.
15.2.1.2 Hot full wall and end vertical repairs in coke oven batteries.
15.2.1.3 Cold Repair of coke oven batteries.
15.2.1.4 Regular running maintenance jobs in Coke Oven Batteries, Coke Dry Cooling Plant
(CDCP), various chutes of Coke Sorting Plant.
15.2.1.5 Capital Repair and Refractory Maintenance of CDCP chambers and its Dust Catching
Bunkers, Dust Cyclones & Boilers.
15.2.1.6 Predespatch Inspection of refractories being procured by VSP.
15.2.2 Materials being used by CRG Refractories :
15.2.2.1 Coke Oven Batteries :
VSP has got 3 numbers of 7 m tall coke oven batteries. The 4th battery is about to be
commissioned. In April, 2009 Each batteries has got zones as follows:
15.2.2.1.1 Bus flue or Sole Flue Zone : It is mainly made up of fireclay bricks & mica insulation
bricks.
15.2.2.1.2 Regenerator Area : It is made up of silica bricks with fire clay checker bricks. In the front
area fireclay bricks and insulation bricks are also used.
15.2.2.1.3 Inclined Flue Zone : This zone is mainly made up of silica bricks.
15.2.2.1.4 Vertical Flue Zone : This zone is also comprises of silica bricks
15.2.2.1.5 Roofing of vertical flue zone : This zone is also made up of silica bricks
15.2.2.1.6 Oven Roofing Zone : Just above the oven, there is a covering of silica bricks, but above
115
that layers, entire bricks work up to top layer is made up of fire clay bricks and insulation
bricks.
Each battery requires around 14000 MT of Silica bricks, 6000 MT of Fireclay bricks and
1000 MT of Insulation bricks for its construction. The 120 M high chimney is lined with
approximately 1000 MT of Fireclay bricks.
15.2.2.2 Coke Dry Cooling Plant :
CDCP consists of fireclay bricks at the Cooling Chamber and Dust Setting Bunker while,
the boiler panels are cast with insulation and fireclay castables. The dust cyclones,
discharging device, blowing devices are lined with fused cast basalt slabs.
15.2.2.3 Coke Sorting Plant :
All the chutes of CSP are lined with fused cast basalt slabs.
15.2.2.4 Coal Chemicals Plant :
15.2.2.5 Major installation in Ammonium Sulphate Plant (ASP) of CCP are lined with Acid proof
bricks and tiles including the floor areas. The pipe still furnace of Tar distillation section
and furnace of HRED section of Benzol Plant is lined with insulation and fireclay castables.
15.3.0 MECHANICAL SECTION :
15.3.1 CRG- Mechanical Section is responsible for repair and maintenance of following
equipments in Coke Oven Zone :-
15.3.1.1 Entire Coke Oven gas withdrawals system in batteries which include Stand Pipes, Goose
Neck, Valve Box, Gas Collecting Mains.
15.3.1.2 Capital repair of Gas Collecting Mains including its full replacement.
15.3.1.3 Repair and maintenance of Coke Oven Battery anchorage systems which include Flash
Plate, Buck Stays, Door Frame, Longitudinal & Transverse Tie Rods, Regulating Springs
and Brackets.
15.3.1.4 Repair and maintenance of heating system equipments like Reversing mechanism, Waste
Heat Box and its branch pipe etc.,
15.3.1.5 Regular mechanical maintenance of batteries except battery machines.
15.3.1.6 Regular repair and revamping of coke oven doors.
15.3.1.7 Apart from the above jobs CRG Mechanical Section is associated with the procurement
of mechanical items required for CRG, along with CO&CCP shop Mechanical Section.
15.4.0 Major Achievement of CRG :
15.4.1 Hot Full Wall repair was done for the first time in India.
15.4.2 Rehabilitation of all the three batteries after a crisis period from 1998 to 2000 in a short
span of time.
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15.4.3 Completion of Cold Repairs of Battery No.2 in a record time of 11 months.
15.4.4 Replacement of Gas Collecting Main in Battery No.1 on coke side in record time.
15.4.5 Capital repair of 12 cooling chambers including DCB of CDCP.
15.4.6 Capital Repair of 4 nos of saturators and 4 nos. of Acid Tanks.
15.4.7 Replacement of Gas Collecting Main in Battery No. 3 on coke side along with main liquor
supply line (partly) and pusher side valve box, Stand pipe assembly (11 Nos) in a record
time of 38 days.
15.4.8 QMS, EMS, DHSMS, 5S Implementation.
15.5.0 Major Repair done by CRG since inception :
15.5.1 Battery No.1 :
G
Repair period: January, 1999 to March, 2005.
G
End vertical repair of 52 ends
G
Full Wall repair of all the heating walls.
Repair period: March, 1999 to March, 2001.
G
Initial hold up repair with 27 heating walls hot end vertical repair till December, 1999.
G
Cold Repair of entire battery from May, 2000 to March, 2001.
G
Initial repair of anchorage system was done from November, 1998 to August, 1999.
G
Completion of hot repair of 123 end flues till June, 2008 in phases.
15.5.4 CDCP :
Capital Repair done on all 12 number of Cooling Chambers and Dust Setting Bunkers
and Dust Cyclones.
15.6.0 CONCLUSION :
CRG is dedicated to keep all the installation in proper health and in its constant endeavour
to prolong the life of Coke Oven Batteries and other units. CRG is involved in regular
inspection of all the lining condition and mechanical installation of Coke Oven Batteries
and its timely maintenance and repair.
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Chapter - 16
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Chapter - 17
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Chapter - 18
CIVIL ENGINEERING DEPARTMENT
1) HISTORY :
Civil Engineering Department was formed by taking over from construction after operation/process
started i.e.., in the year 1990. The activity of the department has fully geared up in 1991 when Blast
Furnace Godavari commissioned.
2) OBJECTIVES OF THE DEPARTMENT :
This department is a service oriented and caters the needs of all units/shops in the Plant pertaining to
civil works like
a. Maintenance and repair of industrial buildings, repair of foundations for machines etc.,
b. Road repairs and maintenance, and formation of additional roads for providing additional/ improved
facilities.
c. Up keeping of ablution of toilet blocks.
d. (I) Checking the alignment of line and level of equipments, EOT crane and other yard mobile
equipment/cranes situated in various departments for effective working of the equipment at
various locations in the shops/yards, as and when shops/customer requirement arises for repairing/
corrective measures are to be taken.
ii) Fixing of coordinators and bench marks for taking up any new roads equipment/buildings/
equipment foundations and certificating the same while and after erection/completion of the jobs
both inside and outside the Plant i.e., Township.
e. Environmental protection and beautification of the Plant by developing parks, landscapes, tree
plantation.
f. Operational requirements like attending capital civil repairs, breakdown jobs, AMR scheme jobs.
g. Cleaning of storm water drains, canteen & surface drains throughout the Plant for prevention of
inundation, water logging, etc., and keep the hygiene & environment around the shops in the
plant.
h. Repainting of equipment in the shops periodically for preventing corrosion.
i. Periodical inspection of RC buildings, underground tunnels, box drains, cooling towers for effective
functioning of the same and suggest remedial measures for up keeping the same.
j. To maintain safety standards as per norms while attending jobs at height, civil repair works as
well as underground box drain cleaning jobs for gas safety.
k. Drinking water facilities are made at Shop level for workmen apart from providing facility at
kiosk.
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l. Maintenance of diversion channel to let out affluent water/storm water.
m. Maintenance of Ash Pond to dibert the ash collected in Ash Pond, through ash slurry pipelines
connected from Thermal Power Plant.
3) Employee profile for undertaking the services for the above is as follows:
S.No Grade Nos
1) E-7 01
2) E-6 to E-0 35
3) JO/JSO 02
4) Foreman/Chargemen 09
5) Technicians 12
6) Mali 02
TOTAL 61
4) Management System and Support provided by the Company.
i) All ISO standards for ISO-9001 for QMS, ISO-14001 for Environment &OHSMS (Safety & Health)
as per ISO-18001 are formulated and being implemented.
5) Regulatory Constraints:
All activities shall be governed as per Factories Act & Labour Act for the employees.
All new buildings for development activities required to be approved by Director of Factories
before execution of the work besides clearance obtained from our Design & Engineering
Department.
All contract employees deployed on the work shall be issued gate passes after obtaining safety
induction by SED and site safety induction for the particular special work in the presence of
department representative.
For hazardous environment works identified, the contract workers who are engaged shall undergo
health check in our OHSRC.
All statutory obligations like PF, ESI etc., of the contract employees shall be looked after by the
concerned contractual agency and monitored by the Engineer-in-charge of the work.
For all minor/major materials consumed in the works, MRC clearance shall be obtained from
State Government authorities for certification of final bills.
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6) Our Key Customers & their requirements:
Our Key customers are all departments in the overall Plant like C&CCD, RMHP, TPP, SP, SMS,
BF, Rolling Mills, CRMP, Stores, Personnel Department, Traffic, FMD, EMD, EnMD, WMD, St.ED,
WCC, CISF, Marketing, Pay & Finance etc., and our function is to attend jobs related to day to
day needs of civil repairs and maintenance jobs pertaining to Area Shop Offices, Canteens,
Laboratories, Control Rooms, Area Repair Shop buildings besides all RC industrial structures,
machine foundations, foundations of the yard equipment, leakage prevention in underground
RC tunnels belonging to conveyors, cable tunnels, etc., periodical painting of equipment for
preventing corrosion and increasing the life span of the equipment, beautification of areas/parks/
gardens, environmental hygiene of the Plant with regard to maintenance of good roads, upkeep
of buildings and surroundings, canteens, ensuring water supply at various places of working and
in buildings on RCC roads, vacuum cleaners are used to arrest dust in order to improve hygienic
conditions.
7) Major Technologies & Facilities :
a. All civil works are estimated and prepare bill of quantities for the requirements projected by the
respective shops as well as works departments which require periodical maintenance of the civil
buildings & equipment painting.
b. All civil works are being carried out by deploying contractual agencies for execution of civil works
including supply of materials.
c. All works after awarding will be supervised as per specifications to suit the needs and requirements
of shops and measurements taken and quantified for making payments to the agencies.
d. Departmentally surveys are conducted for capital repairs, etc.
8) Relationship & Communication Mechanism with Key Customers :
Associating and attending all the points raised in Department Safety Committee meetings, MOU
meetings, SFC meetings for upkeep of buildings, facilities and improvements for good working
conditions, space requirements, repair of machine foundations as and when damaged, water
supply & sanitary repairs & maintenance, etc. Urgent repairs/requirements will be projected by
departments by IOMs, telephonic messages, etc. shall be attended.
9) By constructing & developing new buildings, rooms, roads, extra civil facilities like pavements,
hard standing in various places of the yards create good, safe environmental working conditions
in the entire Plant and adding welfare measures to the employees and provide effective working
conditions.
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10) Continuous Improvement :
a. Conversion of main roads into RCC roads for safe, accident free, strain less riding over roads in
3 years plan.
b. Repair & renovation of RC structures using modified polymer mortars and polymer concretes for
speedy completion without compromising with strength and without hindrance to production.
c. Using special concretes, the foundation blocks under heavy equipment and machinery are made
ready within 24 hours of casting instead of conventional concrete taking 28 days for attaining
strength and equip the foundation ready for erection/use for production use.
d. Cost reduction measures wherever possible are being adopted for road making/repairing like
using SMS slag instead of soling/metalling using BF slag for leveling the areas under concrete
pavements, etc.
e. To contain lateral movement/vibration of foundation, etc., HILTI bolts are used to make effective
use of foundation structures whenever necessary. This fixing will improve stability and life of
structure.
f. Necessary modifications are made to Weigh bridges to record actual weighment of materials,
hot metal, etc.
g. Dust catchers are constantly being used in Shop floors helping dust prevention in areas like
BHS-1 & BHS-2 of BF in order to improve environmental standards.
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Chapter - 19
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Chapter - 20
ELECTRO TECHNICAL LABORATORY
Introduction:
In view of the high degree of sophistication and automation used in VSP, a specialized group for
supporting electronics in drives and PLCs necessitated. Electro Technical Laboratory (ETL) precisely
does the above function. ETL supports electrical groups of different production shops for maintaining
100% availability of the Electronics pertaining to drives and PLCs.
There are approximately 1200 Thyristor Controlled Drives in VSP including..
- Crane Controls
- AC/DC motor controls
- Uninterruptible power supplies
- Computer Numerically Controlled Machines in different shops
There are approximately 300 programmable Controllers Controlling various drives, Process Parameters
and other related equipments of the Plant.
ETL department comprises of Field services, Central laboratory services and Planning.
Field Services:
The department caters to the needs of almost all the Production departments. The following functions
come under the scope of the department:
Predictive and preventive maintenance of thyristor controlled drives and PLCs in order to keep
the breakdown time of the systems at the minimum.
Support shop electrical groups in trouble shooting the systems in case of breakdowns.
Study and analysis of the day-to-day activities to maintain the systems trouble free.
Study and analysis of the performance of the systems by maintaining history records of the
equipment and taking corrective action/ improvisation.
Laboratories:
ETL Laboratories are located centrally in Integralid Aulomolic Devices Repairshop (IADRS) building.
The Laboratories cater to the electronic PCB repair needs.
The major sections of ETL Laboratories are:
Thyristor Controlled Drives Cards Repair Laboratory
Digital Electronic Card Repair Laboratory
General Electronic Laboratory
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The functions carried out by Laboratories are:
Repair of all electronic PCBs pertaining to drive automation.
Repair of most of the electronic PCBs pertaining to Programmable Controllers.
Maintenance of history records for all Electronic PCBs.
Study of the performance of cards, type wise and cardwise, analyzing the defects of the cards
and taking corrective actions to reduce the card failure.
Development of various testing facilities, test jigs, testing procedures, PCB drawings for easy
and quality repair of PCBs.
PLANNING :
Planning section takes care of procurement and storing of various spare PCBs, instruments like
Digital oscilloscopes, function generators, IC testers and components etc. for smooth maintenance of
the equipments.
UPGRADATION :
ETL does the assessment of the old equipment and their maintainability with respect to obsolescence/
supplier support/ spares availability and recommends for upgradation. During upgradation, ETL involves
in engineering, technical specifications, technical recommendations and commissioning of PLCs,
Thyristorised DC drives/ AC drives, UPS & Cranes.
Expansion:
ETL department is actively involved in the expansion activities of the plant.
ETL department takes active participation in preparation of specifications for various electrical &
automatic systems proposed in the expansion plan.
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Chapter - 21
128
129
130
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Chapter - 22
ENGINEERING SHOPS AND FOUNDRY
Engineering shops & Foundry is a set up to meet the requirements of Ferrous & nonferrous
spares of different departments. The Engineering shops & Foundry is divided into Central Machine
Shop (CMS), Steel Structural Shop (SSS), Forge shop (FS), Foundry (FDY), and Utility equipment
repair shop (UERS).
DESCRIPTION OF SHOP FACILITIES
CENTRAL MACHINE SHOP
INPUTS :- Iron & Steel castings, forgings, rolled sections, repair and rectification parts, non ferrous
castings.
Products and Services:- Shafts, Pinions, Gears, Crane Wheels, Rollers, Machining of various
fabrication jobs done in SSS, Repair & reconditioning of various assembly jobs like L&T Column, TK
stands, pulleys, provisioning of gear boxes.
The shop operates on two-shift basis for 300 days in a year and annual production is 5, 200t. For
preparing the raw material for machining, material saws, facing and centering machines, hacksaws,
and gas cutting facilities are provided. The machining section has over 100 major machines including
lathes, milling, boring, and planning, slotting, shaping, grinding and other machines. The assembly
section undertakes medium repair and general overhauling of mechanical equipment. Horizontal and
vertical presses, induction heaters are provided. The tool room has facilities for manufacturing of
special tools, jigs and fixtures, re-grinding of tools and cutter and brazing of tipped tools. The heat
treatment section is provided with annealing, normalizing, tempering furnaces, carbonizing furnaces,
heat treatment furnace with protective gas atmospheres, high frequency hardening machine, quenching
tanks will oil cooling arrangements, welding generator and transformers for normal welding, submerged
arc welding machines etc. Facilities for surface grinding, pipe bending and threading are also provided.
FORGE SHOP
Inputs : Ingots from foundry, blooms from SMS, billets, rods from Mills etc.
Products : Raw material for shafts, couplings, gears, pinions, flanges bull head hammers for sinter
plant hammer crusher, drill rods for blast furnace, v-hooks for SMS, straightening of pallet middle
frames of sinter plant.
The shop is designed for production of forging for shafts, coupling flanges etc. and also of
forged shapes such as crusher hammer heads, special bolts, nuts, etc. There is a facility for repair
and testing of chairs is also existing. The annual production from the shop is about 2,800 tons based
on 300 working days per year and two shifts per day. In heavy forging section, open die forgings of
long shafts, gear blanks, couplings etc. is made with the help of 2-ton bridge type pneumatic hammers.
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Each hammer will be provided with twin chamber heating furnaces. Floor type manipulator and Jib
Crane are provided for handling heavy jobs. In general forging section, 1 ton, 500 Kg, and 200 Kg
hammers with separate heating furnaces are provided. A 2-ton drop stamp hammer with a heating
furnace trimming press etc. is provided for stamping. For cutting them to size, a cold saw, a billet
shear and gas cutting facilities are provided. For stress relieving, a bogie type-annealing furnace is
provided.
STRUCTURAL SHOP
INPUTS: - Various sizes of plates, angles, channels, beams, flats, rounds for fabrication of jobs.
PRODUCTS & SERVICES: All types of fabrication jobs, repair of slag pots of SMS, Mfg. And repair of
tundishes for SMS, Mfg. Of scrap boxes for SMS, for sinter plant, hot metal ladle for SMS, 500 meters
launder for SMS, mfg. Of KAMAG body for FMD, repairing of buckets for LMMM, WRM.
The annual production of fabricated structures are about 3,600 tones The shop operates on 2 shift
basis for 300 days in a year. For marking, cutting to size, forming and bending, guillotine shear,
circular saw plate bender, gas cutting unit etc. Are provided. For welding, transformer, automatic, and
semiautomatic machines and submerged arc welding machines are provided. Painting is carried out
partly with help pf spray guns and partly by hand. Wire brush, spray guns etc. Are provided. A
maintenance section equipped with lathe, shaper, drill etc. are provided for running repair of shop
equipment.
FOUNDRY
INPUTS: Pig Iron, MS scrap, Ferro alloys, graphite electrodes, sodium silicate, silica sand CO2 gas,
moulding additives etc.
PRODUCTS:- Steel, cast iron & non ferrous castings, Emergency containers, tundish covers, bull
gear for SMS, hot metal runners, ladle paw for blast furnace, coke roll liners, sprockets, pallets for
sinter plant, raw supports, bowl for RMHP, guide troughs for WRM, face of scrap bucket for MMSM,
slag pot segments for SSS repair, ingots for forge shop, non ferrous castings like bushes (below 20 kg) etc.
Iron castings up to a weight of 5 tons will be produced. A main frequency coreless induced furnace
with two 2-ton capacity crucibles and a 5T capacity main frequency coreless induction furnace for
melting iron are provided. There is a centralized sand preparation unit. A drier and a bin is provided for
green sand. Belt conveyors transport green sand, prepared mix and burnt sand. Moulds and cores are
drier in 3 ovens lip pour ladles with capacity between 50 kg and 10 tons is provided for handling hot
metal. Two swing frame grinders and two pedestal grinders are provided for finishing of iron castings.
Total annual production is 3,200Tons.
Steel castings up to maximum piece weight of 10 T and Steel Ingots up to 1.3 tons for forging are
produced. An 8 Ton arc furnace and a two-ton medium frequency electric induction furnace is installed
for melting of steel scrap and pig iron. Each of the two sand mixers is having
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1.5-ton batch. A bogie hearth furnace for annealing/ normalizing of plain carbon steel castings and
fixed hearth furnace for heat treatment of manganese steel castings with quenching facility is provided.
The woodwork shop manufactures patterns for foundries. The principal equipment for pattern making
are saws, disc grinding, wood working lather, adequate facilities are provided for saw grinding, painting,
timber and pattern storage etc.
UTILITY EQUIPMENT REPAIR SHOP
INPUTS : sheets, plates, channels, angles, beams, billets, rounds for forge shop for manufacturing
Shafts, steel and iron castings.
PRODUCTS & SERVICES:- Manufacturing. Of impellers to various departments, repair of GCP Id
fan, repair of steam exhausters for SMS, supply of cones & ducts of various sizes, in house
manufacturing of MBC impeller for CCCD, buildup & machining of various components, reclamation
jobs like valve repairs, conveyor idlers, PCM rollers etc. Total annual production is 950 Tons.
Repair of ventilation, air conditioning and water supply equipment is carried out here. There is a
machining section having 15 major machines like lathes, milling, slotting, shaping and grinding
machines, Sheet bending machines, Guillotine shear & semi-folding machine are provided in fabrication
section. 250 kg pneumatic hammer with necessary facilities and a welding section for semi automatic,
automatic and shielded arc welding machines are provided in plumbing section. There is a separate
equipment repair section.
ELECTRICAL SECTION :
Catering to the electrical maintenance requirements of equipments of all shops
Ensuring equipment availability paying timely attention to running complaints and break down
To take up-gradation and technological improvements activities to overcome the problems of
obsolete equipments.
CENTRAL PLANNING SECTION (CPS) :
Central planning section of Engineering Shops & Foundry plays an important role in coordinating
various departments and the shops of ESF for supply of spares, castings, fabricated structures and
repair and does the following activities.
Scrutiny of annual jobs, monthly jobs projected by customer dept.
Preparation of monthly plan based on annual, monthly and MBC projection
Preparation of material procurement plan based on the annual requirement
Inspection of semi/ finished jobs of 5 sections
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Daily monitoring of jobs progress and preparation of daily production report
Preparation of monthly progress
Computerization of details of inter-shop and dispatch to departments.
Drawings control as per the ISO guidelines
Excise duty requirements of ESF
FLOW CHART OF WORK ORDER and JOB PROCESSING
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Chapter - 23
136
2A. Monitoring of ambient air quality
VSP is the first steel plant to implement automatic continuous monitors so as to asses the
ambient air quality parameters on a real-time basis to estimate the air pollution load more accurately.
Accordingly, 4 nos Continuous Ambient Air Monitoring Stations (CAAMS) are being installed at a cost
of Rs. 1.65 crore. These systems are provided to monitor continuously the accurate emission of SPM
as well as SO2, NOx, HC & CO. One station at BC gate is provided with weather monitoring facility.
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2B. Continuous monitoring of Stacks
At present there are 20 major stacks prescribed by the APPCB for monitoring the SPM. Twenty (20)
continuous on-line stack monitoring equipment are installed at a cost of Rs. 3.85 crores. These systems
are provided to monitor continuously the accurate estimation of SPM as well as SO2, NOx. This helps
in accurate estimation of the pollution load and to fine tune operational parameters to reduce emissions.
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139
140
141
142
143
144
Chapter - 24
145
146
147
Chapter - 25
148
149
150
151
152
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Chapter - 26
INFORMATION TECHNOLOGY DEPARTMENT
VSP is the first Steel Plant in India where integrated Automation and computerization is
envisaged right from the DPR stage. Almost all the production and business processes are controlled
by computer in one form or the other. These computers and the related automation systems are
meant to aid all levels of personnel involved in operation and maintenance of the plant. They provide
valuable information for the top management to take both long and short-term decisions.
Steel industry is a combination of complex and large-scale operations and processes. It also
needs fast processing of order data, its distribution to various production units, collection and
dissemination of production and technical data. Computers are being used in steel industry since
1960 for process automation and production controls.
VSP has sizable amount of computerization in built into its design in line with the latest trends
in technology. The main objective of computerization in VSP is to assist the operators in controlling
repetitive jobs, to optimize utilization of scare resources by real time process control and assist in
operation and production management.
The computerization and automation in VSP is envisaged in three levels for effective integration
between planning and processes. The highest level assists management decision- making by collection,
analysis and providing the production and management information on a real time basis and the
lowest level assists the actual process operators by reducing their tedium in the form of automation.
Thus the structure is designed for assisting all levels of operation and management of the plant.
BUSINESS APPLICATION SYSTEMS :
This is for top level of the hierarchy and is consisting of a Central Computer. All the large on-
line business applications covering different business functions of the plant are implemented in this
computer. This generates all the information/reports for the management control. It also stores and
provides long-range plant operating, maintenance, commercial and finance data. Based on the long-
range information this computer plans the production scheduling for the shops. It generates data
regarding the products to be produced, maintenance plans and dispatch plans. These production and
maintenance plans are transmitted to the concerned process control computers/personnel.
Subsequently the actual plant operational, maintenance data are collected.
Some of the important business applications running in VSP are listed below:
1. Payroll System
2. Costing System
3. Financial Accounting System
4. Marketing System
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5. Attendance Recording System
6. Library Information System
7. Materials Management System
8. Maintenance Management System
9. Production Planning and Control System
10. Wagon Information Tracking System
11. On-line TC printing System
12. Human Resource Information System
13. Raw Material Management System
14. Coke Ovens Heating and Regulating system
PROCESS CONTROL SYSTEMS :
The main jobs of the process control computers are memorizing production schedules given by zonal
computers, monitoring the shop production and the material flow in the shops and storing and execution
of process control parameters and algorithms to control the process. They also control the lower level
automation systems. The most important aspect of these computers is the man machine dialogue
envisages. Such computer systems are envisaged in the Blast Furnaces, Steel Melt Shop, Continuous
Casting Machines & Rolling Mills. Apart from these computers, there is a 'Supervisory Control And
Data Acquisition (SCADA)' computer to monitor and control Gas, Power, Water and their distribution
in the plant.
Some of the important process control computers in VSP are listed below :
1. Blast Furnace
a. Display of Mimics
b. Display of on-line trends of furnace parameters
c. Display of historical trends of furnace parameters
d. Paulwurth Report generation
e. Shift Report Generation
f. Daily Report Generation
2. Converter Shop
a. Production scheduling and control
b. Process calculation including dynamic control
c. Logging and reports
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3. Continuous Casting Shop
a. Display of on-line casting machines parameters
b. Display of LD Converter blowing details
c. Display of Mixer hot metal analysis
d. Display of Argon Rinsing station steel analysis data
e. Breakout report generation for casting machines
4. Wire Rod Mill & MMSM
a. Mill control
b. Roll shop management
c. Material Tracking
d. Mill fault monitoring system
e. Logging and reports
5. SCADA
a. Monitoring of plant utilities like Steam, Oxygen, Argon, Compressed air
and Chilled water etc.
b. Power supply from AP Transmission Corporation and VSP's TPP.
c. Coke oven and BF gas parameters monitoring
FIELD LEVEL AUTOMATION SYSTEMS :
This level consists of local automation systems. These systems do logic, sequence, loop control and
indication of process parameters to operation personnel in the plant for taking up timely corrective
actions to achieve the quality production. This level consists of Programmable Logic Control (PLC)
Systems, analog (split architecture type) and microprocessor based instrumentation systems.
The above concept of hierarchical and integrated computer systems in line with the latest technology
is introduced in VSP for the first time in India. This system is contributing a lot in achieving the quality
and productivity of steel with an integrated control of production and processes. Thus VSP is a
trendsetter in computerization in basic industries in India with latest systems and opening new vistas
in computerization in our country.
INTRANET WEB SITE
An intranet web site is also maintained by VSP IT Department and many facilities are hosted in this
site for the convenience of the different sections of the plant and for the benefit of the employees. The
content in this site is updated regularly. Some of the important features/modules hosted in this site are
listed below.
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1. Applications
a. Employee Profile
b. Telephone Directory
c. Library On-line Information
d. Daily Production Report
e. Marketing MIS
2. Departmental Pages
a. Presentations of different business applications developed by IT Department.
b. 'Ukku Vani', a monthly news letter of VSP by Corporate Communications department
c. Presentations of the developmental programs conducted by the HRD department
d. The frequently used application forms used by the employees are posted by Finance
& Accounts department
e. Highlights and MIS reports of many other production and service departments.
3. UTILITIES
a. Circulars
b. Chat
c. Forum
d. Polls
e. Downloads
f. News
4. Data Up loaders :
Data up loaders have been provided for all the stockyards, branches, regional offices and
headquarters to transmit various formatted and non-formatted data and information between
themselves over the VSP's Virtual Private Network.
NETWORK
VSP is having a Gigabit Ethernet Data Communication Network, working on Optical Fiber Cable
(OFC) network. This supports data transfer at the rate of 1000 Mbps on all the main links. The campus
network is divided into eleven zones. These zones are inter-linked to the central core switch using
Single mode type optical fibers. The Central core switch is located at Central Computer Centre.
The 11 Zonal switches are located at Coke Ovens, Sinter Plant, SMS, Central stores, BC Gate,
LMMM, MMSM, Central computer centre, Admin building, Township and General Hospital. Further, a
total of 200 access switches are connected to the network through the 11 zonal switches, using
Multimode/ single mode types fiber optical cable,. The access switches provide connectivity to
approximately 3000 nodes throughout the plant premises, Administration building area and township.
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Chapter - 27
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Chapter - 28
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Chapter - 29
160
Chapter - 30
161
162
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Chapter - 31
QUALITY ASSURANCE AND TECHNOLOGY DEVELOPMENT
QATD stands for Quality Assurance and Technology Development.
QUALITY ASSURANCE
Planned and systematic actions necessary to provide adequate confidence that a product or
service will satisfy given quality requirements.
QUALITY
Quality can be defined in many ways
a) The totality of features and characteristics of a product or service that bear on its ability to
satisfy stated or implied need or fitness of the product or services for the use.
b) Quality is also defined as inversely proportional to the variability.
In other words the quality of product is assured by initiating the control activity right from input
and continued through out the process till product is dispatched to the customer for use. To Assure the
quality the technology has to be continuously modified or improved depending upon the demands
from time to time. This is where the technology development comes into picture. Development is the
continual improvement incidental to the challenges faced to ensure the quality either in input or in the
process or in the inspection of the products.
Quality assurance starts right from checking the quality of raw materials for the compliance to
the purchase specification and quality of in process materials to adherence of set norms and finally
the checking of the products for meeting the specification or customer requirements.
Quality Assurance at VSP consists of Quality control, Process control, Inspection and Testing.
Quality control deals with testing of raw materials, in-process materials and finished / semi-
finished products.
Process control monitors the salient process parameters adherence of the set norms at various
stages.
Inspection and Testing ensures the quality of the products dispatched to the customers.
Quality Assurance is one of the vital functions of any successful organization in the present
day competitive industrial world. The role of QA&TD department in Visakhapatnam Steel Plant is in
line with the above.
164
QUALITY ASSURANCE AND TECHNOLOGY DEVELOPMENT
SECTIONS OF QA & TD DEPARTMENT
1. CO & CCP LAB
! Central Laboratory
! Tar Distillation Plant Laboratory
! MBC Laboratory
! Sample Preparation Station - 1
2. IRON LAB
! Iron Laboratory
! Raw Material Bins Laboratory
3. POWER PLANT LAB
! Thermal Power Plant Laboratory
! Chilled Water Treatment Plant Laboratory
4. STEEL LAB
! Steel Laboratory
5. ROLLING MILLS LAB
! Bloom Inspection
! Billet Inspection
! Light and Medium Merchant Mill Express Laboratory
! Wire Rod Mill Express Laboratory
! Medium Merchant and Structural Mill Inspection
! Spark Testing
6. CENTRAL LAB
! Mechanical Testing (for MMSM Products)
! Refractory Testing
! Metallography
! Non Destructive Testing
! Oil & Water Testing
! Wet Analysis
! Instrumental Analysis
! Environmental Lab
165
IMPORTANT EQUIPMENT & INSTRUMENTS AT QA & TD
CO & CCP LAB
! UV Spectrophotometer
! Coal/ Coke Analyzer
! Gas/ Liquid Chromatography
! CHNS analyzer
! CRI/ CSR equipment
! Plastometer
IRON LAB
! Optical Emission Spectrophotometer
! X-RAY Florescence Spectrophotometer
! RI/ RDI Apparatus
POWER PLANT LAB
! Spectrophotometer
! Flame Photometer
! Turbidity meter
! Conductivity meter
! PH meter
STEEL LAB
! X-Ray Florescence Spectrophotometer
! NO Analyzer
! NOH Analyzer
! C & S Analyzer
ROLLING MILLS LAB
! Universal Testing Machine 20T, 40T, 60T
! Upset Testing Machine
! Hardness Tester
CENTRAL LAB
! X-Ray Florescence Spectrophotometer
! Ultrasonic thickness guage
! Ultrasonic flaw detector
! Magnetic particle tester
! Radiation survey meter
! Metallurgical microscope
166
! Quantitative metallograph
! Vitrinite Reflectance measurement
! UV Spectrophotometer
! Atomic Absorption Spectrophotometer
! Oil Testing equipment
! Flame Photometry
! Total Organic carbon analyzer
! Universal Testing Machine 1000kN, 500kN, 50T, 20T
! Compression Testing Machine 50T
! Rockwell B Hardness Tester
! Rockwell C Hardness Tester
! Brinell Hardness Tester
! Ash Fusion Point tester
! High temperature furnace for Refractory tests
In addition to the above, all the labs are well equipped with sample preparation machines, weighing
balances, furnaces and ovens.
ACTIVITIES
1) Testing
2) Process Control
3) Inspection
4) Certification
5) Handling of Customer Complaints
6) Product Development
7) Pollution control analytical activity
8) Metallurgical failure analysis
Testing :
! Incoming raw materials (Coal, Iron Ore, Limestone, Dolomite,
Sand, Quartzite, Manganese ore and Ferro alloys)
! Coke
! Sinter
! Hot metal
! Slag ( BF & SMS)
! Liquid Steel
! Semi-finished Steel Products
! Finished Steel Products
! By-products of Coke Ovens
! Gases, Water, oils and lubricants
167
! Refractories
! Effluents
Process Control :
G Monitoring of charge coal blend composition on Coke Oven battery parameters
G Charge calculation and monitoring of operating parameters at Sinter Plant and Blast
Furnaces.
G Monitoring of blowing parameters and additions at converter shop, trimming of chemical
composition at argon rinsing station and casting parameters at continuous casting
machines
G Monitoring of heating regime of reheating furnaces and cooling parameters at rolling
mills.
Inspection :
G 100% visual inspection of semis like blooms and billets
G Inspection at intermediate stages of production of steel
G On-line inspection and audit checks of finished product like rebars, wire rods, angles,
channels, flats, beams etc.
G 100% spark testing of all value added products for segregation of mix-ups
Certification :
G Byproducts
Crude tar
PCM
Phenol fraction
Anthracene oil
Pitch, wash oil, naphthalene
Toluene, LSN, HBF
G Pig iron
G Granulated slag
G Semi products
G Finished products
Calibration :
In house calibration of Vernier calipers and Screw gauge is carried out.
Other Activities:
Application engineering: Through marketing department QA&TD department interfaces with the ultimate
users of the plant products and extends technical support.
Technology dissemination: QA&TD department interacts and mediates between various internal
customers/ internal suppliers for the overall improvement.
Publication of Technical Journal: QA&TD brings out "VIZAG QUEST" a technical journal every year
comprising articles reflecting the issues of Quality & Technology linkage of inputs, production,
modifications, maintenance practices.
168
Chapter - 32
RAW MATERIALS DEPARTMENT
Raw materials dept. deals with all the bulk materials received through the RMHP. It is responsible
for the following broad functions.
Indenting.
Monitoring of the receipts as per requirement.
Accounting of the receipts.
Monitoring payment of Railway freight for the receipts.
Lodging claims for non receipt of material and follow up.
The following materials are dealt by RMD.
Coals (Coking coals & boiler coal)
Iron Ore (Fines, lumps, sized, Pellets)
Limestone & Dolomite (BF & SMS grade)
Sand & Quartzite (fines & lumps)
Manganese ore (lumps & fines)
All the raw materials are received in loose condition in open wagons (in case of receipts by rail) and
trucks (in case of receipts by road). The wagons are unloaded by the tipplers and the materials are
carried to the earmarked beds of RMHP by conveyors. The trucks are unloaded at the ground hopper
bunkers of RMHP.
The following are the sources, requirement (as per DPR at 3.0 million ton stage) and suppliers of the
various materials.
Material Source Dist. (in km) Quantity ('000 T) Supplier Mode
Iron ore fines Bacheli/Kirandul (Chattisgarh) 562 3250 NMDC Rail
Iron ore lumps -do- -do- 1753 -do- Rail
Iron ore sized -do- -do- Not envisaged -do- Rail
Prime Coking Coal Bhojudih/Munidih/ 950 1411 BCCL Rail
Sudamdih/Dugda (Jharkhand)
Medium Coking Coal Swang/Kedla/Kathara/ 980 1815 CCL Rail
Rajrappa (Jharkhand)
Imported Hard Coking Coal Australia/USA (Thro' 28 807 Imports Rail
VPT &Gangavaram Port) (Inland)
Imported Soft Coking Coal Australia 28 (Inland) Not envisaged Imports Rail
Boiler Coal Talcher(Orissa) 580 1764 MCL Rail
Imported Boiler Coal Indonesia 28(Inland) Not envisaged Imports Rail
BF Limestone Jaggayyapeta(A.P) 455 363 Captive Rail
BF Dolomite Madharam (A.P) 510 605 Captive Rail
SMS Limestone UAE/Thailand/Oman 28 (Inland) 754 Imports Rail
SMS Dolomite Madharam (A.P) 510 213 Captive Rail
Manganese ore Garbham( A.P) 100 187 Captive Road
Sand/Qtz. fines Local - 78 Captive/Local Road
Qtz. lumps Local - Not envisaged Local Road
169
Material Moist% Ash% VM% Sulphur% MMR Size in mm
Hard 8.0 8.0-10.0 22-28 0.6 1.15-1.25 0-50
Soft 8.0 8.0-10.0 28-32 0.6 0.8-1.0 0-50
Material Moist% Ash% VM% Sulphur% CSN Size in mm
PCC 5.0-8.0 21.0 23.0 0.4 6 0-50
MCC 5.0-8.0 21.0 26.0 0.4 2-3 0-50
Material Moist% Ash% UHV(kcal/kg) Size in mm
Indigenous 12.0 38-40 2400-3360(F grade) -250
Imported 16.0 8.0-10.0 6000 0-50
The prime coking coal quantity as envisaged in the DPR is not available due to various reasons.
Hence the same is substituted by imported hard/soft coking coals. Hence the present requirement of
these two materials together is about 3.0 million tons. The materials from imported sources are received
by ships which are unloaded in either Visakhapatnam Port or Gangavaram Port and are stacked in the
designated plots at the port for subsequent transportation to plant by wagons. In case of Gangavaram
port which is being developed adjacent to the plant, the material will be transported to the plant
through conveyors on completion of the project. Most of the imported materials are envisaged to be
handled through Gangavaram Port in future.
The materials not envisaged in the DPR also have been procured due cost effectiveness, technical
advantage or necessity. Materials from new sources are procured in case of shortage from regular
sources to ensure continuous availability of raw materials to the plant. Similarly, BF coke is procured
from China to cover any gap between the production at Coke ovens and the demand in BF.
Continuous monitoring of the receipts is required due to the huge quantity of raw materials procured
and limited resources available for unloading and stacking. This is essential to ensure that the wagons
are not unduly held up (resulting in demurrage payable to Railways) and materials are stacked separately
without mix up.
Due to the huge movement of wagons over the Indian Railways, sometimes the rakes/wagons destined
for VSP get delivered at other destinations. Claims are lodged with Railways for the consignments not
received. RMD also scrutinizes the freight paid for different raw materials. In case freight is not charged
as per the railway circulars, claim is lodged with railways. Follow up with railways for settlement of the
claims is done by RMD.
QUALITY OF RAW MATERIALS : The quality of the various raw materials are given below.
Imported Coking Coals :
Indigenous Coking Coals :
Boiler Coal :
170
Iron Ore:

