A study to improve the TEF’s at Bar Mill of VISP, Bhadravati

- Samuel Prabhurajan, Dy.General Manager (Mills & RTS)

GRADES MANUFACTURED

• CARBON & ALLOY CONSTRUCTIONAL STEELS

• FREE-CUTTING STEELS

CASE HARDENING STEELS• CONSTRUCTIONAL STEELS• CASE HARDENING STEELS • SPRING STEELS

GRADES

• BALL BEARING STEELS• TOOL & DIE STEELS

• NITRIDING STEELS• SOFT MAGNETIC IRONTOOL & DIE STEELS SOFT MAGNETIC IRON

MAJOR CUSTOMERS

1. DEFENCE UNITS: ORDNANCE FACTORY, AMBAJHARI

ORDNANCE FACTORY KANPUR ORDNANCE FACTORY, KANPUR ORDNANCE FACTORY, KHAMARIA ORDNANCE FACTORY, TRICHY METAL & STEEL FACTORY, ISHAPORE RIFLE FACTORY, ISHAPORE SMALL ARMS FACTORY, KANPUR, HEAVY VEHICLES FACTORY, AVADI

2. RAILWAYS:2. RAILWAYS: INTEGRAL COACH FACTORY, PERAMBUR CENTRAL RAILWAY, MUMBAI RAIL SPRING KARKHANA GWALIOR RAIL SPRING KARKHANA, GWALIOR DIESEL LOCO WORKS, VARANASI SOUTHERN RAILWAY, PODANUR

RAIL WHEEL FACTORY BANGALORE RAIL WHEEL FACTORY, BANGALORE

3. POWER SECTOR: BHEL UNITS, HYDERABAD, TRICHY, HARDWAR

MAJOR CUSTOMERS

4. ENGINEERING INDUSTRY:

SHANTI GEARS, COIMBATORE KIRLOSKAR TOYODA TEXTILE MACHINERY, BANGALOREKIRLOSKAR TOYODA TEXTILE MACHINERY, BANGALORE DYNAMATIC TECH, BANGALORE FERROMATIC MILACRON, AHMEDABAD DEE TEE INDUSTRIES INDORE DEE TEE INDUSTRIES, INDORE BEML UNITS

5 AUTOMOBILE / FORGING INDUSTRY5. AUTOMOBILE / FORGING INDUSTRY: BHARAT FORGE LIMITED, PUNE AHMEDNAGAR FORGINGS LIMITED, PUNE KTTM, Bangalore MERCURY PRECISIONS, CHENNAI CVM PRECISIONS, Bangalore LGB, MYSORE AUTOMOTIVE AXLES LIMITED, MYSORE

MAJOR CUSTOMERS

TATA MOTORS, JAMSHEDPURSIFL THRISSUR SIFL, THRISSUR

MGM INDUSTRIES LIMITED, MYSORE SHARDLOW INDIA LIMITED, CHENNAI,

6. EARTH MOVERS: BEML UNITS BANGALORE MYSORE KOLAR GOLD FIELDS BEML UNITS, BANGALORE, MYSORE, KOLAR GOLD FIELDS L&T, BANGALORE

7. BEARING INDUSTRY: NEI, JAIPUR JINABAKUL FORGE PRIVATE LIMITED, BELGAUMJINABAKUL FORGE PRIVATE LIMITED, BELGAUM DUAL RINGS, HYDERABAD AUSTIN ENGINEERING, JUNAGADH

PROCESS & PRODUCT RANGE OF MILLS

PRIMARY MILL : Capacity – 78000 Tns/Year

Two Pusher type furnaces - 15 T/hr capacity (OFU)One Pusher type furnace 30 T/hr capacity (Wesman)

One CSP - 3 T/hr capacity

One Pusher type furnace - 30 T/hr capacity (Wesman)

