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On
Working of a chilled water plant
ACKNOWLEDGEMENT
I deem it a privilege to have been the student of Chemical engineering
stream in UCT,OU. My heartful thanks to Mr. J.PrabhakarRao,
DM(Training), Technical Training Institute of Visakhapatnam steel plant for
giving an opportunity to do the summer internship.
My heartful thanks to the project guide Mr.K.V.V Prasad Sir Dy.
General Mgr (O), Vizag Steel Plant and Mr.B.S.Rao Sir Asst.General Mgr
(O) who helped me to bring out this project in good manner with their
precious suggestions and rich experience. I take this opportunity to express
my sincere thanks to my project guide for cooperation in accomplishing this
project with a satisfactory conclusion.
I am grateful to all plant In-charges, technicians and other employees
of different dept. working under operation, maintenance and instrumentation
departments for sharing their valuable experience with me.
CONTENTS
INTRODUCTION
PROFILE ON VSP
VARIOUS DEPARTMENTS IN BRIEF
INTRODUCTION
The role of ferrous metals in general and of steel in particular in
national economy is enormous. One cannot name an economic branch where
ferrous metals find no applications. The economic power of country is
determined by its output of steel, since it determines the progress in the
principle economic branches, be it mining, transport, manufacture
engineering or agriculture implements is unthinkable without steel.
An additional impetus for increasing the scope of steel manufacturers
had been the vigorous progress in chemical engineering. It has turned out
that steel can be very profitable combined with certain novel materials for
instance plastic combined with stainless steel are excellent materials fore
making furniture, decorating automobiles internal lining of houses and
building purposes. As a result the manufacture of stainless steel has been
appreciably increased in order to cover these new demands in recent years.
The world for the steel rises continuously and is expected to reach the level
of thousand million tons per year by the end of this century. The steel will
obviously remains the principle structural material in for seeable.
To meet the above requirements the following iron and steel
companies were established:
Tata iron and steel company is the first ever-integrated steel plant in
VISAKHAPATNAM STEEL
PLANT
In order to increase the steel production reasonably high in the nation
and remove the regional imbalances in industrial developments, the
government of India took a great step in setting up the coastal-based steel
plant of India is Visakhapatnam steel plant in Andhra Pradesh. This plant is
located 16km south west of the city limits. A great emphasis has been made
on total automation, seamless integration and efficient up gradiation at
Visakhapatnam steel plant. This has resulted in a great demand for
Visakhapatnam steel plant product in India and abroad which are having
international standards. Visakhapatnam steel plant is considered to be the
first integrated steel plant in India to become fully ISO-9002 certified
company. This certificate covers quality systems of training and marketing
functions over four regional marketing functions and 22 stock yards located
all over the country. The decision of the government of India to set up an
integrated steel plant at Visakhapatnam was announced by the Prime
Minister Smt.Indira Gandhi. The plant was inaugurated formally on 20 th
January 1971 by the prime minister.
The project was estimated to the cost of rupees 3,897.28 crores based
on process on 4th quarter of 1981 but during the implementation of VSP is
has been on served that the project cost as increased substantially over the
sanctioned coast mainly due to this and the approved concept were studied
in 1986 the rationalization has basically been from the point of view of
obtaining maximum output from the equipment already installed panelled
for procurement, achieving the higher level of operation efficiency and
procurement over what was envisaged earlier under the rationalized concept.
3.0 million tons of liquid steel is to be produced in a year and the project is
estimated to cost 5,822 crores based on 4th quarter of 1987.
MODERN
TECHNOLOGY
&
MAJOR
PLANT
FACILITIES
THE MODERN TECHNOLOGY
Visakhapatnam steel plant is the most sophisticated and modern
integrated steel plant in the country. Modern technology has been adopted in
many areas of production, some of them for the first time in the country.