Material Fe% Al
2
O
3
% SiO
2
% Size in mm
Fines 64.5 3.0 3.0 -10
Lumps 65.5 2.25 2.25 10-150
Sized 65 2.0 2.0 10-40

Limestone & Dolomite:

Manganese Ore:

Sand & Quartzite:

Material SiO
2
% Al
2
O
3
% Size in mm
Qtz. Lumps 98 2.3 10-60
Qtz. fines 96 2.3 -3
Sand 85 6.0 -3

Material CaO% MgO% SiO
2
% Size in mm
BF Limestone 44-45 1.0-2.0 9.0-11.0 6-40
SMS Limestone 54.5 1.5 0.5-0.6 30-60
BF Dolomite 29-30 19-20 3.0-4.5 6-80
SMS Dolomite 30-31 20-21 0.9-1.0 25-50
Material Mn% Fe% SiO
2
% Al
2
O
3
% Size in mm
Lumps 28.0 16.0 14.0 7.5 10-60
Fines 28.0 16.0 14.0 7.5 -10
The expenditure on account of the above raw materials constitutes about 60% of the total
expenditure of the company.
171
Chapter-33
REFRACTORY ENGINEERING DEPARTMENT
Steel making process comprises of multiple stages where Iron or Steel is either in molten stages or in
very hot condition .These stages are usually handled by several furnaces, kilns and transportation or
storage vessels. The furnaces, kilns and vessels are basically made of steel or other metal and alloy
structure. In the process of steel making there is every possibility that the structure may get damaged.
Thus any such type of furnaces, kilns and vessels used in steel making process needs to be protected
from pyro-metallurgic reactions. As such, all the vessels are protected with some "refractory" lining
which endures the high temperature and subsequent chemical reactions to facilitate smooth operation
of steel making.
Refractory Engineering Department (RED) in Visakhapatnam Steel Plant meets the need of refractory
lining maintenance and refractory management of all the equipments engaged in the process of steel
making. Following are basic objectives of RED.
1) Planning, procurement and management of Refractory material as per production plan and
operational requirement.
2) Maximizing the availability of equipments by increasing the life of refractory lining for the
equipments required for steel making
3) Doing refractory maintenance in time and bringing down the refractory maintenance period
4) Bringing down the specific refractory consumption per ton of liquid steel
5) Optimization of refractory performance with cost and quality to get maximum benefit either in
terms of productivity or techno-economics
RED is mainly divided into following zones/sections which are scattered throughout the plant. The
central section is located at CRMP Area Shop Office Building.
a) Planning cell
b) Blast Furnace, Sinter Plant & Thermal Power Plant
c) Steel Melt Shop
d) Rolling Mills, Calcining & Refractory Materials Plant & Engg. Shops &Foundry
PLANNING CELL :
This section is located at CRMP ASO building, engaged in job of refractory item procurement (As per
standard specifications, drawings and repair plan), Material and equipment performance monitoring,
material planning for normal and capital repairs etc., RED procures around 37-40,000 tons of refractories
on an average in a year for catering the requirements of different zones starting from Sinter Plant to
Rolling Mills.
172
BLAST FURNACE, SINTER PLANT & TPP :
This office is located near Blast Furnace ASO. Following maintenance activities are generally performed
in Blast Furnace zone.
i) Blast Furnace - Cat-I & Cat-II repairs are done for both BF-1 & 2
ii) BF Stoves - capital repairs are done. First Cat. I capital repair of BF-1 stove No.4 was completed
in 2005.
iii) Tuyeres - Refractory casting done on regular basis
iv) Open Top Ladles, Torpedo Ladles, Cast house maintenance and Pig casting machine runners'
maintenance - done on regular basis.
v) Sinter Machine furnace - Capital repairs are normally carried out.
vi) TPP boilers - casting and patching done for bottom ash hoppers on regular basis
vii) GETS- Refractory relining of pre-heaters.
STEEL MELT SHOP :
This office is located near Ladle Preparation Bay (LP BAY) area. Lining of Steel making LD Converters,
Steel teeming ladle, Tundish , Mixer Hot Metal Ladles, Emergency containers, Hot Metal Mixers and
Snorkel preparation in IRUT section are being done on regular basis by this zone.
Rolling Mills, CRMP& ES&F :
These offices are located near WRM area (for Rolling Mills zone), Foundry area (for ES&F zone) and
in Calcining Plant area (for CRMP Zone). Capital and regular repair in furnaces of LMMM, MMSM &
WRM, maintenance of Lime Flux Kilns at CRMP, Electric Arc Furnace and Induction/Reheating furnaces
at Foundry is being met through this wing of RED. The approximate quantity of refractories consumed
for the regular repair by these zones for the year 2007-08 is 442Tons (Rolling Mills), 90Tons (ES&F) &
296Tons (CRMP). Capital repairs are carried out for Rolling Mill Furnaces on annual basis.
The furnaces/Kilns/Vessels (equipments) maintained by RED in different production units are given
below. All these equipments are maintained either on running/regular repair basis or capital repairs
(once/twice in a year) basis.
Equipment Function Type/quality of refractories used

1. Blast Furnace:

a) 2 nos. Of Blast
Furnaces
Iron Ore to Iron making Mullite, Carbon block, High Alumina,
Fire-clay & Graphite Blocks
b) 2x4Nos. Of Hot Blast
Stoves
Heating of air for iron
making
Fire-clay, Silica, Mullite Corundum,
Fire-clay insulation, Ceramic paper,
Blanket & Alumina Castable
c) 7 Nos. Of Torpedo Ladle
Cars
Transportation of liquid
iron
High Alumina, High grog, Alumina
Carbon Fire-clay insulation & Alumina
Castable
d) 30 Nos. Of Open Top
Ladles
iron
Fire-clay, High Alumina & Alumina
Castable

173
1. Sinter Plant:
2 Nos. of Sinter Machine
Furnace
Sintering of metallurgical
wastes mixed with other
additives
High alumina, Fire-clay, Fire-clay
Insulation, Alumina Castable &
Ceramic paper
2. Thermal Power Plant:
5 Nos. of Boilers Power generation Alumina Castable
2 Nos. of GETS Power generation Alumina Castable, Fireclay Insulation,
Ceramic Paper & High Alumina bricks
3. Steel Melt Shop(SMS):
3 Nos. of LD Converter Making Steel from liquid
hot metal
Magnesia Carbon, Magnesite, &
Alumina Castable
26 Nos. of Steel Teeming
Ladles
steel
Magnesia Carbon, High Alumina,
Alumina Castable & Ceramic paper
50 Nos. of Bloom Tundish Intermediate Storage
before steel casting
Basic spraying mass, High alumina
shapes, Alumina Castable & Ceramic
Paper
2 Nos. of Hot Metal Mixer Intermediate Storage of
Hot Metal
Magnesite, High Alumina, Fire-clay,
Mica Insulation & Ceramic paper
5 Nos. of Hot Metal Mixer
Ladles
Transportation of Hot
Metal from Mixer to
Converter
Fire-clay, High alumina, High grog &
Alumina Castable
40 Nos. of Emergency
Containers
Storage for ladle slag and
excess steel
Fire-clay(MHD quality)
4. Light & Medium Merchant Mill (LMMM
2 Nos. of Walking Beam
Furnaces

Heating of Blooms for
rolling
Precast-prefired, high Alumina,Fire-
clay, Alumina castable & Ceramic
paper
1 No. of Roller Hearth Furnace Heating of Billet for rolling Precast-prefired, high Alumina,Fire-
paper
5. Medium Merchant & Structural Mill (MMSM):
1 No. of Walking Beam
Furnace
Heating of Blooms for
rolling
paper
6. Wire Rod Mill (WRM)
1 No. of Mixed Walking Beam
Furnace(MWBF)
Heating of Billets for
rolling
clay, Alumina castable, Electro-cast
blocks & Ceramic paper
7. Engineering Shops & Foundry (ES&F)
1 No. of Electric Arc
furnace(EAF)
Melting & Production of
Special steel
Magnesite, Mag-Chrome bricks,
Magnesite ramming mass & High
Alumina bricks
10 nos. of ladles (different
capacity)
Transportation of Hot
Metal (Iron/liquid steel)
Fire-clay
2 Nos. of Re-heating furnaces

Heating of steel shapes Ceramic Blanket, High Alumina bricks
&Castable .
4 Nos. of Induction Furnaces
(2 x5MT, 1x1MT, 1x0.5mT)
Melting of Pig/Cast Iron
and non-ferrous items
Silica ramming mass

174
ZDWZDW
EK>&< , &
Kd< d

&
Relentless efforts of RED and the related production units have made it possible to increase the life
expectancy of refractory lining considerably in some major areas. Some of the figures are illustrated
below:
^
E
W h
z

