3 months on project training at TATA STEEL KALINGANAGAR project

1. TATA STEEL
LIMITED,KALINGANAGAR(ORISSA)

2. GURUNANAKDEVENGINEERINGCOLLEGE
THREE MONTHS INDUSTRIAL TRAINING AT
TATA STEEL (KALINGANAGAR,ORISSA)
PRESENTED BY:-
ASHISH KUMAR(1144490)
BABUL RAJAN(1144494)
KUNAL KUMAR(1144526)
MANISH KUMAR(1144531)
Branch-EE(D4/A)

3. TATA STEEL
Founder : Jamsedji Tata
Founded : 1907
Head Quarter : Mumbai
Area Served : World wide
Product : Steel, Long
Steel Products,
Wire products.
Employees : 81,000
Main Plant Location : Jamshedpur
Stock Exchange: Recognized by BSE, NSE

4. • INTRODUCTION
• Established in 1907, Tata Steel is among the top ten global companies
with an annual crude steel capacity of over 28 million tonnes per
annum.
• A geographically diverse steel company, Tata Steel has always believed
that the principle of mutual benefit (between countries, corporations,
customers, employees and communities) is the most effective route to
profitable and sustainable growth. The well managed workflow
network and the company’s commitment to safety, social responsibility,
continuous improvement and transparency has allowed it to withstand
the test of time over the years.
• The Kalinganagar Project - Tata Steel’s second integrated steel plant in India
- is nearing completion, and scheduled to commission its first phase by
MaRCH 2015.

5. • Tata Steel has lined up a series of greenfield
projects in India and outside which includes:-
• 6 million tonne plant in Orissa (India)
• 12 million tonne in Jharkhand (India)
• 5 million tonne in Chhattisgarh (India)
• 3-million tonne plant in Iran
• 2.4-million tonne plant in Bangladesh
• 5 million tonne capacity expansion at Jamshedpur (India)
• 4.5 million tonne plant in Vietnam (feasibility studies
underway)

6. • Tata Steel is India’s 2nd largest & 2nd most profitable company
in private sector with revenue of 1,32,110 crore and net profit
of 12, 350 crore.
• Purpose
• Gain Market Share
• Enter new Market (Entry into European Market )
• Acquire Technology
• Utilization of surplus fund

7. • Values&Ethics
From the time of Jamshetji Tata, ethical behavior is intrinsic to the way Tata
Steel conducts its business. The company believes that business must
operate in a way that respects the rights of all its stakeholders and creates
an overall benefit for society. From human rights to risk management to
values and code of conduct, Tata Steel looks after everything.
• Safety
In Tata Steel, safety of the workers and the contractors comes first.
Thus the company takes full responsibility to make sure that they
provide a safe working place. Personal protective equipments (PPEs)
like boots, goggles and helmets are to be worn by each and every person
who enters the Tata Steel gates.

8. Project Progress:
(as on September 30, 2014)
• Concreting work of 13.76 lakh cubic meters completed by end of
June 2014Structural erection of 1.88 lakh metric tones completed
by end of June 2014Equipment erection of 67,330 metric tones
completed by end June 2014
• The state-of-the-art, Kalinganagar Project is being established in
two modules of three million tones each. The plant, which boasts
of the Blast Furnace of 4330 cum capacity, will roll out high-end
flat products.
• During the first phase, the Blast Furnace will have a capacity of
3.3 Million Tones Per Annum (MTPA) of hot metal and the Coke
Plant will have a capacity of 1.65 MTPA (recovery type oven).
While the Sinter plant will have a capacity of 4.91 MTPA, the
Steel Melting Shop

9. • The project will have a 3X67.5 MW gas-based Captive Power
Plant. New technologies like Granshot Systems & CAS OB will
be introduced in the plant for steelmaking. The plant is also
designed for Zero Liquid Discharge, Waste Recycling Plant
and Central Effluent Treatment Plant. High-end flat products
will be rolled out from Kalinganagar plant.
• Govt of Orissa has allotted around 2000 acres of land to
the Steel Company for the project in Kalinganagar, which
has been registered in favour of Tata Steel.
• Nippon Steel Corporation, Japan has been appointed as
the Technical Consultant for the project.

