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Industrial Training At Essar Steel Ltd.

, Hazira, Surat

Submitted in partial fulfillment of the requirements for Bachelor of Engineering (BE) Mechanical


Star Academy of Technology&Management

In front of rewati range, sanwer road, Indore Prepared By:
Ravi Patel Raj Solanki

Department of Training

Duration: -09-07-2013to27-08-2013

(Essar Bulk Terminal Limited) Essar Steel Limited, Hazira, Surat.
Referred By: Guided By:-

Mr. Sandeep Ralhan

Mr.Dilip Surati


Before we get into thick of thing, we would like thankful to some people who helped us a very much during our training session. The cooperation and support that they gave us in the ESSAR STEEL LTD may very valuable and precious for us. There is saying in Latin language- To those who help you. If you can, you have to help them, otherwise tell other people about them. Therefore at least to those who help us, we render many thanks and we should express our sincere appreciation.

Right from the deepest of hearts, we would like to express our great thanks to the Mr. Dilip Surati department of EBTL, Essar Steel Ltd, Hazira, We are also thankful to the Mr. Sandeep Ralhan and who had given permission to take vocational training at ESSAR, Hazira, Surat. We are also thankful to the ELC department of Essar Steel Ltd.


Hazira, a small village in Surat district (about 27km from Surat city) was selected for the location of the plant. The reasons for selecting this location are as follows:

The place being situated at the very confluence of river Tapi and the Arabian Sea, better navigation transport facility is ensured for the handling of inward and outward cargo.


As a part of our course curriculum, the Mechanical students are required to prepare an industry report. The objective behind preparing this report is to relate the management subjects taught in the classroom to their practical application.

The preparation of this industry report is based on facts and finding noted during the port visit and consultation with the concerned officers of the company the scope of the industry report is limited study of Import Export Operation and port activities carried on for import raw materials and export of finish product such as steel from hazira port (Captive part of Essar steel).

Our work in this report is therefore a humble attempt towards this end.

Port operation To know how to work in port operation. To find the reason for the occurrence of detention of the ship.

To solve the instances of detention; thereby saving companys precious money.

Safety and Security

>> The 1st day of training was SAFETY TRAINING so in that trainer gave us brief information about it so we learned-What is safety? -Why it is required in any industry? >> Accordingly to their working criteria to protect from health hazards company provides safety information to its employees, labors, trainees and others persons which are working in a company. >> Company may arise some kind of problems or effects such as Process Risk Heat & Dust Noise Chemical Lifting Operation Fall Hazards Fire Driving Hazards, etc.

Against such problems company has already safety criteria. In future such problems may create then the company has the ability to protect against it. >> Some gear parts to be needed during operation in the field are-Safety shoes -Safety goggles -safety helmet -hand glows, jackets and safety belt

Essar Port Terminal (EPL)

Indias second largest private sector at EPL.
Essar ports provide a port and terminal services for liquid, dry bulk

and general cargo, exist aggregate capacity of 88MMTPA across two facilities located Vadinar and Hazira.


Essar B u l k Terminal Ltd., Hazira is a company under Essar Ports & Terminals business of the Essar Group. EBTL has been operating captive Essar Steel berths under Magdalla Port of Gujarat Maritime Board. In continuation with the shallow draft berths of Essar Steel, EBTL has commissioned its Deep Water berth (550 M long) connected with the high seas of gulf of Khambatt by a Navigation Channel with a turning circle. The permissible draft for the EBTL berth is 14 meters.

EBTL hazira now operating 30 billion tons all weather deep draft bulk terminals for import of iron ore, coke, coal, limestone, dolomite etc.

EBTL provides pilotage and tug services for the vessel and is equipped with mod ern cranes GSU, equipments, for loading /unloading bulk and break bulk cargo. The terminal is fitted with conveyor systems and shore crane for fast evacuation of cargo.

Raw Materials
Major Imports of raw materials at EBTL and they are

Iron ore (pellet)




Port Operation
1. Navigation 2. Cargo Handling 3. Yard Management

Navigation:The passage of ships: transporter bridges to span rivers without hindering navigation

Pilot: - A person, who boards the vessels and navigates it to the port or jetty, as he has knowledge about the waters there. To provide more information about water levels and weather condition at jetty to the captain of the ship in this pilot wrequireired at the jetty.

The ship will come up to the jetty when the depth of the sea nearer to the jetty is greater than the bottom.

Cargo Handling: After ship anchored at the jetty, the unloading from vessel will start.

To determine how much time required unloading cargo from the ship there will using draft method. In new jetty there are three cranes GSU-1, GSU-2 and GSU-3. GSU means GRAB SHIP UNLOADER.GSU has a lifting capacity of 65 t and unloading capacity of 2500 t/her and also conveyor belt capacity 2500 t/hr, this unloaded material being transferred to the yard. Draft: - Vessel Draft refers to the distance between the vessels waterline and the lowest point of the vessel,

usually the keel. The draft will change if the vessel becomes heavier or lighter.

The time delay in unloading process due to such this kind of problems or factors Weather condition Machines are not working GSU, Conveyor System In yard no storage is available for unloading cargo Solution for this delay time in unloading process The weather condition will naturally so we can it not solve it but we find out that for the next day

weather condition from this data we create a timetable for the next day. For machines if they will not work well then in EBTL maintenance staff there to solve it.