A Lu C SMS ,
A S L SMS ,
A 1 SMS ,
S 8 C SMS <d>^
S 8 C vS <d>^
Since the process of improvement is continuous, the techno-economic practices of refractory

management and adoption of newer technologies will guide the future maintenance of pyro-metallurgical
equipments more efficiently than ever.
175
Chapter - 34
176
177
Chapter - 35
178
Chapter - 36
SPARES MANAGEMENT DEPARTMENT
Introduction
For efficient and trouble free operation of Plant and to be recognized through out the world as a hall
mark for "Continuously growing world class company" , Spares Management Department (SMD) is
running towards dynamic approach of Vision and Mission of VSP. Also, as the world tends very inclined
to '6 sigma' and Statistical Process Control, the approach of SMD is for ensuring availability of Spares/
Materials (i.e., Mechanical, Electrical and Operational consumable, etc.,) within the budget norm to
carry out planned maintenance, replacement of wearing parts at regular intervals in right time of right
quality and right quantity and ensures optimum availability of the equipment. Recently 'Spare Part Cell
(SPC)' is renamed as 'Spares Management Department (SMD)'.
Role of SMD
SMD consists to wings that is SMD-Mechanical and SMD-Electrical. SMD is acting as a nodal agency
between Works department and Non-works department and catering the needs of all its Customer
departments in the plant by procuring SMD (Rationalized Spare Parts-RSP) items, monitoring of issues
& consumption, controlling of indenting & consumption budget, controlling inventory, making MIS
reports, performing pre-dispatch inspection following 'Excise ' formalities and also processing of shop-
floor MPR's and TR's.
What is a Spare part?
Is a part of sub-assembly for substitution that is ready to be replaced if it becomes faulty or worn-out.
The life of spare is less than that of the machine.
Types of Spare Parts:
1. Maintenance Spares: Regular replacement due to wear out. Replaced after a specific period
of service. They can be sub-divided into Fast-Moving, Slow-Moving and Non-Moving.
2. Insurance Spares: Costly in terms of Production. Normally not required for routine maintenance
but needed in case of unforeseen breakdown.
3. Rotable Spares : Rotable Spares are spares that can be repaired and taken back to stock
179
Quantity determination tools / Inventory Categorization: for procuring materials
a) ABC Analysis
ABC stands for 'Always Better Control'
A- Class items : 10% of items constitution 80% of Value
B- Class items : 20% of items constitution 15% of Value
C- Class items : 70% of items constitution 5% of Value
Strict control of procurement with procurement on EOQ(Economic Order Quantity) basis is preferred
for 'A' & 'B' class items. For 'C' items loose control with Safety stock is preferable.
b) FSN Analysis :
F- Fast Moving Items: Items which had at least one issue per year in the past 3-years.
S- Slow Moving Items: Other than insurance items which do not fall under the category of
non-moving or fast moving, which are not consumed regularly.
N- Non-Moving Items: The items which have not been issued even once during the last
5-years.
c) VED Analysis:
The VED analysis is based on the criticality of the item. The items are arranged in descending
order.
V- Vital : Those items which when required and not available, they make the whole system
inoperative. Eg: Clutch wire
E- Essential : Those items which when damaged, and not available, reduce the efficiency of
the system. Eg : Telephone.
D- Desirable : Items are such that even if they are not available, they neither stop the system
nor reduce its efficiency, but will be good if they are present in the system. Eg: Remote the
accounting unit of the item is very important. Preferably requirement should be indicated in
multiples of units, like Kgs/ Nos./ Pairs/Tonnes etc., through EOQ (Economic Order Quantity).
Activities of SMD :
1) Processing of MPR's to indent (Rationalized Spare Parts-RSP items)
180
2) Processing Of MPR to Indent
3) Processing of Technical Recommendations (TRs)
4) Feeding of Indenting and Consumption budgets into computer
5) Processing of Quality Complaints, Trial orders and Sample approvals
6) Issue of SMD items in a controlled way
7) Pre-Dispatch inspection process
8) Inventory Analysis and Monitoring
9) Central Excise Challan Issue
Detailed activities of SMD :
1. Processing of MPR's to indent (Rationalized Spare Parts-RSP items) : Items which are common
for two or three departments called, Rationalized Spare Parts (RSP) are procured by SMD.
Every item is assigned a 13-digit catalog number, which is unique in nature. Depending upon
the projection of various departments and consumption, SMD reviews the stock and
requirements periodically and raises 'Material Procurement Requests' (MPR's) in time. SMD
items and master specifications are made by SMD. MPR's generated are approved by the
competent authority and then converted to indent through online. Any additional budget required
for procurement is approved by concerned competent authority.
AMS (Automatic MPR's System) system involves taking projections (with justification) through
on-line within due date, from different departments, approving, finalizing the quantities and
raising the MPR according to the approved total quantities on-line.
The items under RSP procurement includes Switch gear items of SIEMENS, L&T, GE, CGL
Makes, Light fittings, Cleaning agents. Electric cables, Bearings, Conveyor Belts, Conveyor
idlers, Electrodes, Couplings, Valves, Brake Liners, Submersible Pumps, Fasteners, Tools
and Pipes etc.
2. Processing Of MPR to Indent : MPRs from various departments for Mechanical, Electrical
and Operational items are processed through 'On-line' centrally by SMD and they are converted
to indents for procurement. MPR's received from various departments are put up to MBC
(Make or Buy Committee) and SMC (Slow Moving Committee). MBC decides whether the item
can be manufactured in-house. As per decision, work order will be sent to ES&F by SMD.
181
3. Processing of Technical Recommendations (TR's): Purchase department obtaining offers
from different parties will compile, make comparative statements and send to SMD for technical
recommendations. The TR's are scrutinized for conformity to technical specification (technically
accepted-TA/technically not accepted-TNA) and send back to purchase department through
competent authority for approval.
4. Feeding of Indenting and Consumption Budget into Computer: SMD feeds indenting and
consumption budgets once a year department-wise as per the respective responsibility codes
into central computer and the figures are automatically adjusted as per consumption. The
values are fed as approved by Competent Authority.
5. Processing of Quality Complaints, Trial Orders and Sample approvals : Quality Complaints
against defective supplies are lodged by individual shops through On-line and forwarded to
SMD, and the same are sent to purchase department after clearance by SMD centrally through
On-line. Purchase department. will take up with Suppliers for replacement or repair .After the
quality complaint is cleared by suppliers, the same will be closed through SMD.
6. Issue of SMD Items in a controlled way : Items procured centrally by SMD are issued to
individual departments in a controlled way by SI (Stores Issue) Note Issue System through
online after studying projections, previous consumptions, and stock availability.
7. Pre-Dispatch inspection process : Inspection call, supplier's internal inspection reports and
material test certificate are sent to SMD by purchase department to check the completeness
of internal inspection reports. SMD coordinates with the inspection engineers in organizing
Pre-Dispatch Inspection.
8. Inventory Analysis and Monitoring : Inventory refers to all the idle physical stock of goods
which have economic value. Periodic statement of non-moving and slow-moving items are
made and intimated to the respective departments (which are responsible for the stocks
available) to draw these items from stores as per their site requirements. The levels of
Consumption and Inventory of different shops are discussed during review meetings held by
Maintenance head and Works head.
9. Central Excise Challan Issue : SMD is playing a vital role in fulfilling excise formalities i.e.
issuing excise challan for job works carried outside VSP for repairs, refining, reconditioning or
carrying out operation necessary for the manufacturing of the final product under excise challan
rule viz,4(5)a and 214/86.
182
Chapter - 37
183
184
Chapter - 38
TELECOMMUNICATION DEPARTMENT
In this modern age of industrialization and automation, extensive use of information,
communications and computer technologies is being made in every walk of our lives. In line with these
trends Telecommunication department plays a very vital role in coordinating the activities of various
departments in achieving the assigned targets and accomplishing the desired performance in any
organization. In Visakhapatnam Steel Plant, very wide range of communication systems are provided
for meeting the day to day internal and external communication needs. These are broadly classified
as follow:
i) General purpose communication systems.
ii) Process communication systems.
iii) Monitoring & Signaling Systems.
I) GENERAL PURPOSE COMMUNICATION SYSTEMS :
The following facilities are provided under category of communication and signaling systems:
3000 Lines Electronic Exchange in Plant.
3000 Lines Electronic Exchange in Township.
64 Lines Electronic exchange in Hill Top Guest House.
4000 Lines Electronic Exchange of Bharat Sanchar Nigam Limited (BSNL) in Project Office catering
to the needs of Plant area and Sectors-I to VII in township.
3000 Lines Electronic Exchange of BSNL in Township catering to the needs of Sectors-VIII to XI in
Township.
The 3000 Lines electronic exchange in plant and 3000 lines exchange in township are having
the following facilities:
Extension to extension call, Auto call back, Hot lines, Music on hold, Reminder Alarm,
Subscriber line testing facility, Faults man ring back, Call consult facility, Malicious call tracing facility,
3 party conference Facility and Howler Tone alert etc.
All exchanges of the steel plant are interconnected by means of junction lines and has four
digit closed numbering scheme. For communicating with any subscriber of any exchange no extra
digits have to be dialed and only the desired number is to be dialed.
The 3000 lines exchange in township is interconnected to the BSNL network due to which
all the subscribers of this exchange can receive incoming calls from any part of the world.
185
II) PROCESS COMMUNICATION SYSTEMS :
To facilitate coordinated operation and management of various production shops,
maintenance & service departments, the following process communication facilities are provided:
Shop floor Inter-communication system
Loudspeaker intercom systems
Loudspeaker broadcasting systems
Loudspeaker conference communication systems
Hotline communication systems
VHF communication systems
Mobile Communications facilities
a) Shop floor Inter-Communication Systems :
Shop floor Inter-communication systems are provided in Raw Materials Handling Plant,
Coke & Coal Chemicals Department, Sinter Plant, Blast Furnace, Steel Melt Shop, all Rolling Mills,
Power Distribution, Energy Management Department, Water Management Department, Production
Planning & Monitoring, Calcining & Refractory Materials Plant, Thermal Power Plant and Traffic
Department.
These are small electronic exchanges of 128 port capacity meant for catering to the intra-
shop process communication needs. This exchange numbers can be programmed as normal extension
or one way hot line extension or independent point to point hot line. This is used in the shop floor for
quicker communication. Plant Control Despatcher communication is provided for collecting reports
and monitoring the over all process of the plant. Every day Teleconference is being conducted by
ED(Works) with all Heads of Department (HODs) in the morning with the help of the digital EXCOM
system provided in the plant control.
b) Loudspeaker intercom systems :
Loudspeaker intercom systems are provided in LMMM, WRM & TPP to facilitate
intercommunication between various sections of individual plant units on selective basis. The systems
are quite useful in establishing communication in noisy environment in industries. Since the
communication is carried out by means of microphones and loudspeakers provided in the subscriber
stations, this system is very useful in noisy environment where conventional telephones prove to be
ineffective. With this system it is possible to establish communication between any two stations
having interconnectivity (programmable) on selective basis. By using group call facility it is possible to
communicate to more than one location in a group simultaneously.
c) Loudspeaker broadcasting systems :
Loudspeaker Broad casting systems are provided in C&CCD, BF, SP and SMS departments
for locating operation/maintenance personnel working on the shop floor as well as passing on important
process instructions to all locations in the shop area from the concerned control rooms. The system
consists of centralized amplifier rack with amplifiers, Desk top gooseneck microphone with press to
talk switch, zone selector and a network of loudspeakers connected to the amplifiers. These systems
are very useful for searching the individuals on the shop floor and communicating with them.
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d) Loudspeaker conference communication systems:
Loudspeaker conference communication systems are provided for a group of dedicated
subscribers working in the same operational areas within the major individual units of the plant, so that
operating instructions are communicated between the subscribers in paging mode. However, the
systems are also provided with both paging and private channel communication facilities depending
upon the applications.
These systems are provided in C&CCP to facilitate two way communication between various
sections of the shop. Since communication is carried out by means of microphones and loudspeakers
provided in the subscriber stations, this system is very useful in noisy environment where conventional
telephones prove to be ineffective. The subscriber stations are connected in a group and it is possible
to have communication with any of the two stations in that group. The on going conversation will also
be heard by others connected in a group.
e) Hotline communication systems:
To ensure direct telephone communication between closely related critical locations instant/
direct communication is provided. In this system, specified locations are connected permanently so
that whenever one subscriber lifts his telephone the other will immediately get a ring and communication
can be had without any loss of time. Such systems are provided in C&CCP, BF, SMS, LMMM, MMSM,
TPP, DNW and WMD departments for meeting the critical communication requirements.
f) VHF communication systems:
VHF communication systems are provided for establishing two way communication between
operators inside the cabins of mobile technological equipments and mobile operation/maintenance
personnel with the respective control rooms. These sets play a very important role in C&CCP for
proper coordination of the movements of pusher cars, charging cars, door extractors, electric locos,
lifters during charging, leveling, pushing and dry quenching operations in coke over batteries and
CDCP area. These sets are very essential and useful in ensuring proper communication & coordination
during alignment of oven machines while charging and pushing the ovens and carrying out these
operations safely. VHF sets are used in RMHP & SP area for communication between Control room
to the moving yard machines. Hand held VHF sets are extensively used for establishing instantaneous
communication and effective coordination of operation/maintenance activities in different departments
through out the steel plant.
There are 3 types of VHF sets used in VSP.
G
Walkie talkie (hand held) sets
G
Mobile set
G
Base station (fixed)
g) Mobile Communications facilities:
In order to ensure instantaneous and effective communications among the Senior Officers
and the needy personnel mobile communications system (Cellphones) are provided in Closed User
Group (CUG). This is found very much useful in ensuring timely coordination of production and
maintenance activities in plant and township.
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III) MONITORING AND SIGNALING SYSTEMS :
For monitoring critical operations in different production shops continuously from the concerned
control pulpits, closed circuit television systems are provided in BF, SMS, SP, LMMM, WRM and
MMSM departments. For ensuring fire safety in the plant and informing the Central Fire Station
immediately in case of any fire, a central fire alarm signaling system is provided.
a) Closed Circuit Television Systems:
CCTV systems ensure supervision of critical operating areas of major production units from
their concerned control pulpits. Each of the CCTV systems essentially comprises of Television camera,
television monitor and control console interconnected by means of control cables and video coaxial
cables. Depending upon the requirements at site the system may consist of one camera and one
monitor, or single camera and two monitors, or 4 cameras and single monitor. In case of high
temperature locations the cameras are enclosed in water cooling jackets provided with water cooling
and air purging arrangements. For improving the effectiveness of cooling, Vortec coolers are provided
in case of furnace cameras in LMMM, WRM & MMSM. The cameras in BF are provided with remote
control pan & tilt units and remote controlled zoom lenses for close monitoring of the cast house
operations from the control rooms. In Sinter Plant the CCTV systems facilitate viewing the sintering
process on the sinter machine after the furnace portion. The CCTV systems are very essential in for
carrying out the production activities in different shops. Each CCTV system is provided having technical
features conforming to CCIR-B standard. The CCTV systems are provided at various plant units for
observing critical operations mentioned below:
Hot metal tapping, placements of ladles and availability of transfer cars on tracks, operation of
the conveyor charging the materials into the furnace, slag runners at cast house, functioning of
granulator machine and loading of granulated slag to conveyors in cast house slag granulation plants
in Blast Furnace area;
Alignment of hot metal ladle with respect to mixer spout in mixer area, sub-lance probe handling and
probe attachment operation in converters, skirt positioning and movement of blowing lance through
lance thimbles, movement of sub-lance equipments, IRUT unit area in SMS area;
Operation of hook type bloom tilter, initial pan stand, flying shear, holding furnace, charging
and discharging operations of reheating furnaces, Stand-1 bar mill, straightener and piling and bundling
machine in LMMM area;
Operation of billet charging machine, horizontal loopers, laying heads, charging and discharging
operation of reheating furnaces in WRM area;
Operating of roughing mill, structural mill entry, intermediate mill entry, cooling bed shear, sample
saw, finishing area and reheating furnaces charging and discharging operations in MMSM areas.
In Sinter Plant the CCTV systems facilitate viewing the sintering process on the sinter machine
after the furnace portion.
b) IP Based Surveillance CCTV Systems :
For monitoring the movements of men and material a surveillance system is provided. This
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system consisting of IP Based cameras with video server which will convert analog video signal into
IP pockets ie digital video signal, monitors or PCs and Network Attach Storage (NAS) equipment for
storing the recorded information.
The IP based CCTV camera output is connected to the nearest LAN network. This video
signal can be tapped from any PCs or Monitors which are connected in the LAN network which is
having authorization. The storage equipment NAS is having the capability of storing one week duration
video signals. The NAS is having 1 terra bit capacity.
The installation of 8 nos of cameras are as mentioned below:
i) 2 nos in Plant Main Gate, 1 no in IN gate & 1 no in Out Gate.
ii) 4 nos in BC gate, 1 no in IN gate, 1 no in OUT gate, 1 no in Material IN gate & 1 no in
Material OUT gate.
iii) 1 no in BC gate OUT Road weigh bridge.
iv) 1 no in NSY junction.
These cameras can be operated remotely like PAN, Tilt & Zooming from the LAN connected
PCs with authentication. These connections are provided to the Sr. Officials of VSP, CISF personnel
& Vigilance department etc.
c) Central fire alarm signaling system :
The central fire alarm system is provided for communicating the exact location of outbreak of
fire in any part of the steel plant complex to the central fire station and simultaneous actuation of
sirens to alert personnel of the affected plant zone.
Communication to plant fire brigade station for exact location of fire in any part of the plant is
established either manually breaking the front glass cover of manual fire alarm boxes which are
provided at strategic locations of various plant units all over the plant and/or automatically through
voltage free contacts of plant automatic fire detection and alarm system. On receipt of alarm through
alarm line, the corresponding Fire Alarm panel and the corresponding area on the corresponding
signal lamp shall start automatic flashing on the mimic panel provided in the fire brigade station
indicating the location of fire with simultaneous actuation of audible alarm in the fire brigade station
control room and appliance room as well as hooting of sirens for a preset time interval in the affected
zone. The fire brigade station central control panel shall transmit automatically and simultaneously
the summary alarm signal corresponding to affected alarm zone to the repeater alarm panel provided
at fire fighting and drinking water pump house to alert attending personnel to start fire fighting pumps
immediately. C&CCP is provided with an independent fire alarm and protection system supervised
and controlled by fire brigade station of C&CCP. A summary signal is transmitted to the Central Fire
brigade station from C&CCP zone as well as seeking further assistance from central fire brigade
station, if required.
For sake of simplicity and easy identification of fire-affected area from central fire brigade
station, the plant is divided into a number of alarm zones. To restrict the number of alarm lines from
each alarm zone, a number of manual fire alarm boxes as well as voltage free contacts of automatic
fire detection and protection system of the shops and buildings of the concerned zones are connected
in series/parallel.
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d) Shift change Announcement Siren System:
The shift change announcement siren system is provided for ensuring uniform and accurate
shift timings throughout the plant. This system consists of two(2) nos quartz crystal controlled master
clocks in the Energy & Telecom Centre. The shift timings are programmed in the Master Clock. At the
specified time, the signal will be transmitted for energizing the sirens located at strategic points in
plant area simultaneously at the preset timings.
e) Siren systems in VSP Township & Pedagantyada:
There are 14 Nos of Sirens installed at different locations in Steel Plant Township. These
sirens are blown two times before starting of the shift i.e., once before 30 min and next before 15
minutes of starting of the shift. All the sirens are blown simultaneously. The sirens are controlled by
a master clock. The same type arrangement is provided for Pedagantyada also. These sirens are
helping the employees to reach the work spot well in advance.
IV) PLANT & TOWNSHIP TELEPHONE CABLE NETWORK:
An integrated telephone cable network catering to all the communication and signaling
systems covering auto telephones, dispatcher telephones, hotline connections, fire alarm signalers
etc. is provided inside plant area. Separate cable network is provided in township catering to the
telecom needs of township.
An independent telephone cable network is provided for the DOT telephones covering township
and a part of plant area.
For the loudspeaker intercom systems, loudspeaker broadcasting systems, loudspeaker
conference systems & industrial public address system dedicated cable networks are provided for
individual systems.
For the closed circuit television systems dedicated coaxial, video & control cable networks are
provided for the individual systems in the shops.
V) CENTRAL SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM:
Iron & Steel industry is a highly energy intensive industry using different forms of energy. The
energy network of a steel plant comprises of CO gas, BF gas, LD gas, mixed gas and Fuel oil,
compressed air, oxygen, nitrogen, argon, water system and power distribution system. The economy
of production depends greatly on the specific energy consumption. For closely monitoring the generation
and distribution of energy and rationalization of the distribution based on the available energy the
Central Supervisory Control and data acquisition system is provided in the plant.
The system comprises of Micro VAX II based master station equipment with supervisory
consoles and mimic panels located in the Energy & Telecom Building and 23 Nos Remote Telemetry
Units (RTUs) installed in different plant units and 3 local RTUs for driving the mimic panel in the
Energy Centre. The RTUs will be collecting the signals from the local instrumentation & electrical
systems and transmitting to the master station when polled by the latter. The RTUs are connected to
the master station by under ground telephone cables. Supervisory consoles are also provided in MRS
and EMD department in Area Shop Office-2 of Utilities.
The system enables continuous monitoring of the energy networks in the steel plant and
generation of reports as required for taking strategic decisions in times of crisis.
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The maintenance of RTUs, mimic panel and the cable network between the field/local RTUs &
Modern panel in the Master station is being carried out by the telecom department. In the process of
reducing cost of production and specific energy consumption in the steel plant SCADA system assumes
great importance and proper functioning of the RTUs and the network is ensured by the
Telecommunications department.
VI) DATA COMMUNICATION NETWORK:
VSP is having a Gigabit Ethernet Data Communication Network, working on Optical Fiber
Cable (OFC) network. This supports data transfer at the rate of 1000 Mbps on all the main links. It
comprises of 70 kms of Single mode fibre (9/125 microns), 90 kms of Multimode fibre (62.5/125
microns), 65 kms of UTP cabling. Basically this network is designed as a three tier network with the
following hierarchy.
The campus network is divided into eleven zones. These zones are inter-linked to the central
core switch using Single mode type optical fiber. The Central core switch is located at Central Computer
Centre. The 11 Zonal switches are located at Coke Ovens, Sinter Plant, SMS, Central stores, BC
Gate, LMMM, MMSM, Central computer centre, Admin. Building, Township Exchange and General
Hospital. Further, a total of 200 access switches are connected to the network through the 11 zonal
switches, using Multimode/ single mode type optical fiber cable. The access switches provide
connectivity to approximately 3000 nodes throughout the plant premises, Administration building area
and township using Cat.5e and Cat.6 cables. All the personnel computers in the network are connected
to this wall outlets/I/O's by a UTP patch cords and Network Interface Cards in the PCs.
Different passive components used in the LAN are Optical Fiber cables (SMF&MMF), UTP cables,
fibre and UTP patch cords, fibre and UTP patch panels, SMF and MMF pig-tails, wall outlets, etc.,
Different active components used in the Giga-bit Ethernet LAN are core, access switches,
SMF & MMF media converters, ADSL2+ modems/concentrators, G.SHDSL modems & concentrators,
wireless bridges/routers, access points etc.,
Plant LAN network is extended to township to cover the departments like township exchange,
Town Administration Department, Sports complex, Township maintenance posts Visakha Steel General
Hospital, Human Resource Development Centre etc.,
The passive components of the Datacom network are maintained by Telecom department.
VII) MAINTENANCE OF TELECOM EQUIPMENTS :
Centralised maintenance facilities for all the communication and signaling equipment are
provided in the Energy and Telecom centre building. Two repair sections are provided, one for repair
and testing of telephone instruments and another for repairing of wireless sets, amplifiers and other
electronic equipments used in the Plant. Apart from this repair of wireless sets in C&CCP is carried
out in the wireless laboratory in C&CCP and repair of CCTV cameras and monitors is carried out in the
telecom repair sections in Rolling mills & Blast Furnace. The repair of telephone instruments and
exchange equipments is carried out in township telephone exchange building.
Thus the telecommunication department ensures providing reliable process communication &
monitoring facilities in Plant and efficient & effective communication in plant & township areas enabling
effective coordination, control & monitoring of various activities of production, maintenance & service
departments round the clock in the Steel Plant.
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Chapter - 39
192
.
193
SOURCES OF POWER :
Power requirement of VSP is met through captive generation as well as supply from APSEB grid. The
captive capacity of 286.5 MW is sufficient to meet all the plant needs in normal operation time. In case
of partial outage of captive generation capacity due to break down, shut down or other reasons, the
short fall of power is availed from APSEB grid. Turbo generators of VSP normally operate in parallel
with state grid. Excess generation over and above plant load is exported to APSEB.
The agreements with APSEB provide for a contract demand of 100 MVA and permit export of power.
Tariffs for import / export, demand charges, penalties etc. stipulated. For purpose of billing, import and
export energy is separately metered at Main Receiving Station.
VSPs captive generating capacity comprises of 247.5 MW at Thermal Power Plant, 15 MW at Back
Pressure Turbine Station and 24 MW at Gas Expansion Turbine Station (the later two stations together
contribute about 22 MW of Power). After expansion of VSP at 6.3 MTPA, the plant load will increase
to 430 MW. To meet this increased load demand one TG(67.5 Mw) in main plant, one TG (14 MW) in
Battery-4 & one TG (MW) in BF-3 are also envisaged. Balance load requirement will be met from
APTRANSCO or from any additional sets, which is yet to be finalized.
APSEB SUPPLY NET WORK :
The Power Grid Corporations Sub-Station adjacent to Ukkunagaram is connected to Nunna
Vijayawada are Kalapaka (Visakhapatnam) by 400 KV lines. It is also connected to Jaipur, Orissa
(Eastern Grid) through DC back to back arrangement of 1000 MW capacity and by 400 KV AC double
circuit line. Power is stepped down through a 315 MVA, 400/220 KV auto transformer at Power Grid
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Corporation Sub-Station and is fed to the adjacentAPSEB switching station. This switching station is
also connected to Bommuru, Gajuwaka and Kalapaka Sub Stations by 220 KV double circuit lines.
Bommuru Sub-Station is connected to generating stations at Vijayawada, Lower Sileru, Vijjeswaram,
Kakinada and Jegurupadu. Gajuwaka substation is connected to Upper Sileru. 1000 MW Simhadri
Thermal Power Station is connected to 400 KV substation of Kalapaka. Kalapaka 400 KV substation
is connected to Vemagiri and Khamman 400 KV sub-station on D.C. lines.
Power is supplied to VSP from APSEB switching station over two 220 KV lines on double
circuit towers. Power is received at the Main Receiving Station (MRS) located near Main Gate and
further distributed to various units within the plant.
ESSENTIAL CATEGORY LOADS :
Some of the technological process/equipment requires all time availability of electricity. Such loads
are approx. 70 MW and spread over various plant units. These include exhausters in CO&CCP;
cooling water pump houses in BF, SMS, Rolling Mills, Intake pump house, Kanithi Balacing Reservoir
pump house, TPP auxiliaries, Township pump house, Hospital etc. Disturbance of supply to these
loads may cause wide spread dislocation to the process, involve dangerous situation to equipment
etc. These are classified as special/essential category-l loads. Power supply to them is envisaged
from two sources i.e. from Thermal Power Plant Generator 11 KV switch board through cables and
also from 220 KV sub-station in that area. Depending upon level of captive generation, the 220 KV
system is so configured that in the event of isolation of captive generators from APSEB grid, the load
throw off at TPP and disturbance to -plant units is minimized.
POWER TARIFF :
The prevailing APSEB tariff as on Jan-09 is as given below applicable for HT Consumers. Billing is
done monthly.
Max. Demand Charges Rs. 250 / KVA
Energy Charges
i. 85% of Energy Consummed Rs. 2.80 / KW Hr.
15% of Engergy Consummned Rs. 4.40 / KW Hr.
ii. Fuel surcharge Paise 5 / KW Hr. (Changed from time to time as
per APERC Notification)
iii. Electricity duty Paise 6 / KW Hr.
iv. Mater charges Rs. 1500
POWER DISTRIBUTION
EXTRA HIGH VOLTAGE DISTRIBUTION (220 KV) :
Power from APSEB is received at Main Receiving Station (MRS). The entire plant is configured as five
electrical Load Blocks and Step down Sub-Stations are provided in each block (designated as LBSS
1 to 5) with 220 KV transformers to step down power to 33/11/6.6 KV and for further distribution as
indicated below :
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196
197
198
199
TQM & ISO Cell is a nodal department in works division, for all the activities within the ambit of Total
quality management (TQM) and Quality management system (QMS). It also acts as an
internal-consultant for QMS related activities in VSP.
While the main functions of the TQM & ISO Cell are to develop, implement and maintain, management
systems; the following are some of its functions :
I. TQM related functions :
G
To ensure that the TQM concepts - specially, use of statistical techniques, internal
customer-supplier concept, quality improvement projects (QIPs)-are implemented in works
division and related areas.
G
To coordinate and monitor the activities related to QIPs and MOUs between internal
customers & suppliers.
G
To report to the top management on the progress / performance of QIPs and MOUs.
II. QMS related functions :
G
To ensure the implementation and maintenance of QMS in accordance with the
requirements of ISO 9001:2000, in works division and related areas;
G
To extend guidance and arrange need based training to all, in QMS related activities;
G
To report to the top management on the performance and effectiveness of QMS;
G
To assess and report to the top management about the needs as well as scope for
improvements;
G
To liaison with external agencies on matters related to QMS.
Chapter - 40
TQM & ISO CELL
200
Chapter - 41
TRAFFIC DEPARTMENT
1. Incoming traffic by rail:

COMMODITY
QTY. RECEIVED IN MILLION TONS.
2004-05 2005-06 2006-07 2007-08
Iron Ore 6.308 6.249 6.186 5.994
Coals 4.889 4.989 4.666 4.961
Fluxes 1.638 1.652 1.505 1.569
BF Coke 0.436 0.326 0.237 0.276
TOTAL: 13.271 13.216 12.594 12.800

2004-05 2005-06 2006-07 2007-08
Total No. of Raw Material
rakes received
3894 3744 3528 3596
Freight paid to Railways
(Rupees in Crores)
494 561 587 592

2. Outgoing traffic by rail:

COMMODITY 2004-05 2005-06 2006-07 2007-08
Steel 1.49 1.76 1.97 1.97
Pig Iron 0.06 0.11 0.06 0.02
Granulated Slag 0.72 0.24 0.31 0.41
Others - - - -
TOTAL: 2.27 2.11 2.34 2.40

2004-05 2005-06 2006-07 2007-08
Total No. of Rakes
dispatched
983 924 1052 952
Freight paid to Railways
(Rupees in Crores)
233 250 283 281
Freight charges vary with commodity and distance.

3. Sequence of activities for incoming rakes:
> Rakes arrival forecast from Chief Controller, Waltair Division, E.Co.Railway.
> Weighment of raw material rakes on In-motion Weigh Bridges before entering into
Pre-Tippler Yard.
> Receipt of rakes at Pre-Tippler Yard.
> Taking over of rakes from Railways after TXR examination.
> Tippling of rakes by RMHP Department.
201
> Separation of sick wagons.
> Empty rake formation and handing over to Railways at Empties Yard.
4. Sequence of activities for outgoing rakes:
> Rising of monthly demands of various products from branches/customers by Marketing
Department.
> Conversion of demand to weekly rolling plans by PPM.
> Conversion of weekly rolling plan into rakes planning for each branch/customer.
> Daily indenting of rakes to Railways as per the composition given by Marketing Department
through PPM.
> Arrangement of wagon allotment from Railways by Traffic Dept.
> Taking empties from Railways as per the above composition.
> Placement of wagons by Traffic at various loading points after tareweighment.
> Loading, adjustment, weighment and booking of load wagons.
> Handing over of rakes to Railways in FPEY.
> Movement of rakes from FPEY to branches, customer sidings by Railways.
5. Different types of wagons received by VSP from Railways:

TYPE CARRYING CAPACITY IN TONS.
BOX-C 55.5 to 57.5
Open Wagons
BOX-N 58.2 to 59.3
BOST 55.6 to 55.8
BOY 69 to 71
BCX 55.6 Covered Wagons
BFR 43 to 44.8
Flat Wagons BRH 55.6 to 57.6
BRN 58.2 to 59.3

6. Planning with Railways :
> Communication of yearly plan of raw materials procurement and dispatch of finished products
to Railways.
> Communication of quarterly movement plan of raw materials to Railways.
> Quarterly meeting by CBT (Central Board of Traffic) at Kolkata.
> Monthly steel reconciliation meeting by Railways at Kolkata,
> Review and follow up on daily basis.
> Periodical review by steel ministry along with members of Railway Board.
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7. Technological movements & other misc. movements carried out:
> Movement of hot metal from BF to SMS/PCMs.
> Movement of Pig Iron from PCMs to PSY.
> Movements of Metallurgical waste like flue dust from BFs, mill scale from Rolling Mills and
coke dust from Coke Ovens to Sinter Plant.
8. Details of rolling stock owned by VSP :
a) Diesel Electric Locomotives:

MAKE NOS. HP
DLW Make WDS6 29 1350
BHEL Make 2 1150
TOTAL: 31

b) Wagons:

TYPE OF WAGONS NOS USAGE
Pig Wagons 35 Transporting cast pigs from PCMs to PSY.
BOBS Wagons 11 Transporting metallurgical waste to Sinter Plant.

Heavy Duty Flat
Wagons
12
Skull movement from BF and movement of long products
from LMMM & MMSM to NSY/BCSY.
Tool Van 1 Carrying rerailing equipment.
BOX Type
Special Wagons
8 Transporting wire coils from WRM to NSY, BCSY & EPI.
CG Wagon 1 For calibration of rail weigh bridges.
TOTAL: 68

Details of tracks:

TRACK LENGTH IN KMs
VSP 135
Railways 75
TOTAL: 210

10. Rerailing Equipment :
> 225T Rail Crane
> 50T Rail Crane
> Lukas Hydralic Rerailing Equipment consists of different sets of jacks with capacities ranging
from 10T to 160T.
11. Maintenance activities :
> Maintenance of plants internal rolling stock namely locomotives, wagons and rail cranes in
LWRS.
> Maintenance of railway tracks.
> Maintenance of RRI (Route Relay Interlocking)/SSI(Solid State Interlocking) and signaling
equipment and also Yard Voice Communication/MRTS coordination.
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Chapter - 42
204
205
206
207
208
209
210
211
212
213
Chapter - 43
214
215
OTHER THAN WORKS
DEPARTMENTS
216
217
Chapter - 44
COMPANY AFFAIRS DEPARTMENT
I. HISTORY
With the incorporation of a separate Company i.e. Rashtriya Ispat Nigam Limited (VSP), on 18th
February, 1982 as a Private Company, Limited by shares under the Provisions of the Companies Act,
1956, the Company Affairs Department came into existence with Shri KMA Narayanaswami as its 1st
Company Secretary who held the position from April, 1982 to March, 2004. Shri P Mohan Rao, DGM
(Company Affairs) the present Company Secretary has since taken over charge w.e.f 1st April 2004.
This is a Corporate level Establishment looking after various functions which include, inter alia,
conducting Meetings of the Board, Audit Committee and other Board sub-Committee Meetings, e-
filing and correspondence with the Registrar of Companies, AP and correspondence with Ministry of
Steel and non-Governmental agencies. Company Affairs Department has a unique and special role to
play in VSP in streamlining/formulating delegation of powers, compilation and submission of Company's
Annual Report upto the level of Parliament, generating and maintenance of statutory/classified records/
registers pertaining to the Company's loans, investments, Charge creation and vacation and issues
like correspondence on Trade Marks, Copy Right, Patents etc.
So far, the Company Affairs Deptt has functioned catering to the needs of the Board of Directors under
the Chairmanship of :
S.No. S/Shri Period
From To
1. A S Gill, Secretary (Steel) 08.04.1982 27.07.1983
2. KVB Pantulu 24.03.1982 30.04.1983
3. D R Ahuja 07.10.1984 07.09.1990
4. B N Rath 14.06.1991 31.05.1993
5. J Mehra 01.06.1991 31.03.1997
6. Dr B N Singh 28.11.1997 02.08.2002
7. B K Panda 16.04.2003 30.09.2004
8. Y Siva Sagar Rao 20.10.2004 30.4.2007
9. P K Bishnoi 01.05.2007 Contd
At the time of incorporation of RINL in 1982 as a separate Company, the following were the promoters
of the Company :
1. Shri A S Gill Secretary to the Government of India
2. Shri D N Ghosh Financial Adviser to the Govt of India
3. Shri Suresh Kumar Jt Secretary to the Govt of India.
The first Meeting of the Board of Directors of RINL/VSP was held on 8th April, 1982 at New Delhi
under the Chairmanship of Shri AS Gill, Secretary, Steel and Shri KVB Pantulu was the Managing
Director of the Company. The following were the first Directors of the Company.
218
S/Shri
1. AS Gill Chairman
2. K S Rajan Director
3. D N Ghosh Director
4. T R Prasad Director
5. Suresh Kumar Director
6. S R Ramamurthy Director
7. R K Dang Director
8. K V B Pantulu Managing Director
9. KMA Narayanaswami Company Secretary
At the time of incorporation, the Registered Office of the Company was stated to be situated at the
following address:
Rashtriya Ispat Nigam Limited,
Project Office
P O Gajuwaka
Visakhapatnam 530 026
Andhra Pradesh
and thereafter changed to Administrative Building, Visakhapatnam 530 031
II. ROLE / FUNCTIONS OF THE DEPARTMENT
The Company Affairs Department is concerned with the following functions :
1. Conducting of various Meetings as detailed below:
a) Board of Directors
As per the Provisions of Companies Act, 1956, a sitting Meeting of the Board of Directors is
required to be held at least once in every Quarter. However, such Board Meetings are convened
on average every alternate month considering the requirements of the Company.
As per the Articles/Memorandum of Association of the Company, the maximum number of
Directors on the Board is 14 and minimum is 5.
The Quorum for the Board Meeting is 1/3rd of the present strength. So far 239 Board Meetings
were conducted (as of March 2009) in addition to Resolutions passed by Circulation.
b) Committee of Management (COM)
With a view to facilitate faster decision making and to have more flexibility in operations, powers
were subdelegated by the Board to a Committee of Management (COM) for award of Contracts/
placement of orders. The COM consists of CMD/Chairman and all the Functional Directors of
RINL. The quorum shall consist of Chairman, Director (Finance) and one of the concerned
Functional Director.
c) Annual General / Extraordinary General Meetings :
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i) Annual General Meeting (AGM)
As per the Companies Act, 1956, every Company should, in each year, hold a Meeting called
Annual General Meeting of the Shareholders. So far, RINL had 26 such AGMs. The Annual
Report which includes Production and Financial performance of the Company, is placed in
Parliament. Such Annual Reports for last three years ending with 2007-08 are put on VSP's
website www.vizagsteel.com as part of better Corporate Governance.
ii) Extraordinarily General Meeting (EGM)
Items of business of an urgent nature which need to be transacted and cannot wait till the next
Annual General Meeting are presented in these Meetings. So far RINL had such EGMs
totaling to seven.
As per the Articles of Association of the Company, two Members present in person shall be the
quorum for such Meetings of the Company.
d) Audit Committee
The Audit Committee of the Board was formed during the year 2006-07 in line with the OM
No.18(8)/2005-GM, dated 16th June 2005 issued by Department of Public Enterprises, Govt.
of India. The composition of Audit Committee as on 31.3.2008 was as follows :
Shri R S S L N Bhaskarudu Chairman Independent Director
Dr V K Bhalla Member Independent Director
Dr Jagat Pal Member Independent Director
e) Technology Improvement and Bench Marking Committee:
The Board has constituted a Technology Improvement and Bench Marking Committee and the
composition of the Committee as on 01.03.2009 is as follows :
Committee and the composition of the Committee as on 1.3.09 is as follows :
1. Shri RSSLN Bhaskarudu : Chairman Independent Director
2. Director (Operations) : Member Wholetime Director
3. ED (Works) : Member Sr Executive of the Company
4. GM (D&E) : Member Sr Executive of the Company
5. GM (T&R) & I/c R&D Deptt : Member Sr Executive of the Company
6. DGM (R&D) : Convener Executive of the of the Company
Committee
This Committee monitors and pays special attention, to the assessment of status of the Company's
own technology, acquiring and assimilating new technologies necessary to make it competitive and to
its own R&D efforts and maintaining sustained strength in the technological field. During the year, two
Meetings of the Committee were held.
220
f) High Power Steering Committee (HPSC)
In line with the directions of the Govt of India given, while approving the Expansion Project, the
Board of RINL constituted a High Power Steering Committee for overseeing the implementation
of Expansion of VSP to 6.3 MT per year Liquid Steel with the following Members :
a) Chairman-cum-Managing Director : Chairman
b) Joint Secretary, Ministry of Steel : Member
c) Shri RSSLN Bhaskarudu : Member
Director (Part-time non- official)
c) Director (Finance) : Member
d) Functional Director : Member (In-charge of Projects)
e) Company Secretary : Convener
ED (Finance)/GM (Finance) will be an alternate Member in the absence of Director (Finance).
HOD of the Projects Division in the rank of ED or GM will be a permanent invitee.
g) Committee for Award of Contracts relating to Project Expansion Contracts
In respect of Expansion Project, to approve award of Contracts/Orders valuing upto Rs.500
crores, the Board has constituted a Committee called Committee for Award of Contracts relating
to Project Expansion Contracts.
The composition of the Committee is as follows :
1. Chairman-cum-Managing Director Chairman
2. Director (Finance) Member
3. Director (In-charge of the Projects Division)/ Member
Director (Projects) Member
4. Dr V K Bhalla, Part-time non-official Director, Member
RINL (Independent Director)
5. Dr Jagat Pal, Part-time non-official Director, RINL Member
(Independent Director)
6. Company Secretary Convener
h) Committee for Award of Contracts (CAC)
The constitution of the Committee for Award of Contracts is as follows :
1. Chairman-cum-Managing Director Chairman
2. Dr V K Bhalla, Independent Director Member
221
3. Dr Jagat Pal, Independent Director Member
4. Director (Finance) Member
5. The concerned Functional Director Member
6. Company Secretary Convenor
The above Committee is empowered to approve the proposals relating to AMR Schemes and
other Contracts of Revenue and Capital Nature under Operational and other requirements for
the existing plant and functioning of the Company upto Rs.250 crores.
The above Committee is also empowered to approve all Capital expenditure including Additions/
Modifications/Replacement of the existing facilities or Expansion of existing facilities in each
case (not included in the approved capital budget for the year subject to overall budgetary limit)
as per the above limit upto Rs.250 crores.
2. Delegation of Powers
A Company being a Corporate personality can work/function through the Organization having
different levels of officers/functionaries. To enable effective functioning and quick decision-
making, proper delegation of powers is envisaged coupled with responsibility and accountability.
This goes by the Trust and Authority as well.
In RINL, three tier delegation exists, i.e. :
1. Powers given to the Board of Directors
2. Powers delegated by the Board to various Committees like COM etc. and Chairman-cum-
Managing Director.
3. Powers delegated by CMD to Functional Directors and Officers at various levels in the Company.
The Delegation of Powers (DOP) comprise of General Powers and Functional Powers of various
Departments and are brought out as a printed manual. A soft copy of the same is kept on
Company's intranet portal alongwith various amendments/office orders issued from time to
time.
3. Other Activities
a) Filing of Annual Returns, Charge creation and Charge vacation, filing of various e-forms for
appointment / resignation / retirement of Directors with ROC, Hyderabad, AP.
b) Dealing with matters relating to appointment and fixing of Remuneration of Statutory Auditors
for Annual Accounts and signing of annual accounts alongwith Director (Finance) and CMD in
terms of the Provisions of Companies Act, 1956.
c) Dealing with matters connected to Trade Mark/Design/Patent Registration for VSP's products
and other in-house innovations etc.; Arranging and issue of warning notices for any infringement/
violation of VSP's rights on the same etc.
222
d) Carrying out amendments to the Articles of Association and Memorandum of Association of the
Company on need basis enabling the Company to go for investments, strategic alliances etc.
e) IT enabled environment for Company Affairs Department, ie. a Separate Portal on Intranet,
wherein Annual Reports, DOP amendments and other important communications etc. can be
accessed selectively by heads of Deptt and other Senior Officers.
f) Making available the Annual Reports of the Company on VSP website for last three financial
years.
g) E-Filing of various Forms & Annual Returns with ROC/Hyderabad.
h) Digitalization of all Minutes of various Meetings viz. Board Meeting, Audit Committee and other
Sub-Committee Meetings.
i) Data Management / Sorting for instant access of a particular item of a particular BOD/COM
Meeting in case of a reference requirement etc.
j) Continuous review and revamping of DOP in line with Current / Expansion Project requirements
as VSP is emerging into a Major Steel producer of the country.
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Chapter - 45
Corporate Strategic Management
To achieve sustained superior corporate performance, after having registered a remarkable
turnaround, RINL has focused its attention towards striking a balance between two symbiotic forces
the need for ongoing improvement in operational performance and productivity through constant
rationalization in existing activities, and the need for growth and expansion through continuous
revitalization of strategy, organization and people. To address the strategic needs of the company, a
new department named as Corporate Strategic Management (CSM) was created.
The primary task of CSM is to study world class initiatives and develop suitable framework for their
adoption and implementation on an organization-wide basis at VSP. The initiatives thus identified
guide VSP to achieve its cherished vision of becoming a world class integrated steel plant.
The important jobs carried out are brought out below:
CSM ACTIVITIES
Planning :
Following planning functions are carried out by the department:
G
Formulation of long term plan (Corporate Plan) and Annual Plans (Sustainability Plan)
G
Coordination for finalization of targets for MOU with GoI.
G
Facilitating review of performance through Business Plan Review sessions
G
Preparation of Quarterly Performance Reports for review by Ministry of Steel
G
To build vital database, analysis of which will support performance evaluation and provide inputs
for the Strategic Planning Process in the company.
Awards for Performance excellence :
Coordinate all activities related to major external awards of organizational scale, such as:
G
Prime Minister's Trophy best integrated steel plant in the country
G
CII-EXIM Bank Award for Business Excellence
G
SCOPE Excellence award etc.
Also Chairman's Trophy for Excellence is conducted every year to encourage departments to internalize
concepts of excellence by identifying opportunities for improvement
Knowledge Management :
Facilitate sharing of unique experience / learning among employees through
G
Portal based KM system
G
Face-to-face interactions between employees working in similar areas
224
Chairman-Online :
This is an intranet based forum which provides an opportunity to the employees to directly interact
with the Chairman and express their views, give suggestions on various issues related to business of
the company to bring improvements.
In addition to the above, the department is also involved in coordination with external agencies like
Department of Public Enterprise (DPE), National Sample Survey Organization (NSSO), Ministry of
Steel etc. for providing relevant information, as and when required.
Joint Ventures
Lack of captive sources of major raw material has been identified as strategic weakness of RINL for
its current operation as well as its future growth. Raw material linkage is therefore of strategic importance.
Similarly Inorganic growth through Joint Venture and Acquisition by way of horizontal and vertical
integration has remained strategic objective of RINL. CSM takes all the initiatives required to achieve
this objective in time bound manner. The department also examines all the proposals received and
scans for the new opportunities arised in the external environment.
Steel News
News related to steel production supply chain and also various other issues connected to Steel Making
and Public Sector concern is posted on a daily basis to the server maintained by CSM department.
This news is accessible from the home page of CSM on the intranet (http://csm/index.php) . The
news sources are all reputed online news papers and journals. The News is categorized with Meta
tags for easy retrieval of related past news items. Also there is a searchable database of News articles.
225
Chapter - 46
226
227
228
229
Chapter - 47
MANAGEMENT SERVICES DEPARTMENT
The activities of Management Services Department are broadly divided as follows :
G
Quality Circles
G
Motivational Scheme
G
Suggestion Scheme
G
SPAS
G
Five S
G
EIRS
G
Procedures
QUALITY CIRCLES
QCs - Origin : Dr Ishikawa started the first Quality Control Circle in Japan in 1962. Subsequently
QC movement gained momentum and become a part of work life in all the organizations of Japan.
This concept is also extended to service sector like Hospitals, Banks, Schools etc. At present 40
Countries are following this concept in different organizations.
QCs in India : For the first time in India, Dr S.R. Udpa, then GM started QCs in M/s BHEL in 1980
in Hyderabad unit with a view to empower and involve working level employees in solving their work
related problems.
Quality Circle Forum of India (QCFI) : In order to propagate the QC concept to rest of the
Country, Dr. S.R. Udpa founded a nonprofit body called Quality Circle Forum of India (QCFI) in 1982
at Hyderabad. Subsequently chapters were started in different regions to spread and coordinate the
QC activity in India.
QCs in VSP : Visakhapatnam Steel Plant started QC movement on 1st April 1990 immediately after
commissioning of First coke oven battery to encourage employees' Participation for improving work life.
QC- DEFINITION : A Quality Circle is a small group consisting of first-line employees who continually
control and improve the quality of their work, products and services.
These Small groups:- Operate autonomously, Utilize quality control Concepts and Techniques and
other Improvement tools, Tap members' creativity and Promote self and mutual development.
The Size of the QC group should be 5 - 7(max.) including facilitator. (No. of executives in the QC
group should not exceed 2 including facilitator). It can be more than two, for the departments where
executive strength is considerably more.
QUALITY CIRCLE STRUCTURE
There should be a well defined structure to allow employees to participate in QC activities. This structure
is no way connected with the Company's organizations structure.
Facilitator : Head of the department shall identify facilitators (preferably section in charge). The No.
of facilitators in a Department shall be decided by the HOD depending upon the requirement.
Facilitator should
G
Develop the skills and abilities of the team members.
G
Serve as a resource person to the circles
G
Possess skills to demonstrate, communicate and train
G
Encourage and enhance the QC activities in their area.
230

Encouraging
Participation in National
/international conventions
Recognition Functions
Mementoes
Presentations to Top
management & dinner meets

Empowering
Workshops
Exposure Programmes
News letters
e-compendia
QC portal

QC
QC online Registration
through QCMS
Problem solving
12 Steps 10 Tools
Enter implemented
project details through
QCMS
Project evaluation &
online clearance by HOD
MS evaluation & arrive
credit points to each project
and member

Rewards &
Recognitions

Mementoes based on
Average credit points
& involvement
QC members
Departments
Trophies based on
fulfillment of plan &
Emp. involvement and
Avg credit points of
dept

