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AN OVER VIEW OF VSP

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TRAINING & DEVELOPMENT CENTRE
 , & -
VISION
To be a continuously growing world - class company
We Shall

VSP is our plant - and we work for customer's satisfaction.

"VSP' believes in the best and endeavours to give the best"
« Harness our growth potential and sustain profitable
growth.

"VSP's determination is delete defects in the process"

« Deliver high quality and cost competitive products and

VSP is our Plant - It gave us a status in the society.

be the first choice of customers.

"VSP's enemy is wastage and we fight against it.

VSP is our Plant - Where innovation never ends

« Create an inspiring work environment to unleash the cre-

VSP is our Plant - We think about it's growth.

ative energy of people.

VSP is our Plant - Develop it continuously

VSP is our Plant - We are committed to it.
« Achieve excellence in enterprise management.

VSP is our plant - We sustain it's growth.

"VSP' is our Plant - It stands for Quality

VSP is our plant - keep it clean always.

VSP is our plant - Maintain it properly

« Be a respected corporate citizen, ensure clean and green
environment and develop vibrant communities arounds

VSP is our Plant - Operate it safely

us.
MISSION
To attain 10 millon ton liquid steel capacity through tech-
nological up-gradation, operational efficiency and expan-

Work safely - live happily

sion, to produce steel at international standards of cost
and quality. and to meet the aspirations of the stakehold-
ers.
CORE VALUES
« Committment
« Customer Satisfaction
« Continuous Improvement
« Concern for Environment
« Creativity & Innovation

10.
11.
12.
13.
14.
15.
VSP BELIVES IN THE BEST AND ENDEAVOURS TO GIVE THE BEST

1.
2.
3.
4.
5.
6.
7.
8.
9.
 PLANT
CHEMICAL
COAL
COKE OVENS
1.0 AN OVERVIEW OF VSP

Visakhapatnam Steel Plant, the first coastal based Steel

LAYOUT OF VISAKHAPATNAM STEEL PLANT

Plant of India is located, 16 KM South West of city of Destiny i.e.

TPP
Visakhapatnam. Bestowed with modern technologies, VSP has

SP

CRMP
a installed capacity of 3 Million Tonnes per annum of Liquid Steel

RMHP
RED
Trafic
RMD
and 2.656 Million tonnes of saleable steel. At VSP there is em-

AC & VS
Utlities
MAIN ROAD OR PLANT PLAZA ROAD
phasis on total automation, seamless integration and efficient

PEM

BF
PD
SSD
upgradation, which result in wide range of long and structural

BC Gate
BC ROAD products to meet stringent demands of discerning customers

WMD
SMS

EMD
within India and abroad. VSP products meet exalting Interna-

MILL AROS
tional Quality Standards such as JIS, DIN, BIS, BS etc.

ETL
VSP has become the first integrated Steel Plant in the

EnMD
QATD
WKS CONTS CME
ERS
country to be certified to all the three international standards for

MMSM
11-DNW

Rs
Rs
&
DNW

Tele
quality (ISO-9001), for Environment Management (ISO-14001)

Inst

WRM
FMD

LMMM
LMMM
& for Occupational Health & Safety (OHSAS-18001) The

(W)
ED certificate covers quality systems of all operational, maintenance,

MMSM
MMSM
E.S & F

SYSTEMS service units besides Purchase systems, Training and Market-

TS
SED

SPC

ing functions spreading over 4 Regional Marketing Offices, 20

branch offices and 22 stock yards located all over the country.
CMM

H&L
CED

MAIN GATE
VSP by successfully installing & operating efficiently Rs.
CISF Pass Section
460 crores worth of Pollution Control and Environment Control
MAIN GATE

Equipments and converting the barren landscape by planting

PP GATE

OR
SBI

Project Office
more than 3 million plants has made the Steel Plant, Steel Town-
ship and surrounding areas into a heaven of lush greenery. This
has made Steel Township a greener, cleaner and cooler place,
Building

which can boast of 3 to 40 C lesser temperature even in the peak

Admm

BUS STOP

summer compared to Visakhapatnam City.

&
D
C
T

VSP exports Quality Pig Iron & Steel products to Sri

Lanka, Myanmar, Nepal, Middle East, USA & South east Asia
(Pig iron). RINL-VSP was awarded "Star Trading House" status
32 1
during 1997-2000. Having established a fairly dependable ex- STATISTICAL INFORMATION
port market, VSP plans to make a continuous presence in the
I. Production Performance ('000 Tonnes)
export market.
Having a total manpower of about 16,613 VSP has en- Year Hot Metal Liquid Steel Saleable Steel Labour
Productivity
visaged a labour productivity of 265 Tonnes per man year of Liq-
1998-99 2,510 2,225 21,932 161
uid Steel which is the best in the country and comparable with
1999-00 2,943 2,656 2,382 192
the international levels. 2000-01 3,165 2,909 2,507 211
2.0 BACK GROUND 2001-02 3,485 3,083 2,757 228
2002-03 3,941 3,356 3,056 253
With a view to give impetus to Industrial growth and to
2003-04 4,055 3,508 3,169 262
meet the inspirations of the people from South India, Govern-
2004-05 3,920 3,560 3,173 265
ment of India decided to establish Integrated Steel Plants in Public
Sector at Visakhapatnam (AP) and Hospet (Karnataka) besides II. Commercial Performance (Rs. Crs.)
a special Steel Plant at Salem (Tamil Nadu). The announce-
ment was made in the Parliament on 17th April' 1970 by the then Year Sales Domestic Exports
Turnover Sales
Prime Minister of India late Smt. Indira Gandhi.
1999-00 3,037 2,677 295
A site was selected near Balacheruvu creak near 2000-01 3,436 3,122 322
Visakhapatnam city by a Committee set up for the purpose, keep- 2001-02 4,081 3,710 371
ing in view the tropographical features, greater availability of land 2002-03 5,059 4,433 626
and proximity to a future port. The foundation stone for the plant 2003-04 6,174 5,406 768
was laid by Smt. Gandhi on 20.01.1971. 2004-05 8181 7932 249

