Distribution Networks in Vizag Steel Plant

BLAST FURNACE IN VISAKHAPATNAM
STEEL PLANT
A full semester internship Report submitted in partial fulfilment of the requirement
For the award of degree of
BACHELOR OF TECHNOLOGY
in
ELECTRICAL & ELECTRONICS ENGINEERING
Submitted by
M.SAI KIRAN
(14341A0266)
Under the Esteemed Guidance of
Mr. J.S.V.SIVA KUMAR Mr .I.S.SURYANARYANA
Assistant Professor, EEE Dept. DGM, DNW Dept.
GMRIT Vizag Steel Plant
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
(Accredited by NBA, NAAC with ‘A’ Grade & ISO 9001:2008 Certified Institution)
GMR Nagar, Rajam – 532 127
Andhra Pradesh, India.
APRIL 2018
ACKNOWLEDGEMENT
I would like to sincerely thank Associate Professor Mr. M.VENKATESWARA

RAO Head of the Department, Electrical and Electronics Engineering for providing all the
necessary facilities that led to the successful completion of my term paper report.
It gives me an immense pleasure to express my deep sense of gratitude to our guide

Mr. I.RAVIKIRAN, Assistant Professor, Department of Electrical and Electronics
Engineering whole hearted and invaluable guidance throughout the report.
I am extremely thankful to Dr. C.L.V.R.S.V.PRASAD Principal of the institution for

giving me this opportunity during my academics through curriculum.
I would like to thank my supervisor, Mr. D.K.DWIVEDI, for the patient guidance,
encouragement and advice he has provided throughout my time at the industry. I have been
extremely lucky to have a supervisor who cared so much about my work, and who responded
to my questions and queries so promptly.
I take this opportunity to express my gratitude to all of the Department faculty

members for their help and support. I also thank my parents for the unceasing
encouragement, support and attention. I am also grateful to my partner who supported me
throughout this venture. I am extremely thankful to all the Authors & Writers of my
References
I also place on record, my sense of gratitude to one and all, who directly or indirectly,
have lent their hand in this venture.
Sincerely,
S. NAVEEN KUMAR (15345A0215)

Department of Electrical & Electronics Engineering
CERTIFICATE
This is to certify that mini project Report entitled DISTRIBUTION

NETWORKS IN VISAKHAPATNAM STEEL PLANT submitted by
S.NAVEENKUMAR bearing Reg. No.: 15345A0215 has been carried out in partial
fulfillment of the requirement for the award of degree of B-Tech in Electrical & Electronics
Engineering Branch of GMR Institute of Technology, An Autonomous Institute Affiliated
to JNTUK, KAKINADA, is a record of bonafide work carried out by her under my guidance
& supervision. The results embodied in this report have not been submitted to any other
University or Institute for award of any degree/diploma.
Mr. I.RAVI KIRAN Dr.M.Venkateswara RAO
Assistant Professor Head Of the Department
EEE EEE
Contents
ABSTRACT ............................................................................................................................... 1
1. INTRODUCTION ................................................................................................................. 2
1.1. Benefits of Full Semester Internship to Students ............................................................ 3
1.2. Skills Developed through Full Semester Internship ........................................................ 3
2. PROFILE OF THE COMPANY ........................................................................................... 4
2.1. Location ........................................................................................................................... 5
2.2. Vision .............................................................................................................................. 5
2.3. Mission ............................................................................................................................ 5
2.4. Objectives ........................................................................................................................ 5
2.5. Core values ...................................................................................................................... 6
2.6. Historical perspective ...................................................................................................... 6
2.7. Steel demand ................................................................................................................... 7
2.8. Infrastructure ................................................................................................................... 9
2.8.1. Raw Material Handling Plant ................................................................................... 9
2.8.2. Coke Ovens and Coal Chemical Plant .................................................................... 10
2.8.3. Sinter plant .............................................................................................................. 11
2.8.4. Blast Furnace .......................................................................................................... 13
2.8.5. Calcining and Refractory Material Plant ................................................................ 14
2.8.6. Steel Melt Shop and Continuous Casting ............................................................... 14
2.8.7. Light and Medium Merchant Mill .......................................................................... 15
2.8.8. Wire Rod Mill......................................................................................................... 16
2.8.9. Special Bar and Structural Mills ............................................................................. 16
2.8.10. Thermal power plant ............................................................................................. 17
2.9. SWOT analysis of the industry ..................................................................................... 19
2.9.1. Strengths ................................................................................................................. 19
2.9.2. Weaknesses ............................................................................................................. 20
2.9.3. Opportunities .......................................................................................................... 21
2.9.4. Threats .................................................................................................................... 22
2.10. Major sources for raw materials .................................................................................. 22
2.11. Products and By Products ........................................................................................... 23
3. THE MAKING OF IRON AND STEEL ......................................................................... 24
3.1. The Steelmaking Process .............................................................................................. 26
3.1.1 Iron Ore Agglomeration .......................................................................................... 27
3.1.2. Refractories ............................................................................................................. 28
3.1.3. Alloying Elements .................................................................................................. 29
3.2. Iron making - the reduction of iron ............................................................................... 30
3.3. Chemical Reactions ....................................................................................................... 32
4. DISTRIBUTION NETWORKS IN VIZAG STEEL PLANT ......................................... 34
4.1. Power Requirement ....................................................................................................... 36
4.2. Sources of Power ........................................................................................................... 36
4.3. APSEB Supply Network ............................................................................................... 36
4.4. Different Voltage Levels ............................................................................................... 37
4.5. SCADA ......................................................................................................................... 38
4.6. Essential Category Loads .............................................................................................. 38
4.7. Main Receiving Station ................................................................................................. 38
4.8. Load Block Step down Substations (LBSS) ................................................................. 39
4.9. Indicators for Different faults in MRS and LBSS2 Substations ................................... 40
4.10. Battery Room .............................................................................................................. 42
4.11. Overview of Load Block Step-down Substations ....................................................... 42
4.12. Switch Gear Equipment .............................................................................................. 46
5. METHODOLOGY AND LEARNING ............................................................................... 51
5.1. Modern Technologies Used .......................................................................................... 51
5.2. Methodology for Solving Various Problems ................................................................ 51
6. CONCLUSIONS AND SUGGESTIONS ........................................................................... 53
6.1. Conclusion..................................................................................................................... 53
6.2. Suggestions.................................................................................................................... 54
List of tables
Table 1: Demand for iron and steel in India .............................................................................. 8
Table 2: SWOT analysis .......................................................................................................... 19
Table 3: Major sources for raw materials ................................................................................ 22
Table 4: Iron Ore Classification ............................................................................................... 27
List of figures
Figure 1: Raw material handling plant....................................................................................... 9
Figure 2: Coke Ovens .............................................................................................................. 10
Figure 3: Coal Chemical Plant ................................................................................................. 11
Figure 4: Sinter Plant ............................................................................................................... 12
Figure 5: Material flow diagram for Blast Furnace ................................................................. 13
Figure 6: Light and Medium Merchant Mill ............................................................................ 15
Figure 7: Wire Rod Mill .......................................................................................................... 16
Figure 8: Structural Mill .......................................................................................................... 17
Figure 9: Thermal Power Plant ................................................................................................ 18
Figure 10: Products .................................................................................................................. 23
Figure 11: Steel Plant Operational Process .............................................................................. 24
Figure 12: 220 kv Distribution network block diagram........................................................... 34
Figure 13: Bay diagram of MRS .............................................................................................. 35
Figure 14: LBSS-1 Layout ....................................................................................................... 44
Vizag Steel Plant
ABSTRACT
Visakhapatnam Steel Plant, popularly known as Vizag Steel, is an integrated steel

producer in Visakhapatnam, India built using German and Soviet technology. The company
has grown from a loss-making industry to 3-billion-dollar Turnover Company registering a
growth of 203.6% in just four years. Vizag Steel Plant was conferred Navratna status on 17
November 2010. Founded in 1971, the company focuses on producing value-added steel,
with 214,000 tonnes produced in August 2010, out of 252,000 tonnes total of sellable steel
produced. It is the largest single site plant in India and Asia minor.
Distribution Networks is one of the major departments in Vishakhapatnam Steel Plant

which gives power supply to various plant machinery, motors, lighting etc., and it
continuously monitors the power distribution through SCADA (Supervisory Control and Data
Acquisition) systems. It has a Main Receiving station which receives power from APSEB
(Andhra Pradesh State Electricity Board) and thermal power plant and it distributes power to
various substations in the next level which are termed as Load Block Step-down Substations.
These receive 220 KV from MRS and step down to required voltages.
Distribution channels are behind every product and service that consumers and
business buyers purchase everywhere. Usually, combination on institutions specializing in
manufacturing, wholesaling, retailing and many other areas join force in Distribution
channels.
A Distribution channel is a set of interdependent organization involved in the process

of making a product or service available for use or consumption. Distribution channels
decisions play a role of Strategic importance in the overall presence and success a company
enjoys in the market palace.
S. NaveenKumar (15345A0215) Page |1

Vizag Steel Plant
1. INTRODUCTION
Internship is a supervised learning experience in which students apply their prior

knowledge to develop new skills in a professional setting.
Internships provide invaluable experience and can change students’ lives. Interning
can increase students’ maturity levels and can improve their self-confidence and self-
concepts. They not only benefit students but also the organizations providing them.
Internships can focus on areas in which students can perform service and social-action
assignments. They also strengthen students’ academic resumes on their college applications.
Internships help students to explore various career alternatives, areas of career interest
or possible career opportunities. Internships assist students in developing relationships with
experts in fields of strong interest to them. Students can use internships to try out specific
jobs or types of positions, orientate and test certain occupational areas of interest and
potential future careers. Internships aid students in identifying, clarifying, developing career
goals and professional aspirations and confirming career-path options.
The type of learning that is fostered by internships is experiential. It is active learning

that is based on doing, on what works and in which experience is central. It is learning in the
community, in the real world and in actual work situations. It is interacting and engaging
with the environment, where problem-solving is emphasized. It is learning that is
individualized to meet one’s own needs and interests, and combines learning how to learn on
one’s own (i.e., independent learning) and learning with the help, support and guidance of
others (i.e., cooperative learning). This type of learning can be tied to service and social
action.
At the beginning of the internship I formulated several learning goals, which I wanted
to achieve:
 To understand the functioning and working conditions of a governmental organization.

 To see what is like to work in a professional environment.
 To see if this kind of work is a possibility for my future career.
 To use my gained skills and knowledge.
 To see what skills and knowledge I still need to work in a professional environment.
 To learn about the organizing of a research project (planning, preparation, permissions
etc.)

Vizag Steel Plant
 To learn about research methodologies (field methods/methods to analyse data)

 To get fieldwork experience/collect data in an environment unknown for me.
 To get experience in working in another country/with persons from another culture.
 To enhance my communication skills.
 To build a network.
1.1. Benefits of Full Semester Internship to Students
 Provides them with practical experience in an organization.

 Helps them decide if the industry and the profession is the best career option to pursue.
 Enables them to learn new skills and add to their knowledge base.
 Gives them the opportunity to practice their communication and teamwork skills.
 Allows them to meet new people and practice their networking skills.
 Makes a valuable addition to their resume.
 Opens the door to a job offer or an employment recommendation.
1.2. Skills Developed through Full Semester Internship
 Interpersonal skills, global awareness and understanding issues of diversity.