Dept level selection &
zonal competitions
QC Teams
Leader : QC group will select one of its members as a leader of the group. The leader should be
changed for every project.
Leader should
G
Conduct QC meetings regularly
G
Maintain records of circle activities
G
Prepare reports and presentations.
G
Learn QC techniques and clarify doubts of members
G
Lead the team towards goals
Member : Employees belonging to the same work area or doing similar type of job who want to
perceive development and growth shall become members of the QC group. Member is one among
the equals of a group.
Member should
G
Attend QC meetings regularly
G
Involve and develop the self.
G
Contribute to the success of the group through individual experience and knowledge
G
Learn QC problem solving tools / techniques
G
Respect other members and cooperate with them.
Non-Member : Employees who extend necessary help to the QC group shall become nonmembers.
Nonmembers are not part of the group. Nonmembers can be co-opted by the QC group as per the
requirement.
INSTITUTIONALIZATION OF QCs
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12. STEPS FOR QC PROBLEM SOLVING
S.No. STEP
1 Identification of work related problems
2 Selection of Problem
3 Define the problem
4 Analyze the problem
5 Identification of causes
6 Finding the root causes
7 Data analysis
8 Developing the solution
9 Foreseeing the probable resistance
10 Trial implementation and check performance
11 Regular implementation
12 Follow up / Review
S.No. TOOL PURPOSE / USE
1 Flow Diagram To understand the process/flow and locate the problem.
2 Brain Storming For generation of ideas
3 Data collection Foundation of statistical analysis
4 Cause & Effect diagram To map out all probable causes
5 Graphs Presentation data in pictorial form
6 Pareto diagram To identify vital few causes
7 Histogram To study process variation and assess process capability
8 Stratification To segregate data
9 Scatter diagram For examining the relationship between two variables
10 Control chart For maintaining running control on a process
RECOGNITION
G
Rewarding the QCs with gifts/mementoes
G
Two stage evaluation to select best QCs
G
Mementoes to best facilitators and leaders
G
Awards to best Depts
G
Cash award to best QC teams
G
Case presentation to Top Management
G
Participating in conventions etc.
QC MONITORING :
G
Continuous monitoring & follow -up by MS Dept.
G
Monthly review by WORKS I/c
G
Periodical review by top management
232
SRUJAN VIKAS- THE SUGGESTION SCHEME
OBJECTIVES :
G
To provide an opportunity for creative thinking among employees and their family members so
as to utilize their full potential for advancement and to bring about improvement in their day to
day working through the application of their experience and knowledge.
G
To recognize the positive contribution made by employees in bringing about such improvement.
G
To provide an additional forum for mutual co-operation and collective initiatives in fostering
production, productivity, reducing cost and improving quality.
ELIGIBILITY
All employees in the grade of E-6 and below (including trainee) who are in the regular employment
and their family members (spouse and unmarried children staying with parents), customers, suppliers
and school children are eligible to be covered under the scheme.
If, however, a suggestion is made by an employee as a result of his being placed in a privileged
position having at his disposal information obtained from investigation or studies, he will not be eligible
to avail benefits of the scheme.
SUGGESTIONS :
An idea or proposal concerning one or more of the following will be considered as a suggestion.
G
Improvement in production, productivity and yield.
G
Conservation of raw materials, energy, fuel etc.
G
Cost reduction.
G
Improvement in Safety standards.
G
Improvement in the Quality and design of products.
G
Improvement in maintenance of Plant and equipment.
G
Improvement through change/modification in design of equipment and layout
G
Improvement in customer service.
G
Simplification / modification of work practices, systems, procedures, processes and improvement
in methods.
G
Reduction in wastage, spoilage, rejections.
G
Reduction in environmental pollution.
SUGGESTION EVALUATION COMMITTEES :
The Zonal Suggestion Evaluation Committees (ZSECs) and Apex Level Suggestion Evaluation
Committees (ALSECs) are organized as follows:
I. ZSEC: (Works & Other than Works)
Respective HOD (Not below E-7 grade) Chairman
Respective Zonal Personnel Executive (ZPE) Member- Convenor
Concerned Sectional Head from Dept. Member
Representative from F&A (Not below E-4) Member
Representative from MS (Not below E-4) Member
II. (a)ALSEC: (Works)
Head of Works Division Chairman
Head of Plant Personnel Member-Convenor
233
Head of the Concerned Department Member
Representative from F&A (Not below E-5) Member
Representative from MS (Not below E-5) Member
II. (b) ALSEC: (Other than Works)
Head of MS Department Chairman
Concerned ZPE (Other than Works) Member-Convenor
HOD /Representative nominated by HOD Member (Not below E-5)
Representative from F&A Member(Not below E-5)
Chairman of ZSEC / ALSEC may co-opt members from other departments like D&E, Plant
Design, safety etc. whenever necessary. HOD may nominate representatives of the committee in
case of any changes.
REWARDS :
i. Prima facie acceptable
suggestion
ii. Suggestions resulting in
one time saving
iii. Suggestions resulting in
savings of recurring
nature
A gift item
10% of actual savings subjected
to a maximum of Rs.18,000 and
a minimum of Rs.200
20% of actual savings for the next
5 years subject to a max. of
Rs.18,000 and a min. of Rs.200.
Member-Convenor of the ZSEC in
consultation with head of ZSEC
Up to Rs.2,500 by ZSEC
Above R.2,500 and up to
Rs.10,000 by ALSEC
Upto Rs.25,000 by CMD
EMPOWERED AUTHORITY AMOUNT OF REWARD INDIVIDUAL
ANNUAL AWARDS
The following Awards & Trophies are awarded every year:
(i) Gold & Silver Medals:
Keeping in view the number of implemented suggestions given by the suggestor, the quality and
value of such suggestions, the following individual rewards are presented:
G
Gold Medal to the best suggestor (15 grams 22 cts.)
G
One Silver Medal to the next best suggestor (150 grams)
(ii) Creativity Awards are given to the employees who give highest number of implemented
suggestions during the year
(iii) Trophies:
Three trophies are awarded, based on highest number of implemented suggestions / employee /year
G
one to the main production units
G
one to the services departments
G
one to the Non Works department
(iv) Best suggestors are nominated to participate in the National Conventions
(v) Best suggestions are nominated for Vishwakarma Rashtriya Puraskar
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REVIEW AND MONITORING
The Management Services department shall monitor the functioning of the suggestion scheme.
The functions of the Cell will be:
a) Conduct exposure programmes, workshops, seminars on suggestion scheme and its effective
implementation.
b) Monitor the implementation of the suggestions.
c) Monitor effectiveness of meetings of both ZSECs and ALSECs
d) Liaison and follow up with Convenors of ZSECs and ALSECs
e) Process suggestions for award of Trophies and Gold & Silver Medals, best evaluation committees.
f) Prepare monthly report to top management
g) Conduct Poster / Slogan competition on Suggestion Scheme
h) Publish Annual Compendium of implemented suggestions
i) Conduct Annual Recognition Functions of Suggestion Scheme every year.
5S - WORK PLACE MANAGEMENT
5S, an integrated Japanese concept for Work Place Management, is a scientific approach for
effective organisation of work place through the participation of the employees.
Five S has become a management philosophy, as cleanliness has become an important
requirement. Modern developments call for high level of process accuracy, dust free atmosphere,
proper maintenance, understanding and proper training. Hence 5S have gained paramount
importance.
5S is a silent informer of companys' attitude for quality. It may be noted that 5S is the foundation
for total quality management. Five S can be effectively introduced and practiced in any place
whether it is a factory, office, home, hospital, school, Shopping complex etc.
Five Steps i.e., Seiri, Seiton, Seiso, Seiketsu, Shitsuke each starting with S, are to be taken for
ensuring proper organization, neatness, cleanliness, standardization and discipline in work place
for sustained house keeping and management practices.
MOTIVATIONAL SCHEMES
VSP is a hi-tech capital intensive plant.The plant has to function at very high levels of operational
efficiency for its economic viability.
Designing a strong and effective Motivational Package is essential in order to have a motivated
and committed work-force to achieve and operate consistently at high performance levels and to
be a trend-setter in steel industry.
Incentive scheme
G
All the Non-executives and Executives upto E-6 grade are covered by Performance Linked
Incentive Scheme.
235
G
Scheme is based on two components - production volume and selected Techno Economic Factors
(TEFs) for each production dept. Incentive amount is same for all employees within the department.
G
It is desired to operate units beyond the rated capacities for low cost production and high return.
G
Three important TEFs are identified for each department. 5 levels are considered for each TEF.
G
Additional money multiplication factors on incentive are provided beyond 100% upto around
130% of rated capacity. These factors provide special attention & focus on production beyond
rated capacity for consistently operating at high operational efficiency and profitability.
G
Special sections factors and section change incentive are provided for all the Mills to roll value
added sections, low-productive sections which have demand in the market and also to encourage
employees to carry out roll pass changes as driven by marketing conditions.
SPECIAL PERFORMANCE AWARD SCHEME (SPAS)
OBJECTIVES
G
To encourage employees in turning out outstanding performance and setting new trends by
utilising their ingenuity, capabilities and creativity through individuals initiative, dynamism or team-
work etc.
G
To recognise such outstanding contributions made by the employees either individually or in a
group for the growth of the Company.
G
To give an impetus to the active participation of employees for the growth and excellence of the
Company in carrying out experimental/ innovative/exemplary activities.
ELIGIBILITY
All regular employees comprising of non-executives and executives (including Trainees) up to
the level of E-6 are eligible under the scheme.
The nature of cases that can be considered for award are given below:
a) A theft of Company's property that has been prevented by voluntary action on the part of an
individual or a group of employees.
b) Exemplary devotion to duty under conditions of emergency with glaring difference from others.
c) Profit to the company by settling the issues in time, avoiding huge penalties etc.
d) Any other commendable job, even on one time basis, setting new trends in the performance.
However the proposals not covering above cases will be examined and decided by the Committee
while keeping the recommendations of concerned HOD.
Cases covered under the Srujan Vikas - Suggestion Scheme/Employee Instantaneous Recognition
Scheme (EIRS) are not eligible for award under this scheme.
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Methodology :
AWARD
Works & Mines
G
Award up to Rs.5,000/- per case will be approved by Head of Works.
G
Award amount above 5,000/- and up to 10,000/- per case shall be approved by
Director(Operations).
G
Award amount above Rs.10,000/- and up to 15,000/- will be put up to CMD for approval.
OTHER THAN WORKS & MINES
G
Award amount up to Rs.5,000/- per case will be approved by concerned HOD(not less than E-8 grade)
G
Award amount above Rs.5,000/- and upto Rs.10,000/- per case shall be approved by respective
Functional Director.
G
Award amount above 10,000/- and up to 15,000/- will be put up to CMD for approval.
The award is limited to an amount of maximum Rs.15,000/- for each case.
Convener shall process the cases recommended by the committee, for obtaining necessary
approval and co-ordinate the activities connected with issue of cheques.
The cheques shall be presented to the individual by the respective HOD preferably in a function.
A certificate of recognition to the individual/group is presented.
EMPLOYEE INSTANTANEOUS RECOGNITION SCHEME
OBJECTIVE
To provide instant recognition and encouragement to employees for achieving outstanding
performance and showing individual initiative.
SCOPE
The Employee Instantaneous Recognition Scheme' (EIRS) shall cover Executives upto E-6 grade
and all regular Non-executive employees.
ELIGIBILITY
The eligibility criteria for determining the cases for recognition under the scheme are given below :
a) Any cost saving to the Company because of the individual initiative taken by the employee.
b) An innovative/modification carried out at the instance of the employee resulting in improvement
of processes or equipment availability.
c) Enhanced output in quantifiable terms in a single shift because of the individual effort.
d) Any other commendable job, even on one time basis, setting new trends in performance.
e) Any individual initiative shown by the employee which has proved crucial to resolving a crisis situation.
f) Achievements under Suggestion Scheme, Quality Circles, Quality Improvement Projects etc.,
are excluded from the purview of this scheme.
237
Chapter - 48
MARKETING DEPARTMENT
48.0 Steel Scenario
48.1 World
Steel Industry being one of the core sectors of the economy plays an important role in economic
development of the country. There has been a steady growth in the world crude steel production over
the years. The crude steel production which was in the order of 28 million tonnes (Mt) in the year 1900
has increased to 190 Mt in the year 1950. The second half of the 20th Century witnessed huge growth
of the world crude steel production. The world crude steel production reached a level of 848 Mt in
2000. During 21st Century the growth trend of the steel sector continued with an accelerated pace. In
2004, the world crude steel production surpassed 1 billion tonne mark by registering production of
1069 million tonnes. In the subsequent years, the growth trend is continued till 2007. The growth in the
steel sectors in the preceding 10 years is mainly powered by the growth in China. Region-wise crude
steel production in the last few years is brought below.
Unit: Mt
Region 2002 2003 2004 2005 2006 2007 2008
Europe 208 214 226 221 235 240 230
CIS 101 106 113 113 120 124 114
North America 123 126 134 128 132 133 125
South America 41 43 46 45 45 48 47
Africa 16 16 17 18 19 19 17
Middle East 12 13 14 15 15 16 17
Asia 395 442 510 598 676 762 769
China 182 222 280 356 423 495 500
Japan 108 111 113 112 116 120 119
India 29 32 33 46 49 53 55
World 904 970 1069 1147 1251 1351 1327
After registering year-on-year growth in world crude steel production since 1998, the crude steel production
witnessed negative growth in 2008 due to worldwide economic recession. Thus, the positive growth trend
continued for 9 years. This economic recession is primarily triggered by US economic crisis.
238
48.2 India
At the time of independence, the crude steel production in India was over 1 Mt. Indian Steel industry
got a new lease of life with identification of steel sector as one of the core sectors of economy.
Accordingly, special thrust was given by the Govt. of India for development of the steel sector. After
Independence, in the initial years, three integrated steel plants were started in the public sector.
These steel plants with an initial capacity of 1 Mt each, were set up at Bhilai, Rourkela & Durgapur with
collaboration of the erstwhile USSR, Germany and England respectively. Subsequently, the capacities
of these plants were enhanced. The fourth PSU steel plant was set up at Bokaro in 70s. The next
public sector integrated steel plant to be set up was Visakhapatnam Steel Plant.
The crude steel production in the country was about 15 million tonnes by 1992, when GOI initiated
steps to liberalize Indian Economy. At that time, licensing requirement for setting up steel plants was
removed. The pricing and distribution controls on steel products were also lifted. The system of extending
budgetary support to PSU steel plants has also been done away with. The post liberalization era has
seen impressive growth in the capacity addition in the Steel Sector in the Country.
In the post liberalized era, major integrated steel plants like Essar Steel, JSW Steel, Ispat Industries,
JSPL etc. were set up in addition to many other small capacity steel plants, raising the crude steel
production capacity in the country substantially. Thus, the crude steel production in the country has
increased from about 15 Mt in 1991-92 to about 28 Mt in 2000-01 and further to 55 Mt in 2007-08. It is
projected that the domestic demand for steel will be about 120 Mt by 2012-13 and 200 Mt by 2019-20.
48.2.0 Visakhapatnam Steel Plant
48.2.1 Marketing
For Visakhapatnam Steel Plant, it was a challenge as the plant was set up in a decontrolled regime.
Releasing its responsibilities, VSP stabilized its operations quickly and achieved rated capacity levels
at the earliest. VSP has quickly become a market leader in its range of products. The Plant also
established its presence in the Export Market by exporting iron and steel products to various countries
in its initial years of operation itself. In the domestic market VSP has established its name as a quality
steel producer. The Market Share of VSP amongst the main producers i.e. SAIL, Tata Steel and RINL
has been 42% in 2007-08.
The principal products of VSP include, pig iron, steel products consisting of wire rods, reinforcement
bars, rounds, structures like angles, beams, channels, blooms, billets and squares and by-products
like coal chemicals and ammonium sulphate and granulated slag. The industries, where products of
VSP are used are construction industry, wire drawing industry, bright bar industry, fastener industry
and forging and re-rolling industry. The end users of VSP's products also include electrode
manufacturers, railways, automobile industry, engineering industry, cable industry, etc. While coal
chemicals are used by chemical industries, ammonium sulphate is used in agriculture and granulated
slag is used cement manufacturing. VSP markets majority of its products in the domestic market.
48.2.1 Distribution Network
VSP has a network of 5 Regional Offices and 23 Branch Offices and Stock Yards in various States in
India and are catering to the needs and expectations of the customers in various segments. Further,
VSP has Consignment Sales agents in Raipur, Jamshedpur, Pondicherry, Jammu and Guwahati.
Exports and Byproducts Division are located at Head Quarters. The location of Regional Offices and
Branch Officers are indicated below :
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North
Agra
Chandighar
Ghaziabad
Faridabad
Ludhiana
Jaipur
Kanpur
Dehradun
South
Chennai
Bangalore
Kochi
Coimbatore