Seeds were thus sown for the construction of a modern III. Financial Performance (Rs. Crs.)
& sophisticated Steel Plant having annual capacity of 3.4 Million Year Gross Margin Cash Profit Net Profit
Tonnes of hotmetal. An agreement was signed between Gov- 1998-99 15 (-) 346
ernments of India and the erstwhile USSR on June 12th, 1979 1999-00 252 (-) 130 (-) 562
for setting up of an Integrated Steel Plant to produce structural & 2000-01 504 153 (-) 291
long products on the basis of detailed Project report prepared by 2001-02 690 400 (-) 75
Dr. M.N. Dustur & Company. A Comprehensive revised DPR 2002-03 1,049 915 521
jointly revised by Soviets & Dr. Dastur & Company was submit- 2003-04 2,073 2,024 1,547
ted in Nov' 1980 to Govt. Of India. 2004-05 3,266 3,093 2,008
2 31
% ISTD Award for "Best HR Practices" - 2002
% Prime Ministers Trophy for "Best Integrated Steel
Plant-2002-03
% "World Quality Commitment International Star Award"
in the Gold category conferred by Business Initiative
Directions, Paris
% "Organizational Excellence Award" for 2003-04 conferred
by INSSAN
% National Energy Conservation Award, 2004 and Special
Prize from Ministry of Power, Govt. of India.
The above awards are besides a number of awards at
the local, regional & national level competitions in the area of
Quality Circles, Suggestion Schemes etc.
6.0 Hallmark of Vizag Steel as on organization
Today, VSP is moving forward with an aura of confidence
and with pride amongst its employees who are determined to
give their best for the company to enable it to reach new heights
in organizational excellence.
Futuristic enterprises, academic activity, planned &
progressive residential localities are but few of the plentiful ripple
effects of this transformation and each one of us take immense
pride to uphold the philosophy of mutual (i.e., individual and
societal) Progress.
30
The construction of the Plant started on 1st February
1982. Government of India on 18th Feb'82 formed a new Com-
pany called Rashtriya lspat Nigam Ltd. (RINL) and transferred
the responsibility of constructing, commissioning & operating the
Plant at Visakhapatnam from Steel Authority of India Ltd. to RINL.
Due to poor resource availability, the construction could
not keep pace with the plans which lead to appreciable revision
of the plant cost. In view of the critical fund situation and need to
check further increase in the plant costs, a rationalized concept
was approved which was to cost Rs. 6849 crores based on 4th
Quarter of 1988.
The rationalized concept was based on obtaining the
maximum output from the equipments already installed, planned
/ ordered for procurement and achieving higher levels of opera-
tional efficiency and labour productivity. Thus the plant capacity
was limited to 3.0 Million tonnes of Liquid Steel per annum. In
the process one of the Steel Melt Shops and one of the mills
were curtailed.
The availability of resources were continued to be lower
than what was planned and this further delayed the completion
of the construction of the plant. Finally all the units were con-
structed and commissioned by July' 92 at a cost of Rs. 8529
crores. The plant was dedicated to nation by the then prime
Minister of India Late Sri P.V. Narasimha Rao.
Since Commissioning VSP has already crossed many
mile stones in the fields of production, productivity & exports.
Coke rate of the order of 509 Kg/Ton of Hot metal, average con-
vertor life of 2864 heats an average of 23.6 heats per sequence
in continuous Bloom Caster. Specific energy consumption of 6.07
G Kal/ton of liquid steel, a specific refractory consumption of 8.94
3
kg and a labour productivity of 265 Ton/man year are some of the
peaks achieved (during the year 2004-05) in pursuit of excellence.
2.1 VSP Technology : State-of-the-Art
@ 7 meter tall Coke Oven Batteries with coke dry quenching
@ Biggest Blast Furnaces in the Country
@ Bell-less top charging system in Blast Furnace
Some of the important awards received by VSP are :
% ISO 9002 for SMS and all the downstream units - a
unique distinction in the Indian Steel Industry.
% Indira Priyadarshini Vriksha Mitra Award - 1992-93
% Nehru Memorial National Award for Pollution Control -
1992-93 & 1993-94

@ 100% slag granulation at the BF Cast House % EEPC Export Excellence Award - 1994-95

@ Supressed combustion-LD gas recovery system % Cll (Southern Region) Energy Conservation Award- 1995-96

@ 100% continuous casting of liquid steel. % Golden Peacock (1st Prize) "National Quality Award-96"
IIM in the National Quality Competition - 1996
@ "Tempcore" and "Stelmor" cooling process inLMMM & WRM
respectively % Steel Ministers' Trophy for "Best Safety Performance" - 1996

@ Extensive waste heat recovery systems % Selectedfor"WorldQualityCommitmentAward-1997"ofJ*Ban,Spain

@ Comprehensive pollution control measures % Gold Star Award for Excellent Performance in Productivity