 Networking skills and group dynamics.
 Motivational and leadership skills.
 Organizational skills.
 Communication skills.
 Quantitative skills.
 Critical thinking and problem-solving skills.
 Skills to abstract and adapt.
 Ability to become self-learner.
 Ability to manage information technology tools.
 Identifying and dealing with ethical issues.
 Understanding processes that support delivery and management of information systems
within a specific application environment.

Vizag Steel Plant
2. PROFILE OF THE COMPANY
With a view of Industrial growth and to meet the inspirations of the people from
South India, Government of India decided to establish integrated steel plant in Public Sector
Undertaking at Visakhapatnam (Andhra Pradesh). The announcement was made by the then
Prime Minister of India late Smt. Indira Gandhi in the parliament on 17th April' 1970 for
setting up a 5th integrated steel plant in Visakhapatnam, Andhra Pradesh. The foundation
stone for the plant was laid by Smt. Gandhi on 20.01.1971. The selection committee chose
the site near Balacheruvu creek and the then prime minister did the formal inauguration on
20th January. The consultants, M/s M.N. Dastur & Company (P). Ltd. submitted a techno-
economic feasibility report in February 1972, and a detailed project report for the plant, with
an annual capacity of about 3 million tons of liquid steel in OCTOBER1977.
The Soviets examined the DPR prepared by M.N. Dastur Co and offered technical
and economic co-operation for the same. The Government of India and USSR signed an
agreement on 12th June 1979, for cooperation in setting up the 3.4 million tons integrated
steel plant at Visakhapatnam. In term of this agreement the earlier DPR of Dastur co was
revised jointly by Soviet and Indian design organizations, and a comprehensive revised DPR
for VSP was submitted in November 1980.
The project was estimated to cost Rs.3897.28 crores, based on prices as on 4th quarter
of 1981. But during the implementation of VSP, it has been observed that the project cost has
increased substantially over the sanctioned cost, mainly due to price escalations and under
provisions in DPR estimates. In view of this and the critical fund situation, alternatives for
implementation of VSP with rationalization of approval concept were studied in 1986. The
rationalization has been basically from the point of obtaining the maximum output from the
equipment already installed, planned for procurement, achieving higher levels of operational
efficiency and labour productivity over what was envisaged earlier. Under the rationalized
concept 3.0MT of liquid steel will be produced in a year, and the project is estimated to cost
Rs.6281 crores, based on prices as on first quarter of 1986. The plant is designed to produce
three million tons of liquid steel per annum to be converted to 2.656 million tons per annum
of saleable steel. In addition, Visakhapatnam steel plant will produce annually about 5.56
lakh tons of pig iron and various by-products and benzol products for sale.

Vizag Steel Plant
2.1. Location
The plant is located in Visakhapatnam city, which is on the coast of Bay of Bengal.
Visakhapatnam city is an important commercial centre of Andhra Pradesh. It has the deepest
port and is one of the principal outlets for country’s exporting Iron ore. The city has many
large industries such as The Hindustan petroleum refinery, Bharat heavy Plates and Vessels
ltd., Coromandal Fertilizers, Hindustan zinc, Hindustan Shipyard etc. The city is situated on
the main broad-gauge railway line between Calcutta and Madras and is well connected with
other major cities and state capitals by rail, road and air. The Visakhapatnam steel plant is
located southwest of Visakhapatnam Harbour and is about 26 Km from Visakhapatnam city.
The township and the plant have been built on an area of 27,000 acres, between the national
highway no.5 and the Bay of Bengal.
2.2. Vision
 Harness our growth potential and sustain profitable growth.

 Deliver high quality and cost competitive products and be the first choice of customers.
 Create an inspiring work environment to unleash the creative energy of people.
 Achieve excellence in enterprise management.
 Be respected corporate citizen, ensure clean and green environment and develop vibrant
communities around us.
2.3. Mission
 To attain 16-million-ton liquid steel capacity through technological up-gradation,

operational efficiency and expansion.
 To produce steel at international standards of cost and quality and
 To meet the aspirations of the stakeholders.
2.4. Objectives
 Expand plant capacity to 6.3Mt by 2011-12 with the mission to expand further in
subsequent phases as per Corporate Plan.
 Revamping existing Blast Furnaces to make them energy efficient to contemporary levels
and in the process increase their capacity by 1 Mt, thus total hot metal capacity to 7.5 Mt.
 Be amongst top five lowest cost liquid steel producers in the world.
 Achieve higher levels of customer satisfaction.

Vizag Steel Plant
 Vibrant work culture in the organization.

 Be proactive in conserving environment, maintaining high levels of safety & addressing
social concerns
2.5. Core values
 Commitment
 Customer Satisfaction
 Continuous Improvement
 Concern for Environment
 Creativity & Innovation
2.6. Historical perspective
The finished steel production in India has grown from a mere 1.1 million tonnes in
1951 to 29.27 million tonnes in 2000-2001. During the first two decades of planned economic
development, i.e. 1950-60 and 1960-70, the average annual growth rate of steel production
exceeded 8%. However, this growth rate could not be maintained in the following decades.
During 1970-80, the growth rate in steel production came down to 5.7% per annum and
picked up marginally to 6.4% per annum during 1980-90, which increased to 6.65% per
annum during 1990-2000. Though India started steel production in 1911, steel exports from
India began only in 1964. Exports in the first five years were mainly due to recession in the
domestic iron and steel market. Once domestic demand revived, exports declined. India once
again started exporting steel only in 1975 touching a figure of 1 million tonnes of pig iron
export and 1.4 million tonnes of steel export in 1976-77. Thereafter, exports again declined to
pick up only in 1991-92, when the main producers exported 3.87 lakhs tonnes, which rose to
2.79 million tonnes in 1995-96. The steel exports in 1999-2000 were 2.36 million tonnes and
in 2000-01 it was 2.57 million tonnes. The growth in the steel sector in the earlier decades
since Independence was mainly in the public sector units set up during this period. The
situation has changed dramatically in the decade 1990-2000 with most of the growth
originating in the private sector. The share of public sector and private sector in the
production of steel during 1990-91 was 46% and 54% respectively, while during 2000-01 the
same was 32% and 68% respectively. This change was brought about by deregulation and
decontrol of the Indian iron and steel sector in 1991. A number of policy measures have been
taken since 1991 for the growth and development of the Indian iron & steel sector. Removal
of iron & steel industry from the list of industries reserved for the public sector and also

Vizag Steel Plant
exemption from the provisions of compulsory licensing under the Industries (Development &
Regulation) Act, 1951, deregulation of price and distribution of iron & steel, inclusion of
iron and steel industry in the list of high priority industries for automatic approval for
foreign equity investments up to 74%, lowering of import duty on capital goods and raw
materials etc.
The Indian steel sector was the first core sector to be completely freed from the
licensing regime and the pricing and distribution controls. This was done primarily because
of the inherent strengths and capabilities demonstrated by the Indian iron and steel industry.
During 1996-97, finished steel production shot up to a record 22.72 million tonnes with a
growth rate of 6.2%, while in 1997-98, the finished steel production increased to 23.37
million tons, which was 2.8% more than the previous year. The growth rate has drastically
decreased in 1997-98 and 1998-99 being 2.8% and 1.9% respectively as compared to 20% in
1995-96 and 6.2% in 1996-97. The growth rate in 2000-2001 has improved to a healthy
9.60% with the total production touching 29.27 million tonnes. The production of finished
steel during 2001-02 has been 30.61 million tonnes, which means a lower growth rate of
about 4.5% compared to the previous year. This fall in the growth rate of steel production has
been brought about by several factors that, inter-alia, include general slowdown in the
industrial production and construction activities in the country coupled with lack of growth in
major steel consuming sectors. The total production of finished steel and the share of main
and secondary producers during 90's and up to 2002-03 are given in the annexure.
2.7. Steel demand
Urban Areas: The present steel consumption per capita per annum is about 30 kg
in India, compared to 150 kg in the world, and 350 kg in the developed world. The
estimated urban consumption per capita per annum is around 77 kg in the country, expected
to reach approximately 165kg in 2019-20, implying a CAGR of 5 percent. Apart from the
anticipated growth in the construction, automobile, oil and gas transportation, and
infrastructure sectors of the economy, conscious promotion of steel usage among architects,
engineers and students by the institute of Steel Development and Growth (INSDAG) and the
large producers will drive this additional consumption. Steps would be taken to encourage
usage of steel in bridges, crash barriers, flyovers and building construction. Benefits of steel
usage would be added to the technical education curricula in the country.

Vizag Steel Plant
Category wise estimated demand for iron and steel all India 2011-2012
Category Quantity, *103 t
Bars and rods 10500

Structural 2500
Plates 2250
HR coils/skelp 6600
HR sheets 500
CR coils/sheets 3300
GP/GC sheets 1930
Electrical steel sheets 200
Tin plates 325
Pipes 850
Railway materials 845
Total finished steel 29500
Table 1: Demand for iron and steel in India
Rural Areas: The rural consumption of steel in India remains at around 2 kg per
capita per annum, primarily because steel is perceived to be expensive among the village
folks. Based on the promotional efforts mentioned above, and an active focus on opening
new block level rural stock points, a target is set for raising the per capita rural
consumption of steel to 4 kg per annum by 2019-20, implying a CAGR of 4.4 percent.
Exports: Although the focus of Indian steel industry is on the domestic
market, export will be another window on the demand side. The growth of exports of steel
from India has been around 10 percent per annum over the past decade. That speaks for the
international cost competitiveness of the steel sector. It takes assiduous effort to create,
and hold on to export markets. While the business decision to export will depend on the
prevailing relative prices, the Government would encourage strategic alliances with
buyback arrangements and dedicated export production through 100% export-oriented
units. A growth rate of around 13 percent per annum is envisaged up to 2019-20. The
issues related to exports have been discussed in section 13 on Trade Policy.

Vizag Steel Plant
2.8. Infrastructure
 Raw Material Handling Plant

 Coke Ovens and Coal Chemical Plant
 Sinter plant
 Blast furnace
 Calcining and Refractory Material Plant
 Steel Melt Shop and Continuous Casting
 Light and Medium Merchant Mill
 Medium Merchant and Structural Mill
 Wire rod mill
 Special Bar and Structural Mills
 Thermal power plant
2.8.1. Raw Material Handling Plant
Figure 1: Raw material handling plant

