reportrourkela

8/7/2019 reportrourkela

1/26

Rourkela Steel PlantRourkela steel plant was the torch bearer for Public Sector

Steel Industry in India and carried the banner of the industrial

revolution for the nascent Republic of India. The Steel Plant,now a unit of the Steel Authority of India Limited (SAIL), was astarted during the mid-fifties of the 20th century in

collaboration with the leading steel makers from the FederalRepublic of Germany.

The plant was modernised in the mid-1990s with a number of new units

having state -of-the-art facilities. Most of the old units were also revamped for

effecting substantial improvement in the quality of products, reducing cost and

ensuring cleaner environment.

RSP was the first plant in India to incorporate LD technology(An oxygen steel

making process named after the towns in Austria, Linz and Donawitz, where itwas first developed. It is a modified Bessemer process). It is also the first steel

plant in SAIL and the only one presently where 100% of slabs are produced

through the cost-effective and quality-centeric continuous casting route.

RSP presently has the capacity to produce 2 million tonnes of hot metal, 1.9

million tonnes of crude steel and 1.67 million tonnes of saleable steel. It is

SAILs only plant that produce silicon steels for the power sector, high quality

pipes for the oil & gas sector and tin plates for the packaging industry. Its wide

and sophisticated product range includes various flat, tubular and coatedproducts.


2/26

Special Features of Rourkela Steel Plant:

It is the first Plant in Asia to adopt LD process of steelmaking.

It is the only Plant producing large diameters ERW/SWPipes confirming to most rigid standards of API.

It is the first steel Plant in India to adopt externaldesulphurization of hot metal by calcium carbideinjection process

.

It is the only steel Plant in SAIL producing Cold RolledOriented (CRNO) Steel sheets for use in the electricalindustries with installed capacity of 73000 Ton/yr

Rourkela is the first in vacuum degassing metallurgy.This system has been adopted primarily for productionof silicon steel for the cold rolled non-oriented sheets.

This system consists of vacuum arc refining and vacuumoxygen refining units and degassing facility.

It is the first integrated Steel Plant of SAIL which adopted

the cost effective and quality centered continuouscasting route to process 100% of steel produced.

All the major production departments and some servicedepartments and some service departments certified toISO 9001:2000 QMS.


3/26

UNDERGOING MODERNISATION

Rourkela Steel Plant (RSP) is one of the flagship steel plants

of the Steel Authority of India Limited (SAIL), located in theIndian state of Orissa. It currently has the capacity to produce

1.9 MT of steel p.a. but plans to modernise and more than

double its capacity to 4.2 MT. The plans involve modifyingthe existing units as well as building new ones. To that

purpose SAIL obtained new loans worth more than Rs. 75

billion in the period 2008-09.

The modernisation and expansion of the plant will enablesome technological changes ,which the company claims will

reduce the CO2 emissions per tonne of crude steel production.


4/26

TRAINING COMMENCEMENT

Before the actual beginning of the training all the trainees were requested to

collect their security passes for entering the plant at the HUMAN RESOURCE

DEVELOPMENT dept. of the ROURKELA STEEL PLANT and were

instructed to report sharply at 9 am at the plants auditorium the next

morning.

The next morning i was witness to an overwhelming crowd of future engineers

who were there like me to gain the valuable practical experience the industry

was going to provide and we were all excited. After been seated we had to wait

for sometime for the managers who were incharge of our training to come andinstruct us.

They started with a brief introduction of the plant with a presentation

consisting of videos and slides and also made us aware of the product the plant

manufactures and about its modernization plans. Much stress was given to

safety as industrial plants are prone to accidents . We were directed to wear

safety helmets and shoes all the time and to refrain from wearing loose clothes

as they may get sucked by the machines.

After the presentation the trainees were divided into different groups

depending on the departments they were assigned to on the basis of their

respective engineering field. I was in the group which would undergo training

at the COMMUNICATION ENGINEERING DEPT of the plant . From there

we were guided to the head office of the COMM DEPT called TELECOM

BHAVAN. There the training incharge again subdivided us into a group of five

member each and handed the schedule to us .

An overview of the various communication equipments used in plants for itsefficient running were given to us and also some basic concept of

communication like the type of modulation , multiplexing ,switching were

discussed.


5/26

COMMUNICATION DEVICES USED IN PLANT

Telephone

Public address system

Mobile

Loud Speaker

Push to talk (PTT)

Base communication


6/26

VHF RADIO COMMUNICATION

VHF (Very high frequency) is the radio frequency range from 30 MHz to 300

MHz. VHF propagation characteristics are ideal for short-distance terrestrial

communication, with a range generally somewhat farther than line-of-sight from

the transmitter . Unlike high frequencies (HF), the ionosphere does not usually

reflect VHF radio and thus transmissions are restricted to the local area (and

don't interfere with transmissions thousands of kilometres away). VHF is also

less affected by atmospheric noise and interference from electrical equipment

than lower frequencies. Whilst it is more easily blocked by land features than

HF and lower frequencies, it is less affected by buildings and other less

substantial objects than UHF frequencies. Hence its the best medium of

communication for the plant.