10. • ELECTRICAL DEPARTMENT
Many types of machinery are required to help in the process
of formation of steel. These machines require electrical
energy for running. For that purpose the plant needs
electrical power. Power grids are required by specialized
machines like crane motor, pumps and transformers
without which the entire system may fail. Thus, the
electrical department is a very well established division in
Tata Steel. Moreover, it has multiple departments under it.

11. Motors received in Incoming Area. Note that each motor has a yellow
tag thatcontainsdepartment/locationofthemotorowner,typeofservice
requiredandsuspectedtypeoffailure.

12. Flow of motors in ElectricalRepair Shop

13. • Electrical Repair Shop (ERS)
• Function&Objectives
Any electrical steel plant is bound to have a lot electrical
machines and equipment. These machines, like any other, tend
to get damaged or undergo a breakdown. Thus, they are sent
from the various parts of the steel plant to the Electrical Repair
Shop (ERS). While vanilla repairs are sent outside, niche or
specialized repairing is done under ERS supervision mostly inside the
shop itself. The ERS strictly deals with the repairing and testing of ac
and dc motors.

14. • Typical Work Flow to Repair a Motor
• The ERS has a very well maintained and strictly followed workflow. The
incoming motor comes in with a yellow tag attached to it. This tag
contains the details about the motor and is filled by the various
departments prior sending the motor for repair.
• Not only does this tag contain vital information about the motor, it also
contains the probable defect of the motor, thus reducing the work of
the ERS by a lot. As soon as the motor is brought in the shop, a 6
digit serial number is painted on it. This SOP number is unique for a
particular motor during its tenure in the shop.
• The first 2 digits refer to the year the motor was sent to the
repair shop, the next digit refers to the type of motor while the last 3
digits are a serial number being maintained. The motor is then
cleaned, washed and the oil and grease is cleaned off its parts. In the
washing area, it is essential for the window to be situated opposite to
the side where the motor is washed, so that air can pass freely.

15. • It is then sent to the next section where the motor is dissembled
into its component parts.
• Each and every component part is immediately painted with the
unique SOP number so that the tracking of the parts can easily be
done.
• Once the parts are separated, they are taken to their individual
sections where each part is checked, repaired and tested by skilled
workers.
• The commutator, specific to dc motor, is taken to a specific dc section.
Parts common to both types of motors are repaired together.

16. Squirrel Cage Rotor - Note the one in front has
slanted slots to improveperformance

17. Stator being repaired. The one on left is stripped
of windingspostroasting, the oneon right is
being winded.

18. • Each and every motor has its own specialty and have to be repaired
accordingly. The squirrel cage motor and the bearings all have their
own requirements that have to be matched. Thus, there are sections that
are specialized in the repair of a certain motor parts only.
• For example, there is a roasting and stripping section which concentrates on
the stator part only. Small stators, whose windings have to be changed,
are roasted in a furnace at fiwindings become a little loose.
• The coils are then stripped off the stator in the stripping section and
then sent back to be recoiled by the workers. Stators that are a bit big
in size are not sent to the roasting and stripping section as the process
makes the stator weak and reduces its life expectancy.
• After all the component parts are repaired they are sent to the final
assembly section. Here, all the parts having same SOP number are
assembled and then sent to the testing section within the ERS itself. Almost
90% of the motors being tested are working perfectly by this stage and
are sent back to their respective departments. If by any chance the
motor fails in some stage of the test and another problem is found out,
the motor has to re-go the entire workflow process of the ERS all over again.

19. • Testing of Electrical Machines
Testing of electrical machines is a salient procedure in the workflow of ERS.
After repairing a machine, it is essential to test the same and check if the
repairing has been proper or not. This part can also be considered to
be the overall check of the proper repair and maintenance of the electrical
machine.
• Testing of Motor
The tests that I saw being carried out on an ac motor are as follows
1. No Load Test: In no load condition, voltage is applied and the current
is inspected. If the current flowing in this condition is about 30-40% of the
full load current, the motor is working properly.
2. Megger Value Test: This test measures the insulation strength of the
motor. A high voltage is applied across the winding insulation and the
megger value is noted. It should be noted that before and after each
megger test, the instrument is checked by short circuiting its path.
With megger test we check the insulation between phases and between
phase and ground.

