Technical Manual

of New Units with associated facilities under 2.5 MTPA

LEARN
&
GROW

Steel Authority of India Limited

IISCO Steel Plant, Burnpur

There is little bit of SAIL in everybodys life

Preface

HRD Centre is pleased to present the technical manual of ISP, Burnpur. The aim of the
manual is provide an introduction to all the new units and facilities of the 2.5 MTPA steel
plant. The manual gives detail information about the working of various departments of the
plant. The purpose of technical manual is learning and development of the new entrants
andvarious stake holders of ISP, Burnpur.
HRD Centre would like to thank all the departments of ISP for their valuable contribution in
developing

the

manual.

HRD

Centre

is

grateful

to

Executive

Director

I/C,

Executive Directors, General Managers for their valuable suggestions and support in
developing this manual. We welcome feedback and suggestions for further improvements of
the manual.

Content
Sno

Department

Page. No

1.

ACVS

---------------------------

1-4

2.

BF

---------------------------

5-44

3.

BOF CCP

---------------------------

45-78

4.

C&A

---------------------------

79-83

5.

C&IT

---------------------------

84-92

6.

Capital Repair

---------------------------

93-93

7.

CCAS

---------------------------

94-105

8.

CCMD

---------------------------

106-107

9.

Coke Ovens

---------------------------

108-159

10.

Energy Management

---------------------------

160-163

11.

ERS

---------------------------

164-172

12.

ETL

---------------------------

173-178

13.

Instrumentation

---------------------------

179-187

14.

Marketing

---------------------------

188-194

15.

Medical

---------------------------

195-199

16.

MM

---------------------------

200-202

17.

Operation Garage

---------------------------

203-210

18.

Oxygen Plant

---------------------------

211-222

19.

P&A

---------------------------

223-228

20.

P&BS- 2

---------------------------

229-290

21.

Power Dist.

---------------------------

291-299

22.

PPC

---------------------------

300-302

23.

Projects

---------------------------

303-307

24.

RMHP

---------------------------

308-338

25.

Rolling Mills

---------------------------

339-367

26.

Safety Engineering

---------------------------

368-376

27.

Shops and Central Workshop

---------------------------

377-383

28.

Sinter Plant

---------------------------

384-393

29.

Sports

---------------------------

394-398

30.

Telecom

---------------------------

399-408

31.

Traffic & Raw Materials

---------------------------

409-424

32.

Water Management

---------------------------

425-442

ACVS
AIR CONDITIONING & VENTILATION SYSTEM

A) Introduction
Air Conditioning and Ventilation system or ACVS department of IISCO Steel Plant, Burnpur is
entrusted with the job of round the clock operation and maintenance of various types of Air
conditioning systems- Windows ACs, Packaged ACs, Central ACs, Chiller water units installed
within the plant premises and also outside for their uninterrupted operation and their pro-active,
preventive, corrective and breakdown maintenance.
The ACVS department of ISP maintains 47 Central Air conditioning Plants, 111 Packaged Air
Conditioners, over 900 Room Air Conditioners (Window/Split), 20 Water coolers and 15
Refrigerators.
Central air conditioning plants of capacity 15 to 420 TR are installed in Burnpur Hospital , power
engineering plant control rooms, PEDD, Drawing office, confluence, Deepani.These plants
maintain desired temperature to safe guard control panels in control rooms and provide
comfortable working conditions.
Packed Air Conditioners of capacities 5.5 TR to 30 TR are installed in control rooms of CO &
BPP, Power plants, C&IT, PLC Boiler Control room, MRM etc. Also high ambient temp air
conditioners of Linter make , USA are installed at COB # 10 in pusher cars, charging cars, guide
cars & coke cars.
Room air conditioners of window and split type are installed at various offices and control rooms
inside and outside works area to control temperature for electronic cards & comfortable human
working conditions.

B) Air Conditioner Functioning

IISCO Steel Plant

ACVS
C) Principles of Refrigeration
a. Liquids absorb heat when changed from liquid to gas ( Freon 22, R-124, R134a)
b. Gases give off heat when changed from gas to liquid.
All air conditioners use the same cycle of compression, condensation, expansion, and
evaporation in a closed circuit. The same refrigerant is used to move the heat from one area, to
cool this area, and to expel this heat in another area.
a. The refrigerant comes into the compressor as a low- pressure gas , it is compressed and
then moves out of the compressor as a high-pressure gas.
b. The gas then flows to the condenser. Here the gas condenses to a liquid , and gives off its
heat to the outside air.
c. The liquid then moves to the expansion value under high pressure. This valve restricts
the flow of the fluid, and lowers its pressure as it leaves the expansion valve.
d. The low-pressure liquid then moves to the evaporator, where heat from the inside air is
absorbed and changes it from a liquid to a gas.
e. As a hot low- pressure gas, the refrigerant moves to the compressor where the entire
cycle is repeated.
The four-part cycle is divided at the centre into a high side and a low side. This refers to the
pressure of the refrigerant in each side of the system.

D) Brief Overview of the major Installed Systems at IISCO Steel Plant:

1. Modernization & Expansion

a. Chiller Units
Sno

Area/Customer

Type

Quantity

Capacity/Unit(TR) Total
Tonnage
(TR)

SINTER PLANT

Chiller

5 Nos.

( 3x 155), (2x105)

675

CDCP-COB #11

Chiller

2 Nos.

110

220

PBS#2

Chiller

2 Nos.

220

440

MRS

Chiller

2 Nos.

60

120

WRM

Chiller

6 Nos.

270

1620

BOF

Chiller

6 Nos.

300

1800

CCP

Chiller

4 Nos.

150

600

IISCO Steel Plant

ACVS
b. Packaged A.C. Units
Sno

Department

No

of

units Capacity

installed

of Total Capacity

each unit ( in ( TR)

TR)

WMD

11.0

88

BPP (COB#11)

11.0

22

16.5

99

5.5

11

12

11.0

132

16.5

33

8.5

51

10

11.0

110

16.5

66

5.5

16.5

11.0

22

16.5

33

RMHS (OHP)

CHP (COB#11)

WRM

PBS

16.5

33

OXYGEN

11

55

PLANT
Total = 66

Total 771.5

c. Mobile A.C Units (Lintern Make) for High Ambient Conditions

Department

A.C Type

Capacity/Unit

Total Nos.

COB#10

Split

1.5TR

22

d. Existing Plant

Sno.

Area/Customer

Type

Quantity

PEDD

Chiller

4 Nos.

Drawing Office

Chiller

1 Nos.

Control Gallery

Chiller

2 Nos.

SMS

PAU

2 Nos.

Steel Section Lab

PAU

4 Nos.

Iron Section Lab

PAU

2 Nos.

BF #2

PAU

2 Nos.

IISCO Steel Plant

ACVS
7

Coal Prep. Plant

PAU

2 Nos.

THF

PAU

2 Nos.

Iron Section Lab

PAU

2 Nos.

10

Thyristor

PAU

3 Nos.

11

Telephone Ex.

PAU

2 Nos.

12

C&IT

PAU

2 Nos.

13

Control/ Galari

PAU

2 Nos.

14

Motor House

PAU

2 Nos.

15

ED (W) Office

PAU

1 Nos.

16

BF Distribution

PAU

2 Nos.

17

Bur & Rod

PAU

1 Nos.

18

34 Cabin

PAU

2 Nos.

Type

Quantity

e. Outside Plant Premises

Sno

Area/Customer

Hospital ( Surgical Chiller

7 Nos.

Complex)

Deepani

Chiller

2 Nos.

Confluence

Chiller

3 Nos.

Bharati Bhavan

Chiller

1 Nos.

MD Office

PAU

3 Nos.

Hospital ( X Ray)

PAU

4 Nos.

Old OT Hospital

PAU

1 Nos.

Burnpur Club

PAU

4 Nos.

IISCO Steel Plant

Blast Furnace
BLAST FURNACE

A) Introduction
The purpose of a blast furnace is to chemically reduce and physically convert iron oxides
into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with
refractory brick, where iron ore, coke and limestone are dumped into the top, and
preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend
to the bottom of the furnace where they become the final product of liquid slag and liquid
iron. These liquid products are drained from the furnace at regular intervals. The hot air
that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after
going through numerous chemical reactions.

The aim of Blast Furnace is to produce pig iron from ore and sinter, i.e. iron bearing
materials. Theiron oxide ore and sinter is reduced to iron with the help of CO and this CO
is produced inside theblast furnace by the action of air with coke. Coke serves another
purpose of supplying heat for thereactions and melting iron inside the furnace. Part of the
heat load of the furnace is also provided bythe heat of the blast which is heated up to a
temperature of 1,000C or so before it is introduced intothe furnace. The gangue material
(i.e. unwanted materials like SiO2, AI2O3 etc.) of the ore, sinterand coke are removed as
slag with the help of flux. Other additives like quartzite and Mn are also charged in the
furnace in smallquantities (corrective materials for the proper furnace working and
control of analysis). Except blast and CDI which is fed from the lower part of the furnace
thorough tuyeres, all other materials are chargedfrom the top. The product of the furnace
is pig iron (hot metal), slag and BlastFurnace gas.

Out of 4 Blast Furnaces commissioned way back in 1922, 1924, 1958 & 1958, operation
of 3 furnaces, no.1, no. 4 & no. 3 has been stopped since 2008, 2008 & 2012 respectively.
Presently only one rebuilt furnace no. 2(in Nov. 2007) is in operation having useful
volume 530 m3 & average daily production of 610 MT. The upcoming blast furnace
number 5 is having a useful volume of 4161 m3 and it will produce 7900tpd of hot metal.

IISCO Steel Plant

Blast Furnace
The entire Blast Furnace complex may be divided in the following sections:

1. Furnace Proper
2. Raw Material Charging
3. Stoves
4. Auxiliaries
i.

Pig Casting Machine

ii.

Hot Metal Handling System

iii.

Gas Cleaning Plant and ETP

iv.

Slag Granulation Plant, Dry Pit and Sand Pit

v.

Cooling System

vi.

Coal Dust Injection (CDI)

Description of each of the sections is given below

B) Furnace Proper
Diameter by mm
1. Throat diameter 9800
2. Hearth diameter 13600
3. Belly diameter

15600

The furnace inner profile is designed based on the experience and know-how of POSCO
E&C with the reference profile of the similar scale furnaces designed by POSCO E&C,
which was shown the high productivity and stable operation.
The optimized carbon and ceramic material is arranged around the hearth area. The
furnace cooling system and refractory arrangement will ensure the campaign life of more
than 20 years without the intermediate capital repair.
The most advanced copper staves in the high heat load zone such as bosh, belly and
lower shaft zone (B1,B2.S1,S2), and cast iron staves at the zone of hearth, tuyere, middle
6

IISCO Steel Plant

Blast Furnace
and upper shaft (H1~H4,T1,S3,S4, S5,R1,R2) with integral refractory are arranged. The
furnace under hearth is cooled by water through embedded pipes.
1. Structure and Measuring equipment
Independent furnace tower structure with platforms will be designed for supporting the
equipment of the charging system and the probes for furnace, and providing adequate
space for maintenance and operation of the equipment.

The fixed above burden temperature probe, under burden probe, and profile meter are
fitted in the furnace with the related power supply unit for measuring operation
situation inside the furnace.Reduced gas made from BF bottom will be reacted with
the materials falling down while the gas goes up, and this will make the ores to be
preheated up or deoxidized.

Reduced gas made from BF bottom will be reacted with the materials falling down
while the gas goes up, and this will make the ores to be preheated up or deoxidized.
IISCO Steel Plant

Blast Furnace

2. Blast Furnace(Proper) shell

Design Condition for BF shell

a. Type:

Free standing type

b. Useful volume:

4,150 (Actual: 4,161 )

c. Hearth diameter :

13.6 m

d. Number of Tuyere :

38 EA

e. No. and angle of tap hole :

4 EA, 10

f.

4.6/3.0 kg/

Blast pressure/ Top pressure (Design):

IISCO Steel Plant

Blast Furnace
Design description of shell: The furnace shell is designed so as to endure the load of
some parts of the furnace top charging equipment, the raw materials, molten iron and
slag in the furnace, refractory and other auxiliary equipment, and the design blast
pressure of 4.6 kg/ and the design top pressure of 3.0 kg/. The blast furnace shell
was designed for the maximum operating pressure plus 10%.Considering the molten
iron & slag volume, the hearth diameter is set to be 13.6m. And, pool depth, defined
as the depth from the bottom of hearth to center of T/H, is 3.0m to obtain optimal
accumulated volume of iron and longer campaign life of the hearth. The slope of iron
notch (Tap hole) will be 10 to the horizontal, but the angle between two iron notches
will be 80.
The height of Bosh and Belly are decided to be 3.7m, and 2.5m respectively in order
to have enough melting and reduction function in cohesive zone, to absorb bosh gas
volume expansion and to smooth descending of burden materials.
The outsidetemperatures of shell depend on a number of factors and different
conditions, the design values to be assumed in calculation are 180 on the whole
shell with 300 to be considered on tap hole, tuyere zone, tuyere stock and top cone.

IISCO Steel Plant

Blast Furnace

1,570

* Stock Line

B: 2248m3

17,450

80.564

D
E

G: 436m3

4,200

E: 87m3
4,200
3,000

CL OF TUYERE
13,600

7,800

74.876

3,700

D: 620m3

F: 610m3

2,500

15,600

C: 478m3

CL OF TAP HOLE

<BF shell profile>

WORKING VOLUME

: 3551 (A+B+C+D+E)A: 118m3

USEFUL VOLUME : 4161 (A+B+C+D+E+F)

TOTAL VOLUME
10

: 4597 (A+B+C+D+E+F+G)
IISCO Steel Plant

Blast Furnace
3. Furnace Cooling
Tuyere nozzle/cooler
Design pressure will be approximately1.2times of working pressure.
Working conditions approximately

Tuyere coolers

8 Kg/m2

Tuyere bodies

8 Kg/Cm2

Tuyere noses

10 Kg/cm2 (min)

a. Type: spiral double chamber type with high speed water.

b.Qty: 38sets
c. Material specification
i.

Tuyere nozzle body:

99.9 % copper

ii.

Electrical conductivity:

60% IACS

iii.

Tuyere cooler:

99.5 % copper

iv.

Electrical conductivity:

50 % IACS

v.

Tuyere nose:

Ni-Cr hard facing and ceramic

coating.

Copper staves will be manufactured by rolled slab. Refractory anchoring grooves are
machined into the hot face surface of copper stave. For fixing and lifting elements,
threaded holes are drilled into the stave.In the meanwhile, pipe inlets and outlets for
copper stave are sealed gastight by means of sealing boxes with integrated
expansion bellows, which are welded on the shell and on the cooling pipe of the
stave. And the cooling pipes inlets and outlets are fitted with a seal to prevent
castablefrom flowing into the shell openings.

Cast iron staves: The thinned cast iron stave in hearth, tuyere, middle & upper shaft
area (H1~H4, T1, S3~S5, R1, R2) which contains cast in pipes with integral brick
will be installed. In terms of stave material, high heat conductivity copper for the
IISCO Steel Plant

11

Blast Furnace
copper staves and a material with an excellent thermal shock resistance (Spheroidal
graphite) for cast iron staves(S3~R2) will be used practically. In the structural
aspect, to eliminate the less-cooled zone at the stave, the arrangement of the cast-in
pipes enables to cool uniformly the entire stave.

The staves of Row R1 and

R2 have two serpentine cast-in pipes in one stave due to the thermal load lower than
that of other zones.

For cast iron stave, gas sealing is obtained at the fixed points by the use of
compensators that are welded both on the shell and on the protecting sheath pipes.
At the movable points of upper sealing of the stave, the seal boxes are fixed both on
the shell and welded on the protecting sheath pipes. At the rigid points of lower
sealing of the stave, the seal washers are welded both on the shell and on the
protecting sheath pipes.

12

IISCO Steel Plant

Blast Furnace
Table: Specifications of Stave
Pipe number for
Row

Q'ty

Stave material

Thickness

Each stave
Vetical/
Serpentine
Horizontal

Hearth - H1

38

140

6/0

Hearth H2

38

140

6/0

Hearth H3

38

140

6/0

Hearth H4

38

140

6/0

Tuyere - T1

38

240

6/0

Bosh - B1

44

120

5/0

Belly - B2

44

120

5/0

Lower Shaft S1

44

120

5/0

Lower Shaft S2

44

120

5/0

Middle Shaft
- S3

36

330

6/2

Middle Shaft
- S4

36

330

6/2

Middle Shaft
S5

36

330

6/2

Upper Shaft R1

26

330

Upper Shaft R2

26

330

IISCO Steel Plant

Grey Cast Iron

Copper

Spheroidal
Graphite

13

Blast Furnace
4. Furnace Top Water Spray Equipment
Furnace top water spray system is installed on the top cone for emergency cooling of
furnace inside and adequate steam and nitrogen purging system is fitted on the top
cone area.

Setting temperature

300

Number

8 EA

of

spraying

nozzle
Water Quantity

2 /min/pump 2

Operation

Automatic control by temperature setting and

manual.

To prevent the spray nozzles from being clogged by dust, Nitrogen Gas is used at
time of no water spraying.
5. Furnace Auxiliaries
a. Fixed Above Burden Temperature Probe: 2 set
This device is installed above the stock in order to detect temperature
distribution and analysis of gas.
i.

Type : Fixed type

ii.

Measuring Range : 0 ~ 1,200

iii.

Measuring Point : 6 points with 1 probes (temp and analysis)

7 points with 1 probe (Only temp.)

iv.

Temperature measuring method : Simultaneous and continuous

v.

Cooling method : by N2

b. Under Burden Probe: 1 set

This device is installed at the upper shaft and inserted into the charged material
to analyze the chemical composition and temperature of the gas.

14

i.

Type: Horizontal measuring probe

ii.

Measuring Range: 0 ~ 1,100

IISCO Steel Plant

Blast Furnace
iii.

Driving Method: Hydraulic driving type

iv.

Sample Point: 10 Points

v.

Sample Time: Within 30 minutes for 10 points

vi.

Cooling Method: Water cooled, Nitrogen purge

c. Profile Meter: 1 set

This equipment measures the distribution of charging materials
i.

Type: Micro Wave Level Meter

ii.

Driving Method: Hydraulic driving type

iii.

Measuring Range: 500mm ~ 6,000 mm from antenna

iv.

Cooling method: Water cooled, Nitrogen purge

d. Top Gas Ignition: 1 set

This equipment is to ignite the waste gas setting up above the burden during BF
shut down repair.
i.

Type : Inclined lance inserted through top cone

ii.

Control and Driving Method : Local Control, Electric motor & chain
drive mounted on frame

iii.

Fuel & Air : COG and compressed air

e. Stock line detector: 3sets(Mechanic:1set, Radar: 2sets)

The burden level in the blast furnace is measured by one mechanical stock line
detector used for calibration and normal operation and two radar stock line
detectors for normal operation.

C) Raw Material Charging

Iron ore, sinter and two fraction coke transported to the upper stock house bin through the
belt conveyor charged to the bin through shuttle conveyor. A scheme is envisaged for
supply of requisite quantity of sized raw. Materials from stock house bins to the furnace

IISCO Steel Plant

15

Blast Furnace
by conveyor system and transportation of screened fines for sinter, ore and coke to a
separate fines storage bunkers with discharge arrangement.

This equipment will be provided for discharging and weighing ferrous and coke from the
ferrous and coke bins and for charging to the furnace top with a charging conveyor.The
ore mentioned herein will be a general terms for sinter, sized ore and additive materials.

Sinter and ore will be screened and separated into lump [sinter (+15mm), ore(+8mm)]
and fines [sinter(-15mm), ore(-8mm)] by screen located under bins. Lump sinter and ore
will be weighed by the weighing hopper under the bins. On the other hand fines sinter
and fines ore will be transported to the fines bins through fines conveyors.

The fine ore that is transported through the fine conveyor will be charged to ore fine
bunker. The fine sinter will be sized by the screen which is installed under sinter fine bin,
and then oversized sinter (5~15mm) will be charged to the blast furnace through charging
belt conveyor after returning to small sinter bin of stock house through small sinter belt
conveyor. Also, undersized sinter (~5mm) will be transported to sinter plant or yard.

At coke plant, in a case of the coke that has two (2) kind of grain size is transported to
upper stock house bin, the coke that is separated as 60~80mm through the screen which is
installed at the lower coke bin will be charged to the blast furnace as a hard coke for
charging to center. On the other hand, the coke that is separated as 34 ~ 60 mm will be
charged to the blast furnace as a surface coke.

The undersized coke (-34mm) will be transported to the coke fines bin through fines
conveyor. The transported small-sized coke will be separated as the oversized coke
(8~34mm) and fine coke (-8mm) through the screen which is installed under coke fine
bin.

16

IISCO Steel Plant

Blast Furnace
The oversized coke (8~34mm) will be charged to the blast furnace through the charging
belt conveyor after returning to the nut coke bin of stock house through the nut coke belt
conveyor. The fine coke (-8mm) will be transported to the sinter plant or yard.
Bins have the capacity for 8 ~ 24 hours operation continuously. Fines material will have
arrangement for discharge fines belt conveyor. The electrostatic precipitator isconstructed
to prevent dispersion of dust generated from the stock house.

1. Process Description

IISCO Steel Plant

17

Blast Furnace

Process Diagram of Stock house & Material

18

IISCO Steel Plant

Blast Furnace
2. Coke System
a. Coke Bin
Six (6) coke bins are designed and the effective volume of each bin is 840 m3. This is
based on the storage capacity of 12hours for daily maximum production of 8,000ton
pig iron.

Coke to be transported by CRSC1,2 belt conveyor for the coke of 60~80mm and
CRSC3,4 belt conveyor for the coke of 34~60mm is fed in one of the coke bins to be
selected automatically by the level sensors at the bins.

The surface of the sloping walls at the lower part of bins is lined with basalt material
of 40mm thick. The sloping angle at the lower part of bins is limited to minimum
55degrees (Valley angle) with regard to angle of repose of coke.

A level detector is installed above the each bin for monitoring the level of stored coke
in the bins and control of the shuttle conveyor.

A de-dusting duct with a damper automatically actuated by pneumatics is installed at

each bin for extracting the dust generated when coke is discharged from shuttle
conveyors to the bin.

The slide manual gate is located below the bins. A vibrating feeder of the capacity of
200 ton per hour is fitted below the gate for higher screening efficiency.

A coke screen of the capacity of 200 ton per hour is located below the vibrating
feeder. The screen remove coke fine of 0 to 34mm size.

IISCO Steel Plant

19

Blast Furnace
3. Coke Weighing Hoppers
All of weighing hoppers are respectively mounted on load cells for weighing purposes
and has a hydraulic operated gate for material discharge and a manual gate for controlling
of flow rate of discharge

The signal form the load cell will be displayed by weight value at HMI and used to
control of the screens and vibrating feeders. The stop signal will be calculated by PLC
with result from the last weighing.

During screening coke, the oversize fraction fall into the weighing hoppers and the
undersize fraction below 34mm fall onto the sinter fine conveyor (FCC-1). The
maximum of four (4) screens can be operated simultaneously.

The materials in weighing hoppers are discharged on BFC-1 BC according to coke

batching program in Automatic control mode.

4. Coke Gathering Conveyor

The coke conveyor (BFC-1) feeds the materials into one of two coke surge hoppers via a
hydraulic-actuated change over chute located under the head of BFC-1 belt conveyor.

This belt conveyor run continuously and has the dual drive unit system for stable
operation of blast furnace by connecting the coupling of a standby drive unit when the
duty drive unit are in trouble.

Metal detector is located on the BFC-1 belt conveyor and when the metal is detected the
BFC-1 belt conveyor will be stopped and alarm will give to HMI. And this will also
prohibit the gate of coke weighing hopper from open.

The undersize size fraction during screening sinter is sent via coke fine conveyor (FCC-1,
2) to two coke fine. The small screened by a coke fine screen is transported to the nut
coke bin and coke fines are then removed by FCC-3 belt conveyor.
20

IISCO Steel Plant

Blast Furnace

All of coke belt conveyors run without stop during Automatic mode operation.

The coke sampler is located around the head pulley of BFC-1 belt conveyor, and the
sampling will be done by manual operation at local only when the sampling is required.

5. Coke Fine Conveyor

The coke fines are via conveyor (FCC-1B.C, FCC-2B.C, CRC-3 B.C) of the capacity of
200ton per hour into two coke fine bins. The nut coke screened by a coke fine screen is
transported to the nut coke bin and coke fines are then removed by FCC-3 belt conveyor.

6. Coke Surge Hoppers

The surge hoppers located in the transfer house are filled alternatively, but single hopper
operation can be used. Coke is discharged on the furnace charging conveyor in turn from
the coke surge hoppers.

Each surge hopper is mounted on load cells for weighing purposes and has a hydraulic
operated gate for coke discharge and a manual gate for controlling of flow rate of coke
discharge. The signal from the load cells will be displayed at the HMI and used to control
of the screens. The stop signal will be calculated by PLC with result from the last
weighing.

Each coke surge hoppers has a moisture measurement that is used to measure the
moisture content in the coke.

A level sensor is installed at the sidewall of each hopper to detect the high level of the
filling materials and it gives alarm at HMI and stops the vibrating feeders, screens and
belts.

7. Coke Fine Bin

IISCO Steel Plant

21

Blast Furnace
The coke fines below 34mm size are transported by FCC-1,2 and CRC-3 belt conveyor to
the coke fine bin for screening nut coke and holding purpose prier to removal by belt
conveyor(FCC-3). The coke fine bin of useful volume of 350 m3 is based on the storage
capacity of 8 hours for daily maximum production of 8000ton pig iron.

The surface of the sloping walls at the lower part of bins is lined with basalt material of
40mm thick. The sloping angle at the lower part of bins is limited to minimum 55degrees
(Valley angle) with regard to angle of repose of coke.

The vibrating feeder and manual gate are installed for discharging fine coke in the bin.
One coke fine screen is below the vibrating feeder for screening nut coke of coke fine.
And the level sensor is installed for measurement of the level of deposit coke in the bin.
The level signal is used to stop the FCC-1, FCC-2 and CRC-3 belt conveyor when the
level is high.

8. Ferrous System

a. Ore and Additive Bin

There are two (2) ore bins and four (4) additive bins. The effective volume of each
ore bins is 450 m3 and the effective volume of each additive bins is 100 m3. These
are the based on the storage capacity of 16hours of ore bins and 24hours of additive
bins for daily normal production of 8,000 ton pig iron. There is weigh hopper under
the ore and Additive bins.

Ore / additive materials to be transported by SHC-2 belt conveyor and ORSC-1

shuttle conveyor is fed in one of the ore / additive bins to be selected manual or semiautomatically by the level sensors at the bins.

The surface of the sloping walls at the lower part of bins is lined with basalt material
of 40mm thick. The sloping angle at the lower part of bins is limited to minimum 55
degrees of valley angle with regard to angle of repose of ore/ additive materials.
22

IISCO Steel Plant

Blast Furnace

A level transmitter and a level switch are installed above all of the bins for
monitoring the level of stored materials in the bins. And the de-dusting duct with a
damper automatically actuated by pneumatics is installed at each bin for extracting
the dust generated when ore/additive materials are discharged from shuttle conveyors
to bins.

The slide gate of manual type is located below the bins. A vibrating feeder of the
capacity of 250 ton per hour is fitted below the gate of the ore bins for higher
screening efficiency.

An ore screen of the capacity of 250 ton per hour is located below the vibrating
feeder. The screen remove ore fine of 0 to 8mm size.

A vibrating feeder of the capacity of 50 ton per hour is located below the slide gate of
the additive bins for discharging of additive materials into the weighing hopper.]

The weighing hoppers are located below the ore screens and additive vibrating
feeders for weighing purpose.

b. Sinter Bin
There are six (6) sinter bins. The effective volume of a sinter bin is 800 m3. This is
the based on the storage capacity of 16 hours for daily maximum production of 8000
ton pig iron.

Sinter to be transported by SRC-1 belt conveyor and SRSC-1,2 shuttle conveyor is

fed in one of bins to be selected automatically by the level sensors at the bins.

The surface of the sloping walls at the lower part of bins is lined with basalt material
of 40mm thick. The sloping angle at the lower part of bins is limited to minimum 55
degrees of valley angle with regard to angle of repose of ore/ additive materials.
IISCO Steel Plant

23

Blast Furnace

A level transmitter and a level switch are installed above all of the bins for
monitoring the level of stored materials in the bins. And the de-dusting duct with a
damper automatically actuated by pneumatics is installed at each bin for extracting
the dust generated when sinter materials are discharged from shuttle conveyors to
bins.

The slide gate of manual type is located below the bins. A vibrating feeder of the
capacity of 450 ton per hour is fitted below the gate of the sinter bins for higher
screening efficiency.
The weighing hoppers are located below the screens for weighing purpose and these
hoppers are used to weigh the sinter.

c. Nut coke bin

There is one (1) nut coke bin. The effective volume of a sinter bin is 640 m3. This is
the based on the storage capacity of 12 hours for daily maximum production of 8000
ton pig iron.

Nut coke to be transported by NCC-1 belt conveyor is fed in nut coke bin.

The surface of the sloping walls at the lower part of bins is lined with basalt material of
40mm thick. The sloping angle at the lower part of bins is limited to minimum 55
degrees of valley angle with regard to angle of repose of coke materials.

A level transmitter and a level switch are installed above the entire bin for monitoring
the level of stored materials in the bins. And the de-dusting duct with a damper
automatically actuated by pneumatics is installed at each bin for extracting the dust
generated when sinter materials are discharged from shuttle conveyors to bins.

24

IISCO Steel Plant

Blast Furnace
The slide gate of manual type is located below the bins. A vibrating feeder of the
capacity of 50 ton per hour is fitted below the gate of the nut coke bin discharging nut
coke into the nut coke weighing hopper.
The weighing hopper is located below the vibrating feeder for weighing purpose and
this hopper is used to weigh nut coke.

d. Small Sinter Bin

Two (2) small sinter bins are designed and the effective volume of each bin is 600 m 3.
This is based on the storage capacity of 16hours for daily maximum production of
8,000ton pig iron.

Small sinter to be transported by SSC-1, 2 belt conveyor and SRSC-1 shuttle conveyor
is fed in one of the small sinter bins to be selected automatically by the level sensors at
the bins.

The surface of the sloping walls at the lower part of bins is lined with basalt material of
40mm thick. The sloping angle at the lower part of bins is limited to minimum
55degrees (Valley angle) with regard to angle of repose of small sinter.

A level detector is installed above the each bin for monitoring the level of stored small
sinter in the bins and control of the shuttle conveyor.

A de-dusting duct with a damper automatically actuated by pneumatics is installed at

each bin for extracting the dust generated when small sinter is discharged from shuttle
conveyors to the bin.

The slide gate of manual type is located below the bins. A vibrating feeder of the
capacity of 100 ton per hour is fitted below the gate for discharging small sinter on the
BFC-3 belt conveyor.

IISCO Steel Plant

25

Blast Furnace
9. Ore/ Additive and Sinter Weighing Hoppers
Each one weighing hopper is located per two screens and an additive weighing hopper is
located below four additive vibrating feeders for weighing purpose.
All of weighing hoppers are respectively mounted on load cells for weighing purposes
and has a hydraulic operated gate for material discharge and a manual gate for controlling
of flow rate of discharge.

The signal form the load cell will be displayed by weight value at HMI and used to
control of the screens and belt feeders. The stop signal will be calculated by PLC with
result from the last weighing.

During screening sinter, the oversize fraction fall into the weighing hoppers and the
undersize fraction below 34mm fall onto the sinter fine conveyor (FSC-1). The maximum
of four (4) screens can be operated simultaneously.

During screening ore, the oversize fraction fall into the weighing hoppers and the
undersize fraction below 8mm fall onto the ore fine conveyor (FOC-1). The maximum of
two (2) of 2 screens and 2 vibrating feeders can be operated simultaneously.

The additive materials and nut coke fall into each weighing hopper by vibrating feeders
without screening.

The materials in weighing hoppers are discharged on BFC-2 BC according to ferrous

batching program in Automatic control mode.

Each hopper has a hydraulic operated gate for material discharge and a manual gate for
controlling of flow rate of discharge. The weighing hopper gate is open in order for
preventing the overfilling on the belt.

10. Ferrous BC
a. BFC-2 Belt Conveyor
26

IISCO Steel Plant

Blast Furnace
The ore conveyor (BFC-2) feeds the materials into one of two surge hoppers via a
hydraulic-actuated change over chute located under the head of BFC-2 belt conveyor.
These belt conveyors run continuously and have the dual drive unit system for stable
operation of blast furnace by connecting the coupling of a standby drive unit when the
duty drive unit is in trouble.
Metal detector is located on the BFC-2 belt conveyor and when the metal is detected
the BFC-2 belt conveyor will be stopped and alarm will give to HMI. And this will
also prohibit the gate of ore weighing hopper from open.
The undersize size fraction during screening sinter is sent via sinter fine conveyor
(FSC-1, 2) to two sinter fine. The small screened by a sinter fine screen is transported
to the small sinter bin and sinter fines are then removed by FSC-3 belt conveyor. And
the undersize size fraction during screening ore is sent via ore fine conveyor (FOC1,
2) to an ore fine bin.
All of ferrous belt conveyors run without stop during Automatic mode operation.
b. BFC-3 Belt Conveyor
The small sinter falls on to the small sinter gathering conveyor (BFC-3B.C) of the
capacity of 100 ton per hour by the vibrating feeder. The small sinter on the gathering
conveyor (BFC-3 B.C) feeds into the weighing hopper (Transfer house).

The belt conveyors have the dual drive unit system for stable operation of blast
furnace by connecting the coupling of a standby drive unit when the duty drive unit is
in trouble. Metal detector is located on the BFC-3 belt conveyor and when the metal
is detected the BFC-3 belt conveyor and related Feeder will be stopped and alarm will
give to HMI.

11. Ore Surge Hopper/ Small Sinter Weighing Hopper

Two ore surge hoppers located in the transfer house are filled alternatively with materials
but single hopper operation can be used. One small sinter weighing hopper located in the
transfer house is filled with small sinter transported by BFC-3 belt conveyor. Ferrous
IISCO Steel Plant

27

Blast Furnace
isdischarge on the charging conveyor in turn from the ore surge hoppers by batch call
from the furnace top PLC.

Each ore surge hopper and small sinter weighing hopper are mounted on load cells for
weighing purposes and has an hydraulic operated gate for ferrous discharge and a manual
gate for controlling of flow rate of ferrous discharge. The signal form the load cell will be
displayed at the main control room.

A level sensor is installed at each hopper to detect the high level of the filling materials.
When the detector is activated, it gives alarm at HMI, stops conveyor (BFC-2, BFC-3)
and closes all weighing hopper gate and small sinter vibrating feeder.

12. Sinter/Ore Fine Bin

The undersized sinter fraction is transported via FSC-1,2 and SRC-2 belt conveyor to a
sinter fine bin for screening small sinter and holding purpose prior to removal by belt
conveyor (FSC-3) and the undersized ore fraction is transported via FOC1,2 conveyor to
an ore fine bin.
The effective volume of the sinter fine bin is 250m3 and the volume of the ore fine bin
100m3. These are based on the storage capacity of 8hours for daily maximum production
8000ton pig iron.

The surface of the sloping walls at the lower part of bins is lined with basalt material of
40mm thick. The sloping angle at the lower part of bins is limited to minimum 55degrees
(Valley angle) with regard to angle of repose of small sinter.

The vibrating feeder and manual gate are installed for discharging fine materials in the
bins. One sinter fine screen is below the vibrating feeder for screening small sinter of
sinter fines. And the level sensor at each bin is installed for measurement of the level of
deposit materials in the bins. The level signal is used to stop the FSC1, 2, SRC-2 belt
conveyor or FOC-1, 2 when the level is high.
28

IISCO Steel Plant

Blast Furnace

13. Charging Belt Conveyor

The charging conveyor is to transport the coke and ferrous from the coke surge hoppers
and the ferrous surge hoppers to furnace top. The belt detectors and encoders are installed
for tracing the materials on the conveyor. The start or stop running of the conveyor is
available in the local control panel as well as HMI. And also the selection of control
modes Local/off/remote and duty/standby are available in local control panel.

14. Bin & Hopper Specification

a. Effective Volume and Number of Coke Bins & Weigh Hoppers
Coke Bin

840 6 Bins

Coke Weighing Hopper

26 6Hoppers

b. Effective Volume and Number of Sinter Bins & Weigh Hopper

Sinter Bin

800 6 Bins

Ore Bin

450 2 Bins

Additive Bin

100 4 Bins

Nut Coke Bin

640 1 Bin

Small Sinter Bin

600 2 Bins (small sinter ratio: 20% base)

Sinter Weigh Hopper

18 6 Hoppers

Ore Weigh Hopper

10 2 Hoppers

IISCO Steel Plant

29

Blast Furnace
Nut Coke Weigh Hopper

6 1 Hopper

Additive Weigh Hopper

3 2 Hopper

c. Effective Volume and Number of Fines bin

Coke Fine Bin

350 1 Bin, 100 1 Bin

Sinter Fine Bin

250 1 Bin, 100 1 Bin

Ore Fine Bin

100 1 Bin

d. Transfer Hopper
Coke Surge Hopper

45 2 Hoppers

Ore Surge Hopper

50 2 Hoppers

Small Sinter Weigh Hopper

15 1 Hopper

15. Belt Conveyor Specification

30

Furnace Charging Conveyor

3,600 t/hr

Ore gathering Conveyor

2,200 t/hr

Coke gathering Conveyor

600 t/hr

Sinter Fine Conveyor

600 t/hr

Ore fine Conveyor

400 t/hr

Coke fine Conveyor

200 t/hr

IISCO Steel Plant

Blast Furnace
Small sinter Conveyor

600 t/hr

Nut Coke Recovery Conveyor

100 t/hr

Sinter Shuttle Conveyor

1,000 t/hr

Ore/Additive Shuttle Conveyor

1,000 t/hr

Coke Shuttle Conveyor

450 t/hr

Additive/Ore gathering Conveyor

1200/hr

16. Stock house De-dusting System: 1 set

Type

Electrostatic precipitator

Capacity

13,000 Am3/min

Screen Efficiency

90%

Operating condition
a. Operating time

24 hours/continuous

b. Operating control Main control room / site

D) STOVES
The Hot Blast System is one of main facility to operate the Blast Furnace. The Hot Blast
System is consisting of the Hot Stove Shell, Process Mains, Heat Recovery System, Fan
& Blower, HS Refractory, Chimney stack and various equipments.

The hot air, which is made inside Hot Stove Shell as mixing the Combustion Air and
Mixed Gas (Blast Furnace Gas + Coke Oven Gas), is blown to the Blast Furnace through
the Hot Blast Main & Bustle Main.

IISCO Steel Plant

31

Blast Furnace
The On Gas and On Blast Cycle is continuously repeated in order to blow the
constant hot air. The Waste Gas, which is occurred during the On Gas phase, is used
for heat recovery system and the used waste gas is discharged.
Used Abbreviations

32

PCS

Process Control System

PLC

Programmable Logic Controller

VDU

Video Display Unit

RTD

Resistance Temperature Dependent

LCS

Local Control Station

LCP

Local Control Panel

SP

Set Point

MV

Manipulated Value

PV

Process Value

HB

Hot Blast

CB

Cold Blast

MA

Mixing Air

CA

Combustion Air

MG

Mixed Gas

BG

Blast Furnace Gas

CG

Coke Oven Gas

WG

Waste Gas

IISCO Steel Plant

Blast Furnace
SV

Shutoff Valve

GV

Goggle Valve

IV

Isolation Valve

SN

Snort Valve

CV

Control Valve

BV

Bypass Valve

VV

Vent Valve

1. Safety Precautions
Basic Safety: Observance of safety regulations and good training of the personal are
essential to prevent accidents and to achieve an optimum life time of the equipment.

Before starting operation, check that there is no personnel working close or on

moving installation parts. Check that all padlocks of mechanical and electrical
equipment attached for maintenance reasons have been removed.

Sufficient precautions should be taken when making inspections during operation. In

the area of the stoves, portable CO-gas measuring equipment should be used. For
more safety rules the relevant IISCO Steel Plant Company safety instructions should
be observed.

IISCO Steel Plant

33

Blast Furnace
2. Process Description

3. Ceramic Burner
The burners are designed for the following flow rates:
Maximum

gas

flow

(2

stove 136,000 Nm3/hr

gas

flow

(3

stove 114,400 Nm3/hr

operation)
Maximum
operation)
Minimum gas flow (at start of ramp- 14,000 Nm3/hr
up)

34

Minimum gas flow

54,000 Nm3/hr

Maximum air flow (2 stove operation)

130,000 Nm3/hr

IISCO Steel Plant

Blast Furnace
Maximum air flow (3 stove operation)

116,000 Nm3/hr

Minimum air flow (at start of ramp- 16,000 Nm3/hr

up)
Minimum air flow

64,000 Nm3/hr

Minimum excess air

10%

The ceramic burner is designed to perform complete burning under minimum excess
air conditions. Normally the excess air percentage at the start of the gas period will be
approx 10%, at the end of the gas period the excess air percentage will be around 20
to 30%. The ceramic burner, which has been incorporated, consists of rectangular gas
slots surrounded by air slots on each side.

4. Hot Blast Main

The hot blast main system has proven to be a reliable and stable system, from both a
refractory and steel construction stability standpoint. The following are some of the
principal design features which are included:
i.

The hot blast main form an integral unit with no external thrust forces or
expansion forces transferred to the stoves or to the tuyere stocks.

ii.

The thrust forces over the entire length of the hot blast main are taken up by
external tie rods attached to the hot blast main through thrust collars.

iii.

The hot blast main refractory lining will comprise alumina bricks on the hot
face, with a back-up of three (3) insulation fire brick layers. This design will
accommodate high temperature fluctuations with cold blast mixing. The "flat
arch" design will be applied at all "T" junctions of the hot blast main. In this
design, dense refractory bricks are suspended from the steelwork by stainless
steel anchors.

5. Valves
Each stove is provided with hydraulic actuated shut-off valves for the various media
during the stoves alternating gas and blast cycles. The valve types are:
IISCO Steel Plant

35

Blast Furnace
i.

Water cooled refractory gate valve for isolation of the hot blast outlets and
back draft line (HBSV & BDSV)

ii.

Eccentric disc valve for isolation for pressurization and blow-off (SPSV &
SDSV)

iii.

Eccentric disc valves, for isolating the cold blast line from the hot blast main
(hot blast mixer) (MASV)

iv.

Butterfly valves for flow control (MGCV, CACV, MACV, SPCV & CBCV)

v.

Two/three lever valve for all other valves. (CBSV, MGSV, MGIV, CASV,
WGSV 1 to 6, BGSV)

Other valves included in the hot blast system, but not used in the stoves sequencing
operation, will be sized and specified as follows:
i.

Blow-off type butterfly valve with silencer, for venting the cold blast (snort
valve : CBSN)

ii.

Butterfly valves for isolation of the waste gas heat exchangers. (WGSV 9 to
11 & CASV, BGSV)

iii.

Pressure control vanes with electric motors and two/three lever valves for
isolation of the combustion air fans (Pressure control vanes: CFCV, Two/three
lever valves: CFSV)

iv.

Butterfly and two/three lever valves for isolation of the COG mixing
lines.(Butterfly: CGCV, Two/three lever valves: CGSV, CGIV)

v.

Butterfly and two/three lever valves for pressure control and isolation of the
BFG main (Butterfly: BPCV, Two/three lever valves: BGSV)

vi.

Goggle valves for isolation of the mix gas branches.(MGGV)

All shut-off valves are specified as being hydraulically-operated. The control

valves have pneumatic actuators.

6. Waste Heat Recovery

The heat exchangers have been designed to heat up the combustion air and the blast
furnace gas by using the energy in the hot waste gas.

36

IISCO Steel Plant

Blast Furnace
The stove is built from a construction of various refractory materials to allow it to
withstand the extremes and fluctuations of temperature. During the gas phase,
preheated mixed gas, together with a large quantity of preheated combustion air, is
burned.

The hot gases go along the dome and then through the small channels of the checker
work. The heat is transferred to the checker work and thus the stove is heated. The
waste gases are discharged via the heat exchangers and the stack. When a stove is
sufficiently heated, the gas phase is ended by shutting a number of valves. The stove
is then ready to supply hot air to the blast furnace, in other words, ready for the "On
Blast" cycle. During the blast phase, cold air is blown through the checker work in the
reverse direction. The bricks of the checker work give up their heat to the air passing
through; the air becomes hot and leaves the stove as hot blast. The hot blast enters the
hot blast main and goes to the blast furnace via a bustle main. A central air mixer is
tied in the hot blast main to obtain control over the hot blast temperature. Thus, the
stove functions as a discontinuous heat exchanger. Since the blast furnace needs a
continuous supply of hot blast, three stoves are available. An important task of the
control system is to take care of the control of the hot blast system.

Stove combustion is only one aspect in the control and automation of a hot blast
system. The functions for a complete control system can be divided into the following
four (4) areas:
i.

Stove combustion

ii.

Stove sequencing

iii.

Hot blast and Stoves Common

iv.

Stove Valve Cooling

E) Slag Granulation Plant

The purpose of a slag granulation plant is to produce granulated slag by the quick cooling
of molten slag with water and to separate the granulated slag from the water, to obtain a

IISCO Steel Plant

37

Blast Furnace
product with low moisture content. The plant is designed to handle slag produced by the
furnace, considering the variation in quantity of slag flow and sequence of tapings.

The slag discharged from the blast furnace is separated from the iron at the skimmer and
flows through the slag runners towards the SGP. The two Independent slag granulation
systems granulate molten slag discharged from the blast furnace, each being sized for
maximum slag flow conditions. The molten slag discharged from the blast furnace is
rapidly quenched by water jets at the Spray Box and granulated. The slag sand with water
flows into the granulated slag basin via the Granulated Slag Trough. From there the
granulated slag is dewatered and removed by means of a Screw Conveyor discharging
onto a belt conveyor and conveyed to product silo or yard.

The quality of the produced granulated slag depends on the volume, pressure and
temperature of the water, as well as on the design of the blowing box and the chemistry
and temperature of the slag. Efficient de-watering system has been considered that
normal moisture content in granulated slag shall not exceed 12% after three hours storage
in silo. Granulated slag after dewatering was conveyed up to junction houses including
interconnecting conveyors between junction houses.

1. Transport of the Slurry

The slag sand, originated in the quenching process, is falling into the cushion tank.
The function of the cushion tank is to assure that all slag articles are quenched. The
slag sand is continuously conveyed to the screw conveyor.

2. Steam Emission Stack

The steam generated at the blowing box is led by the hood over the cushion tank to
the stack, installed on top of the cushion tank and released into the atmosphere.

3. The RASA Dewatering Station

The molten slag discharged from the blast furnace is rapidly quenched by water jets at
spray box and granulated. This granulated slag is dewatered and removed by means
38

IISCO Steel Plant

Blast Furnace
of a screw conveyor, discharged onto a belt conveyor and transported to yard or one
of two product silos subsequently discharged into road vehicles.Hot water overflows
from the granulated slag basin to the Rasman Filter (Mesh Roll Type) where fine slag
(wool) is removed.The fine slag deposits on the Rasman Filter are continuously blowdown into the granulated belt conveyor and transported to the product silo or
yard.Cleaned water from the Rasman Filter is directed, via a trough, to the Hot Water
reservoir. The water pumped to the cooling Tower and collected in the Cold Water
Reservoir is pumped to the spray box.

4. Slag Sand conveying and Storage

Screw conveyor continuously lift the slag sand and discharge it onto the conveyor
belt installed beside screw conveyor.The slag sand is carried to the top of the product
IISCO Steel Plant

39

Blast Furnace
silos, discharged onto a reversible belt conveyor and discharged into the silos or the
belt conveyor interconnected to yard.The slag sand is further dewatered in the silos
and the drained water from the silos is pumped back to the granulated slag
basin.Discharging of the silos is done manually. The slag sand can be discharged onto
trucks or other devices by opening the pneumatic actuated gate after three hours of
dewatering.

5. Cooling tower
The cooling tower was designed to cool down the quantity of heat up to a slag flow.
Underneath the cooling tower, there is a cold water reservoir, collecting the cold
water from the cooling tower cells.

6. Closed Loop Water Circuit

The required water in the granulation plant flows in a closed loop water circuit. The
process water is stored in the cold water reservoir below the cooling tower and in the
hot water reservoir beside the cushion tank.The water supply pumps are sucking the
water at the cold water reservoir and pump it to the blowing box.

The two water supply pumps are continuously running. After the water supply pumps
are started, the cooling circuit pumps are switched on. After passing the Rasman
filter, the granulation water flows into the hot water reservoir. From the hot water
reservoir, the water is pumped by the cooling pumps to the cooling tower.

The cooled water is collected and stored in the cold water reservoir below the cooling
tower. The water level in the cold water reservoir is monitored by a level switch.The
water losses, due to the remaining moisture in the granulated slag and the evaporation
at the cooling tower, are compensated by make-up water, which is fed into the cold
water reservoir below the cooling tower. A level transmitter, located in the cold water
reservoir initiates the opening of the make-up water valve.

a. Specification of SGP Equipment

40

IISCO Steel Plant

Blast Furnace
i.

Dewatering Screw Conveyor

Conveying Material
Capacity
Length
Lift Head
Diameter
Power
Trough Angle

ii.

Rasman Filter

iii.

Drum Dia.
Drum Width
Screen
Speed
Gear Box
Air Spry
Water Spry
Water Seal
Stir Water
SGP Cooling Tower

Granulated Slag
550T-slag/hr
13800mm
5556mm
2540mm
180kw x 4P x 415V x 50Hz
20Deg

2330mm
2540mm
20mesh
0.4~4rpm
Cyclo Drive(11kW)
10m3/min x 1.0kg/cm2
270L/min x 2.0kg/cm2
20L/min x 2.0/0.5kg/cm2
200L/min x 2.0kg/cm2

Capacity
Hot/Cold Water Temp.

3000m3/hr x 2sets
85/40 oC(at Wet Bulb 29 oC)

iv.

SGP Belt Conveyor

Number
6sets(550Ton/hr, width-1200mm)
4sets(55Ton/hr, width-500mm)

v.

SGP Product Silo

Capacity

vi.

700Ton x 2sets

Dry Pit: This is to be used only when SGP is not under normal operation or
during metal slag separation during the initial days of furnace commissioning.
Size
Number

IISCO Steel Plant

13m(w)x35m(L)/1set
4sets(2sets/each cast house)

41

Blast Furnace
F) CDI

In the era of growing demand for adoption of energy savings measures for Blast Furnace
Iron Making Technology and decreasing oven availability at Coke Ovens throughout the
world and increasing coke price the PCI or CDI process came into picture. Moreover it is
an environment friendly system and it will be clear from the following data:
For production of 1T of BF coke, 450kg of CO2 is released in atmosphere
For 1T of hot metal production through BF route we emit 1500kg of CO2 in atm.
And to produce 1T of crude steel through CO-> Sinter Plant-> BF->SMS route 2T of
CO2 is emitted in atmosphere.
42

IISCO Steel Plant

Blast Furnace
Substituting a considerable amount of coke by CDI, CO2 emission to the atmosphere can
be reduced.

IISCO Steel Plant

43

Blast Furnace

Improved BF Cooling
i.

As coal injection results in higher heat load on furnace wall, the following
counter-measures are incorporated:

ii.

Enhanced cooling through Cu stave/plate coolers

iii.

Use of Si-C refractory up to bosh / lower shaft

iv.

Better heat transfer by use of closed loop soft water

v.

To avoid jamming in Raw Coal Silo especially in monsoon a lining of HDPE

(High Density Poly Ethylene) with 10mm. Thickness has been provided.

vi.

7 nos. of N2 guns in each silo have been provided to tackle the jamming problem
of raw coal silo.

vii.

44

Top covers of bag filters will be rubber sealed to check air infiltration.
IISCO Steel Plant

BOF-CCP (SMS)
BOF-CCP (STEEL MELTING SHOP)

A) Introduction
The SMS is equipped with 2 Hot metal desulfurization stations, 3 BOF converters
each of capacity 150 T nominal capacity with bottom stirring facility along with Gas
cleaning plants, 3 on-line Argon rinsing stations, 2 Ladle heating furnaces, 1 RH
Degasser, Slag disposal area, Scrap storage and handling, liquid steel treatment and
casting ladle preparation facilities and other auxiliaries.
The BOF SHOP consists of the following bays:
i.

Torpedo-Cum-Desulphurization Bay

ii.

Scrap Bay (on the other side of the shop)

iii.

HM Receipt-Cum-Charging Bay

iv.

Converter Bay

v.

Slag Bay

vi.

Ladle Preparation Bay

vii.

Corridor-cum-Ladle Furnace Bay

viii.

Secondary Refining Bay

A brief description of each station of Steel Melting shop of ISP Burnpur is provided
in the following paragraphs:

B) Hot Metal Desulphurization Unit

In order to remove sulphur from the hot metal, it is necessary to use a sulphideforming agent such as a Calcium compound (CaC2). The sulphide-forming reaction is
promoted in a reducing atmosphere; therefore, it is most economical to desulfurize the
hot metal from blast furnace. Best result in desulfurization is achieved by using coinjection of re-agents based on Magnesium (Mg 97) and Calcium Carbide.
There are two units for hot metal desulfurization at ISP. The hot metal from blast
furnace no.- 5 reaches the HMDS units in torpedo ladles of capacity 350 T and then it
is poured into desulfurization ladles of capacity 150 T.
There are two operating cranes at the torpedo cum desulfurization bay of capacity 280
+ 80/20 T and two 15 T capacity repair trolley for repair of 280 + 80/20 T cranes. The
operating features of HMDS units are described below:

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BOF-CCP (SMS)
Technical Data for Hot Metal Desulfurization Units
(1)

Annual treatment capacity

(2)

Number

of

ladles

2,500,000 tonne

for 30 (nominal)

treatment/station/day
(3)

Capacity of ladle

150 T (nominal)/165T (max.)

(4)

Cycle time (total) matching 50 min

tap-to-tap time

(5)

Free board

0.35 m (min.)

(6)

Number of injection lines

(7)

Operating features

Co injection/ mono injection

(8)

Reagents

(i)

CAD 9 F3

(a)

Tech. CaC2

50-55%

(b)

Coal powder

4%

(c)

Fluorspar

3.5 %

(ii)

Mg 97

(a)

Mg

97%

(b)

Coating

3%

(9)

Injection rates

CaC2:35-40 kg/min, Mg: 8-10

kg/min

(10) Injection time

depends on sulphur drop (~ 15

min)

(11) Temperature drop

Depends on sulphur drop Avg.

approx. 1.5 C/min; max. 25C

(12) Conveying

medium

of Dry nitrogen

reagents
(i)

Pressure

10 bar (min.)

(ii)

Purity

99.9 %

C) Scrap Handling Bay

The scrap yard has been provided for storage of cut-to-size scrap. There is
approximately 10-15 T/heat of scrap which is charged via scrap box. For
simultaneous operation of the converters, 4 boxes per converter should be available
46

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(two scrap boxes in the scrap yard, one in the charging bay and one spare scrap box).
Each scrap box has a capacity of 25 m3.
The return scrap, process scrap and cold pig iron are handled in the scrap yard where
two magnet EOT cranes of capacity 20+ 20 T are available for loading scrap from the
storage pit into one of the scrap boxes. The scrap boxes are placed on mobile scrap
box transfers car (carrying capacity = 75T). After transfer to the charging bay, the
scrap will be charged into the converter by one semi portal crane of capacity 60+60T.
Charging can also be done by two overhead cranes via traverse (capacity = 280+80/20
T).

D) Hot Metal Charging Bay and BOF Converter Bay

The Converter Shop has 3 converters, each of capacity of 150 T with bottom stirring
facility. The 3 BOF converters have been designed including all facilities (e.g. oxygen
blowing equipment, off gas system, bin system etc.) for parallel operation of 2
converters (with possibility of heating the third converter). Total number of heats per
day is 51 from two converters. The average tap to tap time of the converters is around
50 min, as described below
a)

Charging of Scrap

3 min

b)

Charging of Hot Metal

4 min

c)

Oxygen Main Blowing Time

16 min

d)

Sampling after Blowing

2 min

e)

Waiting for Analysis

5 min

f)

Final Blowing / Reblow

2 min

h)

Tapping

7 min

i)

Slag Coating or Slag Splashing

4 min

j)

Deslagging

3 min

k)

Lining Inspection

4 min

Tap-to-Tap time

50 min

There are two hot metal charging EOT cranes of 280+80/20 T capacity and two repair
trolleys of capacity 15 T for maintenance of 280 + 80/20T capacity at the charging
bay. Further, there is one semi portal crane of 60 + 60 T capacity at the charging bay.
There are two cranes at lance repair bay, each of capacity 10 T.
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BOF-CCP (SMS)
Before charging, the converter is inspected for lining condition, after which scrap and
hot metal are charged. Cooling is provided mainly by scrap and cold pig iron and/or
Iron ore. The required fluxes for slag formation will mainly consist of burnt lime and
burnt dolomite. The specific material consumption (kg/T of crude steel produced) and
their composition in BOF converters as per detailed project report are as follows:

S.No. Material

Composition

Requirement

(1)

%C-3.8-4.3, %Si-1.2-1.4,

1080 kg/T

Hot Metal

%Mn-0.3-0.4, %P-0.2,-0.25,
%S -0.04-0.05. Temperature:
1250 - 1280C
(2)

Scrap

as available from plant

80 kg/T

(3)

Calcined

%CaO-84-87, %MgO-3.3,

80 kg/T

lime

%SiO2-3-5, %Al2O3-1.5, LOI3.75. size-25-50 mm

(4)

Calcined

% CaO-53, %MgO-35, %

Dolomite

SiO2-3.5, % Al2O3-1.0, %

25 kg/T

LOI-4.0. size -25-50 mm

The specific oxygen blowing rate will be in the range of 3.3 - 4 Nm/T min, which is
about
500 - 600 Nm/min. For top blowing the converters will be equipped with an
independent oxygen lance system consisting of two oxygen lances. One will be in
blowing position and the other one as standby. The bottom is equipped with an inert
gas (Ar/N2) stirring through bottom porous plugs which along with top lance blowing
help in achieving the close approach to the equilibrium of oxidation reactions. The
bottom blowing rate may vary from 1.8-9 Nm3/min (maximum 600 lpm). Closed
circuit cooling water system has been provided for lance cooling. After the blow,
sample of steel is taken and temperature is measured.
The analysis of steel sample is done in the site container laboratory. Tapping is done
after getting the final desired chemistry and temperature. Tapping temperature is

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about
1660- 1680C.
The liquid steel is then tapped into a 150 T capacity steel ladle, placed on steel
transfer car moving below the converter. Ferro alloy additions are made as per
requirement of the grade of steel. The required amounts of ferroalloys are added to the
ladle during tapping as per grade of steel. The ladle is stirred during and after tapping
for the homogenisation of temperature and composition of liquid steel. For this 3 nos.
on-line Argon Rinsing Stations (ARS) are installed. Following this, steel is analyzed
for composition and its chemistry and temperature are adjusted. If the temperature is
high, it is brought down by further rinsing.
The important operational activities at BOF converter shop have been as described
below:
1. Charging System for Fluxes and Coolants
Flux material for converters will be taken over at the top of flux bunkers within
the steel making plant for further distribution into the different bins. From the high
level bin system including vibrating feeders, weighing hoppers, chutes etc. the
material is charged into the converters continuously during the blow. Mainly,
fluxes such as burnt lime, burnt dolomite as well as coolants like raw dolomite
and iron ore are charged. The required burnt lime and burnt dolomite mixture will
be about 70-80 kg/T of crude steel produced. There are a total of 11 overhead bins
per converter for charging fluxes and coolants, with volume varying from
30-150 m3.

2. Liquid Steel Handling

Following the converter tapping cycle, liquid steel is tapped into a ladle, placed on
a transfer car. The tapped weight is measured by means of loads cells, integrated
in the car. The liquid steel will be tapped slag free from the BOF, in order to
eliminate the negative influence of the furnace slag (FeO, MnO) during further
processing and casting of the steel. To ensure slag free tapping, slag retaining
devices are provided at ISP.

3. Charging System for Ferro Alloys

Ferro alloys (Ferro Silicon and Silico Manganese), Calcined Petroleum Coke and
Aluminum are transferred by means of forklifts to the bins located below the
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BOF-CCP (SMS)
converter platform. From here the high level Ferro alloy bins will be filled by
means of vertical and horizontal belt conveyors for further charging into the ladles
below converters. There are 8 bins in total for ladle addition each of capacity 10
m3 .

4. Gas Cleaning Plant

During the process of converter blowing, a large amount of gas at high

temperature and rich in carbon mono-oxide (CO) comes out through the mouth of
the converter. At this stage this gas is very hot and dust laden, with a flow rate of
about 115,000 Nm3/h. This gas is known as LD gas or converter gas. The
equipment which is installed above the converter mouth functions to cool down,
clean up and to recover the converter gas. About 70-100 m3 of converter gas per
ton of crude steel with a calorific value ranging from 1600-2000 Kcal/N m3 of gas
is recovered.
The amount of the atmospheric air which enters the system at the converter mouth
is controlled by the hood pressure and a movable skirt. At the beginning of the
blow, the off-gas is exhausted into the atmosphere and the CO is burned at the
flare stack. After approx. 2 min. in the blowing process, the CO content will rise
to approx. 30 % and the recovery system will be switched to a gas holder where
the gas is stored for usage. At the end of the blow the CO content will decrease
and the gas is switched back to the flare stack until the blowing process has
finished.
The CO rich gas coming out of the converter is first indirectly cooled in the
converter hood by closed cooling water circulating circuit to bring down its
nominal temperature from 1600 -1700 C to around 900 C. This is called primary
cooling.
The system need to have high dust collecting performance. The recovered gas is
cleaned by wet type gas cleaning systems, which have a capacity to meet the
requirement of dust level less than 50 mg/Nm3. The recovered LD gas is cleaned
in venturi scrubbers. In the first stage, water is sprayed to the gas, for the dust to
form slurry & cooling and in the second stage, safe separation of gas from water
occurs through whirl vane separator. The cleaned gas is then stored in a gas holder
for steady supply to the gas distribution system after cleaning it further in the
electro static precipitator or is exhausted by an ID fan through a flare stack after
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flaring. The gas temperature at the ID fan outlet is about 80-85C. The average
composition of the recovered LD gas is as follows:
S.No. Gas

% composition

(1)

CO

65-70%

(2)

CO2

15-20%

(3)

N2

15-20%

(4)

O2

0.1%

Ar plug
Fig: Working of Basic Oxygen Furnace (Schematic)
The Standard Operating Practices for BOF operation are as follows:
i.

Take overall position of shop.

ii.

Prepare shift plan

iii.

Order hot metal & scrap as per process aim calculation and ordering
calculation or as per turn down condition, of the previous heat

iv.

Lift the Hot metal ladle with Hot Metal Charging Crane

v.

If there is excess slag carry over, pour out the slag by slightly tilting
the ladle.

vi.

If excess slag is charged, go for intermediate deslagging while

blowing.

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BOF-CCP (SMS)
vii.

Bring Hot Metal ladle near converter and engage 80 T hook for
charging.

viii.

Bring preloaded scrap box near converter

ix.

Get the information about exact amount of Hot Metal & Scrap

x.

Press START OF HEAT button

xi.

Dump Bottom Lime batch ( 0 - 4 T , according to the bottom condition

)

xii.

Lift the scrap box with the help of semi-portal crane.

xiii.

Tilt the converter on charging side. Charge hot metal into converter.

xiv.

After completion of charging, make the Converter upright

xv.

Inform to place empty slag pot and record slag pot no.

xvi.

Inspect the empty slag from 9m level, if OK receive it and place it at

safe position and if not OK - take remedial action

xvii.

Start the main blow after main blow calculation or as per level I auto
mode blowing scheme by pressing START OF BLOWING push
button. Within 20 sec. of bath ignition press Ignition push button.

xviii.

Monitor CO % in waste gas, if it goes less than 30 % after 2500 Nm3

O2 blown, press slopping button. If CO % doesnt rise in a minute or
slag comes out from the converter mouth press Heavy Slopping
Button.

xix.

Inform ladle despatcher to place steel ladle as per plan at intermediate

stop position

xx.

Blow will stop at intermediate stop position. Take sample and

temperature, if required

xxi.

Check whether steel ladle has been placed or not. If YES gives
nozzle filling compound & if NO again inform to place ladle
immediately.

xxii.

Continue blow to achieve AIM TEMPERATURE & CHEMISTRY

as per 2nd blow calculation.

xxiii.

Take sample and temperature and decide whether re-blow is required

or not

52

i.

If YES , continue blowing as per re blow calculation

ii.

If NO, do Ferro Alloy calculation and then go for tapping

iii.

Do N2 splashing after tapping if required

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BOF-CCP (SMS)
iv.

Clean Mouth Jam if any, before charging

xxiv.

Do Lance Calibration within 100 heats or alternate day.

xxv.

Change Tap Hole if any of the following condition is achieved.

i.

Tapping duration less than three minutes

ii.

Tap Hole Sleeves are damaged or gap between the sleeves is

observed

xxvi.

Receive clearance from Blower and start tapping

xxvii.

Carry out the following activities:

i.

Ladle addition

ii.

Apply dart when converter goes to final tapping angle

iii.

See the slag & inform slag condition to blower. It will help to
decide addition at the time of splashing.

iv.
xxviii.

Get ready with sample & temp. probe , identification slip

Tapping is terminated by visual observation of tapping stream. In case

slag arrester is used, the stream stops coming out, and subsequently
tapping is terminated, provided it works successfully.

xxix.

Collect ladle sample & temperature by lowering sample pipe with

probe and temperature element with probe into ladle.

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PROCESS FLOW DIAGRAM OF STEEL MELTING SHOP AT ISP
HOT METAL
FROM BF

OXYGEN

HOT METAL
DESULFURIZATION

IRON ORE,
LIME STONE,
DOLOMITE,
DOLOMITE
CONVERTER VESSEL

CALCINED LIME/
DOLOMITE

150 T
STEELLADLE

TRIMMING ADDITIONS (FOR

CHEMISTRY ADJUSTMENTS)

SCRAP

FERRO ALLOYS,
CARBURIZERS, LIME

ARGON RINSING
STATION

ARGON

LADLE FURNACE

RH DEGASSER

ELECTRICAL POWER

ALUMINIUM &
ALLOYING ELEMENTS

TURRET
(BILLET/BLOOM CASTER)

TUNDISH
WATER (CLOSED M/C
COOLING)

WATER (SPRAY

MOULD

/STRAND GUIDE

COOLING)
CAST STRAND

WITHDRAWL &
STRAIGHTENER UNIT
CAST BILLET/ BLOOM /BEAM BLANKS

WIRE ROD
MILL & BAR
MILL

GAS CUTTING M/C

M
BLOOMS

BILLETS
BEAM
BLANKS

UNIVERSAL SECTION MILL

54

FOR SALE

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BOF-CCP (SMS)
E) Slag Bay
The slag from the converter is transported in slag pots placed on slag transfer cars to
the slag handling area. The slag pot transfer cars have a capacity of 90 T. The slag
pots will be handled by overhead cranes for dumping into the slag pits. After that the
slag pots will be coated with a mixture of 1 part lime fines to 3 parts of water for reuse and transferred back. Slag pot size is 18 m3. There are three 120+50 T EOT cranes
and three 5 T capacity repair trolleys for repair and maintenance of 120+50 T EOT
cranes at the slag bay.

F) Ladle Preparation Bay

The empty ladle returning from the caster will be prepared for the next heat as
follows:
i.

Tilting to remove the remaining steel and slag

ii.

Casting nozzle inspection/replacement

iii.

Stirring plug inspection/replacement

iv.

Preheating up to about 1200 C

For preheating purpose, Coke Oven gas is used as a fuel. There is one EOT crane of
capacity 280 + 80/20 T and two 15 T capacity repair trolley for repair of 280 + 80/20
T cranes at Ladle preparation bay.

G) Corridor cum Ladle Furnace

Treatment of hot metal from BOF converter is done at Ladle furnace (LF) as a
secondary refining unit. This ensures high desulfurization rates due to high
temperature achieved via arcing and generation of highly reactive surface created due
to high turbulence through bottom Argon purging (blowing rate: 60 Nm3/hr) and by
top blowing in case of failure of bottom Argon purging. There are two LFs of nominal
capacity 150 T at ISP for treatment of liquid steel.
The Ladle furnace plant is designed for three-phase connection to the high-voltage
power supply. The electrical energy consumption is about 30 kWh/T of crude steel.
The furnace is equipped with a water cooled roof of tubular construction, which has
provision for lifting and lowering by 3 brackets actuated by hydraulic cylinders. The
roof has opening of the entry of electrodes and for other functional requirements like
Aluminium/ Calcium Silicide wire feeding, alloy addition, top lance, temperature and

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BOF-CCP (SMS)
sampling etc. The roof construction ensures extraction of fumes and dust generated
during arcing.
During emergency condition (power failure) the roof is cooled by the water from the
emergency overhead tank. The Ladle transfer car with the liquid metal can be
removed from below the ladle roof during emergency cooling.
The electrodes move up and down by means of hydraulically actuated mechanism.
The electrodes are clamped by clamping devices provided in the electrode arms,
which are in turn supported by electrode columns. The electrode columns are guided
by means of electrode guiding system consisting of a set of guide rollers.
This guiding system ensures proper vertical movement of the electrodes through the
openings in the roof. A central control panel is provided in the control room of the
furnace. All necessary controls (Level 1) are provided in the main control room.

Working Of Ladle Furnace (Schematic)

There is one EOT crane of capacity 20/10 T crane for handling of ferro-alloys by
which approx. 10 - 30 % of the Ferro alloys may be added for correction purpose
during ladle treatment.
The Standard Operating practise at Ladle Furnace is described below:
i.
56

Bring the steel transfer car to lifting position.

IISCO Steel Plant

BOF-CCP (SMS)
ii.

Signal the crane to lift the ladle and place on ladle transfer car.

iii.

Release the crane and signal the LHF control room operator to take
LTC along with ladle to treatment position of LHF.

iv.

Connect Argon hose along with a quick coupling valve to the ladle and
signal the control room operator to open the Argon purging with the
help of push button provided at the control desk.

v.

Observe the Argon purging whether it is vigorous or gentle.

vi.

If purging is not observed, open the by- pass valve by pressing push
button provided at local control desk.

vii.

Observe the purging.

viii.

If the purging is observed wait for 3-5 minutes.

a) Take sample and celox /temperature and record in the log book.
b) If purging is not adequate, resort to arcing for 3-5 minutes.
c) Stop arcing and observe the purging.
d) If Purging is alright, repeat step 1).

ix.

After sending the sample and getting the analysis, process the heat as
per process chart of the particular grade of steel & continue the purging
as per requirement.

x.

Do the temperature adjustment either by cooling with lime or arcing as

the case may be.

xi.

Talk to the caster main control room when the heat is required.

xii.

Add 4-6 bags of rice husk.

xiii.

Send the heat to caster by the crane after stopping the argon flow by
pushing the push button provided at the control desk.

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BOF-CCP (SMS)

Technical Data for Ladle Furnace

(1)

Annual production potential (each LF)

1386000 T (approx)

(2)

Heat size

150 T nominal /165 T (max.)

(3)

Average number of heat / day(each LF)

28

(4)

Maximum number of heat / day (each LF)

32

(5)

No. of roof lifting cylinders

(6)

Hydraulic fluid

Mineral oil (I.S.O. V.G. 46)

(7)

Roof lifting speed

40 mm/s (hydraulic)

(8)

Hydraulic system nominal pressure

180 bar

(9)

Electrode lifting speed

80-100 m/s (hydraulic)

(10) Electrode regulation speed

80 mm/s (max)

(11) Electrode stroke

2.5 m (approx.)

(12) Electrode diameter

450 mm

(13) Ladle transfer car load capacity

250 T

(14) Ladle transfer car speed

30 m/min

(15) Inert gas average flow rate

60 Nm3/h

(16) Inert gas (Ar/N2)

(i)

Flow rate

80 (max)/ 60 (nominal) Nm3/hr

(ii)

Operating pressure at the ladle

8 bar

(iii) Typical inert gas consumption

0.5 Nm3/t

(17) Compressed air

(i)

Pressure

6 bar

(ii)

Purging requirements

450 Nm3/h (max)/ 50

Nm3/h(avg.)

(18) Transformer rating

30,000 KVA, 33 KV

(19) Maximum current

47 KA

(20) Wire feeding system wire size

9-13 mm

(21) Wire operating speed

150 m/min

(22) Temperature rise of hot metal

5 C / min

(23) Minimum Ladle freeboard

500 mm at 165 t heat size

(24) Water requirements

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(i)

Quantity of roof cooling (soft) water

350 m/h.