The VHF devices used by the plant were PTT and BASE

COMMUNICATION

PUSH TO TALK(WALKY TALKY)

The plant is currently using two models of PTT

MOTOROLA GP338---- With 128 channels

MOTOROLA GP328---- With 16 channel

These PTTs are easily programmable . To use this device the plant has to pay a

yearly subscription fee to the Government of India. There range around 3-4

Km. Gp338 is an advanced model and has lot more no of channel and features

than Gp328

GP33

GP32


7/26

As we can see from the pictures GP338 is very user friendly as it has a display

and we can also name the channel so no need to remember the channel no.

PROGRAMMINGThe programming of devices is accomplished by the software

PROFFESIONAL RADIO CPS (customer programming software) which is

provided by the company MOTOROLA itself.

Channels can be assigned to different frequencies.

Devices can also be cloned.


8/26

MODESCSQ or Carrier Squelch is communications with no codes. Codes help filterout unwanted transmissions. Its open to all.

TPL or Tone Private Line modulates at a low frequency.

DPL or Digital Private Line modulates a series of binary codes.

Both users must be on the same TPL or DPL to communicate.

The term Private does not mean unheard. Anyone that can monitor or that has

CSQ can hear your transmission, if they are on the same frequency.

The biggest advantage of DPL over TPL is that there are more different choices

of codes with DPL. In addition, each code can be used either "normal" or

"inverted." Also...it is considered to be more difficult to scan for DPL codes

than TPL, although with some of the newer available receivers, this isn't

necessarily still true. Advantage of TPL is that DPL takes too long to decode--a

significant fraction of a second so wait for the path to be established before

trying to talk.


9/26

BASE STATIONThe base station is one end of a communications link. The other end is a

movable vehicle-mounted radio or walkie-talkie. Base stations can either be in

the form of stationary base stations or they can be mounted on moving vehicle

for maximum flexibility and reach.

Key Advantages

1.One-to-one and one-to-many communication

2.Base-station type two-way radio solutions for ground stations or vehicle-

mounted, which can also be integrated with handheld-type solutions formaximum mobility and flexibility

3.Low cost

4.Simple operation like a walky-talky

It can have upto 255 channels. It requires a 12 volts power supply.

Its range is around 100 to 200 km so it requires an antenna far above the ground

To increase its range further repeaters can be used.It can also be connected with

telephone device. The mouthpiece of the device is the programmable port


10/26

LOUD SPEAKERIt is the very common method of communication. It is used for short distance

communication like to address a congregation of employees at the same time.

Its general purpose is to amplify the sound of user.

It cannot reproduce sound


11/26

PUBLIC ADDRESS SYSTEM

It is becoming increasingly common for industries to incorporate public address

systems for a variety of reasons. Traditionally used for staff announcements and

background music, safety warnings from fire and bomb alerts are becoming

common and a zoned public address system controls a variety of situations

effectively.

The plant has a PA system which can handle upto 80 stations . The stations are

set by the telephone exchange in the plant.

It is the most fastest way of communicating with the employees .

Works on 10 watt power and transmission bandwidth is 10khz.

It has speed dial buttons.

Station

A

Exchan

ge

relays

Station B

Station C

Station D


12/26

EX COMM

Short for executive communication system is used mainly to set up conference

call. In the plant there are two cabinets in the exchange having power unit ,

ringer cards ,line cards ,junction cards and other control card. Whenever

subscriber lifts his handset battery and audio beeps are heard in board along

with visual identification so that operator process the particular key and get

connected to the subscriber

If operator wants to connect to the subscriber he has to press the key from the

operator side . Then the subscriber gets a ring and there is visual on board.

ITI DESPACHERIt is a electromechanical system with manually operated board .

One operator gives the connection to the subscribers .

There is no privacy.

There are 20 to 50 lines for it in the exchange.


13/26

TELEPHONE EXCHANGE

The plant maintained two exchanges for hassle free communication between

its employees present within the plant and also those in the town. The one in the

plant provided the intercom and public address services along with the

connection with the town exchange with the help of junction cable. The

township exchange was present in the town and from there the lines were

distributed throughout the town .

