1.

PARTICULARS OF ORGANISATION
OVERVIEW OF VSP
Rashtriya Ispat Nigam Limited Visakhapatnam Steel Plant (RINL VSP) popularly known as Vizag Steel-
the pride of Steel, a leading Central PSU under the Ministry of Steel is the first shore based
Integrated Steel Plant in the country.
Vizag Steel known for Quality & Customer Service is a market leader in longs with a share of about
10%. It has been supplying various grades of steel for construction of projects of National
importance which include Metros, Power Sector, Bridges, Nuclear complexes and several others.
RINL VSP has exported finish products to countries like USA, UAE, Thailand, Bangladesh, Nepal, Sri
Lanka etc. Its products are made 100% virgin steel, maintaining stringent tolerances both in
chemistry & physical properties. RINL VSP has a wide marketing network spread across the country
and is the preferred steel marker for the customers.
Name of the Organization RASHTRIYA ISPAT NIGAM LTD. (A Navratna Company)
Headquarter VISAKHAPATNAM
Date of Establishment 18TH February 1982
Main Area of Activities Iron and Steel making with finished products like Billets, Wire Rods, Rounds,


Capital Structure:
Authorized capital Rs. 8000crores
Paid-up capital Rs. 7827crores
Physical & Financial Performance Details:
Year Hot metal(00t) Liquid metal(00t) Saleable steel(oot) Turnover (in crores)
Financial Net profit/Loss (Rs. In crs.) Net Worth (In crores)
2009-10 3900 3399 3167 10635 797 12885
2010-11 3830 3424 3077 11517 658 13229
2011-12 3778 3310 2990 14462 1110 13659
2012-13 3814 3071 2900 13651 527

Man Power: The Companys work force stands at 18080 as on 31.12.2011
Mines operated by RIN:
1. Dolomite mines at Jaggayapeta
2. Limestone mines at Madharam,
3. Manganese Mines at Garbham, Vizianagaram, Dist A.P
1.1 INTRODUCTION TO VSP
To put up an integrated steel plant at Visakhapatnam was announced on 17th August
1970 by Smt. Indira Gandhi in Parliament and the formal inauguration was done on 20th January
1971.
The plant annual capacity was 3 million tons of liquid steel in October 1977. USSR helped India in
setting up the 3.4 million tons integrated steel plant at Visakhapatnam in the year 1979. The
estimated project cost is Rs. 6,269.57 tons based on Mills as on first quota of 1986.
VSP became the first integrated steel plant to achieve the distinction of embracing all the process
and products under ISO 9002, ISO 14000, and ISO 18000 for the entire plant.
Bearing a total manpower of about 17,000, VSP has envisaged a labor productivity of not less than
230 tons per man per year of steel which is the best in the country and comparable with the
International Levels.
The primary consideration for fixing up the steel plant in Visakhapatnam was to have location
advantages of port on the coast of Bay of Bengal. However, location advantage could not be utilized
in full by the company due to various constraints and non-development of captive harbor adjoins the
plant site. The main objectives of RINL on its incorporation were to take over the VSP from SAIL with
all its assets, liabilities, rights and obligations and to carry on in India and elsewhere manufacturing,
trading, importing and exporting of iron and steel of all qualities.
1.2 FACILITIES IN VSP
S.NO. DEPARTMENT FACILITIES CAPACITY x1000 tons PRODUCTION x1000 tons
1 COKE OVENS (C&CCD) 3 Batteries of 67 ovens each having volume 41.8 cum with 7mt tall.
2261 2055
2 SINTER PLANT 2 sinter machines of 312 sq. of grate area. 5256 4855.86
3 BLAST FURNACE 2 furnaces of 3200 cum useful 1 volume - bell less top conveyor
charging system. 3400 3485.475
4 SMS 3 LD converters of 133cm capacity, 6 continuous casting machines of 4 stand each.
3000 3082.8
5 A. B. C. ROLLING MILLS LMMM WRM MMSM SALEABLE STEEL FINISHED STEEL 7 stand BD
mill 8 stand RM 5 stand IM 4 stand FM 8 stand RM 6 stand IM 6 stand FM 710 850 850 725
868 752 2575 2365