2.2 Major Sources of Raw Materials % Udyog Excellence Gold Medal Award for Excellence in Steel Industry.
% Excellence Award for outstanding performance in
Raw Material Source
Productivity Management, Quality & Innovation.
Iron Ore Lumps & Fines Bailadilla, MP
% Ispat Suraksha Puraskar (1st Prize) for longest Accident
BF Lime Stone Jaggayyapeta, AP Free Period 1991-94
SMS Lime Stone UAE % Best Labour Management Award from the Govt. of AP
BF Dolomite Madharam, AP % SCOPE Award for Best Turnaround - 2001
SMS Dolomite Madharam, AP % Environment Excellence Award from Greentech
Manganese Ore Chipurupalli, AP Foundation for Energy conservation - 2002
Boiler Coal Talcher, Orissa % Best Enterprise Award from SCOPE, WIPS - 2001-02
Coking Coal Australia % Best Enterprise Award from SCOPE for surpassing MOU
Medium Coking Coal (MCC) Gidi/Swang/Rajarappa/Kargali targets-2003-04

4 29
 conveyor belt is collected and sent to Central Stores for 2.3 Water Supply
further disposal. This is helping in earning the revenue Operational water requirement of 36 mgd is being met
through auctioning of the scrap belt sent to stores. from the yeleru Water supply Scheme.
4.16 Central Maintenance Electrical (CME) Dept 2.4 Power Supply
The Function of CME Operation power requirement of 180 to 200 MW is be-
1. Repairs and Maintenance of all the Large Rotating ing met through Capitve Power Plant. The capacity of the power
Electrical machines of the Plant. The job includes plant is 286.5 MW. VSP is exporting 60 MW power to APSEB.
transportation, Overhauling, Re-erection including 2.5 Major Units
precision alignment.
Department Annual Units (3.0 MT Stage)
Capacity
2. Maintenance of electric of all the illumination throughout
('000 T)
the Plant, which includes street lights, tower lights,
Coke Ovens 2,261 3 Batteries of 67 Ovens & 7 Mtrs. Height
security bondy light. Sinter Plant 5,256 2 Sinter Machines of 312 Sq. Mtr. grate area each
Blast Furnace 3,400 2 Furnaces of 3200 Cu. Mtr. volume each
3. Training of Shop Maintenance Crews in the Basics of
Steel Melt Shop 3,000 3 LD Convertors each of 133 Cu. Mtr.
Motor Maintenance and precision alignment.
Volume and Six 4 strand bloom casters
4.17 Steel Township Lmmm 710 4 Strand finishing Mill
WRM 850 2 x 10 strand finishing Mill
The Steel Plant can take pride in having a clean green MMSM 850 6 strand finishing Mill
well planned township with provision of about 8000 quarters, mar-
2.6 Main Products of VSP
kets, community welfare centres, clubs,. Parks etc. for its em-
ployees & their families besides having a modern hospital with 155 beds. Steel Products By-Products
Angles Nut Coke Granulated Slag
5.0 Achivements & Awards Billets Coke Dust Lime Fines
The efforts of VSP have been recognized at various Channels Coal Tar Ammonium Sulphate
Beams Anthracene Oil
forums. Some of the major awards received by VSP are in the Squares HP Napthalence
area of energy conservation, environment protection, safety, Flats Benzene
quality, Circles, Rajbhasha, MOU, sports and a number of awards Rounds Toulene
Re-bars Zylene
at the individual level.
Wire Rods Wash Oil
28 5
3.0 MAJOR DEPARTMENTS
3.1 Raw Material Handling Plant (RMHP)
VSP annually requires quality raw materials viz. Iron Ore,
fluxes (Lime stone, Dolomite), coking and non coking coals etc.
to the tune of 12-13 Million tonnes for producing 3 Million Tonnes
of Liquid Steel. To handle such a large volume of incoming raw
materials received from different sources and to ensure timely
supply of consistent quality of feed materials to different VSP
consumers, Raw Material Handling Plant serves a vital function.
This unit is provided with elaborate unloading, blending, stack-
ing & reclaiming facilities viz. Wagon Tipplers, Ground & Track
Hoppers, Stock yards Crushing plants, Vibrating screens, Single/
twin boom stickers, wheel on boom and Blender reclaimers.
In VSP peripheral unloading has been adopted for the
first time in the country.
3.2 Coke ovens & Coal Chemical Plant (Co&CCP)
Blast Furnaces, the mother units of any Steel plant re-
quire huge quantities of strong, hard and porous solid fuel in the
form of hard metallurgical coke for supplying necessary heat for
carrying out the reduction and refining reactions besides acting
as a reducing agent.
Coke is manufactured by heating of crushed coking coal
(below 3 mm) in absence of air at temperature of 10000 C and
above for about 16 to 18 hours. A Coke Oven comprise of two
hollow chambers namely coal chamber and Heating Chamber.
In the heating chamber a gaseous fuel such as Blast Furnace
Gas, Coke Oven Gas etc. is burnt. The heat so generated is
conducted through the common wall to heat & carbonize the
Coking Coal placed in the adjacent coal chamber.
Number of ovens built in series one after the other form
a Coke Oven Battery.
6 27
quantity etc., are recorded. As all works are carried out
through work order system, accuracy of data is ensured
which enables in reducing the shut down periods.
4. The activies of CMM are broadly divided into Planned &
Unplanned maintenance and Capital Repairs.
Planned & Unplanned activities :