One Blooming Mill - Single stand 3 Hi, 700 X 2000 mm

p y

Finishing Mill - 3 stand / 3 Hi / 600 X 1800 mm

g g ,

Shearing Machine, Hot Saws, Cooling Bed, Controlled Cooling Pits etc

Product range - 60 to 140 Rounds & Billets, Flats and Bl

Cooling Pits etc

Blooms

PROCESS & PRODUCT RANGE OF MILLS

BAR MILL : Capacity – 36000 Tns/Year

Two Walking Hearth furnaces – 7 T/hr capacity

p y

De-scaling unit

g p y

Roughing Mill - Single stand / 3-High – 520 x 1600mm

Intermediate Mill – 3-stand / 3-High – 440 x 1200 mm

Shearing Machine, Hot saws, cooling bed, controlled

Finishing Mill - 1 stand / 2-High – 420 x 800 mm

Product range (a) 20 to 60 Rounds (b) 36 to 75 Rcs and

Shearing Machine, Hot saws, cooling bed, controlled cooling Pits etc.

g ( ) ( )(c) Flats

High Value Long Products

Majority of VISL Products are specific tailor-made t i l f S ifi iti Si Sh d materials of Specific composition, Size, Shapes and

lengths.

High Value Items Rolled for Defence Units:

GRADE: GOST B 9032-73 Grade III – OA Flats

M&SF I h78 X 14 20

g

M&SF, Ishapore90 X 17.20

M&SF, Ishapore78 X 14.20

OFAJ, Nagpur 230 X 21.20

M&SF, Ishapore 235 X 21.50

High Value Long Products

OFAJ, Nagpur140 Rcs - SAE 9260

OF K96 R 35M 6M 3

OFAJ, Nagpur140 Rcs - B 14

OFAJ, Nagpur105 R 48X3

OF, Kanpur96 Rcs - 35Mn6Mo3

, gpOF, Kanpur

105 Rcs - 48X3

OF, Kanpur 96 / 120 R SSB27

OFAJ, Nagpur 105 Rcs - 45X1

OFAJ Nagpur64 Rcs SSF44

, pOFAJ, Nagpur

96 / 120 Rcs - SSB27

OFAJ, Nagpur64 Rcs - SSF44

High Value Long Products

OFT36 SCS – 709 M40

RFI / OFT46 SCS - EN21

OFT53 RCS - 070 M55

RFISAF, KanpurOFT

32 Rds - EN 39B

RFISAF, Kanpur42 Rds - 655M13OFT

LENGTHY TIE-RODS

Fe410WA-40 dia 14.425 MtrsBhilai Engg Corpn, Bhilai

15Cr90MO55-50 dia 15.15 MtrsFe410WA 50 dia 14 625 Mtrs

Bhilai

15Cr90MO55-36 dia 14.50 Mtrs

Fe410WA 50 dia 14.625 Mtrs

Fe410WA-50 dia 17.20 Mtrs, BSP Bhilai

CI IV 36 dia 17.78 Mtrs

56 Dia 18.20 MtrsBSP, Bhilai

Fe410WA-50 dia 17.00 MtrsFe410WA 50 dia 17.00 MtrsFe410WA-50 dia 17.50 Mtrs

BSL, Bokaro

FFE Mineral India,

15Cr90MO55-36 dia 16.00 MtrsRSP, Rourkela

42CrMO4-32 dia 12.30 MtrsChennai ,M/s JVSL , Bellary

Other High Value Products

Borewell Drill Bits125 Rcs - EN 36C

Central RailwayRifle factory,Ishapore

20.64 Rds - 55Si750 X 38 mm flat-EN24

Crompton GreavesSoft Magnetic Iron

Rifle factory,Ishapore50 X 38 mm flat EN24

Bokaro Steel PlantCRM Rolls

Southern Railways20dia, 22dia, 25dia

Bokaro Steel PlantM/s JVSLRSP (Pipe Plant)

CRM RollsCC Rollers, HSM RollersD2 Rolls RSP (Pipe Plant)D2 Rolls

Other High Value Products

FLATS FOR INTER - PLANTS

BHILAI STEEL PLANTBHILAI STEEL PLANT

40 X 6, 50 X 8, 50 X 10, 50 X 14, 80 X 6, 90 X 20, 100 X 10, 100 X 12

TECHNO ECONOMIC PARAMETERS

Parameters 2017-18 2018‐19(Apr‐Dec)