MISSON:
To attain 16 million ton liquid steel capacity through technological up-gradation, operational
efficiency and, quality and expansion, to produce steel at international standards of cost and quality
and to meet the aspiration of the stakeholders. To be a continuously growing company by producing
steel of International standards and to satisfy the customer by Products and services.
VISION:
To be a continually growing world class company. Deliver high quality and cost competitive products
and be the first choice of the customers. Achieve excellence, enterprise management
OBJECTIVES:
To maximize profits through appropriate strategies including cost reduction measures.To ensure a
continuous presence in the export market with a flexible export strategy.
CORE VALUES:
Commitment
Customer satisfaction
Continuous improvement
Concern for the environment and safety
Creativity & innovation
1.3. Infrastructure Facilities
Location:
The plant is located on the coast of Bay of Bengal. 16Kms to the South West of Visakhapatnam port.
It lies between the northern boundary of National Highway from Madras to Calcutta and 7 Kms. The
south of the Howrah-Madras Railway line. Visakhapatnam is well connected by own with unique
cities of India.
The area enclosed within boundary wall of steel plant is about 2,600 hectares. Additionally 2,600
hectares are occupied by the Steel Plant Township and 350 hectares by the Kaniti Balancing
Reservoir.
Power:
The total requirement of power in VSP is 280 MW where 3.0 Million tons stage is reached.
Parts of this requirement are met from 4x60 MW generators at VSPs own captive power plant.
Two steam turbine generators of 7.5MW each generates power using the waste heat of dry
quenching unit of coke ovens and 2x12.0 MW temperature, pressure recovery turbines will generate
power utilizing high pressure available from temperature gases of BF.
The balance 1.39 MW (about 150MVA) of power is to be supplied by the Andhra Pradesh State
Electricity Board to meet the maximum demand requirement of power at VSP.
Water:
The total water requirement of the plant will be 73 million gallons per day, which is to be met by the
Yeluru water supply scheme, which is an Andhra Pradesh government project.
Auxiliary Facilities:
Extensive facilities have been provided for repair & maintenance as well as manufacture of spares.
The repair shop complex house machine shop. Structural shop, Steel and NF foundry, Forge shop,
Loco & wagon repair shops, Electrical repair shop, Utilities equipment repair shop, Air conditioning &
ventilation system repair shop.
In addition to the above basic units to s\carry out various operations. VSP is having fully equipped
Research & Control Laboratories to monitor and control all the operations carried out at the plant.
It is also having well established Training and Development Center to train the newly recruited
personnel and to conduct refresher courses for the employees and make them able to handle jobs
assigned to them during their regular duties.


RAW MATERIAL LINKAGES:
MATERIAL SOURCE DISTANCE
Iron one lumps and fines Bailadilla (MP) 471 KMS.
BF Grade Limestone Jagayyapeta 455 KMS.
SMS Grade Limestone Badanpur (MP) 1120 KMS.
BF Grade Dolomite Kotmisonar 656 KMS.
SMS Grade Khammam 495 KMS.
Manganese ore Cheepurapalli 495 KMS.
Manganese ore Sandur 100 KMS.