(ii)

Quantity of cooling water for transformer

55 m/h. (at 6.5 kg/cmg

pressure)

(iii) Quantity of water forlive parts ( Soft Water )

approx. 110 m3/h

(iv)

Temperature rise of cooling water (max)

15 C

(v)

Quantity of roof cooling water at emergency

approx. 200 m3/h

(vi)

Inlet pressure at roof header at emergency

4.5 bar

H) RH- Degasser (Part of Secondary Refining bay)

Steels which required further low levels of dissolved Hydrogen and Oxygen will be
further treated in RH-degasser. Recirculation degassing unit uses a vacuum chamber
having two snorkels connected to the chamber bottom. One of the snorkels is
equipped with pipes supplying Argon through its refractory lining. The snorkels of the
vacuum chamber are immersed into the ladle with molten steel. Liquid steel fills the
chamber to a level determined by the atmospheric pressure (1.4m). Argon bubbles
(blowing rate: 150 Nm3/h) floating up in one of the snorkels (up-leg) force the melt to
rise in the snorkel. Through the second snorkel called down leg, the molten steel
flows down back to the ladle producing circulation. The circulation rate may reach
70-100 T/min. The process uses vacuum de-oxidation followed by de-oxidation with
Aluminium as a deoxidizing agent. A variant of conventional RH degasser with water
cooled lance will be used at ISP. The metal inside RH vessel is exposed to vacuum
level of 1 milli bar or less so dissolved gases (H2, N2, O2) in the steel is reduced.
Alloying is done via separate alloying system attached to the top of degasser.
Homogenisation by recirculation of the ladle contents can be achieved in less than
three minutes.
The low pressure coupled with Argon bubbling and high circulation rates greatly
reduces the final Hydrogen content in hot metal to 1.5-2 ppm. The shape control of
sulphide inclusions help in enhancing steel properties during rolling.
The inner oxygen blowing lance is surrounded by a water cooled outer jacket.
Between treatments, the fuel gas is blown down the inner oxygen tube and the
combustion oxygen is blown down the annular gap between the inner oxygen tube
and the outer water cooled jacket. Oxygen and fuel gas mix at the lance tip toproduce
an intense flame which maintains the vessel refractories at high temperature.

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BOF-CCP (SMS)
The ferro-alloy system of both the Ladle Furnaces and the RH Degasser is fed by one
20 / 10 T overhead crane through bottom self discharge buckets.

Technical Data for RH Degasser

(1)

Average number of heat / day

24

(2)

Annual treatment potential

1,000,000 T

(3)

Ladle transfer car speed

24 m/min approx.

(4)

Vacuum Vessels

(i)

Diameter

3.1 m approx.

(ii)

Quantity

3 nos.

(5)

Nozzle internal diameter

500 mm

(6)

Nozzle life

100 150 heats

(7)

Alloy System

(i)

No. & capacity of main bunkers

8, 10 m3

(ii)

No. of main vibro-feeders

(iii)

No. & capacity of main weigh hoppers

2, 500 kg

(iv)

Speed of conveyors

1m/sec

(v)

No. & capacity of micro-alloy bunkers

4, 5m3

(8)

Width of conveyors

650 mm

(9)

Multifunction Top Lance

(i)

Burner rating

2.6 MW approx.

(ii)

Type

oxygen fuel gas

(iii)

Oxygen pressure (supply)

15.5 bar

(iv)

Oxygen flow (burner)

550 Nm3/h max

(v)

CBM pressure

2.5 bar

(vi)

CBM flow (burner)

275 Nm3/h max

(vii)

Oxygen flow rate (blowing)

Approx. 1,800 Nm3/h max

(10)

Vessel Preheater

(i)

Burner rating

2.6 MW approx.

(ii)

Type

oxygen fuel gas

(iii)

Oxygen pressure (supply)

15.5 bar

(iv)

Oxygen flow (burner)

550 Nm3/h max

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(v)

CBM pressure

2.5 bar

(vi)

CBM flow (burner)

275 Nm3/h max

(vii)

Oxygen flow rate (blowing)

Approx. 1,800 Nm3/h max

20 m3/h (emergency)

(viii) Cooling water flow

(11)

Vessel Cooling

(i)

Water quality

Soft water

(ii)

Water pressure

7 bar (normal)/4 bar (emergency)

(iii)

Total flow

150 m3/h(normal)/ 70 m3/h emergency

(12)

Argon pressure

16 bar

(i)

Argon flow (into nozzle)

150 Nm3/h max

(ii)

No. of argon tuyeres

10

(13)

Compressed air/instrument air

(i)

Nitrogen pressure

16 bar

(ii)

N2 requirement (purging)

600 Nm3/h approx.

Working Of Rh Degasser (Schematic)

I) Continuous Casting Shop
The Continuous casting shop comprises the following bays:
i.

Secondary refining bay

ii.

Casting bay

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BOF-CCP (SMS)
iii.

Discharge bay

iv.

Storage bay 1

v.

Storage bay 2

J) Secondary Refining Bay

The secondary refining bay consists of three no. on-line Argon rinsing stationand one
no. off-line RH degasser unit. The ladle turrets of billet casters and bloom cum-beam
blank caster shall also be located in this bay. Emergency steel ladle are placed in this
bay near the ladle turret for draining of liquid steel during emergency. Slag pots for
de-slagging of steel ladles after each cast and slagpot transfer car shall also be located
in this bay. The bay is equipped with three EOT ladle handling cranes of capacity
280+80/20 T.

K) Casting Bay
The bay accommodates casting machine up to the automatic torch cutting machine,
part of discharge roller table and dummy bar storage. The bay also houses tundish
preparation, mould preparation and segment maintenance areas, internal mould
cooling pump house, water distribution room, main electrical building, control rooms,
hydraulic room, etc.
Continuous Casting Machines (Billet Casters and Bloom Caster): The ladle is
transported to the ladle turret on the caster platform after the required metallurgical
adjustments are done LF/RH Degasser. The casting ladle is deposited by the crane on
the ladle turret. After moving to casting position, the ladle outlet is opened and liquid
steel flows into the tundish, which serves as an intermediate container/distributor
between the ladle and the mould.
Two tundish cars are provided and each car is equipped with a drive and positioning
device for tundish change and centering of the tundish outlet nozzles in to the mould.
The moulds are mounted on oscillating tables and the mould copper tubes are cooled
by closed primary cooling water system. Due to mould cooling, a solidified strand
shell is formed and is supported by mould foot rollers and strand guide. In the strand
guides, the hot strands are cooled by water spray cooling. At the end of the strand
guides, pinch roll straightening units are arranged to straighten and withdraw the hot
strand. These units also serve for the insertion and withdrawal of the dummy bar.
The dummy bar is used to seal the mould at the start of casting and to withdraw the
hotstrand to the withdrawal and straightening unit. After the separation of the dummy
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barfrom the hot strand, the dummy bar goes into its storage position in stand by for
the next start of cast.
The continuous caster consists of 6 and 4, respectively, independently controlled
strands for the production of billets / blooms / beam blanks. The strands are cut by
high duty torch cutting machine into the required lengths. The billets / blooms / beam
blanks are transported on the run out roller tables to the final stop. From there they are
either carried over to the cooling bed or are delivered to the hot charging system.
The cast billets, blooms or beam blanks will be charged to the proposed mills in either
hot or cold condition for which hot charging roller tables or cold transfer roller tables
shall be provided. All continuous casting machines are located in the casting bay.
There are two billet casters and one bloom caster. The bay dimensions are: 33 x 483
m. The casting platform of the bay is at 9.8 m elevation.
The standard operating practise for continuous casting machine is as follows
1. Preparatory jobs for start-up of Casting
a. Preparation of Dummy bar head for casting
i.

Adjust the Dummy bar head as per plan at intermediate platform (5.6m).

ii.

Transition piece will be done on the same platform if necessary.

iii.

Clean the dummy bar head and it should be moisture free.

iv.

Installation of inset device for the dummy bar with the hook and pin for
protecting mould from scratches during dummy bar insertion.

v.

Movement of joint on dummy bar head should be proper.

b. Inserting of Dummy bar in to the mould and preparation for casting

i.

Select mode DUMMY BAR INSERT on the OS2 panel.

ii.

Ensure proper Dummy bar pressure and presence of Dummy bar is in

Dummy bar storage device.

iii.

Lift Support roller for the Dummy bar on cutting approach roller table.

iv.

Fulfill all pre conditions and then automatic feeding can be started.

v.

Stop feeding of Dummy bar when Dummy bar is about 500 mm below the
mould.

vi.

Select Inching mode on OS1

vii.

Remove the insert device from the Dummy bar head

viii.

Clean the Dummy bar head with compressed air for removing moisture

ix.

Install packing tube with sealing plates

x.

Selection of prepare to cast on OS1 panel.

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xi.

Lift both the rollers at the withdrawal units.

xii.

Apply cast iron for filling funnel.

xiii.

Oil the copper tube with brush.

c. Precautions after mould packing

i.

Secondary cooling should not be started in Zone-I and incase if started

repacking of mould should be done.

ii.

If oscillation unit, withdrawal and straitening unit started due to any

reason repacking should be done

iii.

Mould should be free from scratches

iv.

Foot rollers turning should be free

v.

Foot rollers should be free from steel splashes and slag.

vi.

Oscillating Device

vii.

Check oscillator readiness for operation

viii.

Set oscillating parameters according to caster practices (for level-I)

ix.

Check water tight connection between water box of the mould and lifting
table of the oscillation unit.

x.

Check water hoses for inlet and outlet for tightness and damages.

xi.

Check drives system (hydro-cylinder).

xii.

Check all cover sheets to be in place and in good condition.

xiii.

Check correct position of scintillation counter

xiv.

Tundish Preparation and Tundish preheating (for open stream casting and
stopper casting)

xv.

Preparation of tundish in tundish maintenance area mainly lining,

installation of well blocks and/or nozzles, gunning, drying and placing the
tundish cover.

xvi.

In case of open stream casting fix the nozzle changing device with correct
calibrated nozzles.

xvii.

Lift the tundish to casting platform.

xviii.

Place tundish on respective tundish car.

xix.

Seal the tundish and tundish cover by ceramic fibre material.

xx.

Tundish Preparation and Tundish Preheating (for open stream casting and
stopper casting)

64

xxi.

Bring the tundish car to cast position.

xxii.

Check the nozzles above the moulds.

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xxiii.

Bring the tundish car to preheating position.

xxiv.

In case of stopper casting mount the emergency cut off gate.

xxv.

Install stopper mechanics and stopper rods

d. Preheating of Tundish and SEN

i.

Check centering of the burner position

ii.

Lowered the ignited burners.

iii.

Start SENs heating 60mins (approximately) before start of cast.

iv.

Ensure stopper rods (for stopper casting) should be opened.

v.

Ensure that nozzle changer should be opened (for open stream casting).

e. Mould Cooling system (Primary Cooling)

i.

Ensured mould cooling water flow and pressure and temperature.

ii.

Adjust the set points on OS2-MMI (as per caster practice).

iii.

Ensure pumps at the water treatment station must be switched on.

iv.

Check emergency cooling readiness.

v.

Ensure mould cooling system ready on OS1.

vi.

Maintain t (temperature difference) 8-12 C between inlet and outlet of

mould cooling temperature. If t is more than 15 C than stop casting.

f. Secondary Cooling
i.

Ensure pumps to be switched on in the water treatment station.

ii.

Ensure inlet pressure and temperature as per casting practices.

iii.

Ensure cooling zones will be operated as per tracking system.

iv.

Select cooling curves as per steel grade.

g. Mould Stirrer Cooling System

i.

Ensure the pumps in water treatment station must be switched on.

ii.

Ensure flow rate of 260 l/min/stirrer.

iii.

Ensure water temperature (difference between inlet and outlet should be

zero degree)

iv.

Check emergency cooling readiness

v.

Ensure inlet temperature of cooling water must not exceed 37C

2. Ready for start Cast

a. Ensure Water, hydraulic, grease lubrication systems to be ready.
b. Check emergency cooling system to be ready.
c. Check emergency function of ladle turret and tundish car to be ready
d. Ensure proper emergency functioning of stopper control
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e. Check mould oil lubrication system readiness only for open stream casting.
f. Select correct casting mode for both open stream and stopper casting.
g. Ensure all systems to be in automatic mode.
h. Following sub-points should be ready:
i.Cans with mould lubrication oil for first adding of oil into the mould or
for
emergency cases (only for open stream casting).
ii.

Casting powder and shovel for adding casting powder into the
mould (only for stopper casting).

iii.

Oxygen lances for tundish nozzle lancing (only for open stream
casting).

iv.

Oxygen lance for ladle slide gate lancing

v.

Argon for stopper rinsing (only for stopper casting).

vi.

Slag fishing bars.

vii.

Sampling devices.

viii.

Temperature tips.

ix.

Tundish covering powder

x.

Ladle shroud.

i. Slag pots, emergency launders and emergency ladle must be capable to receive a
sufficient quantity of liquid steel in emergency situation.
j. Ensure swiveling launders on tundish car must be empty (only for open stream
casting).
k. Check torch cutting machines to be ready.
l. Ensure lamp test on all operating panels should be done.
m. Ensure closing of the cooling chamber doors.

3. Casting Operation
1. Check all preconditions on OS2.
2. Select CAST mode on OS1.
3. Arrival of heats with correct temperature and sample analysis on ladle turret
4. Place the ladle cover on ladle.
5. Connect hydraulic cylinder with ladle slide gate.
6. Switched off the tundish preheater and then tilted upwards.
7. Close the tundish outlet with blind plate of nozzle changer.
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8. Remove cover sheets above the mould opening.
9. Ensure availability all necessary tools (Slag fishing rods, oil cans etc.)
10. Ensure tundish car in upper position.
11. Place tundish car in cast position.
12. Center the tundish above mould openings.
13. Lower the tundish to the casting start level.
14. Place swiveling launders below the nozzles.
15. Rotate ladle turret in cast position.
16. Fix the ladle shroud by means of hydraulic cylinder
17. Open radioactive source for mould level measurement.
18. Ensure tundish weight should be zero in cast position.
19. Ensure READY FOR CAST is glowing permanently on OS1.
20. Open the ladle slide gate, in case not open then ladle shroud should be
removed and by lancing ladle should be opened.
21. Close the ladle slide gate when steel weight in tundish is 15 T (approximately)
and fix the ladle shroud in case ladle is opened by lancing
22. Ensure tundish covering powder to be thrown in to the tundish during the
filling of tundish.
23. Start outer strands 1 and 6 in the beginning followed by 2 and 5 and then
finally 3 and 4.
24. Remove the launder after 5 secs.
25. Fill the mould for 5 secs and then swiveling launder placed for 5 secs and then
again remove the swiveling launder.
26. Fill the mould to its 25 % capacity.
27. Select start cast by pressing button on OS1.
28. Ensure start of withdrawal drives in cast direction.
29. Ensure start of mould oscillation
30. Ensure start of strand tracking.
31. Ensure secondary cooling zones as per tracking system.
32. Ensure switch over from DUMMY BAR PRESSURE to HOT STRAND
PRESSURE to be carried out as per tracking system.
33. Check dummy bar disconnection which will initiate:i.

Lowering the second upper roll of withdrawal unit

ii.

Drive the dummy bar in its storage position.

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iii.

Lowering the disconnecting roll.

34. Ensure length measuring system of the torch cutting is initiated as per tracking
value.
35. Select ladle slide gate operation from manual to AUTO on LC116 when filling
of tundish reaches its set value.
36. Select manual operation by pressing OPEN or CLOSE as per requirement.
37. Select AUTO mould control by pressing AUTO switch on HMI as per
requirement.
38. Take sample from tundish after 10 minutes of start cast.
39. Take first temperature immediately after the start of cast.
40. Take second temperature after 15 minutes and third one as per need.
41. Check mould, if found abnormal take corrective actions.
42. Ensure regularly amount of lubrication oil.
43. Fixed ladle slide gate in AUTO mode by pressing AUTO switch

4.

End of Cast
1. Empty of ladle
i.

Watch the slag when Ladle weight is 20T; if slag appears close the
ladle slide gate.

ii.

Remove the ladle shroud manipulator

iii.

Rotate the turret to bring the empty ladle to load position.

2. Empty of tundish
i.

Reduce casting Speed to 1.5m/min when tundish weight is

approximately 10-12 T.

ii.

Ensure that slag should not flow in the mould.

iii.

Mould deslagging to be done.

3. Closing the tundish

i.

Insert blank pate of nozzle changer.

ii.

Stop outer strands firstly.

iii.

Stop remaining strands.

iv.

Emptying of tundish

5. End of cast and CLEAR machine mode

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a. Stop the withdrawal drives by pushing STOP on OS1 for 1 minute at the end
of cast.
b. Ensure the change of machine status to CLEAR mode by pushing the button
CLEAR.
c. Withdraw the strand after waiting for 1 minute by pressing START from
torch cutting control room.
d. Activate automatic CLEAR machine mode.
e. Press CLEAR on OS1.

6. Break-Out
a. In case of breakout during cast-start, close the tundish and stop withdrawal
units of affected strand.
b. In case breakout during casting:i.

Close the affected strand.

ii.

Casting speed to be reduced for a period of 2 minutes.

iii.

Ensure oscillation drive must be running.

iv.

Spray Cooling to be switched to minimum simultaneously

v.

Casting speed to be accelerated after 2minutes

vi.

Spray water supply increased according to the casting speed.

vii.

Withdraw strand from the machine simultaneously.

viii.

Check whether Strand is sticking inside of the machine or still moving.

ix.

Stop withdrawal drives in case of sticking strand.

x.

Cool down the strand inside the machine.

xi.

Ensure cooling down to be carried out with maximum spray cooling water.

xii.

If withdrawal forces exceed the normal value by 50% due to skull

formation of breakout, stop the affected strand and cool down inside the
machine

xiii.

Action plan for handling ladle breakout

a. Water availability for cooling down spilled over liquid steel
b. Oxygen availability for lancing/gas cutting metal jam occurred
during transit
c. Arrangement for lifting/clearing track jamming during the above
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BOF-CCP (SMS)
d. Availability of experienced crew to handle
derailment/disengagement of moving component
e. Provision for pouring of residual slag metal in emergency
containers
f. Contingency evacuation arrangement for solidified slag, metal
skull of steel ladle if generated during the process
g. Availability of new set of relined hot ladle for continuation of the
process
h. Availability of experienced personnel/representatives from

technology provider with required resources to combat the

emergency and quick return to normalcy

Technical Data for Billet Caster

General features
(1)

Number of machines and strands

2 machines with 6 strands each

(2)

Machine radius

9000 mm

(3)

Strand center distance

1200 mm

(4)

Max. restranding speed

approx. 6.0 m/min

(5)

Max. speed of run-out roller table

40 m/min

(6)

Metallurgical machine length

Max. 27 m

(7)

Designed production capacity

approx. 215 T/h (maximum production of one 6

strand caster)

(8)

(9)

Casting mode

Cutting device

i.

open stream casting with oil lubrication

ii.

Submerge nozzle casting with stopper rod

torch cutting machine

(10) Machine range

100x100 mm2 to 160x160 mm2

(11) Cross sections of billets produced

100x100, 120x120 & 150x150 mm2

(12) Bloom Cut length

6, 9, 12 m

(13) Level of roller table

approx. +800 mm

(14) Annual production of cast steel

1,668,000 T (both billet casters)

(15) Dummy bar insertion speed

6 m/min

(16) Oscillation frequency

40-300 cycles/min

(17) Stroke adjusting range

2 to 9 mm (at standstill = reference point)

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(18) Length of Copper mould

900 mm (approx.)

Operational data for billet caster

(1)

Max. Casting speed (open stream)

(i)

100x100 mm2

5.6 m/min (max.)

(ii)

120x120 mm2

4.2 m/min (max.)

(iii)

150x150mm2

3.5 m/min (max.)

(2)

Max casting speed (closed stream)

(i)

120x120 mm2

3.5 m/min (max.)

(ii)

150x150mm2

2.7 m/min (max.)

(3)

Casting time for 150 T heat

(i)

Open stream

42-72 min

(ii)

Closed stream

55-79 min

(4)

Water flow rate for

(i)

Mould cooling

756 m3/hr per machine

(ii)

Closed m/c cooling

420 m3/hr per machine

(iii)

Spray & open m/c cooling

390 m3/hr per machine

Technical Data for Bloom Caster

General features
(1)

Number of machines and strands

1 machine with 4 strands

(2)

Bow radius

12000 mm

(3)

Strand center distance

2000 mm

(4)

Metallurgical machine length

Max. 37.1 m

(5)

Cutting device

torch cutting machine

(6)

Caster equipped for

(i)

Bloom thickness

200 and 235 mm

(j)

Beam blank thickness

205 & 350 mm

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(7)

Cross sections of cast products

(i)

Blooms

235 x 235 mm2 , 280 x 200 mm2

(ii)

Beam blanks

292 x 205 x 85 mm, 430 x 350 x 90 mm,

686 x 350 x 90 mm

(8)

Bloom Cut length

6 to 12 m

(9)

Annual production of cast steel

832,000 T

(10)

Design frequency range

0-300 strokes/min

(11)

Lifting stroke range

0 - 12 mm ( 6 mm)

(12)

Length of Copper mould

800 mm (approx.)

Operational data for bloom caster

(1)

Max Casting speed (bloom)

(i)

Bloom 235x235 mm

1.3-2 m/min

(ii)

Bloom 280x200 mm

1.3-2 m/min

(2)

Max casting speed (beam blank)

(i)

292x205x85 mm

2.2 m/min

(ii)

430x350x90 mm

1.4 m/min

(iii)

686x350x90 mm

1.2 m/min

(3)

Casting time for 150 T heat

(i)

Bloom (200x280)

42.7-65.6 min

(ii)

Bloom (235x235)

43.3-66.5 min

(iii)

Beam blank production

38-54.1 min

(4)

Water flow rate for

(i)

Mould cooling

1680 m3/hr per machine

(ii)

Closed m/c cooling

1000 m3/hr per machine

(iii)

Spray & open m/c cooling

1000 m3/hr per machine

Tundish & Mould Preparation Area

The facilities for religning and preparation of tundish have been provided at the tundish
preparation area. Two EOT cranes each of capacity 80/20 T and two cantilever cranes each
of capacity 7.5 T have been provided for this area. The tundish capacity is 40 T (nominal)
and 30 T (nominal) for billet and bloom caster respectively.

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One cantilever crane of capacity 7.5 T is dedicated for mould preparation activities, adjacent
to tundish preparation area.

L) Discharge Bay
The bay accommodates remaining part of discharge roller table, cross
transfermechanism, cooling bed, end stops, marking machine, etc. This bay also
accommodates special roller tables for transfer of hot and cold billets from cooling
bedto billet storage bay I & II and up to Mill bay. The billets are also stored in this
bayand dispatched through a rail track and special roller table to mill. This bay shall
beequipped with two EOT cranes of capacity 25/5 T with rotating tongues and
magnets.A control room for transfer and storage of billets has been provided in this
bay.

M) Storage Bay I & II

Special roller tables with collecting beds for billets, bloom cum beam blanks
inspectionand dressing line are accommodated in this bay. Storage banks are provided
forstorage of billets, blooms and beam Blanks and are despatched through special
rollertables for further processing in mills. Each storage bay is equipped with two
EOT cranes of capacity 25/5 T with rotating tongue and magnets.
Important Safety Points to be observed in SMS Operation
1.

General Safety Instructions

a. Use of Personal protective equipment's (PPE): safety helmet, safety shoe, fire
retardant apron, canvas and leather hand gloves, guard, goggles and face
shield
b. Display of safety posters
c. Availability of telephone numbers of fire brigade & ambulance
d. During movements of cranes with load, people at work must be warned not to
come under the moving load.
e. Accidents at site must be reported to the concerned authority without any
delay.
f. The cut or dismantled bricks and debris must not be thrown hazardously;
instead they are kept in a box and removed safely.
g. All handling/transport and rigging equipment's must be checked at regular
intervals and the same are to be kept in good and working condition.

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h. Fire extinguishers/fire buckets and drums must be kept ready at work site.

2.

Gas safety
a. Storage of gas cylinders is forbidden near the furnaces
b. Empty gas cylinders must be taken out of the shop after usage
c. Take care when working with oxygen. Oil and oxygen form a very dangerous
combination which can lead to serious accidents.
d. Clothing saturated with oxygen should be taken of immediately
e. Working with leaking oxygen hoses or couplings is prohibited
f. Usage of inert gases during operation must be done carefully
g. During Coke Oven gas pipeline maintenance, water seal of Coke Oven gas
must be ensured

3.

Fire safety
a. The prohibition of smoking established in the identified operational areas must
be observed conscientiously
b. Fire protection equipment such as fire extinguishers, hydrants, fire-escape
ladders etc must not be used for purposes other than originally intended.
c. Used fire extinguishers must be returned to the competent department under
indication of the reason for the use.
d. Oxygen must not be used for blowing down or blowing out clothing or for
ventilation.

4.

Process Safety to be observed in BOF

a. Safety appliances like fire retardant aprons, full leather gloves, blue glass
fitted helmets, LFC, safety shoes while on job to be used.
b. Ensure converter is free from liquid slag then charging of scrap should start.
c. Scrap loader should be properly aligned with converter before signalling the
crane driver
d. The operator should move to an area where he cannot be hit by falling scrap
e. Before hot metal ladle is lifted, the crane driver should make sure that the
hooks are properly attached
f. The converter operator should ensure that the charging ladle is in correct
position and then signal the crane driver for pouring

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g. Ensure that all persons on the charging side of converter are warned by horn
signal before charging of hot metal
h. Person giving signal to move to an area where he cannot be hit by splashes
during pouring
i. Charging ladles to be checked regularly for sticking slag and hot metal skulls
j. During blowing process dog house doors have to be closed
k. No one should be near vicinity of converter during blowing period
l. Slag pot must be dry. Keep a safe distance from the converter when slag is
being tapped into slag pot.

5. Process Safety to be observed in LHF operation

a. Safety appliances like fire retardant aprons, full leather gloves, blue glass
fitted helmets, LFC, safety shoes while on job to be used.
b. In case of roof leakage stop arcing immediately and move the car away from
the roof.
c. If electrode breaks / falls during arcing - Switch off power supply.
d. During electrode changing ensure no one is below LHF.
e. Ensure no one is in the vicinity during arcing.
f. No hood leakage to be observed
g. Ladle should be free from ring jam and mouth jam
h. LHF car should be switched off during plugging and unplugging of porous
plug

6. Process Safety to be observed in CCP Operation

a. Receiving Ladle from LHF
i.

Ensure proper fixing of ladle crane hooks in trunions

ii.

Check Main Hoist Brake before lifting the heat

iii.

Ensure that no hot spot is there on ladle shell

iv.

Ensure nobody is there under ladle movement area

b. Turret
i.

Ensure Turret arm in lower position

ii.

Place the Ladle slowly & without jerk

iii.

Ensure audio and visual sign of turret movement

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BOF-CCP (SMS)
iv.

Ensure no oil leakage from hose of slide gate system

c. Tundish
i.

Fix emergency nozzle closing device

ii.

Nozzle centering to be done very carefully to avoid breakage of

nozzle(in case of closed casting)

d. Safety during casting operation

i.

Safety appliances like fire retardant aprons, full leather gloves, blue
glass fitted helmets, LFC, safety shoes while on job to be used.

ii.

Ladle freeboard should be in the range.

iii.

Ensure no skull deposit on the ladle and ladle cover.

iv.

Ensure no HOT SPOTS in the ladle.

v.

Ensure crane siren should be activated during transportation of ladle.

vi.

Ensure ladle turret emergency button should be activated during

placement of ladle on the turret.

vii.

Ensure ladle turret emergency button should be activated during

connection/disconnection of ladle slide gate cylinder.

viii.

Ensure after connection/disconnection of ladle slide gate cylinder

emergency button should be deactivated.

ix.

Ensure no person should be present in the vicinity of ladle turret during

its rotation.

x.

Ensure use of protective equipments during ladle lancing.

xi.

Ensure lance holding device must be leak proof.

xii.

Ensure lancing pipe must be free from grease and moisture.

xiii.

Ensure connection of gas and oxygen lance of the lance hose

connected properly.

xiv.

Ensure proper functioning of no return safety device.

xv.

Ensure proper placement of lance with hose after completion of

lancing.

xvi.

Ensure during travelling motion of the tundish car acoustic of siren and
flashing light should be activated.

xvii.

Ensure no person should be present in the vicinity of tundish car during

its travel.

xviii.

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xix.

Ensure moulds and all materials used for packing as well as casting are
free from grease and humidity during packing of the Dummy bar
heads.

xx.

Ensure Tundish covering powder must be dry.

xxi.

Ensure proper functioning (opening, closing) and smooth running of

nozzle changer.

xxii.

Ensure proper connection between shroud and ladle slide gate to be

visually checked before opening of ladle slide gate.

xxiii.

Ensure shroud manipulator should not be immersed in to the steel bath

of the tundish before opening of ladle slide gate.

xxiv.

Ensure sample and temperature tips must be dry.

xxv.

Ensure no HOTSPOTS in the tundish during casting. If HOTSPOTS,

appears stop casting immediately.

xxvi.

In case of tundish breakout move the tundish car by pressing button in

to the emergency casting position.

7.

Safety requirements in Electrical systems

i.

Follow shutdown and Work to Permit Systems

ii.

Recognize a hazard before and during operation and maintenance

iii.

Follow isolation and immobilization systems

iv.

Understand human factors(stress, fatigue, shift work, attitude)

v.

Comply with safety system

vi.

Use correct and sufficient PPE , insulated tools and tackles

vii.

Take care of the work environment and equipment environment

viii.

Eliminate Communication failures

ix.

Upkeep of interlocking and protection systems

x.

Knowledge of different voltages in Panels

xi.

No bypassing of interlocks process, electrical, mechanical (door

interlock etc.)

xii.

Usage of correct tools ( e.g. fuse pullers) and instruments

xiii.

Upkeep of double earthing systems

xiv.

Differentiation of earthing electrical , lightning and electronic

xv.

Maintain insulators and gaps between live busbars and structure

xvi.

Never use earthing as an alternative to neutral

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BOF-CCP (SMS)
xvii.

Knowledge of circuit componentsCT secy. Shorting

xviii.

Be careful of discharge voltages and currents

xix.

Be aware of Electrostatic and electromagnetic fields

xx.

Be aware of radiations, battery fumes, discharges etc.

xxi.

Be aware of Interferencesradio communication systems

xxii.

Give importance to indication and annunciation systems

xxiii.

Be careful of electrical measurements in panels

xxiv.

Circuit modification to be done only with utmost care and after due
approval

78

xxv.

Documentation of all incidents, modifications etc.

xxvi.

Avoid using line testers use test lamps

xxvii.

Safety using test equipments multimeters,meggers, tong tester , CRO

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C&A
COMPUTER & AUTOMATION DEPARTMENT

A. Introduction
Expansion work of IISCO steel plant had been taken up in the year 2008 to make it a 2.5
MTA steel plant. With expansion,came the state of art technology. With the state of art
technology, came the process control computers. Computer & Automation (C&A)
department was formed in late 2011 to manage the process control system &
automation.The department C&IT (Computer and Information Technology) existed in
IISCO to carry the office and business computerization in the areas of personnel, finance
and materials.

B. Structure
C&A Department functions under GM (Electrical) under ED (Works). It is headed by
DGM(C&A).For ease of functioning the areas of automation under C&A has been
divided into six basic zones Raw materials, Iron, Steel, Rolling, Services and Office.

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C&A
.
C. Areas of automation in ISP is as follow
AREA PKG
NO
OHP 01A
CHP 01B

PKG NAME

PARTY M/S

Ore handling Plant

Coal & Coke handling

MCNALLY BHARAT
L&T

NA

COB # 10

TATA STEEL

O2

COB # 11

GIPROKOK/BEC/SOY

03

Coke Dry cooling plant

GIPROKOK/BEC

CHCS (LEVEL 2)
TATA
AUTOMATION
CPMS (LEVEL 2)
SIEMENS
SIEMENS

BMP
SP

01C
O6

Base Mix
Sinter Plant

L&T
L &T/OUTOTEC

ABB
ABB

BF

O7

Blast Furnace

POSCO/NAGARJUNA

O8
11A

Coal Pulverisation and

Injection
HM Desulphurisation

CISRI/BEIJING
ELECT CO
SOMANI/KUTTLER

LEVEL#2
SIEMENS
SIEMENS

11B

Basic Oxygen furnace

SMS SIEMAG

11C

Secondary Refining Unit

(LF+RH)
Continuous Casting Plant

SMS INDIA

CO

SMS

AUTOMATION
SYSTEM
ROCKWELL
ABB

Lime Dolomite Calcination

Plant
Universal Section Mill

FL SMIDTH

LEVEL#2
SIEMENS
LEVEL#2
SIEMENS
LEVEL#2
SIEMENS
ABB

SMS MEER

SIEMENS

BRICKMONT

ROCKWELL

16

Reheating Furnaces (WRM,

BM, USM)
Wire Rod & Bar Mill

DANELLI

SIEMENS

MRS

21

MRS & LDBS - SCADA

AREVA

E-TERRA

EMC

69

Energy management

MASIBUS

CITECT

12A
13
Mills

14
15

80

SEIMENSVAI

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C&A
It is apparent in the above table that there is a wide variety of system implemented and
technology suppliers have customized products. Keeping this in view dedicated
manpower of C&A departmenthas been put in the various automation areas.
D. Scope of Work
For the efficient running of the Plant, smooth working of the automation systems is
essential. Considering this the roles and responsibilities of C&A Deptt has been framed
as mentioned below.
1. Hardware & Software maintenance of Level 2 system.
a. Hardware
i.
Periodic Preventive Maintenance of Systems
ii.
Attending to Hardware problems in System and Network
b. Software
i.
Periodic back up of System Software, Application Software, Database
ii.
Trouble shooting in System Software, Application Software
iii. Maintenance of Database (Maintaining optimal size)
iv.
Achieving of Program and Data
v.
Modification of Application Software as per requirement
vi.
Generation / Modification of Reports for MIS as per requirement
vii.
Maintenance of Automation Interfacing between Departments
2. Maintenance of HMI servers,OPC servers & Operator work stations installed in
all automation system.
i.
Trouble shoot of HMI problem
ii.
Periodic Preventive Maintenance of HMIs
iii. Ensure availability of ready spares
iv.
Ensure communication of OPC Server
v.
Regular backups of Application Software
vi.
Periodic backup and maintenance of Database
vii.
Updating of Anti-Virus Software
3. Maintenance of SCADA system of Energy Management & Power Distribution.
i.
Install/uninstall of Software
ii.
Backupof Application
iii. Maintenance Software and application
iv.
Database Management
v.
Maintenance of Web Server and Client Server
vi.
Trouble shooting of System S/W and Application S/W
vii.
Maintenance of OFC & UTP network
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C&A

4. Maintenance of process area network. Network components, Ethernet & FO.

i.
Identification of Network Equipment, Cable tracing and labeling as per
drawing
ii.
Trouble shoot of Network problem
iii. Periodic Preventive Maintenance of Network
iv.
Ensure readiness of Standby Line
5. General Administrative function
i.
Awarding and Monitoring of AMC
ii.
Handling of customer complaints
iii. Managing of Stores and Spares
iv.
Maintenance of Tools and Tackles
v.
Maintenance of Documents, Drawings and Manuals
vi.
Preserving passwords for Database and System Administration
vii.
Organizing Work related Training for C&A personnel
viii. General office jobs
E. Gearing Up for Automation
1. Develop the skill of work force to repair/maintain the customized system through
training, study, observation and practice.
2. Understanding the process and interlocks.
3. Study of layout of HMIs, servers, network components and routes of fiber optic
cables.
4. Familiarization with alarm and signal.
5. Systematic troubleshooting.
6. Preparedness with spares tools and tackles.
7. Document, SOPs and SMPs.
F. Glossary of Automation
Term
Level 0
Level 1
Level 2
SCADA
PLC
DCS
HMI
OPC
LIU
82

Description
sensors/measuring devices in field e.g. thermocouples, pyrometer
Controllers, PLC/DCS units
Mathematical and logical models to refine and generate set point for level 1
Supervisory control and data acquisition system
Programmable logic controller
Distributed Control System
Human Machine Interface
OLE for Process Control
Light/Line Interfacing Unit
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C&A
FO
OLM

Fiber Optic
Optical Link Module

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C&IT
COMPUTER &INFORMATION TECHNOLOGY DEPARTMENT

A) Introduction
C & IT department formerly known as Data Processing Centre came into existence in
1943.

Initially this department provided support to various administrative

departments like Finance, Personnel and Training. With the advent of computers in
India this department has been entrusted with the work of computerization of various
departments of the work. This department was renamed C&IT in 2006. Earlier this
department used to operate from Evelyns lodge but later it was relocated to Burnpur
works in 1999. Presently this department is located at the ground floor of the general
office building of Burnpur works. This department deals with the information
processing need of the entire Burnpur works. Earlier it used to serve the various data
processing needs of the collieries at Chasnalla, Jitpur & Ramnagore as well as branch
offices of ISP at Kolkata&New Delhi.

The objective of this department is to oversee computerization of various departments

of ISP and implement application of Information Technology in day to day function
of various departments of SAIL-ISP.The various landmarks in the history of this
department is given in the following pages. This department is expected to take a
leading role in implementation of ERP and extension of fiber optic network to new
plant. These two projects when successfully implemented will change the way how
day to day business is conducted at SAIL-ISP.In a nut shell it can be said that C&IT
looks after all the IT needs of SAIL-ISP.

B) Major Milestones in the History of C&IT

Year

Major Events
The data processing started using UNIT Recorder M/c and accounted for

1943

recording financial transactions for Finance department. This department

was located at the General office building of Burnpur works.

1966

84

ICIM104 advanced version of first generation computer was installed. This

M/c supported programming through plug wares.

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C&IT
This department was transferred to Evelyn lodge and it started functioning
1973

as an independent department. This department came to known as Data

Processing Center.

1981

The system were upgraded to ICM1901(second generation computer)

1986

The system were further upgraded to ICM6000 series M/c.

The ICIM39 series of M/c were installed. All the systems, which
Used till now were installed on proprietary basis. But the later plant came

1992

under severe financial crisis for which this department faced a severe fund
crunch. This forced this department to upgrade its infrastructure on rental
basis and this practice was discontinued in November 2013
SUNE450 server with Solaris operating system ORACLE RDBMS server

1999

was installed.This department was relocated to the General office building

of Burnpur works

2006

This department was renamed as computer & Information Technology from

Data Processing Center
Sales Invoice, FINANCIAL ACCOUNTING, EFBS, HRD, COST,

2010

COLLIERY CASHBOOK, COLLIERY INVOICE system in .NET platform

was implemented.

2011
2012
2013

SAIL-ISP portal was implemented

Payroll process, ITAX, FINAL SETTLEMENT system in .NET platform
implemented.
Switched over from rental infrastructure to company owned servers

C) Existing Systems &Applications at C&IT

Financial Accounting, Account closing, Balance sheet, Trial balance

Fixed Asset Register
Cost System
Sales & Invoicing module
Cash Book & Bill passing module
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C&IT
Cenvat & Input Tax credit module
CMMS
Materials Management & Price Stores Ledger Interface with Finance
Hospital Management Information System
Payroll and Allied systems like PF, SESBF, Final settlement, Income Tax, ETDS etc.
Employee Family benefit Scheme
Town Department Modules: i. Quarter Management System
ii.Estate Outsider Billing system
Training Department Modules
Human Resources Information System
Stores Accounting
Procurement & maintenance of H/W & S/W throughout the plant.
Administration of Database, Systems, Network, Intranet Site (Portal), Mail-Server etc.
Extension of network, Enhancement of application modules and maintenance of
existing Software
Visitor gate pass module.
Video Conferencing
Antivirus Server
Internet access to entire plant via proxy server

A number of projects are currently taken up by C&IT for implementation. They are in
various stages of planning and implementation. These projects once implemented will
change the very way day to day business is carried out in SAIL-ISP.

i.

Implementation of ERP

ii.

Extension of computer network to the new plant

iii.

Implementation of biometric attendance system.

iv.

Making SAIL-ISP portal accessible via Internet.Globalization of SAIL-ISP

e-mail address

86

v.

Development of HRMS module for Personnel Department

vi.

High speed Internet connectivity.

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C&IT
D) Infrastructure
Major architectural components in IT infrastructure in SAIL-ISP can be summed up
as follows:
a. Two NETRA T4-1are deployed to host Oracle 11g Database in RAC
environment.
b. Two no of SUNX3-2 Servers deployed with OVM as application server
host and willhave multiple virtual application servers on top of these two
servers to facilitate loadbalancing and high availability of Application
server.
c. EMC VNX 5100 storage is a datacenter class storage being used as a
shared storage.This storage has RAID -1 group dedicated to production
database and application
d. SL150 tape library is used as central tape backup.
e. EMC concertrix DS300B series SAN switch is used as a central SAN
switch for RACimplementation.
f. ORACLE VM3.2 is used to create virtual servers for Application layer
infrastructure.
g. Microsoft TFS is used for version management of Application.
h. EMC networker software is used for backup management of database.
i. CA infrastructure manager is used
j. Oracle Ops center is used for system management of Oracle H/W system.

E) Technical specifications
Technical specifications of the server hardwares installed at Dept. of C&IT is
detailed
In the following section.

1. Hardware
a. Application Server

SUN SERVER X3-2

Processor

2 * Intel Xeon E5 2640 6-core

processors with 2.5 GHz speed with 15

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C&IT
MB L3-cache with QPI technology

Memory Slots

16 DIMM Slots

Memory required

16 GB DDR3 RAM

Memory expandability

Upgradable to 512 GB RAM

Storage

2*600GB 10 K RPM hot pluggable SAS

HDDs

Expansion slots

4 PCI-E slots

Form Factor

Rack

Load balancer

Oracle VM premium per server used for

load balancing software

b. Database Server
SUN/Oracle Netra SPARC T4-1 server
Processor

RISC based SPARC T4 processor, 4

core processor, total 4 cores, 4 MB
cache per processor

Memory required

32 GB DDR3 RAM

Memory expandability

upgradable to 256 GN RAM

Storage

2*600 GB 10 K RPM hot pluggable

SAS HDDs

Expansion slots

3 PCI-E Slots

Form Factor

Rack

OS Support

Solaris 11

Operating System

Solaris 11

Clustering Software

Oracle Solaris cluster enterprise edition

c. Proxy Server
SUN SERVER X3-2
Processor

1*Intel Xeon E5 2640 6-core processors

with 2.5 Ghz speed with 15 MB l3-cache
with QPI technology

88

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C&IT
Memory Slots required

16 DIMM slots

Memory required

16 GB DDR3 RAM

Memory expandability

Upgradable to 512 GB RAM

Storage

2 nos. of 300 GB hot pluggable SAS

hard Disk drives at 10 K rpm

Expansion slots

4 PCI- E Slots

Form Factor

Rack

d. Backup & Storage Management Server

SUN SERVER X3-2
Processor

1* Intel Xeon E5 6240 6-core processors

with 2.5 Ghz speed with 15 MB l3-cache
with QPI technology

Memory Slots required

16 DIMM slots

Memory required

16 GB DDR3 RAM

Memory expandability

Upgradable to 512 GB RAM

Storage

2 nos. of 300 GB hot pluggable SAS

hard Disk drives at 10 K rpm

Expansion slots

4 PCI-E Slots

Form Factor

Rack

Backup Software

NetWorker

e. Storage Area Network (SAN)

EMC VNX 5100 Storage System
Capacity

Configured with 16 TB usable space

under RAID -1+0, using SAS disks
having 6Gbps data access speed

Disks

600 GB 15 K RPM drives

Scalability

The offered array scales upto a raw

capacity of 225 TB, hence it is capable
of delivering 32 TB usable in RAID 1+0

Cache
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Memory 8 GB
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C&IT
Availability

This

is

feature

of

the

native

multipathing software and the array

supports all the native MPIO softwares.
The array supports online expansion and
migration.
Management

Unisphere is provided along with the

array for the management of the same.

Virtualisation support

This feature is supported

Software

GUI based and storage based software

2. Software
Most of the web based applications that have been implemented and those under
development are developed using ASP.NET. The two tiers applications have been
developed using VB.NET.The backend data source in both cases is Oracle
11g.This run in RAC environment enabling high availability in case of failures.

The benefits of running an Oracle database in RAC mode are:

a. High Scalability
b. Greater throughput
c. High availability

3. NETWORK
To support the various web based application and other communication related
needa robust fiber optic network has been implemented and maintained by C&IT.
At present the network covers the entire old plant, hospital, Town Administration
office and CEOs office.There are plans to extend this network to various sites in
the new plant. The diagram of the existing network is provided in the following
page.

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C&IT
F) Diagram of Existing Network

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C&IT
G) Conclusion

C&IT department has evolved over the years from Data Processing Centre to one point
solution to various technical needs of the plant. With time this department has provided
various IT solutions to slow and manual works. This enabled faster and accurate
completion of the job without much manual intervention.
Internal Mailing and portal system has enabled ISP to reduce paperwork and introduced
a new medium of official communication between employees.

Payroll,

financial accounting, sales invoicing, hospital management, quarter

management etc. are online modules developed and maintained by C&IT have made lot
of business process in respective areas easier than before. The application has improved
the way the data is stored and preserved in a standard format in a centralized database.

With the implementation of ERP the business scenarios are going to change further in
the days to come and the role of C&IT will be more prominent in such a changed
scenario.

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Capital Repair & Structural

CAPITAL REPAIR & STRUCTURAL

A) Introduction
Capital Repair was formed in the year 1979 primarily to carry out capital repair of Blast
Furnace. Later on it got involved in weekend and major repair of Rolling Mills, Coal
Handling Plant, Power Blowing Station, Coke Ovens, overhauling of Saturators,
Detarrers at Coke Ovens by product plant, Structural Repairs and emergency requirement
of the plant.

B) Manpower
At present the Department is having only one section consisting of
Executives - 4 Nos.
ISP Employees & Ex ropeway workers. 18 heads
Annexure Workers - 36 heads.

C) Some Special Achievements

1. Revamping of hydraulic Accumulator at Heavy Structural Mill
2. Revamping of centralized AC cooling Towers of Burnpur Hospital.
3. Revamping of 2 nos. EOT crane at Rolling Mill Billet Yard and Ingot Mould
Foundry.

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CCAS
CENTRELIZED COMPRESSED AIR STATION

A) Introduction
CCAS supplies Plant Grade Compressed Air (PGCA) as well as Instrument Grade
Compressed Air(IGCA) to all units in the new plant viz BOF,CCP, Coke Oven, Power
& Blowing Station (PBS), Blast Furnace, Mills, By-Product Plant, Sinter Plant, etc. (at
a set point pressure of 7.73 kg/cm2 .) through a dedicated network of Interplant Pipe
Lines.
IGCA is that part of air which is passed through air dryer so that it is devoid of
moisture & distributed to all units through a dedicated of Interplant Pipe Lines. IGCA
is used mainly for pneumatic valve operations and cooling purposes where as PGCA is
used for blowing and cleaning purposes.
a. Centrifugal Air Compressors
b. Air Dryers
c. Pump House
d. Cooling Tower
e. Water Treatment Plant
B) Centrifugal Air Compressor:
There are five nos. Centrifugal type three staged compressors of M/S Ingersoll Rand
make in CCAS.
Main Specification of these Compressors are given below:
Model

C3000-C150MX3

Speed

32000rpm

Flow rate

18000Nm3/hr

Power Rating

2.5MW

Concept of Centrifugal Compressor:

i.

A dynamic compressor using centrifugal forces to produce air at constant

pressures with varying volumes.

ii.

Work performed on the air by rotating impeller increase the pressure and
velocity with a subsequent drop in velocity through the diffuser resulting in a
further increase in pressure.

94

IISCO Steel Plant

CCAS
iii.

Typically the 2/3 of the pressure developed occurs in the impeller area and 1/3
in the diffuser area.

Working of Centrifugal Compressor

The air goes in ...
Through the Inlet control valve

Flows through the first stage Rotor Assembly ------------------ gains velocity

Goes to the Diffuser ------------------------------------ velocity converted to pressure

A
Intercooler

---------------------------------------------removes

heat

to

improve

efficiency

Moisture Separator-------------------------------------- removes condensate

Air direction changes 180 enters next stage

Sequence of A repeats for 2nd stage and 3rd stage

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CCAS

Controlled flow passes through the Check Valve----------------------- for utilization

(Through interplant pipeline network)

Excess Air passes through the Bypass Control Valve to Silencer to atmosphere.

A Sectional diagram for internals of stages of Centrifugal Compressor

96

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CCAS

C) Air Dryers: Compressed Air Dryers are designed to be non-cyclic, direct expansion type and to
provide high quality compressed air, free of moisture and offer minimum
maintenance. There are 10 nos. air dryers of M/S Sanpar make installed in CCAS
(Model : SXD 1500W, Capacity : 9000 Nm3/hr,
Type: Refrigerant type
Specification of these Air Dryers are given below:Type of Dryer

Non-cyclic,direct

expansion

Refrigeration type
Model No.

SXD 1500W

Capacity

Nm3/hr

Operating Pressure

8 bar (g)

Air Inlet Temperature

46 C

Pressure Dew Point

+3 C

Refrigerant

R407c

Power Supply

415 10% V, 3Ph, 50Hz

Type of Condenser

Water Cooled

Inlet Cooling Water Temperature

32 C

water connection

DN 40

Air Inlet & Outlet Connection

DN 250

Dryer Design

As per ISO 7183

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CCAS

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CCAS
Process Description
Refer Schematic diagram enclosed.
The entire Refrigerated Compressed Air Dryer consists of two cycles:
i.

Closed loop refrigeration cycle

ii.

Open loop compressed air cycle

Closed loop refrigeration cycle

i.

The refrigerant vapor is compressed in refrigerant compressor.

ii.

The high pressure and high temperature refrigeration passes through Water-cooled
condenser.

iii.

The refrigerant is cooled to its condensing temperature in the condenser.

iv.

The high -pressure low temperature refrigerant passes through the filter dryer.

v.

Any moisture trapped in the refrigerant is removed in Filter-dryer.

vi.

The dry refrigerant passes through an expansion valve.

vii.

After expansion, the refrigerant becomes low pressure, low temperature liquid.

viii.

Liquid refrigerant passes through evaporator.

ix.

The liquid refrigerant boils and get itself converted to refrigerant vapor, thanks to the
hot compressed air passing through the evaporator.

x.

After the heat exchanged and having converted into vapour, refrigerant vapours returns
back to the compressor and the cycle repeats in the closed manner.

xi.

A Hot Gas Bypass valve is incorporated to ensure that during partial thermal load on
the dryer, liquid refrigerant do not enter the compressor.

Open Loop Compressed Air Cycle:

i.

The wet, hot, filtered compressed air enters the Air-to-Air heat Exchanger.

ii.

In the air-to-air heat exchanger the incoming wet air is pre-cooled using the outgoing
cold air. The air-to-air heat exchanger, which acts as a pre cooler, reduces the
temperature of the incoming compressed air by exchanging heat to the outgoing cool
air. Condensation taken place during this pre-cooling of compressed air is discharged
through an automatic drain valve.

iii.

The pre-cooled compressed air enters evaporator and gets further cooled to its Pressure
Dew Point by the refrigerant passing through the evaporator.

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CCAS
iv.

The condensed moisture is separated through demister pad, discharged through the
condensate Automatic Drain Valve.

v.

The cold compressed air passes through the Air-to-Air heat exchanger and gets
reheated. Here the air-to-air heat exchanger acts as a re-heater.

vi.

The cold air having got heated up gets the relative humidity lower and dry.

Condensate discharge:
The condensate that gets collected in the demister is discharged through the condensate drain
tap.
Dew point indicator:
A dew point sensor, which is located at the moisture separator, gives signals to the dew point
indicator of the panel. Thus, ensuring continuous visual indication of the dryness of the
outgoing air.
Start up & Operation:
Before starting the dryer check:
i.

Ensure the power supply to the dryer i. e. 41510%V/3Ph/50Hz.

ii.

The air inlet valves are closed and that there is no airflow across the dryer.

iii.

Ensure proper water flow for the condenser.

iv.

The dryer is installed in accordance with the installation instructions.

Note: Ensure that crankcase heater is on for a minimum period of 4 hour before switching ON
the dryer for the first time or when the Dryer is being switched OFF for more than 6 days.
Starting the dryer:
i.

To start the dryer turn the rotary switch to ON position. Alarm & OFF indication

lamps get switched ON.

ii. Wait for Alarm indication lamp to switch OFF; this delay time is essentially given to
protect the compressor.
iii. Press the ON button to switch ON the dryer, notice that OFF indication lamp gets
switched OFF.
iv.

Allow

approximately

five

minutes

for

the

dryer

to

achieve

operating

temperature/pressures.

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IISCO Steel Plant

CCAS
v.

Open the air inlet valve slowly at first to pressurize the dryer. Now open the outlet

valve. The dryer is now ready for ON LINE drying.

Stopping the dryer:
i.

Before stopping the dryer ensure that air supply to the dryer is stopped.

ii.

Push the OFF switch to switch-off the dryer.

iii.

Compressed air should never be passed through the dryer when dryer is in OFF
condition.

Maintenance:
To ensure that dryer operates efficiently, periodic maintenance described below should be
carried out.
Weekly:
i.

Check the automatic condensate Drain.

a. Cleaning of the automatic condensate drain:b. Close the ball valve (1/2) fitted on the Drain attachment assembly.
c. Open the brass manual drain fitted on the automatic drain, so as to drain out
all the condensate collected, there by de-pressurizing the drain.
d. Open the brass union (1/2) fitted on to the Condensate Drain Assembly.
e. Split open the drain bowls, by removing the M5 Allen Head bolts.
f. Clean these bowls & the Aluminum float with pressurized water
g. Ensure that there is no any blockage of the Orifice.
h. Now re-assemble the bowls.
i. Fit the drain back to the drain attachment through the brass union (1/2).
j. Now open the ball valve (1/2)

Monthly:
Electrical
a. Check for any loose connections in the electrical panel box.
Compressor
a. Check the oil level in the compressor sight glass, check for loose connection
and running
b. Amperage of the compressor.
Condenser
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CCAS
Check for leakages in the water connection and setting of water pressure valve.
Annually:
a. Dismantle the drain completely and clean all the components.
b. Check the power consumption of the refrigerant compressor.
D) Pump House
There are 6 pumps installed in CCAS for following purposes.
Function of Pumps House:
i.

For cooling of compressors & its accessories : 4nos. cooling pump (2W+2S)

ii.

For Make Up water in the water circuit system: 2 nos. pump (1W+1S)

Details of pump installed in CCAS are given below:

Make Up Water Pump:

Makers Name

Kirloskar Brothers Limited

No. of Installed Pump 02

Pump type

UP80/30

Head

30 meter

Size

80125mm

Discharge

60m3/hr.

Speed

1460rpm

Pump input

6.72KW,MAT Code SPL, IMP DIA CS/293

MFG

09/11, Prime Motor Rating -930KW

Coupling Detail
Type Love-joy type flexible coupling (SW=150)
Size

102

2542, No.-50/89533

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CCAS

Cooling Water Pump

Makers Name

Kirloskar Brothers Limited

No. of Installed Pump

04

Pump type

UP250/38

Head

15 Meter

Size

250250mm

Discharge

900m3/hr.

Speed

1485rpm

Pump input

122.5KW,MAT Code SPL, IMP DIA CS/293

MFG

09/11, Prime Motor Rating -930KW

COUPLING DETAIL
Type Love-joy type flexible coupling (SW=150)
Size

2542, No.-50/89533

D. Cooling Tower
Cooling tower is used to reduce the temperature of hot water that comes out of the
equipments like compressors, dryers, oil heat exchanger etc.
The cooling tower used in CCAS is of M/S Southern Cooling Tower(P) Ltd. make,
Crossed Flow Forced Draft type & there are 3 cells in unit.
E. Water Treatment Plant
Water Treatment Plant comprises of Chemical dosing, RO plant & Duplex Filter.
a) Chemical Dosing:Chemical treatment on the water is done in two phases in the water
treatment plant viz. online chemical dosing & Biocide Dosing into the sump. The details of
the chemicals used are given below:-

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Name of the System

Name of the Chemicals

Quantity Required and

Dosing Frequencies

Polymeric Dispersant

Initial Quantity added to

(Zeo-291)

The sump- 12.50 Kg. Then for

Online Chemical Dosing

regular dose-2.33Kg/Day
Scale cum Corrosion Inhibitor

Initial Quantity added to

based on Organo Phosphate

The sump- 10.00 Kg. Then for

(Zeo-293)

regular dose-1.43Kg/Day

Non-Oxidising Biocide based Initial Quantity added to

on
Biocide Dosing into the Sump

Quaternary Ammonium The sump- 20.00 Kg. Then for

Salt (Zeo-105)

regular dose-20.00Kg/Month

Oxidising Biocide based on Initial Quantity added to

Trazine Derivatives (Zeo-106)

The sump- 2.00 Kg. Then for

regular dose-6.25Kg/Week

b) RO Plant:

RO System

RO Antiscalant Hardness and Silica (Zeo -400)

70Kg./Month

Chlorin Solution (Zeoline -200)

166.6Ltr./Month

c) Duplex Filter:
The Duplex filter used for the filtration of the water that is entering the compressors. The
Duplex Filter used in CCAS is of M/S Filtration Enggs Pvt. Ltd. It comprises of two
vertical Simplex Filter vessels in which SS elements are properly fitted. The filter has

side entry with outlet at the opposite direction. The two nos. of Simplex Filters are
connected by means of four nos. of butterfly valves. The filters are switched from
standby mode to operation mode using these butterfly valves. When one filter is in

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operation, the other is closed and the element can be taken out for cleaning or backwash
purposes. There is thus zero down time in this design.

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CCMD
CENTRAL CRANE MAINTENANCE DEPARTMENT (CCMD)

A) Introduction
Central Crane Maintenance Department (CCMD), recognized as a critical equipment area
is functional under M.E. (Steel) section of Old Plant.

CCMD looks after the following functions of Old Plant:

a. Ensure reliability of all 81 no. of EOT Cranes mechanically located at Blast
Furnace, Steel Melting Shop and Mill zone of old plant.
Mechanical reliability of EOT Cranes is a conjunction of various aspects. Some of
them are:
i.

Preparation of monthly schedule for inspection, lubrication and

housekeeping.

ii.

Inspection of EOT Cranes by Zonal In-charge in accordance with the

monthly maintenance schedule.

iii.

Annual Load testing of EOT Cranes in static as well as dynamic condition

to ensure their fitness for operation.

iv.

Keep a watch on proper operation of EOT Cranes and highlight any case
of misuse.

v.

Standardize important Crane Spares, procure them and control their

consumption.

vi.

To analyze any breakdown with special emphasis to those repetitive in

nature andderive appropriate remedial measure.

b. Operator Management i.e. deployment of Crane operators round the clock to

different EOT Cranes located at SMS and Mill zone of Old Plant.

In addition to the above, CCMD has extended its presence to New Plant and is currently
involved in the following activities:

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i.

Inspection and identifying defects of EOT Cranes post erection and

assembly.

ii.

Preparation and forwarding of defect sheet after each inspection to Crane

Suppliers through Projects and their subsequent follow-up.

iii.

Preparation of material code for two year running spares as specified by

the Crane Supplier.

iv.

Training and Deployment of Crane Operator to Wire and Rod Mill on

rotational and as on demand basis,

v.

Training and Deployment of Crane Operators to BOF & CCP on rotational

and as on demand basis,

vi.

Identification and Deployment of Crane Operators to BOF & CCP during

special trial of equipments. An important trial recently conducted was of
Caster #1.

vii.

Identifying training needs of Crane Operators and Maintenance Personnel

and nominating them for training at sister plants.

viii.

Developing new Crane Operators by inducting the identified personnel

into a three month On the Job training program.

B) Highlights During 2013-2014 In Relation To New Plant

1. Modification of Main Hoist Beam for re-ladling of liquid steel during trial of Caster
#1,
2. Training of Crane Operators since inception of Crane movement in New Plant and
deploying them during trials of Caster #1 conducted in December 2013 & March
2014.

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COKE OVENS

A) Coke Oven Battery No. 11

The input and output parameter ofBattery No.11 is as mentioned below:-

Requirement of dry coal blend

Production of run-of-oven coke(dry)
Production of blast furnace coke(25-80mm) size fraction (dry)
Generation of coke breeze(-25mmsize fraction) dry
Generation of coke oven gas of calorific value of 4250kcal/Nm3

1.1597Mt/yr
0.8814 Mt/yr
0.7757Mt/yr
0.1057Mt/yr
42365Nm3/hr

The above figures have been worked out based on the following data/norms
Useful oven chamber volume
Gross coking time
Dry equivalent bulk density
Generation of coke oven gas
Yield of dry run of oven coke from dry blend
Yield of dry blast furnace coke(25-80mm)from run-of- oven
coke
Yield of dry coke breeze(-25mm) from run-of-oven coke

41.6m3
17hrs
0.74t/m3
320Nm3/t of dry coal blend
76%
88%
12%

1. Raw material characteristics

Blend Ratio
Prime coking coal (weight %)
Chasnala coal (weight %)

78% of the blend (Imported)

22% of the blend (Indigenous)

2. Input Raw Material Analysis

The indicative and typical analysis of the coal blend on the dry basis is as given
hereunder
Sl. No.
1
2
3
4
5
108

Description
Size
Ash
VM
Moisture
Coking Index

Unit
mm
%
%
%

Range
0-50
11.0 max
25
6-8
Above 20
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6
7
8
9

10

Grey King coke type

Crucible swelling number
Mean max Reflectance
Geiselerplastometer test
i) Fluidity
ii) Fluidity range at 5ddpm
iii)Initial Softening temperature at 5ddpm
Total Sulphur

No.
%

G5
6.5
1.14-1.25

ddpm
C
C
%

600-2000
60
410 15
0.6 max

The coal blend is crushed to 80% (-3mm) in the Coal Handling Plant before being fed to
coal tower of Coke Oven Battery no.11
3. Coke Quality
The coke produced from the coke ovens is of good quality and strong enough to be
suitable for the use in the large blast furnace and have the following characteristics
Coke Ash
V.M.
M40
M10
CSR
CRI

14.5%max
0.8% max
82
7 max
60-62
24 max

4. Basic Design
i.

Top charged, Compound, twin flue, under jet, regenerative heating with partial
recirculation of waste gases.

ii.

The ovens have 3 nos. of charging holes.

iii.

Double gas collecting main (one in pusher side and one in coke side)

iv.

Two waste heat tunnel on pusher side and coke side and

v.

One common tunnel to the chimney

vi.

The battery has 16 pairs (32 nos.) of vertical flues

5. Basics of Battery
i.

Battery refractory

ii.

Civil work viz. nozzle deck and buttress walls, service platforms and benches
chimney and waste gas tunnel

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iii.

Battery anchorage system consisting of flash plates, buck stays tie rods and
springs

iv.

Oven doors and door frames

v.

Under jet heating system for both coke oven gas and mixed gas with
computerized combustion control system.

vi.

Centralized lubrication system for the heating system.

vii.

Oven machines excluding coke car and loco

viii.

Oven machine tracks excluding coke car track

ix.

Oven machines power trolley rails/ collector other than coke car power trolley

x.

Oven top raw gas off-take system and charging hole lids and frames.

xi.

Charging emission control system with high pressure liquor aspiration system,
water sealed AP caps etc.

xii.

Instrumentation and automation systems for the battery including computerized

combustion control system, telecommunication system, fire detection and alarm
system.

xiii.

Spillage conveyor on pusher side and coke side service platform for mechanized
cleaning of service plat form with disposal system.

xiv.

End bench repair facilities for doors and machines including stationary high
pressure hydro jet cleaner.

xv.

Electrics including MCC LT distribution, illumination, power earthing etc.

xvi.

Paving of service platform with fire clay/cast iron liners.

xvii.

Provision of pumps, service water, HPALA etc.

xviii.

Coal tower of capacity 4000t with SS lining coal tower gates, skip hoist, and
other associated facilities.

xix.

Indoor pipelines consists of CO gas line for under firing, mixed gas line for
under firing, supply and return ammonia liquor line, compressed air line,
waterline steam line and gas condensate service

110

xx.

Land based pushing emission control system

xxi.

Gas mixing station

xxii.

Central control room along with instrumentation room.

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6. Pollution Control
The new battery meets the norms published in official gazette by MOEF (Ministry of
Environment and Forest). Government of India dated 3rd February2006 for by-product
recovery type coke ovens.
The following pollution control facilities are incorporated:
a. Zero-leak doors with matching door frames along with cleaning and maintenance
facilities.
b. Zero leak charging hole lids and frames along with cleaning and luting facilities.
c. Water seal AP lids and frames on pusher side and coke side has been provided.
d. High pressure ammoniacal liquor aspiration systems to achieve emission free
charging of ovens.
e. Leak proof stand pipe/goose neck/valve box assembly.
A dust free coke pushing system is provided for the localization of dust emissions during
coke pushing. The system comprises the following facilities:
i.

A hood of special design located on the coke guide door extractor.

ii.

A stationery manifold lengthwise the coke oven battery on coke side

iii.

A stand-alone unit for the treatment of dust laden air. The dust treatment
unit consists of dry cyclones for the first stage of treatment, bag filters
(the second stage) and draft blow machines. The unit is automatically
operated.

The dry method used for the treatment of the dust laden air in high performance units of
modern design makes it possible to guarantee the reduction of the amount of emissions
discharged into the atmosphere down to 20-40mg/m3.
The filter regeneration system is automatically switched on as soon as dust accumulates
on the bag surface.

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The bag filters regeneration is performed automatically as a result of reverse impact
blowing with compressed air from outdoor networks.Due to cyclic nature of coke
pushing from carbonization chambers, the draft blow machines provided with frequency
controlled electric drives permitting to considerably reduce the consumption of electric
power.
7. Specifications of COB#11
Under the 2.5MT modernization programme, one battery of capacity 8,81400t/yr
(approx.) of gross coke production (dry) and high capacity oven is to be installed. The
analogous technical data (based on batteries operating in India) for the design of the
battery is indicated below:
Total length(between buck stays)

15860mm

Total useful length

15020mm

Total height

7000mm

Useful height

6700mm

Width at pusher side

385mm

Width at coke side

435mm

Average width

410mm

Taper
Useful volume of the oven
Axial distance between ovens

50mm
41.6m3
1400mm

Number of flues in heating wall

32

Distance between the flues

480mm

Number of charging holes

No. of gas off takes

Coking time

17hrs

8. Salient Features Coke Oven Battery No 11

i.

Top charged, twin flue, under jet, compound, regenerative heating type with partial
recirculation of waste gases heating system.

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ii.

Waste gas withdrawal system on both sides.

iii.

A hydraulic reversing machine for battery with provision of standby manual

operation.

iv.

Required sets of matching oven machine of latest proven design with hydraulic drive
for door extraction and latch lifting in pusher and platform type guide car and
provision of manual operation of crucial functions.

v.

Adequate and reliable facilities in the oven machines for mechanical cleaning and
maintenance of oven doors, door frames and gas removal system at the oven top.

vi.

Air cooled oven doors with diaphragm type design has been provided. The door is
spring loaded with self-adjusting sealing arrangement unlike conventional doors.

vii.

Battery heating system is designed for under firing with clean coke oven gas with
average heating value of 4250kcal/Nm3 and /or mixed gas with average heating
value of 1000kcal/Nm3.

viii.

U type gas collecting mains with built in valve box and design of ascension pipes
with improved system of adjustment between the gas collecting main and ascension
pipe.

ix.

A gas collecting main with effective sealing between gooseneck and isolation valve
box on both pusher side and coke side isbe provided with automatic functioning
bleeders.

x.

Oven anchorage system comprises of fabricated buck stays with single piece flash
plates, top crosstie rods (with suitable protection for entire length) and bottom cross
tie rods, longitudinal tie rods and necessary regenerator bracings in fireclay zone.

xi.

Sturdy and rugged anchorage and bracing system in which the door frames is held
through cast iron flash plates and not directly placed on the brickwork and held
through buck stays.

xii.

The ascension pipe lids are water sealed to prevent emissions.

xiii.

One set of hydro jet door cleaner consisting of cleaning station (one for pusher side
and one for coke side) of high pressure not less than 600bar

xiv.

One set of door lowering for repair of pusher side and coke side doors.

xv.

Four sets of fixed door racks (2 on pusher side and 2 on coke side)

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Coke Ovens
xvi.

Computerized Heating Control system is provided for ensuring proper coking. The
Model also takes care of oven identification, oven machine interlocking, and oven
scheduling.

9. Service Bunker
There is a coal tower of 4000T useful capacity for storing coal of dry equivalent bulk
density of 740kg/m3. The bunker is located at the east end to allow enough clearance for
the oven machines. At the bottom of coal tower, number of rows(8) of outlet has been
provided. Each row has number of outlets matching the number of charging holes along
the transverse axis. At each outlet, necessary mouth piece and sector gates are provided.
A parking and maintenance platform for charging car at the oven top level has been
provided. The bunker is of RCC construction and lined with stainless steel liners at the
sloping outlets. Level indicators for coal level with transmission devices to the control
room and alarm for alarm for low levels of coal charge are provided. Discharge from
each bunker compartment is through roller supported, horizontal cut off gates which are
operated by charging car operator. The mechanism for opening of the coal tower gates is
on the charging cars.The coal tower has been provided with pneumatic blow down
device to enable free flow coal.
10. Oven Anchorage
The battery anchorage consisting primarily of buck stays, flash plates, cross and
longitudinal tie rods, springs etc. is complete with all accessories. The anchorage system
maintains a positive pressure on the refractory to avoid opening of joints or cracks due
to temperature changes. They are rugged in design to with stand the stresses and loads.
Suitable protection for full length of upper cross tie rods is provided. Material of
construction (MOC) of cross tie rods is Chrome Molybdenum Steel. A set of regenerator
bracings has been provided for loading on the main walls and dividing walls of the
regenerators. Buttress wall are connected together at the top by longitudinal tie rods. To
ensure proper loading, six numbers longitudinal tie rods has been provided with helical
springs,

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Buck stays are provided to transmit load on the heating walls through the flash plates.
They are of rugged design to with stand the stresses and loads during heating up and
battery operation. The buck stays are of welded box type design without any splicing
joint in critical zone and well ventilated. Buck stays on the pusher side and coke side are
held at the battery top level and nozzle decking level by suitable crosstie rods at each
level loaded with helical springs. There are no joints in the cross tie rods. Buck stays are
resting at the bottom on the nozzle decking. The transfer of load from buck stay to the
flash plates and to main wall are through helical spring located inside the buck stay.A set
of regenerator bracings are provided for loading on the main and dividing regenerator
walls, to take care of the differential expansion characteristics of refractories of this
region.
11. Door Body, Door Frame, And Flash Plates
Gas tight doors are provided. Doors have a flexible diaphragm sealing with a spring
loaded sealing strip made of suitable special alloy steel. Doorsare air cooled by keeping
the main door body separated from the diaphragm and the brick holders by an air gap of
approximately 30mm, which keeps the door body cool and prevent door warping. The
flexible diaphragm is able take the shape of the warped door frame. The diaphragm is
held against the door frame by spring loaded plungers mounted on the door body to
allow sealing of oven doors with distorted frames. The doors have provision for manual
adjustment of knife edge pressure. Between flash plates and end bricks and flash plates
and door frames sealing is done with ceramic ropes set in machined grooves.
Matching door frames are adopted Door frame on pusher side and coke side are of
identical design.
Flash plates are of single piece and are loaded at three different levels (top, middle, and
bottom) from buck stays. The design of flash plates ensures that load is transferred
through liner bricks and notthrough central axis of heating wall. Door frame on pusher
and coke side is provided with replaceable sole plate at the bottom.
Chemical composition of HRC is as follows:
C=3.2-3.6%,

P=0.3%Max.,

Mn=UPTO1%,

Cr=0.16-0.4%,

Si=1.4-2.0%

and

S=0.1%Max., Ni=0.07-0.6%
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12. Ascension Pipes, Goose Neck, And Isolation Valves

Isolation valve is provided with flexible sealing between itself and the collecting main
through a liquid seal. Ascension pipe and goose neck are designed for high pressure
ammonia liquor aspiration (HPALA) system for on main charging. The ascension pipe
caps have water sealing for achieving zero leaking from ascension pipe caps. The water
sealed lid is provided with lever along with counter weights for independent opening
/closing of the ascension pipe lids manually. The water sealing have sufficient pressure
head to maintain sealing even during high pressure ammonia liquor aspiration system
during charging. Suitable arrangement is made for supply of industrial water for water
sealing and its recirculation. Leak proof ness of ascension pipe caps conforms to
stipulated norms for leaking AP caps. Spray nozzle design are able to form a spray
pattern so as to cover the entire cross section of goose neck. Goose neck design and
profile facilitate access to every portion of goose neck and valve box for manual
cleaning from gas collecting main platform. Material of construction of ascension pipe
conforms to IS2062-99.Base socket and goose necks are of special castings capable to
withstand high temperatures. Ascension pipe sits on base socket and is packed with
ceramic ropes to prevent leakages.
Low pressure supply ammonia liquor pipeline for individual goose neck and high
pressure liquor aspiration pipeline for individual goose neck for on main charging is
routed along the gas collecting main platform.