Vizag Steel Plant
The Raw Material Handling Plant (RMHP) receives the basic raw materials required
for the steel making process from various sources through railway wagons and by road.
These are stacked by stackers and reclaimed by reclaimers and distributed to various
departments of VSP through conveyor system. The Iron Ore Fines, Iron Ore Lump, Sized
Iron Ore, Limestone (BF&SMS grades), Dolomite (BF & SMS grades), Sand, Quartzite and
Manganese lumps are stacked at Ore & Flux Yard. The Imported Coking Coal (ICC),
Medium Coking Coal (MCC), Boiler Coal (BC) are stacked in Coal Yard. Coke is sent
directly to Blast Furnace after tippling from ore and flux wagon tipplers. These raw materials
are sent to various departments as indicated below:
 Sinter Plant: - Iron Ore Fines, Lime stone (BF), Dolomite, Sand and LD slag.
 Blast Furnace: - Sized Iron Ore, Limestone (BF)/ LD slag, Manganese Lump, Quartzite
and Coke.
 SMS: - Dolomite (SMS), Sized Iron Ore, Dolo chips.
 CRMP: - Limestone (SMS), Dolomite (SMS), Dolo chips.
 TPP: - Crushed Boiler Coal.
 COCCP: - Imported coking coal (ICC), Medium coking coal (MCC).
2.8.2. Coke Ovens and Coal Chemical Plant
Figure 2: Coke Ovens
S. NaveenKumar (15345A0215) P a g e | 10
Vizag Steel Plant
Coal is converted into coke by heating the prepared coal blend charge in the coke
ovens in the absence of air at a temperature of 10000C-1050oC for a period of 16/19 hour.
The volatile matter of coal liberated during carbonization is collected in gas collecting mains
in the form of raw coke oven gas passing through stand pipes and direct contact cooling with
ammonia liquor spray. The gas cooled from 800oC to 80oC is drawn to Coal Chemical Plant
by Exhauster. The residual coke is pushed out of the oven by pusher car through a guide into
coke bucket. The red-hot coke is taken to coke dry cooling plant for cooling.
Figure 3: Coal Chemical Plant
The main by-product in the process of coke making is crude coke oven gas and this
has a lot of valuable chemicals. Coal Chemical Plant recovers Ammonia (NH3), Tar and
Benzol from CO-Gas. The primary by-products from Crude CO Gas are Ammonium
Sulphate (NH4)2SO4, Crude Tar, Crude Benzol and cleaned coke oven gas. The cooled coke
from CDCP (Coke Dry Cooling Plant) is separated into 3 fractions, BF Coke i.e. +25-70 mm,
which is sent to Blast Furnaces, Coke Breeze i.e. +0-15 mm, which is sent to Sinter making
and nut coke i.e., +15-25 mm, which is also used in the Blast Furnaces.
2.8.3. Sinter plant

Sintering is a process of Agglomerating iron ore fines into a porous mass by incipient
fusion caused by combustion with in the mass of the ore particles. Sinter is a hard and porous
Vizag Steel Plant
lump obtained by agglomeration of lines of iron ore, coke, limestone and metallurgical
waster. This department by not wasting the powder and small pieces of iron ore coal
manganese, dolomite and limestone makes Sinter Cakes and put it for reuse. This increases
the productivity of Blast Furnace, improves the quality of pig iron and decreases the
consumption of coke rate.
Figure 4: Sinter Plant

Raw Materials Used in Sinter Plant:
 Iron ore fines (0-10 mm)
 Coke - used as fuel
 Limestone & Dolomite - to maintain required sinter basicity
 Sand - to maintain required sinter basicity
 Metallurgical wastes - to use wastes effectively and thus reduce the cost of sintering
 Lime - to enhance the process of sintering
Sintering Process:
 Preparation of various raw materials.
 Mixing & Blending.
 Mixing with sinter returns in presence of water to form green balls.
 Charging on to the machine.
 Ignition and suction.
Vizag Steel Plant
2.8.4. Blast Furnace
Figure 5: Material flow diagram for Blast Furnace
Iron is produced in the Blast Furnace by smelting iron bearing materials with the help
of coke and air. The solid charge materials like sinter, sized iron ore, coke etc. are charged in
the vertical shaft of the Blast Furnace from top and hot air blast is blown through tuyeres
located at the bottom. The oxygen present in hot air combines with the carbon of coke and
generates heat and carbon monoxide (reducing agent). The reducing gases, while ascending
upwards comes into contact with the descending charge materials. Eventually the charge gets
reduced and hot metal, slag and BF gas are produced. Hot metal and slag is tapped from tap
hole. The Blast Furnace gas which comes out from top of the furnace is cleaned and used as
fuel in the plant. There are a total of three blast furnaces BF1, BF2 and BF3. Their capacities
are as follows: -
 Blast Furnace 1: - 2.5 MT per annum
 Total Capacity: - 7.5 MT per annum
Vizag Steel Plant
2.8.5. Calcining and Refractory Material Plant

CRMP, i.e. Calcining & Refractory Materials Plant is an integrated unit of
Visakhapatnam Steel Plant. This plant plays a significant role in the manufacturing of liquid
steel. The main customer of CRMP is Steel Melting Shop (SMS). There are two units in
CRMP. They are:
1. Calcining Unit:
Calcining plant produces lime and calcined dolomite, which are used for refining of
hot metal to steel in the converter. Lime is produced by calcining limestone and calcined
dolomite is produced by calcining dolomite. Both the raw materials are received and stacked
at RMHP. RMHP reclaims these materials and conveys to LSDS (Limestone & Dolomite
Screening Plant) via a stream of conveyors.
2. Brick Plant:
Brick plant produces Pitch Bonded Magnesia Carbon Bricks for lining of Converters
and Steel Ladles. The Brick Plant has two 1600 T capacity hydraulic presses to press these
bricks. After pressing the green bricks are placed on take-off belt.
2.8.6. Steel Melt Shop and Continuous Casting
Steel is made in steel melting shop in the refractory lined vessels called LD
Converters by blowing oxygen through the hot metal bath. While iron making is a reduction
process, steel making is an oxidation process. The oxygen reacts with impurities like carbon,
silicon, phosphorous, sulphur etc. present in hot metal to produce steel. No external fuel is
required as the silicon & carbon releases huge amount of heat energy. Also, the carbon
reaction releases large quantities of gas rich in carbon monoxide along with huge amount of
dust. The gases released from the converter are collected, cooled, cleaned and recovered for
use as fuel in the steel plant. The entire molten steel at VSP is continuously cast at the radial
type continuous casting machines resulting in significant energy conservation and better-
quality steel. 100% Continuous casting on such a large scale has been conceived for the first
time in India.
SMS-1:
 Three LD converters (modernized with increase in volume to 150 cum. each along with
DOG House facility).
 6 nos. of 4 - Strand Continuous Bloom Casting machines.
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SMS-2:
 Three LD Converters of 150 cum. volume each.

 1 no. of 6- Strand Continuous Billet- cum- Round caster.
 2 nos. of 6- Strand Continuous Billet casters.
 1 no. of 5-strand Continuous Billet-cum-Round caster.
2.8.7. Light and Medium Merchant Mill
Figure 6: Light and Medium Merchant Mill
The cast blooms from continuous casting department are heated and rolled in the
two-high speed and fully automated rolling mills namely Light & Medium Merchant Mill
(LMMM) and Medium Merchant & Structural Mill (MMSM). The billets produced in
LMMM are further rolled in Bar Mill / Wire Rod Mill (WRM). The finished products include
wire rods & long products like reinforcement bars, rounds, squares, flats, angles, channels,
billets etc. Blooms from Continuous Casting Division are rolled into billets, some of which
are sold and rest are sent to Bar Mill/WRM. The continuous two-line Bar Mill comprises of 8
Stand Double Strand roughing train, 2 nos. of 4 Stand Single Strand intermediate train & 2
nos. of 4 Stand Single Strand finishing train. Loopers are provided in between the finishing
stands for tension free rolling in order to obtain good surface quality and tolerances.
Housings are of closed top type. Roll necks are mounted in anti-friction bearings.
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2.8.8. Wire Rod Mill
Figure 7: Wire Rod Mill
WRM-1:
The Mill is high speed 4 strand No-Twist continuous mill designed to produce
8,50,000 Tons of wire rod coils per year. Rolled billets of 125 mm x 125 mm square cross
section, length ranging from 9.8 m to 10.4 m and weighing approximately 1250 kgs are used.
The mill is designed to roll steel stock of 0.9% max. carbon content.
WRM-2:
The Mill is designed to produce 6,00,000 tons per year of rounds in coil form. The
Mill is designed to roll low, medium and high carbon steel, case hardening steel, cold heading
quality steel, electrode steel, spring steel, bearing steel and free cutting steel. The mill shall
use continuous cast billets of 150 mm X 150 mm square cross section, 12 m length and
weighing 2100 kgs approximately, are used as input material.
2.8.9. Special Bar and Structural Mills
Special Bar Mill is designed to produce 7,50,000 tons per year of plain rounds in
straight length and in coil form by using an input of continuous cast billets of 150mm x
150mm x 12m and weighting approximately 2050 kgs. The mill is designed to roll medium
and high carbon steel, case hardening steel, cold heading quality steel, electrode steel, spring
steel, bearing steel and free cutting steel.
Vizag Steel Plant
Figure 8: Structural Mill
The Mill is designed to produce 7,00,000 tonnes per year of structural section in
straight length in approximately 3733 rolling hours and 8,50,000 tonnes per year of structural
sections in straight length in approximately within 4533 rolling hours.an input of Continuous
cast cold bloom of 200 mm x 200 mm x 12 m and weighing approximately 3760 kgs.
2.8.10. Thermal power plant

Boilers:
Thermal Power Plant has 5 Boilers each of 330 T/hr. steam capacity at 101 KSCA and
5400C. The Boilers are of BHEL make, capable of firing combination of fuels namely Coal,
Coke Oven Gas, Blast Furnace Gas and Oil. Crushed coal is conveyed from Raw Material
Handling Plant to TPP through conveyors. The Coal is pulverised in Bow Mills and fired in
the furnace. Normally 4 Boilers are kept in full load operation to produce 247.5 MW of
power, supply steam to 2 Turbo Blowers and process needs. Boilers outlet flue gas is passed
through Electro Static Precipitators to control air pollution. The Fly ash and Bottom ash
generated are pumped in slurry form to Ash Pond through on ground pipelines. The clarified
water is recirculated back to ash system.
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Figure 9: Thermal Power Plant

Turbo Generators:
Thermal power plant has 4 Turbo Generators, three of 60 MW capacity each and the
fourth 67.5 MW. Special features of the turbo sets are:
 Electro Hydraulic Turbine Governing System.
 Controlled extractions at 13 ata and 4 ata for process steam needs in TG 1, 2 & 3.
 Central admission of steam to reduce axial thrust.
 Air cooled Generators.
Power is generated and distributed at 11 KV for essential category loads. Excess power from
TG- 1, 2 and 3 is transferred to 220 KV Plant Grid through step up/down transformers. All
the Power Generated from TG-4 at 11 KV is stepped up through a 220 KV transformer and
transferred to plant grid.
Turbo Blowers:
VSP has 2 Blast Furnaces. To meet the blast air requirement, 3 Turbo Blowers, each
of 6067 NM3/ min. capacity, are installed at TPP. These blowers are of axial type and are the
largest blowers installed in India. To meet the varying needs of Blast Furnace, the blowers
are provided with adjustable stator guide blades in the tower pressure compression stages.
The blowers are provided with suction filters, pre-coolers and inter coolers.
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2.9. SWOT analysis of the industry
The strengths, weaknesses, opportunities and threats for the Indian steel industry
have been tabulated below. The national steel policy lays down the broad roadmap to deal
with all of them.
Strengths Weaknesses
1. Availability of iron ore and coal 1. Unscientific mining
2. Low labour wage rates 2. Low productivity
3. Abundance of quality manpower 3. Coking coal import dependence
4. Mature production base 4. Low R&D investments
5. High cost of debt
6. Inadequate infrastructure
Opportunities Threats
1. Unexplored rural market 1. China becoming net exporter
2. Growing domestic demand 2. Protectionism in the West
3. Exports 3. Dumping by competitors
4. Consolidation
Table 2: SWOT analysis
2.9.1. Strengths
India has rich mineral resources. It has abundance of iron ore, coal and many
other raw materials required for iron and steel making. It has the fourth largest iron ore
reserves (10.3 billion) after Russia, Brazil, and Australia. Therefore, many raw materials
are available at comparatively lower costs. It has the third largest pool of technical
manpower, next to United States and the erstwhile USSR, capable of understanding
and assimilating new technologies. Considering quality of workforce, Indian steel
industry has low unit labour cost, commensurate with skill. This gets reflected in the
lower production cost of steel in India compared to many advanced countries (Table 3).
With such strength of resources, along with vast domestic untapped market, Indian steel
industry has the potential to face challenges successfully.
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2.9.2. Weaknesses
These are inherent in the quality and availability of some of the essential
raw materials available in India, e.g., high ash content of indigenous coking coal
adversely affecting the productive efficiency of iron-making and is generally imported.
Advantages of high Fe content of indigenous are often neutralized by high basicity
index. Besides, certain key ingredients of steel making, e.g., nickel, ferro-molybdenum is
also unavailable indigenously. Systemic Deficiencies However, most of the weaknesses
of the Indian steel industry can be classified as systemic deficiencies. Some of these are
described here. High Cost of Capital Steel is a capital intensive industry; steel companies
in India are charged an interest rate of around 14% on capital as compared to 2.4% in
Japan and 6.4% in USA. Low labour Productivity In India the advantages of cheap
labour gets offset by low labour productivity; e.g., at comparable capacities labour
productivity of SAIL and TISCO is 75 t/man year and 100 t/man year, for POSCO,
Korea and NIPPON, Japan the values are 1345 t/man year and 980 t/man year. High
Cost of Basic Inputs and Services High administered price of essential inputs like
electricity puts Indian steel industry at a disadvantage about 45% of the input costs can be
attributed to the administered costs of coal, fuel and electricity, e.g., cost of electricity is 3
cents in the USA as compared to 10 cents in India; and freight cost from Jamshedpur to
Mumbai is $50/ton compared to only $34 from Rotterdam to Mumbai. Added to this are
poor quality and ever increasing prices of coking and non-coking coal.
Other systematic deficiencies include:

 Poor quality of basic infrastructure like road, port etc.
 Lack of expenditure in research and development.
 Delay in absorption in technology by existing units.
 Low quality of steel and steel products.
 Lack of facilities to produce various shapes and qualities of finished steel on-demand
such as steel for automobile sector, parallel flange light weight beams, coated sheets
etc.
 Limited access of domestic producers to good quality iron ores which are normally
earmarked for exports, and
 High level taxation
Besides these Indian steel makers also lacked in international competitiveness
on determinants like product quality, product design, on-time delivery, post sales
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service, distribution network, managerial initiatives, research and development, information

technology and labour productivity etc. As is evident in Table 1, the weaknesses gets
reflected in India’s poor standing in the global competitiveness as measured in terms of
indicated parameters.
2.9.3. Opportunities
The biggest opportunity before Indian steel sector is that there is enormous scope
for increasing consumption of steel in almost all sectors in India.
Unexplored Rural Market
The Indian rural sector remains fairly unexposed to their multi-faceted use of
steel. The rural market was identified as a potential area of significant steel consumption
way back in the year 1976 itself. However, forceful steps were not taken to penetrate this
segment. Enhancing applications in rural areas assumes a much greater significance now for
increasing per capital consumption of steel. The usage of steel in cost effective manner is
possible in the area of housing, fencing, structures and other possible applications where
steel can substitute other materials which not only could bring about advantages to users but
is also desirable for conservation of forest resources. Other Sectors Excellent potential
exist for enhancing steel consumption in other sectors such as automobiles,
packaging, engineering Industries, irrigation and water supply in India. New steel
products developed to improve performance simplify manufacturing/installation and
reliability is needed to enhance steel consumption in these sectors. Main objective here
have to be improvement of quality for value addition in use, requirement of less material
by reducing the weight and thickness and finally reduction in over al l cost for the e nd
us er . Latest t e chnol og y must b e adopted b y Indian st eel manufacturers for
production of superior quality of steel for these applications. For example, pre-coated
sheets can be used in manufacture of appliances, furnishings, electric goods and public
transport vehicles. Production and supply of superior grades of steel in desired shapes and
sizes will definitely increase the steel consumption as this will reduce fabrication need;
thereby reduce cost of using steel. Few other perceived opportunities are: Export Market
Penetration it is estimated that world steel consumption will double in next 25 years.
Quality improvement of Indian steel combined with its low cost advantages will definitely
help in substantial gain in export market.
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2.9.4. Threats
Slow Industry Growth
The linkage between the economic growth of a country and the growth of
its steel industry is strong. The Indian steel industry is no exception. The growth of the
domestic steel industry between 1970 and 1990 was similar to the growth of the economy,
which as a whole was sluggish. This sluggish growth in the steel industry has resulted
in enhanced rivalry among existing firms. As the industry is not growing the only other
way to grow is by increasing one’s market share. Consequently, the Indian steel industry
has witnessed spurts of price wars and heavy trade discounts, which has done Indian
steel industry no good as a whole. Threat of Substitutes Plastics and composites pose a
threat to Indian steel in one of its biggest markets. For the automobile industry, the other
material at present with the potential to upstage steel is aluminium. However, at present
the high cost of electricity for extraction and purification of aluminium in India
weighs against viable use of aluminium for the automobile industry. Steel has
already been replaced in some large volume applications: railway sleepers (RCC
sleepers), large diameter water pipes (RCC pipes), small diameter pipes (PVC pipes), and
domestic water tanks (PVC tanks).
2.10. Major sources for raw materials
Raw Material Source
Iron ore lumps & fines. Bailadilla, MP.

BF limestone. Jaggayyapeta, A.P.
SMS lime Stone. Dubai
BF Dolomite. Madharam, A.P.
SMS Dolomite. Madharam, A.P.
Manganese ore. Chipurupalli, A.P.
Boiler coal. Talcher, Orissa.
Cocking coal. Australia.
Medium Cocking coal (MCC) Gidi / swang / rajarappa / kargli.
Table 3: Major sources for raw materials
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2.11. Products and By Products
Products:
Billets Plain Rounds Rebars
Wire Rod Coils Angles Forged Rods
Special Steel Structurals Blooms
Figure 10: Products

By Products:
Phenol, Naphtha, Benzol, Ammonium Sulphate, crude coal-tar etc.
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3. THE MAKING OF IRON AND STEEL
Steel is a term given to alloys containing a high proportion of iron with some carbon.
Other alloying elements may also be present in varying proportions. The properties of steel
are highly dependent on the proportions of alloying elements, so that their levels are closely
controlled during its manufacture. The properties of steel also depend on the heat treatment of
the metal.
Steel is by far the most important metal, in tonnage terms, in the modern world, with
the annual global production of over 700 million tonnes dwarfing the approximately 17
million tonnes of the next most prolific, aluminium. The low price and high strength of steel
means that it is used structurally in many buildings and as sheet steel it is the major
component of motor vehicles and domestic appliances. The major disadvantage of steel is
that it will oxidise under moist conditions to form rust. A typical steel would have a density
of about 7.7 g cm-3 and a melting point of about 1650oC.
Figure 11: Steel Plant Operational Process
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Steel refers to any iron-carbon alloy, although steels usually contain other elements as
well. Iron occurs mainly as oxide ores, though it is also found in smaller quantities as its
sulfide and carbonate. These other ores are usually first roasted to convert them into the
oxide. On a world scale the most important ore is haematite (Fe2O3), but in New Zealand the
starting materials are magnetite (Fe3O4) and titanomagnetite (Fe2TiO4). The oxides are
reduced with carbon from coal, through the intermediate production of carbon monoxide.
The carbon initially burns in air to give carbon dioxide and the heat, which is necessary
for the process. The carbon dioxide then undergoes an endothermic reaction with more
carbon to yield carbon monoxide:
C + O2  CO2 H = -393 kJ mol-1

C + CO2  2CO H = +171 kJ mol-1
The oxide ores are then principally reduced by the carbon monoxide produced in this
reaction, the reactions involving very small enthalpy changes:
Fe2O3 + 3CO  2Fe + 3CO2 H = -22 kJ mol-1

Fe3O4 + 4CO  3Fe + 4CO2 H = -10 kJ mol-1
In conventional iron making this reduction occurs in a blast furnace, whereas in Vizag
steel plant a rotary kiln is employed for direct reduction, followed by indirect reduction in an
electric melter. This technology is used because the titanium dioxide present in the ore
produces a slag which blocks conventional blast furnaces as it has a high melting point.
The iron produced in this way always contains high levels of impurities making it
very brittle. Steel making is mainly concerned with the removal of these impurities. This is
done by oxidising the elements concerned by blowing pure oxygen through a lance inserted
into the molten alloy. The KOBM (Klockner Oxygen Blown Maxhutte) used for this in New
Zealand is unusual because oxygen is also blown through holes in the base of the converter.
The oxides produced are either evolved as gases, or combine with limestone to form an
immiscible slag which floats on the surface of the liquid metal and so is easily separated.
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3.1. The Steelmaking Process
Integrated steelmaking operations fall into three main phases:

 Reduction: Iron making
Iron ore, as mined, is a combination of iron with oxygen and various other unwanted
substances, generally known as "gangue". The first metallurgical step is to reduce iron ore to
metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a
fuel and reducing agent. The metallic iron produced by such a furnace contains a relatively
high proportion of carbon (4%) and is passed to the steelmaking process as a liquid at
approximately 1450C, called "hot metal".
 Refining: Steelmaking
The refining of iron to make steel is where the carbon content of hot metal is lowered,
usually to less than 1 % by an oxidation process in a steelmaking furnace. At the same time,
alloying materials are added to the furnace to achieve the required chemical composition of
the final product. The chemical content is controlled very closely during this stage. Originally
most steel was produced by the "Bessemer" and "open hearth" processes but these have been
replaced by the more modern "basic oxygen steelmaking" (BOS) and "electric arc furnace"
(EAF) processes.
The BOS process uses pure oxygen, injected by a lance, for refining the relatively
impure hot metal (and scrap is used for temperature control).
The electric arc furnace uses primarily electrical energy to supply heat to melt scrap
steel, sponge iron, or mixtures of scrap and other iron units. Compared to the BOS process,
the EAF requires less chemical reaction for refining.
 Shaping & Coating

The liquid steel can then be cast or formed into a variety of solid shapes via the
'continuous casting' process. The cast steel can then be forged or rolled in successive steps to
produce anyone of the many required shapes. Rolling is the most common method of
shaping. The modern rolling mill is a huge installation, costing millions of dollars and
incorporating highly complex electronic control systems. The amount of work to which the
steel is subjected, and the schedule on which this work is carried out, have significant effects
on its physical characteristics - it dictates whether the steel can be subsequently bent,
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machined, cut, or subjected to any other engineering operation, or formed into tubes, pipes or
wire.
Once shaped, steel may be coated with other metals such as zinc or tin, or with
organic coatings like paint or PVC.
Name Classification Theoretical maximum

iron content (%)"
Haematite Fe2O3 70.0
Magnetite Fe3O4
72.4
Goethite FeO(OH) 62.8
Siderite FeCO3 48.3
Taconite Wide variety of iron-bearing
rocks, usually 20 to 40%
(actual)
Jaspilite Contains magnetite or
haematite.
Table 4: Iron Ore Classification
3.1.1 Iron Ore Agglomeration