EXCHANGE LAYOUT


14/26

The power supply is 3 phase , emergency supply also available but variation is

high . a step down transformer is used to step down the voltage required to

acceptable level

The battery room provides a back up in case of power failure . supply voltage

is 48v . There are two sets of battery sets in the exchange one is connected and

second charging

The technology used here in the exchange is pulse code modulation and time

division modulation . Prior to this the technology used was C.bot

Cards used in exchange are TONE SENDING card and TIME SWITCH card

The tone sending card is responsible for the dial tone

A card can hold upto 8 numbers of users. When a person calls, the light for that

no on the card flashes in the exchange.

The distribution unit consists of many relays and wires mounted on a rack

which is grounded to make it lightening proof. From here the wires are sent to

the users to their home. When person wants to have his no changed this is done

by relocating the wires here.


15/26

CARDS

1 ) OPERATOR CARD: -Interfaces analog subscriber line terminations with the

digital switch (Capacity: 8 terminations/card).

2 ) TRUNK CARD (JUNCTION): -Functionally identical to OPERATOR

CAR, but interfaces with analog trunk lines.

3 ) ANNOUNCEMENT CARD (ANNC): -Announcement and tones are stored

as DIGITAL PCM samples in this card. Like subscribers, announcement and

ones also are allotted PORTS and connected to PCM 32 channel link. This

card performs self-diagnostic and reports the result to the procedure cards

through the Error Signal.

4 ) PROCEDURE CARD: -Digital switch, which connects two subscribers by

theway of TIME-SLOT INTERCHANGE. It controls the time multiplexing/

demultiplexing functions for the PCM coded voice samples from/to the

termination cards.

5 ) SIGNAL CARDS: -Receives/sends signal information (ON-HOOK, OFF-

HOOK, dial pulses etc.) from/to terminal cards in a multiplexed fashion and is

made available to the procedure card through a standard Rockwell 6502-businterface.

6 ) CONFERENCE CARD (CNF): -Caters for 3 party conferencing (operator,

trunk and supervisor).

7 ) POWER SUPPLY CARD/UNIT (PSU): -Energy source for all the cards.

Input is 48V D.C. from outside and generates +12V, +5V, -12V, and 3-phase

75V r.m.s. (25HZ) In the cadence of 0.4 Secs. ON, 0.2 Secs. OFF, 0.4 Secs. ON

and 2 Secs off.


16/26

THE SYSTEM CABINET

The system cabinet consists of a card cage, mdf frame, and the power

distributor. The system cabinet is made of steel and is chemically treated to give

it a non-corrosive finish. Adequate ventilation has been provided on all sides.The system has two covers that are hinged to facilitate maintenance. These are

normally screwed on by means of ALLENtype bolts to fasten then securely.

The card cage houses the switching network, comprising various functional

cards or modules. Removing the bolts for the front over can access these.

Removing the bolts for the top cover may access the MDF and power fuses. The

card cage consists of card guides /rails in which all the system cards are

inserted. A motherboard is mounted on the rear of the card cage. All the cards

are connector zed and placed in a card frame and the card connectors terminatein a back plane PCB (the MOTHER BOARD) that runs throughout the length of

the back of the frame. Inter card connections are through this back plane. All

the important cards e.g.PSU, PROCESSOR, SIGNAL and ANNC are

duplicated in 128-port system, to make the switch fault tolerant. Polarization of

controller cards has been provided to avoid damage or misuse of the cards by

unauthorized / untrained personnel.


17/26

C bot

This technology was used in the exchange prior to use of automatic

exchange cards.

It is a digital, stored, program-controlled switching system with 256

terminations or ports. It employs a non-blocking 4-wire PCM switching

network.

It is ideal for rural applications since it provides immediate basic

telephone connection with minimum infrastructure. It is easy to install

and possesses a fault-tolerant system with inbuilt redundancy. Besides

requiring no air-conditioning, it withstands dust, wide temperature

fluctuations (-5 to 50 C), humidity and salinity. Moreover, it consumes

very little power, sustaining itself despite frequent power failures due to

low battery drain. A distinguishing feature of the C-DOT 256P RAX is itssimple and flexible connectivity through a satellite wide range of

transmission systems such as UHF, VHF, radio and satellite. Because it is

program-controlled, it can be easily integrated as per the network

requirement through man-machine commands. Thus, proving to be an

extremely cost-effective and viable proposition.


18/26

OUTDOOR EQUIPMENTS

1.Underground jelly filled cable

Cable pair available-2,5,10,20,50,100,200,300,600,800 pairs

Petroleum jelly prevents moisture

Basic colour coding-blue+white.Green+white,White+Brown

Cables classified according to the dimension of conductor used.

2. Junction box

3.Service cable

4.telephone instrumentsKrone tool , Cable Fault Locator , Cable joining Kit

5.Junction Cable- between two Exchange

6.Relay unit

7.Clock Network-Generates 2 pulse /min 50v dc , consists of master clock that

operates the different clock circuits . Slave clock connected

in clock circuits installed at different locations and

connected in series

8.Computer terminalExtension of main Sun Computer System. Extension

Done through optical cables and connected through

Modem at both ends.