" Planned activities are taken up by planning on
regular & periodical interactions with respective
customer departments.
" Unplanned/breakdowns are attended immediately
and given top priority over planned jobs to restore
the equipent back to normalcy so as to reduce the
production loss.
CAPITAL REPAIRS (CR) :
" CMM plays an important role in planning &
coordination of CR activities in the plant.
" Pre-CR activities are given top priority to reduce total
shut down periods.
" Daily feed back and summary of all CR activities
carried out by CMM are recorded. This system
helped in Improving our shut down period.
5. CMM department is playing major role in improving life
of conveyor belts by adopting innovative technological
advancements across the globe.
6. In addition to maintenance activities, as part of Concern
towards Environment, solid waste in the form of scrap
4.15 Central Maintenance Mechanical
1. Central Maintenance Mechnical (CMM) department is
one of the major service departments in VSP which is
carrying out major mechanical maintenance and
conveyor belt replacement activities throughout the plant.
2. In order to Improve response time CMM activities are
carried out through five zonal offices. They are.
" Coke Zone : Supports the needs of C & CCD and
RMHP and the maintenance activities of conveyors
through out the plant.
" Iron Zone : Supports Sinter Plant, Blast Furnace &
CRMP in their maintenance activities.
" Steel Zone : Supports SMS & ASP in the maintenance
activities and looks after the maintenance of EOT
cranes in Central Stores & Gantry cranes of ES & F.
" Mills Zone : Supports LMMM, WRM & MMSM in their
maintenance activities.
" Workshop : Looks after maintenance of all
weighbridges and supports in fabrication works of
departments like CISF, Finance, Personnel etc.,
3. CMM is the first maintenance section in VSP, which is
implementing one of the best ten practices i.e., "Work
Flow and Control Management" as a part of QMS. In
this system internal work order is issued to the respective
zone and feedback is received at Central Office after
work is completed. In the feedback, duration, manpower
and identification of conveyor belt, supplier name &
26
At VSP there are three Coke Oven Batteries, 7 Metre
tall and having 67 Ovens each. Each oven is having a volume of
41.6 cu. metre & can hold upto 31.6 Tonnes of dry coal charge.
The Carbonization takes place at 1000 - 10500 C in absence of
air for 16-18 hours.
Red Hot Coke is pushed out of the oven and sent to
Coke Dry Cooling Plants for cooling to avoid its combustion. There
are 3 Coke Dry Cooling Plants (CDCP) each having 4 cooling
chambers. The capacity of each cooling chamber is 50-52 TPH.
Nitrogen gas is used as the Cooling medium. The heat recovery
from nitrogen is done by generating steam and expanding in two
back pressure turbines to produce 7.5 power each.
The Coal chemicals such as Benzole (& its products),
Tar (& its products), Ammonium Sulphate etc. are extracted in
Coal Chemical Plant from C.O. Gas. After recovering the Coal
chemicals the gas is used as a by product fuel by mixing it with
gases such as BF Gas, LD Gas etc. A mechanical, biological &
Chemical treatment plant takes care of the effluents.
3.3 Sinter Plant (SP)
Sinter is a hard & porous ferrous material obtained by
agglomeration of Iron Ore fines, Coke breeze, Lime Stone fines,
Metallurgical wastes viz. Flue dust, mill scale, LD slag etc.
Sinter is a better feed material to Blast Furnace in com-
parison to Iron Ore lumps and its usage in Blast furnaces help in
increasing productivity, decreasing the coke rate & improving the
quality of Hot Metal produced.
Sintering is done in 2 nos. Of 312 Sq. Metre, Sinter Ma-
chines of Dwight Lloyd type by heating the prepared feed on a
continuous metallic belt made of pallets at 1200-13000 C.
7
 Hot Sinter discharged from Sintering machine is crushed to +5
mm - 50 mm size and cooled before despatching to Blast Furnaces.
Parameters of Sintering Machines are
_ Effective area : 312 Sq. metre
_ Sintering area : 276 Sq. metre
_ Sinter bed height : 300 mm
_ Capacity : 450 T P H each
_ No. Of wind boxes : 26
The dust laden air from the machines are cleaned in
scrubbers & electrostatic precipitators to reduce the dust con-
tent to 100 mg/ m3 level before allowing to escape into the atmo-
sphere and thus helping in maintaining a clean & dust free environment.
3.4 Blast Furnaces (BF)
Hot Metal is produced in Blast Furnaces, which are tall
vertical furnaces. The furnace is named as Blast Furnace as it is
run with blast at high pressure & temperature. Raw Materials
such as sinter/ Iron Ore Lumps, Fluxes (Limestone/Dolomite)
and Coke are charged from the top and hot blast at 11000 C
13000C- and 5.75 KSCG pressure is blown almost from the bot-
tom. The furnaces are designed for 80% Sinter in the burden.
VSP has two 3200 cu. metre Blast Furnaces (largest in
India) equipped with Paulworth Bell less top equipment with con-
veyor charging. Rightly named as "Godavari" & "Krishna" after
the two rivers of AP, the furnaces will help VSP in bringing pros-