East
Kolkata
Bhubswar.
Patna

West
Mumbai
Ahmedabad
Pune
Indore
Nagpur

Andhra
Vizag
Hyderabad

The locations of Branches under various Regions spread all over the country are as follows:
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Out of the total stockyards, three stock yards at Hyderabad, Chennai and Mumbai are owned by VSP.
Handling Contractors are appointed for carrying out stock yard operations at own stock yards and
Consignments Agents (CAs) are appointed for the remaining stock yards to take care of the custody
and carry out handling operations. Consignment Agents, Consignment Sales Agents and Handling
Contractors are appointed on Long term basis as Business Partners. They take responsibility of
unloading, transportation of material from siding to the stockyard, proper stacking, accounting and
delivery of the correct material to the customers. With a view to facilitating the customers for easy
transportation and usage at their end, VSP is supplying steel products in processed form as a value
added service from the stockyards as well as from the head quarters. The material is moved to the
stockyards by rail and road. In order to take advantage of other modes of transport and improve
logistics, material is dispatched by CONCUR. Transportation of material through coastal transport
route is also explored and resorted to in case it is found economical.
RINL, VSP has started the system of appointing District Level Dealers (DLDs) for distributing steel in
the rural markets from 2004-05. Phase-wise implementation of this scheme is planned. Till the end of
2007-08, 134 DLDs have been appointed covering almost all the states in South India and neighbouring
States i.e. Orissa, Chattishgarh and Maharashtra. Ultimately, it is planned to cover all the 603 Districts
in the Country.
VSP's Marketing Department has got total manpower of about 300 employees, out of which over 100
employees are posted at Head Quarter and rest are posted in the Regions, Branches and Stockyards.
48.2.3 Distribution of Iron & Steel Products
The regional distribution of domestic sales of steel during 2007-08 has been : South (incl Andhra) :
55%, West :17%, North: 22% and East: 6%.
VSP maintains its presence in the export market by exporting about 5-10% of the production. VSP
exports the products to various destinations such as Sri Lanka, US, Bangladesh, Middle East, Singapore
etc. Export of materials also takes place for Nepal but through road. VSP's customers include the
following categories :
G
Actual Users : Re-rolling, Forging, Bright bar, Elastic Railway Clips etc.
G
Projects
G
Traders
G
SSICs/NSIC
G
District Level Dealers
VSP allocates steel products to SSICs/NSIC s as per the policy guidelines issued by Ministry of Steel, GOI.
Sales to different customers are made as per the sales policy prepared at the beginning of the year.
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Unit : Value in Rs. Cr, Volume in '000 tonnes
Volume Value Volume Value Volume Value Volume Value Volume Value
PIG IRON (DOM) 57 61 120 198 307 426 186 319 157 329
PIG IRON (EXP) 397 336 110 146 104 118 159 207 255 404
TOTAL PIG IRON 454 397 230 344 411 543 345 525 412 733
IRON SCRAP (DOM) 23 17 6 8 15 17 24 21 23 28
TOTAL IRON 477 414 236 352 426 560 369 547 434 761
STEEL (DOM) 2811 5199 3064 7582 3105 7447 3145 8147 2879 9300
TRADING STEEL (DOM) 0 0 0 0
STEEL (EXP) 345 433 56 102 202 325 121 218 62 150
TOTAL STEEL 3156 5632 3119 7685 3307 7772 3266 8365 2941 9450
BY-PRODUCT 120 143 150 220 217
Other Stores Products /
Freight Recovery
3 1
TOTAL DOMESTIC 5400 7933 8040 8707 9874
TOTAL EXPORT 769 249 443 424 555
GRAND TOTAL 6169 8181 8482 9131 10428
PRODUCT
2003-04 2004-05 2005-06 2006-07 2007-08
48. 2.5 Functions of Marketing Department
At Head Quarters, Marketing, the following Sections are functioning. The functions of each of these
Sections are enumerated below :
2.5.1. Management Information System (MIS) and Ministry Coordination
2.5.2. Special Steel & Product Development
2.5.3. Pricing & Policy
2.5.4. Planning & Despatch
2.5.5. Head-Quarter Sales
2.5.6. By-products
2.5.7. Tender & Scrap Sales Department
2.5.8. Project Sales
2.5.9. BCSY
2.5.10. NSY
2.5.11. BC Gate
2.5.12. Contracts
2.5.13. Exports
2.5.14. Stockyard Development
2.5.15. CRM
2.5.16. Administration
48. 2.4 Sales Performance of VSP
The sales performance of RINL for the period from 2003-04 to 2007-08 is brought below.
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48. 5.1 MIS & MINISTRY COORDINATION
This Section prepares various Reports on performance. Yearly / Monthly Sales Plans are prepared.
Sales analysis and information in desired format is furnished to the Management as and when required.
MIS prepares a Daily Sales Report, which is called as "Daily Flash" before 9 am (Sales of previous
day) for the information of Top Management. MIS prepares monthly marketing performance report in
which following details are included.
- Sales performance
- Movement of stock
- Total sales Vs production
- Month wise total sales report
- Month wise domestic / export sales report
- Region wise/ Branch wise month wise, product wise sales
- Region wise market share
- Sales value and volume
Allocation, Demand Registration, Offer and lifting of steel products by SSICs/NSIC are monitored by
MIS. Further, jobs related to Ministry coordination like responding to queries on various issues, furnishing
data/information for the Consumer Council Meetings, Small Scale Industry Coordination and Review
Meetings etc. are also carried out. MIS prepares the presentations required by the marketing department
from time to time.
48.5.2 SPECIAL STEEL & PRODUCT DEVELOPMENT (SS&PD)
This section deals with the sales of special steel (value added) products. Various branches send their
requirement of special steels to Special Steel & Product Development Section. This data is consolidated
by the Section and after discussing with the PPM Department during the weekly coordination meeting,
used for finalizing the rolling plan. Once the material planned is produced, Special Steels Section
coordinates with Planning and Despatch Section for despatch of the material according to the
requirement. For a new product development, requests from the Branches are received and discussions
held with the Works Dept. regarding feasibility of the production. In case found feasible, coordinates
with Works for producing these products. SS&PD also take customer feedback about the new product
developed. To interact with the customers directly, a team comprising of Works, QA&TD and Marketing
from Head Quarters visit the customer premises at regular intervals and take the feedback on the
quality, product availability and other issues.
The section is also involved in the pricing of special steel product and generation of special report as
required regularly.
48.5.3 PRICING & POLICY
Pricing : The function of pricing section is to fix the price for various products for all the Branches at
the beginning of the month or whenever necessary and communicate the same to the Regions/
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Branches. The Pricing Section maintains price masters and communicates the prices to Regions/
Branches regularly. The section keeps in constant touch with the Market for knowing the price trends
in the Market. This data forms a basis for fixing prices of VSP's products.
Policy : This section looks after the policies of Marketing Department. Various polices are made as per
the market conditions and requirement of the Business. The Section issues Circulars related to various
policies like Credit Sales Policy, Project Sales Policy, LTC Policy, DLDS Policy etc., whenever necessary.
They also examine the various proposals initiated by the Branches and Regions in respect of policy
to study the deviations, if any. Various sales modes for which Policies are formulated are as under :
- Project Sales
- MOUs
- E-auction
- DLDS etc.
- Tender Sales
48.5.4 PLANNING & DESPATCH
This section looks after the Planning & Despatch of materials to various Branches. They consolidate
the requirement projected by the Branches by 20th of a month for the ensuing month and take up with
Works and finalize the rolling plan during the weekly coordination meetings. Accordingly, based on the
production and availability of material as well as target set for the Region and Branches, the section
allocate the material to the Branches. The following are the modes of transport generally resorted to:
- Road
- Rail
- Containers
For Rail despatches various types of rakes with combination of wagons (BOXN, BOXC, BOST, and
CONCUR) are available.
48.5.5 HQ SALES
Head Quarter sales comes under Andhra Region. Customers bring the requisition of material and
contact the concerned in-charge. The In-charge sanctions the proposal according to material availability
and then an offer letter is issued to the customer. With that offer letter customer goes to finance
section and deposit the money and comes back with receipt again to get the delivery order.
48.5.6 BY-PRODUCTS
By products Section deals with sales of products like Coal Chemicals, Granulated Slag, Ammonium
Sulphate, Gases etc. There are sold through Tender Sales, e-auctions, MOUs, On the spot sales etc.
48.5.7 TENDER & SCRAP SALES DEPARTMENT
In tender and scrap sales department two types of sales are being done:
Normal sales
Iron : PCM Jam, PCM Muck and Fines, Iron Chips and Dust etc.
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Steel : Crop Ends of Billets (0.5-3.0 metres), Miss Roll Rounds > 25mm (0.5-3.0 metres), Short Length
Blooms etc.
Tender Sales
E-auction Procedure
- Customers have to register themselves in VSP's website www.vizagsteel.com
- Sending of LOI (letter of Intent) with EMD (Earnest Money Deposit)
- After that various reports as brought out below are generated.
J Bid history
J Customer name, lot no., price
J Eligible candidates list
J Eligible candidates participation in the Tender
J Highest bidder i.e. H-1 list for each lot
J Comparison of Quoted Prices with Reserve Committee Prices
Those who qualify of 90% criteria are awarded with materials. if for some lot there are no eligible
candidates re-tendering is allowed.
48.5.8 PROJECT SALES
Project Sales Section coordinates for sale of steel products to Projects. Since Indian Economy is
growing and lot of investments is taking place for Infrastructure Development and New Projects are
coming up in different Sectors like roads, housing, bridges etc. Criteria are laid down to identify the
Project customers. This section keeps an eye on the ongoing projects and upcoming projects and in
turn contacts the Regions in which it is coming up. There are two modes of Project Sales:
- Participating in Tenders for supplying steel products
- MOUs with Customers for supply of products
For participating in Tenders various delegations of power are there depending on the position of the
executive.
48.5.9 BCSY
Some of the steel products produced in the Plant are shifted to Balacheruvu Stockyard (BCSY) for
dispatch to Stockyards / sale at Head Quarters. For identifying the special steel grade materials
various color codes are followed. There are two modes of despatch from BCSY:
- Rail
- Road
In case of Rail dispatch indents come from Planning & Despatch section, which first goes to PPM
Dept. which in turn raise indent to Traffic Dept. Traffic Dept. raises indent on Railways and get the
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required rakes allocated according to availability. After that, the section sends an online Placement
Memo for required material to BCSY. In BCSY printout of it is taken and given to handling contractor,
who loads the material in the respective wagons as mentioned in the Placement Memo. After loading
is over, all the wagons goes for weighment and if any adjustment is needed an Adjustment Memo is
raised by the Traffic Dept. and the rake goes to the respective Mill Bay where necessary adjustment
is made. After that TXR Clearance Certificate is obtained which is issued by Train Examiner and then
final weighment is done. After handing over of final weighing Forwarding Note is handed over to the
Railways on the basis of which freight payment is made from Finance Dept. Railways then issues RR
which is handed over to BC-Gate by courier. They in turn issue the STC (Stock Transfer Challan)
which goes to the respective branch Online as well as by Courier also.
In case of Road Despatch, BCSY gives the clearance of material availability on the Delivery Orders.
Then the vehicle enters the Plant after getting LSGP (Loading Slip cum Gate Pass) from BC-Gate and
the initial weighment of vehicle is done which is known as Tare Weight. After loading the material final
weighment is done and from BC-Gate Final Challan and Test Certificate are issued, which are handed
over to the concerned person.
48.5.10 NSY
In New Stock Yard all the Crop Ends of all the Mill Products came through internal wagons and all the
defective materials like material containing surface defects, surface irregularities, over and under
sizes are also received. The main functions in NSY are receipts and sales of materials.
Receipts
The materials are received by two modes :
By internal wagons : LMMM/ MMSM/ WRM Crop Ends and Defectives
- Unloading of internal wagon
- Loading and unloading of all items including blooms is done by VSP (Construction Dept.) with
the help of FMD Cranes.
By road : Blooms
- Transportation of blooms from BSY to NSY
- Unloading and stacking is done by HSCL
Sales
Two modes of sales take place. These are Normal Sales (Blooms & Billets) and Tender Sales
Handling
HSCL (Transportation of Blooms & Billets from BSY to NSY & unloading)
Const. Dept. (For handling)
FMD Dept. (Supply & Maintenance of Cranes and Crane Operators)
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48.5.11 BC Gate
Function of BC Gate is to generate documents for both Rail and Road despatches. In case of Rail
Despatch after getting the RRs from Railways, STCs are generated and in case of Road Despatch
first LSGP is issued for entry of vehicle and then after loading final Challan with Test certificates are
issued for exit of vehicle.
48.5.12 CONTRACTS
Contracts section has mainly four functions:
- CA (Consignment Agency) Contract finalization
- CSA (Consignment Sales Agency) Contract finalization
- Transportation contract finalization
- Legal and Arbitration matters related to above mentioned
CA Contract Finalization : VSP is having its own stock-yard at three places i.e. Hyderabad, Chennai
and Mumbai. In these Stockyards Handling Contractor are appointed. For handling the material at
different branches where VSP's own Stockyard is not there CA (Consignment Agents) are appointed.
The finalization of CA Contract is done by this Section. For that Open Tenders are floated for a
particular Stockyard in which Two Bid Systems is followed as indicated below :
PART-1 : Technical Bid + Commercial Bid
PART-2 : Price Bid
After receiving the Quotations, the technical details furnished by the party are evaluated with the
requirements specified in the NIT (Notice Inviting Tender) and those who qualified on those criteria by
TC (Tender Committee), clearance will be given for opening of Price Bid. The L-1 Party will be evaluated
and the contract is awarded to the L-1 Party. The Technical Criteria, which VSP look for are required
land area, no. of cranes, required relevant experience and PF registration. The contract is normally
awarded for five years.
Transportation Contracts Finalization
The procedure for finalizing the Transportation Contract is similar to the above except for the Technical
Criteria. For this the Technical Criteria, VSP look for are PF Registration, Freight Earning Certificate
and IBA (Indian Banker's Association) Certificate.
CSA Contract Finalization
To increase the sales of VSP products in the areas where VSP doesn't have any other sales outlet
consignment sales agency are appointed. At present VSP is having CSA at five places namely :
Jammu (operated by Ludhiana Branch)
Guwahati (operated by Kolkata Branch)
Jamshedpur (operated by Patna Branch)
Raipur (operated by Vizag Branch) and
Pondicherry (operated by Chennai Branch)
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For appointment of CSA concerned BM / RM initiates the proposals and submit it to HQ through RFM
for approval of D(C). On approval RM will indicate the controlling branch to operate the contract.
RM issues the tender documents. The Technical and Commercial Bid are opened at Regional Office
by a committee comprising of RM, RFM and BM concerned. Recommendations made by the committee
are put up to the HQ Committee and the Price Bid of short listed agencies is opened by the HQ
Committee and accordingly the Contract is awarded. A bank collection account is opened at designated
bank for depositing of the sales proceeds by CSA.
Arbitrations and Legal Disputes : Contracts Section also looks for any Legal problems related to
the above mentioned areas.
48.5.13 EXPORTS
This section looks after all the Exports of the materials. At the start of the financial year based on past
data analysis and target set quantities are allocated to various countries. Tenders are floated for the
whole quantity allocated for the particular countries. Sizes, Grades and Chemistry are not mentioned
in the Tender. For participating in Tender EMD is required which was earlier 1%, now US $4 per tonne.
Accordingly the party is finalized by Tender Committee, who qualifies all the criteria and intimated.
After getting the confirmation from the Party, Contract is signed in which details about the Quantity,
Grade, Size and Chemistry are mentioned and after that Rolling Program is finalized in consultation
with PPM Dept. and accordingly material is rolled. The buyer has to give LC (Letter of Credit) in the
prescribed format to VSP. This LC may be issued from any Bank of buyer's choice which is called
Issuing Bank but it should be advised from any Indian Bank, which is known as LC Advising Bank.
Then this LC comes to RINL which is send to LC Confirming Bank. This LC Confirming Bank lodges
its claim to LC Reimbursement Bank. Validity period of LC is normally given as 21 days which can be
extended whenever needed by the buyer. This way payment is made. Material is shifted to port by
generating ESTA (Export Stock Transfer Advice). After loading the material following documents are
generated :
Invoice
Packing List
Bill of loading from Captain of Vessel
Certificate of Origin from Local Chamber of Commerce
Inspection Certificate by BSI
Work Test Certificate from QA&TD
Shipping Bill from customs
Beneficiary Certificate
Copy of fax
The Sales Tax and Excise Duties are exempted in case of Exports. Despatch Benefits are also there as well
as demurrage losses for earlier or late loading respectively from normal schedule are also there.
Advance Licenses Section is a part of Exports. DEPB and DFRC system and Custom Benefits are
looked after by the Advance Licenses Section.
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There are provisions of import duty exemption on the Raw Materials, which has to be used for producing
the finished or semi finished products and to be exported. For that, careful analysis of Export Quantity
has to be made because if the quantity projected for export is not exported, whereas for that raw
material is already imported without paying the import duty, then import duty with penalty is charged.
The quantity of raw material, which has to be imported has to be confirmed from the Works Dept. After
getting confirmation the order is placed. All exports to Nepal take place by road.
48.5.14 STOCKYARD DEVELOPMENT
This Section looks after various jobs connected to opening of New Stockyards, Modifications/Up-
gradation of existing own Stockyards, Acquisition of Properties for Offices/Residences etc. for Regional
Offices/Branches.
48.5.15 CRM (CUSTOMER RELATIONSHIP MANAGEMENT)
To give thrust to customer service activities, a Central CRM Cell is functioning at HQ Marketing. This
CRM Cell is in constant touch with the Regions/Branches for CRM related activities. In line with the
objective of CRM, the following activities are carried out.
A Customer Policy is adopted and feedback is also been collected regularly from
customers.
Various operational guidelines and norms are placed for different sales operations like
issue of offer letter / delivery order, loading at stockyard and refunds etc, to serve the
customer effectively.
For expediting settlement of customer Quality Complaints, E- system has been
implemented on VSP's Intranet, which eliminated lot of paper work in processing of quality
complaints.
For getting customer feedback, a Customer Feedback form is available in the concerned Branch
Sales Office. The Customers can fill it and send to the CRM Section of Marketing. On the basis of
various parameters of feedback form Customer Satisfaction is analyzed and necessary actions are
taken to improve the level of satisfaction. System of replying to Customer Queries on VSP's Portal
within 24 hours has also been implemented. This Section also looks after Internal as well as Govt.
Audits, coordinating for giving replies, ISO Auditing & implementation and Railway Claims.
48.5.16 MARKETING ADMINISTRATION
Monitoring of the Administrative Expenditure Budget (Capital and Revenue) Allocation, Expenditure
and Budget Projections are looked after by this Section. All the Lease Accommodation proposals from
Branches are processed by this Section. Attendance Records of Head Quarters as well as Branches
are maintained by Administration Section. All the Medical Bills of Marketing Dept. employees, Head
Quarter as well as Branches are collected and sent to Personal Dept. for clearance. Stationery
requirement of all the Branches as well as Head Quarter are consolidated by this Section and sent to
Finance for approval. Over Due Outstanding related to Credit Sales for various Branches are also
consolidated here and corresponding Report is prepared. All the correspondence i.e. receiving and
despatching of Couriers and Posts are also done by this Section. This Section also looks after the
requirement of Furniture and Office Equipment of the Head Quarters Marketing.
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Chapter - 49
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251
252
253
254
255
256
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Chapter - 50
MEDICAL & HEALTH SERVICES
The provision of Medical & Health services to VSP employees was initiated in 1983 and was gradually
upgraded to the level of an ultra modern hospital in Dec.1991.
1) Patient -Focused Excellence
2) Valuing Staff and Partners
3) Management by facts
4) Having Ethics-Medical - Personnel
5) Social & Community Health Care
6) Systems Oriented
7) Need based
8) Statutory requirements-OHS&RC
9) Futuristic vision
Different Main Units of Medical &Health Services
1. Visakha Steel General hospital
2. Health Centre-Sector-2
3. EmC_I&II - Inside the plant
4. Peda Gantyada health Centre
5. OHS&RC
6. Mines Hospitals
Special features of the Medical Department of VSP.
VISAKHA STEEL GENERAL HOSPITAL (VSGH)
The central hospital located in the township spread out in a vast area of 10 acres with the
modern facilities for diagnosis and cure of ailments. The following are the special features of
VSGH :
1) Modern outpatient wing with 27 clinics
2) In patient facilities with 160 beds.
3) Well-equipped Casualty Wing
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4) Eight operation theatres
5) Full-fledged laboratory with modern, computerized equipment for Biochemical,
Microbiological and pathological tests, with high level of quality control
6) Full-fledged Blood Bank
7) Full-fledged Radiology Department
8) Modern Main Burns Unit (best of its kind in South India)
9) Modern Intensive care Unit with a Central Monitor
10) NICU- unit
11) Laparosopy equipment (Operative+diagnostic) for Gynaec Dept.)
12) Hysteroscopy
13) Puvatherapy unit
14) Dental Dept.
15) Opthlomology Dept; having modern equipment like FACO Emulsifier
16) Orhopaedic s with C-arm and Orthoroscope, Power drill
17) ENT dept; fully equipment with modern equipment
18) Keratometer
19) SLIT Lamp, SLIT LAMP WITH Apparation tonometer
20) Auto Refroctometer
21) Operating Microscope
22) Nasal Video Endoscopy
23) Audiometry Unit
24) Computerised dental unit
25) Incubators for sick and premature babys
26) Phototherapy Unit
27) Fully Air Conditioned Medical Stores
28) Separate dispensary & well equipped physiotherapy units
29) Well equipped Central Sterilization Unit
30) Central Oxygen supply unit
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31) Eight ambulances.
32) Laundry
33) Modern Mortuary Unit
34) Well organized Administrative Block
35) Library cum Conference Hall where referral books and journals
Cluster type general wards ( as per WHO standards)
The VSGH caters to nearly 40,000 residents of township, with a daily out patient load of
nearly 2,100 to 2,500 and a bed occupancy rate of 85 to 95%.
PERIPHERAL HEALTH UNITS :
OCCUPATIONAL HEALTH SERVICES & RESEARCH CENTRE (OHS&RC)
INTRODUCTION :
The value of Human Resources and well-being of the work-force are becoming essential for an
organization.
Steel industry is notified as a hazardous industry as per the Indian factories act. Occupational Health
and safety hazards of Steel Industry are well documented.
Enlightened employers consider Occupational Health Services as a vital investment in Human
Resources and also as a top managerial function.
DEFINITION
Occupational Health Services (OHS) is a candid and comprehensive, multi-disciplinary,
multidimensional health promotive programme at enterprise level with emphasis on work, workers,
working conditions and, in particular, human relations, involving innumerable and complex psyche-
social factors.
AIMS
G
Provision of comprehensive Occupational Health Care.
G
To achieve highest possible level of health.
G
To maximize production through a healthy workforce.
OBJECTIVES :
1. To promote and maintain the health of employees at levels conducive for international levels of
performance.
2. To formulate guidelines for the prevention of Occupational or Work related diseases (WRD)
260
3. To design and implement preventive health programs for high-risk-groups.
4. To identify/evaluate hazards in the work environment and suggest measures of control.
5. To advise the Management in designing employee health policy/schemes.
6. To educate and enable employees in keeping themselves healthy and fit.
7. To maintain accurate records of health and work environment as required by the Statute.
8. To notify health data as per the Statute.
9. To develop a well-trained, motivated and talented health-team that would take total health
care to grass root levels.
10. To deliver services cost-effectively.
The Occupational Health Services & Research Centre was inaugurated on 4
th
November 1992
to adequately fulfill the above objectives.
The activities commenced from 23rd November 1992. This unit is the only O H S unit in Steel
Industry to * Obtain ISO-9001 ISO-14001 & OHSAS 18001 certifications
* ON GOING HEALTH EDUCATION PROGRAMME FOR EMPLOYEES (since 1997)
* Certificate course on First Aids for employees (since 1999)
FUNCTIONAL UNITS
1. Occupational Medicine Unit
2. Occupational Physiology Unit.
3. Industrial Toxicology Unit.
4. Clinical Laboratory Unit.
5. Radiology Unit.
6. Industrial Hygiene Unit
7. Health Education & Counseling Unit.
8. Storage of Health Records Unit.
9. Health information & Statistics Unit.
10. Eye Testing Unit.
11. Replenishment of First Aid Kits Unit.
12. Emergency Medical Care Units.
13. Audiometer Unit.
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FACILITIES AVAILABLE :
- Routine medical care and follow-up treatment facilities.
- Emergency medical care facilities round the clock-both out patient and inpatient.
- ECG and Digital X-Ray facility
- Clinical-Laboratory & Biochemistry
- Round the clock ambulance services
- Referral & follow-up services (at Visakha Steel General Hospital)
EQUIPMENT AVAILABLE :
- MEDSPIROR (PC BASED) Digital Spiro meter
- AUDIOMETER
- CYGNET SOUND LEVEL METER
- NOISE DOSI METERS
AT VSGH
1) Monitors in each cabin with central monitor
2) Computerized Thread Mill
3) Holter Monitor
4) Defibrillator
5) Bio-thesio meter (Vibration sense)
6) Glucometer
7) ECG Machines
8) Nebulizers
9) Modern Laboratory equipment - Hitachi 902 Biochemical Analyzer, Automated
Hematology Unit, Elisa Reader, Auto tissue processor and Micro photography
Unit
Under Steel Doctors Trust and CSR activities various medical and health camps were
conducted.
Observing WHO day, World AIDS day, World Diabetic Day, Nurses Day & conducting
various suitable programmes to educate employees and their families.
Apart from this general health check up, councelling for adolescents, women in
premenopausal age and obese people.
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De-addiction clinic in VSGH and also in the plant
Health Awareness programmers in schools of townships and rehabilitations colonies.
Distribution of Key chains with condoms and staging street plays in various districts of
A.P. as part of awareness programme for public on AIDS.
Participating successfully in QC & 5S
Representing and participating actively in various national and international seminars
Some of senior doctors were chair persons in some of the national conferences
Few of our employees were awarded JLN awards
Articles both Scientific and general articles written by some of our staff were published
in various journals and magazines
1) Man maintenance programme (MMP)
The employees are scheduled for undergoing statutory medical examinations, with due priority
to hazardous zones in the plant. The facility is also extended to CISF Personnel Canteen
Workers and Contract workers.
2) Periodical Medical Examination (PME)
The employees once covered under MMP are periodically re-examined as per the following
schedule.
1. Works Departments
Hazardous Zones - Once every year
Less Hazardous Zones - Once every 3 years
2. Non-works departments - once every 5 years
3) TOXICOLOGICAL EVALUATION:
The employees working in hazardous areas are evaluated periodically for early identification of
toxic hazards and their prevention.
4) HEALTH EDUCATION :
This is one of the primary prevention activity wherein the employees are oriented on issues of
public health importance with special emphasis on prevention. The topics also include
emergency care aspects in addition to communicable and noncommunicable diseases. In
addition to employees, contract workers are also covered.
Nearly 340 sessions per year on Health education are conducted. Be sides special sessions
are conducted in shop floors.
5) REPLENISHMENT OF FIRST AID KITS:
The 540 first aid kits distributed in the shop-floors are regularly replenished as per the statutory
norms.
263
6) EYE EXAMINATION OF CRANE OPERATORS & HEAVY EQUIPMENT OPERATORS
This statutory requirement is met by regular examination of all the crane operators and heavy
equipment operators for acuity of vision.
7) MAINTENANCE OF HEALTH RECORDS:
Facilities are made available for recording and storing health data of employees for timely
retrieval and analysis.
8) INDUSTRIAL HYGIENE SURVEYS :
Regular inspectional and instrumental surveys are carried out by the industrial hygiene team
for identification and evaluation of work place health hazards and to suggest measures for
control.
9) CANTEEN WORKER MEDICAL EXAMINATION:
This statutory provision in fulfilled in annual basis covering all the canteen workers.
10) ORIENTATION ON OCCUPATIONAL HEALTH :
Special orientation sessions on Occupational health are conducted to employees final year
MBBS students Postgraduate students in social & Prevention Medicine.
11) MEDICAL RESEARCH
Research oriented work on work related diseases is carried out on regular basis.
SPECIAL HEALTH PROGRAMMES :
Periodical examination of at risk groups
Know your blood group programme
Hearing conservation Programme
Immunization against Tetanus
Employee Rehabilitation.
EMERGENCY MEDICAL CARE SERVICES
The units functioning round the clock inside the plant with full complement of staff.
- Fully equipped Ambulances and all emergency Medicines.
HEALTH CENTRE (SECTOR-II)
HEALTH CENTRE (PEDAGANTYADA)
The Peripheral units cater to patients from Rehabilitation Colonies.
264
Chapter - 51
PERSONNEL DEPARTMENT
INTRODUCTION :
One of the primary objectives of Organizations is to develop a well-knit personnel policy and
comprehensive personnel systems that are result-oriented and to develop an organizational culture
which motivates employees to contribute their best towards the achievement of organizational objectives.
In accordance with this objective, VSP has given considerable emphasis on development of human
resources, as well as formulation and implementation of progressive personnel policies, systems,
rules and procedures with an objective to synchronies organizational needs with individual aspirations,
Since inception, VSP has laid emphasis on effective man management as it subscribes to the belief
that effectiveness and success of the organization depend largely on the skills and commitment of the
people.
The rigorous and systematic approach to recruitment - from fresh candidates their upwards-training,
promotions and rewards have all helped to meet the aspirational needs of the individual and thereby
the goals of the organization.
VSP has developed a comprehensive scheme of carrer planning and managerial succession.
In the field of industrial relations, VSP encourages a participative approach. A career with VSP will
mark the beginning a quest for advancement. VSP is a fast expanding organization and provides
ample opportunities to bright yougsters to rise in the organizational hierarchy.
Looking into the rapid growth of the Organization and the multifarious specialized function,
there exists opportunities for a rapid career growth in the area where aptitude lies.
Brief History :
The Personnel & Administration Department was established alongwith establishment of the Company
in the year 1982. Initially, the department was operated from RTC Complex at city which was later
shifted to CISF Barracks and Auxiliary Shops premises respectively located in the plant premises.
Since then the department has professionally spread in the entire plant keeping in view of the
requirement of the personnel working in the Company to give personnel services at the door step of
the internal customers.
Transformation and metamorphoses of the function :
Emphasis on Personnel and Industrial Relations functions have been gradually converted into HR
functions linking with HR strategies and plans for attainment of the organizational goals and objectives
human resources have been put above machines, as after all the machine is made by man. Year after
year, the HRM function has been enriching itself through renewed vigor to meet the challenges and
requirements during project, commissioning and operation stages. The department has met successfully
the requirements at each stage and nurtured itself as a function which can turn around the Company.
Although the HR professionals have seen turbulent period in the initial stages of project and
commissioning, once the systems have set into operation, the fruits of seeds that have been sown by
personnel professionals have starting the yielding results. Apart from highest Labour Productivity in
265
ORGANIZATION CHART (PERSONNEL DIRECTORATE)
Director (Personnel)
GM (TA & A)
ED (P&IR)
GM (MS)
DGM (P) - PP I/c
DGM (P) -
CER & NW
DGM (P) - CC
DGM (P) - Projects
DGM (Admn.)
DGM (TA) I/c
DGM
(Land & Estate)
GM (P & LA)
DGM (P) (LA)