1.4. Main Departments in VSP
1. Coke & Coal, Chemical Department
2. Thermal Power Plant (TPP)
3. Sinter Plant (SP)
4. Raw Materials Handling Plant (RMHP)
5. Blast Furnace (BF)
6. Steel Melting Shops (SMS)
7. Rolling Mills
8. Light & Medium Merchant Mill (LMMM)
9. Wire Rod Mill (WRM)
10. Medium Merchant & Structural Mill (MMSM)
11. Auxiliary Shops
12. Forge Shops
13. Steel Structural Mill
14. Central Machine Shop
15. Foundry
16. Field Machinery Department (FMD)
17. Ore Mines and Quarries (OMQ)
18. Traffic Department (TD)
19. Energy Management Department (EMD)
20. Production Planning and Monitoring (PPM)
21. Safety Eng. Department
22. Quality Assurance& Technology Development (Q, A& TD)
1.4.1. COKING COAL:
Primer & Medium Bengal - Bihar 990 KMS.
ImportedThrough VPT 30 KMS.
Steam Coal Thalcher (Orissa) 580 KMS.

Plant Facilities:
VSP has the following major production facilities:
1. Coke Ovens:
4 Batteries as each of 67 ovens having 7.0 meters height
2. Sinter Plant:
Sinter Machines of 312 sq. Mtr grate area each.
3. Blast Furnace:
2 Blast Furnaces, each having 3200 Cu.M. of useful volume.
4. Steel Melt Shop:
3 LD converters, each of 133Cu. Mtr. Volume and six 4 strand bloom casters
5. Light and Medium Merchant Mill (LMMM):
4stand finishing mill and having a capacity to produce 710,000tons per annum of various
finished products such as rounds, re-bars etc..
6. Wire Rod Mill (WRM):
It is a 4strand, 25 strands fully automated and sophisticated mill. It has a capacity of
8,50,000 Tonnes per year.


7. Medium Merchant & Structural Mill (MMSM):
This mill is a high capacity continuous mill consisting of 20 strands arranged in 3 trains. It has a
capacity of 8,50,000 Tonnes per year capacity.
Besides these main metallurgical units a Captive Power Plant of 247.5 MW capacity, Oxygen plant,
Acetylene plant, Compressed Air Plant, Extensive repair and maintenance facilities form part of the
services available at VSP.
Steel plant can take pride in having a clean & green township with the provision of about 800
quarters, markets, community welfare centers, clubs, etc.., for the employees and their families
besides having a modern hospital with 155 beds.
1.4.2. MODERN TECHNOLOGY:
Seven-meter tall coke oven worth dry quenching of coke using Nitrogen gas, steam generated during
this process is to be used for power generation. 3200cum. Blast furnaces, the longest in the country
with conveyer changing the belt less top equipment.
Gas expansion turbines are provided for power generation by utilizing the e BF gas top pressure. Hot
metal desulphurization provided for 100 percent continuous casting of liquid steel into blooms. High
speed Rolling mills with computerized controls and extensive waste heat recovery system were
provided.
1.4.3. MAJOR PRODUCTION UNITS:
COKE OVENS:

The coal is proposed before charging into coke ovens in coal tower. The prepared coal in the coal
tower is drawn by a changing car on the top of the batteries and charged into the ovens as per the
sequence -0. The charged coal is gradually heated in the absence of air to attain a temperature of
1000-1050 C which generally takes about 16hrs for the coke to be ready. The volatile matter
escaping during carbonization is collected in a gas collection main through stand pipe. The stone is
cooled by Ammonia liquid spray and sent to coal chemical plant. The ready coke is pushed out of the
oven by a pusher car into a coke car and is taken to the dry cooling plant for discharging the hot coke
into cooling chambers.
There are three batteries, each having 7 ovens. Each oven has a volume of 41.6 m2 and can hold
31.6 T of only coal charge.
The heat for carbonization is being supplied is being supplied by a mixture of blast furnace gas and
coke oven gas having a calorific value of 1000 Kcal/NM3.
Batteries are of under jet, compound type having twin heating filled and recalculation of waste
gases.
SINTER PLANT DEPARTMENT:

In Sinter plant ore fines are made into Sinter before being charged into a blast furnace. An initial mix
consisting of ore fines and blue dust, manganese ore, metallurgical wastes, dolo-fines, sand, 80% of
coke fines is prepared. This mix along with sinter returns, sinter screenings 20% of lime fines and
20% of fine coke is stocked in bunkers. Moisturizing and palletizing is carried out in 4.2 * 24m drum
mixer to obtain a homogeneous mixture with partial palletizing and optimum moisture.
10-25 mm size sinter is used as hearth layers of about 40mm thick. This decreases dust entrapment
by exhaust gases, reduce grate bar consumption.
Sinter mix up to 300mm thick is laid on the heath layer. A mixture of coke oven gas and blast furnace
gas having a calorific value of 2,000 Kcal. NM3 is used for ignition.
The prepared sinters is crushed to about 15mm size and cooled by forcing atmospheric air. This
sinter is then sent to blast furnace through conveyors.
BLAST FURNACE:

There are two blast furnaces of 3,200 cubic meter useful volumes, each capable of producing 1.7 Mt
of hot metal per year while operating for 350 days are installed.
There are four hot blast stores for each furnace with a total heating surface of 224,000 square
meters. The dome can be heated to a temperature of 1450 C maximum while the waste flue
temperature is up to 400 C. Stores are heated, by a mixture of blast furnace gas and coke oven gas
having a calorific value of 1100 Kcal/N Cum, up to 1300 C pressure of mixed gas before burners is
600 mm W.C.
Hot metal is discharged into 140 T hot metal ladles by rocking runners in east house.
There are four railway tracks for hot metal transportation, one service sub-track and once track for
flue dust disposal independent running railway tracks are provided for delivery of hot metal to SMS
requirement = 0.5 - 3 T as per blowing conditions Raw or calcines coke - used to increase lining life of
the converter.
Lump coke - Use to preheat the lining of the newly lined converter.
Steel Melting Shop (SMS):

Steel is an alloy of iron with carbon up to 1.8%. Hot metal produced in Blast Furnaces contains
impurities such as Carbon (3.5 - 4.25%), Silicon (0.4 - 0.5%), Manganese (0.3 - 0.4%), sulfur (0.04%
max.) and Phosphorous (0.14% max.) is not suitable as a common Engineering Material. To improve
the quality the impurities are to be eliminated or decreased by the oxidation process.
VSP produces steel, employing three numbers of top blown Oxygen Converters called LD Converters
(L & D stand for Linz &Donawitz - two towns in Austria, where this process was first adopted) or
Basic Oxygen Furnaces/Convertors. Each convertor is having 133 Cu.M. Volume capable of producing
3 Million Tonnes of liquid steel annually. Besides hot metal, steel scrap, fluxes such as calcined lime
or dolomite form part of the charge to the convertors.
ROLLING MILLS:
The cast blooms produced in SMS-CCD does not find many applications as such and are required to
be shaped into products such as Billets, Rounds, Squares, Flats, Angles (equal & unequal), T-bars,
Channels, I-PE beams, HE beams, Wire rods, and Reinforcement bars by rolling them in three
sophisticated high speed high capacity, fully automated rolling mills. They are:
1. Light & Medium Merchant Mills
2. Wire Rod Mills
3. Medium Merchant & Structural Mills.
All the above-mentioned Rolling Mills are HI-TECH Rolling mills with full automation and all modern
equipments.
RAW MATERIAL HANDLING PLANT (RMHP):