perity to the state of Andhra Pradesh.
Provision exists for granulation of 100% liquid slag at
blast furnace cast house and utilization of blast furnace gas top
pressure (1.5-2.0 atmospheric pressure) to generate 12 MW of
8 25
4.13 Electrical Repair Shop (ERS)
Electrical repair shop is provided for medium & capital
repair of different types of LT & HT AC motors, DC
motors, lifting magnets, transformers coils etc. ERS also
carries out repair of large electrical eqpt at site. The Shop
has dismantling & assembling section, winding section,
varnishing section, testing section etc.
4.14.0 Electro Technical Laboratory (ETL)
In view of the high degree of sophistication and
automation used in VSP, a specialized groups for
supporting electronics in drives and PLCs necessitated.
Electro Technical Laboratory(ETL) precisely does the
above function. ETL supports electrical groups of different
production shops for maintaining 100% availability of the
Electronics pertaining to drives and PLCs.
There are approximately 1200 Thyristor Controlled Drives in VSP
including
% Crane Controls
% AC/DC motor controls
% Uninterruptible power supplies
% Computer Numerically Controlled Machines in different shops
There are approximately 300 programmable Controllers
Controlling various drives, Process Parameters and other related
equipments of the plant.
ETL comprises of field services, central laboratory services and planning.
20) Furnace temperature measurement and control : All three
mills have micro processor based controllers of Toshiba,
Japan Make. LMMM and WRM are also provided with
microprocessor based recorders whille MMSM is
provided with date acquisition system. LMMM protection/
starting interlocks are incorporated in PLCs supplied by
M/s SPA computers.
21) Boilers: For safe operation of 5 boilers, instrumentation
system supplied by M/s BHEL has been installed and is
in operation. The important systems consists of Furnace
Safeguard supervisory System & electro hydraulic
turbine control system.
22) A number of Pump Houses are in operation in various
zones of the Plant for providing make up water, cooling
water for fire fighting, chiller water pump houses etc. In
all the pump houses, instrumentation has been provided
for the measurement of flow, pressure, sump level,
bearing temperature monitoring of motors etc.
23. A most modern instrumentation lab with the state of the
art calibrators have been set up for repair and calibration
of ISO instruments. The master standard instruments
are being regularly calibrated at the national; standard
laboratories to ensure their accuracy. This lab facilities
are also utilised for repair of all types of instruments used
in various zones of the plant.
24
power in each furnace by employing gas expansion turbines.
The two furnaces with their novel circular cast house and
four tap holes each are capable of producing 9720 tonnes of Hot Metal
daily or 3.4 Million Tonnes of low sulphur Hot Metal annually.
3.5.1 Steel Melting Shop (SMS)
Steel is an alloy of Iron with carbon upto 1.8%. Hot Metal
produced in Blast Furnaces contains impurities such as Carbon
(3.5-4.25%) Silicon (0.4 - 0.5%), Manganese (0.3-0.4%), Sul-
phur (0.04% max) and Phosphorous (0.14% max) is not suitable
as a common Engineering Material. To improve the quality the
impurities are to be eliminated or decreased by oxidation process.
VSP produces steel employing three numbers of top
blown Oxygen Convertors called LD Convertors (L & D stand for
Linz & Donawitz - two towns in Austria where this process was
first adopted) or Basic Oxygen Furnaces/Convertors. Each con-
vertor is having 133 cu. Metre volume capable of producing 3
Million Tonnes of Liquid Steel annually. Besides Hot Metal, Steel
Scrap, Fluxes such as calcined lime or Dolomite form part of the
charge to the Convertors.
99.5 % pure Oxygen at 15-16 KSCG pressure is blown
in the Convertor through oxygen lance having convergent Diver-
gent copper nozzles at the blowing end. Oxygen oxidises the
impurities present in the Hot metal, which are fixed as slag with
basic fluxes such as lime. During the process heat is generated
by exothermic reactions of oxidation of metalloids viz Si, Mn., P
and Carbon and temperature rises to 17000 C enabling refining
& slag formation.
9
 Different grades of steel of Superior quality can be made 11) Measurement of temperature at sinter machine hearth
by this process by controlling the Oxygen blow or addition of with ‘S’ type thermocouple.
various ferro alloys or special additives such as Fesi, FeMn, Si-
12) Measurement of pressure and temperature of wind
Mn, Coke Breeze, Aluminum etc. in required quantities while liq-
boxes.
uid steel is being tapped from the convertor into a steel ladle.
13) Measurement at burden handling system: Each BHS has
Convertor/LD Gas produced as by product is used as a
17 nos. of bins - 8 nos. of ore and siner, 6 nos. of coke
secondary fuel.
and 3 nos. for additives.
Characteristics of VSP Convertors :
14) In BHS of BF, SILOPILOT, level measuring system is
Capacity - 150 Tones per heat/blow
provided in the bins.