13. Charging Hole And Inspection Hole Frames And Lids

Charging hole frames and lids are designed for magnetic lid lifting arrangement.
Charging hole frames is of round shape. Provision of lug is made in lid for manual
lifting in case of necessity. Charging hole frames and lids are designed for gas leak proof
and conform to stipulated norms for leaking lids. Both lid and frame are lapped for
rotary cleaning arrangement in charging car. Inspectionhole covers at the oven top are of
tumbler type design and frame and cover match to be leak proof. Charginghole frame
and lid inspection hole frame and lid are of special castings capable of withstanding high

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temperature as per its application. Heat resistant castings physical properties conforms to
IS 210 93FG 200/ equivalent. Indicative composition of HRC is as given belowC- 3.23.4%, P-0.3% max., Mn-0.7-1%, Cr-0.4-0.8%, Si-1.6-2.0% and S-0.1%max.
14. Gas Collecting Main
U type Gas collecting mains on both pusher side and coke side is provided. Gas
collecting main is of welded construction with plate thickness suitable to with stand
corrosion due to gas and liquid. However, GCM is fabricated with plates less than 10mm
in thickness. Gas collecting main on both sides is supported from buck stays.
Gas collecting mains is provided with tar chasing system with high pressure ammonia
liquor. Openings with plugs are also provided on the collecting main for manual tar
chasing. Collecting mains has a suitable slope for smooth flow of liquor and tar. Liquor
from coke side and pusher side collecting mains is routed through pipe line stockades.
Walkway with hand rails is provided on the collecting mains. The height of walkway
above the Gas collecting main is such that plugs on gas collecting main is easily
approachable.
Automatic hydraulic seal bleeders are provided (2 numbers) on each collecting mains
which bleed gas when the pressure in the hydraulic main exceeds the designed pressure
limit. (25mm)
15. Cross Over Main And Suction Main
The collecting main on pusher side and coke side is interconnected with cross over main with
hydraulically controlled butterfly valve on pusher side. Hydraulic controller is of split type for
both side and coke side butterfly. Controllers are located in GCM booth on pusher side from
where impulse line is drawn up to actuator of butterfly valves. Cross over main is provided with
compensators to take care of stresses. Cross over main is provided with spray liquors at suitable
points. Cross over main is of welded steel construction with plate thickness not less than 10mm.

16. High Pressure Ammonia Liquor Aspiration (HPALA) System

To control charging emissions from coke oven battery, high pressure ammonia liquor
aspiration system (HPALA) is provided. It consists of high pressure centrifugal
multistage booster pumps for ammonia liquor, spray nozzles, and pipe lines. The low
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pressure ammoniacal liquor, is drawn from the liquor mains, pressurized to about 3035kg/cm2 and injected into goose neck while charging. The charging gases evolved is
sucked into the gas collecting mains, preventing emission of dust and smoke into the
atmosphere. During idle running of HPLA pumps, suitable pressure relieving system
along with necessary instrumentation is provided.

17. Spillage Coke Conveyors

Spillage chain conveyor comprises of an endless chain fixed with scrappers moving over
a stainless steel trough. The chain moves slowly with motor & gear box. The endless
chain discharges the material through a chute to a conveyor belt, which discharges the
material into a bin. The bin to be made empty after it gets filled up.

The spillage conveyors is provided for removing the hot coke spillage likely to fall
during opening of the coke oven doors and pushing of ovens on pusher side and coke
side service platforms. The total system consists of a special chain conveyor fitted with
drag plates running inside a lined trough on the service platform. Spillage chain
conveyor on the return side runs underneath the service platform.
The chain conveyor discharges the material on a belt conveyor which carries the same to
the structural storage hopper (capacity-20 M3) for disposal by trucks.Proper water
spraying arrangement system is provided before belt conveyor to take care of
temperature of coke to be transported on to belt conveyor.
18. Skip Hoist
Leveler bar present in pusher car, levels coal heaps formed inside oven during charging
and distributes it evenly inside oven. Any excess coal is dragged out by the leveler and
is collected inside the hopper of pusher car. This spillage coal is emptied in skip bunker
from time to time and is recirculated back to charging car.
A skip hoist system on pusher side is provided for charging back the spillage coal during
leveling. The skip carries the coal into an overhead steel bunker of 10M3 capacity. The

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collected coal is then discharged into end bunker of the charging car. The skip hoist is
supplied complete with winch structures and electrics.
19. Service Platforms
Service platforms on pusher side and coke side consistof RCC slab supported over
columns. RCC have cast iron paving on pusher side. Coke side platform have CI lining.
Columns and beams on coke side are suitably designed to take load of coke guide car.
Pusher side and coke side service platform have provision for spillage conveyor.

20. Oven Machine Tracks

The tracks for all machines i.e. for pusher car, charging car and guide car are provided
for entire length of the battery.
Length of tracks beyond the battery region is such that one machine can be parked there
for servicing while another is catering to the end oven. All the tracks are provided with
necessary fasteners, buffers and all other accessories.
The tracks, rails, and necessary fittings conforms to Indian standards.. Pertinent data in
respect of machine tracks are as follows:Machine
tracks

Rail

Pusher Car
Charging Car

CR-100
60 kg/m

Center distance
between Rails
(mm)
12000
6820

Platform type
Guide Car

CR-100

7000

Wheel load
(max.)

Maximum
length (mm)

45 t
25 t
(without
coal)
25 t

15600
12900

17500

21. Oven Machines

The following machines are provided

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List of Coke oven Machines

Machines

Unit Qty.

Coke Pusher

Nos. 2

Coal Charging Car Nos. 2

Guide Car

Nos. 2

Coke Pusher machine, Coal Charging Car, and Guide Car are designed with hydraulic
drives. All machines have centralized lubrication system, desert duty a/c operators
cabins.
22. Coke Pusher
The Coke Pusher Machine is of single spot type.
The machine has hydraulic drives for all mechanisms, except for long travel, pusher
ram, leveler, VVVF drives for speed control is provided for long travel, pusher ram and
leveler drives.Leveler muff Mechanical frame cleaning mechanism.Decarbonising
equipment, Leveler coal spillage system, Centralized lubrication system, PLC
Operations.
23. Coal Charging Car
The coal charging car is designed for single spot operation of lid opening /closing and
screw feed charging of ovens.
The charging cars have the following features:
i.

Hydraulic mechanism is provided for operation of hopper gates, telescopic

discharge chutes and coal bin gates opening/closing mechanism.

ii.

The lid lifting mechanism is of magnetic type.

iii.

The speed control of charging car travel and screw feeder of coal charging
mechanism is VVVF type.

iv.

The machine is also be equipped with goose neck and stand pipe cleaning
mechanism.

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v.

Lid luting mixer (consisting of tank with stirrer driven by geared motor) is
installed on the charging car machine.

vi.

The operators cabin is desert duty air conditioned.

vii.

The machine is equipped with hydro jet goose cleaner

viii.

PLC operation.

24. Guide Car

The guide car machine is designed for one spot operations. It removes door and clean
the door frame in one spot operation and move and place the cage of the oven in that
same position. The machine has hydraulic drives for all mechanisms excepting the long
travel.The machine has the following additional features.
i.

Mechanical door cleaner installed in the machine

ii.

Mechanical frame cleaner Dust extraction system. Desert a/c operators cabin.
PLC operation

B) Coke oven Battery #11 Heating Section

1. Features of Battery Heating System
1

System

Underjet twin flue regenerative system

Medium of heating

CO Gas or Mixed Gas

No. of Ovens

74(37x2 blocks)

Number of heating Chambers

76(38x2 blocks)

Axial distance between flues in each 480 mm

heating chamber

No. of CO fuel main in cellar

4( one each in p/s and C/s, in both blocks)

No. of Mixed gas fuel mains in cellar

4( one each in p/s and C/s, in both blocks)

No. of Pre-heaters

2( one for each block)

Discharge of fuel main condensate

Pumped to GC Main

10

Reversing Machines

i. Hydraulically operated
ii. One for each block
iii. Five cylinders for operation, in each block, for:
a) one for CO Gas

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b) one for Mixed Gas
c) one for WHB disk operation
d)two for Air Flap Operation
11

Interlockings

i. Reversing machine comes into pause whenever

fuel gas supply pressure comes below 50mm WC
pressure.
ii. Rev. m/c comes to pause whenever draught
comes below 5 mm WC.

12

CO detectors in cellar

Continuous detectors at 12 locations in cellar ,

with alarm

13

CO gas circuit

As per sketch 1

14

Controlled Vertical Flues

8th (P/s) and 28th (C/s) with a gradient of 40 oC.

15

Vertical Temperature Gradient

50 oC

16

Hydraulic regime system

i. GC Main Type-U, bi-main

ii. Raw Gas Circuit as per sketch-1
iii. Tar removal from GC Main-hydrowashing.
iv. GCM Bleeders provided, two on each side in
each block to relieve gas when pressure exceeds a
set value.

Coke is obtained through destructive distillation of Coal. The heat required is supplied
by burning of Rich Coke Oven(Gas) or Mixed Gas in the heating chambers as per
availability. Rich Co gas is the supply gas from By Product Plant after extracting
valuable by-product chemicals (tar, naphthalene, ammonium sulphate , sulphur) from
Raw CO gas. Mixed gas is a mixture of cleaned blast Furnace and Rich Coke Oven gas
done in mixing Station to achieve the desired calorific value.

2. Gas Mains
There are two Rich Gas mains and two Mixed Gas mains in cellar to cater all the flues of
each Heating Wall. Each Gas Main has automatic pressure control by hydraulically operated
Butterfly Valves.Rich Gas Distribution to flues is done through rich gas distribution headers
and riser pipes. Connection is given to the distribution headers from Rich Gas main through
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pipeline through Isolation and Reversing Cocks.Mixed gas connection to the Waste Heat
Box is through the riser pipe from the Gas main and is provided with isolation and reversing
cocks.

3. Under Firing System

The Battery is having facilities to be heated with CO Gas or mixed Gas. Each Heating wall
comprises of 16 pairs of hair pin flues. The gas burns at the bottom of one half of each pair
of flues and the product of combustion travels up and pass on the other half of flues through
cross over duct.The Regenerators are placed under the heating walls and Oven Chambers.
Flow of Gas, air and Waste Gas is reserved at stipulated interval (usually 30 minutes) and is
achieved by means of Hydraulic Reversing Machine.The supply of CO gas is provided
through gas mains in cellar floor of the battery. The gas is pre-heated in Stream heater
before distribution. The gas raises through the brick nozzles and join the preheated air at the
base of the flue for combustion. Half of the number of regenerators is on the air and other
half operators on waste gas during a cycle.

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4. Reversing Machine
Hydraulic Reversing system is provided for the reversals. The system consists of Reversing
Machine (operated by hydraulic cylinder), Power Pack and accumulator Units. Power pack
consists of pumps, storage, filtering and distribution of hydraulic oil. Accumulators are
provided to take care of Emergency operations. Sensors for identification of failure of the
reversing machine are provided.

5. Water Gas Tunnel

Battery is provided with underground Waste gas Tunnels on both Pusher and Coke Sides.
Cross section of tunnel is designed for an accumulated coking time of 16 hours. The tunnels
are connected to the Chimney, via a common tunnel. Tunnels are resistant to water seepage.
6. Chimney

Chimney provides natural draught for the waste gas generated. It I a 120 m tall concrete
structure lined with fire clay and insulation bricks. The chimney is 8.56 m wide at the
bottom, while it is 4.86 m at the top.
Chimney draught for the battery is automatically controlled from the control room by
hydraulic regulator and butterfly valves. Waste gas analyzer installed inside the chimney
provides data on continuous basis. Proper functioning of Waste Heat boxes and heating
parameters ensures that the waste gas at chimney is within statutory norms.

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C) Coal Route
Coking Coal received in COB#11 by railway wagons is unloaded in wagon tippler no. 3. In
case of emergency Wagon tippler no. 2 under RMHS can be used to unload these coal
wagons.
Coking coal is mainly received from Australia for Hard and soft variety, USA for Hard
variety and indigenous coal from Chasnala. The designed blend for COB#11 is as follows:-

Type

%age

Ash

VM

Australia (Hard)

55%

8-10%

23-24%

USA (hard)

15%

8-10%

27-28%

Australia (Soft)

10%

8-10%

27-28%

Chasnala

20%

18-20%

22-23%

1. Function of Coal Handling Plant

Its function is to receive coal and store it in coal piles. From coal piles coal is reclaimed and
sent to coal silos. From coal silos, coal is blended in proper proportion and the
crushed/pulverized coal is finally sent to coal tower for making it available for charging in
battery.
Coal Handling Plant (CHP) in COB#11 has two major functions:
a. Coal Storage
b. Blend Preparation
In CHP coal received by the rail wagons are stored in yards. In case of emergency it can be
sent to the coal silos (blending bunkers) directly.
In CHP Blend Preparation is done by mixing of different coal in proper proportions and
crushing it into required size after blending.
2. Coal Storage
Wagon Tippler No. 3 is for tippling of coal wagons for tippling. There are 2 belt feeders
(WT-3BFA and WT-3BFB) under the wagon tippler which feeds the coal on the belts for
further transfer. Speed of belt feeders can be adjusted so as to control the material flow on
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the belt. Weigh Feeders feeds the coal to C1C1 or its alternate belt C1C2 using Diverter
Gate. C1C1 and C1C2 are parallel belts which run from Wagon tippler to C1 Junction
House (C1JH). Both the belts have Electro Magnetic Separator (EMS) to remove any
metallic component coming with the coal. In C1JH, C1C1 belt has Auto Sampling Unit
(ASU) which automatically collects sample from the belt and stores it in its bin for
collection. C1C2 on the other hand has Sample Cutter (SC) which cuts the sample on the
belt and gives the chance to collect the sample if the feeding is still in progress. C1C1 and
C1C2 belt feeds the coal to C1RSCA and C1RSCB respectively. C1RSCA and C1RSCB are
reversible shuttle conveyor i.e. it can run in both the direction. These belts can feed four
belts C2C1, C2C2, C7C1 and C7C2. C2C1/C2C2 takes coal to the beds and C7C1/C7C2
takes coal into the blending bunkers (will be discussed later). C2C1 and C2C2 are both
parallel belts and run from C1JH to C2JH. Here C2C1 can feed coal to CST-1 or C3C1
using diverter gate and C2C2 can feed coal to CST-1 or C3C2 using diverter gate. CST-1
belt takes coal to Stacker no. 410 which can stack coal to bed no.1 or bed no.2. C3C1 and
C3C2 are parallel belts running from C2JH to C3JH which feed coal to same belt CST-2.
CST-2 belt takes coal to stacker no. 409 which can stack coal to bed no.3 or bed no. 4.
While if C1RSCA/C1RSCB feeds coal to belt C7C1/C7C2, these belts take coal to C7JH.
C7C1 and C7C2 belts run parallel from C1JH to C7JH and can feed material to C8C1 which
is the belt for coal dust injection (CDI) (will be discussed later in CDI route) or to belt
YJH1C1 which runs from C7JH to YJH1JH. YJH1C1 belt can feed material to Y1 belt or
Y2 belt. Y1 belt is a small belt to change the direction of belt from Y2 which feed material
to Y2A belt. Y2 belt and Y2A belt run parallel to each other and finally stores coal in
Blending Bunkers using Travelling Trippers. Y2 belt has TT1 (Travelling Tripper 1) which
can store coal in silo no. 1, 2, 3, 4, 5, 11, and Y2A belt has TT2 which can store coal in silo
no. 6, 7, 8, 9, 10, and 12. There are a total of 12 silos or blending bunkers with each of
storage capacity of 1250T.
Coal stacked on beds can be reclaimed selectively by reclaimers. 3 Reclaimers are provided
with Reclaimer No. 416 for Bed No. 4, Reclaimer No. 417 for Bed No. 3 & 2 and Reclaimer
No. 418 for Bed No. 1. Reclaimer No. 416 feeds coal to C6C1 belt which run s to C6JH and
feeds coal to C7C1/C7C2 using diverter gate and the same process for Reclaimer No. 417

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and C5C1 belt and Reclaimer No. 418 and C4C1 belt. C7C1/C7C2 belt takes coal to
Blending Bunkers as discussed earlier.
There is also a provision of coal dust injection (CDI) in Blast furnace, thus to supply Coal to
BF from Bed No. 1 using Reclaimer No. 418. However as discussed earlier C8C1 belt
starting from C7JH runs to C8JH and used for carrying CDI Coal only. At C8JH, C8C1
feeds material to CDIC1 belt which takes CDI Coal to CDI Bunkers of Blast Furnace.
3. CHP Blend Preparation
All the 12 Blending bunkers are fitted with a weigh feeders of capacity of feeding max.
150TPH of coal each, except feeders of bunker no. 11 and 12, they have capacity of 50TPH.
The tonnage of coal flow from these feeders can be adjusted, the purpose is to supply
desired/designated coal in prefixed quantity in the blend. These feeders feed coal to belt Y3
and Y3A which run parallel to YJH3JH. Y3/Y3A belt feed coal to Y4 belt which runs from
YJH3JH to YJH4JH. Y4 belt also has one EMS3 (Electro Magnetic Separator No. 3) so that
if any metal piece that might have come in the belt from bunkers is removed from the belt.
Y4 feeds coal to Y5 belt which runs from YJH4JH to Coal Crushing station. Y5 belt also
has ILMS1 (In Line Magnetic Separator) placed at its driver end pulley. ILMS removes any
small metal piece that may have not been removed by EMS. Y5 belt feeds coal to HammerMill Bunker. Purpose of hammer-mill bunker is not only to store coal but also to feed coal
to hammer-mill crushers. All the coal in hammer mill is to be crushed to a crushing index of
80-84% <3.2mm.Three nos. of RPG (rack and pinion gate) one for each crusher, is provided
at the discharge point of the bunker. RPG opens only when crusher has started running.
Three nos. of VF (Vibro-feeder) one for each crusher is provided after RPG to maintain
uniform flow of coal into the crushers. There are three nos. of Hammer Crushers in
COB#11, which crushes the coal by the impact of hammers to desired fineness and prepares
a homogeneous blend of different type of coal. Two nos. of Hammer Crusher remain
operational at a time and one is kept stand-by. 80-83% of coal less than 3.2mm in size is
desired for charging in coke oven. After crushing coal, Hammer Crushers feed the blended
coal to Y6 belt which runs from coal crushing station to YJH4AJH. A water sprinkler line is
provided in Y6 belt to maintain moisture level in the blend at 7-8% which is desired for
charging in battery. Y6 belt also has a metal detector (MD), so if a metal piece comes on the
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belt; it immediately stops the belt giving a chance to remove the piece before charging in
battery. Y6 belt feeds blend coal to Y10, which runs to YJH5JH. An Auto Sampling Unit
(ASU) is provided on Y10 belt which automatically collects the sample and stores it for
collection. Y10 feeds coal to Y11 belt which takes coal to Coal-Tower. Y11 belt can feed
coal to belts Y12 and Y13 belt using a diverter gate. Y12 and Y13 are reversible shuttle
conveyor which can feed four sets of bunkers in coal tower. Thus both the belts can feed
coal tower having a capacity of 4000T blend and crushed coal.

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4. Major equipment & installation in Coal Handling Plant of COB#11:

Sl. No.

Name of equipment

Nos. Installed/ Capacity

1.

Conveyor Belts

44

2.

Belt Weigh Scale

10

3.

Belt Weigh Feeder

12

4.

Belt Feeder

5.

Electro Magnetic Separator

6.

Diverter Gates

11

7.

In Line Magnetic Separator

8.

Auto Sampling Unit

9.

Sample Cutter

10.

Metal Detector

11.

Reversible Shuttle conveyor

12.

Bucket Wheel Reclaimer (Nos.)

13.

Bucket Wheel Reclaimer (Capacity)

14.

Stacker (Nos.)

15.

Stacker (Capacity)

16.

High Tension Motor

17.

Travelling Trippers

18.

Rack and Pinion Gate

19.

Vibro-Feeder

20.

Hammer-mill Crushers

21.

Coal Storage Yard (Nos.)

22.

Coal Storage Yard (Capacity)

23.

Coal Storage Silos

24.

Coal Storage Silos (Capacity)

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2
1400TPH

1.6LAKH T
12
15000T

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25.

Coal Tower (Capacity)

4000T

5. Conveyor Belts Installed in Coal Handling Plant

Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Name of Belt/Belts
WT-3BFA/ WT-3BFB
C1C1/ C1C2
C1RSCA/ C1RSCB
C2C1/ C2C2
C3C1/ C3C2
CST-1
CST-2
C4C1
C5C1
C6C1
C7C1/C7C2
C8C1
CDIC1
YJH1C1
Y1
Y2
Y2A
Y3/Y3A
Y4
Y5
Y6
Y10
Y11
Y12/Y13

Capacity(TPH)

Width(mm)

Length(m)*

1400
1400
1400
1400
1400
1400
1400
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600

2000
1600
1800
1600
1600
1600
1600
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1400

5.5
447.3
9.2
80.9
84.9
379.9
379.9
392.8
392.8
392.8
389.4
309.4
110.0
237.7
12.3
102.1
100.4
120.2
89.1
84.4
151.2
189.1
82.0
9.5

Length given is the distance between centre of driver and driven pulley.

C) Coke Sorting Plant

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Coke Sorting Plant is of 250TPH capacity and will handle coke from COB11 and COB10.
Thecoke sorting plant sorts out the coke into four fractions e.g. 60-80 mm, 30-60 mm, 15-30
mm and0-15 mm.
1. Coke De-dusting Unit
Coke from Coke Dry Cooling Plant is transported to Coke Dedusting Unit byconveyors K-1
& K-2. Below Surge hoppers 2 numbers of Rack & Pinion gates RPG-1 & RPG-2are
provided to control the flow and 2 nos. of Diverter gates DG-12 & DG-13 are provided
todivert the material either to conveyor K3 or K4. Coke from conveyor K3 & K4 is fed
intoDedusting chutes from where the dedusted Coke is conveyed to Coke Crushing Station
byconveyors K5 & K6.

2. Coke Crushing Station

Inside Coke Crushing Station, two Inline magnetic separators ILMS-2 & ILMS-3 are
providedover the conveyors K5 & K6 at their discharge end separating the metallic
materials from thecoke flow, just before Coke gets discharged over to Roller Screens RS1 &
RS2 of capacity 250TPH. Roller screen separate the Coke of size (-)80 mm and the oversize
Coke is fed into Doubleroll crushers CR1 & CR2 of 200 TPH and crushed to the size of ()
80 mm. Below the Screensand Crushers, Coke of size () 80 mm is carried by shuttle
conveyors K7 & K8 which can bepositioned in such a way that they can either feed to
conveyor K9 or K10.

3. Coke Screening Station

The Coke from Coke Crushing Station is transported to Coke screening station by
conveyors K9& K10. In Coke screening station coke carried by conveyor K9 & K10 (-) 80
mm coke fractionis fed over to 30 mm Roller screens RS3 & RS4 of capacity 300 TPH each
where (-) 30 mmfraction is screened and the oversize fraction is fed to 60 mm Roller screens
RS5 & RS6 ofcapacity 250 TPH each. In Coke screening station (80-60 mm) Coke fraction
is collected overconveyor K11 and conveyed to Reversible conveyor P1RCA at Junction
House P1, similarly(60-30 mm) Coke fraction is collected over to conveyor K12 and
conveyed to another Reversibleconveyor P1RCB at Junction House P1.

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Coke fed on the Reversible conveyor P1RCA & P1RCB can either be fed to
conveyorJ9BC1/J9BC2 in Junction House P1. These conveyor J9BC1 & J9BC2 can either
convey thecoke directly to J9B building or deposit coke on Emergency Coke storage area
with the help ofMobile trippers (TT-3 & TT-4) provided over conveyor J9BC1 &
J9BC2.Presently J9BC1 isbeing used to convey material to Coke loading station (CLS) and
J9BC2 to emergency coke yard(ECY).From emergency coke storage, coke can be fed to
J9BC3 by pay loader through 3 groundhoppers GH1, GH2 & GH3.

In J9B, conveyor J9BC1 feeds coke to J10C1, J9BC2 feeds coke to J10C2 and conveyor
J9BC3can either feed to J10C1 or J10C2 by positioning diverter gate DG-17 provided
below conveyorJ9BC3. From J9B, coke will be transported to Blast furnace via Junction
House J10 byconveyors KC5 & KC6 where J10C1 will feed to KC5 & J10C2 will feed to
KC6.However dueto delay in blast furnace operation two additional conveyors KC7 & KRC
were installed after1conveyor KC5 so as to store coke into two bunkers of 400 Tons
capacity each. Wagon loadingarrangement has been made to transport this stored BF coke to
sister plants.

In Coke screening station, (-) 30 mm Coke fraction will be collected over conveyor K13
fromRS3 & RS4 and transported to Junction House P2. In Junction House P2, the conveyor
K-13discharges coke to conveyor K-14. Conveyor K-14 transports the Coke to Reversible
conveyorK-15 which in turn feeds over to 15mm Vibrating screens (VS1 & VS2 of capacity
150 TPH)through vibro feeders VF-8 and VF-9. Screened coke i.e.0-15 mm and 15-30 mm
fractions willbe filled into two separate bunkers. Each bunker is provided with twin outlets
at the bottom suchthat 1 opening will be operated with Rack & Pinion gate and other with
Sector gate (SG-1 & SG-2). Below the Rack & Pinion gates (RPG-3 & RPG-4) vibro
feeders (VF-10 &VF-11 of capacity200 TPH) are provided to feed the coke to conveyor
P3C1 which in turn discharges to JNT1C1at Junction House P3.The bunker having sector
gate opening can be emptied out usingtipper/dumper, this coke is transported to back shunt
yard.

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From existing COB-10, coke will be transported to existing Screen House by conveyor KC2over which Metal detector MD2 is provided to detect the metallic materials in the Coke
flow.From existing screen house the coke will be transported to Junction House KTP1 by
conveyorKC-3 from where it will be discharged to conveyor KC-4 which in turn convey the
Coke to Newcoke crusher house and feeds over to a 80mm Roller screen (RS7). The
oversize coke fractionwill be fed into a Double roll crusher CR3 so that it can be crushed to
(-) 80 mm and will befilled into bunker of capacity 25 m3 below which 1 no. Rod gate RD21 & 1 no. Vibro feederVF-5 shall be provided. Vibro feeder VF-5 will feed the coke to a
Pipe conveyor of cap 200 TPHwhich convey the coke from New coke crusher house to CP3
building , which in turn fill abunker below which 1 no. Rod gate (RD-22) and 1 no. vibro
feeder VF-6 shall be provided toconvey the coke to Junction House KP1 by conveyor
KP1C1. In Junction House KP1 conveyorKP1C1 will feed the coke to KP2C1 which will be
conveyed to Junction House KP3 byconveyor KP3C1 via Junction House KP2. At Junction
House KP3 the conveyor KP3C1discharges the Coke to KP4C1 which in turn fills a RCC
coke bunker of 100 tonne storagecapacity with twin out lets shall be provided over the
conveyors K-9 & K-10 for storing cokecoming from the existing coke plant. Each outlet
will be provided with a Rod gates (RD-16 &RD-17) and a 100 TPH capacity belt weigh to
feed conveyors K9 &K-10.

4. Dust Extraction system is provided in the coke de-dusting unit (CDU). The system
comprises of dust extraction air blasting unit, suction hoods on the coke de-dusting chute,
ducting network, electrically operated dampers, bag filter unit, centrifugal fans, stack
electrics & control. One spark arrestor & one multi-cyclone are provided in the ducting
network at the inlet side of distribution chamber of bag filter unit. Spark arrestor prevents
smoldering particle from entering into bag filter while cyclone separator collects coarser
coke particles thereby preventing them from entering into bag filter. Bag filter unit consists
of distribution chamber, filtering chamber with filter bags & fitting for the bags, outlet
chamber, dust collection hopper with rotary air lock valves & dust storage cum disposal
hopper with rack & pinion gate and disposal chute, structural stair case and platform, timers
etc. Two suction ducts of the ducting network are provided with electrically operated
dampers and manually operated dampers are provided at ducts above conveyor K1 to K6.
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While running the CDU, air blasting unit fan sucks ambient air through air intake louver
&transition piece and blast/supply the air into the CDU through the ducting network. The
dustdisposal from bag filter, multi-cyclone& spark arrestor is through discharge into a
centralpneumatic system (through dust storage hopper).

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D) By-Product Plant in COB # 11 Complex
The objective of By-product plant in COB # 11 is to clean the raw coke oven gas generated
from coke oven battery with removal of impurities like tar, ammonia, hydrogen sulphide
and naphthalene to the extent as it can be effectively used as fuel.The impurities thus
removed from the system are separated in the form of saleable products viz. Crude Coal Tar,
Ammonium Sulphate, Sulphur (99% pure) & Naphthalene. The coke oven gas is available
at 300C at the outlet of byproduct plant.

The By-product plant consists of following Technological Units.

1. Gas condensation/ Tar separation Plant
2. Gravel Filter Unit.
3. Stripper De- acidifier Unit
4. Ammonia Scrubber & Ammonium Sulphate Plant
5. H2S Scrubber&Elemental Sulphur Plant.
6. Naphthalene Scrubber & recovery unit.
7. Storage
a. Raw Material /catalyst Storage for
i.

Sulphuric Acid

ii.

Solar Oil

iii.

Caustic

iv.

Catalyst

b. Finish Product Storage for

i.

Coal Tar

ii.

Ammonium Sulphate

iii.

Naphthalene

iv.

Sulphur

The By-product plant is equipped with adequate flexibility from the point of view of
design, operation and maintenance. Adequate standby facilities are ensuredfor
uninterrupted and smooth operation of the plant.
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NH3- Flushing Liquor

Coke Oven
Battery
Gas + Liquor

PGC
(2W + 1S)

Co
nd
en
sat
e

H2S Scrubber (1W)

NH3 Scrubber (1W)

Gravel Filter Plant

(1W+1S)

De-acidifier
(1W+1S)
De-acidified
Water

142

C. O Gas
(To Network)

Vapour
Co
al
W
at
er

Ammonium Sulphate Plant (1W

+ 1S)

Combined Stripper
(1W+1S)

Enriched
Water
Stripped
Water

St
ea
m

Ca
ust
ic
So
da

Enriched Wash Oil

AMMONIUM SULPHATE

Elementary Sulphur Plant (1 W)

ELEMENTAL SULPHUR
Tail Gas to
PGC
Effluent Water to BOD

Stripped Wash Oil

Naphthalene Scrubber
(1W)

Tar Storage/ Loading

Station (1W+1S)
CRUDE COAL TAR

ETP
(1W+1S)

Gas Exhauster
(1W+1S)

Excess
Coal Water

Tar Separation Plant

(1W+1S)

Down comer
Gas

NH3/Coal Water
Storage (1W)

Naphthalene Recovery
Plant (1W)

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NAPHTHALENE

Coke Ovens

1. Gas Condensation Plant, Tar Separation Plant & Gravel Filter

a. Coke Oven Gas Circuit
Coke Oven Gas (COG) generated from battery gets separated from tar & liquor in
down comer and is sucked by the exhauster through Primary Gas Cooler (PGC)&
Electrostatic Tar Precipitator (E.T.P.). In primary gas cooler, gas is cooled
indirectlyfirst by cooling water followed by chilled water to 20 to 22Deg C from about
82 0C (saturated).The primary gas coolers have tubes horizontally placed with certain
inclination in a rectangular vertical box. The Coke Oven Gas flows in the shell side
and cooling water/chilled water flow in the tube side of PGC.Most of the tar-liquor
condensate is separated from C.O.Gas in the PGCs.

Cooling tower & chilled water plant have been installed for catering the requirement
of primary gas cooler and Heat-exchangers of other units. The chilled water plant is
housed in a separate room. Cooling tower & chilled water plant have standby
provision.System of hot tar-liquor emulsion flushingis there for each PGC for removal
of naphthalene deposit on outside of water tubes. Arrangement of LP steam &
Nitrogen purging to PGC are also made.
b. Electrostatic Tar Precipitator
Electrostatic Tar Precipitators (E.T.P.) is required to remove the remaining tar fog of gas
& the same installed before exhauster. Arrangement for removal of deposited tar in the
ETP tubes is provided. Insulator boxes are provided with electrical heating arrangement.
Inert atmosphere by allowing N2 flow in Insulator boxes is to be maintained
c. Exhauster
Electric Motor driven exhauster sucks the coke oven gas leaving ETP and discharge the
same with a positive head. The discharge head shall be worked out depending upon the
pressure drops in the downstream equipment and desired pressure (700 mm to 1000
mmWG) of CO Gas at the Battery Limit of By-Product. The temperature of CO Gas at

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the discharge of exhauster should be kept minimum. Suction requirement for upstream
of exhauster upto battery is 500 mm WG (indicative).
d. Tar &Ammoniacal Liquor Circuit
The coke oven gas in Gas collecting main is cooled to 820C by spraying
flushing/Ammoniacal liquor. The Ammoniacal Liquor flows in a closed cycle from
down comer to Solid Decanter; to Tar Decanter, Coal water tank and then back to Gas
collecting main via Ammoniacal/flushing liquor pump. Part of coal water is used for
HPLA system in battery. Excess coal water is sent to Ammonia stripper via Gravel filter.

Major portion of tar content in Coke oven gas is condensed in Gas main by flushing
liquor/ Ammoniacal liquor. The tar together with flushing liquor, gas condensate and
coal fines from coke oven flowing through gas collecting main goes to solid decanter.
The coal fines mixed with tar & flushing liquor is known as sludge. The solid decanter
serves to separate sludge from Ammoniacal liquor and tar by settling. Sludge being
heavier, settle at the bottom of solid decanter and sludge is continuously scrapped off by
scrapping conveyors into barrel/ trolley from where it is removed by a dumper/truck.
The Ammoniacal liquor and tar from the decanter overflows into tar decanter. The
Ammoniacal liquor from tar decanter goes to gas mains of battery. Part of this liquor is
used for HPLA system also. Surplus Ammoniacal liquor is generated due to moisture
present in the coal. This excess Ammoniacal liquor is sent to Ammonia stripper via
Gravel Filter.The tar from the tar decanter flows continuously to the Tar Storage Tank
for dispatch.
e. Major Technological Equipment/Facilities for Gas Condensation Plant
This plant comprises of the following major technological equipment

144

Equipment
Primary Gas Cooler

2W+1S

Exhauster (650 Kw, 6.6 KV)

Decanter

1W+1S
1W+1S

Capacity
24000 Nm3/Hr
for Each PGC
47500 Nm3/Hr

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Flushing Liquor Pumps
2W+1S
E.T.P
1W+1S
Centrifugal Pumps for transferring tar, 1 W + 1 S
liquor etc
Tar Storage Tanks
1W+1S
Cooling Tower
2W+1S
Cooling Water Pump
4W+3S
Chilled Water Plant
2W+1S
Chilled Water Pump
1W+1S
Gravel Filter
1W+1S
Heat Exchanger

525 Nm3/Hr
47500 Nm3/Hr

1600 M3

To prevent gaseous emission from various vessels, tanks equipment & vents, a suitable
pollution control measures are taken.

2. Ammonia & H2s Removal and Recovery Section

a. Ammonia & H2S Scrubbing Unit

Coke oven gas which is pressurized by Exhauster is sent to the inlet of the H2S
scrubber. The lower section of H2S Scrubber is designed for final cooling stage to
remove the temperature increased in exhauster. By means of a cooling loop
comprising of cooling stage pumps & cooling Heat Exchanger in which circulating
liquor is cooled by chilled water& the gas is cooled to a temperature of 20-220C.
The upper section of H2S scrubber is used to absorb the major amount of H2S. The
absorption of H2S is performed by using NH3 which is included in the Coke Oven
inlet Gas and which is offered additionally by feeding of ammonia rich solution from
ammonia scrubber & lean solution from Deacidifier.

As the absorption of NH3/ H2S is exothermic in nature, the temperature of the

outgoing gas is not allowed to increase by means of cooling heat exchanger. Further
removal of H2S and removal of major portion of NH3is achieved in NH3 scrubbing
system by means of stripped ammonia liquor.
b. Ammonia stripping & Deacidification Unit
The stripping columns is divided into two parts, free ammonia stripping process takes
place in upper part and in the lower part decomposition of fixed ammonia takes place
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by means of caustic solution. The upper part of the column receives the deacidified
solution from deacidifier & coal water (excess flushing liquor) from gravel filter unit
after pre heated by outlet liquor of column. The stripped off NH3 enter the deacidifier.
The deacidifier strips off NH3, H2S, CO2, HCN from the rich solution received from
H2S scrubber. These vapours from the deacidifier shall enter to the Ammonium
Sulphate plant after proper cooling.
c. Ammonium Sulphate production through Bubbler type saturator route
Ammonia, Hydrogen sulphide gas, CO2& HCN from deacidifier is led to Saturator
where Ammonia is recovered in the form of Ammonium sulphate. Ammonia and H2S
enters in saturator from top and bubbles through a bath of mother liquor where a
constant acidity is maintained by continuous addition of sulphuric acid. Sulphuric
acid is stored in separate storage tanks. The sulphuric acid is fed to the saturators by
gravity from overhead tank. Sulphuric acid is pumped to the overhead tank from
ground level storage tank. The mother liquor is kept under constant circulation by
centrifugal pumps to maintain uniform bath acidity and obtain uniform well
developed crystals from the Saturator. From the Saturator the Hydrogen sulphide with
HCN & CO2 enters the acid catcher, where the liquor droplets entrained in gas is
removed.

Ammonium sulphate crystals produced in the Saturator isejected out together with
mother liquor to the crystal receiving tank. Ammonium sulphate slurry flows from
crystal receiving tank by gravity to the centrifuge continuously for the separation of
mother liquor and salt. Ammonium sulphate from the centrifuge is conveyed by belt
conveyors to the dryer. Drying of ammonium sulphate is carried out in a stainless
steel rotary drier by means of hot air operating with steam and through forced draft
fans. From the drier, spent hot air with entrained dust particles is extracted by suction
fan through cyclone separator and wet scrubbing unit to remove the fine ammonium
sulphate salt before venting to atmosphere. Ammonium sulphate is transferred to the
bagging bunker by a bucket elevator. Dried ammonium sulphate is bagged, weighed
in automatic bagging and weighing machine and then sent to storage or dispatched by
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rail and road. The provision for both railway wagon loading and road truck loading
are kept. Mechanized system for loading of bags is provided.

The Saturator, acid catcher and mother liquor tanks is of special steel alloy as per
DIN 1.4465 or similar in order to resist corrosion. All process pumps are of Alloy-20
construction.
d. Sulphur Recovery Unit
H2S/HCN/CO2vapor coming from drop separator (acid catcher) of saturator enters to
Catalytic Oven Reactor for burning.
The operation of the cracking reactor is characterized by partial burning of sour gas
with air to provide the required temperature for the catalytic cracking stage. Most of
the nitrogen compounds are burnt and reduced to elemental nitrogen and passes the
catalyst bed to crack the remaining ammonia and hydrogen cyanide.

Process gas leaving the catalytical area is post-burnt by providing secondary air, so
that the required ratio of SO2/ H2S is adjusted before the gas is cooled in the waste
heat boiler system (Process Gas Cooler). At the same time the first portion of
elementary sulphur is generated, which is separated in the outlet area of the boiler.
The boiler is used to cool the process gas down to 250 to 2800C. A partial flow is
taken between the Crack-Reactor and the boiler and mixed with the outlet of the LP
boiler to obtain the correct inlet temperature for the Claus reactor. The boiler is
equipped with an internal sulphur separator, where the liquid sulphur that has been
built, is separated from the process gas.

The process gas leaving the boilers is directed to the first of two claus reactors. Both
reactors are filled with alumina based catalyst. The conversion of sulphur dioxide and
hydrogen sulphide to sulphur takes place by the selected temperature of 2500C.

As the Claus reaction is of exothermic natures, the process gas is cooled after the 1st
Claus reactor stage in the Sulphur Condenser, followed by a sulphur separator and
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directed to the 2nd claus reactor stage. Before the process gas is led into the 2nd claus
reactor stage, it is re-heated to enter the claus reactor with the required temperature.
The process gas, leaving the 2nd Claus reactor stage is also cooled in the sulphur
condenser, released from liquid sulphur in the 2nd sulphur separator and directed as
tail gas to the crude gas main ahead of the primary coolers. By this mode of operation
the combined process is free from emissions.

The following reactions take place during the process.

NH3 + O2 (N2) + H2O
HCN + O2 (N2) + H2O + CO2
H2S + O2 SO2 + H2O
NH3 N2 + (H2)
HCN + H2O N2 + (H2) + (CO)
H2S + O2 SO2 + H2O + 519 KJ
2H2S + SO2 3/x Sx + 2H2O + 147 KJ
H2S + O2 SO2 + H2O + 519 KJ
2H2S + SO2 3/x Sx + 2H2O + 147 KJ
The produced liquid sulphur from the boiler, the sulphur condenser and the two
sulphur separators is led via a sealing pot to a storage tank to process further for
producing Sulphur blocks.

e. Major Technological Equipment/Facilities

Equipment

Capacity

NH3 and H2S Scrubbing Unit

H2S Scrubber

1W

47500

Nm3/Hr

Gas Processing
NH3 Scrubber

1W

47500 Nm3/HrGas
Processing

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Enriched water Pumps

1W+1S

Pre Enriched Water Pumps

1W+1S

Internal Cooling Pump

1W+1S

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Final Cooling Pump

1W+1S

Enriched water Tank

2W

Heat Exchangers

6W+3S
Ammonia stripping & Deacidification Unit

De acidifiers

1W + 1 S

Combined Stripper

1W + 1 S

Deacidifier Discharge pumps

1W + 1 S

Stripper Discharge Pumps

1W + 1 S

Stripped water Tank

1W

Stripper water pump

1W+1S

Deacidfier Water Tank

1W

Deacidifier Water Pumps

1W+1S

Stripped waste Water Tank

1W

Stripped waste water pumps

1W + 1 S

Heat Exchangers

8W+8S

Ammonia Recovery Plant

Saturator with acid Catcher

1W + 1 S

Thickener

1W

Centrifuge

1W + 1 S

Sal conveyor system

1W

Bagging system

1W

Mother liquor pumps

1W + 1 S

Wet Scrubbing system

1W

Seal pot

1W
Sulphur Recovery Unit

Catalytic Oven Reactor

1W

Claus reactors

2W

Process Gas Cooler

1W

Sulphur Condenser

1W

Process Gas Heater

1W

COG Blower

1W + 1 S

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Air Blower

1W + 1 S

Vapor Blower

1W + 1 S

Sulphur Storage Tank

1W

Sulphur Drain Pumps

1W + 1 S

Sulphur Solidification Unit

3. Naphthalene Recovery And Removal Section

a. Naphthalene Scrubber
The Coke oven gas from H2S and NH3 scrubbers is taken to Naphthalene scrubber for
naphthalene recovery to the extent of 0.05 gm/Nm3max. Most part of Naphthalene in
CO gas is separated out with tar in Hydraulic mains of coke oven battery, Primary Gas
Cooler and the remaining portion in Naphthalene scrubber. The scrubber is packed with
suitable expanded metal packing to provide larger surface area. A measured quantity of
makeup solar oil is added to fresh oil tank and proportionate quantity of Naphthalene
rich solar oil is removed from the bottom section of scrubber to storage tank. Rich solar
oil is sent to Naphthalene stripping section for recovery of naphthalene by steam
stripping and to get lean solar oil for further use in scrubber.
b. Naphthalene Stripping
A portion of Naphthalene rich solar oil is discharged continuously from the scrubbing
unit to storage buffer tank. The rich solar oil is fed continuously to the Naphthalene
Stripper. The Naphthalene rich solar oil fed to the Naphthalene stripper where
naphthalene is stripped off by steam. Almost naphthalene free solar oil is taken out from
stripping column for reuse in Naphthalene scrubber after proper cooling.

The vapour coming out from Naphthalene stripper contains Naphthalene with oil &
water vapour which is condensed in water cooled condenser. Naphthalene rich oil
getting separated from water in a separator is allowed to cool in water jacketed
Naphthalene tray. Naphthalene crystallises by indirect cooling. The oil content in the

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Naphthalene is 1 % max. Contaminated water from separator goes back to tar separator
unit.
c. Major Technological Equipment/Facilities Naphthalene Scrubbing unit)
Equipment

Capacity
Naphthalene Scrubber

Naphthalene Scrubber

1W

47500

Nm3/Hr

Gas Processing
Solar Oil Circulation Pumps

4W

Enriched Solar Oil Tank

1W

Enriched Solar Oil Pump

1W+1S

Stripped Solar Oil tank

1W

Stripped Solar Oil Pump

1W+1S

Fresh Solar Oil Tank

1W

Heat Exchanger

1W
Naphthalene stripping Unit

Stripper

1W

Wash Oil Stripper

1W

Condenser

1W

Separator

1W

Heat Exchanger

2W+2S

d. Technological Parameters
i.

Coke Oven Gas Processing Capacity: 47460 Nm3/hr (Indicative) Including

Charging gas and Tail Gas

ii.

Design Basis: Following overload factors have been considered:

1. Gas Condensation unit consisting of PGC, ETP have 1.15 times of

gas

Processing Capacity.
2. Exhauster Have 1.15 times of gas Processing Capacity.
3. Other units of by-product plant like H2S, NH3& Naphthalene Scrubber have
1.07 times of gas Processing Capacity.
4. Gas Velocity in gas line is 16 to 20 m/sec.

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iii.

Raw Coke Oven Gas temperature at inlet of PGC: 82 0C Max.

iv.

Raw Coke Oven Gas Composition & Impurities at the inlet of By-Product Plant
(Indicative):

1. Composition of Raw Coke Oven Gas (% by Volume):

Hydrogen

52-59

Carbon monoxide

6-7

Carbon dioxide

3-4

Oxygen

0.3-0.7

Methane

24-28

Nitrogen

4-7

CnHm

1.5-2.5

2. Impurities of Raw Coke Oven Gas (gm/Nm3):

Tar

100-120

Benzol Hydrocarbons

30-36

Hydrogen Sulphide

3-4

Ammonia

10-12

Naphthalene

8-10

3. Impurities in clean Coke Oven Gas (At the outlet of By-Product plant)
Residual Impurities

gm/Nm3

Tar

0.02 (Max.)

Hydrogen Sulphide

0.80 (Max.)

Ammonia

0.03 (Max.)

Naphthalene

0.05 (Max.)

Benzol Hydrocarbons

28-34

4. Quality of flushing Liquor supplied to Coke Oven Battery.

pH
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Suspended Solids

<100 ppm

Pressure

5-6 kg/cm2

Temperature

80-82

5. Yield of Finished Products:

Crude Tar

33.83 kg/TDC

Ammonium Sulphate

15.04 kg/TDC

Elementary Sulphur

1.05 kg/TDC

Naphthalene

0.11g/TDC

6. Quality of Finished Product:

Crude Tar:
Moisture Content,

Less than 4 % (Max)

Specific gravity at 40 0C

1.18

Ammonium Sulphate

As Per IS 826

Sulphur

99 % Purity

Naphthalene

Purity of Naphthalene (Min.Oil Content)

7. Chemical Consumptions:
Sulpuric Acid

1.55 T/Hr

Solar Oil or Wash Oil

49 Kg/hr

Caustic Soda

415 Kg/hr

E) BOD Plant of COB # 11complex

Effluents generated from the Coke Oven and By Product Plant of COB # 11 Complex are treated at
BOD Plant for removal of Ammonia, Phenol, Tar & Oil, Cyanide etc. Treated effluents discharged
into the Reservoir No 2 for internal re-circulation and re-use.

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1. Basic Principle Of The BOD Plant:
a. Physical Treatment
b. Chemical Treatment
c. Biological Treatment
(Three Stage Biological System 1st Stage Activated Sludge Process, Followed by
Nitrification and De-Nitrification Processes)

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BOD Plant Flow Diagram

EFFLEUNT

SKIMMED
TAR/OILTar
+ LiquorSKIMMED TAR &

TAR/OIL
SEPARATION TANK

SKIMMED TAR & OIL TO

SLOP OIL TANK

OIL SUMP

EQUALISATION TANK
WITH SKIMMER

NaOH

DISSOLVED AIR
FLOATATION UNIT

pH ADJUSTMENT

TREATED SEWAGE
TREATED EFFLUENT

BACTERIAL CULTURE

MAGNESIUM
CARBONATE
SETTLING TANK-II

PREPARATION TANK

BACTERIAL CULTURE
PREPARATION TANK

AERATION TANK-II

SETTLING TANK-I

SLUDGE SUMP-I

EXCESS
SLUDGE
SLUDGE SUMP-II

AERATION TANK-

OVERFLOW

SLUDGE THICKNER

DENITRIFICATION
TANK

AMMONIA FIXING
CUM pH
ADJUSTMENT TANK

SLUDGE
RECIRULATION

OVERFLOW
UNDER
FLOW

THICKNED SLUDGE
SUMP

SLUDGE DRYING BED

EXCESS
SLUDGE

METHANOL

ACID

NUTRIENT

SLUDGE
RECIRULATION

UNDER
FLOW

AMMONIA
STRIPPING TOWER

TANK-1

SETTLING TANK-III

SLUDGE FOR DISPOSAL

AERATION TANK-III

TREATED EFFLUENT FOR

DISPOSAL

AERATION TANK 1
SLUDGE SUMP-III

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2. Major Units Of BOD Plant:
i.

Tar and Oil Separation Unit

ii.

Equalization Tanks

iii.

Dissolved Air Flotation (DAF) Unit

iv.

Skimmed Oil sump

v.

pH Adjustment Tank

vi.

Ammonia Stripping Tower

vii.

Ammonia Fixing Tank

viii.

Aeration Tank I

ix.

Settling Tank I

x.

Aeration Tank II

xi.

Settling Tank II

xii.

De-Nitrification Tank

xiii.

Settling Tank - III

xiv.

Aeration Tank - III

xv.

Sludge Sumps

xvi.

Thickener

xvii.

Sludge Drying Bed

xviii.

Chemical House, MCC Room, PLC Room, Office, Laboratory, Chemical Dosing
Units

xix.

Treated Effluent Collection Sump

xx.

Slop Oil Tank

xxi.

Biological Culture Tank

a. Technical Features
Capacity: 40 m3/hr Un-treated Effluents from BPP and COB # 11 and 50 m3/hr Treated
Sewage Water from STP.
b. Treatment Scheme
Effluents generated from Coke oven and By-Product Plant (COB#11 complex) contains
pollutants such as Ammonia, phenol, Tar & oil, cyanide etc. Main function of BOD Plant

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Coke Ovens
is to remove tar and oils by physical and chemical systems and subsequent biological
degradation of Phenols, Ammonia and cyanide.

Initially effluents are received in tar & oil separation tank. The capacity of the tank is
suitable for one hour detention period. The effluent collected in this collection sump
pumped to subsequent tar-oil separator. Tar-oil separator unit is provided with skimming
facilities. From this unit effluents flow by gravity to equalization tank.
The equalization tank capacity with residence time of 24 hours for designed flow of 40
m3/Hr. The equalization tank consists of three compartments, two compartments each
having six hours holding while the third compartment having twelve hours holding
capacity. The equalization tank is provided with necessary tar/oil skimming arrangement,
and epoxy painting in the inside faces of each compartment.

From the equalization tank effluents are pumped to dissolve air floatation unit for
removal of emulsified oils. This unit consists of recirculation pump, air compressor and
all other required accessories. A skimmed tar & oil sump is also provided for collection
and storage of skimmed tar & oil.

Since the skimmed tar & oil contains major portion as water, this skimmed tar & oil is
pumped to slop oil tank for separation of water & tar / oil. In the slop oil tank skimmed
tar & oil allowed to remain for few days for separation of tar and oil. Tar/oil floating on
the top surface is taken out through tapping connection provided for this and

sent for

secondary use. Water from the bottom of the tank taken out and sent back to the
treatment plant.

From the dissolved air flotation unit effluents flow by gravity to pH adjustment tank.
Alkali

is added to raise the pH around 11. This tank is provided with agitator and pH

indicating instrument. pH adjusted effluents are pumped to ammonia stripping tower.

Stripping of ammonia is carried out in an ammonia stripping tower. The tower is of
induced draft cross flow type and provided with suitable packing, effluent distribution
piping, collection basin, adequate capacity aeration fan and all other accessories.
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The ammonia stripped effluents from collecting basin sent to ammonia fixing cum pH
adjustment tank. The residual free ammonia is fixed and pH is brought down to neutral
pH by addition of sulphuric acid. The tank is provided with agitator and pH indicating
instrument. Effluents form ammonia fixing tank are pumped to 1st stage aeration tank i.e.
aeration tank-I. Under normal operation condition part of treated effluent or treated
sewage

water is added at the outlet of ammonia fixing cum pH adjustment tank at the

rate of 40 m3/hr before entering into the biological treatment facilities. The aeration tankI is aerated along with the return sludge by mechanical surface aerator. The tank is made
of RCC and necessary arrangements are provided in the tank for receiving the return
sludge and required nutrients.

The effluents from aeration tank-I flow to settling tank-I where solid particles are settled
out. Overflow from settling tank-I flow to aeration tank-II whereas the underflow is taken
to sludge sump-I. The settling tank is of RCC construction and provided with necessary
scrapping arrangement, overflow weir, inlet and sludge outlet pipes, constant bleed
arrangement and all other accessories required. From the sludge sump-I sludge is
recirculated to aeration tank 1 and excess sludge is disposed to sludge thickener inlet.
The aeration tank-II is used as 2nd stage of the activated sludge process. The tank
consists

of aerators and other facilities for receiving the return sludge and required

magnesium carbonate solution. Bacterial culture tanks

provided at the platform of

aeration tanks.

Effluents from aeration tank-II flow to settling tank-II. The settling tank-II is similar to
settling tank-I. Facilities for collecting settled sludge from settling tank-II and pumping it
to aeration tank-II & sludge thickener inlet, sump is

provided. The nitrified effluents

from aeration tank-II flow to nitrification tank. The tank is operated under anaerobic
condition. Requisite quantity of methanol is added as carbon source. Effluents from denitrification tank flow to settling tank-III. The settling tank-III is similar to settling tank-I.
Similar facilities for collecting settled sludge from settling tank-III and pumping it to
sludge thickener inlet, sump, and pumps provided.

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From the de-nitrification tank, effluent flow to aeration tank-III, where surface aerators
are provided in the aeration tank to supply required dissolved oxygen in the treated
effluent before disposal.

A sludge thickener is provided for thickening the excess sludge received from different
sludge sumps. The thickener is provided with sludge collection arrangement and all other
accessories. The overflow from sludge thickener is fed at the inlet of aeration tank-I
The underflow from sludge thickener is collected in a thickened sludge sump from where
it is pumped to sludge drying bed unit for dewatering of the sludge.

c. Design Specification

Inlet Concentration

Outlet Concentration

7.5 to 9.0

6.0 to 8.0

Temp.

50 - 60 Deg. C

Ambient Temp

Phenol

500 mg/l

1 mg/l

Cyanides

50 mg/l

0.2 mg/l

Tar & Oil

100 350 mg/l

10 mg/l

500 mg/l

Ammonical N2 :50mg/l

SS

100 mg/l

BOD

30 mg/l

COD

250 mg/l

pH

Total Ammonia

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Energy Management Department

ENERGY MANAGEMENT DEPARTMENT

A) Introduction
Energy Management Department looks after the Management and judicious
distribution of various liquid and gaseous fuels in the plant. The department
comprises the following sections.
1. Energy Monitoring Centre
2. Gas Safety
3. Laboratory
4. Additional Gas Boosting Station (AGBS)
5. Mixed Gas Boosting Station (MGBS) For Mills
6. Coke Oven Gas Boosting Station (CGBS) For Sinter Plant
7. Mixed Gas Boosting Station For LDCP
8. Gas Mixing Station For Mills
9. Gas Mixing Station For Sinter Plant
10. Gas Mixing Station For LDCP
11. BOF Gas Holder Operation
12. Energy Accounting And Conservation
13. Indenting And Planning Cell
14. Maintenance ( Mechanical And Electrical)

B) Energy Monitoring Centre

Energy Monitoring Centre is responsible for proper distribution of fuel gases viz.
B.F., C.O. and L.D. gas to all consumers. There is a gas holder for LD gas but there is
no gas holder forBF and Coke Oven gas. The BF and Coke Oven gas network
pressure is maintained by balancing between gas make and consumption
continuously. Surplus gas is burnt before escaping out through flare stacks. During
shortage of gases restrictions are imposed upon the consumers as per the priorities
approved by the Managementfrom time to time.

C) Gas SafetySection
This is very important section of the department. The main objective of this section is
as follows:

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i.

Prevention of hazardous conditions leading to gas poisoning, fire and

explosion in gas lines, equipment and accessories.

ii.

To create awareness among all working people about the basic principle of
gas safety.

iii.

Scheduled and emergency monitoring of gas prone areas of the plants for
presence of carbon monoxide gas in the atmosphere. Maintenance and
repair of oxygen breathing apparatus / gas mask.

iv.

Standby duties and giving job clearance at shop floor level.

D) Laboratory
Some regular and intermittent gas analysis is done to find the percentage of
constituents of the gas. Followings are the analysis jobs done at the laboratory.
i.

Coke Oven gas analysis every day.

ii.

Blast Furnace gas analysis every day.

iii.

Waste gas analysis for Blast Furnace & Coke Oven.

iv.

Dust concentration in BF gas on regular intervals.

E) Additional Gas Boosting Station (AGBS)

Primarily this gas boosting station was installed to supply Coke Oven gas for No.11
battery heating up at required pressure. But after successfully commissioning and
stabilization of No.11 battery, this boosting station is being used to make Coke Oven
gas balance between old and new plant.

F) Mixed Gas Boosting Station (MGBS)

The objective of this boosting station is to supply mixed gas (Coke Oven gas, CBM
and BF gas.)to mills at required pressure.

G) Coke Oven Gas Boosting Station (CGBS)

The objective of this boosting station is to supply Coke Oven gasto Sinter Plant at the
required pressure. After boosting station there is a mixing station for mixing of BF
and Coke Oven gas to be used in the Sinter Plant.
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Energy Management Department

H) Mixed Gas Boosting Station For LDCP

The objective of this boosting station is to supply Coke Oven gas and BF gastoLDCP
at required pressure.

I) GAS MIXING STATION FOR MILLS

This is a PLC operated gas mixing station dedicated for supplying mixed gas (Coke
Oven gas, CBM and BF gas) to Mills. After this mixing station there is a boosting
station for sending this mixed gas to Mills at required pressure.

J) Gas Mixing Station for Sinter Plant

This mixing station is for mixing of Coke Oven gasand Blast Furnace gas to be used
in Sinter Plant. This mixing station is situated after the CGBS where coke oven gas
pressure is first increasedand then mixed with BF gas at the Mixing station.

K) Gas Mixing Station for LDCP

This mixing station is for mixing of Coke Oven gas and BF gas to be used in LDCP.
This mixed gas then goes to gas boosting station. After boosting this mixed gas, it is
then used in LDCP at required pressure.

L) BOF Gas Holder Operation

A gas holder with a capacity of 50000 Nm3 /hr has been installed for recovery and
storage of LD gas, of CV of 1700 2000 Kcal / m3. This LD gas is produced during
the steel making in the converter. This is also called Converter gas which is having a
very high percentage of carbon monoxide gas. LD gas is the most dangerous and
poisonous gas. Persons dealing with this gas need to be very much alert all the time
and requires extra precaution round the clock. The gas is first cleaned, cooled and
then collected in the holder. There are boosters for drawing the gas from the holder
and pump to Power and Blowing Station (P&BS 2). In ISP LD gas will be used only
in P&BS2. Before sending to Power and Blowing Station (P&BS2), this gas is
further cleaned in Electrostatic Precipitators (ESPs).

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M) Energy Accounting andConservation
This section is an important section in Energy Management Department. Daily
performances of plant, planning action, gas balance are the some important jobs are
prepared here.Other jobs are calculations of specific energy consumption, techno
economic energy parameter review, fuel balance, steam balance, energy consumption
targets, cost of energy etc. This section has a continuous vision of specific energy
consumption and tries to find out the cause of its value of increase or decrease.

N) Indenting and Planting Cell

For smooth running of plant there is a planning and indenting cell in EMD. The job is
to plan for financial year and procure materials accordingly through materials
department.

O) Maintenance (Mechanical and Electrical)

There is a maintenance group dedicated to the daily routine checkup of gas pipe lines
and maintenance of equipment as and when required. Following are the salient
features of the jobs.
i.

Pipelines survey and take preventive maintenance job.

ii.

Draining of accumulated water from the pipe lines.

iii.

Regular checking of water seals.

iv.

Pipe line maintenance.

v.

Checking of gas control valves, repair and maintenance of the same.

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Electrical Repair Shop (ERS)

ELECTRICAL REPAIR SHOP (ERS)

A) Introduction
In any integrated steel plant, the importance of an Electrical Repair Shop can very well be
envisioned as it is considered as the Heart of the plant. It is one of the major service shops
which executes repair of all kinds of electrical equipments/machines used inside the plant.
There are various kinds of electrical machines of different ages and specification installed
and running continuously since many years, in different processes of production in IISCO
Steel Plant. General maintenance like cleaning, greasing and physical inspection /
checkups is done by concerned shops where the machines are used. All major repairs like
winding repairs, mechanical repairs, modification in existing winding, periodic
overhauling and innovative repairs etc. are being carried out by Electrical Repair Shop
B) Scope of Repair
Electrical Repair Shop carries out repairs of motors, generators, welding machine, brake &
control coils of all types and capacities.
Repairs from outside agencies are arranged strictly on need basis. Certain repairs like core
staggering, shaft change etc. for which repair facilities are not available in ERS are off
loaded to outside agencies. The repairs are limited in number and applicable for big size
and critical machines only.
C) Manpower Employed
ERS has a present manning of 61 non-executives and 6 executives of various grades. The
shop is headed by DGM (EM) ERS.

D) Methodologyand Process flow

Electrical machines are received from various shops within plant along with its work
order. The work order contains the machine specification, its defect, previous job no. and
any specific requirement by the concerned department.
Receipt & Issue section (R&I) of ERS allots a job no. to each and every machine after
proper verification of the machine and its accompanying work order. The same number is
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tagged on motor body & on all dismantled parts. Thereafter the machine is traced in ERS
by that job number only.
To understand the functioning of Electrical Repair Shop let us consider the following
example.
Suppose a machine is received in Electrical Repair Shop from Blast Furnace department.
Every machine is accompanied by a work order. The work order reveals the information
regarding the specification of the machine such as type, frame size, voltage, current,
capacity, speed and brief note of the problem suffered by the machine and shop's
observation.
The machine is unloaded in Receipt and Issue section and the work order is produced
there. The receipt and Issue section allot a job no. to the machine and sends it to the
Coupling Section.
In coupling section, coupling / pulley from the shaft of the machine is removed. After
removing Coupling, machine is sent to the Dismantling & assembly section for
Dismantling of the machine.
In Dismantling & assembly section, machine is dismantled and stator and rotor is
separated. The mechanical parts are checked here for any mechanical defect and if any
part is found defective then, the part is sent to machine shop of ERS for repair. But if any
part is damaged and needs replacement then a new spare is issued from ERS store and
damaged part is replaced with a new one. Stator and Rotor are sent to Testing section to
find the fault. If there is no fault in the machine, then machine is heated in the Hot Box
and after heating, degreasing and greasing of the bearing machine is assembled again and
sent to testing section for final test.
In Testing section, Stator and Rotor is subjected to 1000 V Flash test to find faults like
grounding or phase to phase fault. If the stator of the machine is burnt, then the stator will
be sent to the Winding section for rewinding. If Stator and Rotor is found healthy then it
will be sent back to Dismantling & Assembly Section for Assembly of the machine.

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After repair, all the components will be returned to the assembly section where it will be
re assembled. The assembled machine will be sent to the testing section where final test
will be conducted. If the test result will be found satisfactory then the machine will be sent
to coupling fixing and finally to Receipt and Issue section from where the machine will be
dispatched to Blast Furnace for use.

Hot Box

Electrical or
mechanical

Fitting Section

ect

Fitting & Dismantling

ctric

Winding Section

Ele

Test Bed

Section

Test Bed

Fitting Section

Def

Coupling Section

Test Bed

al

Receiving & Dispatch

Fitting Section

Mechanic
al Defect

Mechanical Section

problem

E) General Maintenance Job

1. Existing ERS
a. AC LT&DC distribution board of ERS.
b. AC distribution & Control panel of pumps, compressor ladle punch & tilting
mechanism of slag bank area. Maintenance, replacement and repairing of
motors, cable of slag bank area. Illumination of slag bank area.
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c. Maintenance of EOT crane of ERS, machine shop, general store & central
receiving store.
d. Maintenance of machine shop electrical system excluding control panel of big
planner.
e. Illumination of street light up to railway track near old ED office (old plant).
f. Illumination of tower light, high mast tower light.
g. Illumination & electrical of ED (FIN) & ED (MM) building , Vigilance office,
new LT substation for general office supply, SCOB gate area, CISF barrack .
h. Supply of manpower to M&R mill for illumination of shop, tower light and
high mast light under their control.
i. Cables, house wiring associated with illumination, fan, air conditioners of
office are looked after by ERS.
j. Cables and associated equipments of street light/Area light/High mast tower
under ERS control are looked after by ERS

2. New ERS
a. AC LT and DC distribution (PDB & MCC) under ERS control.
b. Operation of Maintenance pump & compressors.
c. Operation of Maintenance of EOT crane in ERS & under ERS control.
d. Transfer car & battery Maintenance.
e. Area & Building illumination under ERS control, including street light, tower
light & high Mast light.
f. Earthing system of ERS including fire fighting & alarm system.
g. Maintenance of motor installed in ERS and under ERS control.
h. PLC controlled panel & other control panel of new ERS.

F) Different Sections of Electrical Repair Shop

To facilitate a systematic repair process the shop is divided into different sections. These
are:
1. Receipt And Issue Section
This section co-ordinates both external and internal activities of ERS and keep all
the records of incoming and outgoing machines, components and spare parts.
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Different production shops unload their machines for repair at R&I Section. Here
job no. is allotted for the machine and it is painted on a suitable place for proper
identification. When spare parts is not available in ERS store required for the
machine like bearings , Slip Rings, commutators, carbon brushes etc. for
replacement. The concerned owner shop of the machine supplies the spare parts.
R&I section has also the system of placing requirements with the owner shops and
collecting them in due time. After successful repair the machines returns to R&I
section, from which it is dispatched to concerned shops.

2. Machine Shop
The section caters to the need of all the mechanical repairs of the machines. It is
engaged in repairs like thread repair, key way repair, coupling boring, mica cutting
etc. The section is equipped with lathe machine, shaper machine, drilling and
punching machines. It is assisted to the welding section, which has both Arc
welding and gas welding facility. This section also makes the small mechanical
parts needed for the repair in case of mechanical defect.

3. Coupling Section
When a Motor with a Pulley/ Coupling Fitted to its shaft, comes to ERS for repair,
coupling section removes the coupling / pulley from its shaft and the motor is sent
to the dismantling & assembly section for dismantling. When motor is repaired and
assembled again, it is sent back to coupling section where coupling/pulley is fitted
again to the shaft and motor is sent to the receipt and issue section for dispatch.

4.

Dismantling & Assembly Section

All the machines received for repair are sent to this section for dismantling. This is
necessary to check the condition of each and every parts of the machine.
Electrical parts like stator winding and rotor winding (AC), Armature and field
(DC), commutators condition, slip ring condition, rocker arm condition, brush
condition etc. are checked up. Then the components are sent to Testing section for
further test and detection of faults.

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Mechanical parts of the machine like bearing, bearing seating, bearing housing
shaft threads, key way, foundation etc. are meticulously checked up and noted. If
any of the components requires mechanical repair then it is sent to the machine
section. If any spare part needs replacement then a new spare part is issued from
ERS Store and its replacement is done in this section itself. After necessary repair
it returns back to the assembly and dismantling section.

After successful repair of both the mechanical and electrical parts the machine is
then assembled here .The assembly sections takes those components of a machine
for assembly which are ready in all respects. Before assembly the components are
thoroughly checked to ensure whether all the repairs as mentioned in work order or
as noticed by assembly group are carried out or not. In case there is some
omission, it is sent to concerned section for further repair. After assembly, the
machine is sent to testing section again for final test.
Assembling and dismantling activities are carried out at two different sections.
i.

AC FITTING SECTIONThis section does the dismantling &assembly of

AC machines only.
Squirrel cage Induction motor And Slip Ring induction motor are sent to
this section.

ii.

DC FITTING SECTION
This section handles the Dismantling & assembly of DC machines only.
The machines which are sent to this section are DC motor, Traction motor,
Traction generator etc.

5. Winding Section
As the very name signifies, winding of stators, rotors, armatures, coils etc are
carried out in this section. When a burnt component is taken up for rewinding, first
the number of poles, insulation class and connection is noted from the name plate.
Then winding is opened and end connection scheme, coil pitch, coil turns, No. of
slots, wire size etc. are noted precisely. One sample coil is removed and is kept for
preparing new coils. Now the old winding is removed, slots are cleaned properly
and slot insulation like Nomex or Manilex paper is provided. Then new coils are
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Electrical Repair Shop (ERS)

put, wedges are fixed and end connections are done according to the original
scheme. Then the component is sent to Testing Section to ensure the insulation
quality and correctness of winding.

If there is any mistake in connections, it is detected in testing section and

component is returned back for rectification. If correctness of winding is ensured
then the component is sent to varnishing section.
Varnishing activities are carried out in this section. When a rewound electrical
component comes to varnish section, it is first dried properly in HOT BOX. This is
done to remove the moisture from it, which is very much detrimental for the
insulation. Then it is dipped thoroughly in the liquid varnish named Elmo 65
varnish. It is done in careful manner to ensure that the varnish reaches each and
every part of the winding. Then the component is kept in the furnace for curing at
100-130 degree cent for several hours depending on the size and rating of the
motor.

The liquid varnish is nothing but a thermo setting resin, when it is kept in furnace
the polymerization reaction takes place and varnish dries up like a moulded thermo
plastics. This provides a perfect bracing of the conductor in the slots. It protects the
winding against the mechanical vibration which develop during operation of the
machine.

After varnishing the component is sent to assembly section for further activity.
This section is engaged in repair activities of all the defective commutators and
slip ring. Here first the end cones are opened, then commutator segments and mica
insulation is checked meticulously for any damage. If required the copper
segments are changed or mica insulation is also changed, end cone Micanite ring
insulation is also developed. Then it is completely assembled after drying, it is sent
for High voltage test to ensure the quality of repair.

Slip rings are also repaired here. Generally the epoxy insulation gets damaged
under adverse operating conditions. Here the defective insulation is removed and it
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is moulded with new epoxy compounds. Then it is required to withstand high
voltage test to ensure quality repair. After successful repair, the commutators and
slip ring are sent to assembly to winding section for further process flow.

6.

Testing Section
The primary objective of testing an electrical machine is to ensure whether it is
suitable for and capable of performing the duty for which it is designed. Testing
section of ERS assures quality of the machine which is successfully repaired.
Testing of electrical machines is carried out in accordance with the provision of
different International and National standards like B.I.S, IEEE etc.
Testing section conducts the following tests on all repaired machines on no load at
ERS besides conducting a set of tests on all machine components in intermediate
stages.

Different components are subjected to different types of tests.

When Stator and Rotor are received from Dismantling and Assembly section then
Stator and Rotor is subjected to 1000 V Flash test to find faults like grounding or
phase to phase fault. If the stator of the machine is burnt, then the stator will be
sent to the Winding section for rewinding. If Stator and Rotor is found healthy then
it will be sent back to Dismantling & Assembly Section for Assembly of the
machine.