The raw material handling plant receives the basic raw materials requires for the steel making
process from various sources through railway wagons. The raw materials like Iron ore fines, Iron ore
lumps, sized iron ore, Limestone, Dolomite, etc.., are stocked in ore and flux yard. Imported coking
coal, medium cooling coal and boiler coal is stocked in a coal yard. These raw materials are sent in
different proportions to nations departments through a conveyor system.
SAILENT FEATURES OF RMHP:
1. A peripheral unloading system for railway wagons coming directly up to the pushers.
2. Blender reclaims for blending of ores and flux in which the bucket wheel has a lateral motion
across the bed.
3. Wheel on bloom reclaims for reclaiming different materials from some bed in ore of flux
yard and same type coals in CHP.
4. Ring Granulators for crushing of boiler coal.
5. PLC control of all systems.
6. Driers for dying SMS sized one.
7. Mixers for mixing lime in purchased and generated fires.
8. Preparation of sized iron ore for use in BF to enable close size range of raw materials.
9. A dust extraction system is provided at various locations of RMHP to absorb the dust
generated during the process.
VARIOUS IRON & STEEL PRODUCTS:
VSP holds forth the promise of adequate simply to the consumers of Iron & Steel product in the
country. Pig iron, Billets, Plain rounds, Reinforcement bars, Plain and Ribbed rods, Equal and
Unequal Angles, Channels and Beams flooring out of VSPs large capacity mills will ensure that the
requirements of all consumers are fully met.
PRODUCTS QUALITY:
Computerized process control of VSP starts right from the hot metal production. Dynamic control of
steel melting operation guarantees steel chemistry strictly as per specifications, product with
International specifications and tolerance, Reinforcement bars of VSP produced through Temp
core cooling process will have high strength coupled with good bend ability are a boon to the
construction sector. VSP wire rods will have high strength and good ductility because of controlled
cooling of wire rods by the STEELMORE cooling.
BY-PRODUCTS:
For consumers wanting suppliers of Naphthalene, Pitch, Anthracite oil, Neonate oil, Coal tar, Wash
oil, Light oil, Benzene, Toluene, Xylene etc.., By products from its 60 Modern coke oven plant will be
useful in many industries.
SMS DEPARTMENT:
In the Steel Melting Shop of Visakhapatnam Steel Plant, LD Process of steel making has been
adopted. The liquid steel obtained from LD process is cast into Blooms through Continuous Casting
Machines (Bloom Casters).
For better exploitation of the available facilities and to have efficient administration in the biggest
department of VSP, the Steel Melting Shop is divided into two major sections.
1. Converter Shop
2. Continuous Casting shop
Each of these shops has been further divided.
CONVERTER SHOP:
1. Bulk Material Handling Section (BMHS)
2. Mixer shop
3. Converter Bay
4. Scrap Yard
5. Slag Yard
6. Ladle Preparation Bar
CONTINUOUS CASTING SHOP:


1. Tundish preparation Bay (TP Bay)
2. Argon Rinsing Station (ARS) & IRUT & LF
3. Continuous Casting Machines
4. Gas Cutting Machines
5. Bloom Storage Yard.
LIGHT & MEDIUM MERCHANT MILL (LMMM):

The cast blooms from the continuous casting department are heated and rolled in the two high
speed and fully automated rolling mills namely Light & Medium Merchant Mill (LMMM) and 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 the rest
is sent to bar Mill/ WRM. The continuous two-line Bar Mill comprises of 8 stand Double Strand
roughing train, 2nos. of Stand Single Strand intermediate train & 2 nos. of 4 Stand 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.
WIRE ROD MILL (WRM):