Volume - 133 Cu. Metre
15) Measurement of Weights of Hopers.
Convertor Sp. Volume - 0.886 Metre Cube per tonne
16) The burden level in the furnance is measured at regular
Tap to Tap Time - 45 mts - 60 mts
interval by means of Selsyn operated stock rod. Top
Height to Diameter ratio - 1.36
pressure is measured and controlled by means of control
Lining i) Working - Tar Dolomite Bricks valves at throttle group of value at GCP.
ii) Permanent - Crome Magnesite Bricks 17) For converter instrumentation, DCS system supplied by
Av. Lining Life - 2445 heats (2004) M/s George Kent, UK has been installed for monitoring
Liquid Steel produced in LD Convertors is solidified in and control of process parameters such as flow,
the form of blooms in continuous Bloom Casters. However, to temperature, pressure, gas analysis.
homogenise the steel and to raise its temperature, if needed,
18) Specialised gas analysers such as H2, O2, CO & CO2
steel is first routed through, Argon rinsing station, IRUT (Injec-
have been provided for analysis and safe operation of
tion Refining & Up temperature) / Ladle Furnaces.
gas recovery plant.
3.5.2 Continuous casting Department (CCD)
19) Measurement of liquid steel temperature : For measuring
Continuous casting may be defined as teaming of liquid
the temperature of liquid steel throw away type
steel in a mould with a false bottom through which partially
solidified ingot/bar (Similar to the shape & cross section of the thermocouples are being used.
mould) is continuously withdrawn at the same rate at which liq-
uid steel is teamed in the mould.
10 23
% Need based standardization, using the above data base.
4) Approval of drawings supplied by Various Suppliers.
5) Engineering Assitance to all Departments.
4. 12. Instrumentation Department
Instrumentation helps us in monitoring and controlling
the process so that product quality is improved, yeild is
maximised, energy consumption is optimal and safety of the plant
is ensured. The important instrumentation system installed in
various zones of VSP are breifly given below:
1) In motion weighing of Raw Materials received.
2) Belt scales provided on conveyors.
3) Level measurements in Bins & Bunkers.
4) Temperature monitoring and Flow Monitoring of Ore &
Coal crushing plants.
5) Blending of coal in mixing bins for attaining derived ash
content through desimeter(weigh batchers).
6) Parameters measured & controlled at CO Battery.
7) Suction and temperature measurement at exhausters:
8) Temperature, pressure and analysis of circulating gases
in coke dry cooling plant:
9) Pressure, temperature, flow, level and other parameters
in the coal chemical plant.
10) Proportionating of materials at RMB for base mix
preperation through weigh batchers and controlled by
varying the speed of the disc feeders and vibro feeders.
22
Facilities at a continuous casting machine include a lift
and Turn table for ladles, Copper mould, oscillating system
tundish, Primary & Secondary Cooling arrangement to cool the
steel bloom. Gas cutting machines for cutting the blooms in re-
quired lengths (Av. 6 metres long)
At VSP we have six-4 strand continuous casting ma-
chines capable of producing 2.82 Million Tonnes/year Blooms of
size 250 x 250 mm and 250 x 320 mm. Entire quantity of molten
steel produced (100%) is continuously cast in radial bloom cast-
ers which help in energy conservation as well as production of
superior quality products.
3.6 Rolling Mills
Blooms produced in SMS-CCD do not find much appli-
cations as such and are required to be shaped into products
such as Billets, rounds, squares, angles (equal & unequal), Chan-
nels, I-PE Beams, HE Beams, Wire rods and reinforcements bars
by rolling them in, three sophisticated high capacity, high speed,
fully automated rolling mills, namely Light & Medium Merchant
Mills (LMMM), Wire Rod Mill (WRM) and Medium Merchant and
Structural Mill (MMSM).
3.6.1 Light & Medium Merchant Mill (LMMM)
LMMM comprises of two units. In the Billet/Break down
mill 250 x 320 mm size blooms are rolled into Billets of 125 x 125
mm size after heating them in two nos. of Walking beam Fur-
naces of 200 Tons/hr capacity each. This unit comprises of 7
stands (2 horizontal 850 x 1200 mm) and 5 alternating vertical &
horizontal stands (730 x 1000 mm & 630 x 1000 mm) Billets are
supplied from this mill to Bar Mill of LMMM & Wire Rod Mill.
The billets for rolling in bar mill of LMMM are first heated
in 2 strand roller hearth furnace of 200 T/h capacity to tempera-
11
ture of 11500 C-12000 C. The bar mill comprises of 26 stands - 8
stand double stand roughing train, 2 nos. of 5 stands, double
strand Intermedial train & two nos 4 stand single strand finishing trains.
The mill is facilitated with temp core heat treatment tech-
nology evaporative cooling system in walking beam furnaces,
automated pilling & bundling facilities, high degree of automa-
tion and computerization.
The mill is designed to produce 710,000 tons per an-
num of various finished products such as rounds, rebars, squares,
flats, angles, channels besides billets for sale.
3.6.2 Wire Rod Mill (WRM)