Rewound stators and rotors of a machine are subjected to 1000 V flash Test to
check insulation. They are also subjected to Drop test to check whether the all
Phase are balanced or not. If test is ok then Stator/ Rotor is sent for varnishing.
When Machine is received after repairing, then machine is tested for No Load
Test. In this machine is tested at its rated voltage without any load for few minutes
and its current and voltage drop is noted down. Its test data is noted down in Test
Report Book.

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Rewound armatures and DC Machines are subjected to Flash Test and Drop test.
Drop test is conducted to check whether there is any short/open circuit in the
winding as well as condition of mica insulation between the commutator segments.
Fields of DC Machines are subjected to Flash Test and Polarity test.
Balancing of rotating parts is also done in this section.

If the component does not comply with the testing norms, then they are sent for
necessary repair and rectification. Good components are sent for final assembly to
the assembly section. After assembly machines are received again at testing
section for final test. Final test includes No Load Run Test and Load test.

7. Planning, Procurement Section And Stores

The requirement for various spares and consumable items is assessed and
accordingly procured for uninterrupted repair activities. It plays a major role in
ERS activities. Hundreds of items which are used in repair process are supplied
from store such as copper wires of different SWG, insulating materials, varnishes,
cables , Tools, carbon brushes, Bearings, etc .

Store issues a spare part when requested by the concerned section for replacement.
It keeps a record of the spare parts issued and spare parts received from other
stores. When an item is about to finish, then store issues a request to buy the item
through indent and request is sent to the Material management department for
further process. When item is received from general store then Store updates its
record of the item. Store also prepares a monthly consumption report and based on
this report, it prepares planning for the next month for the better and timely
availability of the spare parts.

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Electro Technical Lab (ETL)

ELECTRO TECHNICAL LAB

A) Introduction
ETL, Electro Technical Lab department of IISCO Steel Plant deals with PLC & Drive
automation, Electronic panels and power system protection & HV testing in the plant.
The department has been playing a key role by involving in successful commissioning
of automation and power system protection schemes in our upcoming new plant and
maintaining them effectively.
Our new plant has state of the art automation technology and automation systems
form an integral part of the processes. Any problem in the automation system
may result in the total stoppage of the particular process. Hence, ensuring
trouble-free functioning of automation systems is very much essential for the
smooth running of our plant. On the other hand IISCO Steel Plant has numerous
types of electrical equipment operating at different voltages. These include high
tension equipment at LBDS & Main Receiving Station (MRS) from where power
is distributed to different units of plant via different Substation units (LBDS) in the
plant. The power system protection equipment in these areas are very critical for safe
operation & preventing damage to the equipment.
The custodians of these equipment are the shops and departments concerned, who are
responsible for their day-to-day operational and maintenance activities. ETL
department

provides specialized technical support to concerned shop electrical to

maintain them.
ETL provides

technical support for maintenance of

Power protection system

including HV testing, PLC & Drive automation system and electronic panels like
UPS, Micro controllers etc. in order to ensure smooth operation of the plant.
Modifications and additions for better performance of the equipment are

done by

ETL. ETL also ensures that shops adhere to the technological norms in the operation
of the equipment. The important roles of ETL are enumerated below:
i.

Periodic

testing

of

protective

devices

of

electrical

equipment

according to a formulated maintenance plan. Periodic measurement of

parameters of different electrical equipment.
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Electro Technical Lab (ETL)

ii.

Assist the shop electrical in quick liquidation of breakdowns with a

view to reduce equipment downtime.

iii.

Analysis of breakdowns to prevent recurrence of failures.

iv.

Testing and commissioning of electrical equipment after capital

repairs and major overhaul.

v.

Investigation of chronic problems in electrical equipment and their

rectification.

vi.

Association during commissioning of new system.

vii.

Technical

support

to

the

different

shops

in

preparation

of

specifications for technological up gradation and scrutiny of technical

offers of different vendors in association with the project consultants.
viii.

Testing and repair of electronic cards of different equipment to

reduce dependency on outside vendors and cost reduction.

ix.

Conceptualizing automation schemes in consultation with process

personnel.

x.

Conduction of training programs on different electric equipments to

employees for better understanding of equipments.

xi.

Preparation of SOP (Standard Operating Practice) / SMP (Standard

Maintenance Practice) for electric equipment.

xii.

To scrutinize the spare part requirements of electrical equipment like

Drives, PLC and UPS of different shops for better inventory and cost
control.

xiii.

Evaluation of technology during the conception stage of a project;

technology audit and technology

planning so that the plant has a

competitive edge.
xiv.

Testing, repair and calibration of different electrical instruments and

meters.

xv.
174

Study of power system, and suggest measures for improvement.

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Electro Technical Lab (ETL)

xvi.

HV testing of different equipments e.g. transformers, breakers etc.

ETL has been divided into section specialized for specific work. ETL has three groups
looking after different areas. These are as follows:
a. Power Systems & High Voltage Group
b. PLC Automation & Drives Group
c. Electronics Lab & instrument Repair

The above mentioned group is further divided in to sub groups. Each sub group is
assigned a particular set of areas. Though ETL primarily works on equipment at
site, it has well developed test laboratories

for

all

the

above

sections,

having the latest testing equipment and diagnostic tools. In addition to the
requirements of the plant, ETL also provides support for maintenance of medical
equipment in Burnpur Hospital. The detailed working of each of the above groups is
enumerated below:
B) Power Systems & High Voltage Group
This group deals with EHT, HT and LT equipment at our main step
down substations, captive power plants (PBS) and LT substations , the high voltage
testing requirements HT equipment and high voltage safety appliances. The main
functions of this group are as follows:
1. Periodic testing of protection system at all our EHT, HT and LT
substations, captive-power plants and HT equipment like HT motors,
turbo generators and transformers. This is to ensure the reliable operation
of protective devices so, that there is no equipment damage, and minimum
disruption in power supply.
2. Periodic checking of islanding schemes for our captive power plants,
voltage regulators of turbo generators and static exciters of synchronous
motors.
3. Attending breakdowns in the above areas for quick liquidation.
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Electro Technical Lab (ETL)

4. Fault level calculations & load flow study to establish protection settings,
ensuring proper coordination and discrimination.
5. Interaction with outside agencies like DVC regarding our present and
future power supply

needs and coordination for proper protective relay

settings in the supply feeders.

6. Study of power system disturbances and chronic tripping problems and
suggest suitable remedial measures.
7. Interaction with departments like P&BS, POWER DISTRIBUTION and
agencies like MECON and CET for additions and modifications in the
power systems area in the design and implementation stages of the
project.
8. Scheduled

high

voltage

testing

of

motors,

transformers,

circuit

breakers, lightening arrestors, CTs and PTs and other HT equipment at

different substations and power plants.
9. Comprehensive testing of HT transformers and motors, after their overhaul
and repair, or as required during equipment breakdown.
10. Testing of different relays & other auxiliary equipments in lab. including
simulation of configurations
11. Periodic HV testing of safety appliances like hand gloves, rubber mats
and HV Indicators, periodic testing of transformer oil for breakdown voltage.
12. High voltage testing of samples like contactors, insulating materials and other
items sent by different procuring departments as per relevant standards.
13. Involvement in preparation of different SOPs of different HT & LT substation.
14. Simulation of different relay software modules for training as well as analysis
purpose.
C) PLC Automation & Drives Group
This group deals with different PLCs , electrical drives and Electronic panels in
different departments of the plant. The group performs the following functions:
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1. Periodic Checking of PLC & taking Application software backup of PLC for
archiving.
2. Support shop electrical for Preventive maintenance &Trouble shooting of PLC
and its network.
3. Periodic checking & support shop electrical for Troubleshooting of Field bus
networks and equipment.
4. Trouble shooting in IMCC(Intelligent Motor Control Centre)
5. Periodic

checking

of

the

operating

parameters and characteristics of

VVVF drives.
6. Taking drive parameter backup periodically for archiving.
7. Support shop electrical for Preventive maintenance and breakdown
maintenance of drives for quick liquidation of fault.
8. Proactive measures like recording and documentation of parameters of
different

drives and control systems and investigation on deviation of

parameters.
9. Investigation of recurring problems in the drives area and their
rectification.
10. Carrying out innovative modifications in the Automation schemes to achieve
better equipment utilization, energy savings and less equipment downtime.
11. Retrofitting of obsolete PLC and Drive system.
12. Support shop electrical for Preventive Maintenance and troubleshooting of
UPS system.
13. Support shop electrical for Preventive maintenance and troubleshooting of
different electronic controllers.
D) Electronics Lab & instrument Repair
This group deals with the repair of complex electronic cards & modules, testing &
calibration of electrical measuring instruments used all over the plant. This was
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Electro Technical Lab (ETL)

done with a view to reduce the high outside repair costs of these cards by the
respective suppliers. The main functions of this group are as follows:
1. Testing, Repair and trouble shooting of electronic cards of different
equipment. Faults are located and rectified at all levels - equipment
level, module level, card level and component level.
2. Development of circuit diagrams of different cards whenever necessary,
as in most of the cases detailed circuit diagram is not available.
3. Maintaining an inventory of electronic components that are required for
repair of electronic cards.
4. Testing and Repair of measuring instruments like ammeters, voltmeters,
power factor meters, megger, multimeters (analog and digital), clamp
meters, oscilloscopes and signal generators that are used by different
shops.
5. Testing and repairing of metering circuits and transducers.
6. Maintenance of Audio Visual Alarm systems at unmanned railway level
crossings in plant.
The electronics Lab has facilities like computer based In-Circuit IC Tester,
soldering

and

de-soldering

stations and

other

diagnostic

tools. Repair

of

electronic cards at ETL has resulted in substantial savings for the plant.

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Instrumentation
INSTRUMENTATION

A) Introduction
Instrumentation department at ISP is a new department that came into existence on the 11 th
March, 2011 as essential need for an independent Instrumentation department was
envisaged for smooth running of the new state-of-the-art 2.5 MT Expansion project.
During this brief period, the department has grown in line with the Plant needs and the
evolution process is still on. Earlier, the Instrumentation needs of the old Plant were
catered by T&I Department.
Instruments in the industry are basic sense organs and provide information about the
process, production, quality and standard parameters. They also process the information
into workable logics and deliver necessary outputs to meet the quality norms.
Instrumentation Department at ISP is a centralized department and is geared up to meet the
Control & Instrumentation requirements of both old and new plant.
The department is divided into 15 sections to cater to the process monitoring and control
needs of different shops of IISCO Steel Plant. Each section has a team of engineers and
technicians working in close tandem with the operation personnel on a round-the-clock
basis for meeting the department objective.

B) Department Objective
To ensure 100% availability & reliability of Process Parameter Measurements, Interlocks,
Protections and Control Systems for safe operation and resource optimization leading to
enhanced quality and productivity in all sections of the Plant

C) Role & Responsibilities

i.

Testing, Calibration & Maintenance of field instruments (Transmitters, Switches,

Thermocouples, RTDs, I/P Converters, Positioners etc.)

ii.

Control

room

instruments

(indicators,

recorders,

controllers,

Scanners,

Annunciators etc.)
iii.

Functioning of Automatic Control loops for process parameters (Temperature,

Flow, Level, Pressure, Gas-Air ratio, CV, Moisture etc.)

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Instrumentation
iv.

Level 1 Automation/control Systems (DCS & PCS maintenance)

v.

Maintenance of Interlock and Protection systems related to process control

vi.

Process Gas/Liquid Analysers & Gas detectors

vii.

Moisture/Humidity Analysers and CV/Wobbe Index Analysers

viii.

Process Weighing Systems(Best, Transweigh, IPA, Kistler-Morse, Schenck,

Vishay)

ix.

Vibration & Condition Monitoring systems

x.

Radiation Pyrometers & Temperature Scanners

xi.

Flame Detectors/Scanners

xii.

Magnetic, Vortex & Mass Flow Meters

xiii.

Radar, Ultrasonic, Capacitive/RF level sensors

xiv.

Pressure, Flow, Temperature and Level switches

xv.

Dip type temperature measurement systems (Temperature tips & Oxygen Tips)

xvi.

Positioners, I/P Converters, Air Lock Relays, limit switches etc. of Pneumatic
Control Valves/Power Cylinders

xvii.

ISO Activities-Calibration and testing of field, test & master instruments

xviii.

Mechanical Workshop

xix.

Maintenance of Analysers (Oxygen, CO, CO2, H2, H2S, SPM, SOx-NOx, SWAS,
SILICA)

xx.

Turbovisory Systems

xxi.

Maintenance of Foundation Fieldbus equipments & Profibus equipments

D) Sections of the Department

1. New Plant

180

i.

Coke Ovens /CHP/ CDCP/ By-Product Plant#11 Instrumentation

ii.

Lime Dolomite Calcination Plant Instrumentation

iii.

Sintering Plant/BMP/OHP Instrumentation

iv.

Blast Furnace#5 Instrumentation

v.

Oxygen Plant Instrumentation

vi.

BOF Instrumentation

vii.

Continuous Casting Shop Instrumentation

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Instrumentation
viii.

Mill(WRM/BM/USM) Instrumentation

ix.

Power and Blowing Station#2 Instrumentation

x.

Central Compressor Air Station Instrumentation

xi.

Central Repair Shop Instrumentation

xii.

Planning and Contract Cell

2. Old Plant
i.

Power and Blowing Station#1 Instrumentation

ii.

Blast Furnace#5 Instrumentation

iii.

Coke Ovens /CHP/By-Product Plant Instrumentation

B) Coke Ovens /CHP/ CDCP / By-Product Plant#11 Instrumentation

This plant produces metallurgical coke. The process consists of blending of different
stocks of coal, crushing to its desired fineness weighing and heating it in ovens at desired
temperature for a given period. During the process, Coke oven gas is produced from which
valuable organic by-products are extracted.
Major instruments, measurement and control are:
1. Electronic weigh feeding systems with monitoring, controlling and setting the flow
of coal from a central controller for all the silos along with necessary protections
and interlocks(FLSmidth/Kistler Morse Weighing System)
2. Siemens Process Control System (PCS-7) for Coke Oven Batteries Control
3. Electro-Hydraulic actuators(Reineke) for CO Gas Pressure control in Battery
GCM(Gas Collecting Mains)
4. Distributed Control System (Honeywell-Experion DCS) for By-Product Plant
5. Pressure/Differential Pressure transmitters
6. Pneumatic Controllers
7. Radar Type Level transmitters
8. CDCP Boiler Control and related measurements (Siemens PCS-7)
9. Mill Fan and Auxiliary Interlocks and Protection
10. Gas Analysers CO, CO2, H2,O2

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Instrumentation
C) Lime Dolomite Calcination Plant Instrumentation
This shop produces calcined lime and heated dolomite for steel melting shop and sintering
plant respectively.
Following main parameters are measured and controlled through ABB 800 xA DCS
System:
1. Kiln temperature Measurement & Control
2. Draught Measurement
3. Waste gas Pressure Control system
4. Electronic Weighing System

D) Sintering Plant/BMP/OHP Instrumentation

Raw material for sintering plant is obtained from RMHP, Coke Ovens, LDCP, Mills Scale
Storage bins. They are mixed in proportion and fused in furnaces. Sinter is sent to Blast
Furnaces to aid in Iron making.
The major measurement and control include:
1. Belt Weighing/ Rate feeder control in stock bins FLSmidth/Kistler Morse
Weighing System
2. Draft-Wind Box control through ABB 800 xA DCS System
3. Machine protection and interlock loops
4. Mixing and Nodulizing Drum related interlocks and protections
5. Temperature measurement at different stages.

E) Blast Furnace#5 Instrumentation

The major requirements for Blast Furnace are Air Blast from Turbo Blower at constant
temperature, pressure and flow and proper feeding of charge material in furnace. The
furnace is operated with BLT ( Bell Less Top) with Pulverised Coal Dust system. The
major measurement and control system include:

182

1.

Siemens PCS based Instrumentation &Control System

2.

Siemens PCS based Pulverised Coal Dust Injection System

3.

Microprocessor based Weighing System (Schenck)

4.

Stove Dome Temperature measurement system

IISCO Steel Plant

Instrumentation
5.

Gas Analysers CO, CO2, H2

6.

Above Burden/Under Burden Probe/Profile Meter (Paul Wurth)

7.

Amanoscope

8.

Gas Cleaning Plant Related Instrumentation system

9.

Gas air Ratio Control in Stoves

10.

CV Analysers

F) Oxygen Plant Instrumentation

Instrumentation plays a vital role in Oxygen Plant which has Emerson DELTA V DCS
System as its heart. Oxygen Plant supplies oxygen to BOF,CCP and Blast Furnace.The
major measurement and control system include:
1.

Suction and ByPass Control for MAC, BAC and Turbine.

2.

Pre Purification Unit(PPU) Logic& Control

3.

Analysers-Oxygen, Nitrogen and Argon

4.

Pressure Regulating & Monitoring System (PRMS) Control

5.

Cryogenic Measurements

6.

Instruments related to O2/N2/Argon storage tanks

G) BOF Instrumentation:
At BOF, steel is made from pig iron produced in Blast Furnace#5. LD process is employed
for this purpose. Steel made here is sent to Continuous Casting Plant for making
Billets/Bloom/Beam.
The major Control and Instrumentation parameters are:
1. Siemens PCS based Instrumentation &Control System
2. Vibro-feeder weighing System for weighing additives(Sartorius)
3. Liquid Steel Temperature Measurement using throwaway type thermocouples
(ElectroNite)
4. Blow time control
5. Flow and pressure measurement/control of blowing oxygen
6. Lance Height Position Measurement
7. Gas Cleaning Plant and Gas Holder related Instrumentation Systems
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Instrumentation
8. Converter Gas Analysers for O2, CO, CO2

H) Continuous Casting Shop Instrumentation:

The main function of Continuous Casting Shop is to produce steel Billets/Bloom/Beam
directly from the molten steel coming from BOF and to send them to Wire Rod/Bar/USM
Mill
The major measurement and control systems (Siemens PCS-7 based) are:
1. Nucleonic Mould level measurement & control system (Berthhold)
2. Breakout pre-detection System
3. Water flow/ Air Pressure measurement and control of different cooling zones
4. Level measurement of different water tanks
5. Steel temperature& oxygen ppm measurement
6. Electronic weighing system for hopper, tundish, turret (Vishay)

I) Wire Rod Mill/ Bar Mill/ USM Instrumentation:

The Blooms/ Billets are preheated in the reheating furnaces of these mills before being
rolled into different products like angles, channels, TMT rods, plain rods, wires and
structural. Reheating furnaces are equipped with a Rockwell Automation PLC 5562
important control parameters in the process of making finished products are:

184

1.

Furnace Pressure Control

2.

Furnace Soaking Zone Temperature Control--- 4 Nos.

3.

Furnace Heating Zone Temperature Control--- 4 Nos.

4.

Mixed gas Pressure Control --- 6 Nos.

5.

O2 analysers

6.

Temperature before and after rolling at different heavy duty stands

7.

Equalising temperature at cooling bed(I R Pyrometer)

8.

Profile Gauge

9.

Cooling water flow and pressure measurements

10.

Machine Health Monitoring parameters

11.

CV Analysers

IISCO Steel Plant

Instrumentation
J) Power and Blowing Station#2 Instrumentation:
This section is involved in maintaining Control & Instrumentation system of 3 nos Oil/Gas
fired Boilers, 3 nos. Steam Turbo Generators, 3 nos. Steam Turbo Blowers, 1 no. Back
pressure Turbo Generator and DM Plant. max DNA DCS System (BHEL) controls and
monitors all Instrumentation parameters:
1.

Drum Level Control

2.

SuperHeated Steam Temperature Control

3.

Furnace Draft Control

4.

Total Air Flow Control

5.

Secondary Air Flow Control (SADC)

6.

Flame Supervisory Control

7.

Hotwell level control

8.

Turbovisory Instruments(Bently Nevada)

9.

Steam and Water Analysis System (SWAS)-Emerson

10.

Blower Control System (Man Diesel Turbo)

K) Central Compressor Air Station Instrumentation

This section maintains control and instrumentation systems pertaining to5 nos air
compressors, 10 nos dryers, 2 nos flare stack and pump houses under Water Management
Department. Important instruments are:
1.

Anti Surge Control

2.

Magnetic Flow meters

3.

Ignition Control System

4.

Moisture Detectors

5.

Suction Pressure Control

L) Central Repair Shop Instrumentation

Instrumentation Department has a centralised and well equipped laboratory located in
RCRD building. There are facilities for Calibration of Flow, Temperature & Pressure
Transmitters, Pneumatic test bench is provided for the purpose of calibration, repairing,
servicing and overhauling of pneumatic instruments. Facilities for fabrication of K and S
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185

Instrumentation
type Thermocouples and RTDs have also been developed. In the Precision Machine Lab,
all types of precision and mechanical parts and items related to instrumentation are
fabricated. All the test equipment (calibrators) are calibrated in the Instrumentation
Laboratory against measurement standards traceable to national/international standards to
meet the requirement of ISO: 9001: 2008 Quality Management system.

M) Planning and Contract Cell

Planning activities for all the Instrumentation requirements of the Plant is met centrally by
this group. Analysis of various requirements of different sections of the department is done
and procurement action is prioritised. Mechanisation of planning process of is in the
advanced stage for efficiency inventory control. This is done with the internal resources of
the department. Annual Maintenance Contract (Periodic) and other contracts of perennial
nature are also handled and coordinated by this cell.

N) Power and Blowing Station#1 Instrumentation

P&BS#1 has Coal based stoker fired Boilers. Unit A&B Boilers have been renovated
recently and have stand alone Yokogawa controllers for close loop control. Turbo
Generators and DM water Plant are also looked after by this group. Important Control and
Instrumentation parameters are:
1.

Drum Level Control

2.

Deareator Level Control

3.

Burner Management System

4.

Turbogenerator Instruments

5.

DM Plant Instrument

O) Blast Furnace#2 Instrumentation:

The major measurement and control systems include:

186

1.

ABB 800 xA DCS Control System

2.

Stand Alone Controllers for Gas Cleaning Plant (Yokogawa)

3.

Microprocessor based Weighing System (IPA)

4.

Stove Dome Temperature measurement system

IISCO Steel Plant

Instrumentation
5.

Gas Air Ratio Control in Stoves

6.

Raceway Adiabatic Flame Temperature (RAFT) Control

7.

Oxygen Enrichment

P) Coke Ovens /CHP/ By-Product Plant Instrumentation:

This group handles COB#10 and COB#8- both of which have been recently
renovated.COB and BPP#10 has Yokogawa make CENTUM VP DCS Systems. Exhauster
Control is done through Man Diesel and Turbo PLC System. Major controls and
measurements are:
1. Electronic weigh feeding systems with monitoring, controlling and setting the
flow of coal from a central controller along with necessary protections and
interlocks(FLSmidth)
2. Electro-Hydraulic actuators(Reineke) for CO Gas Pressure control in Battery
GCM(Gas Collecting Mains)
3. Pressure/Differential Pressure transmitters
4. Pneumatic Controllers
5. Charging Car Weighing System
6. By Product Plant Measurements, Interlocks and Protection

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Marketing Department
MARKETING DEPARTMENT

A) Functions
Primary products of SAIL units are sold by network of CMO Branches spread all over
the country. However, apart from the prime products, each SAIL unit also generates
many secondary materials/products like Melting scrap generated in Blast Furnaces,
Steel Melting Shop, Rolling Mills ,Coal Chemicals (Benzene, Benzol, Toluene, SB
Oil) and Ammonium Sulphate (SOA) from Coke Oven activities .
Marketing Deptt of ISP is responsible for disposal of Secondary Products, disposal
of idle assets and disposal of defective structural and semis generatedat IISCO Steel
Plant.
Secondary materials shall include materials arising from different processes involved
in Iron and Steel making such as:
a. Melting scrap generated in the Blast Furnaces, Steel Melting Shop, Rolling Mills,
Engineering shops, foundries etc.
b. Re-rollable Steel items/arising like defectives, rejects, cobbles, cuttings &
shearing generated in the Rolling Mills, Continuous Casting department (CCD),
Steel Melting Shop (SMS) etc.
c. Secondary products/By products/Fertilizers/Coal Chemicals generated from Coke
making, screening & transportation activities.
d. Other industrial arising generated in works area like Zinc dross, used rollers,
lubricants, bricks, maintenance /wear scrap, turning/boring scrap etc.
e. Used graphite electrodes, sludge and waste materials including cinder, Mill scale,
Flue dust, Blast Furnace Sludge ,Coal rejects etc.
f. Industrial gases including Nitrogen, Oxygen, Argon etc.

B) Disposal of Secondary Materials generated from Plants

Secondary Materials are all kinds of arising from mines, Coke Ovens, Iron & Steel
Zone, Rolling mills &Auxiliary Shops including defectives, rejects, wear scrap, Ferro
alloys and other miscellaneous items generated from various processes except
surplus/obsolete stores items, idle assets and Blast Furnace Slag.
a. Steps involved in Disposal of Defective Structurals and Semis

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Marketing Department
i.

Supply of defective structural and semis by the concerned Mills to

Designated site for disposal.

ii.

Issuance of Online Forward Auction notice by mjunction on behalf of

Marketing department.

iii.

Fixation of Reserve price by Reserve Price Fixation Committee.

iv.

Auction by m-junction services limited and submission of auction report to

marketing department by m-junction.

v.

Proposal for approval of H-1 price (highest price received in the auction)
by marketing department.

vi.

Issuance of offer letter, collection of payment and issue of delivery order

by Marketing department.

vii.

Delivery of materials to Customer from designated site for disposal.

b. Storage of secondary materials/arising

In order to avoid mix up with the prime materials, the secondary materials/arising
identified for sale shall be removed from the place of generation /main shop and
would be stored for disposal at separate locations.
However, under exceptional circumstances where it is not possible /economically
feasible (reasons to be recorded in writing),the items may be disposed off from the
place of generation with the approval of the Competent Authority.

Identified secondary materials as far as possible shall be stored and dealt

preferably category wise keeping in view uniformity of price and use,
marketability etc. For example, scrap from different mills/departments, which are
likely to fetch different prices, may be stacked separately.
By products/chemicals/used lubricants & oils /fertilizer/ferrous sulphate etc. shall
be stored as per the specific requirement of the item/local conditions.

C) Mode of disposal
To sell all the items covered under the scope in a fair and transparent manner and get
maximum price, any of the following methods may be adopted:
i.

Electronic auction
Electronic auction through Internet.

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189

Marketing Department
ii.

Sale by Open Tender

Secondary materials may be sold through open tender on short term or long
term basis depending upon the existing circumstances e.g stock, storage
capacity, rate of generation and nature of the item etc.

iii.

Sale on fixed price basis

Sale of items on fixed price basis may be taken up, as per necessity, after
taking approval from the competent Authority .Sale on fixed price basis may
be resorted to for continuous disposal of items, in order to avoid accumulation
and interference with the operational activities. Price prevailing on the date of
dispatch /lifting of material shall be applicable.

iv.

Inter Plant transfer

Scope for transferring material such as Scrap, Tar, Sulphuric Acid, Oxygen,
Carbide Sludge, Coke fractions etc. to sister Plants/Units/Subsidiaries of SAIL
for production /use purposes may be explored.

Mode of dispatch of a particular category of material shall be decided with approval

of the competent authority of the Plant/Unit. Alternative transparent modes of
dispatch may be adopted with approval of the competent authority to effect disposal
resulting out of continuous failure of a particular mode of disposal, to prevent any
safety hazard and operational bottlenecks. However, for same material, more than one
mode of disposal on regular basis may be avoided.
Except Ammonium Sulphate and Blast Furnace

Granulated Slag, all the

Secondary Products are Sold through e- auctions which are conducted by Mjunction
Services Pvt. Ltd.
Ammonium Sulphate and BF Granulated Slag are sold through free sale notice issued
time to time. B F Granulated Slag is also supplied to Local Cement Manufacturers on
the basis of free sale notice rate.

D) Terms and conditions of Sale

Items shall be sold lot wise, wherever feasible, on as is where is and with no
complaint basis or as per the Technical Delivery Conditions (TDC) basis, as per the
terms & conditions of the contract.
190

IISCO Steel Plant

Marketing Department

E) Sale decision for Electronic Auction

i.

Reserve price shall be fixed before conducting electronic auction for the sale
of material. The reserve Price can be revised, if even on second time of
auctioning, H-1 bid received is lower than the limit followed by Plant which
should not be less than 90% of the Reserve Price. . No bid received against
any particular lot during auctioning shall also be reckoned as an attempt for
sale for the lot.

ii.

The highest bid (H-1) received, if is equal to or more than the Reserve Price,
Material shall be sold to the H-1 party after receipt of the approval of the
competent authority.

iii.

If the H-1 offer is lower than the Reserve price and is more than or equal to
the limit followed by ISP which is subject to a lower limit of 90% of the
Reserve price , the material may be sold toH-1 bidder depending upon market
condition, after receipt of the approval of the competent authority.

iv.

If H-1 offer is less than 90% of the reserve price, the case may be reauctioned.

v.

In case the H-1 party backs out before or after accepting the sale order, its
EMD may be forfeited and appropriate action as per the terms and conditions
of the electronic auction may be taken. In such cases H-2/H-3 party may be
asked to accept the H-1 rate one by one, after receipt of approval of competent
authority. In case, H-2, H-3 parties do not accept the H-1 rate, re-auctioning
may be resorted to.

F) Sale decision for Open Tender

Reserve Price shall be fixed before tendering for sale of material. The reserve price
can be revised, if even on second time of tendering, H-1 bid received is lower than
90% of the reserve price.No bid received against any particular lot during auctioning
shall also be reckoned as an attempt for sale for the lot.

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191

Marketing Department
i.

If the highest offer (H-1) received, is equal to or more than the Reserve price,
order may be placed on the H-1 party without conducting the negotiations.

ii.

If the H-1 offer is lower than the Reserve price and is more than or equal to
the limit followed by ISP which is subject to a lower limit of 90% of the
Reserve price, negotiations may be conducted with the approval of the
competent authority to bring the offer at par or above the reserve price before
placement of order. However, if negotiations do not succeed to bring the price
at a par with the Reserve price but since the quoted price /negotiated price is
within the specified limit, the order depending upon market conditions may be
placed on H-1 party on quoted /negotiated price.

iii.

If the offer received is less than 90% of the reserve price, negotiations may be
conducted with the approval of the competent Authority .After conducting the
negotiations if the price is not brought within the specified limit, the case may
be re-tendered. However, if the negotiated price is within the limit, order
depending upon market condition may be placed on H-1 party.

iv.

In case the H-1 party backs out before or after accepting the sale order, its
EMD may be forfeited and appropriate action as per the terms and conditions
of the electronic auction may be taken. In such cases H-2/H-3 party may be
asked to accept the H-1 rate one by one, after receipt of approval of competent
authority. In case, H-2, H-3 parties do not accept the H-1 rate , re-auctioning
may be resorted to.

In case more than one party becomes H-1 and found eligible for placement of
order/negotiations, negotiations may be conducted with all of them separately after
receipt of approval of competent authority and order to be placed on the revised H-1
party.
In case, even after negotiations, more than one party remains H-1, the order may be
placed by draw of lot in presence of all H-1 parties at revised H-1 price.

G) Disposal of Idle Assets

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IISCO Steel Plant

Marketing Department
Idle assets are those, which are no longer required of intended purpose and/or retired
from active use. These may be categorized as assets becoming idle:
i.

Due to normal /premature replacement

ii.

Being abandoned after installation & commissioning

iii.

Being found in-operative/uneconomical after procurement.

The major reasons for items becoming idle could be either /or a combination of the
factors

including

technological

up

gradations/modernization

of

plants/processes/inherent design defect/non-availability of spares and/or drawings and

/or inputs (Raw materials/consumables /stores etc.)/change in market scenario
affecting marketability of product/closure of mother units/items given by supplier as a
part of total package found redundant at later stage/changes in pollution control/safety
statutory laws and requirements/damaged items etc.
For management of Idle Assets, CEO of the plant constitutes a committee .The scope
of the committee shall cover identification, declarations, processing for write-off and
disposal of idle assets.

Steps involved in disposal of idle assets:

i.

Respective department initiates proposal for disinvestment of idle assets

giving following details in prescribed format.

ii.

Then the asset is surveyed by the Standing Survey Committee which sends it
for concurrence of Finance and approval of CEO. The Standing Survey
Committee at ISP comprises of members from finance, Drawing &Design
department, and concerned department and headed by GM (Mechanical).

iii.

After approval of CEO, the case is forwarded to Marketing department for

disposal of the dis-invested asset.

iv.

Working group consisting of members from finance, marketing and other

departments prepares a draft tender document and takes approval from Head
of Marketing.

v.

Reserve price is fixed by a Committee called Reserve Price Fixation

Committee .This is followed by issue of auction notice by marketing
department. On due date, auction is conducted by mjunction services ltd.

vi.

After getting auction report from mjunction a proposal is put up for approval
of auction price by Marketing department.

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Marketing Department
vii.

Evaluation of bids and proposal by the Tender Evaluation Committee and

recommendations of the Apex Committee.

viii.

Approval of CEO with concurrence of finance.

ix.

Issuance of offer letter, collection of payment and issue of delivery order.

x.

Delivery of the asset to the Customer.

H) Secondary Products to be Sold by Marketing Dept. in 2014-15

194

Sl. No.

Items Generated As Secondary Products QTY(MT)

Scrap Steel

36000

Mill Scrap/Mrd Scrap

97130

Benzol

588

Benzene

823

Toluene

106

L. S. Naphtha

59

Still Bottom Oil

306

Crude Coal Tar-New Plant

28554

Crude Coal Tar-Old Plant

26861

10.

Ammonium Sulphate New Plant

10266

11

Ammonium Sulphate-Old Plant

7961

12

Elemental Sulphur

898

13

Naphthalene Crystal

94

14

Nut Coke

42500

15

Breeze Coke

37200

16

Granulated Slag-New Plant

383333

17

Granulated Slag-Old Plant

56000

18

BOF Slag

69317

19

Idle Assets

---------(20 Crores)

IISCO Steel Plant

Medical Services
BURNPUR HOSPITAL

A) Medical Facilities & Infrastructure

Total no. of Beds available: 340
Out Patient Department of hospital timing is from 8.00 am to 12.30 pm and between 3 pm
and 6.00 pm.

B) Medical Departments / Specialities available at Burnpur Hospital

i.

General Medicine

ii.

General Surgery

iii.

Gyn & Obs

iv.

Ophthalmology (eye)

v.

ENT

vi.

Orthopedics

vii.

Paediatrics

viii.

Dermatology (Skin)

ix.

Psychiatery

x.

Dental

xi.

Public Health Preventive

xii.

Pubic Health Family Welfare

xiii.

Physiotherapy centre for rehabilitation

xiv.

Occupational Health Service Centre inside Burnpur Works

xv.

Anaesthesia

xvi.

Pathology

xvii.

Radiology

xviii.

Medical Stores

C) Functioning Units / Clinics

i.
Total no. of beds - 340
ii.

Intensive Coronary Care Unit

iii.

Intensive Care Unit

iv.

Intensive Therapy Unit

v.

Dialysis unit

vi.

Well Baby Clinic

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Medical Services
vii.

Leprosy clinic

viii.

Nephrology clinic

ix.

Public Health & BMW Management

x.

Pre Anaesthetic Clinic

xi.

OHS Centre with Speciality clinics

xii.

Chhottadigari Dispensory

xiii.

Operation Theatre - 5 nos

xiv.

Dr.B.C.Roy Ward exclusively for executives.

xv.

Pharmacy for dispensing medicines

D) Investigation facilities
i.

Pathology lab

ii.

Biochemistry lab

iii.

Haemotology lab.

iv.

Microbiology lab

v.

Blood Bank

vi.

Radiology

vii.

USG / Echo Cardiography

viii.

Colour Doppler study

ix.

EEG & TMT

x.

ECG

xi.

Holter Monitor

E) Specialised instruments and equipment

i.

Haemodialysis Machine

ii.

BiPAP non-invasive ventilator

iii.

Auto Analyser

iv.

Cell counter

v.

TURP

vi.

Auto Refractometer

vii.

Multipara cardiac monitor at ICCU, Infusion pump

viii.

OT equipments such as Boyles apparatus, Diathermy machine

196

ix.

Laparoscope, 'C' arm m/c, Ortho O T Table, Anaesthetic ventilator

x.

X-ray machines, Dental X-ray machine

IISCO Steel Plant

Medical Services
xi.

Colour Doppler, Multi-disciplinary operating microscope

xii.

36 channel EEG machine, Holter monitor, TMT

xiii.

Haemodiaysis machines

xiv.

Non-contact tonometer,Ultra Sound AB Scan & Refractometer

xv.

Centralised Oxygen supply with pipeline

xvi.

Defibrillators

xvii.

Modern physiotherapy equipments, Apnae monitor

xviii.

Versascopehysteroscope, Harmonic Scalpel set

xix.

Elisa Reader, Semi Auto analyser for laboratory

xx.

CCU & O.T. centrally air conditioned

F) Administrative Section
i.

Hospital Administration

ii.

Account cell

iii.

Medical Record Room

iv.

Computerised Registration for admission of patients

v.

Mediclaim

G) Service function
i.

Ambulance Section

ii.

Central Sterile Supply Dept. (CSSD)

iii.

Central Linen Supply Dept. (CLSD)

iv.

Mechanised Laundry

v.

Modern Kitchen

vi.

4 cabinet Morgue

H) Allied Service
i.

Electrical sub station

ii.

Telephone exchange

iii.

Air condition section

I) OHS Centre

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Medical Services
For employees of plant curative, investigation & preventive for occupational hazards.
Also conduct programs onawareness on health measures. Periodical camps also
carriedout.

J) Post-retirement medical facilities

Retired employees & their spouses arecovered formedical benefits available at Burnpur
Hospital and alsomajor part of premium paid for them for having medi-claim.

K) Nursing Training School

Process is on to re-start.
i.
Emergency / casualty unit functioning round the clock
ii.

OHS Centre for employees of plant curative, Investigation &preventivefor

Occupational hazards

iii.

Works Clinic attached to OHS centre at ISP works, functioning round the clock.

iv.

Dispensaries at Chhottadigari(peripheral area)

v.

Free camps at adopted villages and neighbouring villages under CSR

vi.

Helps CSR department in holding regular medical camps & medicines arebeing
supplied by Burnpur Hospital.

vii.

Hospital is catering medical services to the retired employees and their spouses.

viii.

Hospital is catering medical services to the corporates such as BSCo.Ltd.BSNL,

DPSC Ltd, Director Gen.(Mines Safety)

ix.

Providing free medical treatment to the inmates of Cheshire Homes, Burnpur.

x.

National Program under family welfare schemes free vasectomy

&tubectomycasesare taken up.

xi.

Medical Board for referral

xii.

Medical Invalidation Board

xiii.

Disability assessment and compensation Board

xiv.

We cater to patients of Chasnalla, Jitpur & Ramnagore collieries

xv.

We give coverage to employees of our Kolkata and New Delhi ISP Offices.

198

IISCO Steel Plant

Medical Services

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199

Materials Management
Materials Management

A) Objective of Materials Management (MM) is to optimize the cost of Input

Materials.

B) Scope of Materials Management includes planning of material, procurement,

Inspection, storage Accounting & Issue of materials.
Before knowing about the functions of Materials Management it is important to know
about the types of materials.
1. Raw Materials: Iron Ore, Coal, Dolomite, Lime stone, Non Ferrous metals , Ferro
Alloys etc.
2. Stores and Spares: Refractory, Rolls, Consumables, Spares.
3. Semi-finished: Blooms, Billets etc.
4. Finished: Wire Rod, Structurals etc.
5. Materials Management division deals mostly with Raw materials (excluding Iron
ore and Coal) and Stores and Spares

C) Units under Material Management:

1. Planning &Vendor Management Cell
2. Purchase
3. Stores
4. Inspection

1. Planning & Vendor Management :

Planning for Spares is done by Planning Cell.Consumableitems are planned by
MMISsection. Vendor management section maintains details regarding each vendor.
This section is responsible for Registration, Renewal of registration, maintaining all
related data on vendors. Each item is identified with a 12 digit item code.

Purchase requests are raised by each department to register its requirement and same
is translated into indent for further procurement action after necessary scrutiny by

200

IISCO Steel Plant

Materials Management
screening committee and respective planning sections. Approximately 2000 indents
are raised in a financial year.
Consumables with predictable pattern of consumption and preferable having more
than one user are declared as Automatic Procurement items (AP Items). Indents for
AP items are raised by MMIS section of MM division based on past consumption
pattern. However, any special requirement of a department needs to be
communicatedto MMIS so that same are includedwhile raising indents.
2. Purchase
Purchase department is organized on the basis of nature of items e.g. Refractory, Raw
materials, Rolls, Electrical consumable, Electrical spares, General consumables etc.
Mechanical spares are however dealt on the basis of shops e.g. Coke oven spares,
Blast Furnace spares and so on.

Indents are normally processed through Single tender, Limited tender, Open/global
tender. Others modes of procurement are Rate Contracts/ MOU, Inter plant stock
transfers, DGS&D Rate contracts. Offers received against tenders are technically
evaluated. Order is placed on lowest technically acceptable vendor.

Total 2500 purchase orders valuing Rs. 200 Crore are issued by purchase department
for stores and spares. Orders for more than Rs. 300 Crores are issued for raw
materials. These will go up significantly with the commissioning of new plant.

3. Stores & Inspection :

Materials are received in stores. Same are checked for conformity to ordered
specification, accounted for and kept in identified location in store.
Main sections of stores are
1. Central Receipt Stores Materials are first received at this place and then sent
to respective sections of stores.
2. Refractory stores All refractory materials are handled and stored at this
section.
3. General Stores- It handles Consumables, Spares, Steel, Lubricants, Cement
and misc. items. Materials meant for disposal are handled by Disposal Stores.
4. Project Stores Project items are kept handled in this store.
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Materials Management
5. Stationery Stores- Handles Stationery items.
6. Medical stores- Handles items related to hospital and is located in Hospital
premises.
Each item is having and Bin Card where receipt and issues are recorded. More than
one lakh bin cards are available in stores. Total inventory available in stores is more
than Rs 130 crores.
GRIN (Goods Receipt and Inspection Note) is the document which is generated for
acceptance or rejection of material.
Users can get the materials issued against Stores Issue Voucher.
Inspection department checks the quality of incoming materials. Materials are
normally checked after receipt at stores. In some cases, inspection is carried at
vendors premises before dispatch. In some critical cases, third party is appointed for
carrying out inspection.
Most of the activities of Materials Management are computerized and Users have an
access to Integrated Maintenance and Materials Management Integrated System
(IMMMS). Various transactions related to creation of item code, vendor code,
generation

of Purchase requests, Indents, issue of enquiry, receipt of offers,

generation of purchase orders, Day book, GRINs etc are being done through IMMMS.
This section is also responsible for bringing out various MIS reports for effective
monitoring of performances.
There will be a big jump in responsibilities of Materials Management with the
commissioning of new plant. Material division is gearing up to fulfil additional
responsibilities.

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Operation Garage
OPERATION GARAGE

A) Introduction
Operation Garage department provides support service to various units of ISP, Burnpur.
Operation Garage is categorised into two sections.
i.

Earth Moving Equipment (EME) Section

ii.

Central Garage Section

B) Earth Moving Equipment (EME) Section:

EME section further divided in to two categories:
1. Operation of EME Equipments
2. Maintenance of EME Equipments

1. Operation of EME Equipments :

Deployment of Earth Moving Equipment in production departments eliminates use of
excessive labour force and support for production. The following jobs are done by
EME:
i.

Removal of wastes from THF-I, THF-II, Duplex area & Stipper shed by
Crawler Loader & Dumpers.

ii.

Coal feeding in hopper by dozer at New CHP ( COKE OVEN)

iii.

Coal feeding in hopper by dozer at Power Blowing station (PBS-I)

iv.

Slag/Scraps removable, by crawler loader and Dumper at ladle house (BF).

v.

Removal of iron ores fines from hopper by Dumper at OHP (BF).

vi.

Iron ore feeding in hopper by Dozer at OHP (BF)

vii.

Dozing of slag granulation at slag bank (BF)

viii.

Removal /dozing of slag boulder from blast furnace slag pit area (BF).

ix.

Removal of mill scale from BBM, HSM, LSM&WRM from dumper & loader.

x.

Shifting of coke nuts at different size from breeze bunker and emergency
bunker to back shunt area at COB#11.

xi.

Removal of sand and formation of intake channel leading to sump of intake

Riverside pump house (RSPH).

xii.

Collection of breakdown spares from mills and other unit to fitting section by
Dumper and general cleaning of plant by Loaders, Shovel &Dozer.

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Operation Garage

Details of EME Equipment:

i.

Dumpers (BEML Make):

Dumper transfers waste from twin hearth furnace to slag bank, slag
scale from ladle house to slag bank area, ore fine from OHP bunker to
yard & shifting of coke nuts from COB # 11 to back shunt are.

ii.

Dozers (BEML Make):

These are deployed for coal feeding, iron ore feeding, removal of slag
in slag pit-I& II , coke breeze dozing in the coke yard at back shunt
area and Site cleaning , levelling & other miscellaneous jobs.

iii.

Excavators (TATA HITACHI Make):

This is used for loading slag, loosening of sticky coal and iron ores
loaded on railway wagons in rainy season. Removal of sand at mouth
and adjacent area of the channel leading to sump of intake of river side
pump house in river Damodar.

iv.

Shovel (L& T Make):

This is used for loading of slag at slag pit-I, slag pit-II and iron ores
fines& other miscellaneous job.

v.

Crawler Pay Loader (CATERPILLAR Make):

These are used for removal of waste from twin hearth furnace-I & II
and loading of coke at emergency bunker of COB#11.

vi.

Tyre Mounted Loader (BEML/ JCB Make):

Used by various department for general cleaning & housekeeping.

vii.

Water Sprinkler (BEML Make):

These are used for sprinkling water on road to control dusty
environment and also used for transporting water on sudden
requirement basisfrom plant.

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Operation Garage
viii.

Mobiles Crane (TIL Make):

Cranes are used formaterial loading / unloading at metal yard, to cater
breakdown job at different unit and also used for handling spares during
maintenance at different departments.

ix.

Rail Crane (TIL& JESSOP Make):

Crane are used re-railing different type of rolling stock, wagons, hot
metal ladle, and slag ladle, at different area of Blast Furnace, Steel
Melting Shops, and different rail yard.Cranes are also used forhandling
of spares during maintenance at Blast Furnace.

x.

Crawler Crane (TATA Make):

Crane are used in MRD dept for scraps loading/unloading/handling and
also used in metal yard for material loading and unloading.

Break up of Earth Moving Equipments

Dozer

Dumper

20

Excavator

Crawler Pay Loader 10

Shovel

Mobile Crane

Water Sprinkler

Skid Steer Loader

Front End Loader

Service Van

Diesel Browser

Lime Tanker

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Operation Garage
Flue Dust Tanker

Tripper 10t

Rail

Crawler Crane

Truck

Pick & Carry Crane 1

TOTAL

87

Total manpower for operation of EME Equipments: 62

2. Maintenance of EME Equipments:

Maintenance shop undertakes the maintenance, and repair of all types of Earth Moving
Equipments operated and 39 nos. of different category of utilities equipment (Viz. Back
Hoe Loader, De-silting machine road sweeping machine road roller, tractor, Pick & carry
crane and Forklift) operated by different departments arealso maintained by EME
Maintenance section. The maintenance equipments are being done at shop floor as well as
various duty posts.
The shop is broadly divided into the following major sections
1.

Inspection of Engine&Equipment Servicing

2.

Central Repair & Testing of Sub-Assemblies & Hydraulics

3.

Crawler mounted equipment Repair Section

4.

Tyre mounted equipment Repair Section

5.

Cranes Repair Section

6.

Central maintenance of Light vehicle Repair Section

7.

Spares & Maintenance planning ,Stores &Contract cell

8.

Electrical Central maintenance section

9.

Inspection of operation of equipment at various duty post

Total manpower for maintenance of EME Equipments: 52

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Operation Garage
C) Central Garage Section:
Vehicles of garage section are mainly utilised to coordinate the various activities of all
departments of plant (such as govt. auditor duty, plant control, laboratory, Dakcollection
& despatch, break down jobs as wells as material such as spares, tools & tackles etc).
The jobs done by Central Garage in general are as follows:
i.

Vehicle to be provided to all senior executives of the plant ( N2N leasing of

vehicles contract with M/S MARUTI SUZUKI INDIA LIMITED)
Vehicle to be provided to all GMs of the plant ( N2N leasing of vehicles contract

ii.

with M/S MARUTI SUZUKI INDIA LIMITED)

iii.

Vehicles provided for VIP visits, outstation movement.

iv.

Vehicles provided in various department such as Safety, Fire, PR, Vigilance,

Estate, Intelligence department & CSR (Mahila Mangal/ WVS).

v.

Vehicles ( Jeep , Mini Bus, Mini Truck, School Bus & Motor Cycle) to be
provided to CISF unit.

vi.

Vehicles are also given in Election Duty and Judiciary Duty on demand.

vii.

Trucks to be provided to different units of plant for various jobs.

viii.

School bus to be provided to Town department & plants functions.

ix.

Department has also entered into Centralised rate contract of various types of
vehicles.

1. Details Of Central Garage Equipments

a. Cars / Jeeps
Cars and Jeeps are mainly utilised to coordinate the various activities of service
departments of plant (such as govt. auditor duty, plant control, laboratory, Dak etc.).
Vehicles are used for movement of people as wells as material such as spares, tools &
tackles etc. Cars are mainly used for movement of senior executives of the plant and
sister plant. In addition to plant duty, jeeps are also used for Election Duty and
Judiciary Duty on demand.

b. Trucks / Tippers
Used mainly for transportation of spares / consumable of stores and also for various
operational requirements. Used mainly for transportation of spares / consumable of
stores and also for various operational requirements. The trucks are required for
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Operation Garage
operation in the following department on regular basis: Coke Oven Battery, RMHP,
Sinter Plant, MRD & Refractory etc. The tippers are deployed majorly in OHP, Raw
Materials, Civil Maintenance and PME Departments.

c. School Bus
These are used on fixed deployment basis for school bus service of five schools which
are in the close vicinity of the plant. It facilitates daily transportation of office
employees. It caters the commuting of Management Trainees, ACT and OCT for plant
and HRD trainings. The facility is also used for Mahila Samaj Function and other
cultural events of plant etc. In addition to plant duty, buses are also used for Election
Duty and Judiciary Duty on demand.

d. Cash Van
These vans are used for secure monetary transactions between Finance/Account
Department and other Financial Institutions (Banks etc.).

TOTAL NOS.OF VEHICLES FOR CENTRAL GARAGE

CAR

JEEP

SCORPIO

TATA SUMO

TATA SPECIO

MARUTI SWIFT

CAS VAN

AMBULANCE

MINI BUS

TATA 407 TRUCK

BUS

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Operation Garage
TRUCK

17

TRIPPER

PLATFORM TRUCK

FOAM TENDER

MOTOR CYCLE

11

TOTAL

75

Total Manpower for Operation of Central Garage Vehicles: 49

2. Automobile Repair Shop (Central Garage)
Automobile Repair Shop undertakes the maintenance, servicing and repair of all types of
Cars, Jeeps, Buses, Trucks and Motor Cycle etc of the plant.
In addition to Garage Vehicles, repair and maintenance facilities are also provided to
Hospital Ambulance, Fire Fighting Vehicles.
The shop is broadly divided into the following major sections.
i. Light Vehicle Repair Section
ii. Servicing Section
iii. Electrical Repair Section
iv. Battery Room
v. Tyre Section
Total manpower for maintenance of Central Garage vehicles: 24

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Operation Garage

D) ORGANISATION CHART FOR OPERATION GARAGE

HOD
DGM (OPERATION GARAGE)

AGM (ELECT) OPRN GAR

AGM (OPERATION GARAGE)

DY.MGR( OPRN GARAGE)

(HEAVY VEHICLE MAINT & OPRN.)

210

MTT (OPRN GARAGE)

IISCO Steel Plant

Oxygen Plant
OXYGEN PLANT

A) Introduction
Oxygen Plant comes under Utilities Department in our 2.5 MT IISCO Steel Plant.
Oxygen plant has two Air separation units each having a capacity of 750 ton per day
(TPD) of Oxygen. The main products are Oxygen, Nitrogen and Argon which are
supplied to other units in our Steel Plant.
Oxygen is primarily used in Basic Oxygen Furnace (BOF) for converting Hot metal
into Steel. In Blast Furnace (BF) oxygen is used for enrichment of blast air.
Nitrogen is used for quenching in Coal Dry Cooling Plant (CDCP) and for purging,
sealing purposes in other units.
Argon is mainly used in Secondary Refining Unit for refining purpose.
Apart from these, there is a provision for filling Oxygen, Nitrogen and Argon in
cylinders and in tankers at 2 x 750 TPD Oxygen Plant as per following pressures:
i.

Oxygen Cylinders: 160 kg/cm2

ii.

Nitrogen Cylinders: 160 kg/cm2

iii.

Argon Cylinders: 160 kg/cm2

iv.

Oxygen Tanker: 28 kg/cm2

v.

Nitrogen Tanker: 28 kg/cm2

vi.

Argon Tanker: 28kg/cm2

B) Process Description
The basic principle of the process is to separate liquid air into its various components
by cryogenic rectification using the different boiling points of the air gases. For the
production of gaseous oxygen the corresponding liquid product is pressurized by
pumps, warmed up and evaporated in the main heat exchanger and distributed to the
lines.
Liquid products are LOX, LAR and LIN
The air separation plant consists of the following parts and sections:
i.

Air Compression and Pre-Cooling system

ii.

Molecular sieve station for the removal of water vapour, most of hydrocarbons
and CO2.

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Oxygen Plant
iii.

Heat exchangers for cooling down the process air close to its dew point and
for warming up the products.

iv.

Booster Air Compressors (BAC) for the additional compression of the process
air before entering the main heat exchanger (MHE).

v.

Refrigeration

vi.

Rectification

vii.

Internal compression of product

C) Air Compression and Pre-cooling system

The process air is filtered by a Suction Air filter system and is compressed to about
4.6 bar (g) by the Air compressor 1101 and enters the direct contact air cooler
2401.16.BE1 at the bottom. It passes through the installed packing, is washed by the
trickling water and cools down to about 16 C before it leaves the cooler at the top.
The washing process removes harmful component such as SO2, SO3 and NH3 out of
the process air to a large extent. There are two streams of water injected into
2401.16.BE1: cooling water at normal temperature at the lower section and chilled
water from the evaporation cooler (2401.17.BE1) .A wire mesh on top of the process
air cooler removes the water mist from the process air.

In the evaporation cooler the dry and pressure-less nitrogen absorbs part of the
injected cooling water. The required heat for the evaporation is provided by the water
which is cooled down by this effect. This water is called chilled water.
The water losses of this system due to evaporation will be recovered by cooling water
out of the cooling water system.

D) Purification with Molecular Sieve

The air purification system comprises two cyclic operating adsorber vessels
(2601.01A/B.BA1). Passing through an absorber vessel, the molecular sieve retains
the remaining moisture, CO2 and potentially hazardous hydrocarbons from the air
stream.

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While one absorber is purifying the air, the other absorber is regenerated. During the
heating cycle the regeneration gas (waste nitrogen gas from the cold box) is heated by
an electrical heater (2602.17.BE1) and desorbs water and CO2 from the molecular
sieve. During the cooling cycle the heater is switched off and the adsorbent is cooled
down with cold dry waste nitrogen gas. After the completion of the regeneration
sequence, the adsorber is pressurized before being switched over to the adsorption
cycle.
The regeneration cycle consists mainly of:
Heating; Cooling; Pressurizing; Depressurizing.
The regeneration gas coming from the rectification unit as waste gas is heated up in
the regeneration gas electrical heater 2602.17.BE1 at heating period. At cooling
period the heater is bypassed. An important indication for sufficient regeneration is
the regeneration peak temperature which appears during the cooling cycle. At the end
of the regeneration cycle the regenerated absorber is set into operation and the other
one starts with a new regeneration cycle.
The cycles are automatically controlled by a program.

E) Process Refrigeration
The dry and purified process air after the molecular sieve unit 2601.01A/B.BA1 splits
into two streams. The first stream is not compressed further. It is cooled down in the
main heat exchanger (3002.16.BE1), to about liquefaction temperature while the cold
gaseous oxygen and nitrogen streams coming from the columns are heated up. The air
is fed to the bottom section of the pressure column (3001.11.BT1).A second stream
splits in two. One is from BAC intermediate stage and other is the BAC final stage
discharge. The BAC intermediate stream cools down in the MHE before entering into
the Expansion Turbine (3401A/B.71.BX1). After expanding in turbine the stream is
fed into the rectification column 3001.11.BT1 .Liquid which appears in the separator
3002.32.BD1 is fed into the rectification column 3001.12.BT1. The BAC final stage
discharge stream is expanded in the rectification column 3001.11.BT 1 after passing
through the MHE 3002.16A/B/C.BE1.

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Oxygen Plant

F) Refrigeration
The refrigeration requirement of the plant is due to insulation losses, heat exchanger
losses and removal of cold liquid out of the Low temperature section. These losses are
met by the Adiabatic Expansion (valve etc.) and by nearly isentropic expansion of the
air in the Expansion Turbine 3401A/B.71.BX1. The Expansion Turbine
3401A/B.71.BX1 is connected with the generator 3402A/B.20.CG1 which serves as
the brake for the turbine.

G) Rectification (Air separation) first part

In the pressure column the process air separates first into an oxygen enriched liquid in
the bottom (sump) and a pure nitrogen gas fraction at the top. The sump liquid goes
via sub-cooler and evaporator to the crude argon condenser and pure argon condenser.
The liquid and gas from the crude argon condenser and the pure argon condenser are
going further to the low pressure rectification column.
The pure nitrogen gas stream at the top of pressure column condenses in the re-boiler/
condenser (main condenser) against the evaporating liquid oxygen coming from the
LP column via LOX process pump.
One part of liquid nitrogen serves as refluxes for low pressure column, other parts sub
cools in sub cooler and used as liquid nitrogen product, taken from the separator and
fed to the LIN storage.
Two reflux streams are going to the low pressure column via sub cooler. One oxygen
enriched air stream from the middle of pressure column and a pure nitrogen stream
from the top.
The pressure gaseous nitrogen production is achieved as follows: Gaseous nitrogen
from the top of pressure column goes to the main heat exchanger. Here it warms up
against the process air and leaves the cold box as a pressure nitrogen product.

H) Rectification (Air Separation) Second Part:

In the low pressure column the separation into a pure oxygen fraction in the bottom
and a pure nitrogen fraction at the top takes place.
Nitrogen fraction:

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Oxygen Plant
Gaseous impure nitrogen stream leaves the top of low pressure column, warms up in
the sub cooler and in the main heat exchanger. After that it serves partly as cooling
gas for evaporation cooler and partly as regeneration gas for the mol sieve station.

Oxygen Fraction: The high pressure gaseous oxygen production is achieved as

follows: Liquid oxygen from the low pressure column goes via internal compressor
pump to main heat exchanger. Here it evaporates and warms up against the process air
and leaves the cold box as a HP gas product.
The pressure gaseous oxygen production is taken from the HP oxygen stream before
entering the main heat exchanger. Here it evaporates and warms up against the
process air and leaves the cold box as PGOX product.
Liquid oxygen product is withdrawn from the oxygen process pump which supplies
the main condenser and goes back to the sump of low pressure column.
The liquid oxygen product sub cools in sub cooler and goes to the storage tank.

I) Argon Production by Rectification

Argon enriched gas from the low pressure column is fed into crude argon column.
Here a separation into crude argon gas at the top and oxygen enriched liquid at the
bottom takes place. The oxygen enriched liquid goes back to low pressure column by
pump. The crude argon gas with an oxygen content of about 0.5% goes to second
crude argon column. The oxygen enriched liquid from the sump of crude argon
column (second part) is fed back by pump as reflux to the crude argon column (first
part). The gas at the top leaves the column with about 1 ppm oxygen and continues to
pure argon column.
Here in the last step of argon rectification mainly N2 and CO is removed. The liquid
argon product is going to storage tank.

J) Plant Components
1. Main Air Compressor (2 Units)
Process gas

Air

Operating Point

Units

Guarantee Minimum

Flow Rate

Nm3/hr

111700

81000

Suction Pressure

Bar a

0.993

0.993

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Oxygen Plant
Discharge Pressure

Bar a

5.6

Make

ATLAS COPCO

5.6

2. Booster Air Compressor (2 Units)

Process gas

Air

Flow rate

Nm3/hr

62660

Operating Point

Units

Section 1

Section 2

Suction Pressure

Bar a

5.3

32.5

Discharge

Bar a

32.5

58

Pressure
Make

ATLAS COPCO

3. Expansion Turbine with Generator (4 Units)

Process gas

Air

Operating Point

Units

Guarantee

Minimum

Flow Rate

Nm3/hr

25800

16000

Inlet Pressure

Bar a

32.3

32.4

Outlet Pressure

Bar a

5.3

5.3

Inlet Temperature

-109

-117

Outlet

-173

-174

427

220

Temperature
Power

at KW

Generator
Coupling
Make

216

CRYOSTAR

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Oxygen Plant

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Oxygen Plant

K) Storage and Distribution of Products

Oxygen, Nitrogen and Argon Distribution to Consumers
S.no

Product

Source

Flow min

Flow max

Pin

P out

m3/hr

m3/hr

Bar

Bar

20000

20000

20

7-10

Consumer

(PRMS)

OXYGEN
1

PGOX (2)

LOX IC+
PRV

PGOX(1)

LOX IC+

ENRICHMENT
20000

20000

20

12-19

PRV
3

HPGOX(5)

LOX IC/

BF FOR

TO BOF, CCP &

GENERAL

76000

40

18-22

BOF

2000

4000

40

12-17

CCP &

BACK UP
4

HPGOX(4)

LOX IC/
BACK UP

GENERAL
PURPOSE

HPGOX (3)

(BUFFER)

10000

10000

40

7-10

BF

LIN IC/

13000

13000

31

31

BOF/CCP

18000

18000

12-

12-17

BF/ OTHER USERS

12-17

FROM LIN TANK

NITROGEN
1

HPGAN

BACK UP
2

MPGAN

N2Comp

17
3

MPGAN (1)

BACK UP

9000

9000

31

THROUGH
VAPORIZER
ARGON
1

GAR

BACK UP

3500

16

16

FROM LAR TANK

THROUGH
VAPORIZER

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Oxygen Plant

L) Liquid Storage Tanks

1. 2000 Ton Liquid Oxygen (LOX) Tanks: 2 NOS.
Liquid oxygen from Air Separation unit is stored in LOX tank, which is insulated by
expanded Perlite. Insulation is covered by Mild Steel Sheet and remaining space is
purged by Low pressure purge Nitrogen. When plant is in shutdown LOX is drawn
from these storage tanks and pumped up to 42 kg/cm2 by centrifugal pump (LOX
Backup) and vaporised in the atmospheric Vaporiser. This gaseous Oxygen is then
supplied through PRMS.

2. 1000 Ton Liquid Nitrogen (LIN) Tanks: 2 NOS.

Liquid nitrogen from Air Separation unit is stored in LIN tank, which is insulated by
expanded Perlite. Insulation is covered by Mild Steel Sheet and remaining space is
purged by Low pressure purge Nitrogen. When plant is in shutdown or when one of
the Nitrogen Compressor (NIC) trips then LIN is drawn from these storage tanks and
pumped up to 33 kg/cm2 by, centrifugal pump (LIN Backup) and vaporised in the
atmospheric Vaporiser. This gaseous nitrogen is then supplied to consumers and also
used as back up instrument air during total power failure for quick start-up of the
plant.

3. 200 Ton Liquid Argon (LAR) Tank: 2 Nos

High purity Liquid Argon from Air separation unit is stored in a LAR tank which is
vacuum insulated and cylindrical in shape, and is provided with 2 centrifugal back up
pumps(LAR backup) ,cold convertor(2 x 25m3 ) and vaporising system. When plant
is in shutdown LAR is drawn from these storage tanks and pumped up to 18 kg/cm2
by centrifugal pump (LAR Backup), vaporised in the atmospheric Vaporiser and
stored in cold convertor and supplied.

4. Oxygen, Nitrogen, Argon Cylinder Filling/Truck Filling Facility:

Liquid Oxygen pump installed in LOX tank area pumps up to 160 bar and after
passing through atmospheric vaporiser, filled in cylinders and given to customers.
LOX tanker filling pump installed in LOX tank area pumps up to 28 kg/cm2 to fill
LOX Trucks.

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Oxygen Plant
Liquid nitrogen is pumped from Liquid Nitrogen tank up to 160 bar and after passing
through atmospheric vaporiser, filled in cylinders and given to customers. LIN tanker
filling pump installed in LOX tank area pumps up to 28 kg/cm2 to fill LIN Trucks.
Liquid Argon pump installed in LAR tank area, pumps up to 160 bar and after passing
through atmospheric vaporiser, filled in cylinders and given to customers. LAR tanker
filling pump installed in LAR tank area, pumps up to 28 kg/cm2 to fill LAR Trucks.

M) Safety Precautions for Oxygen Plant:

1. Oxygen:
i.

Density of Oxygen is more than air and it will accumulate in pits and trenches.
So avoid entering in pits, trenches near area with possible oxygen leakage and
if it is necessary, always check with oxygen meter before going in.

ii.

Oxygen is not combustible but it supports fire. So avoid any combustible

material near Oxygen storage and supply area.

iii.

Any manual valve in Oxygen service must be open slowly. Never strike on
pipes or valves in Oxygen service with hammer or iron rod.

iv.

Liquid Oxygen causes cold burn if it is allowed to come in contact with skin.

v.

Oxygen enrichment can enhance the combustion process. Any type of burning
or smoking is forbidden in Oxygen plant.

vi.

If you have been in oxygen enriched atmosphere you must ventilate your
clothing in the open air for at least 15 minutes before smoking or going near a
source of ignition.

2. Nitrogen/Argon:
i.

Nitrogen and Argon are non-toxic but dont support life and acts as
asphyxiates.

ii.

Rooms where these gases are handled or stored must have good ventilation.

iii.

Liquid Nitrogen/ Argon cause cold burn if it is allowed to come in contact

with skin.

iv.

When liquid nitrogen/ argon evaporate the gas produced is very cold and is
much heavier than air. Thus it can collect in low-lying areas and confined
spaces such as pits and trenches where they may be slow to disperse. If any
person going inside such places, may face oxygen deficiency.

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Oxygen Plant
N) Plant Performance Data
1. Process Air
Parameter

Unit

Flow (Inlet cold Nm3/h

Case A (Guar.)

Case B

Mixed Mode

GAS Mode

111000

110600

box)
Pressure

Bar(a)

5.37

5.41

Temperature

24

24

(Inlet cold box)

2. Oxygen
Parameter

Unit

Case A (Guar.)

Case B

Mixed Mode

GAS Mode

HPGOX
Flow

Nm3/h

11000

12000

Pressure

Bar(a)

40.20

40.20

Temperature

24.2

23

Purity

Vol. % O2

99.5

99.5

Flow

Nm3/h

1000

Pressure

Bar(a)

1.20

1.20

Temperature

-183

-183

Purity

Vol. % O2

99.5

99.5

Flow

Nm3/h

10000

10000

Pressure

Bar(a)

20.6

20.6

Temperature

24.2

23

Purity

Vol. % O2

99.5

99.5

LOX

PGOX

3. Nitrogen
Parameter

IISCO Steel Plant

Unit

Case A (Guar.)

Case B

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Oxygen Plant
Mixed Mode

GAS Mode

HPGAN
Flow

Nm3/h

6500

6500

Pressure

Bar(a)

31.4

31.4

Temperature

24.2

24.2

Impurities

ppm O2

Flow

Nm3/h

9000

9000

Pressure

Bar(a)

16.70

16.70

Temperature

40.1

40.1

Impurities

ppm O2

Flow

Nm3/h

500

Pressure

Bar(a)

1.10

1.10

Temperature

-195

-195

Impurities

ppm O2

PGAN

LIN

4. Argon
Parameter

Unit

Case A (Guar.)

Case B

Mixed Mode

GAS Mode

LAR

222

Flow

Nm3/h

790

790

Pressure

Bar(a)

1.10

1.10

Temperature

-185

-185

Impurities

ppm O2

ppm N2

IISCO Steel Plant

Personnel & Administration

PERSONNEL & ADMINISTRATION
A) Organization Structure
PERSONNEL & ADMINISTRATION
ESTATE2
CORPORATE SOCIAL RESPONSIBILITY
LEGAL CELL
CENTRAL FUNCTION
LAISION & ADMINISTRATION
TOWN SERVICES
EDUCATION
ORGANISATION DEVELOPMENT
CENTRAL PERSONNEL DEPARTMENT
WORKS
NON-WORKS
HINDI CELL (RAJBHASA)
HRD
SPORTS
CONTRACT LABOUR CELL

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Personnel & Administration

B) Chain of Command of Personnel & Administration (As On 1st May 2014)

ED (P&A)

GM (P&A)

GM (HRD)

DGM (PL-OD)

DGM (PL-NW)

GM (PR & CSR)

GM (TS)

DGM (CSR)

DGM TS (CC &

Security)

AGM (PR)

DGM (PL Land,

Estate&
Education)

DGM (PL-New Plant)

AGM (Estate)
DGM (PL-CL & I/c
Sports)
AGM (PL-I&S, I/c
HRIS)& LO for
SC/ST/PH

AGM(TS) Elect.

Dy.Mgr.(TS) Civil
AGM (PL-Non Works)&
LO for OBC
SM (PL-Maint &
Services)
SM (Mills, Shops &
Welfare)

DGM (PL-Welfare)
DGM (PL-Central
Function)

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Personnel & Administration

C) Introduction with Department of Personnel & Administration
1. Organization Development (OD)
Executive Establishment - takes care of all matters relating to executives e.g.
promotions, transfers, pay fixation, grievances, awards, training, postings, etc. #
Custodian of personal dossiers of Executives - headed by DGM(PL) - OD

2. Plant Personnel
Most important area in the Plant Works area (Operation, Maintenance &

i.

Services)
ii.

Head of Plant Personnel DGM (PERSONNEL)

iii.

Deals with all matters relating to Non-Executives e.g. promotions, transfers,

pay fixation, grievances, awards, training, postings, etc. All Personnel
Executives attached to different departments in the Works report to Head of
Plant Personnel. The PEs take care of all the personnel functions in their
respective areas.

a. Activities of the Shop floor PEs

i.

Guide & Advise the Line Managers in matters relating to personnel,

disciplinary action, transfers & postings within the department, awards,
training of workmen, etc.

ii.

Implement rules & regulations

iii.

Attend conciliation, arbitration & court cases

iv.

Grievance Handling of different issues raised by workers

v.

Counseling workers on various issues

vi.

Communication with Unions and workers for maintaining peaceful IR

vii.

Organize Safety meetings at Departmental level

viii.

Organize communication meetings at shop floor level

ix.

Provide employee services like service certificates, NOC for

passports/visa, etc.

b. Non - Works Area (Finance, Materials, Marketing, Personnel)

i.

DGM (PERSONNEL) who is in charge of Works also looks after Non

Works area.

ii.

One AGM(PL-NW) looks after the Non-Works area directly and

reports to DGM (Personnel).

IISCO Steel Plant

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Personnel & Administration

3. Contract Labour Cell

i.

The Section is headed by DGM (PL-CL& I/c Sports) which deals with
statutory compliance related to contract labour of entire plant and matters like:

ii.

Issuance of gate-pass

iii.

Union pass

iv.

Character and antecedent verification of contractor worker

v.

Contractor worker grievance handling

4. Central Functions
i.

CF consists of Recruitment, IR, Final Settlement & Liaison with CO

ii.

Organizes all activities related to recruitment viz. Advertisement, Tests,

Interview, Medical, joining, etc

iii.

Sends IR reports to CO

iv.

Organizes Final Settlement for retiring employees

v.

Liaison with Govt. agencies

vi.

Mediclaim

vii.

EFBS (Employee Family Benefit Scheme)

5. HRD
Organizing training for
i.

New recruits

ii.

Existing employees

iii.

Employees identified for New Plant

6. Legal Cell.
Deals with cases
i.

at local courts, High Court, Supreme Court

ii.

at Industrial Tribunals

iii.

at conciliation with ALC (Asst. Labour Commissioner), RLC (Regional

Labour Commissioner)

7. Estate
226

IISCO Steel Plant

Personnel & Administration

i.

Keeps records of all the estate property of the Company as custodian

ii.

All Company quarters are allotted by Estate Department

iii.

Holds Estate Court which has powers of a Magistrate

8. Security
Takes care of security in the township including vital installations and Hospital

9. Liaison & Administration

i.

Takes care of hospitality during VIP visits at ISP

ii.