AGM (P) - EE
GM (CP&C)
DGM (P)-
Rules & Cord
DGM (P) Rectt. & Welfare
GM (Trg. & HRD)
DGM (Trg.)
AGM (HRD) I/c
AGM (Tenders)
GM (M&HS)
DGM
(Agro forestry)
DGM (CSR
the integrated steel plants of India, Human Resources at Visakhapatnam Steel Plant are breaking
records after records day after day achieving peaks of production, productivity and all round development
of the company.
Organization Structure of Personnel Department :
Human Resources have been given utmost importance with appointment of a Director
(Personnel) to look after whole gamut of HR functions at VSP. ED (P&IR), GM (TA&A), GM (CP & C),
GM (P&LA), GM (Trg. & HRD), GM (M&HS), DGM (CSR), DGM (Agro & Forestry) directly report to
Director (Personnel). While the GM (P&A) looks after recruitment, HR functions of Senior Officers, the
ED (P&IR) looks after HR functions of the rest of the manpower and gives due emphasis to Industrial
Relations, Employees Welfare, Rules & Policies, Plant Personnel, Contract Labour, Canteen
Management, etc.
AGM (P)
Rectt.
AGM (P)
Welfare
266
With a view to extend personnel services at the door step, the Personnel Department
has decentralized its HR functions at shop-floor level with 11 number of Personnel Zones and Executive
Establishment Zones, Common Cadre (JOs), etc. The day-to-day HR functions are taken care at the
shop-floor level, while the corporate functions are dealt centrally from the Administrative Building. This
create access to the employees and help in speedy redressal of the grievance of the employees.
Human Resource Management :
Human Resources are treated as the most important of all resources in the Company.
Its development and welfare have therefore been given the utmost emphasis in the overall policy of
Human Resources Management of the Company. It is believed that people are the key to success and
the performance of the Company depends on them to a great extent. Hence special attention is given
towards people management. For this, the organization has developed the Human Resources Policy
to achieve the plans and targets of the Company. It enables individuals to work efficiently and take
pride in their work besides feeling important. It makes people feel safe, secure and trusted. People in
the organization are encouraged for their efforts through a system of rewards and recognition. Its
environment encourages team working, creativity and invectiveness. In the organization, the
peoples ownership for the work and responsibility is obtained through empowerment. Employees
are one of the main components.
Major components of Human Resource Management :
VSP has established number of Zonal Personnel Units in Works division and Mines at JLM
and MDM for smooth and effective functioning of Personnel Department with a view to maintain
peaceful, cordial and healthy Industrial Relations in the Company.
Integrated Resources Systems have been established in the Company by providing essential
linkages between major systems like manpower planning, recruitment, training, performance
appraisal, career development, employee welfare, motivation and organization development. Within
the broad framework of Human Resource Management thrust is given to :
a) Multi-skilling and job enrichment
b) Labour productivity and manpower utilization
c) Comprehensive employee services including welfare.
HR Policy :
To realize the full potential of employees, the Company is committed to :
i) Provide work environment that makes the employees committed and motivated for
maximizing productivity.
ii) Establish systems for maintaining transparency, fairness and equality in dealing with
employees.
iii) Empower employees for enhancing commitment, responsibility and accountability.
iv) Encourage team-work, creativity, innovativeness and high achievement orientation.
v) Provide growth and opportunities for developing skill and knowledge,
vi) Ensure functioning of effective communication channels with employees.
267
268
269
A number of Human Resources initiatives have been introduced in VSP since inception. Some
of such practices are :
a) Three Union approach of Industrial Relations
b) Informal Grievance Redressal System
c) Multi-skilling and Multi-trade Concept
d) Contained Manpower
e) Gate Monitoring System
f) Special Social Security Schemes, etc.
g) New Work Culture
h) Integrated Human Resource Management
270
Major achievements of the Department :
a) Mandays lost due to Industrial Relations problem have been brought to minimumlevel
b) Labour Productivity has been highest in the Steel Industry in India
c) Low absenteeism levels
d) Commitment of employees to the Core Values
e) Introduction of Non-Unionized Supervisory Cadre (Jr. Officer)
f) Empowerment of Human Resources
g) Job Rotation and Redeployment
h) Social counseling
i) Local Industrial Leadership in Human Resources functions
j) Computerization of Human Resources functions.
Conclusion :
Success of Human Resources functions of Visakhapatnam Steel Plant stems from the relentless
efforts of the VSP work force. This valuable asset of 16500 steel employees have contributed to
positive cultural changes, increased productivity and organizational excellence Undoubtedly
employees are the driving force behind the success of VSP and will continue to play a key role in
shaping the future of VSP. Personnel Directorate is continuously working on the periodic review of
personnel policies, rules and regulations, so that they come upto the changing needs and expectation
of employees.
271
Chapter - 52
272
273
274
275
276
Chapter - 53
Computer Laboratory : 2 Computers labs are established in T&DC advanced Computers
Programmes & Computer literacy programs are being organize regularly. Every year 2000
employees under going training in various PC programmes.
Central Library : In VSP, the Central library was established in the year 1982 with small
collections of books, standards and journals, 25 e-journal, 20,000 Indians and International
standards in order to reach the available literature information to all employees are have
started using IT in our libraries. Recently, e-library started the and library was air- conditined
with modern furnature.
Audio-Visual section : T&DC has a visual section with AV aids such as LCD Projectors,
overhead projectors, 16mm film projector, Opaque film projector, P A System TV & VCR
etc., are available.
277
278
279
The prime objective of HRD Group is to develop company's human resources by making them
emotionally mature and behaviorally trained to cope with the role requirements, attune them with
strong knowledge and information base to enable them create effective teams and also overhaul
systems & structures in HR area commensurate with the organizational Vision, Mission and Objectives.
The following activities are mainly handled by HRD:
G In-house Management Development Programmes
G External Programme Nominations (other than overseas)
G Performance Appraisal for Executives
G Organization Research & Organization Development
G Competency Mapping Exercise
G Membership with Professional Bodies
G Industry-Academy Interaction
G Guest Lectures by Eminent Personalities
In-house MDPs
Annual plan for in-house programmes is made based on training needs reflected in the Performance
Appraisals, Training Needs Survey, meetings of Training Advisory Committee, as well as top
management's priorities & strategies. The programmes are conducted in the 3 halls of Centre for
HRD in the steel township. Faculty is a mix of internal and external experts.
External Nominations
Employees are sponsored for programmes conducted at premier institutes. HRD Group scrutinizes
the proposals for external programmes with a view to ascertain their relevance to current organisational
needs, credentials of the organizers/faculty and also verifies skill profile of the proposed employees
as also the budget availability, before recommending for approval of the competent authority.
Executive Performance Appraisals
Appraisal Cell in HRD monitors and coordinates appraisal reports for all executives. Three sets of
formats are in use. The information available in the appraisal reports is disseminated, analyzed and
sent to concerned agencies for:' necessary action.
Organisation Research
A cell for OD interventions has been created in HRD Group to design and oversee various OD
interventions like internal surveys/studies. Results of such exercise are analysed scientifically for
aiding management to take important decisions on various HR issues. Besides, the Cell is involved in
various open internal communication fora organized for the employees at large.
280
Competency Mapping
HRD organizes continual assessment of executives for 16 defined competencies and maintains confidential
records for futuristic decisions by top management concerning manning of key positions of the company.
Institutional Membership
RINL is a corporate member of different professional bodies of national and international repute.
Hence constant liaison is maintained with them by HRD for deriving all the benefits applicable and
also to duly process the invoices for renewal fees.
Industry-Academy Interaction
In order to maintain healthy industry-academy interactions, students from various institutions in the
country are permitted to have practical in-plant training in the areas of HRM, Marketing, Materials,
Management Services, Corporate Planning, Finance Management etc.
Guest Lectures
With a view to providing an avenue for knowledge sharing and networking with other institutions, talks
are arranged by inviting eminent personalities from different fields of specialization for the benefit of
employees and their families.
HRD Group is alive to the expectations of all the stake holders including customers and employees
and of the company and is ever ready to help the employees put in their best in the coming days at
RINL, where excellence is seen as a continuous journey and not merely as a temporary halt or goal.
281
OTHER
DEPARTMENTS / TOPICS
282
283
Chapter - 54
MINES DEPARTMENT
INTRODUCTION :
RINL/VSP is having captive mines at various places. Some of the raw materials are being met
from these captive mines for making of Iron & Steel. VSP is planning to acquire mines for fulfilling its
requirement of Iron Ore, Coal, Quartzite and Sand.
At present Visakhapatnam Steel Plant is operating four captive mines, namely
Madharam Dolomite Mine (MDM) - MADHARAM for Dolomite.
Jaggayyapeta Limestone mine (JLM) - JAGGAYYAPETA for Limestone
Garbham Manganese Mine (GMM) - GARBHAM for Manganese
Nellimarla/Sarepalli Sand Mine (SSM) - VIZIANAGARAM for Sand.
Visakhapatnam Steel Plant has also been allocated Coking Coal blocks i.e. Mahal and Tenughat-
Jhirki in Bokaro District of Jharkhand and the same are in the planning stage.
Besides these mines, VSP has been allotted quartzite mines at Kintada, Marrivalasa and Pindrangi in
Visakhapatnam District of Andhra Pradesh.
CAPTIVE MINES - LOCATION
Madharam Dolomite Mine : Located in Khammam district, Andhra Pradesh, details of which are
given in Annexure-I
Jaggayyapeta Limestone Mine : Located in Krishna district, Andhra Pradesh, details of which are
given in Annexure-II
Garbham Manganese Mine : Located in Vizianagaram district, Andhra Pradesh details of which are
given in Annexure-III
Nellimarla / Sarepalli Sand Mines : River sand is being excavated in the river Champavathi situated
at villages Nellimarla, Neelamrajupeta, and Sarepalli. The details of the said leases are given in
Annexure-IV. These leases are close to Vizianagaram, at a distance of 90 to 100 Km from
Visakhapatnam city. At present sand is transported from Sarepalli.
Kintada Quartzite Mine : Located in Visakhapatnam district at a distance of 50 km North East from
Visakhapatnam Steel Plant. The said lease is over an area of 3.24 hectares with reserves of about
2,02,000 tons.
Quartzite Leases in Marrivalasa & Pindrangi : Recently Govt of A.P . has granted two Mining
leases over an extent of 151 acres for Quartzite for a period of 30 years in favour of M/s RINL subject
to prior approval of Environmental clearances, Mining plan etc., which are in process.
Mahal and Tenugat-Jhirki Coking Coal Blocks : These blocks have been allocated to RINL by
Ministry of Coal to cater to its requirement of Medium Coking Coal. They are located in Bokaro District
of Jharkhand and would be underground mines. Consultants for conducting technical study and for
mine planning are in the process of being engaged.
284
ANNEXURE - I
Madharam Dolomite Mine
LOCATION OF mine from
Madharam ..................................... 01 km.
Karepalli ......................................... 12 kms.
Yellandu ......................................... 16 kms
Khammam..................................... 50 kms.
Hyderabad ..................................... 245 kms
VISAKHAPATNAM (HQ) ............... 515 kms.
TOPO SHEET NO. : 65/C/2
LONGITUDE : 80
0
13' & 80 14'
LATITUDE : 17 31' & 17 34'
MINING LEASE - DETAILS
100 M Grid Interval
Drilling Pattern
Geological Reserve (in MT) SMS grade - 37.73
BF grade - 3.45
Total - 41.18
Balance Reserve (on 31/12/08) - 33.00 million tonnes
Life of the Mine (approx) 54 Years Present Stage
27 Years (After expansion @ 1.2 mt per annum)
Method of Reserve Calculation Cross Sectional Method
Bulk Density 1.5 T/Cum(loose)
Specific Gravity 2.71-2.78
Hardness (Morh's Scale) 3-4
Reserve Category Proved
Strike N-S Dip 20
0
- 65 towards East, South-East &West.
Geological Formation Pakhals
Tonnage Factor(Insitu) 2.5 T/CuM
SALIENT FEATURES OF EXPLORATION DATA
Dimension of the Ore body
2500 M
80 to 400M
30 M
Length-
Width-
Average thickness-
Extent 950Acres
Initial Lease granted by Govt. of A.P. on 14/7/1980
Period 20 years
Renewal Validity up to 13/7/2020
285
ANALYSIS OF DOLOMITE
Content -50 +25mm 0 to -80 mm
%CaO 30.98 30.51
%Mg O 20.27 20.09
%Si O2 0.84 1.09
%Al2 O3 0.51 1.34
%Fe2 O3 0.91 1.51
%LOI 46.26 45,90
G
The Dolomite deposit in Karepalli area occurs in the form of bands, stretching over a length of
6 Km from North to South. The mining lease at MDM comprises Southern band extending to a
length of about 2.5 Km width ranging from 80 M to 400 M
G
MDM is in operation since 1989. The mine was designed for SMS & Brick grade with a throughput
capacity of 253,000 tpa in one- shift operation per day. However, VSP was operating the mine
and the associated crushing and screening plant in 1 - shift operation for production of SMS
(flux) grade ( - 25 mm to 50 mm ) and brick grade ( 9mm to 25mm ) dolomite. Subsequently,
Management decided to meet the requirement of BF grade dolomite from our captive source at
MDM only. Accordingly three different size specifications were made and certain minor
modifications introduced. The mines operated in 2 shifts for production leaving one for up -keep
of equipments and Development of Mines. Presently, only two grades viz. BF & Flux are being
produced since Brick grade is not required at the main plant.
G
After commissioning the plant at 6.3.Mtpa expansion stage, the requirement of dolomite will go
up to 1 Mtpa. To meet this target, Dasturco had recommended certain modifications which will
be taken up during expansion.
G
The mine is presently developed with three benches. The top bench is the overburden bench with
thickness varying between 0.5 M to 10 M, while the second and third benches are the production
benches with 8 M bench height. For the purpose of mineral conservation, the R.O.M material from
the top is stored at a suitable place for future recovery of dolomite from the admixed muck.
Pollution Measures : Dry fogging system was installed at Crushing and Screening Plant in
addition to the prevailing DE System i.e. Dust Extracting System with an approximate cost of
Rs.70 Lakhs. A wind barrier bearing dimensions of 75 meters length x 7.5 meters height was
constructed to avoid dust generating from Wagon Loading point towards green field.
G
Water Supply : Mineral water is being supplied for drinking purpose to the employees at Township
and Plant, and for other purposes mine discharge water is being used after natural filtration.
G
Power Supply : 11 KV Power Line is provided for power supply to Madharam. Due to frequent
power failures, 33 Kv line from Karepalli has been connected for uninterrupted power supply for
operation of Mines.
G
Afforestation : 87,000 saplings were planted in 160 acres within the mining lease area under
environmental protection.
G
Township : A township consisting of 184 quarters which includes A, B.C, Barracks and Hostel
building with modern amenities were constructed within the lease area. In addition other
infrastructure facilities like School, Hospital, Hostel Building, Community Welfare Centre,
Shopping Complex, Parks and Open Air Auditorium were also provided in the township. A Guest
House with four rooms was provided in the township.
286
ANNEXURE - II
Jaggayyapeta Limestone Mine:
LOCATION OF mines from
JAGGAYYAPETA ......................................... 05 kms.
VIJAYAWADA............................................... 95 kms.
HYDERABAD ............................................... 200 kms
VISAKHAPATNAM ....................................... 400 kms.
VISAKHAPATNAM STEEL PLANT .............. 390 kms.
TOPO SHEET NO. : 65D/1
LONGITUDE : 80
0
02' & 80
0
06'
LATITUDE : 16
0
50' & 16
0
53'
MINING LEASE
200X100M grid interval
Drilling Pattern
Geological Reserve(in MT)-Approx. Proved 38.71
Balance Reserve(31/12-08) 31.38
Life of the Mine 68 Years as per present status
48.27years after expansion @ 6.5 lakhs per anum
Bulk Density 1.50 T/Cum
Specific Gravity 2.72
Reserve Category "A" Category
Strike E - W Dip 2-5o due East
Geological Formation Precambrian Sedimentary formation
Tonnage Factor(Insitu) 2.5 T/Cum
Dimension of the Ore
body(North block)
Length-2416M,Average Width-325M
Max.thickness-22.97M Mean-11.97M
Extent 1295 Hectares
Lease granted by Govt. of A.P. 08/08/1980(Initial)
Period 20 years
Validity upto 08/08/2020
287
G
The limestone deposit at JLM extends over a length of about 5 Km in East-West direction
having an average width of 315-M. The thickness of the limestone varies from 5 M to 25 M
G
JLM is under operation since 1989 for supply of BF grade limestone to Visakhapatnam Steel
Plant. It is designed to produce 5, 00,000 tpa operating for single shift per day. Presently we
are producing about 4, 000,000 tpa only as SMS grade limestone fines is being used in BF to
the extent available as a substitute
G
After expansion of steel Plant to 6.3 MT stage, the requirement of the BF limestone will go up to
6, 31,200 TPA. To meet this target, certain modifications of plant and change in working system
(i.e. 2 shifts production and one shift upkeep of equipments & development of Mines) will be
introduced.
G
The only parameter to be followed is that the size of the limestone i.e. - 70 mm since the
metallurgical properties of the limestone available at the mines are meeting the requirement of
the customer i.e. RMD in VSP.
Water Supply : Mineral Water Plant was commissioned for drinking purpose for township and
mines employees. The required water in general is drawn from Paleru River
through infiltration well for township and mines. Water is also drawn from the
bore well which was dug in the township due to scarcity of water in the river.
Afforestation : About 1, 36,970 trees were planted within the mining lease area under
environmental protection.
Power Supply : HT line was constructed by APSEB for 33 KVA HT supplies to the mining area.
Main Receiving sub-station has been constructed in the lease area.
Railway Line : A railway line of 31 Kms joining Motumarri to Jaggayyapeta Limestone Mine
(JLM) was laid for movement of limestone to Visakhapatnam.
Township : A township consisting of 226 quarters of all categories mentioned in the above
with modern amenities were constructed. In addition other infrastructure facilities
like Schools, Hospital, hostel building, community welfare centre, shopping
complex and an open auditorium were also provided in the township. A four-
roomed guest house was also provided at the township.
288
ANNEXURE - III
Garbham Manganese Mines
LOCATION OF mines from
GARIVIDI ...................................................... 16 kms.
KOMATIPALLI .............................................. 15 kms.
VIZIANAGARAM .......................................... 44 kms
VISAKHAPATNAM ....................................... 92 kms.
VISAKHAPATNAM STEEL PLANT .............. 120 kms.
TOPO SHEET NO. : 65 N/7
LONGITUDE : 83
0
25' 47" & 83
0
28'
LATITUDE : 18
0
22' 03" & 18
0
23' 02"
Mining Lease Area 653.69 Acres
Dimension of the Ore body 1200 M Length 40 M width
Spaced at 100 - 200 M interval.
Drilling Pattern
Geological Reserve estimated 1.02 million tonnes
Balance Reserves as on 31.12.2008 1.6 Lakh tonnes
Bulk Density 1.80
Specific Gravity 2.00
Hardness (Mohr's scale) 2
Reserve Category Proved
Strike E -W Dip 55
0
due South
Geological Formation Archeans Khondalite Formation
Tonnage Factor 2.0 T/Cum
Description I Lease II Lease
Extent 59.04 Ha 205.50 Ha
Lease granted by Govt. of A.P. 08/10/1982 28/01/1983
Period 20years &1st Renewal 20 years 20 years
Validity up to 07/10/2022 26/01/2023
Amalgamation given by Govt. 264.54 Ha
of A P for both the areas
Village Garbham Garbham
MINING LEASE
289
G
The total leasehold area is 264.54 hectares and it is divided into three blocks, namely Central
Garbham, East Garbham and West Garbham. The above mining lease was granted to VSP
during 1982-83.The in-situ reserves of Manganese ore have been estimated at 0.86 MT and
some 0.16 MT could be recovered from waste dumps created by earlier operators before our
lease. The ore occurs up to a depth of 45 M but economical to mine up to 30 M depth only from
ground level. The manganese ore is of the following grade.
G
Mn- 28.00%, Fe-12.53%, Al2O3- 5.96%, SiO2- 21.43%, P-0.28.%, S -Traces
G
GMM is under operation since 1989 for supply of Manganese lumps and fines to Visakhapatnam
Steel Plant. It is designed to produce 50,000 MT by semi mechanized method per annum by
operating in general shift and engaging employees on Casual basis departmentally. Presently
we are producing about 16, 000 tones per/anum only. Initially it was designed for manual
mining and subsequently changed into semi mechanized mine.
G
After commissioning of steel Plant for 6.3 MT stage, the requirement of the Manganese lumps
and fines will be about 3400 tons and 10,800 tons respectively.
G
Ore exploitation is by open cast mines. GMM is presently equipped with a small fleet of
equipments like 1 cub.m capacity Hydraulic excavator, Loader, dozer, 4 Ashok Leyland Dumpers
of 10 ton Capacity etc., Initially Mines Dept. extracted the Mn. Ore in old dumps and continued
up to 2000. Subsequently in-situ mining was also taken up there. As approved by IBM, 4-meter
benches are developed and mining being done. The ore to overburden ratio is about 1:3 and
some areas it is around 1:5. The required size by the customer is (i) lump: - +10 mm to 60 mm
& (ii) fines:- -10 mm. EIA / EMP (Environment Impact Assessment / Environment Management
Plan) was approved by Ministry of Environment & Forests, New Delhi.
Infrastructure : 16 Kms from Garividi. Komatipalli is the nearest railway station on
Vizianagaram -Koraput Railway Line. The Mine is located 120 Kms from
Visakhapatnam. Material is transporting by road through private agency
Power : Power lines 11 KV and 440 KV are passing through the lease area.
Water : There is no perennial water source in the area. The drinking water is
available from the dug borewell. The Garbham main pit is quite old and
water logged. Water is drawn from this pit by the villagers for irrigation
purpose.
Miscellaneous facilities : The Office building is located in the mining lease area. A maintenance
shed has been constructed for maintenance of earth equipments.
290
ANNEXURE - IV
NELLIMARLA SAND MINE - SAREPALLI SAND MINE
LOCATION of mines from : (in Kms)
Salient Features Mahal Tenughat-Jhirki
Location Bokaro Dt. Jharkhand Bokaro Dt. Jharkhand
Area 5.2 Sq Kms 2.5 Sq Kms
No. of seams 22 17
Depth of Mining From - 350 mtrs Not Known but expected to be the
same as Mahal
Quality Steel Grade I to Washery Grade III Steel Grade I to Washery Grade III
Geological Reserves 258.35 Million mt 203.98 Million mt
Inclination of Seams 15 to 250 15 to 25
0
Faults 13 Nos 10 Nos
Railway Line Running through centre of block No line inside block but north of block
River Damodar River is northern boundary Konar Nala is northern boundary
Gas content Degree III Degree III
SALIENT FEATURES OF MAHAL AND TENUGHAT-JHIRKI COKING COAL BLOCKS
NELLIMARLA ........................................ 02 SAREPALLI ............................ 02
VIZIANAGARAM.................................... 10 NELLIMARLA ......................... 07
VISAKHAPATNAM................................. 90 VIZIANAGARAM .................... 17
VISAKHAPATNAM ................. 105
TOPO SHEET NO. : 65N/8 TOPO SHEET NO:65-N/8
LONGITUDE : 83
0
26' 51" & 83
0
27' 27" LONGITUDE:83
0
28' to 83
0
28' 05"
LATITUDE : 18
0
10' 20" & 18
0
11' 00" LATITUDE:18
0
08' to 18
0
09'
Nellimarla Sarepalli
Extent 31.16Hec 64.67Hec
Lease granted by Govt. of A.P. 30.06.99 6.11.2002
Period 20years 20 years
Validity upto 1.07.2019 5.11.2022
Geological Reserves 379500Tonns 277004Tonns
MINING LEASE
G
The Nellimarla Sand Mine was started from the River bed at the rate of 40,000 Tons per Annum
except during monsoon months in 1999. Presently mining is being done from Sarepalli Mine as
the sand deposit in Nellimarla has got depleted.
G
The total activity of excavating sand from the river, loading into the trucks, transporting and
unloading at the main plant. VSP off loaded the job to Private agencies.. Despatches are being
regulated as per the requirement of Main plant at Vizag.
G
Environmental Clearance for Sarepalli Sand Mine was obtained from MOEF New Delhi in 2008
which includes public hearing..
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Chapter - 55
PROJECTS DIVISION
Projects Division of VSP consists of the following departments
a) Design & Engineering Department
b) Project Contracts Department
c) Construction Department
d) Project monitoring
Major activities of various departments are indicated against each of them.
Design & Engg. Department :
Design and Engineering department is the nodal point for realising the following aspects of
VISION, MISSION & OBJECTIVES of VSP.
G
Harness our growth potential & sustain profitable growth, (Vision)
G
To attain 16 MTPY liquid steel capacity through technological upgradation, operational efficiency
and expansion to produce steel at international standards of cost and quality : and to meet the
aspirations of stake holders, (Mission).
In a deregulated and competitive economy driven market, struggling with issues of managing
sustenance of performance, VSP has to focus on what to change. What to change to ? And how to
change ? Design & Engineering department shall handle the above issues in a structured and well
planned manner, so that VSP shall control its destiny, race towards excellence and sustainability with
required speed.
Once the units are handed over as per contractual provisions, services of the consultants or suppliers
will no longer exist. Any further improvements in production and ease of maintenance are taken care
of by Design & Engineering department giving specific emphasis to time, strategic initiatives like
Systematic approach, Bench marking, Six Sigma, etc.
D & E department consists of the following sections to handle the jobs.
G
Technology
G
Mechanical
G
Material Handling
G
Electrical & Instrumentation & Automotive
G
Civil & Structural
G
Utilities
G
Water System
G
Techno Economics and Project Cost Control (TEPCC)
292
G
Projects
G
General Layout and Transport (GL & T)
G
Technical Documentation and Information Section (TDIS).
G
Special Alignments Group (SAG)
Design and engineering department activities are broadly categorized into the following :