Wire Rod Mill is a 4 strand, 25 stands fully automated &
sophisticated mill. The mill has a four zone combination type
reheating furnace (walking beam cum walking hearth) of 200TPH
capacity for heating the billets received from billet mill of LMMM
to rolling temperature of 1200 0C.
The heated billets are rolled in 4 strand. No twist con-
tinuous mill having a capacity of 8,50,000 tonnes of Wire Rod
coils and having the following configuration.
- 7 stand two high 4 strand horizontal roughing train.
- 6 stand two high 4 strand horizontal Intermediate Mills.
- 2 stand 4 strand pre finishing Mill.
- 10 stand 4, strand. No twist finishing mill.
The mill produces rounds in 5.5 - 12 mm range and rebars
in 8-12 mm range.
The mill is equipped with standard and retarded stelmore
lines for producing high quality Wire rods in Low, Medium & High
carbon grade meeting the stringent National & International stan-
12
PEM is doing the planned maintenance jobs and major
breakdown on the equipments like main exhausters, mbc blowers,
mill fans, cph pumps, cdcp feed pumps, cdcp circulating pumps,
main exhausters, straight line cooler fans, boiler id fans etc.
4. 11 Plant Design (PD)
Major Functions
1) Development of detailed Manufacturing Drawing and
Replacement Specification drawings for:
& Import Substitution of Spares and Fast Wearing items.
& Proprietary Substitution.
& Salvaging damaged equipment/sub assemblies/parts.
& Modifications of the existing equipment and structures.
2) Suggesting New Designs and detailing by doing
elaborate Engineering Study and Analysis for:
% Better Operational requirement.
% Minimizing the rate of frequent break downs.
% Reducing Consumption rate of parts.
% Indegenising a part/sub-assembly/assembly of imported
equipment.
3) Standardization:
% To identify the existing standardization in machine
elements to have reduced inventory.
% Preparation of Standards/Norms.
21
vehicles of works departments of VSP.FMD takes care of the
operation, maintenance and repairs of the following types of
equipment.
1. Earthmoving Equipments
a) Dumpers b) Dozers c) Loaders d) Excavators
e) Tippers f) Selfloading & unloading trucks.
2. Mechanical Handling Equipment
a) Cranes b) Tractor trailors c) Forklifts(maintenance only)
3. Vehicles
a) Jeeps b) Trucks
In addition, it also maintains miscellaneous equipments
like industrial vaccum cleaners, Hydraulic access platform truck,
pneumatic tankers, Thermal insulated tankers etc. These
transportation equipments are used for transportation of different
types of materials like Coke, Ores, Limestone, Debris, SMS slag,
bricks, various materials from Stores, tools, tackles etc.
4.10 Power Engineering Maintenance (PEM)
Power Engineering Maintenance (PEM) department is
doing Capital repairs, Breakdown maintenance, Preventive
maintenance of Rotary Equipments like Turbo-Generators, Turbo-
blowers, Turbo compressors, high capacity exhausters, fans
pumps and hydraulic coupling.
In addition to the above, PEM is also doing INSITU
Balancing for high speed rotors through out the plant and Tarpedo
Laddles maintenance jobs.
20
dards viz. BIS, DIN, JIS, BS etc. and having high ductility, uni-
form grain size, excellent surface finish.
3.6.3 Medium Merchant & Structural Mill (MMSM)
This mill is a high capacity continuous mill consisting of
20 stands arranged in 3 trains.
_ Roughing train having a 8 stands (4 two high horizontal
stands, 2 vertical stands and 2 combination stands)
_ Intermediate Train has 6 mill stands as per details given below.
- 2 high horizontal stands
- 2 combination stands
- 2 horizontal stands / two universal stands
_ Finishing Train - consists of 6 stands namely
- 2 combination stands
- 4 horizontal stands / 4 universal stands
The feed material to the mill is 250 x 250 mm size blooms,
which is heated to rolling temperatures of 1200 0C in two walking
beam furnaces. The mill is designed to produce 8,50,000 tons
per annum of various products such as rounds, squares, flats,
angles (equal & unequal), T bars, channels, IPE beams / HE
beams (Universal beams)
4.0 AUXILIARY FACILITIES
4.1 Power Generation & Distribution
The average power demands at all units of VSP when
operating the full capacity will be 221 MW. The captive genera-
tion capacity of 270 MW is sufficient to meet all the plant needs
in normal operation time. In case of partial outage of captive gen-
eration capacity due to break down, shutdown or other reasons.
13
The short fall of power is availed from APSEB grid. The
agreement with APSEB provides for exporting of surplus power
to APSEB. The captive generating capacity comprises of
_ TPP - 247.5 MW ( 3x60 MW + 1 X 67.5 MW)
_ Back pressure Turbines (C&CCD)* - 2 x 7.5 MW
_ D
Gas Expansion Turbines (BF/ces)* - 2x12 MW
(*Power availability from BPT & GET is around 22MW)
shop. Used bearings are dismantled, cleaned, inspected,
serviced and reassembled on the rolls at regular intervals.
Separate bearings for taking radial loads and axial loads are used.
5. Types of Bearings used in LMMM & MMSM
4 row tapered roller bearings
D 4 row cylindrical roller bearings