Central Dispatch functions

iii.

Arrangements for tour of senior executives

10. Town Services

Maintains all the Company quarters in the township
i.

Electricity Supply

ii.

Water Supply

iii.

Sanitation

iv.

Road construction

v.

Street lighting

11. Education
Takes care of all the Company Schools
i.

Burnpur Boys High School (HS)

ii.

Burnpur Free Primary School (Boys)

iii.

Burnpur Girls High School (HS)

iv.

Burnpur Free Primary School(Girls)

v.

ChottodighariVidyapeeth

vi.

Chottodighari Primary School

12. Corporate Social Responsibility (CSR)

All CSR activities are coordinated & organized by this department
i.

Model Steel Villages

ii.

Self employment generating schemes

IISCO Steel Plant

227

Personnel & Administration

iii.

Providing basic needs like roads wells / tube wells for water, solar lamps for
light, community halls etc.

13. Hindi Cell (Rajbhasha)

A must for all Government Organizations
i.

Oversees implementation of Hindi in official communication

ii.

Organizes TOLIC (Town Official Language Implementation Committee)

meetings

iii.

Incentive for use of Hindi in correspondences

14. Sports
The major responsibilities of the department include:
i.

Promote zeal for sports

ii.

Organize in-house sports competitions

iii.

Represent SAIL-ISP at plant level and corporate level sports competitions

15. Other Activities

i.

Long Service Awards

ii.

Training on Retirement Planning

iii.

Quiz

iv.

Counseling of employees

v.

Surprise Checks at shop floor as well as different gates

vi.

Co-ordinate with various agencies in case of serious accidents

vii.

Canteen facilities for employees

viii.

Collective Bargaining

ix.

Convene Bi Partite Forums like Zonal/Central Joint Production Committee

Meetings

x.

Conducting Domestic Enquiries

xi.

Coordinating with Government agencies during elections (Municipal,

Assemblies & Parliamentary)

228

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

POWER & BLOWING STATION-2 (P&BS-2)

A) Preface
Power & Blowing Station-2 (P&BS-2) is a captive power plant for supplying power to
the different shops in the ISP to facilitate the power requirement and to cater emergency
load in case of grid failure.

1. Objectives of Power Plant

i.

To provide reliable and uninterrupted power to the steel making process of

ISP

ii.

To provide required continuous cold air blast for the blast furnace

iii.

To provide required process steam to different steel making process at ISP

iv.

To generate power at an economical rate by gainful utilization of waste gases

v.

To increase the cost efficiency of processes by recovering & utilizing valuable

energy from waste gases

vi.

To utilize the gases generated at different processes of steel making which

cannot be released to the atmosphere due to environmental restrictions

2. Power Generation and Cold Blast Supply

P&BS-II comprises of 3 X 18 MW steam turbo generators and 1X8.375 MW back
pressure turbo generators. Apart from power generation, Power Plant also supplies
the required cold blast to Blast Furnace with 3X3810 Nm3/hr Turbo Blowers. Supply
of cold blast has a priority over power generation.

B) List of MajorUnitsof P&BS-2

BHEL is the turnkey package supplier of the Power & Blowing Station-II. Below are the
major units of P&BS-II:
a.

De- Mineralization Plant (Capacity 150 T/hrs)

b.

Boilers (2 working+1 standby, Capacity: 200 TPH each)

c.

CDCP Boiler (4 Nos. Waste Heat Recovery Boilers for dry quenching of hot coke)

d.

Steam Turbo Generators (2 working+1 standby, Capacity: 18 MW each)

e. Steam Turbo Blowers ( 2 working+1 standby, Capacity: 3810 Nm3/hrs at 5.2 kg/cm2)
IISCO Steel Plant
229

Power & Blowing Station-2 (P&BS-2)

f.

Back Pressure Turbo Generators (Capacity: 8.375 MW).

g.

Cooling Water Pump House

h.

33 KV Gas Insulated Switchgear

i.

Emergency DG Set (750 KVA)

C) Brief Details about P&BS-II

Below is the schematic diagram of the various units of P&BS-2.

Schematic Detail (Diagram No1)

1. DeMineralization Plant:
De Mineralization Plant generates make-up feed water for Power & Blowing
Station 2 Boilers. At first raw water is filtered through Clarifier & RO. Then it is
passed through mechanical filters viz. Dual Media Filter and Activated Carbon
Filters followed by Strong Acid Cation Exchanger, Strong Base Anion Exchanger
and Mixed Bed. Capacity of the DM Plant is 150 T/hr.
230

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

2. Boilers:
There are 3 boilers in the PBS. Out of them 2 are working & 1 is on standby mode.
They are gas operated boilers. The gas fuels used for their operation are BFG, COG,
BOF gas,CBM, LDO. In boiler treated water is converted in steam. This output of
boilers is superheated steam having pressure 66 Kg/cm2 and temperature 490deg C.
The superheated steam generated in CDCP is having the same parameters and is
connected with the main steam header of P&BS-2.
The final superheated steam is used in the following systems:
i.

Steam Turbo Blowers

ii.

Steam Turbo Generators

iii.

Back Pressure Steam Turbo Generator

iv.

As a process steam in Coke Oven by-product plant and Blast Furnace after
reducing pressure and temperature at 9 ata and 13 ata respectively.

Each boiler consists of the following major sections:

i.

Economizer:Feed Water in economizer passes through coils from top to

bottom and flue gas from bottom to top. Entire economizer is divided in 4
blocks.

ii.

Drum:It is specially designed to separate generated steam and water. Dum

internals are consisting for various baffle plates and steam separating
screens.Tri-Sodium Phosphate is dozed in Steam Drum to remove residual
minerals from the drum water. Continuous blow down from drum is done to
maintain adequate phosphate level.

iii.

Air Preheater:It consists of 2 sections. Air flows across the tubes and flue gas
through the tubes downwards. This is of Tubular Type. Here heat from waste
gas is recovered by the fresh air for combustion.

iv.

ID Fan:Two nos. ID Fans are employed to exhaust the products of

combustion from the boiler to atmosphere through chimney. Capacity of each
ID Fan is 80 m3/sec max.

v.

FD Fan:Two nos. FD Fans serve to supply air through air preheater for
combustion. Capacity of each FD Fan is 27.4 m3/sec max.

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231

Power & Blowing Station-2 (P&BS-2)

Fuels used in boilers:

We have the facilities to use the following fuels in the boilers:

i.

Blast Furnace Gas

ii.

BOF Gas

iii.

Coke Oven Gas

iv.

CBM Gas

v.

Light Diesel Oil

3. Coke Dry Chilling Plant (CDCP) Steam:

In addition to the steam generated by Boilers, Power Plant also receive steam
generated by 3 heat recovery boilers at CDCP. The heat so used for generating steam
is recovered from hot coke at CDCP. The generated steam is connected to the Main
steam headers at Power Plant End.

4. Turbo Generators (3 Nos.):

Steam Turbo Generator is electrical generator driven by steam Turbine. The working
of Turbine is as above. The rotating shaft of Turbine is coupled with the rotating
shaft of Generator through Gearbox. Generator is a Electromechanical device which
converts (rotary) mechanical energy into Electrical energy. The output electrical
energy is supplied to the 33KV Bus of plant through transformer & switchgears.

Major Auxiliaries of Turbine:

i.

Oil System consisting of oil Pumps, Oil Tanks, Oil Coolers to supply bearing
lube oil and control oil.

ii.

Condensate systemconsisting condensate extraction pumps to supply

condensate to condensate storage tank.

iii.

Regenerative feed water heating system by low pressure and high pressure
heaters.

iv.

Surface Condenser with 2 pass, cooling water flow capacity 3250 m3/hr and
cooling surface area 1370 m2for cooling exhaust steam of turbine.

232

IISCO Steel Plant

v.

Power & Blowing Station (P&BS-2)

Cooling water pumps for supply cooling water to surface condenser.

vi.

Deaerators (4 Nos.) direct contact type for deaeration(removing oxygen) of

boiler feed water.

vii.

Steam Ejectors for creating and maintaining vacuum in condenser.

Rankine Cycle:
Boiler uses feed water and converts this water to superheated steam. The
superheated steam after doing work in Turbine exits in the condenser. The exciter
exhaust steam Turbines of Turbo-Blowers & Turbo-Generators are cooled by the
cold water from cooling water system and are converted to water in the condenser.
This water is again sent as feed water to boilers. Thus P&BS-2 operates with steamwater cycle like all conventional power plants taking a small percentage (2-3%) as
make up water (DM water) to compensate the losses in the cycle. The name of this
steam-water cycle is Rankin Cycle.

5. Turbo Blowers (3 Nos.)

Steam Turbo Blower is a blower driven by steam Turbine. Turbine is a rotary
mechanical device that extracts energy from fluid flow (steam pressure) into
rotational mechanical motion. The rotary part of turbine is coupled with the rotary
part of blower. Blower is rotary mechanical device which moves the air. Here,
blower extracts the atmospheric air & blows air pressure at outlet. This output air
pressure is used for cold blast process in Blast Furnace.

6. Back Pressure Turbo Generator (3 Nos.)

Back Pressure Turbo Generator is same as Steam Turbo Generator. But here the
output of steam turbine is process steam in addition to electrical power generation.
Hence efficiency of back pressure steam turbine is high.

7. Process Steam Supply Facilities

The steam generated by boilers is also used as low-pressure process steam to other
units of ISP as required for different steel making process. It is supplied at reduced
pressure levels taking it from Main Steam Header & reducing it through a Pressure
Reducing De-superheating Station (PRDS). The process steam is also generated
IISCO Steel Plant
233

Power & Blowing Station-2 (P&BS-2)

through BPTG extractions and exhaust steam. Priority is given to generate process
steam through BPTG as it is a economic process.
Process steam is supplied at two pressure levels
i.

9 ATA 40 TPH to Coke Oven and By Product Plant

ii.

13 ATA 40 TPH to Blast Furnace and Basic Oxygen Furnace

8. Control System
The main equipment and related Auxiliaries of P&BS-II are controlled by a state of
the art distributed control system called Max DNA system. The Blower supplied by
MAN Turbo is controlled by their proprietary control system called Turbolog
However Turbolog is completely integrated with Max DNA control system for
smooth control of Turbo blowers. All the control panels are connected by intra plant
bus. Work stations with PCs are provided for operation and control of the whole
plant.

9. Power Distribution
Power is generated at P&BS-II from STG and BPTG at 11 KV. The same is stepped
up to 33 KV and connected to double bus 33 KV GIS switchboard. Synchronization
between power generated at power plant and grid power is done at 33 KV level at
P&BS-II. Power from grid is received at 220 KV level through two nos. 220 KV
feeders at MRS. Grid power is then stepped down to 33 KV at Main Receiving
Station (MRS) by transformers. P&BS-II is connected to MRS by two nos. of 33
KV feeders called Tie-I & Tie-II.
Power is distributed to different plants at 33 KV& 6.6KV feeders. P&BS-II feed the
vital consumers like:

234

i.

Coke Oven

ii.

Blast Furnace

iii.

Basic Oxygen Furnace

iv.

Wire & Rod mill

v.

Auxiliary Supply of the Power & Blowing Station 2

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

10. Islanding Scheme
In the event of grid disturbance P&BS-II gets islanded from grid and continue to
supply power to critical plants like P&BS-II, Blast Furnace and Coke Oven.

D) Technical Specifications of Boiler

1. Boilers

No of Boilers

3 (2 Working + 1 Standby)

Capacity

200 TPH per Boiler

Working Pressure

66 Kg/cm2

Steam Temp.

4905C

No of Super Heaters

2 (Platen and Final SH)

Furnace Depth

8839 mm

Furnace Width

10973 mm

Furnace Projected Area

514 m2

Furnace Volume

988 m3

2. Fuel Firing System

Fuel Used: BFG, BOF, COG, CBM, LDO

Fuel

Pressure

Max. Flow

CBM

3 Kg/cm2

4600 Nm3/HrPer Boiler

COG

700 mmWC

8900 Nm3/HrPer Boiler

BFG

600 mmWC

120000 Nm3/HrPer Boiler

BOF

1000 mmWC 13150 Nm3/HrPer Boiler

LDO

15 Kg/cm2

IISCO Steel Plant

3.736 KL/HrPer Boiler

235

Power & Blowing Station-2 (P&BS-2)

3. FD Fans Drive Unit (Motor) And Fan

No. of FD Fans/Boiler

2 Nos.

Capacity

27.4 m3/s

Motor Power

175 KW

Speed

1480 rpm

Total Head Developed

466 mmWC

Control

Inlet Guide Vane

4. ID Fan Drive Unit (Motor) and Fan

No. of ID Fans/Boiler

2 Nos.

Capacity

80 m3/s

Motor Power

525 KW

Speed

980 rpm

Total Head Developed

426 mmWC

Control

Hydraulic Coupling + InletDamper

Hydraulic Coupling make

M/s Premium Transmission

Hydraulic coupling type

750 PST

5. Air Preheater (Tubular Air Pre Heater)

236

Total No of tubes

3456 Nos.

Total Heating Surface )

6060 m2

Width

3155 mm

Length

7485 mm

Height

4550 mm

Dia of tube

63.5 mm

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

6. Boiler Feed Pump (BFP)

Quantity

4 Nos. (2W+2S)

Temp. of Feed water

148.5C

Design Flowrate

272 m3/Hr

Discharge Pressure

104.19 Kg/cm2

Operating Speed

2980 rpm

Power Consumption

1300 KW

Voltage

6.6 KV

Pump Head

1135 mm

Hydraulic Coupling Make

M/s Voith Turbo

Hydaulic Coupling Model

487 SVTL

7. Compressor

Make

Kirloskar Pneumatic

Model

TBTDRM

No of compressor

2 Nos.

Operating pressure

7.5 kg/sqcm

8. Soot Blowers & Furnace Temperature Probe

Furnace Temperature Probe

2 Nos./Boiler

Long Retractable Shoot Blowers

10 Nos./Boiler

Rotary Blowers (Economizer)

14 Nos./Boiler

Pressure

30 kg/cm2

Temp.

348C

Flow

8 T/Hr

Travel

0.9 m

Travel Speed

2.9 m/min

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237

Power & Blowing Station-2 (P&BS-2)

9. Dozing System
a. Ammonia Dozing Pump

Total No. of Pumps

4 Nos.

Type of Pumps

Positive Displacement

Make

Swelore engineering Pvt. Ltd.

Stroke

100/minute

Discharge Pressure

9.0 Kg/cm2

Flow

4 Ltr./Hr

b. Hydrazine Dozing Pump

Total No. of Pumps 4 Nos.

Type of Pumps

Positive Displacement

Make

Swelore engineering Pvt. Ltd.

Stroke

100/minute

Discharge Pressure

9.0 Kg/cm2

Flow

8 Ltr./Hr

c. TSP Dozing Pump (High Pressure)

Total No. of Pumps 6 Nos.

238

Type of Pumps

Positive Displacement

Make

Swelore engineering Pvt. Ltd.

Stroke

150/minute

Discharge Pressure

94.0 Kg/cm2

Flow

17 Ltr./Hr

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

10. Elevators

Make

Omega

Total No.

2 Nos.

Motor

10 HP, 960 RPM

Capacity

8 Passengers (544 Kg)

Travel height

9000 Meter

Travel Speed

0.7 Meter/Sec

IISCO Steel Plant

239

Power & Blowing Station-2 (P&BS-2)

Main Steam Header

BOILER
STB

Steam line for Soot Blowers

16.7 ata
62 ata
5 ata

DEA

1.77 ata
STG

LPH
16.7 ata
5 ata

HPH

DEA

1.77 ata

LPH

13
ata
9 ata
Terminal
Point
Point

62 ata

BPTG
13 ata
9 ata

13ata
PRDS

9 ata
Terminal
Point

9ata
PRDS

Steam Line Scheme for Running Boiler, STB, STG& BPTG (Diagram No.2)

240

IISCO Steel Plant

HPH

Power & Blowing Station (P&BS-2)

BOILER#3

Existing feed pump delivery header

Existing feed pump suction header

HPH

BOILER#2

HPH
BFP4
BFP3

HPH
BOILER#1

BFP2
BFP1

HPH

HPH

HPH
Feed Water Line for Boilers (Diagram No.3)

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241

Power & Blowing Station-2 (P&BS-2)

E) Technical Specifications of Turbine & Blower

1. STGs (3Nos.):
Capacity

3X18 MW (2W+1S)

Steam temp.

485C

Steam press.

-62 ata

Normal speed 7700 RPM

Trip speed

8470 RPM

2. STB(3Nos.):
Capacity

3X228,600 NM/hr.(2Working+1Standby)

Steam temp. 485C Steam

Pressure

62 ata.

Rated Speed 5275 RPM

Trip speed

5803 RPM.

3. BPTG(1No.):

Capacity

8.275 MW

RPM of Generator

1500

Pressure

62 ata

Temperature

485C

Normal speed of the Turbine 8000 RPM

Trip speed

8800 RPM

4. Lubrication Oil Circulation System:

a. Oil Coolers (14 Nos.):

Design pressure

21 kg/cm (shell side)

Design temperature 100C

242

(shell side)
IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Design pressure

6 kg/cm (tube side)

Design temperature 65C

(tube side)

b. EOP(For STG & STB):

Technical details Model: ZE50-2200
Serial No

109605-01

Flow

40 m/h

Head

45.5 m

RPM

2900

NPSH

1.6

c. EOP: (for BPTG) ( 1No.)

Flow

30.6 m/h

RPM

2900

Head

43.6m

NPSH 2.5
d. AOP & MOP: (for STG & STB) 12 Nos.
Make

Sulzer

Model

ZE80-2315

Serial No 109622-04/02
Flow

70 m/h

Head

102.3 m

RPM

2945

NPSH

2.0 meter.

e. AOP & MOP: (for BPTG)

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243

Power & Blowing Station-2 (P&BS-2)

Flow

138m/hr.

Head

107.3 m

RPM

2945

NPSH 4.6 M.

f. Jack Oil Pumps - (6Nos.)-For STGs:

Make Tushaco Pumps Pvt.Ltd.

Type

HPG-2A, Sr. No. 102204/6380.

LPM

9, Pressure: 100kg/cm2.

RPM

1450 Motor-3.7KW.

g. Oil Centrifuge Machines (07 Nos.)

Model

OTC- 2-02-137.

Make

Westphalia Separator AG.

Mineral oil system

GmbH.

Maximum Bowl speed

10000 rpm.

Maximum solid separation

2 kg/dm3.

Maximum

heavy

liquid 1 kg/dm3

separation
.
h. Oil Coolers for STGs (6Nos.)

Type

S T TWIN Oil Cooler.

Quantity of oil

48.26Cu.m/Hr.

Surface Area

85sq.m.

No.of

tubes 436.

/cooler

i. Oil Coolers for STBs(6 nos.):

244

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

BHEL, Hyderabad. Serial No: 0960/A to

Make

F.
Item

Twin Oil Cooler. Year of Manufacture:

2000-09.

Shell Side design Pressure & temp

Tube

Side

design

pressure

21 kg/cm2 & 100degree centigrade.

& 6.0 Kg/cm2 & 65 degree centigrade.

temperature
Surface m2: 46. Radiography & Stress Nil.
relief

j. Oil Filters-Duplex Type- (6+6+2 Nos.): For STG, STB & BPTG.
Technical details:

Make

EPE

Process

filters

&

accumulators

Pvt.

Ltd./HYDAC/HYDAC
Model/Type

12-F10-0300-h10*L-50-3-4,1279887/3509171,
1295837/3458882.

Element for STG

1-0120-HIo*-4-00-0-P.

Sr. No.

09/1407/1/2/3 for STG

Maximum operating Pressure 12 bar.

for STG
Capacity for STB & BPTG

2*110liters/ 2*34 liters.

Working Pressure

12 kg/cm2 for STB & BPTG.

Test Pressure for STB & 15 kg/cm2 & 18 kg/cm2.

BPTG
Temperature range

-10 -100 deg. Centigrade.

Flow Rate

1920 LPM & 640 LPM.

Degree of filtration

10 micron.

k. Main Oil Tanks- (07 Nos.)

IISCO Steel Plant

245

Power & Blowing Station-2 (P&BS-2)

Nominal

6.0 cubic meters.

Capacity
Charge

14.71cubic meter

Capacity

l. Oil Tank Vapor Ext. Fan (14 Nos.)

Make

Patels Air Flow Ltd.

Model No

LP-10.25

Capacity

0.11 cubic meter/sec.,

RPM

2880

BHP

0.22

Set Pressure

100mmwc.

Temperature 60 Degree Centigrade.

m. Rundown Tanks/Over Head Tanks - (07 Nos.)

Capacity 7.0 Cubic meter.

5. Condensate System:
a. Condensate Extraction Pumps: (for STG)
Make

KSB

Type

WKTR-100/005

Discharge 74 m/h
Head
Speed

73 m
1460

b. Condensate Extraction Pumps: (for STB)

246

Make

KSB

Type

WKTR-125/003
IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Discharge 94 m/h
Head

73 m

Speed

1470

c. Condensate Transfer Pumps(02Nos.):

Pump type

UP150/53F

Type

WKTR-125/003

Discharge

429.3 m/h

Head

75 m

Speed

1470 rpm

Pump input 116.9 KW

Size

150/200mm

d. Steam Jet Air Ejectors &Main Steam Ejectors: (6 Nos. & 12 Nos.)
Steam Quantity

750kg/hr.

Rated steam pressure

13 atm.

Rated steam temperature 350C

e. Gland Steam Condensers (for STGs & STBs) - (12 Nos.)

Design pressure

16 kg/cm (shell side)

Design temperature 250C

Design pressure

16 kg/cm (tube side)

Design temperature 100C

Test Pressure

(shell side)

(tube side)

20.8 kg/cm (shell & tube side)

f. Gland Steam Condenser (for BPTG) - (2 Nos.)

Design pressure

6 kg/cm (shell side)

Design temperature 340C

Design pressure

6 kg/cm (tube side)

Design temperature 100C

Test Pressure

IISCO Steel Plant

(shell side)

(tube side)

7.8 kg/cm (shell & tube side)

247

Power & Blowing Station-2 (P&BS-2)

g. Surface Condenser- (03+03 Nos.)
Cooling Area

1370 sq.meter.

No. of passes

02.

Exhaust Pressure

0.105 ata.

Quantity of cooling water 3250 cubic meter/Hour.

Temp. ofcooling water

33 ated/41.5 Max.Degree centigrade

6. Heaters for STGs & STBs (HP & LP-06 Nos. each)
a. HP heater:
Design pressure

20 kg/cm(shell side)

Design temperature 214C(shell side)

Design pressure

150 kg/cm(tube side)

Design temperature 334C(tube side)

b. LP heaters:
Design pressure

3.5 kg/cm (shell side)

Design temperature 150C

Design pressure

(shell side)

20 kg/cm (tube side)

Design temperature 150C

Surface area

(tube side)

80

c. DRAIN COOLERS - (06 Nos.)

Shell side design pressure & temperature 3.5 kg/cm2 & 150 centigrade.
Tube side design pressure & temperature 17 kg/cm2 & 100 centigrade.
Surface area

33.0M2

Weight

1850

7. Cooling Water Pumps (13Nos.)

a. Auxiliaries Cooling Water Pumps -3 Nos.
Pump Type 16VMF.
Flow
248

1281M3/Hr.
IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Head

65.2MWC.

RPM

1480.

b. COOLING WATER PUMPS FOR STGs 3Nos.

Make

Jyoti Ltd.

Pump Type VT. Make-Jyoti Ltd.

Flow

750 M3/Hr.

Head

40 MWC.

RPM

960

Power

55 amp./525KW

.
c. COOLING WATER PUMPS FOR STBs 4 Nos.
Make

Mother & Platt.

Pump Type 30 VMF.

Flow

5400 M3/Hr.

Head

34.8 MWC.

RPM

740.

d. COOLING WATER PUMPS FOR SIDE STREAM FILTERS 3Nos.

Pump Type VT.
Flow

750 M3/Hr.

Head

40 MWC.

RPM

960.

8. Cooling Tower & CT Fan: 10NOS.EACH

Make

HamonShriram Cottrell Pvt. Ltd.

Tower Model No

10 RC-U-182-C.

No. Of Cells

(9W+ 1S)

Capacity per cell

2800M3/hour.

FAN:Type&Make:Axial Flow Coolflo.

Blade Material

FRP

HUB

MS hdg

IISCO Steel Plant

249

Power & Blowing Station-2 (P&BS-2)

Fan Shaft

SS 304.

Gear Box Make

Greaves Ltd. (Premium Energy Transmission.)

Model No

B 228

Gear Box Oil Requirement

50 liters.

Lubrication

Splash.

Type of Coupling

Flexible, Non-lubricated

9. EOT Crane (1No.)

Make

Shivpra cranes (P) limited

Capacity

35Ton / 5Ton

Span

24 meter.

Height

of Main/Aux. Hoist ,16 /16 meter

Lift
Operation

Push Button Pendent.L T Gear Box, C T Gear Box, Main & aux. Hoist
Gear Boxes. Other integrated Mechanical part including wheel
carriage system & rails.

Location

Indoor. Main Turbine Hall

250

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

CONDENSATE LINE FOR STG and STB (Diagram No. 4)

Recirculation line
Control
valves

CONDENSER

HOTWELL

CEP-1

Motorized
valve

strainer

NRV

EXPn bellow suction

valve

GSC
Disch
Valve

CEP-2

Ejector (2Nos.)
CST
NRV
CTP-1
IISCO Steel Plant

251
CTP-2

Power & Blowing Station-2 (P&BS-2)

F) ELECTRICALS AND GENERATORS:

1. Turbo Generators
a. M/S BHEL MAKE STEAM TURBO-GENERATORS (STG): 3 Nos.
(2W+1S)
STGs 1, 2, 3 - 18 MW, 22.5 MVA, 11 KV, 50 HZ, 4 POLE, 0.8 PF
STATOR CURRENT=1181A,
ROTOR CURRENT=470A, Vg=150V
BL EXCITER: KW=130, CONT., V=210V,
CURRENT=620, SPEED=1500
EXCIATATION: 451WATT, Vg=35.21, CURRENT=12.8

b. M/S BHEL MAKE BACK PRESSURE TURBO GENERATORS (BPTG): 1

No
BPTG (1No.): 8.275MW, 10.344MVA, 11KV, 50HZ, 4POLE, 0.8PF
STATOR CURRENT=543A, ROTOR CURRENT=395, Vg=107V BL
EXCITER: TYPE- KW=130, CONT., V=210V,
CURRENT=620, SPEED=1500
EXCIATATION: 371WATT, Vg=32.01, CURRENT=11.6

c. M/S BHEL MAKE TOP RECOVERY TURBO- GENERATOR(TRTG):1 NO

TRTG (1No.): 20 MW, 25 MVA, 11KV, 50HZ, 2 POLE, 0.8PF
STATOR CURRENT =1312A,
BL EXCITER: TYPE- KW=224, CONT., V=280V,
CURRENT = 800 A, SPEED = 3000 RPM

2. Transformers, Neutral Grounding Resistors (NGRs) & Remote Tap Changer

Control Panels
a. Transformers
i.

M/S VOLT AMP TRF. LTD.MAKE STG TRANSFORMERS 1, 2, 3 25

MVA, 11/34.5 KV, ONAN, YNd11: 3 nos.

ii.

M/S VOLT AMP TRF. LTD.MAKE BPTG TRANSFORMER - 12 MVA,

11/34.5 KV, ONAN, YNd11: 1 no

252

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

iii.

M/S VOLT AMP TRF. LTD. MAKE TRTG TRANSFORMER - 20

MVA, 11/34.5 KV, ONAN, YND11: 1 NO

iv.

M/S VOLT AMP TRF. LTD.MAKE POWER TRANSFORMERS- PTR

1, PTR 2- 31.5 MVA, 33/6.9 KV, ONAN, Dyn11: 2 nos.

v.

M/S VOLT AMP TRF. LTD.MAKE POWER TRANSFORMER- PTR 3 5 MVA, 33/6.9 KV, ONAN, Dyn11: 1 no.

vi.

M/S VOLT AMP TRF. LTD.MAKE POWER TRANSFORMER- PTR 4 12.5 MVA, 33/6.9 KV, ONAN, Dyn11: 1 no.

vii.

M/S

INTRA

VIDYUT

LTD.

MAKE

STATION

AUXILIARY

TRANSFORMERS - SAT 1 TO SAT 8 - 2 MVA, 6.6/0.433 KV, ONAN,

Dyn11: 8 nos.

b. Remote Tap Changer Control Panels

M/S VOLT AMP TRF. LTD.MAKE REMOTE TAP CHANGER CONTROL
PANELS (RTCC): 7Nos. WITH ELECT. COMPONENTS

c. Lighting Transformers:
M/S SEEKO LTD. MAKE LIGHTING TRANSFORMER 100 KVA,

i.

415/433 V :1 No
M/S SEEKO LTD. MAKE LIGHTING TRANSFORMERS 250 KVA,

ii.

415/433 V: 2 Nos

d. Neutral Grounding Resistors (NGRs)

i.

M/S RESITECH ELECTRICAL PVT.LTD MAKE NGR FOR STG

TRANSFORMERS1,2,3:25MVA,11/34.5KV&

BPTG

TRANSFORMER - 12 MVA, 11/34.5 KVRATING: 400A, 30Sec,

47.63ohmNOS.:4
ii.

M/S RSI SWITCHGEAR PVT.LTD MAKE NGR FOR POWER

TRANSFORMERS-PTR1,PTR2-31.5MVA,33/6.9KV,POWER
TRANSFORMER-PTR3-5MVA,33/6.9KV,

POWER

TRANSFORMER- PTR 4 12.5 MVA, 33/6.9 KVRATING: 600A,

30Sec, 6.35ohm NOS.:4

IISCO Steel Plant

253

Power & Blowing Station-2 (P&BS-2)

3. 33 KV HT SF6 Gas Insulated Switch-Board Panel
M/S Siemens make, 33 KV Gas Insulated Switchgear Panel (21 panels), 3-phase,
2500A,

31.5

KA/3

Sec.consists

of

Breakers(2500Ax4nos,

1250Ax18nos),isolators(2500Ax8nos,1250Ax36nos),earthing switches, current

transformers,

potential

transformers,

relays,

Nos.

of

Marshalling

boxes(extension) and other electrical components for smooth operation of the GIS
Switchboard.

4. 11 KV HT Panel
M/S Arevamake VCB breaker & panel (1250Ax1no, 40KA, 3 Sec) and other
electrical components for smooth operation of the breaker panel: 1 No.

5. 6.6 KV HT Panels& Load Isolating Breakers

M/S BHEL make P&BS main switchboard (59 panels), 6.6kv, 50 Hz, 3 phase,
3150

A,

40

KA/3

sec.

consists

of

VCB

Breakers(3150Ax3nos,1600Ax2nos,630Ax43nos),isolators,earthing switches,
current transformers, potential transformers, relays and other electrical
components for smooth operation of the P&BS main Switchboard

M/S BHEL make Emergency Switchboard (16 panels), 6.6kv, 50 Hz, 3 phase,
1250

A,

40

KA/3

sec.

consists

Breakers(1600Ax3nos,630Ax8nos),isolators,earthing

of

VCB

switches,

current

transformers, potential transformers, relays and other electrical components

for smooth operation of the P&BS Emergency Switchboard

6.6 KV, 630A Load Isolating breakers for station aux. transformers: 8 nos.

6. 415 V LT Panels & BUS Ducts

415V M/S L&T Make following Panels consists of 128 Nos.Air circuit
Breakers(4000Ax12nos,2000Ax4nos,1600Ax3nos,800Ax109nos),

isolators,

MCCBs, MPCBs, isolating switches, contactors, timers, current transformers,

potential transformers, relays and other electrical components for smooth
operation of the LT Switchboard
PMCC -1: 2 incomers, 1 bus coupler, 18 outgoings
254

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

PMCC-2 : 2 incomers, 1 bus coupler, 20 outgoings
PMCC-3 : 2 incomers, 1 bus coupler, 15 outgoings
PMCC-4 : 2 incomers, 1 bus coupler, 17 outgoings
STG MCC-1: 2 incomers, 1 bus coupler, 44 outgoings
STG MCC-2: 2 incomers, 1 bus coupler, 44 outgoings
STG MCC-3: 2 incomers, 1 bus coupler, 44 outgoings
BPTG MCC: 2 incomers, 1 bus coupler, 36 outgoings
TB MCC-1: 2 incomers, 1 bus coupler, 44 outgoings
TB MCC-2: 2 incomers, 1 bus coupler,44 outgoings
TB MCC-3: 2 incomers, 1 bus coupler, 44 outgoings
BOP MCC: 2 incomers, 1 bus coupler, and 230 outgoings
ACDB MCC: 1 incomer, 47 outgoings
ELDB MCC: 2 incomers, 29 outgoings
MLDB MCC: 2 incomers, 1 bus coupler, 35 outgoings
AC MCC: 2 incomers, 1 bus coupler, 53 outgoings
VENT MCC-1: 2 incomers, 1 bus coupler, and 17 outgoings
VENT MCC: 2 incomers, 1 bus coupler, and 21 outgoings
EPCC MCC: 3 incomers, 1 bus coupler, 19 outgoings

415V M/S C&S MAKE- BLT (BOILER) MCC (3 nos.). Consists of 9 Nos.Air
circuit Breakers (800A), isolators, MCCBs, MPCBs, isolating switches,
contactors, timers, current transformers, potential transformers, relays and
other electrical components for smooth operation of the LT Switchboard. Each
BLT MCC has 2 incomers, 1 bus coupler, and 112 outgoings

415V, 4000A TPN Bus Ducts and accessories for 8 Nos. Station Aux.
Transformers: 8nos

IISCO Steel Plant

255

Power & Blowing Station-2 (P&BS-2)

7. 230V AC Panels:
UPS DB-1 Panel (2 Nos. incomings & 90 outgoings),
UPS DB-2 Panel (2nos. incomings & 95 outgoings) &Illumination panels and
distribution boards.
.
8. UPS

UPS- 80 KVA,Make- DB Power Electronics (P) Ltd.Model: synergy i pro

3100,KVA Rating: 2x80kva

UPS- 100 KVA, KVA RATING.: 2X100KVA,Make- HI-REL.,MODEL: I4

(HR-XP-100)

9. 230V DC Panels:
DCDB-1 (2 Nos.Incomings & 60 Nos.Outgoings) & DCDB-2 (2 Nos.Incomings
& 109 Nos. Outgoings) 7.5kw, 220v Scanner Air Fan DC Motor starter panels:
3nos

10. M/S C& S Make 11 KV CT& PTSP (Power Transformer And Surge
Protector) Cubicle Panel, CT&NG Cubicle Panel and 11 KV Bus Duct &
Accessories for STG-1, 2 & 3.

CT&PTSP cubicle:
CT&PTSP cubicle consists of 12 nos. of CTs, 6 nos. of PTs, 3nos of Surge
capacitors and 3 nos. of Lightning Arrestors.
PT(11 KV primary, 110 V secondary, 50 Hz), CT (Rated Voltage 11 KV, 50
Hz, Ratio (1500/1), Surge Capacitors (18 KV, 50 Hz, 0.25 F 10%),
Lighting Arrestors (12 KV, 10 KA for 8/20 s)

CT&NG cubicle:
CT&NG cubicle consists of 1 no. of Neutral Grounding Transformer, 6 nos.
of Current Transformer and 1 no. of Loading Resistor. Secondary of Neutral
Grounding Transformer is connected with Loading Resistor

256

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Loading Resistor (650 V, 150 A for 5 minutes, 50 Hz, 1.22), NGT (11/0.2
KV, 60KVA for 5 minutes, 50 Hz), CT (Rated Voltage 11 KV, Ratio 1500/1,
For E/F protection 200/1)

Bus Ducts & Accessories (11KV, 1600A, TP Segregated phase):

The Bus ducts serve as interconnections between various equipments like
Generator, PTSP cubicle and NG Cubicle. The Bus ducts are of Segregated
Phase type. Bus bars are made of Aluminum. Bus support insulators are made
of Porcelain.EPDM rubber bellows are provided at Generator and CT&NG,
CT&PTSP cubicle end terminations: 3 units

11. M/S C& S MAKE 11 KV CT&PTSP (Power Transformer And Surge

Protector) Cubicle Panel and CT&NG Cubicle Panel & 11 KV Bus Duct &
Accessories for BPTG
a. CT&PTSP cubicle: CT&PTSP cubicle consists of 12 nos. of CTs, 6 nos. of
PTs, 3nos of Surge capacitors and 3nos of Lightning Arrestors
PT(11 KV primary, 110 V secondary, 50 Hz), CT (Rated Voltage 11 KV,
Highest Voltage 12 KV, 50 Hz, Ratio 800/1), Surge Capacitors (18 KV, 50
Hz, 0.25 F 10%), Lighting Arrestors (12 KV, 10 KA for 8/20 s)

b. CT&NG cubicle: CT&NG cubicle consists of 1 no. of Neutral Grounding

Transformer, 6 nos. of Current Transformer and 1 no. of Loading Resistor.
Secondary of Neutral Grounding Transformer is connected with Loading
Resistor
Loading Resistor (650 V, 150 A for 5 minutes, 50 Hz, 1.41), NGT (11/0.2
KV, 60KVA for 5 minutes, 50 Hz), CT (Rated Voltage 11 KV, Highest
Voltage 12 KV, 50 Hz, Ratio 800/1, For E/F protection 100/1)

c. Bus Ducts& Accessories (11KV, 800A, TP Segregated phase):TheBusducts

serve as interconnections between various equipments like Generator, PTSP
cubicle and NGCubicle. The Busducts are of Segregated Phase type. Busbars
are

IISCO Steel Plant

made

of

Aluminum.

Bus

support

insulators

are

made

of

257

Power & Blowing Station-2 (P&BS-2)

Porcelain.EPDMrubber bellows are provided at Generator and CT&NG,
CT&PTSP cubicle end terminations: 1 unit

12. DAVR Panels

a. M/S BHEL make DAVR panel for 18 MW STGs: 3 Nos.
SPECIFICATION:
REGULATOR TYPE: THYRISTOR CONTROLLED
NORMAL INPUT SUPPLY TO AVR: FROM PMG AT 220V AC,
3PH.75HZ.

b. M/S BHEL make DAVR panel for 8.275 MW BPTG: 1 No.

SPECIFICATION:
REGULATOR TYPE: THYRISTOR CONTROLLED
NORMAL INPUT SUPPLY TO AVR: FROM PMG AT 220V AC,
3PH.75HZ.

c. M/S BHEL MAKE DAVR PANEL FOR 14 MW TRTG: 1 NO.

SPECIFICATION:
REGULATOR TYPE: THYRISTOR CONTROLLED
NORMAL INPUT SUPPLY TO AVR: FROM PMG AT 220V AC,
3PH.75HZ.

13. GCD Panels

M/S AREVA MAKE GCD PANEL FOR 18 MW STGS: 3 NOS., 8.275 MW
BPTG: 1NO 14 MW TRTG: 1NO
These

panels

consist

of

Digitalvoltmeters,ammeters,MWmeter,MVARmeter,MVAmeter,PFmeter,Frequen
cy

meter,

Null

voltmeter,

Analogue

dual

volt

&

frequency

meter,Synchroscope,multipoint graphic recorder, temperature scanner, ax. MW

demand indicator,tri-vector meter, discrepancy type breaker control switches with
flasher lamps, different selector switches, LED indicating lamps, push buttons,
semaphore indicators,annunciator windows, different types of transducers,
isolating transformers,phase reversal transformer,aux. contactors,latching relays
for
258

contact

multiplication,hooters,check

synchronization
IISCO Steel Plant

Power & Blowing Station (P&BS-2)

relay,guardrelay,undervoltage relay,autosynchronizer,series flasher relays and
other electrical equipments

14. EACP Panels

M/S BHEL Make Electrical auxiliary control panels for Metering, Indication &
control scheme: 22 Nos.These consist of different digital & analogue electrical
auxiliaries and items for control, metering & indication for 22 nos. panels.

15. GRP PANELS

a. M/S AREVA MAKE GRP PANEL FOR 18 MW STGS: 3 NOS.
These GRP panels contains M/S AREVA make Micom P343 (2Nos.),
P122(1no), P632(1no), P391(1no) Relays along with Trip coil supervision
relays, voltage balancing relays,DC supply supervision relays, High speed
tripping relays, Miniature relays.

The above relays have following protection features:

i.

Over voltage protection: Stage 1&2

ii.

Reverse power

iii.

Low forward power

iv.

Under voltage relay

v.

Under frequency

vi.

Negative sequence current

vii.

Generator differential

viii.

Stator E/F

ix.

Rotor earth fault

x.

Loss of excitation

xi.

Loss of excitation with under voltage

xii.

Generator breaker failure

xiii.

Over current

xiv.

Dead machine

xv.

Pole slipping

xvi.

Phase impedance

xvii.

Generator transformer differential

xviii.

GT Restricted earth fault

IISCO Steel Plant

259

Power & Blowing Station-2 (P&BS-2)

xix.

Generator transformer stand by earth fault

xx.

Over fluxing

xxi.

IDMT over current and Earth fault

xxii.

Generator over fluxing

xxiii.

Generator stand by earth fault

b. M/S AREVA Make GRP Panel for 8.275 MW BPTG: 1NO.

These GRP panels contains M/S AREVA make Micom P343 (2Nos.),
P122(1no), P632(1no), P391(1no)Relays along with Trip coil supervision
relays, voltage balancing relays,DC supply supervision relays, High speed
tripping relays, Miniature relays.
The above relays have following protection features:

260

i.

Over voltage protection: Stage 1&2

ii.

Reverse power

iii.

Low forward power

iv.

Under voltage relay

v.

Under frequency

vi.

Negative sequence current

vii.

Generator differential

viii.

Stator E/F

ix.

Rotor earth fault

x.

Loss of excitation

xi.

Loss of excitation with under voltage

xii.

Generator breaker failure

xiii.

Over current

xiv.

Dead machine

xv.

Pole slipping

xvi.

Phase impedance

xvii.

Generator transformer differential

xviii.

GT Restricted earth fault

xix.

Generator transformer stand by earth fault

xx.

Over fluxing

xxi.

IDMT Over current and Earth fault

xxii.

Generator Over fluxing

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

xxiii.

Generator stand by earth fault

c. M/S AREVA Make GRP Panel for 14 MW TRTG: 1NO.

These GRP panels contains M/S AREVA make Micom P343 (2Nos.),
P122(1no), P632(1no), P391(1no)Relays along with Trip coil supervision
relays, voltage balancing relays,DC supply supervision relays, High speed
tripping relays, Miniature relays.
The above relays have following protection features:
i.

Over voltage protection: Stage 1&2

ii.

Reverse power

iii.

Low forward power

iv.

Under voltage relay

v.

Under frequency

vi.

Negative sequence current

vii.

Generator differential

viii.

Stator E/F

ix.

Rotor earth fault

x.

Loss of excitation

xi.

Loss of excitation with under voltage

xii.

Generator breaker failure

xiii.

Over current

xiv.

Dead machine

xv.

Pole slipping

xvi.

Phase impedance

xvii.

Generator transformer differential

xviii.

GT Restricted earth fault

xix.

Generator transformer stand by earth fault

xx.

Over fluxing

xxi.

IDMT Over current and Earth fault

xxii.

Generator Over fluxing

xxiii.

Generator stand by earth fault

IISCO Steel Plant

261

Power & Blowing Station-2 (P&BS-2)

16. Battery Chargers
a) M/S Chhabi Electricals Private Ltd Make, 220V Float cum boost charger for
1600 AH Lead-Acid battery, Rating- 220V/600A Dual FCB charger: 1 No.
b) M/S Chhabi Electricals Private Ltd Make, 220V Float cum boost charger for
800 AH Lead-Acid battery, Rating- 220V/200A Dual FCB charger: 2 Nos.

17. Battery Banks

220 V DC Battery bank: M/S Exide make battery cells (total 550 Nos): 5 Nos. (3
nos. for DC load & 2 nos. for AC load, UPS).

18. EOT Cranes & DSL T-Bars

a. PBS Turbine hall Crane: M/S Shivpra cranes Pvt. Ltd make, 35/5 Ton. Cap. X
24.0 Meters. SPAN Double Girder EOT Crane :1 No
Motors: 5 Nos.VFD drive control (Make- Siemens Sinamics, power module
240(2 nos.), power module 250 (2nos.). Total: 4 Nos.

b. CWPH crane: M/S Eddy Cranes Engineers Pvt. Ltd make. 15/5T, 8.5M
SPAN: 1 No.
Motors: 4
VFD drives control. (Make- TOSHIBA-VF S11)- 4nos.

19. Lifts
M/S Omega elevators make lift: 2Nos. Motor: 3-phase, 50 HZ, 10 HP, 960 RPM.
Capacity: 544kgs.
VFD Drive: M/S Delta make, Model: VFD-VE, FOC Control: 2 Nos.

20. DG Set and Panel& Electrical Components : One Unit

Alternator- M/S Stamford make, Frame- HCI 634 Y 1,750KVA, 415 V, 1043
Amps, 0.8 pf lag, 3 Phase, 4 wire, 1500 rpm
Control panel- M/S Jakson Engineers ltd.

21. Central LDO (Light Diesel Oil) Loading Station

LDO Unloading & Delivery pump motors & panels: 4Nos. 415v, 5HPx4nos.
262

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

22. Fire Detection & Alarm System

PBS Control room & GIS sub-stn.:2 Units

23. Ventilation System

PBS Building, GIS Sub Stn.& LT Switchboard room: 3Units

24. P&BS2 Drives

Detail spec. of Motor with type,Phase, Frame, KW/HP,
Sl.
No.

Speed/No of Poles, Volt with Tol.( %), Freq. with

Drive

tol.(%), Current, Mounting IM, Protection IP, Cooling

IC, Insul. Cl.., Temp. rise , Duty(S..), Starting Method,

Total
No

Bearing ( DE & NDE), Sl. No, Make

3 squirrel Cage induction motor,
1

Boiler Feed Pump

6.6 KV , 132 A, S1,

1300 Kw, 2980 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-1LA7716-2P, Bhel Make, Sl No.-47198A401-11-02

(BFP 4)
3 squirrel Cage induction motor, 6.6 KV , 62.5 A, S1,
2

Boiler ID Fans

525 Kw, 991 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-1LA7632-6P, Bhel Make, Sl No.- 47918401-21-

05(Boiler 2B)
3 squirrel Cage induction motor,
3

Boiler FD Fans

6.6 KV , 20 A, S1,

175 Kw,1485 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-1LA7500-4, Bhel Make, Sl No.- 47198A401-31-

06(Boiler 2B)
3 induction motor, 6.6 KV , 57.5 A, S1, 525 Kw, 989
4

CW pump for STG

rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-DCV400 3

U1000, Marathon Electrical Make, Sl No- U620188/3
3 induction motor, 6.6KV , 90 A, S1, 810 Kw, 744 rpm,

CW

pump

Blower

for

Turbo 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-VTPC1220,

Bhel Make, Sl No.-2081491/03 (TB 1), 2081491/02 (TB 2),
2081491/04 (TB 3), 2081491/01 (TB 4)

IISCO Steel Plant

263

Power & Blowing Station-2 (P&BS-2)

3 induction motor, 6.6KV, 36 A, S1, 340Kw, 1478 rpm,
6

Aux Cooling Pumps at 50 Hz ,IP 55, Ins.cl-F, temp-50 , Frame-VTPC940, CG

CWPH

Make, Sl No.-2081492/2 ( ACWP 1), 2081492/3 (ACWP

2), 2081492/1 (ACWP 3)

BOP MCC

Export

Feed

Water

Motor( to CDCP)

Portable

water

3 induction motor,

415 10%V , 63 A, S1, 37 Kw,

2960 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2

ND 200 L, CG Make, Sl No.- NADM24556, NADM 24557

supply

pump

3 induction motor,

415v, 2.1A, S1, 1.04Kw, 2950rpm,

50Hz ,IP 54, Ins.cl-F, temp-50 , Frame- , Wilo Make, Sl 2

No.3 Squirrel Cage induction motor, 415 10%V , 0.98 A,

Motor for LP Dosing

pump(Hydrazine)

S1, 0.37 Kw, 1415 rpm, 50 5% Hz , IP 55, Ins.cl-F/B

Rise,Temp- 45 , temp class- T6, Frame- 80, Bharat 4
Bijlee Make, Sl No.- M0905924, M0900554, M0905512,
M0904653
3 Squirrel Cage induction motor, 415 10%V , 0.98 A,

10

Motor for LP Dosing

pump(Amonia)

S1, 0.37 Kw, 1415 rpm, 50 5% Hz , IP 55, Ins.cl-F/B

Rise,Temp- 45 , temp class- T6, Frame- 80, Bharat 4
Bijlee Make, Sl No.- M0903426, M0903427, M0903428,
M0904673
3 induction motor, 415 V , 0.74 A, S1, 0.18 Kw, 880

11

Motor for LP Stirrer-1

rpm, 50 5% Hz , IP 55, Ins.cl-F,Temp- 45 , temp classT6, Frame- 71.M6, Rajendra Electricals Make, Sl No.-11D-

108
3 Squirrel Cage induction motor, 415 10%V , 0.98 A,

12

Motor for HP Dosing

pump

S1, 0.37 Kw, 1415 rpm, 50 5% Hz , IP 55, Ins.cl-F/B

Rise,Temp- 45 , temp class- T6, Frame- 80, Bharat 6
Bijlee Make, Sl No.- M0904588, M0906956, M0904666,
M0905926, M0905925, M0906724
3 induction motor, 415 10%V , 0.74 A, S1, 0.18 Kw,

13

Hydrazine Stirrer

880 rpm, 50 5% Hz , IP 55, Ins.cl-F,Temp- 50 , Frame- 2

71.M6, Rajendra Electricals Make, Sl No.- 11C-165

264

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

3 induction motor, 415 10%V , 0.74 A, S1, 0.18 Kw,
14

880 rpm, 50 5% Hz , IP 55, Ins.cl-F,Temp- 50 , Frame- 2

Motor for HP Stirrer

71.M6, Rajendra Electricals Make, Sl No.-F 11D-107

15

16
17
18

19

20

21

22

23

3 induction motor, 415 V, 0.74 A, 0.18 Kw, 50 Hz, 880

Agitator

rpm, Frame- 71.M6, Remi make

Motor

for

CW

Clorination booster pump

Motor for Air blower
Motor

for

CW

Chlorination evaporator
Motor

for

CW

Acid

dosing pump
Motor

for

Acid

unloading pump
Motor for Bio dispersant
dosing pump
Motor for Anti scalant
dosing pump
Motor

for

Polymoric

dispersant dosing pump

3 induction motor, 415 V, 10 Kw, 50 Hz

3 induction motor, 415 V, 2 Kw, 50 Hz

3 induction motor, 415 V, 6 Kw, 50 Hz

3 induction motor, 415 V, 0.37 Kw, 50 Hz

3 induction motor, 415 V, 2.2 Kw, 50 Hz

3 induction motor, 415 V, 2 Kw, 50 Hz

3 induction motor, 415 V, 2 Kw, 50 Hz

3 induction motor, 415 V, 2 Kw, 50 Hz

3 squirrel Cage induction motor, 415 V 10%, 2.45 A,

24

Motor for AOP for hyd S1, 1.1 Kw, 1410 rpm, 50Hz 5%, IP 55, Ins.cl-F/8 Rise,
coupling of BFP

temp-50 , Frame-T-0803093, Frame- 80 Bharat Bijlee

Make, Sl No.-MA09S43590S (BFP 4)

25

26

27

28

Motor for

Motorised

Valve
Motor

for

Motorised

for

Motorised

Valve
Motor
Valve
Motorised Valve in BFP
main Discharge

IISCO Steel Plant

3 induction motor, 415 V, 5 Kw, 50 Hz

11

3 induction motor, 415 V, 4.9 Kw, 50 Hz

24

3 induction motor, 415 V, 5 Kw, 50 Hz

16

3 induction motor,

415 V, 2.5 Kw, 50 Hz, Avg- 9A,

Lock rotor- 60A, (S2- 15 Minutes), 36 rpm, Frame - K800 4

G4A, Rotork Made
265

Power & Blowing Station-2 (P&BS-2)

29

30

31

Motorised Valve in BFP

Discharge Bypass
Motorised

for

Lock rotor- 3A, (S2- 15 Minutes), 18 rpm, Frame - K30 4

G0A, Rotork Made

for 3 induction motor, 415 V, 0.06 Kw, 50 Hz, 0.29A, S4-

Valve

Scoop Control
Motor

3 induction motor, 415 V, 0.09 Kw, 50 Hz, Avg- 0.5A,

25%, 1400 rpm, Frame- AM 71, Auma Make

Motorised

Valve

3 induction motor, 415 V, , 0.09 Kw

68

BLOWER MCC(for blower)

3 squirrel Cage induction motor, 415 V10%, 131 A , S1,
Lube
32

oil

pump

Motor

drive 75 Kw, 1475 rpm, 50 Hz 5%, IP 55, Ins.cl-F, temp-50 ,

for Type- HX+280S MB4, Make-ABB, Sl No.- 90024189 6

Blower(AOP/MOP)

(TB1/MOP),

(TB2/MOP),

90024193

(TB3/MOP),

90024194 (TB1 /AOP), 90024190 ( AOP/ TB3)

33

34

35

Motor for Jacking oil

pump for Blower

Turning device motor for

Blower
Motor for Oil vapour
extraction fan for Blower

3 induction motor, 415 V 10%, 21 A , S1, 11 Kw, 1460

rpm, 50 Hz 5%, IP 55, Ins.cl-F, temp-50 , Frame- ND 3
160 M, Make-CG, Sl No.- NADH 54A (TB3)
3 induction motor, 415 V, 1.8 A , S1, 0.75 Kw, 1390 rpm,
50 Hz , IP 55, Ins.cl-F, temp-50 , Make- Kirloskar, Sl 3
No.- TNAA34-10K105 (TB 1)
3 induction motor, 415 V, , 0.37 Kw

3 squirrelCage induction motor, 380-420 V , 2.5 A , S1,

36

Oil centrifuge motor for 1.1 Kw, 2850 rpm, 50 Hz, IP 55, Ins.cl-F, temp-50 , ABB
Blower-3

MOTORS Make, Sl No.- 07/06 310 (M2VA80B-2

80B20038-DNV-LR-ABS-GL-RINA BV)

37

Oil centrifuge motor for

Blower-2

3 squirrelCage induction motor, 415V , 2.28 A , S1, 1.1

Kw, 2825 rpm, 50 Hz, IP 55, Ins.cl-F, temp-50 , Weg 1
Make, Sl No.- 1009728733
3 squirrelCage induction motor, 380-420 V , 2.5 A , S1,

38

Oil centrifuge motor for 1.1 Kw, 2850 rpm, 50Hz, IP 55, Ins.cl-F, temp-50 , ABB
Blower-1

MOTORS Make, Sl No.- 07/06 310 (M2VA80B-2

80B20038-DNV-LR-ABS-GL-RINA BV)

266

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Oil centrifuge motor for 3 squirrelCage induction motor,415 V , 1.75 A , S1, 0.75
39

Blower(For oil inlet & Kw, 1405 rpm, 50Hz, IP 55, Ins.cl-F, Frame- 80, Bharat 6
Outlet pump)

Bijlee Make, Sl No.- MA080435

Motor
40

condensate

extraction

pump

for

Blower

41

42

43

44

45

Motor

for

Motorised

for

Motorised

Valve for Blower

Motor

for

Motorised

Valve for Blower

Motor

for

Motorised

Valve for Blower

Motor

37 Kw, 1465 rpm, 50Hz 5%, IP 55, Ins.cl-F/B, temp-50 ,

Make-Bharat Bijlee,

Sl No.- L0905637(TB1/CEP2),

L0905093(TB2/CEP2), L0905091 (TB3/CEP2)

Valve for Blower

Motor

3 squirrelCage induction motor, 373-456 V , 6-3.6 A , S1,

for

Motorised

Valve for Blower

3 induction motor, 415 V, , 0.3 Kw

45

3 induction motor, 415 V, , 4 Kw

3 induction motor, 415 V, , 0.9 Kw

3 induction motor, 415 V, , 0.72 Kw

24

3 induction motor, 415 V, , 1.2 Kw

STG MCC (for STG)

3 induction motor, 415V 10%, 76 A, S1, 45 Kw, 2945
rpm, 50 5% Hz, IP 55, Ins.cl-F, temp-50 , Frame-ND
46

Lube oil pump drive 250 L, CG Make, Sl No- NADT 99601 ( STG 1- MOP),
Motor for STG

NADT 99603 ( STG 2- MOP), NADT 99605 ( STG 2-

AOP), NADT 99602 ( STG 3- MOP), NADT 99606 ( STG

3- AOP)
3 induction motor, 415V 10%, 7.4 A, S1, 3.7 Kw,
1440 rpm, 50 Hz 5%, IP 55, Ins.cl-F, temp-50 , Frame47

Motor for Jacking oil ND 112 M, CG Make, Sl No- HLAM 13689 ( STG 1-JOP
pump for STG

1), INJ 11127 ( STG 1-JOP 2), GKG 10179 ( STG 2-JOP

1), INK 11541 ( STG 2-JOP 2), HLAM 13690 ( STG 3-JOP
1), INK 11536 ( STG 3-JOP 2)

48

Turning

Gear

motor for STG

IISCO Steel Plant

drive

3 induction motor, 415V 10%, 40 A, S1, 22 Kw, 1460

rpm, 50 Hz, IP 55, Ins.cl-F, temp-50 ,
Siemens

Make,

Sl

No-

N8/64123494

Frame-180L, 3
(STG

1),
267

Power & Blowing Station-2 (P&BS-2)

N8/64139365 (STG 2), N8/64123896 (STG 3)

3 Squrrel Cage induction motor, 415 V 10%, 0.81A,

49

Motor for Oil vapour S1, 0.37Kw, 2880 rpm, 50Hz 5%, IP 55, Ins.cl-F/B Rise,
temp-50 , Temp Cl- T6, Frame-80, Bharat Bijlee, Type-

extraction fan for STG

MD0802A3, Sl No.3 squirrelCage induction motor, 380-420 V , 2.5 A , S1,

50

1ST Oil centrifuge motor 1.1 Kw, 2850 rpm, 50Hz, IP 55, Ins.cl-F, temp-50 , ABB
for STG

MOTORS Make, Sl No.- 07/06 310 (M2VA80B-2

80B20038-DNV-LR-ABS-GL-RINA BV)
Oil centrifuge motor for 3 induction motor,
51

STG(For

oil

inlet

& Kw,1405 rpm, 50Hz 5%, IP 55, Ins.cl-F, temp-50 , 6

Outlet pump)
Motor
52

for

380-415 V , 1.75 A, S1, 0.75

Frame-MA080435, Bharat Bijlee make.

Motorised

Valves GS-03/ GS-08 for 3 induction motor, 415 V, , 0.18 Kw

STG
3 induction motor,
53

415 V 10%, 51.9 A, S1, 30 Kw,

Motor for CEP pumps 1460 rpm, 50 Hz ,IP 55, Ins.cl-F/B, temp-50 , Framefor STG

MA20L435, Bharat Bijlee Make, Sl No.-L0905115(CEP 1

STG 1), L0905116 ( CEP 2- STG 1),

54

55

56

57

58

Motor

for

Motorised

Valve for STG

Motor

for

Motorised

Valve for STG

Motor

for

Motorised

Valve for STG

Motor

for

Motorised

Valve for STG

Motor

for

Valve for STG

Motorised

3 induction motor, 415 V, , 2.5 Kw

3 induction motor, 415 V, , 0.09 Kw

12

3 induction motor, 415 V, , 1.2 Kw

3 induction motor, 415 V, , 0.72 Kw

24

3 induction motor, 415 V, , 5 Kw

BPTG MCC

268

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Lube
59

oil

pump

Motor

drive
for

BPTG(AOP/MOP)

60

Turning Gear drive motor

for BPTG

3 induction motor,

415 V 10%, 124 A, S1, 75 Kw,

2960 rpm, 50 Hz 5%, IP 55, Ins.cl-F, temp-50 , FrameND280M, CG Make, Sl No.-NADV 96700 ( AOP ), NADV

96699 ( MOP)
3 induction motor, 415 V 10%, 34 A, 19.5 Kw, 1463
rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame- 1

180M,Siemens Make, Sl No.-N8/64133599

3 Squrrel Cage induction motor, 415 V 10%, 0.85A,

61

Motor for Oil vapour S1, 0.37Kw, 2880 rpm, 50Hz 5%, IP 55, Ins.cl-F/B Rise,
extraction fan for BPTG

temp-50 , Temp Cl- T6, Frame-80, Bharat Bijlee, Sl No.-

M0911980

62

Oil centrifuge motor for

BPTG

3 induction motor, 380-415 V , 2.5 A, S1, 1.1 Kw, 2850

rpm, 50 Hz 5%, IP 55, Ins.cl-F, temp-50 , Frame- 1
M2VA80B-2, ABB Make, Sl No- 08/07 252
3 induction motor,

63

415 V 10%, 1.75A, S1, 0.75Kw,

Motor for oil inlet & oil 1485 rpm, 50Hz 5%, IP 55, Ins.cl-F/G, temp-50 ,
outlet

Frame-MA 080435, Bharat Bijlee, Sl No.-K0937389 (Inlet),

K0937422 (Outlet)
Motor for Condensate 3 induction motor, 415 V , 2.1A, S1, 0.75Kw, 1485 rpm,
64

collection trfr pump for 50Hz , IP 54, Ins.cl-F, temp-50 , Wilo Make, Sl No.- 2
BPTG

65

66

67

68

69

70

Motor

4024289/0610/22800
for

Motorised

Valve for BPTG

Motor

for

Motorised

Valve for BPTG

Motor

for

Motorised

Valve for BPTG

Motor

for

Motorised

Valve for BPTG

Motor

for

Motorised

Valve for BPTG

Motor

for

Motorised

Valve for BPTG

IISCO Steel Plant

3 induction motor, 415 V, , 4 Kw

3 induction motor, 415 V, , 0.9 Kw

3 induction motor, 415 V, , 5 Kw

3 induction motor, 415 V, , 0.09 Kw

3 induction motor, 415 V, , 0.72 Kw

3 induction motor, 415 V, , 1.2 Kw

269

Power & Blowing Station-2 (P&BS-2)

EOP Drive motor
DC Motor, Field Voltage - 220 V, Field Current- 0.6 A,
Armature Voltage - 220 V, Armature Current- 61 A, 11
71

Blowers

EOP

drives Kw, S1, 2900 rpm, IP 55, Ins.Cl- F, temp-50 , MTG- B3,

motor(DC)

Frame AF 82253,

Cooling-IC0141, CG Make, Sl. No.-

DASH 5379 J8A00018 (TB3), DASH 5378 J8A00017 (

TB2)
DC Motor, Field Voltage - 220 V, Field Current- 0.55 A,
Armature Voltage- 220 V, Armature Current- 61 A, 11 Kw,
72

STG

EOP

drives S1, 2900 rpm, IP 55, Ins.Cl- F, temp-50 , MTG- B3,

motor(DC)

Frame AFS 2258, Cooling-IC0141, CG Make, Sl. No.-

DASH 5265 (STG 1), DASH 5264 (STG 2), DASH 5263
(STG 3)
DC Motor, Field Voltage - 220 V, Field Current- 0.55 A,
73

BPTG

EOP

drives Armature Voltage- 220 V, Armature Current- 61 A, 11 Kw,

motor(DC)

S1, 2900 rpm, IP 55, Ins.Cl- F, temp-50 , MTG- B3,

Cooling-1C01, CG Make, Sl. No.- 0A3119262

DC Motor, Field Voltage - 220 V, Field Current- 0.41 A,

74

Motor for Scanner Air

fan(DC)

Armature Voltage- 220 V, Armature Current- 40 A, 7.5 Kw,

S1, 2900 rpm, IP 55, Ins.Cl- F, temp-50 , MTG- B3, 3
Frame AFS 180H, Cooling-IC0141, CG Make, Sl. No.OASH3091 ( Boiler 1),

PMCC-04

75

Motor for Cooling Tower

Fan

3 Squirrel Cage induction motor, 415 V , 157 A, S1, 90

Kw, 1475 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 10
HX+280SMC4, ABB Make, Sl No.- 90017534
3 induction motor,

76

415 V , 228 A, S1, 132 Kw, 1485

Motor for Side stream rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-DV315M,

filter pump

Marathon Electrial Make, Sl No.- 295623070002 (SSFP1),

295623070001 (SSFP2),295623070003 (SSFP3)

77

270

Air scouring blower of

SSF

3 Squirrel Cage induction motor, 415 V , 27.6 A, S1, 15

Kw, 1450 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2
160

L,

Bharat

Bijlee

Make,

Sl

No.-

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

K0932121BE/BBL/0555/09

BOILER MCC (for boiler)

Motor for FD FAN outlet 3 induction motor, 415 V , 0.45 A, S2-15 Minutes, 0.72
78

dampers / Air Heater Kw, 1400 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 6
Bypass damper

79

Motor for ID FAN Inlet /

Outlet gates
Motor

80

AM-71, Auma India Make, Sl No.- JA102-S88

for

Drum

continuous / intermittent
blowdown valve

81

82

83

3 induction motor, 415 V, 2.2 Kw, 50 Hz

3 induction motor,

12

415 V, 1.2 Kw, 50 Hz, Torque

Motors Make (Continuous), Ref- ISS:3251990

Motor for Main steam 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 4 Kw,
vent-reg valve

Antireb Make, Type - M2, Sl No- 4116/08

Motor for SH SPRAY 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 1.2 Kw,
control bypass valve
Motor

for

SB

Antireb Make, Type-M4A, Sl No- 4229-08

PRV 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 1.2 Kw,

Bypass vavle

Antireb Make, Type-- DC2A705BMF/IS

Motor for LDO LOPCV 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 0.102
84

LOFCV

Bypass-PH Kw, Torque Make (Bypass), Instrumentation Ltd. (PCV), 6

valves
85

86

87

Ref-ISS3251996 (By pass), Sl No-VSLVAIr (PCV)

Motor for CBM FCV 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 7.5 Kw,
Bypass vavle
Motor

for

Limit Torque Make, Ref-L120/40, Sl No.- 5543A00

ECO

inlet 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 4 Kw,

valve

Limit Torque Make, Ref-ISS3251996

Motor for Bypass ECO 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 0.09
inlet valve
Motor for Drain Valves -

88

ECO /

ECO inlet line/

Blower/ Drum Header/

PLATEN SH/ Final SH

89

Kw, IP 68, Limit Torque Make, Sl No- L120/10

IISCO Steel Plant

3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 1.2 Kw,

Type- M2, Antireb Motor Make, Sl no- 4160/08 (SH), 18
4104/08 (Platen), 4196/08 (Eco Inlet), 4184/08 (Eco out)

Motor for Main steam 3 induction motor, 415 V,, S2-15Minutes, 50 Hz, 4 Kw,
vent valve

Frame- AM90, Auma Make

271

Power & Blowing Station-2 (P&BS-2)

90

Motor for Main steam

stop valve

main steam valve / SB

Main line-isolating vavle

92

93

94

95

96

Motor for Main steam

inter blo.downdra. Valve
Hoist

drive

for

ID

Fan(handling system)
Hoist

drive

for

FD

Fan(handling system)
Motor

for

Kw, 1400 rpm, IP 67, Frame- AD00132-4/1402, Auma 3

Make

Motor for Integral bypass

91

3 induction motor, 415 V,20 A, S2-15Minutes, 50 Hz, 7.5

Light

oil

pumps

3 induction motor, 415 V,1.06 A, S2-15Minutes, 50 Hz,

0.18 Kw, 917 rpm, Frame- 80, Type- M2, Antireb Make

3 induction motor, 415 V, 50 Hz, 0.09 Kw

3 induction motor, 415 V, 50 Hz, 16 Kw

3 induction motor, 415 V, 50 Hz, 10 Kw

3 Flame Proof induction motor,

415 10%V , 13.5 A,

S1, 7.5 Kw, 2660 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , 6

Frame-LE 132, KIrloskar Make, Sl No.- 09SH2353-1

Damper blower motor at

ID FAN OUTLET

3 induction motor,

415 V , 4.7 A, S2-15 Minutes, 2.2

Kw, 2880 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 6

AM-90, Auma India Make, Sl No.- JA111-01141
3 induction motor, 415 10% V , 13.6 A, S1, 7.5 Kw,

97

Scanner air fan motor AC

2860 rpm, 50 Hz , IP 55 ,Ins. Cl - F, Temp-50 , Frame- 3

IM 132 M, Kirloskar Make, Sl No.- 09SH2064-01
3 induction motor,

98

Motor for LR Blowers

415 10%V , 1.4 A, S2- 30 MIN,

0.45 Kw, 1405 rpm, 50 Hz , IP W55 TESC,Ins. Cl F,

Temp-65 , Frame- CPM 80, Kirloskar Make, Sl No.-

30

UML-75P-395

99

Motor
Blowers

for

ROTARY

3 induction motor, 415 V , 0.61 A, S1, 0.09 Kw, 1425

rpm, 50 Hz , IP W55 TESC, Frame- CFM 71, Kirloskar 42
Make, Sl No.- UML-79P-1335

DM PLANT
3 Squirrel Cage induction motor, 415 V , 14.5 A, S1, 7.5
100

Motor for Air blower for Kw, 1440 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , FrameET

D 132 M, Marathon Electric Make, Sl No.- 115643000001,

115643000002

272

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

3 squirrel Cage induction motor, 415 V , 20.1 A, S1, 11
101

Motor for Effluent feed Kw, 1450 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Framepump

D 160 M, Marathon Electric Make, Sl No.- 10565900040,

10565900041

102

103

104

105

106

Motor for NaOCl Dosing

pump

415 V ,

50 Hz , Mod- V13,

Maximum O/P- 12(LPH), Max Pressure-2.0 Kg per cm 2

square, Milton Roy India Make, Sl No.- 26718/9

Motor for Polymer dosing

pump

3 induction motor, 415 V , 4.6 A, S1, 2.2 Kw, 2830 rpm,

50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-D 90 L, 2

Marathon Electric Make, Sl No.- 115644520004

Motor for Polymer dosing

pump

Motor

1 induction motor,

3 TEFC induction motor,

415 V 10%, 1.07 A, S1,

0.37 Kw, 1410 rpm, 50 Hz , IP 55, Ins.cl-F, temp-45 , 2

Frame-G-DA71SK, Make, Sl No.- INA 0480, INA 10968

for

Coagulant

dosing pump

3 TEFC induction motor,

415 V 10%, 1.07 A, S1,

0.37 Kw, 1410 rpm, 50 Hz , IP 55, Ins.cl-F, temp-45 , 2

Frame-G-DA71SK, Make, Sl No.- INA T49, INA 0106

Motor for Lime dosing

pump

3 squirrelCage induction motor, 415 V , 4.6 A, S1, 2.2

Kw, 2880 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2
D 90L, Marathon Electric Make, Sl No.3 squirrel Cage induction motor, 415 V , 22.1 A, S1, 11

107

Motor for MGF feed Kw, 1450 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Framepump

D 160 M, Marathon Electric Make, Sl No.- 10565900039,

10565900047, 10565900048

108

Motor for Sludge transfer

pump

3 squirrelCage induction motor,

415 V , 7.2A, S1, 3.7

Kw, 2850 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2

D 100L, Marathon Electric Make, Sl No.3 squirrelCage induction motor, 415 V , 10.7 A, S1, 5.5

109

Motor

for

MGF

air Kw, 1440 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-

blower

D 132 S, Marathon Electric Make, Sl No.- 115642990001,

115642990002

110

Motor
Agitator

IISCO Steel Plant

for

Caustic

3 Squirrel Cage induction motor, 415 V , 1.26 A, S1,

0.37 Kw, 910 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , 4
Frame-BPM 80, Kirloskar Make, Sl No.- VBA 60-25
273

Power & Blowing Station-2 (P&BS-2)

111

112

113

Motor for Scale inhibitor

dosing pump

V-230, Hz-50, Make- Milton Roy India Pvt. Ltd., ModelB-92, Max OP- 10.0 (LPH), Max PR-4.0(Kg/sq.cm), Sl. 2
No.-3926,3921.

Motor for SMBS dosing

pump

V-230, Hz-50, Make- Milton Roy India Pvt. Ltd., Model-V11, Max OP- 5.0 (LPH), Max PR-4.0(Kg/sq.cm), Sl. No.- 2
26720,26721.