 Sinter Process
The sinter process was introduced around 1910 to treat flue dust extracted from blast
furnace exhaust gases. It was quickly adapted to agglomerate fine ore and its use spread
rapidly.
At the sinter plant, pre-blended fine ore is mixed with:

 coke breeze (small particles of coke from the screening plant);
 fine fluxes such as fine limestone, dolomite, quartzite, and serpentine;
 mill scale (small flakes of iron oxide from the rolling mills); and
 flue dust and precipitator dust (fine ore bearing particles) collected from the blast furnace
and BOS furnace exhaust gases.
This moistened mixture is coarsened by a granulation process and is then spread as a

layer up to 550 mm thick on a moving grate which travels like an endless belt. The grate
carries the mixture through a furnace, in which gas burners ignite the coke. The coke burns in
horizontal layers which proceed vertically downward as the air for combustion is
continuously drawn down through the mixture as it travels along the moving grate. During
this process the layers reach temperatures of approximately 13000C, fusing the pre- blended
fine ore mix together forming a solid clinker mass.
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This fused mix is broken down into lumps, cooled and screened, forming a sinter product
with a mean size of 23-26 mm which is sent to the blast furnace on conveyors.
In modern practice, the combined iron plus coke burden is self-fluxing and virtually no
limestone is required at the blast furnace. When the flux is added at the sinter plant, the
limestone is precalcined, the sinter strength and chemical reactivity are improved and the
sinter can be prepared at a lower temperature. Consequently the fuel rates (consumptions) and
productivities of both processes improve.
 Pelletising technique
Pelletising was first developed in Sweden. Since the late 1950's it has been
extensively applied to the very large deposits of iron bearing rock called "taconite" which
underlie much of the Mesabi Range in Minnesota (USA).
Low grade run-of-mine ore is crushed and ground to a very fine powder so that the
iron may be separated magnetically from the silica and other unwanted material. A binding
clay such as bentonite is added, also some fluxes, (if required), and the mixture is then
moistened and rolled into 14mm diameter balls in cylindrical balling drums. Initially the
"green" pellets are relatively weak, being cemented together only by the added water. They
are then baked at about 1315C in a shaft furnace, rotary kiln or grate system similar to a
sinter strand. Because of their regular size and shape, and their hard, dense nature, pellets
were considered an ideal feed material for blast furnace operations.
3.1.2. Refractories
Refractories are the class of thermally and chemically resistant substances used as
container materials in the various high temperature metallurgical processes. The steelmaking
furnaces are lined with magnesia, and the slag composition is carefully combined to minimize
attack by FeO, SiO2l and other impurities. The impurities are removed from the liquid steel at
temperatures which may be greater than 16500C.
Carbon is used to line the blast furnace hearth, which contains liquid iron saturated with carbon from
the coke.
Zirconia, magnesia and high alumina refractories are used in equipment like ladles,
tundishes and torpedo cars for handling molten metal.
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Silica is used in coke ovens and silica or high alumina fire bricks are used in blast furnace
stoves.
Various grades of alumina fire clays and bricks are used in other high temperature and
abrasive locations.
Water cooled metal shapes are also used to minimise erosion by cooling, often causing the
formation of a protective covering of frozen slag. Uncommon refractories, such as silicon
carbide and silicon nitride are required in critical applications such as in continuous casting.
3.1.3. Alloying Elements

Alloying elements are added to steel to give particular properties in the final product,
such as hardness, toughness, corrosion resistance, ability to be hardened and machinability.
They are also used to assist in refining, e.g. for deoxidation and desulphurisation.
They include:
 Carbon (C)
 Manganese (Mn)
 Silicon (Si)
 Chromium (Cr)
 Nickel (Ni)
 Aluminium (Al)
 Boron (B)
 Calcium (Ca)
 Cobalt (Co)
 Molybdenum (Mo)
 Titanium (Ti)
 Tungsten (W)
 Nitrogen (N) and
 Phosphorus (P).
Many are added as ferroalloys, of which high carbon ferromanganese (approximately
76% Mn and 7% C, remainder Fe) is the most common. Ferrosilicon, (typically 75% Si, <l
%C), and silicochrome, ferronickel and nickel oxide (which is readily reduced to the metal
during steelmaking) are other major alloys. Many are produced in electric smelting furnaces,
often by quite complicated processes, to serve the steelmaking and foundries industries.
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Carbon may be added in the form of petroleum coke or as specially prepared high
purity brown coal char.
Manganese is added as high, medium, or low carbon ferromanganese, electrolytic

manganese or silicomanganese. They are produced in electric smelting furnaces from
manganese ores and in manganese sinter plants for processing fines which are unsuitable for
addition direct to the furnace. (See Section 6 for details on the effects of alloying elements on
the properties of steel.).
3.2. Iron making - the reduction of iron
Blast Furnace Method

Iron is present in most natural ferrous ores as an oxide, together with some impurities.
Production of iron in the blast furnace is a thermochemical process, during which the metal is
reduced from its oxides by a series of chemical reactions and carburised to reduce its melting
temperature. The majority of impurities present in the ore and fuel are removed as a separate
liquid product called slag.
The modem coke-burning blast furnace is a massive structure, towering up to 100

metres high. The furnace shell consists of a truncated cone-shaped steel casing 30 to 40
metres high, lined with up to a metre of refractory brickwork. The furnace works
continuously and usually operates for up to 15 years before new cooling staves and refractory
lining are required.
Hearth dimensions of blast furnaces vary widely. The largest blast furnaces in the
world, with diameters up to 16 meters, produce over 10,000 tons of hot metal per day.
 Process
Raw materials are continuously fed into the furnace top, producing the iron and slag
which are removed at the base periodically. A hot air blast, together with auxiliary fuels, is
injected into the furnace through the tuyeres. It takes about eight hours for a piece of solid-
feed material to pass through the furnace.
 Charging
The raw materials charged into a blast furnace are:
 iron ore (Fe2O3 + gangue) as lump, sinter and/or pellets, according to availability;
 coke (C + ash) to provide the reducing agent (CO) and the heat necessary to melt the iron;
 minor amounts of limestone, dolomite and quartzite fluxes to control slag chemistry; and
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 Air (O2 + N2) to burn the coke (the air is preheated to about 11500C).
The fluxes are added, mainly as part of the sinter or pellets, to control slag chemistry,
i.e., to make slag containing typically, 34% SiO2, 41 % CaO, 15% Al2O3 and 7% MgO. The
gangue and ash are mainly acidic SiO2 and Al2O3 so the fluxes are primarily basic CaO and
MgO.
The increased availability of natural gas has resulted in it being injected with the air
blast as a supplementary fuel. In some circumstances coke ovens gas is a cost effective
alternative, while in countries with high energy costs, injection of pulverised coal is common.
Productivity is increased by enriching the pre-heated blast air with oxygen.
Humidification of the blast air by adding steam is used to control furnace temperature.
A scale car or a weigh hopper normally weighs all the solid raw materials charged to the
furnace top. The flow rate of injected fuels is measured along with the blast air.
The proportions of the charges depend upon the nature of the raw materials being
used. The order in which they are charged is important, because their distribution in the
furnace affects efficiency.
 Blowing
To increase productivity and efficiency most furnaces today are equipped to operate at
high top pressure (increased pressure at the furnace top). This is achieved by raising the
pressure of the blast air and restricting the passage of gas leaving the furnace top. The
reduction in gas velocity results in greater efficiency of all the important reduction reactions.
To increase productivity and efficiency most furnaces today are equipped to operate at
high top pressure (increased pressure at the furnace top). This is achieved by raising the
pressure of the blast air and restricting the passage of gas leaving the furnace top. The
reduction in gas velocity results in greater efficiency of all the important reduction reactions.
For more efficient smelting, superheated air is used. The turbo-blowers drive the air
through preheated refractory chambers called 'stoves', in which the air is raised to a
temperature of 900- 1200C, and then into the 'bustle pipe' which girdles the 'bosh'. The hot
air enters the furnace combustion zone through water-cooled copper nozzles called 'tuyeres'.
Usually there are three stoves or four serving each furnace. These steel chambers are
refractory lined pressure vessels, filled with a matrix of high duty refractory brick. They act
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as both heat stores and heat exchangers. One or two stoves are 'on blast', supplying heat to the
air blast while the other two are 'on gas' (or combustion) being heated by gas burners firing
blast furnace gas (enriched with coke ovens gas or natural gas). The heat contained in the
preheated blast produces a substantial saving in the coke and/or fuel consumption which
improves the productivity of the furnace.
 Reduction
The heat and carbon monoxide gas generated by combustion of coke and any
supplementary fuel, preheats and reduces the iron ore, as it descends through the furnace.
The melting point of pure iron is 1537C. Because iron passing through the blast
furnace absorbs carbon and other elements, its melting point is lowered to approximately
1150C. Despite its low melting point, the liquid iron in the furnace hearth must be
maintained at about l500C, with slag reaching temperatures about 50C higher (1550C).
This temperature is necessary to obtain sufficient fluidity of the iron and slag to sustain
proper drainage from the furnace hearth and to keep it flowing freely from the tap hole. It is
also important to note that the slag melting point changes with composition and this makes
accurate raw material control and weighing very important.
3.3. Chemical Reactions
The basic reactions that control the ironrnaking processes are relatively few and
simple. They are the reactions between carbon, oxygen, iron and its oxides, and those that
lead to the formation of slag.
 Reactions of carbon
The oxygen in the blast reacts with the incandescent carbon (coke) to produce very high
temperatures:
C + O2 CO2
The incandescent carbon rapidly reduces the CO2, thus: C+C02 2CO
The first reaction is highly "exothermic" (heat releasing); and the second, which
mildly absorbs heat, is called "endothermic".
The great quantities of heat released by carbon reactions melt the burden materials
(except the coke itself) in the melting zone of the furnace. Coke is the only charge material
which retains its solid structure while passing through the furnace. The coke thus provides the
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necessary porosity in the hearth and melting zone as liquid slag and iron are formed, refined
and drained away.
 Reactions involving iron

Reaction 1. At 400-7000C: Fe2O3+ CO 2 FeO + CO2
Reaction 2. At 700-10000c: FeO +CO Fe + CO2
Reaction 3. At 1000-14000C: FeO + C Fe + CO
Reaction 4. At 1400-14500C: Fe melts as it dissolves carbon
Carbon monoxide is the main reducing agent but, at temperatures of above l000C,
the resultant CO2 reacts with the coke to produce more CO, so the FeO appears to react
directly with the C, (reaction 3).
Hydrogen (H2), from the moisture (steam) in the hot blast and from supplementary
fuels, behaves similarly to CO. The fully reduced iron can only become molten after it
absorbs carbon, and so the final reduction/carburization in the melting zone is extremely
complex.
 Slag formation
In modern practice, the great majority of flux is introduced through sinter as
calcined CaO. Note that, when present, MgO reacts similarly throughout. Any lump
limestone added with the burden decomposes rapidly and the decomposition is normally
completed at l0000C. The reaction CaC03 CaO + CO2 is highly endothermic. It is much
preferable for this reaction to occur elsewhere than in the furnace bosh.
The resultant CaO enters the fusion zone and combines with silica (SiO2) and alumina
(Al2O3) to form a liquid slag. The most significant properties of the slag are its melting point
and fluidity (so that it can be removed from the furnace easily) and its basicity (the ratio of
basic oxides, mainly CaO, to acid oxides, mainly SiO2), which determines its chemical
affinity for sulphur, silicon and manganese.
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4. DISTRIBUTION NETWORKS IN VIZAG STEEL PLANT
The department which we have been allocated for our internship at Vishakhapatnam
steel plant is Distribution Networks Department (DNW). This department is assigned to
monitor the power distribution to various sections of the plant. The layout of the distribution
networks department in the plant is shown in below figure:
Figure 12: 220 kv Distribution network block diagram
Vizag Steel Plant
 Bay diagram of MRS