Among these are:
PROFILE ON VSP
MAJOR DEPARTMENTS IN VSP
Raw materials handling plant
Coke ovens and coal chemical division
Sinter plant
Blast furnaces
Steel melt shop
Rolling mills
LMMM (Light and medium merchant mill)
WRM (Wire rod mill)
MMSM (Medium merchant and structure mill)
VSP annually requires quality raw materials like iron ore, fluxes
(dolomite, limestone) coking coal and non-coking coal. It requires 12-13
million tonnes of raw materials, which produce three million tonnes of liquid
steel. It is provided with unloading, stacking and reclaiming facilities, which
include wagon , tippler , ground and track hoppers. The various features are:
Peripheral unloading system for railway wagons
Blender reclaimed for blending of ores and fluxes
Storage yards to facilitate comfortable storage and supply of raw
materials
Ring granulators for crushing of boiler coals
PLC control of all systems
Mixer for mixing lime is purchased and generated fines
Cone crushers for the crushing of lump ore.
1. SINTER PLANT:
Effective area
312 m22
Sintering area
276 m
Capacity
450 m2
Sinter bed height 300mm
2. BLAST FURNACE:
Hot metal is produced in blast furnace, which are tall and vertical.
Raw materials are Iron Ore, Coke, Dolomite, and Limestone. It is charged
from the top and hot blast at 1100c-1300c. there are two B.Fs each with a
volume of 3200m3, each with 4 tap holes and with a daily production of
9720 tons of liquid steel. The technical parameters are:
Effective volume
3200m3
Capacity
4860TPD
Height
33.1m
Number of tap holes
4
Each furnace is facilitated with two Cast Houses, Slag Granulation
Plants. There are 4 Pig Casting Machines to handle the pig iron to cast into
PIGS.
4. ROLLING MILLS:
UTILITIES DEPARTMENT
I have been allotted Utilities department which deals with the generation
and compression of industrial gases like oxygen, nitrogen, argon, acetylene,
compressed air, industrial grade dry air and chilled water for air conditioning
systems.
The utilities play a vital role in the steel manufacturing process by directly
participating in the process and by playing a supportive role for reliable and
safe operation of different steps of the manufacturing process.
All customers expect the uninterrupted delivery of utilities in all the sections
round the clock even during the power failures for safe shutdown of various
units.
Towards the fulfillment of RINL-VSP goals,utilities department has always
accorded top priority for minimization of energy consumption, optimistion
of operating and process parameters and upgradation/ automation of plant
equipment and machinery.
Utilities dept. Consists of
1. Air Separation Plant, designed to produce and meet the consumer
requirements of gaseous oxygen, Nitrogen and Argon through pipe lines and
through gas cylinders.
2. Compressor Houses 1 & 2, designed to produce and meet the
consumer requirements of Plant air and Industrial grade dry air.
3. Chilled water plants 3 & 4, designed to produce chilled water for
meeting the consumer air conditioning requirements.
4.LPG and ACETYLENE Distribution Plant
Products
Oxygen, Nitrogen, Argon gases, liquid Nitrogen,
liquid Oxygen, liquid Argon
Compressor house-1&2 Compressed air and Dry air
Chilled water plantChilled water
3&4
Acetylene plant
Acetylene gas
Air Seperation Plant:
INTRODUCTION:
The chilled water plants are installed in the place where whole large
buildings, shopping mall, Industries, chemical plants, airport, hotel, etc,
comprising of several floors are to be air conditioned. While in the direct
expansion type of central air conditioning plants, refrigerant is directly used
to cool the room air; in the chilled water plants the refrigerant first chills the
water, which in turn chills the room air.
Even at VSP, chilled water and chilled water plants are required for
Ventilation and Air Conditioning system in various departments, plants and
mills.So for this purpose chilled water plants 3&4 are established to meet the
needs of utilities department.
CHILLED WATER PLANT 3:
CWP-III provides air conditioning to Light and medium merchant mill
(LMMM), Wire rod mill(WRM), Medium merchant & Structural
mill(MMSM), Compressor houses-I & II, Steel melting shop, Air Separation
Plant and various electrical sub-stations.
The total quantity of chilled water for meeting the above requirements is
estimated to be 1400M3/hr. The above requirements are based on the water
inlet temperature to chiller of 16oC and outlet temperature from the chiller
of 7oC.
To meet the above requirements 9 nos. (8working, 1 stand by) of chillers
(180M3/hr capacity each) are installed. 3nos (2 working, 1 stand by) of
supply pumps (750M3/hr capacity each) and 4 nos. (3working, 1stand by) of
circulation pumps (600M3/hr capacity each) are installed.
qc
(10.1)