The Wire Rod Mill of VSP is high speed 4 strand No-Twist continuous mill designed to produce
8,50,000 T of wire rod coils. The mills are designed to produce plain wire rods from 5.5 mm to 12.7
mm diameter and Rebar in 8mm, 10mm and 12mm diameter in coil form. However sizes up to
14mm are being rolled presently. The mill is constructed at an elevated level of +5350 mm. Rolled
billets of 125mm * 125mm square cross section, length ranging from 9.8 m to 10.4 m and weighing
approx. 1250 Kgs are used as input material. The mill is designed to roll steel stock of 0.9% max.
Carbon content.
ACHIEVEMENTS:
Commissioned in 1989, it was the shore based, integrated company spread over an area of 5000
sq.km. Since commissioning, VSP has crossed many mile stones in the fields of production,
productivity and exports. Some of the peak achievements are
1. Coke rate of the order of 540 Kg/Ton of Hot metal.
2. Average converter life of 649 heats.
3. An average of 11.5 heats per sequence in continuous Bloom Caster.
4. Specific energy consumption of 7.51 G.Kal/ton of liquid steel.
5. Specific refractory consumption of 15.2 Kg/Ton of liquid steel.
6. Labor productivity of 230 Ton/man/year.
1.5. ACHIEVEMENTS&AWARDS:
The efforts of VSP have been recognized in various for a some of the major awards received by VSP
are in the area of energy conversation, environment protection, safety, quality circles related awards
and a no of awards at the individual level.
Award Purpose Year
National Energy Conversion Award Energy efficiency (first prize for 3 consecutive years and also
a special award for achieving this.) This is the 7th award in a row. 2006
Safety Innovation Award For contribution in innovating, promoting and implementing the
best safety practices presented by institution of engineers(INDIA) 2006
Certificate of Appreciation by Institution of Engineers, AP chapter Excellence in energy
conversion 2005
National Award for Excellence in Water Management by CII Excellence in water management
2005,2004
World Quality Commitment International Star Award Performance excellence, quality
management & quality achievement, given by business Initiative Directors, Paris in Gold Category
2004
Prime Ministers Trophy Best Integrated steel plant 2002-03
Indira PriyadarsiniVrikshmitra Award For massive afforestation efforts. Given by Ministry of
Environment & Forests 2002-03
Environment Excellence Award For Energy Conversation by Greentech Foundation, Delhi
2002
Shield for Best Efforts in rain water Harvesting AP pollution control board 2001

HALLMARK OF VIZAG STEEL ORGANIZATION:
Today VSP moves forward with an aura of confidence and with pride amongst its employees who are
determined to give their best for the company to enable it to reach new heights in organizational
excellence.
The remarkable performance on the production front coupled with prudent financial management
has not only resulted in achieving significant net profits, but also helped RINL emerge as a NET
POSITIVE COMPANY in January 2006 by wiping out all its accumulated losses during 2005-06.
2. MEDIUM MERCHANT STRUCTURAL MILL (MMSM):


Medium Merchant and Structural Mill of Visakhapatnam Steel Plant is a continuous rolling mill
having an annual production capacity of 850000tons of the hot rolled structure of Rounds, Angles,
Flats, Squares, Channels, and Billets.
It is established in the year 1992. It has two furnaces of 150T/hr capacity each, to heat and soak the
blooms to the required rolling temperature. In these furnaces the blooms are reheated up to 1200 C
and rolled to a desired shape by passing through Eight Stand Roughing Mill, Six Stand Intermediate
Mill & Six Stand Finishing Mill. By allowing natural cooling the products are cooled on the cooling
bed. The finished product is cut into no of pieces as per customer requirement by using cold saws
which are six in number. After getting the required product, it comes to the inspection area. Here
inspection done by Quality Assurance and technical Development (QATD) department, further the
finished product is piled or bundled based on the product shape.
In the MMSM the material shifting equipments are operated mainly with hydraulic system. These
are mainly furnace, mill area & finishing area. As compared to all these three areas hydraulic system
is huge in capacity which operates 1000 actuators. Keeping in the view the problem is faced in
existed hydraulic system. i.e. if any problem is occurred in existed system difficult to find and its
rectification takes more time which leads to loss of production and loss of hydraulic oil. These
problems are effects on total production rate. The necessity to go for a modification by bifurcating
the existed hydraulic system arose. So some modifications were. Implemented. These modifications
in the existing hydraulic system which I deal in this project have been very advantageous for the
company.
Major unit process involved
1. Heating of Blooms in Reheating Furnace
2. Rolling of heated Blooms to pre-determined size and shape
3. Cooling and Straightening of Rolled Products
4. Cutting and Packing of products
5. Stacking and Dispatching
2.1. FURNACE AREA:
WALKING BEAM REHEATING FURNACE
HIGHLIGHTS:
1. Components of furnace
2. Equipment specification
3. Furnace construction features
4. Walking beams
5. Combustion system
IMPORTANT COMPONENTS OF THE FURNACE:
The reheating furnace includes the following components:
Furnace structural framework
Walking beam driving mechanism
Walking beam and fixed beams
Combination air fan
Burners
Waste gas exhaust system
Refractory and insulation
Fuel system, evaporation cooling system, lubrication and hydraulic system
Equipment specification:
The walking beam furnace is used for heating blooms of place carbon steel, low alloy steel, free
cutting steel, medium and high carbon steels from ambient to about 1000C. The furnace is charged
in two rows foe 6 mts long blooms and also with a provision of charging 12mt blooms. The
particulars about the walking beam furnace are as given below.
Type