Motor for Acid dosing

pump

V-230, Hz-50, Make- Milton Roy India Pvt. Ltd., Model-B91, Max OP- 6.0 (LPH), Max PR-10.0(Kg/sq.cm), Sl. No.- 2
3923,3924.
3 induction motor,

114

415 V 10%, 63 A, S1, 37 Kw,

Motor for High pressure 2950 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-50 , Framepump

200

L,

Siemens

Make,

Sl

No.-

N8/64278284,

N8/64278285, N8/64278286
3 squirrel Cage induction motor, 415 V , 52.4 A, S1, 30
115

Motor for DMF Feed Kw, 1470 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Framepump

DV

200

L,

Marathon

Electric

Make,

Sl

No.-

1056049S0005, 1056049S0006

116

Motor

for

Chemical

cleaning pump

3 Sqirrel Cage induction motor, 415 V , 14.3A, S1, 7.5

Kw, 2850 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 1
D 132 S, Mrathon Electric Make, Sl No.- 10566136P0002
3 squirrel Cage induction motor, 415 V , 65 A, S1, 37

117

Motor

for

Backwash

pump

Kw, 1470 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , FrameDV

225

S,

Marathon

Electrical

Make,

Sl

No.- 3

1056037SP0002 ( Pump A), 1056037SP0004 ( Pump B),

1056037SP0003 ( Pump C)
3 squirrel Cage induction motor, 415 V , 17 A, S1, 9.3

118

Motor for Air blower for Kw, 1445 rpm, 50Hz , IP 55, Ins.cl-F, temp-50 , FrameDMF

D 160 M, Marathon Electric Make, Sl No.- 115642980001,

115642980002

119

274

Motor for Degasser air

blower

3 Sqirrel cage induction motor,

415 V 10% , 4.61 A,

S1, 2.2 Kw, 1430 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp- 4

50 , Frame-ND 100L , CG Make, Sl No.- 1632J

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

3 Sqirrel cage induction motor, 415 V , 52.4 A, S1, 30

120

Motor for Degassed water

transfer pump

Kw, 1470 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , FrameD

200

L,

Marathon

1056011SP0001,

Electrical

Make,

1056011SP0002,

Sl

No.- 4

1056011SP0003,

1056011SP0004
3 squirrel Cage induction motor, 415 V , 27.1 A, S1, 15
121

Motor for Air blower for Kw, 1460 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , FrameMB

D 160 L, Marathon Electric Make, Sl No.- 115642970001,

115642970002

122

Motor for Amine dosing

pump

3 squirrel Cage induction motor, 415 V , 1.2 A, S1, 0.37

Kw, 910 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2
BPM 80, Kirloskar Make, Sl No.- VBA60-14, VBA60-28
3 Squirrel Cage induction motor, 415 V , 14.3 A, S1, 7.5

123

Motor

DM Kw, 2850 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-

for

Regeneration pump

D 132 S, Marathon Electric Make, Sl No.- 10566136P0003,

1056613P0001

124

125

Motor

for

Caustic

unloading pump

Motor for Acid unloading

pump

3 squirrelCage induction motor,

415 V , 4.6A, S1, 2.2

Kw, 2830 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2

D 90L, Marathon Electric Make, Sl No.3 squirrelCage induction motor,

415 V , 4.6A, S1, 2.2

Kw, 2830 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame- 2

D 90L, Marathon Electric Make, Sl No.3 Sqirrel cage induction motor, 415 V , 14.5 A, S1, 7.5

126

Motor

for

neutralized Kw, 1440 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-

water transfer pump

D 132 M, Marathon Electrical, Sl No.-

105645800001,

105645800002
3 induction motor,

415 V , 1.2 A, S1, 0.37 Kw, 910

rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-BPM 80, 1

127

Motor for Agitator of Kirloskar Make, Sl No.- VBA60-15

Scale Inhibitor

3 induction motor, 415 V 10%, 1.13 A, S1, 0.32 Kw,

910 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-50 , Frame- 1
ND 80,CG Make, Sl No.- JFG 17588

IISCO Steel Plant

275

Power & Blowing Station-2 (P&BS-2)

3 squirrel Cage induction motor, 415 V 10%, 1.13 A,
128

Motor for Agitator of S1, 0.37 Kw, 910 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp50 , Frame-ND 80,CGMake, Sl No.- JFG 10943, FG

SMBS dosing

17593

129

Motor for Agitator of

lime dosing

3 induction motor, 415 V 10%, 1.44 A, S1, 0.55 Kw,

1410 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-ND 2
80,CGMake, Sl No.- NDA4AJ
3 induction motor, 415 V 10% , 53 A, S1, 30 Kw,

130

2960 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp- 40 ,

DM Traqnsfer Pump

Frame-ND 200L,

CG Make, Sl No.- NADM 31891,

NADM 31890

131

Motor for Agitator of

polymer

3 induction motor, 415 V , 1.81 A, S1, 0.75 Kw, 1410

rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,
GA80MG, CG Make, Sl No.- INF2056
3 induction motor,

132

Frame-G- 2

415 V , 1.79 A, S1, 0.55 Kw, 680

rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-ND90L, 1

Motor for Clarifier

CG Make,Efficiency-68 Sl No.- INF2056

3 induction motor, 415 V , 2.91 A, S1, 1.1 Kw, 710 rpm,
133

50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-ND132S, CG 1

Motor for Clarifier

Make,Efficiency-75 Sl No.- INF2056

PMCC-02
134

Condensate

Transfer

Pump

150 Kw, 1405 RPM, ND315L, S1, 245 A, Delta, B3

Make up Water pump to

DM
135

between
Tower(MCC

Plant 3 induction motor, 415 V , 65 A, S1, 37 Kw, 1470 rpm,

cooling 50 Hz , IP 55, Ins.cl-F, temp-50 ,
betwn Marathon

CWPH & CT )

Electric

Make,

Sl

Frame-DV225S, 3

No.-1056037SP0005,

1056037SP0001, 1056037SP0006

AC & VENT
3 Sqirrel cage induction motor, 415 V 10% , 34 A, S1,
136

Condenser water pump

18.5 Kw, 1455 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-50

, Frame-HX+180ML C4, ABB Make, Sl No.- 590234,
590236

276

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

3 induction motor, 415 V (+ 10%, -15%) , 53 A, S1, 30
137

Kw, 1475 rpm, 50 (+3%, -6%) Hz , IP 55, Ins.cl-F, temp-50

Chill water pumps

, Frame-ND 200 M, CG Make, Sl No.- NADM 2695,

NADM 26953
138

3 induction motor, 415 V, 28A, 15 Kw, 1475 rpm, 50 Hz,

Motor for AHU

CG Make Frame- ND180M

3 induction motor,

139

STG

Ventilation

415 V (+ 10%, -15%) , 185 A, S1,

Fan 110 Kw, 1485 rpm, 50 (+3%, -6%) Hz , IP 55, Ins.cl-F/B

rise, temp-50 , Frame - MH315413, Bharat Bijlee Make,

Motor

Sl No.-1105313, 1105311, 1105314, 1105310, 1105312

140

STG Ventilation Pump

Motor

3 induction motor, 415 10% V , 15.91 A, S1, 45 Kw,

1470 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-50 , Type - 4
HX+2253MC4, ABB Make, Sl No.- 82-0B71
3 Sqirrel cage induction motor, 415 V 10% , 39.60 A,

141

LT Ventilation Fan Motor

S1, 22 Kw, 1460 rpm, 50 6% Hz , IP 55, Ins.cl-F/B Rise,

temp-50 ,

Frame-180L, Bharat Bijlee Make, Sl No.-

L1300251

142

LT

Ventilation

Motor

Pump

3 Sqirrel cage induction motor, 415 V 10% , 81 A, S1,

50 Kw, 1470 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-50 , 1
Frame-RX-225SMC4, ABB Make, Sl No.- 820867
3 induction motor,

143

HT

Switchgear

motors

Vent 1475 rpm, 50

415 10% V , 40 A, S1, 22 Kw,

5% Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-ND 180 L, CG Make, Sl No.- NADL-54A, NADE-

54A
EOT Crane(TG Building)
3 Squirrel Cage induction motor, 415, 40 A, S4 - 40%,
144

Main Hoist motor

18.5 Kw, 985 rpm, 50 Hz, IP 55, Ins.cl-F, temp-50 ,

Frame-VD 200 LB, Marathon Electricals Make, Sl No.-

2956381V0002
3 Squirrel Cage induction motor, 415, 1.13 A, S4 - 40%,
145

Aux Hoist motor

5.2 Kw, 955 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-VD 132 M, Marathon Electricals Make, Sl No.295661160037

IISCO Steel Plant

277

Power & Blowing Station-2 (P&BS-2)

3 Squirrel Cage induction motor, 415, 4.4 A, S4 - 40%,
146

Cross Transfer motor

1.9 Kw, 935 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Frame-VD 112 M, Marathon Electricals Make, Sl No.-

295661220012
3 Squirrel Cage induction motor, 415, 6.7 A, S4 - 40%,
147

3.1 Kw, 958 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 ,

Long Travel motor

Frame-VD 200 LB, Marathon Electricals Make, Sl No.-

295661150002, 295661150002
EOT Crane(CWPH Building)
3 induction motor, 415 10% V , 15.91 A, S4, 7.5 Kw,
148

940 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-45 , Frame- 1

Main Hoist motor

ND 132 N, ?? Make, Sl No.- NADG124958T

3 induction motor, 415 10% V , 10.51 A, S4, 3.7 Kw,
149

Auxilary Hoist motor

910 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-45 , Frame- 1

, ?? Make, Sl No.- NHDE12070TOP
3 induction motor, 415 10% V , 1.66 A, S4, 0.55 Kw,

150

Cross Transfer motor

890 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-45 , Frame- 1

ND 80, ?? Make, Sl No.- NADA12146 TOP
3 induction motor, 415 10% V , 4.20 A, S4, 1.5 Kw,

151

880 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp-45 , Frame-, 1

Long Travel motor

?? Make, Sl No.- NADG11884 TOP

IBD Pumps 1,2 ( Boiler 3 squirrelCage induction motor, 415 V , 20.5 A, S1, 11
152

Kw, 2800 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-

3)

(MCC between CWPH & D 160 M, Marathon Electric Make, Sl No.- J10567200001,
CT )
IBD

153

(For

J10567200003
3,4,5,6 3 squirrelCage induction motor, 415 V , 14.3 A, S1, 7.5

Pumps
Boiler

&

2) Kw, 2850 rpm, 50 Hz , IP 55, Ins.cl-F, temp-50 , Frame-

(MCC between CWPH & D 132 S, Marathon Electric Make, Sl No.- 105645810001,
CT )

105645810002, 105645810003, 105645810004

LDO Unloading Pump ( 3 induction motor, 415 10% V , 7.56 A, S1, 3.7 Kw,
154

From Tanker to Main 1450 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp.Cl -T4, 2

Storage)

278

Frame-E 112 M, CG Make, Sl No.-

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

155

LDO

Delivery

Pump

From

Screw 3 induction motor,

415 10% V , 7.4 A, S1, 3.7 Kw,

Main 1450 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp.Cl -T3, 2

Storage to Field Storage )

Frame-E 112 M, CG Make, Sl No.3 induction motor, 415 10% V , 13.7 A, S1, 7.5 Kw,

156

AC Chiller fan motor

1455 rpm, 50 5% Hz , IP 55, Ins.cl-F, Eff.- 87%, Frame- 2

D132 M, CG Make, Sl No.3 induction motor, 415 VAC , 16 A, Rat- CONT., 7.6

157

PBS Lift motor

Kw, 960 rpm, High torque Lift Duty Motor as per IS 8151, 2
Ins.cl-F, Frame- 160, OMEGA Make, Sl No.3 squirrel Cage induction motor, 415 10% V , 267 A,

158

Compressor Motors

S1, 160 Kw, 1485 rpm, 50 5% Hz , IP 55, Ins.cl-F, temp- 2

50 , Type - M2ABA315MLA4, ABB Make, Sl No.-

25. Centralized Air Condition System:

It consists of 2 nos. chillers. This AC system has 4 Compressor motors, 2 Cooling
water

motors, 2 chiller water motors, 2Cooling tower fan motors & 3Air

handling Blower motors

26. Data Concentrator Panels

a. HT Data Concentrator panel
b. LT Data Concentrator panel

27. Earth Pits

Earth pits: 130 nos.
Electronic Earthpits: 4 nos.

28. Illumination
All inside and outside illumination (AC&DC) of PBS-2 complex excluding DM
Plant
Sl. No.

Type of lighting Fixtures

Recessed mounting type down lighter suitable for false ceiling mounting 40.000

IISCO Steel Plant

Quantity

279

Power & Blowing Station-2 (P&BS-2)

&60W GLS lamp
ii

Bulk head GLS wall mounting type

84.000

iii

Industrial type fixture suitable for surface mounting on wall or ceiling & 30.000
1x36W fluorescent tube

iv

Industrial type fixture suitable for surface mounting on wall or ceiling & 228.000
2x36W fluorescent tube

Corrosion resistant industrial batten for TLD 2x36W fluorescent lamp

36.000

vi

Recess mounting type decorative lighting fixture with 2x36W florescent 443.000
lamps, copper blast ,starter & power factor improvement capacitor

vii

Integral well-glass luminary suitable for 1x125W HPMV

64.000

viii

Industrial well glass luminary suitable for 1x70 HPSV lamp with non- 439.000
integral control gear

ix

Street lighting fixture suitable for 125W HPSV lamp with optic reflector & 54.000
acrylic cover

Industrial High bay fixture suitable for 125W HPMV Lamp High bay 40.000
fixture

xi

Industrial High bay fixture suitable for 250W HPMV Lamp High bay 114.000
fixture

xii

Street lighting fixture suitable for 250W HPSV lamp with optic reflector & 12.000
acrylic cover
Grand Total

280

1584.000

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

SCHEMATIC DIAGRAM FOR ELECTRICAL SYSTEMS (Diagram No. 5)

IISCO Steel Plant

281

Power & Blowing Station-2 (P&BS-2)

G) DM Plant
1. List Of Major Equipment:
TAG No.
DP-108-A/B
DT-108-A/B
DP-109-A/B
DT-109-A/B
DP-110-A/B
DT-110-A/B
DP-111-A/B
DT-111-A/B
P-102-A/B
P-103-A/B
P-104-A/B
T-101-I/II/III
SC-112
HRSCR-113
CWS-114
MGFFP-115A/B/C
SCP-116
STP-117-A/B
ET-106
P-107-A/B
AB-105-A/B
MGF-201-A/B
AB-202-A/B
DP-203-A/B
DT-203-A/B
DP-204-A/B
DT-204-A/B
DP-205-A/B
DT-205-A/B
MCF-206-A/B/C
HPP-207-A/B/C
282

Description
NaOCl dosing pump
NaOCl dosing Tank
Polymer dosing pump
Polymer dosing Tank
Coagulant dosing pump
Coagulant dosing Tank
Lime dosing pump
Lime dosing Tank
IBD
Drain
transfer
pump
IBD
Drain
transfer
pump
IBD
Drain
transfer
pump
IBD Drain transfer sump
Stilling Chamber
Clarifier
Clarifier water sump
MGF Feed Pump
Sludge collection Sump
Sludge transfer pump
Equilisation sump

Size/Cap.
10 LPH @ 4 Kg/cm2
0.5 m diaX 0.8 hos
100 LPH @ 4 Kg/cm2
1.1 m dia X 1.5 hos
50 LPH @ 4 Kg/cm2
0.8 m dia X 1.4 hos
1 cum/hr @ 4 Kg/cm2
1.3 m dia X 1.6 hos
60cum/hr @ 3 Kg/cm2

MOC
PP
MSRL
PP
MSRL
PP
MSRL
PP
MSRL
CS

Qty
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)
2 (1w+1S)

30cum/hr @ 3 Kg/cm2

CS

2 (1w+1S)

30cum/hr @ 3 Kg/cm2

CS

2 (1w+1S)

40/40/90 cum
2.1X1.5X2.5 HT
10DX4.8 HT
10X10X3.5 m-0.5 mFB
80cum/hr @ 2.5 Kg/cm2

RCC
RCC
RCC
RCC
Cl

3
1
1
1
3 (2w+1s)

RCC
Cl
RCC

1
2 (1w+1s)
1

Cl
Cl
MSEP
Cl

2 (1w+1s)
2 (1w+1s)
2 (1w+1s)
2 (1w+1s)

PP

2 (1w+1s)

MSRL

2 (1w+1s)

PP
MSRL
PP
MSRL
SS

2 (1w+1s)
2 (1w+1s)
2 (1w+1s)
2 (1w+1s)
3(2w+1s)

SS

3(2w+1s)

5x5x3.5 m HOS
10cum/hr @ 1.5 Kg/cm2
10.8X13.5X4.5 m -0.8
mFB
Effluent Feed pump
160cum/hr @ 1.5 Kg/cm2
Air blower for ES
250cum/hr @ 0.5 Kg/cm2
Multi Grade Filter
3400 dia X 2200 hos
MGF air blowers
4.33cum/hr
@
1.5
2
Kg/cm
Scale inhibitor dosing 101 LPH @ 4 Kg/cm2
pumps
Scale inhibitor dosing 0.7 dia X 1.2 ht
tanks
SMBS dosing pump
101 LPH @ 4 Kg/cm2
SMBS dosing Tank
0.6 dia X 0.9 ht
Acid dosing pump
5 LPH @ 4 Kg/cm2
Acid dosing tank
0.45 dia X 0.65 ht
Micron cartridge filter
80 cum/hr (20 NO
CATR)
High pressure pumps
77.2
cum/hr
@

IISCO Steel Plant

Power & Blowing Station (P&BS-2)

9.5Kg/cm2
CCP-213
Chemical cleaning pump 56 cum/hr @ 2.5Kg/cm2 SS
1
CCT-212
Chemical cleaning tank
1400 diaX1500ht
MSRL 1
MCF-214
Chemical cleaning MCF 56 cum/hr. (16 NO SS
1
CATR)
RO-208-A
Reverse osmosis unit
8-6 ELE-long
7
RO-208-B
Reverse osmosis unit
8-6 ELE-long
4
RO-208-C
Reverse osmosis unit
8-6 ELE-long
2
RO-209-A
Reverse osmosis unit
8-6 ELE-long
7
RO-209-B
Reverse osmosis unit
8-6 ELE-long
4
RO-209-C
Reverse osmosis unit
8-6 ELE-long
2
ROPS-210
RO permeate water 10X10X3.5 m-.5 mFB
RCC
1
storage sump
DMFP-211-A/B
DM feed pump
165 cum/hr
SS
2 (1w+1s)
FBWS-301
Filter backwash sump
10X5X3.3 m 0.6 mFB
RCC
1
BWP-302-A/B/C
Backwash pump
250 cum/hr @ 4 Kg/cm2 Cl
2 (1w+1s)
DMF-303-A/B
Dual media filter
36000DX2200 HOS
MSEP
2 (1w+1s)
AB-306-A/B
DMF Air blower
7.67cum/min@
4000 Cl
2 (1w+1s)
mmWC
ACF-304-A/B
Activated carbon filter
36000DX2200 HOS
MSEP
2 (1w+1s)
SAC-305-A/B
Strong
acid
cation 22000DX3000 HOS
MSRL 2 (1w+1s)
exchanger
DGT-307-A/B
Degasser tower
1800 D X 3300 HOS
MSRL 2 (1w+1s)
DGWT-308-A/B
Degasser water storage 3700 D X 8600 LG
MSRL 2 (1w+1s)
tank
DG-AB-A/B/C/D Degasser air blower
51cum/min
@
100 CS
4(2w+2s)
mmWC
DGWTP-310Degasser water transfer 150 cum/hr @ 3.5 SS
4(2w+2s)
A/B/C/D
pump
Kg/cm2
SBA-401-A/B
Strong
base
anion 2500DX3400 HOS
MSRL 2 (1w+1s)
exchanger
MB-305-A/B
Mixed bed
2400 D X 2900 HOS
MSRL 2 (1w+1s)
AB-403-A/B
Mixed bed air blower
660cum/min @ 4000 Cl
2 (1w+1s)
mmWC
DP-404-A/B
Amine dosing pump
10 LPH @ 4 Kg/cm2
PP
2 (1w+1s)
DT-404-A/B
Amine dosing Tank
450 D X 600 HOS
MSRL 2 (1w+1s)
DMWST-405-A/B DM Water storage tank
1300 D X 1400 HOS
MSRL 2 (1w+1s)
2
DMRP-406-A/B
DM regeneration pump
40 cum/hr @ 3.5 Kg/cm
SS
2 (1w+1s)
BAST-501
Bulk acid storage tank
3000 D X 1600 HOS
FRP
1
BCST-502
Bulk caustic storage 2400 D X 3600 HOS
FRP
1
tank
CUP-503-A/B
Caustic unloading pump 10 cum/hr @ 1.5 Kg/cm2 PP
2 (1w+1s)
2
AUP-506-A/B
Acid unloading pump
11 cum/hr @ 1.5 Kg/cm
PP
2 (1w+1s)
AMT-507-A/B
Acid measuring tank
2400 D X 3600 HOS
FRP
2 (1w+1s)
CDT-508-A/B
Caustic dilution tank for 1400 D X 1500 HOS
FRP
2 (1w+1s)
SBA
AMT-509-A/B
Acid measuring tank for 1300 D X 1400 HOS
FRP
2 (1w+1s)
IISCO Steel Plant

283

Power & Blowing Station-2 (P&BS-2)

CDT-510-A/B
CDT-511
AMT-512
NP-513
PT-514
NWTP-515-A/B

MB
Caustic dilution tank for
MB
Caustic dosing tank for
NP
Acid dosing tank for NP
Neutralization pit
Priming tank
Neutralized
transfer pump

1300 D X 1400 HOS

FRP

2 (1w+1s)

700 D X 600 HOS

FRP

700 D X 600 HOS

FRP
14.8X13.5X4.5 m 0.9 RCC
mFB
700 D X 1000 HOS
MSRL
water 100 cum/hr @ 1.5 SS
Kg/cm2

1
1
1
2

2. Technical Details Of DM Plant Equipment:

a. Regeneration Pump & Motor (2 Nos.):
3 Phase Induction motor
Capacity
40 m3/hr.
KW
7.5
Total head
35 m
RPM
2850
Voltage
415
DE side bearing no.
6208 ZZ
NDE side bearing no. 6207 ZZ
b. Backwash Pump (2 NOS.):
3 Phase Induction motor
Capacity
250 m3/hr.
KW
37
Ampere
65
Total head
30 m
RPM
1470
DE side bearing no.
6313
NDE side bearing no. 6312
c. Degasser Water Transfer Pump (4 NOS.):
Capacity
150 m3/hr.
KW
30
Ampere
52
Total head
35 m
Speed
1450 r.p.m.
DE side bearing no.
6312
NDE side bearing no. 6310 ZZ
284

IISCO Steel Plant

(1w
+1s)

Power & Blowing Station (P&BS-2)

d. N-Pit Water Transfer Pump (2 NOS.):
Capacity
100 m3/hr.
KW
7.5
Ampere
14.5
Total head
155 m
Speed
1440 r.p.m.
DE side bearing no.
6208ZZ
NDE side bearing no. 6207 ZZ

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285

Power & Blowing Station-2 (P&BS-2)

SSF

DM PLANT PROCESS FLOW DIAGRAM (Diagram No.6)

Backwash

Lime dosing

Polymer dosing
NaOCl dosing

IBD

Coagulant dosing

3 nos. pumps

Coagulant dosing

EQUILISATION
SUMP

CLARIFIER
WATER
SUMP

CLARIFIER

STILLING
CHAMBER

EFFLUENT FEED PUMP (2 NOS.)

SLUDGE
TRANSFER TANK

3 nos. pumps

Blower

Scale inhibitor
dosing

BACK WASH
SUMP

MULTI
GRADE
FILTER

Blower

Acid dosing
Sodium Meta Bisulphate
dosing

CHEMICAL
CLEANING TANK
3 nos. h.p
pumps

ACTIVATED
CARBON FILTER
(2 nos.)

R.O
SUMP

DUAL MEDIA
FILTER
(2nos.)

REVERSE
OSMOSIS

MICRON
CARTRIDGE
FILTER

2 nos. pumps

blower

blower

STRONG ACID
CATION (2
nos.)

2 nos. DM
transfer pumps

Amine
dosing
blower

286

DEGASSER
(2 nos.)

STRONG BASE
ANION (2 nos.)

IISCO Steel
MIXEDPlant
BED
(2 nos.)

DM WATER
STORAGE
TANK

To
2 nos. Regeneration pumps CST

Power & Blowing Station (P&BS-2)

e. ET Blower(2 NOS.):
Capacity
250 m3/hr.
KW
7.5
Amp
14.5
Pressure
0.5 Kg/cm2
Speed
1256 r.p.m.
DE side bearing no.
6208ZZ
NDE side bearing no. 6207 ZZ
f. Sludge Pit Pump (2 NOS.):
Capacity
10 m3/hr.
KW
3.5
Amp
7.2
Total head
15 m
Speed
2850r.p.m.
DE side bearing no.
6206 ZZ
NDE side bearing no. 6205 ZZ
g. DM Feed Pump/ R.O Transfer Pump (2 NOS.):
Capacity
165 m3/hr.
KW
30
Ampere
52
Total head
35 m
Speed
1470r.p.m.
DE side bearing no.
6312
NDE side bearing no. 6310 ZZ

h. MGF Feed Pump (3 NOS.):

Capacity
20 m3/hr.
KW
11
Ampere
20
Total head
25 m
Speed
1450 r.p.m.
DE side bearing no.
6309 ZZ
NDE side bearing no. 6209 ZZ
i. DMF Blower (2 NOS.):
Capacity
460 m3/hr.
KW
9.3
Speed
1445r.p.m.
DE side bearing no.
6309 ZZ
NDE side bearing no. 6209 ZZ
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287

Power & Blowing Station-2 (P&BS-2)

j. MGF Blower (2 NOS.):

Capacity
260 m3/hr.
KW
5.5
RPM
1393
Speed
1440r.p.m.
DE side bearing no.
6208 ZZ
NDE side bearing no. 6207 ZZ

k. High Pressure Pumps (3 NOS.):

KW
Ampere
Total head
Speed
Voltage
Max pressure
DE side bearing no.
NDE side bearing no.

37
63
170 m
2950 r.p.m.
415
30 bar
6312 C3
6312 C3

l. Effluent Feed Pump (2 NOS.):

Capacity
160 m3/hr.
KW
11
Ampere
20.1
Total head
15 m
Speed
1450 r.p.m.
Voltage
415
DE side bearing no.
6309 C3
NDE side bearing no. 6209 C3
m. SMBS Dozing Agitator & Pump:
FOR PUMP
DE side bearing no.
6003 ZZ
NDE side bearing no. 6003 ZZ
FOR AGITATOR
DE side bearing no.
6204 ZZ
NDE side bearing no. 6204 ZZ
n. Chemical Cleaning Pump (1 NO.):
Capacity
KW
288

56 m3/hr.
7.5
IISCO Steel Plant

Power & Blowing Station (P&BS-2)

Ampere
Total head
Speed
DE side bearing no.
NDE side bearing no.

14.3
25 m
2850 r.p.m.
6208 ZZ
6207 ZZ

o. MB Blower:
Capacity
66 m3/hr.
KW
15
Ampere
27
Pressure
0.4 Kg/cm2
Speed
1460 r.p.m.
DE side bearing no.
6309 ZZ
NDE side bearing no. 6209 ZZ

p. Clarifier Pump (2 NOS.):

DE side bearing no.
NDE side bearing no.

6205 ZZ
6205 ZZ

q. DM Transfer Pump (2 NOS.):

Discharge
KW
H.M
RPM
NPSH-M
Bearing 1B
Bearing 0B

96 m3/hr.
20.96
55
2960
3
6308
6308

r. DM Transfer Pump Motor(2 NOS.):

3 Ph. Induction motor
KW
30
HP
40
VOLT
415 10%
Frame
ND 200L
EFF (FL)
91%
BRG. DE/NDE 6312-C3
Duty
S1
RelubHrs.
3500
Hz
50 5%
RPM
2960
AMB.
40 DEG. C.
Ampere
53 a.
IISCO Steel Plant

289

Power & Blowing Station-2 (P&BS-2)

Grease

Lith. Based

s. Raw Water Transfer Pump(3 NOS.):

Type
Capacity
Total head
Speed
Drive HP
Tag No.

V0100/400 + CPC
140 m3/hr.
50 m
1450 r.p.m.
37 KW
NWTP-1190

t. Raw Water Transfer Motor (3 NOS.):

Duty
AMB.
WT
Volt
Mfg yr.
Hz
KW
HP
Amps
RPM
EFF
PF
DE side bearing no.
NDE side bearing no.

290

S1
50 DEG. C
315
415
2010
50
37
50
65
1470
92.5%
0.86
6313
6312

IISCO Steel Plant

Power Distribution
POWER DISTRIBUTION

A) Introduction
Power distribution At Power Distribution Department is an important Electrical
department of SAIL-ISP which provides power to different shops for their operation in
2.5MT new plant, 0.5MT old plant and Township ISP
DVC (Damodar Valley Corporation) is the main supplier of power to SAIL-ISPthrough
DVC substation located at Burnpur. It is part of DVC grid and connected to Mejia
thermal power station, capacity of 1340 MW. Other than Mejia it also gets power from
kalyanesweri substation, which are interconnected and in parallel.
i.

There are two 220kV incomers to MRS (Main Receiving Station) at new 2.5MT
Steel plant, ISP and two 33kV incomers to old plant from DVC s/s at Burnpur.

ii.

There are two Captive Power Plants which are named Power and Blowing
Station(PBS #1 & PBS #2)
PBS #1: Capacity 2X10MW + 1X20MW (20MW in Service)
PBS #2: Capacity 3X18 MW + 1X8.275 MW (18MW in Service)

The Total Maximum load as expected of 2.5 MT new steel Plant is of order220MW
(approx.). Total power imported from DVC is around 170MW and captive power plants
generation is around 50MW.
New Plant receives power from DVC through two 220kV lines at MRS (Main Receiving
Station).This power received in MRS is stepped down to 33kV level through 4
transformers. The total load from Different Shops of New 2.5 MT Steel Plant is catered
through 10 number 33kV level substations named as LBDS (Load Block Distribution
Stations). Power supply to various LBDS is from MRS through 33kV cables.At LBDS
the power is again stepped down to 6.6kV level and then distributed to various
shops.There are also 4 Tie lines two each from PBS 1 & 2 at 33kV level in MRS. There
are 6.6kV tie lines at LBDS #1, 2,4,5,8 for emergency from PBS #2 it also supplies

IISCO Steel Plant

291

power to LBDS #1, 2 which are essential load at 33kV level. In case of DVC grid failure,
PBS is islanded and Emergency power is supplied at 6.6kV level through PBS #2.
B) The 220 kV Scheme at MRS

There are two incomers from DVC named I/C-1 & 2 which are fed into Bay-4 & Bay-6
known as the Incomer Bays. Bay-4 & 6 feed the power into the two main buses and the
transfer bus denoted as Bus-A, Bus-B & Tr. Bus respectively in the above scheme. From
the main buses power is fed to Bays 1, 3, 5 & 7 which are called the Transformer Bays.
These bays feed power to the four 80/100MVA transformers which step down the voltage
level to 33KV from 220KV for distribution to the various LBDSs. Bay-2 is called the
Bus Transfer Bay and Bay 8 is the Bus Coupler Bay. Bay-8 is used to synchronize Bus-A
and Bus-B. The bus transfer bay is used to re-route power between the bays when any
equipment of any of the bays requires maintenance or repair.

292

IISCO Steel Plant

Power Distribution
C) The 33 kV Scheme at MRS

The output of each transformer at the MRS goes to a 33KV bus as shown above. All four
transformers have an individual output bus. Each of these buses are coupled with each
other so that one may draw current from the other. As shown in the circuit above the
33KV bus at MRS has outgoing feeders to LBDS 1, 2, 3, 4, 5, 7, 8 & 9 and tie lines to the
old and new CPPs.
Substation name
LBDS #1
LBDS #2
LBDS #3
LBDS #4
LBDS #5
LBDS#6 & 7
LBDS #8
LBDS #9
LBDS #10

IISCO Steel Plant

Shop
Blast Furnace
Coke Oven,BPP, CHP & CDCP
Sinter Plant
BOF-CCP
USM
RMHP
WRM & BM
Oxygen Plant
LDCP

293

294

IISCO Steel Plant

Power Distribution
D) Connectivity at a glance:
1. Two 33KV tie lines exist between MRS and Old CPP.
2. Two 33KV tie lines exist between MRS and New CPP.
3. LBDS#1 has two 33KV feeders from New CPP, one 33KV feeder from MRS, one
6.6KV feeder from New CPP and a 33KV tie line with LBDS#2.
4. LBDS#2 has two 33KV feeders from New CPP, one 33KV feeder from MRS, one
6.6KV feeder from New CPP and a 33KV tie line with LBDS#1.
5. LBDS#3 has two 33KV feeders from MRS.
6. LBDS#4 has two 33KV feeders from MRS and one 6.6KV feeder from New CPP.
7. LBDS#5 has two 33KV feeders from MRS and one 6.6KV feeder from New CPP.
8. LBDS#6 has two 33KV feeders from LBDS#7.
9. LBDS#7 has two 33KV feeders from MRS.
10. LBDS#8 has two 33KV feeders from MRS and one 6.6KV feeder from New CPP.
11. LBDS#9 has two 33KV feeders from MRS.
12. LBDS#10 has two 33KV feeders from LBDS#5.

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295

E) Major Equipments at MRS:

MRS mainly has 2 Main buses A & B one transfer bus, 8 Bays which are 2 incomers, 4
Transformers, 1 Bus Coupler, 1 Transfer Bus coupler at 220kV Yard.33kV indoor s/s has
4 Bus sections with bus couplers and interconnectors. Feeders from these bus sections
feed various LBDS at 33kV level through XLPE Cables.
i.

80/100 MVA Transformers

ii.

SF6 Circuit Breakers

iii.

Isolators

iv.

Lightning Arrestors

v.

220kV Current Transformers

vi.

220kV Potential Transformers

vii.

33kV SF6 Circuit Breakers

viii.

33kV Current Transformers

ix.

33kV Potential Transformers

x.

Earthing Transformer

xi.

Lightening Transformer

xii.

Battery Bank

F) Major Equipment At LBDS :

296

i.

16/20 MVA Transformer:

ii.

25/31.5MVA Transformer:

iii.

6.6 & 33kV Vacuum Circuit Breaker

iv.

Current Transformers

v.

Potential Transformers

vi.

Neutral Grounding resistor(NGR)

vii.

Battery bank

IISCO Steel Plant

Power Distribution
G) Protection Schemes at MRS:

1. 220 KV I/C-1 & I/C-2

a. PROTECTION RELAY-RED 670
b. LINE DIFF. PROTECTION(87L)
c. O/C AND E/F PROTECTION(50/51 & 50N/51N)
2. 220/33 KV TR-1, TR-2, TR-3 & TR-4
a. PROTECTION RELAY-RET 670
b. TRANSFORMER DIFF. PROTECTION(87T)
c. O/C AND E/F PROTECTION(50/51 & 50N/51N)
d. WTI, OTI, PRV, OSR, BUCHHOLZ
3. 220 KV BUS COUPLER
a. PROTECTION RELAY-REF 615
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
4. 220 KV TRANSFER BUS COUPLER
a. PROTECTION RELAY-REF 615
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
5. 220 KV BUSBAR PROTECTION
a. PROTECTION RELAY-REB 670
b. LBB PROTECTION
6. 33 KV I/C-1, I/C-2, I/C-3 & I/C-4
a. PROTECTION RELAY-REF 615
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
7. 33 KV ET-1, ET-2, ET-3 & ET-4
a. PROTECTION RELAY-REF 615 AND SPAJ 115C
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297

b. O/C AND E/F PROTECTION(50/51 & 50N/51N)

c. STAND BY EARTH FAULT PROTECTION
8. 33 KV CCP TIE FDR-1 & 2
a. PROTECTION RELAY-7SD61 & REF 615
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
c. CABLE DIFF. PROTECTION
9. 33 KV OFF LINE TIE FDR-1 & 2
a. PROTECTION RELAY-REF 615
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
10. 33 KV O/G FDR FROM MRS
a. PROTECTION RELAY-REF 615
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
H) Protection Schemes At LBDS:

1. 33 KV INCOMER FROM MRS

a. PROTECTION RELAY-MiCOM P127
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
2. 33 KV TRAFO.FDR.
a. PROTECTION RELAY-MiCOM P122
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
3. 33 KV INCOMER FROM CPP
a. PROTECTION RELAY-MiCOM P127
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
4. 33 KV BUS COUPLER
a. PROTECTION RELAY-MiCOM P132
298

IISCO Steel Plant

Power Distribution
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
5. 6.6 KV INCOMER FROM 33/6.6 KV TRAFO.
a. PROTECTION RELAY-MiCOM P632 AND MiCOM P111
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
c. DIFFERENTIAL AND REF PROTECTION(87T & 64R)
d. STAND BY EARTH FAULT PROTECTION
e. WTI, OTI, PRV, OSR, BUCHHOLZ
6. 6.6 KV BUS COUPLER
a. PROTECTION RELAY-MiCOM P132
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
7. 6.6 KV TRAFO. FDR.
a. PROTECTION RELAY-MiCOM P122
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
8. 6.6 KV MOTOR FDR.
a. PROTECTION RELAY-MiCOM P220
b. O/C AND E/F PROTECTION(50/51 & 50N/51N)
c. THERMAL OVERLOAD PROTECTION
d. EXCESS LONG START
e. LOCKED ROTOR

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299

Production Planning & Control

PRODUCTION PLANNING & CONTROL

A) Introduction
Production Planning & Control (PPC) Department is the overall coordinating
department of Works & acts as the nerve centre of information pertaining to its
various activities. The office of the Chief Executive Officer & the Head of Works is
dependent on PPCD on the first hand/ real time happenings & important data
associated with the Works functions.

The main functions of PPC Department are managed by five different sections viz.:
a. Plant Control
b. Planning
c. Statistical & Management Information System
d. Sales Co-ordination & despatch
e. Road weigh-bridge operation
B) Plant Control
Plant Control runs on 24 x 7 on 365 days basis and continuously does the real-time
monitoring of Plant Activities. Its main function includes:
a. Continuous monitoring on safety & fire related issues.
b. Collection of data on hourly basis related to production, despatch &
forecast on incoming commodities.
c. Follow-up on Mechanical & Electrical breakdowns/ delays, its analysis,
expected time of recovery & co-ordination with the related agencies.
d. Co-ordination with Head of Works, GMs/ DGMs, Line Managers & Shift
in-charges.
e. Day end reporting at 6:00 am on major issues to ED (W) & other senior
executives.
f. Periodic detail reporting to ED (W)
g. Conducting daily tele-conferencing at 08:30 am on weekdays between ED
(W) & all HODS.
h. Preparation of detail report based on above & uploading into intra-net for
information of all employees of ISP.

300

IISCO Steel Plant

Production Planning & Control

C) Planning
a. Long Term
Activities related to Preparation of Annual Production Plan.
i.

Guidelines from Corporate office and commissioning schedule of new

units.

ii.

Guidelines from CEO & ED (Works)

iii.

Discussion with different departments through internal meetings with ED

(W)

iv.

Setting up of Capital Repair plan

v.

Freezing up of shop wise Production targets depending on capital repair

plan & techno - economic parameters

vi.

Raw materials procurement programme

vii.

Other Input requirement

b. Short Term
i.

Based on long term plan, month-wise planning is decided.

ii.

Monthly shut down programmes & Capital repair plans of each production
departments.

iii.

Annual production vis--vis techno parameters & dispatch is distributed

into monthly targets.

iv.

Monthly raw materials procurement & IPT targets are set.

D) Statistical & MIS

Collection of data from different works department, Finance & Marketing for
i.

Documentation & converting to useful information in tailor made formats.

ii.

Daily Flash Report, monthly special steel & quarterly performance reports for
Corporate Office Delhi

iii.

Daily MIS Report

iv.

Preparation of Monthly Statistical Report

v.

Preparation of Annual Operational Plan & Progressive Norm book.

vi.

Preparation of Annual Operational Statistical book.

E) Sales Co-Ordination & Dispatch

Different agencies involved in Production & despatch planning based on Mills

position & market scenario are CMO, RCL, Mills, traffic & PCM through coIISCO Steel Plant

301

Production Planning & Control

ordination of PPCD.
i.

Monthly sales co-ordination meeting at the end of the month for the
succeeding month being chaired by ED (W) in the presence of ED CMO
(LP), SAIL, CMO, SRM, Mills collective, RCL, Traffic & PPCD.

ii.

Based on monthly rolling Plan, weekly meetings on details of rolling of

dispatch able steel of different qualities are set for each section in each mill
in consultation of CMO.

iii.

Based on above, daily meetings are conducted for monitoring & follow-up
& for rake formation.

F) Road Weigh-Bridge Operation

There are 4 nos. of road weigh-bridges under the control of PPCD for operation
purpose only.
i.

1 No. 60 Mt computerised Pit type near Chhotadighari gate : Weighing of

outgoing steel material, coke oven by-products etc.,

ii.

1 No. 80Mt computerised Pit type near Vehicle gate: Weighing of Coke
Fractions, Scraps, granulated slag, Boiler ash..

iii.

2 Nos. 100 Mt Pitiless type near Sanmara gate: For despatches from new plant
units.

302

IISCO Steel Plant

Projects Department
PROJECTS DEPARTMENT

A) The following broad functions of Projects Department based on integrated project

management have been considered:
The Projects is headed by E.D. (Projects). The role of Integrated Project Management
(IPM) is management of capital expenditure schemes comprising Major projects
including ongoing 2.5 MTPA expansion project, Addition /Modification and
Replacement schemes (AMR). Projects function covers all aspects of projects
management viz. Feasibility studies engaging consultant, liaison with Government
agencies, project planning, estimating and proposal, processing for sanction, design &
drawing, preparation of tender documents, issue of tenders, evaluation of tenders,
finalization of orders / contracts, site supervision, monitoring of progress, bill processing,
commissioning and handing over the Plant / Unit to operating / User departments,
contract closure. It may be mentioned that some of the AMR jobs are done by the
respective Plant Departments either through contract or departmentally.

B) Organization Structure Of Projects(Integrated Project Management)

The organization of Projects is designed to function in the Integrated Project
Management system. Integrated project Management hasthe following major sections.
a. Project Execution
b. Project Materials
c. Project Contracts
d. Project Finance & Accounts
e. Personnel & Administration
f. Project Safety
g. Project Planning, Coordination & Monitoring
h. ED I/C(P)s Secretariat& ED (P) Secretariat
i.

Project Engineering, Design & Standardization

1. Project Execution
The scope of project execution includes the following activities:IISCO Steel Plant

303

Projects Department
a. Expansion of ISP
b. AMR Schemes
c. Township Development
The ongoing 2.5 MTPA expansion project comprises 32 Main Packages, 25 Auxiliary
Packages, 47 Auxiliary packages andover 125 enabling infrastructure packages.
These packages are in various stages of implementation. The project jobs mainly
comprises of the following activities which are mostly common to all packages:
a. Construction Planning, Progress Monitoring & Allocation of resources
b. Space allocation for equipment, Construction materials, Offices etc.
c. Site supervision for conformity with drawing and specification including Onsite

quality

control

and

co-ordination

with

Construction

Agencies,

Consultancy/Design Office, Plant Department etc.

d. Total responsibility for site construction work including Civil Work, Site
Fabrication, Structural & Equipment Erection, Trial Runs, Commissioning,
performance Tests, Dealing with Post Commissioning problems and handing over
the plant to the concerned Operations Department
e. Compliance of Safety norms
f. Clearance / Inspection by statutory agencies.
g. Issuance of PAC, commissioning PG test & FAC certification to the party
h. Activities related to closure of contract
i. Identification of additional job, preparation of TS, tendering, order placement &
execution of the job
j. Preparation of acceptance norms for various items of work
k. Inspection and Quality Control in all areas of work including outside
Procurements, Shop Fabrication and Site Work

2. Contracts & Materials

a. All functions relate to placement of orders as follows

304

i.

Tender Documents

ii.

Tendering & Evaluation

iii.

Negotiations
IISCO Steel Plant

Projects Department
iv.

Award of contracts/ Order placement

v.

Coordination for contracts

vi.

Closure of contracts

b. Import License.
c. CAPEX Procurement, Coordination with PAG etc
d. Consultancy Contracts
e. Contract administration
f. Issuance of waybill, Sales Tax: C- form
g. Budget for expansion projects, Coordination with M-Junction
h. Procurement and contract finalization for AMR cases /Non-Plant CAPEX cases
like Town, Hospital etc.
i. Coordination jobs for Investment Planning and PAG clearances.

3. Project (Finance)
a. Verification and passing of bills and accounting thereof.
b. Re conciliation of Taxes & duties for free issue of steel
c. Returns of TDS and Works contracts,C-Form related jobs
d. Monitoring of Bank Guarantees, correspondence for BGs with Bank
e. LC related jobs etc,Capital budget for AMR schemes and Expansion schemes
f. Custom Duty payment
g. All other finance related matters relating to screening of Tender documents and
awarding of contracts

4. Personnel & Administration

a. Administrative matters relating to Department Personnel
b. Office equipment, furniture and housekeeping, stationary
c. All issues related to labour at site, issuance of passes etc
d. Statutory obligations under labour laws
e. All other jobs related to Personnel functions

IISCO Steel Plant

305

Projects Department
5. Project Safety
a. Providing Safety induction training to 100% executives, non-executive, contract
labours
b. Ensuring conducting of periodical safety meeting
c. Monitoring &enforcement of safety
d. Monitoring protocol of erection jobs, commissioning jobs etc
e. Conducing safety checks
f. Safety administration as per statute.
g. Liaison with safety inspectors, etc

6. Project Planning, Co-Ordination & Monitoring

a. Preparation of various networks, bar charts and schedules for the projects
b. Collection of daily field reports and dispatch of MIS to various agencies in time
c. Constantly monitor project schedule / critical path and report to Project CoOrdinator with suggestion for corrective actions in case of slippages
d. Constant planning & monitoring of qualities of construction
e. Preparation of Annual Plan (Budget) for Capital Work & Annual Performance
f. Convene periodical progress review meetings.
7. ED I/C (P)s Secretariat & ED (P)s Secretariat
For Technical & non-technical assistance to ED(P) & coordination

8. Surveyors
At present there are no surveyors in Projects. A Survey team consists of minimum of
4 Survey Officersand 4 non-executives. Surveyors will be required for the Projects
and need to be recruited.

9. Design Bureau & Archives

Design Bureau of ISP is commonly known as Drawing Office and is design wing of
Projects. However, unlike in other SAIL Plants, Design Bureau of ISP does both
Project and plant maintenance jobs. In ISP there is no separate Plant Drawing Office.
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IISCO Steel Plant

Projects Department

It is an engineering division where Civil, Structural and Mechanical Engineering

design and detailing jobs are generally done. Jobs include system design and its
arrangement drawings, detailed design calculations and detailed working drawings,
preparation of Interplant Standards for Steel industry and plant standards. Safe
keeping and preservation of all drawings and documents generated internally and
received from external source are responsibility of Drawing Office. Production and
supply of ammonia and Barcroprints of drawing to different user departments are
routine jobs for Drawing Office. It broadly comprises the following sections
a. Draughting& Tracing Section
b. Clerical Section
c. Barcrograph / Photostat Section
d. Printing Section
e. Computer Aided Design & drafting

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307

RMHP
RAW MATERIAL HANDLING PLANT (RMHP)

A) Introduction
This department has come up under 2.5 MT modernization programme of ISP in 2012.
With this Burnpur got bedding / blending facilities for raw materials for the first time
along with facilities of unloading of all raw materials at one location except coking coal
for coke oven battery no10 and boiler coal of old plant.
1. Salient features of RMHP
Under 2.5MT Expansion of ISP, the principal scheme and material flow in RMHP
comprises the following:
i.

Unloading, of all raw materials for the plant except Coal of existing Coke Ovens
(COB#10).

ii.

Bedding/Blending and Reclaiming facilities in a big stock yard of all Iron ore,
Flux materials, Mn ore, Quartzite.

iii.

Screening of Iron ore Lump & Flux.

iv.

Preparation of Base mix and bedding with required proportion including crushing
& screening of Flux and Coke.

v.

Reclamation of Base mix to Sinter plant.

vi.

Ensuring safe & Pollution free working environment inside the plant and its
surrounding area.

The above scheme facilitates handling of following raw materials in RMHP

Sl.

Material

Source

No.
1

Iron Ore Lump

Kiriburu/ Meghathaburu/ Bolani/ Kalta/ Gua/

Chiria

308

Iron Ore Fines

KBR/ MBR/ Bolani/Gua

Coking Coal (Imported)

Haldia

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4

Coking Coal (Indigenous)

Chasnalla

CDI Coal

Haldia

Limestone (BF/ SP Grade)

Imported/ Kuteshwar

Limestone (SMS Grade)

Imported

Dolomite (BF Grade)

Dalgaon

Dolomite (SMS Grade)

Dalgaon

2. Objective
a. To reduce interference of internal traffic movement and to Unload Raw materials at
the periphery of the plant, by avoiding detention of railway wagons.
b. Bedding of raw materials in different bed by making homogeneous pile of raw
materials received from our captive mines/other sources so as to achieve consistent
quality.
c. Keeping buffer stock of raw materials & their uninterrupted supply to different
consuming units.
d. Preparation of Base Mix & dispatch of the same to Sinter Plant.

3. Major equipment used in RMHP and their function

Wagon Tippler

Used for mechanized unloading of wagons.

Side Arm Charger

For pulling the rake containing loaded wagons on to the

wagon tippler table.

Paddle Feeder

For extracting material from Track Hopper bunker table

and discharging on the conveying system underneath.

Stacker

IISCO Steel Plant

For bedding (Stacking) material in yard.

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RMHP
Barrel Reclaimer/Bucket

For reclaiming material stacked in the beds.

Wheel Reclaimer
Transfer Car

For shifting equipment (Barrel Reclaimer) from one bed to

another in Yard.

Screen

For screening of raw material to desired size.

Rod Mill

For crushing coke from a higher size to a desired Lower

size.

Impact Crusher

For crushing Flux material from a higher size to a Desired

lower size.

Conveyor Belts

For conveying different materials to the destination.

The Raw Material Handling Plant (RMHP) department can be broadly divided into two
main areas namely Ore Handling Plant, OHP (where unloading, stacking and reclamation
of raw material is done), and Base mix Handling Plant, BMP (where Base mix
preparation, stacking, and reclamation is done).
4. Customers of RMHP

310

i.

Blast Furnace : Screened Iron Ore Lump

ii.

Sinter Plant

: Base Mix, Crushed Flux, Crushed Coke

iii.

LDCP

: SMS Grade Lime Stone & Dolomite

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B) Ore Handling Plant (OHP)
OHP - Flow Diagram
IRON ORE FINES, LIME STONE, DOLOMITE, MN ORE, QTZ

BF #5

BASE
MIX

LS (LDP)

LS (SP)

EXISTING
PLANT BF-2

FLUX
SCREENING

Dolo
(LDP)

Mn

DOLO (SP)

I/O Lump

Iron Ore Fines

COAL BED

ORE
SCREENING

WT-2

QTZ I/O Lump

WT-1

TRACK HOPPER

Iron Ore Fines

Iron Ore Lump

LDCP

OHP Flow Diagram

Depending on the types of wagons, raw materials rakes supplied by the mines by means
of Railways are being placed either in wagon tippler or track hopper for unloading. The
types of wagons for unloading in wagon tippler and /or track hopper is as given below
For wagon tippler - BOXN, BOXC, BOST, NBOY
For track hopper - BOBS, NBOBS.

1. Unloading and Stacking of Ore

Two Wagon Tipplers namely, WT1 and WT2 along with a Track Hopper (TH1) have
been envisaged for unloading Iron Ore (lump and fines), Limestone & Dolomite (both
SMS grade and Sinter plant grade), Mn-ore, and Quartzite etc. Normally Iron Ore Lump

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is to be to be unloaded at Track Hopper by means of opening & closing of doors of the
Wagons.
The Wagon Tipplers shall be of Rota Side Discharge Type (Please refer to section A for
Wagon Tippler details) capable of unloading BOXN and BOY wagons up to a gross
weight as stipulated in IS: 10095 2001 with provision of Locomotive to pass through.
The rated unloading capacity shall be 20 Tips/hour. The placement of rakes shall be done
by Side arm chargers which are rail mounted, capable of handling a full rake of wagons.
The Track hopper (for unloading Iron ore lumps only) of 200m hopper-length (length
excludes maintenance area); capable of unloading BOBR/BOBRN wagons, shall have
four (4) paddlefeeders to extract material from track hopper bunker table and discharge
onto the conveying system underneath. The paddle feeders are rail mounted.
From the Wagon Tipplers WT-1/2, the raw material is conveyed through a series of
conveyors, Junction Houses and stacked on to Beds to prepare a stockpile. The three
single-boom stackers (Please refer to section 1.1.3 for Stacker details) over yard
conveyors stores the raw material in the designated place of the yard in bed nos 1 to 6.
Flexibility is in-built in the intermediate Junction Houses to ensure stacking is trouble
free.
From Track Hopper the Iron ore lump is conveyed through series of conveyors and
Junction Houses and at Junction House J2B screening of Iron ore Lump & fines is
provided with two hoppers to collect the fines of (-) 8 mm size materials and suitably
send it to the fines beds (bed no. 1 and 3) time-to-time. The lumps (+) 8 mm size
materials shall go online to the beds (bed no. 2 and 4) for storage. Please refer to Figure 1
for OHP flow diagram.
Suitable interchangeability shall be provided below Wagon Tipplers and Track Hoppers
for conveyors by providing Diverter gates. Electro-Magnetic Separators, In-Line
Magnetic Separators, Metal Detectors, Belt-Weigh-Scales, are provided to make the
system complete and the operation/maintenance smooth.

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Wagon Tippler is used for unloading wagons. It holds the wagon from the top (with the
help of Clamps) to a section of track (fixed to the tippler table) and rotates the track and
wagon to discharge the contents in the wagon in the hoppers provided on to the side.

Technical Specifications for Wagon Tippler:

Make

ELECON

Type Of Wagon Tippler

Side Discharge Wagon Tippler(With Hyd.

Drive & Hyd. Clamping)

Design / Model

MARK III

Material Handled Quantity

Coal, Iron Ore 3 Nos. (1 NO. R.H. & 2

NOS. L.H.)

Gross Weight Of Each

Wagon

110 T (MAX.) As Per RDSO G33

Handled
Max. Weight Of Shunting Loco At 8

130 T

Km/Hr. Can Passover Tippler

Type Of Wagon To Be Handled

Sr. No.

Type Of Wagon

Please refer to Table below.

Overall

Overall

Overall Length

Gross

Tare

Height

Width

Over Coupling

Weight (T)

Weight

(mm)

(mm)

Centres (mm)

(T)

1.

BOX/BOX C

3161

3136

13729

81.3

25.0

2.

BOXN MARK-

3225

3200

10715

81.3

24.28

3735

3136

10715

81.3

24.28

II
3.

BOXN

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Railway Gauge

1676 Mm (Broad Gauge)

Angle Of Tip / Rotation

160 Degree (Max.)

Rail Size

60 Kg/m

Time Cycle:
i.

Weighing of Loaded Wagon

10 Sec.

ii.

Tipping/Forward Rotation

47 Sec.

iii.

Pause

06 Sec.

iv.

Reverse Rotation

47 Sec.

v.

Weighing Of Empty Wagon

10 Sec.

vi.

Total Time Cycle (Tipping)

120 Sec.

No. of Tips Per Hour (Subject To RDSO

20 Rated

Approval)
Overall Dimensions of Tippler

As Per G.A. DRG. TP8682/0

Total Weight Of Tippler Without Counter

97 T (Approx.)

Weight
Clamping Arrangement

Hydraulic

Counter Weight (By Client) In Both End

68 T (Approx.) Total

Frames. [R.C.C. + Steel Scrap]

Wagon Clamps & Side Beam Pad Type

Natural Rubber

Nos. Of Clamp

6 Nos.

Arrangement For Control Of Tipping Angle

Auxiliary Current

Gear Limit Switch

Tippler Drive

Hydraulic Motor With Planetary Gear Box

&Integral Brake, Directly Coupled To Pinion
Qty. = 2 Nos.(1 On Each Side)

314

Hydraulic Power Pack

For Tippler Drive & Clamping

Electric Motor For Tippler Drive

1 x 110 KW x 1500 rpm A.C. SQ. Cage

Electric Motor For

1 x 30 KW x 1500 rpm A.C. SQ. Cage

Power Supply

415V, 50Hz, 3 Ph A.C.

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Technical Specifications of Wagon Tipplers installed in RMHP
SL. No.

PARAMETERS

SPECIFICATIONS

Type of Wagon Tippler

Side Discharge

Material Handled

Iron ore, Limestone, Dolomite, Coal, etc.

Quantity

3 (WT-1, 2, 3)

Gross Weight of each wagon 110 Ton Max. as per RDSO G33
handled

Max. weight of Shunting Loco at 8 130T

Kmph can pass over Tippler table

Types of Wagon Handled

BOX/BOX C, BOXN

Number of Tips per hour

20

Clamping arrangement

Hydraulic

Number of Clamps

10

Tippler Drive

Hydraulic motor with planetary gearbox &

integral brake directly coupled to pinion
(Qty. is 2 No.s per machine)

2. Side Arm Charger

Side Arm Charger is a wagonmarshalling rail mounted equipment to handle loaded
wagons and hauling them on to the tippler table where the contents of the wagons are
discharged into the tippler hopper. The empty wagon is further pushed and cleared off the
tippler table by Side Arm Charger through buffer provided on coupler arm. A side arm
charger is simply a replacement to the erstwhile used Pusher Car. Please refer to Table
for Technical Specifications of Side Arm Chargers.

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Technical Specifications offside Arm Chargers installed in RMHP
SL. No.
1

PARAMETERS

SPECIFICATIONS
58 No.s loaded Wagons with Max. 110 T

Hauling Capacity

Gross Weight of each Wagon on a straight

and leveled track.
2

Quantity

3 (One for each wagon Tippler)

Travel Drive

Rack & Pinion with Hydraulic Motor and

Planetary gearbox with integral brake (Qty.
is 3 No.s per machine)

Arm

Movement

and By Hydraulic Cylinders

Coupler release

3. Paddle Feeder (Technical Details)

316

a. Capacity

1400 TPH (Rated)/1680 TPH (Designed)

b. Quantity

04 Nos

c. Material to be Handled

Iron Ore Lump

d. Total travel

200 m

e. Holding capacity of Hopper

10000 T

f. No. of Travel Wheel

4 Nos.

g. Carriage Travel Drive

Electric Motor with Gear Box

h. Carriage Speed

1.5 m/min

i. Gear Box type

Bevel Helical Gear Box (2.8 Kw)

j. No. of Blades

06

k. Liner of Blades

Hardox 500 (6mm thick both side)

l. Dia. of Paddle Wheel

4000 mm

m. Paddle Wheel Drive

Hydraulics (Make Rexroth)

n. Anti-collision Devices

Infrared Sensor

o. DS Water Tank Capacity

1 Cu. M.

p. Oil Tank Capacity

400

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4. Stacker
A stacker is a rail mounted machine used to make stockpile on beds provided on either
side of the rail track by travelling to and fro along the length of the beds. In RMHP the
stackers make stockpile by CHEVRON method. The entire control and operation of the
machine is done from operators cabin provided on the machine through PLC system.
Please refer to Table for Technical Specifications of Stackers.
Technical Specifications of Stackers installed in RMHP
SL.

PARAMETERS

SPECIFICATIONS

No.
1

Type

Single Boom Slewing & Luffing Stacker

Material Handled

Iron ore (lump & fines), Limestone, Dolomite,

Quartzite, and Base mix

Quantity

5 No.s ( 3 for OHP + 2 for BMP beds)

Stockpile height

12m from top of Rail

Rated Capacity

1400 MTPH for OHP Stackers and 1200 MTPH for

BMP Stackers

Travel Drive

Boom

Conveyor

4 No.s Electric Motors, 7.5KW each

Belt 1400mm for OHP and 1200mm for BMP stackers

width
8

Slewing Drive

Two No.s Slow speed Hydraulic gearless motor,

flange mounted

Luffing Mechanism

Hydraulic (2 No.s Double acting differential type

hydraulic cylinders)

10

Lubrication System

Centralized, Motorized Dual line grease lubrication

system provided for Rail Travel and Slewing
Mechanism

11

Weighing

Micro Processor based Electronic Belt Weigher

provided on the Boom Conveyor. Capacity 1400
MTPH (Rated)

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5. Screening of Iron Ore Lump & Flux

Screening of Iron Ore Lump coming from mines is necessary because it contains lot of
undersize fraction (-10 mm), which adversely affects the blast furnace operation.
Therefore this undersize fraction is screened out at IOL Screening section & then stacked
in the designated bed. From the bed this screened ore is supplied to Blast furnace. Two
numbers of Screens of 1400 TPH capacity is installed at J2A building. Similarly Flux
(Limestone & Dolomite of SMS grade) is also screened at LDS (Lime Dolo Screening
station) to remove -25 mm & then it is supplied to LDCP. There are two numbers of
screens of 600 TPH capacity installed at LDS.
6. Unloading of Coal
In addition to the Raw materials unloaded which are required for RMHP, the department
has been handed over an additional responsibility of unloading coal for Coal Handling
Plant (CHP) department. For this purpose, a dedicated Wagon Tippler (WT-3) is being
operated and maintained by RMHP. In case of failure of WT-3 to unload coal due to
maintenance, coal can be sent through a by-pass route (i.e. L2C1conveyor by WT-2 Ore
Tippler).
7. Storage and Reclamation of Ore
Bedding and storage is possible with the stacker running to and fro on the length of the
pile [or on the length between two defined position in case more than one material is
stored in a bed] marked by travel limit switches, which through a relay sequencing
circuit, with time control-reverses the traveling gear after the travel in each direction
covering the desired length of the pile. The single boom stackers can form a stockpile of
32m wide, 320m long and 12m (maximum) high. Number of optimum layers in a bed is
controlled by stacker speed. Number of layers in a bed determines the homogeneity of the
bed and the number of layer to be kept between 250 to 400 layers. Blending is the
mechanized process of stacking & reclaiming to get optimum result in chemical and
physical characteristics of raw materials, that means the blending is a process of
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homogenization of single/different source of same raw materials over a full length of
pile/bed.
Bed numbers 1, 2, 3, and 4 (bed no. 4 partially) uses Barrel cum Blender Reclaimer
(Please refer to section 1.3.2 for Barrel Reclaimer details) for reclaiming the stored
material from the beds. For reclaiming material from these four beds two barrel
reclaimers are provided with a transfer car to transfer the reclaimers as and when required
from one bed to the other. Two nos Bucket-wheel reclaimers are envisaged for bed nos
4 (partly), 5, and 6.Please refer to section 1.3.3 for Bucket Wheel Reclaimer Details. The
rated capacity of all stacking line conveyors, feeders and stackers etc. is 1400tph and a
designed capacity of 1680tph. The rated capacity of all reclaim line equipment is 1200tph
and a designed capacity of 1440tph.A repair bay, with a closed cover shed is envisaged at
the end of the transfer car bay after bed no. 6 where maintenance for Barrel cum Blender
Reclaimers is taken up.
Reclamation from OHP takes place in the following circumstances
1. Feeding of Iron ore Lumps to Blast Furnace (BF#5) stock house.
2. Transporting Limestone/Dolomite (SP grade) and Iron-ore fines for Base mix
preparation to BMP.
3. Transporting SMS grade Limestone/Dolomite (-) 25mm to Base mix Preparation
plant (BMP), after screening.
4. Transporting Limestone/Dolomite (SMS grade) (+) 25mm to Lime Dolo Calcinations
Plant (LDCP) storage bunkers.
5. Transporting of Iron ore Lump and Dolomite to existing Blast Furnace (BF#2)
through Pipe Conveyor (Please refer to Section 1.3.4 for pipe conveyor details).
Two sets of Auto sampling unit for collecting samples of iron ore have been provided,
one at J2B building and the other at J1 building. The samples collected from samplers are
taken manually for testing purpose. At J2B auto sampling unit the material unloaded at
Track Hopper complex (Iron ore Lumps) is taken for sampling and similarly at J1 auto
sampling unit, the material unloaded at Wagon Tipplers (Iron ore fines, Limestone,
Dolomite, etc.) is taken for sampling.

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RMHP
8. Barrel Reclaimer
A Barrel Reclaimer is a rail mounted machine used for blending and reclaiming the
stacked material from a longitudinal stockpile area of the bed and delivers it to the yard
conveyor. The machine is rail mounted and operates in conjunction with fixed reclaim
conveyors. The machine is centrally controlled from the control desk provided in the
operators cabin on the machine. Please refer to Table 4 for Technical Specifications of
Barrel Reclaimer.
9. Bucket Wheel Reclaimer
A Bucket Wheel Reclaimer is a rail mounted machine used to reclaim the stacked
material on the beds provided on either side of the rail track by travelling (rail mounted)
along the length of the beds and deliver the material to the yard conveyor. Reclamation in
RMHP is done by Block-cutting method. The entire control and operation of the Bucket
Wheel Reclaimer is done from operators cabin provided on the machine through PLC
system. Please refer to Table for Technical Specifications of Bucket Wheel Reclaimers.
Technical Specifications of Barrel Reclaimers installed in RMHP
SL. No.

PARAMETERS

SPECIFICATIONS

1
2
3
4
5
6

Type
Material Handled
Quantity
Stockpile height
Rated Capacity
Travel Drive

7
8

Barrel Conveyor Belt width

Number of Buckets on
Barrel
Bucket Capacity
Lubrication System

Barrel type Blender Reclaimer

Iron ore (Lump & Fines), Base mix
4 No.s (2 for OHP + 2 for BMP area)
12m from top of Rail
1200 MTPH for all four Reclaimers
4 X 15 KW Electric Motors for Idle travel
4 X 1.1 KW Electric Motors for Operational Travel
1200mm
45

9
10

320

350 Litres each

Auto operation centralized lubrication system with
motorized grease pump for LT, Support & guide
Rollers, Barrel Drive bearings, Harrow Mechanism.
Graphite Pad Lubrication system for Rim tyre.

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Technical Specifications of Bucket Wheel Reclaimers installed in RMHP
SL. No.
1

PARAMETERS
Type

SPECIFICATIONS
Rail Mounted, Self Propelled, Boom type, Luffing &
Slewing Bucket Wheel Reclaimer

Material Handled

Iron ore Lump, Limestone, Dolomite, and Quartzite.

Quantity

2 Nos for OHP area

Stockpile height

12m from top of Rail

Rated Capacity

1200 MTPH

Travel Drive

6 No.s Electric Motors, 7.5 KW each

Boom Conveyor Belt width

1200mm

Slewing Drive

2 No.s Slow speed hydraulic gearless motors, flange

mounted

Luffing Mechanism

Hydraulic (2 No.s Double acting differential type

hydraulic cylinders)

10

Lubrication System

Centralized, Motorized Dual line grease lubrication

system provided for Rail Travel and Slewing Mechanism

11

Weighing

Micro Processor based Electronic Belt Weigher provided

on the Boom Conveyor. Capacity 1200 MTPH (Rated)

12

Bucket Wheel Drive

1 No. slow speed hydraulic gearless motor, direct Shaft

driven

13

Bucket Capacity

535 Litres (Approximately) each

10. Pipe Conveyor

A Pipe Conveyor is a pipe formed out of a flat conveyor belt and using all other components
that are used in a standard through conveyor. This pipe is of trough profile at feed end, folded
into pipe at middle, and again opening up at discharge end. Two pipe conveyors have been
envisaged for the new plant out of which one pipe conveyor (Iron ore/Flux conveyor) is
being operated and maintained by RMHP department.

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Since the capacity of the Coke oven battery (COB#11) is inadequate for the Blast Furnace
(BF#5), the balance coke is transported from the existing batteries after screening/sizing to
the new coke sorting plant through pipe conveyor and belt conveyors. Since the topography
of the area from existing plant to the 2.5MT expansion unit is not feasible for normal belt
conveyors, a pipe conveyor has been installed to transfer Coke from existing coke sorting
plant. In addition to the coke pipe conveyor, another pipe conveyor is installed for conveying
Iron ore lump and limestone/dolomite required for the existing Blast furnace (BF#2) which is
under RMHP.Daily requirement of BF#2 (i.e. 1200 tonnes of Iron Ore Lump and 150 tonne
of dolomite) will be met through Ore pipe conveyor.
A common gallery for both pipe conveyors of open type with walkways on both side of the
conveyors and one walkway in-between, except for receiving and discharge ends, where
closed gallery is provided above the open conveyor. Drives for pipe conveyors are electromechanical type with VVVF. Please refer to Table below for Technical details of Pipe
conveyors
Technical details of Pipe Conveyors
SL. No.

PARAMETERS

COKE

IRON ORE/FLUX

CONVEYOR

CONVEYOR

Rated Capacity

200 TPH

600 TPH

Length

1485m

1355m

Pipe Diameter

300mm

300mm

Temperature

<120C

Ambient

Lift (Max. height attained from

12.6m

4.3m

receiving end)

322

Belt Width

1100mm

1100mm

Drive (Electric Motor)

315KW

355KW

Total Number of Idlers used

1236

1151

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Before going into the details of Base mix handling plant (BMP), it is advisable to
understand the basic requirement of the internal customer (Base mix Handling Plant) as
well as external customer of RMHP. Please refer to Table below for Base mix plant
requirement and Table 8 for Sinter plant requirement.
Requirement of internal customer (Base mix plant, BMP)
SL. No.

RAW MATERIAL

TON PER DAY

SIZE RANGE

Iron ore Fines

10140

(-)10 mm - 100%
(-)8 mm - 90%

Flux material

2000

(-)3 mm - 90%
(-)5 mm 100%

Coke breeze (0-15 mm)

800

(-)3 mm - 90%
(-)5 mm 100%

Other metallurgical waste (Mill scale & Flue

390

(-)3 mm

dust + BF return fines)

Requirement of external customer (Sinter Plant, SP):

SL. No.

MATERIAL

TON PER DAY

SIZE RANGE

Crushed coke breeze

160

(-)3 mm - 90%
(-)5 mm - 100%

Crushed limestone &

200

dolomite
3

IISCO Steel Plant

Base mix

(-)3 mm - 90%
(-)5 mm - 100%

13500

(-)8 mm

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RMHP

C) Base mix Handling Plant (BMP)

The raw materials handled by the BMP area are Iron ore fines, Sinter fines, Coke fines,
Limestone (BF grade), Dolomite (BF grade), Coke, and Dust & Mill scales.
Salient Features of Base mix Handling Plant
i.

There are two stacking and storage beds in Base mix yard, with a storage
capacity of 8 days maximum and size being 200m X 32m X 12m.

ii.

Two Slewing Stackers and two Barrel type blender reclaimers are provided
dedicated for each bed.

iii.

One Transfer Car is provided for shifting Barrel Reclaimer from One bed to
the other or to the repair bay.

iv.

Three Rod mills are provided for crushing Coke at a rate of 50 TPH each.

v.

Six Hammer Crushers are installed for crushing Flux material at a rate of 150
TPH each.

vi.

Four Flip Flow screens are provided in Flux screening building for screening
crushed flux material at a rate of 250 TPH for Primary screening and 300 TPH
for Secondary screening.

vii.

Two Flip Flow screens are provided in Coke Crushing building for screening
coke at a rate of 100 TPH.

viii.

There are twenty bunkers in Mixing Bin (MB) building with a storage
capacity based on the volume of 285cu.m for storing various raw materials.

ix.

There are eight bunkers in Flux Bin (FB) building of 200cu.m.Volume with a
storage capacity of 320 Ton each.

x.

There are six bunkers in Coke Breeze (CB) fines building of 200cu.m. volume
with a storage capacity of 100 Ton each.

1. Base mix preparation and Handling

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Various fines of different materials are mixed based on the process requirement of
Sinter Plant and the resulting mixture, whichis called as Base mix, is conveyed to
open storage beds with the help of stackers and then blended with barrel reclaimers
and finally sent to Sinter plant. The Base mix is a homogeneous mixture of IOF,
crushed Coke, crushed Flux (Lime stone & Dolo fines),mill scale, Flue dust etc mixed
in a certain proportion. The standard proportions of various raw materials for
preparation of Base mix are shown in Table below:
2. Raw material mixing proportions for preparation of base mix
SL. No.

RAW MATERIAL

PERCENTAGE

Iron ore Fines

78%

Flux Fines

14%

Coke Fines

05%

Other Metallurgical Waste

03%

Operation of Base Mix Plant is best understood by considering Mixing Bin building
(MB) as an epicenter and analyze the material in-flow to and out-flow from MB,
since all types of Raw materials required to prepare Base mix flow into the MB and
come out of MB as a mixture (Base mix). Please refer to Table 10 for Mixing Bin
building details.
Mixing Bin Building details
Sl.