20. 3. Vibration and Temperature Test: Observation-based in nature, these
tests are an approximation of the proper working of the motor. The
rate of vibration and the degree of temperature rise of the motor
when it is running over a period of time tells us a lot about the condition
of the motor.
4. Checking for abnormal Fan or other sound: The people in charge of the ac
motor testing section are very skilled and deft with their work. From
experience developed over the years, they can tell whether a motor is fine
or not from simple observations like an abnormal sound coming from
the motor fan.

21. • Testing of a Transformer
I observed a 24MVA furnace transformer with a HV/LV ratio 33kV/384V
being tested. The transformer was being tested in LD #2 under the Electrical
Testing Department. One of the unique features of the transformer was that it
had its LT wires on the outside unlike a normal transformer. The tests I saw being
carried out are listed below:
1. IR test: The IR test or Insulation Resistance test measures the insulation
strength between two sheets of insulation in the windings. It is one of the
most common tests to check the insulation of a transformer.
2. PI test: A short form for Polarization Index test, this test is also a
commonly performed test to check the insulation strength of the
transformer. In the insulation sheet, the domains are usually arranged
at random at a particular instant of time. When polarized, these
domains arrange themselves in a proper NS-NS manner. When this happens,
there is hardly any leakage current that might flow through the
insulator, thus letting us calculate its strength. For the domains to
arranged themselves properly and stabilize, it takes about 6-7mins. To be on
the safe side, the transformer is allowed to run for about 10mins and then its
10min IR value is compared with respect to its 1min IR value to finally get its
PI value.

22. 3. Dielectric loss factor/ tan delta test: The charged insulation sheet acts as a
capacitor. However, the impurities that might be present in the
insulation sheet shifts it from an ideal capacitor to a practical one. Thus the
angle of the resultant current shifts from a perfect 900 lead with
respect to applied voltage to an angle less than that. This shift in angle is
represented by d (delta). By calculating this angle and hence finding the
tan of it, we can get the magnitude of current that is in phase with the
applied voltage, i.e., the resistive current. The less the resistive current,
the less the power loss. Hence, for the insulation to be of proper
strength it must be taken care that tan d should be minimum and the
insulation sheets are as near to an ideal capacitor as possible.
4. HV test: In case of fluctuations, the voltage may rise higher than
usual. The insulation should be able to withstand the impact of the high
voltage. The particular breakdown voltage of an insulation sheet is
tested and known from before. That voltage is applied across the
insulation and it is observed. If it trips before the predefined breakdown
voltage, it is a weak insulation and vice versa.

23. 5. Magnetic Balance Test: In a shell type transformer, the path of flow
of flux depends where the voltage is applied. As shown in Figure 8,
if the voltage is applied in R or B, the two fluxes would be 65-
85% and 35-15% respectively. If applied in Y, each part would
be about 45-55%. If by chance the windings are shorted or
grounded in any of them, the phase to phase relationship changes
within each winding and the expected percentage of the flux
distribution goes way out of proportion.
6. Voltage Ratio Test: The primary and secondary side of a
transformer maintains a strict turns ratio. Thus a small voltage is
applied to the primary and the voltage in the secondary is
observed. If it maintains the turns ratio, the transformer is working
fine.
7. Short circuit impedance Test: Another commonly performed
test, this determines the impedance of the transformer at a
particular percentage of applied voltage.

24. 8. Core bolt megger Test: To reduce the eddy current loss in the
transformer core, the core is laminated with insulations in
between each slit of the core. This laminated core is held
together by core bolts, which are also insulated. This core bolt
must be insulated as well otherwise resulting in a short circuit in the
core and leading to high eddy currents. So, this core bolt
megger test is done. It finds out if the insulation of the core
bolt is proper or not.
• Some other tests were also carried out which I did not get to see.
They are listed as follows:
9. Vector group test
10. DC winding resistance Test
11. Turns ratio Test
12. Transformer protection Testing
13. Bushing cap and dielectric Test

25. TestingSection.Mostofthetestingworkhappensinfield
(likethetestingofthefurnacetransformerI saw)

26. PrincipleofMagneticBalanceTest

27. PALLET PLANT
• Pellets are indurated, spheres of ore with a high iron content and
uniform quality.
• Pellet plants can produce two varieties of pellets: blast furnace pellets
and direct reduction pellets (DR pellets). Blast furnace pellets are used in
the coke-based blast furnace process, which is the most common
method of producing hot metal (molten iron for steelmaking). Blast
furnace pellets are delivered mainly to steel mills.
• DR pellets are used in the direct reduction processes to produce sponge
iron, which is an alternative process route, as an initial stage from iron to
steel. The DR process is primarily based on the use of natural gas and has
become increasingly common in countries with access to inexpensive
natural gas