Number Two
Nominal output charge temperature at 250T/hr
Inlet Ambient
Discharge temperature at outlet 12000 C
Temperature difference b/w surface and core 300 C


2.2 MILL AREA
Medium merchant and structural mill is a high capacity continuous mill consisting 20 stands
arranged in 3 trains as given below.
Roughing train having 8 stands (4 two high horizontal stands, 2 vertical stands and 2
combination stands).
Intermediate train having 6 stands (2 high horizontal stands, 2 combination stands and 2
vertical stands
Finishing train having 6 stands (2 high horizontal stands, 2 vertical stands and 2 combination
stand).

SPECIAL FEATURES OF MILL PROPER
Quick stand changing facilities to change set up time.
Automatic engagement of spindles in the working spindles.
Automatic connection of electrical supply, grease, hydraulic, lube oil and roll cooling water
connection without manual introversion.
Hydraulic roll balancing system.
Motorized drive for roll gap adjustment.
Roll neck bearings
Radial: four row cylindrical roll bearings
Axial: antifriction taper roller thrust bearings.
Telescopic spindles.
Possibility to change the gear ratio.
Self-aligned roll cooling water showers.
Movable rest bars for mounting guide and guards.
COOLING WATER DISTRIBUTION TO MILL AREA:
The cooling water is supplied over the support of spindles to the moving supply units. From
the moving supply unit water delivered to the upper horizontal working roll through rising pipes over
a hose coupling, a fixed coupling and nose.
The down horizontal working roll is provided with water from moving supply unit by raising
the pipe through house coupling, fixed coupling and a hose. The welding on pieces is welded to the
chocks of horizontal rolls.
The down horizontal working roll as cooled by a spray attached in the same way as the
spray at the upper roll.
The vertical working rolls are water cooled from the moving supply unit. Water is supplied
to the vertical roll of the driving side from a rising pipe over a hose coupling and a fixed coupling and
the nipple screwed into the hosing cap of the vertical rolls.
PUMPING OF COMPRESSD OIL TO MILL STANDS:
The compressor oil is supplied through a moving supply unit, then by means of a pipe of
16x3k type oil is delivered to the hydraulic cylinder to the balancing the vertical rolls. The hydraulic
cylinders for balancing the horizontal rolls are connected by means of a hose of pipes attached to
the frame of rolling mill by means of grippers. The compressed oil from the driving side is delivered
to the attending side by means of connecting units.
PUMPING OF LUBRICATING GREASE TO MILL AREA:
Lubrication grease to lead from the main distribution to the spindle support stand through
pipes. Hoses are inserted between the pipes with sag that compensate the spindle support travel.
Grease is lead via distributions to six lubrication points on the guide of spindle support and to the
spindle support finger. Grease is led to the stationary supply unit through a branch pipe to lubricate
the two horizontal rolling mills.