Power plant also meets the Air Blast requirements of Blast D Deep groove ball bearings
Furnaces thro' 3 Turbo blowers each of 6067 NM 3/hr capacity.
D 2 row axial tapered roller bearings
Power from APSEB is received at Main Receiving Sta-
D 2 row angular contact ball bearings
tion thro' 220 KV overhead distribution lines. The entire plant is
configured as 5 electrical load blocks (LBSS 1 to 5) and stepdown Types of bearings used in WRM
substations are provided in each block with 220 KV transform-
ers to step down to 33/11/6.6 KV for further distribution. D Morgoal bearing (Oil film bearings)

4.2 Water Management (WMD) D 2 row axial tapered roller bearings

The total water requirements at full capacity utilization 6. Roll Shop-II comprises of roll turning shop, Bearing shop
of 3 MT/yr is 70 MGD, which is met from Yeluru Water Scheme and guide shop catering to the requirement of MMSM.
of A.P. This involved construction of a reservoir at Yeleswaram
Roll turning shop is equipped with six CNC lathes for
and a 153 Km long lined canal to the Kanithi Balancing Reser-
grooving new rolls, as well as redressings. The grooved
voir at plant site.
rolls are assembled with bearings in the bearing shop.
Kanithi Balancing Reservoir has a usable storage ca-
Chocks with bearings serviced periodically. Assembly
pacity of 12.6x106 M3 sufficient to meet plant as well as town
ship requirements for 45 days. There is a network of 28 Pump and service and repair of guides, preparation of strippers
Houses and 23 cooling Towers spread all over the plant to cool used in rolling of Angles, channels, rounds and beams
and recycle water, thus helping in conservation of water. Water is done in guide shop.
losses during the process are made up from Kanithi reservoir.
4.9 Field Machinery Department (FMD)
4.3 Traffic Dept.
Field Machinery, is meant for meeting the requirements
A Steel plant of the size of VSP has to handle around
of earthmoving equipment, mechanical handling equipments, and
60-65 MT traffic comprising of incoming traffic (different raw
14 19
 shop-1, Roll shop-II and Area Repair Shop. The main
activities of this shop is Roll pass Design, grooving of
rolls, assembly of rolls with bearings, preparation of
guides and their service and manufacture/repair of mill
maintenance spares.
2. For the first time in the country, VSP has adopted CNC
technology for grooving of steel rolling mill rolls. High
constant respective accuracy, higher productivity, use of
standard tool for any groove turning, elimination of the
use of different templates,easier to incorporate groove
modification etc., are some of the advantages of CNC
lathes over the conventional one.
3. The Roll Pass Design section takes care of design of
grooves for development of new sections, modification
of existing pass designs for improving the productivity
and quality. Preparation of rolling schedules, groove detail
and distribution and template drgs, part programming for
grooving of rolls on CNC lathes. This section also looks
after procurement of rolls, establishment and improvement
of their performance, failure analysis of rolls etc.
4. Roll Shop-I compraises of a Roll Turning Shop, bearing
shop, a Specialized repair shop and roll storage area
catering to the needs of LMMM and WRM. Roll Turning
shop is equipped with six CNC lathes, CNC template
machine, Notch Milling machine etc. The grooved rolls
are assembled with bearing and chocks in the bearing
18
materials etc.), outgoing traffic (finished / saleable steel
products, pig iron, granulated slag, byproducts etc.) and in
process traffic viz. Cast P I, Mill scrap, Mill scale, hot metal, etc.
Of this 50% is transported by belt conveyors, 45% by
Rail Transport and 5% by Road. VSP has the distinction of hav-
ing peripherial unloading system for the 1st time in Steel Industry.
To handle this huge quantities of traffic, VSP has a fleet
of 31 locomotives, 27 HM ladle cars, 7 torpedo ladle cars, 59
captive wagons of different types, 5 internal Railway stations,
loco and wagon repair shop, number of weigh bridges besides
taking on loan approx. 600 wagons daily from Indian Railways.
4.4 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 1. Forge Shop 2. Structural shop 3.
Foundry 4. Central machine shop 5. Wood Working Shop and 6.
Utility Equipment Repair Shop (UERS).
The Forge shop is designed for 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 structurals of about 4500 tonnes are produced
annually and the input consisting of sheets, plates, channels,
angles beam etc.
In Foundry Iron castings upto a weight of 5 tons and non
ferrous casting upto a weight of 1 ton are produced. 2600 tonnes
of iron castings and 200 tones of non ferrous castings are
produced annualy In steel foundry, steel casting upto maximum
piece weight of 10T are produced. Steel ingots upto 1.3 tonnes
for forging are also produced.
15
 In the Central Machine Shop, various spares are made.
The machining section has over 100 major machine tools in-
cluding lathes, milling, boring, planning, sloting, shapping, grind-
ing and other machines. The Wood working Shop manufactures
patterns for foundries. The shop will require 300 cu.m per year
of wooden patterns.
In Utility Equipment Repair Shop. The Repair of ventila-
tion, air conditioning and water supply equipment is carried out.
4.5 Utilities Dept :
Utilities dept. Consists of 1. Air Seperation Plant 2. Com-
pressor Houses 3. Chilled water plants and Acetylene plants.
The ASP is designed to meet the maximum daily de-
mand of gaseous oxygen, gaseous nitrogen and gaseous ar-
gon. It has 3 units of nominal capacity of 500 tons/day of oxygen.
Compressor Houses (CH) produce Compressed Air
required for the operation of pneumatic devices, for instruments
and controls, pneumatic tools and for general purpose in the vari-
ous production units of steel plants. CH-I has 4 compressors of
capacity of 15,000NM3/hr.
Chilled Water plants (2 Nos) produce chilled water re-
quired for use in the ventilation and air conditioning system in
areas such as office rooms, electrical control room etc. These
plant have twleve units each with a capacity to cool 180 Cu. M/hr
of water from 16 deg.C to 7 deg.C.
Acetylene plant produces Acetylene gas required for gen-
eral purpose cutting and welding. The acetylene plant has three
generators each having capacity of 30 NM3/hr.
16
4.6 Quality Assurance and Technology Development (QA&TD)
The QA & TD dept. has been set up to take care of
activities pertaining to Quality Control of Raw Materials, Semi
finished products and finished products. The QA & TD labs are
provided at major dept. like C&CCD, BF, SMS, Rolling Mills etc.
The dept. controls the process by providing process
charts for production of quality products. QA & TD carries out
final inspection & testing including spark testing of finished prod-
ucts and assigns grades to them.
4.7 Calcining & Refractory Material Plant (CRMP)
CRMP consists of two units - Calcining Plant & Brick
Plant. In calcining plant limestone & dolomite are calcined for
producing lime & calcined dolomite which are used for refining
of steel in the converters.
In calcining plant there are five flux kilns, each of 325 T/
day capacity, At the discharge end of the kiln, fuel is fired through
a burner to generate required heat for calcination. Due to the kiln
rotation & inclination, material flows from the feed and to the
discharge end & gets calcined. The brick plant has two LAEIS
1600 Ton presses & a tempering kiln (upto 3000 C temperature)
for making bricks.
4.8 Roll shop & Repair shop (RS & RS)
1. Roll shop & Repair shop is in the complex of Rolling
Mills catering to the needs of mills in respect of roll
assemblies, guides few Maintenance Spares and roll pass
design. Geographically this dept.is in three areas as Roll
17
VISAKHAPATNAM STEEL PLANT FLOW CHART (3.0 MT STAGE)