Yard Management
Yard management is to manage the material in the storage area. In simple language, how much cargo is coming with ship and for this cargo how much area is available in the yard and how much premises should be required for accumulation is called yard management. Following

formula is used to calculate volume of yard if the known height and diameter.

Conveyor Belt System

The conveyor belt is used to transfer material from port to the yard. In new jetty, there are 4 yards. On conveyor material will be loaded by GSU crane. Direction for two loading material on the conveyor belt is below: Material > Crane Grab > Hopper > Vibrating Feeder > Conveyor Belt Conveyor having a maximum discharging capacity of 2500TPH. Due to the observation of this conveyor we did understand that discharging raw material depends

upon the density of raw material so it is independent of the quantity of raw material therefore the production department must have to know in order to find out how many times s will be remaining for discharging the material due to unloading process. Capacities of conveyor for various materials are o Pellets - 2500 T o Limestone - 1500 T o Coal - 1200 T o Coke 900 T

Conveyor comprising of following parts

Motor: - Its connected with the main power supply

and gear box. This will run pulley of conveyor belt. Gear Box: - Its connected with the motor and adjusts

the speed of conveyor belt.

Coupling: - Its a device used to joint gearbox and

pulley. s Rubber Belt: - Belt will carry material.

Head Pulley: - Which pulley joined at the motor, its

called head pulley.

Carrying Roller: - when the rubber belt carried material for this to provide support roller, its called carrying roller.

Return Roller: - Belt will be returning after discharge the materials. For support it provides a roller called a return roller.

Tail Pulley: - The pulley which opposite side of the head pulley and the end of the conveyor called tail

pulley. With the tail pulley some counter weight will be joined because of tightness the conveyor belt.

Take up Pulley: - This pulley provide nearer head pulley.

Hooter: - Before staring the conveyor belt the hooter will run up to 50 sec. It will indicate that the conveyor will start in few seconds.

Devices of Safety:

Fluid Coupling: - Its a device to joint the motor shaft and gearbox. Its a safety device. When pulley get overloaded at same time the load also increases on motor. In response to this, the temperature becomes increase in fluid coupling.

Duet to which fluid gets heated and its temperature also increase. So at the end, safety valve opens up and fluid come out from the cooling and conveyor system become stop.

Pull Cord Switch: - Pull cord switch also known as Rope Operated Emergency switch is used as a safety switch to stop the conveyor belt in case of an emergency. Pull cord switch is mounted on the walkway side of the conveyor belt, preferably at about every 20-25 meters. When the rope is pulled from any side. The switch get operated. Unless and until the handle is reset to normal position manually cable. Therefore actuation of any one of these Pull Cord Switches will stop the concerned conveyor until the particular switch is manually reset.

Belt Sway Switch: - The switch allows smooth running of the conveyor and protects it from damages by over swaying which can occur due to uneven loading of material.

For normal running of the belt with acceptable swaying, the belt-sway switch is generally mounted on both sides and near the edge of the conveyor belt. Running of the belt with acceptable swaying. When swaying exceeds the normal limit, the belt edge pushes the contact roller, which drives the switch and operates the contacts.

Zero Speed Switch: - The basic principle of speed monitor is a comparison of pulses received from a sensor with standard poles. The unit consists of two parts: CONTROL UNIT and SENSOR PROBE. The sensor is to be installed with its sensing face in close proximity of a rotating object. On this object, flags are to be fixed.

These pulses are fed to the control unit where they are compared with standard pulses to sense the speed.

Emergency Switch: - To stop the conveyor, its providing at nearer to power supply of motor.

Trip Indicator: - Trip indicator and Safety switch with communication card. Signals from all the field safety switches with communication card is given to the trip

indication unit places in the control room. The indication unit changes its o/p signal from NO to NC whenever any fault condition occurs. This signal is further can take for interlocking purpose.

RMHS Department
From this department we have studied that the conveyor is being maintained and operated by RMHS i.e. Raw Material Handling System so it is subject to handle cargo commodities. RMHS has such a system hooked up with their conveyor, which is further (Programmable Logic integrated with their PLC placed on ECR


(Electrical Control Room). PLC then compares the max. Permissible value with system generated value will run the belt and trip conveyor if system generated value is higher than a set value. RMHS has two modes for controlling the running. (1) When the running load goes above 2500TPH then RMHS will stop the conveyor. (2) General is tripping RMHS like belt sway, pull cord, motor over current, etc. will stop running conveyor.

Essar Heavy Engineering

Also we have been spent sometimes in this field of Essar Heavy Engineering. Here following parts are fabricated Pressure Vessel

Heat Exchanger

welding process
1) TIG (tungsten inert gas welding)

2) MIG (metal arc gas welding)

3) SAW (shielded arc welding)

From welding process we understood differences between them. Such main difference is that ARC welding produces pollution to its surrounding and GAS welding.

Diagram of Conveyor belt in EBTL

For Iron Ore / Lime Stone

PATH 1:-


CC 13

NC 10


CC 11

OF 1.04


PATH 2 :-