28. • The object of the process is to transform the pelletized concentrate into
hardened pellets that can be used as blast furnace feed or direct
reduction furnace feed. The transformation is achieved by the traveling
grate and kiln.
• The traveling grate transports the pelletized concentrate through a
series of controlled temperature zones to produce a preheated pellet of
800-900°C, which is dropped into the rotary kiln.
• The rotary kiln finishes the induration and is operated at 1200-1350°C.
The indurated pellets are now dropped into an annular cooler where
the pellets are cooled to a suitable temperature for transporting on a
belt to load out facilities. The gases from the cooler are recycled to the
kiln and the grate, resulting in the Grate-Kiln being the most energy
efficient system for producing indurated pellets.

29. • NEED OF PALLET PLANT
• TO INCREASE HOT METAL OUTPUT TO MEET 3.3 MTPA CURD STEEL PRODUCTION
• TO IMPROVE BLAST FURNACE PERFORMANCE
a)increase in blast furnace productivity
b)decrease in blast furnace fuel rate
c)decrease in hot metal quqlity
d)decrease in slag rate
• EXTENDING THE LIFE OF IRON ORE RESERVERS

30. • WHAT ARE PALLETS?
Pellets are approximately spherical lumps formed by agglomeration of crushed
iron ore fines in presence of moisture and binder, on subsequent induration at
around 1300°C, which suit the requirements of downstream processes e.g. Blast
Furnaces & Direct Reduction.

31. Advantage of pallets:-
• Standardization – uniform size range , generally within a range
of 6–16mm
• Purity – 63–68% iron, mainly Fe O ²³
• High and uniform porosity of 25–30%
• Good bed Permeability–Due to Spherical shape and open
pores
• Cost-effectiveness
• Virtually no loss of ignition
• Fast reduction and high metallization rates
• Fine particles, not suitable for sinter making, are used
• Strength – high and uniform mechanical strength even under
thermal stress in reducing atmospheres
• Transportable – low degradation under abrasive conditions

32. COKING PLANT
A world class blast furnace operation demands the highest quality of raw
materials, operation, and operators. Coke is the most important raw
material fed into the blast furnace in terms of its effect on blast furnace
operation and hot metal quality. A high quality coke should be able to
support a smooth descent of the blast furnace burden with as little
degradation as possible while providing the lowest amount of impurities,
highest thermal energy, highest metal reduction, and optimum
permeability for the flow of gaseous and molten products.

33. • The coke making process involves carbonization of coal to high
temperatures (1100°C) in an oxygen deficient atmosphere in order
to concentrate the carbon.
• The commercial coke making process can be broken down into two
categories:
a) By-product Coke making and
b) Non-Recovery/Heat Recovery Coke making.
• A brief description of each coking process is presented here. The
entire
• coke making operation is comprised of the following steps:-
• Before carbonization, the selected coals from specific mines are
blended, pulverized, and oiled for proper bulk density control.
• The blended coal is charged into a number of slot type ovens
wherein each oven shares a common heating flue with the adjacent
oven.
• Coal is carbonized in a reducing atmosphere and the off-gas is
collected and sent to the by-product plant where various by-
products are recovered. Hence, this process is called by-product
coke making

34. • The coal-to-coke transformation takes place as follows:
• The heat is transferred from the heated brick walls into the coal charge. From
about 375°C to 475°C, the coal decomposes to form plastic layers near each
wall. At about 475°C to 600°C, there is a marked evolution of tar, and
aromatic hydrocarbon compounds, followed by resolidification of the plastic
mass into semi-coke. At 600°C to 1100°C, the coke stabilization phase begins.
• This is characterized by contraction of coke mass, structural development of
coke and final hydrogen evolution.
• During the plastic stage, the plastic layers move from each wall towards the
center of the oven trapping the liberated gas and creating in gas pressure
build up which is transferred to the heating wall.
• Once, the plastic layers have met at the center of the oven, the entire mass
has been carbonized (Figure 2). The incandescent coke mass is pushed from
the oven and is wet or dry quenched prior to its shipment to the blast
furnace.