FLYING SHEARS:
In the mill area there are four flying shears are located. First one is placed before mill area and
remaining after the intermediate, roughing and finishing stands respectively.
2.3. COOLING BED
HIGHLIGHTS OF COOLING BED:
120m long double side rake type cooling bed.
1. Switch with conveyer: serves for guiding the mill products alternatively on left and right side
of cooling bed.
2. Supply conveyer: Serves for mill product transportation in two sides of cooling bed.
3. Separating bars: Serves for separating mill products following quickly one after another.
4. Breaking flaps: Serves for placing mill products from supply converter to cooling bed.
5. Cooling grates: Rake type cooling grate having 45 notches and serves to transport mill
products to outlet conveyer after cooling.
120 numbers of cooling fans are one side of each cooling bed is installed to cool the rolled
materials.
DESCRIPTION ABOUT COOLING BED:
The billets which are coming from the mill are going to cooling bed for cooling the billets into room
temperature. There are two cooling beds in the MMSM area. The billets are transferred to the left
and right side of cooling bed.
The purpose of the switch with conveyer is to distribute the rolled pieces fed in one branch from the
shears to two branches to the supply conveyer of the cooling bed.
The switch with the conveyer is installed ahead of the cooling grate within the cooling area. The
material fed by the conveyer is fed over the one arm conveyer to the area of the switch and here it is
discharged alternatively to the left and right conveyer. The function of the switch resetting is
provided by the pneumatic drive, this moving out plate hence discharging the material to one or the
other branch. The drive consists of two coupled pneumatic cylinders, which with the help of the rack
bar rotates two shafts.
The switch with the conveyer has been constructed for the material discharging alternatively to the
left and right side of the supplying conveyer. The maximum length of the transported rolled piece is
120m. During the operation the switch can be used permanently or can be taken out of the
operation the switch can be taken out of operation and operates as a conveyer to a single arm of the
supplying conveyer.
ROLLER STRAIGHTNER:
Roller straightener is placed behind each side of cooling bed for straightening rolled products.
Total number of rollers is 9.
Number of top rollers are 4. Only axially adjusted and motor driven.
Number of bottom rollers are 5. Axially and vertically a
Adjustable and friction driven.
Speed of straightener is 2.5 to 12m/s
2.4. SAWAREA:
Technical Data:
Blade diameter 1450-1600 mm
Blade thickness 8-10 mm
Blade speed 145 m/s
Feed rate 30-300 mm/s
Return speed 600 mm/s
Material of saw blade Alloyed tool steel
Teeth depth 12 mm
Roller table speed About 2.2 m/s
Roller diameter 212 mm
Roller length About 1600 mm.
No.of rollers 166
Roller material Steel tubes

Manual data: No. of saw 6(L.H.S-3, R.H.S.-3)
DESCRIPTION:

One side of the saw area consists of three saws. They are stationary saw, mobile saw 1(MS 1) and
mobile saw 2(MS 2). Among the three, saw one is stationary which is fixed and remaining 2 are
adjustable according to the length requirement. One traversable stopper is there for levelling sizes.
This stopper is adjustable according to the length requirement. With reference to stationary saw
traversable stopper, mobile saw 1 and 2 will be positioned in required distance.
Purpose &Location:
In this area we will get required length of the final products of the final products located in extension
of the outlet conveyor of the batching grate.
Process:
The products coming from batching area is drawn into the saw area in order to obtain the required
length. Initially the starting ends of the products are settled at the fixed saw, and then the holding
mechanism (clamping beam, compactor) to0 hold the material for cutting. After holding the
products, the saw will move forward to cut the material and then it will be lifted hydraulically and
will return to its initial position with the help of rack and pinion mechanism.
Magnets and transversable stoppers operate simultaneously for the separation of scrap (below 6m
length) and required final products. By using retractable stoppers, scrap CCD the scrap will be
removed and dumped into the scrap bin.
2.5. INSPECTION AREA:
After getting the required products, it comes to the inspection area. Here inspection is done by
Quality Assurance and Technical Dev