MRS is the main substation at which the bus is energized by 220-kv tie lines from
LBSS5 located at Thermal Power Plant and APSEB. There is Gas Insulated Substation
located at MRS which contains switchgear that isolates APSEB lines from the bus. The bus
system used here is two and half bus system which contains two main buses of which any one
bus alone can supply all the feeders to different Load Block Substations and another bus is
transfer bus which can supply only a single feeder alone at a time.
Figure 13: Bay Diagram of MRS
Vizag Steel Plant
4.1. Power Requirement
Integrated Steel Plants are major consumers of electricity, with specific consumption
of power at around 600-650 kWh/Ton of liquid steel. The estimated annual power
requirement of Visakhapatnam Steel Plant, at full level of production in each shop
(corresponding to 3.0 MT of liquid steel), is 1932 million kWh. This corresponds to an
average demand of 221 MW.
4.2. Sources of Power
Power requirement of VSP is met through captive generation as well as supply from
APSEB grid. The captive capacity of 270 MW is sufficient to meet all the plant needs in
normal operation time. In case of partial outage of captive generation capacity due to
breakdown, shutdown or other reasons, the short fall of power is availed from ABSEB grid.
Turbo Generators of VSP normally operate in parallel with state grid. Excess generation over
and above plant load is exported to APSEB.
The agreement with APSEB provides for a contract demand of 150 MVA and permit export
of power. Tariff for import, export, demand charges, penalties etc. are stipulated. For
purpose of billing, import and export energy is separately metered at Main Receiving Station.
4.3. APSEB Supply Network
The Power Grid Corporation’s Sub-station adjacent to Ukkunagaram is connected to

Vijayawada by a 400-kV line. It is also being connected to Jaipur, Orissa (Eastern Grid)
through DC back to back arrangement of 500 MW capacity and by 400 kV AC double circuit
line. Power is stepped down through a 315 MVA, 400/220 kV auto transformer at Power
Grid Corporation Sub-station and is fed to the adjacent APSEB switching station. This
switching station is also connected to Bommuru and Gajuwaka sub-stations by 220 kV
double circuit lines. Bommuru sub-station is connected to generating stations at Vijayawada,
Lower Sileru, Vijjeswaram, Kakinada and Jegurupadu. Gajuwaka sub-station is connected to
Upper Sileru. Two 1000 MW Thermal Power Stations are expected to come up in the next
few years at Visakhapatnam and close to steel plant.
Power is supplied to VSP from APSEB switching station over two 220 kV lines on
double circuit towers. Power is received at the Main Receiving Station (MRS) located near
Main gate and further distributed to various units within the plant.
Vizag Steel Plant
4.4. Different Voltage Levels
 Extra High Voltage Distribution (220 KV)

Power from APSEB is received at Main Receiving Station (MRS). The entire plant is
configured as five electrical Load Blocks and Step down sub-stations are provided in each
block (designated as LBSS 1 to 5) with 220 KV transformers to step down power to
33/11/6.6 KV.
Power is distributed within VSP, between above major blocks and MRS OVER 220
KV lines on double circuit towers. MRS and LBSS5 at TPP are inter connected by three tie
lines for bi-directional power flow. LBSS1 is connected to LBSS5 by two radial lines.
LBSS2, LBSS3 and LBSS4 are connected to MRS by two radial lines each.
To ensure continuity of supply and also facilitate maintenance, the stations are
connected by double circuit lines. MRS and LBSS5 are designed with double bus (Main
Bus-1, Main Bus-2) and transfer bus arrangement. At LBSS1, 2, 3 and 4 provisions are made
so that with only one 220 KV line and two transformers in service, all the loads can be
catered to. The equipment installed is suitable for 15000 MVA fault level. The various
equipment installed in these stations include 220 KV lighting arrestors, current transformers,
potential transformers, isolators, SF6/MOCB circuit breakers, Transformers, Aluminum
pipes, ACSR conductors, insulators structures, Relay and control panels, batteries etc.
 High Voltage Distribution (33/11/6.6 KV)

Two 220/33 KV Transformers installed at MRS feed power to Township step down
station (called as CPRS) through 33 KV cables. Here the voltage is further stepped down to
11 KV by two nos. of 33/11 KV transformers. Outgoing feeders from this station supply
power at 11 KV through cables to township network. 11 KV overhead construction power
lines are connected to this sub-station.
The 33 KV supply form the transformer at LBSS2 feeds SMS ladle furnace
transformer and capacitor banks through cables. This is a highly fluctuating load and the
voltage dips on 220 KV systems can be felt when the furnace is in operation.
 Medium Voltage Distribution (Below 650 V)

In each shop, to cater to Medium and Low voltage load, 11 KV/415 V LCSS are
formed. Power is fed from LCSS to motors, MCC, Power Distribution Boards (PDB),
Lighting Distribution Boards (LDB), ESP transformers etc. and for further distribution. The
3 phase 415 V distribution is solidly earthed neutral system. The transformers are of standard
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rating 1600/1000/750/630/250 KVA in plant and township areas. PVC cables are used for
medium voltage distribution generally.
The secondary windings of converter transformers feed DC converters and other

special equipment for variable speed AC/DC drives. The secondary voltage of these
transformers suits to the particular application for which they are provided.
 Low Voltage Distribution (250 V & Below)
Low voltage distribution consists of power supply on single phase to lighting

equipment, ceiling fans, portable hand tools and domestic appliances etc. For safety reasons,
24 V distribution is also provided to cater to hand lamps etc. in some areas. PVC cables are
used.
4.5. SCADA
The 220 KV 11 KV and 6.6 KV distribution system is monitored by a centralized

Supervisory Control and Data Acquisition system. The plant generation, import/export and
consumption in each unit are monitored through SCADA.
4.6. Essential Category Loads
Some of the technological process/equipment requires all time availability of

electricity. Such loads are approx. 70 MW and spread over various plant units. These
include exhausters in CO & CCP, Cooling water pump houses in BF, SMS, Rolling mills,
Intake pump house, Kanithi Balancing Reservoir pump house, TPP auxiliaries, Township
pump house, Hospital etc. Disruption of supply to these loads may cause wide spread
dislocation to the process, involve dangerous situation to equipment etc. These are classified
as special/essential category-I loads. Power supply to them is envisaged from two sources
i.e. from Thermal Power Plant generator 11 kV switch board through cables and also from
220 kV sub-station in that area. Depending upon level of captive generation, the 220-kV
system is so configured that in the event of isolation of captive generators form APSEB grid,
the load throw off at TPP and disturbance to plant units is minimized.
4.7. Main Receiving Station
It is the main substation at which the bus is energized by 220-kv tie lines from
LBSS5 located at Thermal Power Plant and APSEB. There is Gas Insulated Substation
located at MRS which contains switchgear that isolates APSEB lines from the bus. The bus
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system used here is two and half bus system which contains two main buses of which any one
bus alone can supply all the feeders to different Load Block Substations and another bus is
transfer bus which can supply only a single feeder alone at a time.
4.8. Load Block Step down Substations (LBSS)
These are the substations which receive two or one overhead lines from MRS (except
for LBSS5 which supplies power to MRS) and supply power to different Load Block
Distribution Substations after stepping down to required voltage. These LBDS again supply
power to various load centers which supply power to various loads at different plants.
 LBSS1
Total Load: - 90MW
Number of transformers: - 3 3-winding transformers (220kv/11kv/6.6kv) with a capacity of
80 MVA each.
Loads Connected: - Raw Material Handling Plant, Coke Ovens & Continuous Casting Plant,
Sinter Plant, Blast Furnace
 LBSS2
Total Load: - 85 MW
Number of transformers: - 3 3-winding transformers (220kv/11kv/6.6kv) with a capacity of
80 MVA each and a single two winding transformer (220kv/33kv) with a capacity of 31.5
MVA
Loads Connected: - Blast Furnace, Steel Melting Shop (SMS), Air Separation Plant,
Calcining Refractory Material Plant, Ladle furnace in SMS.
 LBSS3
Total Load: - 25 MW
Number of Transformers: - 3 3-winding transformers (220kv/11kv/11kv) with a capacity of
80 MVA each.
Loads Connected: - Medium Merchant and Structural Mill (MMSM)
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 LBSS4
Total load: - (45-50) MW
Number of Transformers: - 3 3-winding transformers (220kv/11kv/11kv) with a capacity of

80MVA each.
Loads Connected: - Light Medium and Merchant Mill, Wire Rod Mill, Aux. Shops Adm.
Building and Kanithi reservoir pump house.
 LBSS5
Connected to MRS with three overhead lines which supplies power to the bus at MRS
by stepping up the 11kv generated at Thermal Power Plant to 220kv. It even supplies power
to LBSS1 which is directly connected to it instead of taking supply from MRS to reduce
transmission losses.
 LBSS6
Total Load: - 50 MW
Number of Transformers: - 6 transformers of which three are 220 kV/33 kV transformers

with a capacity of 110 MVA and the remaining 3 are 220 kV/11 kV transformers with a
capacity of 63 MVA.
Loads Connected: - Ladle furnace, Structural Mills, Special Bar Mills, extension parts of
Blast Furnace and Steel Melting Shop.
 LBSS7
This substation is different from all other substations which gets four 33 Kv
underground cables from Generation Switch Board 4 i.e. Gas Insulated Substation located at
LBSS5. There are 4 transformers in this substation of 40 MVA capacity each which step
down 33 Kv to 11 Kv. The loads connected are extension parts of Blast Furnace and Steel
Melting Shop.
4.9. Indicators for Different faults in MRS and LBSS2 Substations
 SF6 Gas Low and SF6 Gas Lockout

All the Current transformers, Potential transformers and most of the circuit breakers
in the substation are SF6 gas filled. SF6 gas low indicator will glow if SF6 gas is low in any
of the equipment based on the signal from the corresponding relays. If the gas is rapidly
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decreasing then it may affect the operation of the equipment and in such case SF6 gas lockout
indicator will glow.
 OLBT incomplete
MRS has two and half bus system so as to ensure continuity of supply by transferring
load to another bus while one bus is under maintenance. In such cases bus transfer is done on
load. This operation is known as On Load Bus Transfer (OLBT). If this operation is not
completed correctly then OLBT indicator will glow.
 Pole Discrepancy Trip

In case of Circuit Breaker as the transmission is three phase there will be three poles.
If there is situation in which any of the three poles not operated with remaining poles
operated then a relay sends signal to indicate pole discrepancy trip.
 Protection DC fail
All the relays in the substation are given 220V DC supply. If this DC supply to the
relays fail then it may cause a serious problem during faulty conditions. So, a relay is set to
indicate this fault and by which Protection DC fail indicator will glow.
 Inter-trip
If there is fault after one substation and before another substation then this is termed
as inter-trip as like as differential protection provided for transmission line. In such case
inter-trip indicator will glow.
 Bus Protection trip
If there is fault in the bus bar it is indicated by bus bar differential protection and
then this indicator will glow.
 Local Breaker Backup (LBB) protection trip

For a bus there will be incoming and outgoing feeders. If the breaker in one feeder
fails to trip in faulty condition, then all the other breakers of other feeders connected to a
particular bus will trip as the faulty current flows through them. In such case Local Breaker
Backup protection trip indicator will glow.
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 Bus Isolator relay

At the isolators in the switch yard when the isolator closes there will be a mechanism
which performs changeover between NO (Normally Open) and NC (Normally Close) based
on isolator opened or closed in the bus isolator relay. There are two isolators for each bus
29A and 29B for which two relays are arranged.
 Circuit Breaker TC1 and TC2 faulty
The circuits breakers are provided with two trip coils indicated as Trip coil 1 (TC1)
and Trip coil 2 (TC2). In case there is a fault in any of the two trip coils then this indicator
will glow.
 OLBT occurs
When On Load Bus Transfer (OLBT) is performed then to indicate that a relay is set
and based on the signal from that relay OLBT occurs indicator will glow.
 Local Breaker Backup (LBB) protection timer