19/26

JELLY FILLED CABLE CROSS SECTION

Cable core inside are filled under pressure with petroleum jelly.

Owing to good electrical characteristics of polyethylene insulation and filling

compound they have low loss factor.

Transmission quality greater than PVC cables

PETROLEUM COMPOUND odourless ,harmless ,passive to copper and

aluminium ,sticks to wire and easy to wipe

ADVANTAGE

1 .Better insulation resistance value

2 . low capacitance

3.lower capacitive coupling

4 .Reduced maintenance cost

5.High safety against corrosion


20/26

THERMOSHRINK SLEVE

Used for joining two separate cables

Cross link , thermally stable and thermally shrinkable

Consists of crystalline and non crystalline phase

When heated above crystalline melting point polymer softens and flows.

If subjected ionizing radiation crosslinks form,it melts but doesnt flow

KRONE TOOL-used for terminating cables


21/26

JOINING OF TWO CABLES

1.PREPARATION

Bring the two cable ends with distance between them equal to approx lengthof thermoshrink Sleeve

Mark on both ends of the cable and remove the jacket and steel tape armoure

from this area

Remove the poly AL sheet from the marked position ,avoid conductor

insulation damage

Connect sheet connecting wire on both sides .Tape with master tape and then

wrap with pvc tape

2.CONDUCTOR JOINING

Take one-one pair from both cables and twist two rounds without removing

insulation

Cut conductors leaving 30mm from the twist, insert connectors and press with

plier till it joins

3.SEALING

Make a bag of polyethelyne sheet over joint by wraping on both sides of poly

AL sheets and then wrap with pvc

Pour jelly into the bag and wrap layer of pvc tape

Remove jacket and clean armour

Wrap armour wire atleast 3 rounds tightly and then solder in 3 places

3.CLEANING

Clean hand first

Wrap adhesive aluminium tape around the sheet

Make the surface of Al tape smooth or else it cracks

Clean the rest portion


22/26

Railway Signalling

POINT MACHINE--- is used to change tracks .The one in the plant is supplied

by Siemens


23/26

The machine has two parts electrical and mechanical

Ac 3phase supply induction Base ,Gear ,Gear clamp, DeclampMotor , limit switch ,safety and rods

switch ,connection terminalblock

Working

When operator operates from control room ,the induction motor gets supply

through different relays .It operates in one direction and is stopped by limit

switch .When machine works perfectly the operator gets steady indication light

on the Control board and the train moves. If any trouble i.e. the operator getsa flashing light and a person is immediately send to get it repaired.

Basically here the rotary motion of the motor is transmitted through reduction

gears and transmission assembly and converted into a linear movement of a

toothed rack through a pinion. The gear rack drives the switch rails to

the required position.

If there remains a gap between the tongue rail and the fixed rail then there is a

fault with the machine.

The safety switch when turned on cuts off supply in the 2 out of three phases of

motors supply.

Tongue

Fixed


24/26

Control roomIt has the conrol board to control the changing of the tracks . The operator

observes the board which contains many lines and indication lights. Tracks are

selected by pressing the buttons on the to be selected lines. The light indicator

shows the lines status whether active or not and if it flashes there is some errorin the line. Each indicator light requires 24 V .

Relay room

Relay room consist of complex circuitry

made up of relays in an arrangement of relay

logic that ascertain the state or position of

each signal appliance. As appliances are

operated, their change of position opens some

circuits that lock out other appliances that

would conflict with the new position.

Similarly, other circuits are closed when the

appliances they control become safe to

operate. In plant the relays are supplied bySiemens. Each box has three relays and is

given a 3 phase supply.


25/26

ADVANCED SIGNALLING(USED BY

RAILWAYS)

It is called RRI (Route relay Interlocking) .

The main advantage of this is that it can tell the position

of trains and Automatic Route setting facility is

available,

which means that with single command, points in the

Route, Overlap and Isolation can be operated to the

required condition. While with the one in plant Points have to be operated

individually for setting the Route.


26/26

OVER ALL EXPERIENCE

The knowledge and experience gained in the plant

was valuable in every sense and it really helpedme to understand how engineers apply their skills

of knowledge and management in the practical

world. The interaction with the trainers was very

fruitful as we discussed new technologies and

prospect. I was really amazed by the enthusiasm

they showed in educating us and that made theinteraction a whole lot easier. In due course of

time I was able to befriend

my fellow group members and the environment

seemed more familiar

I hope that this experience that I had gained willhelp me in my future prospects as I believe that I

have given my full sincere attention to it

reportrourkela

Documents