CHAPTER -3 ORGANISATION REVIEW

3.1 Introduction about Organisation Visakhapatnam Steel Plant (VSP) has a capacity of 3 Million Tones per annum of Liquid Steel and 2.656 Million tones of saleable steel. At VSP there is emphasis of total automation, seamless integration and efficient upgradation, which result in wide range of long and structural products to meet stringent demands of customers within India and abroad. VSP products meet exalting International Quality Standards. VSP has become the first integrated Steel Plant in the country to be certified to all the three international standards, for Quality (ISO-9001), for Environment Management (ISO-14001) & for Occupational Health & Safety (OHSAS-18001). VSP has a total manpower of about 16,613, has envisaged a labour productivity of 265 Tones per man year of Liquid Steel which is the best in the country and comparable with international levels. Major Departments in VSP 1. Raw Material Handling Plant (RMHP) 2. Coke Ovens & Coal Chemical Plant (Co&CCP) 3. Sinter Plant (SP) 4. Blast Furnaces (BF) 5. Steel Melting Shop (SMS) 6. Continuous Casting Department (CCCD) 7. Rolling Mills a) Light & Medium Merchant Mill (LMMM) b) Wire Rod Mill (WRM)

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c) Medium Merchant & Structural Mill (MMSM) 8. Auxiliary Facilities a) Power Generation & Distribution b) Water Management (WMD) c) Traffic Department d) Engineering Shops & Foundry (ES&F) e) Utilities Department f) Quality Assurance and Technology Development (QA&TD) g) Calcining & Refractory Material Plant (CRMP) h) Roll Shop & Repair Shop (RS & RS) i) Field Machinery Department (FMD) j) Power Engineering Maintenance (PEM) k) Plant Design (PD) l) Instrumentation Department m) Electrical Repair Shop (ERS) n) Electro Technical Laboratory (ETL) o) Central Maintenance Mechanical (CMM) p) Central Maintenance Electrical (CME) q) Steel Township The present work is carried out in Central Machine Shop which belongs to Engineering Shops and Foundry. 3.2 Engineering Shops & Foundry (ES&F). Engineering Shops are set up to meet the requirements of Ferrous & Non Ferrous spares of different departments. This complex is divided into the following shops  Forge Shop  Structural Shop  Foundry  Central Machine Shop (CMS)

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 Wood Working Shop  Utility Equipment Repair Shop (UERS) These Shops are meant to cater the repair/reconditioning of plant and equipment and manufacture of spares required for Visakhapatnam Steel Plant. The shop is supported by well established Central Laboratory for Quality Assurance. The Forge Shop is designed for the production of shafts, coupling flanges etc. and also of forge shapes such as crusher hammer heads, special bolts, nuts etc. In the Structural Shops, the fabricated structural of about 4500 tones are produced annually and the input consisting of sheets, plates, channels, angles beam etc. In the Foundry, 2600 tones of iron castings and 200 tones of non-ferrous castings are produced annually. The Wood Working Shop manufactures patterns for foundries. The shop requires 300 cu.m of wooden patterns per year. In the Utility Equipment Repair Shop, the repair of air conditioning and water supply equipment and ventilation equipment is carried out. 3.2.1 Central Machine Shop (CMS) CMS is a maintenance job shop and designed to carry out the following manufacturing/service jobs  Machining of castings, forging, and rolling sections.  Heat treatment and reconditioning of parts.  Tool-room work including manufacturing and repair of jigs and fixtures, regrinding and sharpening of cutting tools.  Dismantling, repair and assembly of worn out machinery and equipment.
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The shop has four longitudinal bays and one cross bay. Heavy and Medium duty machines are located in the first two bays. The third bay has the Light machines, the machines for material preparation and Tool room. The forth bay houses Heat Treatment and Thermal Surfacing Sections. The fifth bay, the Cross bay connecting other four bays is the fitting and assembly bay and the bay also houses some of the Heavy Machine Tools. Each bay is provided with 3 EOT Cranes of adequate capacity. In the CMS, various spares are made. The machining section has over 100 major machine tools including lathes, milling, boring, planning, slotting, shaping, grinding and other machines.

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CENTRAL MACHINE SHOP LAYOUT

A
HEAVY AND MEDIUM DUTY M/C’S

M

N

hh

VGVGDAAAAAAAAAAAAAAAAAA B
LONGITUDINAL BAYS  AB BAY- Heavy and Medium Duty machines
HEAVY AND MEDIUM DUTY M/C’S

BBBB BSDSADSAXC B
FITTING & ASSEMBLY

 BC BAY- Heavy and Medium Duty machines  CD BAY- Light Duty machines

MATERIAL PREPARA TION

 DE BAY- Fitting and Assembly CROSS BAY

C

TOOL ROOM

 MN BAY- Fitting and Assembly
HEAT TREATMENT

LIGHT DUTY M/C’S OFFICE

D
FITTING & ASSEMBLY

E

LONGITUDINAL BAYS AB BAY- Heavy and Medium Duty machines BC BAY- Heavy and Medium Duty machines CD BAY- Light Duty machines DE BAY- Fitting and Assembly CROSS BAY MN BAY- Fitting and Assembly

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