When LBB occurs the protection timer starts. If below some set time the fault is
cleared then protection timer stops and the time is set to zero. If the fault doesn’t clear then a
trip occurs.
4.10. Battery Room
It consists of lead acid batteries which are connected in series. These are charged
by two chargers namely Charger-1 and Charger-2. There are two modes of operation for
these chargers namely Boost mode and Float mode. There is a selector switch to make a
change over between these modes. In float mode the batteries are charged with low currents
and in boost mode the batteries are charged with high currents. The power stored in these
batteries are used under emergency purposes. The capacity of these batteries is 250 ampere-
hours at 10-hour rate. Specific gravity of the solution in the battery should not be less than
1180.
4.11. Overview of Load Block Step-down Substations
All the Load Block Step down Sub-Stations 2, 3, 4 receives power from MRS at
220 KV level and the LBSS-1 receives power from LBSS-5. At the LBSS-1, 2 the voltage is
stepped down from 220 KV to 11 KV/ 6.6 KV by 3 winding transformers Star/Delta/Delta.
At LBSS-2, another transformer of 220 KV / 33 KV, 31.5 MVA is installed for feeding
Vizag Steel Plant
power to ladder furnace. At LBSS-3 and LBSS-4 the voltage is stepped down from 220 KV
to 11 KV /11 KV by 3 winding transformer (Star / Delta / Delta). At LBSS-5 three
transformers of rating 50/63 MVA, 220/11 KV are connected to GSB-1 at Thermal Power
Plant, to which 3 x 60 MW Turbo-generators are also connected. Fourth Transformer at
LBSS-5 is of 220 / 11 /11 KV, 31.5 / 40 / 50 MVA is connected to the GSB-2 and 3 at TPP,
to which 2x 12 MW GETGs (Gas Expansion Turbo Generators) and 2 x 7.5 MW BPTGs
(Back Pressure Thermal Generators) are connected. Fifth transformer is of 220/11 KV, 90
MVA at LBSS-5 is directly connected to 67.5 MW Turbo-generators at TPP. The 11 KV and
6.6 KV switch boards located inside the LBSS Buildings are connected to the Transformers
secondaries through totally enclosed bus ducts. High capacity 11 KV motors like feed air
compressor in ASP (Air Separation Plant), primary air compressors in compressor house-1
and exhausters of sinter plant are feed from LBSS itself.
All the step-down actions are taken place with necessary precautions. And all the
lines are connected by the well tested protective equipment in order to prevent damage to the
system in case of any faults.
From MRS the power is distributed to all the LBSS through 2 lines and at Bus-1
the AP TRANSCO incoming lines are connected. At bus 2 all the outgoing feeders are
connected during normal operating conditions. There is another bus called as auxiliary bus.
Under fault conditions if any one of the buses one or two is damaged then the power is
transferred from that bus to auxiliary bus and then the service is continued until the bus is
repaired. This auxiliary bus is operated by operating the by-pass. From Bus 1 the power is
transferred to the Bus 2, by closing the bus coupler.
Each line is named as 1 Bay. There are 14 Bays at MRS. Each bay is named with a
certain alphabet and it consists of a line isolator and a circuit breaker, a transfer bus isolator
and 2 Bus isolators. From MRS the power has been distributed to the township stepdown
substation(called as CPRS) and then to household consumers through A Bay. Through B bay
and C bay the power has been fed to LBSS-2 from MRS at 220 KV Level. By means of H
Bay, and G Bay, the power has been fed to the LBSS-4 from MRS at 220 KV Level.
Similarly, to LBSS-3 the power has been fed through M Bay and L Bay and to LBSS-5 the
power has been fed through N-Bay, P Bay and R-Bay.
LBSS-1 receives power from LBSS-5 through 2 number of 220 KV transmission

lines. This 220 KV is further stepped down to 11 KV and 6.6 KV by using 3 numbers of 3
Vizag Steel Plant
winding transformers of 80 MVA of star/delta/delta. Each having secondaries of 11 KV and

6.6 KV. LV1 of each transformer is connected to 11 KV Switch Board and LV2 of each
transformer is connected to 6.6 KV Switch Board from the Switch Board the power has been
fed to different loads viz., Coke Oven, Chemical Plant, RMHP.
Figure 14: LBSS-1 Layout

LBSS-2 receives power from MRS through 2 numbers of 220 KV Lines named L2 &
L2 and L2, L1 (B Bay and A-Bay). This 220 KV is stepped down to11 KV and 6.6 KV by 3
numbers of transformers of 80 MVA of star/delta/delta.

Each having secondaries of 11 KV and 6.6 KV.LV1 of each transformer is
connected to 11 KV Switch Board and LV2 of each transformer is connected to 6.6 KV
Switch Board. Each secondary is connected to Earthing cum Stationery Transformer (EST)
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and from the switch boards the power is fed to different loads namely, BF1, BF2, SMS,
CRMP, ASP. There is one more transformer of 220 / 33 KV, 31.5 MVA is installed to Feed
the power to Ladder furnace.

LBSS-3 receives power from MRS through 2 numbers of 220 KV transmission lines
named L3 and L2 and L2 and L1. This 220 KV is stepped down to 11KV through 3 number
of transformers of 80 MVA of Star/delta/delta is having secondaries of 11 KV. LV1 of each
transformer is connected to 11 KV Switch Board and LV 2 of each Transformer is connected
to 11 KV Switch Board. From the switch boards the power has been fed to different loads
viz., MMS (Medium Merchant Stationery Mill).
Vizag Steel Plant
LBSS-4 receives power from MRS through 2 number of 220 KV transmission line
named L4 and L1 and L4 and L2. This 220 KV is further stepped down to11 KV by using
three numbers of 3 winding transformers of star/delta/delta. Each having secondaries of 11
KV, LV1 of each transformer is connected to 11KV Switch Board and LV2 of each
transformer is connected to another 11 KV Switch Board. From the switch board the power
has been fed to the different loads like LMMM, WRM, Stores, Pump House.
4.12. Switch Gear Equipment
Switch-yard as a main connecting link between the generating plant and transmission
systems has a large influence on the security of supply. As the switch-yard handles large
amount of power, it is considered essential that it remains secure and service able to supply
the out-going transmission system even under conditions of major equipment or bus bar
failure. The choice of bus switching scheme is governed by various factors which ultimately
aim and achieving the objective of the security.
In all these regions, there are switchgears. The switchgear in generating stations
can be classified as:
 Main switch gear

 Auxiliary switch gear
Main switchgear comprises of circuit breakers, isolators, bus bars, current

transformers, potential transformers, etc. In the main circuit of generator-associated
transformers of transmission lines. It is generally of Extra High Voltage and outdoor type.
Auxiliary switchgear is generally indoor type and controls the various auxiliaries
of the generator, turbine, boiler and the station auxiliary.
Bus bars are conducting bars to which a number of local feeders are connected.
They operate at constant voltage and are insulated from earth and from each other. Isolator is
a no-load switch designed to operate under no-load conditions. Therefore, the isolator opens
only after the opening of the circuit breaker. While closing, isolator closes first and then
circuit breaker. Lighting arrestors connecting between conductor and earth, divert the high
voltage surges. It is also installed near the transformer terminals. Isolator is also called as
disconnecting switch or simply disconnected.
Vizag Steel Plant
 Lightning Arrestors
Lightning is one of the most serious causes of over voltages. If the power
equipment especially at the outdoor sub-station is not protected the over-voltage will cause
burning of the insulation. It is absolutely, necessary to provide protection against the
traveling surges caused by lighting. Such protective device is called lightning arrestors or
surge diverters. They are connected between the line and earth at the sub-station when the
traveling surge reach the diverter and attain the prefixed voltage a spark is formed across the
gap. The diverter then provides a low impedance path to earth. The surge diverter should
provide a path of low impedance only when the traveling surge reaches, the surge diverter
neither before it nor after it. A good Lightning Arrestor or Surge diverter must posses the
following conditions:
 It should not absorb any current during the normal operation. At over voltage surges it
must provide an easy path to earth.
 After the first discharge of the current has taken place through them they must be capable
of carrying the discharge current for some interval of time without any damage to
themselves.
 After the over voltage discharge it must be capable of interrupting the normal frequency
current from flowing to the ground as soon as the voltage reaches below the break down
value.
 Circuit Breakers
For low voltage circuits, fuses are used to isolate the faulty circuit. But for high
voltage circuits isolation is achieved by the Circuit Breaker. The circuit breaker can close the
circuit as well as break the circuit without any replacement for low capacities a fuse
combined with circuit breaking arrangement is quite useful and economical. The following
are the requirements for a circuit breaker or a switch gear:
 It must safely interrupt the normal working current as well as short-circuit current.
 After occurrence of fault the switch gear must isolate the faulty circuit as quickly as
possible.
 It must have high sense of discrimination i.e., in systems where in alternate arrangements
have been made for continuity of supply it should isolate the only faulty circuit without
effecting the healthy one.
Vizag Steel Plant
 It should not operate when over current flows under healthy condition. There are different
types of circuit breakers among those air blast circuit breaker, magnetic blast circuit
brakes and oil circuit breaker are there.
 Current Transformers
Current Transformers are used in current circuits in protection systems employing

secondary relays. This transformer is to measure large currents. The primary which is usually
of few turns or even a single turn or thick copper or brass bar is inserted into the core of the
transformer is connected in series with the load. The secondary current is normally rated for
5A or 1A and the number of turns in the secondary will be high. When the current
transformer has two secondary windings then one winding is connected to the protective
relay system and the other is to indicating / metering circuit.
Current transformer windings are polar in nature. The current transformers with
1A rating secondaries can handle 25 times more burden than the current transformers of 5A
secondaries. Current Transformers of 1A Secondaries are normally used in the protection of
220 KV – 440 KV Transmission lines where the substation apparatus is located at a
considerable distance from the control room, where the relays are situated. The magnitude of
the current which flows through the secondary winding of a CT is a function of the primary
current, the transformation ratio and also the impedance of the secondary circuit. CT’s
normally operate under conditions close to short circuit conditions. The Secondary winding
burden further depends upon the method of connection of the CT secondary, the relay
windings and the kind of short circuit experienced. CT’s used for extra high voltage network
protection must be capable of accurately transmitting currents both during steady state
process and under transient conditions in order to permit operation of the protective devices
correctly.
The reasons for choosing proper CT’s for extra high voltage network protection are:
 The time constants of DC components in the short circuit currents of EHV networks are
large.
 The ratio of the short circuit current to the rated current is very high, due to increased
energy concentration.
 High Speed relaying is essential to protect electrical equipment during fault and to
increase system stability.
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 Potential Transformers
Instrument Transformers are of means of extending the range of A.C. instruments
like ammeters, voltmeters, V.A.R. meters, Walt-meters. They are two types of potential
transformers. The primary of the potential transformers is connected across the transmission
line whose voltage may range from 2.4 KV to 220 KV. The secondary voltage is standardized
at 110 KV. The load connected to the secondary is referred to as burden.
The requirements of the good potential transformers are:

 Accurate turns ration, n = Vp/Vs. The difficulty in maintaining the accurate turn’s ratio is
due to resistance and reactance of the winding sand the value of the exciting current of the
transformer.
 Small leakage reactance. The leakage reactance is due to the leakage of the magnetic
fluxes of the primary and secondary voltages. They can be minimized by keeping the
primary, secondary windings as close as possible subject to insulation problem as the
primary is at high voltage.
 Small magnetic current. This can be achieved by making the reluctance of the core as
small as possible and flux density in the core is also low, and it is very less than 1 wb
/m2.
 Minimum Voltage Drop: The resistance of the windings is made as small as possible.
The Primary as it carries high voltage should be heavily insulated. Hence it is

immersed in oil and the terminals are brought out to porcelain bushing. Now-a-days synthetic
rubber insulation like styrene is used avoiding oil and porcelain. When the load or burden on
the secondary is increased. The secondary current increases with corresponding increase in
primary current so that transformation ratio remains the same.
 Relays
Protective relays are devices which close and open electrical circuits for control of
circuit breakers, when the quantity they are designed to respond to, reaches a pre-determined
value (Current, Voltage, Power, Impedance etc.). According to their functions in the relay
protection scheme relays are divided into main relays and auxiliary relays. The main relays
are the protective elements, which respond to any change in the actuating quantity e.g.
Current, voltage, power. The auxiliary relays are those which are controlled by other relays
to perform some supplementary functions such as time delay, multiplying the number of
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contacts, passing a command pulse from one relay to another relay, acting upon circuit
breaker closing (or) opening, energizing a signal or alarm etc.
Relays are classified to how they are connected. “Primary Relays” are those whose
measuring elements are directly connected in the circuit. The secondary relays are those
whose measuring elements are connected to the circuit, they protect through instrument
transformers (Current and voltage). Thus, protective relaying is one of several features of the
system design connected with minimising damage to the equipment and interrupts power
supply when fault occurs. It is therefore necessary a second line of defence is provided to
protect the electrical equipment when the main protective system fails. The main one is
called as Primary and the other is called as Backup Protection.
 Isolators and Earthing Switches

Isolator is a no-load switch designed to operate under no-load conditions therefore
the isolator opens only after the opening after the circuit breaker. While closing, isolator
closes first and then circuit breaker. Isolator is also called as disconnecting switch or simply
disconnector. It is interlock with circuit breaker such that wrong operation is avoided.
Earth Switch is connected between the line conductor and earth. Normally it is open
and it is closed to discharge the voltage trapped on the isolated or disconnected line. When
the line is disconnected from the supply end, there is some voltage on the line to which the
capacitance between the line and earth is charged. This voltage is significant in HV systems.
Before commencement of maintenance work, it is necessary that these voltages are
discharged to earth by closing the earthing switch. Normally the earthing switches are
mounted on the frame of the isolator.
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5. METHODOLOGY AND LEARNING
5.1. Modern Technologies Used
Modern Technology has been adopted in many areas of production, some of them for
the first time in the country. They are as follows:
 Selective crushing of coal.

 7 meters tall coke ovens.
 Dry quenching of coke.
 On ground blending of sinter base mix.
 Conveyor charging and bell less top for blast furnace.
 Cast house slag granulates for blast furnace.
 100% continuous casting of Gas expansion turbines for power generation utilizing blast
furnace top gas pressure.
 Hot metal de-sulphurization.
 Extensive treatment facilities of effluents for ensuring proper environmental protection.
 Computerization for process control.
 Sophisticated high speed high production mills.
5.2. Methodology for Solving Various Problems
In Vizag Steel Plant, power will be generated at 11kv at Thermal Power Plant. In any
industry, the main motto of the department associated to distribution networks would be to
reduce the losses in distribution and to ensure continuity of supply. To fulfil this moto the
generated power is stepped up to 220kv for transmission to various departments for reducing
line losses and to ensure continuity of supply in case of any fault at Thermal Power Plant or
at the substation residing there is a facility to import power from APTRANSCO Grid.
Incoming lines to any substation in Vizag Steel Plant come from MRS (Main
Receiving Station) to which supply comes from both Thermal Power Plant as well as
APTRANSCO. One of the substations named LBSS 1 is farther from MRS and is nearer to
Thermal Power Plant. So, feeding LBSS 1 from MRS would result in increase of
transmission losses. To rectify this problem supply is directly given from the substation at
Thermal Power Plant to LBSS 1 through two incoming 220kv lines.
Vizag Steel Plant
Formerly, there used to be oil circuit breakers in the substations. There was incident in
which one of the oil circuit breakers blasted, which would severe damage if there were any
men in the substation. To rectify this problem most of the oil circuit breakers are replaced by
SF6 gas circuit breakers. These breakers won’t blast and even they are more efficient than oil
circuit breakers.
There was a trip which occurred in one of the substations where I was assigned for
one month. It is a very high current which may affect the oil properties in the circuit breaker.
To ensure this oil sample is sent for testing which resulted in negative results. So, we
replaced the entire oil in the circuit breaker.
At another substation one of the circuit breaker is faulty. The mechanical components
of the circuit breaker aren’t working but the electrical components are fine. To rectify this
problem, we used an old circuit breaker which was kept aside as it’s electrical components
aren’t working properly. We replaced the electrical components of the old circuit breaker
with the electrical components of the new circuit breaker.
Vizag Steel Plant is one of the major steel producing organizations in India. It has a
Thermal Power Plant by which it generates almost the complete power required for its
operation. But, the technologies which are employed here for production are very old except
for a few like WRM-2 due to which the rate of production of products is affected. If these old
technologies are replaced by new technologies which can produce more number of products
in less time, then the company can make more profits.
Vizag Steel Plant
6. CONCLUSIONS AND SUGGESTIONS
6.1. Conclusion
One of the primary objectives of the industries is to develop a well-knit personnel

policy and a comprehensive personnel programme that will be result-oriented and to develop
organizational objectives. In accordance with this objective, Visakhapatnam Steel Plant
(RINL) has given considerable emphasis on development of human resources, as well as
formulation and implementation of progressive personnel policies, systems, rules and
procedures to synchronise organizational needs/ business plan with individual aspirations.
VSP has laid emphasis on effective man management as it believes that effectiveness and
success of the organization depend largely on the skills and commitment of the people.
The rigorous and systematic approach to recruitment from fresh candidates their
upwards training, promotions and rewards have all helped to meet the aspirational needs of
the individual and thereby the goals of the organization. VSP has developed a comprehensive
scheme of career planning and managerial succession. The size of the organization has
necessitated the development of a computer culture which motivates employees to contribute
their best towards the achievement of organizational based Personnel Inventory System. In
the field of industrial relations, VSP encourages a participative approach. A career with VSP
will mark the beginning for a quest for advancement. VSP is a fast expanding organization
and provides ample opportunities to bright youngsters to rise in the organizational hierarchy.
Looking into the rapid growth of the organization and the multifarious specialized function,
there exists opportunities for a rapid career growth in the area where aptitude lies. The
Company has an exclusive Training and Development Centre to take care of the training
requirements of the officers and workmen as well as the newly recruited Management
Trainees etc. The training initiative includes special need based Programs and orientation
programs catering to the requirements of various departments of the company.
Visakha steel plant produce not less than 262 tones per man year of liquid steel which
is the best in the country comparable with International levels. Visakhapatnam Steel Plant,
the first coastal based steel plant of India is located 16kmssouth west of city of destiny i.e.
Visakhapatnam. Bestowed with modern technologies, VSP has an installed capacity of 3
million tons per annum of liquid steel and 2.656 million tons of saleable steel. At VSP there
is emphasis on total automation, seamless integration and efficient up gradation, which
results in wide range of long and structural products to meet stringent demands of discerning
Vizag Steel Plant
customers which India and abroad. VSP products meet exaltinginter national quality
standards such as JIS, DIN, BIS and BS etc.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)and for occupation health and safety (OHSAS-18001),
VSP exports quality pig iron and steel products to Srilanka, Myanmar, Nepal, Middle East of
USA and South East Asia(pig iron).Having a total manpower of about 16755 VSP has
envisaged a labor productivity is not less than 262 tones per man year of liquid steel which is
the best in the country comparable with International levels.
6.2. Suggestions
There is a need of linking business strategy and cultural strategy to the training and
development activities. Then it will be easy to identify how the training supports the strategy.
Identify a minimum acceptable level of effectiveness for training and development
curriculum. So that the expected results can be easily evaluated in the process of functioning.
Each and every training and development activity has to be measured as soon as the
training program is completed and feedback given to trainee, trainer and concerned
department for future improvement/development. A variety of terms have been used by
researchers, academicians and practitioners to describe the research area selected by the
researcher. Live training, training and development, employee development, learning and
development and human resource development. The researcher selected training and
development mainly with regard to its impact and effectiveness.

Distribution Networks in Vizag Steel Plant

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BLAST FURNACE IN VISAKHAPATNAM

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

I would like to sincerely thank Associate Professor Mr. M.VENKATESWARA

It gives me an immense pleasure to express my deep sense of gratitude to our guide

I am extremely thankful to Dr. C.L.V.R.S.V.PRASAD Principal of the institution for

I take this opportunity to express my gratitude to all of the Department faculty

S. NAVEEN KUMAR (15345A0215)

This is to certify that mini project Report entitled DISTRIBUTION

Mr. I.RAVI KIRAN Dr.M.Venkateswara RAO

Assistant Professor Head Of the Department

Visakhapatnam Steel Plant, popularly known as Vizag Steel, is an integrated steel

Distribution Networks is one of the major departments in Vishakhapatnam Steel Plant

A Distribution channel is a set of interdependent organization involved in the process

S. NaveenKumar (15345A0215) Page |1

Internship is a supervised learning experience in which students apply their prior

The type of learning that is fostered by internships is experiential. It is active learning

 To understand the functioning and working conditions of a governmental organization.

S. NaveenKumar (15345A0215) Page |2

 To learn about research methodologies (field methods/methods to analyse data)

1.1. Benefits of Full Semester Internship to Students

 Provides them with practical experience in an organization.

1.2. Skills Developed through Full Semester Internship

 Interpersonal skills, global awareness and understanding issues of diversity.

S. NaveenKumar (15345A0215) Page |3

2. PROFILE OF THE COMPANY

S. NaveenKumar (15345A0215) Page |4

 Harness our growth potential and sustain profitable growth.

 To attain 16-million-ton liquid steel capacity through technological up-gradation,

S. NaveenKumar (15345A0215) Page |5

 Vibrant work culture in the organization.

2.5. Core values

2.6. Historical perspective

S. NaveenKumar (15345A0215) Page |6

2.7. Steel demand

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Category Quantity, *103 t

Bars and rods 10500

S. NaveenKumar (15345A0215) Page |8

 Raw Material Handling Plant

2.8.1. Raw Material Handling Plant

Figure 1: Raw material handling plant

S. NaveenKumar (15345A0215) Page |9

2.8.2. Coke Ovens and Coal Chemical Plant

Figure 2: Coke Ovens

Figure 3: Coal Chemical Plant

2.8.3. Sinter plant

Figure 4: Sinter Plant

2.8.4. Blast Furnace

Figure 5: Material flow diagram for Blast Furnace

2.8.5. Calcining and Refractory Material Plant

2.8.6. Steel Melt Shop and Continuous Casting

 Three LD Converters of 150 cum. volume each.

2.8.7. Light and Medium Merchant Mill

Figure 6: Light and Medium Merchant Mill

2.8.8. Wire Rod Mill

Figure 7: Wire Rod Mill

2.8.9. Special Bar and Structural Mills

Figure 8: Structural Mill

2.8.10. Thermal power plant

Figure 9: Thermal Power Plant

2.9. SWOT analysis of the industry

Table 2: SWOT analysis