Production ,MT 0.010 0.0053

A il bili % f l d h 1 33 42Availability, % of calender hour 75.71 33.42

Utilisation, % of available hour 72.09 69.08

Rolling rate / production rate, T/hr 7.41 7.93Yield ,% 96.26 96.57

Specific fuel/ heat consumption, Gcal /T 0.9398 0.6455Specific power consumption, kwh / T 140.96 121.02Specific water consumption, M3 /T 96.62 43.66

Specific roll consumption, Kg/T 0.01 0.01p p gSpecific lubricant consumption, L/T 0.01 0.01

Specific rolling oil consumption, L/T 98.60 79.33Specific rolling oil consumption, L/T 98.60 79.33Quality diversion,% Nil Nil

R lli f 40 di G d MSIS 2062Rolling of 40 mm dia, Grade MSIS 2062, M/S. BHEL

Period : 03/11/2018 to 20/11/2018

ROLLING ROLLING

PRODUCTIONOIL

CONSUMPTIONPOWER

YIELD RATE

INPUT OUTPUT Ltr/tnCONSUMPTION % Tns/hr

INPUT OUTPUT Ltr/tnKwh/tn

97 38 8 822407 2344 59.81 101 97.38 8.82

COST BENEFIT ANALYSIS

Particulars Norm Three shift operation

TEF Rate V.Cost TEF Rate V.Cost

Rs/Unit Rs/Tn Rs/Unit Rs/TnMill Utilisation 18 HrsProduction 150 TnsProduction 150 TnsPower(KWh/tn) 130 7.64 993 101.4 7.64 775Fuel(Ltrs/tn) 70 32.00 2240 59.81 32.00 1914General Stores 92 78General Stores 92 78Pur.Refractories 139 139Own Refractories etc 75 75Services 362 362Services 362 362Shop & Fdry charges 27 27

T t l 3928 3370Total 3928 3370Savings (Rs/Tn) 558

R lli Yi ld 98% 97 38%Rolling Yield 98% 97.38%

Savings considering Yield Impact 556

2407 X 556 - 13,38,292

Rolling of 90X17.2 mm Flats for M/s MSFPeriod of study: 21/01/2019 to 29/01/2019

OILROLLING

YIELDRATE OFROLLING

PRODUCTIONOIL

CONSUMPTIONPOWER

YIELD ROLLING

INPUT OUTPUT Ltr/tnCONSUMPTION

/ K h/

% Tn/hr

/ Kwh/tn

1200 1160 57.51 100.53 96.66% 10.44

COST BENEFIT ANALYSIS

Particulars Norm Three shift operationParticulars Norm Three shift operationTEF Rate V.Cost TEF Rate V.Cost

Rs/Unit Rs/Tn Rs/Unit Rs/TnMill Utilisation 20 HrsProduction 150 TnsPower(KWh/tn) 130 7.64 993 100.53 7.64 768( )Fuel(Ltrs/tn) 70 32.00 2240 57.51 32.00 1840General Stores 92 78Pur Refractories 139 139Pur.Refractories 139 139Own Refractories etc 75 75Services 362 362

h d hShop & Fdry charges 27 27

Total 3928 3290Savings (Rs/Tn) 638

Rolling Yield 98 00% 96 66%Rolling Yield 98.00% 96.66%

Savings considering Yield I t 629Impact 629

1200 Tns X 629 - 7,54,800

BENEFITS DERIVED DUE TO THE STUDY

Case:1 Rolling of 40 mm dia, Grade MSIS 2062, M/S. BHEL

R 13 38 292Rs. 13,38,292

Case : 2 Rolling of 90 X 17 2 mm Flats for M/S MSFCase : 2 Rolling of 90 X 17.2 mm Flats for M/S MSF

Rs. 7,54,800Rs. 7,54,800