35. COKESIDEOFABY-PRODUCTCOKEOVENBATTERY.Theovenhasbeen
pushedandrailroadcarisfullofincandescentcokethatwillnowbetakentothe
quenchstation

36. BF-OHP3B Overhead Ion Blower
• The Overhead Ion Blower BF-OHP3B is based on HDC-AC
technology, an improvement that offers high ionizing
performance and easy maintenance.
• The blower provides consistent static elimination over a
wide area. The overhead blower is the ideal choice to
neutralize static electricity in Medical Packaging,
Electronics and Semiconductor applications.
• With its excellent ion balance and fast static decay rates
at low pressure, the BF-OHP3B is the perfect tool for
ionization when benchtop space is at a premium.

37. BF-SZAII blower
• The BF-SZAII blower is a small profile ionizer, and is a
great choice to address static problems in locations
that have physical restrictions.
• The ionizer is ideally suited for both the Electronics
industry along with the Life-Sciences market where
ESD events can cause process issues, and destruction
to electronic components.
• The blower can also be used for in-tool applictions
and for spot ionization, instead of using compressed
air technology.

38. • Winstat BF-X4MB Wide Coverage 2-Fan Ionizing Blower
The Winstat BF-X4MB Wide Coverage 2-Fan Ionizing Blower’s light-
weight design makes this blower the ideal choice for ionization at the
workbench, or directly above the worksurface. The blower will help
remove static in a wide range of applications especially in the
Electronics and Medical Device Manufacturing Industry. With its
excellent ion balance and fast decay rates

39. • PowerGeneration,Distributionand Control
• Tata Steel’s own power generation division is of high importance.
Internal power generation is critical to achieve the reliability required
for safety of the steel factory.
• Tata Steel’s in-house in-plant generation along with power
generated by Tata Power at mehandhsal (near kalinganagar) and
supply from grid through dubri caters to the need to the power
supply in kalinga nagar and the steel works.
• Power House #4
Power House 4 consist of three generators of 12.5MW, 20MW and
25MW capacity. 12.5 MW has a special back pressure turbine, and so the
exhaust from steam blowers can be used to run the turbine of 12.5 MW.
At PH4, I a saw huge water tube boiler of capacity 63kg/cm2 and
temperature 4850C producing 136TPH of steam. This steam is passed
through a turbine which in turn rotates thee generators of 12.5MW, 20MW
and 25MW capacity. Of the three, the former is back fed by steam from
power house #5 while the other two are fed into a condenser. These
generators provide stability and reliability of electrical system during outage.

40. • Electrical Power Distribution
The main sources of power are the grid and Jojobera
generation. The in-plant generation caters to basic safety load
and improves reliability inside the plant.
• Load Despatch Center (LDC)
Load Dispatch Centre, Tata Steel is the nerve center of power
supply of the whole of kalinganagar. Equipped with one of the
best SCADA systems in the world for Electrical Transmission &
Distribution, LDC has become phenomenal in regulating the power
generation and distribution not only at Tata Steel Works but also at
almost all of the industries and Town at kalinganagar.

41. • Load Balancing and Scheduling
Tata Steel requires power for running its steel producing operations
as well as giving power to the whole town of kalinganagar. For it to do
this, the works take 30MW from each of the two boilers in PH#3, 20MW
and 25MW (and sometimes 12.5MW) from PH#4, 30MW from PH#5
and 120MW from PH#6. Except these internal power supplies, Tata
Steel also draws power from Tata Power, DVC and TRT. For it to get
power, the company needs to give power to the outside sources as
well. With different tariffs being paid Tata Steel draws power and in
return gives them power at a price too. Tata Power gives about 67.5MW
in one line and 120MW in each of the other four lines. TRT give
10MW and 16MW in their two lines while DVC gives 132kV at
120MVA level and 400kV at 160MW level (to be changed to 200MW
from October 2013).

42. • Power System Failure Recovery
Power failure can have disastrous consequences in a steel
plant with potential hazard of accidents. In case of failure, LDC
helps in quick recovery by
• Providing consolidated real time view of the power network to
operators
• Enabling operators to decide on alternate ways to restore power
• Providing data to perform post-mortem analysis so that the
cause and effect is clearly established and future such events
prevented.

43. Figure10:HighPressureSteamNetworkofPowerHouse4