Material

No.

Number

Volume

of Bins

(Cu.M.)

Tonnage

Net Capacity In
Tons

Iron ore fines

285

627

627 x 8= 5016

Flux fines

285

456

456 x 4= 1824

Coke fines

285

142.5

142.5 x 4= 570

Mill scale

285

513

513 x 2= 1026

Sinter fines

285

513

513 x 2= 1026

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RMHP

Materials flow to Mix Bin building is as follows:

a. Iron ore fines
There are two sources from which Iron ore fines are conveyed to MB. One is
being Iron ore fines beds of OHP and the other Blast furnace Stock House.
Iron ore fines is reclaimed from two dedicated OHP beds by Barrel type
blender reclaimers and sent directly to MB bins. Please refer to Table 10 for
MB bins details. As stated in 1.3.1, Iron ore lump after screening is being sent
from OHP beds & then to BF#5. The lump sent by OHP is also screened at
Blast Furnace to avoid Iron ore fines which is generated during the process of
transportation and return fines so obtained is sent to MB building.
b. Flux
Flux is a mixture of Lime stone & Dolomite in certain proportion required in
sinter making. The main function of the flux is to take care of gangue in Blast
Furnace & also to increase the rate of reaction to form the good quality slag.
Flux acts as a binder in sinter making to increase the sinter strength.
Limestone and Dolomite from OHP beds (bed no.s 5 and 6) are conveyed and
stored in Flux Bin (FB) building. From FB building flux is conveyed to Flux
Crushing Building (FCB) where 6 No.s of Hammer Crushers (CR-1, 2, 3, 4,
5, 6) are installed for crushing the material, and subsequently to Flux
Screening Building (FSB) where 4 Nos Flip Flow screens (FF-3, 4, 5, 6) are
installed to screen the material. After screening, the flux material (-) 3mmsize
is fed to MB Building. The Hammer Crushers are used for crushing Lime
stone & Dolomite Lumps to required size i.e. (-3 mm) of about 90 %.
c. Coke Breeze
Another important in gradient in base mix is crushed coke of size fraction (3mm) 85 % min. There are two sources from which Coke fines are received

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by MB building. One is being Coke Sorting Plant of Coke Oven and the other
Blast Furnace Stock House. Coke conveyed by either of the above two
sources will be conveyed to the Coke Breeze (CB) fines building. In CB, 6
nos bunkers of effective storage volume (capacity) of 200cu.m. each has been
provided to store Coke fines. As and when required, the stored coke fines can
be carried to Coke crushing building (KCB) where 2 No.s of Flip Flow
Screens (FF-1,2) and 3 No.s of Rod Mills (RM-A, B, C) are installed for
crushing Coke. After screening, the Coke fines (-) 3mm size is fed to MB
Building.
d. Sinter Fines
Sinter fines which are returned from Blast Furnace Stock House is directly fed
to MB bins.

e. Mill Scale and Flue Dust

Mill scale and Flue dust is collected and transported by dumpers tostorage
shed and stored on ground. They are sent as and when required to MB
building by loading onto conveyors through 3 fixed hoppers (FH-1, 2, 3) with
the help of pay-loaders.
Specification of Impactor Crusher

IISCO Steel Plant

i.

Make

: Pennsylvania

ii.

Location

: Flux Crushing Building

iii.

Type

: Reversible Hammer Crusher

iv.

Material Handled

: Flux (Limestone & Dolomite)

v.

Quantity

: 6 Nos.

a.

Primary

: 3 Nos.

b.

Secondary

: 3Nos.

vi.

Crushing Capacity

: 150 TPH

vii.

Crushing

: 1200 rpm

viii.

Feed Size

: 25 mm to 50 mm

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RMHP
ix.

Product Size

: 3 mm (80%)

x.

Number of Hammer Rows: 3 rows with 5 nos per row.

Specification of Coke Crusher

i.

Make

: Mcnally Sayaji

ii.

Location

: Coke Crushing Building (KCB)

iii.

Type

: Rod Mill

iv.

Material Handled

: Coke Breeze

v.

Quantity

: 3 Nos

vi.

Capacity

: 50 TPH

vii.

Mill Speed

: 14.7 RPM

viii.

Mill Inching Speed

: 3 RPM

ix.

Feed Size

: -30 mm to +15(10%) -15 mm (90%)

x.

Product Size

: -3mm (90%) & - 5mm (98%)

xi.

Mill Nominal Size

4.8 long , 3.2 dia

xii.

Rod Size

4500 mm long x 100 mm dia

a. 4500 mm long x 90 mm dia

b. 4500 mm long x 75 mm dia
c. 4500 mm long x 65 mm dia
The Base mix is prepared in Mixing Building (MB) with the help of Belt Weigh
Feeders, BWFs (which enables mixing of various materials as per the required
proportions) provided below the bins. The Mix discharged from the BWFs is sent
to stack in the Base mix beds (2 beds) with the help of two Single boom slewing
stackers by conveying through various conveyors. Bed blending is possible with
the stacker running to and fro on the length of the pile. Two dedicated Barrel type
Blender Reclaimers are used to reclaim the stacked base mix and conveyed
through a series of conveyors. A sample cutter is provided to the conveyor BMC6 inside TT-5 Junction House to get sample of Base Mix for analysis before
sending it to Proportioning bins of Sinter Plant.

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In addition to Base mix, Coke fines (Coke Crushing Building) and Flux fines
(Flux Screening Building) are sent to Sinter Plant for fine tuning.

f. Yard equipment
The equipment which are installed on the storage yard/beds are generally termed
as Yard equipment which are of M/s Elecon make. Although the details of these
equipments have already been elucidated in various sections, the Table 11 below
would be a ready reference of the details of these yard equipment installed in
RMHP. The numbers in the brackets are the machine numbers designated for that
particular machine.

Installation details of Yard equipment

Sl.No.
1

Name Of The Equipment

Ohp Area

Rail mounted single boom Three

luffing slewing stacker

(411,

Bmp Area

Capacity In Tph

Two

(414, OHP = 1400

412, 415)

BMP = 1200

413)
2

Bucket Wheel Reclaimer

Two

(419, -

OHP = 1200

420)
3

Barrel

type

blender Two

(421, Two

(423, OHP = 1200

Reclaimer

422)

424)

BMP = 1200

Transfer Car

One (425)

One (426)

NA

D) Utility Section

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RMHP
The Utility section can be best understood if both OHP area and BMP area utilities are
studied separately.
1. OHP Utilities
Major divisions in OHP Utilities are elucidated below:
2. Fire Protection System
There are two Pump Houses in OHP area namely, Pump House-1 which is dedicated
to Fire Protection System, and Pump House-2 which is dedicated to mainly Dust
Suppression and Make-up Water System in the area.
The Fire Protection System consists of following Sub-Systems:
a. Hydrant System (installed as per TAC fire protection manual) with fire
network covering OHP (with 299 Hydrant points), BMP (with 359 Hydrant
points), Sinter Dispatch Conveyors, Water Treatment Plant, and LBDS-6.
Please refer Table 12 for Pumping arrangement of Hydrant System.
b. Medium Velocity Water Spray System (MVWS) for cable cellar and cable
tunnels for LCSS-1A (DV-1), LCSS-2A (DV-2), LCSS-3A (DV-3), LCSS-4A
(DV-4), LCSS-5A (DV-5), and LCSS-6A (DV-6 & 7) using Deluge Valves.
Please refer Table 13 for Pumping arrangement of MVWS System.
c. Clean Agent (Inergen Gas based) system for Dispatcher, PLC Rooms at
LCSS-5A, and Wagon Tippler control room. Inergen is a blend of inert
atmospheric gases that contains 52% nitrogen, 40% argon, 8% carbon dioxide,
used for fire suppression system agent. It is considered a clean agent for use in
gaseous applications.
d. Portable fire extinguishers at various locations as follows: -

330

i.

Electrical rooms.

ii.

Administration building.

iii.

Pump Houses.

iv.

Junction Houses and different buildings in OHP area.

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RHMP
Pumping arrangement of Hydrant System
Sl.

Pump Details

Drive

Quantity

No.

Capacity

Remarks

(Cu.M. /Hr.)

Main Fire Pumps

Electric Motor

273 at 88 mwc

Stand-by Pump

Diesel Engine

273 at 88 mwc

Jockey Pumps

Electric motor

20 at 88 mwc

For
pressurizing
the entire
system

Pumping arrangement of MVWS System

Sl.

Pump Details

Drive

Quantity

No.
1

Capacity

Remarks

(Cu.M. /Hr.)
Main Fire Pumps

Electric

273 at 88 mwc

Motor
2

Stand-by Pump

Diesel Engine

273 at 88 mwc

Jockey Pumps

Electric

20 at 88 mwc

For

motor

pressurizing
the entire
system

3. Water reservoir for Hydrant & MVWS system

Characteristics
i. Reservoir Volume is 1100 cum.
ii. The reservoir is provided with two interconnected compartments.
The two pumping systems are inter-connected so that in case of failure one system
can be utilized to cater to the needs of the other. The piping network for Hydrant
System will consist of underground and above ground piping with Hydrants at
Strategic locations.

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RMHP
4. Dust Suppression
The Dust Suppression and Make-up Water System consist of following Sub-systems:
i.

DS-1 which is Plain Water Dust Suppression System for Track Hopper. 2
Nos Pumps are installed at Pump House-2 for this purpose.

ii.

DS-2 which is Plain Water Dust Suppression System for Stockyard. 2

Nos Pumps are installed at Pump House-2 for this purpose.

iii.

DS-3/4/5/6 which is Plain Water Dust Suppression System for Paddle

Feeders

iv.

(8 Nos Pumps are installed on Paddle Feeders).

DFDS-1 which is Dry Fog based Agglomerative Dust Suppression System

for 29 Junction Houses. 3 Nos Compressors and 2 Nos Pumps are
installed at Pump House-2.

v.

PW-1 which is Potable Water System for Wagon Tippler Control Room,
Administrative Building, Canteen Building, FLD-1, LDB, LDS, LCSS1A, LCSS-2A, LCSS-3A, LCSS-4A, LCSS-5A, LCSS-6A, Toilet-1,
Toilet-2, Toilet-3. 2 Nos Pumps are installed at Pump House-2 for this
purpose.

vi.

MW-1 which is Make up water system for Air washer of the Ventilation
System & AC Cooling Tower at Wagon Tippler Control Room, LCSS-1A,
LCSS-2A,LCSS-3A, LCSS-4A, LCSS-5A, LCSS-6A.2 Nos Pumps are
installed at Pump House-2 for this purpose.

vii.

SP-1 which is Sump Pump arrangement for Track Hopper Sump Pit (4
Nos), Wagon Tippler Sump Pit (2Nos), Sump pit at J0 Building (2Nos),
and 2Nos Portable pumps for miscellaneous usage.

There is an RCC Storage Tank (RCC TANK-II) near Pump House-II which will get
continuous Industrial Water Supply by IISCO at Location N-9952/E-7358 @
255 cu.m. /Hr. at 1 to 1.5 Kg/Sq.cm. pressure. This RCC Storage Tank will supply
water to the Dust Suppression System for DS-1 to DS-6, DFDS-1, and MW-1.There
is another RCC Storage Tank (RCC Tank-III) near Pump House-II which will also
get continuous Drinking Water Supply by IISCO at location N-9952/E-7358 @ cu.m.

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RHMP
/Day at 1.5 to 2 kg/Sq.cm. pressure. This RCC Storage Tank will supply water to the
Potable Water System (PW-1).

5. Ventilation System
Air washer type pressurized ventilation (supply and Exhaust) has been considered for
Cable vault & Switch gear rooms at LCSS-1A, 2A, 3A, 4A, 5A, 6A.Please refer to
Table 14 and Table 15 for Ventilation Exhaust and Suction fans details and their
locations installed in OHP area.
Ventilation Exhaust Fans
SL.No.

LOCATION

INSTALLED

CAPACITY

QUANTITY

(Cu.m. /Hr.)

Track Hopper

82500

J0 Building

86000

J0 Tunnel

86000

Wagon Tippler Building

65000

Wagon Tippler Tunnel

65000

Ventilation Suction Fans

Sl. No.

Location

Installed Quantity

Capacity
(Cu.M. /Hr.)

Track Hopper

74000

J0 Building

78000

J0 Tunnel

78000

Wagon Tippler Building

58000

Wagon Tippler Tunnel

58000

6. BMP Utilities

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RMHP
Major divisions in BMP Utilities are elucidated below along with the schedule of
pumps mentioned in Table below:

Schedule of Pumps for DS/SW/PW/CW System/Flow:

Sl. No.

Pump Tag No.

Capacity

Application

(Cu.M.

Quanti
ty

/Hr.)
1

DFDS-1A/1B

12

Dry Fog Dust

Suppression System
2

DFDSC-

850

DFDS Compressor

70

Stockpile Dust

1A/1B/1C/1D/1E/1F
3

SPDSP-1A/1B

Suppression System
4

FHDSP-2A/2B

18

Fixed Hopper Dust

Suppression System
5

SW-3A/3B

Service Water

PWP-4A/4B

Potable Water

CWP-5A/5B

16

Cooling Water

7. Dust Suppression (DS) and Dry Fog Dust Suppression System (DFDS):
Plain water type dust suppression system is considered for Base mix stockpile, fixed
hoppers & Dust/Scale. Plain water type sprinkler type dust suppression system is used
for the stockpiles shortly called as SPDS. Plain water spray type dust suppression
system is used for Emergency coke storage yard and fixed hoppers near emergency
coke storage area.

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RHMP
Dry fog type DS system is used for controlling the fugitive dust generated during the
handling of material in all transfer points and other buildings.
8. Service Water Flow
Service water pump located in Pump House-C will take industrial water from RCC
tank located adjacent to the Pump House-C and supplies to the overhead PVC service
water storage tanks at control rooms, administrative buildings, workers rest room,
canteen& coke crushing station. This water from overhead tank is delivered to toilets
of MCC rooms, make-up water required for water cooled PAC units and for air
washer units of respective MCC rooms by gravity.
9. Potable Water Flow
Potable water pump (OWP-4A/4B) located in Pump House-C will take potable water
from RCC potable water tank located adjacent to the Pump House-C and supplies to
the overhead PVC storage tanks at Control rooms, administrative buildings, workers
rest room, canteen & coke crushing station.
10. Cooling Water Flow
Cooling water pump (CWP-5A/5B) located in Pump House-C will take cooling water
RCC water tank located adjacent to Pump House-C and supplies this water to the Rod
Mill Bearings in KCB building. The return hot water from Mill bearings will be
routed through the conveyor galleries and will be drained to RCC tank near Pump
House-C, while dissipating heat along the travel length of approximately 470m.
11. Air Blasters
In each bunker, 8 number of air blasters of capacity 150lt. each is provided for
blasting compressed air to loosen the sticky material inside the bunkers. Two screw
air compressors are installed in the compressor house. Please refer to Table 17 for list
of buildings for which Air Blaster system has been considered, along with the
capacities of their respective Air Blast Compressors (ABC) at BMP.

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RMHP
Air Blasters details
Sl.

Air Blaster

Number Of

No.

Compressor

Air Blasters

Location/Building

Cubic Feet
Per Minute
(Cfm)

ABC-6A/6B

160

Mixing Bin Building

162.5

ABC-7A/7B

48

Coke Breeze fines bunkers

125

12. Ventilation and Pressurization System

Air washer type pressurized ventilation (supply and Exhaust) has been considered for
Cable vault & Switch gear rooms at LCSS-1C, 2C.
13. Water Cooled Packaged Air Conditioning System
Two 100% capacity (1W+1S) Water cooled Packaged Air Conditioning Units (PAC)
having water cooled condenser with 100% standby condensing water pumps along
with forced draft cooling tower are provided for Dispatcher Control room/
Engineering. Station /PLC room,LCSS-2C.One 100% capacity (1W+0S) Water
cooled Packaged Air Conditioning Units (PAC) having water cooled condenser with
100% standby condensing water pumps along with forced draft FRPcooling tower is
provided for Intelligent MCC rooms, LCSS-1C, 2C.

14. Safety/Auxiliary devices

It is a dust prone department due to handling of various types of fines hence use of
Dust Mask, safety goggles, safety helmet, safety shoes etc is a must. Housekeeping is
a major challenge in smooth operation of this department and requires special
attention.Spillage of material, water, oil, belt conveyor pieces is to be controlled by
effective housekeeping. This also leads to personal and equipment health & safety. It
makes the surrounding area operation friendly.

336

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RHMP
i.

Each conveyor is protected against damage to the edge of the belt due to
excessive sidewise movement by providing an adequate number of belt sway
switches at an interval of 100m. The belt sway switches are of addressable
type, i.e. that particular switch which was operated can be traced from Central
control room.

ii.

For emergency stop, adequate numbers of pull cord switches are provided at
an interval of 30m. Additionally each conveyor is provided with one Zero
speed switch for sensing beltspeed. In case the speed of belt goes below preset
value, it will trip the conveyor. The pull cord switches are also of addressable
type.

iii.

Chute Block Switch is provided at each leg of chute & will trip the conveyor
in case of blockage of Chute.

iv.

Limit Switches like end limit switch, for Wagon Tipplers, Side Arm Chargers,
Stackers, Bucket Wheel Reclaimers, Barrel Reclaimers, Shuttle Conveyors,
and position limit switch for Shuttle Conveyors etc. are provided.

v.

Hold backs are provided in inclined conveyors to protect it from reverse

running in case of power failure.

vi.

Anti collision switches for moving equipments like yard equipments are
provided to avoid collision of equipment running simultaneously in
same/different beds.

vii.

Temperature sensors installed on bearings of Hammer Crushers and HT

motors.

viii.

Suitable interlocks are provided in all possible equipment to ensure men and
machine safety.

E) Few noticeable points about RMHP:

1. All OHP area equipment are PLC controlled and all BMP area equipment are DCS
controlled.

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RMHP
2. VFDs are installed for Belt Weigh feeders of BMP area, Travel drives of Stackers,
Barrel Reclaimers, Bucket Wheel Reclaimers, and Barrel drives of Barrel Reclaimers
for speed control.
3. There is a Central Control Room at LCSS-5A near E.D. (Works) building for
operation of complete processes of Ore Handling Plant (OHP) area.
4. There is a Central Control Room at LCSS-2C for operation of complete processes of
Base mix handling plant (BMP) area.
5. Addressable type Pull cord Switches (PCS) and Belt sway switches (BSS) are
installed in all conveyors by which the location of operated PCS/BSS can be traced
from Central Control Room.
6. There are six Load Control Sub-Stations (LCSS) at OHP and three LCSSs at BMP
area.
7. An Administrative building for RMHP is situated near BMP area in which View
monitors are installed for 24 hrs monitoring of processes in both OHP and BMP
areas.

338

IISCO Steel Plant

Rolling Mills
ROLLING MILLS

A) Introduction
RollingMills Complex is the last processing unit in an integrated steel plant where
steel is given shape in to structural, coils, rebars, bars etc as per market requirement.
Old Rolling Mills Complex at ISP was having Blooming Mill, Billet Mill, Heavy
Structural Mill, Light Structural Mill and Merchant Mill. All these mills were phased
out on 31.03.2014.New Rolling Mills Complexconsists of Wire Rod Mill, Bar Mill
and Universal Section Mill under 2.5 MT Expansion and Modernisation programme
of ISP. Facilities available in these mills are as follows:

B) Wire Rod Mill (WRM)

Wire Rod Mill consortium comprising of M/s Danieli, Italy, M/s Danieli Engineering
Limited, India, M/s Shriram EPC, India, and Mecon Ltd, India as consultant.WRM
has been positioned at elevated platform at +5.0 meter. Installed capacity of WRM is
0.55 MT/ year. WRM is a continuous mill consisting of 16 nos of 2-Hi stands
alternate horizontal and vertical followed by 2 passes and 8 passes Fast Finishing
Blocks, 4 passes Twin Module Block, Laying Head, Roller Conveyor, C-Hook Area,
Compacting and Tying Machine. Feed stock is continuous cast 150X150X12000 mm
billets weighing 2065 kg.Roll building is being done in Guide Shop with the help of
Robot and Roller Guide setting for blocks being done with Optical Guide Setting
Instrument. Facility for on-line profile measurement is available.
1. Wire Rod Mill Layout

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Rolling Mills
2. Flow Diagram of Wire Rod Mill

3. Steel Grades and Product Mix.

Sl No
1
2
3
4
5
6
7
8
9

Steel Grades
Carbon steel
Spring steel
Electrode quality
Ball bearing quality
Free cutting
Cold heading
Low alloy
Forging quality
Rebar

Product range in coil form

5.5-22.0 mm
5.5-22.0 mm
5.5-22.0 mm
5.5-22.0 mm
5.5-22.0 mm
5.5-22.0 mm
5.5-22.0 mm
5.5-22.0 mm
6.0,8.0,10.0 & 12.0 mm.

4. Detailed Product Mix

Plain round coils (mm)
5.5
8.0
16.0
6.0
9.0
20.0
6.5
10.0
22.0
7.0
12.0
7.5
14.0
340

Rebar coils (mm)

6.0
8.0
10.0
12.0

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Rolling Mills

5. Product Tolerance
Product
Plain Wire Rod
Rebar

Size (mm)
5.5 22.0
6.0,8.0,10.0 & 12.0

Tolerance (mm)
(+/-) 0.10
IS 1786:2008

Ovality
70 %

6. Coil Characteristics

Actual
situation

Outside
Dia
(mm)
1250

Inside Dia
(mm)
850/900

1250

850/900

Height before/and
after compacting
& tying (mm)
2000/1500
(plain wire rod)
2800/1800 (rebar)

Weight
(kg)

No
straps.

2000

2000

7. Major Mill Parameters

Parameters
Maximum rolling speed
Mill utilization factor
Yield %
Specific roll consumption
Specific fuel consumption
Avg rolling rate

115 m/s
76.4 %
97.0
0.135kg/t
0.270 G Cal/t
100t/hr

8. Major Areas in WRM are as follows

a. Billet Yard Area.
b. Reheating Furnace.
c. Mill Area & Roll Shop.
d. Water Treatment Plant &Chiller Plant.
e. Despatch Area.
a. Billet Yard Area
Stacking of billets of 150X150X12000 mm, weighing 2065 kg in 17 layers of 80
billets each in alternate disposition arranged in each stack. Total storage capacity
is 50544 T.
b. Reheating Furnace
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341

of

Rolling Mills
Walking beam type reheating furnace consortium comprising of M/s
BricmontInc, USA, M/s Micco,India. The furnace has an inside effective
length of 19350 mm and width of 12900 mm.

Furnace Technical Data

Sl
No
1

Description

Wire Rod Mill

Bar Mill

Universal Section Mill

Type of furnace

2
3
4
5
6
7
8
9
10
11
12
13

Fce capacity(tph)
Discharge temp (max)
Fuel
CV of gas
Air temperature
No of burners
Maximum scale loss
Automation
Combustion system
Gas pressure
Air pressure
Nitrogen pressure

Side charging &

side discharging.
150
1250 0C
Mixed gas.
2500 kcal/Nm3
(+) 500 0C
30
0.6 %
Level 2
Recuperative
700-800 mm WC
6 Kg/cm2
6 Kg/cm2

Side charging &

side discharging.
160
1250 0C
Mixed gas.
2500 kcal/Nm3
(+) 500 0C
30
0.6 %
Level 2
Recuperative
700-800 mm WC
6 Kg/cm2
6 Kg/cm2

Front charging & end

discharging.
180
1250 0C
Mixed gas.
2500 kcal/Nm3
(+) 500 0C
61
0.6 %
Level 2
Recuperative
700-800 mm WC
6 Kg/cm2
6 Kg/cm2

Cold billets are placed on charging grid by means of magnet fitted EOT
cranes. Hot billets are charged directly from CCP on to the charging roller
table. Billet is being stopped at the entrance of the furnace. The piece is then
crowded to ensure that it is cantered on the charging roller table. The piece is
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IISCO Steel Plant

Rolling Mills
positioned inside the furnace by in-furnace charging roller table. Once the
billet has been placed inside the furnace, the walking beam lifts and advances
the product inside the furnace. The maximum walk length is 225 mm. When
the billet is requested by the mill and a piece at the discharge end of the
walking beam mechanism, the door will open, the walking beam will move
one walk and place the heated billet on to the discharge roller table. The
discharge rolls will accelerate and advance billet in to the mill.
Two combustion air blowers are provided to supply combustion air to the
furnace. Only one is required to operate for the furnace combustion system,
the second is provided as standby.The air is preheated in two pass dual bundle
type recuperator. The temperature of the combustion air from recuperator is
controlled by the furnace control system by adjusting the position of the hot
air bleed valve. By bleeding hot air out of the system more cold air enters the
recuperator and affectively lowers the temperature to avoid damage of
recuperator. The safety circuit monitors the furnace combustion system and
shuts down the furnace when unfavourable condition exists.
The furnace pressure control system maintains a slightly positive pressure at
the discharge door by automatically adjusting the position of the waste gas
damper to maintain a set point near +0.06 mbar.
The furnace level-2 system takes information from the base control system
(level-1) to optimize furnace efficiency. Furnace operation is being controlled
from HMIs located in furnace control pulpit.
c. Mill Area
i.

IISCO Steel Plant

Billet charging and discharging area

Cold billets are charged on the pawl type cold charging table by magnet
fitted EOT cranes. The billets are put one at a time on to the reheating
furnace charging roller table by means of hydraulically operated charging
device. Hot billets from CCP come directly on to thecharging roller
table.Before being charged, billets are weighed by means of load cell
located under the furnace entry roller table. Billets are heated inside the
furnace to rolling temperature (1100-1150 0C). Billet auto charging and
discharging facility is also available.

343

Rolling Mills

344

ii.

Descaler
Billets before entering in to the mill is descaled by means of high pressure
water descaler (250 bar max) during its travel on the roller table.

iii.

Mill Housings (Roughing & Intermediate)

The roughing and intermediate mill is composed of 16 noshousingless
cartridge type stands with sound rigidity and very limited yielding. The
products are continuously rolled according to schedule by mill stands in HV arrangement with fixed rolling line and without bar torsion. Roll pass
design optimised and arranged in families with common passes for several
finished products. To give the mill maximum flexibility each stand is
driven by independent motor. To obtain a very short stoppage of the
rolling process, an off-line quick stand changing system has been provided
for mill finishing stands. During rolling process nose and tail cropping are
carried out automatically by start/stop crop shear located after stand 4 and
10. In emergency situation the bar can also be chopped automatically by
these shears.

iv.

Finishing Blocks
At the exit stand of pre-finishing mill (stand -16), the rolled stock is
conveyed to the 2-passes+8-passes Fast Finishing Blocks. Each finishing
block is driven through a single motor shaft and consists of rolling units
with tungsten carbide rings arranged at 900 one in comparison to other for
rolling without torsion to get high quality finished products.

IISCO Steel Plant

Rolling Mills

v.

DSC & QTR Systems

The DSC system is a in-line process which is performed during and after
the rolling operations for the purpose of obtaining prime quality products
to fulfil the requirement of the customer. DSC line after the block consists
of a water cooling line made up of cooling zones plus equalizing zones.

vi.

High Speed Shear

High speed cropping shear is located in front of the Twin Module Block to
perform head and tail coil trimming. This operation is necessary because
these parts of the coil vary in technological properties as compared with
rest of the coil. A microprocessor controls the diverter speed in accordance
with the blade position for ensuring an accurate setting of cropping
length.In emergency situation the bar can also be chopped automatically
by this shear.

vii.

Twin Module Block (TMB)

4-passes TMB enables ultra-high speed production of an extended size
range with very close tolerances. TMB fitted with automatic quick
changing facilities.

viii.

Laying Head
Laying head provides formation of regular and constant shape and size
ofthe wire rod loops falling on to the roller conveyor.

ix.

Roller type cooling conveyor

The roller type cooling conveyor performs the final cooling of the wire rod
loops. Multi section type with independently variable speed drive to vary
loop control points and eliminates cold spots. Retaining hoods are
provided for slow cooling and fans for fast cooling. Step is provided at
cooling conveyor for spacing of wire rod turns.

x.

Coil forming pit and C-Hook

At the end of the roller conveyor, the wire rod loops are collected in a coil
forming station to form a regular shaped coil. The reforming station is
made up by two vertical trestles. One for loop collection and coil
formation, the other for coil transfer and loading in C-hook conveyor. The

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two trestles are mounted on a rotating platform to allow the above
operating cycles alternatively. The trestle in discharging position is tilted
900and the coil is picked up and transferred in a horizontal position to the
hook of the C-Hook conveyor. The C-Hook conveyor brings the coil to the
compacting and tying machine. Compacting and tying is done by
SundBirsta tying and compacting machine.
d. Water Treatment Plant
Water treatment plant for wire rod and bar mill is designed for catering the
process water for both the mills. It is a centralized water supply unit which
houses all the water supply equipment and treatment processes.
The basic purpose of the water treatment plant is to provide a suitable quality
of process water at desired flow rate and pressure and also to apply essential
treatment to the water in order to keep that quality maintained. These
treatments include physical filtration and chemical dosing.
It not only provide centralized water supply but is also highly automated. It is
capable of being controlled remotely from a single station HMI (human
machine interface). This water treatment plant is equipped with highly
automated systems which are governed by PLC (programmable logic
controller). PLC is programmed with set of logics which, during the operation
of the plant governs the running of several equipment according to the changes
in various parameters.
Besides the supply of water to mill it also take care of minimal wastage of the
process water by recycling of the waste water. It has got state of the art waste
water treatment facility which allows the recycling of the waste water from
even sludge.
Main Pump House Area consists of:
i.

5 water collection tank

ii.

29 pumps

iii.

4 blowers

iv.

3 anthracite sand filters

v.

10 chemical dosing units: Main pump house are provides housing

to several equipment and is consisting of 5 major water collection
tanks and 7 cooling tower cells.

e. Non-contact water circuit

It is the circuit which is mainly to supply water for:
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i.

Motor cooling

ii.

Heat exchangers for cooling lubrication oil and hydraulic oil

iii.

Roller table cooling

iv.

Inter-cooling in compressor

This water called non-contact water or indirect cooling water because it cools
these components without making direct contact with it. It flows in closed
coils or circuits and picks up the heat via metallic conduction. It mainly carries
heat and less physical impurities.
Its treatment includes physical filtration through self-cleaning filter and
chemical dosing for conditioning of water.
f. Contact water circuit
These circuits are meant for supplying water for:
i.

Cooling the rolls in roll stands.

ii.

Cooling the rings in the fast finishing block.

iii.

For descaling.

iv.

Heat treatment in water boxes.

v.

Other contact cooling.

This water is called contact water because it directly sprays over the
components it is supposed to cool. It carries a big amount of scale and other
physical impurities and is requires rigorous treatment for its cleaning and
reusability maintenance.
This water called contact water or direct cooling water because it cools
components by making direct contact with it. It sprays over the rolls and hot
metal and picks up the heat via direct contact. It carries heat and a lot of
physical impurities including scale, oil etc.
Its treatment includes physical filtration by settling scale and skimming oil in
scale pit and longitudinal settling basin. Its treatment also includes
conditioning of water by chemical dosing.

g. Raw/make-up water circuit

This circuit provides the make-up to the system whenever required. It takes
the water from the takeover point or customer supply point, treats the water
and stores it for the make-up supply.
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h. Waste water treatment circuit

It is the part of water treatment plant where the reusable water is recovered
from the waste water. This waste water comes from the blow down of tanks,
drain water, backwash water from sand filters, backwash water from selfcleaning filters etc.
The waste water treatment process is to separate the dirt from water by the
means of flocculation. Flocculation is the process of settling down the dirt in
the dirt-water mixture by making the dirt heavier. This is achieved by using a
chemical called flocculent. It is a poly-electrolyte which increases the mass of
dirt by adhering to it and results in its settlement.
The waste water gets collected in the drain pit where it is continuously
agitated by a mixer. This water is the transferred to sludge thickener where it
is added with flocculants. Clean water is recovered from there and is sent to
LSB. The settled sludge is transferred into the sludge collecting tank. From
there it is sent to the dewatering unit where the sludge cakes are formed as
product.

i. Coil Storage Area

Considering each coil weight of 2.0 T, 5 levels for the coils (10 coils on the
highest level) having storage capacity of 12720 T. Coil despatch facility by
rail and road is available.

C) Bar Mill (BM)

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Bar Mill consortium comprising of M/s Danieli, Italy, M/s Danieli Engineering
Limited, India, M/s Shriram EPC, India, and Mecon Ltd, India as consultant. Installed
capacity of Bar Mill is 0.90 MT/ year. Bar Mill having equipment facilities similar to
stand 16 of WRM. One additional facility is available in between descaler and pinch
roll is Endless Welding Rolling Machine. This machine allows rolling of an endless
bar eliminating billet gap time. Material yield increases 2.0 % and production
increases approx 5.0 %. Stand 14 is a convertible stand and can be used as horizontal
or vertical as per rolling schedule. Slit rolling technique is used for rolling bars from
8.0 mm to 18.0 mm. Slit bar after stand 16 goes to two 6-passes Fast Finishing Block
where roll units are arranged at 450 for rolling without torsion.

Bar Mill Layout

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1. QTB
After the blocks a QTB water quenching line for making rebars. QTB is a surface
quenching and self-tempering process. The first stage is a drastic water cooling
operation applied to the bar as it leaves the last stand. At the end of this operation, the
bar surface has the martensite layer an austenite core and an intermediate layer
composed of a mixture of martensite and austenite. In the second stage, the bar leaves
the area of water cooling and is exposed to air. The core reheats the quenched surface
layer by conduction and the martensite formed during the first stage is subjected to
self-tempering which ensures adequate ductility while maintaining a high yield
strength. The third stage occurs on the cooling bed. The product of this transformation
is a mixture of ferrite and pearlite or ferrite, pearlite, bainite.
2. Rotary Flying Shear
At cooling bed inlet, a continuous rotary flying shear cut the rolled stock to a multiple
lengths.
3. Double Twin Channel
Double Twin Channel bar delivery system brakes and discharges one bar per notch of
the cooling bed. Start/stop walking beam type cooling bed collects and cools the bars.
At cooling bed exit side the layer of bars is cut to final length on static mode by a
heavy duty cold shear equipped with a gauge beam. An additional roller table after
bar counting area is provided to recover short bars.

4. Bar Bundling Facility

The layers of bars are regularly transferred to the bar bundling facilities by means of
transfer trolleys. Automatic counting machine performscounting operation of number
of pieces. SundBirsta makehydraulically controlled tying machines perform bundle
tying operation.

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5. Steel Grades and Product mix

Sl No
Steel Grades
1
Rebar
2
Low-Medium carbon
3
Low alloy

Product range in coil form

8.0-40.0 mm
8.0-40.0 mm
8.0-40.0 mm

6. Detailed Product Mix

Bar Size (mm)
8.0
18.0
32.0
10.0
20.0
36.0
12.0
22.0
40.0
14.0
25.0
16.0
28.0
7. Product Tolerance
Product

Size (mm)
8.0-40.0 mm

Rebar

Tolerance (mm)
IS 1786:2008

Ovality

8. Bundle Characteristics
Length (m)
6-9-12

Weight (kg)
2000-5000

Tying with
wire
2-3-4

9. Major Mill Parameters

Parameters
Maximum rolling speed
Mill utilization factor
Yield %
Specific roll consumption
Specific fuel consumption
Avg rolling rate

40 m/s
76.4 %
96.5
0.200 kg/t
0.293 G Cal/t
163 t/hr

10. Bundle Storage Area

Considering each bundle 12 m long and with a weight of 4 ton, there are approx. 30
bundles for each layer. Considering also 12 layers of bundles in each stack, approx.
80640 T is the bundle storage area. Bundles are despatched by rail and road.

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D) WRBM-Roll Shop
Roll Shop is the heart of the Rolling Mills. The objective of having Roll Turning
Shop is to provide turned Rolls & Tungsten Carbide Rings to Rolling Mills.
Additionally, for supporting the production of TMT bars, notching & branding
operation on Rolls & Tungsten Carbide(TC) Rings are also carried out in Roll
Turning Shop. All these turning, notching & branding operations on Rolls & Tungsten
carbide Rings are done by Computerised Numerically Controlled (CNC) machines
supplied by M/s ATOMAT, Italy.
Another important operation performed at Roll Shop is Labyrinth Ring fitting for
bearing fitting. For which Labyrinth Ring, Inner Ring & Spacers are cleaned properly,
heated with some special electrical heating device & fitted to cleaned Roll neck.
Computerised Numerically Controlled (CNC) machines are used for machining i.e.
turning/grinding, notching & marking operations on Rolls and Tungsten Carbide
Rings as per the pass design to roll different sizes of plain rounds and TMT barsat
WRM as well as Bar Mill . The following machines are commissioned at WRBM roll
Shop CNC Machines Installed
Sl.
No.

CNC machines

No.
CNC

of

Software used

1.

AT 830E CNC

2.

AT 830NTE CNC

CNC

3.

AT 710E CNC

Sinumerik 840 Di, Interface

4.

AT 710EN CNC

with ROLL DATABASE &

5.
6.

CNC Lathe suitable for Steel

Guide Redressing
CNC Universal milling M/C

Control

Network Connection is ROLL

1

WORK

There are altogether 4 CNC lathes (AT830E & AT830 NTE) for machining rolls. The
AT830E CNC Machines are used for turning of Rolls and AT 830NTE CNC
Machines are used for turning, notching & branding of Rolls. Similarly, AT 710E
CNC machines are used for grinding of T.C Rings and AT 710EN CNC is a combined
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grinding, notching & branding machine for T.C Rings. Guide rollers redressing are
also done in the AT 710 series of machines with the help of special attachment.

Pictorial view of the TC Ring grinding operation at WRBM Roll Shop

Other than the CNC machines, the conventional machines that are installed in the
Roll Shop are as follows:
i.

Double Head Pedestal Grinder

ii.

Shaping machine

iii.

Radial Drilling machine

iv.

Universal Horizontal Lathe

v.

Horizontal Band Saw machine

vi.

Knife Grinder

The above mentioned machines can be used for performing various machining
operations at Roll Shop. To mention a few, the Shaping machine is a general purpose
shaper, suitable for cutting plane and formed surface of medium and small size workpiece of various kinds whereas Universal Horizontal Lathe is able to take operation
like internal and external cylindrical turning, facing and other sorts of turnings; and is
able to cut Metric, Inch, Module and D.P threads; to drill, ream and broach grooves.
In addition to the above operations, gap-bed lathe is able to turn flat-type and
irregular-shaped work-pieces.

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Rolling Mills
To run the above mentioned sophisticated machines a group of operators have been
trained in different Roll Shops in India as well as abroad.
E) Chiller Plant
The chiller plant is a centralized unit for air conditioning in the various rooms in both
B.M. and W.R.M. It chills the water circuit through its evaporator to create cooling of
the air circuit which runs in the rooms where the cooling is required.
The chiller plant consists of 6 chiller unit which provides centralized service. These
chiller unit are compact and consisting of partial automation. The operators interface
is a console where operator can manage the parameters and take the information about
the running process. Besides the chiller units the chiller plant also consists of other
components like water pumps, cooling towers etc. it houses the whole system in a
single housing.
The chiller plants centralized placement is connected to various rooms to be cooled
via a network of chilled water pipes. The water goes to the components called AIR
HANDELING UNIT or AHU. These AHUs are responsible for the cool air in the
ECRs and pulpits. The AHUs cools the air with the help of chilled water circuit.
There are 10 air handling unit in wire rod mill.

1. Air Handling Unit

The air handling unit is the component which runs the air circuit through the cooling
space and cools the air with the help of running chilled water.
These AHUs are located at different location in both WRM and BM. They are
mounted on the top of every cooling space in closed rooms. These air handling units
are connected to the chilled water supply via a network of chilled water pipes. These
pipes are insulated to reduce ingression of heat from surrounding. There are 18 air
handling unit as clear from the diagram they are of different capacity according to the
requirement of cooling space .
The AHUs consist of:
i.
ii.
iii.
iv.
i.

Housing
Cooling coils
Air blower
Air filters
Housing: it is a box like structure that is installed with other mentioned
components.

ii.

Cooling coils:these are finned stacking of coils in which the chilled water,
supplied from the chilled water pumps, run. These coils are finned to increase

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the surface area of contact with air hence, increasing the heat transfer. The air
comes through the coil and gets cooled.
iii.

Air blowers: these are the blowers which send air into the cooling space and
suck the air in AHU rooms. Air that comes into AHU rooms is the returning
air from the cooling space that is carrying back the heat. The air goes to the
cooling space via duct arrangement.

iv.

Air filters: these are fabric strainers for air. They are mounted in a matrix form
on the housing, right outside the cooling coil arrangement. The air that goes
through the cooling coils first gets filtered by these air filters.

F) Universal Section Mill

1. Salient Features
i.

Annual Capacity - 600,000 t/a (rated capacity)

800,000 t/a (Possible capacity)

ii.

Reheating Furnace- 180 t/h (Cold charging)

210 t/h (hot Charging)

iii.

Starting Material- Beam Blank & Bloom. Source : CCM 3

iv.

Finished Products- Structural of different Section

v.

Initial Length(Min/Max)- 6m/12m

vi.

Length of Finished product 160 m (max.)

vii.

Steel Grade-

Carbon Structural Steel, low alloy Structural Steel, Hyten

Steel & high tensile steel grade, SAILMA, Corrosion resistant steel ,DMR
Steel grade
viii.

Yield

Starting material into reheating furnace

Scale
Crop cutting, scrap

100%
1.5%
1%

Finishing losses
Production yield

1%
96.5%

2. Input Materials
Beam Blank

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Blooms

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Rolling Mills

Bloom Size: 200x280 mm will be used for Equal Angles & Blub Bars sections.
3. Product Mix:
Product

Size Range

Input Material

Beams with parallel

flange (IPE)

240 750

H Beam (HE)

200-450

BB1 for 240-270

BB2 for 300 to 550
BB3 for 600 & 750
BB2 for 200 to 450

Channels

200-400

Equal Angles

150-200

Special Sections
(Sheet pile, Z Section
etc)
Total

BB1 for 200 to 250

BB2 for 260 to 400
Mini Slab(280 x
200)
BB2

Annual
Production
1, 50,000
(25%)
1,
50,000(25%)
1,
30,000(21%)
1,
50,000(25%)
20,000 (3%)

6, 00,000(100
%)

4. Brief Description of U.S.Mill Process Flow:

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The beam blanks or blooms will be charged to the reheating furnaces into two
ways:
i.

Hot , directly fed from the C.C.P

ii.

Cold, charged by cranes on to the cod charging grids

From the hot charging roller table or from the cold charging grid the beam blanks
will be transferred to the reheating furnace. A weighing scale will be installed in
the charging roller table for measuring the weight of the individual beam blanks.
The furnace discharge roller table will feed the starting material to a high pressure
(opp. Pr. At nozzles of abt. 205 bar) water descaler.
Afterwards the materials will be delivered to the reversing roughing mill stand
where the leader section for the tandem mill will be produced. Shifting & centring
units in front of & behind the roughing mill stand will guide the material to the
roll groove according to pass schedule. Based on the various starting sizes mainly
5 to 7 runs (max. 9 runs) will be rolled on the BD Mill Stand.
Downstream the roughing mill there is foreseen space for installing a crop saw for
cropping bended head ends to avoid troubles during biting in the tandem mill.
Behind the crop saw, the material will be transferred to the Universal Tandem
Mill with the stand arrangements:UR - E - UF
Whereby,
UR/UF = Universal Stands
E

= Flange Edging Stand.

For automatic changing of rolls and guides the operator side housing including the
complete roll set with guide will be shifted out of the mill line. After a side shift of
the shifting platform the completely assembled new roll & guide set cartridge will
be connected with the stand housing and both together will be shifted into mill
line.
Downstream the tandem mill, there will a hot saw which will serve for cropping
and sample taking.
The cooling bed is designed as a combined walking beam type/ chain type cooling
bed.
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Rolling Mills
Straightening of the sections behind the cooling bed is carried out by a double
support CRS- Roller straightening m/cs.
Behind the straighter the sections will be collected on a layer collecting bed for
performing cutting of layers. The layers will be cut by cold saws
Two by two fixed strap type bundling machines are behind the straightening m/cs
for automatic bundling.

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Process Flow Chart in USM

Work & Extension

Roller Table

Extension & Lift

able Work Roller
Table

Turn up & Turn

Down Device

Shiftable cold saw

Grip Type Tilter &

Shifting/ Centering
Device

Shifting &
Centering Device

Layer Collecting
Device

Cold Saw Roller

Table

Weighing System

Breakdown Mill

Tandem Mill Stand

(UR, E, UF)

Horizontal Roller
Straightener

Fixed Cold Saw

Reheating Furnace

Grip Type Tilter&

Shifting/ Centering
Device

Lift able Work &

Extension Roller
Table

Cooling Bed

Crop end Removal

Device

De-scaler

Work roller Table

Online Measuring
Device

Charging System

Inlet Roller Table

Hot Saw

Piling & Loading

Equipment

5. Major areas in US Mill

a. Reheating furnace
i.

Two way Charging(Hot & Cold)

ii.

Walking Beam Type Furnace with plastic refractory on roof

iii.

Capacity-180t/h (Cold Charge) to 210 t/h (Hot Charge)

iv.

Charging type- Front Charging & End discharging

v.

Uniform Heating (Bottom, top & side fired burner)

vi.

Size-25908 X 12900 wall to wall (L X B)

vii.

Temperature range- 1150 C 1250 C

viii.

Fuel: Mixed Gas

ix.

CV: 2000-2500 Kcal/m3

x.

No. of burners & Different zones: 61 in 3 zone(Preheating, Heating &

Soaking Zone

xi.

Scale disposal system:

xii.

Door lifting system: Chain Sprocket system

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Rolling Mills
Furnace Charging System

Reject Roller
Table
Cold
Charge
Grid 1/2

Hot
Charging
from CCP

Run in
Roller
Table

Breakdown
Mill Area

Furnace
D/Roller Table
Walking beam
furnace

Weighing
System

Inlet R/Table

Discard
Mechanis
m
b. BD Mill Area
i.

Descaler -HP water descaling device

ii.

W.P 210 bar; Water Consumption- HP water 20 m3/s

iii.

Approach Roller table

iv.

Length 19 m; No. of R/ Table -14; Speed -0-1.2 m/s

v.

Extension Roller Table

vi.

Length-28.5m; Roller Table speed 0-5m/s; No. of R/ Table 12

vii.

Work roller table-

viii.

Length 8 m; No. of R/ Table 6, Individual Geared motor driven ; Speed 05 m/s

ix.

Shifting device with grip type tilter- Hydraulically operated

x.

Two high Reversing B.D Mill stand with syn. Motor (4000KW @ 360960 rpm)

360

xi.

Roll Dia : 900 mm to 1100 mm

xii.

Double roll changing Device.

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Rolling Mills

Double Roll

Changing

Device
Work &
Extension Roller

Descaler

Table

Grip Type
tilter &
shifting
device

Reversing & 2
high BD mill
Stand

Grip Type
tilter &
shifting

device
Work &
Extension Roller
Table

Tandem
Mill Area

c. Equipment in Tandem Mill Area

i.
ii.

iii.

Extension Roller Table Length-113 m; No of R/Table-55; Speed 0-8

m/s, Individual Geared motor driven
Two high Mill stand UR having Horizontal and vertical roll with
antifriction bearing in roll bearing assembly. Balancing of top roll by
hydraulic cylinder as well as vertical chocks by hydraulic cylinder.
Drive- Sync. reversible motor rating 4000 kW @ 390-1140 rpm
Horizontal Edger Mill Stand EDGER with balancing of top roll by
hydraulic cylinder.
Drive- Sync. Reversible motor 1500 KW @ 473-1300 rpm
Dia -800-1000 mm

iv.

Two high Mill Stand UF having horizontal and vertical with

antifriction bearing in roll bearing assembly. Balancing of top roll by
hydraulic cylinder as well as vertical chocks by hydraulic cylinder.
Drive- Sync. Reversible motor rating 4000 KW @ 390-1140 rpm

v.

Shifting & Centring Device (in & out)

To guide the rolled material to the centre line in TD mill

vi.

Liftable Work Roller Table- guiding the rolled material according to

pass line in TD mill
Length 8 m; No of R/Table -5 ; Roller Speed- 0-8 m/s

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vii.

Extension Roller Table

Length 135 m; No R/Table 85 hollow; Speed 0-8 m/s

viii.
ix.

Quick Changing Equipment for Roll & guide

On Line measuring System -To permit reliable production within the
tolerance limits with proactive corrections on the rolling mill lines.

d. Equipment in Hot Saw Area

i.

Pendulum Hot sawTo cut-off crop ends of finished product entering cooling bed
Saw Blade dia- 1650-1800 mm; Blade thickness -12 mm

ii.

Crop end removal deviceTo remove scrap in buckets

iii.

Sample Grid with pusherTo remove and collect samples at the exit side of Hot saw.

iv.

Blade changing Crane

e. Equipment in Cooling Bed Area

i.

Run in roller Table

ii.

Length-87 m ; No of R/table -54 ( hollow type); Individual Geared

motor driven ; Roller Speed 0-8 m/s; Individual Geared motor driven

iii.

Walking beam cooling bed

Transferring finished product from Run in R/Table to Exit carrying
transfer.
Length -86.4 m; No of walking beams-108

iv.

Exit carrying transfer

Transport of bars from cooling bed to the run-out roller table

v.

Run out roller table

vi.

Length-87 m ; No of R/table-35, hollow; Individual Geared motor

driven ; Roller Speed 0-6 m/s

f. Equipment in Straightening Machine Area

362

i.

Horizontal Roller Straight machine

ii.

No of driven straightening shafts -9 individual driven

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Rolling Mills
iii.

No of vertical guide rolls-2 entry side; 2 exit side

iv.

Dia of straightening rolls - 950-1000 mm

v.

Straightening Speed- 0.1-3/6 m/s

vi.

Roll Changing time -20 min

vii.

Scale disposal system- Scale will be disposed to flume with the help of
pump.

viii.

Quick changing equipment for rolls

g. Equipment in Collecting Bed Area

i.

Straightening Roller Table

ii.

Length- 98 m ; Roller Table Speed- 0-6 m/s, No of R/Table-49

Individual Geared motor driven

iii.

Layer collecting bed

iv.

B/w Straightening Roller Table & layer roller table

v.

Length -86 m; Transport Distance -6500 mm

vi.

Turn-up turn-down device

vii.

To lift & turn one bar to be visually controlled

viii.

Tilting Angle 900C

ix.

Tilting levers driven by hydraulic cylinders

h. Equipment in Cold Saw Area

i.

Layer Roller table

Length -110 m; No of R/Table-50; Roller Table Speed 0-2.5 m/s
Drive- Individual Geared motor driven

ii.

Shift able roller table

To find any desired sawing position
Length- 7.5 m; No of R/Table 4; Roller Table Speed 0-2.5 m/s
Drive- Hydraulic cylinders

iii.

Shiftable cold saw

To cut sales length of single piece or layers

iv.

Fixed cold saw

saw blade dia -1650-1800 mm ; thickness -12 mm

v.
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Cold Saw roller table

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Rolling Mills
Length -33 m; No of R/Table-17; Roller Table Speed 0-2.5 m/s
Drive-individual by Geared motor & coupling
vi.

Crop end removal device

For collecting crop ends
Crop ends up to 1000 mm and from 1100-2000 mm will be
collected in separate
bucket

vii.

Adjustable length gauge carriage

Length setting range 6-24 m
No stopper car 1; Car Speed 0.03-0.6 m/s;
Rolled Stock weight -18 Tonnes (max)
Material Speed 0.25 m/s Noise Protection Cover

viii.

Noise Protection Cover

To minimize the noise generated during cutting of material.

i. Pilling & Loading Equipment

i.

Pilling Equipment consists of 2 pilling machines (12 m length, 12 m

wide). Finished products longer than 13 m can be piled by using electrical
synchronisation of 2 m/cs.
i.

Pilling System

ii.

Run in & Run out roller table

iii.

Pilling Machine

iv.

Single bar labelling System

ii.

Binding Roller Table- 2 in number

iii.

Pile Compacting device-2 in number

iv.

Binding Machines- 4 in number

v.

Fixed End Stop- 2 in number

j. Auxiliary System

364

i.

EOT Cranes

ii.

Water System
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Rolling Mills
iii.

Hydraulic System

iv.

Lubrication System

v.

Grease system

vi.

Fire Fighting system

vii.

Media Lines.

viii.

Ventilation System

ix.

Air Conditioning System

EOT Crane (Total 14 Crane)

Despatch bay

4 nos of 20 T capacity

Finishing bay

2 nos of 20 T cap

Roll prep bay

1 of 50 T cap, 1 of 30 T cap, 1 of 20 T cap

Cooling bed bay

1 no of 20 T cap

Bloom storagebay

2 nos of 20 T cap

Mill bay

1 of 50 T cap,1 of 30 T cap

Auxiliary system

Covering area

Hydraulic System
Hydraulic system 1(130 bar)

Beam charging system, B D Mill stand, Roll

change device, preparation area,tilter

Hydraulic system 2(300 bar)

T D mill stand UR, Edge E,T D Mill stand

UF

Hydraulic system 3 (130 bar)

T D Mill centering Device, TD mill E-stand

shifting, Roll shop equipment, fixed cold
saw, movable cold saw, piling m/c, loading
grid, discharge transfer

Hydraulic system 4 (300 bar)

Hot saw, cooling bed, layer collecting bed,

straightening m/c, compact unit

Bulk oil storage unit

2 nos tank-1 for fresh oil, 1 for waste oil

Central Lub System

Central grease lubricating system I

For furnace area

Central grease lubricating system II

B D mill area

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Rolling Mills
Central grease lubricating system III

T D mill area

Central grease lubricating system IV

Cooling bed area

Central grease lubricating system V

Straightener & cross transfer

Central grease lubricating system VI

Piling bed area

Grease filing unit

1 no

High Pressure Water System

H P water system I

For descaling box

H P water system II

For one hot saw & 2 cold saw

Sump pump

10 nos for auxiliary cellar

6. Water System
a. Indirect cooling water circuit
b. Direct cooling water circuit
c. Pump houses:a. Main pump houses
b. Primary scale pit pump house
c. Secondary scale pit pump house
d. Fire-fighting pump house

d.

Cooling tower

e.

Water treatment plant

a. Sludge thickener
b. Filter press building-for making cake from the scale.
c. Pressure filter
d. Oil skimmer

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Rolling Mills

Power distribution after LBDS 5

LBDS 5

ECR-2

ECR-1

3
PCC
FED.FROM 6
2MVA TXF.

FROM 2
TXF
OF
2MVA

ECR-3

2 TXF
FOR
LDB

2 PCC
FED
FROM 4
TXF OF

ECR-4

1 TXF FOR CB
ROLLER
TABLE
&
AUX.

2 TXF OF 2 MVA
FOR 1 PCC.

2MVA

1TXF FOR
BDM MOTOR,1
TXF FOR
BDMROLLER

2 TXF FOR
SHARING LOAD
IN FURNANCE.

TABLE & DRIVES

3 TXF FOR TANDEM MILL

MOTORS, 1 FOR T.MILL

ROLLER TABLE &AUX.

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Safety Engineering Department

SAFETY ENGINEERING DEPARTMENT

A) Introduction
Accidents in a plant affect productivity, and morale of workforce. All accidents,
regardless of their consequences, are symptoms of production inefficiency. Accident
free production is regarded as an efficient production. Many activities and processes
in a steel plant can present situations which involve risk to safety and health of
employees, and risk of damage and loss to plant equipment and product. Hence it
is a moral, economic as well as legal duty of all especially the front line
executives - to prevent, control or guard against such risks and their possible ill
effects. With an objective to achieve elimination of human suffering, damage to
material and equipment, and resultant loss of production.

The erstwhile Indian Iron and Steel Company (IISCO), one of the oldest steel plants of
the country has been amalgamated with Indias largest steel maker, Steel Authority of
India Limited (SAIL) with effect from 16th February 2006. Following merger, IISCO
has now been renamed as IISCO Steel Plant (ISP). ISPs annual hot metal production
capacity is envisaged to go up to 2.5 million tonnes (MT) from a level of 0.35 MT in
2004-05. The plant which was earlier written off is now being written about. The
spotlight is now on ISP, the fifth integrated steel plant of SAIL.

ISP, one of the oldest integrated steel plants, started production of iron away back in
1870 in its Kulti Works of Bengal Iron Works Company. ISPs Burnpur Works was
incorporated on 11th March 1918, started iron making in 1922 and steel making in
1939.In the early 1960s, it expanded further to become a million tonnes steel plant.
ISP has got an integrated steel plant at Burnpur, Captive collieries at Chasnalla, Jitpur
and Ramnagore. It produces a wide range of products, starting from pig iron to finished
steel products, mainly heavy, medium and light structural and special sections. ISP has
pioneered the production of centre-still Z section used in the production of wagons and Z
type sheet pilling section used in construction of barrages, bridges foundations and other
projects and colliery arch section used for roof support in collieries. Its Merchant Mill &
Heavy Structural Mill is equipped with ISO: 9001, and the Rolling Mill complex has
acquired ISO: 14001.
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B) Safety Policy
IISCO Steel Plant is committed to:
i.

The safety of its employees and the people associated with it, including those
living

ii.

in the neighbourhood of its plants and units,

Pursue the safety efforts in a sustained and consistent way by establishing

safety

goals, demanding accountability for safety performance and

providing the resource

to make safety programmes work.

C) Guiding Principles
i.

We firmly believe that all accidents are preventable.

ii.

All employees are responsible and accountable for maintaining laid down
safety standards.

iii.

Safety standards shall be incorporated in all our work procedures.

iv.

Imparting training to create safety consciousness and to work safely shall

form key elements of our safety programme.

v.

We shall make collective efforts to enhance safety through participative

safety committees and fora.

vi.

We shall perform all works in consonance with the local, State and Central
Acts, and Rules and Regulations on Safety.

vii.

Comprehensive audits of the safety performance shall form an essential part

of our safety programme.

viii.

We strive to achieve continual improvement in our safety performance.

D) Objectives of Safety Engineering Department (SED)

Although Safety is established as the direct responsibility of the line managers, the
Safety Engineering Department is vitally concerned with all aspects of safety and is
available at all times to perform services that will enable the plant to achieve the
best possible safety performance. It functions as a staff department assisting
the management in accident prevention, by:
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Safety Engineering Department

i.

Apprising the managers where they are falling short of safety standards.

ii.

Creating safety awareness amongst all the employees, both executives

and non-executives.

iii.

Recommending to managers latest appropriate safe practices, procedures

and safety aids that will give protection to employees from occupational
hazards at all times.

iv.

Assisting the managers to maintain their shop in compliance with legal

regulations.

v.

Furnishing statistics on safety aspects to SAIL, other plants, local

management and managers so as to improve on past performance.

E) Organisational Structure of SED

The department is headed by GM and Safety Officers are looking after technical
aspects of safety and enquiry related issues, for all accident cases. Besides these,
we are looking after other activities eg. Training of regular employees (Executive
and non-executive) as well as contractual workers, Safety Protocols, Safety Statistics
and Procurement, and Inventory Control of PPEs.

F) Functional Activities of the Department

Accident Prevention Activities:
1. Adherence to accident prevention plan, to control accidents
2. Assisting maintenance departments in preparation of protocols for jobs carried out
by multi-departmental agencies; and safety supervision during capital repair and
during break-down jobs for enforcement of job safety.
3. Investigation of all serious accidents.
4. Enforcing use of PPEs (Personal Protective Equipment) at shop floor.
5. Monitoring implementation of recommendations of enquiry committees for all
types of accidents.
6. Identify & conduct of special studies of major hazards and develop preventive
steps for elimination and assist in preparation of job safety rules (incorporation
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Safety Engineering Department

in SOP/SMP) and revisions from time to time.
7. Regular inspection of unsafe conditions/acts at the shop floor, as per schedule
and check-lists.
8. Participate in apex committee inspections and monitor implementation of
identified unsafe conditions/acts for their elimination.
9. Administration of basic safety induction training to all new recruits and conduct
safety appreciation courses for front line executives and regular / contractual
workers and supervisors.
10. Assist all departments in organising Safety Week Celebrations, Safety Exhibitions
and display of Safety related posters and slogans at various locations in the
plant to generate Safety awareness for accident prevention.
11. Organise Safety Audit of major accident hazard (MAH) units by Inter Plant Audit
Teams as per statutory requirements.

G) Post Accident Activities

a.

Investigation and Enquiries:

As soon as an accident or a dangerous occurrence takes place, or immediately after

the knowledge of such occurrence, the Safety Engineering Department investigates
jointly with the shop representatives / line supervisors to find out the cause, and
recommends steps to prevent the recurrences, and participates as member in various
committees which enquire into serious disabling injury accidents and serious near
miss accidents to find out the facts and causes of the accidents and to recommend
preventive measures.

b.

Reporting of Accidents:
i) All the accidents resulting in injuries are reported to ED (Works)
ii) In case of serious/fatal accidents and dangerous occurrences, after the
Investigation, immediate information is sent to CEO/ED (Works).
iii) As soon as the occurrences of such serious / fatal accidents or immediately
after the knowledge of such accidents, the messages are forwarded to the legal
authorities.

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Safety Engineering Department

c.

Accident Statistics and Analysis:

i.

Analyse the statistics in different departments to strike at the root

cause of the accidents and thereby suggest concrete safety programme to
reduce the accidents.

ii.

Reporting of these statistics to SAIL Safety Organisation.

iii.

These statistical analysis are discussed in Departmental Safety Committee

and JPC (operation zone & maintenance zone) for corrective measures.

d.

Review:
Safety aspects discussed daily by senior management team during morning
conference. Departmental Safety Committees are reviewing various safety issues
during their meetings held regularly. Safety issues are also discussed at the
monthly meetings of Zonal Joint Production /Maintenance Committee. Central
Committee for S.H.E. reviews the safety aspects in their quarterly meetings.

H) Joint Participation
Various committees are formed eg. Departmental Safety Committee and SHE (Safety,
Health & Environment) committee as a member to discuss safety related problems
and arrive at solutions to strengthen Safety.

I) RAIL-ROAD SAFETY:
1. Checking of road worthiness of contractors' transport vehicles inside the
plant.
2. Monitoring of rail traffic at rail road crossings inside the plant.
3. Conducting special campaigns to enforce use of crash helmets by two
wheeler riders inside plant.
4. Surprise checks for 100% presence of LOCO Crews.
5. Vehicle speed limits checking by Speed-gun.
6. Blinker light checking at all level crossings and blind corners.
7. Road Illumination checking on regular basis.
8. Conducting Rail-Road safety awareness programmes.
9. Fencing of unauthorised routes.

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J) LIASION ACTIVITIES
The department maintains close liaison with statutory authorities such as
Inspector of Factories, Certifying Surgeon, SAIL Safety Organisation and
other Safety Organisations, to fulfil legal obligations and corporate Safety
action plans.

K) Highlights / Other Important Activities:

1.

Regularly Safety competitions are held in the plant. Competitions are

having the advantage that they generate in every employee, an interest to
get involved/ associated with the safety activities. Competitions not only
add to the knowledge but more often new talents also come forward with
new ideas. A number of safety competitions are organised by SED, like
Poster Competition, Slogan, Safety Essay, Debate, Drama /Skit, Quiz,
Housekeeping etc. are held every year and winners are awarded for
encouraging them. Sit and Draw Posters Competition are also held for
School going Children to generate Safety consciousness amongst them.

2.

Inter Department Housekeeping competitions are held for raising the

standard of cleanliness in various departments. Total plant has been
divided in different zones and best & 2nd best in Zone are awarded the
trophy. A panel of Judges nominated by M.D. conducts the inspections &
evaluates the departments effort in improving the housekeeping of the
department.

3.

Safety Awards: In order to improve extra impetus to safety management, various

safety awards are awarded by ISP, SAIL & JCSSI.SAIL Safety Award & Ispat
Surkshya Puraskar award have been instituted by JCSSI and all the member plants of
JCSSI participate in it. Ispat Suraksha Puraskar - These awards have been instituted
by JCSSI.

4.

To make the employees aware about safety aspects, hazards of the work environment
and risk involved in it, the safety posters are very beneficial tool. Safety posters
depicting the general and specialized safety aspects are pasted at strategic locations

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Safety Engineering Department

of the plant & in the departments so that it catches the eyes of the employees of the
company and they get familiarized with dangers, situations and work procedures.
Posters on various subjects are obtained from JCSSI also Awarded safety posters
drawn by our own employees during various competitions are also displayed in the
departments.

5.

National Safety Day Celebration

Every year National Safety Day is celebrated on 4th, March with lot of activities like
a. Safety banners are displayed at four different locations.
b. Pinning of badges & reading of safety pledge on 4th, March.
c. Safety flag hoisting at the celebrated place by MD and prizes are distributed to the
winners of Safety Competitions.
d. Safety messages are telecast in our local T.V. Channel
e. National Safety Day Function is organized in Companys Auditorium chaired by
the Managing Director.

6.

Training And Workshop

Training programmes on safety management are organized by SED at HRD centre
for executives, wherein inputs on safety clauses of Factories Act.& Rules, disaster
management, behavioral safety, norms & standard etc are given. Job specialize
safety training and trade specific training programmes are conducted at HRD centre
for regular employees. All the contract labours are given induction training before
deployment to jobs by safety department .Workshops are held on different topics at
individual department. Level for executive & Non Executives for mutual sharing of
Knowledge / Skill. Meeting on S.H.E. (Safety, Health & Environment) held every
quarter under the chairmanship of ED (Works). Representatives of all functional
trade unions were present in the meeting.

7.

Induction Training For New Entrants (Regular & Contractor)

Safety Induction Training, to create consciousness about safe working, is very much
necessary for the new entrants. Induction training is imparted to make them aware
about the hazards and risk involved in the plant and the jobs, for both regular and

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IISCO Steel Plant

Safety Engineering Department

contractor worker. Service of Safety Engineering Department is utilized for imparting
Safety Induction Training. Safety Induction Training for Contractor workers are being
held at our safety training centre Burnpur. In this Training Programme new entrants
are taught about the programme and policy of the company regarding safety. Various
unsafe hazards inside the Factory, unsafe condition and activities generally prevailing
in the plant and how to overcome those condition or behaviour, appropriate uses of
PPES for each job, etc. are discussed.
Reflective Safety Sign Boards have been displayed at strategic locations inside the
plant for generation of safety awareness amongst the employees regarding Rail / Road
Safety.

8.

Joint Participation
a. Inspection of Shop- Inspection is a routine job for SED and its review of working
condition are the key job to prevent the accident
b. Conducting

Apex

Safety

Committee

Meeting

and

implementing

the

recommendations of the committee.

c. Conducting departmental Safety meeting every month in each department. In this
meeting the raising points regarding unsafe conditions / unsafe practices is being
discuss and to eliminate the problems.
d. Zonal Joint Production Committee Meeting for Iron & Steel is being held in
every months Where Safety of the whole plant is discuss and the problems in
connection with the safety is being solved by the concerned agencies.

9.

Inspection Committees
i.

Cable gallery inspection committee ensure the vital electrical installation inside
the plant, every month and take necessary action against the any unsafe
condition.

ii.

Oil Cellar Inspection Committees inspect and ensure the safe condition inside the
oil cellars, every month.

iii.

Structural inspection committees identify the unsafe condition of structural in

different zones and take necessary steps to rectify it.

10.

Statutory Provisions

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Safety Engineering Department

a. Inspection and testing of all the lifting tools and tackles is conducted every year
by competent person.
b. Inspection and testing of all non-fired pressure vessels is conducted every year by
competent person.
c. Inspection and testing of all EOT cranes is conducted every year by competent
person.

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Shops and Central Workshop

SHOPS AND CENTRAL WORKSHOP

A) Existing Shops
The existing shops play the vital role of supplying spares for the works since the central
workshop is now under construction. The major units of the existing Shops are given
below.
1. Machine Shop
2. Structural shop
3. Forge Shop
4. Foundries
a) LMS/Foundry
b) Ingot Mould Foundry

c) Steel Foundry
B) Main Activities

i.

Re conditioning of worn out spares

ii.

Manufacturing of new spares

iii.

Overhauling and repair of equipment sub-assemblies.

iv.

Modification/rectification of spares for new plant

C) Flow Process:
A brief description of the process of spare manufacture from the order stage to the
dispatch stage is given below:
Work order for a job is placed on the shops by the concerned department based on the
monthly job list as finalized at the end of every month at the monthly meetings. Jobs are
categorized in the order of priorities. The plan is processed for execution by the shop
planning section. The jobs are then scheduled on various machines/equipment as per the
sequence of operation. The completed jobs are collected by the ordering department.

D) Machine Shop
Machine Shop is divided into the following Sections
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Shops and Central Workshop

1. Machining Section

The machining section carries out machining operation of various new and reclaimed
spares. The general purpose machine tools available for performing the above are as
follows:
a) Lathes

(Max swing over bed 1600 mm, Length 5m)

b) Shapers

(Max Stroke 26")

(Max Table size 7 miter)

c) Planning Machines
d) Slotter

(Max Stroke 36 inch)

e) Vertical Boring Machine

(Max Dia 84 inch )

f) Radial Drill Machine

(Max Drill, Size 3.5 inch)

g) Horizontal Boring Machine (Max Spindle Dia 150 mm)

The section is also provided withfollowing :

Gear Cutting Hobbing Machine (Max hob Dia 8 Inch, max DP 1.5, Max Job

i.

Dia 48 Inch)
ii.

Milling Machine (HMT) (Table Size 40 X 10.75, Centre Ht - 5)

iii.

Milling Machine (CINCINATI) (Table Size 78 x16, Centre Ht 7.5)

iv.

Surface Grinding Machine (Table Size 44 X 14)

The section has two bays Heavy and light bays having EOT cranes of 15T and 3T
respectively for material handling.

2. Assembly Section
Performs the following functions:
a) Planned manufacture of new assemblies
b) Repair/Re-conditioning of parts/sub assembliesof various departments on
regular basis and during scheduled repairs, capital repair or at breakdown

The following equipmentare housed in this section:

378

a) Horizontal Hydraulic Press:

200 Ton Capacity

b) Vertical Hydraulic Press :

100 Ton Capacity

IISCO Steel Plant

Shops and Central Workshop

c) EOT Crane

15T Capacity

d) Induction heater for Shrink Fitting Jobs

Max

150

DegCelsius
e) Radial Drill & Shaping Machine

E) Structural Shop
This section performs the following important functions:
a)

Repair / Recondition of Damaged Structures

b)

New Fabrication of Steel Structures

c)

Bending of M.S.Plates Up to a Thickness of 32 MM.

d)

Press Work and Straightening Job

The Following Equipmentare housed in this Section:

a)

Vertical Hydraulic Press Of 500t Capacity

b)

Plate Bending Machines : bend plates of thickness ranging from 6 mm to 32 mm

c)

Angle Bending machine : bends angle as per requirement

d)

Plasma Cutting Machine : can cut Stainless Steel Plate of thickness max 12 mm

e)

Welding Transformers

f)

Radial Drill Machine

g)

Shearing Machine for M. S. Sheet Up To 3 Mm Thickness.

F) Forge Shop
This shop makes various forgings from cut billets as raw material for machining after
getting orders from planning sections.
The equipment available in this section are:
a) 1 Ton Capacity Pneumatic Hammer Machine

1 No.

b) 0.75 Ton Capacity Pneumatic Hammer Machine 1 No

c) 15 cwt Massey Pneumatic hammer

1 No

d) Coal Fired Forging Furnace

4 Nos.

e) Blower

2 No.

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Shops and Central Workshop

G) Foundries
1. LMS/Foundry:
Produces Cast Iron Bottom Plates and other general castings and non-ferrous castings
for different departments.Cast iron castings are poured directly with hot metal
received from No - 2 Blast furnace. For Non-ferrous castings, there are two tilting
type crucible furnaces (cap - 750 Kg and cap - 350 kg) for melting purposes. This
Foundry has two bays having two EOT cranes( 20 ton and 15 Ton capacity).It is also
equipped with one small pattern Shop, Two sand millers (capacity of each-500 Kg)
and one heating Oven for drying cores and small moulds.

2.

Ingot Mould Foundry

Produces Cast Iron Ingot Moulds for our Steel melting Shop1.Cast iron Ingot
Moulds are poured directly with hot metal received from No 2 Blast furnace. This
Foundry has two EOT cranes (20 ton and 16 Ton capacity). It is also equipped with
two sand millers (capacity of each-600 Kg), one sand Mixer (capacity 700 Kg) and
one Sand drier for drying wet sand.