G
Project reports & approvals
G
Conceptual planning & Basic Engineering
G
Detailed Engineering
G
Design Supervision
G
Supervision of testing & commissioning
G
Obtaining approvals & Liaison with Statutory bodies
G
Preparation of cost estimates & monitoring project cost
G
Indexing, storage & retrieval of technical documents
PROJECT REPORTS & APPROVALS
G
Providing of necessary information to the MOS, GOI from time to time
G
Selecting the most appropriate & state of art technologies & equipment
G
Preparation of project reports for capacity enhancement / modernization /
up-grade-tion.
G
Scrutiny, evaluation of project reports to ensure selection of appropriate technologies
& equipment.
G
Obtaining various approvals for projects from Government of India (GOI), Expenditure
Finance Commission (EFC), Public Investment Board (PIB), Environmental clearance,
etc.
G
Engaging consultants wherever required.
CONCEPTUAL PLANNING
G
Examine in depth the proposals for modifications / alterations for debottle necking and
for improvement, during operation of plant and carryout engineering of the same, if
considered beneficial.
G
Prepare concept, scheme, layout, cost estimate etc, for Additions, Modifications,
Replacements (AMR) and other non-AMR projects.
G
The expansion of the plant to 6.3 MTPY liquid steel and further.
293
G
Preparation of schemes etc, for incorporation of stipulations made by statutory bod- is
like Ministry of Environment and Forests, Government of India. A.P. Pollution Control
Board, Director of Factories, Inspectorate of Explosives, Inspectorate of Boilers, etc.
G
Review the automation in various units of plant for replacement with latest technologies.
DETAILED ENGINEERING.
G
Preparation of clear & complete technical specifications.
G
Evaluation of offers w.r.t compliance with scope of work, meeting technical requirements
& function, latest technology for process, energy conservation & environment, to avoid
contractual problems at later stage etc and to bring all parties technically at par.
G
Preparation of technical recommendations & participation in Tender committee
meetings.
G
Approval of vendor drawings, Quality Assurance Plans (QAP), Billing schedules for
release of payments.
G
Evaluate tenability of claims raised by contractors during execution of contract.
G
Preparation of working drawings for Energy & water conservation, mitigation of pol-
lution in work environment, improve production, ease of maintenance & operation.
G
Accord clearance for layouts with coordinates for buildings, structures, under ground &
over ground for additional facilities
G
Indenization of suppliers drawings.
G
Design of road & rail net work.
G
Identification of areas for Horticulture, Afforestation and preparation of working draw-
ings for the same.
G
Coordinate with port trust & Gangavaram port for handling movement of imported coking
coal.
G
Coordinate with various suppliers, consultants and obtain all required data, drawings in
time.
DESIGN SUPERVISION :
G
Suggest and evaluate the change in material specification or equipment specification
during construction of the plant in case of non availability without affecting the
technological requirements.
G
Effect design modifications in respect of any mis match wherever caused due to site
conditions and non adherence of drawings, battery limits, issue sketches / schemes /
drawings wherever required.
G
Providing design supervision during construction and erection work to ensure the
294
schemes / project is carried out in accordance with approved design specification /
drawings.
G
Interpretation of drawings and other data to the construction, erection agencies.
G
Inspection of structures, building columns and preparation of suitable modification
schemes wherever required.
SUPERVISION OF TESTING & COMMISSIONING
Design department shall finalise the procedures for preliminary acceptance and final
acceptance tests, performance guarantee tests and participate to ensure that the contractual obligations
agreed in the contract work is carried as per approved drawings and standards by various contractors.
OBTAINING APPROVALS & LIAISON WITH STATUTORY BODIES :
G
Obtaining Government of Indias clearance for projects, incorporating the changes in
the project based on various suggestions indicated by government.
G
Obtaining environmental clearance from PCB for the projects.
G
Furnish information / additional data / replies sought by Ministry / planning commission,
PIB etc.
G
Liaison with various statutory authorities to obtain approvals of factory inspector, state
electricity boards, explosive inspector, Boiler inspector Ministry of Environment and
Forests, etc.
INDEXING, STORAGE & RETRIEVAL OF TECHNICAL DOCUMENTS :
G
Receipt and codification of drawings and documents from various sources.
G
Retrieval and issue of drawings and documents to various departments.
G
Storage and preservation of documents.
G
Computerizations of Technical Documentation and Information.
G
Digitization of documents and drawings.
MAJOR PROJECTS / AMR SCHEMES :
Some of the major projects / schemes / latest technologies to improve production from concept
to commissioning (implemented or in the process of implementation) carried out by Design and
Engineering department are indicated below :
i) Slag splashing to improve lining life of L.D converters
ii) Oxygen enrichment in the cold blast air supply to BF
iii) Ensuring availability of utilities like nitrogen and cooling water during total & extended
power failure.
295
iv) Implementation of water pumping scheme from Godavari to ensure reliable water supply
to VSP.
v) Implementation of automation in various units of plant including CCM & LD Shop.
vi) Upgradation / modernization of technology necessitated due to non availability of spares
i.e. PLCs instruments, electrics etc.
vii) Replacing the Soviet gas cutting machines with latest gas cutting machines at
Continuous Casting Department of SMS.
viii) Pulverized coal injection in the BFs to reduce coke rate.
ix) Upgradation / modernization of CCM-2 to increase the speed of machine and there by
production.
x) Modification of water box at Wire rod Mill.
xi) Upgradation of balance CCMS
xii) Augmentation of SMS water system to facilitate upgradation of balance CCMs.
xiii) Conversion of wire tying mks to strapping mks in rollingmills.
xiv) Implimation of fecalite for combined blawing of LD canvertes of SMS-1
xv) Additional bunkers for feroalloy charging
PROJECTS CONTRACTS DEPARTMENT :
Major activities are broadly categories as
G
Enlistment of contractors
G
Preparation of Special conditions of contract (SCC), General conditions of contract
(GCC), payment terms of contract.
G
Issue notice inviting tenders (NIT)
G
Formulate prequalification criteria (PQC)
G
Preparation & Issue of tender documents to tenderers
G
Scrutinise tender requisitions for PQC.
G
Scrutiny & evaluation of commercial offers
G
Preparation of contract documents
G
Handling arbitration cases
G
Preparation of estimate by areas consultants and getting the same.
296
CONSTRUCTION DEPARTMENT :
The construction department supervises the work carried out by various contractors, ensures
that best work practices are adopted and the project is built in time.
Construction departments activities are broadly categorised into the following
G
Contract Management
G
Construction supervision to ensure quality
G
Accounting of materials & processing bills of contractors
G
Processing gate passes, work permits, shut downs, etc.
G
Monitoring and reporting of progress of work
G
Implementing statutory obligations
G
Ensure adherence to safety practices
CONTRACT MANAGEMENT :
G
Scrutinise extra claims put forth by agencies and recommend as the case may be for
due consideration.
G
Preparing all documents required for handing over / taking over the unit by works
division.
G
Prepare all documentation for closing of contracts.
CONSTRUCTION SUPERVISION, TO ENSURE QUALITY :
G
Coordinate with various departments of VSP and different agencies between civil,
structural, mechanical and electrical contractors for planning of erection and com-
missioning activities.
G
Ensuring overall quality of work at site by continuous supervision, collection of samples
as and when required.
G
Ensuring proper storage, handling of plant and equipment by the suppliers / contract- tours.
G
Check and give stage-wise clearance for the various construction activities.
G
Coordinate with all agencies / departments for start-up, trails and initial operation of
each unit.
MONITORING AND REPORTING PROGRESS OF WORK :
G
Review the progress of work by various agencies in different zones to ensure com-
pliancy with the time schedules.
G
Monitor the receipt of equipment and supplies at site for ensuring timely erection and
commissioning.
G
Monitoring timely erection, testing, commissioning of various units and follow up action
on progress of work at site.
297
G
Review the performance of various agencies against the schedules / targets with a
view to ensure the project is implemented according to the schedule.
G
Preparation of various management reports like status of various civil, structural and
equipment erection work with reference to total quantities.
G
Maintain daily record of man power deployed by various agencies.
ACCOUNTING OF MATERIALS AND PROCESSING BILLS OF CONTRACTORS :
G
Prepare SI notes, scrutiny of material requisitions for drawal / return of material by
agencies.
G
Accounting of various materials supplied by contractors, issue of materials by VSP to
contractors.
G
Carryout joint measurements along with respective agencies, certification of the same,
process, scrutinize and recommend the RA bills and final bills of agencies for payment.
G
Enter measurements in M book, bill forms, and put up duly filled in forms.
G
Processing interim and final deviation statements of the works executed.
IMPLEMENTATION OF STATUTORY OBLIGATIONS :
G
Ensure compliance with all statutory laws of the land i.e. payment of minimum wages /
PF remittances / labour license / insurance / workmen compensation act etc by
contractors
G
Check wage sheets, PF remittance of workers submitted by contractors and certify
while forwarding the bills
PROCESSING OF GATE PASSES, WORK PERMITS, SHUT DOWNS ETC.
G
Processing the Gate pass for personnel, equipment, safety / height pass, work permits,
shut down permits.
ENSURE ADHERENCE TO SAFETY PRACTICES :
G
Enforce use of safety applicances by contractors / workers during erection, safety
training of all personnel deployed inside the factory for project work ; ensure use of
correct tools and tackles
PROJECT MONITORING :
Preparation of timely feed back information to Management on progress, delays and critical
activities of project AMR schemes and other projects.
Preparation and submission of the following progress reports to management regularly
G
Status of specifications / engineering / tendering / ordering / approval of vendor drawings.
G
Status of civil / structural / equipment erection with reference to total quantities
G
Status of construction activities / erection / testing & commissioning
G
Furnish periodical reports on actual expenditure with respect to estimates.
G
Interpretation of bar- charts to Management.
G
Analysis of delays occurred, delays likely to occur.
G
Preparation of various reports to Management regarding activities of project wing.
298
Chapter - 56
Expansion of the plant to 6.3 MTPY (Liquid Steel)
GENERAL :
Keeping in view the upturn in global and domestic steel demand, VSP has envisaged to increase the
plant capacity to 6.5 Mt per year of hot metal and 6.3 Mt per year liquid steel with corresponding
increase in the production capacities of all its upstream and down stream units.
The product mix of plant was decided considering the likely future market in India up to 2012 - 13
based on information published by various agencies from time to time i.e a) Report on Task force
constituted by Govt. of India in September 1992., b) ICRA sector focus series # 4, 1995, c) Report of
the working group on Iron and Steel industry for the 9th five year plan, December 1996, d) Technical
paper presented by Dr. Sushim Banerjee - Published in Steel Scenario, Vol. 8, Qr-3., e) Paper presented
by ERU - Iron & Steel Review, January 2000.
The demand for bars and rounds from 2007 - 2008 and 2012 - 2013 is computed as around 8 to 10.8
MTPY, where as the computed future domestic availability of bars and rounds shall be 6.6 and 7.2
MTPY respectively. Therefore, there will be substantial domestic demand for bars and rounds in
future. In veiw of above, it was decided to expand the plant for production of long products.
The additional facilities envisaged to achieve 6.3 Mt per year liquid steel and corresponding changes
in the production capacities of upstream and downstream units are indicated as annexure - I.
PROJECT SCHEDULE :
All the facilities are required to be commissioned in 36 months, except the Special Bar Mill and Structural
MIll which are required to be commissioned in 48 months from date of approval of project by Govt. of
India i.e. 28-10-2005.
LAYOUT OF MATERIAL FLOW SHEET
The tentative plant material flow sheet indicating the capacities of major process equipment and the
raw materials required for 6.3 MT stage is indicated in the enclosed drg. no. DE EXP-001 and the
dispositions of various existing and proposed units in expansion is shown in drg. No.DE-EXP-002.
BRIEF DETAILS OF VARIOUS EXPANSION UNITS :
RAW MATERIAL HANDLING SYSTEM (RMHS) :
One number additional tippler each for ore and flux is envisaged to cater to the needs of expansion.
The coal is proposed to be inported and received at Gangavaram port and transported directly to coal
yard by conveyers.
One additional wheel on boom reclaimer will be provided at ore & flux yards. Two new base mix piles
dedicated for sinter plant will be provided adjacent to the existing base mix piles. One new twin boom
stacker and one blender reclaimer will be provided to manage movement to and from the piles.
299
A new closed loop lump ore sizing system with associated facilities is envisaged. New facilities of flux
and fuel sizing as well as base mix proportioning, bedding are envisaged to cater to the needs of
Sinter machine-3 Closed loop crushing and screening facilities for flux materials and open loop
crushing for fuel sizing are envisaged.
SINTER MACHINE - 3
Considering about 80% sinter ratio in the burden for the new BF - 3, the requirement of charge sinter
will be 3.25 Mt per year. One new sinter machine of 400 sq.m area is envisaged.
Design basis of new sinter plant is :
Product sinter 3611,000 tonnes / year
Charge sinter 3250,000 tonnes / year
Screening at BF stock house 10%
Operating days in an year 330
Operating hours per year 7,920
Daily product sinter 10,950 tonnes / day
No. of strand 1
Product sinter size 5-50 mm
Temperature of sinter
at cooler discharge 100 oC
Blast Furnace - 3 :
The design basis of BF-3 to produce 2.5 Mt per year hot metal is indicated below.
Hot metal Capacity 2.5 MPTY
Production Capacity 7,150 thm/day (av.)
Useful volume 3,800 cu m
Productivity 2.15 t/cu m (working volume) / day
Top gas pressure 2.5 kg/sq cm (g)
Oxygen enrichment 3-6%
Hearth dia meter 13.0 m
No. of tuyers 34
No. of tap holes 4
Hot blast temperature 1200
0
C (1300 oC max)
Structure Free standing
300
Copper staves will be installed in the high heat zone of BF i.e., both belly and lower stack in order to
get better thermal efficiency. Rest of the stack and throat portions are cooled by cast iron staves
similar to existing BFs. Three nos hot blast stoves shall be provided to supply hot blast at 1200 oC.
Maximum hot blast temperature shall be 1300 oC. The stoves will be fired with BF gas / mixed gas.
Enrichment of cold blast with oxygen is envisaged. Cast house is provided with slag granulation
system. Wet gas cleaning system (GCP) to achieve a gas cleanness of 5 mg/ NM3 with a moisture
content of 5 mg/NM3 in the gas shall be provided. Gas expansion turbine and generator is envisaged
to generate electric power utilizing pressure of the top BF gas. Coal dust injection system designed
for 200 kg/ ton of hot metal injection rate is envisaged.
STEEL MELT SHOP - 2 :
Annex - (1)
Converter Shop :
Two (2) nos. cu m LD converters (nominal capacity 150 tons of liquid steel), complete with bottom
inert gas stirring, oxygen lance system, flux and additive charging system, ferro-alloy storage and
charging system, relining device, cooling fan, lance deskulling and retipping facility, slag stopper
facility, gas cleaning plant, converter dog house, self propelled transfer cars and secondary emission
electrical equipment, instrumentation control, automation, process control computer (level-2) system,
utility services, hydraulics, pneumatic system and lubrication system and associated pipework along
with necessary allied technological structures are being installed at Visakhapatnam Steel Plant under
6.3 Mtpa expansion.
Design Basis :
No. of LD Converters 2 nos. of 150 m
3
each
Nominal Capacity of each Converter 150 t
Capacity of the new Plant 2.8 Mtpa
Overall height of Converter 9,085 mm
Height/Diameter ratio (inside new lining) 1.44
Specific Volume 1 m
3
/t
Converter Operation mode 2/2
Possible operating days per year 362
No. of heats/day 56 from 2 Converters
No. of heats per year 18, 760
Tapping weight 150 t (average)
Tapping temperature 1680
0
C
Blowing time 16 minutes (max)
Oxygen flow rate 600 Nm
3
/minute (max)
301
Hot metal input 1025 kg/t
Scrap input 50-55 kg/t
Iron ore input 20 kg/t
Continuous casting machine :
The operating parameters of casters are as follows :
Heat size Nominal 150 tonne
Production of liquid steel 2.8 Mt
Production of cast billets 2.4 Mt
Production of cast rounds 0.330 Mt
Yield, liquid steel to cast
production 97.5 %
Caster availability 320 days / year
No. of Casters 3
No. of strands per caster 6
Sectional to be east
Billet easters 150mm x 150 mm; 200mm x 200mm
Billet cum ronnd caster 150mm x 150 mm squares
220mm, 280mm & 350mm tonnds
Average casting speed.
150 sq 3.5 m per min
200 sq 2.0 m per min
220 1.7 m per min
280 1.1 m per min
350 0.6 m per min
Average casting time in min.
150, 200 Sq 45
220, 280, 350 cp 50
WIRE ROD MILL - 2 (WRM-2) :
The mill will be designed to produce wire rod size of 5.5 mm to 20 mm. The capacity of wire rod mill-
2 shall be 6,00,000 tonnes / year. The mill shall comprise [8 stand roughing train, 6 stand intermediate
trains, two stand pre finishing train and two groups of 10 stand no twist blocks.] Single strand rushing
- 6 strands, Two strands Intermediates mill-10 stands, Two limm-pnefenising mill - 2 stands, No-twist
mill - standards reduial signamill - 4 stands.
302
SPECIAL BAR MILL :
The Mill will produce bars of sizes 20 mm to 45 mm. The capacity of mill shall be 7,50,000 tonnes /
year. The mill shall comprise 6 stand roughing train, 6 stand prefinishing train and 6 stand intermediate
train, 3 steel finicshing / siging gramp.
STRUCTURAL MILL :
The mill shall use billets of 200 mm sq size and 12 m length. The capacity of mill shall be 7,00,000
tonnes / year. The mill will comprise 7 stand roughing train, The mill will produce beam 5 stand
intermediate train, and angles, channels, Flats, Tees, Rounds and spanners 5 stand finishing train.
CALCINING PLANT :
Considering specific consumption of flux as 66 kg per ton of liquid steel, two vertical shaft kilns of
capacity 500 TPD each are envisaged.
POWER PLANT :
The additional power requirement for the expansion units is about 200 MW. One (1) 67.5 MW generator
(TG-5) and a boiler to generate 330 ton/hour steam are envisaged. In order to meet the cold blast of
BF-3, one turbo blower (TB-4) is envisaged in TPP & BH.
Balance power is envisaged to be out sourced / purchased.
WATER SYSTEM :
In order to conserve water to the maximum extent, independent recirculating systems with cooling
towers, pump houses and treatment units have been envisaged. Make up water will be supplied to
individual recirculating system. The additional make up water requirement to expansion units will be
around 13 MGD. Make up water requirement, zone wise is indicated in the enclosed annexure.
UTILITIES :
AIR SEPARATION PLANT : (ASP)
To meet the additional requirement of oxygen, nitrogen and argon, two ASP units of 850
TPD of oxygen each are envisaged. ASP is envisaged on BOO basis.
CHILLED WATER PLANT :
Three nos. chilled water plants of rating 1200 TR, 1200 TR and 6500 TR shall be located at BF-3, SP-
3 and mills area respectively to meet the expansion needs.
ENVIRONMENTAL MANAGEMENT :
AIR POLLUTION CONTROL MEASURES (APC) :
List of proposed air pollution control measures for new units of expansion are indicated as annex-II.
WATER POLLUTION CONTROL MEASURES :
To minimize pollution of receiving body the expansion plan envisages two approachers.
303
i) Enhance thewaste water recycling to the extent practicable so as to reduce make up
water consumption.
ii) Aim for zero discharge of process effluent containing organic pollutants. Water
discharged through the storm water is collected at the outlets balacheruvu, Appikonda,
treated and refused in the plant to an extent of approx 5 MGD.
iii) Rain water percolation points shall be provicdeel for all buildings to recharge the
acquefices.
The specific consumption rate of make up water will be maintained within 4 cum / tls excluding power
plant. Make up water will not be used for non production facilities like dust suppression, slag granulation,
ash handling etc. The colling tower blow down water will be utilized within the plant to the maximum
extent practicable.
CONSTRUCTION VOLUME :
For construction purpose the total project has been decided under nine (9) zones which are RMHS,
SP, BF, Calcining Plant, SMS, RM, TPP, ASP (BOO), Power Plant (BOO basis).
The quantum of major construction work involved in 6.3 MTPY liquid steel expansion stage is given
below.
APPROXIMATE QUANTITIES OF CONSTRUCTION WORK
Item of work Unit Quantity
Earth work cu m 32,00,000
Piling 600 mm dia, 125 ton Nos 26,100
capacity
Concreting of all grades cu m 9,50,000
Structural steelwork ton 1,85,000
Roof sheeting & cladding sq m 7,00,000
Equipment Erection tonne 1,02,000
The tentative major construction materials for the above work are as follows :
Cement : 4,75,000 MT
Reinforcing steel : 1,20,000 MT
Coarse aggregates : 6,55,000 cum
Fine aggregates : 3,40,000 cum
Structural steel : 2,04,000 MT
304
Sheeting material : 8,40,000 sq. m
Legend :
MGD : Million Gallons per Day
Mt : Million tonne
MT : Metric Tonne
MTPY : Million Tonne Per Year
TR : Tons of refrigeration
Cum : Cubic meter
Sq m : Square meter
TPD : Tonnes Per Day
MW : Mega Watt
Thm : Tonnes of hot metal
ESTIMATED COST OF THE PROJECT
Description Foreign Local Total
currency currency
equivalent (Rs in (Rs in
crores) crores)
A. Plant Cost
Land & site development etc. - 41 58
Civil work - 663 1213
Structural work - 787 1341
Plant & equipment 1,250 3,846 7837
Erection charge incl.
Supervision of erection, training etc. 127 387 932
Design, engineering, Project management
and consultancy Services - 353 342
Sub - total (A) 1,377 6,077 7,454
B. Other Fixed Investment
Spares 27 93 115
Start-up expenses - 42 42
Sub-total (B) 27 135 162
C. Total Fixed Investment (A+B) 1,404 6,212 7,616
D. Contingency 70 311 135
E. Interest during construction - 214 119
F. Development / expansion of mine 3 45 95
G. Total Capital Requirement 1,477 6,782 12225
305
ANNEX - I
List of major addl. facilities / units envisaged in the expansion of plant to 6.3 MT
liquid steel
i. Raw Material Handling Plant :
a. Ore-side Ore tippler (1), ore stacking conveyors (1-stream),
Twin-boom stacker, wheel-on-book reclaimer,
Ore- beds-3, Lump ore Screening plant, Lump ore
crushing plant, reclaiming conveyors for Sinter Plant
/ Blast Furnace etc.
b. Coal Handling Plant Coal beds (5), Stacker-cum-reclaimer (2) reclaiming
conveyors etc.
ii. Sinter Machine - 3 1 x 400 sq.m grate area, to produce 3.25 Mt / yr. charge
sinter
iii. Blast Furnace - 3 1 x 3800 cu.m useful volume with all auxiliary facilities
and Pulverized Coal Injection to produce 2.5 Mt / yr
hot metal
iv. Steel Melt Shop - II 2 x 150 t. converters with secondary metallurgy
facilities to produce 2.8 Mt / yr liquid steel.
2 x 6 strand billet caster
1 x 6 strand round caster
v. Rolling Mills 1 x 600,000 t / yr : Wire Rod Mill - 2
1 x 750,000 t / yr : Special Bar Mill
1 x 700,000 t / yr : Structural Mill
vi. Calcining & Refractory Vertical shaft kiln : 2 x 500 t/day
Material Plant
306
vii. Augmentation of 1 x 67.5 MW Turbo Generator (TG-5)
Existing Thermal 1 x 418000 N Cum / hr Turbo Blower (TB-4)
Power Plant & Blower 1 x 330 t/hr, multi - fuel fired boiler
House (TPP & BH)
viii Auxiliary Facilities Power systemrms, substations & power distribution
systems. Water systems / utilities / yard piping /
drainage / sewage and all other related service
facilities Additional yards, tracks, roads, flyover etc.
ix. Captive Mines i. Augmentation of MDM crushing & screening plant
from a throughput rate of 250 t / hr to 400 t / hr
and conveying system and uprating the loading
system from 350 t / hr to 2000 t/hr.
ii. Uprating the existing loading rate at JLM from 350
t/hr to 2000 t./hr.
iii. Provision of 30 t/hr crushing & screening unit in
GMM.
iv. Develop Kintada Quartize mine for and annual
production of 50,000 t.
x Power Plant (PP) 2 x 67.5 MW capacity with all necessary facilities.
(BOO Basis)
xi Air Separation Plant 2 x 850 t/day oxygen
(BOO Basis)
307
ANNEX - II
LIST OF PROPOSED APC MEASURES FOR NEW UNITS RMHS, RMBBS, COKE
OVENS AND SINTER PLANT BF, LD SHOP, LIME KILN AND MILL FURNACES
Sl. Proposed New Emission Control Devices Design Target
No. Units/Facilities Point Source Fugitive
(Stacks) (Workzone)
1. Raw Materials - - Covered - closed Work zone
stockpile / conveyors dust level 5 mg / N
bedding and - Dry fogging cum (max)
blending system for - De stack outlet
station and conveyors transfer dusts below 50
material handling point, crushing mg/ N cu m
& screening plants - Open work zone
- De systems < 600 mcg / cu m
of material
transfer points
based on bag
filters
2. Sinter Plant - Emission - Stock House - Stack dust 50
Unit No. 3 Optimised Waste gas for mg / N cu m
Sintering Sinter M/c - Stack SO2 < 280
(EOS) is is cleaned in mg/N cu m - -
preferred the ESP. Stack No x < 200
- Use of low - DE System with mg / N cu m
H2S fuel gas ESP and bag - Closed work
Electrostatic filters one enrisaged. zone dust < 5
precipitator- mg/N cu m
Tall
combustion
Stack
308
3. Blast Furnace - Heat BF Stock - Stack dust 50
No. 3 Recovery House DE mg / N cu m
from BF System with - Workzone dust
Stoves Tall ESP 5 mg / N cu m for
Stack for BF - BF Cast indoor
Stove Flues House DE
System with
ESP
- Fume
extraction for
Slag
Granulation
Plant
4. Steel Melt - Secondary - Stack dust 50
Shop New LD Emission mg/N cu m
converters control of LD
with LF, RH Shops Bag Filters for
LF and RH
with ESP - Fume
Extraction
System for
Casters in CCD
5. New Mills - Efficient - Stack dust 50
Mill Furnaces combustion mg / N cu m
control with - SO
2
200 mg/N
low NOx cu m at 3% 0
2
burners - NOx 370 mg/N
- Use of low cu m
H2S fuel gas
Stack
309
6. Lime Kiln Stack De System Dust 50 mg/N
New Lime Kiln with bag cu m
Filters Dust content in
wrt zone : 5mg/Nm
3
7. Captive Power Stack ESP is - Dust 50 mg/N
Plant Envisaged cu m
for cleaning - SO2 500 mg/N
of exhaust cu m
1 x TG gases from - NOX 650 mg/N
(Unit#5) the boils cu m for coal fire
1 x TB - NOX 150 mg/N
(Unit # 4) cu m for gas fire

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ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES

ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES

ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES

Since the process of improvement is continuous, the techno-economic practices of refractory

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