3. Steel Foundry
Produces Cast Steel Slag Pots for our own Blast Furnace and Steel Melting
Shop.Recently we supplied BSP and DSP Slag Pots also. Cast Steel slag pots are
poured directly with liquid steel received from SMS 1. It is also equipped with one
sand Mixer (capacity 500 Kg) for making prepared sand.

H) Major Achievements
1. Total 777 Nos. of bent Crane rails (CR 80: 50 Nos., CR 100: 297 Nos. and
CR 120: 430 Nos.) straightened for our new project during the period from
2010 2011 to 2013 2014.
2. Manufactured 9 Nos. of BSP Slag pots Cap 16 Cu. M) and 12 Nos. of DSP slag
pots (Cap 12 Cu. M) in 2013 2014.
3. Fabrication of Stainless Steel Heat Shield for CDCP
4. Stainless Steel Cone for CDCP Mill fan inlet line
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5. Stainless steel roller vibrating plates20 Nos. (New CHP)
6. Stainless Steel charging lid for No11 battery
7. Fabrication of Emergency Bucket for CCP Hot Trial
8. Modification of 110 Ton ARROL Crane Beam for CCP Hot Trial
9. Wagon Wheel Arrester For Wagon Tripler of Ore Handling Plant
10. Modification of Tundish handling tackle for BOF
11. Wagon Wheel Arrester For Wagon Tripler of Ore Handling Plant
12. 48 Inch Dia. nominal bore pipe bending and welding 160 Miter running length
for BF.

I) Central Workshop
The central workshop is being constructed under 2.5 MT expansion project of ISP to
cater to the need of heavy duty and critical spares for BF, coke oven, BOF-CCP,
universal mill, W & R mill etc. The shop layout area is 120 m X 74 m and consisting of
the following sections:
1. Heavy Machine Area
2. Light Machine Area
3. Assembly Area
4. Fabrication Area
5. Forging Area (Future Plan)
6. Heat Treatment Area (Future Plan)
7. Stock Yard And Scrap Yard
8. Raw Material Space
9. Office, Store, Conference Room, PDB Room Etc.

J) New Equipments
The following new equipment will be installed in the Central Workshop:
1.

CNC Flame/Plasma Cutting Machine

2.

Hydraulic Press Brake

3.

Heavy Duty Centre Lathe

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Shops and Central Workshop

4.

Moving Column Floor Type CNC Vertical And Horizontal Milling

Machine

5.

CNC Vertical Turning And Boring Machine

6.

Bridge Type CNC Plano Milling Machine

7.

CNC Lathe (Light Duty)

8.

CNC Lathe

K) Future Plan:
1. Balancing Facility
2. Hydraulic Lab

L) The Main Activities Envisaged Are As Following:

1. Heavy Duty Machining, Turning & Boring, Assembling jobs that are beyond the
capability of Area Repair Shops.
2. Reconditioning of various rolling stock wheels and crane wheels.
3. Fabrication of furnace doors, chill and chutes.
4. Contour Turning, Facing, Grooving of complex profiles in CNC Machines.
5. Machining of Forged Shafts, Axles, Pins
6. Plasma / Flame Cutting of various M.S. / S.S Plates in thickness varying from 1mm to
150mm.
7. Bending Steel Plates of Various Thickness

M) List of EOT Cranes For New Central Workshop:

The Central Work Shop will be equipped with thefollowing cranes for ease of material
handling activities:

382

1.

Under slung crane single girder capacity 5T for store area

1 No

2.

EOT crane Capacity 50/10 t for heavy machine area.

1 No

3.

EOT crane Capacity 30/10 T for light machine area

1 No

4.

EOT crane Capacity 30/10T for Assembly area

1 No

5.

EOT crane Capacity 15/5 T for fabrication area

1No

6.

Goliath crane capacity 20/5 T for open stock yard

1No
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Shops and Central Workshop

7.

Transfer car capacity 30 T

1 No

In addition to the above it is proposed to procure the following equipment for material
handling to various sections:
1.

One pick and carry crane of 12 Ton capacity

2.

One fork lifter of 3 Ton capacity

N) Jobs expected to be carried out

1. Different jobs of Sinter Plant, Coke Ovens, BOF CCP, WR&BM, RMHP etc.
2. Fabrication of Stainless Steel Heat Shield for CDCP
3. Stainless Steel Cone for CDCP Mill fan inlet line
4. Stainless steel roller vibrating plates20 Nos. (New CHP)
5. Stainless Steel charging lid for No11 battery

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Sinter Plant
SINTER PLANT

A) Introduction
The old plant was operating without Sinter with most outdated technology with old
equipment through the ingot route resulting in low yield and high cost of production at SAILISP. As a part of corporate plan 2012, Capacity Expansion of ISP is being taken up by
installation of a new stream of 2.5 MTPAcapacity Crude Steel in the green-field area.In the
2.5 MTPA new stream expansion, a Blast furnace of 4060 m useful volume will be installed.
In order to cater to 80% sinter requirement as prepared B.F. burden, a state of art sinter plant
complex comprising of 2 x 204 m sinter machines along with associated facilities have been
envisaged to produce 3.88 MTPA gross sinter.

Iron ores size (-8 mm) generated during various stage of mining and screening at mines are a
major source of iron ore fines. The technology of Sintering was started in 20 th century as a
mean to utilize these undersize iron ore fines and other metallurgical waste. Now it is a major
source of feed to blast furnace due to its excellent metallurgical properties.
Sintering is basically an agglomeration of iron ore fines, coke breeze and flux at high
temperature (1050C to 1150C). Sinter is produced as a combined result of locally limited
melting, grain boundary diffusion and re-crystallization of iron oxides.

Basically following are the benefits of using sinter

i.

Utilization of fines - otherwise, a waste.

ii.

Calcinations of raw flux outside Blast Furnace (BF).

iii.

Better reducibility due to porous structure.

iv.

Presence of glassy matter in sinter helps slag formation in BF.

v.

Reduction in coke rate in blast furnaces.

vi.

BF productivity follows increasing trend up to 80% sinter in BF burden.

Thus, Blast Furnace operation with sinter results in:
a. More wide acceptability
b. Lower Si hot metal

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c. Decrease in coke rate
d. Increase in productivity

B) Design Parameters:
Unit

Value
2

No. of Sinter Machine x Area

no. x m

Productivity

ton/m /hr.

2 x 204

1.2

RatedDesign

1.4

Annual Sinter Production (Gross)

Ton

3,877,500

Size of product Sinter

mm

5-40

days x hr.

330 x 24

mmWC

1600

Machine bed height (total)

mm

700

Cooler area

202

Cooler retention time

Hr.

Temp. of Hot Sinter

800-850

Annual working regime

Under grate suction

Cold Sinter

< 100

Dust content in exhaust gases

< 50

mg/Nm

C) Raw Materials
The various raw materials used for producing sinter are as follows
Sl.No.

Material

Size(mm)

T/yr

Iron ore fines

-8 mm

3386000

Lime stone

-3 mm

267000

Dolomite

-3 mm

263500

Coke breeze

-3 mm

253200

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Sinter Plant
5

Flue dust

Mill scale

-3 mm

Calcined lime

-1 mm

69800

D) The major Sinter Plant Facilities are as follows:

i.

Proportioning Bin building 1 & 2

ii.

Mixing & Nodulising Drum & Calcined Lime Building 1 & 2.

iii.

Sinter Machine Building 1 & 2

iv.

Sinter Cooler 1 & 2.

v.

Waste gas fan building 1 & 2

vi.

Main ECR Building 1 & 2

vii.

Waste Gas System Electrical Building 1 & 2

viii.

Plant dedusting systems 1 & 2

ix.

Common Stacks for waste gas ESP & Plant De dusting ESP unit 1 & 2

x.

Sinter crushing Building( common for both plant)

xi.

Sinter Screening Building ( Common for both plants)

xii.

Conveyors, Junction houses and conveyor galleries.

xiii.

Re-circulating water pump house

xiv.

Complete fire protection system

xv.

Chiller plant

xvi.

DG set building

xvii.

Cooling tower

xviii.

Cable tunnel & cable conduit

xix.

Area Repair Shop

xx.

Electrical Repair shop

xxi.

Administrative & welfare building

xxii.

Ablution Block sinter plant inside sinter plant area

xxiii.

Car and scooter parking shed inside sinter plant area

xxiv.

Drainage and sewerage inside Sinter Plant area.

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E) Raw Material Section

1. Storage and Proportioning Unit
The storage and proportioning unit shall house 11 steel bins in one row for storage of
different materials. Blended mix is fed by one Purchasers belt conveyor from RMHS
yard upto Junction house C for further transporting to the top of proportioning bins ,
whereas trimming crushed lime stone / coke breeze additions by a separate Purchasers
belt conveyor from RMHS yard upto Junction house D for further transporting to the top
of proportioning bins .The conveyors from these junction houses for base mix and flux/
coke breeze are included in this package and shall discharge on to the shuttle conveyor
located above the bins.

2. Storage capacity of proportioning bins for sinter plant 1 / 2

Sl. No.

Material

Size
(mm)

No.
of
bins

Each bin
Volume,

Moisture,

Storage

(Effective)

Capacity, t

m3

Storage
capacity, hr
(approx)

1.

Blended mix

-8

500

5.4

4500

15.6

2.

Lime Stone

-3

300

2.0

960

284

3.

Coke breeze

-3

300

1.0

360

58

4.

In plant

-5

200

340

3.0

-1

50

100

Sinter returns
5.

ESP dust

All bins are provided with single outlets. The bins for blended mix are lined with SAIL
HARD liner and SS lining is provided in conical portion for bins for Calcined lime fines.
The bin for sinter returns is of stone box construction. Air blasters is provided for smooth
flow in base mix. Bin aerations systems is provided for bins of ESP dust and Calcined
lime.

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Sinter Plant
The proportioned raw mix constituents from bins is extracted by means of belt weigh
feeders on corresponding dosing conveyors and fed to a combined mixing and nodulising
drum. The return fines bin with single outlet is equipped with standby trolley mounted
weigh feeder. Mixer/ Granulator is provided below bin below ESP dust.

3. Flow- Diagram

F) Combined Mixing and Nodulising Unit

This unit houses two lime fine bins of100 cu.m. capacity with loss in weight feeders for
feeding to the conveyor discharging to the mixing and nodulising drum.

Bag filters of

suitable capacity is provided at the top of lime bins for dedusting purpose. Lime fines from
lime tankers is pneumatically transported to lime bins.
The Mixing and nodulising unit comprisesof combined mixing and nodulising drum proper,
girth gear & pinion, steel tyres, support & thrust roller assembly, water spraying arrangement,
grease/ oil lubrication system, discharge chute & hood with fume stack, complete with
mounted electrics & instruments.
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Sinter Plant
The combined mixing and nodulising drum of size 4m x 15 m long with a coefficient of
filling of 15% is mounted on steel tyre support rollers and have a atomized water spray
arrangement with pipes projecting into the drum to provide water addition in mixing and
nodulising portions of the drum. The drum is complete with drive, gear box, lubrication
system and automatic spray lubrication system for the girth gear and pinions with associated
services etc. The drum with rubber lined conical mixing section have replaceable lifter for
through mixing in first section and nodulising.

G) Sintering and cooling unit

Sintering & Cooling unit houses shuttle distributors, sinter machines with raw mix & hearth
layer feeding systems, ignition furnaces, post heat hoods, wind boxes, wind main, double
cone valves, pallet lifting & lowering stations, crash decks, hot sinter breakers, grizzly,
circular sinter coolers, cooler fans etcalongwith handling equipment.
H) Description of Major technological equipments are given below

1. Ignition Furnace and post heat hood:

Ignition furnace provided after the sinter mix feed system, is fabricated from mild steel
rolled sections and mounted on wheels. The hood is lined with high alumina/fire clay
refractory bricks to withstand temperatures up to 1300 Deg. C. Platforms is provided for
access to the side wall mounted burners and gas/air valves for inspection, regulation and
maintenance. Facilities for lifting and handling are provided.

C V of gas

2000 Kcal/Nm3

Type of gas

Mixed gas (CO + BF gas)

Duty

24 hours continuous

Burner Mounting

Side wall

Ignition hood temperature

1000 - 1300 Deg.C

Specific heat consumption

15000 KCal/t of gross sinter

The ignition furnace is designed for providing optimum ignition time and with necessary
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Sinter Plant
instrumentation and control & regulation system etc& safety device. Negative pressure
ismaintained inside ignition furnace. Post heat hood is located after ignition furnace which
will
avoid sudden chilling of sinter. Cooler hot air at 350 400 deg. C is used in post heat hood as
well as combustion air in ignition hood.

2. Sintering Machine Proper

The sinter machine proper comprises of 204m2 sintering area, comprising SG iron spring
loaded pallet assemblies with high chrome grate bars, charging end lifting sprocket with
drive assembly, discharge end lowering sprocket, machine structural frame work, rail
supports, curved pallet guides, wind boxes, down comers with expansion joints, wind box
supports, dust hoppers at feed & discharge ends, sinter machine return side chutes, machine
discharge stations with heat compensating mechanism, crash deck, automatic centralised
lubrication system, shaft mounted gear box, main drive, clean up hoppers and grids and
empty pallet lifting device, waste gas main, hoppers, dust valves, isolating dampers, water
spray at discharge end etc. One no. 2 t goods cum passenger elevator is provided at sinter
machine building for access to different floors of Sinter building, main control building and
proportioning bin building.
3. Sintering Machine

390

Type

Down-draught off-strand cooling

Feed Capacity (Rated)

600 tph

Pallet width

3.0 m

Pallet length

1.0 m

Area under suction

204 m2

Hearth layer depth

40 - 50 mm

Sinter mix depth

650 mm

Total bed height

700 mm

Speed range

1 4 m/ min

No. of pallets including spares

164 + 10 (spares)

Type of drive

VVVF, reversible, asynchronous motor

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Sinter Plant

4. Waste Heat Recovery Unit

Effective cooler waste heat recovery units is provided near cooler which

houses

combustion air fans, hot air fans & multi cyclone, etc.
Hot air at 350 400 deg. C coming out from first section of hot sinter receiving section
of cooler is supplied to ignition furnace for use as combustion air. The hot air is cleaned
in a multi cyclone and pressurized by combustion air fans before supplying to the ignition
furnace.
Hot air coming out from the second section of hot sinter receiving section of cooler is fed
to post heat hood to avoid sudden chilling of raw mix after ignition by the hot air fan.
Duct work from cooler to ignition furnace and post heat hood will be complete with
fixed/ sliding supports & compensators, air intake valves and other instruments.

5. Circular Annular Dip Rail Deep Bed Sinter Cooler

The circular annular dip rail deep bed type sinter cooler is provided for cooling of < 200 mm
size hot sinter discharged from sinter breaker. The unit comprises ring girders, spokes,
pallets, support rollers, rails, side plates, drive ring, hot sinter receiving hopper, drive units,
guide ring, guide rollers, support structures, air seals, hoods and complete lubrication
system. The cooler speed is controlled by VVVF drive to achieve a cooling time of approx.
one hour.
Throughput

390 t/h

Area

202 m2

Mean diameter

22.5 m

Trough width

3.5 m

Cooler side wall height

1.6 m

Bed height

1.5m (max)

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Sinter Plant
Hot sinter temperature

800-850 deg. C

Temperature of cooled sinter

100 deg. C

Retention time

1 hour (approx.)

Annular sinter cooler comprises the following:

i.

Annular ring girder is fabricated from rolled steel sections to form main rotating
support structure for the cooler.

ii.

Cooler support rollers (two per cooler draft) are mounted on forged steel shafts.

iii.

Two circular cooler tracks is provided on which the rotating structure of cooler is
supported. One track is on either side of the ring girders. The ring girder are
mounted on RCC circular walls.

iv.

At the discharge point of the cooler, the inner and outer rail tracks are dip
allowing pallet segment trailing edge to dip, thus causing the sinter material to
discharge off the grate into the receiving hopper.

v.

Sinter receiving hopper is of stone box type design to prevent excessive wear.

vi.

Cooler Drive Unit

vii.

Two sets of friction pulleys and pressure pulleys drive the cooler friction plates.
The friction pulley is driven by helical gear box motor drive unit.

viii.
ix.

Cooler Guide Rail

The cooler guide rail is supported by separate supporting structure. This is a
fabricated section, for contact with cooler guide rollers.

x.

Cooler guide rollers is provided and equally spaced about the outside ring girder
of the cooler to ensure smooth rotation of the structure along the circular path,
during operation.

xi.

Rotating structure of the cooler is supported on a static concrete structure, the

side walls of which form a chamber into which air will be blown for cooling of
the sinter. Two air tight double access doors are provided in the outer wall for
removal of fines. Three rectangular fabricated flanges are provided on the outer
concrete wall for connection of forced draught fans.

xii.
392

Sealing arrangement
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Sinter Plant
xiii.

The sealing arrangement consists of laminex & rubber, cover plates and steel
parts.

xiv.

Complete Cooler Hoods

xv.

Dust hoods are provided over the feed and discharge points of the cooler are
connected to the dedusting unit.

xvi.

Vibro-feeder

xvii.

The discharge of sinter from the hopper to the heat resistant belt conveyor is by
means of a VVVF controlled vibro feeder for control of level on the discharge
hopper of cooler. The belt conveyor feeds cold sinter to the cold sinter crusher in
cold sinter crushing building.

xviii.
xix.

Cooling air fans

Three numbers of cooler fans are provided for supply of air for cooling of hot
sinter. There is provision for emergency sinter cooling with water sprays on the
belt conveyor.

6. Waste Gas Handling Unit

Waste gas handling unit consists of Waste gas dedusting ESPs, waste gas fan, duct work
from wind main of sintering & cooling building to waste gas ESP & waste gas ESP to
exhaust fan & exhaust fan to separate RCC stack for each sinter plant.
Electrostatic precipitators for each strand for de-dusting of waste gases before the fans.
Electrically driven dust valves and drag link chain conveyors are provided for discharge of
dust from waste gas main and electrostatic precipitator. The collected dust is recycled in the
process, if the alkali content is within limits.

7. Plant De-dusting
The dust laden air from the discharge ends of cooler and sinter machine discharge end,
proportioning bins (except base mix, calcined lime bins), sinter screens, vibro feeders, and
all other dust generating points like conveyor transfer points, etc. are connected to ESPs of
plant dedusting system before being discharged to the atmosphere.

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Sports Department
SPORTS DEPARTMENT

A) Introduction
With the revival of IISCO Steel Plant after its merger with SAIL, it was our
responsibility to infuse life in Social and Cultural milieu of Burnpur. Sports being
the major driving force for youth, it was appropriate to use it as a fulcrum to
revive Burnpur have lost glory in the field of Sports. With the full support of
higher management and guidance from SAIL Corporate Sports, the Sports
Department of ISP started taking lead and since then Sports activities started
making their presence and importance felt to the people of Steel Township.
Recently after a gap of 33 Years National Boxing Championship was organized
by ISP at Burnpur in which around 400 Participants and Officials from different
States and Units took part. For the first time ISP organized National (Inter
Institutional) Table Tennis Championship at Burnpur which was widely covered
by Media at National level. The Highlights of the Sports at ISP are as under.

B) Our Objective
1. To create and develop a strong base of sports.
2. To contribute to employees welfare by providing sports facilities.
3. To project a positive image of the Organization and enhance the sense of pride
through laurels in national sporting events.
4. To promote sports & games in Steel Township as well as in schools.

C) Our Focus
1. To be pioneer centre in Bengal and on the Indian Corporate scene.
2. To assist employees wards for achieving excellence in sports.
3. To encourage the voluntary Organizations / Clubs specializing in sports in and
around Burnpur.
4. To provide quality input, Infrastructures, coaching and motivation.
5. To be in the front line of sports / games.

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Sports Department
D) Our Initiatives
1. Coaching
a. Coaching camp for junior boys and girls invarious disciplines under the
concept - Catch them young
b. Sporting talents
c. Intensive coaching to raise the performance standard up to National / International level.
d. Providing standardized playing equipments for training.
e. Selection of teams at sub-junior / junior andsenior level for various
competitions.

2. Organizing
a. Local tournaments round the year in various disciplines.
b. National / State / Dist. / Sub-divisional / Inter steel and SAIL Inter Plant
Sports competitions in various disciplines.
c. Guidance / assistance to local organizations in holding Divisional / District
/ Zonal / National level tournaments.
d. Assistance to ISP Schools for preparation of teams / organizing
competitions.

3. Area of Activities
Outdoor

Indoor

Athletics

Badminton.

Basketball

Bridge

Boxing

Table Tennis

Hockey

Chess

Cycling

Weight Lifting.

Football

Power Lifting

Cricket

Body Building

Handball
Kabaddi
Volleyball

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Sports Department
Mountaineering
Gymnastic and Yoga

4. Sports Infrastructural Facilities available at ISP

a. ISP Sports House Complex
i.

Basketball and Volleyball court

ii.

Handball and Kabaddi court

iii.

Bridge and Chess center

iv.

Weight Lifting Gymnasium

v.

Multi Gymnasium with sophisticated Equipments.

vi.

Indoor Badminton and Table Tennis Hall.

b. Burnpur Stadium
i.

Football Ground

ii.

Athletic Practice Ground

c. Burnpur Cricket Ground

d. New Riverside Ground

i.

Cricket Coaching Camp

ii.

Chess Coaching Center

iii.

Fitness Center

e. ISPBoxing Stadium
i.

Boxing Ring

ii.

Wrestling Arena

iii.

Gymnastic Arena

iv.

Yoga Center

f. ISP School Coaching Center

396

i.

Cricket Pitch

ii.

Volleyball Court

iii.

Basketball Court
IISCO Steel Plant

Sports Department
iv.

Kabaddi and Khokho Court

g. ISP Table Tennis Academy

Established

August 2009

Cadets

30 boys and Girls selected from various Schools.

Venue

Sports House Indoor Hall

Coaching

A Coach of national level engaged for this purpose only.

Age Group

Between 12 to 16 Years.

Performance

Cadets have started representing District and State in various tournaments

Target

To win medal inNationals and represent Country

h. SAIL Football Academy

The achievements of Burnpur in Football are legendary. There was a time
when it had carved a niche alongside the top Football Clubs of the Country.
With the decline of the Company, Sports particularly Football also saw its
strength beingsapped but despite all , the Football remained the first love of
the people of Burnpur.

SAIL had nurtured the game of Football at Bokaro by establishing an

Academy a decade back and the result has been quite encouraging. Spurred on
by the success of the Football Academy at Bokaro as well as keeping in view
the past achievements, SAIL decided to replicate the Academy on the fertile
sporting field of Burnpur and a residential Football Academy was established
at Burnpur in March 2009. The Academy envisaged at Burnpur is the next step
for Cadets who graduate from the SAIL Football Academy Bokaro. The
Cadets of SAIL Football Academy Burnpur represent SAIL Senior Team in
Kolkata IFA League and different tournaments in various parts of the country.
We are sure that this Academy will take the cadets to greater heights and earn
glory for SAIL, ISP and our beloved Country. Needless to mention here that
this is another feather in SAILs Endeavour to fulfill its Corporate Social
Responsibility.

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Sports Department
i. Strength of Academy
A residential Academy with total strength of 34 Cadets selected from
different parts of the country by a panel of experts consisting of ExNational and International players.
j. Facilities
i.
Free fooding,lodging,training,education, medical facility ,
ii.

Monthly stipend to all Cadets.

iii.

Separate Residential complex with double bed furnished rooms,

Dining hall, Recreation hall , Multi-Gym , Computer room , Guest
room for visitors , Library etc.

398

iv.

Football Ground with dressing room facilities.

v.

Sports Kits and Gears, Casual dresses, School Uniforms.

IISCO Steel Plant

Telecommunication Department
TELECOMMUNICATION DEPARTMENT

A) Introduction
Telecommunication

plays

an

important

role

in

our

life

today.

Generally,

telecommunication is the transmission of signal over a distance for purpose of sending

information. By sharing information, human can get such a development today.
Information is even considered to be one of the standard criteria to assess life quality of a
man. In earlier time telecommunication was done slowly by mean of simple methods
such as the use of smoke signals, drums, semaphore, flags or heliograph, and usually
could transfer a bit of information. For a longer distance and more detail message, pigeon
post was used.

Since the electronics was established and applied in communication, telecommunication

has made a great advance towards all the fields of life today. Telecommunication is now
understood as a system consists of three prime elements: a transmitter that takes
information and converts it into a signal and transmits; a transmission medium that
carries the signal; and a receiver unit that receives the signal and converts it back into
usable information. In modern communication processes there is also one important
element control unit which switches the communications and does the peripheral
intelligence work. Telecommunication has a significant social, cultural and economic
impact on modern society.Social impact,it can be said that telecommunication bring
people nearer. By using mobile phone, internet people in over the world can talk to each
other, sharing information, photographs, profiles, events.

In steel industries telecommunication plays a vital role for effective, safe, smart,
competent & speedy production of steel & other steel products.In SAIL-ISP,
Telecommunication department mainly looking after two areas:
a. Telecommunication
i.

Intercom Landline Telephone

ii.

BSNL CUG Mobile Connections

iii.

BSNL Landline & Broad Band Services

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Telecommunication Department
iv.

Internet USB Modems other than BSNL Service Providers

v.

Walkie-Talkie Monitoring

vi.

Close Circuit Video Monitoring

vii.

Support Maintenance of LSIS & LSBC

viii.

Telephone Repair Shop

ix.

Store & Planning

b. Railway Signaling

B) Telecommunication
1. Intercom Landline Telephone
a. Plant Telephone Exchange
For the 2.5 MT new stream of expansion project for the deployment of a fully
Modular & Non-blocking, Distributed Architecture based SIP (Session Initiation
Protocol) based Communication Server to provide telephony services along with a
SIP based audio conference bridge.

There is anAlcatel Lucent make Server Based Telephone Exchange installed in

Plant area comprising with 3 nos. of Call Servers for Plant, Township & Remote
Location Units. There is a back up installed in Township Exchange for all the 3
Call Servers in case of failure of Plant Call Servers.The Alcatel-Lucent OmniPCX
Enterprise Communication Server offers a standards based open-distributed
communications server for both medium and large enterprises, managing both
traditional and IP configurations.

Fig: Communication Server

Plant Telephone Exchange has been equipped with 3000 subscriber lines, wired
with 6000 subscriber lines &extendable up to 12000 subscriber lines.
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Telecommunication Department
Along with Call Servers in New Server Based Telephone Exchange there are also
following Servers connected to this Exchange through switches.
b. Audio Conference Bridge - Omni Touch Team Work Server
OmniTouch My Teamwork is an application enabling employees to collaborate
remotely with colleagues or external participants. SIP based Audio Conference
Bridge of 150 ports fully integrated to the Telephony system.Maximum 150
Subscriber can be included in one Conference.Daily Morning Conference of
senior executives has started from Feb, 2014 through Server based Conference
system.

c. Complaint Handling Server - Amadeus AccuVoice- P

In todays business, every industry is faced with razor sharp competition. To win
the market, it is important to have happy customers. This increased demand for
Customer Satisfaction gives way to a 24 X 7 (24 hours a day, 7 days a week)
Customer Service. It is very expensive proposition to have a human operated
customer service centre. TheCustomer Service Representatives will get tired of
answering phone calls after a while, usually with deteriorating quality of service,
even resulting in an unfriendly service. Therefore, the right choice for industries is
to have an IVR (Interactive Voice Response) System, which is an automated Call
Centre. The proposed system answers an incoming call through an automated
fault logging system. This IVRS based serveris for registering the complaints
automatically through phone call& there rectification regarding landline telephone
system.

d. Management and Call Billing - OmniVista 4760 NMS

NMS stands for Network Management System. The Alcatel-Lucent OmniVista
4760 NMS suite is a comprehensiveset of applications designed to help telecom
managers and administrators in their day-to-day tasks and aid them in making
strategic choices in their converged networks, due to reliability, assured
availability, performance information, access security, configuration management

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Telecommunication Department
and telecommunication cost tracking. It is a software tool for the maintenance &
monitoring of features & facilities provided to the subscribers.
e. Remote Maintenance Access RMA
The RMA (Remote Maintenance Access) system is an external server used to
perform configuration and maintenance operations. Maintenance is performed
locally or remotely, via the modem.

f. Remote Location Units (RLU)

RLUs can also be considered as mini telephone exchanges installed at different
location in new modernization site including Hospital.There are 14 RLUs in
totalalocatedat major units of plant. Each RLU has been equipped with 200
subscriber lines & Expandable up to 500 subscriber lines.All the Remotely
Located Units will have survivable media gateways registered to the centralised
communication server at Plant exchange over the IP network using OFC
backbone.

g. Township Exchange
There is an Alcatel Lucent make Server Based Telephone Exchange installed in
Township Exchange which comprises of 3 call servers (Back up for Call Servers
installed in Plant Exchange).Township Exchange has been equipped with 1000
subscriber lines & extendable up to 2000 subscriber lines.

h. Plant & Township Cable Lines

Cable laying work within plant & township is looked after by Telecom
Department. There are different types of cables used for the different & required
communication. 200 pair, 100 pair, 50 pair, 20 pair & 10 Pair jelly filled
armoured PVC cables are being used. Also, 50 pair, 20 pair, 10 pair, 5 pair & 1
pair (twin wire) unarmoured PVC cables are also being used
For proper maintenance of telephone, it has been divided into following 3 (three)
areas:
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Telecommunication Department
i.

Township Zone: Covering areas North town, South town, Riverside,

Pump House, Riverside Township, Air Strip, Hospital andEvelyn Lodge
Township.

ii.

Existing Plant Zone: Covering areas Coke Oven Battery#10, Old CHP,
Gates, Machine Shops, Blast Furnace#2, Old Power Plant, Safety, Fire,
Environment, General Offices, Stores andall other establishments
functioning in existing area.

iii.

Modernization Plant Zone: Covering area Raw Material Handling

Plant, Sinter Plant, Base Mix Plant, Coke Oven Battery#11, Blast
Furnace#5, Continuous Casting Plant, Basic Oxygen Furnace, Oxygen
Plant, Wire Rod Mill & Bar Mill, Universal Section Mill, Main Receiving
Station, Power Blowing Station, LDCP and all the associated offices &
sites.

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Telecommunication Department
TELEPHONE EXCHANGE FULL NETWORK OF SAIL-ISP
Plant
Exchange

Main Electric
Room (440V)
B1

B2

CABLE
ROOM

MDF
AS

FCBC

CALL
SERVERS

Main
Circuit
Breaker
1

UPS

Bt-1

Bt-2

ES
Township
Exchange
CS

DS

(1 Nos.)

(8 Nos.)

ES

ES

RLU
SUBSCRIBERS

ES

AS
DB

404

MDF

PCS
MG

1 - 14

IISCO Steel Plant

SUBSCRIBERS

MG

LIU

Telecommunication Department
LIU - Light Interface Unit, AS - Alcatel Switch, CS - Core Switch (1 Nos.), DS - Distribution
Switch (8 Nos.),DB - Distribution Box, ES - Edge Switch (LIU is present within ES only), MDF
- Main Distribution Frame, MG - Media Gateway, RLU - Remote Location Unit, FCBC - Float
cum Boost Charger (O/P = 48 V DC, 50 Hz), Bt-1, Bt-2 -Battery Back-Up for UPS (O/P = 220V
AC, 50Hz), B1, B2 - Battery Back-Up for FCBC
Note: From Township Exchange the lines are given to the subscribers in the same manner as
given in the Plant Exchange through MDF & Cable Room present in Township Exchange.

2. BSNL CUG Mobile Connections

For cost effective as well as fast communication among the employees of SAIL-ISP,
the BSNL CUG (Common User Group) mobile SIM is being provided to the
executives of plant. Through this CUG SIM all calls & messages within the common
user group are free. Billing as well as the maintenance of the SIM is looked after by
Telecommunication Department.

3. BSNL Landline & Broadband Services

There is a BSNL Landline & Broad band facility provided to all senior executives &
at needful locations. The Billing, line maintenance, Modem maintenance, etc is
looked after by the Telecom Department.

4. Internet USB Modems other than BSNL Service Providers

For the uninterrupted working through internet, high speed modems provided to the
senior executives of SAIL-ISP. The maintenance of those modems is looked after by
Telecommunication Department.

5. Walkie-Talkie Monitoring
For the efficient & fast production of Steel Walkie-Talkie facility has also been
provided by Telecommunication Department. Maintenance of Walkie-Talkies is
looked after by Telecommunication Department.
6. Close Circuit Video Monitoring
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Telecommunication Department
Telecommunication Department is looking after the Close Circuit Video Monitoring
through CCTV cameras for surveillance as well as monitoring purpose. These CCTV
cameras have been installed at different locations in plant.
For Surveillance purpose there are presently 10 nos. of CCTV cameras have been
installed at Gates & Weigh Bridges.

Sl. No. Location

Nos. of

Type of cameras

cameras
1.

Tunnel Gate

Fixed

2.

SCOB Gate

Fixed

PTZ

3.

Vehicle Gate

Fixed

4.

Sanmara Gate

PTZ

Fixed

PTZ

5.

Weigh Bridge-60 Ton (Steel)

All these cameras except at Sanmara gate are being viewed through Fiber Optic
network. Sanmara Gate is yet to be connected with Fiber Optic network.
For monitoring purpose there are approx. 234 nos. of CCTV cameras are to
beinstalled in the modernization site. Presently, following nos. of CCTV cameras
have
Sl. No.

Location

Qty

Make/Model

1.

Sinter Plant

11

Bosch/LTC 0455/51

2.

WRM

10

Pelco/CC3651H-2X

3.

By-Product Plant (COB#11)

Bosch/LTC 0455/51

4.

Coal Handling Plant

10

Pelco/C10DN-6X

been

installed.

7. Support Maintenance of LSIS & LSBC

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Telecommunication Department
LSIS stands for Loudspeaker Intercommunication System & LSBC stands for
Loudspeaker Broadcasting System. These two have been used for the announcement
at work sites from a control roomand also from different locations of that unit. LSIS
is based on two way communication whereas LSBC is based on one way
communication. Telecommunication Department provides the support maintenance
for these two systems of communication.

8. Telephone Repair Shop

There is a Telephone Repair Shop where the faulty telephone sets & related
accessories are being repaired by the Telecommunication Department.

9. Store & Planning

Telecommunication Department keeps proper store for its spares. As per the
requirement & use the relevant planning is being done. There is also a record
maintained for the store material.

C) Railway Signalling
In a steel plant, timely and efficient supply of raw materials and dispatch of finished
goods is very essential. For this, we require railway yards to be functioning smoothly.
Thus, Railway Signaling Scheme plays a vital role in the supply chain of steel
production.In the old plant, changing of tracks and giving of signals to train are done
manually. As a result, more manpower is required and efficiency as well as safety
decreases. In the new plant, the railway yards are being automated using the state of the
art Panel Interlocking technology based on Indian railways pattern which reduces
manpower and improves safety.

The Railway Signalingschemeat Damodar Yard (Raw material Handling Yard) is looked
after by Telecommunication Department. The Railway Signaling Scheme at this yard
incorporates Route Relay Interlocking system which provides for the failsafe operation of
Signals and point machines for the smooth movement of locos.
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Telecommunication Department
Main equipments at Damodar Yard consist of:
a. Electric Point machine:There are 31 point machines which are used for movement of
tongue rails.In the event of a power failure or emergency the point can be operated
manually.
b. Relays:Signaling relays have applications such as Route Relay Interlocking, Panel
Interlocking, Automatic Signaling, Point Operation and Track Circuiting. There are
around 1780 nos. of indoor and 231 nos. of outdoor relays.
c. Track circuit: There are 62 track circuits to detect the correct position of railway
engine/ wagon on the track and thereby giving signal accordingly.
d. Signals: There are various types of signals like main, routing, shunt and calling on
signals to display stop or move signals to loco driver.
e. Control cum indication panel: It has push buttons for setting of route, setting of
individual point machines and giving of signal. There is also provision for emergency
cancellation of set routes. Whenever a route is set all the point machines on that route
are automatically set and set route is shown by yellow LEDs on the Indication
panel.When the loco arrives,itsmovement is shown by transformation of yellow LED
to red LED showing occupied track and subsequently clears the section in rear as it
moves on.

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TRAFFIC & RAW MATERIALS (T&RM) DEPARTMENT

A) Introduction
T&RM department is concerned with the transportation of incoming raw materials,
inter-process materials and outgoing finished products. This transportation involves
both the intra-plant movement and railway rake movement.
a. Railway rake movement can be either inward rake movement for supply of
raw materials or empty rake for dispatch of the materials from the plant.
b. For dispatch & receipt of rakes ISP has three railway sidings;
i.

SCOB sidings - Dispatch finished products of new plant.

ii.

BCME sidings - Inward coal receipt & dispatch of coke and pig iron
from old plant.

iii.

Damodar siding for receipt of incoming raw materials.

ISP Burnpur is the only plant of SAIL which is served by two different zones of
Indian Railways; South Eastern Railways (SER) through its division at Adra and
Eastern Railways (ER) through its division at Asansol.
The key areas of working can be summarized as
a. Planning and procurement of raw materials
b. Placement and withdrawal of wagons.
c. Up keeping of the tracks for movement.
d. Maintenance of the Diesel Locomotives used for hauling.
e. Attending to disruptions & derailments.
Based on the above key functions; T&RM department has been divided into five sections;

a. Raw Material.
b. Movement.
c. Permanent Way (PW).
d. Diesel Loco Maintenance.
e. Carriage & Wagon.

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B) Raw Material Section
Raw Material Section is responsible for planning and procurement raw materials. The
incoming raw materials & inputs obtained by ISP are:
Sl

Item

No

Source

Consuming Unit

Remarks

Meghataburu, Kiriburu,
1

Iron Ore Fines

Gua,
Manoharpur,Kalta,

Sinter Plant

For use in BF

Barsua, Bolani
Meghataburu, Kiriburu,
2

Iron Ore Lump

Gua, Manoharpur,
Kalta,

BF#2,BF#5

Barsua, Bolani
3

Lime Stone

Kuteshwar

Sinter Plant

Lime Stone

Jaisalmer, Imported

LDCP

Dolomite

BISRA

BF#2

Dolomite

Dalgaon, Bhutan

Quartzite

Local Purchase

BF

LD Slag

BSL

BF#2

Coking Coal

Chasnalla

Coke Oven

Imported Coking Coal

Haldia, Dhamra,

(Australia Hard)

Paradip Ports

Imported Coking Coal

Haldia, Dhamra,

(US Hard)

Paradip Ports

Imported Coking Coal

Haldia, Dhamra,

(New Zealand Hard)

Paradip Ports

Imported Coking Coal

Haldia, Dhamra,

(Australia Soft)

Paradip Ports

Imported Coking Coal

Haldia, Dhamra,

(New Zealand Soft)

Paradip Ports

Boiler Coal

ECL Mines

10

11

12

13

14
15
410

For use in BF
For use in
Steel Making

Sinter Plant,

For use in

LDCP, BOF

BF#5 & BOF

Coke Oven

Coke Oven

Coke Oven

Coke Oven

Coke Oven
Boilers
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Traffic & Raw Materials Department

1. Planning of Procurement of Raw Materials

At the beginning of financial year the production plan is projected in Annual Business
Planning Meeting at Corporate level to finalize the annual targets of each production
units. Accordingly Hot Metal, Liquid Steel, Saleable Steel production targets are also
finalized. In line with above, all the production units Blast Furnace, Sinter Plant,
Coke Oven, Steel Melting Shop project their production targets and give the Raw
Material, Coal and Flux requirement. The requirement for Boiler Coal is given by
Boiler Plant.

2. Procurement of Iron Ore Lump &Fines Rakes

As per monthly requirement of Iron Ore, depending on Hot Metal production target,
the supply of rakes is regulated on weekly and daily basis through close co-ordination
with RMD (Raw Material Division) and Rail Movement Cell and BF/Sinter/SMS
Depts., to receive the rakes in such a way that bunching of rakes is minimized and a
safe level (seven days stock) of stock is maintained.

The iron ore lump for BF#2 is received at Transit Bunker through ISPB siding by
S.E.Railway. However, the iron ore lump for BF#2 may also be received at Track
Hopper of new plant for sending to BF#2 of old plant.

The iron ore fines and iron ore lump rakes required for Sinter Plant and BF#5 are
received at Damodar Yard through S.E.Railway and unloaded in Tippler#301(Fines)
and Track Hopper (lump).

3. Procurement of Coking Coal Rakes

ISP is procuring Indigenous PCC (Prime Coking Coal) from Chasnalla. PCC
procurement for the new plant and old plant from Chasnalla is done in close coordination with CCSO and Chasnalla Collieries as per requirement and consumption
depending on oven pushing.
Imported coking coals are procured through close co-ordination with Corporate
Office, CMO (T&S), Ports and Rail Movement Cell. For old plant the rakes are
received at BCME through E. Railway and for new plant the rakes are received at

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Traffic & Raw Materials Department

Damodar Yard through S.E.Railway. The rakes are regulated as per consumption
depending on Oven Pushing through 10 days loading programme.

4. Procurement of other Raw Materials

Lime Stone (For Sinter Plant) -Kuteshwar, It is SAIL RMD Mines .Procurement for
the new plant is done in close co-ordination with RMD. For LDCP we take Lime
stone from Jaisalmer (A Rajasthan State Govt. mines) and Haldia Port (Imported).

Dolomite for BF#2 is procured from BISRA Stone & Lime Co. Ltd, Birmitrapur. For
Sinter Plant and use in LDCP/BOF Low Silica Dolomite is procured from Dalgaon,
Bhutan.

For Quartzite procurement ISP has taken procurement action to get the quartzite in
wagons through Rail Route.

5. Boiler Coal:
Boiler Plant gives its annual coal requirement. Based on that monthly requirement and
plan is given to CCSO, Dhanbad, under Operations, Corporate Office, NewDelhi. The
allotment of coal rakes are taken from ECL, Headquarters on weekly/10 days basis for
supply to BCME siding, ISP.

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C) T&RM Movement Section
T&RM-MOVEMENT
SECTION

STEEL SECTION

IRON SECTION

NORTH YARD

SOUTH YARD

DAMODAR YARD

Connected with
ER
through
HSME
for
C/Coal, B/Coal,
Flux
Rake
reception
for
existing plant,
Feeding
of
empty wagons
supply to PCM,
Coke Loading.

Connected with
SER
through
Burnpur for I/Ore
lump
rake
reception
for
existing
plant,
feeding of B.F.
Coke
through
high line & power
house coal for
power plant

Connected
with
SER
through
Damodar
for
reception of raw materials
and caol for the New Plant.
Equipped with three nos. of
tipplers & one no. of Track
Hopper

WestYard
B. Fce Yard
Connected with EC Railway
through HSME for reception of
empty rakes for steel, Pig Iron &
G. Slag loading and despatch.

Handling of Hot Metal for

BOF, Feeding of PCM & G.
Slag yard management.

The principal role of T&RM department comes under movement section. The whole
transportation i.e. from incoming materials to products which has to be dispatched is looked
upon by this section.
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Traffic & Raw Materials Department

Day to day planning is done by this section to check intraplant movement of different
materials placing of empty wagons at different production departments of steel plant and
dispatching of loaded wagons are the major role of this department.
Moreover, loaded wagons which are handed over by railways have to be unloaded in
specified time frame in order to prevent demurrage charged by Indian railways.
Brief description of different areas of Movement Section as mentioned above are:

1. Traffic (Iron):
Traffic (Iron) is mainly concerned with the movement of incoming raw materials i.e.
coal, iron ore and flux materials such as limestone, dolomite etc. Moreover, intraplant
movement of various output of the existing B.Fce and Coke Oven are also monitored
by this section. Dispatching of pig iron and coke are the prime area of outward
movement of this section.
In Order to make sure on monitoring of movement, Traffic (Iron) has been further
divided into the following yards which are: Damodar Yard, South Yard and North
Yard.

a. Damodar Yard
Damodar yard is built to cater the needs of new plant. Its connected to South Eastern
Railways through Damodar Station Main Line & it will handle the entire inbound
loaded rake to new plant. It has ten lines named in the numerical sequence & total
running length of yard is 24 Km. Damodar yard is equipped with the advanced Route
Relay Interlocking system (RRI) to prevent conflicting movements through an
arrangement of tracks such as junctions or crossings & for this it has a total of thirty
one motorized points that can be operated from RRI cabin.

For the first time in the history of SAIL, Indian Railways will bring their loco inside
the plant. To facilitate the movement of railways electric locomotive, all the lines are
electrified by OHE of 25 KV.

All loads will go over the in motion weigh bridge of 150 ton capacity provided at the
main entry side of Damodar yard for weighing all in coming raw material rakes.
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Traffic & Raw Materials Department

Presently ISP has three WDS locos - 06 of 1350 HP for shunting purpose in DMY &
a loco pit is built at the Burnpur end of line no: 03 for carrying out all the locomotive
maintenance jobs.

There are three tipplers & one track hopper for the unloading of loaded rakes. Coal &
flux are unloaded in tipplers while iron lumps are unloaded in track hopper. Track
hopperof length 200 meter connected with line no: 01 & 02 can handle up to 18
wagons at a time. Tippler 302 connected with line no: 09 & 10 is specifically for
unloading of coal rakes while tippler 301 connected with line no: 06 & 07 is for
unloading of fluxes, iron fines & coal rakes. Tippler 300 connected with line no: 04 &
05 is specifically for unloading of iron ore fines rakes. A sick line (line no: 11) has
been provided near the out haul of tippler 302 for attending sick wagons.

b. Hot Metal Handling:

Our new plant is provided with a blast furnace (BF # 05) of 4060 m3 volume. The hot
metal produced will mainly go to the BOF Shop by Torpedo ladles of 350 ton
capacity each with the help of BHEL locomotives. Excess metal will be taken care
off by PCM for pig casting. For repairing & checking the ladles will be shifted to
LRS.

c. South yard:
This Yard is directly connected to South Eastern Railways through Burnpur Station.
Different storage space has been provided in this yard for handling and storing
different raw materials and products of the existing plant, i.e.
i.

Limestone

ii.

Dolomite

iii.

LD Slag

iv.

Mn Ore

v.

BF Coke

vi.

Nut Coke

vii.

Power House Coal

Lump Iron Ore rakes are directly placed from Burnpur Station to South yard on track
hoppers. Iron ores are unloaded in the bunkers from which these materials are directly

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Traffic & Raw Materials Department

transported to Iron Ore Stock Yard with the help of conveyor belts. A total of 18
bunkers are there in South yard. Each bunker has a capacity of 200 MT.

d. North Yard:
North yard is connected to Eastern railways through Asansol Divisions Hirapur
Exchange Yard (HSME). Like South yard, it also handle&Store differentstocks like:
i.

Coking Coal

ii.

Coke Breeze

iii.

Nut Coke

iv.

SMS grade limestone

v.

SMS grade dolomite chips

Wagons containing Coking coal are placed in Box tippler for unloading to feed
existing Coke Oven Batteries. Through this yard pig iron and coke rakes are also
dispatched to different destinations.
An electronic weigh bridge as well as a Mechanical Weighbridge have also been
installed in this yard to check the weighments.

2. Traffic (Steel)
This section has also been divided into two yards
i.

East Yard, and

ii.

West Yard

a. East Yard:
It caters to the requirement of existing Steel Melting Shop, Rolling Mills and partly of
Blast Furnace for its feeding of raw materials, disposal of liquid steel, steel ingots and
disposal of waste materials like furnace jam and steel scraps arising from SMS., mill
scale, scrap generated from mills, defective structural etc.

b. West Yard:
This yard is modernized with the idea of catering to the requirement of despatch from
New Plant. It has got 12 lines measuring about 17 KM and 6 nos. of WDS-6AD
Locomotives are there to cater to the New Plant requirement.
.
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Traffic & Raw Materials Department

Presently this yard caters to the requirement of steel dispatch from existing mills by
placement of empty wagons and dispatch of the loaded wagons after complying with
the required railways formalities.In addition facilities are there at JHORABUDI for
taking care of COKE&SINTER dispatch as and when required.

Provision has been made in the Yard to facilitate for direct reception of Inward Traffic
e.g. Empty Rakes & Billets etc by Railway Pilot through full length OHE
arrangement in Line #8 &#9 with switchover facility. Provision has also been made to
draw the loaded outbound Rakes by Railway Pilot.

In the New Plant this yard will cater to the job of receiving Empty Rakes & feeding of
empties to various Mills, Pig Machines and Granulated slag for loading, receiving
loaded wagons, regrouping them, rake formation and hand over the rakes to Railways
after completion of Field Commercial formalities.

D) Permanent Way Engineering

1. Introduction
Permanent way or Track is the rail-road on which Locomotives and Rolling
Stocks run. It basically consists of two parallel rails placed at a specified distance
in between. The rails are fastened to sleepers. The sleepers are embedded in a
layer of Ballast of specified thickness and the ballasts are spread over the
formation or sub-grade.
Therefore the basic components of Railway track are
i.

Rails

ii.

Sleepers

iii.

Fittings &fastenings

iv.

Ballasts

v.

Formation or Sub- grade.

Each of the components of track has a basic function to perform.

ISP has Broad Gauge (1676 mm) tracks made up of 45 kg, 52 kg & 60 kg rails.

2. Points & Crossings or Turnouts

Points and crossings are provided to transfer railway vehicles from one track to
the other. The points or switches give the facilities of diverting the vehicles and
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Traffic & Raw Materials Department

crossings provide gaps in the rails to be crossed by flanged wheels. A complete set
of points and crossings along with lead rails is called a turnout. A turnout is
designated right hand or left hand turnout depending upon whether the traffic is
diverted to the right or to the left by turnout.

3. Important terms used for Turnout:

i.

Turnout: It is an arrangement of points & crossings with lead rails by

means of which rolling stock may be diverted from one track to another
track.

ii.

Tongue Rail: It is a tapered movable rail made of

high

carbon

or

manganese steel to withstand wear. A tongue rail is also called sometimes

a switch rail.
iii.

Stock Rail: It is a running rail against which a tongue rail operates.

iv.

Switch: Pair of tongue and stock rails with necessary connections and
fittings form a switch.

v.

Points: Pair of tongue rails with their stock rails is termed as points.

vi.

Crossing: A crossing is a device introduced at the junction where two rails

cross to permit the wheel flange of a railway vehicle to pass from one track
to another track.

4. Function of the Department

It is a Service department and its function is to ensure smooth running of the
Locomotives & Rolling Stocks on railway tracks by proper maintenance of laid
tracks inside the plant to achieve the production target of all production units and
smooth dispatch of finished products through rail-road.

5. Main Activity of the Department

Manual Maintenance of tracks

418

i.

Preventive Maintenance

ii.

Break down Maintenance

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Traffic & Raw Materials Department

6. Safety
Our all efforts are to achieve Zero accident by maintaining the following action
plan without faili.

use of safety PPE

ii.

Maintaining SOP & SMP on job

iii.

Safety talks every day before starting the job

iv.

Discussion with employees regarding the possible hazards of awarded

jobs.

v.

Maintaining proper House Keeping

vi.

Conducting monthly safety meeting & counseling with last injured person

7. Length of Railway Tracks

The department is maintaining about 125 km of railway tracks in existing plant in
which approximately 47 km. length of tracks are in regular use. Hot Metal & Ingot
routes are laid by 52 kg rails which are about 12 km length and rest length are laid
by 45 kg rails. In addition to these tracks recently about 300 m length of tracks at
Box Tippler line are made up of 60 kg rails.

Damodar Yard

25 Km

In Plant

18 Km

West Yard

15Km

Blast Furnace

7km

Steel Melting Shop (East Yard)

4km

South Yard

8.5km

North Yard

9.6km

West Yard

10km

Slag Bank (Iron)

4km

Slag Bank (Steel)

3.5km

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Traffic & Raw Materials Department

8. SOPs & SMPs for the Department

SOPs FOR THE DEPARTMENT

ARRANGING SAFETY TALKS FOR 05 MINUTES EVERYDAY BEFORE

STARTING OF JOBS TO THE EMPLOYEES WHO HAVE BEEN ALLOTED
JOBS IN PWE AREAS.

ENSURING 100% USE OF SAFETY APPLIANCES (PPEs) IN WORKS &

WORKING

AREAS

FOR

REGULAR

AS

WELL

AS

CONTRACTUAL

EMPLOYEES.

BEFORE

STARTING

THE

OPERATION/PRODUCTION/CONCERN

JOBS

ON

DEPARTMENTS

RAIL-TRACKS,
ARE

BEING

INFORMED IN ADVANCE & RED FLAGS ARE BEING FIXED AT BOTH ENDS
OF THE TRACKS.

ENSURING CLEANING AND HOUSEKEEPING OF WORKING AREAS ON

REGULAR BASIS.

REMOVING ALL RAILWAY SCRAP MATERIALS LYING BESIDES THE

TRACKS AFTER COMPLETION OF THE JOBS FOR EASY MOVEMENT OF
EMPLOYEES & ROLLING STOCKS I.e.; MAKING THE SURROUNDING FREE
FROM ACCIDENT.

CHECKING OF GAS CUTTING & WELDING SETS, TOOLS & TRCKLES ON

REGULAR BASIS IS MUST IN THE DEPARTMENT.

DURING WORKING WITH ACCETYLINE CYLINDER IN HOT AREAS THE

CYLINDER IS KEPT ATLEAST 30 ( FEET) AWAY FROM THE HEAT-SOURCE
& WET GUNNY BAGS ARE PROVIDED TO PROTECT THE CYLINDER FOR
ANY MISFORTUNE.

RAIL TRACK MATERIALS ARE PROPERLY STACKED IN STORES/YARDS &

TOOLS/TRACKLES ARE PROPERLY KEPT IN THE DEPARTMENT.

SMPs FOR PWE DEPARTMENT

INSPECTION OF TRACKS ARE CARRIED OUT DAILY & NEXT DAYs JOBS
ARE PLANNED ACCORDINGLY.

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LUBRICATION OF TURN OUT POINTS, CROSSING,LEVER BOXES JOINTIISCO Steel Plant

Traffic & Raw Materials Department

BOLTS ETC.ARE DONE ON DAILY BASIS.TIGHTENING OF LOOSE BOLTS
OF THE TRACKS IN ALL THE YARDS & PROCESS AREAS ARE DONE ON
REGULAR BASIS.

IMMEDIATE ATTENTIONS ARE BEING PAID IN CHANGING WORN

OUT/BROKEN RAILS, SLEEPERS TO AVOID THE DERAILMENT OF
LOCOS/ROLLING STOCKS.

KUCHCHA DRAINS ARE CUT BEFORE MONSOON & ON REGULAR BASIS

TO DRAIN OUT THE ENTRAPED WATER FROM/ BETWEEN THE TRACKS.

PACKING OF DEPRESSED TRACKS WITH STONE/ SLAG BALLAST FOR

LEVELLING OF DEPRESSED RAIL-TRACKS ARE BEING CARRIED OUT
REGULARLY.

CHECKING OF GAUGE, DE-WEEDING & CESS LOWERING, CLEANING OF

RAIL-COLLARS OF THE TRACKS IS DONE ON DAILY/REGULAR BASIS.

FOR MAJOR OR CRITICAL AREAS JOBS, PROTOCOL IS BEING PREPARED

AND CONCERN DEPARTMENTS ARE TAKEN INTO CONFIDENCE.

E) DIESEL LOCO MAINTENANCE:

Diesel Loco maintenance section is having two shops:
i.

Remodeled Diesel Loco Shop at existing plant location.

ii.

Damodar Yard Diesel Loco Shop at new plant.

Our mottos:
i.

To ensure safe working environment for zero accident.

ii.

To follow SMPs in all the activities of new & old locomotives.

To cater to the requirement of 2.5 MTPA plant under modernization and expansion,
12 Nos. of diesel locomotives have been purchased and these have been deployed as
follows:

Sl.

Yard Location

No.

Locomotive
Type

Nos.

Functions

Deployed

1.

Damodar Yard

WDS6AD

Yard operation

2.

West Yard

WDS6AD

Yard operation

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Traffic & Raw Materials Department

3.

#5 Blast Furnace & BOF-

BHEL - SPP

CCP Area

Torpedo Ladle
movement

1. Loco Fleet of SAIL - ISP, Burnpur:

MAKE & TYPE

CAPACITY

QTY.

GE - Single Unit

235 HP

2 Nos.

GE - Double Unit

600 HP

9 Nos.

BHEL - Single Unit

350 HP

2 Nos.

BHEL - Double Unit

700 HP

4 Nos.

BHEL - SPP

700 HP

3 Nos.

DLW - WDS6AD

1350 HP

9 Nos.

TOTAL FLEET SIZE

29 os.

2. Important Assembly Systems in locomotives:

Lubricating system, Fuel oil system, Engine Cooling water system, Pneumatic system,
Under Carriage (Gear box & transmission system with traction motors), Generator
sets, Electrical control Panels.

3. Remodeled Diesel Loco Shop:

Maintenance Practices being followed at Remodeled Diesel Loco Shop:

Regular Servicing
Schedule Major Maintenance
Capital Repair

once in every 3 to 4 days

once in a month
4 locomotives in a
year

4. Jobs carried out in old and new Diesel Loco Shop:

422

i.

Regular Servicing.

ii.

Schedule Maintenance.

iii.

Engine Overhauling.

iv.

Pneumatics appliances overhauling.

v.

Under carriage maintenance.

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Traffic & Raw Materials Department

vi.

Electrical appliances overhauling.

vii.

Capital Repair.

viii.

Daily Inspection, Trip schedule, Monthly Schedule, Quarterly schedule, Half

yearly schedule specially for WDS6AD locomotives.

5. Facilities available at Remodeled Loco Shop:

2(Two) Nos. of 30 Ton E.O.T Cranes, 1 (One) No. of 50/10 Ton E.O.T crane, Battery
charging Unit, Air Compressor units, Engine Testing Machine, High pressure water
jet machine etc. to support regular maintenance functions.

6. Facilities to be added to ease maintenance activities of new locomotives:

Water Demineralization Plant, Ultra sonic Cleaners, Screw Jacks, Hydraulic jacks,
5Nos. of 5Ton Jib cranes.

7. Damodar Yard Diesel Loco Shop:

A new diesel loco shop has come up at Damodar yard under modernization and
expansion plan. 3 Nos. WDS6AD locos plying at Damodar yard are being maintained
here as per railway normsby a competent external agency.

8. Maintenances Practices being followed at Damodar yard Loco Shop:

Daily Check-up, Trip schedule, Monthly Schedule, Quarterly schedule, half yearly
schedule is being carried out in this shop as per stipulated railway standards.

9. Facilities available at Damodar yard Loco Shop:

The shop is equipped with 1 No. of 20/5 EOT Crane and working pit.
10. Further facilities are going to be added:
1 No. of Air Compressor Unit, Battery charging unit, Bench type single spindle
drilling machine, Power hacksaw, Lap master, Ultrasonic cleaner, 30 tonnes capacity
screw jacks etc.

F) CARRIAGE & WAGON SECTION

This section is specialized in dealing with RE-RAILING of locomotives, wagons
hoppers etc. inside the plant.

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Traffic & Raw Materials Department

The section is equipped with Break-Down Vans(B.D.Van)-containing Wooden
Blocks of different sizes, Hadfield Plates, Packing plates, Chains &Slings, Shabbals,
Dshakle, , Hydraulic Jacks(Large-1, Med-2, small 2)with attachments (like platform
etc.) which are handled by highly skilled persons for re-railing.

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Water Management Department

WATER MANAGEMENT DEPARTMENT

A) Water Supply in Steel Plants

Water is essential for human survival and well-being and important to many sectors of
the economy. However, resources are irregularly distributed in space and time, and
they are under pressure due to human activity.

How can water resources be managed sustainably while meeting an ever increasing
demand?
Freshwater accounts for only 2.5% of the Earths water, and most of it is frozen
inglaciers

andcaps.

The

remaining

unfrozen

freshwater

is

mainly found

asgroundwater, with only a small fraction present above ground or in the air.

Water is an essential requirement in steel production and availability of water in

adequate quantitythrough-out the year is ensured when the site is selected for
construction of a steel plant for variousprocess requirements (industrial water),
drinking and also fire fighting.

B) Industrial Water Supply:

Industrial water is used for the following purposes
i.

As a carrier of heat (cooling)

ii.

As a carrier of waste material

iii.

As water seal to prevent the escape of gases to atmosphere

iv.

For conversion to steam

v.

Fire fighting.

1. Carrier of Heat
Most of the water in a steel plant is used for removal of heat as in the
following processes
i.

For condensation of steam after use in Turbo Generators, Turbo

Blowers & TurboCompressors.

ii.

IISCO Steel Plant

For cooling of products (e.g.HRM, PCM etc.)

425

Water Management Department

iii.

For cooling of equipments (e.g. Blast Furnace shells, Lances in

Converter shop, Skid pipes &doors of Reheating Furnaces, Furnace
elements in Foundries, Bearings of various equipments,etc.)

2. Carrier of Waste Material:

Dust catching in Coke Oven & Blast Furnace Gases, Scrubbers & other hydro
dust removal systems,Mill scale flushing, etc.

3. Gas Seals:
As gas seals in Gas Cleaning Plants and Gas Holders to prevent the escape of
gases to atmosphere.

4. Generation of Steam:
Used for generation of heat in Power Plants, Waste Heat Boilers and
evaporation cooling systems.

5. Fire Fighting:
In an integrated steel plant there are many fire prone areas like Liquid Fuel
Station, Oil Cellars,Cable Galleries, Oil & gas pipelines, Chemical Plants,
Coal Feeders, Conveyors, etc. Fire Hydrants(indoor & outdoor) are provided
for fire fighting all over the plant. Most of the fire hydrants in ISP use
industrial water.Different systems are adopted for circulation of industrial
water in an industry.

The water can be collected after use and re-used (re-circulation system) or can
be discharged back tothe natural streams / rivers (once through system). For
the latter the source should be sufficientlylarge enough for the continuous
supply of water throughout the year. This system is hardly used now days as
there is an ever increasing demand of water and source of water to meet huge
demands isvery rare. Also, the government is enforcing stringent pollution
control regulations & restrictions oneffluents discharged.
In steel plants re-circulation schemes are adopted. Re-circulation schemes can
be broadly classified as
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i.

Centralised re-circulation system with cooling ponds

ii.

Local re-circulation system with cooling towers.

In central re-circulation system, most of the plant units draw water from one
singlesystem anddischarge water back into the system. In the local recirculation system,each of the plant units draw only the make-up water
required from the central source and the water is re-circulated within the unit
itself. Centralised system is adopted in the old IISCO PLANT and Local
recirculation system is adopted in the new plant.

All the units in the new plant such as BF, BOF-CCP,LDCP,PBS,SINTER

PLANT , etc. are designed considering zero discharge and only process loss in
the form of evaporation and leakages are made up with Makeup water.

C) Water Supply System in IISCO Steel Plant

Water required for process and drinking for IISCO steel plant is drawn from the river
DAMODAR. The estimated requirement of water for ISP when the old plant and the
new 2.5 million tonne unit start full-fledged working is estimated to be 27.5 MGD.
For the withdrawalof water from Damodar we have a contract agreement with DVC.

Listed below are some important points in the contract with DVC.
i.

The existing contract with DVC envisages that up to 12MGD the cost of
drawing water from Damodar is free and an exceeding this amount water
charges are to be paid at Rs one per cum.

ii.

Although from Oct12 DVC has terminated the above contract and demanding
formation of a new contract which will scrape the free water supply and water
charges will rise to Rs 5.7/cum. But since no new agreement has been signed
so far this proposal is under negotiation.
Water required for ISP is drawn by the intake pump house located at River
Damodar.

D) A Brief of existing Intake pump house &Old and New pump house.

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Water Management Department

Water supply system covers up to battery limit and will comprises of the under mentioned
pump houses.
i.

River water intake pump house (RWIPH).

ii.

Raw Water sump and pump house (RWSPH).

1. Intake Pump House:

There are 5 nos. of pumps out of which pump No. 1,2,3& 4 have the capacity
2500 Cu.M. / hr., 22M.Hd., 190 KW. 2 Nos. always run and 2 Nos. in standby
mode. There are 4 delivery lines (24 dia.) 1&2 / 2&3/3&4 are mutually inter
connected. 5th pump capacity 1365 Cu.M./ hr. 105 M. Hd., 540 KW. Dedicatedly
supplies water to Town through 24 line, and it can also supply water to the
works by diversion near Tunnel Gate (New Booster pump house). Deliveryline of
No. 5 pump supplying water to Town Deptt.Have no inter connection.
4 delivery lines are emerging from Intake Pump House. No. 1 line (inter
connection of 1&2), No. 2 line (inter connection No.2&3), No. 3 line (inter
connection No.3&4) are meeting at alum pit from where ultimate one delivery
channel goes to new pump house settle tank NO-1. There are 2 valve chambers
outside the premises of intake pump house just by side of the connecting road
towards new pump house. One valve chamber is for delivery line towards Town
Dept. (No. 5th pump) another valve chamber is for line no. 1,2&3.

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Fig:Settling ponds:
a. Old Pump House:
In alum pit chemical is being added periodically. The Chemical mixed water then
goes to settling tank No. 1 and then water goes through NO-1 to NO-2 and from
NO-2 to NO- 3 after settling, water goes to tank NO-4.
From Settling tank 4 (280000Cu.M.) water is drawn by 2 no. of pumps installed
in new pump house (there are 4 pumps, 2 w + 2 s) these pumps are designated as
pump no. 6,7, 8 & 9. Pump 6 & 7 have the capacity 1800 Cu.M./hr. Hd = 97.6
M., Hp 900/670 KW, RPM 1485. Pump 8 & 9 have the same capacity and head
but HP is 1850/625 KW.
There are four number of delivery lines

12,18,24 & 27 line. These lines

particularly 12, 18 & 24 are supplying the water to Town department and 27
line supplying the water to the reservoir at Burnpur Works. Through 24 line
water can also supply to the reservoir by diversion at Booster pump House near
tunnel gate.
There is a Pressure filter plant to supply the water Riverside colony and park
(Nehru Park) , Pump houses and Pump house colony . The raw water is directly
taken from settle Tank No-4 through 27 Line to the tank. From tank raw water
lifted through the pumps to the clarifiers and from there water goes to the pressure
filters and from pressure filters it is taken to the Overhead Tank by high lift
pumps.
There are 04 No of pumps 02 (1W+1S) for supplying water to clarifier and the
rest two numbers of pumps (1W + 1S) supplying water to the overhead tank.

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Water Management Department

Pump house
b. New Pump House.
Purpose

To draw water from source & send it to new reservoirs.

Pumps

5 Pumps each of capacity 1870 cum per hour (3W+2S)

Alum Dosing

To improve clarity.

Settling Ponds

Water then allowed to flow through 04 settling ponds to provide

enough settling time (semi treated water).

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Pump House

To draw water from settling pond & send to Works Reservoir.

Pipeline

7.5 Km cross country 900mm CMDI Pipe line.

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This illustration depicts the flow of water in the new plant

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E) Break up of Water Requirement for ISP.

Requirement of Industrial water

27.14 MGD including Losses

Requirement of Drinking Water Township and old plant 1350 cum/hr

Requirement of Drinking Water new plant

100 cum/hr

In ISP drinking water is supplied to the old plant and the town ship in the form of filtered
water and industrial water is supplied into the central recirculating system.
In the new plant drinking water and makeup water is supplied from the water treatment
plant and make up water is supplied to the local recirculation systems of the individual
units.

F) Unit Wise Requirement of Make Up Water For ISP.

10%
CCP

16%

5%

4%RHF 2%
2% PCM
18%

TPP-TPS

BLAST
FURNACE

RMHS

15%

BOF

16%

The major requirement of makeup water in steel plant is for the units such as BOF, BF,
RMHS, CCP AND TPP-TPS.

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All other units such as sinter plant(2%), oxygen plant (5 %) etc. require relatively lesser
water quantities of make-up water.

G) Components of Water Management Department.

a. INTAKE PUMP HOUSE
b. RESERVOIR
c. RAW WATER PUMP HOUSE
d. MAKE UP & DRINKING WATER PUMP HOUSE
e. WATER TREATMENT PLANT
f. OVER HEAD TANK
g. LOCAL CIRCULATION NETWORKS

H) Reservoirs:
ISP has 2 nos. of cooling ponds in the OLD plant and two nos. of reservoirs in the new
plant , the capacity of the reservoirs in the new plant is 160000 cum and 120000
cumrespectively. The capacity of the two reservoirs in the old plant is .9 lakh cum and 4.5
lakh cum.

I) Raw Water Pump house

Draws raw water from works Reservoir &sends it to (RWTP) Raw Water Treatment
Plant.
Pumps: 5 nos., each of capacity 1350 M3 / Hrs. & 20 M. Head.
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J) Make Up & Drinking Water pH

Pumps: 4 sets
i.

For pumping MW to OH Tank

ii.

For pumping water to RGF called filter feed pump

iii.

For providing Service Water

iv.

Filter water pump

K) Distribution Network

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L) Shop Wise Requirement Of MW
MW
Unit

Title

Requirement
m3/h (Max)

RMHS 01A

MBE Letter Dtd

24.06.09

RMHS 01B

Hours
working

288

5180

210

5180

115

5180

26

8760

8760

Remark

Schematic
diagram for
service water &
Potable water
system

RMHS 01C

Schematic
diagram for
SW/PW & CW
system

Coke oven

water

battery

consumption
and water
removal data

CDCP

UG network of
water supply &
sewerage Flow
diag

By product

P&ID for

plant

cooling water

Sinter plant

Blow down goes to

120

8760

UF & RO having

system

capacity-32m3/hr

P&ID for

RO-having capacity 7

utilities-Water
system

122

7920

m3/hr, filter softening

plant waste, Blow
down goes to RO

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Water Management Department

Blast Furnace

P&ID Cooling

Blow down, waste

water

from filtration plant

system(1/5)

are stored in
722

8760

backwash pit and

recycled in the
system after
treatment

CDI

Flow diagram
for cooling

8760

water system
Pig Casting

Process Flow

process losss-

Machine

diagram of

55m3/hr, Evp loss-

water

70

2190

circulating

15m3/hr, no water is
drain out

system
HMHS

Flow diagram
of industrial
water for

8760

HMHS
USM

Water mass

Blowdown of ICW

balance for

goes to ACVS, There

ICW & DCW

is no blowdown in
85

6000

DCW, Dewatering
system is also
planned, no water is
drain out

RHF

Design Criteria

Blowdown goes to

of Auxiliaries

RO-having capacity
157

6800

12 m3/hr, Lamella
clarifier is provided to
dewater the waste of
filtration plant

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Water Management Department

WR&BM

Process Flow

Blowdown goes to

Diagram

RO having capacity100

6000

20 m3/hr, Treatment
unit is provided to
dewater the waste of
filtration plant

Air

Process flow

Separation

diagram of

Plant

cooling water

RO Plant having
180

7920

21

8160

capacity of 22m3/hr
for treating blowdown

system
Top pressure

Cooling water

recovery

system control

Turbine

flow chart

Power &

Water Balance

Blowing

diagram

Blowdown goes to
506

8160

Station
LBDS

RO (having capacity
155m3/hr)

Tech Data
sheet of pumps

27

8760

8760

8760

8760

335

8760

for LBDS
GA of pumps
for LCSS
IPPL

Intermittent
requirement for
filling up U
Seal, Flare
Stack, Etc

BOD Plant

Water
requirement

LDO Storage

As Discussed,
no water is
required

Package 11-

Make-up water

14 - CCP

requirement in

IISCO Steel Plant

Blowdowngoes to
SST, hence utilised in
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Water Management Department

area

CCP Area

system

Package 11-

Make-up water

Blowdown goes to

14 - BOF

requirement in

area

BOF Area

375

8760

GCP and Condenser

cooling circuit, hence
utilised in system

Lime &

Schematic

Dolomite

Flow Diagram

plant

for Cooling

10

8760

Tower
Centralised

Integrated

Compressed

P&ID for Water

Air station

supply system

ACVS

MW FOR CCP
Chiller Plant

Blowdown 7.5m3/hr
54

8760

16.2

8760

25

8760

8760

8760

8760

100

8760

25

8760

goes to treatment unit

MW for
ventilation &
AC Consumers
of BOF Shop
proper
Data Sheet of
cooling Tower
MRS

P&ID FOR AC
SYSTEM
P&ID FOR AC
SYSTEM

Drinking
Water
Misc

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M) Further Projects to be Under Taken

a. The effluent to be generated from new units will further to be treated at a common
facility to ensure zero discharge from new units.
b. Similarly schemes are being prepared by Centre for Engineering & Technology of
SAIL for treatment of effluent arising from old plant and township sewage.

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